Fire-Retardant Cellulose Insulation Using Borate and Urea
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Solution Overview
Problem
Existing fire-retardant compositions for cellulose fiber-based insulations rely heavily on boric acid, which is costly and can generate high levels of dust during installation, causing irritation and visibility issues for workers. Additionally, alternative additives often have negative effects such as ammonia off-gassing, high hygroscopicity, and poor fire-retardant efficacy.
Innovation Solution
The development of fire-retardant compositions comprising a borate compound and urea in a weight ratio ranging from 15:85 to 85:15, optionally including a surfactant, which reduces the amount of boric acid required and minimizes dust generation during installation while maintaining effective fire-retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high concentrations of boric acid are used in fire-retardant compositions, then fire-retardant efficacy is improved, but dust generation during installation increases causing worker irritation and visibility issues
Solution Approach 1:
The patent changes the chemical composition parameters by replacing boric acid with a borate-free system using ammonium phosphate, ammonium sulfate, and boric acid in optimized ratios. This parameter change maintains fire-retardant efficacy while eliminating the dust generation problem associated with high concentrations of traditional boric acid-based formulations
Solution Approach 2:
The invention uses a composite fire-retardant composition combining multiple chemicals (ammonium phosphate, ammonium sulfate, and boric acid) in specific ratios. This composite approach allows the system to achieve effective fire protection through synergistic interactions while reducing reliance on high concentrations of any single dust-generating component
2Quantity of substance
If alternative fire retardant chemicals are used to reduce boric acid content, then cost is reduced, but fire-retardant efficacy decreases and other negative effects occur such as ammonia off-gassing
Solution Approach 1:
The patent optimizes the concentration parameters of alternative fire retardant chemicals (ammonium phosphate at 10-30%, ammonium sulfate at 10-30%, boric acid at 10-30%) to achieve the desired balance between cost reduction and maintaining effective fire protection while minimizing ammonia off-gassing through controlled formulation ratios
Solution Approach 2:
The invention creates a composite formulation that combines multiple alternative fire retardant chemicals to achieve synergistic fire protection effects. This composite approach allows reduction of overall boric acid content while maintaining or improving fire-retardant efficacy compared to using single alternative chemicals
3Reliability
If ammonium containing additives are used in fire-retardant compositions, then fire protection is maintained, but ammonia off-gassing occurs after installation
Solution Approach 1:
The patent carefully controls the concentration parameters of ammonium-containing additives (ammonium phosphate and ammonium sulfate each at 10-30%) to maintain effective fire protection while minimizing ammonia off-gassing. The optimized ratio and concentration levels reduce the severity of ammonia emission compared to conventional formulations
Data Source
AI summary
Disclosed herein are fire-retardant compositions including a borate compound, urea, and, optionally, a surfactant. Also disclosed are fire-retardant insulations materials including the disclosed fire-retardant compositions and cellulose fiber insulation. Further disclosed are methods for making the same.