Phosphorus Flame Retardant for Polyurethane Foams
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Solution Overview
Problem
Phosphorus compounds used as flame retardants in polyurethane foams are often not soluble in polyol formulations, leading to compatibility issues and reduced effectiveness.
Innovation Solution
A phosphorus-containing flame retardant is developed by reacting active hydrogen-containing compounds such as polyols, polyamines, and amino alcohols with phosphorus-containing compounds, creating a compatible and effective flame retardant for polyurethane foams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphorus compounds are added as flame retardants, then flame retardant properties are improved, but solubility in polyol formulations deteriorates
Solution Approach 1:
The patent modifies the chemical structure parameters of phosphorus compounds by introducing specific alkyl chains (C1-C8), alkoxyethyl groups (C1-C4), and cyclic structures with 3-9 carbon atoms. These parameter changes enhance solubility in polyol formulations while preserving flame retardant effectiveness through maintained phosphorus content and reactive functionality.
Solution Approach 2:
The invention creates composite molecular structures combining phosphorus-containing functional groups with organic moieties such as alkyl chains, alkoxyethyl groups, and cyclic structures. This composite approach integrates the flame retardant properties of phosphorus compounds with the solubility characteristics of polyol-compatible organic structures.
2Reliability
If traditional halogen-containing flame retardants are used, then flame retardant effectiveness is improved, but environmental and health concerns worsen
Solution Approach 1:
The patent replaces harmful halogen-containing compounds with phosphorus-based alternatives that provide equivalent or superior flame retardant effectiveness without the environmental and health hazards. This conversion transforms the harmful halogen category into a beneficial phosphorus category, maintaining safety performance while eliminating toxic effects.
3Reliability
If higher concentrations of flame retardants are added, then flame retardant properties are improved, but physical properties like tensile strength and tear resistance deteriorate
Solution Approach 1:
The patent optimizes the concentration parameter of phosphorus compounds to achieve effective flame retardancy at lower levels compared to traditional additives. The modified chemical structure provides enhanced efficiency, allowing formulation at concentrations that maintain both flame retardant properties and mechanical strength without the need for high loading levels.
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
The solution enhances the flame retardant properties of polyurethane foams while maintaining physical properties like tensile strength and tear resistance, outperforming traditional halogen-containing flame retardants at lower concentrations.
Implementation Method 1
The reaction mixture includes: (a) at least one active hydrogen-containing compound... with (b) at least one phosphorus containing compound... wherein X is a leaving group
Data Source
AI summary
Embodiments of the invention include a phosphorus containing flame retardant which may be the reaction product of a reaction mixture where the reaction mixture includes at least one active hydrogen-containing compound and at least one phosphorus containing compound. The at least one active hydrogen-containing compound is selected from the group of a first polyol having a hydroxyl functionality of at least 3, a polyamine having an amine functionality of at least 2, and an amino alcohol having a combined amine and hydroxyl functionality of at least 2. The at least one phosphorus containing compound has the general formula (1), (2) or combination thereof.