Non-flammable compositions

Abstract

A non-flammable composition is formulated to include ceramic powder, graphite, mica and ZrO.sub.2. The non-flammable composition is capable of being applied to an external surface of an item, or may be incorporated into the substrate material used to form an item prior to the item's manufacture. The non-flammable composition provides both fire-resistance and fire-retardant properties to the items that are treated thereby.

Claims

1. A non-flammable material comprising: ceramic powder at a proportion of 23-24%; graphite at a proportion of 34-35%; mica at a proportion of 20-21%; and ZrO.sub.2 at a proportion of 21-22%.

2. The material of claim 1, wherein said material comprises particles having a nanometer-sized dimension.

3. The material of claim 1, further comprising: polymeric material.

4. The material of claim 3, wherein said polymer material comprises particles having a nanometer-sized dimension.

5. The material of claim 1, wherein said material is in a water suspension.

6. The material of claim 5, wherein said water suspension is at a proportion of about 20%.

7. A method of making an item with the material of claim 1, comprising: treating the item with said material.

8. The method of claim 7, wherein said treating step is performed by solvent deposition, mechanical deposit, or sol-gel.

9. The method of claim 7, wherein said treating step includes coating.

10. The method of claim 7, wherein said treating step includes soaking.

11. The method of claim 7, wherein said treating step includes integrating said material into a target material forming at least a part of said item.

12. An item including the material of claim 1, wherein said item comprises a railroad tie or a telephone pole.

13. An item including the material of claim 1.

Description

DETAILED DESCRIPTION

(1) The embodiments disclosed herein relate to non-flammable compositions, which are defined herein as compositions having fire-resistant properties (i.e. resists burning or starting on fire) and/or fire-retardant properties (i.e. slows the spread of fire that has started).

(2) Specifically, the non-flammable compositions may be mixed or otherwise incorporated into other target materials, items or objects. For example, such target materials include, but are not limited to polymers, elastomers, or dyes, and the non-flammable compositions act as a heat repellant preventing the temperature of the target raw material from increasing, when subjected to fire thereby making the item non-flammable. It should also be appreciated that the term item is defined herein as any object, fabric, or combination thereof. For example, such item may include railroad ties or telephone poles, which are formed of natural or synthetic materials.

(3) The non-flammable composition comprises a mix or combination of materials, such as inorganic materials for example, at suitable concentrations. In some embodiments, the non-flammable composition may be formed by mixing, or otherwise combining, the following combination of materials:

(4) 1) Ceramic material, such as ceramic powder, at proportions ranging from 15-35%, preferably 20-30%;

(5) 2) Graphite at proportions ranging from 0.5-40%, preferably 10-35%;

(6) 3) Mica at proportions ranging from 10-30%, preferably 15-25%; and

(7) 4) Zirconia dioxide (ZrO.sub.2) at proportions ranging from 10-30%, preferably 15-25%.

(8) In other embodiments, the non-flammable composition includes:

(9) 1) Ceramic material, such as ceramic powder, at a proportion of 23-24%;

(10) 2) Graphite at a proportion of 34-35%;

(11) 3) Mica at a proportion of 20-21%; and

(12) 4) Zirconia dioxide (ZrO.sub.2) at a proportion of 21-22%.

(13) Furthermore, it should be appreciated that the proportion of ceramic material may be between 20-40%, and 25-35%, as well as anywhere up to 45%; the proportion of graphite may be between 5-35%, 10-30%, and 15-25%, as well as anywhere up to 40%; the proportion of mica may be up to 30%; and the proportions of zirconia dioxide may be up to 30%.

(14) It should be appreciated that the term Ceramic powder or material, as used herein, refers to materials that contain SiO.sub.2. In addition, the ceramic powder or material may be greater than or equal to the amount of other inorganic oxides in the non-flammable material, such as CaO, Al.sub.2O.sub.3, CeO.sub.2, Na.sub.2O. K.sub.2O, B.sub.2O.sub.3, ZnO, F, Li.sub.2O, ZrO.sub.2, SrO, TiO.sub.2, as well as pigments. In some embodiments, ceramic powders or materials containing SiO.sub.2 that exceed around 60% of the inorganic oxides of Al.sub.2O.sub.3, ZnO, Na.sub.2O, K.sub.2O may include Calcined Alumina Powder, Alumina Oxide Powder, Silicon Nitride Powder, Ceramic Frit Glass, and the like.

(15) With respect to graphite, any suitable form may be used. The percentage of graphite can be reduced for the purpose of reaching improved product aesthetics and allowing a lighter item or product color, if desired. However, in some embodiments, titanium dioxide may be added to the non-flammable composition to achieve a desired color of the target product or item being formed or treated.

(16) Mica encompasses a group of silicon minerals whose chemical composition can be expressed as: X.sub.2Y.sub.4-6Z.sub.8O.sub.20(OH,F).sub.4,

(17) where X is K, Na or Ca;

(18) Y is Al, Mg or Fe, Mn, Cr, Ti, or Li; and

(19) Z is Si or Al, however it should be appreciated that in some embodiments Fe.sup.3+ or Ti may also be included into the non-flammable composition.

(20) In some embodiments, Mica may encompass common mica, which is expressed by the chemical formulas: K.sub.2Al.sub.2(AlSi.sub.3O.sub.10(F.sub.3OH).sub.2, KAl.sub.2(AlSi.sub.3O.sub.10(F.sub.3OH).sub.2, or (KF).sub.2(AL.sub.2O.sub.3).sub.3(SiO.sub.2).sub.6(H.sub.2O), which is also known as muscovite.

(21) Finally, ZrO.sub.2 (Zirconium Dioxide) in any suitable form may be utilized. It should be appreciated that Zirconium Dioxide may be replaced with any inorganic oxide material. In other embodiments, the non-flammable composition may be configured so that the Zirconium Dioxide is replaced with Magnesium Hydroxide.

(22) In some embodiments, the non-flammable composition may be produced by combining the ingredients discussed above using any suitable technique, such as by mixing. In the case of mixing the ingredients of the non-flammable composition, any mechanical mixing technique may be used, such as those provided by mixers of any suitable capacity. In addition, the ingredients utilized in the non-flammable composition may be combined in any desired order or sequence.

(23) The non-flammable composition includes a variety of properties, including one or more of non-inflammable, biodegradable, non-toxic and water-proof.

(24) As previously discussed, the non-flammable composition may be utilized as either an additive to be incorporated into the raw target materials that used to form or manufacture an item or may be used as a coating or other surface treatment that is applied to the surface of the item after the item has been formed or manufactured.

(25) Accordingly, the non-flammable composition may be mixed, or otherwise combined, with any other target material, such as polymeric materials, such as in the case of manufacturing plastic items. It should be appreciated that the target material may comprise nanometer sized particles. In some embodiments, the non-flammable material may be particleized, or formed into particles, such as nanometer-sized particles, before being added to a target material used to form an item, or before being applied to the surface of the item. For example, the non-flammable composition may be first ground or made into particles in order to achieve a uniform separation of the total mass and, to achieve the formation of items that have durability, and sustainability, as well as fire-resistant/retardant properties.

(26) The non-flammable composition can also be used to form a rigid cladding layer, sheeting or covering that is applied or otherwise placed upon the item. Such cladding layer may be formed by means of producing a suspension of the non-flammable composition into water at a proportion of about 20%, whereupon the suspension is coated or applied on the item using a paint brush, spray, roller, or any other suitable means. For example, during an experimental trial with a flame cutter, a wooden box coated with the non-flammable composition resisted catching on fire when exposed to a temperature near 2200 C.

(27) In another aspect, the surface of item may be treated by soaking the surface of the item to be protected in the non-flammable composition. Soaking may be performed utilizing any suitable technique, such as solvent deposition, mechanical deposit, sol-gel, and the like. Such soaking augments the prevention of thermal degradation and the development of combustion products when a treated item is exposed to fire. Alternatively, the non-flammable composition may be applied to items, by air or water jetting, so that the non-flammable composition acts as a fire extinguishing material.

(28) Therefore, it can be seen that the objects of the various embodiments disclosed herein have been satisfied by the structure and its method for use presented above. While in accordance with the Patent Statutes, only the best mode and preferred embodiments have been presented and described in detail, with it being understood that the embodiments disclosed herein are not limited thereto or thereby. Accordingly, for an appreciation of the true scope and breadth of the embodiments, reference should be made to the following claims.