US4374207A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Intumescent flexible polyurethane foam
Assignee: GFC FOAM Corp A CORP OF DE
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Filing: 1980-10-24
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Granted: 1983-02-15
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Expires: 2000-10-24
Abstract
Abstract Flexible, resilient, polyurethane foam having improved flame retardancy and intumescent properties is prepared from a reaction mixture comprising a polyether polyol, an organic polyisocyanate, a blowing agent, a surfactant, a catalyst, a flame retardant, and hydrated alumina. Alternatively, the mixture also comprises a low-viscosity linear polyester. The hydrated alumina is predispersed in a mixture comprising flame retardant and low-viscosity linear polyester, and alternatively a char former and a fugitive viscosity modifier.
Inventors
- 👤 Herman Stone
- 👤 Peter D. Pauly
- 👤 Pcolinsky, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 23:03
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/0066; C08G; C08G18/00; C08G18/06; C08G18/28; C08G18/40; C08G18/4009; C08G18/4018; C08J9/0014; C08K; C08K5/00; C08K5/0008; C08K5/0066; C08G2110/00; C08G2110/0008; C08G2110/0041; C08G2110/0058; C08G2110/0066; C08G2110/0083; C08J2375/00; C08J2375/04
Claims Analysis
Total Claims: 37
Claim 1
Independent Claim
101 words
In the process for the manufacture of a flexible, resilient, flame retardant and intumescent polyurethane foam from a reaction mixture consisting essentially of at least one polyether polyol, at least one organic polyisocyanate, at least one flame retardant, at least one blowing agent, at least one surfactant, and at least one catalyst, the improvement wherein the amount of said flame retardant is from about 30 to about 160 phr, and said reaction mixture also contains from about 200 to about 400 phr of hydrated alumina uniformly dispersed in from about 10 to about 100 phr of a low-viscosity, linear, polyester diol.
Claim 2
Dependent Claim
101 words
In the process for the manufacture of a flexible, resilient, flame retardant and intumescent polyurethane foam from a reaction mixture consisting essentially of at least one polyether polyol, at least one organic polyisocyanate, at least one flame retardant, at least one blowing agent, at least one surfactant, and at least one catalyst, the improvement wherein the amount of said flame retardant is from about 30 to about 160 phr, and said reaction mixture also contains from about 200 to about 400 phr of hydrated alumina uniformly dispersed in from about 10 to about 100 phr of a low-viscosity, linear, polyester diol.
Claim 3
Dependent Claim
92 words
The process of claim 1 wherein the reaction mixture also contains at least one char former selected from the group consisting of low molecular weight aldehydes, aldehyde generators, partially or completely etherified urea/formaldehyde condensates, melamine, and melamine derivatives having the formula ##STR2## wherein A, B, D, E, F, and G are selected from the group consisting of hydrogen, methylol, and ROCH 2 -- in which R is an alkyl radical containing from 1 to 4 carbon atoms, and wherein at least one of A,B,D,E,F and G is methylol or RCOH 2 --.
Claim 4
Dependent Claim
37 words
The process of claim 1 wherein said hydrated alumina and said flame retardant, and said low-viscosity linear polyester diol are first blended into a uniform dispersion before being mixed with the other components of said reaction mixture.
Claim 5
Dependent Claim
22 words
The process of claim 3 wherein said uniform dispersion also comprises at least one char former as set forth in claim 2.
Claim 6
Dependent Claim
16 words
The process of claim 3 wherein said uniform dispersion also comprises a low-boiling, fugitive, halogenated hydrocarbon.
Claim 7
Dependent Claim
29 words
The process of claim 1 wherein said polyether polyol comprises a dispersion of a polyhydrazodicarbonamide in a polyol prepared by the reaction of alkylene oxides and a polyhydric initiator.
Claim 8
Dependent Claim
23 words
The process of claim 1 wherein at least one polyether polyol is a polyether polyol that has been modified with acrylonitrile and/or styrene.
Claim 9
Dependent Claim
23 words
The process of claim 1 wherein said organic polyisocyanate is a mixture of 2,4-tolylene diisocyanate and 2,6 tolylene in a ratio of 80/20.
Claim 10
Dependent Claim
11 words
The process of claim 1 wherein said flame retardant comprises tris(1,3-dichloropropyl)phosphate.
Claim 11
Dependent Claim
11 words
The process of claim 1 wherein said flame retardant comprises tris(2-chloroethyl)phosphate.
Claim 12
Dependent Claim
12 words
The process of claim 1 wherein said flame retardant comprises tetrakis(2-chloroethyl)ethylene diphosphate.
Claim 13
Dependent Claim
15 words
The process of claim 1 wherein said flame retardant comprises tetrakis(2-chloroethyl)ethylene diphosphate and decabromodiphenyl oxide.
Claim 14
Dependent Claim
32 words
The process of claim 1 wherein the amount of said flame retard- and is from about 50 to about 145 parts by weight per 100 parts by weight of said polyether polyol.
Claim 15
Dependent Claim
33 words
The process of claim 1 wherein the amount of said low-viscosity linear polyester diol is from about 35 to about 80 parts by weight per 100 parts by weight of said polyether polyol.
Claim 16
Dependent Claim
30 words
The process of claim 1 wherein the amount of hydrated alumina is from about 230 to about 350 parts by weight per 100 parts by weight of said polyether polyol.
Claim 17
Dependent Claim
31 words
The process of claim 2 wherein the amount of said char former is from about 5 to about 30 parts by weight per 100 parts by weight of said polyether polyol.
Claim 18
Dependent Claim
31 words
The process of claim 16 wherein the amount of said char former is from about 10 to about 25 parts by weight per 100 parts by weight of said polyether polyol.
Claim 19
Dependent Claim
12 words
The process of claim 2 wherein said char former comprises hexa (methoxymethyl)melamine.
Claim 20
Dependent Claim
11 words
The process of claim 2 wherein said aldehyde generator is hexamethylenetetramine.
Claim 21
Dependent Claim
31 words
The process of claim 5 wherein the amount of said halogenated hydrocarbon is from about 2 to about 20 parts by weight per 100 parts by weight of said polyether polyol.
Claim 22
Dependent Claim
12 words
The process of claim 5 wherein said halogenated hydrocarbon is methylene chloride.
Claim 23
Dependent Claim
11 words
The process of claim 5 wherein said halogenated hydrocarbon is trichloromonofluoromethane.
Claim 24
Dependent Claim
8 words
The product of the process of claim 1.
Claim 25
Dependent Claim
8 words
The product of the process of claim 2.
Claim 26
Dependent Claim
8 words
The product of the process of claim 3.
Claim 27
Dependent Claim
8 words
The product of the process of claim 4.
Claim 28
Dependent Claim
8 words
The product of the process of claim 5.
Claim 29
Dependent Claim
8 words
The product of the process of claim 6.
Claim 30
Dependent Claim
8 words
The product of the process of claim 7.
Claim 31
Dependent Claim
8 words
The product of the process of claim 13.
Claim 32
Dependent Claim
8 words
The product of the process of claim 14.
Claim 33
Dependent Claim
8 words
The product of the process of claim 17.
Claim 34
Dependent Claim
8 words
The product of the process of claim 18.
Claim 35
Dependent Claim
8 words
The product of the process of claim 19.
Claim 36
Dependent Claim
8 words
The product of the process of claim 20.
Claim 37
Dependent Claim
22 words
The process of claim 3 wherein the amount of low-viscosity, linear polyester diol is from about 35 phr to about 100 phr.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-02-14 | 1986-08-16 | 1987-02-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-02-14 | 1990-08-16 | 1991-02-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-02-14 | 1994-08-16 | 1995-02-15 | $7700.00 | Window Closed / Lapsed |