Use of low triphenylphosphate, high phosphorous content isopropyl phenyl phosphates as flame retardants in polyurethane or polyisocyanurate foams
AssigneeHickory Springs Manufacturing Company
InventorsWilliam J. Layman, JR., Arthurt G. Mack, Techen Tsao, Jeffrey T. Aplin, Hoover Chew
Life of this patent
Estimating the term…
Abstract
The present invention relates to the use of low triphenyl phosphate, high phosphorous content aryl phosphates with high ortho alkylation as flame retardants in polyurethane or polyisocyanurate foams or polyurethane or polyisocyanurate foam formulations.
Claims23
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The polyurethane or polyisocyanurate foam formulation according to claim 21 wherein said polyurethane or polyisocyanurate foam formulation is a flexible polyurethane foam formulation or a rigid polyurethane foam formulation.
The polyurethane or polyisocyanurate foam formulation according to claim 21 wherein said polyurethane or polyisocyanurate foam or polyurethane or polyisocyanurate foam formulation further contains at least one additional component selected from blowing agents, surfactants, antioxidants, diluents, and the like.
The polyurethane or polyisocyanurate foam formulation according to claim 22 wherein said alkylated triaryl phosphate ester contains greater than about 90 wt % monalkylphenyl diphenyl phosphates, based on the total weight of the alkylated triaryl phosphate ester.
The polyurethane or polyisocyanurate foam formulation according to claim 21 wherein said alkylated triaryl phosphate ester contains less than about 0.5 wt % TPP based on the total weight of the alkylated triaryl phosphate ester.
The polyurethane or polyisocyanurate foam formulation according to claim 21 wherein said alkylated triaryl phosphate is made by a process comprising:
- a. reacting an alkylated phenol stream comprising less than about 1 mole % phenol and up to about 25 mole % dialkyl phenol, both based on the total weight of the alkylated phenol, with POCl3 in the presence of a first catalyst under first reaction conditions including temperatures ranging from about 80° C. to about 210° C. thereby producing a first reaction product comprising greater than about 75 mole % monoalkylated phenyl-dichloro phosphates, based on the total moles of the first reaction product;
- and
- b. reacting the first reaction product with an alcohol selected from aryl alcohols, alkyl alcohols, alkylated aryl alcohols, and mixtures thereof in the presence of a second catalyst under second reaction conditions including temperatures ranging from about 90° C. to about 260° C. thereby producing' an alkylated triaryl phosphate ester;
- or by a process comprising:
- a. reacting an alkylated phenol stream comprising less than about 1 mole % phenol and up to about 25 mole % dialkyl phenol, both based on the total weight of the alkylated phenol, with POCl3 in the presence of a first catalyst under first reaction conditions including temperatures ranging from about 80° C. to about 210° C. thereby producing a first reaction product comprising greater than about 75 mole % monoalkylated phenyl-dichloro phosphates, based on the total moles of the first reaction product;
- and
- b. sequentially reacting the first reaction product with more than one alcohol selected from aryl alcohols, alkyl alcohols, alkylated aryl alcohols, and mixtures thereof in the presence of a second catalyst under second reaction conditions including temperatures ranging from about 70° C. to about 260° C. thereby producing an alkylated triaryl phosphate ester.
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A polyurethane or polyisocyanurate foam composition comprising at least one isocyanate, polyol, or combination thereof, and a flame retarding amount of an alkylated triaryl phosphate ester, wherein said alkylated triaryl phosphate ester contains at least one of (a) monoalkylphenyl diphenyl phosphates, (b. di-(alkylphenyl. phenyl phosphates, (c. dialkylphenyl diphenyl phosphates;
- (d. trialkylphenyl phosphates;
- (e. alkylphenyl dialkylphenyl pphenyl phosphates, and less than about 1 wt % triphenyl phosphate (“TPP”. and in the range of from about 5 to about 10 wt % organic phosphoous content, wherein the alkyl moieties of the alkylated phenyl phosphates and TPP are selected from methyl, ethyl, n-propopyl, isopropyl, isobutyl, tertiary-butyl, isoamyl and tertiary-amyl groups, all based on the total weight of the alkylated triaryl phosphate ester.
Dependencies are inferred from the claim text.