Expandable graphite flame retardant layer for polyurethane and latex foam

A flexible foam composition comprising:

• a cured flexible foam body having at least one surface, the flexible foam body selected from the group consisting of polyurethane flexible foam, latex flexible foam, and combinations thereof, wherein the cured flexible body is in the form of a continuous layer;
• and
• an expandable graphite layer comprising a plurality of expandable graphite particles applied to the cured flexible foam body on the at least one surface without distributing the expandable graphite layer in the flexible foam body wherein the expandable graphite layer is present in a dry coating weight of from about 10 g/m2 to about 25,000 g/m2, wherein the expandable graphite particles have an average particle size between about 0.01 μm to about 10,000 μm, and wherein the expandable graphite layer further includes an adhesion agent comprising a water-based binder, water, and a surfactant;
• the adhesion agent adhering the expandable graphite particles to the at least one surface of the cured flexible foam body;
• wherein the flexible foam composition further comprises an antimicrobial package, at least one thermally-conductive material, in the absence of red phosphorus;
• and wherein the expandable graphite layer applied to the cured flexible foam body generates an airflow loss compared to a cured flexible foam body without the expandable graphite layer of about 14% to about 22% as determined by ASTM D3574 Test G.

A flexible foam composition comprising:

• a cured flexible foam body having at least one surface, the flexible foam body selected from the group consisting of polyurethane flexible foam, latex flexible foam, and combinations thereof, wherein the cured flexible body is in the form of a continuous layer;
• and
• an expandable graphite layer comprising a plurality of expandable graphite particles applied to the cured flexible foam body on the at least one surface without distributing the expandable graphite layer in the flexible foam body wherein the expandable graphite layer is present in an amount effective to retard the flammability of the cured flexible foam body, and wherein the expandable graphite layer further includes an adhesion agent comprising a water-based binder, water, and a surfactant;
• the adhesion agent adhering the expandable graphite particles to the at least one surface of the cured flexible foam body comprises;
• wherein the flexible foam composition further comprises aluminum trihydrate, at least one thermally-conductive material, in the absence of red phosphorus;
• and wherein the expandable graphite layer applied to the cured flexible foam body generates an airflow loss compared to a cured flexible foam body without the expandable graphite layer of about 14% to about 22% as determined by ASTM D3574 Test G.