Spray foams containing non-halogenated fire retardants

Patent metadata

Field	Value
Publication number	US-2016017127-A1
Application number	US-201514750397-A
Country	US
Kind code	A1
Filing date	Jun 25, 2015
Priority date	Jul 18, 2014
Publication date	Jan 21, 2016
Grant date	—

Abstract

A spray foam formulation used to form a spray foam insulation layer in a wall structure is described. The formulation may include the reaction product of a polyisocyanate compound and a polyol compound; a fire retardant chosen from at least one of a non-halogenated fire retardant; and a reactive halogen-containing fire retardant, and a carbohydrate. The spray foam insulation layer has an insulative R value of 3.0 to 7.2 per inch, and a density of between about 0.3 to about 4.5 pcf. Further, spray foam insulation made from the spray foam formulation may have fire retardant characteristics that are equivalent to or better than a similar spray insulation foam insulation using non-reactive halogenated fire retardants such as tris(1-chloro-2-propyl)phosphate (TCPP).

First claim

What is claimed is:

1 . An insulated structure, comprising:
a plurality of structural support members coupled together to form a frame; a plurality of first wall boards attached to an exterior side of the frame to form an exterior wall or surface of the structure; and a spray foam insulation positioned within at least one of the wall cavities of the structure, the spray foam insulation comprising a spray foam having an insulative R value of 3.0 to 7.2 per inch and a density of between about 0.3-4.5 pcf, the spray foam made from a formulation that comprises:
a reaction product of a polyisocyanate compound and a polyol compound;
a fire retardant chosen from at least one of a non-halogenated fire retardant, and a reactive halogen-containing fire retardant; and
a carbohydrate.

2 . The insulated structure of claim 1 , wherein the non-halogenated fire retardant comprises diethyl hydroxymethylphosphonate.

3 . The insulated structure of claim 1 , wherein the insulated structure further comprises a plurality of second wall boards attached to an interior side of the frame to form an interior wall or surface of the structure, wherein the structural support members, the first wall boards, and the second wall boards define a plurality of wall cavities.

4 . The insulated structure of claim 1 , the formulation for the spray foam further comprises an additional non-halogenated phosphorous-containing compound.

5 . The insulated structure of claim 4 , wherein the additional non-halogenated phosphorous-containing compound comprises triethyl phosphate.

6 . The insulated structure of claim 1 , wherein the formulation for the spray foam further comprises a non-halogenated organo-phosphate compound.

7 . The insulated structure of claim 1 , wherein the formulation for the spray foam further comprises a non-halogenated organo-phosphite compound.

8 . The insulated structure of claim 1 , wherein the carbohydrate comprises sucrose.

9 . The insulated structure of claim 1 , wherein the carbohydrate comprises high-fructose corn syrup.

10 . The insulated structure of claim 1 , wherein the formulation for the spray foam does not contain a non-reactive halogen-containing compound.

11 . The insulated structure of claim 1 , wherein the formulation for the spray foam does not contain TCPP (tris(1-chloro-2-propyl)phosphate).

12 . A method of insulating a component of a building, comprising:
coupling a plurality of structural support members together to form a frame; attaching a plurality of first wall boards to an exterior side of the frame to form an exterior wall or surface of the structure; attaching a plurality of second wall boards to an interior side of the frame to form an interior wall or surface of the structure, wherein the structural support members, the first wall boards, and the second wall boards define a plurality of wall cavities; and positioning a spray insulation material within at least one of the wall cavities of the structure to insulate an interior space of the structure, wherein the spray insulation material comprises a spray foam having an insulative R value of 3.0 and 7.2 per inch and a density of between about 0.3 to about 4.5 pcf, the spray foam made from a spray foam formulation that comprises:
a reaction product of a polyisocyanate compound and a polyol compound;
a fire retardant chosen from at least one of a non-halogenated fire retardant, and a reactive halogen-containing fire retardant; and
a carbohydrate.

13 . The method of claim 12 , wherein the non-halogenated fire retardant comprises diethyl hydroxymethylphosphonate.

14 . The method of claim 12 , wherein the spray foam formulation further comprises a water-based blowing agent.

15 . The method of claim 11 , wherein the water-based blowing agent is water.

16 . The method of claim 10 , wherein the spray foam formulation further comprises a fluorocarbon-containing blowing agent.

17 . A spray foam formulation used in an insulation layer in a wall structure, the spray foam formulation comprising:
a reaction product of a polyisocyanate compound and a polyol compound; a fire retardant chosen from at least one of a non-halogenated fire retardant, and a reactive halogen-containing fire retardant; and a carbohydrate, wherein the insulation layer has an insulative R value of 3.0 to 7.2 per inch, and a density of between about 0.3 to about 4.5 pcf, and wherein the insulation layer exhibits an Appendix X and an ASTM E-84 performance equivalent with or better than a similar spray insulation layer having a non-reactive halogenated fire retardant tris(1-chloro-2-propyl)phosphate (TCPP).

18 . The spray foam formulation of claim 17 , wherein the insulation layer is an open cell insulation layer having a density between about 0.3-0.7 pcf.

19 . The spray foam formulation of claim 17 , wherein the insulation layer is a closed cell insulation layer having a density between about 2.0-4.0 pcf.

20 . The spray foam formulation of claim 17 , wherein the non-halogenated fire retardant comprises diethyl hydroxymethylphosphonate.

21 . The spray foam formulation of claim 17 , wherein the formulation further comprises at least one organo-phosphate compound.

22 . The spray foam formulation of claim 17 , wherein the at least one organo-phosphate compound is triethyl phosphate (TEP).

23 . The spray foam formulation of claim 17 , wherein the at least one organo-phosphate compound is a blend of butyl diphenyl phosphate, dibutyl phenyl phosphate, and triphenyl phosphate.

24 . The spray foam formulation of claim 17 , wherein the carbohydrate is chosen from sucrose and high-fructose corn syrup.

Assignees

• Johns Manville

Inventors

• Snider Scott
• Wang Lance
• Asrar Jawed

Classifications

• C08G18/4804

  Two or more polyethers of different physical or chemical nature · CPC title

• C08G18/4027

  Mixtures of compounds of group C08G18/54 with other macromolecular compounds · CPC title

• C08J2205/052

  Closed cells, i.e. more than 50% of the pores are closed · CPC title

• C08J9/0019

  halogenated · CPC title

• C08J9/0038

  containing phosphorus · CPC title