US 12,391,814 B2
Open cell polyurethane flame-retardant foams
Anthony J. Taylor, Medina, OH (US); Andrew P. Shinko, Uniontown, OH (US); and Mark A. Keen, Uniontown, OH (US)
Assigned to ICP CONSTRUCTION, INC., Andover, MA (US)
Filed by ICP Construction, Inc., Andover, MA (US)
Filed on Dec. 27, 2021, as Appl. No. 17/562,514.
Prior Publication US 2023/0203259 A1, Jun. 29, 2023
Int. Cl. C08G 18/08 (2006.01); C08G 18/12 (2006.01); C08G 18/16 (2006.01); C08G 18/18 (2006.01); C08G 18/20 (2006.01); C08G 18/22 (2006.01); C08G 18/24 (2006.01); C08G 18/30 (2006.01); C08G 18/32 (2006.01); C08G 18/42 (2006.01); C08G 18/61 (2006.01); C08G 18/76 (2006.01); C08G 77/46 (2006.01); C08J 9/00 (2006.01); C08J 9/14 (2006.01); C08K 5/521 (2006.01); C08L 75/04 (2006.01); C08G 101/00 (2006.01)
CPC C08J 9/0038 (2013.01) [C08G 18/12 (2013.01); C08G 18/14 (2013.01); C08G 18/2081 (2013.01); C08G 18/242 (2013.01); C08G 18/302 (2013.01); C08G 18/4213 (2013.01); C08G 18/61 (2013.01); C08G 18/7671 (2013.01); C08G 77/46 (2013.01); C08J 9/146 (2013.01); C08K 5/521 (2013.01); C08G 2101/00 (2013.01); C08G 2110/0041 (2021.01); C08J 2203/162 (2013.01); C08J 2205/05 (2013.01); C08J 2207/04 (2013.01); C08J 2375/06 (2013.01)] 18 Claims
 
1. A two-component open cell polyurethane spray foam composition comprising:
an A-side comprising:
at least one A-side diisocyanate and at least one HFO propellant that comprises trans 1,3,3,3 tetrafluoropropene;
a B-side comprising:
B-side reactants comprising at least one aromatic polyol, at least one B-side plasticizer, at least one surfactant, at least three catalysts, water and at least one HFO propellant that comprises trans 1,3,3,3 tetrafluoropropene;
said at least three catalysts consisting of:
at least one organo-tin containing catalyst and
at least one potassium containing catalyst; and
at least one dimorpholino-based ether catalyst, wherein no catalyst other than the at least one organo-tin containing catalyst, the at least one potassium containing catalyst, and the at least one dimorpholino-based ether catalyst are present in the two-component open cell polyurethane spray foam composition;
a molar ratio of the at least one potassium-containing catalyst to the at least one organo-tin containing catalyst being at least approximately 1.5:1.0;
the at least one surfactant comprising a polysiloxane polyoxyalkylene block copolymer surfactant;
the B-side water comprising at least 8 weight percent of said B-side reactants;
an open cell polyurethane spray foam formed from the two-component open cell polyurethane foam composition has a Class B rating with a flame spread between 25 and 75 inclusive and a smoke developed of under 450 using ASTM E 84 testing protocol;
the open cell polyurethane spray foam having a density of approximately 1 pcf (pounds per cubic foot) or less;
the open cell polyurethane spray foam having an R-value of approximately 3.2 or greater; and
an open cell content of at least 90% in the open cell polyurethane spray foam.