JP2011252111A - Highly flame-retardant polyurethane foam - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a highly flame-retardant polyurethane foam which is a polyurethane foam using a nonhalogen type flame retardant as a flame retardant, to which remarkably excellent flame retardancy satisfying the V-0 standard of UL-94 vertical burning test is imparted with only a small compounding amount of the flame retardant, and which is therefore excellent in characteristics and a foaming property required for the polyurethane foam.SOLUTION: The highly flame-retardant polyurethane foam is obtained by foaming a polyurethane foam compound formed by compounding a polyol, an isocyanate, a foaming agent, and a flame retardant, and includes a phosphorus based flame retardant, a melamine flame retardant, and expanded graphite as flame retardants with the compounding ratio (weight ratio) of 0.2-0.6 phosphorus based flame retardant, 0.1-0.4 melamine flame retardant, and 0.3-0.6 expanded graphite (the sum total of expanded graphite, phosphorus based flame retardant, and melamine flame retardant is set to be 1), and the sum total of the compounding amounts of the flame retardants is 42-50 pts.wt with respect to 100 pts.wt of the total polyol.

Description

  The present invention relates to a highly flame retardant polyurethane foam, and more particularly to a non-halogen high flame retardant polyurethane foam using a non-halogen flame retardant as a flame retardant, and particularly UL-94 with a small amount of flame retardant. The present invention relates to a highly flame-retardant flexible polyurethane foam excellent in the original physical properties and foamability of polyurethane foam in order to exhibit remarkably excellent flame retardancy satisfying the V-0 standard in a vertical combustion test.

  Conventionally, polyurethane foam has been used in a wide range of fields such as electrical appliances such as OA equipment and plasma televisions, and other household products. In these applications, excellent flame retardancy is an essential requirement.

  In addition, for plasma TV applications, in addition to flame retardancy, it is also conductive, and since it is installed compressed in the gap of electronic equipment, it has flexibility to follow the shape of the gap and high compression repulsion Is needed. With respect to such required characteristics, polyurethane foam is excellent in flexibility as compared with other materials, and particularly can exhibit a compression repulsion force, and thus is suitably used as a core material for electrical appliances.

In such applications, after processing the polyurethane foam core or product, it is necessary to satisfy the flame retardant standards belonging to the respective applications.
In recent years, high flame retardancy has been strongly demanded for low-power applications such as plasma televisions, and in particular, V-0 in the UL-94 vertical combustion test can be achieved as an index of flame retardancy. It has become essential.

  As a method for imparting flame retardancy to a polyurethane foam, it has been generally practiced to use a halogen-based flame retardant. Although extremely excellent flame retardancy can be imparted by blending halogen flame retardants, halogen flame retardants have a problem of generating corrosive halogen gas at the time of combustion, and from the viewpoint of environmental protection in recent years, There is a demand for a technique for imparting flame retardancy using a non-halogen flame retardant containing no halogen instead of a halogen flame retardant.

  Conventionally, the most typical non-halogen flame retardant is a phosphate ester flame retardant, but this is inferior in the effect of imparting flame retardancy compared to halogen flame retardant, and its usage is considerably large. There is a need to. In addition, since it is liquid, when it is blended in a large amount, required properties other than flame retardancy such as compression resilience are impaired, and the foaming balance at the time of urethane reaction is lost, making foam formation difficult. There was a problem. Further, since the liquid flame retardant has plasticity itself and functions as a plasticizer, if the blending amount is large, the melted product and its ignitability at the time of combustion increase, and V- in the UL-94 vertical combustion test. 0 standard cannot be achieved.

  As non-halogen flame retardants other than such phosphorous liquid flame retardants, magnesium hydroxide, thermally expandable graphite, etc. are also known. It is necessary to considerably increase the amount, and in the same manner as in the case of the phosphate ester flame retardant, because of the large amount of flame retardant, required characteristics other than flame retardance such as compression resilience are impaired, There is a problem that the foaming balance at the time of urethane reaction is lost and foam formation becomes difficult.

  Patent Document 1 describes an electromagnetic shielding gasket in which 10 to 35 parts by weight of expansive graphite and 15 to 45 parts by weight of melamine are blended with respect to 100 parts by weight of a base resin obtained by reacting polyol and isocyanate. There is a description that 1 to 15 parts by weight of a phosphorus-based flame retardant may be blended.

  Patent Document 2 describes a non-halogen flame retardant synthetic resin composition in which a polyurethane resin and a phosphorus-based composition such as expansive graphite and polyphosphate and tricresyl phosphate are blended. In this Example of Patent Document 2, 100 parts by weight of polyurethane resin is mixed with 85 parts by weight of ammonium polyphosphate or red phosphorus, 85 parts by weight of expandable graphite, and 10 to 35 parts by weight of tricresyl phosphate. .

JP 2002-198679 A JP-A-2005-133054

However, the technology of Patent Document 1 does not provide sufficient flame retardancy, and in particular, cannot achieve the V-0 standard in the UL-94 vertical combustion test with a single polyurethane foam.
Even with the technology of Patent Document 2, it cannot be said that the flame retardancy is sufficient, and since the flame retardant is used in a large amount, the original physical properties and foamability of the polyurethane foam are considered to be greatly impaired.

  In other words, it is possible to increase flame retardancy by using different flame retardants in combination, but as with the case of using flame retardants alone, the required amount of addition increases, and as a result, polyurethane foam other than flame retardant inherently The physical properties of the resin are impaired, and foaming control becomes difficult. Therefore, it is desired to develop a technology for increasing the flame retardancy while suppressing the blending amount of the flame retardant for obtaining the required flame retardancy.

  The present invention has been made in view of the above-described conventional situation, and is a polyurethane foam using a non-halogen flame retardant as a flame retardant, and is a V- An object of the present invention is to provide a highly flame-retardant polyurethane foam that can impart remarkably excellent flame retardancy that satisfies the 0 standard, and therefore has excellent properties and foamability required for polyurethane foam.

  As a result of intensive studies to solve the above problems, the present inventors have used the above three types of flame retardants as a flame retardant, that is, a phosphorus-based flame retardant, a melamine flame retardant, and expanded graphite. I found out that the problem can be solved.

  The present invention has been achieved based on such knowledge, and the gist thereof is as follows.

[1] A highly flame-retardant polyurethane foam obtained by foaming a polyurethane foam compound comprising a polyol, an isocyanate, a foaming agent and a flame retardant, wherein the flame retardant is a phosphorus-based flame retardant, a melamine flame retardant, and It contains expanded graphite, and the mixing ratio (weight ratio) of the phosphorus flame retardant, melamine flame retardant and expanded graphite is phosphorus flame retardant: 0.2 to 0.6, melamine flame retardant: 0.1 to 0.4. Expanded graphite: 0.3 to 0.6 (however, the total of expanded graphite, phosphorus flame retardant and melamine flame retardant is 1), and the total blended amount of the flame retardant is 100 parts by weight of the total polyol. Highly flame-retardant polyurethane foam, characterized in that it is 42 to 50 parts by weight based on the weight.

[2] The highly flame-retardant polyurethane foam according to [1], wherein the total amount of the flame retardant is 45 to 50 parts by weight with respect to 100 parts by weight of the total polyol.

[3] A highly flame-retardant polyurethane foam according to [1] or [2], wherein the polyol is a polyether-based polyol.

[4] The highly flame-retardant polyurethane foam according to any one of [1] to [3], wherein the polyol contains a phthalic acid-modified polyester polyether polyol.

[5] The highly flame-retardant polyurethane foam according to [4], wherein the proportion of the phthalic acid-modified polyester polyether polyol in 100 parts by weight of the polyol is 15 to 30 parts by weight.

According to the present invention, as a flame retardant, an excellent synergistic effect by combining three types of flame retardants, a phosphorus-based flame retardant, a melamine flame retardant, and expanded graphite in a predetermined blending ratio, with a small amount of flame retardant addition, Excellent flame retardancy satisfying the V-0 standard in the UL-94 vertical combustion test can be obtained.
For this reason, the highly flame-retardant polyurethane foam excellent also in the polyurethane foam physical property and foamability can be provided, without causing the problem of the fall of the polyurethane foam physical property and foamability by the high mixing | blending of a flame retardant.

  In the present invention, in order to obtain even more excellent flame retardancy, the total amount of the flame retardant is preferably 45 to 50 parts by weight with respect to 100 parts by weight of the total polyol (claim 2).

  Further, it is preferable to use a polyether-based polyol as the polyol (Claim 3), and it is further preferable to use a phthalic acid-modified polyester polyether polyol as the polyol (Claim 4), in which case 100 parts by weight of the polyol is used. It is preferable that the ratio of the phthalic acid modified polyester polyether polyol is 15 to 30 parts by weight.

  Hereinafter, embodiments of the highly flame-retardant polyurethane foam of the present invention will be described in detail.

  The highly flame-retardant polyurethane foam of the present invention is a highly flame-retardant polyurethane foam obtained by foaming a polyurethane foam composition comprising a polyol, an isocyanate, a foaming agent and a flame retardant, and the flame retardant is phosphorous. A flame retardant, a melamine flame retardant, and expanded graphite, and the mixing ratio (weight ratio) of the phosphorus flame retardant, melamine flame retardant and expanded graphite is a phosphorus flame retardant: 0.2 to 0.6, melamine flame retardant : 0.1 to 0.4, expanded graphite: 0.3 to 0.6 (however, the total of expanded graphite, phosphorus-based flame retardant and melamine flame retardant is 1), and the blending amount of the flame retardant Is 42 to 50 parts by weight with respect to 100 parts by weight of the total polyol.

  The highly flame-retardant polyurethane foam of the present invention uses polyol, isocyanate, foaming agent and flame retardant as essential raw materials, and further contains a catalyst, a crosslinking agent, a foam stabilizer, and other additives as necessary. Manufactured by foaming a polyurethane foam formulation.

[Polyol]
There is no restriction | limiting in particular in the polyol in this invention, What is used as a raw material polyol of normal polyurethane foams, such as polyether polyol and polyester polyol, can be used conveniently.
That is, in the present invention, as the flame retardant, it is possible to realize excellent flame retardancy with a synergistic effect by using three kinds of phosphorus flame retardant, melamine flame retardant and expanded graphite at a predetermined blending ratio. There is no restriction | limiting in particular in the kind of polyol, The target flame retardance can be acquired even if what kind of polyol is used.

  As an example of the polyol used in the present invention, a polyether-based polyol, for example, various types having a viscosity at 25 ° C. of 200 to 2000 mPa · s and a hydroxyl value of about 20 to 80 mg-KOH / g, which are used for the production of ordinary polyurethane foams. 1 type or 2 types or more of these polyether-type polyols are mentioned. In the present invention, the polyether polyol refers to a polyether polyol in a broad sense including a polyester polyether polyol.

  In the present invention, as a flame retardant, excellent flame retardancy can be realized with a synergistic effect by using three types of phosphorus-based flame retardant, melamine flame retardant, and expanded graphite at a predetermined blending ratio. In some cases, the effect can be obtained more reliably by using an ether-based polyol. Although the details of this reason are not clear, the polyether-based polyol has low viscosity, and the three types of flame retardants can be dispersed and mixed sufficiently uniformly during the preparation of the polyurethane foam formulation. It is presumed that the synergistic effect of flame retardancy by using can be more effectively exhibited.

  Therefore, as a preferred embodiment of the present invention, the polyol is mainly composed of a polyether-based polyol, and even if it contains a polyol other than the polyether-based polyol, it is 10 parts by weight or less, preferably 5 parts per 100 parts by weight of the total polyol. Less than parts by weight, more preferably, all polyols are polyether polyols.

  In the present invention, in order to further improve the flame retardancy, a phthalic acid-modified polyester polyether polyol may be included as a part of the polyether polyol constituting the polyol.

  Phthalic acid-modified polyester polyether polyol is obtained by ester bonding phthalic acid to the hydroxyl part of polyester polyether polyol. By using phthalic acid-modified polyester polyether polyol, flame retardancy and drip resistance are improved. In addition to reducing the required amount of the flame retardant, it is possible to improve the problem of a decrease in drip resistance due to a large amount of the flame retardant. Further, the phthalic acid-modified polyester polyether polyol is effective for improving the compression resilience, and enables the realization of a polyurethane foam having a large compression resilience and a small decrease in the compression resilience with time.

The polyester polyether polyol used for phthalic acid modification preferably has a viscosity at 25 ° C. of 40,000 to 80,000 mPa · s as a modified phthalic acid and a hydroxyl value of about 54 to 58 mg-KOH / g.
Moreover, it is preferable that the number of functional groups of the phthalic acid modified polyester polyether polyol obtained by modifying such a polyester polyether polyol with phthalic acid is 1.5 to 4.5.

  In the present invention, such a phthalic acid-modified polyester polyether polyol can be used preferably in an amount of 15 to 30 parts by weight, more preferably 20 to 30 parts by weight in 100 parts by weight of the total polyol. If the amount of phthalic acid-modified polyether ester polyol used is larger than the above range, the polyurethane foam compound will have high viscosity and foaming will be impaired. The effect of improving resilience and drip resistance cannot be obtained sufficiently.

<Isocyanate>
As the isocyanate, any normal isocyanate used as a polyurethane foam raw material can be used. For example, tolylene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), triphenyl diisocyanate, polymethylene polyphenyl isocyanate, hexamethylene Examples thereof include diisocyanate and isophorone diisocyanate. These may be used alone or in combination of two or more.

  Although the compounding quantity of isocyanate is not restrict | limited in particular, It is preferable to mix | blend isocyanate so that the isocyanate index of a polyurethane foam compound may be about 90-120 normally. If this isocyanate index is too small, the resinification reaction of the polyurethane foam may not proceed, and if it is too large, the resinification reaction proceeds too much, becoming closed cells and shrinking.

<Foaming agent>
As a foaming agent, water and an organic compound having a low boiling point can be used alone or in combination. Examples of the low boiling point organic compound include trichloromonofluoromethane, dichlorodifluoromethane, monochlorodifluoromethane, trichlorotrifluoroethane, and methylene chloride.

  The blending amount of the foaming agent varies depending on the type of foaming agent used. For example, when water is used as the foaming agent, the amount is preferably about 1.5 to 5.0 parts by weight with respect to 100 parts by weight of the polyol.

<Flame Retardant>
In the present invention, as a flame retardant, three components of a phosphorus flame retardant, a melamine flame retardant (that is, melamine resin powder) and expanded graphite, a phosphorus flame retardant: 0.2 to 0.6, a melamine flame retardant: 0.1 to 0.4, expanded graphite: 0.3 to 0.6 (however, the combined ratio (weight ratio) of expanded graphite, phosphorus flame retardant and melamine flame retardant is 1). Is required.

  Among these, although there is no restriction | limiting in particular as a phosphorus flame retardant, since it is excellent in a flame retardance provision effect and the drip-proof improvement effect functions notably, it is preferable to use a phosphate ester flame retardant.

  Specific examples of phosphate ester flame retardants include triphenyl phosphate, trixylenyl phosphate, cresyl diphenyl phosphate, trimethyl phosphate, triethyl phosphate, tributyl phosphate, trioctyl phosphate, diethylphenyl phosphate, dimethylphenyl phosphate, resorcinol Diphenyl phosphate or a polymer of phosphate ester is used. These may be used individually by 1 type, may use 2 or more types together, and may use 1 type or 2 types or more of phosphorus flame retardants other than a phosphate ester type flame retardant.

  Below, the action mechanism of the improvement effect of the flame retardant of this invention by using these three types of flame retardants by a predetermined | prescribed compounding ratio is demonstrated.

  The combustion mechanism of polyurethane foam is the generation of a fuel source (flame) in the oxidation reaction field (combination of combustion substance and oxygen) → propagation of radiant heat to polyurethane foam → thermal decomposition of polyurethane foam → thermal diffusion in polyurethane foam → oxidation It is considered a combustion cycle such as propagation of heat to the reaction field → generation of heat source (flame), and in order to improve the flame retardancy of polyurethane foam, it is important to cut off the linkage of this combustion cycle as much as possible .

  Furthermore, in order to satisfy the V-0 standard in the UL-94 vertical combustion test which is the object of the present invention, it is required that no combustion droplets are generated, that is, excellent drip resistance.

  Phosphorus flame retardants act comprehensively on this combustion cycle, but liquid flame retardants such as phosphate ester flame retardants are plastic substances themselves, so the incorporation of phosphorus flame retardants When there is too much quantity, a flame retardance will fall because a phosphorus flame retardant melts at the time of combustion. When there are too few compounding quantities of a phosphorus flame retardant, the flame retardance improvement effect by having mix | blended the phosphorus flame retardant cannot fully be acquired. That is, phosphorus-based flame retardants such as phosphate ester-based flame retardants have a function of reducing heat generation energy and thereby stopping combustion by an oxygen blocking effect and an endothermic effect by forming a phosphoric acid film during combustion. However, if the amount of the phosphorus-based flame retardant is small, such an effect cannot be obtained, the heat generation energy at the time of combustion increases, and the combustion continues.

  The melamine flame retardant has the effect of suppressing the propagation of heat in the above-mentioned combustion cycle. If the amount of the melamine flame retardant is too small, the propagation of heat cannot be sufficiently suppressed, and the flame retardant The improvement effect cannot be obtained sufficiently. When there is too much melamine flame retardant, it melts and the melamine flame retardant itself becomes a drip. In addition, the amount of other flame retardants must be relatively reduced, and the flame retardant improvement effect of the other flame retardants cannot be obtained.

  Expanded graphite mainly has the function of preventing the formation of an oxidation reaction field in the combustion cycle by preventing the bonding between the combustion substance and oxygen. If the amount of expanded graphite is small, such an effect can be obtained. It cannot be obtained sufficiently, the flame easily rises, and the combustion easily spreads. However, if the amount of the expanded graphite is too large, the expanded graphite is excessively expanded and easily falls as a polyurethane foam, and as a result, the V-0 standard in the UL-94 vertical combustion test cannot be satisfied.

  In the present invention, the above-described effects of imparting flame retardancy of the phosphorus-based flame retardant, the melamine flame retardant, and the expanded graphite are sufficiently exhibited, and the synergistic effect obtained by using these three types in combination is sufficient. In order to obtain the above, the use ratio of the phosphorus flame retardant, the melamine flame retardant and the expanded graphite is, by weight ratio, phosphorus flame retardant: 0.2 to 0.6, melamine flame retardant: 0.1 to 0.4, Expanded graphite: 0.3 to 0.6, preferably phosphorus flame retardant: 0.2 to 0.3, melamine flame retardant: 0.1 to 0.2, expanded graphite: 0.4 to 0.5 (However, the total of expanded graphite, phosphorus flame retardant and melamine flame retardant is 1.)

  According to the present invention, the combined amount of these three types as a flame retardant is reduced by an excellent synergistic effect by using these phosphorus flame retardant, melamine flame retardant and expanded graphite in combination at a predetermined blending ratio. Therefore, the total amount of phosphorus flame retardant, melamine flame retardant and expanded graphite is 42 to 50 parts by weight, preferably 100 parts by weight of polyol. Can be suppressed to 45 to 50 parts by weight. If the total blending amount is too small, sufficient flame retardancy cannot be obtained, and if it is too large, the physical properties and foaming properties of polyurethane foam may be lowered, which is not preferable.

<Catalyst>
As the catalyst, both amine-based and tin-based catalysts can be suitably used. As the amine-based catalyst, 6-dimethylamino-1-hexanol, tetramethylhexamethylenediamine, pentamethyldiethylenetriamine, dimethylcyclohexylamine. Bis- (dimethylaminoethyl) ether, tetramethylpropylenediamine, trimethylaminoethylpiperazine, tetramethylethylenediamine, dimethylbenzylamine, methylmorpholine, ethylmorpholine, triethylenediamine, etc., as the tin-based catalyst, stannous octate, Examples thereof include dibutyltin dilaurate and stannous 2-ethylhexylate used in the examples described later. These catalysts may be used individually by 1 type, and may use 2 or more types together.
The compounding amount of the catalyst is usually 0 to 5 parts by weight, preferably 0.1 to 1 part by weight with respect to 100 parts by weight of the polyol.

<Crosslinking agent>
As the cross-linking agent, it is preferable to use a monomer having two or more hydroxyl groups. By using such a cross-linking agent, the cross-linking density is increased, the strength and hardness of the foam are increased, and as a result, the shape retention is increased. be able to. Examples of the monomer having two or more hydroxyl groups include ethylene glycol and diethylene glycol. In addition, as a crosslinking agent, the diethanolamine which can function as an amine catalyst can also be used. These crosslinking agents can be used alone or in combination of two or more.

  Although a crosslinking agent is used as needed, when using a crosslinking agent, the usage-amount is about 0.5-5 weight part with respect to 100 weight part of polyol normally.

<Foam stabilizer>
Examples of the foam stabilizer include organopolysiloxanes, alkyl carboxylates, and alkylbenzene sulfonates.
The blending amount of the foam stabilizer is usually 0 to 5 parts by weight, preferably 0.5 to 2 parts by weight with respect to 100 parts by weight of the polyol.

<Other additives>
Various additives can be blended in the polyurethane foam composition according to the present invention as necessary, for example, colorants such as pigments (coloring agents), fillers such as calcium carbonate, antioxidants, ultraviolet absorption. Agents, light stabilizers, conductive materials such as carbon black, antibacterial agents, punching agents and the like can be blended.

<Manufacturing method>
The highly flame-retardant polyurethane foam of the present invention is produced by foam-molding a polyurethane foam formulation containing the above-described components according to a conventional method.

In addition, the density of the highly flame-retardant polyurethane foam of the present invention is not particularly limited and is appropriately designed according to the use, but is usually about 20 to 100 kg / m ³ .

EXAMPLES Next, although this invention is demonstrated in detail based on an Example, this invention is not limited by the following Examples, unless the summary is exceeded.
The materials used in the following examples and comparative examples are as follows.

Polyol 1: “GS-3000” manufactured by Sanyo Chemical Industries
(Polyether polyol)
Number average molecular weight = 3000
Hydroxyl value = 56 mg-KOH / g
Polyol 2: “Accor 3P-56D” manufactured by Mitsui Chemicals Polyurethanes Co., Ltd.
(With phthalic acid-modified polyester polyether polyol)
Mixture with non-modified polyester polyether polyol)
Phthalic acid-modified polyester polyether polyol content = 75% by weight
Phthalic acid-modified polyester polyether polyol:
Viscosity (25 ° C.) = 15000 mPa · s
Hydroxyl value = 56 mg-KOH / g
Non-modified polyester polyether polyol:
Viscosity (25 ° C.) = 475 mPa · s
Hydroxyl value = 56 mg-KOH / g

Isocyanate: “T80” manufactured by Nippon Polyurethane Industry Co., Ltd.
(Tolylene diisocyanate (TDI)
(2,4-TDI: 2,6-TDI = 80: 20))

Crosslinking agent 1: Diethanolamine (Daihachi Chemical Industry Co., Ltd.)
Cross-linking agent 2: “Accor T880” manufactured by Mitsui Chemicals, Inc. (polyoxyalkylene poly)
All)

Flame retardant 1: “Daiguard 880” (aliphatic condensed phosphate ester) manufactured by Daihachi Chemical Industry Co., Ltd.
Flame retardant 2: Melamine resin powder lot No. manufactured by Mitsui Chemicals, Inc. G09908-C
Flame retardant 3: “SYZR 502FP” (expanded graphite) manufactured by Sanyo Trading Co., Ltd.

Foam stabilizer: “NIAX” manufactured by Momentive Performance Materials Japan
SILICON L-638 "(silicone-based foam stabilizer)

Tin-based catalyst: “Nikka Octix Tin” (2-ethylhexyl acid) manufactured by Nippon Chemical Industry Co., Ltd.
Stannous (active ingredient amount 28% by weight)
Amine-based catalyst 1: "TEDA L33" manufactured by Tosoh Corporation (with dipropylene glycol)
Mixture of triethylenediamine)
Amine-based catalyst 2: “TOYOCAT ET33B” manufactured by Tosoh Corporation (bis (2-dimethyl)
Ruaminoethyl) a mixture of ether and dipropylene glycol)

Coloring agent: “Polyton Black UE-19500” manufactured by Dainippon Ink & Chemicals, Inc.
(Black color agent)
Punching agent: “TEXTER-2” manufactured by Croda Japan

  The density and air permeability of the polyurethane foams produced in the examples and comparative examples were measured by the method described in JIS K6400. Moreover, the flame retardance was determined by UL-94 combustion test. That is, a 127 mm × 12.7 mmt × 12.7 mmt sample was produced, and a vertical combustion test was performed according to the UL-94 test method.

[Examples 1-12, Comparative Examples 1-7]
Polyurethane foam blends having the composition and isocyanate index shown in Tables 1 to 3 were prepared, and foamed at 20 ° C. to produce a flexible polyurethane foam.
About this flexible polyurethane foam, the sample density and air permeability were measured, and the results are shown in Tables 1 to 3.
Moreover, it evaluated by the test method of the V-0, V-1, and V-2 material classification of UL-94 vertical combustion test, and the result was shown to Tables 1-3.

  As is clear from Tables 1 to 3, in Comparative Examples 1 to 7 in which the blending ratio of the phosphorus-based flame retardant, the melamine flame retardant, and the expanded graphite is out of the scope of the present invention, the flame retardant is low in the UL-94 vertical combustion test. Although flame retardancy satisfying the V-0 standard cannot be obtained, in Examples 1 to 12, in which the blending ratio of the phosphorus-based flame retardant, the melamine flame retardant, and the expanded graphite is within the scope of the present invention, 100 parts by weight of the polyol is used. On the other hand, the flame retardant which satisfies the V-0 standard in the UL-94 vertical combustion test can be obtained with a small amount of the flame retardant of 42 to 50 parts by weight.

Claims (5)

A highly flame-retardant polyurethane foam obtained by foaming a polyurethane foam composition comprising a polyol, an isocyanate, a foaming agent and a flame retardant,
The flame retardant includes a phosphorus flame retardant, a melamine flame retardant and expanded graphite,
The mixing ratio (weight ratio) of the phosphorus flame retardant, melamine flame retardant, and expanded graphite is as follows: phosphorus flame retardant: 0.2 to 0.6, melamine flame retardant: 0.1 to 0.4, expanded graphite: 0 .3 to 0.6 (however, the total of expanded graphite, phosphorus flame retardant and melamine flame retardant is 1),
A highly flame-retardant polyurethane foam, wherein the total amount of the flame retardant is 42 to 50 parts by weight with respect to 100 parts by weight of the total polyol.   The highly flame-retardant polyurethane foam according to claim 1, wherein the total amount of the flame retardant is 45 to 50 parts by weight with respect to 100 parts by weight of the total polyol.   The highly flame-retardant polyurethane foam according to claim 1 or 2, wherein the polyol is a polyether-based polyol.   The highly flame-retardant polyurethane foam according to any one of claims 1 to 3, wherein the polyol contains a phthalic acid-modified polyester polyether polyol.   The highly flame-retardant polyurethane foam according to claim 4, wherein the proportion of the phthalic acid-modified polyester polyether polyol in 100 parts by weight of the polyol is 15 to 30 parts by weight.