Processes and Manufacturing Methods to Produce an Aqueous Thermosetting Fire-Rated Fire-Retardant Polymeric Adhesive Composition for Manufacturing Interior or Exterior Fire-Rated Cellulosic Products

Abstract

Disclosed is a fire-retardant non-corrosive composition, as well as a process for the production of porous materials, wherein the process is conducted in the presence of the said fire-retardant, non-corrosive composition. The fire-retardant, non-corrosive composition of the subject application includes a flame-retardant agent, preservative composition, casein liquid modified melamine resin adhesive, and a monomeric-polymeric MDI catalyst. The composition material and the product resulting from the process of the subject application have fire retardant, non-corrosive properties and protection from fungus and insects.

1 . An aqueous, fire-retardant, non-corrosive composition for application to wood products, said composition comprising a pre-blended combination of: a) a flame-retardant agent; b) a preservative composition; c) a casein liquid modified melamine resin adhesive; and d) a monomeric-polymeric MDI catalyst; wherein the amounts of the flame-retardant agent, preservative composition, casein liquid modified melamine resin adhesive, and monomeric-polymeric MDI catalyst are determined by stipulated design factors for a given wood product. 
     
     
         2 . The aqueous fire-retardant composition of  claim 1  wherein the flame-retardant agent is an aqueous condensate, comprising 1,3,5-triazine-2,4,6-triamine phosphate. 
     
     
         3 . The aqueous fire-retardant composition of  claim 1 , wherein the preservative composition comprises 98% disodium octaborate tetrahydrate and 2% inert Na 2 B 8 O 13 , 4H 2 O. 
     
     
         4 . The aqueous fire-retardant composition of  claim 1 , wherein the monomeric-polymeric MDI catalyst comprises a liquid mixture of monomeric methylene diphenyl diisocyanate isomers and polyisocyanates. 
     
     
         5 . The aqueous fire-retardant composition of  claim 1 , wherein the weight ratio of the flame-retardant agent to the monomeric-polymeric MDI catalyst ranges from approximately 50:1 to 300:1, and wherein the weight ratio of the casein liquid modified melamine resin adhesive to the preservative composition ranges from approximately 1:1 to 1:10. 
     
     
         6 . The aqueous fire-retardant composition of  claim 1 , wherein the casein liquid modified melamine resin adhesive comprises 2,4,6-triamino symtriazine. 
     
     
         7 . The aqueous fire-retardant composition of  claim 6  wherein the casein liquid modified melamine resin adhesive is a modified melamine having a free formaldehyde concentration of less than about 0.5% by weight. 
     
     
         8 . A fire-retardant substance comprising: a) a finely divided material selected from the group consisting of cellulosic material, mineral material, organic waste material, and inorganic waste material; b) a flame-retardant agent; c) a preservative composition; d) a casein liquid modified melamine resin adhesive; and e) a monomeric-polymeric MDI catalyst; wherein the combination of the flame-retardant agent, the preservative composition, the casein liquid modified melamine resin adhesive; and the monomeric-polymeric MDI catalyst, are an aqueous solution; and wherein the relative amounts of the of the flame-retardant agent, the preservative composition, the casein liquid modified melamine resin adhesive, and the monomeric-polymeric MDI-catalyst, are determined by stipulated design factors for said finely divided material. 
     
     
         9 . The fire-retardant substance of  claim 8  wherein the flame-retardant agent comprises an aqueous solution of 1,3,5-triazine-2,4,6-triamine phosphate. 
     
     
         10 . The fire-retardant substance of  claim 8 , wherein the monomeric-polymeric MDI catalyst comprises a liquid mixture of monomeric methylene diphenyl diisocyanate and polyisoisocyanates. 
     
     
         11 . The fire-retardant substance of  claim 8 , wherein the weight ratio of the fire-retardant agent to the monomeric polymeric MDI catalyst ranges from approximately 50:1 to 300:1, and wherein the weight ratio of the casein liquid modified melamine resin adhesive to the preservative composition ranges from approximately 1:1 to 1:10. 
     
     
         12 . The fire-retardant substance of  claim 8 , wherein the preservative composition is 98% disodium octaborate tetrahydrate, and 2% Na 2 B 8 O 13 , 4H 2 O. 
     
     
         13 . The fire-retardant substance of  claim 8 , wherein the casein liquid modified melamine resin adhesive comprises a 2,4,6-triaminosymtriazine. 
     
     
         14 . The fire-retardant substance of  claim 13 , wherein the casein liquid modified melamine resin adhesive is a modified melamine having a free formaldehyde concentrate of less than 0.5% by weight. 
     
     
         15 . A method for production of a fire-retardant and fungus resistant product, comprising the steps of: a) receiving a product material for incorporation of a fire-retardant and fungus-resistant product; b) applying a pre-determined amount of an aqueous, non-corrosive, fire-retardant solution to the product material, wherein the solution includes a fire-retardant agent, a monomeric-polymeric MDI catalyst, in an amount sufficient for polymerization of the aqueous, fire-retardant, non-corrosive solution, a casein liquid modified melamine resin adhesive; and a preservative composition; and wherein the amount of the aqueous fire-retardant solution is determined by stipulated design factors for a given product material; and c) assembling a manufactured fire-retardant and fungus-resistant product. 
     
     
         16 . The method of  claim 15 , wherein the fire-retardant agent is an aqueous condensate, comprising 1,3,5-triazine-2,4,6-triamine phosphate. 
     
     
         17 . The method of  claim 15 , wherein the monomeric-polymeric MDI catalyst comprises a liquid mixture of monomeric methylene diphenyl diisocyanate isomers and polyisocyanates. 
     
     
         18 . The method of  claim 15 , wherein the weight ratio of the flame-retardant agent to the monomeric-polymeric MDI catalyst ranges from approximately 50:1 to 300:1, and wherein the weight ratio of the casein liquid modified melamine resin adhesive to the preservative composition ranges from approximately 1:1 to 1:10. 
     
     
         19 . The method of  claim 15 , wherein the preservative composition is 98% disodium octaborate tetrahydrate, and 2% Na 2 B 8 O 13 , 4H 2 O. 
     
     
         20 . The method of  claim 15 , wherein the casein liquid modified melamine resin adhesive is a 2,4,6-triaminosymtriazine. 
     
     
         21 . The method of  claim 20 , wherein the liquid melamine adhesive is a modified melamine having a free formaldehyde concentration of less than about 0.5% by weight. 
     
     
         22 . The method of  claim 15 , wherein the product material is selected from the group consisting of wood-based fibers, wood-based particles, cellulose wafers, wood strands, straw, cane, organic waste products, and inorganic waste products, and combinations thereof. 
     
     
         23 . The method of  claim 15 , wherein the manufactured product is selected from the group consisting of oriented strand board, medium density fiber board, wood particle board, fiber mat, pressboard, gypsum fiber board, fiber board, cement fiber board, wood, lumber, wood substrates, structural wood assemblies, wood particle board doors and wood frames, structural laminated veneer lumber, scaffold planks, laminated glu-lam structural wood beams, plastic laminate(s), pipe insulation, hydraulic additive, foam insulation panel(s), paper, structural plywood, mineral fiber board, modified density overlay, and insulation and combinatios thereof.