Flame-retardant, non-shrinking ureaformaldehyde foams and process of making same

Claim 1

A PROCESS FOR PREPARING A SUBSTANTIALLY NON-SHRINKING, FLAME-RETARDENT, SOLID UREA-FORMALDEHYDE FOAM WHICH COMPRISES (1) PREPARING A DISPERSION OF (A) AN AQUEOUS UREA-FORMALDEHYDE RESIN SOLUTION HAVING A UREA-FORMALDEHYDE SOLIDS CONTENT BETWEEN ABOUT 50% AND ABOUT 65%, THE BALANCE WATER, (B) BETWEEN ABOUT 14% AND ABOUT 30% BY WEIGHT BASED ON THE WEIGHT OF THE UREA-FORMALDEHYDE RESIN SOLIDS OF A POLYETHYLENE GLYCOL HAVING A MOLEUCLAR WEIGHT BETWEEN ABOUT 200 AND ABOUT 600 AND (C) AT LEAST ABOUT 0.6% BY WEIGHT ON THE SAME BASIS, OF A DIALKYL ALKANEPHOSPHONATE WHEREIN THE ALKYL GROUPS CONTAIN FROM 1 TO 2 CARBON ATOMS, (2) PREPARING A FOAMED HARDENER SOLUTION CURING AGENT COMPRISING AN AQUEOUS SOLUTION CONTAING A SMALL PROPORTION OF A FOAMING AGENT AND BETWEEN ABOUT 2% AND ABOUT 6% OF PHOSPHORIC ACID, (3) MIXING THE REISN SOLUTION AND THE FORAMED CURING AGENT SOLUTION IN A WEIGHT RATIO BETWEEN ABOUT 0.5 PART AND ABOUT 2.3 PARTS FOAMED-CURING AGENT SOLUTION PER PART OF RESIN SOLUTION TO FORM A SUBSTANTIALLY HOMOGENEOUS FOAM, AND CURING THE FOAM.