Flame retardant flexible polyurethane foam containing finely divided inorganic salt wherein a mold of said salt contains at least five moles of water

Claim 2

In a flame retardant flexible polyurethane foam prepared under foam producing conditions from an aromatic polyisocyanate, a polyether polyol having an equivalent weight from about 500 to about 2500 and a functionality from about 2.0 to about 4.0, antimony oxide and a polyhalogenated aromatic compound wherein the improvement comprises employing in the foam forming reaction mixture the following ingredients in parts by weight based on 100 parts of said polyether polyol: (a) from about 4 to about 30 parts of antimony oxide; (b) from about 4 to about 40 parts of a polyhalogenated aromatic compound; and (c) from about 30 to about 60 parts of a finely divided hydrated inorganic salt wherein a mole of said salt contains at least 5 moles of water of hydration; and employing a ratio of isocyanate equivalents to total equivalents of active hydrogen containing materials in the foam forming reaction mixture within a range of from about 0.90:1.0 to about 1.0:1.0.

Claim 3

A foam according to claim 1 wherein there is additionally present a minor amount of a cross-linking polyol.

Claim 4

A foam according to claim 1 wherein (c) is a hydrated alkali or alkaline earth metal inorganic salt.

Claim 5

A foam according to claim 3 wherein (c) is magnesium sulfate heptahydrate.

Claim 6

A foam according to claim 3 wherein (c) is magnesium orthophosphate octahydrate.

Claim 7

A foam according to claim 3 wherein (c) is sodium pyrophosphate decahydrate.

Claim 8

A flame retardant flexible polyurethane foam which comprises the product of reaction under foam producing conditions of: (a) an aromatic polyisocyanate mixture selected from the group consisting of (i) from about 5 to about 95 percent by weight of toluene diisocyanate and from about 95 to about 5 percent by weight of polymethylene polyphenyl polyisocyanate, and (ii) from about 50 percent to about 80 percent by weight of 2,4-toluenediisocyanate and 50 percent to about 20 percent by weight of 2,6-toluene-diisocyanate; (b) a polyether triol having an equivalent weight from about 500 to about 2500; (c) a minor amount of a cross-linking polyol; (d) the following ingredients in parts by weight based on 100 parts of said polyether triol: (i) from about 4 to about 30 parts of antimony oxide; (ii) from about 4 to about 40 parts of a polyhalogenated aromatic compound; and (iii) from about 30 to about 60 parts of a finely divided hydrated alkali or alkaline earth metal inorganic salt wherein a mole of said salt contains at least 5 moles of water of hydration; and wherein the ratio of isocyanate equivalents to total equivalents of active hydrogen containing materials falls within a range of from about 0.90:1.0 to about 1.0:1.0.

Claim 9

A flame retardant flexible polyurethane foam which comprises the product of reaction under foam producing conditions of: (a) an aromatic polyisocyanate mixture selected from the group consisting of (i) from about 5 to about 95 percent by weight of toluene diisocyanate and from about 95 to about 5 percent by weight of polymethylene polyphenyl polyisocyanate, and (ii) from about 50 percent to about 80 percent by weight of 2,4-toluenediisocyanate and 50 percent to about 20 percent by weight of 2,6-toluene-diisocyanate; (b) a polyether triol having an equivalent weight from about 500 to about 2500; (c) a minor amount of a cross-linking polyol; (d) the following ingredients in parts by weight based on 100 parts of said polyether triol: (i) from about 4 to about 30 parts of antimony oxide; (ii) from about 4 to about 40 parts of a polyhalogenated aromatic compound; and (iii) from about 30 to about 60 parts of a finely divided hydrated alkali or alkaline earth metal inorganic salt wherein a mole of said salt contains at least 5 moles of water of hydration; and wherein the ratio of isocyanate equivalents to total equivalents of active hydrogen containing materials falls within a range of from about 0.90:1.0 to about 1.0:1.0.

Claim 10

A foam according to claim 7 wherein the hydrated salt (diii) is an alkali metal inorganic salt.

Claim 11

A foam according to claim 7 wherein the hydrated salt (diii) is an alkaline earth metal inorganic salt.

Claim 12

A foam according to claim 7 wherein the aromatic polyisocyanate mixture (a) is about a 50/50 weight percent mixture of 2,4 and 2,6-toluenediisocyanate.

Claim 13

A foam according to claim 7 wherein the polyhalogenated aromatic compound (dii) is decabromodiphenyl ether.

Claim 14

A foam according to claim 7 wherein the ratio of isocyanate equivalents to total equivalents of active hydrogen containing materials is about 1.0:1.0.

Claim 15

A foam according to claim 10, 11, or 12 wherein the hydrated salt is magnesium sulfate heptahydrate.