Fire retardant coatings and bodies, and methods of use
View Patent ↗Fire retardant coating systems and solid body cast systems comprise a first part comprising at least one ingredient having NCO functionality; and a second part comprising at least one ingredient having an active hydrogen functionality that is co-reactive with the NCO, wherein the first part and the second part are formulated so that when the parts are mixed together they form a cured coating or a solid body. The coating system or solid body cast system comprises a first fire retardant ingredient that is a phosphorus-based compound, a second fire retardant ingredient that is an intumescent material, and a third fire retardant ingredient that is a brominated ingredient. Methods for preparing a fire retardant coating or solid body are also described.
1. A fire retardant coating system comprising:
a. a first part comprising at least one ingredient having NCO functionality; and
b. a second part comprising at least one ingredient having an active hydrogen functionality that is co-reactive with the NCO;
wherein the coating system comprises at least three fire retardant ingredients that are:
i) a first fire retardant ingredient that is a phosphorus-based fire retardant compound,
ii) a second fire retardant ingredient that is different from the first fire retardant ingredient and that is an intumescent material; and
iii) a third fire retardant ingredient that is different from the first and second fire retardant ingredients and that is a brominated fire retardant ingredient; and
wherein the first part and the second part are formulated so that when the parts are mixed together they form a cured coating having a density of greater than 40 pounds per cubic foot.
2. The fire retardant coating system of claim 1 , wherein the first fire retardant ingredient is a phosphate-based compound.
3. The fire retardant coating system of claim 1 , wherein the active hydrogen of the second part is provided by a hydroxy functionality.
4. The fire retardant coating system of claim 1 , wherein the active hydrogen of the second part is provided by an amine functionality.
5. The fire retardant coating system of claim 1 , wherein the brominated fire retardant ingredient is a brominated compound having an active hydrogen functionality that is co-reactive with the NCO of the first part.
6. The fire retardant coating system of claim 1 , wherein the brominated fire retardant ingredient is a brominated compound having a functionality that is co-reactive with the active hydrogen of the second part.
7. The fire retardant coating system of claim 1 , wherein the brominated fire retardant ingredient is a brominated compound that is not co-reactive with the reactants of the first or second part of the coating system.
8. The fire retardant coating system of claim 1 , wherein the intumescent material is expandable graphite.
9. The fire retardant coating system of claim 1 , wherein
i) the first fire retardant ingredient is a phosphate-based compound that is APP,
ii) the second fire retardant ingredient that is an intumescent material that is expandable graphite; and
iii) the third fire retardant ingredient that is a brominated fire retardant ingredient having a hydroxy functionality.
10. A method of preparing a fire retardant coating comprising
a. providing a fire retardant coating system of claim 1 , and
b. mixing the first part and the second part together so that they form a cured coating having a density of greater than 40 pounds per cubic foot.
11. A fire retardant coating made by the method of claim 10 .
12. A method for protecting a surface from fire damage, comprising
a) forming the coating of claim 11 as fire barrier on a surface to be protected.
13. A solid body cast polyurethane, polyurethane/urea or polyurea polymer system comprising fire retardant comprises:
a. a first part comprising at least one ingredient having NCO functionality; and
b. a second part comprising at least one ingredient having an active hydrogen functionality that is co-reactive with the NCO;
wherein the solid body cast system comprises at least three fire retardant ingredients that are:
i) a first fire retardant ingredient that is a phosphorus-based fire retardant compound,
ii) a second fire retardant ingredient that is different from the first fire retardant ingredient and that is an intumescent material; and
iii) a third fire retardant ingredient that is different from the first fire retardant ingredient and that is a brominated ingredient additionally having an active hydrogen functionality that is co-reactive with the NCO of the first part; and
wherein the first part and the second part are formulated so that when the parts are mixed together they form a solid body having a density of greater than 40 pounds per cubic foot.
14. The solid body cast system of claim 13 , wherein the first fire retardant ingredient is a phosphate-based compound.
15. The solid body cast system of claim 13 , wherein the active hydrogen of the second part is provided by a hydroxy functionality.
16. The solid body cast system of claim 13 , wherein the active hydrogen of the second part is provided by an amine functionality.
17. The solid body cast system of claim 13 , wherein the brominated fire retardant ingredient is a brominated compound having an active hydrogen functionality that is co-reactive with the NCO of the first part.
18. The solid body cast system of claim 13 , wherein the brominated fire retardant ingredient is a brominated compound having a functionality that is co-reactive with the active hydrogen of the second part.
19. The solid body cast system of claim 13 , wherein the brominated fire retardant ingredient is a brominated compound that is not co-reactive with the reactants of the first or second part of the solid body cast system.
20. The solid body cast system of claim 13 , wherein the intumescent material is expandable graphite.
21. The solid body cast system of claim 13 , wherein
i) the first fire retardant ingredient is a phosphate-based compound that is APP,
ii) the second fire retardant ingredient that is an intumescent material that is expandable graphite; and
iii) the third fire retardant ingredient that is a brominated fire retardant ingredient having a hydroxy functionality.
22. A method of preparing a solid body cast system comprising
a. providing a fire retardant solid body cast system of claim 13 , and
b. mixing the first part and the second part together and causing them to cure in a mold so that they form a cured solid body.
23. A solid body made by the method of claim 22 .
24. The fire retardant coating system of claim 1 , wherein when the parts are mixed together they form a cured coating having a density of greater than 50 pounds per cubic foot.
25. The fire retardant coating system of claim 1 , wherein when the parts are mixed together they form a cured coating having a density of greater than 60 pounds per cubic foot.
26. The method of claim 10 , wherein the first part and the second part are mixed together so that they form a cured coating having a density of greater than 50 pounds per cubic foot.
27. The method of claim 10 , wherein the first part and the second part are mixed together so that they form a cured coating having a density of greater than 60 pounds per cubic foot.
28. The fire retardant coating system of claim 1 , wherein the coating formulation is substantially free of blowing agents, so that no gas cells are formed in the final coating.
29. The solid body cast polyurethane of claim 13 , wherein when the parts are mixed together they form a solid body having a density of greater than 50 pounds per cubic foot.
30. The solid body cast polyurethane of claim 13 , wherein when the parts are mixed together they form a solid body having a density of greater than 60 pounds per cubic foot.