Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K21/00—Fireproofing materials
  • C09K21/06—Organic materials
  • C09K21/08—Organic materials containing halogen
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/4009—Two or more macromolecular compounds not provided for in one single group of groups C08G18/42 - C08G18/64
  • C08G18/4045—Mixtures of compounds of group C08G18/58 with other macromolecular compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4804—Two or more polyethers of different physical or chemical nature
  • C08G18/4816—Two or more polyethers of different physical or chemical nature mixtures of two or more polyetherpolyols having at least three hydroxy groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/4829—Polyethers containing at least three hydroxy groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/58—Epoxy resins
  • C08G18/582—Epoxy resins having halogens
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/65—Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
  • C08G18/66—Compounds of groups C08G18/42, C08G18/48, or C08G18/52
  • C08G18/6603—Compounds of groups C08G18/42, C08G18/48, or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38
  • C08G18/6607—Compounds of groups C08G18/42, C08G18/48, or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203
  • C08G18/6611—Compounds of groups C08G18/42, C08G18/48, or C08G18/52 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203 having at least three hydroxy groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/04—Oxygen-containing compounds
  • C08K5/05—Alcohols; Metal alcoholates
  • C08K5/053—Polyhydroxylic alcohols
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/04—Oxygen-containing compounds
  • C08K5/06—Ethers; Acetals; Ketals; Ortho-esters
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K5/00—Use of organic ingredients
  • C08K5/49—Phosphorus-containing compounds
  • C08K5/51—Phosphorus bound to oxygen
  • C08K5/52—Phosphorus bound to oxygen only
  • C08K5/521—Esters of phosphoric acids, e.g. of H3PO4
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K21/00—Fireproofing materials
  • C09K21/06—Organic materials
  • C09K21/12—Organic materials containing phosphorus
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2110/00—Foam properties
  • C08G2110/0025—Foam properties rigid
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2115/00—Oligomerisation
  • C08G2115/02—Oligomerisation to isocyanurate groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
  • C08K3/00—Use of inorganic substances as compounding ingredients
  • C08K3/32—Phosphorus-containing compounds
  • C08K2003/329—Phosphorus containing acids
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2201/00—Properties
  • C08L2201/02—Flame or fire retardant/resistant

Definitions

• the process of homogeneously blending solid or wax-like non-readily soluble flame retardants in the liquid precursors of polyurethane foams typically needs to be carried out with heating. It would be beneficial to provide the flame retardant in the form of a preformed liquid composition, thereby obviating the need to perform the blending process with the polyurethane foam precursors under heating, and thus considerably simplifying the process of manufacturing the foam. This may be especially useful in view of the fact that the preparation of polyurethane foams is very often carried out outdoors, e.g., at construction sites.
• the present invention is concerned with the class of flame retardants obtainable by reacting tetrabromobisphenol A (chemically named 4, 4 ' -isopropylidene-bis (2, 6- dibromophenol) with epichlorohydrin (chemically named chloromethyl oxirane) .
• the reaction of tetrabromobisphenol A with epichlorohydrin is known to yield various reactive epoxides having high bromine content, which may be used as such, or in the form of their end-capped derivatives, as flame retardants in polymeric compositions.
• the aforementioned epoxides and end-capped derivatives thereof are identified by formula (1) :
• n the degree of polymerization
• Ri and R 2 are independently selected from the group consisting of the following monovalent radicals:
• liquid flame retardant composition which comprises:
• n the degree of polymerization
• Ri and R 2 are independently selected from the group consisting of the following monovalent radicals:
• the liquid composition comprises flame retarding agent represented by the following formula (1'):
• m is the weight average degree of polymerization and is in the range between 0.05 and 1.0, and more preferably, in the range between 0.05 and 0.7, and Ri and R 2 are as defined above.
• An especially preferred flame retarding agent falling within the scope of formula (1) above is a mixture comprising symmetric epoxy resins represented by the following Formula (Ia) :
• the epoxy-terminated flame retarding agent represented by Formula (Ia) has an average epoxy equivalent weight of not less than 350 g/eq (wherein m equals 0.063), and more preferably of not less than 370 g/eq (wherein m equals 0.113), and even more preferably in the range between 380 and 420 g/eq.
• the epoxy equivalent weight (EEW) is defined as the molecular weight of the substance divided by the number of epoxy groups contained therein, and may be measured by methods known in the art (e.g., "Encyclopedia of polymer science and engineering” John Wiley & Sons, Vol. 6 (1986) ) .
• the flame retarding agent identified by Formula (Ia) is accordingly provided in the form of a mixture comprising the following epoxides:
• the epoxy equivalent weight of the monomer is 328 g/eq.
• the epoxy equivalent weight of the dimer is 628 g/eq.
• the preferred flame retarding agent identified by Formula (Ia) is a mixture having average epoxy equivalent weight in the range between 385 and 415 g/eq, which mixture is composed mostly of the monomer of Formula (Ia-I) and the dimer of Formula (Ia-II), with the trimer (Ia-III) and possibly higher order oligomers of the diglycidyl ether of tetrabromobisphenol A being present in a total amount not greater than 15%.
• the preferred profile of the molecular weights distribution of the various epoxy resins composing the flame retarding agent of Formula (Ia) is as follows (the ranges are given in terms of weight percent relative to the total weight of the flame retarding agent of Formula (Ia) ) :
• the monomer identified as (Ia-I) 55 - 70%
• the dimer identified as (Ia-II) 20 - 35%
• the trimer identified as (Ia-III) 5 - 10%
• High order oligomers less than 5%
• the flame retarding agent represented by Formula (Ia) can be prepared by methods known in the art and is also commercially available.
• the flame retarding agent of Formula (Ia) having an average epoxy equivalent weight of about 400 g/eq is commercially available under the trade name F-2001 (Dead Sea Bromine Group) .
• F-2001 is used to designate the mixture identified above.
• the flame-retardant of Formula (Ia) is typically produced by reacting tetrabromobisphenol A with epichlorohydrin, optionally in an inert solvent such as toluene or methyl isobutyl ketone, in the presence of a base (e.g., an aqueous solution of sodium hydroxide) under heating.
• a base e.g., an aqueous solution of sodium hydroxide
• the average epoxy equivalent weight of the product namely, the distribution of the various epoxy resins of Formulas (Ia- I), (Ia-II) and (Ia-III) within the product mixture, may be controlled by modifying the ratio of the reactants. The lower the concentration of epichlorohydrin used, the higher the epoxy equivalent weight of the resulting mixture.
• Another preferred sub-class of flame retarding agents falling within the scope of Formula (1) includes the tribromophenol-terminated derivatives, wherein both end units Ri and R 2 have the following meaning:
• a preferred flame retarding agent to be used according to the present invention comprises one or more tribromophenol-terminated compounds represented by Formula (Ib) :
• n is an integer in the range between 0 and 5, and more preferably in the range between 0 and 4.
• the flame retarding agent to be used according to the present invention is bis (2,4,6- tribromophenyl ether) -terminated tetrabromobisphenol A-epichlorohydrin resin, which is provided in the form of various mixtures comprising the individual derivatives represented by Formula (Ib):
• the aforementioned resin is provided in the form of a mixture which is essentially composed as follows (the composition of the mixture may be determined by GPC; the ranges are given in terms of weight percent of the individual compound relative to the total weight of the mixture) :
• the monomer (Ib-I) 55-70%, and preferably about 65-70%;
• the dimer (Ib-II) 20-35%, and preferably about 25-30%;
• the aforementioned resin is provided in the form of a mixture comprising: The monomer (Ib-I) : 30-50%, and preferably about 35-45%; the dimer (Ib-II) : 5-15%, and preferably about 7-13%; the trimer (Ib-III): 5-20%, and preferably about 10-15%.
• Higher order oligomers 20-40%, and preferably 25-35%; and less than 10% a compound of Formula (1) wherein the end units Ri and R 2 are different.
• n is an integer in the range between 0 and 5, and more preferably in the range between 0 and 4, can be prepared by methods known in the art and is also commercially available (e.g., F-3014 and F-3020 manufactured by Dead Sea Bromine Group, which correspond to the first and second mixtures with the compositions identified above, respectively) .
• the tribromophenol- terminated resins of Formula (Ib) may also be obtained by reacting the mixture of epoxy resins identified by Formula (Ia) with tribromophenol, possibly in a solvent.
• the reaction is carried out under heating in the presence of a catalyst (e.g., Li based catalyst) or an inorganic base, such as sodium hydroxide or potassium hydroxide, or an organic base, such as tertiary amine, quaternary ammonium salt or a quaternary phosphonium salt.
• a catalyst e.g., Li based catalyst
• an inorganic base such as sodium hydroxide or potassium hydroxide
• an organic base such as tertiary amine, quaternary ammonium salt or a quaternary phosphonium salt.
• flame retarding agents to be used according to the present invention may comprise both symmetrical and unsymmetrical derivatives (wherein Ri and R 2 in Formula (1) are the same or different, respectively) .
• the invention provides a liquid composition that contains the flame retarding agent identified by Formula (1) above, and more specifically, by Formulas (Ia) and (Ib) .
• the liquid composition is essentially homogeneous, such that the formation of a separate phase containing the flame retarding agent represented by said structural formulas from the liquid medium is substantially prevented.
• substantially prevented in this context is used to indicate that the liquid composition may exist either in the form of a clear, stable solution or as a composition in which a second phase (e.g. a precipitate) is formed, wherein said second phase contains the flame retarding agent in an amount which does not exceed 5% of the total weight of said agent in the composition.
• the weight concentration of the flame retarding agent of Formula (1) in the composition of the present invention is in the range between 10 and 60%, and more preferably in the range between 20 and 45%, such that the bromine content of the composition provided by the present invention is not less than 5%, and preferably not less than 15% (w/w) . More preferably, the bromine content is not less than 25% (w/w) .
• the liquid component according to the composition of the invention which allows for the dissolution of the flame retarding agent of Formula (1) therein, is either a polyol or an ester of phosphoric acid (phosphate esters) , or a mixture thereof.
• polyol refers to a compound containing two or more hydroxyl groups, and preferably to hydroxyl-containing polymers which are hydroxyl-containing polyethers or polyesters.
• a polyol it is preferred to use a polyol the number of hydroxyl groups thereof is not less than 3, or a mixture of such polyols.
• the polyols to be used according to the present invention are polyether polyols.
• This class of polyols is obtained by the ring opening addition reaction of one or more alkylene oxides (e.g., ethylene oxide and propylene oxide) with a suitable reactant containing active hydrogen atoms, such as alcohols, amines and acids; more specifically, said reactant may be selected from the group consisting of diols, triols, novolac resins, pentaerythritol, sorbitol, sucrose, ethylenediamine, diethylenetriamine and the like.
• alkylene oxides e.g., ethylene oxide and propylene oxide
• a suitable reactant containing active hydrogen atoms such as alcohols, amines and acids
• said reactant may be selected from the group consisting of diols, triols, novolac resins, pentaerythritol, sorbitol, sucrose, ethylenediamine, diethylenetriamine and the like.
• Polyester-polyols may also be used according to the present invention; this class of polyols is obtained by the condensation reaction of dicarboxylic (or polycarboxylic) acid, such as adipic acid, phthalic acid or the like, with diols and triols (e.g., ethylene glycol, propylene glycol, diethylene glycol and the like) .
• a particularly preferred polyol to be used according to the present invention is a glycerol- based polyether polyol.
• the hydroxyl number of the polyol is preferably in the range of 150 to 850 mg KOH/g, and more preferably in the range of from 200 to 600 mg KOH/g.
• the term "hydroxyl number” indicates the number of reactive hydroxyl groups available for reaction, and is expressed as the number of milligrams of potassium hydroxide equivalent to the hydroxyl content of one gram of the sample.
• the polyol to be used according to the present invention may be either a non-halogenated polyol, or halogenated polyol, or a mixture thereof.
• halogenated polyols are described in US 4,067,911, which is incorporated herein by reference. More preferred, however, are the non-halogenated polyols.
• the weight concentration of the polyol (s) relative to the total weight of the composition is preferably between 10 and 70%, and more preferably between 20 and 60%, and most preferably between 40 and 60%.
• ester of a pentavalent acid of phosphorus namely, an ester of phosphoric acid
• triesters - trialkyl phosphates - such as tri (monochloroalkyl) phosphate or tri (dichloroalkyl) phosphate, with tris (2- chloropropyl) phosphate being especially preferred.
• alkyl preferably refers to C 1 -C 5 alkyl. It should be noted that the phosphate ester may be either symmetric or un- symmetric, containing identical or different alkyl groups, respectively.
• the weight concentration of the ester of phosphoric acid relative to the total weight of the composition is preferably between 10 and 70%, and more preferably between 20 and 60%, and most preferably between 40 and 60%.
• composition according to the present invention is prepared by heating, preferably under stirring, suitable quantities of the flame retarding agent of Formula (1) together with the liquid component, which is either a polyol or an ester of a pentavalent acid of phosphorus, or a mixture thereof, until a clear solution is obtained, following which the liquid composition is cooled and stored until use.
• the liquid component which is either a polyol or an ester of a pentavalent acid of phosphorus, or a mixture thereof
• the composition according to the present invention is prepared by introducing into a suitable vessel the liquid component, heating the same to a first temperature in the range between 50 and 6O 0 C, adding the flame retarding agent of Formula (1) into said vessel, preferably under stirring, and heating the resulting mixture to a second temperature in the range between 65 and 100°C.
• a clear solution is generally obtained following a heating period of about 60 to 120 minutes at said second temperature.
• the mixture is then cooled to give the liquid flame retardant composition of the present invention in the form of a clear, stable solution.
• the liquid composition is capable of retaining the form of a stable solution at ambient temperature for not less than 50 days, and more preferably for not less than 70 days, and even more preferably not less than 90 days.
• ambient temperature is from 20 to 25°C.
• the liquid composition is capable of retaining the form of a stable solution at -18°C for at least three days.
• the aforementioned stability tests may be performed by producing the liquid flame retardant according to the relevant composition, storing the same under the relevant conditions and following the waiting period (s) specified above, observing the composition to determine the presence or absence of a precipitate therein.
• tribromoneopentyl alcohol a flame retarding agent represented by the structure of Formula 2 :
• the combination of the flame retarding agent of Formula (1) together with tribromoneopentyl alcohol in the liquid composition of the present invention is especially useful regarding the contemplated application for polyurethane foams, as will be discussed and exemplified in more detail below.
• the weight concentration of tribromoneopentyl alcohol is in the range between 10 and 50%, and more preferably in the range between 20 and 40%, relative to the total weight of the composition.
• Tribromoneopentyl alcohol is commercially available from Dead Sea Bromine Group under the trade name FR-513. Methods for preparing tribromoneopentyl alcohol are described in US 3,932,541.
• An especially preferred liquid flame retardant composition according to the present invention is a solution comprising 20-40 wt% of the flame retarding agent of Formula (1) , and more preferably, of Formulas (Ia) or (Ib) as defined above, and 20-40 wt% of tribromoneopentyl alcohol, dissolved in one or more solvents selected from the group consisting of non-halogenated polyether-polyols, and more specifically, glycerol based polyether-polyols (e.g., Alcupol C-5710) and halogen-containing esters of phosphoric acid, and more specifically, tris (2-chloropropyl) phosphate.
• solvents selected from the group consisting of non-halogenated polyether-polyols, and more specifically, glycerol based polyether-polyols (e.g., Alcupol C-5710) and halogen-containing esters of phosphoric acid, and more specifically, tris (2-chloropropyl
• the liquid composition may contain additional ingredients that are generally useful for the contemplated application of the flame retardant composition, namely, for the preparation of rigid polyurethane foams.
• the composition may include an antioxidant, preferably at a concentration of up to 2000 ppm, which is used for stabilizing the polyol solvent present in the composition.
• a phenolic antioxidant which may be selected from the group consisting of 2, ⁇ -di-tert-butyl-p-cresol, 4,4'- methylenebis (2, 6-di-tert-butylphenol) , 2,2 ' - methylenebis (4, 6-di-tert-butylphenol) and octadecyl 3,5-di- tert-butyl-4-hydroxyhydrocinnamate, and mixtures thereof.
• the novel composition of the present invention is particularly useful as a flame retardant for polyurethane and polyisocyanurate foams.
• the liquid composition provided by the present invention is a solution that contains the flame retarding agent of Formula (1), and more preferably of Formulas (Ia) and (Ib) , optionally in combination with tribromoneopentyl alcohol, as a solute, and may therefore be directly added to the liquid mixture of reactants used for preparing polyurethane and polyisocyanurate foams, whereby the blending operation of said mixture is considerably simplified and a uniform distribution of the components to be reacted is readily obtained in said mixture.
• the new flame retardant compositions of the present invention may be added to standard formulations suitable for obtaining rigid polyurethane foams (by continuous, discontinuous or spray methods) or polyisocyanurate foams.
• the present invention provides a process, which comprises: providing a preformed liquid composition containing a flame retarding agent of Formula (1) , and more preferably of Formula (Ia) or Formula (Ib) , wherein said agent is dissolved in a liquid comprising one or more polyols and/or one or more esters of phosphoric acid, wherein tribromoneopentyl alcohol is preferably present in said liquid composition; and mixing said liquid composition with additional quantities of one or more polyols, thereby affording a polyol component suitable for the preparation polyurethane or polyisocyanate foams.
• polyol component is meant the total quantity of polyols that needs to be reacted to afford the foam.
• the flame-retardant liquid composition of the present invention constitutes about 10 to 40% by weight of the polyol component.
• the resulting polyol component is subsequently reacted with an isocyanate component in the presence of a blowing agent and a catalyst, to obtain the polyurethane or polyisocyanate foam.
• the liquid composition containing the flame retarding agent of Formula (1) preferably together with tribromoneopentyl alcohol, is used in a sufficient amount in order to allow the final foam to satisfy the requirements of the DIN 4102 B2 test.
• the bromine content of the final foam is typically not less than 1%.
• the amount of the liquid composition of the invention is adjusted such that the bromine content of the final foam is in the range of 1 to 15%, and more preferably in the range of 2 to 10%, and most preferably in the range of 2 to 5%, relative to the total weight of the foam.
• the process according to the present invention for preparing the polyol component may be conveniently carried out on-site.
• the preformed liquid composition containing the flame retarding agent of Formula (1) preferably together with tribromoneopentyl alcohol, is mixed on-site with one or more polyols (such as the polyether-polyols and polyester-polyols listed above) , to give the polyol component of the foam, followed by the addition of a blowing agent and a catalyst, and possibly a surfactant, to said polyol component.
• a blowing agent and a catalyst, and possibly a surfactant to said polyol component.
• Suitable blowing agents to be used according to the present invention are well known in the art and include, for example, water (which produces carbon dioxide upon reaction with isocyanate) and low-boiling organic liquids, such as pentane or halogenated hydrocarbons (e.g., methylene chloride) .
• the amount of the blowing agent may vary within a broad range.
• reaction catalyst intended for accelerating the reaction between the polyol component and the diisocyanate component, it is common to use aromatic and/or aliphatic amines, or organic metal salts, or mixtures thereof.
• Amine catalysts may be selected from the group consisting of triethylenediamine, dimethylethanolamine (DMEA) , tetramethylbutanediamine (TMBDA) , dimethylcyclohexylamine (DMCHA) , and triethylamine (TEA) .
• Organometallic salts are preferably based on the following metals: tin, zinc, manganese, magnesium, bismuth, antimony, lead and calcium.
• stannous compounds such as stannous octoate and stannous dibutyltindilaurate.
• the weight concentration of the catalyst, relative to the polyol component is in the range between 1 and 5% (wt%) .
• a surfactant in a small amount, up to 2% of the weight of the polyol component in the preparation of the polyurethane foam.
• silicones may be used.
• Suitable isocyanates to be used according to the present invention may be selected from the group consisting of aliphatic, cycloaliphatic, araliphatic, aromatic or heterocyclic polyisocyanates, such as 4, 4' -diphenylmethane diisocyanate, toluylene diisocyanate, isopropyl diisocyanate and hexamethylene diisocyanate.
• the amount of the diisocyanate that is required for producing the foam is calculated according to the hydroxyl number of the polyol component and any other reactive hydrogen- containing compounds present. It is also possible to use the diisocyanate in a slight excess.
• the rigid polyurethane foams may be prepared by either continuous, discontinuous or spray methods, which are well known in the art .
• a discontinuous process all the components are mixed and poured into a mould, normally made of wood or metal, to form the foam.
• the foam is removed from the mould as a block. The block is cured and then is cut into panels, half shells or other shapes .
• the reaction mixture is dispersed from a traversing head onto a conveyor, which is covered with a paper in order to facilitate release of the foam.
• a conveyor which is covered with a paper in order to facilitate release of the foam.
• the sides are supported by vertical conveyors.
• the foam is cut into buns and stored for a specified time. Later, the foam can be cut into the required shape.
• Spray techniques are used for filling molds and panels and for applying foam to plane surfaces. Spraying is particularly useful in applications where large areas are involved, such as tanks or building walls. Sprayed rigid foam coatings provide both physical strength and improved insulation.
• the present invention also relates to a process for preparing flame-retarded rigid polyurethane foams, which comprises reacting a polyol component and diisocyanate component in the presence of one or more flame retardant agents represented by Formula (1) above, and more preferably by Formula (Ia) or (Ib), at least one blowing agent, at least one catalyst, at least one surfactant and at least one phosphate ester as described above, to form a rigid polyurethane foam.
• one or more flame retardant agents represented by Formula (1) above and more preferably by Formula (Ia) or (Ib)
• at least one blowing agent at least one catalyst, at least one surfactant and at least one phosphate ester as described above
• the resulting rigid polyurethane foam is characterized by a structural unit corresponding to the flame retardant of Formulas (Ia) or (Ib) , preferably at a concentration of 1 to 5% relative to the total weight of the foam; this rigid polyurethane foam forms another aspect of the present invention.
• brominated epoxy resin commercially available as F-2001
• F-2001 brominated epoxy resin having the following characteristics: EEW of 398 grams per mole and bromine content of 49% (w/w) , 300 grams methyl isobutyl ketone and 155 grams of tribromophenol .
• the mixture was stirred until all solids dissolve and then 0.75 grams of tributyl amine was added.
• the reaction mixture was heated slowly to reflux and the reaction continued for 6 hours.
• the procedure described above may be modified in order to obtain different resins of Formula (Ib) , namely, mixtures comprising the monomer (Ib-I) , the dimer of Formula (Ib- II), the trimer of Formula (Ib-III) and higher oligomers in different proportions, by changing the weight ratio of the reactants (e.g., reacting 574 g of YDB 400 or F-2001, 294.6 g of tribromophenol and 127 g of tetrabromobisphenol A) .
• reactants e.g., reacting 574 g of YDB 400 or F-2001, 294.6 g of tribromophenol and 127 g of tetrabromobisphenol A
• Liquid flame-retardant compositions which contain the epoxy resins of Formula (Ia)
• Table 1 summarizes the compositions of several liquid flame-retardant formulations of the present invention and stability tests carried in respect thereto, which compositions are based on a flame retarding agent of Formula (Ia) , or a combination thereof with tribromoneopentyl alcohol.
• the general preparative procedure was as follows:
• the flame retarding agent F-2001 or F-2001 and subsequently FR-513, or vice versa
• the resulting mixture was heated for about two hours at 70-100 0 C, until a clear solution was obtained. After cooling to room temperature, a stable solution was obtained.
• the values given for the stability represent the length of time during which the compositions have been stored under ambient temperature conditions without the formation of a precipitate. The tests are continuing and thus the values given are not the limits of the stability.
• liquid compositions of the present invention were used as flame retardants in standard formulations for rigid polyurethane foams .
• the foams were prepared either by continuous or discontinuous processes (Examples 7-11 and Examples 12-16 below, respectively) .
• Terol 516 - Polyester polyol having a hydroxyl value of 305 mg KOH/g.
• Alcupol R-2510 - Glycerol initiated polyether polyol having a hydroxyl value of 250 mg KOH/g.
• the procedure for the foam preparation was as follows: The polyols, water, surfactant, the F-2001 based flame retardant compositions of Examples 2 to 6 (abbreviated "FR of Example x" in table 2 below) phosphate esters and catalysts were weighed and placed in a mixing beaker and mixed to form a homogeneous solution. To this solution was added pentane, and after additional mixing, the polymeric isocyanate. The mixture was stirred at 3000 rpm for 6 sec and poured into another beaker. The foam that formed was kept at least 24 hr at room temperature and then removed from the beaker and cut into test specimens with a saw. The samples were then tested for flammability according to the DIN 4102 B2 test procedure (a flame height of 15.0 cm or less means that the foam has passed the test) . Table 2 summarizes the ingredients and parameters for the foam preparation and the results of the testing of the foams.
• Cream time The time between the discharge of the foam ingredients from the mixing beaker and the beginning of the rise of the foam.
• Gel time The time between the discharge of the foam ingredients from the mixing beaker and the time that the foam will stick to an introduced probe, and strings out from it when withdrawn.
• Tack-free time The time between the discharge of the foam ingredients from the mixing beaker and the time that the outer skin of the foam mass loses its stickiness or adhesive quality.
• Cure time The time required for sufficient reaction completion to develop the desired polymer properties such as strength, dimensional stability, elongation, etc.
• the procedure for the foam preparation was as follows: The polyols, water, surfactant, F-2001 based flame retardant compositions of Examples 2 to 6 (abbreviated "FR of Example x" in table 3 below) phosphate esters and catalysts were weighed and placed in a mixing beaker, and mixed to form a homogeneous solution. To this solution was added the polymeric isocyanate, then the mixture was stirred at 3000 rpm for 15 sec and poured into another beaker. The foam that formed was kept at least 24 hr at room temperature and then removed from the beaker and cut into test specimens with a saw. The samples were then tested for flammability according to the DIN 4102 B2 test procedure (a flame height of 15.0 cm or less means that the foam has passed the test) . Table 3 summarizes the ingredients and parameters for the foam preparation and the results of the testing of the foams.
• Liquid flame-retardant compositions which contain the tribromophenol-terminated resins of Formula (Ib)
• Table 4 summarizes the compositions of several liquid flame-retardant compositions of the present invention and stability tests carried out in respect thereto, which compositions are based on a flame retarding agent of Formula (Ib) , or a combination thereof with tribromoneopentyl alcohol.
• the general preparative procedure was as follows:
• the flame retarding agent F-3014, or F-3014 and subsequently FR- 513, or vice versa
• the resulting mixture was heated for about two hours at 65- 100 0 C, until a clear solution was obtained. After cooling to room temperature, a stable solution was obtained.
• the values given for the stability represent the length of time during which the compositions have been stored under ambient temperature conditions without the formation of a precipitate. The tests are continuing and thus the values given are not the limits of the stability.
• compositions of Examples 17-27 were used for the preparation of rigid polyurethane foams according to the following procedure:
• Liquid flame-retardant compositions which contain the tribromophenol-terminated resins of Formula (Ib)
• Table 6 presents the ingredients of several liquid flame- retardant compositions of the present invention and stability tests carried out in respect thereto, which compositions are based on a flame retarding agent of Formula (Ib), or a combination thereof with tribromoneopentyl alcohol.
• the compositions were obtained by mixing the ingredients at 70°-90°C and subsequent cooling.
• compositions of Examples 39-42 were used for the preparation of rigid polyurethane foams according to the previously described procedures.
• Table 7 summarizes the ingredients and parameters for the foam preparation and the results of the testing of the foams.
• composition according to Example 20 which is a solution of 20% F-3014 and 30% FR-513 in polyol C5710 (with a bromine content of 34%) , was compared with a 50% solution of FR-513 in polyol C5710 (-37% bromine) in respect to their flame retarding efficacy in rigid polyurethane foams .
• the two compositions were incorporated in pentane-blown continuous foaming systems to give the foams as described in Table 8 below.
• Table 8 Pentane-blown B2 continuous system using compositions based on F-3014 (mixed at 20°C)
• the composition of the invention shows better flame retardancy (flame height 11.4 cm) than the FR composition based on FR-513 only (flame height 11.8 cm) despite the fact that the bromine content in the second composition is higher.

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