PIPA Based Combustion-Modified Flexible Foam

摘要

A process for forming a combustion-modified ether (CME) polyurethane foam includes providing a polyol component including a PIPA polyol that is a dispersion having a solids content from 10 wt % to 75 wt %, based on a total weight of the PIPA polyol, providing an isocyanate component that includes at least one polyisocyanate, providing an additive component that includes at least one flame retardant, and forming a reaction mixture including the polyol component, the isocyanate component, and the additive component to form a CME polyurethane foam. The reaction mixture has an isocyanate index from 90 to 150. The PIPA polyol is a reaction product of a mixture including at least a low equivalent weight polyol having a number average hydroxyl equivalent weight of less than 80, a polyisocyanate compound having a number average isocyanate equivalent weight that is less than 225, and a liquid base poly ether polyol having a number average hydroxyl equivalent weight of at least 200 and at least 80% of secondary hydroxyl groups based on a total amount of hydroxyl groups in the liquid base polyether polyol.

主权项

1. A process for forming a combustion-modified ether (CME) polyurethane foam, the process comprising:
providing a polyol component including a PIPA polyol that is a dispersion having a solids content from 10 wt % to 75 wt %, based on a total weight of the PIPA polyol, the PIPA polyol being a reaction product of a mixture including at least a low equivalent weight polyol having a number average hydroxyl equivalent weight of less than 80, a polyisocyanate compound having a number average isocyanate equivalent weight that is less than 225, and a liquid base polyether polyol having a number average hydroxyl equivalent weight of at least 200 and at least 80% of secondary hydroxyl groups based on a total amount of hydroxyl groups in the liquid base polyether polyol; providing an isocyanate component that includes at least one polyisocyanate; providing an additive component that includes at least one flame retardant; and forming a reaction mixture including the polyol component, the isocyanate component, and the additive component to form a CME polyurethane foam, the reaction mixture having an isocyanate index from 90 to 150, wherein the CME polyurethane foam has a resiliency value below 45% and meets Crib 5 flammability test requirements.