According to one embodiment, a halogen free roof system is described. The roof system includes a structural deck that is positioned above joists or other support members. Polyisocyanurate foam insulation is positioned atop the structural deck. The polyisocyanurate foam insulation has an isocyanate index greater than 200 and includes a polyisocyanurate core having a halogen free fire retardant. A water proof membrane is positioned atop the polyisocyanurate foam insulation. The polyisocyanurate core is able to form a sufficiently stable char when exposed to flame conditions such that the polyisocyanurate core is able to pass the ASTM E-84 test.

An object of the present invention is to provide a modified silicone resin foam that can be foamed without generating hydrogen as a by-product, while maintaining excellent texture and flexibility. The present invention provides a modified silicone resin foam obtained by curing a foamable liquid resin composition, the foamable liquid resin composition containing 100 parts by weight of a base resin, 0.1 to 5 parts by weight of a silanol condensation catalyst, and 2 to 40 parts by weight of a chemical foaming agent, the base resin including a polymer having in its molecular chain at least one silyl group that contains a hydrolyzable group bonded to a silicon atom and can be crosslinked by forming a siloxane bond, the polymer having a backbone composed of oxyalkylene units, the foam having an ASKER FP hardness of 60 or less in a 25° C. atmosphere.

Polyurethane foams which are highly flame resistant are described, as well as the production of such polyurethane foams by the reaction between a natural polyol, such as sucrose or a blend of mono- or disaccharides in place of the standard hydrocarbon-based polyol component, a polyisocyanate and water in the presence of a suitable polyurethane forming catalyst and a flame retardant, and optionally one or more components such as surfactants and/or emulsifiers. The resultant polyurethane foam has a bio-based solid content ranging from about 17% to 30%, may be formulated in a variety of foam densities for a variety of applications, and exhibits a high degree of fire and burn resistance, as exhibited by the flame spread index and the smoke spread values.

An open cell spray polyurea foam for use in an insulation layer in a wall structure may include a polyurea. The polyurea may be a reaction product of an isocyanate compound and water. The open spray polyurea foam may also include a filler. The majority of the filler may exist in the spray foam formulation as an unreacted first fire retardant. The spray foam formulation may further comprise a second fire retardant, and the insulation layer may exhibit a fire retardancy sufficient to pass Appendix X and/or ASTM E-84.

The present disclosure provides for an isocyanate-reactive composition that can react with an isocyanate compound in a reaction mixture to form a polyurethane-based foam. The isocyanate-reactive composition includes an isocyanate reactive compound and a combustion modifier composition. The isocyanate reactive compound has an isocyanate reactive moiety and an aromatic moiety. The combustion modifier composition includes both phosphorus from a halogen-free flame-retardant compound and a transition metal from a transition metal compound. The combustion modifier composition can have a molar ratio of the transition metal to phosphorus (mole transition metal:mole phosphorous) of 0.05:1 to 5:1.

C

A flame-retardant rigid polyurethane foam contains a flame retardant, the foam having a ratio of the maximum peak intensity ratio (P1) of the foam after moist heat treatment of the foam for one week at a temperature of 80° C. and a humidity of 85% to the maximum peak intensity ratio (P2) of the foam before this moist heat treatment of 85% or more (P1/P2x100). The P1 and P2 each refer to the ratio of the maximum peak intensity of 1390 to 1430 cm.sup.−1 to the maximum peak intensity of 1500 to 1520 cm.sup.−1 when the infrared absorption spectrum is measured at a position 5 to 10 mm from the surface of the foam, and the average intensity of 1900 to 2000 cm.sup.−1 is adjusted to zero.

According to one embodiment, a polyisocyanurate foam board is described. The foam board includes a polyisocyanurate core that is produced from: an isocyanate, a polyol, and a phosphorous containing non-halogenated fire retardant. The foam board also includes a facer material that is applied to at least one surface of the polyisocyanurate core. The polyisocyanurate core has an isocyanate index greater than about 200 and is able to forms a sufficiently stable char when exposed to flame conditions to enable the polyisocyanurate core to pass the ASTM E-84 test. The foam board has an initial R-value of at least 6.40 and exhibits an ASTM E1354-11b test performance that is equivalent with or better than a similar foam board having a halogenated fire retardant, such as tris(2-chloroisopropyl)phosphate (TCPP).

A spray foam formulation used to form a spray foam insulation layer in a wall structure is described. The formulation may include the reaction product of a polyisocyanate compound and a polyol compound; a fire retardant chosen from at least one of a non-halogenated fire retardant; and a reactive halogen-containing fire retardant, and a carbohydrate. The spray foam insulation layer has an insulative R value of 3.0 to 7.2 per inch, and a density of between about 0.3 to about 4.5 pcf. Further, spray foam insulation made from the spray foam formulation may have fire retardant characteristics that are equivalent to or better than a similar spray insulation foam insulation using non-reactive halogenated fire retardants such as tris(1-chloro-2-propyl)phosphate (TCPP).

A method of forming a void, channel and/or vascular network in a polymeric matrix comprises providing a pre-vascularized structure that includes a matrix material and a sacrificial material embedded in the matrix material in a predetermined pattern, where the matrix material comprises a monomer and the sacrificial material comprises a polymer. A region of the matrix material is activated to initiate an exothermic polymerization reaction and generate a self-propagating polymerization front. As the polymerization front propagates through the matrix material and polymerizes the monomer, heat from the exothermic reaction simultaneously degrades the sacrificial material into a gas-phase and/or liquid-phase byproduct. Thus, one or more voids or channels having the predetermined pattern are rapidly formed in the matrix material.

The use of long-chain phosphoric acid esters as additives in aqueous polymer dispersions for production of porous polymer coatings, preferably for production of porous polyurethane coatings, is described.