Phosphorus-Containing Polyol for Halogen-Free Flame Retardancy
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Solution Overview
Problem
Current flame retardants for polyurethanes, particularly polyurethane foams, face challenges such as toxicity, environmental concerns, and adverse effects on mechanical properties due to halogenated compounds, and existing halogen-free alternatives like solid or liquid flame retardants cause production issues and impair foam properties.
Innovation Solution
A phosphorus-containing polyol is synthesized through a reaction with a phosphorus-containing compound, offering a halogen-free flame retardant that improves mechanical properties and can be easily blended with common polyols, providing tailored flame retardancy for flexible and rigid foams without emissions or production disruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogenated flame retardants (e.g., bromine-containing compounds) are used, then flame retardancy effectiveness is improved, but toxicological safety and environmental compatibility deteriorate
Solution Approach 1:
The invention changes the chemical composition parameters by using phosphorus-containing compounds (phosphates, phosphonates, phosphites) instead of halogenated compounds, maintaining flame retardancy through phosphorus-based mechanisms while eliminating toxicological and environmental hazards associated with halogens
Solution Approach 2:
The invention employs readily available phosphorus-containing compounds that can be easily integrated into polyurethane production, replacing complex halogenated flame retardants with simpler, more environmentally compatible alternatives that achieve comparable or superior flame safety
2Object-affected harmful factors
If solid flame retardants (e.g., melamine, ammonium polyphosphate) are used, then halogen-free flame retardancy is achieved, but processing difficulty and production efficiency deteriorate
Solution Approach 1:
The invention changes the physical state parameter from solid to liquid by using phosphorus-containing compounds in liquid form, which eliminates processing difficulties associated with solid particles (separation phenomena, metering unit abrasion) while maintaining effective flame retardancy
Solution Approach 2:
The invention uses liquid phosphorus-containing flame retardants that can be easily pumped, mixed, and incorporated into polyurethane formulations through standard liquid handling equipment, avoiding the mechanical wear and separation issues caused by solid particles
3Ease of manufacture
If liquid flame retardants (e.g., triethyl phosphate, diethyl ethane-phosphonate) are used, then processing ease is improved, but emissions and odor increase
Solution Approach 1:
The invention changes the chemical structure parameters by selecting phosphorus-containing compounds with specific molecular structures (phosphates, phosphonates, phosphites) that have lower volatility and reduced odor, while maintaining liquid state for easy processing
Solution Approach 2:
The invention converts the potential harm of liquid flame retardants (emissions and odor) into benefits by carefully selecting phosphorus-containing compounds that maintain liquid state for processing ease but have superior environmental compatibility and reduced emissions compared to traditional liquid flame retardants
4Reliability
If existing flame retardants are used, then flame retardancy is achieved, but mechanical properties of polyurethane foams deteriorate
Solution Approach 1:
The invention creates a composite effect by combining phosphorus-containing flame retardant functionality with polyol structure, allowing the flame retardant to be an integral part of the polyurethane matrix rather than a separate additive, thereby maintaining mechanical properties while achieving effective flame retardancy
Solution Approach 2:
The phosphorus-containing compounds serve multiple functions: they provide flame retardancy through phosphorus-based mechanisms, maintain mechanical properties by being structurally compatible with polyurethane, and ensure environmental compatibility by eliminating halogens, achieving multi-functionality in a single additive system
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 phosphorus-containing polyol effectively enhances flame retardancy and mechanical properties of polyurethane foams, achieving performance comparable to halogen-containing foams while avoiding their drawbacks, with improved processing and reduced environmental impact.
Implementation Method 1
a phosphorus containing polyol, obtainable or obtained by a process comprising the reaction of at least one polyol with a phosphorus containing compound
Data Source
AI summary
The present invention relates to a phosphorus containing polyol, obtainable or obtained by a process comprising the reaction of at least one polyol with a phosphorus containing compound of the general formula (I) as defined herein, as well as the process for preparing a phosphorus containing polyol, comprising the reaction of at least one polyol with a phosphorus containing compound of the general formula (I). Furthermore, the present invention relates to the use of a phosphorus containing polyol as disclosed herein as a flame retardant, to a process for the preparation of a polyurethane and the polyurethane as such.