US 12,240,958 B2
Expandable graphite flame retardant layer for polyurethane and latex foam
Courtney Peterson, Fort Smith, AR (US); Heidi Stojanovic, Fort Smith, AR (US); Aubrey Nicole Scherrey, Fort Smith, AR (US); and Mark L. Crawford, Alma, AR (US)
Assigned to L&P Property Management Company, South Gate, CA (US)
Filed by L&P Property Management Company, South Gate, CA (US)
Filed on Feb. 20, 2023, as Appl. No. 18/171,418.
Application 18/171,418 is a continuation of application No. 16/415,962, filed on May 17, 2019, granted, now 11,613,621.
Prior Publication US 2023/0203266 A1, Jun. 29, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. C08J 9/36 (2006.01); C09D 1/00 (2006.01); C09D 5/18 (2006.01)
CPC C08J 9/365 (2013.01) [C09D 1/00 (2013.01); C09D 5/185 (2013.01); C08J 2205/06 (2013.01); C08J 2321/02 (2013.01); C08J 2375/04 (2013.01); Y10T 428/249958 (2015.04); Y10T 428/249987 (2015.04); Y10T 428/249991 (2015.04)] 18 Claims
 
1. A flexible foam composition comprising:
a cured flexible foam body having at least one surface, the flexible foam body selected from the group consisting of polyurethane flexible foam, latex flexible foam, and combinations thereof, wherein the cured flexible body is in the form of a continuous layer; and
an expandable graphite layer comprising a plurality of expandable graphite particles applied to the cured flexible foam body on the at least one surface without distributing the expandable graphite layer in the flexible foam body, wherein the expandable graphite layer further includes an adhesion agent comprising a water-based binder, water, and a surfactant; the adhesion agent adhering the expandable graphite particles to the at least one surface of the cured flexible foam body;
wherein the flexible foam composition further comprises an antimicrobial package, aluminum trihydrate, at least one plasticizing agent, at least one thermally-conductive material, in the absence of red phosphorus;
and wherein the expandable graphite layer applied to the cured flexible foam body generates an airflow loss compared to a cured flexible foam body without the expandable graphite layer of about 14% to about 22% as determined by ASTM D3574 Test G.