Heat-resistant materials and their manufacturing methods

Abstract

A composite material is provided for protecting against fire and thermal energy from a heat source while minimizing harmful emissions and health risks. The heat-resistant composite material includes a first fabric layer, a second fabric layer bonded to the first fabric layer, and an intumescent fire-resistant material between the first and second fabric layers. The composite material includes an adhesive bonding the first and second fabric layers together, and is configured to melt or otherwise lose its adhesion at a threshold temperature level. This allows the fire-resistant material to swell or expand in areas of the fabric layer exposed to the heat source, while maintaining adhesion of the fabric layer in areas not exposed to such heat. Thus, the composite material swells and absorbs heat while still maintaining adhesion to the substrate it is designed to protect.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION This specification relates generally to fire-resistant and / or heat-resistant composite materials for absorbing thermal energy from a heat source and methods for making such composite materials. [Background technology]

[0002] To protect vehicles, building interiors, or individuals from fire, explosions, or other heat sources, heat-resistant and flame-retardant materials have been developed. These materials include, for example, flame-retardant coatings or materials such as asbestos, magnesium oxide, gypsum, vermiculite, and silicates; flame-resistant fabrics such as fiberglass cloth, polybenzimidazole fiber (PBI), Kevlar®, aramid, flame-retardant cotton, and melamine; or synthetic rubbers such as neoprene. Unfortunately, some of the most effective flame retardant materials, such as asbestos and halogen-based flame retardants, polymer-based flame retardants, or organophosphate flame retardants, pose potentially toxic health risks and / or harmful emissions. For example, most flame retardants are physically mixed with the materials in a product, rather than chemically bonded to them. Therefore, they continually migrate from the product into dust, food, and water, where they can be ingested by individuals and / or inhaled. In some cases, flame retardants can be released as reaction products with fire, leading to potentially harmful health risks or emissions in the environment.

[0003] Another drawback of existing heat-resistant materials is that they are generally relatively bulky and heavy, making them less than optimal for many applications. For example, threats that military vehicles typically face include landmines, mortar fire, and IED attacks. For military applications, thermal protection must be both effective and practical. Therefore, the military needs an alternative to traditional materials such as asbestos for thermal insulation that is safe and fire-resistant, yet lightweight and portable. In another example, fires in electric vehicles equipped with high-voltage lithium-ion batteries pose a risk to vehicle occupants and also pose a risk of electric shock to emergency responders. However, these batteries are relatively small and typically fit into limited space within the vehicle. Therefore, the heat-resistant material for the battery casing must be lightweight and compact to protect the vehicle from battery fires while avoiding a degradation of the vehicle's overall performance. Summary of the Invention

[0004] Therefore, what is needed are improved heat-resistant materials that provide effective protection against fire and thermal energy from heat sources while minimizing harmful emissions and health risks. In particular, it is desirable to provide lightweight, portable, and compact materials that can be used in a variety of applications, such as protecting military vehicles, electric batteries, buildings, individuals, etc.

[0005] The following presents a simplified summary of the claimed subject matter in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview of the claimed subject matter. It is not intended to identify key or critical elements of the claimed subject matter, nor is it intended to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts of the claimed subject matter in a simplified form as a prelude to the more detailed description that is presented later.

[0006] Composite heat-resistant materials and methods for making such materials are provided. In one embodiment, the heat-resistant composite material includes a first fabric layer, a second fabric layer bonded to the first fabric layer, and an intumescent fire-resistant material between the first and second fabric layers, coated on or incorporated within at least one of the fabric layers. The composite material is thin, lightweight, flexible, relatively inexpensive to manufacture, and emits minimal (or no) harmful chemicals when exposed to fire or excessive heat. These materials can be used as protective coverings for substrates or surfaces in a variety of applications, including vehicles (e.g., military vehicles), electric batteries, buildings, insulation blankets, protective clothing, cargo netting, hospital drapes, sheets, or mattress covers.

[0007] In some embodiments, the composite material includes an adhesive bonding the first and second fabric layers together. The adhesive is configured to melt or otherwise lose its adhesion at a threshold temperature level. This allows the fire-resistant material to swell or expand in areas of the fabric layers exposed to a heat source, while maintaining adhesion of the fabric layers in areas not exposed to such heat. Thus, the composite material swells and absorbs heat while still maintaining adhesion to the substrate it is designed to protect. In embodiments, the adhesive melts or otherwise loses adhesion between the first and second layers at a temperature of about 30° C. or greater, preferably about 60° C. or greater. Suitable adhesives include fabric or wood epoxy glues, cyanoacrylates, urethanes, acrylics, hot melt adhesives, pressure sensitive adhesives, reactive adhesives, wet adhesives, solvent-based adhesives, rubber-based adhesives, contact adhesives, and the like. In a preferred embodiment, the adhesive comprises fabric or wood glue.

[0008] The adhesive can be applied to one or both of the first and second layers. In certain embodiments, the composite includes at least two layers of adhesive, one layer applied between the fire-resistant material and the first outer layer of fabric and the other layer applied between the fire-resistant material and the second outer layer of fabric. In another embodiment, the fire-resistant material is mixed or otherwise incorporated into one or both outer layers of fabric. In this embodiment, the composite can include a single layer of adhesive between the first and second outer layers of fabric. The fire-resistant material is configured to expand or swell when heat is applied to the fire-resistant material. Suitable materials for the fire-resistant material include melamine, melamine polyphosphate, aluminum trihydroxide, antimony trihydroxide, phosphorus, ammonium polyphosphate, halogenated organic materials, PBDEs, TBBPA, mica and mica derivatives, vermiculite and vermiculite derivatives, basalt, graphite, polybutylene terephthalate, and combinations thereof. In a preferred embodiment, the fire-resistant material includes vermiculite, vermiculite derivatives, basalt, graphite, or combinations thereof.

[0009] The outer fabric layer may comprise any material suitable for providing a covering or protective layer to a surface. Suitable materials for the fabric layer include glass, fiberglass, fiberglass mat, fiberglass, glass cloth, woven or nonwoven fabric, etc. In a preferred embodiment, the outer layer comprises glass, fiberglass, or glass cloth. The composite material may have a total thickness of about 0.05 mm to about 1.0 mm, or about 0.1 to about 0.3 mm, preferably about 0.2 mm. The material may have a mass of less than about 200 kg / m2, or about 600 kg / m2 to about 1000 kg / m2.

[0010] In some embodiments, the fire-resistant material is incorporated into the first and second glass cloth layers by blending the fire-resistant material with one or more materials that provide adhesion between the fire-resistant material and the glass cloth layers. In one such embodiment, the fire-resistant material is blended with a polymer to form a composition that adheres to the cloth layers. This composition may or may not include an additional binder to promote bonding between the fire-resistant material and the cloth layers. In exemplary embodiments, the composition comprises from about 0.5 grams / m to about 10 grams / m of binder, preferably from about 1 gram / m to about 4 grams / m, and more preferably about 2 grams / m. The ability to keep the amount of binder in the composition substantially low reduces the amount of material released into the environment upon exposure to fire or excessive heat.

[0011] In another aspect, a heat-resistant composite material includes a first fabric layer, a second fabric layer bonded to the first fabric layer, and an intumescent fire-resistant material between the first and second fabric layers that is coated on or incorporated within at least one of the fabric layers. In this "military-grade" embodiment, the composite material is configured to absorb significant amounts of heat or fire that a military vehicle might be subjected to. In particular, the heat-resistant material is capable of absorbing or withstanding temperatures of approximately 1100°C for extended periods of time. In embodiments, the refractory material comprises a blend of vermiculite, clay, and aluminum trihydroxide. The enumeration herein of desirable objects met by various embodiments herein is not meant to imply or suggest that any of these objects, individually or collectively, are present as essential features of the most general embodiment herein or its more specific embodiments. [Brief explanation of the drawings]

[0012] [Figure 1] 1 shows a heat-resistant composite material. [Figure 2] 2 shows the material of FIG. 1 with the central portion expanded after heating. [Figure 3] 1 illustrates another embodiment of a heat-resistant composite material. [Figure 4] 1 shows test data obtained from the heat resistant composite materials described herein. DETAILED DESCRIPTION OF THE INVENTION

[0013] This specification and the accompanying drawings depict exemplary embodiments and should not be construed as limiting, with the claims defining the scope of this specification, including equivalents. Various mechanical, compositional, structural, and operational changes can be made without departing from the scope of this specification and claims, including equivalents. In some instances, well-known structures and techniques have not been shown or described in detail to avoid obscuring the description. Like numbers in two or more figures represent the same or similar elements. Furthermore, elements and their related aspects described in detail with respect to one embodiment may, whenever possible, be included in other embodiments where they are not specifically shown or described. For example, if an element is described in detail with respect to one embodiment but not with respect to a second embodiment, the element can still be claimed to be included in the second embodiment. Furthermore, the depictions herein are for illustrative purposes and do not necessarily reflect the actual shape, size, or dimensions of the system or illustrated components.

[0014] It should be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the," as well as the use of the singular form of any word, include plural referents unless expressly and unambiguously limited to one referent. As used herein, the term "include" and its grammatical variations are intended to be open-ended, and the enumeration of items in a list does not exclude other similar items that may be substituted for or added to the listed items. Unless otherwise indicated, all quantitative values ​​are approximate, whether preceded by words such as "about" or "approximately." The materials, methods, and examples described herein are illustrative only and are not intended to be limiting.

[0015] Composite heat-resistant materials and methods for making such materials are provided. The composite materials described herein are designed to be relatively inexpensive to manufacture and to emit very little (or no) harmful chemicals when exposed to heat or fire, thereby minimizing harmful emissions and health risks. Furthermore, because the materials are thin, flexible, and lightweight, they can be used as protective coverings for substrates or surfaces in a variety of applications, such as building and construction materials, including electrical wires, cables, and insulation materials; welding applications; aerospace and marine safety; fire protection; and reducing the penetration or escape of heat and / or fire into or from vehicles, aircraft, ships, electric batteries, buildings, insulation blankets, protective clothing, mattresses, cargo nets, hospital curtains, sheets or mattress covers; transportation products, such as automobile, airplane, and train seats, seat covers and fillers, bumpers, overhead compartments, and other components; electronic and electrical equipment, such as computers, laptops, phones, televisions, and home appliances; and furniture, such as foams, upholstery, mattresses, carpets, curtains, and fabric blinds.

[0016] In one embodiment, the materials disclosed herein are configured for use in military applications, such as tanks, Humvees, armored trains, reconnaissance vehicles, self-propelled anti-aircraft or artillery vehicles, tactical vehicles, trucks, helicopters, aircraft, armored personnel carriers, and other armored vehicles, to protect the interior of the vehicle or aircraft from heat associated with projectiles or other high-temperature munitions fired at the vehicle or aircraft. In this embodiment, the composite material is secured to or incorporated into the interior or exterior surface of the vehicle body or frame. The composite material can be secured by any method suitable to one skilled in the art, such as by applying an epoxy, glue, or other adhesive between the composite material and the vehicle frame. Suitable adhesives include cyanoacrylate adhesives and epoxies, Pratley® epoxy glue, epoxy steel putty, polyurethane glue, ethyl cyanoacrylate (CA), and the like. In one such embodiment, a vehicle cover is provided that includes a composite material described herein. The vehicle cover may be removable from the vehicle during use, or may be configured to be fixed to the vehicle during use (i.e., the cover does not extend over windows or other portions of the vehicle that should not be covered during use). The vehicle cover may include any suitable material and may include multiple layers of material. The composite material may be incorporated into one of the layers and / or sandwiched between one or more layers of the cover. Alternatively, composite materials can be configured for use in enhancing the safety of interior portions of vehicles or aircraft, such as seats, interior frames, instrument panels, seat covers and fillers, bumpers, overhead compartments, engine compartments, and hollow spaces between the interior and exterior sheet metal of a vehicle. The composite materials may be affixed to the exterior or interior surfaces of these interior structures or incorporated into the materials used to form these structures. For example, traditional seating materials consist of multi-layered or homogenous sheets, either shaped or contoured, cut from a range of commercially available grades of polyurethane foam. These foams are highly resilient and designed for superior cushioning, and are used in a wide range of automobile, truck, and commercial seating applications. Military seat cushions utilizing this same polyurethane foam construction can include the composite materials disclosed herein to enhance the heat resistance of these seats.

[0017] In another embodiment, the material may be configured for use on or in camouflage materials such as woven layers, knits, twills, fleeces, nonwovens, staple fibers, continuous filaments, yarns, tapes, and combinations thereof. Camouflage materials may include, for example, clothing, tents, tactical gear, etc. The composite material may be secured to the exterior or interior surfaces of these materials or incorporated within the materials. In one such embodiment, the garment is heat-resistant or flame-resistant. The garment is shaped to cover at least a portion of a wearer's body. The garment comprises a composite material as described herein and may also comprise other materials, such as woven or nonwoven fabrics. The fabric may also include additional flame-resistant or heat-resistant fibers, such as flame-retardant cellulose fibers, meta-aramid fibers, para-aramid fibers, or fiber-resistant viscose (FR viscose).

[0018] In another embodiment, the composite materials described herein are configured for use with a flame-retardant or heat-resistant mattress. The materials may be configured to cover at least a portion of the surface of the mattress or may be combined with additional flame-retardant or heat-resistant fibers, such as flame-retardant cellulose fibers, meta-aramid fibers, para-aramid fibers, fiber-resistant viscose (FR viscose), etc. In another embodiment, the materials described herein are configured for use with building and construction materials, including electrical wires, cables, insulation, windows, doors, walls, floors, roofs, interior beams, columns, and slabs. In this embodiment, the composite material may be secured to the exterior or interior surface of a structure or incorporated into the materials used in the structure. For example, the composite material may be incorporated into building insulation materials such as fiberglass, foam board, spray foam, cellulose, or injected foam. Alternatively, the composite material may be secured to the surface of these structures using a suitable adhesive, such as adhesive tape (e.g., pressure-sensitive tape, glass cloth adhesive tape), epoxy, glue, cyanoacrylate adhesives and epoxies, polyurethane glue, jeweler's glue (e.g., E600 or Beacon 527 glue), silicone gel glue, or the like.

[0019] In another embodiment, these materials are configured for use in protecting electronic devices from high temperatures. In one such embodiment, the composite material is specifically designed for use in protecting batteries from high temperatures (e.g., temperatures associated with explosive lithium batteries) outside the battery case or within the battery itself. In this embodiment, the composite material can be secured to the interior or exterior surface of the battery case using a suitable adhesive, such as epoxy-glass prepreg or other suitable adhesives described above. Alternatively, the composite material can be incorporated into the material used to form the battery case, such as polypropylene resin, carbon fiber reinforced plastic (CFRP), glass fiber reinforced plastic (GFRP), reinforced fabrics, metallized plastic films, aluminum and aluminum alloys, and other metal alloys. In another embodiment, the composite material is configured for use in providing additional insulation for pipes, blankets, personal protective clothing, and other thermal and fire protection products. In this embodiment, the composite material may be applied to or used in conjunction with a heat-resistant fabric, such as a fiberglass fabric, an aluminized fabric, or a welding blanket. Alternatively, the composite material may be incorporated into one or more of these heat-resistant fabrics.

[0020] Referring now to Figure 1, a high-temperature resistant composite material 10 includes first and second outer layers 12, 14 and a high-temperature resistant material 20 therebetween. Material 10 further includes at least one adhesive layer 16 between the inner and outer layers 12, 14. In some embodiments, material 20 may include a second adhesive layer 18. In other embodiments, adhesive layers 16 and 18 are formed together as a single layer. Adhesive layers 16, 18 may bond outer layers 12, 14 directly to one another, or may bond outer layers 16, 18 to high-temperature resistant material 20 (as shown in Figure 1). 2 shows composite material 10 when sufficient heat has been applied to the central portion of composite material 10. As shown, adhesive layers 16, 18 have melted through in the central portion of material 10. This eliminates the bond between outer layers 12, 14, allowing refractory material 20 to expand or swell and absorb a significant portion of the heat. At the same time, the outer portions of adhesive layers 16, 18, which have not been exposed to sufficient heat to melt, remain adhered to outer layers 12, 14. This ensures that the composite remains substantially intact and attached to the surfaces it is designed to protect.

[0021] 3 illustrates another embodiment of a composite material 10'. As shown, the composite material 10' includes inner and outer layers 12', 14' and an adhesive layer 16 therebetween. A fire-resistant material 20 is incorporated into or mixed with one or both of the outer layers 12', 14'. As with the previous embodiment, the adhesive layer 16 is configured to melt or otherwise lose its adhesion above a certain temperature. As with the previous embodiment, when sufficient heat is applied to a portion of composite material 10, adhesive layer 16 may melt or otherwise lose its adhesion, causing layers 12', 14' to separate from one another in that portion of material 10. This allows heat-resistant material 20 to expand or swell to absorb the applied heat. The composite materials 10, 10' may each have a total thickness of about 0.05 mm to about 1.0 mm, or about 0.1 to about 0.3 mm, preferably about 0.2 mm. The thickness of the composite materials 10, 10' may vary depending on the particular application and the amount of heat absorbed by the material. It is anticipated that a temperature difference (ΔT) of 200°C (0.05 mm) to 1000°C (military grade) may be observed between the fire-exposed side and the backside. The thickness of the material may be about 0.7 to about 1.0 mm.

[0022] The outer layers 12, 14 may comprise any material suitable for providing a covering or protective layer to a surface. Suitable materials for the outer layers 12, 14 include glass, fiberglass, fiberglass mat, fiberglass, glass cloth, woven or nonwoven fabrics, tapes, etc. In preferred embodiments, the outer layers 12, 14 comprise glass, fiberglass, or glass cloth. The adhesive layers 16, 18 comprise a material configured to melt or otherwise lose its adhesion above a certain temperature. In certain embodiments, the material is specifically configured to melt or otherwise lose its adhesion above about 30° C., preferably above about 60° C. Suitable materials for the adhesive layers include fabric or wood glue, epoxies, cyanoacrylates, urethanes, acrylics, hot melt adhesives, pressure sensitive adhesives, reactive adhesives, wet adhesives, solvent-based adhesives, rubber-based adhesives, contact adhesives, and the like. In a preferred embodiment, the adhesive layer comprises fabric or wood glue.

[0023] The heat-resistant material 20 may comprise any suitable material capable of expanding or swelling to absorb heat. Suitable materials include, but are not limited to, melamine, melamine polyphosphate, aluminum trihydroxide, antimony trihydroxide, phosphorus, ammonium polyphosphate, halogenated organic materials, PBDEs, TBBPA, mica and mica derivatives, vermiculite and vermiculite derivatives, basalt, graphite, polybutylene terephthalate, and combinations thereof. In a preferred embodiment, the fire-resistant material includes vermiculite, vermiculite derivatives, basalt, graphite, or combinations thereof. The fire-resistant material 20 may be applied as a layer between the inner and outer layers 12, 14, or may be incorporated into or coated on each of these layers. In one embodiment, the fire-resistant material is incorporated into the first and second glass cloth layers by blending the fire-resistant material with one or more materials that provide adhesion between the fire-resistant material and the glass cloth layers. In certain embodiments, the fire-resistant material is blended with a polymer such as polyvinyl alcohol (PVOH), acrylic, styrene butadiene (SBR), or combinations thereof, with or without additional binder materials. In an exemplary embodiment, material 20 includes a binder in an amount of from about 0.5 grams / m² to about 10 grams / m², preferably from about 1 gram / m² to about 4 grams / m², and more preferably about 2 grams / m². Suitable materials for the binder include PVOH, acrylic, SBR, and combinations thereof.

[0024] Applicant has discovered that blending the fire resistant material with polymers such as polyvinyl alcohol (PVOH), acrylic and / or styrene-butadiene (SBR), and containing little or no binder, reduces the amount of material released from the fire resistant material when subjected to heat, particularly if the composite is exposed to fire or excessive heat. In some embodiments, the three-layer laminate is bonded with two layers of adhesive. The materials of the outer layers 12, 14 may include woven and non-woven glass, making them difficult to bond. The flame-retardant material of the heat-resistant layer 20 is also somewhat rough, making these materials more difficult to bond. In certain embodiments, for example, for use in military applications, higher grade materials may be used for the outer layers 12, 14 to increase the heat resistance of the composition. In these embodiments, the outer layers 12, 14 may include a higher expandable graphite coating on a basalt backing, resulting in a thicker and tougher composition. [Example]

[0025] Figure 4 shows the results of tests conducted by applicant on a composite material having outer layers 12, 14 of woven glass fabric and a heat-resistant layer 20 containing vermiculite. The outer layers were attached with wood glue. The composite material was exposed to a fire. Nine separate thermocouples (labeled TC1 through TC9) were placed near the side of the composite facing away from the fire, with a 50 mm air gap between them. The graph on the left side of Figure 4 shows the temperature change of the material over time for each thermocouple. As shown, the thermocouples in the center of the fire (i.e., TC4-TC6) maintained a substantially constant temperature of about 15°C for about 10 minutes before beginning to increase in temperature. The thermocouples on either side of the fire (TC1-TC3 and TC7-TC9) maintained a substantially constant temperature of about 15°C and only experienced a temperature increase of about 5°C or less at the 16-minute mark.

[0026] The wood glue in the center of the fire (i.e., located on the periphery of TC4-TC6) lost its adhesion at approximately 60°C. Therefore, in the center of the fire, the adhesive began to melt or otherwise lose its adhesion, allowing the fire-resistant material to swell or expand in areas of the fabric layer exposed to the heat source. At the same time, the wood glue on either side of the fire (i.e., located at TC1-TC3 and TC7-TC9) maintained adhesion of the fabric layer in areas not exposed to such heat. Thus, the composite expanded and absorbed heat in the center of the fire, but remained adhered to the substrate it was designed to protect. While the devices, systems, and methods have been described in detail herein in accordance with certain preferred embodiments thereof, many modifications and variations therein may be made by those skilled in the art. Accordingly, the foregoing description should not be construed as limited thereby, but should be construed as including such obvious variations as may be set forth above, and should be construed as limited only by the spirit and scope of the following claims.

[0027] For example, in a first aspect, a first embodiment is a heat resistant composite that includes a first fabric layer, a second fabric layer in contact with the first fabric layer, and an intumescent fire resistant material between the first and second fabric layers. The second embodiment is the first embodiment, where the first fabric layer is bonded to the second fabric layer. A third embodiment is any combination of the first two embodiments, where the first fabric layer and the second fabric layer comprise glass. A fourth embodiment is a combination of any of the first three embodiments, wherein the first fabric layer and the second fabric layer comprise fiberglass. A fifth embodiment is any combination of the first four embodiments, wherein the refractory material is configured to expand when heat is applied to the refractory material.

[0028] A sixth embodiment is any combination of the first five embodiments, wherein the fire resistant material comprises a material selected from the group consisting of melamine, melamine polyphosphate, aluminum trihydroxide, antimony trihydroxide, phosphorus, ammonium polyphosphate, halogenated organic materials, PBDEs, TBBPA, mica and mica derivatives, vermiculite and vermiculite derivatives, basalt, graphite, polybutylene terephthalate, and combinations thereof. A seventh embodiment is any combination of the first six embodiments, wherein the refractory material comprises vermiculite. An eighth embodiment is any combination of the first seven embodiments, wherein the refractory material comprises basalt. A ninth embodiment is any combination of the first eight embodiments, further comprising an adhesive between the first layer and the second layer. A tenth embodiment is any combination of the first nine embodiments, wherein the adhesive substantially loses adhesion between the first layer and the second layer at a temperature of about 60° C. or greater.

[0029] An eleventh embodiment is any combination of the first ten embodiments, wherein the adhesive comprises fabric or wood glue. A twelfth embodiment is any combination of the first eleven embodiments, further comprising a polymer mixed with the fire resistant material. A thirteenth embodiment is any combination of the first twelve embodiments, wherein the polymer is selected from the group consisting of polyvinyl alcohol (PVOH), acrylic, styrene-butadiene (SBR), and combinations thereof. A fourteenth embodiment is any combination of the first thirteen embodiments, wherein the refractory material further comprises graphite. A fifteenth embodiment is any combination of the first fourteenth embodiment, wherein the refractory material further comprises basalt.

[0030] A sixteenth embodiment further includes a binder between the first layer and the second layer, the binder being about 2 grams / m2 of binder per area of ​​the first layer and the second layer. 2 any combination of the first 15 embodiments, wherein A seventeenth embodiment is any combination of the first sixteen embodiments, wherein the composite material is from about 0.05 mm to less than about 1.0 mm thick. An eighteenth embodiment is any combination of the first seventeen embodiments, wherein the first fabric layer and the second fabric layer each include a first surface and a second surface opposite the first surface, and the first surface of the first fabric layer is adhered to the second surface of the second fabric layer. A nineteenth embodiment is any combination of the first eighteen embodiments, wherein the fire resistant material is applied as a coating to the first surface of the first fabric layer. A twentieth embodiment is any combination of the first nineteen embodiments, wherein the fire resistant material is applied as a coating to the second surface of the second fabric layer. A twenty-first embodiment is a combination of any of the first twenty embodiments, wherein the fire resistant material is incorporated into at least one of the first fabric layer and the second fabric layer.

[0031] In another aspect, a first embodiment is a heat resistant composite material including a first layer and a second layer in contact with each other, wherein a first portion of the first layer and a second layer are configured to separate from each other when a threshold amount of heat is applied to the first portion, and a second portion of the first layer and a second layer are configured to remain adhered to each other when the threshold amount of heat is applied to the first portion. The second embodiment is the first embodiment, where the first layer is adhered to the second layer. A third embodiment is any combination of the first two embodiments, where the threshold heat amount is a temperature of about 30° C. or greater. A fourth embodiment is any combination of the first three embodiments, where the threshold heat amount is a temperature of about 60° C. or greater. A fifth embodiment is any combination of the first four embodiments, further comprising an adhesive between the first layer and the second layer, wherein the adhesive substantially loses adhesion between the first layer and the second layer at a temperature of about 60° C. or greater.

[0032] A sixth embodiment is any combination of the first five embodiments, wherein the adhesive comprises fabric or wood glue. A seventh embodiment is a combination of any of the first six embodiments, wherein the first fabric layer and the second fabric layer comprise glass or fiberglass. An eighth embodiment is any combination of the first seven embodiments, further comprising an intumescent fire-resistant material configured to expand when heat is applied to the fire-resistant material. A ninth embodiment is any combination of the first eight embodiments, wherein the fire resistant material comprises a material selected from the group consisting of melamine, melamine polyphosphate, aluminum trihydroxide, antimony trihydroxide, phosphorus, ammonium polyphosphate, halogenated organic materials, PBDEs, TBBPA, mica and mica derivatives, vermiculite and vermiculite derivatives, basalt, graphite, polybutylene terephthalate, and combinations thereof. A tenth embodiment is any combination of the first nine embodiments, wherein the refractory material comprises vermiculite.

[0033] An eleventh embodiment further includes a binder between the first layer and the second layer, the binder being about 2 grams / m2 of binder per area of ​​the first layer and the second layer. 2 any combination of the first ten embodiments, wherein the number of A twelfth embodiment is any combination of the first eleven embodiments, wherein the composite material is less than about 1.0 mm thick. A thirteenth embodiment is any combination of the first twelve embodiments, wherein the first fabric layer and the second fabric layer each include a first surface and a second surface opposite the first surface, and the first surface of the first fabric layer is adhered to the second surface of the second fabric layer. A fourteenth embodiment is any combination of the first thirteen embodiments, wherein the fire resistant material is applied as a coating to the first surface of the first fabric layer. A fifteenth embodiment is any combination of the first fourteenth embodiment, wherein the fire resistant material is applied as a coating to the second surface of the second fabric layer. A sixteenth embodiment is any combination of the first fifteen embodiments, wherein the fire resistant material is incorporated into at least one of the first fabric layer and the second fabric layer.

[0034] In another aspect, a first embodiment is a composite material for use in a vehicle, the composite material including a first fabric layer, a second fabric layer bonded to the first fabric layer, and an intumescent fire-resistant material between the first and second fabric layers. The second embodiment is the first embodiment, where the material is configured to be incorporated into the structure of a vehicle. A third embodiment is any combination of the first two embodiments, further comprising an adhesive configured to secure the composite material to a surface of the vehicle structure.

[0035] In another aspect, a first embodiment is a composite material for use in building structures, the composite material including a first fabric layer, a second fabric layer bonded to the first fabric layer, and an intumescent fire-resistant material between the first and second fabric layers. The second embodiment is the first embodiment, where the material is configured to be incorporated into the structure of a building. A third embodiment is any combination of the first two embodiments, where the material is configured to be incorporated into the insulation of a building. A fourth embodiment is any combination of the first three embodiments, further comprising an adhesive configured to secure the composite material to a surface of a building structure.

[0036] In another aspect, a first embodiment is a composite material for use in a battery, the composite material including a first fabric layer, a second fabric layer bonded to the first fabric layer, and an intumescent fire-resistant material between the first and second fabric layers. The second embodiment is the first embodiment, where the material is configured to be incorporated into the casing of the battery. A third embodiment is any combination of the first two embodiments, further comprising an adhesive configured to secure the composite material to a surface of the battery casing.

[0037] In another aspect, a first embodiment is a composite material for use in a garment, the composite material including a first fabric layer, a second fabric layer bonded to the first fabric layer, and an intumescent fire-resistant material between the first and second fabric layers. The second embodiment is the first embodiment, where the composite material is configured to be incorporated into a garment.

Claims

1. a first fabric layer; a second fabric layer in contact with the first fabric layer; and an intumescent fire-resistant material between the first fabric layer and the second fabric layer; A heat-resistant composite material comprising:

2. The composite material of claim 1 , wherein the first fabric layer is bonded to the second fabric layer.

3. The composite material of claim 1 , wherein the first fabric layer and the second fabric layer comprise glass.

4. The composite material of claim 1 , wherein the first fabric layer and the second fabric layer comprise fiberglass.

5. The composite material of claim 1 , wherein the refractory material is configured to expand when heat is applied to the refractory material.

6. 10. The composite material of claim 1, wherein the fire resistant material comprises a material selected from the group consisting of melamine, melamine polyphosphate, aluminum trihydroxide, antimony trihydroxide, phosphorus, ammonium polyphosphate, halogenated organic materials, PBDE, TBBPA, mica and mica derivatives, vermiculite and vermiculite derivatives, basalt, graphite, polybutylene terephthalate, and combinations thereof.

7. The composite material of claim 1 , wherein the refractory material comprises vermiculite.

8. The composite material of claim 1 , wherein the refractory material comprises basalt.

9. The composite material of claim 1 , further comprising an adhesive between the first layer and the second layer.

10. 10. The composite material of claim 9, wherein the adhesive substantially loses adhesion between the first layer and the second layer at a temperature of about 60°C or greater.

11. 11. The composite material of claim 10, wherein the adhesive comprises fabric or wood glue.

12. The composite material of claim 6 further comprising a polymer mixed with the fire resistant material.

13. 13. The composite material of claim 12, wherein the polymer is selected from the group consisting of polyvinyl alcohol (PVOH), acrylic, styrene-butadiene (SBR), and combinations thereof.

14. The composite material of claim 6 , wherein the refractory material further comprises graphite.

15. The composite material of claim 6 , wherein the refractory material further comprises basalt.

16. Further comprising a binder between the first layer and the second layer, the binder having a density of about 2 grams / m2 per area of ​​the first layer and the second layer. 2 10. The composite material of claim 1, wherein the composite material is less than 100% by mass.

17. 10. The composite material of claim 1, having a thickness of about 0.05 mm to less than about 1.0 mm.

18. 2. The composite material of claim 1, wherein the first fabric layer and the second fabric layer each include a first surface and a second surface opposite the first surface, and the first surface of the first fabric layer is bonded to the second surface of the second fabric layer.

19. 20. The composite of claim 18, wherein the fire resistant material is applied as a coating to the first surface of the first fabric layer.

20. 20. The composite of claim 18, wherein the fire resistant material is applied as a coating to the second surface of the second fabric layer.

21. The composite of claim 1 , wherein the fire resistant material is incorporated into at least one of the first fabric layer and the second fabric layer.

22. comprising a first layer and a second layer in contact with each other; the first layer and a first portion of the second layer are configured to separate from each other when a threshold amount of heat is applied to the first portion; the first layer and the second portion of the second layer are configured to remain adhered to one another when a threshold amount of heat is applied to the first portion. Heat-resistant composite material.

23. 23. The composite material of claim 22, wherein the first layer is adhered to the second layer.

24. 23. The composite of claim 22, wherein the threshold thermal dose is a temperature of about 30°C or greater.

25. 23. The composite of claim 22, wherein the threshold thermal budget is a temperature of about 60°C or greater.

26. 25. The composite material of claim 24, further comprising an adhesive between the first layer and the second layer, wherein the adhesive substantially loses adhesion between the first layer and the second layer at a temperature of about 60°C or greater.

27. 27. The composite material of claim 26, wherein the adhesive comprises fabric or wood glue.

28. 23. The composite material of claim 22, wherein the first fabric layer and the second fabric layer comprise glass or fiberglass.

29. 23. The composite material of claim 22, further comprising an intumescent fire-resistant material configured to expand when heat is applied to the fire-resistant material.

30. 30. The composite material of claim 29, wherein the fire resistant material comprises a material selected from the group consisting of melamine, melamine polyphosphate, aluminum trihydroxide, antimony trihydroxide, phosphorus, ammonium polyphosphate, halogenated organic materials, PBDE, TBBPA, mica and mica derivatives, vermiculite and vermiculite derivatives, basalt, graphite, polybutylene terephthalate, and combinations thereof.

31. 31. The composite material of claim 30, wherein the refractory material comprises vermiculite.

32. Further comprising a binder between the first layer and the second layer, the binder having a density of about 2 grams / m2 per area of ​​the first layer and the second layer. 2 23. The composite material of claim 22, wherein the composite material is less than 1 / 2 .mu.m.

33. 23. The composite material of claim 22, which is less than about 1.0 mm thick.

34. 23. The composite material of claim 22, wherein the first fabric layer and the second fabric layer each include a first surface and a second surface opposite the first surface, and the first surface of the first fabric layer is adhered to the second surface of the second fabric layer.

35. 23. The composite of claim 22, wherein the fire resistant material is applied as a coating to the first surface of the first fabric layer.

36. 23. The composite of claim 22, wherein the fire resistant material is applied as a coating to the second surface of the second fabric layer.

37. 23. The composite of claim 22, wherein the fire resistant material is incorporated into at least one of the first fabric layer and the second fabric layer.

38. 1. A composite material for use in a vehicle, comprising: a first fabric layer; a second fabric layer adhered to the first fabric layer; and an intumescent fire-resistant material between the first fabric layer and the second fabric layer; Composite materials, including:

39. 40. The composite material of claim 38 configured to be incorporated into the structure of the vehicle.

40. 40. The composite material of claim 38, further comprising an adhesive configured to secure the composite material to a surface of the vehicle structure.

41. 1. A composite material for use in building structures, comprising: a first fabric layer; a second fabric layer adhered to the first fabric layer; and an intumescent fire-resistant material between the first fabric layer and the second fabric layer; Composite materials, including:

42. 42. The composite material of claim 41 configured to be incorporated into the structure of the building.

43. 43. The composite material of claim 42 configured to be incorporated into the thermal insulation of the building.

44. 42. The composite material of claim 41, further comprising an adhesive configured to secure the composite material to a surface of the building structure.

45. 1. A composite material for use in a battery, comprising: a first fabric layer; a second fabric layer adhered to the first fabric layer; and an intumescent fire-resistant material between the first fabric layer and the second fabric layer; Composite materials, including:

46. 46. ​​The composite material of claim 45 configured to be incorporated into the casing of the battery.

47. 46. ​​The composite material of claim 45, further comprising an adhesive configured to secure the composite material to a surface of a casing of the battery.

48. 1. A composite material for use in clothing, comprising: a first fabric layer; a second fabric layer adhered to the first fabric layer; and an intumescent fire-resistant material between the first fabric layer and the second fabric layer; Composite materials, including:

49. 49. The composite of claim 48 configured to be incorporated into the garment.

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