Flame retardant polyurethane composition and method of manufacture thereof

• US 6,653,361 B2
• Filed: 04/25/2002
• Issued: 11/25/2003
• Est. Priority Date: 12/29/2000
• Status: Expired due to Fees

• Current Assignee: World Properties Incorporated
• Original Assignee: World Properties Incorporated
• Inventors: Svoboda, Petr, Gilman, Amy L., Simpson, Scott S.
• Primary Examiner(s): COONEY, JOHN M
• Application Number:
  US10/132,667
• Publication Number:
  US 20030040548A1
• Time in Patent Office: 579 Days
• Field of Search: 521/110, 521/112, 521/117, 521/119, 521/122, 521/123, 521/126, 521/127, 521/128, 521/129, 521/131, 521/159, 521/171, 521/176, 521/174
• US Class Current: 521/171
• CPC Class Codes: C08G 18/0885 using additives, e.g. absorbing agents
• CPC Class Codes: C08G 18/381 having bromine atoms
• CPC Class Codes: C08G 18/4072 Mixtures of compounds of group C08G18/63 with other macromolecular compounds
• CPC Class Codes: C08G 18/632 onto polyethers
• CPC Class Codes: C08G 18/6674 with compounds of group C08G18/3203
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/0066 ≥ 150kg/m3
• CPC Class Codes: C08G 2190/00 Compositions for sealing or packing joints
• CPC Class Codes: C08G 2290/00 Compositions for creating anti-fogging
• CPC Class Codes: C08K 3/2279 of antimony
• CPC Class Codes: C08K 5/12 of cyclic polycarboxylic acids
• CPC Class Codes: C08K 5/3417 condensed with carbocyclic rings
• CPC Class Codes: C08L 75/04 Polyurethanes

Abstract

A polyurethane foam or elastomer comprises an organic polyisocyanate component, an active hydrogen-containing component reactive with the polyisocyanate component, wherein the viscosity of this component is less than about 500 cP at room temperature, a catalyst component, a surfactant, and a flame retarding composition. The components may be low VOC. A preferred flame retarding composition comprises an antimony-based compound, a halogenated, active hydrogen-containing component reactive with the polyisocyanate component, and a halogenated flame-retarding agent. Such polyurethanes are useful as gaskets, seals, padding, in automotive applications, and the like.

Claims

1. A flame retardant polyurethane foam formed from a composition comprising:

an organic polyisocyanate component;

an active hydrogen-containing component substantially reactive with the polyisocyanate to form a polyurethane, wherein the viscosity of the active hydrogen-containing component is less than about 500 cP at room temperature;

a surfactant;

a catalyst having substantial catalytic activity in the curing of said mixture; and

a flame retarding composition comprising;

an antimony-based compound;

a halogenated, active hydrogen-containing component reactive with the polyisocyanate component; and

a halogenated flame retarding agent, wherein the molar ratio of total halogen to antimony is about 2.0;

1 to about 24.0;

1, and further wherein the total composition comprises at least about 12 weight percent halogen.

2. The foam of claim 1, wherein the wherein the molar ratio of total halogen to antimony is about 3.0:

1 to about 18.0;

1.

3. The foam of claim 1, wherein the wherein the molar ratio of total halogen to antimony is about 4.0:

1 to about 16.0;

1.

4. The foam of claim 1, wherein the viscosity of the active hydrogen-containing component is less than about 300 cP at room temperature.

5. The foam of claim 1, wherein the viscosity at room temperature of a mixture of the active hydrogen-containing component, surfactant, flame retarding composition, and catalyst is less than about 8000 cP at room temperature.

6. The foam of claim 1, wherein the antimony-based compound is antimony trioxide.

7. The foam of claim 1, wherein the halogenated, active hydrogen-containing component is a brominated polyol.

8. The foam of claim 1, wherein the composition is low VOC.

9. The foam of claim 1, wherein the molar ratio of total halogen to antimony is about 10:

1 to about 24.0;

1.

10. The foam of claim 1 having a UL 94 rating of V-0, V-1, HF1 or HBF.

11. The foam of claim 9, wherein the foam has a thickness of less than about one-half inch and a density of about 10 to about 65 pcf.

12. The foam of claim 1 having a UL 94 rating of V-0 and HFB, wherein the foam has thickness of about 12 to about 500 mils and a density of about 10 to about 30 pcf.

13. The foam of claim 1 having a 70°

C. compression set of less than about 10% after 50% compression for 22 hours, a compressive force deflection of less than about 30 psi, and a tear strength greater than about 5 pli.

14. The foam of claim 1 having a 70°

C. compression set of less than about 10% after 25% compression for 22 hours, a compressive force deflection of greater than about 50 psi, and a tear strength greater than about 5 pli.

15. An article of manufacture comprising the foam of claim 1.

16. A gasket comprising the foam of claim 1.

17. A gasket comprising the foam of claim 10.