CN101218300B - 阻燃剂组合物以及包含该组合物的聚氨酯泡沫塑料 - Google Patents
阻燃剂组合物以及包含该组合物的聚氨酯泡沫塑料 Download PDFInfo
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- CN101218300B CN101218300B CN2006800245534A CN200680024553A CN101218300B CN 101218300 B CN101218300 B CN 101218300B CN 2006800245534 A CN2006800245534 A CN 2006800245534A CN 200680024553 A CN200680024553 A CN 200680024553A CN 101218300 B CN101218300 B CN 101218300B
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- flame retardant
- phosphate
- retardant composition
- flame
- retardant
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Abstract
本发明涉及用在聚氨酯泡沫塑料中的阻燃剂组合物，该阻燃剂组合物包括：(a)包括磷酸三苯基酯和一种或多种烷基取代的磷酸三苯基酯的磷酸酯混合物；和(b)可溶于所述磷酸酯混合物的多元醇交联剂。本发明还涉及包含这些阻燃剂组合物的软质聚氨酯泡沫塑料。
Description
本发明要求于2004年5月4日提交的美国临时专利申请No.60/677,792的优先权，该申请的全部内容引入本申请作为参考。
1.发明领域：
本发明涉及阻燃剂组合物，更特别地涉及用在聚氨酯泡沫塑料中的液态磷酸酯阻燃剂组合物。
2.发明背景：
软质聚氨酯泡沫塑料被广泛用作例如家具、床垫和汽车等中的减震或衬垫材料。通常将阻燃剂加入到泡沫塑料中。然而，很难发现这样的阻燃剂，其能够经济地获得足够的阻燃性能，并且对泡沫塑料的物理性质不会造成不良影响。
在美国软质板行业使用的阻燃剂主要是满足两种可燃性测试。它们是汽车行业和California Bureau of Home Furnishings 117A&D使用的MVSS302测试(实际为两种测试的组合)。已知磷酸芳基酯能够满足这些要求，但是，在能够获得足够阻燃性能的水平下，它们可能破坏性地使泡沫塑料(尤其是低密度泡沫塑料)软化至一些物理性质(例如回弹性)不能满足商品化可接受的水平。例如，丁基化磷酸三苯基酯(本领域公知的为磷酸三苯基酯和一种或多种丁基取代的磷酸三苯基酯的混合物)是一种特别有效的阻燃剂。但是，它的使用往往会使泡沫塑料软化。
有许多涉及阻燃剂和/或改善聚氨酯泡沫塑料物理性质的文献被公开。例如，美国专利No.6,855,741公开了一种改进的软质聚氨酯泡沫塑料，其通过包含多元醇化合物、异氰酸酯、非卤素发泡剂，以及选自邻苯二甲酸烷基苄基酯、磷酸酯和苯甲酸酯的增塑剂和交联剂/增链剂例如间苯二酚或者聚氧乙烯基多元醇的组合物的反应制备而成。该专利涉及通过向泡沫塑料中加入增塑剂例如邻苯二甲酸酯或磷酸酯对聚氨酯泡沫塑料进行软化，所述聚氨酯泡沫塑料已经通过使用水作为发泡剂被硬化。该专利并不涉及为了保持泡沫塑料可接收的物理性能而“硬化”泡沫塑料，其通过向泡沫塑料中加入磷酸芳基酯阻燃剂而被软化。
因此，仍然需要提供一种能够保持聚氨酯泡沫塑料可接受的物理性质的方法，该聚氨酯泡沫塑料往往通过加入芳基磷酸酯阻燃剂而被软化。
3.发明概述
根据本发明，通过提供一种包括如下物质的液态阻燃剂组合物来获得这些或者其他目标：
(a)包括磷酸三苯基酯和烷基取代的磷酸三苯基酯的磷酸酯混合物；和
(b)可溶于所述磷酸酯混合物(a)的多元醇交联剂。
更进一步，本发明提供一种包含有效阻燃量的前述液态阻燃剂的聚氨酯泡沫塑料。
此处，令人惊讶地发现，采用包含磷酸三苯基酯和烷基取代的磷酸三苯基酯与多元醇交联剂混合的阻燃剂磷酸酯混合物，当加到聚氨酸酯泡沫塑料中时，不仅提供能够通过可燃性测试的泡沫塑料，而且提供具有可接受物理性质(例如回弹性)的泡沫塑料，这与不包含磷酸酯阻燃剂的泡沫塑料相似。
4.发明详述
本发明液体阻燃剂组合物包括磷酸三苯基酯和一种或多种烷基取代的磷酸三苯基酯组合与多元醇交联剂的混合物。混合物中存在的烷基取代的磷酸三苯基酯可以是具有结合到相同或不同苯环上的直链和/或支链烷基(优选C1-C4烷基)的单-、二-和/或三烷基取代的磷酸三苯基酯。所述烷基可以各自连接到苯环的邻位、间位和对位上。
可用于本发明实践的示例性磷酸酯阻燃剂混合物包括，例如，磷酸三苯基酯和烷基取代的磷酸三苯基酯，例如磷酸甲苯基二苯基酯，磷酸乙苯基二苯基酯，磷酸二乙苯基二苯基酯，磷酸正丙基苯基二苯基酯，磷酸异丙基苯基二苯基酯，磷酸二异丙基苯基二苯基酯，磷酸正丁基苯基二苯基酯，磷酸异丁基苯基二苯基酯，磷酸叔丁基苯基二苯基酯，磷酸二甲苯基苯基醚，磷酸双-(乙基苯基)苯基酯，磷酸双-(导丙基苯基)苯基酯，磷酸双-(叔丁基苯基)苯基酯，磷酸三甲苯基酯，磷酸三-(乙基苯基)酯，磷酸三-(异丙基苯基)酯，磷酸三-(叔丁基苯基)酯及其混合物。
基于磷酸酯混合物的总重量，本发明的阻燃剂磷酸酯混合物优选包括约20wt.％或更多、通常约20wt.％-约80wt.％的磷酸三苯基酯组份，和通常约80wt.％-约20wt.％的烷基取代的磷酸三苯基酯。可选择地，用于本发明实践的磷酸酯阻燃剂混合物优选磷的总量为至少约8.3wt.％的磷，更优选为至少约8.5wt.％的磷。
本发明的优选实施方案中，磷酸酯混合物是丁基化的磷酸三苯基酯，即，磷酸三苯基酯与一种或多种叔丁基取代的磷酸三苯基酯的混合物。特别优选的丁基化磷酸三苯基酯是购自Supresta LLC.的商品，名称为Phosflex 71B。
基于混合物的总重量，本发明的磷酸酯阻燃剂组合物包括约90-99wt.％、优选94-99wt.％的磷酸酯混合物和1-10wt.％、优选1-6wt.％的多元醇交联剂。组合物通常是在室温至约50℃的条件下混合磷酸酯混合物与多元醇交联剂而制得。
用于本发明的多元醇交联剂可以是固态或者液态，通常可以是本领域公知溶于磷酸酯混合物的任何一种多元醇交联剂。这种交联剂包括，例如，聚醚型多元醇，聚酯型多元醇，前述物质(例如从丙三醇，山梨醇、木糖醇、甘露醇、葡萄糖苷、1，3，5-三羟基苯得到)的支化衍生物等。优选的多羟基交联剂是三官能或者更高官能的多元醇化合物。
对于本发明的目的，聚酯多元醇是特别优选的。适当聚酯多元醇的代表性例子包括邻苯二甲酸酯基、乙二醇基和二甘醇基芳香族和脂肪族聚酯型多元醇。
用在本发明中的多元醇交联剂通常具有的羟值范围为约25-约500、优选约50-约250、更优选约50-约150。用于本发明实践的代表性多元醇交联剂(包括优选的聚酯型多元醇)在下表1中列出。
在另外一个具体实施方案中，本发明涉及包含阻燃有效量的任一种前述磷酸酯阻燃剂组合物的软质聚氨酯泡沫塑料。通常磷酸酯阻燃剂组合物在聚氨酯泡沫塑料中的含量为，每100份用来制备泡沫塑料的基础多元醇为5-25份(pphp)、优选10-20份。
优选，聚氨酯泡沫塑料基础组合物包括制备聚氨酯泡沫塑料领域中公知的任何一种或者多种基础多元醇基组份与在制备软质聚氨酯泡沫塑料领域中公知的甲苯二异氰酸酯(TDI)的组合。
包含磷酸酯阻燃剂混合物的聚氨酯泡沫塑料的密度通常范围为1.0-2.0磅/立方英尺(pcf)。
聚氨酯泡沫塑料形成过程
在通常的过程中，搅拌的同时在第一个烧杯中混合多元醇、阻燃剂、水、胺催化剂和硅树脂表面活性剂。在另外一个烧杯中，称重甲苯二异氰酸酯(TDI)。将有机锡催化剂置于注射器中。第一个烧杯以2100转/分钟的速度搅拌10秒，并在继续搅拌的同时将有机锡催化剂注入其中。总共搅拌约20秒后，将TDI加到混合物中。然后再继续搅拌另外的约10秒，将静置后的流体混合物迅速放置到16英寸×16英寸×5英寸的盒中，然后测量乳液(cream)和发泡(rise)时间。一旦泡沫停止升起，将泡沫塑料置于70℃的烘箱中约20分钟以固化。
以下提供一种根据本发明特别优选的软质聚氨酯泡沫塑料的配方：
典型的泡沫塑料配方(1.0Pcf)(磅/立方英寸)
组份 份数
聚醚多元醇 100
水 5.6
磷酸酯FR混合物* 18-20
胺混合物 0.25
Niax
L620 1.0
辛酸锡 0.55
TDI 80/20 71.2
TDI指数 110
*加入多元醇交联剂的磷酸酯混合物
可包括其他的添加剂，例如，举例来说，着色剂、染料、填料、抗氧化剂和防静电剂，所有这些都是本领域中通常使用的。
测试方法
进行以下的标准测试：
A.回弹性能测试(CT90)测试D
测试方法概要：此方法包括在特定的温度和时间条件下使泡沫塑料样品挠曲(deflect)，记录对样品厚度的影响。
装置：所述装置包括两个或更多这样放置的板，放置方式使得所述板能够通过螺钉或夹具保持互相平行，且板之间的空隙可以借助间隔物调整到要求的挠曲厚度。
测试样品：所述测试试样应当具有相互平行的顶面和底面和基本上垂直的侧面。每种样品应该取三个试样进行测试。如果任一值偏离中值超过20％，则需要再对其他两个试样进行测试，记录所有五个试样的中值。
过程
1.所有测量过程在23℃+/-2℃和50％的相对湿度环境下进行。烘箱应保持在70℃+/-2℃。
2.使用字盘式度量计测量厚度达到且包括25mm。
3.将测试试样置于所述装置中，使其挠曲至其厚度的50+/-1％，75+/-1％，或90+/-1％。
4.15分钟内将挠曲的样品和所述装置置于机械对流空气烘箱中22小时；然后移去所述装置。
5.从所述装置中立即移去所述样品，复原30-40分钟后用字盘式度量计对其进行测量。
6.计算压缩形变值，该值表示为测试样品的原始厚度减去最终厚度除以原始厚度的百分比。
B.压陷性能(IFD)测试B1(标定挠曲)
测试方法概述：该方法是公知的，因为压陷性能测试和IFD值的结果构成测量在泡沫塑料制品中产生25％或者其他指定压陷所需的力。
装置：一种具有圆平压脚面积为323cm2的装置，其通过能够适应样品角度的旋转接头与压力测试装置相连，并且以这样的方式安装，所述方式使得产品或试样能够以0.4-6.3mm/s的速度挠曲。放置所述装置以将所述样品支撑在水平板上。
测试试样：测试试样应当由整个产品样品或其适当的部分组成，除了试样的尺寸绝不会小于380×380×20mm。应当测试一个试样。
过程：
7.将测试试样放置在所述装置的支撑板上。放置所述试样使得压脚(indentor foot)在泡沫塑料的中心。
8.通过两次降低压脚使总挠曲至整个厚度部分的25％，来预挠曲要被测试的区域。通过在压脚周围划线用铅笔标记测试区域的位置。预挠曲后使样品恢复6+/-分钟。
9.将压脚与样品接触，并确定在对压脚施加接触力后的厚度。压陷样品至该厚度的25％，并在60秒后以牛顿记录所述力。该值为IFD值。
C.Cal TB 117 A测试
该测试是采用十二秒点燃时间的小型垂直测试。样品尺寸为12″×3×1/2″。12秒后移去点燃源。如果样品继续燃烧，开启秒表。未通过的标准包括：样品单个燃烧超过8英寸或者平均燃烧6英寸。时间标准要求单个试样的余辉或余焰不超过10秒，或者平均余辉或余焰不超过不超过5秒。
D.Cal.TB 117 D测试
该测试为闷烧测试，其中香烟作为棉布被料下的点火源。泡沫塑料样品被标准丝绒棉覆盖，并被放置在小的木制架中以形成椅状。样品背面为8″×7″×2″，椅座为8″×4″×2″。测试前称重样品，测试完成后再称重。如果泡沫塑料损失其重量超过20％，则被判定未通过。
丁基化磷酸三苯基酯混合物用于各种泡沫塑料，单独或者与多元醇一起进行测试，如下文进一步所述。
结论
表1为测试结果。数据表明根据本发明获得了改进结果。15或更小的CT90值为优选的。
表1：1.0 pcf泡沫塑料的压缩测试和IFD数据
| 实施例 | 阻燃剂(1)(混合比) | 产品类型和羟值(mg.KOH.g.) | 在b-TPP中的可溶性 | 24小时CT90 | IFD | 气流(cfm) |
| 1 | b-TPP* | NA | 26 | 24 | 5.8 | |
| 2 | Fyrol |
NA | 14 | 25 | 5.8 | |
| 3 | StepanpolPS2352(97∶3)(Stepan) | 邻苯二甲酸酯-二甘醇基芳香族聚酯多元醇羟值240 | 可溶 | 15 | 24 | 6 |
| 4 | StepanpolPS2352(98∶2)(Stepan) | 邻苯二甲酸酯-二甘醇基芳香族聚酯多元醇羟值240 | 可溶 | 15 | 25 | 5.3-5.7 |
| 5 | Niax DP1022(97∶3)(GE) | 1，3-丁二醇羟值1200 | 可溶 | 23 | 29 | 6.2 |
| 6 | Fomrez2C53(95∶5)(Crompton) | 丙三醇支化的己二酸二甘醇酯聚酯多元醇羟值52 | 可溶 | 13 | 24 | 5.6-5.8 |
| 7 | Fomrez2C53(97∶3)(Crompton) | 丙三醇支化的己二酸二甘醇酯聚酯多元醇羟值52 | 可溶 | 12 | 26 | 5.5-5.9 |
| 8 | Fomrez2C53(98∶2)(Crompton) | 丙三醇支化的己二酸二甘醇酯聚酯多元醇羟值52 | 可溶 | 14 | 25 | 5.4-5.6 |
| 9 | Niax FH 200(97∶3)(GE) | 聚酯多元醇/溶剂混合物羟值150-160 | 可溶 | 15 | 26 | 5.5 |
| 10 | Niax FH 200(95∶5)(GE) | 聚酯多元醇/溶剂混合物羟值150-160 | 可溶 | 14 | 29 | 5.5 |
| 11 | 三羟甲基丙烷(95/5) | 脂肪族三元醇羟值1255 | 可溶 | 失败 | 27 | 6.0 |
| 12 | 三乙醇胺 | 可溶 | 失败 | 3.8-5.6 |
| 13 | Voranol230(95/5)(Dow) | 聚醚多元醇羟值106-119 | 可溶 | 失败 | 5.7-6.1 | |
| 14 | Voranol230(97/3)(Dow) | 聚醚多元醇羟值106-119 | 可溶 | 20 | 5.7-5.8 |
| 15 | Bisphenol A(97∶3) | 芳香族二元醇 | 可溶 | 25 | 5.6-6.1 | |
| 16 | Resorcinol(97∶3) | 芳香族二元醇羟值1018 | 可溶 | 21 | 5.7-5.8 | |
| 17 | Sorbitol(97∶3) | 糖醇羟值1845 | 不溶 | |||
| 18 | 季戊四醇(95∶5) | 脂肪族多官能醇 | 不溶 | |||
| 20 | 甘油(95∶5) | 不溶 | ||||
| 21 | 蔗糖(95∶5) | 不溶 | ||||
| 22 | 丙三醇(95∶5) | 不溶 |
(1)实施例1和2分别仅包括b-TPP和Fyrol FR-2。所有其它的实施例包括b-TPP与上述所列的多元醇以所示比例(b-TPP∶多元醇)的混合物。
*b-TPP：丁基化磷酸三苯基酯(Phosflex 71B，从Supresta，LLC得到，包括约40％磷酸三苯基酯(TPP)，约40-46％磷酸对-叔丁基苯基二苯基酯和约12-18％磷酸二(对-叔丁基苯基)苯基酯的混合物)
**Fyrol
FR-2：磷酸三(二氯异丙基)酯
Cal 117结果
实施例1、3-16的泡沫塑料样品通过Cal 117测试，它们具有20份的丁基化磷酸三苯基酯/添加剂混合物。
尽管上述描述包括许多详细说明，但这些说明不应当作为本发明的限制，而仅仅作为其优选实施方式的示例。本领域技术人员可以在本发明的范围和主旨内构思许多其它的实施方式。
Claims (10)
1.一种用在聚氨酯泡沫塑料中的阻燃剂组合物，所述阻燃剂组合物包括：
(a)包括磷酸三苯基酯和一种或多种烷基取代的磷酸三苯基酯的磷酸酯混合物；和
(b)可溶于所述磷酸酯混合物的三官能或者更高官能的多元醇交联剂。
2.根据权利要求1所述的阻燃剂组合物，其中所述的烷基为C1-C4烷基。
3.根据权利要求1所述的阻燃剂组合物，其中所述的磷酸酯混合物是磷酸三苯基酯和一种或多种丁基取代的磷酸三苯基酯的混合物。
4.根据权利要求1所述的阻燃剂组合物，其中所述的多元醇为聚酯多元醇。
5.根据权利要求3所述的阻燃剂组合物，其中所述磷酸酯混合物包括磷酸叔丁基苯基二苯基酯和磷酸双-(叔丁基苯基)苯基酯。
6.一种阻燃性聚氨酯泡沫塑料，其包括阻燃量的权利要求1所述的阻燃剂组合物。
7.一种阻燃性聚氨酯泡沫塑料，其包括阻燃量的权利要求2所述的阻燃剂组合物。
8.一种阻燃性聚氨酯泡沫塑料，其包括阻燃量的权利要求3所述的阻燃剂组合物。
9.一种阻燃性聚氨酯泡沫塑料，其包括阻燃量的权利要求4所述的阻燃剂组合物。
10.一种阻燃性聚氨酯泡沫塑料，其包括阻燃量的权利要求5所述的阻燃剂组合物。
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US67779205P | 2005-05-04 | 2005-05-04 | |
| US60/677,792 | 2005-05-04 | ||
| PCT/US2006/016997 WO2006119369A1 (en) | 2005-05-04 | 2006-05-03 | Flame retardant composition and polyurethane foams containing same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101218300A CN101218300A (zh) | 2008-07-09 |
| CN101218300B true CN101218300B (zh) | 2011-09-14 |
Family
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2006800245534A Expired - Fee Related CN101218300B (zh) | 2005-05-04 | 2006-05-03 | 阻燃剂组合物以及包含该组合物的聚氨酯泡沫塑料 |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US20090215915A1 (zh) |
| CN (1) | CN101218300B (zh) |
| CA (1) | CA2607278A1 (zh) |
| TW (1) | TW200710142A (zh) |
| WO (1) | WO2006119369A1 (zh) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102008038054A1 (de) | 2008-08-16 | 2010-02-18 | Lanxess Deutschland Gmbh | Halogenfreie, flammgeschützte Polyurethanschaumstoffe mit geringem Scorch |
| US8921439B2 (en) * | 2010-09-23 | 2014-12-30 | Icl-Ip America Inc. | Monohydroxy cyclic phosphonate substantially free of polyhydroxy phosphonate, process for making same and flame retardant flexible polyurethane foam obtained therefrom |
Family Cites Families (17)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3880946A (en) * | 1973-12-18 | 1975-04-29 | Ford Motor Co | Powder paint compositions including carboxyl terminated polyether crosslinking agent |
| LU74540A1 (zh) * | 1976-03-12 | 1977-09-27 | ||
| US4374207A (en) * | 1980-10-24 | 1983-02-15 | G.F.C. Foam Corporation | Intumescent flexible polyurethane foam |
| US4317889A (en) * | 1980-10-24 | 1982-03-02 | Tenneco Chemicals, Inc. | Intumescent flexible polyurethane foam |
| US4514524A (en) * | 1984-07-13 | 1985-04-30 | Stauffer Chemical Company | Intumescent flexible polyurethane foam |
| US4544678A (en) * | 1984-11-19 | 1985-10-01 | Stauffer Chemical Company | Filled or extended polyurethane foam containing polyethylene glycol softening agent |
| US4746682A (en) * | 1987-04-01 | 1988-05-24 | Fmc Corporation | Polyurethane flame retardant |
| JPH0284421A (ja) * | 1988-06-04 | 1990-03-26 | Achilles Corp | 衝撃吸収性ポリウレタンフォーム及びその製造方法 |
| CA2029460C (en) * | 1989-11-14 | 2004-01-06 | Gerald Fesman | Viscosity reduction of high viscosity fluid flame retardants for polyurethanes |
| CN1264400A (zh) * | 1997-07-25 | 2000-08-23 | 亨茨曼Ici化学品有限公司 | 以氟化烃发泡的硬质聚氨酯防火泡沫体 |
| ES2241282T3 (es) * | 1998-05-21 | 2005-10-16 | Huntsman Int Llc | Espumas de poliuretano rigidas sopladas con hidrocarburo que tienen un comportamiento de inflamabilidad mejorado. |
| AU5314400A (en) * | 1999-06-01 | 2000-12-18 | Solutia Inc. | Composition for use in flexible polyurethane foams |
| US7288577B1 (en) * | 1999-09-09 | 2007-10-30 | Supresta U.S. Llc | Polyurethane foam containing flame retardant blend of non-oligomeric and oligomeric flame retardants |
| DE60316431T2 (de) * | 2002-05-20 | 2008-06-12 | Great Lakes Chemical Corp., West Lafayette | Mischungen von (alkylsubstituierten) triarylphosphatestern mit phosphor enthaltenden flammschutzmitteln für polyurethanschaumstoffe |
| US20040171722A1 (en) * | 2003-02-28 | 2004-09-02 | Brown William R. | Flame retardant polyurethanes and additive compositions for use in producing them |
| DE602005019917D1 (de) * | 2004-12-02 | 2010-04-22 | Chemtura Corp | Scorchfester flammgeschützter polyurethanschaumstoff |
| DK1861458T3 (da) * | 2005-03-21 | 2009-12-14 | Chemtura Corp | Flammehæmmere og flammehæmmende polymerer |
-
2006
- 2006-05-03 CA CA002607278A patent/CA2607278A1/en not_active Abandoned
- 2006-05-03 CN CN2006800245534A patent/CN101218300B/zh not_active Expired - Fee Related
- 2006-05-03 TW TW095115765A patent/TW200710142A/zh unknown
- 2006-05-03 US US11/919,848 patent/US20090215915A1/en not_active Abandoned
- 2006-05-03 WO PCT/US2006/016997 patent/WO2006119369A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| CN101218300A (zh) | 2008-07-09 |
| TW200710142A (en) | 2007-03-16 |
| CA2607278A1 (en) | 2006-11-09 |
| US20090215915A1 (en) | 2009-08-27 |
| WO2006119369A1 (en) | 2006-11-09 |
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