Composition and a method for controlling reaction pressures during the foaming process resulting in an easily flame retarded foam-in place insulation

Abstract

A low reactive pressure flame-retardant polyurethane foam made by reacting together a polymeric isocyanate, a polyol, an aqueous solution of a carbohydrate, calcium acid phosphate, sodium aluminum sulfate, sodium bicarbonate, and a flame retardant. A blowing agent may be present.

What is claimed is: 
     
       1. A low reactive pressure flame-retardant polyurethane foam made by reacting together a .[.polymeric isocyanate.]. .Iadd.polyisocyanate, .Iaddend.a conventional polyol, a surfactant, .[.a blowing agent.]. and an aqueous solution .Iadd.or slurry .Iaddend.of a carbohydrate, calcium acid phosphate, sodium aluminum sulfate, sodium bicarbonate, and flame retardant. 
     
     
       2. The polyurethane foam according to .[.claim 1.]. .Iadd.claims 1, 15, 16 or 17 .Iaddend.wherein the carbohydrate is selected from the group consisting of cornstarch, corn syrup, dextrose, sucrose, and molasses. 
     
     
       3. The polyurethane foam according to .[.claim 2.]. .Iadd.claims 1, 15, 16 or 17 .Iaddend.wherein the carbohydrate is cornstarch. 
     
     
       4. The polyurethane foam according to .[.claim 2.]. .Iadd.claims 1, 15, 16 or 17 .Iaddend.wherein the carbohydrate is corn syrup. 
     
     
       5. The polyurethane foam according to .[.claim 1 including.]. .Iadd.claims 16 or 17 wherein the blowing agent is .Iaddend.a hypochlorite salt selected from the group consisting of calcium hypochlorite and sodium hypochlorite. 
     
     
       6. The polyurethane foam according to .[.claim 1.]. .Iadd.claims 1, 15, 16 or 17 .Iaddend.wherein the flame retardant is selected from the group consisting of sodium chloride, calcium chloride, alkali metal borates, tri-cresyl phosphate, tris(2-chloroethyl) phosphate, tris(chloropropyl) phosphate, O,O-diethyl-N,N-bis(2-hydroxyethyl) aminomethyl phosphate, antimony oxide, alumina, and antimony oxychloride. 
     
     
       7. The polyurethane foam according to .[.claim 1.]. .Iadd.claims 15 or 16 .Iaddend.wherein the blowing agent is selected from the group consisting of methylene chloride, ethylenetrichloride, trichloromonofluoromethane, dichlorodefluoromethane, and dichlorotetrafluoroethane. 
     
     
       8. The polyurethane foam according to .[.claim 1.]. .Iadd.claims 1, 15, 16 or 17 .Iaddend.including a catalyst. 
     
     
       9. A method for making a flame-retardant polyurethane foam comprising: a. .[.dissolving.]. .Iadd.mixing .Iaddend.a carbohydrate, calcium acid phosphate, sodium aluminum sulfate, sodium bicarbonate, surfactant, and a flame retardant selected from the group consisting of sodium chloride, calcium chloride, alkali metal borates, tri-cresyl phosphate, tris(2-chloroethyl phosphate), tris(chloropropyl)-phosphonate, O,O-diethyl-N,N-bis-(2-hydroxyethyl)aminoethyl phosphate, antimony oxide, alumina, and antimony ocychloride, to form an aqueous solution; .Iadd.or slurry .Iaddend.   b. mixing the aqueous solution .Iadd.or scurry .Iaddend.with .[.polyether.]. .Iadd.conventional .Iaddend.polyol;   c. .[.adding to.]. .Iadd.mixing with .Iaddend.the polyol-aqueous solution .Iadd.or slurry .Iaddend.mixture a .[.polymer isocyanate.]. .Iadd.polyisocyanate .Iaddend.and .[.mixing.].;   d. allowing the mixture to .[.faom.]. .Iadd.foam.Iaddend..   
     
     
       10. The method of .[.claim 9.]. .Iadd.claims 9, 13, 25 or 26 .Iaddend.wherein the carbohydrate is selected from the group consisting of cornstarch, corn syrup, dextrose, sucrose and molasses. 
     
     
       11. The method of .[.claim 10.]. .Iadd.claims 9, 13,25 or 26 .Iaddend.wherein the carbohydrate is cornstarch. 
     
     
       12. The method of .[.claim 10.]. .Iadd.claims 9, 13, 25 or 26 .Iaddend.wherein the carbohydrate is corn syrup. 
     
     
       13. The method of claim 9 wherein a blowing agent is added to the polyol-aqueous solution .Iadd.or slurry .Iaddend.mixture. 
     
     
       14. The method of .[.claim 9.]. .Iadd.claims 9, 13, 25 or 26 .Iaddend.wherein a catalyst is present in the aqueous solution .Iadd.or slurry .Iaddend.of step (a). .Iadd.15. A polyurethane foam according to claim 1 wherein the polyisocyanate is polymeric isocyanate. .Iaddend. .Iadd.16. The polyurethane foam according to claim 1 wherein a blowing 
     
     
        agent is incorporated in the reaction mixture. .Iaddend. .Iadd.17.  The polyurethane foam according to claim 1 wherein the polyisocyanate is a polymeric isocyanate and a blowing agent is incorporated in the reaction mixture. .Iaddend. .Iadd.18. The low reactive polyurethane foam made by reacting together a polyisocyanate, a conventional polyol, a surfactant, and an aqueous solution or slurry of a carbohydrate, calcium acid phosphate, sodium aluminum sulfate, and sodium bicarbonate. .Iaddend. .Iadd.19. The polyurethane foam according to claim 18 wherein the polyisocyanate is a polymeric isocyanate. .Iaddend. .Iadd.20. The polyurethane foam according to claim 19 wherein a blowing agent is incorporated in the reaction mixture. .Iaddend. .Iadd.21. The polyurethane foam according to claim 18 wherein the polyisocyanate is a polymeric isocyanate and a blowing agent is incorporated in the reaction mixture. .Iaddend. .Iadd.22. The polyurethane foam according to claims 18, 19, 20 or 21 wherein the carbohydrate is selected from the group consisting of cornstarch, corn syrup, dextrose, sucrose and molasses. .Iaddend. .Iadd.23. The polyurethane foam according to claims 18, 19, 20 or 21 wherein the carbohydrate is cornstarch. .Iaddend. .Iadd.24. The polyurethane foam according to claims 18, 19, 20 or 21 wherein the carbohydrate is corn syrup. .Iaddend. .Iadd.25. The polyurethane foam according to claims 20 or 21 wherein the blowing agent is a hypochlorite salt selected from the group consisting of calcium hypochlorite and sodium hypochlorite. .Iaddend. .Iadd.26. The method of claim 9 wherein the polyisocyanate is a polymeric isocyanate. .Iaddend. .Iadd.27. The method of claim 9 wherein the polyisocyanate is a polymeric isocyanate and a blowing agent is incorporated in the polyol aqueous solution or slurry. .Iaddend. .Iadd.28. A method for making a polyurethane foam comprising: a. mixing a carbohydrate, calcium acid phosphate, sodium aluminum sulfate, sodium bicarbonate and surfactant to form an aqueous solution or slurry;   b. mixing the aqueous solution or slurry with a conventional polyol;   c. mixing with the polyol-aqueous mixture a polyisocyanate and;   d. allowing the mixture to foam. .Iaddend. .Iadd.29. The method of claim 28 wherein the polyisocyanate is a polymeric isocyanate. .Iaddend. .Iadd.30. The method of claim 28 wherein a blowing agent is added to the polyol-aqueous solution or slurry. .Iaddend. .Iadd.31. The method of claim 28 wherein the polyisocyanate is a polymeric isocyanate and a blowing agent is incorporated in the polyol aqueous solution or slurry. .Iaddend. .Iadd.32. The method of claims 28, 29, 30 or 31 wherein the carbohydrate is selected from the group consisting of cornstarch, corn syrup, dextrose, sucrose and molasses. .Iaddend. .Iadd.33. The method of claims 28, 29, 30 or 31 wherein the carbohydrate is cornstarch. .Iaddend. .Iadd.34. The method of claims 28, 29, 30 or 31 wherein the carbohydrate is corn syrup. .Iaddend. .Iadd.35. The method of claims 13, 30 or 31 wherein the blowing agent is selected from the group consisting of methylene chloride, ethylenetrichloride, trichloromonofluoromethane, dichlorodifluoromethane and dichlorotetrafluoroethane. .Iaddend. .Iadd.36. The method of claims 28, 29, 30 or 31 wherein a catalyst is present in the aqueous solution or slurry of step (a)..Iaddend.