Compositions: coating or plastic – Coating or plastic compositions – Inorganic settable ingredient containing
Reexamination Certificate
2001-02-26
2004-05-04
Colaianni, Michael (Department: 1732)
Compositions: coating or plastic
Coating or plastic compositions
Inorganic settable ingredient containing
C106S677000, C106S795000, C264S035000, C264S257000, C264S333000
Reexamination Certificate
active
06730160
ABSTRACT:
BACKGROUND OF INVENTION
1. Field of Invention
The subject invention is generally related to asbestos-free, cellulose-based insulating materials and is specifically directed to an insulating material that can be cured to form a structural building material or an insulating layer on site at room temperature.
2. Description of the Prior Art
In the building industry in particular, the structural elements used, such as for example ceilings, walls, partitions, girders and columns and the like, must have adequate fire resistance. To this end, there are legal provisions in many local and national codes that stipulate the period for which the structural elements have to withstand a fire. The walls, installed materials and even sealed openings in such structural elements (for cables and slots for tubes or joints) have to show the same fire resistance as the structural elements in which they are situated. Accordingly, a number of fireproofing compounds are used, for example, to coat the structural elements to make them fireproof or to increase the fire resistance of the sealing systems for the openings.
The sheaths and insulations of electrical cables and plastic pipes consist of inflammable materials which, after ignition, can spread the fire very quickly and which, in addition, conceal the danger of filling workshops and escape routes with smoke and, at the same time, of forming corrosive or toxic combustion products. These risks can generally be minimized by fireproof coatings.
DE-PS 20 65 117 describes a fireproofing compound which contains chlorinated hydrocarbons, antimony trioxide and asbestos fibers in addition to other substances in an aqueous polymer emulsion. This compound is used as a protective coating for electrical cables. In the event of fire, however, the chlorine-containing compound gives off not only chlorine compounds, but also hydrogen chloride gas that is both toxic and highly corrosive. In addition, the fireproofing compound described in DE-OS 20 65 117 contains antimony trioxide which is regarded as a carcinogenic substance and also asbestos fibers which are now known to have a health-damaging effect.
DE-PS 20 39 969 also describes a fireproofing compound containing chlorinated hydrocarbons. The compound in question may also contain asbestos and antimony compounds as further components. Accordingly, the fireproofing compound according to DE-PS 20 39 969 also has the unfavorable properties mentioned above and shows adverse health-damaging effects.
Although the fireproofing compound disclosed in DE-OS 27 24 604 avoids the use of asbestos fibers, it still contains chlorinated hydrocarbons and antimony trioxide. Accordingly, the fireproofing compound according to this document also shows unfavorable health-damaging effects.
The use of a fire-retarding compound for coating electrical cables and lining cable runways is described in DE-PS 28 44 693. The problem addressed by the invention to which this document relates was to modify the fireproofing compound described in DE-PS 20 39 969 in such a way that asbestos need no longer be used. However, the compound used in accordance with DE-PS 28 44 693 still contains an organic halogen compound and, optionally, antimony compound which leads to the disadvantages already described.
Halogen-free fireproofing compounds are also known from the prior art, but contain large quantities of health-damaging antimony compounds, such as antimony trioxide for example. Despite a high content of antimony compounds, these known fireproofing compounds show poor fireproofing properties. For example, cables with a halogen-free sheath and a halogen-free insulation, such as telephone cables with PE sheaths and insulations, cannot be protected with a commercially available product of this type in such a way that the requirements of DIN 4102, Part 1 (Class B1 Building Materials—Flame-Resistant Building Materials) are satisfied.
Because of the risks associated with fires involving PVC cables (heavy smoke generation, evolution of toxic and corrosive gases), numerous attempts have also been made to replace PVC by polyolefins or by halogen-free elastomers. However, the fire risks attending these new types of cables are often no less than those attending PVC cables and can even be greater.
The search for an insulating and fireproofing compound that is less hazardous to the environment and to human health than known fireproofing compounds has resulted in numerous new technologies. It is required that the dangers associated with the insulating material be minimized while the same time maintaining an effective structural, insulating and fireproofing integrity.
One example of a cellulose based material is shown and described in U.S. Pat. No. 5,496,881, entitled: “Composition for Forming Fireproof Coatings and Caulking and a Method of Use”, issued to Annemaier, et al on Mar. 3, 1996. This patent teaches an aqueous composition for forming fireproof coatings and caulking. The composition is halogen, asbestos and antimony-free. The composition contains 5-20% by weight of a binder resin; 10-60% by weight of a particulate flame proofing agent; 0.2 to 27.5% by weight of non-asbestos inorganic fibers with an average length of 300 micron; 0.1 to 10% by weight of a plasticizer; and water.
Other materials, such as board stock and structural materials have also been developed using a cellulose mixture. U.S. Pat. No. 5,611,882, entitled: “Board Stock and Method of Manufacture from Recycled Paper”, issued to Riebel, et al, on Mar. 18, 1997, discloses a cellulose mixture including a protein based adhesive binder and colorant. The mixture can be compression molded or extruded and upon curing in the presence of microwave or radio frequency energy or in thermally controlled appliance, produces board or shape formed stock. The produced stock exhibits colorations and a grain pattern comparable to natural stone. Unlike stone, the material exhibits a lightweight, low density, structural rigidity and ready machinability. A preferred method includes admixing separate, colorized batches of feedstock, each feedstock includes shredded waste newsprint, soybean flour, water and a colorant; reducing the moisture content of each feedstock or a proportioned admixture of several feedstocks, such as by air drying or compressing or performing the admixture in the presence of heat; compacting the admixture to final shape; and curing the shaped material. Final forming and finishing apparatus complete the process.
In addition the need for inexpensive, useful and versatile structural materials continues to plague the building industry, particularly where costs of materials and unavailability of a transportation infrastructure or lack of skilled labor make building of new structures and repair of older structures both difficult and expensive. Moreover, these conditions generally exists in areas where costs is a significant issue to the inhabitants. As an example, while of superior durability, face brick, cut stone and/or floor tile, manufactured of materials which are permanent and non-deteriorating such as fired clay or concrete or natural stone, are often rejected in such regions even though such materials are universally accepted. Reasons for such acceptance include proven longevity, reasonable and permanent closure and resistance to the elements of weather, incombustibility and general appreciation of the styles and colors available which enhance the individual structures on which the face brick, cut stone and/or floor tile is installed. However, the weight, necessity of skilled labor for installation and cost of the installed face brick, cut stone and/or floor tile system have been primary reasons for not using or even considering usage of brick, cut stone and/or floor tile except those regions where usage is presumed as normal or preferred, or where style and visual effect have been primary considerations.
Often face brick, cut stone and/or floor tile cannot be installed on an existing interior wall or floor without significant structural modifications because of the weight of the product.
Colaianni Michael
Jackson Walker L.L.P.
Poe Michael I.
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