Blends of tetrahalophthalate esters and phosphorus-containing flame retardants for polyurethane compositions

• US 7,423,069 B2
• Filed: 05/05/2003
• Issued: 09/09/2008
• Est. Priority Date: 05/06/2002
• Status: Expired due to Fees

• Current Assignee: Great Lakes Chemical Corporation (Lanxess AG)
• Original Assignee: Crompton Corporation (Lanxess AG)
• Inventors: Phillips, Matthew D., Falloon, Stephen B., Rose, Richard S., Buszard, David
• Primary Examiner(s): COONEY, JOHN M
• Application Number:
  US10/429,429
• Publication Number:
  US 20040030011A1
• Time in Patent Office: 1,954 Days
• Field of Search: 521/106, 521/107, 521/108, 521/170, 521/174, 521/130
• US Class Current: 521/106
• CPC Class Codes: C08K 5/12 of cyclic polycarboxylic acids
• CPC Class Codes: C08K 5/523 with hydroxyaryl compounds
• 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 tetrahalophthalate esters and phosphorus-containing flame retardant having at least about 5 wt. % phosphorus additives. The combined weight of the tetrahalophthalate ester and the phosphorus-containing flame retardant comprises about 5 to about 20% by weight of the flexible polyurethane foam compositions or reaction mixtures. The ratio of the tetrahalophthalate ester to the phosphorus-containing flame retardant is from about 80:20 to about 20:80 percent by weight and preferably from about 60:40 to about 40:60 percent by weight.

Claims

1. A reaction mixture for the preparation of flame retardant flexible polyurethane foam comprising:

a dialkyl tetrahalophthalate ester;

a phosphorus-containing flame retardant having at least about 5 wt. % phosphorus.

2. A flame retardant composition according to claim 1, wherein the combined weight of the dialkyl tetrahalophthalate ester and the phosphorus-containing flame retardant comprises about 5 to about 20% by weight of the polyol portion of the composition.

3. A flame retardant composition according to claim 2, wherein the ratio of the dialkyl tetrahalophthalate ester to the phosphorus-containing flame retardant is from about 80:

20 to about 20;

80 percent by weight.

4. A flame retardant composition according to claim 3, wherein the ratio of the dialkyl tetrahalophthalate ester to the phosphorus-containing flame retardant is from about 60:

40 to about 40;

60 percent by weight.

5. A flame retardant composition according to claim 1, wherein the dialkyl tetrahalophthalate ester has the general formula:

6. A flame retardant composition according to claim 5, wherein R₁ and R₂ are linear or branched C₁ to C₁₂ alkyl groups and X is Br.

7. A flame retardant composition according to claim 6, wherein the dialkyl tetrahalophthalate ester comprises di(2-ethylhexyl)tetrabromophthalate.

8. A flame retardant composition according to claim 1, wherein the phosphorus-containing flame retardant comprises at least one of a phosphate, a phosphonate, a phosphinate, a phosphite and a phosphine oxide.

9. A flame retardant composition according to claim 8, wherein the phosphorus-containing flame retardant comprises at least one of triethyl phosphate, tri-n-butyl phosphate, tri-isobutyl phosphate, tris(2-ethylhexyl) phosphate, dimethylmethyl phosphonate, resorcinol bis (diphenyl phosphate), dimethylpropyl phosphonate, triphenyl phosphate, and isodecyl diphenyl phosphate.

10. A flame retardant composition according to claim 8, wherein the phosphorus-containing flame retardant has the general formula:

11. A flame retardant composition according to claim 10, wherein the phosphorus-containing flame retardant comprises at least one a neopentyl bis(diphenyl phosphate), a tricresyl phosphate, a bisphenol-A bis(diphenyl phosphate), a butylated triphenyl phosphate, and an isopropylated triphenyl phosphate.

12. A flame retardant composition according to claim 11, wherein the phosphorus-containing flame retardant comprises an isopropylated triphenyl phosphate.

13. A flexible foamed article made from the flame retardant composition of claim 1.

14. A method of providing flame retarded flexible polyurethane compositions which comprises including about 2 to about 20% by weight of polyol of a blend of a dialkyl tetrahalophthalate ester and a phosphorus-containing flame retardant having at least about 5 wt. % phosphorus as a component of a flexible polyurethane foam reaction mixture.

15. A method of providing flame retarded flexible polyurethane compositions according to claim 14, wherein the dialkyl tetrahalophthalate ester and a phosphorus-containing flame retardant are preblended together before being added to the flexible polyurethane foam reaction mixture.

16. A method of providing flame retarded flexible polyurethane compositions according to claim 14, wherein the ratio of the dialkyl tetrahalophthalate ester to the phosphorus-containing flame retardant is from about 80:

20 to about 20;

80 percent by weight.

17. A method of providing flame retarded flexible polyurethane compositions according to claim 16, wherein the ratio of the dialkyl tetrahalophthalate ester to the phosphorus-containing flame retardant is from about 60:

40 to about 40;

60 percent by weight.

18. A method of providing flame retarded flexible polyurethane compositions according to claim 14, wherein the dialkyl tetrahalophthalate ester has the general formula:

19. A method of providing flame retarded flexible polyurethane compositions according to claim 18, wherein R₁ and R₂ are linear or branched C₁ to C₁₂ alkyl groups, and X is Br.

20. A method of providing flame retarded flexible polyurethane compositions according to claim 19, wherein the dialkyl tetrahalophthalate ester comprises di(2-ethylhexyl)tetrabromophthalate.

21. A method of providing flame retarded flexible polyurethane compositions according to claim 14, wherein the phosphorus-containing flame retardant comprises at least one of a phosphate, a phosphonate, a phosphinate, a phosphite and a phosphine oxide.

22. A method of providing flame retarded flexible polyurethane compositions according to claim 21, wherein the phosphorus-containing flame retardant comprises at least one of triethyl phosphate, tri-n-butyl phosphate, tri-isobutyl phosphate, tris(2-ethylhexyl) phosphate, dimethylmethyl phosphonate, resorcinol bis (diphenyl phosphate), dimethylpropyl phosphonate, triphenyl phosphate, and isodecyl diphenyl phosphate.

23. A method of providing flame retarded flexible polyurethane compositions according to claim 21, wherein the phosphorus-containing flame retardant has the general formula:

24. A method of providing flame retarded flexible polyurethane compositions according to claim 23, wherein the phosphorus-containing flame retardant comprises at least one a neopentyl bis(diphenyl phosphate), a tricresyl phosphate, a bisphenol-A bis(diphenyl phosphate), a butylated triphenyl phosphate, and an isopropylated triphenyl phosphate.

25. A method of providing flame retarded flexible polyurethane compositions according to claim 24, wherein the phosphorus-containing flame retardant comprises an isopropylated triphenyl phosphate.

26. A flexible foamed article made from the flame retardant composition of claim 14.

27. A flexible polyurethane foam reaction mixture which comprises;

a dialkyl tetrahalophthalate ester;

a phosphorus-containing flame retardant having at least about 5 wt. % phosphorus; and

a flexible polyurethane foam reaction mixture.

28. A flexible polyurethane foam reaction mixture according to claim 27, wherein the combined weight of the dialkyl tetrahalophthalate ester and the phosphorus-containing flame retardant comprises about 5 to about 20 % by weight of the polyol part of the composition.

29. A flexible polyurethane foam reaction mixture according to claim 28, wherein the ratio of the dialkyl tetrahalophthalate ester to the phosphorus-containing flame retardant is from about 80:

20 to about 20;

80 percent by weight.

30. A flexible polyurethane foam reaction mixture according to claim 29, wherein the ratio of the dialkyl tetrahalophthalate ester to the phosphorus-containing flame retardant is from about 60:

40 to about 40;

60 percent by weight.

31. A flexible polyurethane foam reaction mixture according to claim 27, wherein the dialkyl tetrahalophthalate ester has the general formula:

32. A flexible polyurethane foam reaction mixture according to claim 31, wherein R₁ and R₂ are linear or branched C₁ to C₁₂ alkyl groups and X is Br.

33. A flexible polyurethane foam reaction mixture according to claim 32, wherein the dialkyl tetrahalophthalate ester comprises di(2-ethylhexyl)tetrabromophthalate.

34. A flexible polyurethane foam reaction mixture according to claim 27, wherein the phosphorus-containing flame retardant comprises at least one of a phosphate, a phosphonate, a phosphinate, a phosphite and a phosphine oxide.

35. A flexible polyurethane foam reaction mixture according to claim 34, wherein the phosphorus-containing flame retardant comprises at least one of triethyl phosphate, tri-n-butyl phosphate, tri-isobutyl phosphate, tris(2-ethylhexyl) phosphate, dimethylmethyl phosphonate, resorcinol bis (diphenyl phosphate), dimethylpropyl phosphonate, triphenyl phosphate, and isodecyl diphenyl phosphate.

36. A flexible polyurethane foam reaction mixture according to claim 34, wherein the phosphorus-containing flame retardant has the general formula:

37. A flexible polyurethane foam reaction mixture according to claim 36, wherein the phosphorus-containing flame retardant comprises at least one of a neopentyl bis(diphenyl phosphate), a tricresyl phosphate, a bisphenol-A bis(diphenyl phosphate), a butylated triphenyl phosphate, and an isopropylated triphenyl phosphate.

38. A flexible polyurethane foam reaction mixture according to claim 37, wherein the phosphorus-containing flame retardant comprises an isopropylated triphenyl phosphate.

39. A flexible foamed article made from the flame retardant composition of claim 27.