Note: Descriptions are shown in the official language in which they were submitted.
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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;
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
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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
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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.
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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
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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.
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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
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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
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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
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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
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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
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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%.
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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
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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
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(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
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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
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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,
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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
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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
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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
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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.
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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
GLUCAPON-425
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
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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
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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:
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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
24
CA 02499114 2005-03-O1
FIRE-6UI-CA
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:
