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Title:
METHOD OF FORMING A FIRE RETARDANT SOLID WOOD PRODUCT
Document Type and Number:
WIPO Patent Application WO/2022/261756
Kind Code:
A1
Abstract:
A method of pressure treating a solid wood product, comprises applying a first vacuum to an interior chamber of a pressure vessel having the solid wood product therein, and directing a fire retardant resin product into the interior chamber after discontinuing the first vacuum application. The fire retardant resin product is a liquid comprising between about 4% and about 12% total product weight of a phosphorous or nitrogen compound, between about 4% and about 12% total product weight of cyanoguanidine; between about 6% and about 14% total product weight of a urea formaldehyde resin, and between about 70% and about 78% total product weight of water. The method further comprises applying a first positive pressure to the interior chamber having the solid wood product and the fire retardant resin product therein to direct the fire retardant resin product into the solid wood product.

Inventors:
MANOUDIS PANAGIOTIS N (CA)
ASLANIDOU DIMITRA (CA)
POWELL MATTHEW (CA)
Application Number:
PCT/CA2022/050944
Publication Date:
December 22, 2022
Filing Date:
June 14, 2022
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
ZEROIGNITION TECH INC (CA)
International Classes:
C09K21/14; B27K3/00; B27N9/00; C08K3/016; C08K3/32; C08K5/315; C08L61/24
Domestic Patent References:
WO2015187414A12015-12-10
WO2012164143A22012-12-06
Foreign References:
US4373010A1983-02-08
US3159503A1964-12-01
CA917334A1972-12-19
CA907233A1972-08-08
GB2099830A1982-12-15
US3874990A1975-04-01
EP0527303A11993-02-17
Attorney, Agent or Firm:
RIDOUT & MAYBEE LLP et al. (CA)
Download PDF:
Claims:
THAT WHICH IS CLAIMED:

1. A method of forming a fire retardant solid wood product, comprising: applying a first vacuum to an interior chamber of a pressure vessel having the solid wood product therein; directing a fire retardant resin product into the interior chamber after discontinuing the first vacuum application, the fire retardant resin product being a liquid comprising: between about 4% and about 12% total product weight of a phosphorous or nitrogen compound; between about 4% and about 12% total product weight of cyanoguanidine; between about 6% and about 14% total product weight of a urea formaldehyde resin; and between about 70% and about 78% total product weight of water; and applying a first positive pressure to the interior chamber having the solid wood product and the fire retardant resin product therein to direct the fire retardant resin product into the solid wood product.

2. The method of Claim 1, comprising applying a second vacuum to the interior chamber after discontinuing the first positive pressure and removing any excess fire retardant resin product therefrom.

3. The method of Claim 1, comprising, after discontinuing the first positive pressure, heating the interior chamber having the solid wood product therein to above an ambient temperature for a selected time period to cure the fire retardant resin product directed into the solid wood product, the cured fire retardant resin product reducing, minimizing, or preventing leaching of a fire retardant component of the fire retardant resin product from the solid wood product.

4. The method of Claim 1, comprising, after discontinuing the first positive pressure, heating the interior chamber having the solid wood product therein to a temperature of about 70°C or above for a time period of at least 10 hours to cure the fire retardant resin product directed into the solid wood product, the cured fire retardant resin product reducing, minimizing, or preventing leaching of a fire retardant component of the fire retardant resin product from the solid wood product.

5. The method of Claim 1, wherein directing the fire retardant resin product into the interior chamber comprises directing a combination of: about 8% total product weight of the phosphorous or nitrogen compound; about 8% total product weight of cyanoguanidine; about 10% total product weight of the urea formaldehyde resin; and about 74% total product weight of water, into the interior chamber.

6. The method of Claim 1, comprising, before directing a fire retardant resin product into the interior chamber: directing a liquid, copper-containing wood preservative into the interior chamber after discontinuing the fnst vacuum application; applying a second positive pressure to the interior chamber having the solid wood product and the wood preservative therein to direct the wood preservative into the solid wood product; and applying a third vacuum to the interior chamber after discontinuing the second positive pressure and removing any excess wood preservative therefrom.

7. The method of Claim 1, comprising forming slits in the solid wood product prior to directing the solid wood product into the interior chamber.

8. The method of Claim 1, wherein applying the first positive pressure comprises applying a positive pressure cycle to the interior chamber having the solid wood product and the fire retardant resin product therein, the positive pressure cycle oscillating between a pressure minimum and a pressure maximum, the fnst positive pressure being the pressure maximum of the positive pressure cycle, to direct the fire retardant resin product into the solid wood product.

9. The method of Claim 1, comprising forming the fire retardant resin product, prior to directing the fire retardant resin product into the interior chamber, by: adding between about 4% and about 12% total product weight of a phosphorous or nitrogen compound to between about 70% and about 78% total product weight of water to form a first mixture, while agitating the first mixture; adding between about 4% and about 12% total product weight of cyanoguanidine to the first mixture to form a second mixture, while agitating the second mixture and dissolving the cyanoguanidine; and adding between about 6% and about 14% total product weight of a urea formaldehyde resin to the second mixture to form the fire retardant resin product, while agitating the fne retardant resin product.

10. The method of Claim 9, wherein adding the phosphorous or nitrogen compound comprises adding about 8% total product weight of the phosphorous or nitrogen compound to about 74% total product weight of water.

11. The method of Claim 9, wherein adding the phosphorous or nitrogen compound comprises adding between about 4% and about 12% total product weight of an 85% phosphoric acid solution.

12. The method of Claim 9, wherein adding cyanoguanidine comprises adding about 10% total product weight of cyanoguanidine.

13. The method of Claim 9, wherein dissolving the cyanoguanidine comprises heating the second mixture at a temperature of greater than about 45 °C until the cyanoguanidine is dissolved and the second mixture is a clear solution.

14. The method of Claim 9, wherein dissolving the cyanoguanidine comprises agitating the second mixture at room temperature using a high shear mixer device.

15. The method of Claim 9, wherein adding the urea formaldehyde resin comprises adding about 10% total product weight of the urea formaldehyde resin.

16. The method of Claim 9, wherein adding the urea formaldehyde resin comprises adding a melamine urea formaldehyde resin.

17. The method of Claim 16, comprising varying a melamine content to change a material characteristic of the melamine urea formaldehyde resin.

18. The method of Claim 9, comprising varying a formaldehyde to urea ratio of the urea formaldehyde resin, or varying a % solids content within the urea formaldehyde resin, to change a material characteristic of the urea formaldehyde resin.

Description:
METHOD OF FORMING A FIRE RETARDANT SOEID WOOD PRODUCT

BACKGROUND

Field of the Disclosure

Aspects of the present disclosure are directed to method of forming a fire retardant solid wood product by pressure treating the solid wood product with a fire retardant product including a resin component.

Description of Related Art

In some instances, it may be desirable to have certain solid wood products, such as those used as building materials (e.g., timber, lumber, plywood, etc.), exhibit fire retardant or fire resistant properties. However, a fire retardant treatment of a solid wood product is often a surface treatment with a fire retardant that may have limited penetration into the product. It may be even less likely for such a fire retardant surface treatment to achieve penetration into the product at the cellular level. Accordingly, such fire retardant surface treatment of solid wood products may have limited efficacy, particularly if the integrity of the treated surface layer of the solid wood product is compromised. Moreover, solid wood products receiving such a fire retardant surface treatment may be prone to having the fire retardant component(s) of the surface treatment leach out of the solid wood product, which may also adversely affect the efficacy of the fire retardant treatment.

Thus, there exists a need for an improved method of forming a fire retardant solid wood product, as well as a fire retardant substance capable of imparting a fire retardant characteristic to a solid wood product, while alleviating possible shortcomings such as limited efficacy and/or leaching, associated with fire retardant surface treatments for solid wood products.

SUMMARY OF THE DISCFOSURE

The above and other needs are met by aspects of the present disclosure which includes, without limitation, the following example embodiments and, in one particular aspect, provides a method of forming a fire retardant solid wood product. Such a method comprises applying a first vacuum to an interior chamber of a pressure vessel having the solid wood product therein, and then directing a fire retardant resin product into the interior chamber after discontinuing the first vacuum application. The fire retardant resin product is a liquid comprising between about 4% and about 12% total product weight of a phosphorous or nitrogen compound, between about 4% and about 12% total product weight of cyanoguanidine, between about 6% and about 14% total product weight of a urea formaldehyde resin, and between about 70% and about 78% total product weight of water. A first positive pressure is then applied to the interior chamber having the solid wood product and the fire retardant resin product therein to direct the fire retardant resin product into the solid wood product.

The present disclosure thus includes, without limitation, the following example embodiments: Example Embodiment 1: A method of forming a fire retardant solid wood product, comprising applying a first vacuum to an interior chamber of a pressure vessel having the solid wood product therein; directing a fire retardant resin product into the interior chamber after discontinuing the first vacuum application, the fire retardant resin product being a liquid comprising between about 4% and about 12% total product weight of a phosphorous or nitrogen compound; between about 4% and about 12% total product weight of cyanoguanidine; between about 6% and about 14% total product weight of a urea formaldehyde resin; and between about 70% and about 78% total product weight of water; and applying a fust positive pressure to the interior chamber having the solid wood product and the fire retardant resin product therein to direct the fire retardant resin product into the solid wood product.

Example Embodiment 2: The method of any preceding example embodiment, or combinations thereof, comprising applying a second vacuum to the interior chamber after discontinuing the fust positive pressure and removing any excess fire retardant resin product therefrom.

Example Embodiment 3: The method of any preceding example embodiment, or combinations thereof, comprising, after discontinuing the first positive pressure, heating the interior chamber having the solid wood product therein to above an ambient temperature for a selected time period to cure the fire retardant resin product directed into the solid wood product, the cured fire retardant resin product reducing, minimizing, or preventing leaching of a fire retardant component of the fire retardant resin product from the solid wood product.

Example Embodiment 4: The method of any preceding example embodiment, or combinations thereof, comprising, after discontinuing the first positive pressure, heating the interior chamber having the solid wood product therein to a temperature of about 70°C or above for a time period of at least 10 hours to cure the fire retardant resin product directed into the solid wood product, the cured fire retardant resin product reducing, minimizing, or preventing leaching of a fire retardant component of the fire retardant resin product from the solid wood product.

Example Embodiment 5: The method of any preceding example embodiment, or combinations thereof, wherein directing the fire retardant resin product into the interior chamber comprises directing a combination of about 8% total product weight of the phosphorous or nitrogen compound; about 8% total product weight of cyanoguanidine; about 10% total product weight of the urea formaldehyde resin; and about 74% total product weight of water, into the interior chamber.

Example Embodiment 6: The method of any preceding example embodiment, or combinations thereof, comprising, before directing a fire retardant resin product into the interior chamber, directing a liquid, copper-containing wood preservative into the interior chamber after discontinuing the first vacuum application; applying a second positive pressure to the interior chamber having the solid wood product and the wood preservative therein to direct the wood preservative into the solid wood product; and applying a third vacuum to the interior chamber after discontinuing the second positive pressure and removing any excess wood preservative therefrom.

Example Embodiment 7: The method of any preceding example embodiment, or combinations thereof, comprising forming slits in the solid wood product prior to directing the solid wood product into the interior chamber.

Example Embodiment 8: The method of any preceding example embodiment, or combinations thereof, wherein applying the first positive pressure comprises applying a positive pressure cycle to the interior chamber having the solid wood product and the fire retardant resin product therein, the positive pressure cycle oscillating between a pressure minimum and a pressure maximum, the first positive pressure being the pressure maximum of the positive pressure cycle, to direct the fire retardant resin product into the solid wood product.

Example Embodiment 9: The method of any preceding example embodiment, or combinations thereof, comprising forming the fire retardant resin product, prior to directing the fire retardant resin product into the interior chamber, by adding between about 4% and about 12% total product weight of a phosphorous or nitrogen compound to between about 70% and about 78% total product weight of water to form a fust mixture, while agitating the first mixture; adding between about 4% and about 12% total product weight of cyanoguanidine to the first mixture to form a second mixture, while agitating the second mixture and dissolving the cyanoguanidine; and adding between about 6% and about 14% total product weight of a urea formaldehyde resin to the second mixture to form the fire retardant resin product, while agitating the lire retardant resin product.

Example Embodiment 10: The method of any preceding example embodiment, or combinations thereof, wherein adding the phosphorous or nitrogen compound comprises adding about 8% total product weight of the phosphorous or nitrogen compound to about 74% total product weight of water.

Example Embodiment 11: The method of any preceding example embodiment, or combinations thereof, wherein adding the phosphorous or nitrogen compound comprises adding between about 4% and about 12% total product weight of an 85% phosphoric acid solution.

Example Embodiment 12: The method of any preceding example embodiment, or combinations thereof, wherein adding cyanoguanidine comprises adding about 10% total product weight of cyanoguanidine.

Example Embodiment 13: The method of any preceding example embodiment, or combinations thereof, wherein dissolving the cyanoguanidine comprises heating the second mixture at a temperature of greater than about 45 °C until the cyanoguanidine is dissolved and the second mixture is a clear solution.

Example Embodiment 14: The method of any preceding example embodiment, or combinations thereof, wherein dissolving the cyanoguanidine comprises agitating the second mixture at room temperature using a high shear mixer device. Example Embodiment 15: The method of any preceding example embodiment, or combinations thereof, wherein adding the urea formaldehyde resin comprises adding about 10% total product weight of the urea formaldehyde resin.

Example Embodiment 16: The method of any preceding example embodiment, or combinations thereof, wherein adding the urea formaldehyde resin comprises adding a melamine urea formaldehyde resin.

Example Embodiment 17: The method of any preceding example embodiment, or combinations thereof, comprising varying a melamine content to change a material characteristic of the melamine urea formaldehyde resin.

Example Embodiment 18: The method of any preceding example embodiment, or combinations thereof, comprising varying a formaldehyde to urea ratio of the urea formaldehyde resin, or varying a % solids content within the urea formaldehyde resin, to change a material characteristic of the urea formaldehyde resin.

These and other features, aspects, and advantages of the present disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined or otherwise recited in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosure, in any of its aspects and embodiments, should be viewed as intended, namely to be combinable, unless the context of the disclosure clearly dictates otherwise.

It will be appreciated that the summary herein is provided merely for purposes of summarizing some example aspects so as to provide a basic understanding of the disclosure. As such, it will be appreciated that the above described example aspects are merely examples and should not be construed to narrow the scope or spirit of the disclosure in any way. It will be appreciated that the scope of the disclosure encompasses many potential aspects, some of which will be further described below, in addition to those herein summarized. Further, other aspects and advantages of such aspects disclosed herein will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described aspects.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 schematically illustrates a pressure vessel implemented in a pressure treatment process for wood products, with certain wood products disposed in the interior chamber thereof and air being evacuated from the interior chamber by an applied vacuum; FIG. 2 schematically illustrates a fire retardant resin product being directed into a solid wood product by the application of a positive pressure to the interior chamber of the pressure vessel having the solid wood product and the fire retardant resin product therein, according to one aspect of the present disclosure;

FIG. 3 schematically illustrates the evacuation of the interior chamber of the pressure vessel following the pressure treatment of the solid wood product;

FIG. 4 schematically illustrates a flowchart associated with a method for forming a fire retardant resin product, according to one aspect of the present disclosure; and

FIG. 5 schematically illustrates a flowchart associated a process for forming a fire retardant solid wood product using the fire retardant resin product, according to one aspect of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all aspects of the disclosure are shown. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

Aspects of the present disclosure are directed to a method or process for forming a fire- resistant solid wood product which, in one aspect, is performed with a pressure treatment system for wood products, generally indicated by element 100 in FIG. 1. In one example pressure treatment process for the preservation of solid wood (e.g., timber, lumber, plywood), is the so-called “full-ceH” or Bethell process. In such a process, the solid wood product 200 to be treated is loaded on tram cars, which are run into the interior chamber 400 of a large steel cylinder or pressure vessel 300. After the cylinder door is closed and bolted, a wood treatment material or substance is admitted into the pressure vessel 300 and a positive pressure is applied to the interior chamber 400 of the pressure vessel 300 until the required absorption of the wood treatment material into the wood product 200 has been obtained/achieved.

That is, in one aspect, the method comprises applying a first vacuum to an interior chamber 400 of a pressure vessel 300 having the solid wood product 200 therein (Block 400 in FIG. 4), for example, to remove as much air as practicable from the wood cells of the solid wood product 200. A fire retardant resin product 450 (see, e.g., FIG. 2) is then directed into the interior chamber 400 after discontinuing the first vacuum application (Block 440 in FIG. 4), in particular instances without admitting air back into the interior chamber 400. According to particular aspects of the present disclosure, and as addressed further herein, the fire retardant resin product is a liquid comprising between about 4% and about 12% total product weight of a phosphorous or nitrogen compound, between about 4% and about 12% total product weight of cyanoguanidine, between about 6% and about 14% total product weight of a urea formaldehyde resin, and between about 70% and about 78% total product weight of water. In some aspects of the present disclosure, the fire retardant resin product 450 directed into the interior chamber 400 comprises a combination of about 8% total product weight of the phosphorous or nitrogen compound, about 8% total product weight of cyanoguanidine, about 10% total product weight of the urea formaldehyde resin, and about 74% total product weight of water.

After the interior chamber 400 of the pressure vessel 300 is filled with the fire retardant resin product 450, a positive pressure is applied to the interior chamber 400 having the solid wood product 200 and the fire retardant resin product 450 therein, to direct the fire retardant resin product 450 into the solid wood product 200 (Block 480 in FIG. 4), until the required absorption of the fire retardant resin product 450 is obtained/attained (see, e.g., FIG. 2). FIG. 2 further schematically illustrates the progression of the absorption of the fire retardant resin product (see, e.g., element 250 A) over a cross- section of the solid wood product 200 in response to the applied positive pressure, in contrast to the portion of the cross-section that has not yet absorbed the fire retardant resin product (see, e.g., element 250B).

In some aspects, the method comprises applying a second vacuum to the interior chamber 400, after discontinuing the first positive pressure and removing any excess fire retardant resin product 450 from the interior chamber 400 (see, e.g., FIG. 3), for example to remove any excess amounts of the fire retardant resin product 450 (e.g., pools or droplets thereof) remaining on the treated solid wood product 200.

Moreover, in some particular instances, after discontinuing the first positive pressure, the method includes heating the interior chamber 400 having the treated solid wood product 200 therein, to above an ambient temperature and for a selected time period, in order to cure or at least partially cure the fire retardant resin product 450 directed into and remaining in the treated solid wood product 200. The cured fire retardant resin product may, in some instances, reduce, minimize, or prevent leaching of one or more fire retardant components of the fire retardant resin product from the treated solid wood product 200. In one particular aspect, after discontinuing the first positive pressure, the interior chamber 400 having the treated solid wood product 200 therein is heated to a temperature of about 70°C or above for a time period of at least 10 hours to cure the fire retardant resin product in the solid wood product. One skilled in the art will appreciate, however, that the curing process implementing heat and time can be varied as necessary or desired to achieve suitable curing of the fire retardant resin product. For example, a relatively higher curing temperature may require less time to cure the fire retardant resin product, while a relatively lower curing temperature may require more time to cure the fire retardant resin product.

In some aspects, before directing the fire retardant resin product into the interior chamber 400 as in the disclosed process to treat the solid wood product 200, the solid wood product 200 can first be treated with conventional preservative materials or substances such as, for example, a liquid, copper- containing wood preservative (e.g., ACQ, or alkaline copper quat; ACC or acid copper chromate;

CC or ammoniacal copper citrate; and CBA or CA-B copper azole are arsenic-free wood treatments). Such a process involves, for example, directing a liquid, copper-containing wood preservative into the interior chamber after discontinuing the first vacuum application; applying a second positive pressure to the interior chamber having the solid wood product and the wood preservative therein to direct the wood preservative into the solid wood product; and applying a third vacuum to the interior chamber after discontinuing the second positive pressure and removing any excess wood preservative therefrom. Following application of the third vacuum to the interior chamber 400, the interior chamber can then be fdled with the fire retardant resin product, as otherwise disclosed herein, to infuse the fire retardant resin product into the solid wood product 200. In this manner, the fire retardant resin product, once cured, can serve to contain the wood preservative within the interior of the solid wood product, and therefore also reduce, minimize, or prevent leaching of one or more components (e.g., copper) of the wood preservative from the solid wood product.

In some aspects, the pressure treatment process can be modified as necessary or desired in order, for example, to enhance the absorption of the wood preservative and/or the fire retardant resin product by the solid wood product 200. For example, in one aspect, one or more slits are formed in the solid wood product (e.g., in any external surface thereof) prior to directing the solid wood product 200 into the interior chamber 400. In other instances, the first positive pressure applied in connection with the fire retardant resin product in the interior chamber and or the second positive pressure applied in connection with the optional wood preservative in the interior chamber can be a pulsed or cycled pressure application, with the first and/or second positive pressure being the maximum positive pressure applied in the pulse or cycle. For example, in the case of the first positive pressure applied in connection with the fire retardant resin product in the interior chamber, a positive pressure cycle applied to the interior chamber can oscillate between a pressure minimum (equal to or greater than ambient pressure) and a pressure maximum, with the first positive pressure being the pressure maximum of the positive pressure cycle.

FIG. 5 schematically illustrates a flowchart associated with a method or step for forming a fire retardant resin product, according to one aspect of the present disclosure, which can be an additional step in the disclosed method of forming a fire retardant solid wood product as disclosed herein. Such a method or step of forming a fire retardant resin product comprises, for example, adding between about 4% and about 12% total product weight of a phosphorous or nitrogen compound to between about 70% and about 78% total product weight of water to form a first mixture, while agitating the first mixture (Block 500). In some aspects, the phosphorous compound or nitrogen compound comprises, for example, phosphoric acid and, in particular instances, an 85% phosphoric acid solution. In particular aspects, about 8% total product weight of a phosphorous or nitrogen compound, such as an 85% phosphoric acid solution, is added to about 74% total product weight of water. During the addition of the phosphorous or nitrogen compound to the water in a stirring apparatus (e.g., an overhead stirrer such as an IKA Nanostar 7.5 stirrer equipped with a 4-bladed propeller as the stirrer), the mixture is stirred and mixed for about 10 minutes, with the stirring apparatus being operated at about 400 rpm.

Subsequently, between about 4% and about 12% total product weight of cyanoguanidine to the first mixture to form a second mixture, while agitating the second mixture and dissolving the cyanoguanidine (Block 540). Cyanoguanidine may otherwise be referred to herein or known, for example, as dicyandiamide, dicyanodiamide, or 1 -cyanoguanidine. In one particular aspect, about 10% total product weight of the cyanoguanidine is added to the first mixture to form the second mixture. In addition, the cyanoguanidine is gradually added to the first mixture, which continues to be stirred/agitated. In order to dissolve the cyanoguanidine, the second mixture can be heated at an elevated temperature (e.g., >45°C) until the cyanoguanidine is fully dissolved (e.g., 1-2 hrs). In another manner, the second mixture can be processed at ambient temperature (e.g., room temperature) using a high shear mixing device (e.g., mixer or stirrer) for, e.g., 18-24 hrs at 500 rpm). In either instance, the cyanoguanidine will substantially completely dissolve and result in the second mixture being a clear solution.

Following preparation of the second mixture, between about 6% and about 14% total product weight of a urea formaldehyde resin is added to the second mixture to form the fire retardant resin product, again while agitating the combined urea formaldehyde resin and second mixture (e.g., the fire retardant resin product) during the combination (Block 580). In particular aspects, adding the urea formaldehyde resin comprises adding about 10% total product weight of the urea formaldehyde resin to the second mixture. The urea formaldehyde resin comprises, for example, a melamine urea formaldehyde resin.

In some aspects, the composition of the melamine urea formaldehyde resin is proportional to the material properties exhibited by the resin. As such, in some instances, the melamine content of the resin can be varied to change a material characteristic of the melamine urea formaldehyde resin.

In other instances, a formaldehyde to urea ratio of the urea formaldehyde resin can be varied, or a % solids content within the urea formaldehyde resin can be varied, to change a material characteristic of the urea formaldehyde resin.

EXAMPLE:

1. To prepare 1000 gr of the fire retardant resin product, 80 gr of phosphoric acid (85%) is added to 740 gr of water during stirring, and the mixture is mixed for 10 min at 400 rpm;

2. 80 gr of solid cyanoguanidine is gradually added to the mixture during stirring. There are two ways to dissolve the cyanoguanidine: 1) Heat the mixture at >45°C until the cyanoguanidine is fully dissolved (1-2 hr); or 2) Process the mixture at room temperature using a high shear mixer for 18-24 hr at 500rpm. In either case, the cyanoguanidine is dissolved in the mixture and the result is the mixture in the form of a clear solution. 3. 100 gr of MUF resin is gradually added to the mixture during stirring and further mixed for

15 min at 300 rpm to achieve the final fire retardant resin product.

In some aspects, the resulting fire retardant resin product comprises between about 4% and about 12% total product weight of a phosphorous or nitrogen compound; between about 4% and about 12% total product weight of cyanoguanidine; between about 6% and about 14% total product weight of a urea formaldehyde resin; and between about 70% and about 78% total product weight of water.

In particular aspects, the fire retardant resin product comprises about 8% total product weight of the phosphorous or nitrogen compound; about 8% total product weight of cyanoguanidine; about 10% total product weight of the urea formaldehyde resin; and about 74% total product weight of water. As disclosed, the phosphorous compound or nitrogen compound comprises, for example, an 85% phosphoric acid solution, and the urea formaldehyde resin comprises, for example, a melamine urea formaldehyde resin.

The final fire retardant resin product exhibits, for example, is a relatively low pH (e.g., pH 1.6-1.8 after blending). In addition, this liquid may exhibit some changes over time. For example, as the MUF resin ages, colloidal particles may be formed, followed by clustering of those colloidal particles. As such, over time, the MUF resin components may change from a clear liquid to a colloidal dispersion, wherein the colloidal particles of the MUF resin remain relatively evenly distributed in the final composition, without significant settling out. In addition, over time, the dicyandiamide (cyanoguanidine) may slowly react, separately, with the phosphoric acid and the components of the MUF resin, which may be manifest in a slow increase of the pH value of the final composition (e.g., after 6 months of storage the pH may be >3.5). In some instances, the colloidal particles/clusters may settle, though the composition can be re-homogenized by agitation (e.g., shaking the container) following extended storage. These factors indicate that the resin product forms a mixture having lower risk of premature curing (e.g., the fire retardant component does not act as a catalyst for the urea formaldehyde resin), as well as a lower risk of the fire retardant component reacting with free formaldehyde from the urea formaldehyde resin.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these disclosed embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that embodiments of the invention are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the invention. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and/or functions, it should be appreciated that different combinations of elements and or functions may be provided by alternative embodiments without departing from the scope of the disclosure. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated within the scope of the disclosure. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

It should be understood that although the terms first, second, etc. may be used herein to describe various steps or calculations, these steps or calculations should not be limited by these terms. These terms are only used to distinguish one operation or calculation from another. For example, a first calculation may be termed a second calculation, and, similarly, a second step may be termed a first step, without departing from the scope of this disclosure. As used herein, the term “and/or” and the “/” symbol includes any and all combinations of one or more of the associated listed items.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms

“comprises”, “comprising”, “includes”, and/or “including”, when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and or groups thereof. Therefore, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.