Phosphorus-containing compounds useful for making halogen-free, ignition-resistant polymers

1. A process for making a curable phosphorus-containing epoxy resin composition comprising blending:

(I) a phosphorus-containing compound comprising the reaction product of:

(A) at least one organophosphorus compound having a group selected from the group H—P═O, the group P—H, and the group P—OH; and

(B) at least one compound having the following Formula (V):

wherein

R1 each independently is hydrogen or an alkyl group having from 1 to 10 carbon atoms;

Y is a functional group selected from hydroxy, carboxylic acid, carboxylate, acid anhydride, and amine;

X is a hydrocarbylene group;

R″ is a hydrocarbyl group having from 1 to 8 carbon atoms, R is alkyl or aryl group having from 1 to 12 carbon atoms;

p each independently represents a number from zero to 4; and

a and b each independently represent a number equal to or greater than zero; and

(II) at least one epoxy resin.

2. A process in accordance with claim 1 wherein the epoxy resin is selected from group consisting of a phenol epoxy novolac, a cresol epoxy novolac, a polyoxazolidone ring containing epoxy resin, a bromine free epoxy resin, a brominated epoxy resin, a phosphorous-containing epoxy resin, and mixtures thereof.

3. A process in accordance with claim 1 further comprising blending a catalyst.

4. A process in accordance with claim 3 wherein the catalyst is a compound selected from the group consisting of an amine-containing compound, a phosphine-containing compound, an ammonium-containing compound, a phosphonium-containing compound, an arsonium-containing compound, a sulfonium-containing compound, a heterocyclic nitrogen-containing compound and mixtures thereof.

5. A process in accordance with claim 4 wherein the catalyst is selected from the group consisting of benzyldimethylamine, tris-(dimethylaminomethyl)phenol, 1,8-diazabicyclo(5.4.0) undec-7-ene, 2-phenylimidazole, N-methylimidazole, 2-ethyl-4-methylimidazole, 1,2-dimethylimidazole, 2-methylimidazole and mixtures thereof.

6. A process for making a curable phosphorus-containing epoxy resin composition comprising blending:

(I) a phosphorus-containing compound comprising the reaction product of:

(A) at least one organophosphorus compound having a group selected from the group H—P═O, the group P—H, and the group P—OH; and

(B) at least one compound having the following Formula (VI):

wherein

R1 each independently is hydrogen or an alkyl group having from 1 to 10 carbon atoms;

Y is a functional group selected from hydroxy, carboxylic acid, carboxylate, acid anhydride, and amine;

X is a hydrocarbylene group;

R″ is a hydrocarbyl group having from 1 to 8 carbon atoms, R is alkyl or aryl group having from 1 to 12 carbon atoms;

p each independently represents a number from zero to 4; and

a and b each independently represent a number equal to or greater than zero; and

(II) at least one epoxy resin.

7. A process in accordance with claim 6 wherein the epoxy resin is selected from group consisting of a phenol epoxy novolac, a cresol epoxy novolac, a polyoxazolidone ring containing epoxy resin, a bromine free epoxy resin, a brominated epoxy resin, a phosphorous-containing epoxy resin, and mixtures thereof.

8. A process in accordance with claim 6 further comprising blending a catalyst.

9. A process in accordance with claim 8 wherein the catalyst is a compound selected from the group consisting of an amine-containing compound, a phosphine-containing compound, an ammonium-containing compound, a phosphonium-containing compound, an arsonium-containing compound, a sulfonium-containing compound, a heterocyclic nitrogen-containing compound and mixtures thereof.

10. A process in accordance with claim 9 wherein the catalyst is selected from the group consisting of benzyldimethylamine, tris-(dimethylaminomethyl)phenol, 1,8-diazabicyclo(5.4.0) undec-7-ene, 2-phenylimidazole, N-methylimidazole, 2-ethyl-4-methylimidazole, 1,2-dimethylimidazole, 2-methylimidazole and mixtures thereof.