Fiberglass composites with improved flame resistance from phosphorous-containing materials and methods of making the same

Patent metadata

Field	Value
Publication number	US-2016273156-A1
Application number	US-201615171103-A
Country	US
Kind code	A1
Filing date	Jun 2, 2016
Priority date	Jun 10, 2011
Publication date	Sep 22, 2016
Grant date	—

Abstract

Fiberglass products with increased flame resistance are described. The products may include fiberglass-containing thermal insulation that include a plurality of glass fibers coated with a phosphorous-containing flame retardant. The flame retardant may include an organophosphorous compound having a substituted or unsubstituted organophophorous group bonded to a substituted or unsubstituted amide group by a substituted or unsubstituted alkyl group. The fiberglass products may further include fiberglass composites that are about 50 wt. % to about 98 wt. % glass fibers, about 2 wt. % to about 50 wt. % of a binder; and a phosphorous-containing flame retardant. Also described are methods of making fiberglass products with increased flame resistance. These methods may include the steps of contacting glass fibers and/or fiberglass products with a flame retardant mixture that includes a phosphorous-containing compound.

First claim

What is claimed is:

1 . A method of making glass fibers with improved flame resistance, the method comprising:
contacting glass fibers with an aqueous flame retardant mixture comprising an organophosphorous compound having a substituted or unsubstituted organophophorous group bonded to a substituted or unsubstituted amide group by a substituted or unsubstituted alkyl group; and drying the glass fibers to form the fibers with improved flame resistance.

2 . The method of claim 1 , wherein the flame retardant mixture further comprises one or more additional flame retardant compounds selected from the group consisting of vermiculite, expandable graphite, a metal hydroxide, carbon black, and a halogen-containing compound.

3 . The method of claim 1 , wherein the flame retardant mixture further comprises one or more compounds selected from the group glycerin, sorbitol, sugar, starch, protein, and latex.

4 . The method of claim 1 , wherein the flame retardant mixture further comprises one or more binder precursors selected from the group consisting of a carboxylic acid, an anhydride, an alcohol, a vinyl compound, a polyol, a polymerization catalyst, an accelerator, a corrosion inhibitor, and an extender.

5 . The method of claim 1 , wherein the flame retardant mixture further comprises kaolinite, mica, talc, fly ash, gypsum, montmorillonite, bentonite, smectite, calcium carbonate, clay, THA, or titanium dioxide.

6 . The method of claim 1 , wherein the flame retardant mixture contacts the glass fibers by spraying, coating, or dipping the flame retardant mixture on the glass fibers.

7 . The method of claim 1 , wherein the drying of the glass fibers comprises blowing heated air on the glass fibers.

8 . The method of claim 1 , wherein the drying of the glass fibers comprises heating the glass fibers in an oven.

9 . The method of claim 1 , wherein the method further comprises forming the fibers with improved flame resistance into a fiberglass insulation batt.

10 . The method of claim 1 , wherein the method further comprises forming the fibers with improved flame resistance into a fiberglass mat.

11 . The method of claim 1 , wherein the method comprises forming the fibers with improved flame resistance into a fiberglass composite that has a higher passage rate for a flame penetration test of a UL 181 Standard compared to the same fiberglass composite that did not have fibers treated with the flame retardant mixture.

12 . A method of making a fiberglass composite with increased flame resistance, the method comprising:
combining glass fibers with a binder composition; curing the combination of glass fibers and the binder composition to form the fiberglass composite; and applying a flame retardant mixture to the fiberglass composite, wherein the flame retardant mixture comprises an organophosphorous compound having a substituted or unsubstituted organophophorous group bonded to a substituted or unsubstituted amide group by a substituted or unsubstituted alkyl group.

13 . The method of claim 12 , wherein the fiberglass composite comprises fiberglass insulation batt or fiberglass duct insulation.

14 . The method of claim 12 , wherein the fiberglass composite with increased flame resistance has a higher passage rate for a flame penetration test of a UL 181 Standard compared to the same fiberglass composite that was not treated with the flame retardant mixture.

15 . A method of making a fiberglass composite with increased flame resistance, the method comprising:
combining glass fibers with a binder composition; applying a flame retardant mixture to the combination of the glass fibers and the binder composition, wherein the flame retardant mixture comprises an organophosphorous compound having a substituted or unsubstituted organophophorous group bonded to a substituted or unsubstituted amide group by a substituted or unsubstituted alkyl group curing the combination of the glass fibers, the binder composition, and the flame retardant mixture to form the fiberglass composite.

16 . The method of claim 15 , wherein the fiberglass composite with increased flame resistance has a higher passage rate for a flame penetration test of a UL 181 Standard compared to the same fiberglass composite that was not treated with the flame retardant mixture.

Assignees

• Johns Manville

Inventors

• Zheng Guodong
• Asrar Jawed
• Leed Elam A

Classifications

• B32B2262/101

  Glass fibres · CPC title

• B32B2260/021

  Fibrous or filamentary layer · CPC title

• D10B2101/06

  Glass · CPC title

• B32B2305/076

  Prepregs · CPC title

• D06M2200/30

  Flame or heat resistance, fire retardancy properties · CPC title