Foam insulation with enhanced fire and smoke performance

Patent metadata

Field	Value
Publication number	US-10563033-B2
Application number	US-201715718273-A
Country	US
Kind code	B2
Filing date	Sep 28, 2017
Priority date	Sep 28, 2017
Publication date	Feb 18, 2020
Grant date	Feb 18, 2020

Abstract

A polyisocyanurate foam insulation product includes polyisocyanurate foam produced from reacting an isocyanate and a polyol blend having a functionality of at least 2.2. The isocyanate and the polyol blend are reacted so that the polyisocyanurate foam has an isocyanate index equivalent with or greater than 300. The polyisocyanurate foam includes a fire retardant and includes between 0.02 and 0.45 weight percent of a zinc salt compound. The foam insulation board exhibits a flame spread of no greater than 25 and a smoke index of no greater than 50 when exposed to flame conditions in accordance with an ASTM E-84 test.

First claim

What is claimed is:

1. A foam insulation board comprising:
a polyisocyanurate foam produced from reacting:
an isocyanate; and
a polyol blend, the polyol blend having a functionality of at least 2.2;

wherein:
the isocyanate and the polyol blend are reacted so that the polyisocyanurate foam has an isocyanate index equivalent with or greater than 300;
the polyisocyanurate foam includes a blowing agent;
the polyisocyanurate foam includes a fire retardant; and
the polyisocyanurate foam includes between 0.02 and 0.45 weight percent of a zinc salt compound;

the foam insulation board exhibits a flame spread of no greater than 25 and a smoke index of no greater than 50 when exposed to flame conditions in accordance with an ASTM E-84 test;
wherein the polyisocyanurate foam is a closed cell foam having a cell size of 120 μm or less.

2. The foam insulation board of claim 1 , wherein the zinc salt compound comprises a zinc carboxylate.

3. The foam insulation board of claim 2 , wherein the polyisocyanurate foam includes between 0.045 and 0.23 weight percent of the zinc carboxylate.

4. The foam insulation board of claim 2 , wherein the polyisocyanurate foam includes between 0.045 and 0.14 weight percent of the zinc carboxylate.

5. The foam insulation board of claim 1 , wherein the fire retardant is non-halogenated.

6. The foam insulation board of claim 5 , wherein the fire retardant comprises diethyl hydroxymethyl phosphonate (DEHMP).

7. The foam insulation board of claim 1 , wherein the fire retardant comprises one or more compounds selected from the group of compounds consisting of an organo-phosphate, an organo-phosphite, and an organo-phosphonate.

8. The foam insulation board of claim 1 , wherein the fire retardant comprises tris(2-chloroisopropyl)phosphate (TCPP).

9. The foam insulation board of claim 1 , wherein the foam insulation board has an R-value per inch of at least 6.6 and a long-term thermal resistance (LTTR) of 5.9 R-value per inch for a foam insulation board having a thickness of 3 inches and a density of 1.6 lb/ft 3 .

10. The foam insulation board of claim 1 , wherein the polyisocyanurate foam is a rigid foam having a density of less than 2.0 lbs/ft 3 .

11. The foam insulation board of claim 1 , wherein the polyisocyanurate foam is a rigid foam having a density of less than 1.7 lbs/ft 3 .

12. The foam insulation board of claim 1 , wherein the polyisocyanurate foam has an isocyanate index of between 350 and 450.

13. The foam insulation board of claim 12 , wherein the polyisocyanurate foam has an isocyanate index of between 350 and 400.

14. The foam insulation board of claim 1 , wherein the blowing agent comprises a hydrocarbon gas, a fluorocarbon gas, or water.

15. An insulated structure comprising the foam insulation board of claim 1 .

16. A foam insulation board comprising:
a polyisocyanurate foam produced from reacting:
an isocyanate; and
a polyol blend, the polyol blend having a functionality of at least 2.2;

wherein:
the isocyanate and the polyol blend are reacted so that the polyisocyanurate foam has an isocyanate index of between 350 and 450;
the polyisocyanurate foam includes a blowing agent;
the polyisocyanurate foam includes a fire retardant; and
the polyisocyanurate foam includes between 0.045 and 0.23 weight percent of a zinc carboxylate compound;

the foam insulation board exhibits a flame spread of no greater than 25 and a smoke index of no greater than 50 when exposed to flame conditions in accordance with an ASTM E-84 test;
wherein the foam insulation board has an R-value per inch of at least 6.6 and a long-term thermal resistance (LTTR) of 5.9 R-value per inch for a foam insulation board having a thickness of 3 inches and a density of 1.6 lb/ft 3 .

Assignees

• Johns Manville

Inventors

• Nandi Malay
• Wang Lance
• Asrar Jawed

Classifications

• E04D13/1643

  the roof structure being formed by load bearing corrugated sheets, e.g. profiled sheet metal roofs · CPC title

• E04D11/02

  Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition (gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17) · CPC title

• E04D3/351

  at least one of the layers being composed of insulating material, e.g. fibre or foam material · CPC title

• C08J9/146

  only fluorine as halogen atoms · CPC title

• C08J9/125

  Water, e.g. hydrated salts · CPC title