Novel fire retardant materials and method for producing same

Abstract

An inherently fire retardant material that exhibits endothermic properties when exposed to high temperature and flame. The subject material is prepared by reacting a natural or synthetic polymer containing hydroxyl groups with an inorganic ammonium salt.

What is claimed:  
     
         1 . A fire retardant composition prepared by reacting a natural or synthetic polymer containing hydroxyl groups with an inorganic ammonium salt containing at least two ammonium groups per molecule.  
     
     
         2 . The fire retardant composition according to  claim 1  prepared by reacting a solution containing ammonium hydroxide and the natural or synthetic polymer containing hydroxyl groups with an inorganic ammonium salt containing at least two ammonium groups per molecule.  
     
     
         3 . The fire retardant composition according to  claim 1  wherein the salt is a diammonium salt selected from the group consisting of diammonium phosphate, diammonium sulfate, diammonium chromate, and diammonium borate.  
     
     
         4 . The fire retardant composition according to  claim 3  wherein the diammonium salt is diammonium phosphate.  
     
     
         5 . The fire retardant composition according to  claim 1  wherein the composition comprises cross-linked natural or synthetic polymer wherein the linking group contains nitrogen.  
     
     
         6 . The fire retardant composition according to  claim 1  which additionally contains an antisolubility agent.  
     
     
         7 . The fire retardant composition according to  claim 1  which is in liquid form.  
     
     
         8 . The fire retardant composition according to  claim 1  which has been dried to a powder or a coating.  
     
     
         9 . The fire retardant composition according to  claim 1  which does not ignite at temperatures less than or equal to 3,500° F.  
     
     
         10 . The fire retardant composition according to  claim 1  wherein the polymer is a hydroxyl group containing polysaccharide.  
     
     
         11 . The fire retardant composition according to  claim 10  wherein the polysaccharide is a hydroxyl group containing cellulose.  
     
     
         12 . The fire retardant composition according to  claim 10  wherein the polysaccharide is a hydroxyl group containing starch.  
     
     
         13 . The fire retardant composition according to  claim 1  wherein the polymer is a hydroxyl group containing petroleum.  
     
     
         14 . The fire retardant composition according to  claim 1  which additionally contains borax.  
     
     
         15 . A fire retardant composition prepared by reacting a natural or synthetic polymer containing hydroxyl groups with a phosphate compound capable of cross-linking the natural or synthetic polymer containing hydroxyl groups.  
     
     
         16 . The fire retardant composition according to  claim 15  wherein the phosphate is selected from the group consisting of magnesium phosphates, ammonium phosphates, calcium phosphates, sodium phosphates, potassium phosphates, and mixtures thereof.  
     
     
         17 . The fire retardant composition according to  claim 15  wherein the polymer is a hydroxyl group containing polysaccharide.  
     
     
         18 . The fire retardant composition according to  claim 17  wherein the polysaccharide is a hydroxyl group containing cellulose.  
     
     
         19 . The fire retardant composition according to  claim 17  wherein the polysaccharide is a hydroxyl group containing starch.  
     
     
         20 . The fire retardant composition according to  claim 15  wherein the polymer is a hydroxyl group containing hydrocarbon.  
     
     
         21 . A cross-linked polysaccharide fire retardant composition prepared by reacting a polysaccharide containing hydroxyl groups with a cross-linking agent that is an inorganic ammonium salt, a phosphate or both.  
     
     
         22 . A cross-linked cellulose fire retardant composition prepared by reacting a cellulose containing hydroxyl groups with a cross-linking agent that is an inorganic ammonium salt, a phosphate or both.  
     
     
         23 . A cross-linked starch fire retardant composition prepared by reacting a starch containing hydroxyl groups with a cross-linking agent that is an inorganic ammonium salt, a phosphate or both.  
     
     
         24 . A cross-linked synthetic polymer fire retardant composition prepared by reacting a synthetic polymer containing hydroxyl groups with a cross-linking agent that is an inorganic ammonium salt, a phosphate or both.  
     
     
         25 . A method of preparing an inherently fire retardant natural or synthetic polymer wherein said method comprises reacting a hydroxyl group containing natural or synthetic polymer with an inorganic ammonium salt containing at least two ammonium groups per molecule.  
     
     
         26 . The method according to  claim 25  wherein the reaction is done in solution.  
     
     
         27 . The method according to  claim 25  comprising reacting a solution containing ammonium hydroxide and the natural or synthetic polymer containing hydroxyl groups with an inorganic ammonium salt containing at least two ammonium groups per molecule  
     
     
         28 . The method according to  claim 25  wherein the inorganic ammonium salt is a diammonium salt selected from the group consisting of diammonium phosphate, diammonium sulfate, diammonium chromate, and diammonium borate.  
     
     
         29 . The method according to  claim 28  wherein the diammonium salt is diammonium phosphate.  
     
     
         30 . The method according to  claim 25  wherein the polymer is a hydroxyl group containing polysaccharide.  
     
     
         31 . The method according to  claim 30  wherein the polysaccharide is a hydroxyl group containing cellulose.  
     
     
         32 . The method according to  claim 30  wherein the polysaccharide is a hydroxyl group containing starch.  
     
     
         33 . The method according to  claim 25  wherein the polymer is a hydroxyl group containing petrochemical.  
     
     
         34 . A method of preparing an inherently fire retardant natural or synthetic polymer wherein said method comprises reacting a hydroxyl group containing natural or synthetic polymer with a phosphate capable of cross-linking the polymer.  
     
     
         35 . The method according to  claim 34  wherein the phosphate is selected from the group consisting of magnesium phosphates, ammonium phosphates, calcium phosphates, sodium phosphates, potassium phosphates, and mixtures thereof.  
     
     
         36 . A method of preparing a cellulose-based fire retardant composition, comprising: 
 a. adding cellulose having a hydroxyl group to water, thereby forming a solution;    b. adding ammonium hydroxide to the solution;    c. subsequently adding a diammonium salt to the solution and binding diammonium groups to the cellulose; and    d. crosslinking the cellulose, thereby forming a cellulose-based fire retardant composition.    
     
     
         37 . The method according to  claim 36 , further comprising heating the solution prior to adding the cellulose or after at least one of adding the cellulose, adding the ammonium hydroxide, or adding the diammonium salt.  
     
     
         38 . The method according to  claim 36 , wherein said cellulose is selected from the group consisting of hydroxy ethyl cellulose, hydroxy propyl cellulose, hydroxy isopropyl cellulose, hydroxy butyl cellulose, hydroxy pentyl cellulose and a combination thereof.  
     
     
         39 . The method according to  claim 36 , wherein said cellulose is hydroxy ethyl cellulose.  
     
     
         40 . The method according to  claim 36 , wherein the diammonium salt is selected from the group consisting of diammonium phosphate, diammonium sulfate, diammonium chromate, diammonium borate, and combinations thereof.  
     
     
         41 . The method according to  claim 40  wherein the diammonium salt is diammonium phosphate.  
     
     
         42 . The method according to  claim 36  wherein the solution is a saturated cellulose solution.  
     
     
         43 . The method according to  claim 36 , wherein a ratio of diammonium salt to cellulose is about 1.6:1.  
     
     
         44 . The method according to  claim 36 , further comprising heating the cellulose and water solution to a temperature of about 60-70.degree. C.  
     
     
         45 . The method according to  claim 36 , further comprising, after adding the diammonium salt, heating the solution to about 90.degree. C.  
     
     
         46 . A method of preparing a cellulose-based fire retardant composition, comprising: 
 a. adding cellulose powder having a hydroxyl group to liquid ammonia to form a solution;    b. subsequently adding diammonium phosphate to the solution and binding diammonium phosphate groups to the cellulose; and    c. crosslinking the cellulose, thereby forming a cellulose-based fire-retardant composition.    
     
     
         47 . A method of preparing a cellulose-based fire retardant composition, comprising: 
 a. adding one or more cellulose polymers having a hydroxy group to water, thereby forming a solution;    b. catalytically binding a diammonium group to the one or more cellulose polymers in solution; and    c. crosslinking the one or more cellulose polymers, thereby forming a cellulose-based fire retardant composition.    
     
     
         48 . A fire retardant composite material comprising: 
 a. an inherently fire retardant natural or synthetic polymer composition; and    b. a non-water soluble material 
 wherein the inherently fire retardant natural or synthetic polymer composition was prepared by reacting a solution of a hydroxyl group containing natural or synthetic polymer with an inorganic ammonium salt having at least two ammonium groups per molecule.  
   
     
     
         49 . The fire retardant composite according to  claim 48  wherein the polymer is a hydroxyl group containing cellulose.  
     
     
         50 . The fire retardant composite according to  claim 48  wherein the polymer is a hydroxyl group containing starch.  
     
     
         51 . The fire retardant composite according to  claim 48  wherein the polymer is a hydroxyl group containing petrochemical.  
     
     
         52 . The fire retardant composite according to  claim 48  wherein the non-water soluble material is selected from the group consisting of glass, metal, wood, paper, furniture, insulation, plywood, carpet, linen, clothing, thread, rubber, mortar, concrete, ceramic, fiberglass, polymers, carbonaceous materials, and mixtures thereof.  
     
     
         53 . The fire retardant composite according to  claim 48  wherein the composite has been formed by blending.  
     
     
         54 . The fire retardant composite according to  claim 48  which is a fiber impregnated with the inherently fire retardant composition.  
     
     
         55 . The fire retardant composite according to  claim 48  which is a wooden material pressure treated with the inherently fire retardant composition.  
     
     
         56 . The fire retardant composite according to  claim 48  in the form of a laminate or sheet.  
     
     
         57 . The fire retardant composite according to  claim 48  which is in the form of an insulating material for use in construction applications.  
     
     
         58 . The fire retardant composite according to  claim 48  which is essentially magnesium, bromine, antimony and ATH free.  
     
     
         59 . The fire retardant composite according to  claim 48  which is a molded article.  
     
     
         60 . The fire retardant composite according to  claim 48  produced in the form of a powder, foam, slurry, or coating  
     
     
         61 . The fire retardant composite according to  claim 48  which is an open or closed cell foamed polyurethane composite.  
     
     
         62 . A fire retardant composition comprising a cross-linked natural or synthetic polymer wherein the cross-linking moiety comprises —N—P—N—.