Flame and dripping ember retardant flexible polyurethane foams

Claim 2

In a process for preparing flexible polyurethane foam by the reaction of a polyester polyol and an organic polyisocyanate wherein the improvement comprises: adding to the polyurethane forming reactants a blowing agent comprising water, polyurethane forming catalyst, surfactant, and a flame and dripping ember retardant effective amount of an additive combination comprising (1) halogenated flame retardant, and (2) water or alcohol soluble uncrosslinked urea-formaldehyde resin which is unreactive with said organic polyisocyanate.

Claim 3

The process of claim 1 wherein the halogenated flame retardant is selected from the group consisting of tris(1,3-dichloropropyl)phosphate, tris(2,3-dibromopropyl) phosphate, dichloromethylene-bis(di-2-chloroethyl)phosphate, tris(2-chloroethyl)phosphate, tris(2-chloropropyl)phosphate, 2,2-bis (chloromethyl)-1,3 propylene, bis-di(2-chloroethyl)phosphate, bis(dichloropropyl) tribromoneopentyl phosphate, tetrakis(2-chloroethyl) ethylene diphosphate, pentabromodiphenyl oxide, bis(pentabromophenoxy) ethane, bis(tetrabromophthalimide)ethane, tetrabromobisphenol A, hexabromocyclododecane, bis(tribromophenoxy)ethane, octabromodiphenyl oxide, tribromoneopentyl alcohol, chlorinated paraffin, brominated paraffin, and mixtures thereof.

Claim 4

The process of claim 1 wherein the combined weight of said halogenated flame retardant and said urea-formaldehyde resin is from about 8 to about 20 weight percent of the total weight of reaction mixture, and the weight ratio of said halogenated flame retardant to said urea-formaldehyde resin is from about 4:1 to about 1:1.

Claim 5

The process of claim 3 wherein the weight ratio of said halogenated flame retardant to said urea-formaldehyde resin is from 3:1 to 2:1.

Claim 6

The process of claim 1 wherein the surfactant is a mixture of fatty acid amides.

Claim 7

The process of claim 1 wherein the resin is a methylated urea-formaldehyde resin.

Claim 8

A flexible polyurethane foam prepared from polyester polyol and organic isocyanate which contains a flame and dripping ember retardant effective amount of (1) halogenated flame retardant, and (2) water or alcohol soluble uncrosslinked urea-formaldehyde resin which is unreactive with said organic isocyanate.

Claim 9

A flexible polyurethane foam prepared from polyester polyol and organic isocyanate which contains a flame and dripping ember retardant effective amount of (1) halogenated flame retardant, and (2) water or alcohol soluble uncrosslinked urea-formaldehyde resin which is unreactive with said organic isocyanate.

Claim 10

The foam of claim 7 wherein the halogenated flame retardant is selected from the group consisting of tris(1,3-dichloropropyl)phosphate, tris(2,3-dibromopropyl)phosphate, dichlormethylene-bis(di-2-chloroethyl) phosphate, tris(2-chloroethyl)phosphate, tris(2-chloropropyl)phosphate, 2,2-bis(chloromethyl)-1,3 propylene bis-di(2-chloroethyl)phosphate, bis(dichloropropyl) tribromoneopentyl phosphate, tetrakis(2-chloroethyl) ethylene diphosphate, oligomeric phosphate ester as described in Canadian Pat. No. 1,127,176, pentabromodiphenyl oxide, bis(pentabromophenoxy) ethane, bis(tetrabromophthalimide)ethane, tetrabromobisphenol A, hexabromocyclododecane, bis(tribromophenoxy)ethane, octabromodiphenyl oxide, tribromoneopentyl alcohol, chlorinated paraffin, brominated paraffin, and mixtures thereof.

Claim 11

The foam of claim 7 wherein the combined weight of said halogenated flame retardant and said urea-formaldehyde resin is from about 8 to about 20 weight percent of the total weight of foam, and the weight ratio of said halogenated flame retardant to said urea-formaldehyde resin is from about 4:1 to about 1:1.

Claim 12

The foam of claim 9 wherein the weight ratio of halogenated flame retardant to urea-formaldehyde resin is from 3:1 to 2:1.

Claim 13

The foam of claim 7 wherein the urea-formaldehyde resin is a methylated urea-formaldehyde resin.

Claim 14

A composition for enhancing the flame retardance and dripping ember retardance of polyurethane foams which comprises (1) halogenated flame retardant, and (2) water or alcohol soluble urea-formaldehyde resin.

Claim 15

A composition for enhancing the flame retardance and dripping ember retardance of polyurethane foams which comprises (1) halogenated flame retardant, and (2) water or alcohol soluble urea-formaldehyde resin.

Claim 16

The composition of claim 12 wherein the halogenated flame retardant is selected from the group consisting of tris(1,3-dichloropropyl)phosphate, tris(2,3-dibromopropyl)phosphate, dichloromethylene-bis(di-2-chloroethyl)phosphate, tris(2-chloroethyl)phosphate, tris(2-chloropropyl)phosphate, 2,2-bis(chloromethyl) 1,3 propylene bis-di(2-chloroethyl)phosphate, bis(dichloropropyl) tribromoneopentyl phosphate, tetrakis (2-chloroethyl) ethylene diphosphate, pentabromodiphenyl oxide, bis(pentabromophenoxy)ethane, bis(tetrabromophthalimide)ethane, tetrabromobisphenol A, hexabromocyclododecane, bis(tribromophenoxy)ethane, octabromodiphenyl oxide, tribromoneopentyl alcohol, chlorinated paraffin, brominated paraffin, and mixtures thereof.

Claim 17

The composition of claim 12 wherein the weight ratio of said halogenated flame retardant to said urea-formaldehyde resin is from about 4:1 to about 1:1.

Claim 18

The composition of claim 14 wherein the weight ratio of said halogenated flame retardant to said urea-formaldehyde resin is from 3:1 to 2:1.

Claim 19

The composition of claim 12 wherein the urea-formaldehyde resin is a methylated urea-formaldehyde resin.

Claim 20

The composition of claim 12 in liquid form.

Claim 21

The composition of claim 17 wherein all or a portion of the urea-formaldehyde resin is non-settleably suspended in a liquid halogenated flame retardant medium.

Claim 22

The composition of claim 18 wherein a major portion of said halogenated flame retardant is selected from the group consisting of tris(2-chloroethyl)phosphate, tris(beta-chloropropyl)phosphate, tris(dichloropropyl)phosphate, or mixtures thereof.