Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
2000-11-27
2002-12-10
Szekely, Peter (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
C524S123000, C524S124000, C524S126000, C524S127000, C252S609000, C106S018140
Reexamination Certificate
active
06492444
ABSTRACT:
This application concerns novel flame retardant organic phosphorus-phosphorus oxyacid compounds and compositions. These compounds contain two or more phosphorus atoms in each molecule. The flame retardant compounds of this invention may be utilized as flame retardants by incorporating these compounds within or coating a more flammable organic material. In particular, it relates to flame retardant compounds and a flame retardant organic resin compositions, which are free from toxicity problems due to the absence of halogen gas generated during combustion or molding as in the use of a halogen-containing flame retardant compound.
BACKGROUND OF THE INVENTION
Basic nitrogen containing salts of organic polyphosphorus compounds were produced by Blount in U.S. Pat. No. 6,054,515 and utilized in flame retardant compositions. The organic phosphorus-phosphorus oxyacids compounds of this invention are novel. These novel compounds are an improvement over the basic salts of organic polyphosphorus compounds because they are a much better flame retardant compounds and cost less to produce. When the organic phosphorus-phosphorus oxyacid compound is incorporated in or on a flammable organic material it produces an intumescent composition. When this intumescent composition is exposed to a flame for a few seconds it begins to char and form bubbles within the char thereby protects the substrate against heat and fire damage for an appreciable time. This intumescence also reduces the amount of smoke produced. The organic phosphorus-inorganic phosphorus oxyacid compounds promote initial intumescence at a low temperature, which is much lower that required when a basic nitrogen salt of organic polyphosphorus compound or an organic phosphorus compound is utilized as the flame retardant compound. The flame retardant compounds of this invention will also with stand a higher temperature than the organic phosphorus compounds and basic nitrogen containing salts of organic polyphosphorus compounds before decomposing, and allows them to be mixed in thermoplastic resin to produce flame retardant reins.
The object of this invention is to produce organic phosphorus-inorganic phosphorus oxyacid compounds, it's salts and compositions containing these compounds which are capable of rendering organic material less flammable. These flame retardant compounds may be used in the production of insulation foam, flexible foams, building components, coating agents, surfactants, molded plastic products and many other uses.
SUMMARY OF THE INVENTION
In one respect, the invention comprises reacting phosphorus halogen compounds, containing phosphorus atom with a valence of 3-4, with an inorganic phosphorus oxyacid compounds with phosphorus atoms with a valence of 5 and an organic compound to produce organic phosphorus-inorganic phosphorus oxyacid compounds. Another aspect, the invention comprises utilizing the organic phosphorus-phosphorus oxyacid of this invention by incorporating in, or apply on a more flammable organic material to render the organic material less flammable. Another aspect of the invention is a process to prepare the organic phosphorus-phosphorus oxyacid compound comprising contacting and reacting:
A) a phosphorus halide compound containing a phosphorus atom with a valence of 3-4;
B) an inorganic phosphorus oxyacid compound containing a phosphorus atom with a valence of 5;
C) an organic compounds that will react with a phosphorus halide or a phosphorus oxyacid; under conditions sufficient to prepare the organic phosphorus-inorganic phosphorus oxyacid compound.
Organic phosphorus-phosphorus oxyacid compounds has the general formula of:
(R)
w
(P)
x
(PO
4
)
y
H
z
Wherein x is a number 1-4, y is a number 1-3, z is a number 3 to 9 and w is a number 1-3 and selected from the compounds containing a radical selected from the group consisting of:
—SH, —CH
2
Cl, —CH
2
Br, CH
2
I, —CN, —NO, —COCl, —COBr, —SO
2
Cl, —SO
2
Br, —COOH, —S
2
OH, COO—,
—NH
2
, Zn—, —MgCl, ═Hg, —OH, and —N—P═.
Another aspect of this invention is to produce a flame retardant composition which comprising mixing and reacting:
A) a phosphorus halide compound containing a phosphorus atom having a valence of 3-4;
B) an inorganic phosphorus oxyacid compound containing a phosphorus atom with a valence of 5;
C) an organic compounds that will react with a phosphorus halide and/or a phosphorus oxyacid; then add and mix or react
D) carbonization auxiliaries;
then add and mix
E) carbonization accelerating compounds;
F) heat reflecting substance;
G) filler;
under conditions sufficient to prepare the organic phosphorus-inorganic phosphorus oxyacid compound.
In another aspect, according to this invention there is provided a flame retardant basic salt of organic phosphorus-phosphorus oxyacid compound and composition produced by a process comprising of mixing and reacting:
A) phosphorus halide compound containing a phosphorus atom having a valence of 3-4;
B) inorganic phosphorus compound containing a phosphorus atom having a valence of 5;
C) organic compound that will react with a phosphorus halide or a phosphorus oxyacid; then add, mix and react;
H) basic inorganic or organic salt forming compound, thereby producing a basic salt of organic phosphorus-phosphorus oxyacid;
then add and mix
D) carbonization auxiliaries;
E) carbonization accelerating compounds;
F) heat reflecting compound;
G) filler;
under conditions sufficient to prepare the salt of organic phosphorus-phosphorus oxyacid.
In another aspect, according to this invention, there is provided a flame retardant thermoplastic resin composition which comprises (1) thermoplastic resin, (2) organic phosphorus-phosphorus oxyacid or it's salt, (3) carbonization auxiliaries, (4) metal containing compound having a carbonization accelerating effect, (4) comb-like polymer and (5) filler.
The components may be utilized in any suitable amount but preferably:
1. An phosphorus halogen compound, which contains a phosphorus atom containing a valence of 3 or 4, in the amount of 25 to 100 parts by weight;
2. Inorganic phosphorus oxyacid compound, which contains a phosphorus atom with a valence of 5, in the amount of 10 to 100 parts by weight;
3. Organic compound that will react with a phosphorus halide and/or phosphorus oxyacid, in the amount of 10 to 100 parts by weight;
4. An amount of 5% to 30% by weight of the flame retardant compound or composition is added to or on the flammable organic material;
5. Basic salt forming compound in the amount of 0 to 100 parts by weight;
6. metal containing compound having a carbonization accelerating effect in the amount of 0 to 30 parts by weight;
7. Comb-like polymer, in the amount of 0 to 30 parts by weight
8. Heat reflecting compound, in the amount of 0 to 30 parts by weight.
9. Carbonization auxiliaries, in the amount of 0 to 100 parts by weight.
10. Filler, in the amount of 0-200 parts by weight.
COMPONENT A
Any suitable phosphorus halide compound, that contains a phosphorus atom with a valence of 3-4, may be used in this invention, such as, but not limited to, phosphorus trihalides such as phosphorus trichloride, phosphorus tribromide, phosphorus triflouide, phosphorus triiodide, and phosphorus with a valence of 5 such as phosphorus pentachloride, phosphorus pentabromide, phosphorus pentaflouride, and phosphorus oxyhalides, such as phosphorus oxytrihalides such as phosphorus oxytrichloride, phosphorus oxytribromide and phosphorus oxytriflouride. Phosphorus trichloride is the preferred phosphorus halide compounds.
COMPONENT B
Any suitable inorganic phosphorus oxyacid compound which contains a phosphorus atom with a valence of 5 may be used in this invention. Suitable inorganic phosphorus compounds include, but not limited to, phosphoric acid, polyphosphoric acid, pyrophosphoric acid, phosphorus oxide, salts of hydrogen phosphoric acid, phosphonic acid, ammonium hydrogen phosphate, ammonium polyphosphate, triphosphorus acid, phosphinic oxide, phosphorus esters, phosphorus trioxide, phosphorus pentioxide, metaphosphoric acid, phosphorus acid, hypopho
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