Liquid Flame Retardant Composition for Ambient Polyol Blending
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Solution Overview
Problem
The process of homogeneously blending solid or wax-like non-readily soluble flame retardants in polyurethane foam precursors typically requires heating, which complicates the manufacturing process, especially when conducted outdoors.
Innovation Solution
A stable liquid flame retardant composition is created by dissolving solid or highly viscous epoxides and their end-capped derivatives in polyols or esters of phosphoric acid, preventing precipitation and allowing for their incorporation into the polyurethane foam system at ambient temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If solid or wax-like flame retardants are blended in liquid precursors with heating, then homogeneous distribution is achieved, but process complexity increases and outdoor application becomes difficult
Solution Approach 1:
The patent changes the physical state parameter of the flame retardant from solid/wax-like to liquid form by reacting tetrabromobisphenol A with epichlorohydrin to produce liquid epoxide compounds. This parameter change eliminates the need for heating during blending, allowing direct mixing at ambient temperature while maintaining homogeneous distribution.
Solution Approach 2:
The flame retardant is prepared in advance in liquid form through the reaction of tetrabromobisphenol A with epichlorohydrin. This preliminary conversion to liquid state enables direct incorporation into the foam formulation without requiring subsequent heating and blending operations, simplifying the overall process.
2Quantity of substance
If solid flame retardants are used, then high bromine content is achieved, but solubility in liquid precursors is poor requiring heating
Solution Approach 1:
The patent changes the solubility parameter by converting the solid tetrabromobisphenol A into liquid epoxide derivatives through reaction with epichlorohydrin. This transformation maintains the high bromine content while dramatically improving solubility in the liquid polyol precursor, eliminating precipitation issues during storage and processing.
3Stability of the object's composition
If heating is applied for blending, then homogeneous mixture is obtained, but energy consumption increases and outdoor processing becomes impractical
Solution Approach 1:
The patent changes the temperature parameter requirement by producing liquid flame retardant compounds that are miscible with the polyol precursor at ambient temperature. This eliminates the need for heating during the blending operation, reducing energy consumption and enabling practical outdoor application at construction sites.
4Ease of manufacture
If liquid flame retardant composition is used, then heating is eliminated, but precipitation during storage must be prevented
Solution Approach 1:
The patent changes the chemical structure parameter by selecting specific epoxide compounds with appropriate molecular weight and polarity that match the polyol precursor. This structural compatibility ensures complete solubility and prevents precipitation during storage, while maintaining the liquid state for easy processing.
Solution Approach 2:
The patent creates a composite liquid composition by combining the epoxide-derived flame retardant with the polyol precursor in specific ratios. This composite formulation ensures thermodynamic compatibility and long-term storage stability without precipitation, while maintaining the simplified liquid handling advantages.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the blending process, ensures uniform distribution of flame retardants in polyurethane foams, and maintains stability over long storage periods, enhancing the foam's burning characteristics and bromine content.
Implementation Method 1
dissolve considerable quantities of one or more of these solid or highly viscous flame retardants and structural analogues thereof in a liquid which is either a polyol or an ester of phosphoric acid
Implementation Method 2
The resulting stable liquid composition may be conveniently used for delivering the flame retarding agent to the foaming system, to allow their incorporation into the rigid polyurethane foam
Data Source
AI summary
A liquid flame retardant composition having one or more flame retarding agents, which are the epoxides obtainable by reacting tetrabromobisphenol A with epichlorohydrin and their end-capped derivatives represented by Formula (1), is provided. The liquid composition is especially useful in the preparation of rigid polyurethane foams.