Polyurethane foam and method for manufacturing the same

A polyurethane foam composition with expanded graphite, phosphorus-based flame retardant, and aluminum hydroxide addresses the lack of flame retardancy and resilience in existing foams, achieving V-0 standards with low hardness and resilience through a specific manufacturing process.

JP7864669B2Active Publication Date: 2026-05-25TOKYO QUALITY ONE CORP
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Patent Information

Authority / Receiving Office
JP · JP
Patent Type
Patents
Current Assignee / Owner
TOKYO QUALITY ONE CORP
Filing Date
2023-08-04
Publication Date
2026-05-25

AI Technical Summary

Technical Problem

Existing polyurethane foams lack sufficient flame retardancy, mechanical properties, and resilience, particularly in applications requiring high heat resistance and low rigidity.

Method used

A polyurethane foam composition comprising polyether polyol, diphenylmethane diisocyanate-based isocyanate, water, catalyst, and a flame retardant mixture of expanded graphite, phosphorus-based flame retardant, and aluminum hydroxide, with specific mass ratios and manufacturing process involving coating and heating between continuous webs.

Benefits of technology

The foam achieves high flame retardancy, low hardness, and excellent resilience, meeting V-0 standards with low 25% compression hardness and 50% compression residual strain, suitable for thin and lightweight applications.

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Abstract

To provide a polyurethane foam that exhibits high flame retardancy while ensuring low hardness and superior restorability and a method for producing the same.SOLUTION: The present invention provides a polyurethane foam composed of a foam of a composition containing a polyether polyol A, a diphenylmethane diisocyanate-based isocyanate B, water C, a catalyst D, and a flame retardant E containing expanded graphite, a phosphorous flame retardant, and aluminum hydroxide, and a method for producing the same.SELECTED DRAWING: None
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