# US 10,870,984 B2 · Spray foams containing non-halogenated fire retardants

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- Number: US 10,870,984 B2
- Document ID: US10870984B2
- Status: Granted
- Kind: B2
- Application number: 15/730,485
- Filed: 2017-10-11
- Published: 2018-02-01
- Granted: 2020-12-22
- Earliest claimed: 2014-07-18
- Assignees: Johns Manville
- Applicants: Johns Manville
- Inventors: Scott Snider; Lance Wang; Jawed Asrar
- Web page: https://patentgrep.com/patent/US10870984B2

## CPC

- E04B 1/941: {Building elements specially adapted therefor}
- C08G 18/092: {oligomerisation to isocyanurate groups}
- C08G 18/163: {covered by C08G18/18 and C08G18/22}
- C08G 18/3878: {having phosphorus}
- C08G 18/4027: {Mixtures of compounds of group C08G18/54 with other macromolecular compounds}
- C08G 18/42: Polycondensates having carboxylic or carbonic ester groups in the main chain
- C08G 18/4804: {Two or more polyethers of different physical or chemical nature}
- C08G 18/546: {Oxyalkylated polycondensates of aldehydes}
- C08J 9/0019: {halogenated}
- C08J 9/0023: {containing oxygen}
- C08J 9/0038: {containing phosphorus}
- C08J 9/141: {Hydrocarbons}
- C08J 9/146: {only fluorine as halogen atoms}
- C08K 5/5333: Esters of phosphonic acids
- E04B 1/7604: {fillings for cavity walls}
- E04B 1/94: against fire ({fire protection of partitions E04B2/7403, E04B2/7409; supporting constructions for ceilings having the capability of expansion in case of fire E04B9/08}; fire-fighting A62C, {e.g. fire prevention or containment A62C2/00}; impregnation of wood or similar materials B27K; {fireproof paints C09D5/18; fireproofing materials C09K21/00; flame-resistant papers D21H5/0002; coverings or linings, e.g. for walls or ceilings, in general E04F13/00}; fireproof doors E06B5/16; {firebreak devices for pipes or the like passing through walls F16L5/04; protection of pipes by means of non-inflammable material F16L57/04})
- C08G 2101/00: Manufacture of cellular products
- C08G 2110/0041: having specified density
- C08G 2110/005: < 50kg/m3
- C08G 2110/0058: ≥50 and <150kg/m3
- C08G 2115/02: to isocyanurate groups
- C08J 2201/022: premixing or pre-blending a part of the components of a foamable composition, e.g. premixing the polyol with the blowing agent, surfactant and catalyst and only adding the isocyanate at the time of foaming
- C08J 2205/05: Open cells, i.e. more than 50% of the pores are open
- C08J 2205/052: Closed cells, i.e. more than 50% of the pores are closed
- C08J 2207/04: Aerosol, e.g. polyurethane foam spray
- C08J 2375/04: Polyurethanes
- 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})
- 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)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)

## Abstract

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).

## Claims

### Claim 1

A spray foam formulation used in an insulation layer in a wall structure, the spray foam formulation comprising:
a reaction product of a polyisocyanate compound and a polyol compound, wherein the polyol compound comprises at least one of a polyester polyol, a polyether polyol, or a Manich polyol;
a fire retardant comprising a reactive halogen-containing fire retardant;
10 wt. % to 26 wt. % water based on a total weight of the spray foam formulation; and
an unreacted carbohydrate,
wherein the 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, and
wherein the insulation layer exhibits an Appendix X modified NFPA 286 standard and an ASTM E-84 performance equivalent with or better than an identical insulation layer except for having a non-reactive halogenated fire retardant tris(1-chloro-2-propyl)phosphate (TCPP).

### Claim 2 (depends on 1)

The spray foam formulation of claim 1, wherein the insulation layer is an open cell insulation layer having a density between about 0.3-0.7 pcf.

### Claim 3 (depends on 1)

The spray foam formulation of claim 1, wherein the insulation layer is a closed cell insulation layer having a density between about 2.0-4.0 pcf.

### Claim 4 (depends on 1)

The spray foam formulation of claim 1, wherein the spray-foam formulation further comprises a non-halogenated fire retardant.

### Claim 5 (depends on 4)

The spray foam formulation of claim 4, wherein the non-halogenated fire retardant comprises at least one of an organo-phosphate compound or diethyl hydroxymethylphosphonate.

### Claim 6 (depends on 5)

The spray foam formulation of claim 5, wherein the at least one organo-phosphate compound is triethyl phosphate (TEP).

### Claim 7 (depends on 5)

The spray foam formulation of claim 5, wherein the at least one organo-phosphate compound is a blend of butyl diphenyl phosphate, dibutyl phenyl phosphate, and triphenyl phosphate.

### Claim 8 (depends on 1)

The spray foam formulation of claim 1, wherein the unreacted carbohydrate is chosen from sucrose and high-fructose corn syrup.

### Claim 9

An insulation layer formed with a spray foam formulation comprising:
a reaction product of a polyisocyanate compound and a polyol compound, wherein the polyol compound comprises at least one of a polyester polyol, a polyether polyol, or a Manich polyol;
a fire retardant comprising a reactive halogen-containing fire retardant;
an unreacted carbohydrate; and
10 wt. % to 26 wt. % water based on a total weight of the spray foam formulation.

### Claim 10 (depends on 9)

The insulation layer of claim 9, wherein the insulation layer has an insulative R value of 3.0 to 7.2 per inch.

### Claim 11 (depends on 9)

The insulation layer of claim 9, wherein the insulation layer has a density ranging from 0.3 to 4.5 pounds per cubic feet.

### Claim 12 (depends on 9)

The insulation layer of claim 9, wherein the insulation layer exhibits an Appendix X modified NFPA 286 standard performance that is the same or better than a spray insulation layer comprising (i) a reaction product of a polyisocyanate compound and a polyol compound, (ii) a carbohydrate, (iii) water, and (iv) a fire retardant that includes tris(1-chloro-2-propyl)phosphate (TCPP).

### Claim 13 (depends on 9)

The insulation layer of claim 9, wherein the insulation layer exhibits an ASTM E-84 performance that is the same or better than a spray insulation layer comprising (i) a reaction product of a polyisocyanate compound and a polyol compound, (ii) a carbohydrate, (iii) water, and (iv) a fire retardant that includes tris(1-chloro-2-propyl)phosphate (TCPP).

### Claim 14 (depends on 9)

The insulation layer of claim 9, wherein the spray-foam formulation further comprises a non-halogenated fire retardant.

### Claim 15 (depends on 14)

The insulation layer of claim 14, wherein the non-halogenated fire retardant comprises triethyl phosphate (TEP).

### Claim 16 (depends on 14)

The insulation layer of claim 14, wherein the non-halogenated fire retardant includes (i) a reactive fire retardant and (ii) a non-reactive fire retardant, and further wherein a ratio of the reactive fire retardant to the non-reactive fire retardant is greater than or equal to 1.

### Claim 17 (depends on 9)

The insulation layer of claim 9, wherein the unreacted carbohydrate includes at least one sugar selected from the group consisting of sucrose and high-fructose corn syrup.

### Claim 18

An insulation layer formed with a spray foam formulation comprising:
a reaction product of a polyisocyanate compound and a polyol compound, wherein the polyol compound comprises at least one of a polyester polyol, a polyether polyol, or a Manich polyol;
10 wt. % to 25 wt. % of at least one fire retardant selected from the group consisting of a non-halogenated fire retardant, and a reactive halogen-containing fire retardant;
20 wt. % to 50 wt. % of an unreacted carbohydrate; and
10 wt. % to 26 wt. % water based on a total weight of the spray foam formulation.

### Claim 19 (depends on 18)

The insulation layer of claim 18, wherein the at least one fire retardant comprises diethyl hydroxymethylphosphonate.

### Claim 20 (depends on 19)

The insulation layer of claim 19, wherein the at least one fire retardant further comprises triethyl phosphate (TEP).

### Claim 21 (depends on 18)

The insulation layer of claim 18, wherein the unreacted carbohydrate comprises high-fructose corn syrup.

### Claim 22 (depends on 18)

The insulation layer of claim 18, wherein the insulation layer exhibits an Appendix X modified NFPA 286 standard performance that is the same or better than a spray insulation layer comprising (i) a reaction product of a polyisocyanate compound and a polyol compound, (ii) a carbohydrate, (iii) water, and (iv) a fire retardant that includes tris(1-chloro-2-propyl)phosphate (TCPP).

### Claim 23 (depends on 18)

The insulation layer of claim 18, wherein the insulation layer exhibits an ASTM E-84 performance that is the same or better than a spray insulation layer comprising (i) a reaction product of a polyisocyanate compound and a polyol compound, (ii) a carbohydrate, (iii) water, and (iv) a fire retardant that includes tris(1-chloro-2-propyl)phosphate (TCPP).