CA2499114A1 - Fire retardant compositions with mold inhibitor - Google Patents
Fire retardant compositions with mold inhibitor Download PDFInfo
- Publication number
- CA2499114A1 CA2499114A1 CA 2499114 CA2499114A CA2499114A1 CA 2499114 A1 CA2499114 A1 CA 2499114A1 CA 2499114 CA2499114 CA 2499114 CA 2499114 A CA2499114 A CA 2499114A CA 2499114 A1 CA2499114 A1 CA 2499114A1
- Authority
- CA
- Canada
- Prior art keywords
- composition
- mold inhibitor
- fire retardant
- weight
- paint
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Landscapes
- Fireproofing Substances (AREA)
- Chemical And Physical Treatments For Wood And The Like (AREA)
Abstract
Fire retardant composition has a mold inhibitor. The composition can embrace a mixture of a substantially neutral ammonium phosphate salt in combination with an active hydrogen-containing nitrogenous organic compound spumific, e.g., urea, and with a hydroxyl-containing carbonific, e.g., a polyol, and further with the mold inhibitor. Such a composition can be made by contacting a phosphoric acid with ammonia to form the ammonium phosphate, contacting the ammonium phosphate with the spumific, the carbonific, and the mold inhibitor, under conditions sufficient to form the composition; and can be used by contacting it with a flammable substrate under conditions sufficient to be flame retardant or mold inhibitory, or both.
Another aspect or embodiment is an intumescent fire retardant latex paint having a mold inhibitor. The paint can be in a form of a finish paint or primer. Such a paint can be made by contacting latex paint-forming ingredients with a fire retardant and a mold inhibitor, under conditions sufficient to form the paint; and can be used by contacting it with a flammable substrate under conditions sufficient to be flame retardant or mold inhibitory, or both. Another aspect is an article of manufacture comprising, in combination, the aforesaid composition or paint, which has the mold inhibitor, and the flammable substrate or a residue of the same.
Another aspect or embodiment is an intumescent fire retardant latex paint having a mold inhibitor. The paint can be in a form of a finish paint or primer. Such a paint can be made by contacting latex paint-forming ingredients with a fire retardant and a mold inhibitor, under conditions sufficient to form the paint; and can be used by contacting it with a flammable substrate under conditions sufficient to be flame retardant or mold inhibitory, or both. Another aspect is an article of manufacture comprising, in combination, the aforesaid composition or paint, which has the mold inhibitor, and the flammable substrate or a residue of the same.
Description
FIRE RETARDANT COMPOSITIONS WITH MOLD INHIBITOR
FIELD AND PURVIEW OF THE INVENTION
In general, the invention concerns a fire retardant composition with a mold inhibitor, methods to make and use it, and a substrate combined with the composition or residue thereof.
In one embodiment, the composition can have a first fire retardant agent of an ammonium phosphate substance, plus a carbonific, for example, glucose or pentaerythritol, and a nitrogenous spumific, for example, urea, which are mixed with the mold inhibitor. A generally clear, aqueous liquid can be formed. In another embodiment, the composition can be an intumescent fire retardant latex paint with a mold inhibitor.
BACKGROUND TO THE INVENTION
Various fire retardants are known. Compositions are known that typically contain fire suppressing salts such as an ammonium phosphate or ammonium sulphate for aerial applications to combat forest fires. See, U.S. patent Nos. 3,196,108; 3,257,316; 3,309,324;
3,634,234;
3,730,890; 3,960,735; 4,447,336; 4,447,337; 4,606,831; 4,822,524; 4,839,065;
4,983,326 and 6,162,375. Others are known to have fire suppressants such as carbonaceous matter, organic phosphorous compounds, organic halides, or borates. See, U.S. patent Nos.
4,668,710;
4,686,241; 5,246,652; 5,968,669; 6,001,285; 6,025,027; 6,084,008 and 6,130,267.
As can be appreciated, in addition to fire retardants used to combat forest fires, intended as a temporary measure to be washed away once the fire threat is minimized, prevention of the spread of fire is an important consideration sought in many everyday materials and construction applications such as paper, fabrics, wood, and many plastics. Much research has been conducted to determine how to reduce and/or eliminate the potential fire hazards caused by these materials.
In general, all organic and some inorganic materials will burn under appropriate conditions. With solid materials, this involves decomposition of the solid to produce gases that burn, rather than burning of the solid per se. The actual burning occurs in four main stages:
Heating: an ignition source raises the temperature of the item;
FIELD AND PURVIEW OF THE INVENTION
In general, the invention concerns a fire retardant composition with a mold inhibitor, methods to make and use it, and a substrate combined with the composition or residue thereof.
In one embodiment, the composition can have a first fire retardant agent of an ammonium phosphate substance, plus a carbonific, for example, glucose or pentaerythritol, and a nitrogenous spumific, for example, urea, which are mixed with the mold inhibitor. A generally clear, aqueous liquid can be formed. In another embodiment, the composition can be an intumescent fire retardant latex paint with a mold inhibitor.
BACKGROUND TO THE INVENTION
Various fire retardants are known. Compositions are known that typically contain fire suppressing salts such as an ammonium phosphate or ammonium sulphate for aerial applications to combat forest fires. See, U.S. patent Nos. 3,196,108; 3,257,316; 3,309,324;
3,634,234;
3,730,890; 3,960,735; 4,447,336; 4,447,337; 4,606,831; 4,822,524; 4,839,065;
4,983,326 and 6,162,375. Others are known to have fire suppressants such as carbonaceous matter, organic phosphorous compounds, organic halides, or borates. See, U.S. patent Nos.
4,668,710;
4,686,241; 5,246,652; 5,968,669; 6,001,285; 6,025,027; 6,084,008 and 6,130,267.
As can be appreciated, in addition to fire retardants used to combat forest fires, intended as a temporary measure to be washed away once the fire threat is minimized, prevention of the spread of fire is an important consideration sought in many everyday materials and construction applications such as paper, fabrics, wood, and many plastics. Much research has been conducted to determine how to reduce and/or eliminate the potential fire hazards caused by these materials.
In general, all organic and some inorganic materials will burn under appropriate conditions. With solid materials, this involves decomposition of the solid to produce gases that burn, rather than burning of the solid per se. The actual burning occurs in four main stages:
Heating: an ignition source raises the temperature of the item;
2. Decomposition: when sufficiently heated, the item begins to change its properties and break down, forming combustible gases;
3. Ignition: combustible gas production increases until a concentration is reached that allows for sustained, rapid oxidation, when exposed to an ignition source; and 4. Combustion and propagation: combustion of the gases becomes self propagating if the heat generated is sufficient to be radiated back to the item and continue the decomposition process.
Decades ago, most furnishings in the home were made from natural materials including wool, cotton, and horse hair, which were relatively flame resistant; so, if a fire started in the home, it would generally take some eight to ten minutes before flashover would occur, depending on the location of the lire, and availability of flammable materials in close proximity to the source of the fire. If discovered quickly enough, the fire department would arrive to extinguish the blaze before it grew too rapidly and flashover occurred.
Flashover, of course, occurs when the rate of combustion and flame spread in the dwelling becomes so rapid that the air becomes super heated, which causes all exposed flammable surfaces to erupt into flames, i.e., "flash over." This produces the equivalent of an explosion, blowing out doors and windows, and causing serious bodily injury or death. Nowadays, most everyday household materials are extremely flammable themselves, being made not only of paper and wood but also synthetic fabric and plastic, the latter, or course, made from petroleum products. Thus, flashover is of increasingly serious concern. Some of these modern materials may practically burst in flames with a short exposure to the ignition source, and flashover may occur before the fire department can get to the home, even if notified promptly. As can readily be appreciated, therefore, the residential fires of today may be quite tragic when compared to those of past years.
In addressing this, conventional intumescent systems have been developed. They typically include as essential components: (1) an acid-forming substance, which may be referred to as a "catalyst"; (2) an expanding agent, which causes formation of a foamed (intumescent) layer by emission of an inert or non-combustible gas, which agent may be referred to as a "spumific"; and (3) a binder such as a thermoplastic resin, which contributes to the film-forming properties of the system and provides a portion of a char skeleton, and which is usually referred to as a "carbonific." A component may have more than one function. Such phosphate-catalyzed intumescent compositions can be composed of components selected from among the following:
1. As the acid source {catalyst), usually amino phosphates, mainly ammonium polyphosphates, ammonium orthophosphate, and melamine phosphate, say, in an amount of about 25% by weight of the total formulation.
2. As the spumific, melamine, melamine salts, melamine derivatives, urea and/or dicyandiamide.
3. As the carbonific, a polyhydroxy compound, usually a polyol, which is decomposed by liberated phosphoric acid to form an ester that results in formation of the char (carbonification), for example, pentaerythritol, dipentaerythritol, tripentaerythritol, or certain sugars, starches or starch derivatives.
Two disadvantages with these conventional systems are cost and opacity. Opaque compounds such as ammonium polyphosphate in powder form, powdered amines and carbonific components are often employed. These tend to be not only expensive, owing to the materials and their labor-intensive production, but also less desirable aesthetically, say, on woodwork where its exposed surface is sought after as an architectural feature.
In address of the foregoing, Michael J. Mabey discovered a fire retardant, which, in general, is a composition comprising a mixture of a substantially neutral ammonium phosphate salt in combination with an active hydrogen-containing nitrogenous organic compound, and with a hydroxyl-containing carbonific. It can be made by contacting a phosphoric acid with ammonia to form the ammonium phosphate, contacting the ammonium phosphate with the active hydrogen-containing nitrogenous organic compound and the hydroxyl-containing carbonific under conditions sufficient to form the composition; and can be used by contacting it with a flammable substrate under conditions sufficient to be flame retardant. Also disclosed was an article of manufacture comprising, in combination, the fire retardant composition and the flammable substrate or a residue of the same. Typical amounts by weight of preferred components effective therein are listed as follows:
Mono/diammonium phosphates 20~70%
Diluent (solvent) of water 25~50%
Urea 2.5~15.0%
Glucose 4.0~ 12.0%
Polysaccharide resin 2.0-r40.0%
GLUCOPON-425 surfactant 0.2~1.2%
Potassium salicylate solution 0.01 ~0.1 %.
That Mabey composition is indeed highly effective and desirable. Indeed, that composition, which, again, relates to ammonium phosphate containing fire retardant coatings preferably for interior woodwork, is preferably embodied as WOOD GARD liquid available from NO-BURN, INC.
As for other intumescent fire retardants, certain of these can be in the form of an intumescent composition, coating or paint. Note, U.S. patent Nos. 5,989,706;
Decades ago, most furnishings in the home were made from natural materials including wool, cotton, and horse hair, which were relatively flame resistant; so, if a fire started in the home, it would generally take some eight to ten minutes before flashover would occur, depending on the location of the lire, and availability of flammable materials in close proximity to the source of the fire. If discovered quickly enough, the fire department would arrive to extinguish the blaze before it grew too rapidly and flashover occurred.
Flashover, of course, occurs when the rate of combustion and flame spread in the dwelling becomes so rapid that the air becomes super heated, which causes all exposed flammable surfaces to erupt into flames, i.e., "flash over." This produces the equivalent of an explosion, blowing out doors and windows, and causing serious bodily injury or death. Nowadays, most everyday household materials are extremely flammable themselves, being made not only of paper and wood but also synthetic fabric and plastic, the latter, or course, made from petroleum products. Thus, flashover is of increasingly serious concern. Some of these modern materials may practically burst in flames with a short exposure to the ignition source, and flashover may occur before the fire department can get to the home, even if notified promptly. As can readily be appreciated, therefore, the residential fires of today may be quite tragic when compared to those of past years.
In addressing this, conventional intumescent systems have been developed. They typically include as essential components: (1) an acid-forming substance, which may be referred to as a "catalyst"; (2) an expanding agent, which causes formation of a foamed (intumescent) layer by emission of an inert or non-combustible gas, which agent may be referred to as a "spumific"; and (3) a binder such as a thermoplastic resin, which contributes to the film-forming properties of the system and provides a portion of a char skeleton, and which is usually referred to as a "carbonific." A component may have more than one function. Such phosphate-catalyzed intumescent compositions can be composed of components selected from among the following:
1. As the acid source {catalyst), usually amino phosphates, mainly ammonium polyphosphates, ammonium orthophosphate, and melamine phosphate, say, in an amount of about 25% by weight of the total formulation.
2. As the spumific, melamine, melamine salts, melamine derivatives, urea and/or dicyandiamide.
3. As the carbonific, a polyhydroxy compound, usually a polyol, which is decomposed by liberated phosphoric acid to form an ester that results in formation of the char (carbonification), for example, pentaerythritol, dipentaerythritol, tripentaerythritol, or certain sugars, starches or starch derivatives.
Two disadvantages with these conventional systems are cost and opacity. Opaque compounds such as ammonium polyphosphate in powder form, powdered amines and carbonific components are often employed. These tend to be not only expensive, owing to the materials and their labor-intensive production, but also less desirable aesthetically, say, on woodwork where its exposed surface is sought after as an architectural feature.
In address of the foregoing, Michael J. Mabey discovered a fire retardant, which, in general, is a composition comprising a mixture of a substantially neutral ammonium phosphate salt in combination with an active hydrogen-containing nitrogenous organic compound, and with a hydroxyl-containing carbonific. It can be made by contacting a phosphoric acid with ammonia to form the ammonium phosphate, contacting the ammonium phosphate with the active hydrogen-containing nitrogenous organic compound and the hydroxyl-containing carbonific under conditions sufficient to form the composition; and can be used by contacting it with a flammable substrate under conditions sufficient to be flame retardant. Also disclosed was an article of manufacture comprising, in combination, the fire retardant composition and the flammable substrate or a residue of the same. Typical amounts by weight of preferred components effective therein are listed as follows:
Mono/diammonium phosphates 20~70%
Diluent (solvent) of water 25~50%
Urea 2.5~15.0%
Glucose 4.0~ 12.0%
Polysaccharide resin 2.0-r40.0%
GLUCOPON-425 surfactant 0.2~1.2%
Potassium salicylate solution 0.01 ~0.1 %.
That Mabey composition is indeed highly effective and desirable. Indeed, that composition, which, again, relates to ammonium phosphate containing fire retardant coatings preferably for interior woodwork, is preferably embodied as WOOD GARD liquid available from NO-BURN, INC.
As for other intumescent fire retardants, certain of these can be in the form of an intumescent composition, coating or paint. Note, U.S. patent Nos. 5,989,706;
5,925,457;
5,645,926; 5,603,990; 5,064,710; 4,635,025; 4,345,002; 4,339,357; 4,265,791;
4,241,145;
4,226,907; 4,221,837; 4,210,452; 4,205,022; 4,201,677; 4,201,593; 4,137,849;
4,028,333;
3,955,987 and 3,934,066. The intumescent fire retardant may be associated with latex. Note the latter two ('987 and '066) patents. Various organizations, for example, the Cary Company, Addison, Illinois, U.S.A., Kemco International Associates, St. Pete, Florida, U.S.A., and Verichem, Inc., Pittsburgh, Pennsylvania, U.S.A., may make available certain components for certain paints and coatings including flame retardant and smoke suppressant additives, and certain biocides. A highly effective fire retardant intumescent latex paint, NO-BURN (Reg. U.S.
Pat. & Tm. Off) PLUS, is commercially available from NO-BURN, INC., Wadsworth, Ohio, U.S.A., which can be employed, for example, in homes and commercial structures, to provide fire resistant properties to the structure.
See, certain parts of Kish et al., patent application publication No. US
2005/0022466 A1.
However, it would be desirable to improve upon the art.
SOME OBJECTS OF THE INVENTION
It is a general object to improve upon the art.
It is a more particular object and part of this invention to provide mold-inhibition to a fire retardant, notably the aforementioned composition discovered by Mr. Mabey, while retaining desirable properties of the composition. Note WOOD GARD liquid.
It is another more particular object and desire to provide mold-inhibition to a fire retardant, notably for an intumescent latex paint formulation such as NO-BURN
PLUS, while retaining desirable properties of the composition.
It is an especially desirable object to provide for control of toxic black mold (Stachybotrys chartarum), a problematic mold of serious concern, on the surface of materials that are coated with such compositions.
These and other objects are satisfied if not wholly at least in part by the present invention.
FULL DISCLOSURE OF THE INVENTION
In general, the present invention provides, in one aspect, a fire retardant composition having a mold inhibitor, which can comprise a mixture of a substantially neutral ammonium phosphate salt in combination with an active hydrogen-containing nitrogenous organic compound, and with a hydroxyl-containing carbonific, and further with the mold inhibitor. Such a composition can be made by contacting a phosphoric acid with ammonia to form the ammonium phosphate, contacting the ammonium phosphate with the active hydrogen-containing nitrogenous organic compound, the hydroxyl-containing carbonific, and the mold inhibitor, under conditions sufficient to form the composition; and can be used by contacting it with a flammable substrate under conditions sufficient to be flame retardant or mold inhibitory, or both.
Another aspect is an article of manufacture comprising, in combination, the fire retardant composition having the mold inhibitor, and the flammable substrate or a residue of the same.
Also provided, in general, is an intumescent fire retardant latex paint having a mold inhibitor. The paint can be in a form of a finish paint or primer. Such a paint can be made by contacting latex paint-forming ingredients with a fire retardant and a mold inhibitor, under conditions sufficient to form the paint; and can be used by contacting it with a flammable substrate under conditions sufficient to be flame retardant or mold inhibitory, or both. Another aspect is an article of manufacture comprising, in combination, the paint having the mold inhibitor, and the flammable substrate or a residue of the same.
The invention is useful in retarding fire and controlling mold and so forth fauna.
Significantly, by the invention, an effective, cost-efficient, aesthetically pleasing and/or generally safe fire retardant having mold inhibition is provided. The invention ameliorates or solves one or more of the problems in the art. For instance, flammable construction stock such as wooden board stock is provided with good fire retardant ratings and effective mold control;
application of the composition is simple and easy; and a clear formulation can be provided to highlight the beauty of natural woodwork. A particular embodiment provides for control of toxic black mold in a fire retardant. Addition of the mold inhibitor adds notable value to the fire retardant. The composition of the invention can advantageously be applied directly to a wide range of materials, including wood, plywood, oriented strand board and chip board sheathing, paper, fabrics, corrugated board materials, and so forth and the like. The composition is moderately inexpensive and safe to manufacture, store, transport and use. One of the many advantages of the present composition is that, since it can be applied directly to materials, this greatly reduces the financial and environmental costs of rendering materials fire retardant.
Further, building materials may be rendered fire retardant during or after construction by direct application of the present composition, which may eliminate much cost and difficulty in building construction. Application to inside substrates is particularly beneficial. The composition may be considered to be an intumescent fire retardant/mold inhibitor. In certain embodiments, the invention may be considered an improvement in kind over that of the aforementioned Mabey ammonium phosphate containing lire retardant coating composition.
Significantly, as well, by another embodiment of the invention, an effective, cost-efficient, aesthetically pleasing and/or generally safe fire retardant latex paint having mold inhibition is provided. This embodiment of the invention ameliorates or solves one or more of the problems in the art. For instance, flammable construction stock such as wooden board stock is provided with good fire retardant ratings and effective mold control; and, in addition to fire retardancy, mold inhibition can be provided by the paint to paper or paper-coated wallboard products including gypsum core, paper-coated wallboard. Application of the paint is simple and easy, and coverage can be excellent. A particular embodiment provides for control of toxic black mold in a fire retardant. Addition of the mold inhibitor adds notable value to the fire retardant. The paint of the invention can advantageously be applied directly to a wide range of materials, including wood, plywood, oriented strand board and chip board sheathing, paper, fabrics, corrugated board materials, and so forth and the like. The composition is moderately inexpensive and reasonably safe to manufacture, store, transport and use. One of the many advantages of the present composition is that, since it can be applied directly to materials, this greatly reduces the financial and environmental costs of rendering materials fire retardant.
Further, building materials may be rendered fire retardant during or after construction by direct application of the present composition, which may eliminate much cost and difficulty in building construction. Application to inside substrates is particularly beneficial. The composition may be considered to be an intumescent fire retardantlmold inhibitor latex paint. The paint of the invention can have a "Class A" fire rating. Embodiments of the invention can be considered improvements in kind the NO-BURN PLUS intumescent fire retardant latex paint, adding to such, in particular, exceptional value and utility, noting along these lines salient parts of the aforementioned publication by Kish et al.
Numerous further advantages attend the invention.
The invention can be further understood by the additional detail set forth below. The same, like that set forth above, is to be taken in an illustrative and not necessarily limiting sense.
Broadly hereby, a fire retardant composition is combined with a mold inhibitor.
I. Ammonium phosphate containing fire retardant coatings Broadly, in this aspect or embodiment, an ammonium phosphate containing fire retardant can be combined with a mold inhibitor.
A foundation of certain preferred embodiments of this aspect or embodiment of the invention is that a clear or substantially clear fire retardant surface treatment can result from reacting phosphoric acid with ammonium hydroxide in a stoiehometric ratio sufficient to make an aqueous solution of substantially neutral pH, which includes monoammonium and diammonium phosphates, in an exothermic reaction. The solution, which is an example of an essentially or substantially neutral ammonium phosphate salt, next is contacted or combined, perhaps reacted, with an active hydrogen-containing nitrogenous organic compound such as urea, and also with a hydroxyl-containing carbonific such as glucose or pentaerythritol to produce a typically viscous fire retardant solution.
To that solution or a precursor stage thereof is added the mold inhibitor.
Preferably, the mold inhibitor is added to the viscous fire retardant solution, especially promptly or immediately upon its manufacture. Notably, incorporation of the mold inhibitor, which may be a fungicide, into a very fresh fire retardant solution can be much more simple and effective than when the fire retardant solution is cold or has been standing for any significant time. This can be especially so when the fire retardant solution is a preferred embodiment of the aforementioned Mabey composition or modification thereof and the mold inhibitor is a fungicide such as didecyldimethylammonium chloride (diDe-diMe-AmCI), an alkyldimethylbenzylammonium chloride (Alk-diMe-Bz-AmCI), and/or another mold inhibitor that is chemically compatible and stable in the solution, and so forth and the like.
Accordingly, the composition of the invention may be considered, in certain embodiments, to be a substantially if not essentially neutral ammonium phosphate salt in a matrix of a urea and a hydroxyl-containing carbonific, which has the mold inhibitor. The composition can form a coating and typically dries on the substrate.
The term, "fire retardant composition," as employed herein is a composition that, when applied to a flammable material, provides thermal protection for the material.
In general, this may be done by reducing or perhaps even eliminating the tendency of the material to burn and/or by reducing the rate of flame spread along the surface of the material.
Preferably, use of the fire retardant composition, for example, on a solid material such as wood substrate, reduces surface burning characteristics significantly, say, at least about 10%, at least about 25%, or at least about 50%, when compared to corresponding but untreated material, as tested by an appropriate test.
For example, the test may be the ASTM E84 Steiner Tunnel Test. Without being bound by any theory, the preferred fire retardant composition of the present invention, based in general on the aforementioned Mabey fire retardant, is believed to operate generally as follows: The fire retardant composition decomposes under the heat of the fire to produce a nonflammable gas as well as a light weight char, which occurs at a lower temperature than the item on which it is applied would release flammable gases. The char formed as the ammonium phosphate breaks down, releasing ammonia gas, which leads to reaction of the phosphate with the carbon-bearing compounds to form a nonflammable ester. As the nitrogen-containing compounds break down to release non-flammable gas, the gas becomes trapped in the carbon mass, tending to puff it up, forming a char pillow. The char pillow, by reducing air flow, and hence, oxygen, and by reducing or blocking heat-transfer to the surface, tends to reduce the burning-propensity of the treated surface. As a result, fire is robbed of fuel and oxygen, generates less heat and smoke, and may in some circumstances extinguish itself.
The term, "mold inhibitor," as employed herein is an agent that can kill, control, or prevent growth of mold, mildew, or fungus, and so forth and the like flora, especially when formulated with a basic fire retardant composition. A mold inhibitor may be fire retardant or fire accelerative, but, in the latter case, does not accelerate fire to a degree that the overall composition which contains the mold inhibitor cannot be considered to be a fire retardant composition. Preferably, however, use of the fire retardant composition with mold inhibitor, for example, on a solid material as the substrate, reduces growth of the flora of interest significantly, say, at least about 60%, at least about 85%, or at least about 99% or even at least about 99.9%, if it does not kill it outright, for a significant time, say, at least about thirty days, at least about six months, or at least about 360 days or a year, if not, in effect, indefinitely, as tested by appropriate test methodology. For example, the test method may be by ASTM D5590-94, Determination of Resistance of a Coating Material to Fungal Growth.
As the substantially neutral ammonium phosphate salt, any suitable ammonium phosphate, to include ammonium polyphosphates, and mixtures thereof, may be employed.
Preferably, however, the substantially neutral ammonium phosphate salt is a mixture which contains monoammonium and diammonium phosphates. The salt may be employed per se, or in conjunction with a diluent. Preferably, a diluent is employed, and, advantageously, the diluent acts as a solvent. Beneficially, the diluent is evaporative, which is to say that it can evaporate in the final product, leaving the fire retardant composition with mold inhibitor, or a residue thereof, with the substrate to which it applied, typically in a film type coating. As such, the diluent acts as a carrier. The diluent can be any suitable substance, including a hydroxyl-containing liquid such as an alcohol, water, or mixture thereof. Water is preferred. In one advantageous embodiment, the substantially neutral ammonium salt can be provided as an aqueous solution having monoammonium and diammonium phosphates by reacting an about from sixty to ninety-five, preferably about from seventy to ninety, percent by weight solution of phosphoric acid with an about from fifteen to forty, preferably about from twenty to thirty-three, percent by weight solution of aqueous ammonia in a ratio sufficient to produce a mixture with a substantially neutral pH, say, about from six to seven and a half, preferably about from 6.6 to 7Ø Such a solution may be commercially obtained.
The substantially neutral ammonium phosphate salt is combined with the active hydrogen-containing nitrogenous organic compound, i.e., the spumific; the hydroxyl-containing carbonific; and the mold inhibitor. The combination, or contact, of the components may be carried out in any suitable order. Thus, an initial contact may be salt to spumific to prepare a salt-spumific intermediate, followed by contact with the carbonific; an initial contact may be salt to carbonific to prepare a salt-carbonific intermediate, followed by contact with the spumific; or the spumific and carbonific may be initially mixed, with that mixture contacted with the salt.
The mold inhibitor may be added at any suitable stage, and may accompany any suitable component or intermediate. Preferably, however, the mold inhibitor is added to the freshly prepared fire retardant composition made from the substantially neutral ammonium phosphate salt, spumific, and carbonific, especially while the composition is still warm from contact and reaction of the initial components. Other components) such as wetting agent(s), defoaming agent(s), and so forth, may also be added at suitable time(s). Preferably, however, when the composition includes such other component(s), these are included in an initial fire retardant composition, and the mold inhibitor is added afterwards, preferably, again, while the initial fire retardant composition is fresh, especially warm. Conditions are those sufficient to form the fire retardant composition with mold inhibitor of the invention.
As the hydrogen-containing nitrogenous organic compound, or spumiftc, any suitable substance may be employed. Preferably, the spumific is compatible with the other components employed, and further is soluble therewith or with any diluent employed. For instance, urea or a substituted urea may be employed. Preferably, however, the spumific is urea.
As the hydroxyl-containing carbonific, any suitable substance may be employed.
Preferably, the carbonific is compatible with the other components employed, and further is soluble therewith or with any diluent employed, especially water. For instance, a polyol, to include a carbohydrate such as a sugar or starch, may be employed. The polyol thus may be a compound such as glycerol, pentaerythritol, dipentaerythritol, tripentaerythritol; a sugar, say, a monosaccharide such as a triose, tetrose, pentose, hexose, heptose, or octose, to include an aldose or a ketose, or a disaccharide, a trisaccharide, a polysaccharide, and so forth; or a starch. A
combination of polyols may be employed. Thus, for instance, the spumific can include a six-carbon aldose, with which the polysaccharide may be employed.
As the mold inhibitor, any suitable substance may be employed. Preferably, the mold inhibitor is compatible with the other components employed, and further is soluble therewith or with any diluent employed. For instance, the mold inhibitor may be a quaternary organic ammonium halide, to include a quaternary alkyl ammonium halide, especially such a halide having at least one short chain and at least one medium chain alkyl group, for example, two of each, and an otherwise corresponding quaternary alkyl aromatic ammonium halide. The halide is advantageously a chloride. The short chain alkyl group may be inclusive of, separately at each occurrence, a one- to an about five-carbon group, especially a one- to four-carbon group, for example, a methyl, ethyl, propyl, and so forth group. The medium chain alkyl group may be inclusive of, separately at each occurrence, an about six- to an about thirty-carbon group, especially a six- to an about twenty-carbon group, for example, a hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl group, a thirteen-, fourteen-, fifteen- or sixteen-, seventeen-, eighteen-, nineteen-, or twenty-carbon group, and so forth. Preferably, the short chain alkyl group is methyl and/or ethyl, especially methyl, and the medium chain alkyl group is an eight- to twelve-carbon group, to include a mixture thereof, especially decyl, which can be present as an n-alkyl group. The halide is advantageously a chloride. For example, the mold inhibitor employed may be diDe-diMe-AmCI. An aromatic group, to include an aryl, alkaryl and/or arylalkyl group, for example, a benzyl and/or ethylbenzyl group, may be present, for instance, in a quaternary organic to include a quaternary alkyl aromatic ammonium halide mold inhibitor, for example, Alk-diMe-Bz-AmCI. The mold inhibitor may be a mixture containing more than one mold inhibitor compound. An increase in concentration of a quaternary ammonium halide mold inhibitor can provide for a corresponding reduction in the amount of an ammonium phosphate or ammonium orthophosphate.
The mold inhibitor is employed in any amount sufficient to provide for kill, control or prevention of growth of the target organism(s). It may be employed by weight of the final product in an amount up to about fifteen or twenty percent or more, to include, independently at each occurrence, lower values in specified ranges of about one tenth, about one half, about one, and about two percent, and upper values in specified ranges of about ten, about eight, about five and one half, and about four percent. A preferred amount of the mold inhibitor by weight of the final product, which may be coupled with a lower or an upper value amount as noted above or elsewhere herein to provide another value for a specified range, is generally about three percent.
A wetting agent, or surfactant, may be added. Preferably, any surfactant is biodegradable.
Generally, when employed, the surfactant is present in an amount sufficient to effectively release surface tension in the composition and to allow it to effectively and evenly penetrate the substrate before substantial evaporation of a diluent. Any suitable surfactant may be employed.
In preferred practice of the present invention, however, since the fungicide may function as a surfactant agent, particularly if it is of the quaternary ammonium salt variety, as are diDe-diMe-AmCI and Alk-diMe-Bz-AmCI, if surfactant activity is desired, it typically is not necessary to provide any additional surfactant. If an added surfactant is desired, the added surfactant may notably be a nonionic alkylpolyglycoside surfactant, which, for instance, may be commercially available, for example, under the mark GLUCOPON (Henkel Corporation). The GLUCOPON
surfactants are more readily biodegradable than conventional petroleum-based surfactants, and have been found to be much safer in testing with land and marine animals, while advantageously offering performance comparable to conventional surfactants in the fire retardant compositions of the invention. GLUCOPON surfactants, which were specifically formulated for cleaning product formulation technology, are made from renewable raw materials: glucose from corn, and fatty alcohol from coconut and palm kernel oils. The surfactant is typically supplied as an aqueous solution containing 50% to 70% active matter, having an alkaline pH
(11.5-12.5) with no preservative added. Some GLUCOPON surfactants are also available at neutral pH with an anti microbial preservative added. Although perhaps any grade of GLUCOPON
surfactant may be used successfully, GLUCOPON-425 may notably be employed as an added surfactant.
A defoaming agent may be added. Any suitable defoaming agent may be used, for instance, a salicylate salt, or a silicon compound. The defoaming agent may be potassium salicylate, which is also known to function as a preservative.
Any suitable amount of a component may be employed. Some typical amounts as percents by weight of generally preferred components effective in the practice of the invention are listed as follows, of which any specified components or characteristics are exemplary and for purposes of illustration, and which listed amounts may be taken as approximate:
Mono/diammonium phosphates) 2070%
Diluent, e.g., solvent, say, 2550%
water Spumific, e.g., urea beads 2.515.0%
Sugar, e.g., glucose 4.012.0%
Polysaccharide resin 2.040.0%
Added surfactant, e.g., GLUCOPON-4250.21.2%, advantageously none Added defoaming agent, e.g., potassium salicylate in solution 0 or 0.010.1% or 0.010.5%
Mold inhibitor, e.g., diDe-diMe-AmCI0.110%, to include 0.55.5%.
As an alternative, more detailed or preferred formulation to the preferred formula listed above, or as another manner of expressing such, typical amounts as percents by weight (unless otherwise specified or known from context or art) of components effective in the practice of the invention are listed as follows, again, of which any specified components or characteristics are exemplary and for purposes of illustration, and which listed amounts may be taken as approximate:
Ammonium orthophosphate (40% aqueous solution) 5070%
Polysaccharide resin, e.g., Lorama LPR76 (45% aqueous solution) 2030%
Sugar, e.g., granulated cane sugar SN10%
Spumific, e.g., urea 5~7%
Added defoaming agent, e.g., potassium salicylate in solution 0 or 0.01 ~0.1 /0.5%
Mold inhibitor, e.g., Alk-diMe-Bz-AmCI
(80% aqueous solution) 0.55%.
These ingredients may be stirred until dissolved, making a mixture free of solids and forming a clear liquid with pH, say, about 6.8. However, the mixture may be slightly cloudy or even in some cases more cloudy, or with strata in some cases, yet be effective and appealing.
It is to be understood, however, that many suitable materials may be used as the fire retardant and mold inhibiting agents of the present composition. In the preferred embodiment, the fire retardant compound is made from a combination of mono and diammonium phosphate salts formed from reacting about from 75% to 85% solutions of phosphoric acid (H3POa) with aqueous ammonia (NHa) in sufficient stoichiometric ratios to produce a generally pH neutral solution, and then further reacting the carbon rich material as above and the nitrogen rich urea to form a viscous liquid. To this mixture is added the wetting agents and the defoaming agents mentioned earlier. While this composition is fresh, and still warm, the mold inhibitor is added.
Each of the starting compounds to make the preferred embodiment is commercially available.
The mixture is stirred, again, preferably to dissolve the ingredients and provide a clear solution.
As noted above, strata may appear. The mixture is preferably stirred again before application.
As an aqueous solution, the pH of the final product can be approximately neutral, for instance, about from five and one half to eight, say, about from six to seven and a half, preferably about from 6 to 7, more preferably and independently at each occurrence about from 6.2 or 6.6 to 6.8 or 6.9. Along these lines, in general, too high a pH, say, above 6.8 or so, may release a discernable ammonia smell, and too low a pH, say, below 6.6 or so, may engender corrosion on certain substrates with which the product comes into contact. The final product may have any suitable density or specific gravity, for instance, about from one to one and a half, say about from one and a tenth to one and a third. The specific density may be about from 1.15 to 1.3, to include about from 1.18 to 1.25, without the mold inhibitor; and may be, in general, about from 1.10 to 1.17 with the mold inhibitor. Active fire retardant composition component ingredients, less the mold inhibitor, may be present in any amount, to include about from 40% to 60%, preferably about from 45% to 55%, say, about 48% ~ about 0.5%, to include about 48% ~
about 0.3%, of the total weight of the fire retardant composition component of the invention.
In terms of total weight percent of the final composition, to include the added mold inhibitor, the active ingredients can be present in any effective amount, to include about from 40%
to 70%, preferably about from 45% to 55%, say, about 50% + about 0.5% or 51 % + about 0.5%.
The fire retardant composition with mold inhibitor of the invention may penetrate to some degree, which may be a small amount. It may reside substantially on the surface of the substrate. However that may be, preferably, once dried, it leaves a substantially transparent film on the surface of a flammable solid substrate. This results in a composition or residue of the same, which is believed to be relatively safe in application and after drying.
Suitable precautions, however, should be undertaken. This results also in a versatile fire retardant composition with mold inhibitor, which can be employed in situations in which the aesthetic appearance of a substrate such as neutral or stained woodwork is to remain visible, or in which it would be beneficial to retain visual integrity of another substrate. The preferred liquid composition of the present invention is readily absorbed to an extent by porous materials such as wood, fabric, paper, cardboard, and so forth and the like, where it may remain, in essence, indefinitely, if protected from rain and other forms of excess moisture.
Advantageously, there is nothing in the formulation of the present invention known to be substantially harmful to wood per se, plywood, or any other wood product in general. Further, since the present fire retardant composition with mold inhibitor is often only applied to the surface, it should not interact with, degrade, or otherwise deteriorate plywood, sheathing, or other types of glued or composite wood products, particularly deep in the substrate.
The fire retardant composition with mold inhibitor of the invention may be applied to the materials by any suitable method. Known methods may be employed. The composition may be applied by spraying, say, by hand-held trigger sprayers, pump-up pressure sprayers, or any other type of manual or automatic power-assisted spraying apparatus, including by power paint rollers (saturated rollers); airless sprayers; brushing; dipping; and so forth.
Advantageously, the composition is applied by spraying. Brushing is a simple, effective expedient.
These and other application processes are well known in the art and are subject to many variations. The fire retardant composition with mold inhibitor of the present invention is applied at any suitable concentration or rate to produce a material treated with an effective amount of fire retardant and mold inhibitor.
Among benefits of the composition of the invention, in general, is that, rather than worrying about putting out a fire, it prevents or substantially retards one from burning. If a fire would start, such a composition automatically reacts to the fire by combining with the combustible gases and tars, converting them to carbon char, nitrogen and carbon dioxide, which delays, retards, or extinguishes the source of combustion before the fire takes hold. Its characteristics can also help improve the environment about a structure on fire by eliminating the production of a significant amount, say, up to some 90%, of the smoke and toxic gases produced by a regular fire, which is important because the majority of fire deaths are caused by inhalation of toxic smoke and fumes long before the fire ever gets close to the victims.
Moreover, the mold inhibition properties of the present composition can help protect structural integrity of a building structure or parts) thereof to which it is applied, for example, to floor, ceiling or attic joists, sub flooring, flooring, wooden or composite wall, ceiling or roof boards or sheets, and so forth. In a significant way, too, the health of occupants or visitors can be aided from detrimental effects of mold that otherwise would have been present.
II. Intumescent fire retardant latex paint with mold inhibitor Broadly, in this aspect or embodiment, an intumescent fire retardant latex paint is combined with a mold inhibitor.
A foundation of preferred embodiments of this aspect or embodiment of the invention is that an intumescent fire retardant latex paint base can be prepared, and during or after its preparation can be added the mold inhibitor. The mold inhibitor, for example, may be added to the base immediately upon its manufacture. Conditions are those sufficient to form the fire retardant paint with mold inhibitor of the invention. Stirring or other agitation of the present paint can enhance its uniformity.
The term, "fire retardant paint," as employed herein, is a latex composition that, when applied to a flammable material, provides thermal protection for the material.
In general, this may be done by reducing or perhaps even eliminating the tendency of the material to burn and/or reducing the rate of flame spread along the surface of the material.
Preferably, use of the fire retardant paint, for example, on a solid material as the substrate, reduces surface burning characteristics significantly, say, at least about 10%, at least about 25%, or at least about 50%, when compared to untreated material, as tested by an appropriate test. For example, the test may be the ASTM E84 Steiner Tunnel Test. Without being bound by any theory, the preferred fire retardant paint of the present invention, based in general on the Form #2 fire retardant paint of the aforementioned publication by Kish et al., more preferably the NO-BURN
PLUS paint, can be considered to be an intumescent fire reactant. Although it looks and applies like regular paint, its chemical composition changes drastically when introduced to heat. Thus, when heat is applied, the fire retardant paint of the invention may "foam up" to form an intact, fire-resistive "char-barrier" to protect the treated surface. As a result, fire is robbed of fuel and oxygen, generates less heat and smoke, and may in some circumstances extinguish itself. Fire retardant paint formulations can vary, but may include ingredients added with water such as follows in approximate percentages:
Ammonium phosphate solids 15~30% by weight Thermoplastic latex resin, e.g., polyvinyl acetate type 10~30% by weight Nitrogenous spumific, e.g., melamine powder 7~13% by weight Carbonific, e.g., polyol 7~13% by weight Titanium dioxide and/or other inert inorganic opacifying agent 510% by weight Soda lime borosilicate or other glass 1~5% by weight Ester alcohol 0.5~1.5% by weight Hydroxyalkylcellulosic 0.1 ~ 1 % by weight Wetting and/or other agents) 0.1~2% by weight.
A more particular base intumescent fire retardant latex paint formulation follows:
Water (bulk) 25~33% by weight Ammonium polyphosphate powder 20~21 % by weight Vinyl acetate latex (aqueous) 21~22% by weight Melamine powder 910% by weight Pentaerythritol 8.59.5% by weight Titanium dioxide powder 7~8% by weight Glass bubbles (0.120.63 g/cc) 1 ~2% by weight 2,2,4-trimethyl-1,3-pentanediol monoisubutyrate 0.60.8% by weight Hydroxyethylcellulose 0.20.4% by weight Wetting andlor other agents ~l% by weight.
To such a base fire retardant latex paint formulation or any other suitable fire retardant latex paint formulation, or precursor part thereof, is provided the mold inhibitor in any suitable amount. The mold inhibitor may be added in an amount by weight of base fire retardant latex paint formulation, independently at each occurrence, about from 0.1% to 15%, to include about from 0.5% to 10%, about from 1% to 5%, and about from 2% to 4%. For instance, the mold inhibitor may be added at about 3% by weight of the base fire retardant latex paint formulation.
As the ammonium phosphate, any suitable ammonium phosphate salt, to include ammonium polyphosphates, and mixtures thereof, may be employed.
Advantageously, it is a solid, which may be provided as a powder. Such a salt may be a mixture which contains monoammonium and diammonium phosphates. Such a salt may be commercially obtained.
As the thermoplastic latex resin such as a polyvinyl acetate latex, any suitable polyvinyl acetate latex type polymer, copolymer or mixture thereof, or the like, may be employed. The polyvinyl acetate type latex component may be provided as an aqueous emulsion.
Also, other thermoplastic latex resins that may function in this capacity would include such resins as polyvinyledene chloride resins and so forth and the like, although perhaps not functioning as effectively as the preferred vinyl acetates.
As the nitrogenous spumific, any suitable hydrogen-containing nitrogenous organic compound may be employed. Preferably, the spumific is compatible with the other components employed, and further is dispersible therewith. For instance, melamine may be employed.
As the carbonific, any suitable hydroxyl-containing organic compound may be employed.
Preferably, the carbonific is compatible with the other components employed, and further is soluble or dispersible in the water or other diluent employed. For instance, a polyol may be employed. The polyol may be a compound such as glycerol, pentaerythritol, dipentaerythritol, tripentaerythritol; a sugar, say, a monosaccharide such as a triose, tetrose, pentose, hexose, heptose, or octose, to include an aldose or a ketose, or a disaccharide, a trisaccharide, a polysaccharide, and so forth; and/or a starch. A combination of polyols may be employed.
Pentaerythritol is a preferred selection.
As the opacifying agent, titanium dioxide powder is preferred. Although pure titanium dioxide powder may be employed, more commonly it is employed in a grade that contains other inert inorganic substances, for example, aluminum hydroxide and/or amorphous silica. An opacifying agent such as titanium dioxide can be employed in an aqueous dispersion form.
A glass additive such as borosilicate and/or other glass may be provided, preferably in the form of glass bubbles of a size in the range of a powder. This improves the body of the paint and may provide it with thixotropic or other advantageous viscous flow properties.
As the ester alcohol, any suitable ester alcohol may be employed. The ester alcohol may be an alkanol alkylate, for example, 2,2,4-trimethyl-1,3-pentanediol monoisubutyrate. The ester alcohol functions as a coalescent for film integrity, and so forth.
As the hydroxyalkylcellulosic, any hydroxyalkylcellulose or suitable analog or derivative thereof may be employed. It may be hydroxymethylcellulose or hydroyethylcellulose, preferably the latter. The hydroxyalkylcellulosic functions to improve the flow and rheology of the finished paint solution or suspension, reducing sag and improving film build.
Wetting and/or other agents) may be employed. Such agents) can include what may be considered surface tension lowering agents, surfactants, defoaming agents, dispersing agents, paint preservatives, which may be biocidal, and so forth and the like. Thus employed in minor amounts may be a pigment dispersing agent such as an alkali metal salt of a polymeric carboxylic acid, say, the sodium salt of a copolymer of malefic acid; a defoamer colloid such as an acrylic polymer, say, sodium polyacrylate; a silicone surfactant such as a polyether modified alkyl polysiloxane, say, a polyether modified poly-dimethyl-siloxane, which may be employed neat or preferably in solution with a suitable solvent, say, about half dipropyleneglycol monomethyl ether (48%); a paint preservative/biocide such as containing 1,2-benzisothiazol-3(2H)-one, say, as an aqueous mixture containing 1,2-benzisothiazol-3(2H)-one, sodium hydroxide, and dipropyleneglycol; and a rheology modifier such as a hydrophobically modified ethylene oxide urethane block copolymer, which may be employed in an organic solvent mixture such as a mixture of butyl carbitol and water or without the organic solvent, say, in water only.
For instance, such wetting andlor other agents) can include compounds or compounds such as follows, the percentages of which relate to the base latex paint formulation and are given by weight, and may be considered to be approximate:
Pigment dispersing agent sodium salt of polymeric malefic acid (NaOH stabilized) 0.10.3%
Defoamer colloid sodium polyacrylate 0.10.3%
Silicone surfactant polyether modified poly-dimethyl-siloxane in dipropyleneglycol monomethyl ether (48%) 0.01 ~0.1 Paint preservativelbiocide 1,2-benzisothiazol-3(2H)-one in an aqueous mixture containing 1,2-benzisothiazol-3(2H)-one, sodium hydroxide, and dipropyleneglycol 0.010.05%
Rheology modifier hydrophobically modified ethylene oxide urethane block copolymer in water 0.250.1%.
Other additives) may be employed.
As the mold inhibitor, any suitable substance may be employed. Preferably, the mold inhibitor is compatible with the other components, and further is soluble or suspendable therewith. For instance, the mold inhibitor may be a quaternary organic ammonium halide, to include a quaternary alkyl ammonium halide, especially such a halide having at least one short chain and at least one medium chain alkyl group, for example, two of each, and an otherwise corresponding quaternary alkyl aromatic ammonium halide. The halide is advantageously a chloride. The short chain alkyl group may be inclusive of, separately at each occurrence, a one-to an about five-carbon group, especially a one- to four-carbon group, for example, a methyl, ethyl, propyl, and so forth group. The medium chain alkyl group may be inclusive of, separately at each occurrence, an about six- to an about thirty-carbon group, especially a six- to an about twenty-carbon group, for example, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, a thirteen-, fourteen-, fifteen- or sixteen-, seventeen-, eighteen-, nineteen-, or twenty-carbon group, and so forth. Preferably, the short chain alkyl group is methyl and/or ethyl, especially methyl, and the medium chain alkyl group is an eight- to twelve-carbon group, to include a mixture thereof, especially decyl, which can be present as an n-alkyl group. The halide is advantageously a chloride. For example, the mold inhibitor employed may be didecyldimethylammonium chloride. An aromatic group, to include aryl, alkaryl and/or arylalkyl, for example, a benzyl and/or ethylbenzyl group may be present, for instance, in a quaternary organic to include a quaternary alkyl aromatic ammonium halide mold inhibitor, for example, alkyldimethylbenzylammonium chloride. The mold inhibitor may be a mixture containing more than one mold inhibitor compound. An increase in concentration of any quaternary ammonium halide mold inhibitor may provide for a corresponding reduction in the amount of ammonium phosphate or ammonium orthophosphate.
Tints) and/or colors) may be added to obtain a pastel or colored paint.
The fire retardant paint with mold inhibitor of the invention may penetrate to some degree, say, a small amount. It may reside substantially on the surface of the substrate.
However that may be, preferably, once dried, it leaves a generally opaque film on the surface of a flammable solid substrate even though more than one coat may be needed to cover completely.
This dried film results in a composition or residue of the same, which is believed to be relatively safe in application and after drying. Suitable precautions, however, should be undertaken. This results also in a versatile fire retardant paint with mold inhibitor, which can be employed in situations in which a painted surface is desired. Advantageously, there is nothing in the formulation of the present invention known to be substantially harmful to wood per se, plywood, any other wood product, or the paper of gypsum board, in general. Further, since the present fire retardant paint with mold inhibitor is typically applied on the surface, it should not interact with, degrade, or otherwise deteriorate plywood, sheathing, other types of glued or composite wood products, or paper-clad or paper products, particularly deep in the substrate.
The present fire retardant paint with mold inhibitor may be applied to the materials by any suitable method. Known methods may be employed. The paint may be applied by spraying, say, by hand-held trigger sprayers, pump-up pressure sprayers, or any other type of manual or automatic power-assisted spraying apparatus, including by power paint rollers (saturated rollers);
airless sprayers; brushing; dipping; and so forth. Advantageously, the wet paint is applied by spraying. Brushing is a simple, effective expedient. These and other application processes are well known in the art and are subject to many variations. The fire retardant paint with mold inhibitor of the present invention is applied at any suitable concentration or rate to produce a material treated with an effective amount of fire retardant and mold inhibitor. One may wish to treat all the heavy paper backing on all the drywall (gypsum board) for purposes of enhanced fire resistance and to prevent the growth of mold on this surface, which has been shown to support the growth of mold under conditions conducive to the same and is used extensively in cladding and partitions in residential and commercial building structures.
III. Examples The following examples further illustrate the invention. Therein, parts and percentages are given by weight, unless otherwise specified.
Example 1 In a clean, appropriately sized mixing tank, the following raw materials were added under constant agitation:
32 gallons (320 1b.) of 49% solution of mono/diammonium phosphate (a reaction product of 75% to 85% liquid phosphoric acid and 27% ammonia in ~.vater at a ratio sufficient to produce a pH of 6.8, the reaction of which is exothermic, which serves to heat the mixture);
170 grams of potassium salicylate solution in water;
1135 grams GLUCOPON-425 nonionic alkylpolyglycoside surfactant (Henkel Corp.);
32 1b. urea beads (fertilizer grade);
40 Ib. glucose.
All these ingredients were stirred until completely dissolved, until the mixture was free of solids and formed a clear liquid with a pH of 6.8 To this mixture, while the solution was still quite warm, was added 132 1b. of JA250-3 polysaccharide resin (Lorama Chemicals, Mississauga, Ontario), which serves to thicken the mixture and contribute solids for the char-forming reaction.
While this mixture was still warm, 3% of BARDAC-2280 didecyldimethylammonium chloride fungicide (an aqueous mixture having 80% active component) (Lonza, Inc., Fair Lawn, N.J.) was added and stirred into the mixture using a high sheer mixer.
A retained sample was drawn from the completed batch and was analyzed for specific gravity, pH, and clarity. The specific gravity was 1.256 @ 19C; the pH was 6.8, and the sample passed the clarity test, i.e., the liquid was clear to slightly opaque, with no precipitants visible, notably by the naked eye. The finished product was pumped to a storage tank for later filling, or was filled into proper containers.
Example 2 The liquid composition of Example 1 was applied to the surface of Red Oak tongue and grooved flooring at a rate of 300 square feet per U.S. gallon in two coats, and allowed to dry in a conditioned room at 72 degrees F and 50% relative humidity until the product had dried and reached a constant mass. Once dried to constant mass, the panels were tested under the ASTM
E84 procedure, which resulted in a Flame Spread Rating of 35.
Untreated Red Oak tongue and grooved flooring from the same batch of lumber was tested under the ASTM E84 procedure to determine the inherent flammability of the panels. The identical but untreated panels had a flame spread rating of 70, which serves to demonstrate the effectiveness of the fire retardant properties of the ammonium phosphate containing coating composition of this invention.
Example 3 The liquid composition of Example 1 was applied in a thin layer by brush to the surface of small, uniformly sized pieces of wood, i.e., Douglas Fir plywood and Spruce lumber, and subjected to the ASTM D5590-94 test method, employing the mold species known as Stachybotrys chartarum. After the required duration of the test, the untreated samples were completely covered with mold growth while the treated samples were mold free.
The results are outlined in Report Number 030819-8, "Evaluation of Fungicidal Resistance of Coatings Materials," conducted by PBR Laboratories, Inc., Edmonton, Alberta, Canada.
Example 4 The procedure of Example 1, employing a didecyldimethylammonium chloride fungicide, was basically repeated, except that no added surfactant such as the nor added defoamer such as the potassium salicylate was added. An equivalent amount of water replaced the GLUPACON-425. The resultant product was most satisfactory.
Example 5 A commercial formulation was prepared, generally according to the procedures of Examples 1 and 4. The protocol for the same is generally as follows:
A. An appropriately sized mixing tank is selected and checked for cleanliness.
If necessary, it is cleaned using hot water and a detergent solution, and rinsed.
B. Raw materials are weighed and added to a mixing tank, beginning with water.
C. After all raw materials have been added, solution is allowed to mix for 60 minutes or until all solids appear to be dissolved.
D. A retained sample is drawn, and analyzed for specific gravity, pH, and clarity.
If approved by quality control, the product is released to be filled.
2. If the retained sample fails any of the tests, then corrective measures are implemented, and another retained sample is drawn and tested.
E. Approved finished product is pumped to a storage tank for later filling, or filled into proper containers.
This finished coating formulation has the following ingredients, in general:
Ammonium phosphate/orthophosphate (40% aqueous solution) 59.0%
Lorama LPR76 polysaccharide resin (45% aqueous solution) 24.24%
Granulated cane sugar 7.29%
Urea 5.78%
Mason CS428* alkyldimethylbenzylammonium chloride (80% aqueous solution) 3.69%.
*Mason CS428 (Mason Chemical Co., Arlington Heights, Ill.) is classified as a surfactant (MSDS). It contains alkyldimethylbenzylammonium chloride (02_16) (CAS #68424-85-1) (80% by weight); ethanol (CAS #64-17-5) (10% by weight);
and water (10% by weight).
This aqueous formulation provides a superior home fire retardant with mold resistance.
Wood is the primary resource of most of the homes in the U.S.A. and Canada.
The formulation can be applied by spraying or brushing during manufacturing, building, or remodeling of the home to protect its internal wood components. All such wood components, including wall studs, flooring, rafters, trusses, joists, exterior sheathing, roofing and decking, the entire "skeleton" of the structure, are treated at the "dried-in" from the weather stage, giving special attention to the attic. In addition, the potential exists to treat all the heavy paper backing on all the drywall (gypsum board) for purposes of enhanced fire resistance and to prevent the growth of mold on this surface, which has been shown to support the growth of mold under conditions conducive to the same, such gypsum board, of course, being used with framing materials to substantially provide interior cladding and partition walls in most domestic and commercial building structures.
As well, the formulation can be applied by spraying or brushing to flammable components of an existing structure, for example, exposed wood structural components of an older home such as the exposed floor joists and subflooring accessible in a basement or crawl space, and so forth. Again, special attention is given to the attic area and its joists, studs, flooring, studs, walls, trusses and ceiling (roof sheathing).
In such cases, superior fire resistance ratings with mold resistance are provided.
Example 6 In a clean, appropriately sized Cowles mixer, the following component ingredients were added in the order shown to make a base intumescent latex paint, with percentages by weight:
Water, bulk 21.41 TAMOL 731A NaOH stabilized sodium salt of polymeric malefic acid (Rohm and Haas) 0.16%
RHODOLINE 226/35 sodium polyacrylate (Rhodia Canada, Inc.) 0.10%
BYK-346 polyether modified poly-dimethyl-siloxane in dipropyleneglycol monomethyl ether (48%) (BYK-Chemie USA, Inc.) 0.05%.
Further added under agitation were the following component ingredients:
TI-PURE titanium dioxide pigment (DuPont Chemicals) 7.39%
EXOLIT AP 422 ammonium polyphosphate powder (Clariant Canada, Inc.) 20.69%
TECH PE 200 technical pentaerythritol (Hercules Canada, Inc.) 9.00%
Powder melamine (DSM Melamine Americas, Inc.) 9.47%.
The mixture was ground for ten minutes, and the bottom and sides of the mixer were scraped.
Then added was the following component ingredient:
NATRASOL 250 MXR hydroyethylcellulose (Hercules Canada, Inc.) 0.31%.
The mixture was ground to a smooth paste to a 2~3 fineness. Then added, with mixing, were the following component ingredients:
RHODOLINE 226/35 sodium polyacrylate 0.10%
PROXEL GXL aqueous mixture containing 1,2-benzisothiazol-3(2H)-one, sodium hydroxide, and dipropyleneglycol (Brenntag Canada, Inc.) 0.03%
TEXANOL 2,2,4-trimethyl-1,3-pentanediol monoisubutyrate (Eastman Chemical Company) 0.75%
StanChem 5238 vinyl acetate copolymer emulsion (54-56% polymer/solids, 44-46% water) (StanChem, Inc.) 21.77%
Water, bulk 6.71 SCOTCHLITE K25 glass bubbles (3M Canada) 1.52%
ACRYSOL RM-8W hydrophobically modified ethylene oxide urethane block copolymer in water (Rohm and Haas) 0.56%.
This provided a base intumescent fire retardant latex paint, which was pumped to a storage tank for later filling, or filled into proper containers.
To a sample of the base intumescent fire retardant latex paint was added with stirring 3.0% Mason CS428 alkyldimethylbenzylammonium chloride (80% aqueous solution) (Mason Chemical Co.) which is classified as a surfactant according to its material safety data sheet (MSDS). It contains alkyldimethylbenzylammonium chloride (C~2_~6) (CAS #68424-85-1) (80%
by weight): ethanol (CAS #64-17-5) (10% by weight); and water (10% by weight) to provide an intumescent fire retardant latex paint with mold inhibitor.
The finished intumescent fire retardant latex paint with mold inhibitor can be pumped to a storage tank for later filling, or filled into proper containers.
Example 7 The base and finished liquid paints of Example 6 were applied to the surface of Douglas fir tongue and groove decking at a rate of 300 square feet per U.S. gallon in two coats, and the painted decking was allowed to dry in a conditioned room at 70 degrees F and 50% relative humidity until the paints had dried and reached a constant mass. Once dried to constant mass, the decking panels were tested under the ASTM E84 procedure and resulted in respective Flame Spread Ratings of "5" for the base paint and "0" for the finished paint with mold inhibitor.
When untreated Douglas fir decking panels from the same batch of tongue and groove decking were tested under the ASTM E84 procedure to determine the inherent flammability of the panels, the otherwise identical but untreated panels had a flame spread rating of "55."
This serves to demonstrate the effectiveness of the fire retardant properties of the latex paint composition of this invention, especially with mold inhibitor.
Example 8 The finished paint of Example 6 was applied in a thin layer by brush to the surface of SPF plywood, and subjected to the ASTM D5590-94 test method, employing the mold species known as Stachybotrys chartarum. After the required duration of the test, the untreated samples were completely covered with mold growth while the treated samples were mold free. The base intumescent latex paint of Example I, i.e., without the added Mason CS428 mold inhibitor, similarly applied to the surface of SPF plywood, showed growth rates of "4"
(maximum growth after the 30-day duration).
CONCLUSION TO THE INVENTION
The present invention is thus provided. Various aspects, features, steps, subcombinations and combinations of the invention can be employed with or without reference to other aspects, features, steps, subcombinations or combinations in its practice, and numerous adaptations and modifications can be effected within its spirit, the literal claim scope of which is particularly pointed out as follows:
5,645,926; 5,603,990; 5,064,710; 4,635,025; 4,345,002; 4,339,357; 4,265,791;
4,241,145;
4,226,907; 4,221,837; 4,210,452; 4,205,022; 4,201,677; 4,201,593; 4,137,849;
4,028,333;
3,955,987 and 3,934,066. The intumescent fire retardant may be associated with latex. Note the latter two ('987 and '066) patents. Various organizations, for example, the Cary Company, Addison, Illinois, U.S.A., Kemco International Associates, St. Pete, Florida, U.S.A., and Verichem, Inc., Pittsburgh, Pennsylvania, U.S.A., may make available certain components for certain paints and coatings including flame retardant and smoke suppressant additives, and certain biocides. A highly effective fire retardant intumescent latex paint, NO-BURN (Reg. U.S.
Pat. & Tm. Off) PLUS, is commercially available from NO-BURN, INC., Wadsworth, Ohio, U.S.A., which can be employed, for example, in homes and commercial structures, to provide fire resistant properties to the structure.
See, certain parts of Kish et al., patent application publication No. US
2005/0022466 A1.
However, it would be desirable to improve upon the art.
SOME OBJECTS OF THE INVENTION
It is a general object to improve upon the art.
It is a more particular object and part of this invention to provide mold-inhibition to a fire retardant, notably the aforementioned composition discovered by Mr. Mabey, while retaining desirable properties of the composition. Note WOOD GARD liquid.
It is another more particular object and desire to provide mold-inhibition to a fire retardant, notably for an intumescent latex paint formulation such as NO-BURN
PLUS, while retaining desirable properties of the composition.
It is an especially desirable object to provide for control of toxic black mold (Stachybotrys chartarum), a problematic mold of serious concern, on the surface of materials that are coated with such compositions.
These and other objects are satisfied if not wholly at least in part by the present invention.
FULL DISCLOSURE OF THE INVENTION
In general, the present invention provides, in one aspect, a fire retardant composition having a mold inhibitor, which can comprise a mixture of a substantially neutral ammonium phosphate salt in combination with an active hydrogen-containing nitrogenous organic compound, and with a hydroxyl-containing carbonific, and further with the mold inhibitor. Such a composition can be made by contacting a phosphoric acid with ammonia to form the ammonium phosphate, contacting the ammonium phosphate with the active hydrogen-containing nitrogenous organic compound, the hydroxyl-containing carbonific, and the mold inhibitor, under conditions sufficient to form the composition; and can be used by contacting it with a flammable substrate under conditions sufficient to be flame retardant or mold inhibitory, or both.
Another aspect is an article of manufacture comprising, in combination, the fire retardant composition having the mold inhibitor, and the flammable substrate or a residue of the same.
Also provided, in general, is an intumescent fire retardant latex paint having a mold inhibitor. The paint can be in a form of a finish paint or primer. Such a paint can be made by contacting latex paint-forming ingredients with a fire retardant and a mold inhibitor, under conditions sufficient to form the paint; and can be used by contacting it with a flammable substrate under conditions sufficient to be flame retardant or mold inhibitory, or both. Another aspect is an article of manufacture comprising, in combination, the paint having the mold inhibitor, and the flammable substrate or a residue of the same.
The invention is useful in retarding fire and controlling mold and so forth fauna.
Significantly, by the invention, an effective, cost-efficient, aesthetically pleasing and/or generally safe fire retardant having mold inhibition is provided. The invention ameliorates or solves one or more of the problems in the art. For instance, flammable construction stock such as wooden board stock is provided with good fire retardant ratings and effective mold control;
application of the composition is simple and easy; and a clear formulation can be provided to highlight the beauty of natural woodwork. A particular embodiment provides for control of toxic black mold in a fire retardant. Addition of the mold inhibitor adds notable value to the fire retardant. The composition of the invention can advantageously be applied directly to a wide range of materials, including wood, plywood, oriented strand board and chip board sheathing, paper, fabrics, corrugated board materials, and so forth and the like. The composition is moderately inexpensive and safe to manufacture, store, transport and use. One of the many advantages of the present composition is that, since it can be applied directly to materials, this greatly reduces the financial and environmental costs of rendering materials fire retardant.
Further, building materials may be rendered fire retardant during or after construction by direct application of the present composition, which may eliminate much cost and difficulty in building construction. Application to inside substrates is particularly beneficial. The composition may be considered to be an intumescent fire retardant/mold inhibitor. In certain embodiments, the invention may be considered an improvement in kind over that of the aforementioned Mabey ammonium phosphate containing lire retardant coating composition.
Significantly, as well, by another embodiment of the invention, an effective, cost-efficient, aesthetically pleasing and/or generally safe fire retardant latex paint having mold inhibition is provided. This embodiment of the invention ameliorates or solves one or more of the problems in the art. For instance, flammable construction stock such as wooden board stock is provided with good fire retardant ratings and effective mold control; and, in addition to fire retardancy, mold inhibition can be provided by the paint to paper or paper-coated wallboard products including gypsum core, paper-coated wallboard. Application of the paint is simple and easy, and coverage can be excellent. A particular embodiment provides for control of toxic black mold in a fire retardant. Addition of the mold inhibitor adds notable value to the fire retardant. The paint of the invention can advantageously be applied directly to a wide range of materials, including wood, plywood, oriented strand board and chip board sheathing, paper, fabrics, corrugated board materials, and so forth and the like. The composition is moderately inexpensive and reasonably safe to manufacture, store, transport and use. One of the many advantages of the present composition is that, since it can be applied directly to materials, this greatly reduces the financial and environmental costs of rendering materials fire retardant.
Further, building materials may be rendered fire retardant during or after construction by direct application of the present composition, which may eliminate much cost and difficulty in building construction. Application to inside substrates is particularly beneficial. The composition may be considered to be an intumescent fire retardantlmold inhibitor latex paint. The paint of the invention can have a "Class A" fire rating. Embodiments of the invention can be considered improvements in kind the NO-BURN PLUS intumescent fire retardant latex paint, adding to such, in particular, exceptional value and utility, noting along these lines salient parts of the aforementioned publication by Kish et al.
Numerous further advantages attend the invention.
The invention can be further understood by the additional detail set forth below. The same, like that set forth above, is to be taken in an illustrative and not necessarily limiting sense.
Broadly hereby, a fire retardant composition is combined with a mold inhibitor.
I. Ammonium phosphate containing fire retardant coatings Broadly, in this aspect or embodiment, an ammonium phosphate containing fire retardant can be combined with a mold inhibitor.
A foundation of certain preferred embodiments of this aspect or embodiment of the invention is that a clear or substantially clear fire retardant surface treatment can result from reacting phosphoric acid with ammonium hydroxide in a stoiehometric ratio sufficient to make an aqueous solution of substantially neutral pH, which includes monoammonium and diammonium phosphates, in an exothermic reaction. The solution, which is an example of an essentially or substantially neutral ammonium phosphate salt, next is contacted or combined, perhaps reacted, with an active hydrogen-containing nitrogenous organic compound such as urea, and also with a hydroxyl-containing carbonific such as glucose or pentaerythritol to produce a typically viscous fire retardant solution.
To that solution or a precursor stage thereof is added the mold inhibitor.
Preferably, the mold inhibitor is added to the viscous fire retardant solution, especially promptly or immediately upon its manufacture. Notably, incorporation of the mold inhibitor, which may be a fungicide, into a very fresh fire retardant solution can be much more simple and effective than when the fire retardant solution is cold or has been standing for any significant time. This can be especially so when the fire retardant solution is a preferred embodiment of the aforementioned Mabey composition or modification thereof and the mold inhibitor is a fungicide such as didecyldimethylammonium chloride (diDe-diMe-AmCI), an alkyldimethylbenzylammonium chloride (Alk-diMe-Bz-AmCI), and/or another mold inhibitor that is chemically compatible and stable in the solution, and so forth and the like.
Accordingly, the composition of the invention may be considered, in certain embodiments, to be a substantially if not essentially neutral ammonium phosphate salt in a matrix of a urea and a hydroxyl-containing carbonific, which has the mold inhibitor. The composition can form a coating and typically dries on the substrate.
The term, "fire retardant composition," as employed herein is a composition that, when applied to a flammable material, provides thermal protection for the material.
In general, this may be done by reducing or perhaps even eliminating the tendency of the material to burn and/or by reducing the rate of flame spread along the surface of the material.
Preferably, use of the fire retardant composition, for example, on a solid material such as wood substrate, reduces surface burning characteristics significantly, say, at least about 10%, at least about 25%, or at least about 50%, when compared to corresponding but untreated material, as tested by an appropriate test.
For example, the test may be the ASTM E84 Steiner Tunnel Test. Without being bound by any theory, the preferred fire retardant composition of the present invention, based in general on the aforementioned Mabey fire retardant, is believed to operate generally as follows: The fire retardant composition decomposes under the heat of the fire to produce a nonflammable gas as well as a light weight char, which occurs at a lower temperature than the item on which it is applied would release flammable gases. The char formed as the ammonium phosphate breaks down, releasing ammonia gas, which leads to reaction of the phosphate with the carbon-bearing compounds to form a nonflammable ester. As the nitrogen-containing compounds break down to release non-flammable gas, the gas becomes trapped in the carbon mass, tending to puff it up, forming a char pillow. The char pillow, by reducing air flow, and hence, oxygen, and by reducing or blocking heat-transfer to the surface, tends to reduce the burning-propensity of the treated surface. As a result, fire is robbed of fuel and oxygen, generates less heat and smoke, and may in some circumstances extinguish itself.
The term, "mold inhibitor," as employed herein is an agent that can kill, control, or prevent growth of mold, mildew, or fungus, and so forth and the like flora, especially when formulated with a basic fire retardant composition. A mold inhibitor may be fire retardant or fire accelerative, but, in the latter case, does not accelerate fire to a degree that the overall composition which contains the mold inhibitor cannot be considered to be a fire retardant composition. Preferably, however, use of the fire retardant composition with mold inhibitor, for example, on a solid material as the substrate, reduces growth of the flora of interest significantly, say, at least about 60%, at least about 85%, or at least about 99% or even at least about 99.9%, if it does not kill it outright, for a significant time, say, at least about thirty days, at least about six months, or at least about 360 days or a year, if not, in effect, indefinitely, as tested by appropriate test methodology. For example, the test method may be by ASTM D5590-94, Determination of Resistance of a Coating Material to Fungal Growth.
As the substantially neutral ammonium phosphate salt, any suitable ammonium phosphate, to include ammonium polyphosphates, and mixtures thereof, may be employed.
Preferably, however, the substantially neutral ammonium phosphate salt is a mixture which contains monoammonium and diammonium phosphates. The salt may be employed per se, or in conjunction with a diluent. Preferably, a diluent is employed, and, advantageously, the diluent acts as a solvent. Beneficially, the diluent is evaporative, which is to say that it can evaporate in the final product, leaving the fire retardant composition with mold inhibitor, or a residue thereof, with the substrate to which it applied, typically in a film type coating. As such, the diluent acts as a carrier. The diluent can be any suitable substance, including a hydroxyl-containing liquid such as an alcohol, water, or mixture thereof. Water is preferred. In one advantageous embodiment, the substantially neutral ammonium salt can be provided as an aqueous solution having monoammonium and diammonium phosphates by reacting an about from sixty to ninety-five, preferably about from seventy to ninety, percent by weight solution of phosphoric acid with an about from fifteen to forty, preferably about from twenty to thirty-three, percent by weight solution of aqueous ammonia in a ratio sufficient to produce a mixture with a substantially neutral pH, say, about from six to seven and a half, preferably about from 6.6 to 7Ø Such a solution may be commercially obtained.
The substantially neutral ammonium phosphate salt is combined with the active hydrogen-containing nitrogenous organic compound, i.e., the spumific; the hydroxyl-containing carbonific; and the mold inhibitor. The combination, or contact, of the components may be carried out in any suitable order. Thus, an initial contact may be salt to spumific to prepare a salt-spumific intermediate, followed by contact with the carbonific; an initial contact may be salt to carbonific to prepare a salt-carbonific intermediate, followed by contact with the spumific; or the spumific and carbonific may be initially mixed, with that mixture contacted with the salt.
The mold inhibitor may be added at any suitable stage, and may accompany any suitable component or intermediate. Preferably, however, the mold inhibitor is added to the freshly prepared fire retardant composition made from the substantially neutral ammonium phosphate salt, spumific, and carbonific, especially while the composition is still warm from contact and reaction of the initial components. Other components) such as wetting agent(s), defoaming agent(s), and so forth, may also be added at suitable time(s). Preferably, however, when the composition includes such other component(s), these are included in an initial fire retardant composition, and the mold inhibitor is added afterwards, preferably, again, while the initial fire retardant composition is fresh, especially warm. Conditions are those sufficient to form the fire retardant composition with mold inhibitor of the invention.
As the hydrogen-containing nitrogenous organic compound, or spumiftc, any suitable substance may be employed. Preferably, the spumific is compatible with the other components employed, and further is soluble therewith or with any diluent employed. For instance, urea or a substituted urea may be employed. Preferably, however, the spumific is urea.
As the hydroxyl-containing carbonific, any suitable substance may be employed.
Preferably, the carbonific is compatible with the other components employed, and further is soluble therewith or with any diluent employed, especially water. For instance, a polyol, to include a carbohydrate such as a sugar or starch, may be employed. The polyol thus may be a compound such as glycerol, pentaerythritol, dipentaerythritol, tripentaerythritol; a sugar, say, a monosaccharide such as a triose, tetrose, pentose, hexose, heptose, or octose, to include an aldose or a ketose, or a disaccharide, a trisaccharide, a polysaccharide, and so forth; or a starch. A
combination of polyols may be employed. Thus, for instance, the spumific can include a six-carbon aldose, with which the polysaccharide may be employed.
As the mold inhibitor, any suitable substance may be employed. Preferably, the mold inhibitor is compatible with the other components employed, and further is soluble therewith or with any diluent employed. For instance, the mold inhibitor may be a quaternary organic ammonium halide, to include a quaternary alkyl ammonium halide, especially such a halide having at least one short chain and at least one medium chain alkyl group, for example, two of each, and an otherwise corresponding quaternary alkyl aromatic ammonium halide. The halide is advantageously a chloride. The short chain alkyl group may be inclusive of, separately at each occurrence, a one- to an about five-carbon group, especially a one- to four-carbon group, for example, a methyl, ethyl, propyl, and so forth group. The medium chain alkyl group may be inclusive of, separately at each occurrence, an about six- to an about thirty-carbon group, especially a six- to an about twenty-carbon group, for example, a hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl group, a thirteen-, fourteen-, fifteen- or sixteen-, seventeen-, eighteen-, nineteen-, or twenty-carbon group, and so forth. Preferably, the short chain alkyl group is methyl and/or ethyl, especially methyl, and the medium chain alkyl group is an eight- to twelve-carbon group, to include a mixture thereof, especially decyl, which can be present as an n-alkyl group. The halide is advantageously a chloride. For example, the mold inhibitor employed may be diDe-diMe-AmCI. An aromatic group, to include an aryl, alkaryl and/or arylalkyl group, for example, a benzyl and/or ethylbenzyl group, may be present, for instance, in a quaternary organic to include a quaternary alkyl aromatic ammonium halide mold inhibitor, for example, Alk-diMe-Bz-AmCI. The mold inhibitor may be a mixture containing more than one mold inhibitor compound. An increase in concentration of a quaternary ammonium halide mold inhibitor can provide for a corresponding reduction in the amount of an ammonium phosphate or ammonium orthophosphate.
The mold inhibitor is employed in any amount sufficient to provide for kill, control or prevention of growth of the target organism(s). It may be employed by weight of the final product in an amount up to about fifteen or twenty percent or more, to include, independently at each occurrence, lower values in specified ranges of about one tenth, about one half, about one, and about two percent, and upper values in specified ranges of about ten, about eight, about five and one half, and about four percent. A preferred amount of the mold inhibitor by weight of the final product, which may be coupled with a lower or an upper value amount as noted above or elsewhere herein to provide another value for a specified range, is generally about three percent.
A wetting agent, or surfactant, may be added. Preferably, any surfactant is biodegradable.
Generally, when employed, the surfactant is present in an amount sufficient to effectively release surface tension in the composition and to allow it to effectively and evenly penetrate the substrate before substantial evaporation of a diluent. Any suitable surfactant may be employed.
In preferred practice of the present invention, however, since the fungicide may function as a surfactant agent, particularly if it is of the quaternary ammonium salt variety, as are diDe-diMe-AmCI and Alk-diMe-Bz-AmCI, if surfactant activity is desired, it typically is not necessary to provide any additional surfactant. If an added surfactant is desired, the added surfactant may notably be a nonionic alkylpolyglycoside surfactant, which, for instance, may be commercially available, for example, under the mark GLUCOPON (Henkel Corporation). The GLUCOPON
surfactants are more readily biodegradable than conventional petroleum-based surfactants, and have been found to be much safer in testing with land and marine animals, while advantageously offering performance comparable to conventional surfactants in the fire retardant compositions of the invention. GLUCOPON surfactants, which were specifically formulated for cleaning product formulation technology, are made from renewable raw materials: glucose from corn, and fatty alcohol from coconut and palm kernel oils. The surfactant is typically supplied as an aqueous solution containing 50% to 70% active matter, having an alkaline pH
(11.5-12.5) with no preservative added. Some GLUCOPON surfactants are also available at neutral pH with an anti microbial preservative added. Although perhaps any grade of GLUCOPON
surfactant may be used successfully, GLUCOPON-425 may notably be employed as an added surfactant.
A defoaming agent may be added. Any suitable defoaming agent may be used, for instance, a salicylate salt, or a silicon compound. The defoaming agent may be potassium salicylate, which is also known to function as a preservative.
Any suitable amount of a component may be employed. Some typical amounts as percents by weight of generally preferred components effective in the practice of the invention are listed as follows, of which any specified components or characteristics are exemplary and for purposes of illustration, and which listed amounts may be taken as approximate:
Mono/diammonium phosphates) 2070%
Diluent, e.g., solvent, say, 2550%
water Spumific, e.g., urea beads 2.515.0%
Sugar, e.g., glucose 4.012.0%
Polysaccharide resin 2.040.0%
Added surfactant, e.g., GLUCOPON-4250.21.2%, advantageously none Added defoaming agent, e.g., potassium salicylate in solution 0 or 0.010.1% or 0.010.5%
Mold inhibitor, e.g., diDe-diMe-AmCI0.110%, to include 0.55.5%.
As an alternative, more detailed or preferred formulation to the preferred formula listed above, or as another manner of expressing such, typical amounts as percents by weight (unless otherwise specified or known from context or art) of components effective in the practice of the invention are listed as follows, again, of which any specified components or characteristics are exemplary and for purposes of illustration, and which listed amounts may be taken as approximate:
Ammonium orthophosphate (40% aqueous solution) 5070%
Polysaccharide resin, e.g., Lorama LPR76 (45% aqueous solution) 2030%
Sugar, e.g., granulated cane sugar SN10%
Spumific, e.g., urea 5~7%
Added defoaming agent, e.g., potassium salicylate in solution 0 or 0.01 ~0.1 /0.5%
Mold inhibitor, e.g., Alk-diMe-Bz-AmCI
(80% aqueous solution) 0.55%.
These ingredients may be stirred until dissolved, making a mixture free of solids and forming a clear liquid with pH, say, about 6.8. However, the mixture may be slightly cloudy or even in some cases more cloudy, or with strata in some cases, yet be effective and appealing.
It is to be understood, however, that many suitable materials may be used as the fire retardant and mold inhibiting agents of the present composition. In the preferred embodiment, the fire retardant compound is made from a combination of mono and diammonium phosphate salts formed from reacting about from 75% to 85% solutions of phosphoric acid (H3POa) with aqueous ammonia (NHa) in sufficient stoichiometric ratios to produce a generally pH neutral solution, and then further reacting the carbon rich material as above and the nitrogen rich urea to form a viscous liquid. To this mixture is added the wetting agents and the defoaming agents mentioned earlier. While this composition is fresh, and still warm, the mold inhibitor is added.
Each of the starting compounds to make the preferred embodiment is commercially available.
The mixture is stirred, again, preferably to dissolve the ingredients and provide a clear solution.
As noted above, strata may appear. The mixture is preferably stirred again before application.
As an aqueous solution, the pH of the final product can be approximately neutral, for instance, about from five and one half to eight, say, about from six to seven and a half, preferably about from 6 to 7, more preferably and independently at each occurrence about from 6.2 or 6.6 to 6.8 or 6.9. Along these lines, in general, too high a pH, say, above 6.8 or so, may release a discernable ammonia smell, and too low a pH, say, below 6.6 or so, may engender corrosion on certain substrates with which the product comes into contact. The final product may have any suitable density or specific gravity, for instance, about from one to one and a half, say about from one and a tenth to one and a third. The specific density may be about from 1.15 to 1.3, to include about from 1.18 to 1.25, without the mold inhibitor; and may be, in general, about from 1.10 to 1.17 with the mold inhibitor. Active fire retardant composition component ingredients, less the mold inhibitor, may be present in any amount, to include about from 40% to 60%, preferably about from 45% to 55%, say, about 48% ~ about 0.5%, to include about 48% ~
about 0.3%, of the total weight of the fire retardant composition component of the invention.
In terms of total weight percent of the final composition, to include the added mold inhibitor, the active ingredients can be present in any effective amount, to include about from 40%
to 70%, preferably about from 45% to 55%, say, about 50% + about 0.5% or 51 % + about 0.5%.
The fire retardant composition with mold inhibitor of the invention may penetrate to some degree, which may be a small amount. It may reside substantially on the surface of the substrate. However that may be, preferably, once dried, it leaves a substantially transparent film on the surface of a flammable solid substrate. This results in a composition or residue of the same, which is believed to be relatively safe in application and after drying.
Suitable precautions, however, should be undertaken. This results also in a versatile fire retardant composition with mold inhibitor, which can be employed in situations in which the aesthetic appearance of a substrate such as neutral or stained woodwork is to remain visible, or in which it would be beneficial to retain visual integrity of another substrate. The preferred liquid composition of the present invention is readily absorbed to an extent by porous materials such as wood, fabric, paper, cardboard, and so forth and the like, where it may remain, in essence, indefinitely, if protected from rain and other forms of excess moisture.
Advantageously, there is nothing in the formulation of the present invention known to be substantially harmful to wood per se, plywood, or any other wood product in general. Further, since the present fire retardant composition with mold inhibitor is often only applied to the surface, it should not interact with, degrade, or otherwise deteriorate plywood, sheathing, or other types of glued or composite wood products, particularly deep in the substrate.
The fire retardant composition with mold inhibitor of the invention may be applied to the materials by any suitable method. Known methods may be employed. The composition may be applied by spraying, say, by hand-held trigger sprayers, pump-up pressure sprayers, or any other type of manual or automatic power-assisted spraying apparatus, including by power paint rollers (saturated rollers); airless sprayers; brushing; dipping; and so forth.
Advantageously, the composition is applied by spraying. Brushing is a simple, effective expedient.
These and other application processes are well known in the art and are subject to many variations. The fire retardant composition with mold inhibitor of the present invention is applied at any suitable concentration or rate to produce a material treated with an effective amount of fire retardant and mold inhibitor.
Among benefits of the composition of the invention, in general, is that, rather than worrying about putting out a fire, it prevents or substantially retards one from burning. If a fire would start, such a composition automatically reacts to the fire by combining with the combustible gases and tars, converting them to carbon char, nitrogen and carbon dioxide, which delays, retards, or extinguishes the source of combustion before the fire takes hold. Its characteristics can also help improve the environment about a structure on fire by eliminating the production of a significant amount, say, up to some 90%, of the smoke and toxic gases produced by a regular fire, which is important because the majority of fire deaths are caused by inhalation of toxic smoke and fumes long before the fire ever gets close to the victims.
Moreover, the mold inhibition properties of the present composition can help protect structural integrity of a building structure or parts) thereof to which it is applied, for example, to floor, ceiling or attic joists, sub flooring, flooring, wooden or composite wall, ceiling or roof boards or sheets, and so forth. In a significant way, too, the health of occupants or visitors can be aided from detrimental effects of mold that otherwise would have been present.
II. Intumescent fire retardant latex paint with mold inhibitor Broadly, in this aspect or embodiment, an intumescent fire retardant latex paint is combined with a mold inhibitor.
A foundation of preferred embodiments of this aspect or embodiment of the invention is that an intumescent fire retardant latex paint base can be prepared, and during or after its preparation can be added the mold inhibitor. The mold inhibitor, for example, may be added to the base immediately upon its manufacture. Conditions are those sufficient to form the fire retardant paint with mold inhibitor of the invention. Stirring or other agitation of the present paint can enhance its uniformity.
The term, "fire retardant paint," as employed herein, is a latex composition that, when applied to a flammable material, provides thermal protection for the material.
In general, this may be done by reducing or perhaps even eliminating the tendency of the material to burn and/or reducing the rate of flame spread along the surface of the material.
Preferably, use of the fire retardant paint, for example, on a solid material as the substrate, reduces surface burning characteristics significantly, say, at least about 10%, at least about 25%, or at least about 50%, when compared to untreated material, as tested by an appropriate test. For example, the test may be the ASTM E84 Steiner Tunnel Test. Without being bound by any theory, the preferred fire retardant paint of the present invention, based in general on the Form #2 fire retardant paint of the aforementioned publication by Kish et al., more preferably the NO-BURN
PLUS paint, can be considered to be an intumescent fire reactant. Although it looks and applies like regular paint, its chemical composition changes drastically when introduced to heat. Thus, when heat is applied, the fire retardant paint of the invention may "foam up" to form an intact, fire-resistive "char-barrier" to protect the treated surface. As a result, fire is robbed of fuel and oxygen, generates less heat and smoke, and may in some circumstances extinguish itself. Fire retardant paint formulations can vary, but may include ingredients added with water such as follows in approximate percentages:
Ammonium phosphate solids 15~30% by weight Thermoplastic latex resin, e.g., polyvinyl acetate type 10~30% by weight Nitrogenous spumific, e.g., melamine powder 7~13% by weight Carbonific, e.g., polyol 7~13% by weight Titanium dioxide and/or other inert inorganic opacifying agent 510% by weight Soda lime borosilicate or other glass 1~5% by weight Ester alcohol 0.5~1.5% by weight Hydroxyalkylcellulosic 0.1 ~ 1 % by weight Wetting and/or other agents) 0.1~2% by weight.
A more particular base intumescent fire retardant latex paint formulation follows:
Water (bulk) 25~33% by weight Ammonium polyphosphate powder 20~21 % by weight Vinyl acetate latex (aqueous) 21~22% by weight Melamine powder 910% by weight Pentaerythritol 8.59.5% by weight Titanium dioxide powder 7~8% by weight Glass bubbles (0.120.63 g/cc) 1 ~2% by weight 2,2,4-trimethyl-1,3-pentanediol monoisubutyrate 0.60.8% by weight Hydroxyethylcellulose 0.20.4% by weight Wetting andlor other agents ~l% by weight.
To such a base fire retardant latex paint formulation or any other suitable fire retardant latex paint formulation, or precursor part thereof, is provided the mold inhibitor in any suitable amount. The mold inhibitor may be added in an amount by weight of base fire retardant latex paint formulation, independently at each occurrence, about from 0.1% to 15%, to include about from 0.5% to 10%, about from 1% to 5%, and about from 2% to 4%. For instance, the mold inhibitor may be added at about 3% by weight of the base fire retardant latex paint formulation.
As the ammonium phosphate, any suitable ammonium phosphate salt, to include ammonium polyphosphates, and mixtures thereof, may be employed.
Advantageously, it is a solid, which may be provided as a powder. Such a salt may be a mixture which contains monoammonium and diammonium phosphates. Such a salt may be commercially obtained.
As the thermoplastic latex resin such as a polyvinyl acetate latex, any suitable polyvinyl acetate latex type polymer, copolymer or mixture thereof, or the like, may be employed. The polyvinyl acetate type latex component may be provided as an aqueous emulsion.
Also, other thermoplastic latex resins that may function in this capacity would include such resins as polyvinyledene chloride resins and so forth and the like, although perhaps not functioning as effectively as the preferred vinyl acetates.
As the nitrogenous spumific, any suitable hydrogen-containing nitrogenous organic compound may be employed. Preferably, the spumific is compatible with the other components employed, and further is dispersible therewith. For instance, melamine may be employed.
As the carbonific, any suitable hydroxyl-containing organic compound may be employed.
Preferably, the carbonific is compatible with the other components employed, and further is soluble or dispersible in the water or other diluent employed. For instance, a polyol may be employed. The polyol may be a compound such as glycerol, pentaerythritol, dipentaerythritol, tripentaerythritol; a sugar, say, a monosaccharide such as a triose, tetrose, pentose, hexose, heptose, or octose, to include an aldose or a ketose, or a disaccharide, a trisaccharide, a polysaccharide, and so forth; and/or a starch. A combination of polyols may be employed.
Pentaerythritol is a preferred selection.
As the opacifying agent, titanium dioxide powder is preferred. Although pure titanium dioxide powder may be employed, more commonly it is employed in a grade that contains other inert inorganic substances, for example, aluminum hydroxide and/or amorphous silica. An opacifying agent such as titanium dioxide can be employed in an aqueous dispersion form.
A glass additive such as borosilicate and/or other glass may be provided, preferably in the form of glass bubbles of a size in the range of a powder. This improves the body of the paint and may provide it with thixotropic or other advantageous viscous flow properties.
As the ester alcohol, any suitable ester alcohol may be employed. The ester alcohol may be an alkanol alkylate, for example, 2,2,4-trimethyl-1,3-pentanediol monoisubutyrate. The ester alcohol functions as a coalescent for film integrity, and so forth.
As the hydroxyalkylcellulosic, any hydroxyalkylcellulose or suitable analog or derivative thereof may be employed. It may be hydroxymethylcellulose or hydroyethylcellulose, preferably the latter. The hydroxyalkylcellulosic functions to improve the flow and rheology of the finished paint solution or suspension, reducing sag and improving film build.
Wetting and/or other agents) may be employed. Such agents) can include what may be considered surface tension lowering agents, surfactants, defoaming agents, dispersing agents, paint preservatives, which may be biocidal, and so forth and the like. Thus employed in minor amounts may be a pigment dispersing agent such as an alkali metal salt of a polymeric carboxylic acid, say, the sodium salt of a copolymer of malefic acid; a defoamer colloid such as an acrylic polymer, say, sodium polyacrylate; a silicone surfactant such as a polyether modified alkyl polysiloxane, say, a polyether modified poly-dimethyl-siloxane, which may be employed neat or preferably in solution with a suitable solvent, say, about half dipropyleneglycol monomethyl ether (48%); a paint preservative/biocide such as containing 1,2-benzisothiazol-3(2H)-one, say, as an aqueous mixture containing 1,2-benzisothiazol-3(2H)-one, sodium hydroxide, and dipropyleneglycol; and a rheology modifier such as a hydrophobically modified ethylene oxide urethane block copolymer, which may be employed in an organic solvent mixture such as a mixture of butyl carbitol and water or without the organic solvent, say, in water only.
For instance, such wetting andlor other agents) can include compounds or compounds such as follows, the percentages of which relate to the base latex paint formulation and are given by weight, and may be considered to be approximate:
Pigment dispersing agent sodium salt of polymeric malefic acid (NaOH stabilized) 0.10.3%
Defoamer colloid sodium polyacrylate 0.10.3%
Silicone surfactant polyether modified poly-dimethyl-siloxane in dipropyleneglycol monomethyl ether (48%) 0.01 ~0.1 Paint preservativelbiocide 1,2-benzisothiazol-3(2H)-one in an aqueous mixture containing 1,2-benzisothiazol-3(2H)-one, sodium hydroxide, and dipropyleneglycol 0.010.05%
Rheology modifier hydrophobically modified ethylene oxide urethane block copolymer in water 0.250.1%.
Other additives) may be employed.
As the mold inhibitor, any suitable substance may be employed. Preferably, the mold inhibitor is compatible with the other components, and further is soluble or suspendable therewith. For instance, the mold inhibitor may be a quaternary organic ammonium halide, to include a quaternary alkyl ammonium halide, especially such a halide having at least one short chain and at least one medium chain alkyl group, for example, two of each, and an otherwise corresponding quaternary alkyl aromatic ammonium halide. The halide is advantageously a chloride. The short chain alkyl group may be inclusive of, separately at each occurrence, a one-to an about five-carbon group, especially a one- to four-carbon group, for example, a methyl, ethyl, propyl, and so forth group. The medium chain alkyl group may be inclusive of, separately at each occurrence, an about six- to an about thirty-carbon group, especially a six- to an about twenty-carbon group, for example, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, a thirteen-, fourteen-, fifteen- or sixteen-, seventeen-, eighteen-, nineteen-, or twenty-carbon group, and so forth. Preferably, the short chain alkyl group is methyl and/or ethyl, especially methyl, and the medium chain alkyl group is an eight- to twelve-carbon group, to include a mixture thereof, especially decyl, which can be present as an n-alkyl group. The halide is advantageously a chloride. For example, the mold inhibitor employed may be didecyldimethylammonium chloride. An aromatic group, to include aryl, alkaryl and/or arylalkyl, for example, a benzyl and/or ethylbenzyl group may be present, for instance, in a quaternary organic to include a quaternary alkyl aromatic ammonium halide mold inhibitor, for example, alkyldimethylbenzylammonium chloride. The mold inhibitor may be a mixture containing more than one mold inhibitor compound. An increase in concentration of any quaternary ammonium halide mold inhibitor may provide for a corresponding reduction in the amount of ammonium phosphate or ammonium orthophosphate.
Tints) and/or colors) may be added to obtain a pastel or colored paint.
The fire retardant paint with mold inhibitor of the invention may penetrate to some degree, say, a small amount. It may reside substantially on the surface of the substrate.
However that may be, preferably, once dried, it leaves a generally opaque film on the surface of a flammable solid substrate even though more than one coat may be needed to cover completely.
This dried film results in a composition or residue of the same, which is believed to be relatively safe in application and after drying. Suitable precautions, however, should be undertaken. This results also in a versatile fire retardant paint with mold inhibitor, which can be employed in situations in which a painted surface is desired. Advantageously, there is nothing in the formulation of the present invention known to be substantially harmful to wood per se, plywood, any other wood product, or the paper of gypsum board, in general. Further, since the present fire retardant paint with mold inhibitor is typically applied on the surface, it should not interact with, degrade, or otherwise deteriorate plywood, sheathing, other types of glued or composite wood products, or paper-clad or paper products, particularly deep in the substrate.
The present fire retardant paint with mold inhibitor may be applied to the materials by any suitable method. Known methods may be employed. The paint may be applied by spraying, say, by hand-held trigger sprayers, pump-up pressure sprayers, or any other type of manual or automatic power-assisted spraying apparatus, including by power paint rollers (saturated rollers);
airless sprayers; brushing; dipping; and so forth. Advantageously, the wet paint is applied by spraying. Brushing is a simple, effective expedient. These and other application processes are well known in the art and are subject to many variations. The fire retardant paint with mold inhibitor of the present invention is applied at any suitable concentration or rate to produce a material treated with an effective amount of fire retardant and mold inhibitor. One may wish to treat all the heavy paper backing on all the drywall (gypsum board) for purposes of enhanced fire resistance and to prevent the growth of mold on this surface, which has been shown to support the growth of mold under conditions conducive to the same and is used extensively in cladding and partitions in residential and commercial building structures.
III. Examples The following examples further illustrate the invention. Therein, parts and percentages are given by weight, unless otherwise specified.
Example 1 In a clean, appropriately sized mixing tank, the following raw materials were added under constant agitation:
32 gallons (320 1b.) of 49% solution of mono/diammonium phosphate (a reaction product of 75% to 85% liquid phosphoric acid and 27% ammonia in ~.vater at a ratio sufficient to produce a pH of 6.8, the reaction of which is exothermic, which serves to heat the mixture);
170 grams of potassium salicylate solution in water;
1135 grams GLUCOPON-425 nonionic alkylpolyglycoside surfactant (Henkel Corp.);
32 1b. urea beads (fertilizer grade);
40 Ib. glucose.
All these ingredients were stirred until completely dissolved, until the mixture was free of solids and formed a clear liquid with a pH of 6.8 To this mixture, while the solution was still quite warm, was added 132 1b. of JA250-3 polysaccharide resin (Lorama Chemicals, Mississauga, Ontario), which serves to thicken the mixture and contribute solids for the char-forming reaction.
While this mixture was still warm, 3% of BARDAC-2280 didecyldimethylammonium chloride fungicide (an aqueous mixture having 80% active component) (Lonza, Inc., Fair Lawn, N.J.) was added and stirred into the mixture using a high sheer mixer.
A retained sample was drawn from the completed batch and was analyzed for specific gravity, pH, and clarity. The specific gravity was 1.256 @ 19C; the pH was 6.8, and the sample passed the clarity test, i.e., the liquid was clear to slightly opaque, with no precipitants visible, notably by the naked eye. The finished product was pumped to a storage tank for later filling, or was filled into proper containers.
Example 2 The liquid composition of Example 1 was applied to the surface of Red Oak tongue and grooved flooring at a rate of 300 square feet per U.S. gallon in two coats, and allowed to dry in a conditioned room at 72 degrees F and 50% relative humidity until the product had dried and reached a constant mass. Once dried to constant mass, the panels were tested under the ASTM
E84 procedure, which resulted in a Flame Spread Rating of 35.
Untreated Red Oak tongue and grooved flooring from the same batch of lumber was tested under the ASTM E84 procedure to determine the inherent flammability of the panels. The identical but untreated panels had a flame spread rating of 70, which serves to demonstrate the effectiveness of the fire retardant properties of the ammonium phosphate containing coating composition of this invention.
Example 3 The liquid composition of Example 1 was applied in a thin layer by brush to the surface of small, uniformly sized pieces of wood, i.e., Douglas Fir plywood and Spruce lumber, and subjected to the ASTM D5590-94 test method, employing the mold species known as Stachybotrys chartarum. After the required duration of the test, the untreated samples were completely covered with mold growth while the treated samples were mold free.
The results are outlined in Report Number 030819-8, "Evaluation of Fungicidal Resistance of Coatings Materials," conducted by PBR Laboratories, Inc., Edmonton, Alberta, Canada.
Example 4 The procedure of Example 1, employing a didecyldimethylammonium chloride fungicide, was basically repeated, except that no added surfactant such as the nor added defoamer such as the potassium salicylate was added. An equivalent amount of water replaced the GLUPACON-425. The resultant product was most satisfactory.
Example 5 A commercial formulation was prepared, generally according to the procedures of Examples 1 and 4. The protocol for the same is generally as follows:
A. An appropriately sized mixing tank is selected and checked for cleanliness.
If necessary, it is cleaned using hot water and a detergent solution, and rinsed.
B. Raw materials are weighed and added to a mixing tank, beginning with water.
C. After all raw materials have been added, solution is allowed to mix for 60 minutes or until all solids appear to be dissolved.
D. A retained sample is drawn, and analyzed for specific gravity, pH, and clarity.
If approved by quality control, the product is released to be filled.
2. If the retained sample fails any of the tests, then corrective measures are implemented, and another retained sample is drawn and tested.
E. Approved finished product is pumped to a storage tank for later filling, or filled into proper containers.
This finished coating formulation has the following ingredients, in general:
Ammonium phosphate/orthophosphate (40% aqueous solution) 59.0%
Lorama LPR76 polysaccharide resin (45% aqueous solution) 24.24%
Granulated cane sugar 7.29%
Urea 5.78%
Mason CS428* alkyldimethylbenzylammonium chloride (80% aqueous solution) 3.69%.
*Mason CS428 (Mason Chemical Co., Arlington Heights, Ill.) is classified as a surfactant (MSDS). It contains alkyldimethylbenzylammonium chloride (02_16) (CAS #68424-85-1) (80% by weight); ethanol (CAS #64-17-5) (10% by weight);
and water (10% by weight).
This aqueous formulation provides a superior home fire retardant with mold resistance.
Wood is the primary resource of most of the homes in the U.S.A. and Canada.
The formulation can be applied by spraying or brushing during manufacturing, building, or remodeling of the home to protect its internal wood components. All such wood components, including wall studs, flooring, rafters, trusses, joists, exterior sheathing, roofing and decking, the entire "skeleton" of the structure, are treated at the "dried-in" from the weather stage, giving special attention to the attic. In addition, the potential exists to treat all the heavy paper backing on all the drywall (gypsum board) for purposes of enhanced fire resistance and to prevent the growth of mold on this surface, which has been shown to support the growth of mold under conditions conducive to the same, such gypsum board, of course, being used with framing materials to substantially provide interior cladding and partition walls in most domestic and commercial building structures.
As well, the formulation can be applied by spraying or brushing to flammable components of an existing structure, for example, exposed wood structural components of an older home such as the exposed floor joists and subflooring accessible in a basement or crawl space, and so forth. Again, special attention is given to the attic area and its joists, studs, flooring, studs, walls, trusses and ceiling (roof sheathing).
In such cases, superior fire resistance ratings with mold resistance are provided.
Example 6 In a clean, appropriately sized Cowles mixer, the following component ingredients were added in the order shown to make a base intumescent latex paint, with percentages by weight:
Water, bulk 21.41 TAMOL 731A NaOH stabilized sodium salt of polymeric malefic acid (Rohm and Haas) 0.16%
RHODOLINE 226/35 sodium polyacrylate (Rhodia Canada, Inc.) 0.10%
BYK-346 polyether modified poly-dimethyl-siloxane in dipropyleneglycol monomethyl ether (48%) (BYK-Chemie USA, Inc.) 0.05%.
Further added under agitation were the following component ingredients:
TI-PURE titanium dioxide pigment (DuPont Chemicals) 7.39%
EXOLIT AP 422 ammonium polyphosphate powder (Clariant Canada, Inc.) 20.69%
TECH PE 200 technical pentaerythritol (Hercules Canada, Inc.) 9.00%
Powder melamine (DSM Melamine Americas, Inc.) 9.47%.
The mixture was ground for ten minutes, and the bottom and sides of the mixer were scraped.
Then added was the following component ingredient:
NATRASOL 250 MXR hydroyethylcellulose (Hercules Canada, Inc.) 0.31%.
The mixture was ground to a smooth paste to a 2~3 fineness. Then added, with mixing, were the following component ingredients:
RHODOLINE 226/35 sodium polyacrylate 0.10%
PROXEL GXL aqueous mixture containing 1,2-benzisothiazol-3(2H)-one, sodium hydroxide, and dipropyleneglycol (Brenntag Canada, Inc.) 0.03%
TEXANOL 2,2,4-trimethyl-1,3-pentanediol monoisubutyrate (Eastman Chemical Company) 0.75%
StanChem 5238 vinyl acetate copolymer emulsion (54-56% polymer/solids, 44-46% water) (StanChem, Inc.) 21.77%
Water, bulk 6.71 SCOTCHLITE K25 glass bubbles (3M Canada) 1.52%
ACRYSOL RM-8W hydrophobically modified ethylene oxide urethane block copolymer in water (Rohm and Haas) 0.56%.
This provided a base intumescent fire retardant latex paint, which was pumped to a storage tank for later filling, or filled into proper containers.
To a sample of the base intumescent fire retardant latex paint was added with stirring 3.0% Mason CS428 alkyldimethylbenzylammonium chloride (80% aqueous solution) (Mason Chemical Co.) which is classified as a surfactant according to its material safety data sheet (MSDS). It contains alkyldimethylbenzylammonium chloride (C~2_~6) (CAS #68424-85-1) (80%
by weight): ethanol (CAS #64-17-5) (10% by weight); and water (10% by weight) to provide an intumescent fire retardant latex paint with mold inhibitor.
The finished intumescent fire retardant latex paint with mold inhibitor can be pumped to a storage tank for later filling, or filled into proper containers.
Example 7 The base and finished liquid paints of Example 6 were applied to the surface of Douglas fir tongue and groove decking at a rate of 300 square feet per U.S. gallon in two coats, and the painted decking was allowed to dry in a conditioned room at 70 degrees F and 50% relative humidity until the paints had dried and reached a constant mass. Once dried to constant mass, the decking panels were tested under the ASTM E84 procedure and resulted in respective Flame Spread Ratings of "5" for the base paint and "0" for the finished paint with mold inhibitor.
When untreated Douglas fir decking panels from the same batch of tongue and groove decking were tested under the ASTM E84 procedure to determine the inherent flammability of the panels, the otherwise identical but untreated panels had a flame spread rating of "55."
This serves to demonstrate the effectiveness of the fire retardant properties of the latex paint composition of this invention, especially with mold inhibitor.
Example 8 The finished paint of Example 6 was applied in a thin layer by brush to the surface of SPF plywood, and subjected to the ASTM D5590-94 test method, employing the mold species known as Stachybotrys chartarum. After the required duration of the test, the untreated samples were completely covered with mold growth while the treated samples were mold free. The base intumescent latex paint of Example I, i.e., without the added Mason CS428 mold inhibitor, similarly applied to the surface of SPF plywood, showed growth rates of "4"
(maximum growth after the 30-day duration).
CONCLUSION TO THE INVENTION
The present invention is thus provided. Various aspects, features, steps, subcombinations and combinations of the invention can be employed with or without reference to other aspects, features, steps, subcombinations or combinations in its practice, and numerous adaptations and modifications can be effected within its spirit, the literal claim scope of which is particularly pointed out as follows:
Claims (27)
1. A fire retardant composition having a mold inhibitor.
2. The composition of claim 1, which comprises a mixture of a substantially neutral ammonium phosphate salt in combination with an active hydrogen-containing nitrogenous organic compound spumific, and with a hydroxyl-containing carbonific, and further with the mold inhibitor.
3. The fire retardant composition of claim 2, which is aqueous.
4. The fire retardant composition of claim 3, wherein the spumific is urea;
the carbonific is a polyol; and the mold inhibitor is a quaternary organic ammonium halide.
the carbonific is a polyol; and the mold inhibitor is a quaternary organic ammonium halide.
5. The composition of claim 2, which includes the following formulation:
Mono/diammonium phosphate(s) about 20-70% by weight Diluent about 25-50% by weight Active hydrogen-containing nitrogenous organic compound spumific about 2.5-15.0% by weight Sugar about 4.0-12.0% by weight Polysaccharide resin about 2.0-40.0% by weight Added surfactant 0 to about 1.2% by weight Added defoaming agent 0 to about 0.5% by weight Mold inhibitor about 0.1-10% by weight.
Mono/diammonium phosphate(s) about 20-70% by weight Diluent about 25-50% by weight Active hydrogen-containing nitrogenous organic compound spumific about 2.5-15.0% by weight Sugar about 4.0-12.0% by weight Polysaccharide resin about 2.0-40.0% by weight Added surfactant 0 to about 1.2% by weight Added defoaming agent 0 to about 0.5% by weight Mold inhibitor about 0.1-10% by weight.
6. The composition of claim 5, wherein the diluent includes water; the spumific is urea;
the mold inhibitor is a quaternary organic ammonium halide.
the mold inhibitor is a quaternary organic ammonium halide.
7. The composition of claim 6, wherein at least one of the added surfactant and the defoaming agent is substantially absent.
8. The composition of claim 6, wherein the mold inhibitor is present at about 0.5-5.5%
by weight.
by weight.
9. The composition of claim 8, wherein the mold inhibitor is a quaternary alkyl ammonium chloride or a quaternary alkyl aromatic ammonium chloride.
10. The composition of claim 9, wherein the mold inhibitor is didecyldimethylammonium chloride.
11. The composition of claim 9, wherein the mold inhibitor is alkyldimethylbenzylammonium chloride.
12. The composition of claim 2, which includes the following formula:
Ammonium orthophosphate (as if 40% aqueous solution) about 50-70% by weight Polysaccharide resin (as if 45% aqueous solution) about 20-30% by weight Sugar about 5-10% by weight Urea about 5-7% by weight Quaternary organic ammonium halide mold inhibitor (as if 80% aqueous solution) about 0.5-5%.
Ammonium orthophosphate (as if 40% aqueous solution) about 50-70% by weight Polysaccharide resin (as if 45% aqueous solution) about 20-30% by weight Sugar about 5-10% by weight Urea about 5-7% by weight Quaternary organic ammonium halide mold inhibitor (as if 80% aqueous solution) about 0.5-5%.
13. The composition of claim 12, wherein the mold inhibitor is alkyldimethylbenzyl ammonium chloride.
14. The composition of claim 2, which has an approximately neutral pH.
15. The composition of claim 14, wherein the pH is about from five and a half to eight.
16. The composition of claim 15, wherein the pH is about from 6 to 7.
17. A method for using a fire retardant composition with a mold inhibitor, which comprises providing the composition of claim 1; and contacting said composition with a flammable substrate under conditions sufficient to be flame retardant and mold inhibitory.
18. An article of manufacture comprising, in combination, the composition of claim 1 or a residue of said composition; and a flammable substrate.
19. A method for making a fire retardant composition having a mold inhibitor, which comprises contacting a phosphoric acid with ammonia to form an ammonium phosphate, contacting the ammonium phosphate with an active hydrogen-containing nitrogenous organic compound, a hydroxyl-containing carbonific, and the mold inhibitor, under conditions sufficient to form the composition.
20. The method of claim 19, wherein the phosphoric acid is reacted with ammonium hydroxide in a stoichometric ratio sufficient to make an aqueous solution of approximately neutral pH, which includes monoammonium and diammonium phosphates to provide an essentially or substantially neutral ammonium phosphate salt; which salt next is contacted with an active hydrogen-containing nitrogenous organic spumific, and also with the hydroxyl-containing carbonific to produce a viscous fire retardant solution; and to that solution is promptly added the mold inhibitor.
21. The method of claim 20, wherein the spumific is urea; the carbonific is a polyol; and the composition is aqueous, and at least substantially clear to cloudy when viewed by the naked eye, with a pH about from 6 to 7.
22. A fire retardant latex paint having a mold inhibitor.
23. The paint of claim 22, which includes an ammonium phosphate, a thermoplastic latex resin, a nitrogenous spumific, a carbonific, an inert inorganic opacifying agent, glass beads, an ester alcohol, a hydroxyalkylcellulosic, wetting and/or other agent(s), and a mold inhibitor.
24. The paint of claim 23, which is formulated with water, and which is represented by the following general formulation, in which percentages are by weight:
Ammonium phosphate solids about 15~30%;
Thermoplastic latex polyvinyl acetate type resin about 10~30%;
Nitrogenous spumific as a melamine powder about 7~13%;
Polyol carbonific about 7~13%;
Titanium dioxide and/or other inert inorganic opacifying agent about 5~10%;
Soda lime borosilicate or other glass about 1~5%;
Ester alcohol about 0.5~1.5%;
Hydroxyalkylcellulosic about 0.1~1%;
Wetting and/or other agent(s) about 0.1~2%; and Quaternary organic ammonium halide about 0.1~15%.
Ammonium phosphate solids about 15~30%;
Thermoplastic latex polyvinyl acetate type resin about 10~30%;
Nitrogenous spumific as a melamine powder about 7~13%;
Polyol carbonific about 7~13%;
Titanium dioxide and/or other inert inorganic opacifying agent about 5~10%;
Soda lime borosilicate or other glass about 1~5%;
Ester alcohol about 0.5~1.5%;
Hydroxyalkylcellulosic about 0.1~1%;
Wetting and/or other agent(s) about 0.1~2%; and Quaternary organic ammonium halide about 0.1~15%.
25. The paint of claim 24, which is represented by the following general formulation, in which percentages are by weight:
Water (bulk) about 25~33%;
Ammonium polyphosphate powder about 20~21%;
Vinyl acetate latex (aqueous) about 21~22%;
Melamine powder about 9~10%;
Pentaerythritol about 8.5~9.5%;
Titanium dioxide powder about 7~8%;
Glass bubbles (0.12~0.63 g/cc) about 1~2%;
2,2,4-trimethyl-1,3-pentanediol monoisubutyrate about 0.6~0.8%;
Hydroxyethylcellulose about 0.2~0.4%;
Wetting and/or other agents about 1%; and Quaternary organic ammonium halide about 0.5~10%.
Water (bulk) about 25~33%;
Ammonium polyphosphate powder about 20~21%;
Vinyl acetate latex (aqueous) about 21~22%;
Melamine powder about 9~10%;
Pentaerythritol about 8.5~9.5%;
Titanium dioxide powder about 7~8%;
Glass bubbles (0.12~0.63 g/cc) about 1~2%;
2,2,4-trimethyl-1,3-pentanediol monoisubutyrate about 0.6~0.8%;
Hydroxyethylcellulose about 0.2~0.4%;
Wetting and/or other agents about 1%; and Quaternary organic ammonium halide about 0.5~10%.
26. The paint of claim 25, wherein said halide is an alkyldimethylbenzylammonium chloride.
27. The paint of claim 26, wherein said chloride is present in an amount by weight of about from 2% to 4%.
Applications Claiming Priority (10)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10/957,775 | 2004-10-04 | ||
| US10/957,775 US20050022466A1 (en) | 2004-10-04 | 2004-10-04 | Fire resistance rating system |
| US11/002,730 | 2004-12-02 | ||
| US11/002,730 US6982049B1 (en) | 2003-12-03 | 2004-12-02 | Fire retardant with mold inhibitor |
| CA2,494,605 | 2005-01-21 | ||
| US64624505P | 2005-01-24 | 2005-01-24 | |
| US60/646,245 | 2005-01-24 | ||
| US11/044,624 US7587875B2 (en) | 2004-10-04 | 2005-01-27 | Fire resistance rating system |
| US11/044,624 | 2005-01-27 | ||
| CA2,495,270 | 2005-02-01 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2499114A1 true CA2499114A1 (en) | 2006-04-04 |
Family
ID=36141702
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2499114 Abandoned CA2499114A1 (en) | 2004-10-04 | 2005-03-01 | Fire retardant compositions with mold inhibitor |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2499114A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11104811B2 (en) | 2016-11-10 | 2021-08-31 | Ppg Coatings Europe Bv | Surfactants for intumescent foam stabilization |
-
2005
- 2005-03-01 CA CA 2499114 patent/CA2499114A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11104811B2 (en) | 2016-11-10 | 2021-08-31 | Ppg Coatings Europe Bv | Surfactants for intumescent foam stabilization |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US6982049B1 (en) | Fire retardant with mold inhibitor | |
| US7482395B2 (en) | Intumescent fire retardant latex paint with mold inhibitor | |
| US6989113B1 (en) | Fire retardant | |
| US9005642B2 (en) | Intumescent fire retardant paint with insecticide | |
| US20070176156A1 (en) | Fire retardant composition with insecticide | |
| CN102702962B (en) | Expanding fire-proof paint | |
| US8715540B2 (en) | Aqueous and dry duel-action flame and smoke retardant and microbe inhibiting compositions, and related methods | |
| US8080186B1 (en) | Fire mitigation and moderating agents | |
| CA2852870C (en) | Fire resistant coating and wood products | |
| KR101575299B1 (en) | Flame-retardant treatment method using eco-friendly fire retardant composition for wood containing construction material and fire retardant coating wood containing construction material | |
| US20050138888A1 (en) | Fire resistance rating system | |
| CN104774509A (en) | Fireproof paint | |
| US9453116B2 (en) | Low-temperature intumescent fire retardant | |
| CN109439083A (en) | A kind of ultrathin expansion type steel structure aqueous fire-proof coating and preparation method thereof | |
| CN105778694B (en) | A kind of expansion type facing fire retardant coating | |
| CN102695750A (en) | Alginate-based building materials | |
| JP2003238902A (en) | Composition for intumescent fireproof coating for indoor use | |
| CN101550294A (en) | New use of white sugar used as carbonific in fire-proof paint and technics formula thereof | |
| US12018199B2 (en) | Fire retardant and fire blocking composition for use in forest fires, and method of making same | |
| CN108912939A (en) | A kind of transparency swelling type water flame-proof paint and its preparation method and application | |
| RU2526063C2 (en) | Kl-1v cable fireproofing composition | |
| US10920147B2 (en) | Flame or fire retarding agents and their manufacture and use | |
| CA2499114A1 (en) | Fire retardant compositions with mold inhibitor | |
| RU2224775C1 (en) | Fire-proof swelling paint | |
| CA2574692A1 (en) | Fire retardant and so forth composition with insecticide |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Dead |
Effective date: 20131202 |