Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
2000-08-24
2003-04-08
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...
C558S061000, C558S097000, C558S098000, C558S099000, C558S111000, C558S127000, C558S155000
Reexamination Certificate
active
06545073
ABSTRACT:
This application concerns novel organic phosphorus-inorganic phosphorus oxyacid compounds, it's basic salts 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 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-inorganic 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-inorganic 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, its basic 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, molded plastic products and as hydraulic fluids, lubricants, surfactants, molded plastic products and many other uses.
SUMMARY OF THE INVENTION
In one respect, the invention comprises reacting organic phosphorus compounds, containing phosphorus atom with a valence of 3-4, with inorganic phosphorus oxyacid compounds with phosphorus atoms with a valence of 5 to produce organic phosphorus-inorganic phosphorus oxyacid compounds. Another aspect, the invention comprises utilizing the organic phosphorus-inorganic 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-inorganic phosphorus oxyacid compound comprising serially contacting and reacting:
A) an organic phosphorus 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; under conditions sufficient to prepare the organic phosphorus-inorganic phosphorus oxyacid compound.
Another aspect of this invention is to produce a flame retardant composition which comprising mixing and reacting:
A) an organic phosphorus 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;
then add and mix
C) carbonization auxiliaries
D) carbonization accelerating compounds
G) heat reflecting substance
F) 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-inorganic phosphorus oxyacid compound produced by a process comprising of serially mixing and reacting:
A) organic phosphorus compound containing a phosphorus atom having a valence of 3-4;
B) inorganic phosphorus compound containing a phosphorus atom having a valence of 5; then mix and react;
C) basic salt forming compound thereby producing a basic salt of organic phosphorus-inorganic phosphorus oxyacid;
then add and mix
D) carbonization auxiliaries
E) carbonization accelerating compounds
F) filler
under conditions sufficient to prepare the salt of organic phosphorus-inorganic 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-inorganic phosphorus oxyacid, (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. Organic phosphorus compound, which contains a phosphorus atom containing a valence of 3-4, 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. An amount of 5% to 30% by weight of the flame retardant compound or it's basic salt or it's composition is added to or applied on the flammable organic material;
4. Basic salt forming compound in the amount of 0 to 100 parts by weight;
5. metal containing compound having a carbonization accelerating effect in the amount of 0 to 40 parts by weight;
6. Comb-like polymer, in the amount of 0 to 100 parts by weight
7. Heat reflecting compound, such as titanium oxide, in the amount of 0 to 30 parts by weight.
8. Filler, in the amount of 0 to 400 parts by weight.
9. Carbonization auxiliaries, 0-100 parts by weight.
Component A
Any suitable organic phosphorus-compound, that contains a phosphorus atom with a valence of 3-4, may be used in this invention, such as, but not limited to, organic phosphites, phosphonates, phosphate, hydrogen phosphites, hydrogen phosphates, polyphosphates, polyphosphonates, polyphosphites, phosphites-phosphates, phosphorus esters, polyphosphorus esters, acid phosphates, polyphosphonate esters, diphosphonic acid esters, phosphorus esters and phosphines, alkyl chlorophosphines and mixtures thereof. The organic phosphonate are the preferred organic phosphorus compound.
Suitable organic phosphates include alkyl phosphites, dialkyl phosphites, trialkyl phosphites, dialkyl hydrogen phosphite, diaryl phosphites, aryl-alkyl phosphites, triaryl phosphites, dialkyl-aryl phosphites, etc. Suitable organic phosphonates include dialkyl alkyl phosphonates, aryl-alkyl phosphonates, diaryl alkyl phosphonates, etc. Suitable organic phosphates include alkyl dihydrogen phosphates, dialkyl hydrogen phosphates, trialkyl phosphates, aryl dihydrogen phosphates, diaryl hydrogen phosphates, triaryl phosphates, aryl-dialkyl phosphate, diaryl alkyl phosphate, etc. Commercially available organic phosphorus compounds which contain a phosphorus atom with a valence of 3 or 4 such as those produced by “ALBRIGHT & WILSON which include ANTIBLAZE CU, a cyclic phosphonate ester, ANTIBLAZE N, a cyclic phosphonate ester, ANTIBLAZE V225, a mixture of alkyl and aryl phosphate esters, ANTIBLAZE V400, an organo phosphate/phosphonate, ANTIBLAZE V490, an organo phosphonate ester, ANTIBLAZE 1045, a cyclic diphosphate ester, ANTIBLAZE DMHP-HP, dimethyl hydrogen phosphite, ANTIBLAZE TEP-HP, triethyl phosphite”, and other commercially available organic phosphorus compounds which contains phosphorus atoms with 3-4 valences.
Component B
Any suitable inorganic phosphorus oxyacid compound which contains a phosphorus atom with a valence of 5 may be used in this invent
LandOfFree
Organic phosphorus-inorganic phosphorus oxyacids compounds... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Organic phosphorus-inorganic phosphorus oxyacids compounds..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Organic phosphorus-inorganic phosphorus oxyacids compounds... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-3074520