Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4833—Polyethers containing oxyethylene units
  • C08G18/4837—Polyethers containing oxyethylene units and other oxyalkylene units
  • C08G18/4841—Polyethers containing oxyethylene units and other oxyalkylene units containing oxyethylene end groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/08—Processes
  • C08G18/16—Catalysts
  • C08G18/18—Catalysts containing secondary or tertiary amines or salts thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4804—Two or more polyethers of different physical or chemical nature
  • C08G18/4816—Two or more polyethers of different physical or chemical nature mixtures of two or more polyetherpolyols having at least three hydroxy groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4833—Polyethers containing oxyethylene units
  • C08G18/4837—Polyethers containing oxyethylene units and other oxyalkylene units
  • C08G18/4845—Polyethers containing oxyethylene units and other oxyalkylene units containing oxypropylene or higher oxyalkylene end groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
  • C08G18/72—Polyisocyanates or polyisothiocyanates
  • C08G18/74—Polyisocyanates or polyisothiocyanates cyclic
  • C08G18/76—Polyisocyanates or polyisothiocyanates cyclic aromatic
  • C08G18/7657—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings
  • C08G18/7664—Polyisocyanates or polyisothiocyanates cyclic aromatic containing two or more aromatic rings containing alkylene polyphenyl groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/02—Elements
  • C08K3/04—Carbon
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/32—Phosphorus-containing compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L75/00—Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
  • C08L75/04—Polyurethanes
  • C08L75/08—Polyurethanes from polyethers
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K21/00—Fireproofing materials
  • C09K21/02—Inorganic materials
  • C09K21/04—Inorganic materials containing phosphorus
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K21/00—Fireproofing materials
  • C09K21/06—Organic materials
  • C09K21/12—Organic materials containing phosphorus
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0025—Foam properties rigid
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0083—Foam properties prepared using water as the sole blowing agent
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/32—Phosphorus-containing compounds
  • C08K2003/321—Phosphates
  • C08K2003/322—Ammonium phosphate
  • C08K2003/323—Ammonium polyphosphate

Definitions

• the present invention relates to polyurethane foams having reduced flammability, smoke and toxicity, for use in railways.
• Polyurethane (PU) foam obtained by reacting organic diisocyanates and/or polyisocyanate with compounds containing at least two reactive hydrogen atoms, for example polyoxyalkylenepoly- amines and/or preferably organic polyhydroxyl compounds, in particular polyetherols having molecular weights of, for example, from 300 to 6000 g/mol, and, if desired, chain extenders and/or crosslinkers having molecular weights upto about 400 g/mol in the presence of catalysts, blowing agents, flame-retardants, auxiliaries, and/or additives is known and has been described many times.
• These PU foams find wide applications in areas, such as but not limited to, auto motive seating/arm rests, foamed carpet backing and furniture.
• Hazard levels have been designated, reflecting the degree of probability of per sonal injury as the result of a fire. The levels are based on dwell time and are related to opera tion and design categories. HL1 is the lowest hazard level and is typically applicable to vehicles that run under relatively safe conditions (easy evacuation of the vehicle). HL3 is the highest hazard level and represents most dangerous operation/design categories (difficult and/or time- consuming evacuation of the vehicle, e.g. in underground rail cars). For each application type, different test requirements for the hazard levels are defined.
• the requirements are very stringent.
• the MARHE of equal to or less than 50 kW/m 2 , determined according to ISO 5660-1, smoke optical density (D s ) of less than 200 m 2 /m 2 , determined according to ISO 5659-2 and toxicity index (CIT g ) of less than 0.75, determined according to ISO 5659-2, is difficult to achieve.
• D s smoke optical density
• CIT g toxicity index
• the presently claimed invention is directed to a polyurethane foam obtained by reacting a reactive composition comprising:
• (C) a flame-retardant mixture comprising (i) 70 wt.% to 99 wt.% of expandable graphite and (ii) 1 wt.% to 30 wt.% of ammonium polyphosphate, based on the total weight of the flame-retardant mixture, wherein the weight ratio between the flame-retardant mixture and the isocyanate reactive component is in between 1:5 to 5:1.
• the presently claimed invention is directed to a process for preparing the above-mentioned polyurethane foam by reacting the reactive composition comprising the isocy anate component and the isocyanate component, in the presence of the flame-retardant mix ture, wherein the weight ratio between the flame-retardant mixture and the isocyanate reactive component is in between 1:5 to 5:1.
• the presently claimed invention is directed to a shaped article comprising the above-mentioned polyurethane foam.
• the presently claimed invention is directed to a process for preparing the above-mentioned shaped article.
• the presently claimed invention is directed to a railway component com prising the above-mentioned polyurethane foam.
• An aspect of the present invention is embodiment 1, directed to a PU foam obtained by reacting a reactive composition comprising:
• (C) a flame-retardant mixture comprising (i) 70 wt.% to 99 wt.% of expandable graphite and (ii) 1 wt.% to 30 wt.% of ammonium polyphosphate, based on the total weight of the flame-retardant mixture, wherein the weight ratio between the flame-retardant mixture and the isocyanate reactive com ponent is in between 1:5 to 5:1.
• the PU foam in the embodiment 1 is a flexible PU foam.
• the flexible PU foam has a density in between 50 kg/m 3 to 120 kg/m 3 determined according to DIN EN ISO 845.
• the isocyanate component (A) and the isocyanate reactive component (B) in the embodiment 1 is present in a mix ratio, (A):(B), in between 10:4.0 to 4.0:10.
• the isocyanate component (A) and the isocyanate reactive component (B) in the embodiment 1 are present at an index in between 40 to 200.
• the index is in between 40 to 180, or 40 to 160.
• the index is in be tween 40 to 150, or 50 to 150, or 60 to 140.
• the index is in between 60 to 130, or 60 to 120, or 60 to 110, or 60 to 100, or 80 to 100.
• the isocyanate index describes the molar ratio of NCO groups to isocyanate reactive groups.
• An index of 100 relates to the ratio of 1 :1.
• the isocyanate component (A) can be referred as A-side component or iso-side, while the isocyanate reactive component can be referred as B-side component or resin-side.
• the isocyanate component (A) in the embodiment 1 comprises an aromatic isocyanate or an aliphatic isocyanate. It is to be understood that the isocyanate includes both monomeric and polymeric forms of the aliphatic or aromatic isocyanate. By the term “polymeric”, it is referred to the polymeric grade of the aliphatic or aromatic isocyanate comprising, inde pendently of each other, different oligomers and homologues.
• the isocyanate has an NCO content in between 20 wt.% to 50 wt.%, or in be tween 20 wt.% to 40 wt.%, or in between 30 wt.% to 40 wt.%, or in between 30 wt.% to 35 wt.%.
• the aliphatic isocyanate is selected from tetramethylene 1,4-diisocyanate, pentamethylene 1,5-diisocyanate, hexamethylene 1,6-diisocyanate, decamethylene diisocya nate, 1 ,12-dodecane diisocyanate, 2,2,4-trimethyl-hexamethylene diisocyanate, 2,4,4-trimethyl- hexamethylene diisocyanate, 2-methyl-1,5-pentamethylene diisocyanate, cyclobutane- 1, 3-diiso- cyanate, 1,2-, 1,3- and 1,4-cyclohexane diisocyanates, 2,4- and 2,6-methylcyclohexane diisocy anate, 4,4'- and 2,4'-dicyclohexyldiisocyanates, 1,3,5-cyclohexane triisocyanates, isocy- anatomethylcyclohexan
• the isocyanate component (A) in the embodiment 1 comprises an aromatic isocyanate. In another embodiment, the isocyanate component (A) in the embodiment 1 con sists of the aromatic isocyanate only.
• Suitable aromatic isocyanate is selected from toluene diisocyanate; polymeric toluene diisocya nate, methylene diphenyl diisocyanate; polymeric methylene diphenyl diisocyanate; m-phe- nylene diisocyanate; 1,5-naphthalene diisocyanate; 4-chloro-1 ; 3-phenylene diisocyanate; 2,4,6- toluylene triisocyanate, 1 ,3-diisopropylphenylene-2, 4-diisocyanate; 1 -methyl-3, 5-dieth- ylphenylene-2, 4-diisocyanate; 1 , 3, 5-triethylphenylene-2, 4-diisocyanate; 1 ,3,5-triisoproply-phe- nylene-2, 4-diisocyanate; 3,3'-diethyl-bisphenyl-4,4'-diisocyanate
• the aromatic isocyanate is selected from toluene diisocyanate; poly meric toluene diisocyanate, methylene diphenyl diisocyanate; polymeric methylene diphenyl diisocyanate; m-phenylene diisocyanate; 1,5-naphthalene diisocyanate; 4-chloro-1 ; 3-phenylene diisocyanate; 2, 4, 6-toluylene triisocyanate, 1,3-diisopropylphenylene-2, 4-diisocyanate; 1-me- thyl-3,5-diethylphenylene-2, 4-diisocyanate; 1 , 3, 5-triethylphenylene-2, 4-diisocyanate; 1 ,3,5- triisoproply-phenylene-2, 4-diisocyanate; 3,3'-diethyl-bisphenyl-4,4'-diisocyanate; 3,5,3',5'-t
• the aromatic isocyanate is selected from toluene diisocyanate; poly meric toluene diisocyanate, methylene diphenyl diisocyanate; polymeric methylene diphenyl diisocyanate; m-phenylene diisocyanate; 1,5-naphthalene diisocyanate; 4-chloro-1; 3-phenylene diisocyanate and 2, 4, 6-toluylene triisocyanate.
• the aromatic isocya nate is selected from toluene diisocyanate; polymeric toluene diisocyanate, methylene diphenyl diisocyanate and/or polymeric methylene diphenyl diisocyanate; m-phenylene diisocyanate.
• the isocyanate comprises methylene diphenyl diisocyanate and/or poly meric methylene diphenyl diisocyanate.
• Methylene diphenyl diisocyanate is available in three different isomeric forms, namely 2,2'-meth- ylene diphenyl diisocyanate (2,2'-MDI), 2,4'-methylene diphenyl diisocyanate (2,4'-MDI) and 4,4'-methylene diphenyl diisocyanate (4,4'-MDI).
• Methylene diphenyl diisocyanate can be classi fied into monomeric methylene diphenyl diisocyanate and polymeric methylene di-phenyl diiso cyanate referred to as technical methylene diphenyl diisocyanate.
• Polymeric methylene diphe nyl diisocyanate includes oligomeric species and methylene diphenyl diisocyanate isomers.
• polymeric methylene diphenyl diisocyanate may contain a single methylene diphenyl diisocyanate isomer or isomer mixtures of two or three methylene diphenyl diisocyanate iso mers, the balance being oligomeric species.
• Polymeric methylene diphenyl diisocyanate tends to have isocyanate functionalities of higher than 2.0. The isomeric ratio as well as the amount of oligomeric species can vary in wide ranges in these products.
• polymeric meth ylene diphenyl diisocyanate may typically contain 30 wt.-% to 80 wt.-% of methylene diphenyl diisocyanate isomers, the balance being said oligomeric species.
• the methylene diphenyl diiso cyanate isomers are often a mixture of 4,4'-methylene diphenyl diisocyanate, 2,4'-methylene di phenyl diisocyanate and very low levels of 2,2'-methylene di-phenyl diisocyanate.
• reaction products of isocyanates with polyols and their mixtures with other diisocyanates and polyisocyanates can also be used.
• the isocyanate component (A) in the embodiment 1 is polymeric MDI, as described hereinabove.
• the isocyanate component (A) in the embodiment 1 can further comprises ingredients which are non-reactive with isocyanate.
• ingredients include flame retardants, surfactants, catalysts, and other additives, as described herein.
• the isocyanate reactive component (B) in the embodiment 1 comprises:
• the polyether polyol in the embodiment 1 has the average functionality in between 1.9 to 5.0 and a OH value in between 10 mg KOH/g to 1000 mg KOH/g. In another embodiment, the average functionality is in between 1.9 to 4.0 and the OH value in between 10 to 500 mg KOH/g. The OH value is determined according to DIN 53240.
• Suitable polyether polyols are obtainable by known methods, for example by anionic polymeri zation with alkali metal hydroxides, e.g., sodium hydroxide or potassium hydroxide, or alkali metal alkoxides, e.g., sodium methoxide, sodium ethoxide, potassium ethoxide or potassium isopropoxide, as catalysts and by adding at least one amine-containing starter molecule, or by cationic polymerization with Lewis acids, such as antimony pentachloride, boron fluoride etherate and so on, or fuller’s earth, as catalysts from one or more alkylene oxides having 2 to 4 carbon atoms in the alkylene moiety.
• alkali metal hydroxides e.g., sodium hydroxide or potassium hydroxide
• alkali metal alkoxides e.g., sodium methoxide, sodium ethoxide, potassium ethoxide or potassium isopropoxide
• Lewis acids such
• Starter molecules are generally selected such that their average functionality is in between 2.0 to 5.0. Optionally, a mixture of suitable starter molecules is used.
• Starter molecules for polyether polyols include amine containing and hydroxyl-containing starter molecules.
• Suitable amine containing starter molecules include, for example, aliphatic and aro matic diamines such as ethylenediamine, propylenediamine, butylenediamine, hexamethylene- diamine, phenylenediamines, toluenediamine, diaminodiphenylmethane and isomers thereof.
• Suitable starter molecules further include alkanolamines, e.g. ethanolamine, N-methyleth- anolamine and N-ethylethanolamine, dialkanolamines, e.g., diethanolamine, N-methyldiethano- lamine and N-ethyldiethanolamine, and trialkanolamines, e.g., triethanolamine, and ammonia.
• alkanolamines e.g. ethanolamine, N-methyleth- anolamine and N-ethylethanolamine
• dialkanolamines e.g., diethanolamine, N-methyldiethano- lamine and N-ethyldiethanolamine
• trialkanolamines e.g., triethanolamine, and ammonia.
• amine containing starter molecules are selected from ethylenediamine, phenylenediamines, toluenediamine and isomers thereof.
• Hydroxyl-containing starter molecules are selected from sugar alcohols, for e.g. glucose and pentaerythritol; polyhydric phenols, resols, e.g., oligomeric condensation products formed from phenol and formaldehyde, trimethylolpropane, glycerol, glycols such as ethylene glycol, propyl ene glycol and their condensation products such as polyethylene glycols and polypropylene gly cols, e.g., diethylene glycol, triethylene glycol, dipropylene glycol, and water or a combination thereof.
• the hydroxyl-containing starter molecule is glycerol.
• Suitable alkylene oxides having 2 to 4 carbon atoms are, for example, ethylene oxide, propyl ene oxide, tetrahydrofuran, 1,2-butylene oxide, 2,3-butylene oxide and styrene oxide.
• Alkylene oxides can be used singly, alternatingly in succession or as mixtures.
• the alkylene oxides are propylene oxide and/or ethylene oxide.
• the alkylene oxides are mixtures of ethylene oxide and propylene oxide that comprise more than 50 wt.-% of propylene oxide.
• the starter molecules undergo alkoxyla- tion reaction with the alkylene oxides to obtain the polyether polyols.
• Good processing herein refers to the ability of the reactive composition to consistently produce good quality foam in an industrial setting. Good processing is indicated by consistently uniform cell structure, complete mold fill ing, consistently good surface appearance, consistent foam density and consistency in foam physical properties as the foam is produced over time.
• the polyether polyol in the embodiment 1 is a first polyether polyol having a OH value of 35 mg KOH/g, prepared by an addition reaction of propylene oxide and ethylene oxide with glycerol as an initiator molecule, with terminal EO block and functionality of 3.0.
• the polyether polyol in the embodiment 1 is a second polyether polyol having a OH value of 41 mg KOH/g, prepared by an addition reaction of propylene oxide and ethylene oxide with glycerol as an initiator molecule, with terminal PO block and functionality of 3.0.
• the polyether polyol in the embodiment 1 is a mixture comprising the first polyether polyol and the second polyether polyol.
• the polyether polyol in the embodiment 1 is present in an amount in be tween 70 wt.% to 98 wt.%, based on the total weight of the isocyanate reactive component.
• surfactants known in the art can be used in the present inven tion.
• One type of surfactant is a silicone-based surfactant.
• Silicone-based surfactants for the present invention are selected from hydrolysable polyether-polysiloxane block copolymers, non- hydrolysable polyether-polysiloxane block copolymers, cyanoalkylpolysiloxanes, polyether silox- ane, polydimethylsiloxane, and polyether-modified dimethylpolysiloxane.
• the surfactant in the isocyanate reactive component in the embodiment 1 comprises a polyether polysiloxane and/or polyether siloxane.
• polyether polysiloxane is a polyether polysiloxane of general formula (I),
• Ri4 and Ri5 is, independent of each other, selected from bivalent alkylene, cycloalkylene, alkenyl, aryl; n is an integer in between 1 to 10; j and k is, independent of each other, an integer in between 0 to 10; and x and y is, independent of each other, an integer in between 1 to 10000.
• alkyl herein refers to an acyclic saturated aliphatic group including linear or branched alkyl saturated hydrocarbon radical denoted by a general formula C P H2 +1 and wherein p denotes the number of carbon atoms such as 1 , 2, 3, 4 etc.
• alkyl refers to an unsubstituted, linear or branched, C1-C 30 alkyl group.
• the unsubstituted linear C1-C 30 alkyl is selected from methyl, ethyl, propyl, butyl, pentyl, hexyl, hep- tyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, henicosyl, docosyl, tricosyl, tetracosyl, pentacosyl, hexacosyl, heptacosyl, octacosyl, noncosyl and triacontyl.
• it is selected from methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl and eicosyl.
• alkenyl refers to an unsubstituted, linear acyclic unsaturated aliphatic group including a linear alkenyl unsaturated hydrocarbon radical denoted by a general formula C P H2 -1 and wherein p denotes the number of carbon atoms such as 1, 2, 3, 4 etc.
• alkenyl refers to an unsubstituted linear C2-C30 alkenyl selected from 1- propenyl, 1-butenyl, 1-pentenyl, 1-hexenyl, 2-hexenyl, 1-heptenyl, 2-heptenyl, 1-octenyl, 2-oc- tenyl, 1-nonenyl, 2-nonenyl, 1-decenyl, 2-decenyl, 1-undecenyl, 2-undecenyl, 1-dodecenyl, 2- dodecenyl, 1-tridecenyl, 2-tridecenyl, 1-tetradecenyl, 2-tetradecenyl, 1-pentadecenyl, 2-penta- decenyl, 1-hexadecenyl, 2-hexadecenyl, 1-heptadecenyl, 2-heptadecenyl, 1-octadecen
• it is selected from 1-propenyl, 1-butenyl, 1- pentenyl, 1-hexenyl, 2-hexenyl, 1-heptenyl, 2-heptenyl, 1-octenyl, 2-octenyl, 1-nonenyl, 2-non- enyl, 1-decenyl, 2-decenyl, 1-undecenyl, 2-undecenyl, 1-dodecenyl, 2-dodecenyl, 1-tridecenyl, 2-tridecenyl, 1-tetradecenyl, 2-tetradecenyl, 1-pentadecenyl, 2-pentadecenyl, 1-hexadecenyl, 2-hexadecenyl, 1-heptadecenyl, 2-heptadecenyl and 1-octadecenyl.
• unsubstituted linear C2-C30 alkenyl selected from 1-propenyl, 1-butenyl, 1-pentenyl, 1-hexenyl, 2-hexenyl, 1-heptenyl, 2-heptenyl, 1-octenyl, 2-octenyl, 1-nonenyl, 2-nonenyl, 1-decenyl, 2-de- cenyl, 1-undecenyl, 2-undecenyl, 1-dodecenyl, 2-dodecenyl, 1-tridecenyl, 2-tridecenyl, 1- tetradecenyl, 2-tetradecenyl, 1-pentadecenyl and 2-pentadecenyl.
• unsubstituted linear C2-C30 alkenyl selected from 1-propenyl, 1-butenyl, 1-pentenyl, 1-hexenyl, 2-hexenyl, 1-heptenyl and 2-heptenyl.
• cycloalkyl refers to an unsubstituted or branched C3-C10 cycloalkyl having a monocyhack or bicyclic 3 to 10 membered saturated cycloaliphatic radical.
• the unsubstituted or branched C3-C10 cycloalkyl is a monocyclic or bicyclic C3-C10 compound.
• the representative ex amples of unsubstituted or branched C3-C10 monocyclic and bicyclic cycloalkyl is selected from cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, bicyclo[2.2.1]heptyl and bicy- clo[3.1.1]heptyl.
• the C3-C10 monocyclic and bicyclic cycloalkyl can be further branched with one or more equal or different alkyl groups, as described hereinabove.
• the representative examples of branched C3-C10 monocyclic and bicyclic cycloalkyl include, but are not limited to, methyl cy clohexyl, dimethyl cyclohexyl, etc.
• aryl refers to a monocyclic, bicyclic or tricyclic hydrocarbon ring system having pref erably 6 to 14 carbon atoms, wherein at least one carbocyclic ring is having a 4p+2n-electron system, wherein 'r' is the number of aromatic rings.
• An aryl moiety may be unsubstituted, mono- substituted or identically or differently polysubstituted. Examples of aryl moieties include, but are not limited to, phenyl, 1-naphthyl, 2-naphthyl or anthracenyl.
• heteroaryl refers to an aromatic monocyclic, bicyclic or a tricyclic hydrocarbon having 5, 6, 7, 8, 9, 10, 11, 12, 13 or 14 carbon atoms, or even 5, 6, 9 or 10 atoms, in which one to four carbon atoms are replaced by identical or different heteroatoms including oxygen, sulfur and ni trogen.
• Heteroaryl moieties may comprise 1, 2, 3, 4 or 5, or 1, 2, or 3, heteroatoms inde pendently selected from oxygen, sulfur and nitrogen.
• a heteroaryl moiety may be unsubstituted or monosubstituted or identically or differently polysubstituted.
• suit able heteroaryl moieties are selected from furyl, pyridyl, oxazolyl, thiazolyl, pyrazolyl, pyrimidi- nyl, pyrrolyl, isooxazolyl, triazolyl, tetrazolyl, pyridazinyl, isothiazolyl, benzothiazolyl, benzooxa- zolyl, benzimidazolyl, quinolinyl and isoquinolinyl.
• alkylene refers to acyclic saturated hydrocarbon chains, which combine different moieties.
• alkylene groups are selected from -CH 2 -CH 2 -, -CH 2 - CH(CH 3 )-, -CH 2 -CH(CH 2 CH 3 )-, -CH 2 -CH(n-C 3 H 7 )-, -CH 2 -CH(n-C 4 H 9 )-, -CH 2 -CH(n-C 5 Hii)-, -CH 2 - CH(n-C 6 Hi 3 )-, -CH 2 -CH(n-C 7 H 15 )-, -CH 2 -CH(n-C 8 H 17 )-, -CH(CH 3 )-CH(CH 3 )-, -(CH 2 ) 3 -, -(CH 2 ) 4 -, - (CH 2 ) 5 -, -(CH 2 ) 6 -, -(CH 2 ) 8 -, -(CH 2 )IO-, -C(CH 3 )2-, -CH 2
• C 2 -C 10 alkylene is selected from one or more of -CH 2 -CH 2 -, CH 2 -CH(CH 3 )-, -CH 2 -CH(CH 2 CH 3 )-, -CH 2 -CH(n-C 3 H 7 )-, -CH 2 -CH(n-C 4 H 9 )-, -CH2-CH(n-C 6 H 13 )-, and -(CH 2 ) 4 -.
• the polyether polysiloxane of general formula (I) is a polyether polysiloxane of general formula (l)(a),
• Ri, R 2 , R 3 and R 4 is, independent of each other, selected from alkyl, alkenyl, Ri 4 -0-(-Ri 5 -0-) j - (CnH2rr)k-;
• Ri 4 and Ri 5 is, independent of each other, selected from bivalent alkylene, cycloalkylene, alkenyl, aryl; n is an integer in between 1 to 10; j and k is, independent of each other, an integer in between 0 to 10; and z is an integer in between 1 to 10000.
• R 2 and R 3 is, independent of each other, an alkyl selected from methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl and decyl. In another embodiment, it is se lected from methyl, ethyl, propyl, butyl, pentyl and hexyl. In still another embodiment, R 2 and R 3 are identical and are selected from methyl, ethyl, propyl, butyl, pentyl and hexyl. In yet another embodiment, R 2 and R 3 comprise of methyl.
• n is an integer between 1 to 8, or in between 1 to 6, or even in between 1 to 4 in the general formula (l)(a).
• x and y are, independent of each other, an integer in between 1 to 10000, or in between 1 to 5000, or in between 1 to 1000, or in between 1 to 500, or in between 10 to 500, or even in between 10 to 250, or even still in between 10 to 100 in the general for mula (l)(a).
• the concatenations denoted by x and y are distributed to form a block polymeric structure or a random polymeric structure, as is understood by the person skilled in the art.
• the non-ionic surfactant comprises a polyether siloxane represented by the general formula (II)
• Ri 4 and Ri 5 is, independent of each other, selected from bivalent alkylene, cycloalkylene, alkenyl, aryl; m is an integer in between 1 to 10; j and k is, independent of each other, an integer in between 0 to 10; and z is an integer in between 1 to 10000.
• polyether siloxane is represented by the general formula (ll)(a),
• R 5 , R 6 , R 7 and Rs is, independent of each other, selected from alkyl, alkenyl, Ri 4 -0-(-Ri 5 -0-) j - (CnH2rr)k-;
• Ri 4 and Ri 5 is, independent of each other, selected from bivalent alkylene, cycloalkylene, alkenyl, aryl; m is an integer in between 1 to 10; j and k is, independent of each other, an integer in between 0 to 10; and z is an integer in between 1 to 10000.
• the surfactant in the embodiment 1 is present in an amount in between 0.01 wt.% to 5.0 wt.%, based on the total weight of the isocyanate reactive component.
• the amine catalyst in the embodiment 1 comprises a tertiary amine.
• Suitable catalysts can be selected from trimethylamine, triethylamine, triethylenediamine, di- methylethanolamine, N-methylmorpholine, N,N-dimethylbenzylamine, N,N-dimethylethanola- mine, N,N,N',N'-tetramethyle-1,4-butanediamine, N,N-dimethylpiperazine, bis(dimethylami- noethyl)ether, bis(2-dimethylaminoethyl) ether, morpholine, 4, 4'-(oxydi-2,l-ethanediyl)bis, triethy lenediamine, pentamethyl diethylene triamine, dimethyl cyclohexyl amine, N-acetyl N,N-dime- thyl amine, N-coco-morpholine, N,N-dimethyl aminomethyl N-methyl ethanol amine, N, N, N'- trimethyl-N'-hydroxyethyl bis(
• the amine catalyst is selected from trimethylamine, triethylamine, trieth ylenediamine, dimethylethanolamine, N-methylmorpholine, N,N-dimethylbenzylamine, N,N-di- methylethanolamine, N,N,N',N'-tetramethyle-1,4-butanediamine, N,N-dimethylpiperazine, bis(di- methylaminoethyl)ether, bis(2-dimethylaminoethyl) ether, morpholine, 4, 4'-(oxydi-2,l- ethanediyl)bis, triethylenediamine, pentamethyl diethylene triamine, dimethyl cyclohexyl amine, N-acetyl N,N-dimethyl amine, N-coco-morpholine, N,N-dimethyl aminomethyl N-methyl ethanol amine, N, N, N'-trimethyl-N'-hydroxyethyl bis(a
• the amine catalyst in the embodiment 1 is selected from trimethyla mine, triethylamine, triethylenediamine, dimethylethanolamine, N-methylmorpholine, N,N-dime- thylbenzylamine, N,N-dimethylethanolamine, N,N,N',N'-tetramethyle-1,4-butanediamine, N,N- dimethylpiperazine, bis(dimethylaminoethyl)ether, bis(2-dimethylaminoethyl) ether, morpho line, 4, 4'-(oxydi-2,l-ethanediyl)bis, triethylenediamine, pentamethyl diethylene triamine, dimethyl cyclohexyl amine, N-acetyl N,N-dimethyl amine, N-coco-morpholine, N, N, N', N'-tetramethyl hexane diamine, l,8-diazabicyclo-5,4,0-und
• the amine catalyst in the embodiment 1 is triethylenediamine, di methylethanolamine, N-methylmorpholine, N,N-dimethylbenzylamine, N,N-dimethylethanola- mine, N,N,N',N'-tetramethyle-1,4-butanedia ine, morpholine, 4, 4'-(oxydi-2,l-ethanediyl)bis, tri- ethylenediamine, pentamethyl diethylene triamine, l,8-diazabicyclo-5,4,0-undecene-7, N,N-di- morpholinodiethyl ether, N-methyl imidazole and dimethylaminopropylamine.
• the amine catalyst in the embodiment 1 comprises triethylenedia- mine and/or dimethylaminopropylamine.
• the amine catalyst in the embodiment 1 may be present together with suitable solvents.
• suitable solvents for instance, 1,4-butanediol and dipropylene glycol can be used as suitable solvents.
• the amine catalyst in the embodiment 1 is present in an amount in between 0.01 wt.% to 5.0 wt.%, based on the total weight of the isocyanate reactive component.
• the isocyanate reactive component also comprises water, which performs the function of a blowing agent.
• the water in the embodiment 1 is present in an amount in between 1.0 wt.% to 10.0 wt.%, based on the total weight of the isocyanate reactive component.
• the isocyanate reactive component in the embodiment 1 further com prises at least one additive.
• Suitable additives are selected from blowing agents, cell openers, dyes, pigments, IR absorbing materials, stabilizers, plasticizers, antistats, fungistats, bacterio- stats, hydrolysis controlling agents, curing agents, antioxidants, alkylene carbonates, carbona- mides and pyrrolidones.
• the additives can be present in an amount in between 0.1 wt.% to 5.0 wt.%, based on the total weight of the isocyanate reactive component.
• the flame-retardant mixture comprises (i) 70 wt.% to 99 wt.% of expandable graphite and (ii) 1 wt.% to 30 wt.% of ammonium polyphosphate, based on the total weight of the flame-retardant mixture.
• the flame-retardant mixture can be added directly to the isocya nate reactive component to obtain the reactive composition in the embodiment 1.
• the flame-retardant mixture can be added as a separate component, similar to the isocyanate component and the isocyanate reactive component, to obtain the reactive composition in the embodiment 1.
• the weight ratio between the flame-retardant mixture and the isocyanate reactive component is in between 1:5 to 5:1. In one embodiment, the weight ratio is in between 1:3 to 3:1. In another embodiment, it is 1:2.
• the expandable graphite in the flame-retardant mixture in the embodiment 1 is well known in the art.
• Examples include crystalline compounds that maintain a laminar structure of the carbon that has grown a graphite interlayer compound by treating natural flaky graphite, pyrolytic graphite, Kish graphite, or another such powder by concentrated sulphuric acid, nitric acid, or another such inorganic acid and concentrated nitric acid, perchloric acid, per manganate acid, bichromate, or another such strong oxidizing agent.
• Expandable graphite that has been neutralized by ammonia, an aliphatic lower amine, alkali metal compound, alkaline earth metal compound, or the like is preferably used.
• Examples of alkali metal compounds and alkaline earth metal compounds include hydroxides, oxides, car bonates, sulfates, organic acid salts, and the like of potassium, sodium, calcium, barium, mag nesium and the like.
• the expandable graphite in the flame-retardant mixture in the embodi ment 1 is formed of graphite, with H 2 SO 4 or SO 4 , for example, having two free negative va lences, which attach to two free positive valences of a hydrocarbon ring, incorporated between the planes of the graphite mesh.
• H 2 SO 4 or SO 4 for example, having two free negative va lences, which attach to two free positive valences of a hydrocarbon ring, incorporated between the planes of the graphite mesh.
• the flame-retardant mixture in the embodiment 1 also com prises ammonium polyphosphate.
• Ammonium polyphosphate is known for its flame-retardant properties.
• Ammonium polyphosphate is an inorganic salt of polyphosphoric acid and ammonia.
• the chemical formula of ammonium polyphosphate is [NH4PC>3] n , with n being greater than 100.
• the chain length (n) of ammonium polyphosphate is both variable and can be branched, and can be greater than 100, preferably greater than 1000.
• the ammonium polyphosphate may or may not be encapsulated. Suitable encapsulated ammonium polyphosphates are described in US Pat. nos. 4,347,334, 4,467,056, and 4,639,331, herein incorporated by reference. Such encapsulated ammonium polyphos phates contain a hardened water insoluble resin enveloping the individual ammonium polyphos phate particles.
• the resin may be a phenol-formaldehyde resin, an epoxy resin, surface reacted silane, a surface reacted melamine, or a melamine-formaldehyde resin.
• flame-retardants that may be optionally added as part of the flame-retardant mixture or directly to the isocyanate reactive component and/or the isocyanate component include phos phorus compounds selected from tris(2-chloroethyl)phosphate (TCEP), tris(2-chloropropyl)phos- phate (TCPP), tris(2,3-dibromopropyl)phosphate, tris(1,3-dichloropropyl)phosphate, tris(2- chloroisopropyl)phosphate, tricresylphosphate, tri(2,2-dichloroisopropyl)phosphate, diethyl-N, N- bis(2-hydryethyl)aminoethylphosphonate, tris(2,3-dibromopropyl)phosphate, tri(1 ,3-dichloropro- pyl)phosphate, diammonium phosphate, diethyl ethanephospho
• Another aspect of the present invention is embodiment 2, directed to a process for preparing the above-mentioned polyurethane foam by reacting the reactive composition comprising the isocy anate component and the isocyanate component, in presence of the flame-retardant mixture, wherein the weight ratio between the flame-retardant mixture and the isocyanate reactive com ponent is in between 1:5 to 5:1.
• the isocyanate reactive component and the flame-retardant mixture is mixed, prior to reacting with the isocyanate component.
• Suitable techniques for preparing the PU foam are well known to the person skilled in the art.
• One of the advantages of the present invention is that the reactive composition in the embodi ment 1 can be obtained using any of the conventional techniques of foaming and allowed suffi cient time for the composition to cure and form the PU foam.
• the process described in the embodiment 2 can be a slabstock process or a closed mold molding process.
• Slabstock foam is a large bun which is cut into the required shape and size for use.
• Closed mold molding process can be either so-called hot molding pro cess or a cold molding process, wherein the foaming takes place in a closed mold. After the foam has cured, the mold is opened, and the foam is removed. An integral skin can be formed onto the surface of the foam in the mold.
• a film, fabric, leather or other coverstock can be in serted into the mold prior to introducing the reactive composition, to produce the PU foam in the embodiment 2.
• the reactive composition is first obtained by mixing the isocyanate component (A) and the isocyanate reactive component (B) in the embodiment 1.
• the B-side component is a premix comprising the appropriate amounts of the polyether polyol, surfactant, amine catalyst, water, flame-retardant mixture and optionally additives, as described herein.
• elevated temperatures, above 40°C may be required to mix the components.
• the B-side component is mixed together at a temperature less than 40°C.
• the B-side compo nent is then mixed with the A-side component at suitable mix ratio.
• the resulting reactive com position is subjected to conditions sufficient to cure the reactive composition, thereby obtaining the PU foam.
• the reactive composition is either introduced into a suitable mold, so that a foam ing or curing reaction takes place within the mold to form the desired PU foam.
• the A-side component, pre-mixed with the flame-retardant mixture, and the B-side component can be mixed in a suitable mixing device and directly poured in a mold.
• nozzles may be used, with the mixing being carried out at high pressures, for instance more than 50 bars.
• the reactive composition can be poured in the mold and conditions sufficient for PU foam provided.
• the PU foam, as described herein, meets the EN-45545-2 standard.
• the EN-45545-2 standard specifies the requirements for fire behaviour during combustion of materials and products used in railway vehicles, for e.g. trains.
• any material composition typically refers to a coating material, for e.g. fabric, natural leather, artificial leather, etc., polymer, plywood, wooden board, special textiles, etc.
• the PU foam as described herein, has a density in between 50 kg/m 3 to 120 kg/m 3 determined according to DIN EN ISO 845 and also meets the requirements as per EN-45545-2. That is, to say, that the PU foam has a maximum average heat release (MARHE) of equal to or less than 50 kW/m 2 determined according to ISO 5660-1 HL3, smoke optical density (D s ) of less than 200 m 2 /m 2 and toxicity index (CIT g ) of less than 0.75, both determined according to ISO 5659-2 HL3.
• MARHE maximum average heat release
• D s smoke optical density
• CIT g toxicity index
• FIG. 3 Another aspect of the present invention is embodiment 3, directed to a shaped article comprising the above-described PU foam.
• the PU foam can be molded into any desired shape and used for purposes requiring reduced flammability, smoke and toxicity as per EN-45545-2 stand ards, particularly meeting the requirements of R21 HL3 category.
• Another aspect of the present invention is embodiment 4, directed to a process for preparing above-described shaped article, said process comprising the step of molding the PU foam in a mold.
• the reactive composition can be directly subject to a suitable mold and provided with sufficient conditions to obtain the PU foam having the desired shape.
• the shaped article is a railway component.
• railway component is a molded or extruded train seat component or a cladding.
• the cladding in the embodiment 5 is an interior vertical surface selected from room dividers, flaps, boxes, hoods and louvres; an interior door or lining for internal and external doors; a window insulation; a kitchen interior surface; an interior horizontal surface se lected from ceiling panelling, flaps, boxes, hoods and louvres; a luggage storage area selected from overhead and vertical luggage racks, luggage containers and compartments; a driver’s desk application selected from panelling and surfaces of driver’s desk; an interior surface of gangways selected from interior sides of gangway membranes (bellows) and interior linings; a window frame; an optionally folding table with downward facing surface; an interior or exterior surface of air ducts, or a device for passenger information.
• the railway component includes upholstery of seat, couchettes and berths in rail vehicles. The railway component meets the flammability requirements in accordance with DIN EN 45545-2 standards.
• a polyurethane foam obtained by reacting a reactive composition comprising:
• (C) a flame-retardant mixture comprising (i) 70 wt.% to 99 wt.% of expandable graphite and (ii) 1 wt.% to 30 wt.% of ammonium polyphosphate, based on the total weight of the flame-retardant mixture, wherein the weight ratio between the flame-retardant mixture and the isocyanate reactive component is in between 1:5 to 5:1.
• the aromatic isocyanate is selected from toluene diisocyanate; polymeric toluene diisocyanate, methylene diphenyl diisocyanate; polymeric methylene diphenyl diisocyanate; m-phenylene diisocyanate; 1,5- naphthalene diisocyanate; 4-chloro-1; 3-phenylene diisocyanate; 2,4,6-toluylene triisocya nate, 1,3-diisopropylphenylene-2, 4-diisocyanate; 1 -methyl-3, 5-diethylphenylene-2,4-diiso- cyanate; 1 , 3, 5-triethylphenylene-2, 4-diiso
• polyurethane foam according to embodiment VII or VIII, wherein the aromatic isocya nate comprises methylene diphenyl diisocyanate and/or polymeric methylene diphenyl diisocyanate.
• XI I The polyurethane foam according to one or more of embodiments I to XI, wherein the at least one surfactant is selected from polyether polysiloxane and/or polyether siloxane.
• XI I I The polyurethane foam according to one or more of embodiments I to XII, wherein the at least one surfactant is present in an amount in between 0.01 wt.% to 5.0 wt.%, based on the total weight of the isocyanate reactive component.
• XVI. The polyurethane foam according to one or more of embodiments I to XV, wherein the at least one amine catalyst is selected from trimethylamine, triethylamine, triethylenedia- mine, dimethylethanolamine, N-methylmorpholine, N,N-dimethylbenzylamine, N,N-di- methylethanolamine, N,N,N',N'-tetramethyle-1,4-butanediamine, N,N-dimethylpiperazine, bis(dimethylaminoethyl)ether, bis(2-dimethylaminoethyl) ether, morpholine, 4, 4'-(oxydi-2,l- ethanediyl)bis, triethylenediamine, pentamethyl diethylene triamine, dimethyl cyclohexyl amine, N-acetyl N,N-dimethyl amine, N-coco-morpholine, N,N-dimethyl aminomethyl N- methyl ethanol
• XVI I The polyurethane foam according to one or more of embodiments I to XVI, wherein the at least one amine catalyst comprises triethylenediamine and/or dimethylaminopropylamine.
• XVI 11 The polyurethane foam according to one or more of embodiments I to XVII, wherein the at least one amine catalyst is present in an amount in between 0.01 wt.% to 5.0 wt.%, based on the total weight of the isocyanate reactive component.
• XXI The polyurethane foam according to one or more of embodiments I to XX, wherein water is present in an amount in between 1.0 wt.% to 5.0 wt.%, based on the total weight of the isocyanate reactive component.
• XXI I The polyurethane foam according to one or more of embodiments I to XXI, wherein the isocyanate reactive component further comprises at least one additive.
• XXIII The polyurethane foam according to embodiment XXII, wherein the at least one additive is selected from blowing agents, cell openers, dyes, pigments, IR absorbing materials, stabi lizers, plasticizers, antistats, fungistats, bacterio-stats, hydrolysis controlling agents, curing agents, antioxidants, alkylene carbonates, carbonamides and pyrrolidones.
• the at least one additive is selected from blowing agents, cell openers, dyes, pigments, IR absorbing materials, stabi lizers, plasticizers, antistats, fungistats, bacterio-stats, hydrolysis controlling agents, curing agents, antioxidants, alkylene carbonates, carbonamides and pyrrolidones.
• XXIV The polyurethane foam according to embodiment XXII or XXIII, wherein the at least one additive is present in an amount in between 0.1 wt.% to 5.0 wt.%, based on the total weight of the isocyanate reactive component.
• XXV The polyurethane foam according to one or more of embodiments I to XXIV, wherein ex pandable graphite is present in an amount in between 75 wt.% to 85 wt.%, based on the total weight of the flame-retardant mixture.
• XXVI The polyurethane foam according to one or more of embodiments I to XXV, wherein am monium polyphosphate is present in an amount in between 5 wt.% to 15 wt.%, based on the total weight of the flame-retardant mixture.
• XXX.A shaped article comprising the polyurethane foam according to one or more of embodi ments I to XXVII or as obtained according to embodiment XXVIII or XXIX.
• XXXI A process for preparing the shaped article according to embodiment XXX, said process comprising the step of molding the polyurethane foam in a mold.
• XXXI I A railway component comprising the polyurethane foam according to one or more of em bodiments I to XXVII or as obtained according to embodiment XXVIII or XXIX.
• XXXI 11 The railway component according to embodiment XXXII, wherein the railway component is a molded or extruded train seat component or a cladding.
• XXXIV The railway component according to embodiment XXXII, wherein the cladding is an inte rior vertical surface selected from room dividers, flaps, boxes, hoods and louvres; an inte rior door or lining for internal and external doors; a window insulation; a kitchen interior surface; an interior horizontal surface selected from ceiling panelling, flaps, boxes, hoods and louvres; a luggage storage area selected from overhead and vertical luggage racks, luggage containers and compartments; a driver’s desk application selected from panelling and surfaces of driver’s desk; an interior surface of gangways selected from interior sides of gangway membranes (bellows) and interior linings; a window frame; an optionally fold ing table with downward facing surface; an interior or exterior surface of air ducts, or a de vice for passenger information.
• XXXV The railway component according to one or more of embodiments XXXII to XXXIII, wherein the railway component meets the flammability requirements in
• the aforementioned raw materials were added in the amounts mentioned in Table 1 in both the A-side and B-side components (all in wt.%). Both the A-side and B-side components, along with the flame-retardant mixture were then added to a mixing cup and subjected to a mixing at rpm of 1500 to obtain a desired index.
• the temperature of A-side and B-side components was main- tained between 20 ⁇ 2°C and the mixing ratio (Resin-side : Iso-side) was kept at 100:30-35.
• Table 2 Properties of IE 1 determined in accordance with respective standard methods The inventive PU foam was tested for MARHE, smoke optical density and toxicity index accord ing to respective standard methods. The results have been summarized in Table 3 below. Table 3: DIN EN 45545-2 test results for inventive PU foams IE 1 & IE 2
• the PU foam meets the requirements of DIN EN 45545-2. More importantly, the inventive PU foams IE 1 and IE 2 have MARHE values £ 50 kW/m 2 , smoke optical density (D s ) ⁇ 200 m 2 /m 2 , and toxicity index (CIT g ) ⁇ 0.75. Thus, the inventive PU foams can be used for making railway components.

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