WO2002079315A1 - Blend of organophosphorus flame retardant, lactone stabilizer, and phosphate compatibilizer - Google Patents

Blend of organophosphorus flame retardant, lactone stabilizer, and phosphate compatibilizer Download PDF

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Publication number
WO2002079315A1
WO2002079315A1 PCT/US2001/051604 US0151604W WO02079315A1 WO 2002079315 A1 WO2002079315 A1 WO 2002079315A1 US 0151604 W US0151604 W US 0151604W WO 02079315 A1 WO02079315 A1 WO 02079315A1
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Prior art keywords
alkyl
flame retardant
composition
phosphate ester
hydrogen
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PCT/US2001/051604
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French (fr)
Inventor
Barbara A. Williams
Lambertus A. De Kleine
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Akzo Nobel N.V.
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Priority to DE60133482T priority Critical patent/DE60133482T2/en
Priority to EP01273813A priority patent/EP1334149B1/en
Priority to JP2002578327A priority patent/JP2004519547A/en
Priority to CA002428540A priority patent/CA2428540A1/en
Priority to US10/433,968 priority patent/US7122135B2/en
Priority to KR10-2003-7006418A priority patent/KR20030063377A/en
Publication of WO2002079315A1 publication Critical patent/WO2002079315A1/en

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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/04Oxygen-containing compounds
    • C08K5/15Heterocyclic compounds having oxygen in the ring
    • C08K5/151Heterocyclic compounds having oxygen in the ring having one oxygen atom in the ring
    • C08K5/1535Five-membered rings
    • C08K5/1539Cyclic anhydrides
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/49Phosphorus-containing compounds
    • C08K5/51Phosphorus bound to oxygen
    • C08K5/52Phosphorus bound to oxygen only
    • C08K5/521Esters of phosphoric acids, e.g. of H3PO4
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40High-molecular-weight compounds
    • C08G18/48Polyethers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40High-molecular-weight compounds
    • C08G18/48Polyethers
    • C08G18/4833Polyethers containing oxyethylene units
    • C08G18/4837Polyethers containing oxyethylene units and other oxyalkylene units
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/04Oxygen-containing compounds
    • C08K5/15Heterocyclic compounds having oxygen in the ring
    • C08K5/151Heterocyclic compounds having oxygen in the ring having one oxygen atom in the ring
    • C08K5/1535Five-membered rings
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00Foam properties
    • C08G2110/0008Foam properties flexible
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00Foam properties
    • C08G2110/0083Foam properties prepared using water as the sole blowing agent
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K2201/00Specific properties of additives
    • C08K2201/014Additives containing two or more different additives of the same subgroup in C08K
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S521/00Synthetic resins or natural rubbers -- part of the class 520 series
    • Y10S521/906Polyurethane cellular product containing unreacted flame-retardant material

Definitions

  • the present invention relates to the combination of three components in a flame retardant additive formulation that, when incorporated in a polyurethane foam, results in a considerable reduction in the discoloration (also referred to as "scorch") of that polyurethane foam as to compared to when only the two organophosphorus components of the combination are employed.
  • the present invention relates to the use of a solubilizing monomeric phosphate ester component with a combination of an organophosphorus flame retardant, which in certain embodiments can be an oligomeric phosphate ester, and a benzofuran-2-one (or "lactone”) stabilizer.
  • solubilizing component retards the normal solution instability that would be observed, over time, if just the organophosphorus flame retardant and benzofuran-2-one stabilizer were used together.
  • organophosphorus flame retardant and benzofuran-2-one stabilizer were used together.
  • Other advantages of the solubilizing component for example, PHOSFLEX® TBEP brand from Akzo Nobel Functional
  • Chemicals are that the viscosity is reduced when an oligomeric organophosphorus flame retardant is used and, unlike other flammable compatibilizers , the flame retardant performance is not influenced to an appreciable degree.
  • the more solution-stable composition of the present invention allows for a reduction of scorch, which normally occurs, for example, when a phosphate ester flame retardant is used, in low-density polyurethane flexible foams .
  • An essential component in the flame retardant blend of the present invention is an organophosphorus flame retardant which is present in a predominant amount compared to the other two components of the three part flame retardant blend of this invention.
  • the amount of the organophosphrus additive in the blend will range from about 60% to about 98%, by weight of the blend, more preferably from about 80% to about 96%.
  • Representative examples of such flame retardants include tris (dichloroisopropyl) phosphate, tris (2-chloroisopropyl) phosphate, and tris (2-chloroethyl) phosphate.
  • the organophosphorus flame retardant component can be an oligomeric organophosphorus flame retardant, preferably having a phosphorus content of no less than about 5%, by weight and, in preferred embodiments when an organophosphate is desired, at least three phosphate ester units therein (i.e., at least two phosphate ester repeat units and a phosphate capping unit) .
  • oligomeric as used herein is meant to exclude either monomeric or dimeric species .
  • a representative organophosphorus additive of this type is generally described in U.S. Patent No. 4,382,042 to T.A. Hardy with the non-halogenated versions being preferred (e.g., especially the ethyl group-containing composition) .
  • organophosphate oligomers can be formed by reacting phosphorus pen oxide with the selected trialkyl phosphate (e.g., triethyl phosphate) to form a polyphosphate ester containing P-O-P bonds that is then reacted with epoxide (e.g., ethylene oxide) to form the desired product.
  • epoxide e.g., ethylene oxide
  • n (which designates the "repeat” phosphate ester units) can range, on a number average basis, from 2 to about 20, preferably from 2 to about 10
  • R is selected from the group consisting of alkyl and hydroxyalkyl and R' is alkylene.
  • the alkyl and alkylene groups will generally contain from about two to about ten carbon atoms .
  • oligomeric phosphates for use herein will comprise ethyl and ethylene groups as the alkyl and alkylene moieties, will have a hydroxy functionality of no more than about 30 mg KOH/g, will have an acid number of no more than about 2.5 mg KOH/g, and will have a phosphorus content that ranges from about 15% to about 25%, by weight. It is referred to herein after as "PEEOP" (or “poly (ethyl ethyleneoxy) hosphate”) .
  • oligomeric phosphonate-containing materials as component (b) .
  • oligomeric phosphonate-containing materials are intended to be included. These have the same structure as depicted above for the oligomeric phosphate species with the exception that the internal (bracketed) RO- on the left side of the structure may be R- and one of the terminal -OR structures on the right side of the formula may be —R.
  • a representative and commercially available example of an additive of this type is FYROL 51 from Akzo Nobel Chemicals Inc. which is made by a multistep process from dimethyl methylphosphonate, phosphorus pentoxide, ethylene glycol, and ethylene oxide.
  • FYROL ® PNX is a preferred product of this type for use herein. It is an oligomeric phosphate ester (CAS # 184538-58-7) of the formula:
  • n (which designates the "repeat” phosphate ester units) is, on a number average basis, of from about 2 to about 20, R is ethyl, and R' is ethylene. This preferred has a phosphorus content of about 19 wt% and a viscosity at 25°C of about 2000 mPa. s .
  • the second essential component of the flame retardant blend of the present invention is of the type of benzofuran-2-one stabilizer that is described in U.S. Patent No. 5,869,565, which is incorporated herein by reference for its illustration of such an additive.
  • the structure of this class of stabilizer is provided in the following formulae:
  • R_ f R 7 , Re, R 9 and Rio are each independently of the other C 1 -C 4 alkyl or C 1 -C 4 alkoxy, the others being hydrogen, or R 7 to Rio are hydrogen, or at most two of these radicals are each independently of the other methyl or methoxy
  • Ri is -O-CHR 3 -CHR 5 -O-CO—R 6
  • R 2 and R 4 are each independently of the other hydrogen or C ⁇ _C 6 alkyl
  • R 3 is hydrogen or C 1 -C 4 alkyl
  • R 5 is hydrogen, phenyl or C ⁇ -C 6 alkyl
  • R 6 is C 1 -C 4 alkyl.
  • HP-136 brand product from Ciba Specialty Chemicals is a preferred species for use herein and is (5,7-di-t-butyl-3 (3,4 dimethylphenyl) -3H-benzofuran-2-one, wherein R 2 and R 4 are each t-butyl and two of Ri , R7 , Re, R9 and Rio are each methyl .
  • This stabilizer component is present in the flame retardant blend of the present invention at from about 0.05% to about 1.0%, by weight of the blend, more preferably from about 0.2% to about 0.5%.
  • R is independently selected from alkyl , alkoxyalkyl , or haloalkyl containing up to about 8 carbon atoms in the alkyl , alkoxyalkyl and/or haloalkyl groups. It is present at from about 1% to about 40%, by weight of the blend, more preferably from about
  • Representative compounds of this type that can be selected include tributoxyethyl phosphate, tri (1,3 dichloroisopropyl) phosphate, tributyl phosphate, tri (2-chloroethyl)phosphate, triethylphosphate, tri (2-chloroisopropyl)phosphate, isopropylated triarylphosphate, and a tert-butylated triphenyl phosphate mixture.
  • a monomeric phosphate compatibilizers from the same general type of organophosphorus compound that could be selected for the predominant component of this invention (which will normally be a compound that does not form a compatible blend with the benzo-2-furanone stabilizer
  • the present invention contemplates that a differing compound from within that class will be selected so that there are three components in the flame retardant blend.
  • the previously described flame retardant blend can be incorporated in conventional polyurethane foams at use levels of up to about 24 parts by weight per one hundred parts of polyol (which will normally contain antioxidants for scorch inhiubition) to confer the desired degree of flame retardancy and antiscorch behavior on those foams .
  • System 1 which is described below, uses FYROL ® 38 as a solubilizer for the lactone additive HP-136 with FYROL ® PNX.
  • System 2 uses a phosphate ester, PHOSFLEX ® TBEP as a solubilizer for HP-136 with the FYROL ® PNX material.
  • a microwave oven test method was used as a means to determine the degree of discoloration in the tested foams with a numerical scale of 1 to 5 being used to assign the degree of scorch present in the foam.
  • a value of 1 was assigned to a white foam control showing no discoloration, whereas the value of 5 was assigned to a very dark brown scorch pattern. The values increased from 1 to 5 with increasing discoloration.
  • Foams prepared with either system (flame retardant, solubilizer, and lactone additive) produced foams with a 1.5 to 2.0 rating, whereas without the use of the HP-136 lactone stabilizer the level of scorch was rated at 2.5 to 3.0.
  • the nominal density was 1.20 pcf (pounds per cubic foot) .
  • Fyrol ® PNX mixed with only HP-136 was difficult to dissolve and did not form a clear, stable solution; therefore, a compatibilizer or solubilizer, in accordance with the present invention, was necessary to maintain a stable solution.
  • the formulation components mentioned in Table A, above, were combined and poured into a (8.0" x 8.0" x 5.0") box and allowed to rise freely. The foam was then placed in a GE PROFILE SENSOR microwave oven and heated for one hundred and twenty seconds. The foam was removed from the oven. It was cooled to room temperature for two hours . The foam bun was cut into a 1 inch slice in a perpendicular to rise direction and was examined for its discoloration rating.
  • a second set of foams was produced using system 2 but the scorch characteristics of the foams were measured using a colorimeter (namely, the DR LANGE Micro Color apparatus) .

Abstract

A flame retardant blend, suitable for incorporation into a polyurethane foam, comprises: an oligomeric organophosphorus flame retardant, preferably an organophosphate, having a phosphorus content of no less than about 10%; a benzofuran-2-one stabilizer; and a monomeric phosphate ester containing alkyl and/or haloalkyl groups to act as a solubilizing addtive for the oligomeric organophosphorus flame retardant and benzofuran-2-one stabilizer.

Description

BLEND, OF ORGANOPHOSPHORUS FLAME RETARDANT, LACTONE STABILIZER, AND PHOSPHATE COMPATIBILIZER
The present invention relates to the combination of three components in a flame retardant additive formulation that, when incorporated in a polyurethane foam, results in a considerable reduction in the discoloration (also referred to as "scorch") of that polyurethane foam as to compared to when only the two organophosphorus components of the combination are employed. In addition, the present invention relates to the use of a solubilizing monomeric phosphate ester component with a combination of an organophosphorus flame retardant, which in certain embodiments can be an oligomeric phosphate ester, and a benzofuran-2-one (or "lactone") stabilizer. The presence of this solubilizing component retards the normal solution instability that would be observed, over time, if just the organophosphorus flame retardant and benzofuran-2-one stabilizer were used together. Other advantages of the solubilizing component (for example, PHOSFLEX® TBEP brand from Akzo Nobel Functional
Chemicals) are that the viscosity is reduced when an oligomeric organophosphorus flame retardant is used and, unlike other flammable compatibilizers , the flame retardant performance is not influenced to an appreciable degree. The more solution-stable composition of the present invention allows for a reduction of scorch, which normally occurs, for example, when a phosphate ester flame retardant is used, in low-density polyurethane flexible foams .
An essential component in the flame retardant blend of the present invention is an organophosphorus flame retardant which is present in a predominant amount compared to the other two components of the three part flame retardant blend of this invention. The amount of the organophosphrus additive in the blend will range from about 60% to about 98%, by weight of the blend, more preferably from about 80% to about 96%. The organophosphorus flame retardant can be a monomeric phosphate ester of the type conventionally used which has the formula 0=P(OR)3, where R is selected from alkyl and haloalkyl groups having from 1 to about 6 carbon atoms in such groups . Representative examples of such flame retardants include tris (dichloroisopropyl) phosphate, tris (2-chloroisopropyl) phosphate, and tris (2-chloroethyl) phosphate.
Alternatively, the organophosphorus flame retardant component can be an oligomeric organophosphorus flame retardant, preferably having a phosphorus content of no less than about 5%, by weight and, in preferred embodiments when an organophosphate is desired, at least three phosphate ester units therein (i.e., at least two phosphate ester repeat units and a phosphate capping unit) . The term "oligomeric" as used herein is meant to exclude either monomeric or dimeric species . A representative organophosphorus additive of this type is generally described in U.S. Patent No. 4,382,042 to T.A. Hardy with the non-halogenated versions being preferred (e.g., especially the ethyl group-containing composition) . These preferred organophosphate oligomers can be formed by reacting phosphorus pen oxide with the selected trialkyl phosphate (e.g., triethyl phosphate) to form a polyphosphate ester containing P-O-P bonds that is then reacted with epoxide (e.g., ethylene oxide) to form the desired product. This preferred oligomeric organophosphate flame retardant is of the formula:
R0-[P(O)-O-R'-O-]n-P(O) (OR) 2
I
OR where n (which designates the "repeat" phosphate ester units) can range, on a number average basis, from 2 to about 20, preferably from 2 to about 10 , and R is selected from the group consisting of alkyl and hydroxyalkyl and R' is alkylene. The alkyl and alkylene groups will generally contain from about two to about ten carbon atoms . Especially preferred oligomeric phosphates for use herein will comprise ethyl and ethylene groups as the alkyl and alkylene moieties, will have a hydroxy functionality of no more than about 30 mg KOH/g, will have an acid number of no more than about 2.5 mg KOH/g, and will have a phosphorus content that ranges from about 15% to about 25%, by weight. It is referred to herein after as "PEEOP" (or "poly (ethyl ethyleneoxy) hosphate") .
It is within the contemplation of the present invention to utilize oligomeric phosphonate-containing materials as component (b) . Both substantially pure phosphonate and phosphonate/phosphate compositions are intended to be included. These have the same structure as depicted above for the oligomeric phosphate species with the exception that the internal (bracketed) RO- on the left side of the structure may be R- and one of the terminal -OR structures on the right side of the formula may be —R. A representative and commercially available example of an additive of this type is FYROL 51 from Akzo Nobel Chemicals Inc. which is made by a multistep process from dimethyl methylphosphonate, phosphorus pentoxide, ethylene glycol, and ethylene oxide.
The product "FYROL® PNX" is a preferred product of this type for use herein. It is an oligomeric phosphate ester (CAS # 184538-58-7) of the formula:
RO- [P (O) -O-R' -O-] „-P (O) (OR) 2
I OR
where n (which designates the "repeat" phosphate ester units) is, on a number average basis, of from about 2 to about 20, R is ethyl, and R' is ethylene. This preferred has a phosphorus content of about 19 wt% and a viscosity at 25°C of about 2000 mPa. s .
The second essential component of the flame retardant blend of the present invention is of the type of benzofuran-2-one stabilizer that is described in U.S. Patent No. 5,869,565, which is incorporated herein by reference for its illustration of such an additive. The structure of this class of stabilizer is provided in the following formulae:
Figure imgf000005_0001
wherein either two of R_ f R7, Re, R9 and Rio are each independently of the other C1-C4 alkyl or C1-C4 alkoxy, the others being hydrogen, or R7 to Rio are hydrogen, or at most two of these radicals are each independently of the other methyl or methoxy, and Ri is -O-CHR3-CHR5-O-CO—R6, R2 and R4 are each independently of the other hydrogen or Cι_C6 alkyl, R3 is hydrogen or C1-C4 alkyl, R5 is hydrogen, phenyl or Cι-C6 alkyl, and R6 is C1-C4 alkyl. The HP-136 brand product from Ciba Specialty Chemicals is a preferred species for use herein and is (5,7-di-t-butyl-3 (3,4 dimethylphenyl) -3H-benzofuran-2-one, wherein R2 and R4 are each t-butyl and two of Ri , R7 , Re, R9 and Rio are each methyl . This stabilizer component is present in the flame retardant blend of the present invention at from about 0.05% to about 1.0%, by weight of the blend, more preferably from about 0.2% to about 0.5%.
The third essential component of the blend is a monomeric phosphate ester of the formula 0=P-(OR)3, where R is independently selected from alkyl , alkoxyalkyl , or haloalkyl containing up to about 8 carbon atoms in the alkyl , alkoxyalkyl and/or haloalkyl groups. It is present at from about 1% to about 40%, by weight of the blend, more preferably from about 1% to about 20%. Preferred are substituents that are halogenated (e.g. , chlorinated) or alkoxyalkyl with the carbon atom content in the substituent being between one and four carbon atoms. Representative compounds of this type that can be selected include tributoxyethyl phosphate, tri (1,3 dichloroisopropyl) phosphate, tributyl phosphate, tri (2-chloroethyl)phosphate, triethylphosphate, tri (2-chloroisopropyl)phosphate, isopropylated triarylphosphate, and a tert-butylated triphenyl phosphate mixture. While it is possible to select a monomeric phosphate compatibilizers from the same general type of organophosphorus compound that could be selected for the predominant component of this invention (which will normally be a compound that does not form a compatible blend with the benzo-2-furanone stabilizer, the present invention contemplates that a differing compound from within that class will be selected so that there are three components in the flame retardant blend. The previously described flame retardant blend can be incorporated in conventional polyurethane foams at use levels of up to about 24 parts by weight per one hundred parts of polyol (which will normally contain antioxidants for scorch inhiubition) to confer the desired degree of flame retardancy and antiscorch behavior on those foams .
The present invention is further described by the Examples that follow.
EXAMPLES
System 1, which is described below, uses FYROL® 38 as a solubilizer for the lactone additive HP-136 with FYROL® PNX. System 2 uses a phosphate ester, PHOSFLEX® TBEP as a solubilizer for HP-136 with the FYROL® PNX material.
A microwave oven test method was used as a means to determine the degree of discoloration in the tested foams with a numerical scale of 1 to 5 being used to assign the degree of scorch present in the foam. A value of 1 was assigned to a white foam control showing no discoloration, whereas the value of 5 was assigned to a very dark brown scorch pattern. The values increased from 1 to 5 with increasing discoloration. Foams prepared with either system (flame retardant, solubilizer, and lactone additive) produced foams with a 1.5 to 2.0 rating, whereas without the use of the HP-136 lactone stabilizer the level of scorch was rated at 2.5 to 3.0. The nominal density was 1.20 pcf (pounds per cubic foot) . This microwave test method is described in the Journal of Cellular Plastics (Dec.1979) in an article entitled " A Rapid Predictive Test for Urethane Foam Scorch" by Reale and Jacobs .
The following Examples illustrate the formulations used to produce flexible foams .
TABLE A - System 1
Figure imgf000008_0001
* the three components of System 1, which included FYROL PNX, solubilizer and HP-136, were heated at 70°C for four hours
TABLE A-l
Figure imgf000008_0002
Fyrol® PNX mixed with only HP-136 was difficult to dissolve and did not form a clear, stable solution; therefore, a compatibilizer or solubilizer, in accordance with the present invention, was necessary to maintain a stable solution. The formulation components mentioned in Table A, above, were combined and poured into a (8.0" x 8.0" x 5.0") box and allowed to rise freely. The foam was then placed in a GE PROFILE SENSOR microwave oven and heated for one hundred and twenty seconds. The foam was removed from the oven. It was cooled to room temperature for two hours . The foam bun was cut into a 1 inch slice in a perpendicular to rise direction and was examined for its discoloration rating.
The performance of system 1 using the FYROL PNX oligomeric organophosphate, lactone stabilizer (HP-136, whose active ingredient is 5, 7-di-t-butyl-3- (3, 4-dimethylphenyl) -3H- benzofuran-2-one) and the phosphate ester FYROL® 38 is tri [1,3 dichloroisopropyl] phosphate with an antioxidant package (as described in U.S. Patent No. 4,477,600) is provided in Table B:
TABLE B - System 1
Figure imgf000009_0001
In the runs reported for Table B the weight ratio of FYROL PNX to phosphate ester was 25:75 and the 9.0 parts refers to the parts per weight of this combination per 100 parts by weight of polyol used to make the foam. The weight percentage of antioxidant, when present, was 1.0%, based on the weight of the flame retardant and the solubilizer. In Run 3 in Table B where Fyrol® PNX was mixed only with the HP-136 lactone, it was difficult to dissolve and a clear, stable solution was not formed. The following Example illustrates the formulation used to produce the present flexible foams .
A second set of foams was produced using system 2 but the scorch characteristics of the foams were measured using a colorimeter (namely, the DR LANGE Micro Color apparatus) .
The performance of system 2 using FYROL® PNX (the oligomeric organophosphate) , the lactone stabilizer (HP-136) , whose active ingredient is 5 , 7-di-t-butyl-3- (3, 4- dimethylphenyl) -3H-benzofuran-2-one) and the phosphate ester solubilizer, PHOSFLEX® T-BEP (tributoxyethyl phosphate) , is provided in Table D :
Figure imgf000011_0001
b* = yellowness, with a lower number being indicative of a less colored foam.
In the runs reported for Table D the weight ratio of FYROL PNX to phosphate ester was 95 : 5 and the 8.0 parts re ers to the parts per weight of this combination per 100 parts by weight of polyol used to make the foam. The weight percentage of HP-136 brand antioxidant, when used in system 2, was 0.25 %, based on the weight of the flame retardant and the solubilizer.
The foregoing Examples , since they are presented to merely exemplify the present invention, should not be construed in a limiting sense. The scope of protection that is desired is set forth in the Claims that follow.

Claims

Claims :
1. A flame retardant composition which comprises: a predominant amount of an organophosphorus flame retardant; a benzofuran-2-one stabilizer; and a monomeric phosphate ester compatibilizer .
2. A composition as claimed in Claim 1 wherein the organophosphorus flame retardant is an oligomeric organophosphorus flame retardant which is a phosphate ester containing at least three phosphate ester units therein.
3. A composition as claimed in Claim 2 wherein the phosphate ester is of the formula
RO-[P(0)-0-R'-0-]n-P(0) (OR) 2
I
OR
where n is, on a number average basis, of from about 2 to about 20, R is ethyl, and R' is ethylene.
4. A composition as claimed in Claim 1 wherein the benzo uran-2-one stabilizer has the formula
Figure imgf000012_0001
wherein either two of Ri, R7, Re, R9 and Rio are each independently of the other C1-C4 alkyl or C1-C4 alkoxy, the others being hydrogen, or R7 to Rio are hydrogen, or at most two of these radicals are each independently of the other methyl or methoxy, and Rx is -O-CHR3-CHR5-O-CO—R6, R2 and R4 are each independently of the other hydrogen or Cι-C6 alkyl, R3 is hydrogen or C1-C4 alkyl, R5 is hydrogen, phenyl or Cι-C6 alkyl, and R6 is C1-C4 alkyl .
5. A composition as claimed in Claim 4 wherein the benzofuran-2-one stabilizer is (5, 7-di-t-butyl-3 (3, 4 dimethylphenyl) -3H-benzofuran-2-one .
6. A composition as claimed in Claim 1 wherein the monomeric phosphate ester compatibilizer is of the formula 0=P-(OR)3, where R is independently selected from alkyl, alkoxyalkyl , or haloalkyl containing up to about 8 carbon atoms in the alkyl , alkoxyalkyl and/or haloalkyl groups .
7. A composition as claimed in Claim 1 wherein the organophosphous flame retardant is a monomeric phosphate ester having the formula 0=P(OR)3, where R is selected from alkyl and haloalkyl groups having from 1 to about 8 carbon atoms in such groups .
8. A flame retardant composition which comprises : from about 80% to about 98%, by weight of an organophosphorus flame retardant; from about 0.05% to about 1.0%, by weight of a benzofuran-2-one stabilizer; and from about 1% to about 40%, by weight of a monomeric phosphate ester compatibilizer.
9. A composition as claimed in Claim 8 wherein the organophosphorus flame retardant is an oligomeric organophosphorus flame retardant which is a phosphate ester containing at least three phosphate ester units therein.
10. A composition as claimed in Claim 9 wherein the phosphate ester is of the formula RO- [P (0) -0-R' -0- ] n-P (0) (OR) 2
I
OR
where n is, on a number average basis, of from about 2 to about 20, R is ethyl, and R' is ethylene.
11. A composition as claimed in Claim 8 wherein the benzofuran-2-one stabilizer has the formula
Figure imgf000014_0001
wherein either two of Ri , R7 , Re , R9 and Rio are each independently of the other C1-C4 alkyl or C1-C4 alkoxy, the others being hydrogen, or R7 to Rio are hydrogen, or at most two of these radicals are each independently of the other methyl or methoxy, and Rx is -O-CHR3-CHR5-O-CO—R6, R2 and R4 are each independently of the other hydrogen or Cι_C6 alkyl , R3 is hydrogen or C1-C4 alkyl, R5 is hydrogen, phenyl or Cι-C6 alkyl, and Rε is C1-C4 alkyl .
12. A composition as claimed in Claim 11 wherein the benzofuran-2-one stabilizer is (5 , 7-di-t-butyl-3 (3 ,4 dimethylphenyl) -3H-benzofuran-2-one.
13. A composition as claimed in Claim 8 wherein the monomeric phosphate ester compatibilizer is of the formula 0=P-(OR)3, where R is independently selected from alkyl, alkoxyalkyl , or haloalkyl containing up to about 8 carbon atoms in the alkyl , alkoxyalkyl and/or haloalkyl groups .
14. A composition as claimed in Claim 8 wherein the organophosphous flame retardant is a monomeric phosphate ester having the formula 0=P(OR)3, where R is selected from alkyl and haloalkyl groups having from 1 to about 8 carbon atoms in such groups .
15. A flame retarded polyurethane foam that comprises the composition of any of claims 1 to 14.
PCT/US2001/051604 2000-11-13 2001-11-13 Blend of organophosphorus flame retardant, lactone stabilizer, and phosphate compatibilizer WO2002079315A1 (en)

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DE60133482T DE60133482T2 (en) 2000-11-13 2001-11-13 MIXTURE OF ORGANOPHOSPHOR FLAME PROTECTION AGENT, LACTON STABILIZER, AND PHOSPHATE COMPATIBILIZATION AGENT
EP01273813A EP1334149B1 (en) 2000-11-13 2001-11-13 Blend of organophosphorus flame retardant, lactone stabilizer, and phosphate compatibilizer
JP2002578327A JP2004519547A (en) 2000-11-13 2001-11-13 Mixture of organophosphorus flame retardant, lactone stabilizer and phosphate compatibilizer
CA002428540A CA2428540A1 (en) 2000-11-13 2001-11-13 Blend of organophosphorus flame retardant, lactone stabilizer, and phosphate compatibilizer
US10/433,968 US7122135B2 (en) 2000-11-13 2001-11-13 Blend of organophosphorus flame retardant, lactone stabilizer, and phosphate compatibilizer
KR10-2003-7006418A KR20030063377A (en) 2000-11-13 2001-11-13 Blend of organophosphorus flame retardant, lactone stabilizer, and phosphate compatibilizer

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EP2612876A1 (en) 2012-01-03 2013-07-10 Basf Se Flame-proof polyurethane foams
EP2687535A1 (en) 2012-07-20 2014-01-22 LANXESS Deutschland GmbH Halogen-free poly(alkylene phosphate)
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WO2005118699A1 (en) * 2004-04-27 2005-12-15 Supresta Llc Low scorching flame retardants for colored polyurethane foams
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EP3660064A1 (en) 2018-11-28 2020-06-03 LANXESS Deutschland GmbH Compositions with enhanced efficacy as flame retardants
EP3660065A1 (en) 2018-11-28 2020-06-03 LANXESS Deutschland GmbH Compositions with enhanced efficacy as flame retardants

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