# US 10,118,985 B2 · Open cell spray fire-retardant foam

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- Number: US 10,118,985 B2
- Document ID: US10118985B2
- Status: Granted
- Kind: B2
- Application number: 14/661,737
- Filed: 2015-03-18
- Published: 2016-09-22
- Granted: 2018-11-06
- Earliest claimed: 2015-03-18
- Assignees: Johns Manville
- Applicants: Johns Manville
- Inventors: Scott Snider; Lance Wang; Jawed Asrar
- Web page: https://patentgrep.com/patent/US10118985B2

## CPC

- C08G 18/4837: {and other oxyalkylene units}
- C08G 18/18: containing secondary or tertiary amines or salts thereof
- C08G 18/3218: {containing cyclic groups having at least one oxygen atom in the ring}
- C08G 18/40: High-molecular-weight compounds {(C08G18/2805 takes precedence)}
- C08G 18/6611: {having at least three hydroxy groups}
- C08G 18/7621: {being toluene diisocyanate including isomer mixtures}
- C08G 18/7664: {containing alkylene polyphenyl groups}
- C08G 18/7671: {containing only one alkylene bisphenyl group}
- C08G 18/7837: {containing allophanate groups}
- C08J 9/04: using blowing gases generated by a previously added blowing agent
- C08G 2110/005: < 50kg/m3
- C08G 2110/0083: prepared using water as the sole blowing agent
- C08G 2115/02: to isocyanurate groups
- C08J 2205/05: Open cells, i.e. more than 50% of the pores are open
- C08J 2207/04: Aerosol, e.g. polyurethane foam spray
- C08J 2375/04: Polyurethanes
- C08L 2201/02: Flame or fire retardant/resistant
- E04B 1/7604: {fillings for cavity walls}
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})

## Abstract

Embodiments of the present technology may include an open cell spray polyurethane foam. The foam may include a polymer. The polymer may formed by the polymerization of a reaction product of (1) a saccharide with an epoxide and (2) an isocyanate. The reaction product may have greater than 25 weight percent and less than 99 weight percent of the saccharide. The foam may exhibit a fire retardancy sufficient to pass flame tests in accordance with Appendix X and/or ASTM E-4.

## Claims

### Claim 1

An open cell spray polyurethane foam, the foam comprising a polyurethane formed by a polymerization of:
a polyether polyol consisting of a product formed by a reaction of reactants consisting of a saccharide with an epoxide, wherein greater than 25 wt. % and less than 99 wt. % of the polyether polyol is from the saccharide; and
an isocyanate, wherein:
the saccharide is sucrose, and
the foam excludes greater than 10 wt. % free sucrose.

### Claim 2 (depends on 1)

The foam of claim 1, wherein the foam exhibits a fire retardancy sufficient to pass flame tests in accordance with at least one of Appendix X and ASTM E-84.

### Claim 3 (depends on 1)

The foam of claim 1, wherein the epoxide comprises ethylene oxide, propylene oxide, or a mixture thereof.

### Claim 4 (depends on 1)

The foam of claim 1, wherein the foam further comprises a flame retardant that does not include a product formed from the saccharide.

### Claim 5 (depends on 1)

The foam of claim 1, wherein greater than 30 wt. % and less than 89 wt. % of the polyether polyol is from the saccharide.

### Claim 6 (depends on 1)

The foam of claim 1, wherein greater than 40 wt. % and less than 89 wt. % of the polyether polyol is from the saccharide.

### Claim 7 (depends on 1)

The foam of claim 1, wherein greater than 50 wt. % and less than 89 wt. % of the polyether polyol is from the saccharide.

### Claim 8 (depends on 1)

The foam of claim 1, wherein the polyether polyol comprises a molecular formula of:
wherein:
a, b, c, and d are non-negative integers, and
a+b+c+d is from 1 to 23.

### Claim 9 (depends on 1)

The foam of claim 1, wherein two hydroxyl groups of the sucrose react with the epoxide.

### Claim 10 (depends on 1)

The foam of claim 1, wherein the epoxide comprises ethylene oxide, propylene oxide, or a mixture thereof.

### Claim 11 (depends on 1)

The foam of claim 1, wherein the foam has a density of between about 0.3 pcf and 0.7 pcf.

### Claim 12 (depends on 1)

The foam of claim 1, wherein the foam excludes free sucrose.

### Claim 13 (depends on 1)

The foam of claim 1, wherein the epoxide comprises a mixture with more ethylene oxide than propylene oxide.

### Claim 14 (depends on 1)

The foam of claim 1, wherein the polyether polyol comprises a hydroxyl group bonded to a primary carbon, and the hydroxyl group comprises an oxygen atom from the epoxide.

### Claim 15 (depends on 1)

The foam of claim 1, wherein the epoxide comprises a mixture of ethylene oxide and propylene oxide.

### Claim 16 (depends on 15)

The foam of claim 15, wherein the polyether polyol comprises two hydroxyl groups of the sucrose reacted with the epoxide.

### Claim 17 (depends on 1)

The foam of claim 1, wherein the polyurethane is formed by a polymerization consisting of the polyether polyol and the isocyanate.

### Claim 18

A formulation for forming an open cell spray foam, the formulation comprising by weight:
16-61% a polyether polyol consisting of a product formed by a reaction of reactants consisting of a saccharide with an epoxide, wherein greater than 25 wt. % and less than 99 wt. % of the polyether polyol is from the saccharide, wherein the formulation excludes greater than 10 wt. % free sucrose.

### Claim 19 (depends on 18)

The formulation of claim 18, further comprising:
0-30% polyol;
9-36% TCPP;
2-16% amine catalyst;
3-22% emulsifier;
0.3-4% surfactant; and
9-36% water.

### Claim 20 (depends on 18)

The formulation of claim 18, wherein the saccharide is sucrose.