THERMALLY STABLE FLAME RESISTANT FLEXIBLE POLYURETHANE FOAM

• Main Author: PLAVER F. MICHAEL
• Format: Patent
• Language: English
• Published: 01.05.2014
• Subjects: CHEMISTRY; COMPOSITIONS BASED THEREON; MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONSONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS; METALLURGY; ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP

The present invention relates to a reactive formulation used to make a flame resistant flexible polyurethane foam which is particularly suited for use in under the hood vehicle applications which require sound deadening and vibration management and a process to make said foam. Said foam is particularly suitable for such applications because desirable flame resistant properties are achieved after exposure to heat over an extended period of time. In particular, the flame resistant flexible polyurethane foam is made from a reactive formulation comprising an A side comprising (i) one or more organic isocyanate and a B side comprising (ii) one or more isocyanate-reactive component, (iii) a flame retardant component comprising a combination of red phosphorus, expandable graphite, and optionally sodium citrate wherein the flame retardant component does not contain ammonium polyphosphate; and (iv) one or more additional component selected from a catalyst, a blowing agent, a cell opener, a surfactant, a crosslinker, a chain extender a filler, a colorant, a pigment, an antistatic agent, reinforcing fibers, an antioxidant, a preservative, or an acid scavenger wherein the resulting foam achieves after heat aging at 150 C for seven days a V-0 rating at 0.5 inch according to Underwriters' Laboratories Standard 94 Flammability Test.