Reduced flammability flexible polyurethane foam

Abstract

A method of forming a flexible polyurethane foam that passes BS 5852:2006 source V (Crib 5) test. The method includes providing a modified polyisocyanate polyaddition (PIPA) 5 polyol formed by contacting a PIPA polyol dispersion with at least one carboxylic acid having a melting point above zero degree Celsius and present in a carrier solvent. The PIPA polyol dispersion has a polyol liquid phase content of 60 wt.% to 90 wt.% and a solid particle phase content of 10 wt.% to 40 wt.% based on a total weight of the PIPA polyol dispersion. From 10 weight percent (wt.%) to 80 wt.% of the modified PIPA polyol is combined with 90 wt.% to 20 10 wt.% of at least another polyether polyol based on a total weight of a polyol blend of the PIPA polyol and the at least another polyether polyol, where thepolyether polyol is formed with propylene oxide and ethylene oxide and has an equivalent weight of 1,000 to 2,000 and a functionality of 3 to 6. The combination of the modified PIPA polyol and the polyether polyol are reacted with a polyisocyanate and a blowing agent to form the flexible polyurethane foam.

Description

technical field

[0001] The present disclosure relates to polyurethane foams, and more particularly to flexible polyurethane foams with reduced flammability. Background technique

[0002] Polyurethane foams are typically prepared by the reaction of polyisocyanates with polyols, typically hydroxyl-functional polyoxyalkylene polyether polyols. By controlling the functionality of the polyisocyanate and the molecular weight and functionality of the polyol, it is possible to prepare polyurethane foams ranging from extremely soft flexible foams to very rigid foams.

[0003] To improve the mechanical properties of polyurethane foams, it has become common to utilize polyols containing dispersed solids. Commonly used polyol dispersions are, for example, so-called "graft polyols", which are stable dispersions of vinyl polymers, generally homopolymers or copolymers of acrylonitrile and styrene. Such polyols can increase the load-bearing capacity of polyurethane foams, for example, whe...

Examples

example

[0033] All parts and percentages are by weight unless otherwise indicated. As used herein, the terms combustion modified, flame retardant and similar terms refer to the performance of a material in laboratory flammability tests and are not meant to describe performance under actual fire conditions.

[0034] The following materials are mainly used:

[0035] Voranol TM 6150 is a 6000 Mw ethylene oxide (EO) terminated trifunctional polyol (available from The Dow Chemical Company) for the production of high resilience (HR) foams.

[0036] Voralux TM HF 505 is a high Mw EO terminated hexafunctional polyol (commercially available from The Dow Chemical Company) for the production of HR foams.

[0037] Voranol TM CP 1421 is a cell opener (commercially available from The Dow Chemical Company) with a high EO content and containing a trifunctional polyol.

[0038] High Resilient (HR) PIPA 20% is a PIPA polyol based on triethanolamine and TDI 80 / 20 polyisocyanate in HR carrier polyol...

technical field

[0001] The present disclosure relates to polyurethane foams, and more particularly to flexible polyurethane foams with reduced flammability. Background technique

[0002] Polyurethane foams are typically prepared by the reaction of polyisocyanates with polyols, typically hydroxyl-functional polyoxyalkylene polyether polyols. By controlling the functionality of the polyisocyanate and the molecular weight and functionality of the polyol, it is possible to prepare polyurethane foams ranging from extremely soft flexible foams to very rigid foams.

[0003] To improve the mechanical properties of polyurethane foams, it has become common to utilize polyols containing dispersed solids. Commonly used polyol dispersions are, for example, so-called "graft polyols", which are stable dispersions of vinyl polymers, generally homopolymers or copolymers of acrylonitrile and styrene. Such polyols can increase the load-bearing capacity of polyurethane foams, for example, whe...

Examples

example

[0033] All parts and percentages are by weight unless otherwise indicated. As used herein, the terms combustion modified, flame retardant and similar terms refer to the performance of a material in laboratory flammability tests and are not meant to describe performance under actual fire conditions.

[0034] The following materials are mainly used:

[0035] Voranol TM 6150 is a 6000 Mw ethylene oxide (EO) terminated trifunctional polyol (available from The Dow Chemical Company) for the production of high resilience (HR) foams.

[0036] Voralux TM HF 505 is a high Mw EO terminated hexafunctional polyol (commercially available from The Dow Chemical Company) for the production of HR foams.

[0037] Voranol TM CP 1421 is a cell opener (commercially available from The Dow Chemical Company) with a high EO content and containing a trifunctional polyol.

[0038] High Resilient (HR) PIPA 20% is a PIPA polyol based on triethanolamine and TDI 80 / 20 polyisocyanate in HR carrier polyol...