Foam insulation with enhanced fire and smoke performance
AssigneeJohns Manville
InventorsMalay Nandi, Lance Wang, Jawed Asrar
Life of this patent
Estimating the term…
Abstract
A polyisocyanurate foam insulation product includes polyisocyanurate foam produced from reacting an isocyanate and a polyol blend having a functionality of at least 2.2. The isocyanate and the polyol blend are reacted so that the polyisocyanurate foam has an isocyanate index equivalent with or greater than 300. The polyisocyanurate foam includes a fire retardant and includes between 0.02 and 0.45 weight percent of a zinc salt compound. The foam insulation board exhibits a flame spread of no greater than 25 and a smoke index of no greater than 50 when exposed to flame conditions in accordance with an ASTM E-84 test.
Claims18
A method of producing a foam insulation board comprising:
- reacting an isocyanate with a polyol blend to form a polyisocyanurate foam, the polyol blend having a functionality of at least 2.2 and the isocyanate and the polyol blend being reacted so that the polyisocyanurate foam has an isocyanate index equal to or greater than 300;
- adding a blowing agent to the polyisocyanurate foam;
- adding a fire retardant to the polyisocyanurate foam;
- and
- adding between 0.02 and 0.45 weight percent of a zinc salt compound to the polyisocyanurate foam;
- wherein the foam insulation board exhibits a flame spread of no greater than 25 and a smoke index of no greater than 50 when exposed to flame conditions in accordance with an ASTM E-84 test;
- and
- wherein the polyisocyanurate foam is a closed cell foam having a cell size of 120 μm or less.
A method of producing a foam insulation board comprising:
- reacting an isocyanate with a polyol blend to form a polyisocyanurate foam, the polyol blend having a functionality of at least 2.2 and the isocyanate and the polyol blend being reacted so that the polyisocyanurate foam has an isocyanate index equal to or greater than 300;
- adding a blowing agent to the polyisocyanurate foam;
- adding a fire retardant to the polyisocyanurate foam;
- and
- adding between 0.02 and 0.45 weight percent of a zinc salt compound to the polyisocyanurate foam;
- wherein the foam insulation board exhibits a flame spread of no greater than 25 and a smoke index of no greater than 50 when exposed to flame conditions in accordance with an ASTM E-84 test;
- and
- wherein the foam insulation board has an R-value per inch of at least 6.6 and an long-term thermal resistance (LTTR) of 5.9 R-value per inch.
Dependencies are inferred from the claim text.