Flexible Polyurethane Foam and Method of Producing Same

A method of producing a flexible polyurethane foam, said method comprising the steps of:

• providing an isocyanate component which is substantially free of toluene diisocyanate and comprises;
• polymeric diphenylmethane diisocyanate, and
• a monomeric diphenylmethane diisocyanate component comprising 2,4′-diphenylmethane diisocyanate and 4,4′-diphenylmethane diisocyanate;
• providing an isocyanate-reactive component comprising a polyether polyol having a molecular weight of from about 700 to about 20,000 and a plurality of terminal caps which are substantially free of ethylene oxide groups;
• and
• reacting the isocyanate component and the isocyanate-reactive component in the presence of a blowing agent, thereby producing the flexible polyurethane foam;
• wherein the flexible polyurethane foam is substantially free of supplemental flame retardant additives and exhibits flame retardance under flammability tests according to California Technical Bulletin 117 regulations.

A flexible polyurethane foam comprising the reaction product of:

• an isocyanate component which is substantially free of toluene diisocyanate and consists essentially of;
• polymeric diphenylmethane diisocyanate component present in said isocyanate component in an amount of from about 5 to about 25 parts by weight based on 100 parts by weight of said isocyanate component, and
• a monomeric diphenylmethane diisocyanate component present in said isocyanate component in an amount of from about 75 to about 95 parts by weight based on 100 parts by weight of said isocyanate component and comprising 2,4′-diphenylmethane diisocyanate and 4,4′-diphenylmethane diisocyanate, and
• an isocyanate-reactive component comprising;
• a polyether triol having a molecular weight of from about 700 to about 20,000 and having the following general structure:
• wherein each A is an independently selected bivalent hydrocarbon group having from 2 to 4 carbon atoms;
• each B is a bivalent hydrocarbon group having 3 carbon atoms;
• and x, y and z are each integers greater than 1;
• in the presence of a blowing agent;
• wherein said flexible polyurethane foam is substantially free of supplemental flame retardant additives and exhibits flame retardance under flammability tests according to California Technical Bulletin 117 regulations.