Flame resistant flexible polyurethane foam

Patent metadata

Field	Value
Publication number	US-9822213-B2
Application number	US-201414895052-A
Country	US
Kind code	B2
Filing date	Jul 22, 2014
Priority date	Jul 25, 2013
Publication date	Nov 21, 2017
Grant date	Nov 21, 2017

Abstract

A method of forming a flame resistant flexible polyurethane foam that has a V-0 rating, according to Underwriters Laboratories Standard 94 Flammability Test, includes forming a reaction mixture that has an isocyanate component and an isocyanate-reactive component, and the isocyanate-reactive component includes a polyol component. The isocyanate component includes at least 30 wt % of a biuret modified aromatic diisocyanate, based on a total weight of the isocyanate component, and an isocyanate index of the reaction mixture is less than 100. The polyol component includes at least 5 wt % of a filled polyether polyol and at least 65 wt % of one or more other polyols that are different from the filled polyether polyol, based on a total weight of the isocyanate-reactive component.

First claim

The invention claimed is:

1. A method of forming a flame resistant flexible polyurethane foam, the method comprising:
forming a reaction mixture that includes an isocyanate component and an isocyanate-reactive component, the isocyanate-reactive component including a polyol component, wherein:
the isocyanate component includes:
from 40 wt % to 60 wt % of a biuret modified aromatic diisocyanate, based on a total weight of the isocyanate component, and the biuret modified aromatic diisocyanate being a diphenylmethane diisocyanate,
from 5 wt % to 50 wt % of an aromatic diisocyanate mixture, based on the total weight of the isocyanate component, the aromatic diisocyanate mixture including at least two different aromatic diisocyanates, and
from 5 wt % to 50 wt % of a polycarbodiimide-modified aromatic diisocyanate, based on the total weight of the isocyanate component, an isocyanate index of the reaction mixture being less than 100, and

the polyol component includes at least 5 wt % of a filled polyether polyol and at least 65 wt % of one or more other polyols different from the filled polyether polyol, based on a total weight of the isocyanate-reactive component; and

forming a polyurethane foam that has a V-0 rating, according to Underwriters Laboratories Standard 94 Flammability Test, using the reaction mixture.

2. The method as claimed in claim 1 , wherein the polyol component includes from 5 wt % to 25 wt % of the filled polyether polyol, based on the total weight of the isocyanate-reactive component, the filled polyether polyol being a polyurea filled polyether polyol.

3. The method as claimed in claim 2 , wherein the polyurea filled polyether polyol includes from 10 wt % to 40 wt % of a polyurea composite, based on a total weight of the polyurea filled polyether polyol.

4. A method of forming a flame resistant flexible polyurethane foam, the method comprising:
forming a reaction mixture that includes an isocyanate component and an isocyanate-reactive component, the isocyanate-reactive component including a polyol component, wherein:
the isocyanate component includes at least 30 wt % of a biuret modified aromatic diisocyanate, based on a total weight of the isocyanate component, an isocyanate index of the reaction mixture being less than 100,
the polyol component includes at least 5 wt % of a filled polyether polyol and at least 65 wt % of one or more other polyols different from the filled polyether polyol, based on a total weight of the isocyanate-reactive component, wherein the one or more other polyols different from the filled polyether polyol include:
15 wt % to 40 wt % of at least one second grafted polyether polyol, which is different from the filled polyether polyol, based on the total weight of the isocyanate-reactive component,
20 wt % to 60 wt % of at least one low molecular weight polyol having an average molecular weight of less than or equal to 5000, based on the total weight of the isocyanate-reactive component, and
5 wt % to 30 wt % of at least one high molecular weight polyol having an average molecular weight of greater than 5000, based on the total weight of the isocyanate-reactive component

forming a polyurethane foam that has a V-0 rating, according to Underwriters Laboratories Standard 94 Flammability Test, using the reaction mixture.

5. The method as claimed in claim 1 , wherein a weight percentage of the filled polyether polyol in the reaction mixture is greater than a weight percentage of the biuret modified aromatic diisocyanate in the reaction mixture, based on a total weight of the reaction mixture.

6. A method of forming a flame resistant flexible polyurethane foam, the method comprising:
forming a reaction mixture that includes an isocyanate component and an isocyanate-reactive component, the isocyanate-reactive component including a polyol component, wherein:
the isocyanate component includes at least 30 wt % of a biuret modified aromatic diisocyanate, based on a total weight of the isocyanate component, an isocyanate index of the reaction mixture being less than 90,
the polyol component includes at least 5 wt % of a filled polyether polyol and at least 65 wt % of one or more other polyols different from the filled polyether polyol, based on a total weight of the isocyanate-reactive component, and an amount of the filled polyether polyol in the reaction mixture is from 10 wt % to 12 wt % and an amount of the biuret modified aromatic diisocyanate in the reaction mixture is from 10 wt % to 12 wt %, based on a total weight of the reaction mixture; and

forming a polyurethane foam that has a V-0 rating, according to Underwriters Laboratories Standard 94 Flammability Test, using the reaction mixture.

7. The method as claimed in claim 1 , wherein the reaction mixture excludes substantially any flame retardant additives including any one of ammonium polyphosphate, melamine, expandable graphite, red phosphorus, and sodium citrate.

Assignees

• Dow Global Technologies Llc

Inventors

• Honkomp David J

Classifications

• C08G18/0876

  the dispersing or dispersed phase being a polyol · CPC title

• C08G18/485

  containing mixed oxyethylene-oxypropylene or oxyethylene-higher oxyalkylene end groups · CPC title

• C08G18/409

  Dispersions of polymers of C08G in organic compounds having active hydrogen · CPC title

• C08G18/4072

  Mixtures of compounds of group C08G18/63 with other macromolecular compounds · CPC title

• C08G18/7831 Primary

  containing biuret groups · CPC title