ABSTRACT
A new generation of highly flame-resistant, open-cell, flexible polyurethane-polychloroprene hybrid foam materials has been developed utilizing Foam-One technology. Foam-One is a batch process of manufacturing polyurethane flexible slabstock foams under variable pressure settings varied from 1.0 psi (7 kPa absolute) to about 27.5 psia (189.6 kPa absolute). This equipment helped enable us to make a revolutionary family of fire-resistant foams utilizing entirely new technology. The new foam materials will easily meet fire-testing standards required by the federal agencies.* In addition to fire-resistant properties, these new low-density foam grades show excellent comfort and physical properties. The applications of this new technology include foam products such as seat cushions for airline, ground transportation and contract furniture applications and, mattresses for dormitories, military, marine and naval ships, hospitals, nursing homes, youth/crib bedding, and psychiatric facilities. In this paper, the variations of physical properties of the base foams with respect to variable pressure settings and the fire performance characteristics and physical properties of these polyurethane-polychloroprene hybrid foam materials will be discussed.
