Reeves Brothers, Inc.

Reeves Bros. Inc.

Knoll International Holdings, Inc.

Michael A Ricciardi

Fred N Teumac

Gregory W Howard

Ronald L Murph

Flexible polyurethane foam prepared from foam forming compositions of a polyether polyol, an organic isocyanate compound, a blowing agent, and a curing agent of a melamine derivative in an amount effective to rapidly cure the resultant foam and improve the compression set properties of the foam, the amount of curing agent generally ranging from about 0.01 up to about 2 parts by weight based on 100 parts polyether polyol. Also, flame retardant polyether polyurethane foam prepared from foam forming components of a polyether polyol, an organic isocyanate compound, water, a liquid phosphorus ester in an amount of about 4 to 10 parts by weight and the curing agent in an amount of 0.4 to 2 parts by weight, each based on 100 parts by weight of the polyether polyol in the composition. The most preferred curing agent has the formula

Flame retardant internally cured polyurethane foam having improved

Methods for rapidly curing flexible polyether-derived foam in situ by adding to the foam forming composition an ammonia containing material having a decomposition temperature below the temperature of the highest reaction exotherm of the foam-forming composition and decomposing the ammonia containing material by exposure to the heat of the exotherm produced by reaction of the foam-forming components to release ammonia to cure the foam by contact therewith.

Rapid cure of polyurethane foam with ammonium containing materials

Compositions and methods for providing a flexible flame retardant polyether polyurethane foam prepared from foam forming components of a polyether polyol, an organic isocyanate compound, water, a liquid phosphorus ester in an amount of about 4 to 10 parts by weight and melamine in an amount of 1 to 5 parts by weight, each based on 100 parts by weight of the polyether polyol in the composition. Between 15 and 500 percent by weight melamine is used to replace a minor portion of the amount of ester (i.e., less than half) which would normally be used to achieve substantially the same degree of flame retardance in the foam.

Flame retardant melamine containing polyurethane foam

Flexible polyurethane foam forming compositions comprising a polyether polyol, an organic isocyanate compound, a blowing agent, and a curing agent, preferably melamine, in an amount effective to rapidly cure the resultant foam and improve the compression set properties of the foam, the amount of curing agent generally ranging from about 0.25 up to about 4 parts by weight based on 100 parts polyether polyol. Also, the composition of polyurethane foams and methods of forming same from such foam-forming compositions.

Melamine cured polyurethane foam with improved properties

A method for manufacturing a molded polyurethane article from a polyurethane foam forming composition, wherein the composition includes a polyol, an organic isocyanate compound and water, with the polyol being a polymer dispersion formed by free radical initiated polymerization of an ethylenically unsaturated monomer mixture having between 51 and 99 weight percent of an acrylic monomer with a polyoxyalkylene polyether polyol, wherein the monomer mixture represents between about 25 to 75 weight percent of the dispersion. After the foam is formed from the foam forming composition, it is molded under heat and pressure to form a molded polyurethane article.

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Statesville, NC, United States of America

Michael A Ricciardi