Description:

FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10; rule 13)

1. TITLE OF THE INVENTION– A FIRE RETARDING COMPOSITION AND PREPARATION METHOD THEREOF
2. Applicant(s)
NAME: NIPPONPLY INDUSTRIES PVT LTD
NATIONALITY: INDIAN
ADDRESS: B-101, WESTGATE , Nr. YMCA CLUB, S.G.HIGHWAY AHEMDABAD – 380015 GUJARAT
3. PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed.

 
The said application is improvement and modification of earlier filed patent application no 202121010451 dated 12 March 2021.

A FIRE RETARDING COMPOSITION AND PREPARATION METHOD THEREOF

FIELD OF INVENTION
The present invention relates to an environmental protection fire retarding composition for furniture. More particularly, the present invention relates to a fire retarding composition comprising of UV-curable oligomer, UV curable flame retardants, photo initiators and one or more excipients. The present invention relates to a fire retarding composition for passive fire protection and the preparation method thereof.

BACKGROUND OF THE INVENTION
At present, along with people's growth in the living standard, to the also enhancing day by day of demand of wood furniture and decoration, but the frequent generation of fire incident has been caused very big harm for people's lives and properties and living environment, and the protection of environment has brought certain influence.

Wood can be used to construct almost any part of a home from the roofing and exterior walls to the floor and interior architectural elements as well as basic domestic items like furniture and cabinets. However, in recent years the cost of solid timber wood has increased dramatically as its supply shrinks due to the gradual depletion of old-growth and virgin forests. Indeed, it is particularly expensive to manufacture solid hardwood furniture and architectural features from such material because typically less than half of the harvested timber wood is converted to natural solid wood lumber, the remainder being discarded as scrap.

Wood-based panels are made of agroforestry wood or other non-wood plants, which are separated into various unit materials by certain mechanical processing, with or without the application of adhesives and other additives. It mainly includes three types of products, such as plywood, shavings (slack) and fiberboard. Wood products, especially wood products used in the building construction industry, are commonly treated with chemical fire retardants that reduce the inherent ability of the wood to catch fire and combust. However, the inherent flammability of the wood restricts its use in high fire-risk situations. The best method for imparting flame retardancy to wood is by application of a coating containing flame retardants (FRs) onto the wood substrate.

FR is a simple molecule or polymer with self-extinguishable characteristics. The FRs can be included in the coating either by physical mixing (additive FRs) or by being covalently bonded to the coating matrix (reactive FRs). Owing to their non-leaching behaviour, reactive FRs are preferable to additive FRs in fire protection coatings because the latter leach off as the coating ages. FRs are classified as halogenated, phosphorus-based, nitrogen-based, boron-based, silicon-based biochar-based, and metal oxide-based FRs depending on their elemental makeup. Halogenated FRs are known to be among the finest FRs that may be employed in a wide range of polymers. These halogenated FRs, however, have been fraught with regulatory scrutiny due to their carcinogenicity, predisposition to produce persistent organic pollutants, and tendency to bio-accumulate that poses health-hazard. As a result, of late, the demand to design and develop economically viable non-halogenated reactive FRs as an alternative to their halogenated counterparts has piqued the interest of material chemists.

U.S. Pat 2002168476A1, a kind of fire retardant that provides comprises phosphoric acid guanidine radicals’ urea, phosphoric acid and boric acid, and the material that is primarily aimed at has timber and composite wood product and method of manufacture and use thereof.

As the wood and the materials are of big harm for fire incidents and are of big harm for people’s lives and the living environment. The decorative wood panels of the parent application are improved to make them fire resistant. Thus, there is a constant need to develop various alternatives or solutions to overcome the problems of wood fire.

OBJECTIVE OF THE INVENTION
The principle object of the present invention is to overcome the problem of wood of catching fire to avoid fire accidents.

The main object of the present invention is to provide a fire retarding composition for furniture, wooden flooring, and panels, furniture components used for interior & exterior decoration for passive fire protection a) to contain a fire to the compartment of fire origin, b) slow a fire from spreading from the compartment of fire origin, c) slow the heating of structural members, d) prevent the spread of fire through intentional openings i.e. door, ducts.

Another object of the present invention is to provide a fire retarding composition that is eco-friendly (Green product), sustainable and prevent surface from moisture penetration (mildew), which increase lifecycle of furniture.

Another object of the present invention is to provide a fire retarding composition that is non-toxic and maintenance free from stains, water, oil, cleaning chemicals.
Another object of the present invention is to provide a fire retarding composition that is applicable on the wood substrate to mitigate the risk of fire due to short circuit, cigarette butt, and spillage of flammable liquid on surface.

Another object of the present invention is to provide a fire retarding composition that is economically friendly, budget friendly and import substitute. This will enable us to export being complying flame retardant norms.

Another object of the present invention is to provide a fire retarding composition that retain natural beauty of decorative surface with anti-fingerprint & anti-bacterial properties.

SUMMARY OF THE INVENTION
The main aspect of the present invention is to provide a fire retarding composition for passive fire protection, for furniture.

Another aspect of the present invention is to provide a fire retarding composition for furniture that comprises a UV-curable oligomer, UV curable flame retardants, photo initiators and one or more excipients.

Another aspect of the present invention is to provide a fire retarding composition for furniture and the process for preparing the same.

DESCRIPTION OF THE INVENTION
The detailed description set forth below is intended as a description of exemplary embodiments and is not intended to represent the only forms in which the exemplary embodiments may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and/or operating the exemplary embodiments. However, it is to be understood that the same or equivalent functions and sequences which may be accomplished by different exemplary methods are also intended to be encompassed within the spirit and scope of the invention.

As defined herein, all scientific and technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs.

Although any process and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described.

As stated in the present invention herein, the singular forms “a,” “an” and “the” specifically also encompass the plural forms of the terms to which they refer, unless the content clearly dictates otherwise. The term “about” is used herein to means approximately, in the region of, roughly, or around.

As stated herein, that it follows in a transitional phrase or in the body of a claim, the terms “comprise(s)” and “comprising” are to be interpreted as having an open ended meaning. That is, the terms are to be interpreted synonymously with the phrases “having at least” or “including at least”. When used in the context of a process, the term “comprising” means that the process includes at least the recited steps, but may include additional steps. When used in the context of a composition, the term “comprising” means that the composition includes at least the recited features or components, but may also include additional features or components.

The main embodiment of the present invention is to a fire retarding composition for furniture.
Another embodiment of the present invention is to provide a fire retarding composition for furniture, panels, wooden flooring, furniture components wherein the said composition comprises a UV-curable oligomer, UV curable flame retardants, photo initiators and one or more excipients.

According to another embodiment, the said UV-curable oligomer comprises a combination of acrylate monomers, acrylate oligomer, talc and photo initiators.

According to another embodiment, the said UV flame retardants comprises a combination of acrylate monomers, acrylate oligomer, talc, fused silica and photo initiators.

According to another embodiment, the said acrylate monomer is selected from butyl acrylate, 1,6-hexanediol diacrylate (HDDA), Tripropylene glycol diacrylate (TPGDA) and Trimethylolpropane triacrylate (TMPTA), more preferably butyl acrylate.

According to another embodiment, the said acrylate monomer used is in the range of 1 to 100%, more preferably 5 to 50% and most preferably 10 to 30%.

According to another embodiment, the said acrylate oligomer is selected from hydroxypropyl methacrylate, urethane acrylate, Polyester acrylate and epoxy acrylate resins, more preferably hydroxypropyl methacrylate.

According to another embodiment, the said acrylate oligomer used is in the range of 10 to 150%, more preferably 25 to 100% and most preferably 35 to 60%.

According to another embodiment, the said photo initiators are selected from benzophenone, camphorquinone, bisacylphosphine oxide, 1-phenyl-1,2-propanedione and benzoyl peroxide, more preferably benzophenone.

According to another embodiment, the said photo initiators is used in the range of 0.1 to 20%, more preferably 0.5 to 15% and most preferably 1 to 12%.

According to another embodiment, the said fillers can be selected from calcium carbonate, barium sulphate, calcium sulphate, talc, zinc oxide and aluminium trihydroxide, more preferably talc.

According to another embodiment, the said talc is used in the range of 1 to 100%, more preferably 5 to 50% and most preferably 7 to 30%.

According to another embodiment, the said fused silica is used in the range of 0.1 to 20%, more preferably 0.5 to 15% and most preferably 1 to 12%.

According to another embodiment the said composition is coated on wood substrates.

According to another embodiment the said composition is coated on flat panel objects like building components, furniture and flat wood panels, wooden flooring, irregular furniture, decorative objects and three-dimensional wood articles.

According to another embodiment the process of preparing the fire retarding composition comprises the following steps:
a) Applying UV-curable oligomer coat comprising of acrylate monomers, acrylate oligomer, talc and photo initiators.
b) Applying another coat over the coat of step (a), that comprises of UV flame retardants comprises of acrylate monomers, acrylate oligomer, talc, fused silica and photo initiators.
c) Applying the third coat of dead matt, gloss or high gloss coat on the coat of step (b) to obtain the required finish.

According to another embodiment the said composition is coated in layers, wherein the said layers are base coat, top coat matt and top coat gloss.

According to another embodiment the preferred coating method is selected from spray coating, roller coatings and curtain coatings.

According to another embodiment the preferred coating material is stain, chemical, water and solvent & UV curable oligomers.

The invention is further illustrated by the following examples which are provided to be exemplary of the invention and do not limit the scope of the invention. While the present invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the present invention.

EXAMPLES
EXAMPLE 1: FINAL COMPOSITION OF UV-CURABLE OLIGOMERS:
The said UV-curable oligomers (base coat) comprises of the following composition:
Sr. No. Ingredients Amount
1. Butyl acrylate 22%
2. Hydroxypropyl methacrylate 55%
3. Benzophenone 3%
4. Talc 20%
Table 1: Final composition of the first layer coating material
EXAMPLE 2: FINAL COMPOSITION OF UV-CURABLE FLAME RETARDANTS
The said UV-curable oligomers (top coat matt) comprises of the following composition:
Sr. No. Ingredients Amount
1. Butyl acrylate 25%
2. Hydroxypropyl methacrylate 45%
3. Benzophenone 10%
4. Talc 10%
5. Fused silica 10%
Table 2: Final composition of the second layer coating material

EXAMPLE 3: FINAL COMPOSITION OF TOP COAT GLOSS:
The UV antiscratch top coat gloss comprises the following final composition:
Sr. No. Ingredients Amount
1. Butyl acrylate 32%
2. Hydroxypropyl methacrylate 48%
3. Benzophenone 10%
4. Fused silica 10%
Table 3: Final composition of the top coat gloss coating material

EXAMPLE 4: PROCESS FOR APPLYING THE FLAME RETARDING COMPOSITION
The process of applying the flame retarding composition on the surface comprises the following steps:
a) Applying UV-curable oligomer coat comprising of acrylate monomers, acrylate oligomer, talc and photo initiators.
b) Applying another coat over the coat of step (a), that comprises of UV flame retardants comprises of acrylate monomers, acrylate oligomer, talc, fused silica and photo initiators.
c) Applying the third coat of dead matt, gloss or high gloss coat on the coat of step (b) to obtain the required finish.

Thus, the final composition of the flame retarding composition is applicable on the wood substrate to mitigate the risk of fire due to short circuit, cigarette butt, spillage of flammable liquid on surface. The composition is non-toxic and maintenance free from stains, water, oil, cleaning chemicals. Also, the composition is economically friendly, budget friendly and import substitute. This will enable us to export being complying flame retardant norms.
, Claims:CLAIMS
We claim,
1. A fire retarding composition, wherein the said composition comprises a UV-curable oligomer, UV curable flame retardants, photo initiators and one or more excipients.
2. The fire retarding composition as claimed in claim 1, wherein said UV-curable oligomer comprises a combination of acrylate monomers, acrylate oligomer, talc and photo initiators.
3. The fire retarding composition as claimed in claim 1, wherein said UV flame retardants comprises a combination of acrylate monomers, acrylate oligomer, talc, fused silica and photo initiators.
4. The fire retarding composition as claimed in claim 1, wherein said acrylate monomer is selected from butyl acrylate, 1,6-hexanediol diacrylate (HDDA), Tripropylene glycol diacrylate (TPGDA) and Trimethylolpropane triacrylate (TMPTA).
5. The fire retarding composition as claimed in claim 1, wherein said acrylate monomer used is in the range of 1 to 100%, more preferably 5 to 50% and most preferably 10 to 30%.
6. The fire retarding composition as claimed in claim 1, wherein said acrylate oligomer is selected from hydroxypropyl methacrylate, urethane acrylate, Polyester acrylate and epoxy acrylate resins.
7. The fire retarding composition as claimed in claim 1, wherein said acrylate oligomer is used in the range of 10 to 150%, more preferably 25 to 100% and most preferably 35 to 60%.
8. The fire retarding composition as claimed in claim 1, wherein the said photo initiators are selected from benzophenone, camphorquinone, bisacylphosphine oxide, 1-phenyl-1,2-propanedione and benzoyl peroxide.
9. The fire retarding composition as claimed in claim 1, wherein the said photo initiators is used in the range of 0.1 to 20%, more preferably 0.5 to 15% and most preferably 1 to 12%.
10. The fire retarding composition as claimed in claim 1, wherein the fillers can be selected from calcium carbonate, barium sulphate, calcium sulphate, talc, zinc oxide and aluminium trihydroxide.
11. The fire retarding composition as claimed in claim 1, wherein talc used in the range of 1 to 100%, more preferably 5 to 50% and most preferably 7 to 30%.
12. The fire retarding composition as claimed in claim 1, wherein said fused silica is used in the range of 0.1 to 20%, more preferably 0.5 to 15% and most preferably 1 to 12%.
13. The fire retarding composition as claimed in claim 1, wherein the said composition is coated in layers, wherein the said layers are stain coat, base coat, top coat matt or top coat gloss.
14. The fire retarding composition as claimed in claim 1, wherein the process of preparing the composition comprises following steps:
a) Applying UV-curable oligomer coat comprising of acrylate monomers, acrylate oligomer, talc and photo initiators.
b) Applying another coat over the coat of step (a), that comprises of UV flame retardants comprises of acrylate monomers, acrylate oligomer, talc, fused silica and photo initiators.
c) Applying the third coat of dead matt, gloss or high gloss coat on the coat of step (b) to obtain the required finish.

Dated this 14th Feb, 2025