Abstract:
A composite liner includes first and second basalt fabric layers with at least one of the first and second basalt fabric layers formed from woven basalt fibers. The composite liner further includes a core positioned between the first and second basalt fabric layers, where the first and second basalt fabric layers are secured to the core.

Description:
The present application claims the benefit of U.S. Provisional Application Ser. No. 61/696,959, filed Sep. 5, 2012, the entire disclosure of which is hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is directed to a tent liner and, more particularly, to a composite basalt fabric tent liner and protective composite basalt blanket. 
     2. Description of Related Art 
     Large tents are used by military personnel for troop deployment and serve a variety of functions, including use as command posts, barracks, and kitchens. These tents generally must meet certain ratings for fire resistance. The materials or chemicals typically used to meet the fire resistance ratings, however, give off toxic gases containing halogen and phosphorus. Also, the materials used in the construction of the tents also give off smoke and typically melt and drip when exposed to fire. Further, air-filled supports are frequently used in tent construction. Fire damage to these air-filled supports could result in a total collapse of the tent. U.S. Pat. Nos. 5,421,128 and 5,735,083 disclose air-filled supports or air beam structures and are each hereby incorporated by reference in their entirety. 
     Fire blankets are used to protect a user from fire-related injuries and are also utilized as fire extinguishing devices by smothering fires. Furthermore, fire blankets are also utilized to protect structures and other property in addition to protecting a person. 
     SUMMARY OF THE INVENTION 
     In one embodiment, a composite liner includes first and second basalt fabric layers with at least one of the first and second basalt fabric layers formed from woven basalt fibers. The composite liner further includes a core positioned between the first and second basalt fabric layers, where the first and second basalt fabric layers are secured to the core. 
     The liner may be embodied as a protective blanket. The core may be a basalt mat core. The core may also comprise reflective foil. One of the first and second basalt fabric layers may be non-woven basalt scrim. At least one of the first and second basalt fabric layers may be a woven basalt fabric having a weight of about 12-19 oz./yd. sq. The liner may further include a layer of tent material secured to the composite liner. The core may include a synthetic fiber thermal insulation core. The first and second basalt fabric layers may be a woven basalt fabric having a weight of about 12-19 oz./yd. sq., with the core being a basalt mat core. The first and second basalt fabric layers may be a woven basalt fabric having a weight of about 12-19 oz./yd. sq., with the core comprising reflective foil. 
     In another embodiment, a composite tent liner includes a sleeve defining an interior space configured to receive an air-filled support of a tent structure. The sleeve includes first and second basalt fabric layers with at least one of the first and second basalt fabric layers formed from woven basalt fibers. The sleeve also includes a core positioned between the first and second basalt fabric layers, where the first and second basalt fabric layers are secured to the core. The sleeve may be cylindrical in shape. The composite tent liner may further include an air-filled support received within the interior space of the sleeve. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial cross-sectional view of a liner or blanket according to one embodiment of the present invention. 
         FIG. 2  is a perspective view of a liner according to a second embodiment of the present invention. 
         FIG. 3  is a cross-sectional view of the liner shown in  FIG. 2 . 
         FIG. 4  is a cross-sectional view of the liner shown in  FIG. 2 , showing the liner positioned around an air-filled support. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For purposes of the description hereinafter, spatial orientation terms, if used, shall relate to the referenced embodiment as it is oriented in the accompanying drawing figures or otherwise described in the following detailed description. However, it is to be understood that the embodiments described hereinafter may assume many alternative variations and embodiments. It is also to be understood that the specific arrangements illustrated in the accompanying drawing figures and described herein are simply exemplary and should not be considered as limiting. 
     Referring to  FIG. 1 , one embodiment of a liner  10  includes a basalt mat core  12  and first and second layers of basalt fabric  14 ,  16  positioned on opposite sides of the basalt mat core  12 . The first and second layers of basalt fabric  14 ,  16  are adhered to or attached to the basalt mat core  12 . The teem “attached” refers to any arrangement of forming a bond so that layers of basalt fabric  14 ,  16  cannot be easily peeled or separated from the basalt mat core  12 . The first and second layers of basalt fabric  14 ,  16  may be formed from woven layers of basalt, such as the woven basalt fabric commercially available from Textile Solutions Holding, and in the range of about 12-19 oz./yd. sq., although other suitable weight basalt fabrics may be utilized. One or both of the basalt fabric layers  14 ,  16  may also be formed from non-woven basalt veil or scrim. The basalt mat core  12  may be formed from basalt mat or felt that generally includes basalt fibers that are mechanically formed into mats of varying thicknesses, such as the felt mats sold by Basalt Specialty Products Inc. The first and second layers of basalt fabric  14 ,  16  may be attached to the basalt mat core  12  via stitching, using a film adhesive, an epoxy, a water-based adhesive, or any other suitable adhesives. The stitching may be fiberglass, Kevlar® fiber, or Nomex® fiber thread, although other suitable thread for the stitching may be utilized. Examples of suitable film adhesives include polyester adhesive films (PAF series), which are commercially available from Adhesive Films, Inc. More specifically, the PAF  110  and PAF  130  polyester adhesive films from Adhesive Films, Inc. may be suitable. Very thin, flexible urethane films and high temperature nylon-based films may also be utilized. An example of a suitable water-based adhesive is the DS 7000 series adhesive from Collano Adhesives in Switzerland. 
     Referring again to  FIG. 1 , in a particular embodiment, the liner  10  is positioned adjacent to an inner surface  18  of tent material  20  used to construct a tent. The liner  10  may be used to cover the entire inner surface  18  of the tent material  20  forming the tent, although the liner  10  may also be positioned adjacent to an outer surface  22  of the tent material  20 . The liner  10  is loosely secured to the tent material  20  via any suitable fastening arrangement. The liner  10  may be stitched to the tent material  20  or may be attached to the tent material  20  using an adhesive, such as a film adhesive, a two-component epoxy, a water-based adhesive, or other suitable adhesive. The liner  10  may also be secured to the tent material  20  using any other suitable mechanical fastening arrangement, such as riveting, tying with rope, etc. The liner  10  may be formed integrally with the tent material  20  or may be formed separately and subsequently attached to the tent. 
     Although the embodiment of the liner  10  discussed above includes two layers of basalt fabric  14 ,  16  and the basalt mat core  12 , other arrangements for the liner  10  may be utilized. For example, the liner  10  may be formed from one or more layers of basalt fabric without the basalt mat core  12 . The basalt mat core  12  of the liner  10  may be a reflective foil core with two layers of basalt fabric positioned on opposite sides of the reflective foil core. Further, the basalt mat core  12  of the liner  10  may also be formed from a synthetic fiber thermal insulation core with two layers of basalt fabric positioned on opposite sides of the synthetic fiber thermal insulation core. The synthetic fiber thermal insulation used for the core may be THINSULATE® fiber sold by 3M Corporation. 
     Referring to  FIGS. 2-4 , the liner  10 , discussed above and shown in  FIG. 1 , is embodied as a sleeve  30 . The sleeve  30  is generally cylindrical and defines an interior space  32  that is sized and shaped to receive an air-filled support  34  used in the construction of tents. In particular, the sleeve  30  is configured to surround the air-filled support  34 . Such air-filled supports  34  are utilized to establish a tent structure (not shown) and a fire within the tent structure could cause the air-filled support  34  to collapse. The sleeve  30  and air-filled support  34  are not drawn to scale with the size of the sleeve  30  being illustrated larger for clarity. The sleeve  30  surrounds the air-filled support  34  and is configured to protect the air-filled support  34  from fire damage. The sleeve  30  may sufficiently protect the air-filled support  34  from damage thereby maintaining the structural integrity of the tent structure until the fire can be extinguished or until the tent structure can be evacuated. The sleeve  30  may include any of the liner configurations discussed above. 
     During testing, the liner  10  with thin layers of basalt fabric  14 ,  16 , with or without a basalt mat core  12 , has unexpectedly been found to protect the tent material  20  from damage, even from very intense fire. Further, the liner  10  with layers of basalt fabric  14 ,  16 , with a fiber core that would otherwise melt or combust, has unexpectedly been found to protect the tent material  20  from damage, even from very intense fire. The liner  10  has been found to protect the interior contents of a tent from damage even from an exterior fire that totally consumes the tent material. Although the liner  10  is discussed above in connection with tents, the liner  10  may also be used to protect fire fighting stations, equipment, or used as an emergency protective shelter during a forest fire. In particular, the liner  10  can also be used as external protection and function as a blanket. The liner  10  can be used as an external blanket to protect other objects, such as tents, temporary structures, or permanent structures or buildings, from potential fires. In contrast to conventional fire-resistant materials or chemical treatments of materials, the liner  10  generates little to no smoke or hazardous combustion products. In addition to its fire-resistance properties, the liner  10  also has thermal insulating and sound absorption properties. Accordingly, the liner  10  protects tents from incidental fire and increases time to extinguish fires in and around the tent structure. The liner  10  also protects air-filled supports  34  from being damaged and resulting in collapse of the tents. 
     This invention has been described with reference to the preferred embodiments. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations.