Intumescent flexible polyurethane foam

Claim 2

In a process for preparing a flexible, resilient, flame retardant and intumescent polyurethane foam by the reaction of a polyether polyol and an organic polyisocyanate wherein the improvement comprises: adding to the polyurethane forming reactants at least one blowing agent, at least one surfactant, at least one catalyst and a flame and dripping ember retardant effective amount of an additive combination comprising: i. a polyester polyol, ii. an halogenated flame retardant, and iii. 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)tribromoneopentylphosphate, 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 additive combination is from about 40 to about 50 weight percent of the total weight of the reaction mixture.

Claim 5

The process of claim 1 wherein the weight ratio of said polyester polyol to said halogenated flame retardant to said urea-formaldehyde resin is from about 5:4:1 to about 7.5:1.5:1.

Claim 6

The process of claim 1 wherein the weight ratio of said polyether polyol to said polyester polyol is from about 1:3 to about 1:1.

Claim 7

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

Claim 8

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

Claim 9

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

Claim 10

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

Claim 11

The foam of claim 8 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)tribromoneopentylphosphate, tetrakis(2-chloroethyl)ethylene diphosphate, pentabromodiphenyl oxide, bis(pentabromophenoxy)ethane, bis(tetrabromophthalimide)ethane, tetrabromo-bisphenol A, hexabromocyclodedecane, bis(tribromophenoxy)ethane, octabromodiphenyl oxide, tribromoneopentyl alcohol, chlorinated paraffin, brominated paraffin, and mixtures thereof.

Claim 12

The foam of claim 8 wherein the combined weight of said polyester polyol, said halogenated flame retardant and said urea-formaldehyde resin is from about 40 to about 50 weight percent of the total weight of the foam.

Claim 13

The foam of claim 10 wherein the weight ratio of said polyester polyol to said halogenated flame retardant to said urea-formaldehyde resin is from about 5:4:1 to about 7.5:1.5:1.

Claim 14

The foam of claim 8 wherein the resin is a butylated urea-formaldehyde resin.

Claim 15

The foam of claim 8 wherein the resin is a methylated urea-formaldehyde resin.

Claim 16

The foam of claim 8 wherein the weight ratio of said polyether polyol to said polyester polyol is from about 1:3 to about 1:1.

Claim 17

A composition for enhancing the flame retardance and dripping ember retardance of polyether urethane foams which comprises: i. a polyester polyol, ii. an halogenated flame retardant, and iii. water or alcohol soluble urea-formaldehyde resin.

Claim 18

A composition for enhancing the flame retardance and dripping ember retardance of polyether urethane foams which comprises: i. a polyester polyol, ii. an halogenated flame retardant, and iii. water or alcohol soluble urea-formaldehyde resin.

Claim 19

The composition of claim 15 wherein the halogenated flame retardant is selected from the group consisting of tris(1,3-dichlorpropyl)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 20

The composition of claim 15 wherein the weight ratio of said polyester polyol to said halogenated flame retardant to said urea-formaldehyde resin is from about 5:4:1 to about 7.5:1.5:1.

Claim 21

The composition of claim 15 wherein the weight ratio of said polyether polyol to said polyester polyol is from about 1:3 to about 1:1.

Claim 22

The composition of claim 15 wherein the resin is a butylated urea-formaldehyde resin.

Claim 23

The composition of claim 15 wherein the resin is a methylated urea-formaldehyde resin.