CA1201858A - Adhesive for fireproofing and fiber encapsulation - Google Patents
Adhesive for fireproofing and fiber encapsulationInfo
- Publication number
- CA1201858A CA1201858A CA000432707A CA432707A CA1201858A CA 1201858 A CA1201858 A CA 1201858A CA 000432707 A CA000432707 A CA 000432707A CA 432707 A CA432707 A CA 432707A CA 1201858 A CA1201858 A CA 1201858A
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- CA
- Canada
- Prior art keywords
- liquid
- mixture
- adhesive
- fireproof
- range
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J1/00—Adhesives based on inorganic constituents
- C09J1/02—Adhesives based on inorganic constituents containing water-soluble alkali silicates
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- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Adhesives Or Adhesive Processes (AREA)
- Paints Or Removers (AREA)
- Fireproofing Substances (AREA)
Abstract
ADHESIVE FOR FIREPROOFING
AND FIBER ENCAPSULATION
ABSTRACT OF THE DISCLOSURE
A fireproof adhesive material is provided which accomplishes fiber encapsulation and permits the development of spray on type fireproof insulation. The fireproof adhesive material incorporates a predetermined quantity of sodium silicate in liquid form with which is mixed a quantity of surfactant/water solution sufficient to render the cured fireproof adhesive flexible and to provide for emulsification in the liquid state thereof. The adhesive also includes a sufficient quantity of silicone water repellent to render the cured adhesive durable, chemical resistant and water repellent. Further, the adhesive material may include a liquid stabilizer, plasticizer compound to enhance the flexibility of the cured adhesive. For odor control, a quantity of a malodor control agent may also be incorporated.
The fireproof adhesive material is prepared in the form of a liquid mixture wherein the ingredients of the mixture are basically incompatible and wherein the ingredients are introduced during continuous agitation in a particular order and after being placed in assembly, the incompatible liquid constituents are forced together by agitation for a sufficient period of time to render the mixture substantially inseparable. Upon curing, the adhesive mixture forms a solid, pliable or flexible mass having good surface adhesion. When in the liquid form the mixture has a quality of efficient penetration and fiber encapsulation to render hazardous fibers nonviable and fireproof.
AND FIBER ENCAPSULATION
ABSTRACT OF THE DISCLOSURE
A fireproof adhesive material is provided which accomplishes fiber encapsulation and permits the development of spray on type fireproof insulation. The fireproof adhesive material incorporates a predetermined quantity of sodium silicate in liquid form with which is mixed a quantity of surfactant/water solution sufficient to render the cured fireproof adhesive flexible and to provide for emulsification in the liquid state thereof. The adhesive also includes a sufficient quantity of silicone water repellent to render the cured adhesive durable, chemical resistant and water repellent. Further, the adhesive material may include a liquid stabilizer, plasticizer compound to enhance the flexibility of the cured adhesive. For odor control, a quantity of a malodor control agent may also be incorporated.
The fireproof adhesive material is prepared in the form of a liquid mixture wherein the ingredients of the mixture are basically incompatible and wherein the ingredients are introduced during continuous agitation in a particular order and after being placed in assembly, the incompatible liquid constituents are forced together by agitation for a sufficient period of time to render the mixture substantially inseparable. Upon curing, the adhesive mixture forms a solid, pliable or flexible mass having good surface adhesion. When in the liquid form the mixture has a quality of efficient penetration and fiber encapsulation to render hazardous fibers nonviable and fireproof.
Description
~2()~858 ADHESIVE FOR FIREPROOE'ING
AND FIBER ENCAPSULATION
FIELD OF THE INVENTION
~ his invention relates generally to fireproof adhesive materials and more specifically concerns a fireproof adhesive material having efficient fiber penetration and encapsulation as well as rendering the fiber fireproof. More specifically, this invention concerns a fireproof adhesive material which is efficiently combined with fibrous and 10~ pulverant materials to form a spray on type insulation having efficient thermal insulating quality as well as being of ~fireproof nature.
BACKGROU~D OF THE INVENTION
` Due to the extensive loss of life and property typically caused by ~ires, a large number of materials have been developed as fireproof coatings which have been somewhat successful in retarding the spread of f~lame. Virtually all of the known fireproof insulation materials are combustible to some degree or have a relatively limited heat retarding `~ 20 therm~al~capability.~ Moreover, many of the materials developed liberate hazardo~s toxic fumes when subjected to fire and are thus disadvantageous from the standpoint of pulmonary hazard2 It has also been aonsidered desirable to provide a thermal insulation material which may also function as a fireproof adhesive and which is applicable as an integral constituent of interior coatings for metal buildings and other relatively smooth flexible surfaces. In many cases, it is virtually impossihle to provide a material having efficient $~
, .
~20~58 flexibility and adhesive character for attachment to the smooth surfaces of a sheet metal building and which are also of fireproof nature. Generally, fireproof materials are of rigid character due to their typical silaceous content, thereby rendering them relatively unsuitable as a flreproof adhesive for use on flexible objects and surfaces.
Another area of significant concern is the recent diæcovery that asbestos fibers and fibrils have a carcinogenic charaeter and are perhaps responsible for a large number of human deaths due to lung cancer resulting from an occupation wheré prolonged contact with asbestos materials occurred. It is well known that many private and public buildings contain wall and ceiling structures which include asbestos materials.
It has been determined that these materials continuously liberate asbestos fibers and ~ibrils which could represent a hazard to persons occupying the premises especially for prolonged periods of time. It is desirable therefore to provide a material or a combination of materials that may be utilized to accomplish efficient fireproofing, thermal insulation and protection against asbestos contamination~
Heretofore, it has been belie~ed impractical to provide a single material having efficient protective capabilities in all three of these areas. The present invention therefore relates to a material having efficient qualities in each of these three areas of public concern.
Fireproofing As mentioned above, various materials have been utilized to provide substantially fireproof coatings on wall and ceiling structures of buildings and on metal structural support members in an attempt to provide a fire retarding capability that, in e~fect, retards the spread of flame.
These materials are intended to limit the development of heat to such extent that fire spreading and development will be retarded to thus provide firemen with ample time to reach the scene and extinguish the fire before substantial damage has been done. In most cases, a material having fire retarding ~2~)~85~3 capability is required to successfully pass tests to determine the capability of the material to retard the development and spreading of fire. One such test is the ~merican Society for Testing and Materials El19-~O Standard Methods of Fire Test of Building Constructions and Materials. This test is intended to provide data to enable regulatory agencies to determine the suitability of assemblies for use in locations where fire resistance of a specified duration is re~uired. This standard is not utilized to measure and descri~e the properties of materials or assemblies in response to heat and flame under controlled laboratory conditions. It is also not used to describe or appraise the fire haxard of materials or assemblies under actual conditions. The results of this test are t~pically used as elements of fire risk assessment which takes into account all of the factors which are pertinent to an assessment of the fire hazard of a particular end use.
Exposure may not be representative of all fire conditions, which may vary with changes in the amount, nature and distribution of fire loading, ventilation, compartment size and configuration, and heat sink characteristics of the compartment. It does, however, provide a relative measure of fire performance of assemblies under the specified fire exposure conditions. Any variations from the conditions that are tested may substantially alter the performance characteristics of the assembly. In this test, a fire, typically developed by natural gas, is directed on an insulated surface and thermocouples opposite the insulated surface are utilized to measure temperature increase as the fire is continued. A material is said to fail this test if the thermocouples show a temperature rise to 250F within a predetermined minimum period of time. Various other tests are also conducted to determine the heat insulation and ~ire retarding capability of materials. For the most part, it is extremely difficult for any known fireproofing coating material to achieve a fire rating approaching one hour.
~20~1~51~1 Heat Insulation Another area of concern is the capability oE a fireproofing material to also function for the purpose of heat insulation and to remain in place even on flexible surfaces such as the interior walls of a sheet metal buildiny. It is well known that the metal of sheet metal buildings tends to radiate heat when heated during ambient conclitions such as hot summer days, etc. It has been found practical to provide the interior surfaces of metal buildings with coatings of thermal insulation material to retard heat radiation. Most thermal materials capable of adhering to the flexible interior metal wall structures of sheet metal buildings are capable of providing only minimal protection from the standpoint of fireproofing. In some cases, thermal insulation material is composed of urethane foam, a highly flammable material which yields toxic gases when aflame. It is desirable therefore to provide a fireproof coating material which also functions as a ; heat insulating material and which has the capability of ef~icient adherence to flexible wall structures as well as the capability of adhering to various metal and non-metal structures such as typically are utiliged in the cons~ruction industry for commercial and residential structures.
Asbestos Encapsulation Asbestos has long been utilized as a construction material because o its heat and fire retarding characteristics. It has also been utilized as an efficient structure for sound absorption and for formation of ceiling surfaces of building structures because of its fairly lightweight character. It has been recently discoveredl however, that asbestos fibers are carcinogeni~ and when deposited in the lungs of animals and humans, are difficult to expel. Moreover, asbestos has been determined to constitute a health hazard when utiliged in building structures in such a manner that asbestos fîbers and fibrils are liberated which can become entrained in the air and breathed by persons occupying the premises. Vntil recently, exposure to asbestos 8~8 was generally considered an occupational health hazard for asbestos workers. However, now it has been learned that an equally serious exposure problem exists that can occur in all types of buildings in which certian asbestos containing materials have been used for fireproofing, insulation and decoration. Asbestos ~ihers can be released from these materials and contaminate the building environment.
Individuals who are then exposed to the asbestos could develop lung cancer or cancers of other parts of the body due to the carcinogenic character of the fibers. Unfortunately, detection of asbestos related diseases is difficult since the latency period between exposure and appearance of the disease is sometimes as great as from twenty to forty years.
During the year 1982 a requirement was published in the Federal Register calling attention to a recently adopted Environmental Protection Agency regulation which required that public and private school facilities be visually inspected for friable materialsO According to this regulation, if friable material is located, it must be analyzed for asbestos content and the results of the analysis must be posted in district administration offices and in faculty and custodial workrooms and lounges in the affected buildings. Schools in which friable asbestos containing material exists must post warnings about the health hazards of asbestos and instructions about methods to be used by school employees to avoid or reduce exposure to asbestos. For purposes of this regulation, friabla material is defined as any material applied onto ceilings, walls, structural members, piping, duct work and any other part of the building structure which, when dry, may be crumbled, pulverized or reduced to powder by hand pressure.
Where large quantities of asbestos fibers are present in friable materials, it is vixtually assured that a requiremen~
will be made to reduce or eliminate such materials by construction operations. It is desirable therefore to provide means for simply and efficiently rendering building structures safe when asbestos containing friable materials are determined to be present in building structures which are continuously ~2~
occupied by humans. Such materials are widely utilized in school buildings and office buildings.
Sound Absorption In school buildings and ofEice structures as well as in many other commercial buil~ings and homes, many different materials are utilized for the purpose of sound absorption.
For the most part, these materials take the form of flammable materials unless otherwise treated to provide a fireproof or fire retarding capability. In many cases, friable asbestos containing materials have been utili~ed for the purpose of sound absorption. These materials therefore are subject to the concern from the standpoint of asbestos contamination discussed above. It is desirable therefore to provide materials having the capability of efficient sound absorption and which also are capable of providing efficient fireproofing and asbestos encapsulation to thereby render most sound absorption materials both fireproof and environmentally safe from the standpoint of health.
SUMMARY OF THE I~VE~TION
Briefly stated, the present invention is a liquid fireproofing adhesive composition comprising an aqueous suspension or emulsion contalning a major amount of an alkali metal silicate ana minor amounts of a water repellent agent and a surfactant. Preferably the composition also contains a minor amount of a liquid stabilizer plasticizer compound and further preferably contains a minor amount of a malodor control agent. The alkali metal referred to herein may be Na, K, I,i, Rb, or Sc; however, Na and K are preferred. The present emulsions are substantially stable and do not tend to separate or phase.
It is therefore a primary feature of the present invention to provide a fireproof adhesive material having the capability of utili~ation with other fibrous or particulate materials to form a spray on insulation having efficient fireproofing capability.
1211~8~;8 It is another feature of this invention to provide a novel fireproof adhesive material having sufficient flexibility for adhesion to the interior walls of most metal and nonmetal buildings to ~herefore provide efficient heat insulation charac-teristics as well as efficient fireproofing capability.
It is an even further feature of the present invention to provide a novel fireproof adhesive material which has the capability of fiber encapsulation and which is capable of eficiently penetrating fibrous materials and developing fiber encapsulation thus rendering the fibers thereof safe from the standpoint of potentially carcinogenic character.
Among the several ~eatures of this invention is contemplated the provision of a novel fireproof aahesive material which may be incorporated with other pulverant materials and sprayed onto building surfaces to provide efficient sound absorption as well as accomplish fireproofing of the building surfaces.
It is also a feature of this invention to provide a novel fireproof adhesive material which will retard any flame spread when cooperatively assembled with other pulverant materials in the form of a spray on coating.
It is also a feature of this invention to provide a novel fireproof adhesive material incorporating basically incompatible constituents which are assembled in such a manner as to yield a substantially inseparable liquid fireproof adhseive that may be simply and efficiently applied to provide for the fireproofing of the surfaces of buildings and other structures.
It is also an important feature of this invention to provide a novel method of manufacturing a fireproof adhesive material wherein basically incompatible constituents of the adhesive material are assembled in particular quantity in a particular order to thereby accomplish efficient development of a colloidal suspension that will remain substantially inseparable for extended periods of time.
~2~ 8 It is also a feature of this invention to provide a novel fireproof adhesive ma-terial which may be efficiently assembled, is low in cost and reliable in use.
Thus, broadly, the invention contemplates a fireproof adhesive mixture in liquid form, which comprises a prede-termined quantity oE liq~lid sodium silicate, a quant:ity of surfactant/water solu-tion sufficien-t to render the cured fireproof adhesive flexible and to provide for emulsifica-tion in the liquid state thereof, and a sufficient quantity of silicone water repellent to render the cured adhesive durable, chemical resistant and water repellent.
The adhesive mixture is in the form of a substantially inseparable liquid suspension in the uncured state and is cured upon exposure to the atmosphere to a solid flexible mass.
In a further embodiment, the invention contemplates a fireproof adhesive mixture in l.iquid form which comprises a quantity of liquid sodium silicate in the range of from about 90% to about 97% of the mixture by volume, a quantity of surfactant/
water solution in the range of from about 0.01% to about 0.1%
of the mixture by volume to r~nder the cured fireproof a~hesive flexible and to provide for emulsification in the liquid state thereof, a quantity of silicone water repellent in the range of from about 0.02% to about 0.2% of the mixture by volume to render the cured adhesive durable, chemical resistant and water repellent, and a quantity of a liquid stabilizer plasticizer compound in the range of from about 1.0% ~o about 5.0% of the mixture by volume to enhance the flexibility of the cured adhesive.
The adhesive mixture is in the form of a subs~antially inseparable - liquid suspension in the uncured state and is cured upon exposure to the atmosphere to a solid flexible mass.
A further embodiment of the invention provides a liquid fireproof adhesive material capable of hardening upon exposure : to air at ambient temperature to form a solid, resilient mass having good adhesion to metal and nonmetal surfaces, comprising the following constituents by volume to form a batch volume of adhesive liquid of about 401 gallons, comprising:
(a) 370.0 gallons sodium silicate;
~b) 10.0 gallons ethylene glycol;
-8a-(c) 1.0 pounds Ultra-Wet* D.S. (flake) Surfac-tant;
(d) 5.0 gallons water; and (e) 15.0 gallons silicone water repellent.
The inventive concept also includes a process for the manufacture of fireproof adhesive mixture of liquid form which comprises loading a mixing system having a mixing vessel and a motorized liquid agitating mechanism with liquid sodium silicate in the range of from about 90% to about 97% of the mixture by volume, initiating agitation of the liquid sodium silicate with the motorized liquid agitating mechanism, and slowly introducing a liquid stabili~er plasticizer into the mixing vessel while continuously agitating the liquid mixture. The liquid stabilizer plasticizer is in the range of from about 1.0% to 5.0% of the mixture by volume. A surfactant is mixed with water to provide a surfactant/water solution in the range of from about 0.01% to about 0.1% of the mixture by volume. The surfactant/water solution is slowly introduced into the mixing vessel while continuously agitating the mixture. Silicone water repellent is slowly intro-duced into the mixing vessel in the range of from about 0.02%
to about 0.2% of the mixture by volume. The mixture is continu-ously mixed in the mixing vessel for a sufficient period of time to develop a substantially inseparable liquid mixture.
The inventive process produces the following inventive material: a liquid fireproofing adhesive composition which comprises an aqueous emulsion containing an alkali metal silicate in the range of from about 90% to about 97% of the aqueous emul-sion by volume, a silicone water repellent in the range of from about 0.02% to about 0.2% of the aqueous emulsion by volume and a surfactant in the range of from about 0.01% to about 0.1% of the aqueous emulsion by volume.
Briefly, the fireproof adhesive material of this invention incorporates a predetermined quantity of liquid alkali metal silicate, preferably sodium silicate within which iS mlxed a quantity of surfactant/water solution sufficiently to render the cured fireproof adhesive material flexible and *trade mark -8b-to provide for emulsification in the liquid state thereof.
The adhesive mixture also preferably includes a sufficient quantity of silicone water repellent to render the cured adhesive material durable, chemically resistant and water repellent. Further, the adhesive mixture, when applied, is in the form of a substantially inseparable li~uid suspension in the uncured state and, becomes cured to a hardened or solid form upon exposure to atmosphere thereby transforming from the liquid state to a solid flexible mass having efficient adhesion to most metal and nonmetal surfaces. The fireproof adhesive material may also incorporate a sufficient quantity of a liquid stabilizer plasticizer compound to enhance the flexibility of the cured adhesive.
The particular constituents of the fireproof adhesive material are mixed in accordance with a process wXerein basically incompatible constituents are forced in assembly to thereby yield a substantially inseparable suspension which will remain in liquid form for substantial periods of time and, which upon being exposed to the atmosphere, will become cured within a relatively short period of time to form a resilient mass having efficient adhesion to most surfaces. The constituents are mixed in a powered mechanical mixer wherein the range of mixing speed is sufficiently high to prevent crystallization of the materials during assembly and is sufficiently low to prevent heat induced crystallization that would otherwise result in the destruction of the material for the purposes of an adhesive.
The blades of the mixer turn sufficiently s]ow that the mixture is assembled by means of cutting or shearing activity . ~
g rather than beating. The adhesive material ~ay also incorporate a malodor control agent to ensure against the presence of undesirable odor~.
DETAI~BD DESCRIPTION OF PREFERRED EMBODIMENT
Although the present invention is not limited to ths manufacture of the adhesive material hereof by means of a "batch" process' where a particular quantity of fireproof adhesive material is manufactured, for purposes of simplicity, t-he present invention is discussed herein particularly as it relates to a batch manufacturing process. ~urther, the size of the particular batch set forth in the examples following is representative only of the particular dimension of a pilot manufacturing plant having the capability of manufacturing small batches of fireproofing adhesive material for test purposes. The respective percentages of the various constituents incorporated in the adhesive material will not vary significantly therefore even though a much larger batch process may be involved or a continuous manufacturing process may be involved. The various constituents of the fireproof adhesive material are discussed by volume rather than by percentage as they relate to the particular batch volume being processed by the pilot plant.
~ s mentioned abo~e, the various constituents of the fireproof adhesive material are basically incompatible. If assembled without any form of agitation or if agitated improperly, these materials will assume various composite forms including a complete or partial crystalline form or a form where certain constituents either float on top of other liquid constituents or settle to the bottom thereby resulting in stratification due to improper mixing. In order to mix these constituents to form an inseparable liquid or a colloidal suspension, the materials must be mixed in accordance with a process to be discussed hereinbelow.
After a number of preliminary tests were conducted it was determined that the character of agitation is ~L2(~858 critically important to proper manufacture of fireproof adhesive material. For this reason, a mixing machine was selected having a mixing vessel of suf~icient dimension to contain approximately S~0 gallons of liquid material. A
mixing machine was provided incorporating an electric motor, belt driven liquid mixing mechanism having a rotary impeller type high shear blade assembly. It was determined through experimentation,that a liquid cutting or shearing blade yields proper mixing capability as compared to a conventional mixîng blade. The incompatible materials of the ~ireproof adhesive material are more properly mixed b~ a cutting or shearing activity rather than being beaten by the mechanical activity of a more conventional mixing blade. It was determined that a cutting type mixer blade would accomplish efficient suspension of the particles of the liquid materials without generating sufficient frictional heat on the materials to result in premature crystallization. It was also determined that mixing speeds must be conducted within a speed range of from about 500 to 3000 RPM, preferably about 800 RPM
to about 2500 RPM. It was further determined that a range of from about 1~00 to 1900 RPM is an optimum speed range for efficient cutting activity that yields desirable mixing of the various constituents involved in the fireproof adhesive material.
The principal constituent of the fireproof adhesive material is an alXali metal silicate, preferably sodium silicate or water glass which is incorporated in the mixture in a volumetric range in the batch sample produced of from about 300 ~allons to about ~50 gallons.
The alkali metal silicates, Xnown as the soluble silicates, are generally produced by fusing a high purity source of the appropriate alkali metal, e.g., soda ash and silica sand at high temperatures, e.g., 1300 - 1500~ C.
Products in which the silica-to-alkali weight ratio is around
AND FIBER ENCAPSULATION
FIELD OF THE INVENTION
~ his invention relates generally to fireproof adhesive materials and more specifically concerns a fireproof adhesive material having efficient fiber penetration and encapsulation as well as rendering the fiber fireproof. More specifically, this invention concerns a fireproof adhesive material which is efficiently combined with fibrous and 10~ pulverant materials to form a spray on type insulation having efficient thermal insulating quality as well as being of ~fireproof nature.
BACKGROU~D OF THE INVENTION
` Due to the extensive loss of life and property typically caused by ~ires, a large number of materials have been developed as fireproof coatings which have been somewhat successful in retarding the spread of f~lame. Virtually all of the known fireproof insulation materials are combustible to some degree or have a relatively limited heat retarding `~ 20 therm~al~capability.~ Moreover, many of the materials developed liberate hazardo~s toxic fumes when subjected to fire and are thus disadvantageous from the standpoint of pulmonary hazard2 It has also been aonsidered desirable to provide a thermal insulation material which may also function as a fireproof adhesive and which is applicable as an integral constituent of interior coatings for metal buildings and other relatively smooth flexible surfaces. In many cases, it is virtually impossihle to provide a material having efficient $~
, .
~20~58 flexibility and adhesive character for attachment to the smooth surfaces of a sheet metal building and which are also of fireproof nature. Generally, fireproof materials are of rigid character due to their typical silaceous content, thereby rendering them relatively unsuitable as a flreproof adhesive for use on flexible objects and surfaces.
Another area of significant concern is the recent diæcovery that asbestos fibers and fibrils have a carcinogenic charaeter and are perhaps responsible for a large number of human deaths due to lung cancer resulting from an occupation wheré prolonged contact with asbestos materials occurred. It is well known that many private and public buildings contain wall and ceiling structures which include asbestos materials.
It has been determined that these materials continuously liberate asbestos fibers and ~ibrils which could represent a hazard to persons occupying the premises especially for prolonged periods of time. It is desirable therefore to provide a material or a combination of materials that may be utilized to accomplish efficient fireproofing, thermal insulation and protection against asbestos contamination~
Heretofore, it has been belie~ed impractical to provide a single material having efficient protective capabilities in all three of these areas. The present invention therefore relates to a material having efficient qualities in each of these three areas of public concern.
Fireproofing As mentioned above, various materials have been utilized to provide substantially fireproof coatings on wall and ceiling structures of buildings and on metal structural support members in an attempt to provide a fire retarding capability that, in e~fect, retards the spread of flame.
These materials are intended to limit the development of heat to such extent that fire spreading and development will be retarded to thus provide firemen with ample time to reach the scene and extinguish the fire before substantial damage has been done. In most cases, a material having fire retarding ~2~)~85~3 capability is required to successfully pass tests to determine the capability of the material to retard the development and spreading of fire. One such test is the ~merican Society for Testing and Materials El19-~O Standard Methods of Fire Test of Building Constructions and Materials. This test is intended to provide data to enable regulatory agencies to determine the suitability of assemblies for use in locations where fire resistance of a specified duration is re~uired. This standard is not utilized to measure and descri~e the properties of materials or assemblies in response to heat and flame under controlled laboratory conditions. It is also not used to describe or appraise the fire haxard of materials or assemblies under actual conditions. The results of this test are t~pically used as elements of fire risk assessment which takes into account all of the factors which are pertinent to an assessment of the fire hazard of a particular end use.
Exposure may not be representative of all fire conditions, which may vary with changes in the amount, nature and distribution of fire loading, ventilation, compartment size and configuration, and heat sink characteristics of the compartment. It does, however, provide a relative measure of fire performance of assemblies under the specified fire exposure conditions. Any variations from the conditions that are tested may substantially alter the performance characteristics of the assembly. In this test, a fire, typically developed by natural gas, is directed on an insulated surface and thermocouples opposite the insulated surface are utilized to measure temperature increase as the fire is continued. A material is said to fail this test if the thermocouples show a temperature rise to 250F within a predetermined minimum period of time. Various other tests are also conducted to determine the heat insulation and ~ire retarding capability of materials. For the most part, it is extremely difficult for any known fireproofing coating material to achieve a fire rating approaching one hour.
~20~1~51~1 Heat Insulation Another area of concern is the capability oE a fireproofing material to also function for the purpose of heat insulation and to remain in place even on flexible surfaces such as the interior walls of a sheet metal buildiny. It is well known that the metal of sheet metal buildings tends to radiate heat when heated during ambient conclitions such as hot summer days, etc. It has been found practical to provide the interior surfaces of metal buildings with coatings of thermal insulation material to retard heat radiation. Most thermal materials capable of adhering to the flexible interior metal wall structures of sheet metal buildings are capable of providing only minimal protection from the standpoint of fireproofing. In some cases, thermal insulation material is composed of urethane foam, a highly flammable material which yields toxic gases when aflame. It is desirable therefore to provide a fireproof coating material which also functions as a ; heat insulating material and which has the capability of ef~icient adherence to flexible wall structures as well as the capability of adhering to various metal and non-metal structures such as typically are utiliged in the cons~ruction industry for commercial and residential structures.
Asbestos Encapsulation Asbestos has long been utilized as a construction material because o its heat and fire retarding characteristics. It has also been utilized as an efficient structure for sound absorption and for formation of ceiling surfaces of building structures because of its fairly lightweight character. It has been recently discoveredl however, that asbestos fibers are carcinogeni~ and when deposited in the lungs of animals and humans, are difficult to expel. Moreover, asbestos has been determined to constitute a health hazard when utiliged in building structures in such a manner that asbestos fîbers and fibrils are liberated which can become entrained in the air and breathed by persons occupying the premises. Vntil recently, exposure to asbestos 8~8 was generally considered an occupational health hazard for asbestos workers. However, now it has been learned that an equally serious exposure problem exists that can occur in all types of buildings in which certian asbestos containing materials have been used for fireproofing, insulation and decoration. Asbestos ~ihers can be released from these materials and contaminate the building environment.
Individuals who are then exposed to the asbestos could develop lung cancer or cancers of other parts of the body due to the carcinogenic character of the fibers. Unfortunately, detection of asbestos related diseases is difficult since the latency period between exposure and appearance of the disease is sometimes as great as from twenty to forty years.
During the year 1982 a requirement was published in the Federal Register calling attention to a recently adopted Environmental Protection Agency regulation which required that public and private school facilities be visually inspected for friable materialsO According to this regulation, if friable material is located, it must be analyzed for asbestos content and the results of the analysis must be posted in district administration offices and in faculty and custodial workrooms and lounges in the affected buildings. Schools in which friable asbestos containing material exists must post warnings about the health hazards of asbestos and instructions about methods to be used by school employees to avoid or reduce exposure to asbestos. For purposes of this regulation, friabla material is defined as any material applied onto ceilings, walls, structural members, piping, duct work and any other part of the building structure which, when dry, may be crumbled, pulverized or reduced to powder by hand pressure.
Where large quantities of asbestos fibers are present in friable materials, it is vixtually assured that a requiremen~
will be made to reduce or eliminate such materials by construction operations. It is desirable therefore to provide means for simply and efficiently rendering building structures safe when asbestos containing friable materials are determined to be present in building structures which are continuously ~2~
occupied by humans. Such materials are widely utilized in school buildings and office buildings.
Sound Absorption In school buildings and ofEice structures as well as in many other commercial buil~ings and homes, many different materials are utilized for the purpose of sound absorption.
For the most part, these materials take the form of flammable materials unless otherwise treated to provide a fireproof or fire retarding capability. In many cases, friable asbestos containing materials have been utili~ed for the purpose of sound absorption. These materials therefore are subject to the concern from the standpoint of asbestos contamination discussed above. It is desirable therefore to provide materials having the capability of efficient sound absorption and which also are capable of providing efficient fireproofing and asbestos encapsulation to thereby render most sound absorption materials both fireproof and environmentally safe from the standpoint of health.
SUMMARY OF THE I~VE~TION
Briefly stated, the present invention is a liquid fireproofing adhesive composition comprising an aqueous suspension or emulsion contalning a major amount of an alkali metal silicate ana minor amounts of a water repellent agent and a surfactant. Preferably the composition also contains a minor amount of a liquid stabilizer plasticizer compound and further preferably contains a minor amount of a malodor control agent. The alkali metal referred to herein may be Na, K, I,i, Rb, or Sc; however, Na and K are preferred. The present emulsions are substantially stable and do not tend to separate or phase.
It is therefore a primary feature of the present invention to provide a fireproof adhesive material having the capability of utili~ation with other fibrous or particulate materials to form a spray on insulation having efficient fireproofing capability.
1211~8~;8 It is another feature of this invention to provide a novel fireproof adhesive material having sufficient flexibility for adhesion to the interior walls of most metal and nonmetal buildings to ~herefore provide efficient heat insulation charac-teristics as well as efficient fireproofing capability.
It is an even further feature of the present invention to provide a novel fireproof adhesive material which has the capability of fiber encapsulation and which is capable of eficiently penetrating fibrous materials and developing fiber encapsulation thus rendering the fibers thereof safe from the standpoint of potentially carcinogenic character.
Among the several ~eatures of this invention is contemplated the provision of a novel fireproof aahesive material which may be incorporated with other pulverant materials and sprayed onto building surfaces to provide efficient sound absorption as well as accomplish fireproofing of the building surfaces.
It is also a feature of this invention to provide a novel fireproof adhesive material which will retard any flame spread when cooperatively assembled with other pulverant materials in the form of a spray on coating.
It is also a feature of this invention to provide a novel fireproof adhesive material incorporating basically incompatible constituents which are assembled in such a manner as to yield a substantially inseparable liquid fireproof adhseive that may be simply and efficiently applied to provide for the fireproofing of the surfaces of buildings and other structures.
It is also an important feature of this invention to provide a novel method of manufacturing a fireproof adhesive material wherein basically incompatible constituents of the adhesive material are assembled in particular quantity in a particular order to thereby accomplish efficient development of a colloidal suspension that will remain substantially inseparable for extended periods of time.
~2~ 8 It is also a feature of this invention to provide a novel fireproof adhesive ma-terial which may be efficiently assembled, is low in cost and reliable in use.
Thus, broadly, the invention contemplates a fireproof adhesive mixture in liquid form, which comprises a prede-termined quantity oE liq~lid sodium silicate, a quant:ity of surfactant/water solu-tion sufficien-t to render the cured fireproof adhesive flexible and to provide for emulsifica-tion in the liquid state thereof, and a sufficient quantity of silicone water repellent to render the cured adhesive durable, chemical resistant and water repellent.
The adhesive mixture is in the form of a substantially inseparable liquid suspension in the uncured state and is cured upon exposure to the atmosphere to a solid flexible mass.
In a further embodiment, the invention contemplates a fireproof adhesive mixture in l.iquid form which comprises a quantity of liquid sodium silicate in the range of from about 90% to about 97% of the mixture by volume, a quantity of surfactant/
water solution in the range of from about 0.01% to about 0.1%
of the mixture by volume to r~nder the cured fireproof a~hesive flexible and to provide for emulsification in the liquid state thereof, a quantity of silicone water repellent in the range of from about 0.02% to about 0.2% of the mixture by volume to render the cured adhesive durable, chemical resistant and water repellent, and a quantity of a liquid stabilizer plasticizer compound in the range of from about 1.0% ~o about 5.0% of the mixture by volume to enhance the flexibility of the cured adhesive.
The adhesive mixture is in the form of a subs~antially inseparable - liquid suspension in the uncured state and is cured upon exposure to the atmosphere to a solid flexible mass.
A further embodiment of the invention provides a liquid fireproof adhesive material capable of hardening upon exposure : to air at ambient temperature to form a solid, resilient mass having good adhesion to metal and nonmetal surfaces, comprising the following constituents by volume to form a batch volume of adhesive liquid of about 401 gallons, comprising:
(a) 370.0 gallons sodium silicate;
~b) 10.0 gallons ethylene glycol;
-8a-(c) 1.0 pounds Ultra-Wet* D.S. (flake) Surfac-tant;
(d) 5.0 gallons water; and (e) 15.0 gallons silicone water repellent.
The inventive concept also includes a process for the manufacture of fireproof adhesive mixture of liquid form which comprises loading a mixing system having a mixing vessel and a motorized liquid agitating mechanism with liquid sodium silicate in the range of from about 90% to about 97% of the mixture by volume, initiating agitation of the liquid sodium silicate with the motorized liquid agitating mechanism, and slowly introducing a liquid stabili~er plasticizer into the mixing vessel while continuously agitating the liquid mixture. The liquid stabilizer plasticizer is in the range of from about 1.0% to 5.0% of the mixture by volume. A surfactant is mixed with water to provide a surfactant/water solution in the range of from about 0.01% to about 0.1% of the mixture by volume. The surfactant/water solution is slowly introduced into the mixing vessel while continuously agitating the mixture. Silicone water repellent is slowly intro-duced into the mixing vessel in the range of from about 0.02%
to about 0.2% of the mixture by volume. The mixture is continu-ously mixed in the mixing vessel for a sufficient period of time to develop a substantially inseparable liquid mixture.
The inventive process produces the following inventive material: a liquid fireproofing adhesive composition which comprises an aqueous emulsion containing an alkali metal silicate in the range of from about 90% to about 97% of the aqueous emul-sion by volume, a silicone water repellent in the range of from about 0.02% to about 0.2% of the aqueous emulsion by volume and a surfactant in the range of from about 0.01% to about 0.1% of the aqueous emulsion by volume.
Briefly, the fireproof adhesive material of this invention incorporates a predetermined quantity of liquid alkali metal silicate, preferably sodium silicate within which iS mlxed a quantity of surfactant/water solution sufficiently to render the cured fireproof adhesive material flexible and *trade mark -8b-to provide for emulsification in the liquid state thereof.
The adhesive mixture also preferably includes a sufficient quantity of silicone water repellent to render the cured adhesive material durable, chemically resistant and water repellent. Further, the adhesive mixture, when applied, is in the form of a substantially inseparable li~uid suspension in the uncured state and, becomes cured to a hardened or solid form upon exposure to atmosphere thereby transforming from the liquid state to a solid flexible mass having efficient adhesion to most metal and nonmetal surfaces. The fireproof adhesive material may also incorporate a sufficient quantity of a liquid stabilizer plasticizer compound to enhance the flexibility of the cured adhesive.
The particular constituents of the fireproof adhesive material are mixed in accordance with a process wXerein basically incompatible constituents are forced in assembly to thereby yield a substantially inseparable suspension which will remain in liquid form for substantial periods of time and, which upon being exposed to the atmosphere, will become cured within a relatively short period of time to form a resilient mass having efficient adhesion to most surfaces. The constituents are mixed in a powered mechanical mixer wherein the range of mixing speed is sufficiently high to prevent crystallization of the materials during assembly and is sufficiently low to prevent heat induced crystallization that would otherwise result in the destruction of the material for the purposes of an adhesive.
The blades of the mixer turn sufficiently s]ow that the mixture is assembled by means of cutting or shearing activity . ~
g rather than beating. The adhesive material ~ay also incorporate a malodor control agent to ensure against the presence of undesirable odor~.
DETAI~BD DESCRIPTION OF PREFERRED EMBODIMENT
Although the present invention is not limited to ths manufacture of the adhesive material hereof by means of a "batch" process' where a particular quantity of fireproof adhesive material is manufactured, for purposes of simplicity, t-he present invention is discussed herein particularly as it relates to a batch manufacturing process. ~urther, the size of the particular batch set forth in the examples following is representative only of the particular dimension of a pilot manufacturing plant having the capability of manufacturing small batches of fireproofing adhesive material for test purposes. The respective percentages of the various constituents incorporated in the adhesive material will not vary significantly therefore even though a much larger batch process may be involved or a continuous manufacturing process may be involved. The various constituents of the fireproof adhesive material are discussed by volume rather than by percentage as they relate to the particular batch volume being processed by the pilot plant.
~ s mentioned abo~e, the various constituents of the fireproof adhesive material are basically incompatible. If assembled without any form of agitation or if agitated improperly, these materials will assume various composite forms including a complete or partial crystalline form or a form where certain constituents either float on top of other liquid constituents or settle to the bottom thereby resulting in stratification due to improper mixing. In order to mix these constituents to form an inseparable liquid or a colloidal suspension, the materials must be mixed in accordance with a process to be discussed hereinbelow.
After a number of preliminary tests were conducted it was determined that the character of agitation is ~L2(~858 critically important to proper manufacture of fireproof adhesive material. For this reason, a mixing machine was selected having a mixing vessel of suf~icient dimension to contain approximately S~0 gallons of liquid material. A
mixing machine was provided incorporating an electric motor, belt driven liquid mixing mechanism having a rotary impeller type high shear blade assembly. It was determined through experimentation,that a liquid cutting or shearing blade yields proper mixing capability as compared to a conventional mixîng blade. The incompatible materials of the ~ireproof adhesive material are more properly mixed b~ a cutting or shearing activity rather than being beaten by the mechanical activity of a more conventional mixing blade. It was determined that a cutting type mixer blade would accomplish efficient suspension of the particles of the liquid materials without generating sufficient frictional heat on the materials to result in premature crystallization. It was also determined that mixing speeds must be conducted within a speed range of from about 500 to 3000 RPM, preferably about 800 RPM
to about 2500 RPM. It was further determined that a range of from about 1~00 to 1900 RPM is an optimum speed range for efficient cutting activity that yields desirable mixing of the various constituents involved in the fireproof adhesive material.
The principal constituent of the fireproof adhesive material is an alXali metal silicate, preferably sodium silicate or water glass which is incorporated in the mixture in a volumetric range in the batch sample produced of from about 300 ~allons to about ~50 gallons.
The alkali metal silicates, Xnown as the soluble silicates, are generally produced by fusing a high purity source of the appropriate alkali metal, e.g., soda ash and silica sand at high temperatures, e.g., 1300 - 1500~ C.
Products in which the silica-to-alkali weight ratio is around
2:1 are water soluble, whereas those in which the ratio is above 2.5:1 must be dissolved by steam under pressure.
Sodium silicate is by ar the most common alkali metal ~.i, ~, silicate and is preferred, since it is readily obtainable and relatively inexpensive. ~le term alXall metal silicate is a generic term given to a farnily of chemicals composed of alkali metal oxide (AlkO2) and silica (SiO2) anc1 usually, but not always, water. A broad range of alkali metal o~ide to silica oxide may ~e used in the present composition, preferably from 1:1 to 1:6; however, alkali metal oxide to silica ratios of 1:2.5 to 1:4 are preferred. Silicates in which the alkali metal are less than about 1:2.5 are sticky and tacXy, changing slowly from liquid to solid with loss of water; whereas, those with a weight ratio above 4:1 are handleable materials in relative low solids content solutions. The alkali metal silicates are normally employed in water solutions with the solids content as concentrated as can be conveniently handled.
Generally, the alkali metal silicates will be employed in solution viscosities up to 400 centipose at 20C, preferably about 150 to 350 centipose at 20C. Thus, one of ordinary skill in the art can select the alkali metal silicate solution having the desired ratio of alkali to silica, solids content and viscosity for processing and end product properties ~e.g., hardening rate, solids content and the like) within these ranges with a minimum of experimentation.
An optimum volume of sodium silicate for a particular batch volume of about 401 gallons of the adhesive material was found to be in the order of 370 gallons.
Further, the temperature range for the sodium silicate in preparation of the adhesive material was determined to be in the range of from about 50F to about 150F. An optimum temperature was determined to be in the order of 100F. At a temperature of 50F the sodium silicate liquid is of fairly viscous nature and is relatively reluctant to accept the other incompatible constituents of the adhesive mixture. At temperatures above 150F the sodium silicate has a significant tendency for crystallization and either will not efficiently accept the other incompatible constituents in swch manner as to form a colloidal suspension or will become crystallized to such extent that development of a liquid colloidal suspension ~z~s~
becomes relatively impossible.
The liquid stabilizer plasticizer compoun~ is, preferably a liquid diol, which is liquid at 0C, has 2 to 4 carbon atoms and is soluble in water. Suitable diols include ethylene glycol (1,2-ethanediol), 1,2-propanediol, 1.3-propanediol, 1,2-butanediol, and 2,3-butanediol.
The surfactant is preferably an anionic, nonionic or amphoteric surfactant as those are generally known in the art.
~ nionic surface~acti~e emulsifying agents, such as alXali soaps having the general formula, RCOOM, wherein RCOO
~epresents a fatty acid containing from 3 to 25 carbon atoms (represented by R) and M is an alkali metal, such as sodium, potassium, lithium, and the like, can be used. For example, mixed fatty acids derived from tallow, cocoanut oil, palm oil, etc., are especially useful. Examples of suitable alkali soaps include the sodium and postassium salts of oleic acid, palmitic acid, stearic acid, linoleic acid, and the like.
Other anionic surfactants include an acid derived from other sources such as resin, for example, the sodium salts of abietic acid or isomers thereof.
Other anionic type surface-active agents which can be used include the aliphatic and alkyl aromatic sulfonates having the general formula:
R
~ S03M
R
wherein R is an aliphatic radical, aromatic radical (including alkaryl~, or hydrogen atom and M is an alkali metal. Examples of suitable sulfonat~ type surfactants include the petroleum sulfonates, such as isopropylnaphthalene sulfonate, sodium heptybiphenyl sulfonate, sodium salts of polymerized alkyl aryl sulfonic acids, and the like.
Typical of surface active agents containing sulfate or sulfonate groups are the salts of sulfated fatty alcohols, containing 8-18 carbon atoms, alkylbenzene-sulfonic acid containing 8-18 carbon atoms in the alkyl chains, or sulfated condensates of phenol, Cg_lg alkylphenol, or Cg_la fatty alcohols with ethylene oxide. The cations of the salts are usually æodium, potassium, or ammonium ions.
The nonionic sur~actants are compositions such as ethylene oxide or propylene oxide condensation products of compounds containing reactive hydrogen atoms. Suitable nonionic surfactants include compounds such as ethers having the general formula R-(OCH2CH2)n-OH wherein R is an aromatic radical or an a~iphatic radical containing up to 20 carbon atoms and n is an integer between 1 and 8.
An example of amphoteric surfactants is C-cetyl petaîne.
A more complete list of useful anionic, nonionic and amphoteric suractants can be found in the 1964 publication, "Detergents and Emulsifiers", John W. McCutcheon, Inc., Morristown, New Jersey, and in Schwartz and Perry, "Surface Active Agents", New York Interscience, Inc., 1949.
Suitable silicone water repellents include the alkali metal salts of hydrocarbon substituted silantriol (sometimes called silonlates)l of the general formula:
t [ R Sli - O ] Alkali Metal OH
Alkali metal wherein Ris a hydrocarbyl radical having 1 to 16 carbon atoms of alkyl, aryl, arakyl, alkaryl, including non reactive substituents such as chlorine, bromine fluorine or iodine. the hydrocarbyl radicals include, for example, methyl, ethyl, docyl, phenyl, naphthyl, biphenyl, benzyl, xylyl and the like. Formula I is believed to be the hydrous form which can be dried to [R SiO2] alkali metal.
Since the final composition of the present invention is an aqueous solution, the various components may all be admixed as aqueous solutions.
The water serves both as the carrier for the components and the continuous phase for the emulsion which results from the present combination of components, and will generally comprise from about 40 to 70 wt. ~ of the inal (total) composition, more preferably about 55 to 65 wt. % of ,. ~
the composition. Exclusive of water the components of the fireprooing composition are preferably present by weight in the following amounts:
Wt. %
Alkali metal silicate 80 to 98~
more preferably gO to 95%
Surfactant .01 to .5%
more preferably .03 to 1~
Silicon water repellent 1 to 6%
more preferably 2 to 3%
Diol 1 to 10%
more preferably 3 to 7%
Malodor Control Agent .05 to 1~
more preferably .13 to .4%
With the mixing vessel of the mixing apparatus containing approximately 370 gallons of sodium silicate a sufficient quantity of a liquid stabilizer plasticizer compound is introduced while continuously agitating the sodium silicate with the mixing machine cutting blade operating at an RPM range of from 1800 to 1900 RPM. In one suitable form of the invention the liquid stabilizer plasticizer compound takes the form of ethylene glycol which is mixed at a range of from about 5 gallons to about 20 gallons to the sodium silicate contained in the mixing vessel. Preferably an optimum quantity of ethylene glycol is about 10 gallons which is quite slowly introduced to the sodium silicate liquid during continuous agitation. For example, the ethylene glycol is introduced at a rate not substantially exceeding 5 gallons per minute. Introduction of the~ethylene glycoI, if too fast will shock the sodium silicate liquid thereby resulting in immediate crystallization. It is necessary therefore to introduce the ethylene glycol to the agitatiny sodium silicate with such slowness that the sodium silicate remains liquid during total introduction of the ethylene glycol. The ethylene glycol provides the fireproof adhesive material with an antifreeze quality rendering it compatible for shippin~, ~L2V1858 handling and storage in relatively low temperature environments such as might occur during winter. Further, the ethylene glycol provides liquid stabilization and also functions as a plasticizer compound to enhance the flexibility of the cured adhesive after it h~s been applied.
A quantity of surfactant material is then dissolved in water and this water/surfactant mixture is introduced into the agitating mixture within the mixer vessel. In order to prevent shocking of the sodium silicate which would result in immediate crystallization, the water/surfactant mixture is introduced at approximately the same or slower speed of introduction as described above in connection with the ethylene glycol.
After the ethylene glycol has been completely introduced and dispersed within the mixture in the mixing vessel a quantity of liquid silicone water repellent is introduced into the mixing vessel, its introduction also being slow as described above in connection with the ethylene glycol and surfactant/water constituents of the mixtureO Again, the viscosity of the mixture within the mixing vessel will determine the rate of silicone water repellent introduction.
If the material is of fairly viscous nature the silicone water repellent must be introduced quite slowly. If the mixture is of normal viscosity whih occurs at a temperature of about 100F, the silicone water repellent may be introduced more rapidly without shocking the mixture and causing immediate crystallization. ~o a batch of the volume set forth above, the volume of liquid silicone repellent will be in the order of from 10 gallons to 20 gallons, the optimum volume thereof being in the order of 15 gallons. After slow introduction of the silicone water repellent material is completed, agitation is continued for a sufficient period of time for the cutting blade of the mixing mechanism to establish a colloidal or inseparable mixture. After this has occurred, the mixing apparatus may be deenergized and the adhesive mixture within the mixing vessel may be transferred to drums, tanks or other storage vessels for storage and handling. When properly mixed ~;20:~851 3 the adhesive material will not become stratified due to settling and floating but rather will remain a homogeneous liquid con-sistency capable oE being picked up by the pumps for handling or the venturies oE adhesive spra~ing apparatus for spray application to surfaces.
The silicone water repellent liquid may -take the form of sodium methyl silanolate solution which provides the adhesive mixture with excellent thermal and oxidative stability, water repellency, durability, chemical and corrosive resistance and good durability.
A waterproof fire resistant adhesive mixture manufactured in accordance with the above will typically be of malodorous character. To eliminate or minimize this malodorous character and to further enhance the flexibility of the resulting cured fireproof adhesive material a quantity of a suitable deodorant material may be introduced during the mixing phase. An example of a suitable malodor control agent which also provides additional flexibility control is a water activated malodor control concentrate which is manufactured and sold under the trademark OXFORD AIR-O-SYN
by Oxford Chemicals of Atlanta, Georgia. The malodor control agent comprises a mixture of surfactant, water/ alcohol and aromatic oils. The surfactant of the malodor control agent may be of the anionic, nonanionic or amphoteric form described above.
The malodor control agent is not necessary to the functional character of the fireproof adhesive material and may be eliminated if desirable. It is provided simply to provide the adhesive mixture with a pleasing odor. To a batch of adhesive material such as set forth above water activated malodor control con-centrate in the order of from 2 quarts to 5 quarts is typically introduced into the mixture, the optimum quantity being in the order of 3-1/2 quarts. This malodor control concentrate will effectively render the resulting fireproof adhesive ~aterial substantially free of any objectionable odors. In addition to providing malodor control, the OXFORD AIR-O-SYN malodor control concentrate also enhances the flexibility of the resulting, cured fireproof adhesive material. The bonding matrix due to : "~
; ,, the presence of the surfactant and water constituents has a penetrating capability when applied to such .~urfaces as wallboard, asbestos ceiling tiles and panels, etc. I-ts penetrating characteristic can be controlled by changing the wa-ter and surfactant content within the parameters set forth hereinbe.low, such control of the pe.netrati.ng characteristic being determined by the particular fibrous surfaces to be penetrated. As the bonding matrix penetrates into the fibrous material in its uncured state, it surrounds and encapsulates the individual fibers. In the case of asbestos encapsulation it is desired that the asbestos fibers be completely coated or encapsulated by th~ Donding matrix to provide the asbestos fibrils with a carcinogenic barrier in the form of a coating. Upon curing of the matrix to a substantially hardened character any fracturing of the asbestos ~ibers will not laden the surrounding air with unencapsulated asbestos fibrils. Any released asbestos fibrils will be encapsulated by the matrix coating and rendered harmless from the standpoint of carcinogenics. The bonding matrix is applied to the fibrous material and is allowed to become somewhat cured or hardened. The asbestos wall or ceiling structure or coating may then be removed by suitable mechanical means without releasing nonencapsulated asbestos fibrils into the atmosphere.
Following is a graphical representation of the low range, optimum and high range values for the various volumes of constituents, temperatures and mixing speeds which may be employed in the manufacture of fireproof adhesive material according to the present invention. Although specific materials are identified, it is not intended that the present '~
~20~8SI~
~18-invention be restricted to utilization of the specific materials and volumes set for~h. Other suitable materials may be substituted for those set forth within the spirit and scope of the present invention.
Adhesive Constituent Low Range Optimum High Range 1. Liquid Sodium Silicate 320.0 gal 370.0 gal 420.0 gal 2. Mi~ing Temp. 50 F 100 F 150 F
10 3. Ethylene Glycol (Regular) 5.0 gal 10.0 gal 15.0 gal 4. Surfactant-Ultra Wet D.S. (Flake~ 0.5 lb. 1.0 lb. 2.0 lb.
5. Water 2.0 gal 5.0 gal 8.0 gal 6. Malodor Control Agent 1.0 qt. 3.5 qt. 5.5 qt.
7. Silicone Water Repellent 10.0 gal 15~0 gal 20.0 gal 8. Mixing Speed 500 RPM 1800 - 3000 RPM
Since many of the particular constituents of the fireproof adhesive material may be variously obtained in various grades, more specific identification of the various constituents are as follows.
The sodium silicate most widely utilized is silicate of soda, grade 40, which is obtained rom the Diamond Shamrock Corporation, 351 Phelps Court, P. O. Box 2300, Irving, Texas 75061. Tha` silicate of soda is soluble in water and is a ''~', 120~5~
colorless, turbid liquid with an odor of none to slightly soapy. This sodium silicate has a specific gravity of 1.30-1.71 at 20C in comparison to water at a specific gravity of 1 at the same temperature. The liquid sodium silicate material has a boiling point of from 214F-216F. In the fireproof adhesive material, the sodium silicate functions as a fireproof bonding material and enhances the rapidity of setting after thé material has been applied. Additionally, it functions as a rust inhibitor, and provides resistance to vermin. I~ is also inorganic and nontoxic.
The sodium methyl silanolate solution may ~e of the type manufactured by Union Carbide Corporation, Silicones and Urethanes Intermediates, Old Ridgebury Road, Danbury, Connecticut 06817, under the identifyi.ng symbol R-20. The physical form of this material is solution in water having a clear appearance and a water white color. The apparent specific gravity of the material at 25/25C is 1.209. The active ingredients by weight is 30~. It has a viscosity at 25C of 10 centipoises. The sodium methyl silanolate solution has excellent thermal and oxidative stability, is water repellent and provides the cured adhesive material with excellent durability. It is also chemical resistant and noncorrosive and may be efficiently sprayed ~rom the standpoint o~ application.
The ethylene glycol constituent may be obtained from Dow Chemical Corporation, U.S.A., Midland, Michigan 48640.
This particular product may be identified at ethylene glycol (regular) and is a low density material in the form of a colorless, practically odorless liquid. The ethylene glycol has a boiling point of 387.1F and a vapor pressure of 0.12 MM~G at 25C. It is soluble in water, completely miscible and has a specific ~ravity of 1.1155 at 20/20C. The ethylene glycol functions to lower the freezing point of the fireproof adhesive material and also functions as a stabilizer and plasticizer for the adhesive material to enhance the flexibility and adhesion thereof.
~,...
~,,.
~20-The surfactant constituent of the fireproof adhesive material may conveniently ~ake the form of Ultra-Wet ~S*
(flake) sodium alkylate sulonate which i'; manufactured by Arco Chemical Company, Division of Atlantic Richfield Company, 1500 Market Street, Philadelphia, Pennsylvania 19101. The Ultra-Wet DS surEactant is a unique sodium alkylate sulfonate free flowing flake. It is utilized in aqueous media to provide or enhance surface activity, such as detergency, wetting, sudsing, dispersing and emulsifying. It is especially effective in hard water areas. This surfactant is completely soluble in water and is biodegradable.
The malodor control agent may conveniently taXe the form of a water activated malodor control concentrate being a mixture of surfactant, water, alcohol, and aromatic oils and manufactur~d by Oxford Chemicals, P. O. Box 80202, Atlanta, Georgia ~0366, and sold under the trade name OXFORD AIR-O~SYN.
This constituent is utilized in diluted mixture with water and is effective to render the odor characteristics of the resulting adhesive material from none to slightly soapy. The fireproof adhesive material will therefore have a relatively pleasant odor that will not disturb persons who are involved in spray application of the same.
From the standpoint of percentages by volume the sodium silicate constituent of the mixture is in the range of from about 90~ to about 97%. The surfactant/water solution is in the range of from about 0.01% to about 0.1%. The silicone water repellant is in the range of from about 0.02~ to about 0.2%. The liquid stabilizer plasticizer compound is in the range of from about 1.0% to about 5.0~. The silicon/water repellent is in the range of from about 1.0~ to about ~.0~.
The resulting fireproof adhesive material is of liquid form and has excellent adhesion to most metal and nonmetal surfaces. The element ingredients are largely inorganic and form upon solidification a permanent, flexible matrix which is nontoxic and highly stable. In addition, the temperature, light intensity and humidity likely to be encountered in occupied space should not con~ribute significantly to the deterioration or destabilization of the *trade mark .. ~
~z~
cured fireproof adhesive matrix. The fireproof adhesive material is highly resistant to acute thermal shock including open flame. The slight alteration in physical form of materials includin~ encap~ulated particles from insulation, plaster or wallboard due to physical or mechanical abuse or removal or ther~al shock should not result in the significant release of small particles or fibers. The adsorption and absorption of -the bonding matrix into asbestos fibers and fibrils results in entombment and encapsulation. Disruption of the encapsulation by mechanical abrasion, including sanding, should not result in disruption of large fibers into fibrils. Ingestion of encapsulated materials should not result in the bio-availability of fibrils since the solid matrix is not destroyed by digestive acids or enzymes. The bonding matrix will significantly reduce dust released by abrasion. Particles released by abrasion will be large for the most part and not appreciably absorbed by the pulmonary or gastrointestinal system of humans and animals. The fireproof adhesive material may be mixed during spray application with inert insulation particulate to form a protective, fireproof coating also having thermal insulation quality. A fireproof coatin~ of this nature effectively provides fire protectionj thermal insulation, sound absorption and, where required, asbestos fiber encapsulation.
In view of the foregoing, it is clear that the present invention is one well adapted to attain all of the objects, features and advantages hereinabove set forth, together with other advantages which will become obvious and inherent from a description of t~e invention itself. It will be understood that certain combinations and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the present invention.
f 'r^
! ~
~Z~)18S8 As many pos~ible embodiments may be made of this invention without departing from the spirit or scope thereof, it i5 to be understood that all matters hereinabove set forth are to be interpreted as illustrative and not in any limiting sense .
,
Sodium silicate is by ar the most common alkali metal ~.i, ~, silicate and is preferred, since it is readily obtainable and relatively inexpensive. ~le term alXall metal silicate is a generic term given to a farnily of chemicals composed of alkali metal oxide (AlkO2) and silica (SiO2) anc1 usually, but not always, water. A broad range of alkali metal o~ide to silica oxide may ~e used in the present composition, preferably from 1:1 to 1:6; however, alkali metal oxide to silica ratios of 1:2.5 to 1:4 are preferred. Silicates in which the alkali metal are less than about 1:2.5 are sticky and tacXy, changing slowly from liquid to solid with loss of water; whereas, those with a weight ratio above 4:1 are handleable materials in relative low solids content solutions. The alkali metal silicates are normally employed in water solutions with the solids content as concentrated as can be conveniently handled.
Generally, the alkali metal silicates will be employed in solution viscosities up to 400 centipose at 20C, preferably about 150 to 350 centipose at 20C. Thus, one of ordinary skill in the art can select the alkali metal silicate solution having the desired ratio of alkali to silica, solids content and viscosity for processing and end product properties ~e.g., hardening rate, solids content and the like) within these ranges with a minimum of experimentation.
An optimum volume of sodium silicate for a particular batch volume of about 401 gallons of the adhesive material was found to be in the order of 370 gallons.
Further, the temperature range for the sodium silicate in preparation of the adhesive material was determined to be in the range of from about 50F to about 150F. An optimum temperature was determined to be in the order of 100F. At a temperature of 50F the sodium silicate liquid is of fairly viscous nature and is relatively reluctant to accept the other incompatible constituents of the adhesive mixture. At temperatures above 150F the sodium silicate has a significant tendency for crystallization and either will not efficiently accept the other incompatible constituents in swch manner as to form a colloidal suspension or will become crystallized to such extent that development of a liquid colloidal suspension ~z~s~
becomes relatively impossible.
The liquid stabilizer plasticizer compoun~ is, preferably a liquid diol, which is liquid at 0C, has 2 to 4 carbon atoms and is soluble in water. Suitable diols include ethylene glycol (1,2-ethanediol), 1,2-propanediol, 1.3-propanediol, 1,2-butanediol, and 2,3-butanediol.
The surfactant is preferably an anionic, nonionic or amphoteric surfactant as those are generally known in the art.
~ nionic surface~acti~e emulsifying agents, such as alXali soaps having the general formula, RCOOM, wherein RCOO
~epresents a fatty acid containing from 3 to 25 carbon atoms (represented by R) and M is an alkali metal, such as sodium, potassium, lithium, and the like, can be used. For example, mixed fatty acids derived from tallow, cocoanut oil, palm oil, etc., are especially useful. Examples of suitable alkali soaps include the sodium and postassium salts of oleic acid, palmitic acid, stearic acid, linoleic acid, and the like.
Other anionic surfactants include an acid derived from other sources such as resin, for example, the sodium salts of abietic acid or isomers thereof.
Other anionic type surface-active agents which can be used include the aliphatic and alkyl aromatic sulfonates having the general formula:
R
~ S03M
R
wherein R is an aliphatic radical, aromatic radical (including alkaryl~, or hydrogen atom and M is an alkali metal. Examples of suitable sulfonat~ type surfactants include the petroleum sulfonates, such as isopropylnaphthalene sulfonate, sodium heptybiphenyl sulfonate, sodium salts of polymerized alkyl aryl sulfonic acids, and the like.
Typical of surface active agents containing sulfate or sulfonate groups are the salts of sulfated fatty alcohols, containing 8-18 carbon atoms, alkylbenzene-sulfonic acid containing 8-18 carbon atoms in the alkyl chains, or sulfated condensates of phenol, Cg_lg alkylphenol, or Cg_la fatty alcohols with ethylene oxide. The cations of the salts are usually æodium, potassium, or ammonium ions.
The nonionic sur~actants are compositions such as ethylene oxide or propylene oxide condensation products of compounds containing reactive hydrogen atoms. Suitable nonionic surfactants include compounds such as ethers having the general formula R-(OCH2CH2)n-OH wherein R is an aromatic radical or an a~iphatic radical containing up to 20 carbon atoms and n is an integer between 1 and 8.
An example of amphoteric surfactants is C-cetyl petaîne.
A more complete list of useful anionic, nonionic and amphoteric suractants can be found in the 1964 publication, "Detergents and Emulsifiers", John W. McCutcheon, Inc., Morristown, New Jersey, and in Schwartz and Perry, "Surface Active Agents", New York Interscience, Inc., 1949.
Suitable silicone water repellents include the alkali metal salts of hydrocarbon substituted silantriol (sometimes called silonlates)l of the general formula:
t [ R Sli - O ] Alkali Metal OH
Alkali metal wherein Ris a hydrocarbyl radical having 1 to 16 carbon atoms of alkyl, aryl, arakyl, alkaryl, including non reactive substituents such as chlorine, bromine fluorine or iodine. the hydrocarbyl radicals include, for example, methyl, ethyl, docyl, phenyl, naphthyl, biphenyl, benzyl, xylyl and the like. Formula I is believed to be the hydrous form which can be dried to [R SiO2] alkali metal.
Since the final composition of the present invention is an aqueous solution, the various components may all be admixed as aqueous solutions.
The water serves both as the carrier for the components and the continuous phase for the emulsion which results from the present combination of components, and will generally comprise from about 40 to 70 wt. ~ of the inal (total) composition, more preferably about 55 to 65 wt. % of ,. ~
the composition. Exclusive of water the components of the fireprooing composition are preferably present by weight in the following amounts:
Wt. %
Alkali metal silicate 80 to 98~
more preferably gO to 95%
Surfactant .01 to .5%
more preferably .03 to 1~
Silicon water repellent 1 to 6%
more preferably 2 to 3%
Diol 1 to 10%
more preferably 3 to 7%
Malodor Control Agent .05 to 1~
more preferably .13 to .4%
With the mixing vessel of the mixing apparatus containing approximately 370 gallons of sodium silicate a sufficient quantity of a liquid stabilizer plasticizer compound is introduced while continuously agitating the sodium silicate with the mixing machine cutting blade operating at an RPM range of from 1800 to 1900 RPM. In one suitable form of the invention the liquid stabilizer plasticizer compound takes the form of ethylene glycol which is mixed at a range of from about 5 gallons to about 20 gallons to the sodium silicate contained in the mixing vessel. Preferably an optimum quantity of ethylene glycol is about 10 gallons which is quite slowly introduced to the sodium silicate liquid during continuous agitation. For example, the ethylene glycol is introduced at a rate not substantially exceeding 5 gallons per minute. Introduction of the~ethylene glycoI, if too fast will shock the sodium silicate liquid thereby resulting in immediate crystallization. It is necessary therefore to introduce the ethylene glycol to the agitatiny sodium silicate with such slowness that the sodium silicate remains liquid during total introduction of the ethylene glycol. The ethylene glycol provides the fireproof adhesive material with an antifreeze quality rendering it compatible for shippin~, ~L2V1858 handling and storage in relatively low temperature environments such as might occur during winter. Further, the ethylene glycol provides liquid stabilization and also functions as a plasticizer compound to enhance the flexibility of the cured adhesive after it h~s been applied.
A quantity of surfactant material is then dissolved in water and this water/surfactant mixture is introduced into the agitating mixture within the mixer vessel. In order to prevent shocking of the sodium silicate which would result in immediate crystallization, the water/surfactant mixture is introduced at approximately the same or slower speed of introduction as described above in connection with the ethylene glycol.
After the ethylene glycol has been completely introduced and dispersed within the mixture in the mixing vessel a quantity of liquid silicone water repellent is introduced into the mixing vessel, its introduction also being slow as described above in connection with the ethylene glycol and surfactant/water constituents of the mixtureO Again, the viscosity of the mixture within the mixing vessel will determine the rate of silicone water repellent introduction.
If the material is of fairly viscous nature the silicone water repellent must be introduced quite slowly. If the mixture is of normal viscosity whih occurs at a temperature of about 100F, the silicone water repellent may be introduced more rapidly without shocking the mixture and causing immediate crystallization. ~o a batch of the volume set forth above, the volume of liquid silicone repellent will be in the order of from 10 gallons to 20 gallons, the optimum volume thereof being in the order of 15 gallons. After slow introduction of the silicone water repellent material is completed, agitation is continued for a sufficient period of time for the cutting blade of the mixing mechanism to establish a colloidal or inseparable mixture. After this has occurred, the mixing apparatus may be deenergized and the adhesive mixture within the mixing vessel may be transferred to drums, tanks or other storage vessels for storage and handling. When properly mixed ~;20:~851 3 the adhesive material will not become stratified due to settling and floating but rather will remain a homogeneous liquid con-sistency capable oE being picked up by the pumps for handling or the venturies oE adhesive spra~ing apparatus for spray application to surfaces.
The silicone water repellent liquid may -take the form of sodium methyl silanolate solution which provides the adhesive mixture with excellent thermal and oxidative stability, water repellency, durability, chemical and corrosive resistance and good durability.
A waterproof fire resistant adhesive mixture manufactured in accordance with the above will typically be of malodorous character. To eliminate or minimize this malodorous character and to further enhance the flexibility of the resulting cured fireproof adhesive material a quantity of a suitable deodorant material may be introduced during the mixing phase. An example of a suitable malodor control agent which also provides additional flexibility control is a water activated malodor control concentrate which is manufactured and sold under the trademark OXFORD AIR-O-SYN
by Oxford Chemicals of Atlanta, Georgia. The malodor control agent comprises a mixture of surfactant, water/ alcohol and aromatic oils. The surfactant of the malodor control agent may be of the anionic, nonanionic or amphoteric form described above.
The malodor control agent is not necessary to the functional character of the fireproof adhesive material and may be eliminated if desirable. It is provided simply to provide the adhesive mixture with a pleasing odor. To a batch of adhesive material such as set forth above water activated malodor control con-centrate in the order of from 2 quarts to 5 quarts is typically introduced into the mixture, the optimum quantity being in the order of 3-1/2 quarts. This malodor control concentrate will effectively render the resulting fireproof adhesive ~aterial substantially free of any objectionable odors. In addition to providing malodor control, the OXFORD AIR-O-SYN malodor control concentrate also enhances the flexibility of the resulting, cured fireproof adhesive material. The bonding matrix due to : "~
; ,, the presence of the surfactant and water constituents has a penetrating capability when applied to such .~urfaces as wallboard, asbestos ceiling tiles and panels, etc. I-ts penetrating characteristic can be controlled by changing the wa-ter and surfactant content within the parameters set forth hereinbe.low, such control of the pe.netrati.ng characteristic being determined by the particular fibrous surfaces to be penetrated. As the bonding matrix penetrates into the fibrous material in its uncured state, it surrounds and encapsulates the individual fibers. In the case of asbestos encapsulation it is desired that the asbestos fibers be completely coated or encapsulated by th~ Donding matrix to provide the asbestos fibrils with a carcinogenic barrier in the form of a coating. Upon curing of the matrix to a substantially hardened character any fracturing of the asbestos ~ibers will not laden the surrounding air with unencapsulated asbestos fibrils. Any released asbestos fibrils will be encapsulated by the matrix coating and rendered harmless from the standpoint of carcinogenics. The bonding matrix is applied to the fibrous material and is allowed to become somewhat cured or hardened. The asbestos wall or ceiling structure or coating may then be removed by suitable mechanical means without releasing nonencapsulated asbestos fibrils into the atmosphere.
Following is a graphical representation of the low range, optimum and high range values for the various volumes of constituents, temperatures and mixing speeds which may be employed in the manufacture of fireproof adhesive material according to the present invention. Although specific materials are identified, it is not intended that the present '~
~20~8SI~
~18-invention be restricted to utilization of the specific materials and volumes set for~h. Other suitable materials may be substituted for those set forth within the spirit and scope of the present invention.
Adhesive Constituent Low Range Optimum High Range 1. Liquid Sodium Silicate 320.0 gal 370.0 gal 420.0 gal 2. Mi~ing Temp. 50 F 100 F 150 F
10 3. Ethylene Glycol (Regular) 5.0 gal 10.0 gal 15.0 gal 4. Surfactant-Ultra Wet D.S. (Flake~ 0.5 lb. 1.0 lb. 2.0 lb.
5. Water 2.0 gal 5.0 gal 8.0 gal 6. Malodor Control Agent 1.0 qt. 3.5 qt. 5.5 qt.
7. Silicone Water Repellent 10.0 gal 15~0 gal 20.0 gal 8. Mixing Speed 500 RPM 1800 - 3000 RPM
Since many of the particular constituents of the fireproof adhesive material may be variously obtained in various grades, more specific identification of the various constituents are as follows.
The sodium silicate most widely utilized is silicate of soda, grade 40, which is obtained rom the Diamond Shamrock Corporation, 351 Phelps Court, P. O. Box 2300, Irving, Texas 75061. Tha` silicate of soda is soluble in water and is a ''~', 120~5~
colorless, turbid liquid with an odor of none to slightly soapy. This sodium silicate has a specific gravity of 1.30-1.71 at 20C in comparison to water at a specific gravity of 1 at the same temperature. The liquid sodium silicate material has a boiling point of from 214F-216F. In the fireproof adhesive material, the sodium silicate functions as a fireproof bonding material and enhances the rapidity of setting after thé material has been applied. Additionally, it functions as a rust inhibitor, and provides resistance to vermin. I~ is also inorganic and nontoxic.
The sodium methyl silanolate solution may ~e of the type manufactured by Union Carbide Corporation, Silicones and Urethanes Intermediates, Old Ridgebury Road, Danbury, Connecticut 06817, under the identifyi.ng symbol R-20. The physical form of this material is solution in water having a clear appearance and a water white color. The apparent specific gravity of the material at 25/25C is 1.209. The active ingredients by weight is 30~. It has a viscosity at 25C of 10 centipoises. The sodium methyl silanolate solution has excellent thermal and oxidative stability, is water repellent and provides the cured adhesive material with excellent durability. It is also chemical resistant and noncorrosive and may be efficiently sprayed ~rom the standpoint o~ application.
The ethylene glycol constituent may be obtained from Dow Chemical Corporation, U.S.A., Midland, Michigan 48640.
This particular product may be identified at ethylene glycol (regular) and is a low density material in the form of a colorless, practically odorless liquid. The ethylene glycol has a boiling point of 387.1F and a vapor pressure of 0.12 MM~G at 25C. It is soluble in water, completely miscible and has a specific ~ravity of 1.1155 at 20/20C. The ethylene glycol functions to lower the freezing point of the fireproof adhesive material and also functions as a stabilizer and plasticizer for the adhesive material to enhance the flexibility and adhesion thereof.
~,...
~,,.
~20-The surfactant constituent of the fireproof adhesive material may conveniently ~ake the form of Ultra-Wet ~S*
(flake) sodium alkylate sulonate which i'; manufactured by Arco Chemical Company, Division of Atlantic Richfield Company, 1500 Market Street, Philadelphia, Pennsylvania 19101. The Ultra-Wet DS surEactant is a unique sodium alkylate sulfonate free flowing flake. It is utilized in aqueous media to provide or enhance surface activity, such as detergency, wetting, sudsing, dispersing and emulsifying. It is especially effective in hard water areas. This surfactant is completely soluble in water and is biodegradable.
The malodor control agent may conveniently taXe the form of a water activated malodor control concentrate being a mixture of surfactant, water, alcohol, and aromatic oils and manufactur~d by Oxford Chemicals, P. O. Box 80202, Atlanta, Georgia ~0366, and sold under the trade name OXFORD AIR-O~SYN.
This constituent is utilized in diluted mixture with water and is effective to render the odor characteristics of the resulting adhesive material from none to slightly soapy. The fireproof adhesive material will therefore have a relatively pleasant odor that will not disturb persons who are involved in spray application of the same.
From the standpoint of percentages by volume the sodium silicate constituent of the mixture is in the range of from about 90~ to about 97%. The surfactant/water solution is in the range of from about 0.01% to about 0.1%. The silicone water repellant is in the range of from about 0.02~ to about 0.2%. The liquid stabilizer plasticizer compound is in the range of from about 1.0% to about 5.0~. The silicon/water repellent is in the range of from about 1.0~ to about ~.0~.
The resulting fireproof adhesive material is of liquid form and has excellent adhesion to most metal and nonmetal surfaces. The element ingredients are largely inorganic and form upon solidification a permanent, flexible matrix which is nontoxic and highly stable. In addition, the temperature, light intensity and humidity likely to be encountered in occupied space should not con~ribute significantly to the deterioration or destabilization of the *trade mark .. ~
~z~
cured fireproof adhesive matrix. The fireproof adhesive material is highly resistant to acute thermal shock including open flame. The slight alteration in physical form of materials includin~ encap~ulated particles from insulation, plaster or wallboard due to physical or mechanical abuse or removal or ther~al shock should not result in the significant release of small particles or fibers. The adsorption and absorption of -the bonding matrix into asbestos fibers and fibrils results in entombment and encapsulation. Disruption of the encapsulation by mechanical abrasion, including sanding, should not result in disruption of large fibers into fibrils. Ingestion of encapsulated materials should not result in the bio-availability of fibrils since the solid matrix is not destroyed by digestive acids or enzymes. The bonding matrix will significantly reduce dust released by abrasion. Particles released by abrasion will be large for the most part and not appreciably absorbed by the pulmonary or gastrointestinal system of humans and animals. The fireproof adhesive material may be mixed during spray application with inert insulation particulate to form a protective, fireproof coating also having thermal insulation quality. A fireproof coatin~ of this nature effectively provides fire protectionj thermal insulation, sound absorption and, where required, asbestos fiber encapsulation.
In view of the foregoing, it is clear that the present invention is one well adapted to attain all of the objects, features and advantages hereinabove set forth, together with other advantages which will become obvious and inherent from a description of t~e invention itself. It will be understood that certain combinations and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the present invention.
f 'r^
! ~
~Z~)18S8 As many pos~ible embodiments may be made of this invention without departing from the spirit or scope thereof, it i5 to be understood that all matters hereinabove set forth are to be interpreted as illustrative and not in any limiting sense .
,
Claims (38)
1. A fireproof adhesive mixture in liquid form, comprising:
(a) a predetermined quantity of liquid sodium silicate;
(b) a quantity of surfactant/water solution sufficient to render the cured fireproof adhesive flexible and to provide for emulsification in the liquid state thereof;
(c) a sufficient quantity of silicone water repellent to render the cured adhesive durable, chemical resistant and water repellent; and (d) said adhesive mixture being in the form of a substantially inseparable liquid suspension in the uncured state and curing upon exposure to the atmosphere to a solid flexible mass.
(a) a predetermined quantity of liquid sodium silicate;
(b) a quantity of surfactant/water solution sufficient to render the cured fireproof adhesive flexible and to provide for emulsification in the liquid state thereof;
(c) a sufficient quantity of silicone water repellent to render the cured adhesive durable, chemical resistant and water repellent; and (d) said adhesive mixture being in the form of a substantially inseparable liquid suspension in the uncured state and curing upon exposure to the atmosphere to a solid flexible mass.
2. A fireproof adhesive as recited in Claim 1, including:
a sufficient quantity of a liquid stabilizer plasti-cizer compound to enhance the flexibility of the cured adhesive.
a sufficient quantity of a liquid stabilizer plasti-cizer compound to enhance the flexibility of the cured adhesive.
3. A fireproof adhesive as recited in Claim 2, wherein:
(a) said sodium silicate is in the range of from about 90% to about 97% of said mixture by volume;
(b) said surfactant/water solution is in the range of from about 0.01% to about 0.1% of said mixture by volume; and (c) said silicone water repellent is in the range of from about 0.02% to about 0.2% of said mixture by volume.
(a) said sodium silicate is in the range of from about 90% to about 97% of said mixture by volume;
(b) said surfactant/water solution is in the range of from about 0.01% to about 0.1% of said mixture by volume; and (c) said silicone water repellent is in the range of from about 0.02% to about 0.2% of said mixture by volume.
4. A fireproof adhesive as recited in Claim 3, including:
a quantity of a liquid stabilizer plasticizer compound in the range of from about 1.0% to about 5.0% of said mixture by volume.
a quantity of a liquid stabilizer plasticizer compound in the range of from about 1.0% to about 5.0% of said mixture by volume.
5. A fireproof adhesive mixture in liquid form, comprising:
(a) a quantity of liquid sodium silicate in the range of from about 90% to about 97% of said mixture by volume;
(b) a quantity of surfactant/water solution in the range of from about 0.01% to about 0.1% of said mixture by volume to render the cured fireproof adhesive flexible and to provide for emulsification in the liquid state thereof;
(c) a quantity of silicone water repellent in the range of from about 0.02% to about 0.2% of said mixture by volume to render the cured adhesive durable, chemical resistant and water repellent; and (d) a quantity of a liquid stabilizer plasticizer compound in the range of from about 1.0% to about 5.0% of said mixture by volume to enhance the flexibility of the cured adhesive; and (e) said adhesive mixture being in the form of a substantially inseparable liquid suspension in the uncured state and curing upon exposure to the atmosphere to a solid flexible mass.
(a) a quantity of liquid sodium silicate in the range of from about 90% to about 97% of said mixture by volume;
(b) a quantity of surfactant/water solution in the range of from about 0.01% to about 0.1% of said mixture by volume to render the cured fireproof adhesive flexible and to provide for emulsification in the liquid state thereof;
(c) a quantity of silicone water repellent in the range of from about 0.02% to about 0.2% of said mixture by volume to render the cured adhesive durable, chemical resistant and water repellent; and (d) a quantity of a liquid stabilizer plasticizer compound in the range of from about 1.0% to about 5.0% of said mixture by volume to enhance the flexibility of the cured adhesive; and (e) said adhesive mixture being in the form of a substantially inseparable liquid suspension in the uncured state and curing upon exposure to the atmosphere to a solid flexible mass.
6. A fireproof adhesive as recited in Claim 2 or Claim 5, wherein:
said liquid stabilizer plasticizer compound is ethylene glycol.
said liquid stabilizer plasticizer compound is ethylene glycol.
7. A fireproof adhesive as recited in Claim 1, Claim 2, or Claim 5, wherein said surfactant/water solution comprises:
sodium alkylate sulfonate dissolved in water.
sodium alkylate sulfonate dissolved in water.
8 . A fireproof adhesive as recited in Claim 4 or Claim 5, wherein:
said surfactant/water solution comprises sodium alkylate sulfonate/water solution in the range of from about 1.0% to about 4.0% of said mixture by volume.
said surfactant/water solution comprises sodium alkylate sulfonate/water solution in the range of from about 1.0% to about 4.0% of said mixture by volume.
9. A fireproof adhesive as recited in Claim 4, wherein:
said fireproof adhesive mixture is mixed at a temperature range of from about 50°F to about 150°F.
said fireproof adhesive mixture is mixed at a temperature range of from about 50°F to about 150°F.
10. A fireproof adhesive as recited in Claim 5, wherein:
said fireproof adhesive mixture is mixed at a temperature range of from about 50°F to about 150°F.
said fireproof adhesive mixture is mixed at a temperature range of from about 50°F to about 150°F.
11. A fireproof adhesive as recited in Claim 4, Claim 9, or Claim 10, wherein:
said mixture is mixed by means of a power driven shear type impeller blade driven at an RPM range of from about 500 RPM
to about 3000 RPM.
said mixture is mixed by means of a power driven shear type impeller blade driven at an RPM range of from about 500 RPM
to about 3000 RPM.
12. A fireproof adhesive as recited in Claim 1, Claim 4, or Claim 5, wherein silicone water repellent comprises:
sodium methyl silanolate.
sodium methyl silanolate.
13. A fireproof adhesive as recited in Claim 1, Claim 4, or Claim 5, including:
a malodor control agent.
a malodor control agent.
14. A liquid fireproof adhesive material capable of hardening upon exposure to air at ambient temperature to form a solid, resilient mass having good adhesion to metal and non-metal surfaces, comprising the following constituents by volume to form a batch volume of adhesive liquid of about 401 gallons, comprising:
(a) 370.0 gallons sodium silicate;
(b) 10.0 gallons ethylene glycol;
(c) 1.0 pounds Ultra-Wet* D.S. (flake) Surfactant;
(d) 5.0 gallons water; and (e) 15.0 gallons silicone water repellent.
(a) 370.0 gallons sodium silicate;
(b) 10.0 gallons ethylene glycol;
(c) 1.0 pounds Ultra-Wet* D.S. (flake) Surfactant;
(d) 5.0 gallons water; and (e) 15.0 gallons silicone water repellent.
15. A liquid fireproof adhesive material as recited in Claim 14, wherein:
the constituents (a) - (e) are mixed, with said sodium silicate being at a temperature range of from about 50°F to about 150°F.
*trade mark
the constituents (a) - (e) are mixed, with said sodium silicate being at a temperature range of from about 50°F to about 150°F.
*trade mark
16. A liquid fireproof adhesive material as recited in Claim 14, wherein:
the constituents (a) - (e) are mixed with a shear type impeller blade driven at an RPM range of from about 500 RPM
to about 3000 RPM.
the constituents (a) - (e) are mixed with a shear type impeller blade driven at an RPM range of from about 500 RPM
to about 3000 RPM.
17. A process for the manufacture of fireproof adhesive mixture of liquid form, comprising:
(a) loading a mixing system having a mixing vessel and a motorized liquid agitating mechanism with liquid sodium silicate in the range of from about 90% to about 97% of said mixture by volume;
(b) initiating agitation of said liquid sodium silicate with said motorized liquid agitating mechanism;
(c) slowly introducing a liquid stabilizer plasticizer into said mixing vessel while continuously agitating the liquid mixture, said liquid stabilizer plasticizer being in the range of from about 1.0% to 5.0% of said mixture by volume;
(d) mixing a surfactant with water to provide a surfactant/water solution in the range of from about 0.01% to about 0.1% of said mixture by volume;
(e) slowly introducing said surfactant/water solution into said mixing vessel while continuously agitating said mixture;
(f) slowly introducing silicone water repellent into said mixing vessel in the range of from about 0.02% to about 0.2% of said mixture by volume; and (g) continuing mixing of the mixture in said mixing vessel for a sufficient period of time to develop a substantially inseparable liquid mixture.
(a) loading a mixing system having a mixing vessel and a motorized liquid agitating mechanism with liquid sodium silicate in the range of from about 90% to about 97% of said mixture by volume;
(b) initiating agitation of said liquid sodium silicate with said motorized liquid agitating mechanism;
(c) slowly introducing a liquid stabilizer plasticizer into said mixing vessel while continuously agitating the liquid mixture, said liquid stabilizer plasticizer being in the range of from about 1.0% to 5.0% of said mixture by volume;
(d) mixing a surfactant with water to provide a surfactant/water solution in the range of from about 0.01% to about 0.1% of said mixture by volume;
(e) slowly introducing said surfactant/water solution into said mixing vessel while continuously agitating said mixture;
(f) slowly introducing silicone water repellent into said mixing vessel in the range of from about 0.02% to about 0.2% of said mixture by volume; and (g) continuing mixing of the mixture in said mixing vessel for a sufficient period of time to develop a substantially inseparable liquid mixture.
18. A process as recited in Claim 17, wherein:
said mixture is mixed at a temperature range of from about 50°F to about 150°F.
said mixture is mixed at a temperature range of from about 50°F to about 150°F.
19. A process as recited in Claim 17, wherein:
said mixture is mixed with a shear type impeller blade being rotatably driven at a range of from about 500 RPM
to about 3000 RPM.
said mixture is mixed with a shear type impeller blade being rotatably driven at a range of from about 500 RPM
to about 3000 RPM.
20. A process as recited in Claim 17, Claim 18 or Claim 19, wherein:
said liquid stabilizer plasticizer is ethylene gylcol.
said liquid stabilizer plasticizer is ethylene gylcol.
21. A process as recited in Claim 17, Claim 18 or Claim 19, wherein said surfactant comprises:
Ultra-Wet* D.S.(flake) surfactant.
Ultra-Wet* D.S.(flake) surfactant.
22. A process as recited in Claim 17, Claim 18 or Claim 19, including:
introducing a quantity of malodor control agent into said mixture before said step of continuing mixing.
introducing a quantity of malodor control agent into said mixture before said step of continuing mixing.
23. A liquid fireproofing adhesive composition comprising an aqueous emulsion containing an alkali metal silicate in the range of from about 90% to about 97% of said aqueous emulsion by volume, a silicone water repellent in the range of from about 0.02% to about 0.2% of said aqueous emulsion by volume and a surfactant in the range of from about 0.01% to about 0.1% of said aqueous emulsion by volume.
24. The liquid fireproofing adhesive composition according to Claim 23 wherein a liquid stabilizer plasticizer composition is present in the range of from about 1.0% to about 5.0% of said aqueous emulsion by volume.
25. The liquid fireproofing adhesive composition according to Claim 24 wherein a malodor control agent is present.
26. The liquid fireproofing adhesive composition according to Claim 24 wherein the alkali metal is Na.
27. The liquid fireproofing adhesive composition according to Claim 26 wherein said water repellent is a silicone water repellent.
*trade mark
*trade mark
28. The liquid fireproofing adhesive composition according to Claim 27 wherein said silicone water repellent is an alkali metal salt of hydrocarbon substituted silantriol.
29. The liquid fireproofing adhesive composition according to Claim 28 wherein said surfactant is an anionic, nonionic or amphoteric surfactant.
30. The liquid fireproofing adhesive composition according to Claim 29 wherein said surfactant is anionic.
31. The liquid fireproofing adhesive composition according to Claim 30 wherein said surfactant is an aromatic sulfonate.
32. The liquid fireproofing adhesive composition according to Claim 31 wherein said surfactant is an alkaryl sulfonate.
33. The liquid fireproofing adhesive composition according to Claim 32 wherein liquid stabilizer plasticizer composition is a diol having 2 to 4 carbon atoms.
34. The liquid fireproofing adhesive composition according to Claim 33 wherein said diol is ethylene glycol.
35. The liquid fireproofing adhesive composition according to Claim 24 containing, exclusive of water from 80 to 98 wt. % alkali metal silicate, from .01 to .5 wt. %
surfactant, from 1 to 6 wt. % water repellent and from 1 to 10 wt. % liquid stabilizer plasticizer which is a diol.
surfactant, from 1 to 6 wt. % water repellent and from 1 to 10 wt. % liquid stabilizer plasticizer which is a diol.
36. The liquid fireproofing adhesive composition according to Claim 35 wherein water comprises from 40 to 70 wt. % of the total composition.
37. The liquid fireproofing adhesive composition according to Claim 35 containing exclusive of water from 90 to 95 wt. % sodium silicate, from .03 to 1 wt. % alkaryl sulfonate, from 2 to 3 wt. % silicone water repellent and from 3 to 7 wt.
% diol having 2 to 4 carbon atoms.
% diol having 2 to 4 carbon atoms.
38. The liquid fireproofing adhesive composition according to Claim 35 wherein said silicon water repellent is an alkali metal salt of hydrocarbon substituted silantriol and said diol is ethylene glycol.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US47671483A | 1983-03-18 | 1983-03-18 | |
| US06/476,714 | 1983-03-18 | ||
| US50860783A | 1983-06-28 | 1983-06-28 | |
| US06/508,607 | 1983-06-28 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1201858A true CA1201858A (en) | 1986-03-18 |
Family
ID=27045260
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000432707A Expired CA1201858A (en) | 1983-03-18 | 1983-07-19 | Adhesive for fireproofing and fiber encapsulation |
Country Status (14)
| Country | Link |
|---|---|
| KR (1) | KR840007888A (en) |
| AU (1) | AU557155B2 (en) |
| BR (1) | BR8304474A (en) |
| CA (1) | CA1201858A (en) |
| DE (1) | DE3326738A1 (en) |
| DK (1) | DK362383A (en) |
| FI (1) | FI833046A (en) |
| FR (1) | FR2542753A1 (en) |
| GB (1) | GB2136824B (en) |
| IT (1) | IT1197695B (en) |
| NL (1) | NL8303362A (en) |
| NO (1) | NO832913L (en) |
| PT (1) | PT77523B (en) |
| SE (1) | SE8304394L (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4710309A (en) * | 1986-12-04 | 1987-12-01 | American Sprayed-On Fibers, Inc. | Lightweight soundproofing, insulation and fireproofing material and method |
| US5478389A (en) * | 1991-09-25 | 1995-12-26 | Loomis Family Trust | Pollution remedial composition and its preparation |
| DE4137593C2 (en) * | 1991-11-15 | 1994-01-20 | Fraunhofer Ges Forschung | Modified, transparent, aqueous alkali silicate solution, process for its preparation and its use for the production of transparent hydrogels |
| US5607503A (en) * | 1993-09-03 | 1997-03-04 | Refract-A-Gard Pty Limited | Silica-based binder |
| US5589229A (en) * | 1993-09-14 | 1996-12-31 | Howard; Richard | Composition and method for preventing moss growth on roofs |
| US5366767A (en) * | 1993-09-14 | 1994-11-22 | Richard Howard | Composition and method for preventing moss growth on roofs |
| GB9511237D0 (en) * | 1995-06-03 | 1995-07-26 | Crompton Design Mfg | Adhesives |
| CN107640915A (en) * | 2017-10-23 | 2018-01-30 | 秦皇岛玻璃工业研究设计院有限公司 | A kind of refractory heat-insulating glass and preparation method thereof |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB892119A (en) * | 1957-07-01 | 1962-03-21 | Diamond Alkali Co | Improvements in or relating to adhesive compositions |
| GB892118A (en) * | 1957-07-01 | 1962-03-21 | Diamond Alkali Co | Improvements in or relating to the preparation of cellulosic products using adhesivesilicate compositions |
| US3844805A (en) * | 1972-07-14 | 1974-10-29 | Ralston Purina Co | Dry cutting compound for protein glues and method of use |
| FR2295104A1 (en) * | 1974-10-09 | 1976-07-16 | Chollet Jacques | FLAMMABLE ADHESIVE COMPOSITION CONTAINING A SILICATE |
| DK276678A (en) * | 1977-06-28 | 1978-12-29 | Woellner Werke | ADHESIVE CONTAINING FINE DISTRIBUTED INORGAN POWDER AND ORGANIC POLYMERS |
-
1983
- 1983-07-19 CA CA000432707A patent/CA1201858A/en not_active Expired
- 1983-07-21 AU AU17157/83A patent/AU557155B2/en not_active Ceased
- 1983-07-25 DE DE19833326738 patent/DE3326738A1/en not_active Withdrawn
- 1983-08-09 DK DK362383A patent/DK362383A/en not_active Application Discontinuation
- 1983-08-12 NO NO832913A patent/NO832913L/en unknown
- 1983-08-12 SE SE8304394A patent/SE8304394L/en not_active Application Discontinuation
- 1983-08-12 IT IT48850/83A patent/IT1197695B/en active
- 1983-08-18 BR BR8304474A patent/BR8304474A/en unknown
- 1983-08-25 FI FI833046A patent/FI833046A/en not_active Application Discontinuation
- 1983-08-30 FR FR8313927A patent/FR2542753A1/en active Pending
- 1983-09-30 NL NL8303362A patent/NL8303362A/en not_active Application Discontinuation
- 1983-10-19 PT PT77523A patent/PT77523B/en unknown
- 1983-11-15 GB GB08330416A patent/GB2136824B/en not_active Expired
- 1983-12-29 KR KR1019830006281A patent/KR840007888A/en not_active Application Discontinuation
Also Published As
| Publication number | Publication date |
|---|---|
| AU557155B2 (en) | 1986-12-11 |
| SE8304394L (en) | 1984-09-19 |
| DE3326738A1 (en) | 1984-09-20 |
| DK362383D0 (en) | 1983-08-09 |
| GB2136824B (en) | 1986-07-09 |
| KR840007888A (en) | 1984-12-11 |
| PT77523A (en) | 1983-11-01 |
| AU1715783A (en) | 1984-09-20 |
| FR2542753A1 (en) | 1984-09-21 |
| DK362383A (en) | 1984-09-19 |
| FI833046A (en) | 1984-09-19 |
| IT1197695B (en) | 1988-12-06 |
| FI833046A0 (en) | 1983-08-25 |
| GB8330416D0 (en) | 1983-12-21 |
| GB2136824A (en) | 1984-09-26 |
| PT77523B (en) | 1986-03-18 |
| BR8304474A (en) | 1985-02-20 |
| IT8348850A0 (en) | 1983-08-12 |
| SE8304394D0 (en) | 1983-08-12 |
| NL8303362A (en) | 1984-10-16 |
| NO832913L (en) | 1984-09-19 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |