Foam boards including non-halogenated fire retardants

Patent metadata

Field	Value
Publication number	US-9815256-B2
Application number	US-201414299605-A
Country	US
Kind code	B2
Filing date	Jun 9, 2014
Priority date	Jun 9, 2014
Publication date	Nov 14, 2017
Grant date	Nov 14, 2017

Abstract

According to one embodiment, a polyisocyanurate foam board is described. The foam board includes a polyisocyanurate core that is produced from: an isocyanate, a polyol, and a phosphorous containing non-halogenated fire retardant. The foam board also includes a facer material that is applied to at least one surface of the polyisocyanurate core. The polyisocyanurate core has an isocyanate index greater than about 200 and is able to forms a sufficiently stable char when exposed to flame conditions to enable the polyisocyanurate core to pass the ASTM E-84 test. The foam board has an initial R-value of at least 6.40 and exhibits an ASTM E1354-11b test performance that is equivalent with or better than a similar foam board having a halogenated fire retardant, such as tris(2-chloroisopropyl)phosphate (TCPP).

First claim

What is claimed is:

1. A polyisocyanurate foam board comprising:
a polyisocyanurate core produced from a reacting an A-side chemical and a B-side chemical, wherein
the A-side chemical consists of polyisocyanate, and
the B-side chemical consists of:
between 50-75% by weight of polyester polyol;
between 4-8% by weight of a metal catalyst;
between 0.1-0.5% by weight of an amine catalyst;
between 6-12% by weight of diethyl hydroxymethyl phosphonate (DEHMP) fire retardant;
between 0.1-0.3% by weight of water; and
between 10-25% by weight of pentane blowing agent;
wherein the polyisocyanurate core has an isocyanate index between 200-350,
wherein the polyisocyanurate core comprises 3 to 5% by weight of the DEHMP fire retardant, and
wherein the polyisocyanurate core forms a sufficiently stable char when exposed to flame conditions in accordance with ASTM E-84 that enables the polyisocyanurate core to pass the ASTM E-84 test;
a facer material applied to at least one surface of the polyisocyanurate core;
wherein the polyisocyanurate foam board comprises an initial R-value of at least 6.40, and wherein the polyisocyanurate foam board exhibits an ASTM E1 354-11b performance equivalent with or better than a similar polyisocyanurate foam board having a halogenated fire retardant tris(2-chloroisopropyl)phosphate (TCPP).

2. The polyisocyanurate foam board of claim 1 , wherein the polyisocyanurate core comprises an average foam cell size of less than about 200 microns.

3. The polyisocyanurate foam board of claim 1 , wherein the polyisocyanurate foam board has a density of between about 1.5 and 10 lbs/ft 3 .

4. The polyisocyanurate foam hoard of claim 1 , wherein the facer includes:
a reinforced cellulosic felt facer;
an un-coated polymer bonded glass fiber mat;
a coated polymer bonded glass fiber mat; or
a metal foil.

5. A method of forming a polyisocyanurate foam board comprising:
reacting an A-side chemical and a B-side chemical to form a polyisocyanurate core, wherein:
the A-side chemical consists of polyisocyanate, and
the B-side chemical consists of:
between 50-75% by weight of polyester polyol;
between 4-8% by weight of a metal catalyst;
between 0.1-0.5% by weight of an amine catalyst;
between 6-12% by weight of diethyl hydroxymethyl phosphonate (DEHMP) fire retardant;
between 0.1-0.3% by weight water; and
between 10-25% by weight of pentane blowing agent;

wherein the polyisocyanurate core has an isocyanate index between 200-350, and
wherein the polyisocyanurate core comprises 3 to 5% by weight of the DEHMP fire retardant,
coupling a facer material with at least one surface of the polyiscoyanurate core; wherein the polyisocyanurate core forms a sufficiently stable char when exposed to flame conditions that enables the polyisocyanurate core to pass the ASTM E-84 test, and
wherein the polyisocyanurate foam board comprises an initial R-value of at least 6.40, and the polyisocyanurate foam board exhibits an ASTM E1354 Cone Calorimeter test performance that is equivalent with or better than a similar polyisocyanurate foam board having a halogenated fire retardant tris(2-chloroisopropyl)phosphate (TCPP).

6. The method of claim 5 , wherein the polyisocyanurate core comprises an average foam cell size of less than 200 microns.

7. The method of claim 5 , wherein the polyisocyanurate foam board has a density of between about 1.5 and 10 lbs/ft 3 .

8. The method of claim 5 , wherein the facer includes:
a glass fiber reinforced cellulosic felt;
an un-coated polymer bonded glass fiber mat;
a coated polymer bonded glass fiber mat; or
a metal foil.

Assignees

• Johns Manville

Inventors

• Nandi Malay
• Wang Lance
• Asrar Jawed

Classifications

• B32B17/10

  of synthetic resin · CPC title

• B32B27/065

  of foam · CPC title

• B32B2419/04

  Tiles for floors or walls · CPC title

• B32B15/046

  of foam · CPC title

• B32B2266/0214

  Materials belonging to B32B27/00 · CPC title