Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Cellular products or processes of preparing a cellular...
Patent
1997-04-18
1999-09-28
Cooney, Jr., John M.
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Cellular products or processes of preparing a cellular...
521155, 521169, C08G 1804
Patent
active
059589930
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The present invention relates to anti-fogging flame retardants useful in polyurethane foams and to a process for imparting flame retardancy to a polyurethane foam by incorporating such anti-fogging flame retardants into the polyurethane foam.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,746,682 to J. Green relates to a polyurethane flame retardant containing a polybrominated diphenyl oxide and an alkylated triaryl phosphate ester.
Certain disclosures exist in the prior art in regard to organic diphosphates of the general class ##STR1## where R can be substituted or unsubstituted alkylene, arylene, alkylene arylene, or other divalent connecting radical (e.g., diphenylene sulfone -SO-, -S-, -SO.sub.2 -), and the like and R.sub.1 can be substituted or un-substituted aryl or alkyl. Examples of some disclosures include the following: U.S. Pat. Nos. 3,492,373; 3,869,526 and 4,203,888; British Patent No. 2,061,949; and Japanese Patent Publication Nos. 57/174,331; 71/22,584; 74/40,342 and 82/55,947.
Also relating to this class of compounds are copending U.S. patent application Ser. No. 374,717, filed Jul. 3, 1989, entitled "Novel Aromatic Bisphosphated" which covers compounds where R.sub.1 is aryl and R is --C.sub.6 H.sub.4 SO.sub.2 H.sub.4 -- and U.S. patent application Ser. No. 374,716, filed Jul. 3, 1989, also entitled "Novel Aromatic Bisphosphates" which covers compounds where R.sub.1 is also aryl and R is a neopentyl group of a halogenated neopentyl group.
U.S. Pat. No. 4,049,617 discloses a group of flame retardant phosphorus esters containing one to three 1,3,2-dioxophosphorinane rings. These flame retardants contain an hydroxyl radical so that they are capable of reacting into the polymeric chain of, e.g., polyurethane, thereby imparting a durable flame retarded polymeric composition.
Most of these flame retardants suffer from the drawback that when incorporated in polurethane compositions, they are too volatile or contain volatile impurities which will be released when the polyurethane is heated. This is becoming an increasingly significant problem in the automobile industry because the new aerodynamic designs employ, for example, a flatter windscreen which increases the surface area of sun penetration into the auto on warm, sunny days, This often leads to internal temperatures above 100.degree. C. and thus evolution of volatile products from polyurethane parts in the auto. These volatile products produce a thin film in the auto which is particularly noticeable on the windscreen. This phenomena has been termed, "fogging".
Automakers are beginning to demand polyurethanes which exhibit significantly less fogging in order to eliminate this problem. Accordingly, there is a need for flame retardant compositions which provide adequate flame retardancy in polyurethane foam compositions and reduce the amount of fogging which occurs upon heating of these compostions. This and other objects of the present invention will become apparent from the summary and detailed description which follow.
SUMMARY OF THE INVENTION
The present invention relates to a process for imparting flame retardancy to a polyurethane foam comprising the step of incorporating in said polyurethane foam 0.5-50.0 php (php=parts per hundred polyol) of at least one flame retardant phosphate ester represented by the formulas I-III: ##STR2## wherein n=1-10; R is selected from linear or branched C.sub.2 -C.sub.20 alkyl, and C.sub.6 -C.sub.20 aryl, optionally halogenated; and each R.sub.1 is independently selected from linear or branched C.sub.1 -C.sub.10 alkyl, C.sub.6 -C.sub.20 aryl, and C.sub.7 -C.sub.30 aralkyl, the aryl and aralkyl groups being optionally halogenated; ##STR3## wherein R.sub.2 is selected from hydrogen, C.sub.6 -C.sub.20 aryl, C.sub.6 -C.sub.20 substituted aryl, -P(O)(OR.sub.1).sub.2 wherein R.sub.1 is as defined above, and the group: ##STR4##
In a second aspect, the present invention relates to polyurethane foam compositions which comprise 0.5-50.0 php of at least one flame retardant phosphate ester rep
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Blundell Cefn
Wuestenenk Johan Antonie
Akzo Novel nv
Cooney Jr. John M.
Mancini Ralph J.
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