Compositions – Fire retarding – For wood or cellulosic material other than textile
Reexamination Certificate
2000-08-28
2002-07-23
Anthony, Joseph D. (Department: 1714)
Compositions
Fire retarding
For wood or cellulosic material other than textile
C252S608000, C252S609000, C252S601000, C528S259000, C528S094000, C523S179000
Reexamination Certificate
active
06423250
ABSTRACT:
FIELD
The invention concerns urea being condensated with itself to produce cyanuric acid and cyamelide. The invention also concerns their preparation and use. These condensation compounds are useful to produce flame retardant plastics, to flame retard natural products, and may be reacted with phosphorus and/or boron containing compounds to produce other flame retardant compounds. These condensation compounds may also be reacted with aldehydes to produce cyanuric acid and cyamelide resins for use as molding compounds, as an adhesive, coating resin or as a flame retardant compound.
BACKGROUND
The heating of urea to produce urea condensation compounds, such as biuret and a mixture of cyanuric acid and cyamelide, is known in the arts, but the further condensation of flame retardant urea and buiret to produce a mixture of cyanuric acid and cyamelide which are improved flame retardant compounds is novel. The condensation of isocyanuric acid and/or cyanic acid, (which are produced by heating urea), produces the flame retardant, cyanuric acid and cyamelide compounds, is novel. The mixture of cyanuric acid and cyamelide compounds and their phosphorus and/or boron salts may be used as flame retardant compounds in plastics and natural products. Urea and melamine were utilized as a flame retardant compound by Fracalossi, et al., in U.S. Pat. No. 4,385,131. Melamine was utilized as flame retardant compounds in polyurethanes by Yukuta, et al., in U.S. Pat. No. 4,221,875 and by Grinbergs et al., in U.S. Pat. No. 4,745,133. Amino phosphates was utilized by Blount in U.S. Pat. No. 5,010,113.
What is lacking and what is needed are useful, safe and inexpensive flame retardant compound mixture of cyanuric acid and cyamelide. The urea condensation compounds, cyanuric acid and cyamelide, and their aldehyde resins are novel flame retardant compounds. What is additionally lacking are compositions having the urea condensation compounds, cyanuric acid and cyamelide, and/or their salts employed therein.
SUMMARY
In one aspect, the invention comprises of the flame retardant mixture of cyanuric acid and cyamelide. Another aspect of the invention is a process to prepare a, mixture of cyanuric acid and cyamilide by heating and reacting:
(A) urea with itself or biuret;
under conditions sufficient to prepare the urea condensation mixture of cyanuric acid and cyamelide. The urea is first heated to produce isocyanuric acid and/or cyanic acid then reacted with urea to form biuret then further heated to form a mixture of cyanuric acid and cymelide.
In another aspect, the invention comprises cyanuric acid and cyamelide salts of phosphorus and/or boron containing compound and a process to prepare cyanuric acid and cyamelide salts of a phosphorus and/or boron containing compound employing phosphorus and/or boron containing compound that will react with the mixture of cyanuric acid and cyamelide under conditions sufficient to prepare the cyanuric acid and cyamelide salt of a phosphorus and/or boron containing compound, comprising serially contacting, heating and reacting:
(A) urea with itself;
(B) phosphorus and/or boron containing compound that will react with an amino condensation compound;
component A is first heated with itself or with biuret sufficient to produce cyanuric acid and cyamelide then component B is added and reacted.
An addition aspect of this invention is the production of a mixture of cyanuric acid-aldehyde and cyamelide-aldehyde resins, and a process to prepare a mixture of cyanuric acid and cyamelide-aldehyde resins under conditions sufficient to prepare the mixture of cyanuric acid-aldehyde and cyamelide-aldehyde resins comprising serially contacting, heating and reacting:
(A) a mixture of cyanuric acid and cyamelide produced by heating urea;
(C) aldehyde; and a
(D) a basic or acidic catalyst;
An additional aspect of the invention is use of the mixture cyanuric acid and cyamelide compounds, cyanuric acid and cyamelide salts of phosphorus and/or boron compounds and cyanuric and cyamelide-aldehyde resins as flame retardant compounds. The flame retardant use comprises contacting a more flammable organic material with the mixture of cyanuric acid and cyamelide and/or cyanuric acid and cyamelide salts of phosphorus and/or boron containing compounds and/or cyanuric acid and cyamelide-aldehyde resins thereof under conditions sufficient to lower the combustibility of the otherwise more flammable organic material, for example plastics, natural products or polyurethanes. Thus, a further aspect of the invention is a flame-retardant composition comprising a more flammable organic material incorporated therewith or applying on a flame retardant amount of a mixture of cyanuric acid and cyamelide and/or a mixture of cyanuric acid and cyamelide salts of a phosphorus and/or boron containing compound, and/or cyanuric acid and cyamelide-aldehyde resin, carbonization auxiliaries, metal compounds that accelerates the carbonization process, heat reflecting compounds and fillers.
The flame-retardant compounds of this invention are produced by heating urea (Component A) with urea or biuret to above the melting point of urea to about 160 degree C. at ambient pressure for 0.1-3 hrs. Upon heating above the melting point urea forms a very reactive compound isocyanic acid which will react with itself or other urea or other organic or inorganic nitrogen containing compounds especially amino compounds. In order to increase the flame retardant properties and carbonization properties of the mixture of cyanuric acid and cyamelide compounds, a carbonization auxiliary, such as, phosphorus acidic compounds, or organic phosphorus compounds that will react with an amino compound; boric acid, etc., is added to the melted cyanuric and cyamelide compounds mixed and/or reacted. Other carbonization auxiliaries may be mixed with the mixture of cyanuric acid and cyamelide compounds such as urea phosphate, melamine phosphate, magnesium phosphate, etc., to produce the flame retardant cyanuric acid and cyamelide composition. The mixture of cyanuric acid and cyamelide may be further reacted with an aldehyde in the presence of a neutral or basic or acidic catalyst by mixing and heating the mixture of cyanuric acid and cyamelide compounds with the aldehyde, usually in an aqueous medium, to just below the boiling point of the components at ambient or an elevated pressure thereby producing a cyanuric acid and cyamelide-aldehyde resin. Carbonization auxiliaries may be added to the mixture of cyanuric acid and cyamelide compounds or the cyanuric acid and cyamelide-aldehyde resin. The mixture of cyanuric acid and cyamelide compounds and cyanuric acid and cyamelide-aldehyde resins with or without carbonization auxiliaries and fillers may be reacted with or added to or applied on a more flammable organic material.
It is preferable to produce the mixture of cyanuric acid and cyamelide by utilizing urea which is heated sufficent to produce a mixture of cyanuric acid and cyamelide.
Component A
Urea is utilized as component A and may be in the form of a powder, crystals or a solid. Any suitable urea may be utilized that will condensate when heated to form a mixture of cyanuric acid and cyamelide. The mixture is utilized in the amount of 100 parts by weight when reacted with another compound.
Component B
Any suitable aldehyde may be reacted with the cyanuric acid and cyamelide compounds. Suitable aldehydes include, but not limited to, formaldehyde, paraformaldehyde, acetoaldehyde, butyraldehyde, chloral, and other alkyl aldehydes, furfural, benzyl aldehyde and other aromatic aldehydes. Aqueous formaldehyde is the preferred aldehyde. The aldehyde is utilized in the amount of 0 to 200 parts by weight. When it is utilized it is used in the amount of 25 to 100 parts by weight.
Component C
Any suitable carbonization auxiliaries may be utilized in this invention. Suitable carbonization auxiliaries are compounds that in the presence of fire assist the formation of a carbonization foam or char, such as, additives that produce acidic components in the pyrolysis mixtu
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