Tough, fire resistant polyurethane foam and method of manufacture thereof

• US 6,559,196 B2
• Filed: 06/28/2001
• Issued: 05/06/2003
• Est. Priority Date: 06/28/2000
• Status: Expired due to Term

• Current Assignee: World Properties Incorporated
• Original Assignee: World Properties Incorporated
• Inventors: Narayan, Sujatha, Simpson, Scott S.
• Primary Examiner(s): COONEY, JOHN M
• Application Number:
  US09/893,744
• Publication Number:
  US 20020040978A1
• Time in Patent Office: 677 Days
• Field of Search: 521/170, 521/174, 521/172, 521/173
• US Class Current: 521/174
• CPC Class Codes: C08G 18/0876 the dispersing or dispersed phase being a polyol
• CPC Class Codes: C08G 18/0885 using additives, e.g. absorbing agents
• CPC Class Codes: C08G 18/222 metal compounds not provided for in groups C08G18/225 - C08G18/26
• CPC Class Codes: C08G 18/3853 containing cyanurate and/or isocyanurate groups
• CPC Class Codes: C08G 18/4018 Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48
• CPC Class Codes: C08G 18/4072 Mixtures of compounds of group C08G18/63 with other macromolecular compounds
• CPC Class Codes: C08G 18/409 Dispersions of polymers of C08G in organic compounds having active hydrogen
• CPC Class Codes: C08G 18/4277 Caprolactone and/or substituted caprolactone
• CPC Class Codes: C08G 18/4841 containing oxyethylene end groups
• CPC Class Codes: C08G 18/632 onto polyethers
• CPC Class Codes: C08G 18/797 containing carbodiimide and/or uretone-imine groups
• CPC Class Codes: C08G 2101/00 Manufacture of cellular products
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/0066 ≥ 150kg/m3
• CPC Class Codes: C08G 2290/00 Compositions for creating anti-fogging
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 9/30 by mixing gases into liquid compositions or plastisols, e.g. frothing with air

Abstract

Compositions for the formation of temperature resistant, tough, flame retardant polyurethane foams, comprising a low VOC polyisocyanate component wherein the isocyanate is a low functionality isocyanate; a low VOC active-hydrogen containing component substantially reactive with the low functionality isocyanate to form a polyurethane; a surfactant composition; and a catalyst component, wherein the total mass loss of the foam is less than 1% by weight as measured by ASTM E595. The foams are useful as gasketing materials, for example.

Claims

1. A flexible polyurethane foam, formed from a foamable composition comprising:

a low VOC organic polyisocyanate component having an average isocyanate functionality from 2.00 to 2.25, inclusive;

a low VOC active hydrogen-containing component substantially reactive with the low functionality polyisocyanate to form a polyurethane,

a surfactant composition; and

a catalyst composition having substantial catalytic activity in the curing of said foamable composition, wherein the total mass loss of the flexible foam is less than about 1% by weight as measured by ASTM E595 and wherein the foam has a density of about 10 to about 50 pounds per cubic foot.

2. The foam of claim 1, wherein the polyisocyanate component has the formula Q(NCO)_i wherein Q is an aromatic organic radical having the valence of i, and i has an average value from 2.20 to 2.25, inclusive.

3. The foam of claim 2, wherein the organic polyisocyanate component is a polymeric diphenylmethane-4,4′

-diisocyanate having an average isocyanate functionality of 2.20.

4. The foam of claim 1, wherein the active hydrogen-containing component comprises a polyether polyol, a grafted polyether polyol, a filled polyether polyol, a polyester polyol, a polyurea polyol, or a combination comprising at least one of the foregoing polyols.

5. The foam of claim 4, wherein the active hydrogen-containing component comprises a polyoxyalkylene diol, a polyoxyalkylene triol, a polyoxyalkylene diol with polystyrene and/or polyacrylonitrile grafted onto the polymer chain, a polyoxyalkylene triol with polystyrene and/or polyacrylonitrile grafted onto the polymer chain, a polyurea polyol, a polyhydrazodicarbonamide polyol, a polyester polyol, or a combination comprising at least one of the foregoing polyols.

6. The foam of claim 4, wherein the active hydrogen-containing component comprises at least two polyoxyalkylene diols of different molecular weights, and a polyester polyol.

7. The foam of claim 4, wherein the active hydrogen-containing component comprises a polyoxyalkylene diol with polystyrene and/or polyacrylonitrile grafted onto the polymer chain, a polyoxyalkylene triol with polystyrene and/or polyacrylonitrile grafted onto the polymer chain, and a polyester polyol.

8. The foam of claim 4, wherein the active hydrogen-containing component comprises a polyoxyalkylene diol, a polyoxyalkylene triol with polystyrene and/or polyacrylonitrile grafted onto the polymer chain, a chain extender diol, and a polyester polyol.

9. The foam of claim 4, wherein the active hydrogen-containing component comprises a polyoxyalkylene diol, a polyoxyalkylene triol, a chain extender diol and a polyester polyol.

10. The foam of claim 4, wherein the active hydrogen-containing component comprises a polyhydrazodicarbonamide polyol, a polyoxyalkylene diol, a chain extender diol and a polyester polyol.

11. The foam of claim 4, wherein the active hydrogen-containing component further comprises a low molecular weight polyhydric alcohol chain extender having a molecular weight from about 80 to about 400.

12. The foam of claim 4, wherein the active hydrogen component comprises an ethylene oxide capped polyether oxide diol having a molecular weight from about 2000 to about 3500;

a polyether oxide diol having a molecular weight from about 1000 to about 3000; and

a polyester diol having a molecular weight from about 400 to about 600.

13. The foam of claim 7, wherein the active hydrogen-containing component comprises a polyester diol having a molecular weight in the range from about 400 to about 600, and one or a mixture of a polyether diol having polystyrene and polyacrylonitrile grafts and having a molecular weight in the range from about 1500 to about 4000.

14. The foam of claim 7, wherein the active hydrogen-containing component comprises a low molecular weight diol, a polypropylene oxide diol having a molecular weight from about 500 to about 2000, a polypropylene oxide diol having a molecular weight from about 2000 to about 4000, and a polycaprolactone-based diol having a molecular weight from about 400 to about 600.

15. The foam of claim 14, wherein the low molecular weight diol comprises 3-methyl-1,5-pentanediol and 2-methyl-1,3-propanediol.

16. The foam of claim 7, wherein the active hydrogen-containing component comprises a low molecular weight diol having a molecular weight from about 50 to about 250, a polyether oxide diol having a molecular weight from about 1500 to about 4000, a polyester diol having a molecular weight from about 400 to about 600, and a polyether triol having polystyrene and polyacrylonitrile grafts and a molecular weight from about 1500 to about 4000.

17. The foam of claim 1, wherein the hydroxyl number of the non-isocyanate components is in the range from about 28 to about 1250.

18. The foam of claim 1, wherein the ratio of the equivalents of isocyanate in the polyisocyanate to the equivalents of active hydrogen in the active hydrogen-containing component is from about 0.8 to about 1.2.

19. The foam of claim 1, wherein the ratio of the equivalents of isocyanate in the polyisocyanate to the equivalents of active hydrogen in the active hydrogen-containing component is from about 1.0 to about 1.05, inclusive.

20. The foam of claim 1, wherein the surfactant composition, the catalyst composition, or both, are low VOC.

21. The foam of claim 1, further comprising a filler.

22. The foam of claim 1, further comprising a low VOC filler.

23. The foam of claim 1, further comprising a flame retardant filler.

24. The foam of claim 23, wherein the flame retardant filler is a low VOC, non-halogenated filler.

25. The foam of claim 1, further comprising an acrylic overcoat.

26. The foam of claim 1, further comprising a low VOC antioxidant composition.

27. The foam of claim 1, wherein the foam passes FMVSS 302.

28. The foam of claim 1, having the following properties:

29. The foam of claim 1, having the following properties:

30. The foam of claim 1, having the following properties:

31. The foam of claim 1, having the following properties:

32. The foam of claim 1, having the following properties:

33. The foam of claim 1, wherein the total mass loss of the foam is less than about 0.8% by weight as measured by ASTM E595.

49. The foam of claim 22, wherein the filler is melamine cyanurate, alumina trihydrate, or a mixture comprising at least one of the foregoing fillers.

34. A flexible polyurethane foam, formed from a foamable composition consisting essentially of

a low VOC organic polyisocyanate component having an average isocyanate functionality from 2.00 to 2.25, inclusive;

a low VOC active hydrogen-containing component substantially reactive with the low functionality polyisocyanate to form a polyurethane,

a low VOC surfactant;

a low VOC, non-halogenated flame retardant filler; and

a low VOC catalyst having substantial catalytic activity in the curing of said foamable composition, wherein the total mass loss of the flexible foam is less than about 1% by weight as measured by ASTM E595, the foam passes MVSS 302, and the foam has a density of about 10 to about 50 pounds per cubic foot.

35. The foam of claim 34, wherein the total mass loss of the foam is less than about 0.8% by weight as measured by ASTM E595.

36. A flexible polyurethane foam, formed from a foamable composition consisting essentially of

a low VOC organic polyisocyanate component having an average isocyanate functionality from 2.00 to 2.25, inclusive;

a low VOC active hydrogen-containing component substantially reactive with the low functionality polyisocyanate to form a polyurethane,

a low VOC surfactant;

a low VOC, non-halogenated flame retardant filler;

a low VOC antioxidant package; and

a low VOC catalyst having substantial catalytic activity in the curing of said foamable composition, wherein the total mass loss of the flexible foam is less than about 1% by weight as measured by ASTM E595, the foam passes FMVSS Standard 302, and the foam has a density of about 10 to about 50 pounds per cubic foot.

37. The foam of claim 36, wherein the total mass loss of the foam is less than about 0.8% by weight as measured by ASTM E595.

38. A flexible polyurethane foam, formed from a foamable composition consisting essentially of

a low VOC organic polyisocyanate component having an average isocyanate functionality from 2.00 to 2.25, inclusive;

a low VOC active hydrogen-containing component substantially reactive with the low functionality polyisocyanate to form a polyurethane,

a low VOC surfactant;

a low VOC, non-halogenated flame retardant filler; and

a low VOC catalyst having substantial catalytic activity in the curing of said foamable composition, wherein the total mass loss of the flexible foam is less than about 1% by weight as measured by ASTM E595, the foam has a density of about 10 to about 50 pounds per cubic foot, the foam passes MVSS 302, and further wherein the foam has the following properties;

39. The foam of claim 38, having the following properties:

40. The foam of claim 38, having the following properties:

41. The foam of claim 38, having the following properties:

42. The foam of claim 38, having the following properties:

43. A flexible polyurethane foam, formed from a foamable composition consisting essentially of

a low VOC organic polyisocyanate component having an average isocyanate functionality from 2.00 to 2.25, inclusive;

a low VOC active hydrogen-containing component substantially reactive with the low functionality polyisocyanate to form a polyurethane,

a low VOC surfactant;

a low VOC, non-halogenated flame retardant filler,

a low VOC antioxidant package; and

a low VOC catalyst having substantial catalytic activity in the curing of said foamable composition, wherein the total mass loss of the flexible foam is less than about 1% by weight as measured by ASTM E595, the foam has a density of about 10 to about 50 pounds per cubic foot, the foam passes MVSS 302, and further wherein the foam has the following properties;

44. The foam of claim 43, having the following properties:

45. The foam of claim 43, having the following properties:

46. The foam of claim 43, having the following properties:

47. The foam of claim 43, having the following properties:

48. A method of forming a tough fire retardant flexible polyurethane foam, comprising

reacting a low VOC organic polyisocyanate component, wherein the polyisocyanate component has an isocyanate functionality from 2.00 to 2.25 with a mixture comprising

a low VOC active hydrogen-containing component substantially reactive with the low functionality polyisocyanate to form a polyurethane,

a surfactant composition;

and

a catalyst composition having substantial catalytic activity in the curing of said foamable composition;

dispersing an inert gas throughout the reacted mixture by mechanically beating the mixture to form a froth; and

curing the froth mixture to form a cured polyurethane flexible foam, wherein the total mass loss of the foam is less than about 1% by weight as measured by ASTM E595, and the foam has a density of about 10 to about 50 pounds per cubic foot.