Flame retardant rigid polyurethane syntactic foam

Abstract

A rigid polyurethane syntactic foam obtained by mixing an organic polyol, a polyisocyanate, a catalyst for the reaction of the polyol and polyisocyanate, microballoons and a flame retardant. The flame retardant is a substantially colorless, compatible flame retardant with a viscosity of less than 100 centipoise at 23.9.degree. C., with a volatility such that it does not evaporate from the reaction exotherm and with a reactivity such that it is non-reactive in the mixture to the extent that the physical properties of the foam are not substantially changed compared to the physical properties of a foam without the flame retardant. An example of the flame retardant is tris(2-chloroethyl)phosphate. A combination of the polyol and polyisocyanate are liquid at 25.degree. C. and the amount of microballoons present are sufficient to provide a non-castable mixture in the absence of the flame retardant and the amount of flame retardant is sufficient to provide a castable mixture which will flow in a mold cavity filling the details. The castable mixture can also contain noncombustible flexible fibers, such as glass fibers of less than 25 mm to improve the flexural strength. The mixture cures to a mechanically strong and structural material which is like wood except it is a flame retardant.