Polyurethane foam compositions and process for making same

摘要

The present invention generally relates to polyurethane foam composition. In one embodiment, the present invention relates to polyurethane foam compositions that have increased and/or improved fire-retardant properties due to the inclusion of one or more liquid and/or solid fire-retardants. In another embodiment, the present invention relates to polyurethane foam compositions that have increased and/or improved fire-retardant properties due to the inclusion of one or more intumescent materials (e.g., expandable graphite (EG)). In still another embodiment, the present invention relates to polyurethane foam compositions that have increased and/or improved fire-retardant properties due to the inclusion of expandable graphite.

主权项

1. A sprayed polyurethane foam formed from a combination comprising:
(a) at least one isocyanate component, wherein the at least one isocyanate component comprises:
(i) at least one intumescent compound;(ii) at least one isocyanate compound; and(iii) at least one anti-settling compound, (b) at least one polyol component, wherein the at least one polyol component comprises:
(i) at least one intumescent compound;(ii) at least one polyol compound; and(iii) at least one anti-settling compound, and wherein components (a) and (b) are sprayed at a ratio of about one to one by volume to yield a sprayed polyurethane foam composition, wherein the at least one intumescent compound is a particle-based expandable graphite compound where at least 90.55 percent by weight of the particles of the expandable graphite compound have a particle size in the range of 250 microns to 500 microns, and wherein the sprayed polyurethane foam contains between about 7.5 percent by weight to 12.5 percent by weight of the particle-based expandable graphite compound and passes a fire test selected from UL 1715.