In-situ foaming system for forming flame-retardant polyurethane foam in situ

Abstract

An in-situ foaming system for forming a flame-retardant polyurethane foam in situ comprising a first liquid containing a polyisocyanate (A), a second liquid containing a polyol (B), a trimerization catalyst (C), a foaming agent (D), a foam stabilizer (E), and additives (F) comprising red phosphorus and at least one member selected from the group consisting of phosphoric acid esters, phosphate-containing flame retardants, bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, and metal hydroxides.

1 - 7 . (canceled) 
     
     
         8 . A flame-retardant polyurethane resin composition comprising:
 a polyisocyanate (A),   a polyol (B),   a trimerization catalyst (C),   a foaming agent (D),   a foam stabilizer (E), and   additives (F) comprising red phosphorus and at least one member selected from the group consisting of phosphoric acid esters, phosphate-containing flame retardants, bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, metal hydroxides and needle-shaped fillers.   
     
     
         9 . The flame-retardant polyurethane composition according to  claim 8 , wherein the gross calorific value measured with heating a sample of the polyurethane foam at a radiant heat intensity of 50 kW/m 2  for 10 minutes for a cone calorimeter test based on ISO-5660 is not less than 2 MJ/m 2  and not more than 7.1 MJ/m 2 . 
     
     
         10 . The flame-retardant polyurethane composition according to  claim 8 , wherein the gross calorific value measured with heating a sample of the polyurethane foam at a radiant heat intensity of 50 kW/m 2  for 20 minutes for a cone calorimeter test based on ISO-5660 is not less than 4.1 MJ/m 2  and not more than 10.3 MJ/m 2 . 
     
     
         11 . The flame-retardant polyurethane composition according to  claim 8 , wherein
 the trimerization catalyst (C) is contained within a range of 0.1 to 10 parts by weight,   the foaming agent (D) is contained within a range of 0.1 to 30 parts by weight,   the foam stabilizer (E) is contained within a range of 0.1 to 10 parts by weight,   the additives (F) is contained within a range of 4.5 to 70 parts by weight,   the red phosphorus is contained within a range of 3 to 18 parts by weight, and   a total of the at least one member selected from the group consisting of phosphoric acid esters, phosphate-containing flame retardants, bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, metal hydroxides and needle-shaped fillers is contained within a range of 1.5 to 52 parts by weight, based on 100 parts by weight of a total of the polyisocyanate (A) and the polyol (B).   
     
     
         12 . The flame-retardant polyurethane foam being formed from a flame-retardant polyurethane resin composition comprising:
 a polyisocyanate (A),   a polyol (B),   a trimerization catalyst (C),   a foaming agent (D),   a foam stabilizer (E), and   additives (F) comprising red phosphorus and at least one member selected from the group consisting of phosphoric acid esters, phosphate-containing flame retardants, bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, metal hydroxides and needle-shaped fillers.   
     
     
         13 . The flame-retardant polyurethane foam according to  claim 12 , wherein the gross calorific value measured with heating a sample of the polyurethane foam at a radiant heat intensity of 50 kW/m 2  for 10 minutes for a cone calorimeter test based on ISO-5660 is not less than 2 MJ/m 2  and not more than 7.1 MJ/m 2 . 
     
     
         14 . The flame-retardant polyurethane foam according to  claim 12 , wherein the gross calorific value measured with heating a sample of the polyurethane foam at a radiant heat intensity of 50 kW/m 2  for 20 minutes for a cone calorimeter test based on ISO-5660 is not less than 4.1 MJ/m 2  and not more than 10.3 MJ/m 2 . 
     
     
         15 . The flame-retardant polyurethane foam according to  claim 12 , wherein
 the trimerization catalyst (C) is contained within a range of 0.1 to 10 parts by weight,   the foaming agent (D) is contained within a range of 0.1 to 30 parts by weight,   the foam stabilizer (E) is contained within a range of 0.1 to 10 parts by weight,   the additives (F) is contained within a range of 4.5 to 70 parts by weight,   the red phosphorus is contained within a range of 3 to 18 parts by weight, and   a total of the at least one member selected from the group consisting of phosphoric acid esters, phosphate-containing flame retardants, bromine-containing flame retardants, boron-containing flame retardants, antimony-containing flame retardants, metal hydroxides and needle-shaped fillers is contained within a range of 1.5 to 52 parts by weight, based on 100 parts by weight of a total of the polyisocyanate (A) and the polyol (B).