In-situ foaming system for forming flame-retardant polyurethane foam in situ

Patent metadata

Field	Value
Publication number	US-10280275-B2
Application number	US-201515029797-A
Country	US
Kind code	B2
Filing date	Feb 27, 2015
Priority date	Feb 27, 2014
Publication date	May 7, 2019
Grant date	May 7, 2019

Abstract

An in-situ foaming system for forming a flame-retardant polyurethane foam in situ comprising a first liquid containing a polyisocyanate (A), a second liquid containing a polyol (B), a trimerization catalyst (C), a foaming agent (D), a foam stabilizer (E), and additives (F) comprising red phosphorus and at least one member selected from the group consisting of phosphoric acid esters, phosphate-containing flame retardants, bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, and metal hydroxides.

First claim

The invention claimed is:

1. The flame-retardant polyurethane foam being formed from a flame-retardant polyurethane resin composition comprising:
a polyisocyanate (A),
a polyol (B),
a trimerization catalyst (C),
a foaming agent (D),
a foam stabilizer (E), and
additives (F),
wherein the additives (F) comprise red phosphorus, phosphoric acid esters, and at least one member selected from the group consisting of bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, metal hydroxides and needle-shaped fillers, and
wherein the gross calorific value measured with heating a sample of the polyurethane foam at a radiant heat intensity of 50 kW/m 2 for 10 minutes for a cone calorimeter test based on ISO-5660 is not less than 2 MJ/m 2 and not more than 7.1 MJ/m 2 .

2. The flame-retardant polyurethane foam being formed from a flame-retardant polyurethane resin composition comprising:
a polyisocyanate (A),
a polyol (B),
a trimerization catalyst (C),
a foaming agent (D),
a foam stabilizer (E), and
additives (F),
wherein the additives (F) comprise red phosphorous, phosphoric acid esters, and at least one member selected from the group consisting of bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, metal hydroxides and needle-shaped fillers, and
wherein the gross calorific value measured with heating a sample of the polyurethane foam at a radiant heat intensity of 50 kW/m 2 for 20 minutes for a cone calorimeter test based on ISO-5660 is not less than 4.1 MJ/m 2 and not more than 10.3 MJ/m 2 .

3. The flame-retardant polyurethane foam according to claim 1 , wherein
the trimerization catalyst (C) is contained within a range of 0.1 to 10 parts by weight,
the foaming agent (D) is contained within a range of 0.1 to 30 parts by weight,
the foam stabilizer (E) is contained within a range of 0.1 to 10 parts by weight,
the additives (F) is contained within a range of 4.5 to 70 parts by weight,
the red phosphorus is contained within a range of 3 to 18 parts by weight, and
a total of the phosphoric acid esters and the at least one member selected from the group consisting of bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, metal hydroxides and needle-shaped fillers is contained within a range of 1.5 to 52 parts by weight, based on 100 parts by weight of a total of the polyisocyanate (A) and the polyol (B).

4. The flame-retardant polyurethane foam according to claim 2 , wherein
the trimerization catalyst (C) is contained within a range of 0.1 to 10 parts by weight,
the foaming agent (D) is contained within a range of 0.1 to 30 parts by weight,
the foam stabilizer (E) is contained within a range of 0.1 to 10 parts by weight,
the additives (F) is contained within a range of 4.5 to 70 parts by weight,
the red phosphorus is contained within a range of 3 to 18 parts by weight, and
a total of the phosphoric acid esters and the at least one member selected from the group consisting of bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, metal hydroxides and needle-shaped fillers is contained within a range of 1.5 to 52 parts by weight, based on 100 parts by weight of a total of the polyisocyanate (A) and the polyol (B).

5. A method of heat-insulating vehicles or buildings comprising applying the flame-retardant polyurethane foam of claim 1 to vehicle or buildings.

6. A method of heat-insulating vehicles or buildings comprising applying the flame-retardant polyurethane foam of claim 2 to vehicle or buildings.

Assignees

• Sekisui Chemical Co Ltd

Inventors

• Okada Yousuke
• Okada Kazuhiro

Classifications

• C08G18/4211

  derived from aromatic dicarboxylic acids and dialcohols · CPC title

• C08K3/02

  Elements · CPC title

• C09K21/12

  containing phosphorus · CPC title

• C08J9/0038

  containing phosphorus · CPC title

• C08G18/3206

  aliphatic · CPC title