Superior Products International has been experimenting with and developing the uses of "insulation and fire protection" ceramics for over 10 years. This category of ceramic functionality is new to the engineering fields. Only in recent years has the idea of insulation been associated with this new breed of ceramics.

Superior Products International began in the late 1980's to set up an extensive R&D procedure to gather ceramic compounds from all areas of the world for testing. Superior Products International knew that this area had not been thoroughly explored before, nor had any extensive documentation been presented for this application. In contrast, many articles and studies have been devoted to the abrasion resistant ceramic compounds and how they can be used in manufacturing and industrial markets.

Insulative ceramics are completely different and separate from those used for abrasion resistance. As noted in this category, no extensive studies have been performed to determine which ceramic compounds, either natural or manmade would be best suited for eliminating heat transfer. Some studies have acknowledge the "reflection" of heat by mere radiation of sunlight, but since very limited study has been performed, it was thought that reflection was all that this new category of ceramic could provide.

Superior Products International initially worked in the early 1990's with the aid of Marshall Space Center Laboratories, and it was discovered that no real research had been performed across the broad spectrum of possible ceramic compounds in order to determine the scope of ceramics stopping or slowing "heat conduction" rather than merely radiant heat reflection. It was also decided that Superior Products International would continue the R&D work over the next several years to discover the possibilities of this new design of ceramics. An extensive search was organized and begun to locate all possible types of ceramics compounds in the world market for trial-and-error testing. A system was designed to take each compound through a series of heat conduction tests to find its ability to stop heat conduction. More than 1,000 compounds were received and tested. From this R&D period, eight different compounds were identified as having the ability not only to catch and throw heat away from their surfaces in a manner similar to reflection but also to control heat conduction.

Superior Products International chose three of these ceramic compounds to develop its insulation coating called SUPER THERM. This is a thin film coating that will protect against heat migration equal to six inches of fiberglass batt insulation when applied over surfaces facing the heat source. Eight of the ceramic compounds were also chosen to work in combination with one another to capture surface heat, stop heat conduction and glaze or harden to stop flame, smoke or gas penetration. This product is the focus of this presentation and the name of the product is SP2001F.

SP2001F is a unique blend of eight different ceramic compounds chosen out of over 6 years of research and 1000 compounds that combine and work together to form a heat block against extreme heat migration. Since the coating surface will come in direct contact with flame, a char enhancer was added to form a small char on the surface. When the char forms, it brings the ceramics up and into the char to allow the char to be tough and remain in place during actual fire conditions. This coating is a ceramic hybrid that is unique to the industry. It is not fragile, it becomes surface hard; and because of the ceramics, it will continue to insulate against extreme heat migration during a direct or indirect fire. Whatever surface is covered with this coating is able to offer extreme heat insulation through any substrate coated.

This is not an intumiscent coating, but instead, a pliable film that reacts to flame. In comparison, intumiscent coatings swell upon contact with fire and form a char that is extremely lightweight and fragile, leaving them susceptible to damage during a fire from strong winds, flying debris and sprinkler systems. Once the char is brushed off, the existence of fire protection is eliminated. Clean-up of all surface areas (direct and indirect exposure) is extensive from the swelled coating.

Cementious materials are very expensive to apply and have poor appearance. Some will emit toxic fumes during a fire.

Cellulose materials look like a shag rug on the surface and will be affected over time by condensation and humidity.

Unlike most fire barriers requiring 2-3 inches thickness (50-70mm), SP2001F requires only 8 to 10 mm (350-400 mils) over wood and porous substrates, over metal 7 to 8 mm (300-350 mils) thickness to provide fire protection. The competing fire protection materials are either cementious and must be trowled on over wire mesh - which is time-consuming in its application and inflexible in its finished state, or blown-on cellulose - which is somewhat fragile and subject to surface damage. Intumiscent paints are applied thinly but when activated become fragile after expanding out to meet the flame. In other situations, two wallboard sections (5/8 inch thick-14mm each) are nailed together to provide fire protection. This is labor-intensive and impractical in most major construction areas. SP2001F relies upon the dense combination of eight ceramic compounds to catch the heat of the flame. When flames contact the face of the coating, it begins a glazing or surface hardening that becomes tough while sealing off any pores to heat, smoke or gas passages. When the coating surface completely hardens, it forms a solid block against heat conduction. The SP2001F will set hard and hold constant for the duration of the fire.