Fog reduction in polyurethane foam using phosphate esters

• US 5,958,993 A
• Filed: 04/18/1997
• Issued: 09/28/1999
• Est. Priority Date: 08/30/1994
• Status: Expired due to Term

• Current Assignee: ICL-IP America Inc. (ICL Group Ltd.)
• Original Assignee: Akzo Nobel N.V. (Nouryon BV)
• Inventors: Blundell, Cefn, Wuestenenk, Johan Antonie
• Primary Examiner(s): COONEY, JOHN M
• Application Number:
  US08/793,439
• Time in Patent Office: 893 Days
• Field of Search: 521/168, 521/169, 521/155
• US Class Current: 521/168
• CPC Class Codes: C08G 18/48 Polyethers
• CPC Class Codes: C08G 2110/0008 flexible
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent
• CPC Class Codes: C08G 2290/00 Compositions for creating anti-fogging
• CPC Class Codes: C08K 5/521 Esters of phosphoric acids, e.g. of H3PO4
• CPC Class Codes: C08K 5/527 Cyclic esters
• CPC Class Codes: C08L 75/04 Polyurethanes

Abstract

A process for imparting flame retardancy to a polyurethane foam comprising the step of incorporating in said polyurethane foam 0.5-50.0 php of at least one flame-retardant phosphate ester is disclosed. Also disclosed is a flame-retardant polyurethane foam composition which comprises a polyurethane foam and 0.5-50.0 php of at least one flame-retardant phosphate ester, as well as the use of a flame-retardant phosphate ester to impart flame retardancy to a polyurethane foam. An example of such a phosphate ester is resorcinol bis(diphenyl phosphate). These flame retardants have the advantage that they reduce fogging caused by evaporation of volatile components from polyurethane foam compositions.

Claims

1. A process for imparting flame retardancy to a polyurethane foam comprising the step of incorporating in said polyurethane foam 0.5-50.0 php of at least one flame retardant phosphate ester represented by the formula:

##STR5## wherein n=1-10;

is selected from linear or branched C₂ -C₂₀ alkyl, and C₆ -C₂₀ aryl, optionally halogenated; and

each is independently selected from C₆ -C₂₀ aryl groups, the aryl groups being optionally halogenated.

2. The process of claim 1 wherein 3-25 php of said at least one flame retardant phosphate ester is employed.

3. The process of claim 1 wherein in said process a second flame retardant other than said at least one flame retardant phosphate ester is incorporated into said polyurethane foam.

4. The process of claim 3 wherein said second flame retardant is selected from the group consisting of halogenated diphenyl oxides, haloalkyl phosphates and phosphonate flame retardants.

5. The process of claim 1 wherein said at least one flame retardant phosphate ester is resorcinol bis(diphenyl phosphate).

6. A flame retardant polyurethane foam composition which comprises a polyurethane foam and 0.5-50.0 php of at least one anti fogging flame retardant phosphate ester represented by the formula:

##STR6## wherein n=1-10;

R is selected from linear or branched C₂ -C₂₀ alkyl, and C₆ -C₂₀ aryl, optionally halogenated; and

each R₁ is independently selected from C₆ -C₂₀ aryl groups, the aryl groups being optionally halogenated.

7. The composition of claim 6 which comprises 3-25 php of said at least one flame retardant phosphate ester.

8. The composition of claim 6 which comprises a second flame retardant other than said at least one flame retardant phosphate ester.

9. The composition of claim 6 wherein said at least one flame retardant phosphate ester is resorcinol bis(diphenyl phosphate).