Manufacture of fire retardant foams
AssigneeImperial Chemical Industries PLC
InventorsErnst O. Dueber, Louis Muller
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Abstract
The invention provides a process for the manufacture of polymeric foams by reacting at least one isocyanate-containing component and water, in which process the isocyanate-containing component comprises a dispersion of a solid fire retardant additive in a liquid isocyanate prepolymer having a free NCO content between 2 and 15% by weight. The invention also provides new fire retardant compositions comprising a dispersion of a solid fire retardant in liquid isocyanate-containing prepolymer compositions based on a diphenylmethane diisocyanate component and a polyol component.
Claims14
A process for the manufacture of polymeric foam by reacting at least one isocyanate-containing component and water, wherein the improvement is characterised in that the isocyanate containing component comprises a dispersion of a solid fire retardant additive in a liquid isocyanate prepolymer having a free-NCO content between 2 and 15% by weight, said prepolymer being the reaction product of an excess amount of organic polyisocyanate and one or more compounds containing a plurality of isocyanate-reactive groups.
A fire retardant composition comprising a dispersion of a solid fire retardant in a liquid isocyanate-containing prepolymer composition, characterised in that the liquid isocyanate-containing prepolymer composition has an average isocyanate functionality greater than 2 and an NCO content of from 2 to 15% by weight as obtained by reacting an isocyanate reactive polymer having an average nominal functionality of from 2 to 6, and an average equivalent weight of from about 500 to 5000 with a stoichiometric excess of a diphenylmethane diisocyanate composition containing at least 2% by weight of 2,4'-diphenylmethane diisocyanate and having an average isocyanate functionality in the range from 2 to 2.3
A fire retardant composition comprising a dispersion of a solid fire retardant in a liquid isocyanate-containing prepolymer composition, characterised in that the liquid isocyanate-containing prepolymer composition has an average isocyanate functionality greater than 2 and an NCO content of from 2 to 15% by weight obtained by reacting:
- (i) a polyol component comprising at least one polyoxyalkylene polyol containing oxyethylene residues, said polyol component having an average nominal functionality of from 2 to 6, an average hydroxyl equivalent weight of from about 500 to about 5000 and an average oxyethylene content of from 5 to 30% on a weight basis of total oxyalkylene residues, and
- (ii) a stoichiometric excess, relative to the polyol component, of a diphenylmethane diisocyanate composition containing at least 2% by weight of 2,4'-diphenyl-methane diisocyanate on a weight basis of diisocyanate components, and having an average isocyanate functionality in the range from 2 to 2.3.
A fire retardant composition comprising a dispersion of a solid fire retardant in a liquid isocyanate-containing prepolymer composition characterised in that the liquid isocyanate containing prepolymer composition is obtained by reacting an isocyanate-reactive polyoxyalkylene polymer with a diphenylmethane diisocyanate containing composition, characterised by
- an average isocyanate functionality of the prepolymer composition greater than 2,
- an --NCO content of the prepolymer composition of from 2 to 12% by weight;
- an oxyethylene content in the isocyanate-reactive polyoxyalkylene polymer in the range from 5 to 30% on a weight basis of total oxyalkylene residues;
- an average nominal functionality of the isocyanate reactive polyoxyalkylene polymer of from 2 to 6;
- a total diphenylmethane diisocyanate content in the diphenylmethane diisocyanate--containing composition of at least 60% by weight;
- a2,4' diphenylmethane diisocyanate isomer content in the diphenylmethane diisocyanate--containing composition of at least 5%;
- an average isocyanate functionality of the diphenylmethane diisocyanate--containing composition of from 2 to 2.3.
Dependencies are inferred from the claim text.