Flame-Retardant Polyurethane Sealing Material
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Solution Overview
Problem
Conventional polyurethane foams with high water cut-off properties and low density lack flame retardancy, and existing non-halogen foams with low flammability do not meet water cut-off performance standards under 100 mmAq pressure, while solid flame retardants compromise foam quality and liquid phosphate esters cause fogging issues.
Innovation Solution
A polyurethane foam-based flame-retardant sealing material using a polyol component with a hydroxyl-terminated prepolymer, a non-halogen or halogen-containing non-condensed phosphate ester as a liquid flame retardant, and an isocyanate index of 100 to 150, ensuring excellent water cut-off performance and passing FMVSS302 flammability tests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If solid flame retardant (melamine) is used to improve flame retardancy, then low flammability is achieved, but foam state deteriorates and water cut-off performance decreases
Solution Approach 1:
The patent changes the physical state parameter of the flame retardant from solid to liquid, and specifically selects a liquid phosphate ester-type flame retardant with controlled viscosity (10 to 1000 cSt at 25°C) and molecular weight (200 to 5000) to achieve both flame retardancy and good foam state without compromising water cut-off performance
Solution Approach 2:
The patent uses a composite approach by combining specific polyol components (polyether polyol with hydroxyl value 20-100 and polyester polyol with hydroxyl value 20-100) with liquid phosphate ester flame retardant to create a polyurethane foam system that simultaneously achieves flame retardancy, good foam state, and excellent water cut-off performance
2Object-affected harmful factors
If liquid phosphate ester-type flame retardant is used to improve flame retardancy, then low flammability is achieved, but water cut-off performance deteriorates under 100 mmAq pressure
Solution Approach 1:
The patent precisely controls the molecular weight parameter of the liquid phosphate ester flame retardant (200 to 5000) and its viscosity (10 to 1000 cSt at 25°C) to optimize the balance between flame retardancy and water cut-off performance under high pressure conditions
Solution Approach 2:
The patent employs a composite polyol system combining polyether polyol and polyester polyol with specific hydroxyl values (20-100 each) to work synergistically with the liquid phosphate ester flame retardant, achieving both flame retardancy and maintained water cut-off performance under 100 mmAq pressure
3Object-affected harmful factors
If amount of liquid phosphate ester flame retardant is increased to improve flame retardancy, then low flammability is achieved, but fogging property deteriorates and cloudiness occurs
Solution Approach 1:
The patent optimizes the molecular weight parameter of the liquid phosphate ester flame retardant (200 to 5000) to achieve sufficient flame retardancy at lower concentrations, thereby preventing fogging and cloudiness that occur with excessive additive amounts
Solution Approach 2:
The patent applies the principle of partial action by using the liquid phosphate ester flame retardant at optimized moderate levels rather than excessive amounts, achieving adequate flame retardancy (passing FMVSS302) while avoiding the harmful side effects of fogging and cloudiness
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The material achieves long-lasting water cut-off performance under 100 mmAq pressure and passes FMVSS302 flammability tests, while maintaining low flammability and preventing fogging, even when compressed with transparent materials.
Implementation Method 1
a polyurethane foam formed from a polyurethane raw material containing a polyol component, an isocyanate... wherein the polyol component contains 80 to 100 parts by mass of a hydroxyl-terminated prepolymer obtained by the reaction of a polyether polyol and an isocyanate
Data Source
AI summary
A flame-retardant sealing material comprising a polyurethane foam formed from a polyurethane raw material containing a polyol component, an isocyanate, a water repellent, a flame retardant and the like, wherein the polyol component contains a hydroxyl-terminated prepolymer obtained by the reaction of a polyether polyol and an isocyanate, the water repellent is a polybutadiene polyol or the like, the flame retardant is (1) a non-halogen non-condensed phosphate ester or (2) a halogen-containing non-condensed phosphate ester, which are liquid at ordinary temperature, and the isocyanate index is 100 to 150.