Spray Foam Fire Retardant Formulation
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Solution Overview
Problem
The use of non-reactive halogenated fire retardants in spray foams poses health and environmental concerns, making it challenging for polyurethane and polyisocyanurate foams to pass modern fire tests, necessitating the development of formulations with enhanced fire resistance using reactive halogenated and non-halogenated fire retardants.
Innovation Solution
The development of spray foam formulations incorporating reactive halogenated and non-halogenated fire retardants, such as halogenated polyether-polyols, organo-phosphorous compounds, and carbohydrates, which react with the polymer matrix or thermally decompose to form a char, thereby increasing the fire resistance of the foams without relying on non-reactive halogenated compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-reactive halogenated fire retardants (e.g., TCPP) are used in spray foam formulations, then fire resistance is improved, but health and environmental hazards increase due to off-gassing
Solution Approach 1:
The patent changes the chemical parameters of fire retardants from non-reactive halogenated compounds to reactive halogenated compounds and non-halogenated compounds. This parameter change eliminates off-gassing while maintaining fire resistance through char formation and radical scavenging mechanisms.
Solution Approach 2:
The patent uses composite fire retardant systems combining reactive halogenated fire retardants (for gas-phase radical scavenging) and non-halogenated fire retardants (for char formation). This composite approach achieves effective fire protection without the harmful emissions of non-reactive halogenated compounds.
2Object-generated harmful factors
If non-reactive halogenated fire retardants are eliminated from formulations, then health and environmental safety is improved, but fire test performance deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters by eliminating non-reactive halogenated fire retardants and substituting them with reactive halogenated fire retardants and non-halogenated fire retardants in specific concentration ranges, thereby maintaining fire test performance without harmful emissions.
Solution Approach 2:
The patent introduces non-halogenated fire retardants as intermediary substances that promote char formation, working synergistically with reactive halogenated fire retardants to achieve fire protection performance previously provided only by non-reactive halogenated compounds.
3Object-generated harmful factors
If reactive halogenated and non-halogenated fire retardants are used instead of non-reactive halogenated compounds, then formulation complexity increases, but fire resistance without off-gassing is achieved
Solution Approach 1:
The patent manages formulation complexity by optimizing the concentration parameters of reactive halogenated fire retardants (0.1-10 wt%) and non-halogenated fire retardants (1-20 wt%), creating a balanced system that achieves fire protection without off-gassing while maintaining practical manufacturability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These formulations demonstrate similar or better fire performance in ASTM E-84 and ASTM E1354 tests compared to foams using non-reactive halogenated fire retardants, eliminating the need for TCPP and other non-reactive halogenated compounds, while providing enhanced fire resistance and insulation properties.
Implementation Method 1
carbohydrates are included as char forming agents that thermally decompose into a char, which increases the resistance of the spary foam article to flame penetration
Implementation Method 2
imparts increased fire resistance to the foams by generating both gas-phase, radical scavenging chlorine groups
Data Source
AI summary
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).