Blends of alkyl substituted triaryl phosphate esters with phosphorus-containing flame retardants for polyurethane foams

• US 20060116432A1
• Filed: 01/17/2006
• Published: 06/01/2006
• Est. Priority Date: 05/20/2002
• Status: Active Grant

• Current Assignee: Great Lakes Chemical Corporation (Lanxess AG)
• Original Assignee: Great Lakes Chemical Corporation (Lanxess AG)
• Inventors: Phillips, Matthew D., Falloon, Stephen B., Rose, Richard S.
• Granted Patent: US 7,390,839 B2
• Time in Patent Office: Days
• US Class Current: 521/107
• CPC Class Codes: C08G 18/48 Polyethers
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/005 < 50kg/m3
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent
• CPC Class Codes: C08K 2201/014 Additives containing two or more different additives of the same subgroup in C08K
• CPC Class Codes: C08K 5/49 Phosphorus-containing compounds C08K5/0091 takes precedence
• CPC Class Codes: C08L 75/04 Polyurethanes

Abstract

Flame retardant flexible polyurethane foam compositions, methods of flame retarding flexible polyurethane foam compositions, articles made therefrom and flame retardants that comprise blends of (alkyl substituted) triaryl phosphate ester and phosphorus-containing flame retardant having at least about 5 wt. % phosphorus additives. The combined weight of the (alkyl substituted) triaryl phosphate ester and the phosphorus-containing flame retardant comprises about 5 to about 40% by weight of the flexible polyurethane foam compositions or reaction mixtures. The ratio of the (alkyl substituted) triaryl phosphate ester to the phosphorus-containing flame retardant is from about 95:5 to about 50:50 percent by weight.

Claims

1. A flame retardant polyurethane composition comprising:

an alkyl substituted triaryl phosphate ester;

a phosphorous-containing flame retardant having at least about 5 wt % phosphorus selected from the group consisting of;

triethyl phosphate, tris(2-ethylhexyl)phosphate, isodecyl diphenyl phosphate, resorcinol bis(diphenyl phosphate), tri-n-butyl phosphate, tri-isobutyl phosphate, or a mixture thereof; and

a flexible polyurethane foam reaction mixture including at least one polyol and at least one isocyanate.

2. The flame retardant polyurethane composition of claim 1, wherein the combined weight of the alkyl substituted triaryl phosphate ester and the phosphorus-containing flame retardant comprises about 5 to about 40% by weight of the polyol.

3. The flame retardant polyurethane composition of claim 1, wherein the ratio of the alkyl substituted triaryl phosphate ester to the phosphorus-containing flame retardant is from about 95:

5 to about 50;

50 percent by weight.

4. The flame retardant polyurethane composition of claim 3, wherein the ratio of the alkyl substituted triaryl phosphate ester to the phosphorus-containing flame retardant is from about 95:

5 to about 80;

20 percent by weight.

5. The flame retardant polyurethane composition of claim 1, wherein the alkyl substituted triaryl phosphate ester includes one or more compounds having the general formula:

6. The flame retardant polyurethane composition of claim 5, wherein the alkyl substituted triaryl phosphate ester comprises at least one of tricresyl phosphate, butylated triphenyl phosphate, and isopropylated triphenyl phosphate.

7. The flame retardant polyurethane composition of claim 6, wherein the alkyl substituted triaryl phosphate ester comprises a mixed isopropylated triphenyl phosphate containing about 8.6% phosphorus and also having about 35 wt. % of non-alkylated triphenyl phosphate.

8. The flame retardant polyurethane composition of claim 1, wherein the phosphorus-containing flame retardant comprises resorcinol bis(diphenyl phosphate).

9. The flame retardant polyurethane composition of claim 1, wherein the phosphorus-containing flame retardant consists of at least one of triethyl phosphate, tris(2-ethylhexyl)phosphate, and isodecyl diphenyl phosphate.

10. The flame retardant polyurethane composition of claim 1, wherein the phosphorus-containing flame retardant consists of at least one of tri-n-butyl phosphate and tri-isobutyl phosphate.

11. A flame retardant polyurethane composition comprising:

a flexible polyurethane foam reaction mixture including at least one polyol and at least one isocyanate; and

a flame retardant additive comprising an alkyl substituted triaryl phosphate ester; and

a phosphorus-containing flame retardant selected from the group consisting of;

triethyl phosphate, tris(2-ethylhexyl)phosphate, isodecyl diphenyl phosphate, resorcinol bis(diphenyl phosphate), tri-n-butyl phosphate, tri-isobutyl phosphate, wherein the ratio of the alkyl substituted triaryl phosphate ester to the phosphorus-containing flame retardant is from about 95;

5 to about 80;

20 percent by weight.

12. The flame retardant polyurethane composition of claim 11 wherein the phosphorus-containing flame retardant includes at least about 5 wt. % phosphorus.

13. The flame retardant polyurethane composition of claim 11, wherein the combined weight of the alkyl substituted triaryl phosphate ester and the phosphorus-containing flame retardant comprises about 5 to about 40% by weight of the polyol.

14. The flame retardant polyurethane composition of claim 11, wherein the alkyl substituted triaryl phosphate ester includes one or more compounds having the general formula:

15. The flame retardant polyurethane composition of claim 14, wherein the alkyl substituted triaryl phosphate ester comprises at least one of tricresyl phosphate, butylated triphenyl phosphate, and isopropylated triphenyl phosphate.

16. The flame retardant polyurethane composition of claim 15, wherein the alkyl substituted triaryl phosphate ester comprises a mixed isopropylated triphenyl phosphate containing about 8.6% phosphorus and also having about 35 wt. % of non-alkylated triphenyl phosphate.

17. The flame retardant polyurethane composition of claim 11, wherein the phosphorus-containing flame retardant comprises resorcinol bis(diphenyl phosphate).

18. The flame retardant polyurethane composition of claim 11, wherein the phosphorus-containing flame retardant consists of at least one of triethyl phosphate, tris(2-ethylhexyl)phosphate, and isodecyl diphenyl phosphate.

19. The flame retardant polyurethane composition of claim 11, wherein the phosphorus-containing flame retardant consists of at least one of tri-n-butyl phosphate and tri-isobutyl phosphate.

20. A flame retardant additive for use in flame retarding a flexible polyurethane foam reaction mixture including at least one polyol and at least one isocyanate, the flame retardant additive comprising:

an alkyl substituted triaryl phosphate ester; and

a phosphorus-containing flame retardant having at least about 5 wt. % phosphorus and including at least one monomeric phosphorus-containing compound selected from the group consisting of;

triethyl phosphate, tris(2-ethylhexyl)phosphate, isodecyl diphenyl phosphate, resorcinol bis(diphenyl phosphate), tri-n-butyl phosphate, tri-isobutyl phosphate, wherein the combined weight of the alkyl substituted triaryl phosphate ester and the phosphorus-containing flame retardant comprises about 5 to about 40% by weight of the polyol.

21. The flame retardant additive of claim 20, wherein the ratio of the alkyl substituted triaryl phosphate ester to the phosphorus-containing flame retardant is from about 95:

5 to about 80;

20 percent by weight.

22. The flame retardant additive of claim 20, wherein the alkyl substituted triaryl phosphate ester has the general formula:

23. The flame retardant additive of claim 22, wherein the alkyl substituted triaryl phosphate ester comprises at least one of tricresyl phosphate, butylated triphenyl phosphate, and isopropylated triphenyl phosphate.

24. The flame retardant additive of claim 23, wherein the alkyl substituted triaryl phosphate ester comprises a mixed isopropylated triphenyl phosphate containing about 8.6% phosphorus and also having about 35 wt. % of non-alkylated triphenyl phosphate.

25. The flame retardant additive of claim 20, wherein the phosphorus-containing flame retardant comprises resorcinol bis(diphenyl phosphate).

26. The flame retardant additive of claim 20, wherein the phosphorus-containing flame retardant consists of at least one of triethyl phosphate, tris(2-ethylhexyl)phosphate, and isodecyl diphenyl phosphate.

27. The flame retardant additive of claim 20, wherein the phosphorus-containing flame retardant consists of at least one of tri-n-butyl phosphate and tri-isobutyl phosphate.

28. A method of making flame retarded flexible polyurethane compositions comprising the step of:

adding to a flexible polyurethane foam reaction mixture about 5 to about 40% by weight of polyol of a flame retardant additive comprising;

an alkyl substituted triaryl phosphate ester; and

a phosphorus-containing flame retardant having at least about 5 wt. % phosphorus selected from the group consisting of;

triethyl phosphate, tris(2-ethylhexyl)phosphate, isodecyl diphenyl phosphate, resorcinol bis(diphenyl phosphate), tri-n-butyl phosphate, tri-isobutyl phosphate.

29. The method of claim 28, further comprising the step of pre-combining the alkyl substituted triaryl phosphate ester and the phosphorus-containing flame retardant prior to the step of adding the flame retardant additive to the flexible polyurethane foam reaction mixture.

30. The method of claim 28, wherein the ratio of the alkyl substituted triaryl phosphate ester to the phosphorus-containing flame retardant is from about 95:

5 to about 80;

20 percent by weight.

31. The method of claim 28, wherein the alkyl substituted triaryl phosphate ester has the general formula:

32. The method of claim 31, wherein the alkyl substituted triaryl phosphate ester comprises at least one of tricresyl phosphate, butylated triphenyl phosphate, and isopropylated triphenyl phosphate.

33. The method of claim 32, wherein the alkyl substituted triaryl phosphate ester comprises a mixed isopropylated triphenyl phosphate containing about 8.6% phosphorus and also having about 35 wt. % of non-alkylated triphenyl phosphate.

34. The method of claim 33, wherein the phosphorus-containing flame retardant comprises resorcinol bis(diphenyl phosphate).

35. The method claim 33, wherein the phosphorus-containing flame retardant consists of at least one of triethyl phosphate, tris(2-ethylhexyl)phosphate, and isodecyl diphenyl phosphate.

36. The method of claim 33, wherein the phosphorus-containing flame retardant consists of at least one of tri-n-butyl phosphate and tri-isobutyl phosphate.