201033266 六、發明說明： 【發明所屬之技術領域】 本發明涉及特別適用於製造軟墊傢倶和枕頭的阻燃乳 膠泡沬組合物。 【先前技術】 已知並已經報導了乳膠泡沬、它們的製造工藝和其用 途。乳膠通常被定義爲橡膠顆粒的水中的懸浮液，其可以 完全由天然橡膠或由天然橡膠和合成橡膠如SBR的混合物 ^ 組成。這樣的懸浮液可以包含皂或其他分散劑。一般而言， 存在兩種用於生產乳膠泡沫（也叫作乳膠泡沬橡膠）的方 法。存在Dunlop製法和Talalay製法。兩種製法都通過起 泡程序來產生泡沫。此程序包括將氣體分散在合適的乳膠 中，然後使乳膠顆粒聚結並在水相中形成連續的橡膠相。 由於皂在水中失活，所以含水皂膜破裂，這又導致乳膠膜 破裂。此後，固化和乾燥膨脹的基材以形成穩定的乳膠泡 ❹ 沬。在Dunlop製法中，諸如氟矽酸鈉的化學膠凝劑用於使 乳膠的橡膠顆粒凝結，同時使皂失活。兩種製法之間的主 要差異涉及在固化步驟之前在加熱的模具中處理乳膠泡 沫。在Talalay製法中，倒入模具中的乳膠組合物的體積是 小的，留下膨脹的空間。從封閉的模具中抽出空氣，使得 乳膠通過所產生的真空而膨脹’以便模具被完全塡充膨脹 的乳膠。通過快速冷卻到-30°C來防止泡沫坍塌，以產生 冷凍的乳膠泡沫。在此時，使二氧化碳氣體通過乳膠並將 201033266 溫度升高到約115 °C，這樣就使泡沬固定和硬化。然後將泡 沫從模具中取出。在Dunlop製法中，模具被塡充至邊緣。 沒有應用真空，也沒有利用任何冷凍技術。而是在合適的 高溫下在模具中固化乳膠胞狀結構。對於涉及乳膠泡沬的 製備的更多細節，可參考仍A/ner五〇/ 化工技術百科全 書），1994 版權，John Wiley & Sons, Inc.中的標題爲 “Foamed Plastics (泡沬塑料）”的文本，尤其是第11頁，第3.3.1 節，關於 “ Frothing (起泡）”；和 E.W. Madge，Laiez Foa/n 乳膠泡沬橡膠），John Wiley & Sons, Inc.，New York, 1 9 62。還參見下面的線上描述，其複件被’附到此處並構成 此處的一部分： • http://www.dunloplatexfoam.com/latex.php # http://www.latexfoam.com/index.php?did=12 # http://ezinearticles.com/7The-Two-Main-Processes-Of-Latex-Mattress-Production-Explained — Dunlop-vs-Talalay&id=1053851 • h ttp : "irpec. 1 gm · gov. my/prd_l atexf oam. html ° 通常，主要或完全由天然橡膠形成的乳膠泡沬傾向於 是柔性的。由合成乳膠的混合物形成的乳膠泡沫傾向於更 具剛性的。在柔性泡沬和硬質泡沬之間不存在明顯的嚴格 且徹底的界限或劃分。在兩種類型的泡沫之間建立分類的 一種常規方法出現在AS TM測試程序D 1566-82中，其出 201033266 現在ASTM, Philadelphia，PA, 1982的第37卷中。該分類指 出柔性泡沫是當在15°C到25t下以每5秒1圈的速率繞2.5 cm心軸纏繞20 X 2.5 X 2.5 cm件時不會破裂的泡沬。硬質 泡沫在這些測試條件下破裂。乳膠泡沫可區別於記憶泡沬 或粘彈性泡沫，因爲後者由塑膠得到，且泡沬顯示出由通 過施加壓力而引起的變形的相對慢的回復。相比之下，乳 膠泡沫由橡膠（天然橡膠或天然橡膠和人造橡膠的混合物） 製成，且泡沬顯示出由通過施加壓力而引起的變形的相對 快的回復。 對於許多用途如製造軟墊傢倶和枕頭來說，所必需的 是，乳膠泡沬應是有效地阻燃的。例如，達到BS 5 852源1 和2是必須滿足的要求。 儘管在現有技術中已經廣泛地硏究用於各種聚合組合 物如聚氨酯的許多阻燃劑，但有效地阻燃乳膠組合物的問 題涉及某些特定的固有問題。例如，如美國專利第4,239,670 號在第3欄第1— 11行中所指出的： 一些阻燃劑化合物當被添加到乳膠中時，使該乳膠變 得不穩定。不穩定意味著乳膠凝聚和/或在粘度上具有明顯 的變化。在一些情況中，不穩定性可能是由向對pH極度敏 感的乳膠中添加特定類型的阻燃劑化合物引起的。通常， 這樣的變化、凝聚和/或流變性質變化是不期望的，這是因 爲乳膠不能用於它們的預期的目的。例如，存在對添加磷 酸氫二銨是不穩定的許多乳膠。 近年來，已經表示出關於使用某些溴阻燃劑的一些關 201033266 注。因此，如果可以找到一種採用無任何溴組分的阻燃劑 組合物有效地阻燃乳膠泡沫而同時避免前述美國專利中提 及的問題的方法，那將是所期望的。本發明被認爲獲得此 期望的結果。 【發明內容】 按照本發明，提供了阻燃乳膠組合物、阻燃乳膠泡沬 和用於生產這樣的阻燃組合物和阻燃泡沬的製法技術，所 述組合物通過將阻燃量的三聚氰胺和至少一種液態氯烷基 磷酸酯合倂到其中而形成。因此，本發明除了別的以外提 供了一種阻燃未固化的乳膠組合物，該乳膠組合物在固化 之前已經與三聚氰胺和至少一種液態氯烷基磷酸酯共混。 本發明除了別的以外還提供了一種通過在模具中固化乳膠 組合物、由乳膠製劑生產固化的乳膠組合物的製法，所述 乳膠製劑包括天然橡膠或天然橡膠和合成橡膠（如，苯乙 烯-丁二烯橡膠）的混合物，所述製法的特徵在於，在模 具中處理乳膠組合物之前，將三聚氰胺和至少一種液態氯 烷基磷酸酯阻燃劑與乳膠組合物混合以由此生產阻燃固化 的乳膠組合物。本發明還提供了所得到的、由本發明的製 法形成的固化的組合物，所述固化的組合物包括固化的泡 沬組合物。 本發明的上述和其他特徵由隨後的描述和所附的申請 專利範圍所涵蓋、被包括在隨後的描述和所附的申請專利 範圍中以及從隨後的描述和所附的申請專利範圍中將變得 更進一步明顯。 201033266 【實施方式】 本發明除了別的以外提供了一種阻燃未固化的乳膠製 劑，該乳膠製劑由包括以下物質的組分形成：（a)天然橡 膠的乳膠或天然橡膠和合成橡膠（如，.苯乙烯-丁二烯橡 膠）的混合物的乳膠，（b )阻燃劑，所述阻燃劑是通過將 (i )三聚氰胺和（ii )至少一種液態氯烷基磷酸酯引入乳 膠製劑中形成的。典型的這種類型的製劑是這樣的製劑： 其中被引入乳膠製劑中的液態氯烷基磷酸酯的量在每一百 重量份用於形成製劑的（a)的乳膠的10份到25份的範圍 內，且被引入乳膠製劑中的三聚氰胺的量在每一百重量份 用於形成乳膠製劑的（a )的乳膠的1 0份到30份的範圍內。 理想地，被引入乳膠製劑中的三聚氰胺的量超過被引入乳 膠製劑中的液態氯烷基磷酸酯的量。當使用由天然橡膠和 合成橡膠的混合物或混合物形成的乳膠時，所使用的特定 的橡膠及其相對比例根據本領域技術人員已知的原理來選 擇，以在固化時生產具有所期望的柔性或剛性的固化的乳 膠組合物。 本發明除了別的以外還提供了由熱固化上述製劑中的 任一種形成的固化的阻燃組合物。理想地，固化的阻燃組 合物是以固化的泡沫的形式。 本發明提供了一種由乳膠製劑生產固化的阻燃乳膠組 合物的較佳製法，所述乳膠製劑包括天然橡膠的乳膠或天 然橡膠和合成橡膠如苯乙烯-丁二烯橡膠的乳膠，其中製 劑在攪拌（即，當被物理地轉化成泡沬時）下和沒有凝膠 -7- 201033266 形成時被引入在70°c到100°C範圍內的溫度下被預熱一段 時間的模具中，導致所述製劑固化。該製法的特徵在於， 在模具中處理乳膠組合物之前，將乳膠組合物與三聚氰胺 和至少一種液態氯烷基磷酸酯阻燃劑混合。 本發明除了別的以外還進一步提供了生產固化的阻燃 組合物的較佳製法，所述製法包括： • 形成乳膠製劑並使其起泡，乳膠製劑由包括以下物 質的組分形成：（a)天然橡膠的乳膠或天然橡膠和合成橡 膠如苯乙烯一丁二烯橡膠的乳膠，（b)三聚氰胺，和（c) 至少一種液態氯烷基磷酸酯阻燃劑，所述液態氯烷基磷酸 酯阻燃劑具有至少 30 wt%的氯含量和至少7 wt%的磷含 量；然後將矽氟化鈉以在每一百重量份用於形成製劑的（a ) 的所述乳膠的量的5重量份到10重量份的範圍內的量引入 製劑中；以及 • 當沒有凝膠形成時，將所述製劑引入在約70°C到 約100°C範圍內的溫度下被預熱一段時間的模具中，導致所 述製劑固化。 在進行該製法中，被引入乳膠製劑中的至少一種液態 氯烷基磷酸酯阻燃劑組合物的量通常在每一百重量份用於 形成乳膠製劑的乳膠的10份到25份的範圍內，且被引入 乳膠製劑中的三聚氰胺的量通常在每一百重量份用於形成 乳膠製劑的乳膠的1 0份到30份的範圍內。如上所述’所 期望的是，使用於形成柔性乳膠製劑的三聚氰胺的量大於 用於形成乳膠製劑的液態氯烷基磷酸酯.組合物的量。 201033266 . 用於生產固化的阻燃組合物的本發明的又一個較佳製 法，該製法包括： • 由包括以下物質的組分形成乳膠製劑：（a )天然 橡膠的乳膠或天然橡膠和合成橡膠如苯乙烯-丁二烯橡膠 的乳膠，（b)三聚氰胺，和（c)至少一種液態氯烷基磷 酸酯阻燃劑，所述液態氯烷基磷酸酯阻燃劑具有至少30 wt%的氯含量和至少7 wt%的磷含量； • 用所述乳膠製劑部分地塡充可封閉的模具，並使所 ❹ 述製劑在封閉的模具內經受真空條件，以生產塡充封閉的 模具的泡沫； • 快速地冷卻模具的內容物以生產冷凍的乳膠泡 沫，且然後使二氧化碳氣體通過乳膠並將溫度升高到泡沫 被固化的溫度；以及 籲從模具中移出固化的泡沬。 取決於溫度和製劑的組成，所施加的真空度可以變 \ Q 化，但在任何情況下都足以將乳膠製劑轉化成塡充封閉的 模具的泡沫乳膠製劑。在真空大小還沒有被確定的任何情 況下，可以進行一個或兩個不多的預試驗，其中封閉的模 具中的壓力被逐漸減小（即，其中真空被逐漸增加），以 便確定用於達到形成所期望的泡沫的合適的真空條件。同 樣地，取決於乳膠組合物的組成，固化溫度可以變化，但 在任何情況下都足夠高以便固化（即，硬化）泡沬。通常， 這樣的溫度在約100°C到約130°C的範圍內，但在最佳溫度 參 還沒有被確定的任何情況下，這可以通過使用選定的乳膠 201033266 製劑進行少數簡單試驗的簡單權宜手段而容易地確定。 μ 關於用於實現按照本發明所提供的阻燃性的組分或成 分’三聚氰胺在化學上已知爲2,4,6-三胺-三井。三聚氰胺 被預分散在乳膠漿料中是較佳的。而且，在固化之前，液 體形式的乳膠製劑可以被有效地攪拌以確保製劑的均勻 性。 可用於實踐本發明的氯烷基磷酸酯是在低至20 °C的溫 度下爲液態的那些氯烷基磷酸酯。較佳的是具有至少30 〇 wt%的氯含量和至少7 wt%的磷含量的氯烷基磷酸酯。許多 這樣的產品可在市場上得到。例如，且不以任何方式將本 發明僅限制於下面的材料，可有效利用諸如由 Albemarle Corporation得到的以下阻燃劑組合物的商業購得到的阻燃 劑·· Antiblaze® V6阻燃劑（典型的磷含量10.50 wt%，典 型的氯含量36.50 wt%) 、Antiblaze® V66阻燃劑（典型的 磷含量10.3 wt%，典型的氯含量32.9 wt%) 、Antiblaze® Q TL-10-ST阻燃劑（典型的磷含量10.6 wt%，典型的氯含量 36.5 wt%)和Antiblaze® WR-30-LV阻燃劑（典型的磷含量 7.2 wt%，典型的氯含量35.9 wt%)。 其他合適的液態氯烷基磷酸酯是已知的並可以被使 用。一些非限制性的實例包括三（氯甲基）磷酸酯、三（2 一氯乙基）磷酸酯和三（2_氯異丙基）磷酸酯。 如本領域眾所周知的，用於製備乳膠（latices )(也 叫作乳膠（latexes))和泡沫乳膠的橡膠混合物由天然橡 膠乳膠或天然橡膠乳膠和合成橡膠乳膠的混合物製成，天 -10- 201033266 . 然橡膠乳膠通常是基於從各種世界範圍內的橡膠源獲得的 合適的天然橡膠，且合成乳膠通常是基於苯乙烯一丁二烯 橡膠（SBS )。 在本發明的實踐中形成的由天然橡膠和合成橡膠的混 合物形成的阻燃乳膠和阻燃泡沬乳膠通常包含在20 wt %到 80 wt %範圍內的天然橡膠乳膠和在85 wt %到15 wt %範圍內 的合成橡膠乳_ (通常是苯乙烯一丁二烯橡膠乳膠）。本 發明的其他阻燃乳膠由100 %天然合成橡膠製成。 v 用於形成本發明的阻燃乳膠混合物、阻燃乳膠和阻燃 泡沫的氯烷基磷酸酯和三聚氰胺的量通常爲在1〇重量份 到25重量份的範圍內的液態氯烷基磷酸酯組合物和在！ 〇 重量份到30重量份的範圍內的三聚氰胺。可以將三聚氰胺 以粉末形式或以預分散形式（漿料）添加到乳膠配合物中。 在模具中處理乳膠混合物之前，將液態阻燃劑添加到乳膠 混合物中。在Dunlop類型的製法的情況下，在添加矽氟化 @ 鈉（NSF)之後且在任何情況下在模具中處理乳膠混合物之 前將液態阻燃劑添加到乳膠混合物中是較佳的。在Talalay 製法中’液態阻燃劑必須剛好在塡充模具之前與其他組分 混合。 在進行用於生產乳膠泡沬的本發明製法中，利用 Talalay製法或Dunlop製法的程序來進行本製法是所期望 的。然而，如果期望的話，可以使用其他製法技術。 用於以實驗室規模生產本發明的乳膠泡沫的合適程序 包括使用培烤混合器（bakery mixer )、在其中形成泡沫的 -11 - 201033266 模具、所需的天然乳膠-苯乙烯丁二烯（SBS)乳膠混合物、 矽氟化鈉、液態氯烷基磷酸酯阻燃劑組合物和三聚氰胺。 液態氯烷基磷酸酯阻燃劑組合物和三聚氰胺可以用作預成 型的阻燃劑混合物，或者它們可以用作單獨的阻燃劑組 分。所使用的實驗室程序包括以下步驟： • 預熱模具以使其溫度維持在70°C。 • 將160克乳膠混合物、24克液態氯烷基磷酸酯阻 燃劑組合物和40克三聚氰胺添加到混合器中，並在50每 © 分鐘轉數（rpm)至高達25 0 rpm範圍的混合器全速下使這 些組分混合4分鐘。 • 當繼續混合時，在30秒的時間段內將8.8克矽氟 化鈉添加到混合物中’並繼續混合另外一分鐘。 • 將混合物倒入模具中並將模具放在被維持在 100°C下的烘箱中35分鐘。 • 允許產物和模具冷卻，且然後從模具中移出冷卻 ⑬ 的產物並用水洗滌產物。 下面的實施例是示例性的且並不期望將本發明僅限制 於所使用的程序。 實施例1 使用上面的程序，使用以下組分：商購得到的柔性 80/20床具乳膠配合物、氯烷基磷酸酯阻燃劑（Antiblaze® TL-10-ST; Albemarle Corporation);來自 DSM 的三聚氰胺 GPH，粒度<300微米，18-20% ;以及由商購得到的粉末製 備的矽氟化鈉溶液。然後使所得到的本發明泡沬經受標準 -12- 201033266 BS 5 852 ( 1 990 )源1和源2測試程序。這些測試的結果槪 括在表中。 實施例2 爲了比較的目的，除了不使用阻燃劑組分之外，以與 實施例1相同的方式製備泡沫。然後使所得到的比較泡沫 經受標準BS 5 85 2 ( 1 990 )源1和源2測試程序。這些測試 的結果也槪括在表中，其中除了所使用的乳膠的量之外， 各種量用每一百份乳膠的份數（wt/wt)來說明，該術語被 ❹縮寫爲pph。 表 所使用的組分和量 實施例1 (本發明） 實施例2 (比較） 所使用的乳膠的量 100份 100份 矽氟化鈉 5.5 pph 5.5 pph 氯烷基磷酸酯 15 pph Jnr. m 三聚氰胺 25 pph /frtr. 無 BS 5852測試結果 BS 5852 源 1 合格 失敗 BS 5852 源 2 合格 未測試 在說明書或其申請專利範圍中任何地方通過化學名稱 或化學式提及的組分，無論是以單數還是以複數提及，都 被視爲它們在與通過化學名稱或化學類型提及的另一種物 質（如，另一種組分、溶劑或其他）接觸之前就存在。重 要的不是在所得到的混合物或溶液中發生什麼化學變化、 -13- 201033266 . 轉化和/或反應（如果存在的話），這是因爲這樣的變化、 轉化和/或反應是在按照本公開內容所要求的條件下將指 定的組分放在一起的自然結果。因此，各組分被視爲與進 行所期望的操作或形成所期望的組合物有關的將被放在一 起的成分。並且，雖然以下的申請專利範圍可以以現在時 (“ comprises (包括）” 、“ is (是）”等）提及物質、 組分和/或成分，但根據本公開內容，該提及是指剛好在其 與一種或多種其他物質、組分和/或成分首次接觸、共混或 ® 混合之前就存在的物質、組分和/或成分。 在本說明書的任一部分中提及的每一個和全部專利、 出版物或線上參考文獻通過引用被全部併入本公開內容 中，如同完全在本文提出一樣。 除了可能另外清楚地指出之外，冠詞“ a( —）”或“ an (―)”如果在本文中使用以及如本文所使用的，並不期 望將申請專利範圍限制爲且不應被理解爲將申請專利範圍 0 限制爲冠詞所指的單個要素。更確切地說，冠詞“ a(—) ” 或"an ( —”如果在本文中使用以及如本文所使用的， 被期望涵蓋一個或多個這樣的要素，除非上下文中的文本 另外清楚地指出。 本發明可以包括本文所述的材料和/或程序，由本文所 述的材料和/或程序組成，或基本上由本文所述的材料和/ 或程序組成。 本發明在其實踐中容許進行相當大的改變。因此，前 述描述並不期望將本發明限制爲且不應被理解爲將本發明 -14- 201033266 限制爲上文所呈現的特定的範例。 【圖式簡單說明】 Μ 。 【主要元件符號說明】 Μ 。 ❹201033266 VI. Description of the Invention: [Technical Field of the Invention] The present invention relates to a flame-retardant latex foam composition which is particularly suitable for the manufacture of cushioned furniture and pillows. [Prior Art] Latex foams, their manufacturing processes, and their uses have been known and reported. Latex is generally defined as a suspension of rubber particles in water, which may consist entirely of natural rubber or a mixture of natural rubber and synthetic rubber such as SBR. Such suspensions may contain soap or other dispersing agents. In general, there are two methods for producing latex foams (also known as latex foam rubber). There are Dunlop method and Talalay method. Both processes produce foam through a foaming process. This procedure involves dispersing the gas in a suitable latex and then coalescing the latex particles to form a continuous rubber phase in the aqueous phase. Since the soap is inactivated in water, the aqueous soap film ruptures, which in turn causes the latex film to rupture. Thereafter, the expanded substrate is cured and dried to form a stable latex foam. In the Dunlop process, a chemical gelling agent such as sodium fluorophthalate is used to coagulate the rubber particles of the latex while inactivating the soap. The main difference between the two processes involves treating the latex foam in a heated mold prior to the curing step. In the Talalay process, the volume of the latex composition poured into the mold is small, leaving room for expansion. Air is drawn from the closed mold so that the latex expands by the vacuum created so that the mold is completely filled with the expanded latex. The foam is prevented from collapsing by rapid cooling to -30 ° C to produce a frozen latex foam. At this point, the carbon dioxide gas is passed through the latex and the temperature of 201033266 is raised to about 115 °C, thus fixing and hardening the foam. The foam is then removed from the mold. In the Dunlop process, the mold is filled to the edge. No vacuum was applied and no refrigeration technology was utilized. Instead, the latex cell structure is cured in a mold at a suitable elevated temperature. For more details on the preparation of latex foams, refer to the still A/ner 〇 / Chemical Technology Encyclopedia), 1994 Copyright, John Wiley & Sons, Inc. under the heading "Foamed Plastics" Text, especially page 11, section 3.3.1, on “Frothing”; and EW Madge, Laiez Foa/n Latex Foam Rubber), John Wiley & Sons, Inc., New York , 1 9 62. See also the online description below, the copy of which is 'attached here and forms part of this: • http://www.dunloplatexfoam.com/latex.php # http://www.latexfoam.com/index. Php?did=12 # http://ezinearticles.com/7The-Two-Main-Processes-Of-Latex-Mattress-Production-Explained — Dunlop-vs-Talalay&id=1053851 • h ttp : "irpec. 1 Gm · gov. my/prd_l atexf oam. html ° In general, latex foams formed primarily or entirely from natural rubber tend to be flexible. Latex foams formed from a mixture of synthetic latexes tend to be more rigid. There are no distinct strict and complete boundaries or divisions between flexible foams and rigid foams. One conventional method of establishing a classification between two types of foams is found in ASTM Test Procedure D 1566-82, which is in 201033266 and now in Volume 37 of ASTM, Philadelphia, PA, 1982. This classification indicates that the flexible foam is a foam that does not break when wound 20 x 2.5 X 2.5 cm around a 2.5 cm mandrel at a rate of 1 turn every 5 seconds at 15 ° C to 25 t. The rigid foam broke under these test conditions. Latex foam can be distinguished from memory foam or viscoelastic foam because the latter is obtained from plastic and the foam exhibits a relatively slow recovery of deformation caused by the application of pressure. In contrast, latex foam is made of rubber (natural rubber or a mixture of natural rubber and elastomer), and the foam exhibits a relatively fast recovery of deformation caused by application of pressure. For many uses, such as making upholstered furniture and pillows, it is essential that the latex foam should be effectively flame retardant. For example, reaching BS 5 852 sources 1 and 2 is a requirement that must be met. While many flame retardants for various polymeric compositions such as polyurethanes have been extensively studied in the prior art, the problem of effectively flame retarding latex compositions involves certain specific inherent problems. For example, as indicated in U.S. Patent No. 4,239,670, at col. 3, lines 1-11: Some flame retardant compounds, when added to the latex, render the latex unstable. Unstable means that the latex is agglomerated and/or has a significant change in viscosity. In some cases, instability may be caused by the addition of a particular type of flame retardant compound to the latex that is extremely sensitive to pH. In general, such changes, agglomeration and/or rheological properties are undesirable because latex cannot be used for their intended purpose. For example, there are many latexes that are unstable to the addition of diammonium hydrogen phosphate. In recent years, some notes on the use of certain brominated flame retardants have been indicated in 201033266. Accordingly, it would be desirable to find a method for effectively flame retarding a latex foam using a flame retardant composition free of any bromine component while avoiding the problems mentioned in the aforementioned U.S. patent. The present invention is believed to achieve this desired result. SUMMARY OF THE INVENTION According to the present invention, there are provided a flame-retardant latex composition, a flame-retardant latex foam, and a process for producing such a flame-retardant composition and a flame-retardant foam, the composition having a flame retardant amount The melamine and at least one liquid chloroalkyl phosphate are combined and formed therein. Accordingly, the present invention provides, among other things, a flame retardant uncured latex composition which has been blended with melamine and at least one liquid chloroalkyl phosphate prior to curing. The present invention provides, among other things, a process for producing a cured latex composition from a latex formulation by curing a latex composition in a mold, the latex formulation comprising natural rubber or natural rubber and synthetic rubber (eg, styrene - a mixture of butadiene rubber) characterized in that melamine and at least one liquid chloroalkyl phosphate flame retardant are mixed with a latex composition to produce a flame retardant cure prior to treating the latex composition in a mold. Latex composition. The present invention also provides the resulting cured composition formed by the process of the present invention, the cured composition comprising a cured foam composition. The above and other features of the present invention are covered by the following description and the appended claims, and are included in the following description and the appended claims, and It is even more obvious. 201033266 [Embodiment] The present invention provides, among other things, a flame-retardant uncured latex formulation formed from a component comprising: (a) a latex of natural rubber or a natural rubber and a synthetic rubber (eg, a latex of a mixture of styrene-butadiene rubber, (b) a flame retardant formed by introducing (i) melamine and (ii) at least one liquid chloroalkyl phosphate into a latex formulation of. A typical preparation of this type is one in which the amount of liquid chloroalkyl phosphate introduced into the latex formulation is from 10 parts to 25 parts per hundred parts by weight of the latex used to form the formulation (a). The amount of melamine to be incorporated into the latex formulation is in the range of 10 parts to 30 parts per 100 parts by weight of the latex of (a) used to form the latex formulation. Desirably, the amount of melamine introduced into the latex formulation exceeds the amount of liquid chloroalkyl phosphate introduced into the latex formulation. When a latex formed from a mixture or mixture of natural rubber and synthetic rubber is used, the particular rubber used and its relative proportions are selected according to principles known to those skilled in the art to produce the desired flexibility upon curing or A rigid, cured latex composition. The present invention provides, among other things, a cured flame retardant composition formed by thermally curing any of the above formulations. Desirably, the cured flame retardant composition is in the form of a cured foam. The present invention provides a preferred process for producing a cured flame retardant latex composition from a latex formulation comprising a latex of natural rubber or a latex of a natural rubber and a synthetic rubber such as styrene-butadiene rubber, wherein the formulation is Stirring (ie, when physically converted to foam) and in the absence of gel-7-201033266 when introduced into a mold that is preheated for a period of time at a temperature in the range of 70 ° C to 100 ° C, resulting in The formulation is cured. The process is characterized in that the latex composition is mixed with melamine and at least one liquid chloroalkyl phosphate flame retardant prior to treating the latex composition in the mold. The present invention further provides, among other things, a preferred process for producing a cured flame retardant composition comprising: • forming and foaming a latex formulation formed from a component comprising: (a a latex of natural rubber or a rubber of a synthetic rubber such as styrene-butadiene rubber, (b) melamine, and (c) at least one liquid chloroalkyl phosphate flame retardant, said liquid chloroalkyl phosphate The ester flame retardant has a chlorine content of at least 30 wt% and a phosphorus content of at least 7 wt%; then sodium strontium fluoride is used in an amount of 5 parts by weight of the latex used to form the formulation (a) per 100 parts by weight. An amount ranging from parts by weight to 10 parts by weight is introduced into the formulation; and • when no gel is formed, the formulation is introduced to be preheated for a period of time at a temperature ranging from about 70 ° C to about 100 ° C. In the mold, the formulation is allowed to cure. In carrying out the process, the amount of at least one liquid chloroalkyl phosphate flame retardant composition introduced into the latex formulation is usually in the range of 10 parts to 25 parts per hundred parts by weight of the latex used to form the latex formulation. And the amount of melamine introduced into the latex formulation is usually in the range of from 10 parts to 30 parts per hundred parts by weight of the latex used to form the latex formulation. As noted above, it is desirable that the amount of melamine used to form the flexible latex formulation is greater than the amount of liquid chloroalkyl phosphate used to form the latex formulation. 201033266. A further preferred process of the invention for producing a cured flame retardant composition comprising: • forming a latex formulation from a component comprising: (a) a latex of natural rubber or natural rubber and synthetic rubber a latex of styrene-butadiene rubber, (b) melamine, and (c) at least one liquid chloroalkyl phosphate flame retardant having at least 30 wt% of chlorine a content and a phosphorus content of at least 7 wt%; • partially filling the closable mold with the latex formulation, and subjecting the preparation to a vacuum condition in a closed mold to produce a foam filling the closed mold; • Quickly cool the contents of the mold to produce a frozen latex foam, and then pass the carbon dioxide gas through the latex and raise the temperature to the temperature at which the foam is cured; and the removal of the solidified foam from the mold. Depending on the temperature and the composition of the formulation, the degree of vacuum applied can be varied, but in any case sufficient to convert the latex formulation into a foamed latex formulation that is filled with a closed mold. In any case where the vacuum size has not been determined, one or two less pre-tests can be performed in which the pressure in the closed mold is gradually reduced (ie, where the vacuum is gradually increased) in order to determine Suitable vacuum conditions to form the desired foam. Likewise, depending on the composition of the latex composition, the curing temperature can vary, but in any case is sufficiently high to cure (i.e., harden) the foam. Typically, such temperatures are in the range of from about 100 ° C to about 130 ° C, but in any case where the optimum temperature is not determined, this can be a simple expedient for a few simple tests using the selected latex 201033266 formulation. It is easy to determine by means. μ Regarding the component or component for realizing the flame retardancy provided according to the present invention, 'melamine is chemically known as 2,4,6-triamine-tripby. It is preferred that the melamine is predispersed in the latex slurry. Moreover, the latex formulation in liquid form can be effectively agitated to ensure uniformity of the formulation prior to curing. Chloroalkyl phosphates useful in the practice of the invention are those chloroalkyl phosphates which are liquid at temperatures as low as 20 °C. Preferred are chloroalkyl phosphates having a chlorine content of at least 30% by weight and a phosphorus content of at least 7 wt%. Many of these products are available on the market. For example, and without limiting the invention to the following materials in any way, commercially available flame retardants such as the following flame retardant compositions obtained from Albemarle Corporation, Antiblaze® V6 flame retardant (typically Phosphorus content 10.50 wt%, typical chlorine content 36.50 wt%), Antiblaze® V66 flame retardant (typical phosphorus content 10.3 wt%, typical chlorine content 32.9 wt%), Antiblaze® Q TL-10-ST flame retardant Agent (typical phosphorus content 10.6 wt%, typical chlorine content 36.5 wt%) and Antiblaze® WR-30-LV flame retardant (typical phosphorus content 7.2 wt%, typical chlorine content 35.9 wt%). Other suitable liquid chloroalkyl phosphates are known and can be used. Some non-limiting examples include tris(chloromethyl)phosphate, tris(2-chloroethyl)phosphate, and tris(2-chloroisopropyl)phosphate. As is well known in the art, rubber mixtures for the preparation of latices (also known as latexes) and foamed latex are made from natural rubber latex or a mixture of natural rubber latex and synthetic rubber latex, day-10-201033266 However, rubber latexes are generally based on suitable natural rubbers obtained from a variety of rubber sources worldwide, and synthetic latexes are typically based on styrene-butadiene rubber (SBS). Flame-retardant latexes and flame-retardant foam emulsions formed from a mixture of natural rubber and synthetic rubber formed in the practice of the present invention typically comprise natural rubber latex in the range of 20 wt% to 80 wt% and 85 wt% to 15 wt% Synthetic rubber latex _ (usually styrene-butadiene rubber latex) in the range of wt%. Other flame retardant latexes of the present invention are made from 100% natural synthetic rubber. v The amount of chloroalkyl phosphate and melamine used to form the flame retardant latex mixture, flame retardant latex and flame retardant foam of the present invention is usually in the range of from 1 part by weight to 25 parts by weight of liquid chloroalkyl phosphate Composition and at!三 Parts by weight to 30 parts by weight of melamine. The melamine may be added to the latex complex in powder form or in a pre-dispersed form (slurry). A liquid flame retardant is added to the latex mixture prior to treating the latex mixture in the mold. In the case of the Dunlop type of process, it is preferred to add a liquid flame retardant to the latex mixture after the addition of strontium fluoride @ sodium (NSF) and in any case prior to treating the latex mixture in the mold. In the Talalay process, liquid flame retardants must be mixed with other components just prior to filling the mold. In carrying out the process of the present invention for producing latex foam, it is desirable to carry out the process using the procedures of the Talalay process or the Dunlop process. However, other recipe techniques can be used if desired. Suitable procedures for producing the latex foam of the present invention on a laboratory scale include the use of a bakery mixer, a -11 - 201033266 mold in which the foam is formed, and the desired natural latex-styrene butadiene (SBS). a latex mixture, sodium strontium fluoride, a liquid chloroalkyl phosphate flame retardant composition, and melamine. The liquid chloroalkyl phosphate flame retardant composition and melamine can be used as a pre-formed flame retardant mixture, or they can be used as a separate flame retardant component. The laboratory procedure used included the following steps: • Preheat the mold to maintain its temperature at 70 °C. • Add 160 grams of latex mixture, 24 grams of liquid chloroalkyl phosphate flame retardant composition and 40 grams of melamine to the mixer and mix at 50 revolutions per minute (rpm) up to 25 0 rpm These components were mixed for 4 minutes at full speed. • When mixing is continued, add 8.8 grams of sodium sulphide to the mixture over a 30 second period' and continue mixing for another minute. • Pour the mixture into the mold and place the mold in an oven maintained at 100 ° C for 35 minutes. • Allow the product and mold to cool, and then remove the product of cooling 13 from the mold and wash the product with water. The following examples are illustrative and are not intended to limit the invention only to the procedures used. Example 1 Using the above procedure, the following components were used: commercially available flexible 80/20 bed latex complex, chloroalkyl phosphate flame retardant (Antiblaze® TL-10-ST; Albemarle Corporation); from DSM Melamine GPH, particle size < 300 microns, 18-20%; and sodium bismuth fluoride solution prepared from commercially available powders. The resulting inventive foam was then subjected to the standard -12-201033266 BS 5 852 (1 990) source 1 and source 2 test procedures. The results of these tests are included in the table. Example 2 For the purpose of comparison, a foam was prepared in the same manner as in Example 1 except that the flame retardant component was not used. The resulting comparative foam was then subjected to the standard BS 5 85 2 (1 990) source 1 and source 2 test procedures. The results of these tests are also included in the table, in which the amounts are stated in parts per hundred parts of latex (wt/wt), except for the amount of latex used, which is abbreviated as pph. Components and amounts used in the Table Example 1 (Invention) Example 2 (Comparative) The amount of latex used 100 parts 100 parts cesium fluoride 5.5 pph 5.5 pph chloroalkyl phosphate 15 pph Jnr. m melamine 25 pph /frtr. No BS 5852 test results BS 5852 Source 1 Qualified failure BS 5852 Source 2 Qualified Not tested The components mentioned by chemical name or chemical formula anywhere in the specification or its patent application, whether in singular or References to the plural are considered to exist before they are contacted with another substance (eg, another component, solvent or other) referred to by chemical name or chemical type. What is important is not what chemical changes occur in the resulting mixture or solution, -13-201033266. Conversion and/or reaction (if present), as such changes, transformations and/or reactions are in accordance with the present disclosure. The natural result of putting the specified components together under the required conditions. Thus, each component is considered to be a component that will be placed in association with the desired operation or formation of the desired composition. Also, although the following patent claims may refer to substances, components and/or components at the present time ("including", "is", etc.), according to the present disclosure, the reference refers to A substance, component, and/or ingredient that is present just prior to its first contact, blending, or blending with one or more other substances, components, and/or ingredients. Every and every patent, publication or online reference mentioned in any part of this specification is hereby incorporated by reference in its entirety in its entirety in its entirety in its entirety. Except as otherwise expressly indicated, the articles "a", "an", "an", "an", and "an" are used as used herein and are not intended to limit the scope of the application to the Limit the scope of patent application 0 to the individual elements referred to in the article. Rather, the articles "a(-)" or "an (-), as used herein and as used herein, are intended to encompass one or more of such elements unless the context It is noted that the invention may comprise materials and/or procedures as described herein, consisting of, or consisting essentially of, the materials and/or procedures described herein. The invention is permissible in its practice. The foregoing description is not intended to limit the invention, and should not be construed as limiting the invention to the specific examples presented above. [Simplified illustration] Μ . [Main component symbol description] Μ 。 ❹
-15--15-