Compositions – Fire retarding – For wood or cellulosic material other than textile
Reexamination Certificate
2001-05-24
2002-12-10
Anthony, Joseph D. (Department: 1714)
Compositions
Fire retarding
For wood or cellulosic material other than textile
C252S608000, C252S607000, C252S601000, C523S179000, C528S259000, C521S094000, C521S095000
Reexamination Certificate
active
06491850
ABSTRACT:
FIELD
The invention concerns urea being heated with other organic compounds containing an active hydrogen and other active radicals to produce urea-organic compounds condensate. The invention also concerns their preparation and use. The urea-organic compound condensates are useful to produce flame retardant plastics, natural products, resins and compounds. These flame retardant resins and compounds may be reacted with phosphorus and/or boron containing compounds to produce other flame retardant compounds. The urea-organic compound condensate resins and compounds may also be reacted with aldehydes to produce urea-organic compounds condensate-aldehyde resins for use as molding resin or as a flame retardant compound. The urea-organic compound condensates will react with polyisocyanates to produce foams for insulation and other products. The urea-unsaturated polyester condensate will react with unsaturated compounds such as styrene in the presence of a catalyst to produce flame retarded polyester resins.
BACKGROUND
The heating of urea with other organic compounds to produce flame retardant, urea-organic compounds condensates, is novel. The condensation of isocyanuric acid and/or cyanic acid, (which are produced by heating urea),with other reactive organic compounds to produce flame retardant resins and compounds is novel. The urea-organic compound condensates and their phosphorus and/or boron salts are 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 inexpensive nitrogen containing organic resins and compounds with a plurality of nitrogen moieties. The urea-organic compound condensate and/or their salts of this invention are novel flame retardant compounds. What is additionally lacking are compositions having such urea-organic compound condensates and/or their salts employed therein.
SUMMARY
In one aspect, the invention comprises urea-organic compounds condensates. Another aspect of the invention is a process to prepare urea-organic compound condensate comprising serially contacting
(A) urea
(B) organic compounds with active hydrogen or radical that will condensate or react with urea;
under conditions sufficient to prepare the urea-organic compound condensate;
(C) water;
the urea and the reactive compound are mixed, heated and reacted. The water may be added to the condensate then heated or may be added with the urea and organic compound before heating or utilized to make emulsions.
In another aspect, the invention comprises urea condensation-organic compound condensate salt of phosphorus and/or boron containing compound and a process to prepare a urea-organic compound condensate salt of a phosphorus and/or boron containing compound employing phosphorus and/or boron containing compound that will react with the urea-organic compound condensate under conditions sufficient to prepare the urea-organic compound condensate salt of a phosphorus and/or boron containing compound, and a process to prepare a urea-organic compound condensate salts of a phosphorus and/or a boron containing compound comprising serially contacting
(A) urea
(B) organic compound that will condensate or react with urea
(D) phosphorus and/or boron containing compound that will react with a urea-organic compound condensate.
An addition aspect of this invention is the production of urea-organic compound condensate-aldehyde resins and a process to prepare urea-organic compound condensate-aldehyde resins under conditions sufficient to prepare the urea-organic compound condensate-aldehyde resin comprising serially contacting
(A) urea
(B) organic compound that will condensate or react with urea
(C) water
(E) aldehyde
(J) a basic or acidic catalyst
An additional aspect of the invention is use of the urea-organic compound condensates in the production of urea-organic compound condensate salts of phosphorus and/or boron compounds and in the production of urea-organic compound condensate-aldehyde resins. The flame retardant use comprises contacting an otherwise more flammable organic material with the urea-organic compound condensate and/or urea-organic compound condensate salts of phosphorus and/or boron containing compounds and/or urea-organic compound condensate-aldehyde resins and/or urea-organic compound condensate composition thereof under conditions sufficient to lower the combustibility of the flammable organic material, for example plastics, natural products or polyurethanes. Thus, a further aspect of the invention is a flame-retardant composition comprising an otherwise more flammable organic material incorporated therewith a flame retardant amount of a urea-organic compound condensate and/or a urea-organic compound condensate salt of a phosphorus and/or boron containing compound, and/or urea-organic compound condensate-aldehyde resin, carbonization auxiliaries and fillers.
The flame-retardant resins and compounds of this invention are produced by heating urea (Component A) with a reactive organic compound (Component B) to above the melting point of urea to about 140-170 degree C. at ambient or elevated pressure for 1-3 hrs. Upon heating above the melting point urea form a very reactive compound isocyanic acid and/or cyanic acid which will react with itself or other organic or inorganic compounds especially organic compounds which have reactive hydrogens. In order to increase the flame retardant properties and carbonization properties of the urea-organic compound condensate, a carbonization auxiliary, such as, phosphorus acidic compounds, organic phosphorus compounds, boron compounds, etc., that will react with a urea-organic compound condensate, is added to the melted urea-organic compound condensate, mixed and/or reacted. Other carbonization auxiliaries may be mixed with the urea-organic compound condensate to produce the flame retardant urea-organic compound condensate composition. The urea condensation-organic compound condensate may be further reacted with an aldehyde in the presence of a neutral or basic or acidic catalyst by mixing and heating the urea-organic compound condensate 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 urea-organic compound condensate-aldehyde resin. Fillers and carbonization auxiliaries may be added to or reacted with the urea-organic compound condensates or the urea-organic compound condensate-aldehyde resin. The urea-organic compound condensates and urea-organic compound condensate-aldehyde resins with or without carbonization auxiliaries and fillers may be reacted with or added to or applied to a more flammable organic material.
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 react with a reactive organic compound. Urea is utilized in the amount of 50 to 100 parts by weight.
Component B
Any suitable reactive organic compound, except amino compounds which must be added with another organic compound, that will react with isocyanic acid and/or cyanic acid may be utilized in this invention. Suitable organic saturated, unsaturated or substituted compounds may be an aliphatic, aromatic, cyclic, aliphatic-aromatic or aliphatic-cyclic compound such as, but not limited to, alcohols, polyalcohols, epoxides, polyepoxides, epihalohydrins, organic acids, polycarboxylic acids and hydrides, thioalcohols, phenols, thiophenols, halogenated alcohols and polyalcohols, halogenated organic compounds, halogenated organic acids and polycarboxylic acids, sulphonic acid chlorides, organic ester, organic ethers, thioethers, ketones, nitriles, sulphonic acids, imides, alkyl carbonates, oils, fats, carb
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