Post-foaming composition for protection against fire and/or heat

Abstract

Inert and hydrocarbon gases, such as propellant gases, maintain a pressure in a bottle to ensure that a formed composition can be dispensed to an intended destination. The carrier releases soluble hydrocarbon gases and the water drops dissolve inert gases, so the liquid is inflated and creates upstanding foam. This foam maintains the texture and water content up to 6-24 hours, depending on the ratio of the fire-resistant component. As heat reaches the foam, the heat-resistant silicate component becomes activated. Strong heat causes evaporation of the moisture of the carrier, and then the bound water of the silicates evaporates from the foam, with a honeycomb-structure left behind which is a good thermal insulator and is able to protect the object. Above approximately 350° C., a ceramic protective layer forms, while the water content of the foam inside the foam migrates outwards towards the dry crust.

Claims

1. An alkaline post-foaming composition for protection against fire or heat, the composition comprising: a propellant ingredient of an inert gas of between 0.5% and 6% by weight; one or more aliphatic hydrocarbons added to the propellant ingredient of between 0.1% and 10% by weight, the one or more aliphatic hydrocarbons having an atmospheric boiling point under 20° C., with a vapor pressure at 20° C. of between 1 and 5 bar; a fire-resistant component selected from the group consisting of an alkali metal silicate, an alkaline earth metal silicate, and a combination of thereof; a solvent medium of greater than 0% and less than 75% by weight; foam enhancement component selected from the group consisting of an organic soap-forming base and an inorganic soap-forming base, the foam enhancing component of greater than 0% and less than 18% by weight; and a carrier material selected from the group consisting of fatty acids, fatty alcohols, salts of fatty alcohols, esters, aldehydes, and amides, the carrier material of between 0.5% and 20% by weight, wherein the carrier material is configured for the capture of at least a portion of propellant gas or mixture of gases.

2. The composition of claim 1, wherein the foam enhancement component is the organic soap-forming base selected from the group consisting of triethanolamine, diethanolamine, monoethanolamine, morpholine, iso-propanol amine, amino methyl propanol, and aminomethyl-propanediol.

3. The composition of claim 1, wherein the foam enhancement component is the inorganic soap-forming base of foam enhancement component consisting of sodium hydroxide and potassium hydroxide.

4. The composition of claim 1, wherein the one or more aliphatic hydrocarbons is selected from the group consisting of propane, n-propane, isopropane, butane, n-butane, isobutane, pentane, n-pentane, isopentane, and neopentane.

5. The composition of claim 1, wherein the carrier material further comprises a component selected from the group consisting of stearic acid, myristic, palmitic, lauric acid, and C4-C36 atom fatty acids.

6. The composition of claim 1, wherein the inert gas is selected from the group consisting of argon, nitrogen, helium, and xenon.

7. The composition of claim 1, wherein the fire-resistant component is made of aqueous solution selected from the group consisting of sodium silicate, potassium silicate, calcium silicate, aluminum silicate, magnesium silicate, lithium silicate, and cesium silicate.

8. The composition of claim 1, wherein the foam enhancement component is at least partially comprised of a component selected from the group consisting of a surfactant, a wetting agent, and a viscosity enhancing substance.

9. The composition of claim 8, wherein the foam enhancement component includes the surfactant selected from the group consisting of polyethylene glycol, polypropylene glycol, polyethylene glycol stearate, alkyl polyglycosides, sodium stearate, potassium stearate, polyethylene glycol alkyl ether, octaetylene glycol monododecyl ether, pentaethylene glycol monododecyl ether, polypropylene glycol alkyl ether, glucoside alkyl ethers, decyl glucoside, lauryl glucoside, octyl glucoside, polyethylene glycol octyl phenyl ethers, polyethylene glycol alkyl ethers, glyceryl laurate, polysorbate, cocamide monoethanolamine, cocamide diethanolamine, cocamide dodecyl oxide, polyethoxylated tallow amine, polyoxyethylene, and stearyl ether.

10. The composition of claim 8, wherein the foam enhancement component includes the wetting agent selected from the group consisting of glycerol, ethylene glycol, propylene glycol, butylene glycol, and sorbitol.

11. The composition of claim 8, wherein the foam enhancement component includes the viscosity enhancing substance selected from the group consisting of carboxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl cellulose, methyl cellulose, ethyl cellulose, hydroxybutyl methyl cellulose, alkyl glycol, polyacrylic acid, alkyl-modified cellulosic polymer, guar gum, xanthan gum, agar, alginic acid, gum arabic, carrageenan, and starch.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) The mechanism of action of the post-foaming composition according to the invention is as follows. Inert and hydrocarbon gases, such as propellant gases, maintain a pressure in the bottle to ensure that the composition can be dispensed to the intended destination. The carrier releases soluble hydrocarbon gases and the water drops dissolve inert gases, so the liquid is inflated and creates upstanding foam. This foam maintains the texture and water content up to 6-24 hours, depending on the ratio of the fire-resistant component. As heat reaches the foam, the heat-resistant silicate component becomes activated. Strong heat causes evaporation of the moisture of the carrier, and then the bound water of the silicates evaporates from the foam, with a honeycomb-structure left behind which is a good thermal insulator and is able to protect the object. Above approximately 350° C., a ceramic protective layer forms, while the water content of the foam inside the foam migrates outwards towards the dry crust. For this reason, the crust thickens quickly, and the inside of the foam will be emptied. The crust shields up to 810° C.

(2) The inert gas contents of propellant gases are responsible for the inflammability of the gas mixture, and so the hydrocarbon gas dissolved in the foam material and left in the bottle could not reach a flammable concentration. By filling additional inert gas in the bottle, a large part of the combustible gas will dissolve, and the composition of the gaseous mixture left in the bottle will be formed based on the partial pressures. The post-foaming composition of the invention is well suited against fire of solid objects, as well as hydrocarbon tank fires, due to the mechanism of action of the hydrocarbon gas-inert gas mixture in the composition.

(3) Hereinafter examples of post-foaming compositions of this invention described in detail. It should be noted that the disclosed compositions do not take up all the possible components, but their related compounds in the respective component shown include substantially the same effects in the compositions.

(4) By the preparation of the foam composition, firstly an aqueous solution is made of fatty acids or fatty alcohols and their salts, esters, or aldehydes, with amides used as a carrier. During dissolution of the carrier material, the water is heated to the melting point of the carrier, and the solution is made by saponification and hydrolysis. For this, both the well-known soap-cooking alkalis (NaOH, KOH) or other soap-forming material (such as Triethanolamine) can be used. After this, the fire-resistant silicate additive can be dissolved in the prepared soap solution. The solution is cooled, thickening to become gelatinous in consistency, which may be gelled further as needed with the known thickening agents of the industry (such as sodium carboxyl-methyl cellulose, xanthan gum, and other similar agents). The foaming and water drop properties of the composition may be slightly improved further, such as by the addition of a small amount of surfactant material (such as polyethylene glycol).

(5) Example 1

(6) In the given composition, 170 g of water is heated to over 70° C., with 22 g of stearic acid acting as a carrier. Ten g of triethanolamine, a soap-forming organic base of foam enhancement, was added, and heating was discontinued after the stearic acid dissolved. Subsequently, 4 g of carboxymethyl cellulose, a viscosity enhancement of foam enhancement, was admixed. The solution is cooled down to the temperature near 0° C. and diluted by adding 100 g ice. Then, 4 g of polyethylene glycol stearate and 12 g of polyethylene glycol powder was added to the cooled solution as a surfactant foam enhancement ingredient, and is agitated vigorously while a uniform white mass is formed.

(7) Then, depending on the desired degree of fire resistance, up to 100 g, in this case 70 g, of sodium silicate solution was added with vigorous stirring to the mass obtained. Then, to avoid further thickening, 155 g of ice and/or water was added, and the mixture was maintained near 0° C. temperature. Finally, after 30 minutes, some more water added is thin the composition to reach flowable consistency. The obtained liquid mixture was then filled into a pressure-resistant bottle equipped with a valve, which was evacuated below 0.05 bar previously, and then sealed.

(8) After the bottle is filled with the specific mixture, 5 g per kilogram of isobutane as a hydrocarbon propellant material ingredient and argon gas as an inert propellant gas was filled over, until the cylinder pressure does exceed the design pressure, but a minimum pressure of 20 bar is reached. The mixture is shaken well and thus brought the finished composition in a ready for use state. By spreading over the specific composition, if applied on a wood block, a 2 cm thick layer of foam provided sufficient protection against direct gasoline fire even after 9 minutes.

(9) Example 2

(10) The composition is prepared of cooking oil, frying fat triglycerides, by mixing 330 g of used frying oil and 108 g stearic acid as carriers, and the mixture is heated to a temperature above 70° C., the heating and stirring being continued until the stearic acid dissolved. Simultaneously, 266 g of water, 28 g of potassium hydroxide, and 17 g of sodium hydroxide as an inorganic soap-forming base of foam enhancement ingredient, were charged into a vessel made of suitable material, and heated to about 80° C., in addition to the continuous mixing of the components. Then the two mixtures are combined and uniformly mixed. Subsequently, 560 g of sodium silicate solution as a fire-resistant ingredient, and 3200 g of water was added with vigorous stirring. The resulting low viscosity solution was cooled down to a temperature of about 5° C.

(11) The obtained liquid mixture was then filled into a pressure-resistant bottle equipped with a valve, which was evacuated below 0.05 bar previously, and then sealed. After the bottle is filled to two-thirds with the specific mixture, 20 g per kilogram of isobutane as a hydrocarbon propellant material ingredient and argon gas as an inert propellant gas was filled over, until the cylinder pressure does not exceed the design pressure, but a minimum pressure of 20 bar is reached.

(12) The mixture is shaken well, and the finished composition is ready for use. After spreading over the specific composition, the composite solidified, depending on the ambient temperature. According to the fire resistance, the composition reached a lower level compared to that of Example 1.

(13) Example 3

(14) In another composition, 9 grams of cetyl stearyl alcohol (C14-C16), and 6 grams of myristic acid as a carrier, were mixed with 100 g of water and heated above 56° C. until the alcohol melted and formed an oily layer on the water surface. Then, with continued stirring, triethanolamine as an organic soap-forming base was added until the oily layer completely dissolved; in one example, 8 grams of triethanolamine were used. Then, 3 grams of polyethylene glycol stearate as a surfactant, and 50 g of sodium silicate solution as fire-resistant component, were mixed, and then approximately 1 gram of methyl cellulose as a viscosity-increasing additive was added and the solution was well mixed.

(15) The obtained liquid mixture was then cooled down and filled into a pressure-resistant bottle equipped with a valve, which was evacuated below 0.05 bar previously, and then sealed. After the bottle is filled to two-thirds with the specific mixture, 10 g per kilogram of isobutane hydrocarbon as a propellant material ingredient and nitrogen gas as an inert propellant gas is filled over, until that the cylinder pressure does not exceed the design pressure, but a minimum pressure of 20 bar is reached.

(16) The finished post-foaming composition was then ready for use; after application, the composition had an expansion ratio of about 4, forming a highly viscous, stable layer and adhered to surfaces up to about 1 cm thick layer. Fire resistance was excellent and unchanged even in direct flame. The foam material floated well on hydrocarbon fluids (such as petrol) surface, and not dissolved therein.

(17) Example 4

(18) In another embodiment, about 20 grams of lauric acid as a carrier were mixed in 200 g of water, and then heated above 60° C., with 2 to 3 g of potassium hydroxide mixed as inorganic soap-forming base until the oily layer was dissolved. Then, 10 grams of polyethylene glycol stearate as a surfactant was mixed together with 100 g of sodium silicate solution as a fire-resistant component, and then 4 grams of methyl cellulose and 15 grams of xanthan gum as viscosity-increasing additives was added to the solution and well mixed.

(19) The obtained liquid mixture was then cooled down and filled into a pressure-resistant bottle equipped with a valve, which was evacuated below 0.05 bar previously, and then sealed. After the bottle was filled to two-thirds with the specific mixture, 10 g per kilogram of propane as a hydrocarbon propellant material ingredient and argon gas as an inert propellant gas was filled over, until that the cylinder pressure does not exceed the design pressure, but a minimum pressure of 20 bar is reached.

(20) After application, the specific composition was completely hardened, suitable to cut with a knife, and of a springy consistency, with excellent fire-retardant properties. The density was about 0.3 g/cm.sup.3. The foam material floated well on hydrocarbon fluid (such as petrol) surfaces, and not dissolved therein.

(21) Another sample of the resulting liquid mixture was further diluted with 500 g water per kilogram of base material and filled to a bottle identically to the first sample. The mixture was shaken well and thus brought the finished composition ready for use. After spreading of the specific composition, it was found that after application of the composition it was similar to whipped cream in consistency and had excellent fire-retardant properties. The foam material floated well on hydrocarbon fluid (such as petrol) surfaces, and not dissolved therein.

(22) Example 5

(23) In another embodiment, about 10 g cetyl-stearyl alcohol (C14-C16) and 10 g of magnesium stearate as a carrier were mixed into 200 g of water and then heated above 80° C. Then, 2-4 g of potassium hydroxide as an inorganic soap-forming base foam improvement ingredient were mixed until the carrier is completely dissolved. Then, about 100 g of sodium silicate as a fire-resistant ingredient and 5 g of xanthan gum as a viscosity enhancer were mixed in, and the solution was cooled down and thinned with about 50 g of ice.

(24) The obtained liquid mixture was then filled into a pressure-resistant bottle equipped with a valve, which was evacuated below 0.05 bar previously, and then sealed. After the bottle was filled to two-thirds with the specific mixture, 10 g per kilogram of propane as a hydrocarbon propellant material ingredient and argon gas as an inert propellant gas were filled over, until the cylinder pressure does not exceed the design pressure, but a minimum pressure of 20 bar reached.

(25) The mixture was shaken well and, thus, brought the finished composition ready for use. After spreading over the specific composition, a thick, creamy foam was generated, with an expansion ratio of about 10. The flame resistance of the foam was also very good. The foam material floated well on hydrocarbon fluid (such as petrol) surfaces, and not dissolved therein.

(26) Example 6

(27) In another example, about 21 g of stearic acid methyl ester as a carrier was added to 137 g of water and heated above about 60° C. Then, the carrier is melted and forms an oily layer on the liquid surface. Then, 2-3 g of potassium hydroxide as an inorganic soap-forming base is mixed into the hot liquid, while the carrier is completely dissolved. Then, 73 g sodium silicate as a fire-resistant component was added and stirred well.

(28) The solution suddenly thickened, so 150 g of ice and water was added, until it is completely cooled. The liquid was mushy in texture. The obtained liquid mixture was then filled into a pressure-resistant bottle equipped with a valve, which was evacuated below 0.05 bar previously, and then sealed. After the bottle is filled to two-thirds with the specific mixture, 20 g per kilogram of isobutane as a hydrocarbon propellant material ingredient and argon gas as an inert propellant gas was filled over, until the cylinder pressure does not exceed the design pressure, but a minimum pressure of 20 bar is reached.

(29) The mixture was shaken well and thus brought the finished composition ready for use. A thick, creamy foam was generated after application, with an expansion ratio of about 10. The flame resistance of the foam is good. The foam material floated well on hydrocarbon fluid (such as petrol) surfaces, and not dissolved therein. After application of the foam, it was completely balanced, moderate, and creamy, with the particles included in the solution not being found. The fire resistance and durability of the foam obtained was good.

(30) Example 7

(31) In an embodiment, about 8 g of stearic acid methyl ester and 8 g of cetyl stearyl alcohol as carrier components were added to 165 g of water and heated above about 60° C. Then, the carrier was melted and formed an oily layer on the liquid surface. Then, 2 g of potassium hydroxide as an inorganic soap-forming base were mixed in until the carrier is completely dissolved. Then, 80 g sodium silicate as a fire-resistant component was added and stirred well. The liquid cooled down to a temperature close to 0° C. by adding 122 g of ice and water. Then, 5 g of polyethylene glycol stearate as a surfactant foam enhancement ingredient, 4 g of methyl cellulose, and 25 g of carboxymethyl cellulose solution as viscosity enhancing components were mixed in.

(32) In the first application example of the Example 7 composition, the obtained liquid mixture was then filled into a pressure-resistant bottle equipped with a valve, which was evacuated below 0.05 bar previously, and then sealed. After the bottle was filled to two-thirds with the specific mixture, 60 g per kilogram of isobutane hydrocarbon propellant material ingredient was added.

(33) In the second application example of Example 7 composition, the liquid mixture was filled into a bottle in the same way, and then 20 g per liter of isobutane as a hydrocarbon propellant ingredient was added to the mixture through the filling valve. Finally, further argon gas as an inert propellant gas was filled over, until the cylinder pressure did not exceed the design pressure, but a minimum pressure of 20 bar was reached.

(34) The mixture shaken well and thus brought the finished composition ready for use. A creamy foam was obtained after application of the first application of Example 7, with an expansion ratio of approximately 10. The foam has low fire resistance.

(35) The foam obtained was of a more solid and creamy consistency in the second application of Example 7, with an expansion ratio of approximately 12. The foam had high fire resistance. It was found that, above the optimal hydrocarbon content, all properties of the foam decrease significantly.

(36) The post-foaming composition according to the invention is widely useful in all cases, when a large amount of cost-effective, durable, homogeneous, high expansion ratio, fireproof, and good heat insulating foam should be generated quickly, and utilized against the effects of fire and/or heat for a long period.