Flame retardant foam, method of manufacture, and articles using the same

Patent metadata

Field	Value
Publication number	US-2026071039-A1
Application number	US-202519318606-A
Country	US
Kind code	A1
Filing date	Sep 4, 2025
Priority date	Sep 9, 2024
Publication date	Mar 12, 2026
Grant date	—

Abstract

A flame retardant foam including polyurethane; and flame retardant additives, wherein the flame retardant foam has a density of 8 to less than 11.7 pounds per cubic foot (128 to less than 187 kilograms per cubic meter), a thickness of 2.7 to 8 millimeters, or 2.8 to 8 millimeters, or 3 to 8 millimeters, and a UL 94 rating of V-0.

First claim

What is claimed is:

1 . A flame retardant foam comprising:
polyurethane; and flame retardant additives, wherein the flame retardant foam has a density of 8 to less than 11.7 pounds per cubic foot (128 to less than 187 kilograms per cubic meter), a thickness of 2.7 to 8 millimeters, or 2.8 to 8 millimeters, or 3 to 8 millimeters, and a UL 94 rating of V-0.

2 . The flame retardant foam of claim 1 , wherein the flame retardant foam has a density of 9 to 11 pounds per cubic foot (144 to 176 kilograms per cubic meter).

3 . The flame retardant foam of claim 1 , wherein the flame retardant foam has a thickness of 3 to 8 millimeters.

4 . The flame retardant foam of claim 1 , wherein the flame retardant foam has a thickness of 3.5 to 7.5 millimeters.

5 . The flame retardant foam of claim 1 , wherein the flame retardant foam has a thickness of 5 to 7 millimeters.

6 . The flame retardant foam of claim 1 , wherein the flame retardant foam has
a density of 9.4 to 10.9 pounds per cubic foot (151 to 175 kilograms per cubic meter), and a thickness of 3.5 to 6.3 millimeters.

7 . The flame retardant foam of claim 1 , wherein the flame retardant foam has a density of 8 to less than 9.9 pounds per cubic foot (128 to less than 159 kilograms per cubic meter).

8 . The flame retardant foam of claim 1 , wherein the flame retardant foam has
a density of 9.0 to 9.8 pounds per cubic foot (147 to 157 kilograms per cubic meter), and a thickness of 3.5 to 6 millimeters.

9 . The flame retardant foam of claim 1 , wherein the flame retardant additives comprise:
graphite; and ammonium polyphosphate.

10 . The flame retardant foam of claim 1 , wherein the flame retardant foam has
a compression force deflection of 0.4 to 4 pounds per square inch (2.8 to 28 kilopascals), at 25% deflection and determined in accordance with ASTM D3574-17, a compression set of 0 to 10%, determined in accordance with ASTM D 3574-95 Test D at 70° C., or a combination thereof.

11 . A method of forming the flame retardant foam of claim 1 , the method comprising:
combining an active hydrogen-containing component comprising a polyol, an isocyanate component comprising a polyisocyanate, and the flame retardant additives to form an uncured polyurethane foam; and curing the uncured polyurethane foam to form the flame retardant foam.

12 . The method of claim 11 , further comprising mechanically frothing the uncured polyurethane foam.

13 . The method of claim 11 , further comprising chemically blowing the uncured polyurethane foam.

14 . The method of claim 11 , wherein the graphite comprises expandable graphite, 50 to 80 mesh size, and having a 180 to 250° C. onset temperature for expansion.

15 . The method of claim 11 , wherein the ammonium polyphosphate is uncoated or coated with melamine or silane and has a particle size of 7 to 20 micrometers.

16 . The method of claim 11 , wherein the uncured polyurethane foam comprises 5 to 30 weight percent, or 10 to 20 weight percent, or 14 to 18 weight percent, of the graphite, based on a total weight of the uncured polyurethane foam.

17 . The method of claim 11 , wherein the uncured polyurethane foam comprises 5 to 30 weight percent, or 5 to 20 weight percent, or 10 to 15 weight percent, of the ammonium polyphosphate, based on a total weight of the uncured polyurethane foam.

18 . The method of claim 11 , wherein the flame retardant additives further comprise a liquid phosphate flame retardant.

19 . The method of claim 18 , wherein:
the liquid phosphate flame retardant comprises phenol, isobutylenated, phosphate (3:1) with 2.5 to 25 weight percent of triphenyl phosphate; the uncured polyurethane foam comprises 0.1 to 15 weight percent, or 0.5 to 10 weight percent, or 1 to 5 weight percent, of the liquid phosphate flame retardant, based on a total weight of the uncured polyurethane foam; or a combination thereof.

20 . The method of claim 11 , wherein the uncured polyurethane foam further comprises 0.1 to 10 weight percent, or 4 to 8 weight percent, of surfactant, based on a total weight of the uncured polyurethane foam.

Assignees

• Rogers Corp

Inventors

• Puglisi Joseph
• Le An

Classifications

• C08J2205/05

  Open cells, i.e. more than 50% of the pores are open · CPC title

• C08J9/141

  Hydrocarbons · CPC title

• C08J9/0038

  containing phosphorus · CPC title

• C08J9/0066

  Use of inorganic compounding ingredients · CPC title

• C08J2367/02

  Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence) · CPC title