FLAME RETARDING AND SMOKE RETARDING MIXTURE

Abstract: Flame retarding and smoke retarding mixture consisting of: 70-96 weight % monoammonium phosphate and/or diammonium phosphate and/or ammonium sulphate, 1-20 weight % NaHCO3, 1-10 weight % EDTA, 0-28 weight % phosphoric acid (85 %), 0-5 weight % normal additives, method for producing a solution of the above-mentioned mixture and the application of the mixture for impregnation.

Description: Flame retarding and smoke retarding mixture. The present invention concern a flame retarding and smoke retarding mixture, a method for producing a solution of the mixture and the application of the mixture for treating materials that are normally combustible. Means are known how to apply different substances and mixtures to treat materials that are normally combustible to make them less combustible and work as smoke retardants. Different chemical compounds with flame retarding or smoke retarding characteristics are described in US Patent Specifications nos. 4,168,175; 4,342,669 and 4,438,028 and GB Patent Specification no. 1,462,828. None of the mixtures described in these specifications give completely satisfactory results, since each mixture gives better results in one area than it does in other areas. US Patent Specification no. 4,595,414 describes the impregnation of cellulose materials with a mixture of monoammonium phosphate, diammonium phosphate, a freely-chosen corrosion inhibitor and a surfactant. This mixture has subsequently been found to be most effective for nonflammable impregnation of cellulose textiles. The difficulty with such impregnation substances is that they give a relatively hard, stiff cellulose. Phosphates can also contain colourful contaminants. US Patent Specification no. 4,514,327 describes a fire retardant mixture consisting of ammonium sulphate, borax, boric acid and monoammonium phosphate. This mixture will not supply wood with enough impregnation substance to meet the Norwegian classification for a fire retardant. In the production method filtration is mentioned through filters sized 5 micrometres, which will involve a very expensive process. Boric compounds such as borax and boric acid are a l so classified as health risks, partly because of the damage that can be done to the central nervous system. The use of such compounds must thus be considered unfortunate both in the production process and when utilizing the product such as in impregnated clothes. This patent specification does not cover the use of EDTA or NaHCO . GB Patent Specification no. 2,165,270 describes a fire retardant mixture consisting of water-soluble monosodium phosphate, ammonium sulphate and borax and/or boric acid for the impregnation of porous materials. As mentioned above, this compound will also represent a danger. This specification does not mention the use of EDTA or NaHCO to improve the impregnation and the fire retardant characteristics. DE Patent Specification no. 2,732,561 describes a mixture that consists of ammonium ions, zinc ions, earth alkaline metal ions, chloride ions, bromide ions and phosphate ions. This patent speci ication also does not cover the use of EDTA or NaHCO and the fire tests are not done in accordance with any standard. The main objective of the present invention is produce a mixture that gives better results than any existing known products for the impregnation of materials that are normally combustible to prevent the combustion of the treated materials, prevent smoke development should they be ignited or exposed to excessive heat. A second objective of the present invention is to produce a mixture for the impregnation of textiles made of materials such as rayon, cotton and wool, or other combustible, water-absorbent materials; and the impregnation of wood, paper and other cellulose (wood) products, as well as other organic materials. A further objective with the present invention is to produce a nontoxic mixture that is neutral as far as colour is concerned. The invention, the method and applications of it are stated in the Claims. If a mixture is produced and used in accordance with the invention this will result in wood and textiles being impregnated to make them nonflammable and prevent smoke development should they be ignited or exposed to excessive heat. The invention will now be described in more detail where reference will be made to the figures, where Figure 1 shows the results from a technical fire test of spruce paneling impregnated with a mixture in accordance with the invention, and Figure 2 shows the same as Figure 1, but impregnated pine is used as the test material. The present invention has been developed to produce a mixture that is soluble in water for the treatment of materials that are normally are combustible so as to act as a flame retardant and smoke retardant. The mixture in accordance with the present invention is composed of: 70-96 weight % monoammonium phosphate and/or diammonium phosphate and/or ammonium sulphate, 1-20 weight % NaHC0 3 , 1-10 weight % EDTA, 0-28 weight % phosphoric acid (85%), 0-5 weight % normal additives. The amounts given above are calculated in weight percentage on the basis of the total weight of the mixture. The mixture can contain less amounts of one or more additives such as surfactants, thickening agents, conservation agents or corrosion inhibitors. The mechanism underlying the advantageous effect has not been completely explained. It is assumed that the following factors may be influential: The addition of sodium hydrogen carbonate causes delayed migration and the so_called beating of the dried mixture from the treated material, at the same time as the treated material obtains a softer and smoother surface. The addition of sodium hydrogen carbonate also makes it easier to remove the air from the mixture according to the invention during the impregnation process. Sodium hydrogen carbonate in the mixture will give off CO - gas when heat is applied which will prevent the ignition of the material. The addition of EDTA causes the contaminants in the components to be separated by being soluble in water and becoming residue. The pH value of the solution is to be from 3.50 to 9.00. A pH value between 6.70 and 6.80 gives least corrosion and reduces the need for the addition of corrosion inhibitors for the impregnation of wood. After impregnation and drying EDTA acts as a lattice binding agent for mixtures that thereby become more stable, at the same time as it acts as a flame retardant. Production of a solution of such a mixture A suitable amount of water is to be heated to between 30- 70°C in an appropriate vessel and is kept at a stable temperature within the above-mentioned limits during the entire mixing process. The mixing vessel should be made of stainless steel or plastic, and equipped with a stirring device that gives good circulation in the liquid. a) Ammonium sulphate is added to the water under constant stirring. Stirring continues until all the ammonium sulphate is dissolved, a minimum of 10 minutes stirring. b) Mono- or diammonium phosphate is added to the mixture from step a) under constant stirring until all of it is dissolved, a minimum of 10 minutes stirring. c) The mixture from step b) has sodium hydrogen carbonate added in small portions under constant stirring. The reaction in the mixture after the addition of each portion of sodium hydrogen carbonate is to be completed before a new portion of sodium hydrogen carbonate is added. d) EDTA is added under constant stirring until all of it is dissolved, a minimum of 10 minutes stirring. Thereafter the agitator is stopped and the mixture is allowed to stand in the mixing vessel for 3-4 hours while the solid contaminants are allowed to precipitate. After this the supernatant is filtered to remove particles with a diameter larger than 100 micrometres (10 micrometres for the impregnation of wood). The concentration of the mixture in the form of the solids in the solution can be adjusted to the planned application of the solution, this can vary from 5 and 45 weight percentage of solids calculated on the basis of the weight of the total solution. Impregnation of wood The impregnation of wood is best done in a conventional impregnation unit consisting of two horizontal, cylindrical tanks where one is above the other. The two tanks are connected by a pipe that has a valve fitted. The impregnation unit also consists of the equipment required to form a vacuum or pressurize the two tanks. A suitable unit for this is described in NO Patent no. 155,835. In relation to the present invention it is not necessary to describe the impregnation unit in more detail. Wood that is to be impregnated is placed in the lower tank and the upper tank is filled with a solution of the mixture in accordance with the present invention. The impregnation process starts by the formation of a vacuum in the upper and lower tanks to remove almost all the air from the tanks and the wood in the lower tank. When wood is to be treated, the solution must not contain particles with diameters greater than 10 micrometres, and the solution must contain between 15 and 45 weight percentage of solids calculated on the basis of the weight of the total solution. Once almost all the air has been removed, the connection between the two tanks is opened to allow the solution from the upper tank to run into the lower tank containing the wood. When the solution has run into the lower tank the valve seals the connection between the tanks and the lower tank is pressurized to about 12 bar for 1-4 hours. Then the pressure is released from the lower tank and the solution is drained. The wood is removed and dried in the conventional manner. Following drying the wood is to be supplied with 15 to 30 weight percentage of the mixture calculated on the basis of the weight that wood normally has with a water content between 10-70% prior to impregnation. Impregnation of textiles Textiles made of materials such as rayon, cotton, wool, compound textiles or textiles of other combustible, water-absorbent materials, are dipped in the solution or sprayed by the solution. The concentration of the solution will depend on the method of treatment and this will typically be within a range from 5 to 20 weight percentage of solids calculated on the basis of the weight of the total solution, where particles with a diameter larger than 100 micrometres are filtered away. When dipping, the excess liquid is squeezed out. then the textiles are dried, and after drying the textiles must be supplied increased weight of between 10 and 15 per cent in the form of solids from the mixture. Impregnation of paper and other paper products Paper and paper products can be impregnated in the same way as textiles. Technical fire tests The effectiveness of the mixture has been demonstrated in technical fire tests of three different materials: a) spruce paneling, b) pine and c) .cotton curtains. Samples a) and b) were impregnated with the same mixture in accordance with the invention, produced in accordance with the method described above, where the finished mixture had the following constituents: ammonium sulphate 105 g monoammonium phosphate 154 g diammonium phosphate 105 g EDTA 28 g NaHCO 8.4 g water 600 g. The wood in a) and b) was impregnated in accordance with NO Patent Specification no. 155,835, where a) was impregnated at 12 bar for one hour to give a absorption of impregnation agent of an average of 45 weight%, based on the weight of the non-impregnated wood and the dry ingredients in the impregnation mixture, and b) was impregnated at 12 bar for two hours to give an average absorption of impregnation agent of 43 weight%, based on the weight of the non-impregnated wood and the dry ingredients in the impregnation mixture. After being dried in the normal way, samples a) and b) were subjected to technical fire tests in accordance with Norwegian Standard NS-INSTA 412. The results are presented in Figures 1 and 2. The curtain, sample c), was impregnated by washing in a standard washing machine, where the impregnation mixture consisted of: water 874.5 g ammonium sulphate 22.8 g monoammonium phosphate 87.4 g EDTA 5.0 g NaHC0 3 5.0 g UFS75 0.7 g U6 4.6 g. The impregnation solution which here was supplied with a total weight of lOOOg, had a content of 12.02 weight percentage dry constituents apart from the additives. The additive UFS75 is a softener that has an anti_static effect, U6 is an emulgator; both are from Unger Fabrikker in Fredrikstad, Norway. The curtains were washed in the normal way, rinsed and spun, then the final rinsing program had the rinsing solution replaced by the above__mentioned impregnation solution. After spinning and drying, the curtains were supplied 12.7 weight% impregnation agent, based on the weight of the non_impregnated curtains and dried impregnation agent. The curtains were then cut into smaller pieces and subjected to technical fire tests in accordance with test method IMO Res. 471 (XII). The results are given in the following table. Test results a) The results of the spruce paneling test are given i Figure 1, this shows that the impregnated spruce paneling satisfied the technical fire specifications in NS 3903 by a good margin, both with respect to temperature and performed exceptionally well concerning smoke development, which is practically 0. After 10 minutes testing the temperature was measured to be about 140° lower than the acceptable 5 temperature limit. During the entire test, there was no smoke development of any note, this was well inside the acceptance criterion. b) The results for pine show a little less resistance at the start compared to spruce, but this evens out after 10 about 6 minutes and, at the end of the test, pine gives a slightly better result than spruce. There is however more smoke density for pine than with spruce, nevertheless the results for pine were within the technical fire test specifications by a good margin. 15 c) The results from the technical fire tests for impregnated cotton curtains are given below, where the product satisfies the stipulated demands for resistance to ignition by flames in accordance with IMO Res. A. 471 (XII). 20 Burner Ignition After- Length of Surface Ignitio position time (s) flame burnt/carbon- flaring of cott time (s) ized matter Flames Yes/No (mm) (mm) 0 55 0 78 0 45 0 90 0 95 0 85 0 90

Claims: CLAIMS : 1. Flame retarding and smoke retarding mixture of a type that contains ammonium phosphates, ammonium sulphates and phosphoric acid, characterized by the mixture also containing N 3.HCO•__ and EDTA (ethylene dia ine tetra-acetic acid) so that the total mixture consists of: 70-96 weight % monoammonium phosphate and/or diammonium phosphate and/or ammonium sulphate, 1-20 weight % NaHCO , 1-10 weight % EDTA, 0-28 weight % phosphoric acid (85%), 0-5 weight % normal additives. 2. Mixture as claimed in Claim 1, characterized by it being soluble in water and giving a concentration of 5 to 45 weight percentage solids calculated on the basis of the total weight of the mixture. 3. Method for producing a solution of the flame retarding and smoke retarding mixture as claimed in the previous Claims, characterized by it consisting of the following steps: 1: Heating water in a mixing vessel to a temperature from 30°C to 70°C, thereupon keeping this temperature constant throughout the whole procedure of dissolving the mixture, 2: Ammonium sulphate is added to the heated water from step 1 under constant stirring until all the ammonium sulphate is dissolved, a minimum of 10 minutes stirring, 3: Mono- and/or diammonium phosphate is added to the mixture under constant stirring until all the ammonium phosphate is dissolved, a minimum of 10 minutes stirring, 4: Sodium hydrogen carbonate is added to the mixture in small portions under constant stirring, in a way that the reaction in the mixture after the addition of each portion of sodium hydrogen carbonate is completed before a new portion of sodium hydrogen carbonate is added, 5: EDTA is added under constant stirring until all of it is dissolved, a minimum of 10 minutes stirring, thereafter the mixture is allowed to stand in the mixing vessel for 3-4 hours while the solid contaminants are allowed to precipitate, and 6: Supernatant from step 5 above is decanted and filtered, where particles with a diameter larger than 100 micrometres are removed. 4. Method as claimed in Claim 3, particularly for the impregnation of wood, characterized by particles with a diameter larger than 10 micrometres being removed. 5. Application of a solution of the flame retarding and smoke retarding mixture as claimed in Claims 1-3, for the impregnation of wood and textiles of materials such as rayon, cotton and wool, or other waterabsorbent materials that normally are combustible.

Inventors: VALSOE ARVE, VALSOE, ARVE
Applicants: FIRE GUARD SCANDINAVIA AS
Application year: 1990
Main classification: D06M11
IPC codes: B27K3, C09K21, D06M11, D06M13, D06M101