Silicone backbone prepolymers for flame resistant polyurethanes

Patent metadata

Field	Value
Publication number	US-9284458-B2
Application number	US-201214119095-A
Country	US
Kind code	B2
Filing date	Jun 14, 2012
Priority date	Jun 30, 2011
Publication date	Mar 15, 2016
Grant date	Mar 15, 2016

Abstract

Embodiments of the invention provide for coatings that include the reaction product of at least a sodium silicate solution, at least one isocyanate reactive component having at least one of a hydroxyl and an amine functionality of between about 2 and about 4, at least one intumescent filler, at least one filler, optionally a suspension agent and at least one prepolymer having isocyanate functional groups. The prepolymer includes the reaction product of a prepolymer reaction mixture. The prepolymer reaction mixture includes at least one isocyanate, at least one polyol having an hydroxyl functionality of between about 2 and about 6, and at least one silicone surfactant having at least one isocyanate reactive moiety.

First claim

The invention claimed is:

1. A coating comprising the reaction product of a reaction system, the reaction system comprising:
at least one prepolymer having isocyanate functional groups, wherein the prepolymer comprises the reaction product of a prepolymer reaction mixture comprising:
at least one isocyanate;
at least one polyol having an hydroxyl functionality of between about 2 and about 6; and
at least one silicone surfactant having at least one isocyanate reactive moiety;

a sodium silicate solution
at least one isocyanate reactive component having at least one of a hydroxyl and an amine functionality of between about 2 and about 4;
at least one intumescent filler that is at least one of expandable graphite and melamine;
at least one filler that is different from the intumescent filler; and
optionally a suspension agent.

2. The coating of claim 1 , wherein the at least one silicon surfactant has a hydroxyl number between about 30 and about 100 MgKOH/g and a hydroxyl functionality of between about 2 and about 4.

3. The coating of claim 2 , wherein the at least one silicone surfactant comprise at least a polydimethylsiloxane-polyalkyleneoxide.

4. The coating of claim 2 , wherein from 2 to 30 weight % of the prepolymer reaction mixture comprises the at least one silicone surfactant.

5. The coating of claim 4 , wherein the sodium silicate solution has a weight ratio of SiO 2 /Na 2 O of between about 1.4/1 and about 3.5/1.

6. The coating of claim 1 , wherein the at least one isocyanate reactive component has an equivalent weight per isocyanate-reactive group of between about 31 and about 125 daltons.

7. The coating of claim 6 , wherein the at least one filler that is different from the intumescent filler comprises at least one of barium sulfate (BaSO 4 ), aluminum oxide (Al 2 O 3 ), aluminum hydroxide (Al(OH) 3 ), magnesium hydroxide (Mg(OH) 2 ) calcium carbonate (CaCO 3 ), mica, and talc.

8. The coating of claim 1 , wherein the at least one optional suspension agent comprises calcinated clay.

9. The coating of claim 1 , wherein the at least one isocyanate comprises at least one polymeric polymethylene polyphenylisocyanate and at least one mixture of 4,4′-methylene diphenyl isocyanate and 2,4′-methylene diphenyl isocyanate.

10. A method of producing a coating of claim 1 , the method comprising:
reacting a reaction system, the reacting system comprising:
the at least one prepolymer having isocyanate functional groups, wherein the prepolymer comprises the reaction product of a prepolymer reaction mixture comprising:
the at least one isocyanate;
the at least one polyol having an hydroxyl functionality of between about 2 and about 6; and
the at least one silicone surfactant having at least one isocyanate reactive moiety;
the sodium silicate solution
the at least one isocyanate reactive component having at least one of a hydroxyl and an amine functionality of between about 2 and about 4;
the at least one intumescent filler;
the at least one filler; and
optionally the suspension agent.

Assignees

• Bruchertseifer Christian
• Anater Mark T
• Dow Global Technologies Llc

Inventors

• Bruchertseifer Christian
• Anater Mark T

Classifications

• C08G18/3206

  aliphatic · CPC title

• C08K3/04

  Carbon · CPC title

• C08G18/12 Primary

  using two or more compounds having active hydrogen in the first polymerisation step · CPC title

• C08K3/36

  Silica · CPC title

• C08G18/324

  containing only one aromatic ring · CPC title