Polyurethane Foam Flame Retardancy via Chemical Bonding
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Solution Overview
Problem
Conventional flexible polyurethane foams for automotive seats suffer from deteriorated flame retardancy after washing, failing to meet safety regulations for vehicle fires.
Innovation Solution
A polyurethane foam composition is developed, containing a polyol mixture with a phosphorus-based flame retardant having hydroxyl groups at both terminals, a carbon-based flame retardant, an isocyanate, a foaming agent, and an additive, which prevents flame retardant components from being lost during washing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid halogen-based phosphate ester is physically dispersed in polyurethane matrix to obtain flame retardancy, then flame retardant property is improved, but flame retardancy deteriorates after washing due to loss of polar phosphate ester
Solution Approach 1:
The patent changes the chemical structure parameters of the flame retardant from conventional liquid halogen-based phosphate ester to solid ammonium polyphosphate, and changes the bonding mode from physical dispersion to chemical bonding with polyol through hydroxyl groups. This parameter change transforms the flame retardant from washable-but-loss-prone to chemically bonded and wash-resistant, resolving the contradiction between initial flame retardancy and retention after washing
Solution Approach 2:
The patent creates a composite material system where ammonium polyphosphate is chemically integrated with polyol through hydroxyl groups, forming a new composite polyol mixture. This composite structure ensures the flame retardant becomes an integral part of the polyurethane matrix rather than a physically dispersed additive, preventing loss during washing while maintaining flame retardancy
2Ease of operation
If conventional polyurethane foam is made washable to meet hygiene requirements, then washability is improved, but flame retardancy deteriorates drastically after washing
Solution Approach 1:
The patent performs preliminary chemical bonding of the flame retardant (ammonium polyphosphate) to the polyol through hydroxyl groups before foam formation. This preliminary chemical integration ensures that when the foam undergoes washing, the flame retardant is already securely bonded and cannot be washed away, thus maintaining flame retardancy even after washing operations
Solution Approach 2:
The patent changes the chemical state of the flame retardant from physically dispersed to chemically bonded by utilizing hydroxyl groups in ammonium polyphosphate to form chemical bonds with polyol. This parameter change in bonding nature allows the foam to be both washable and maintain flame retardancy, resolving the contradiction between washability and flame safety
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 solution maintains excellent flame retardancy of the polyurethane foam even after washing, ensuring compliance with safety regulations and providing improved washability and heat resistance.
Implementation Method 1
a phosphorus-based flame retardant containing hydroxyl groups (—OH) at both terminals
Implementation Method 2
a carbon-based flame retardant
Implementation Method 3
a foaming agent
Data Source
AI summary
Provided are a polyurethane foam composition with excellent flame retardancy, a polyurethane foam containing the same, and an automotive internal material. Specifically, the polyurethane foam composition, according to an exemplary embodiment of the present disclosure, contains: 50 to 70 wt % of a polyol mixture containing a polyol, a phosphorus-based flame retardant containing hydroxyl groups (—OH) at both terminals, a carbon-based flame retardant, a foaming agent, and an additive; and 30 to 50 wt % of an isocyanate.