Blends of tetrahalophthalate esters and phosphorus-containing flame retardants for polyurethane compositions
View Patent ↗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.
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:
wherein R 1 and R 2 can be the same or different and represent a C 1 to C 20 linear, branched or cyclic alkyl group, and X is Cl or Br.
6. A flame retardant composition according to claim 5 , wherein R 1 and R 2 are linear or branched C 1 to C 12 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:
wherein each R 3 is independently either H or a linear or branched C 1 to C 6 alkyl group, X is a residue of an aromatic or aliphatic diol, and n is 0 or 1.
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:
wherein R 1 and R 2 can be the same or different and represent a C 1 to C 20 linear, branched or cyclic alkyl group, and X is Cl or Br.
19. A method of providing flame retarded flexible polyurethane compositions according to claim 18 , wherein R 1 and R 2 are linear or branched C 1 to C 12 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:
wherein each R 3 is independently either H or a linear or branched C 1 to C 6 alkyl group, X is a residue of an aromatic or aliphatic diol, and n is 0 or 1.
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:
wherein R 1 and R 2 can be the same or different and represent a C 1 to C 20 linear, branched or cyclic alkyl group, and X is Cl or Br.
32. A flexible polyurethane foam reaction mixture according to claim 31 , wherein R 1 and R 2 are linear or branched C 1 to C 12 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:
wherein each R 3 is independently either H or a linear or branched C 1 to C 6 alkyl group, X is a residue of an aromatic or aliphatic diol, and n is 0 or 1.
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 .