Phosphorus-Based Polyurethane Urea Polyols Flame Retardancy
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Solution Overview
Problem
There is a need to enhance the flame retardant properties of polyurethane foams, which existing polymer polyols have not adequately addressed.
Innovation Solution
A polymer polyol dispersion is created by forming PIPA and/or PHD particles in situ in a polyol blend, incorporating a phosphorus-based flame retardant, amine co-reactant, catalyst, and polyisocyanate, where the phosphorus-based flame retardant is added in specific concentrations and reacts with the polyol and phosphorus-containing compounds to enhance flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional polymer polyols (SAN, PHD, PIPA) are used to improve load-bearing foam properties, then foam mechanical strength is improved, but flame retardant properties remain insufficient
Solution Approach 1:
The patent combines flame retardant functionality with polymer polyol particles by incorporating phosphorus-containing compounds into PIPA and PHD particle structures. This merging allows the particles to simultaneously provide mechanical reinforcement and flame retardant protection, resolving the contradiction between strength enhancement and fire resistance.
Solution Approach 2:
The invention creates composite polymer polyol particles containing phosphorus-containing compounds within the PIPA/PHD matrix. These composite particles exhibit both the mechanical properties of conventional polymer polyols and the flame retardant characteristics of phosphorus-based additives, addressing both requirements simultaneously.
2Object-affected harmful factors
If phosphorus-based flame retardants are added to polyol blends, then flame retardant properties are improved, but the complexity of the reaction system increases
Solution Approach 1:
The phosphorus-containing compounds are incorporated into the polymer polyol particles during their formation stage rather than being added separately later. This preliminary action integrates the flame retardant function into the particle structure itself, simplifying the overall system by eliminating the need for separate flame retardant addition steps.
Solution Approach 2:
The polymer polyol particles serve multiple functions: mechanical reinforcement, viscosity modification, and flame retardancy. By making the particles multi-functional through phosphorus incorporation, the system complexity is reduced as one component (the particle) replaces what would otherwise require multiple separate additives.
3Strength
If PIPA and PHD particles are formed by introducing co-reactants into polyol blends, then polymer polyol properties are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the flame retardant additive function with the polymer polyol particle formation process. By incorporating phosphorus-containing compounds during particle synthesis, the manufacturing process produces a dual-functional product (mechanical reinforcement + flame retardancy) in one step, rather than requiring separate processing steps for each function.
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 resulting polyurethane foams exhibit improved flame retardant properties due to the incorporation of phosphorus-based flame retardants within the PIPA and/or PHD particles, effectively addressing the need for enhanced fire resistance.
Implementation Method 1
a reaction mixture comprising: at least one polyol; and at least one phosphorus containing compound having the general formula (1), (2) or combination thereof
Implementation Method 2
PIPA (polyisocyanate polyaddition) polyols (dispersions of polyurethane and/or polyurethane-urea particles)
Data Source
AI summary
Embodiments of the invention include a polymer polyol dispersions. The polymer dispersions include a reaction product of a reaction system, where the reaction system includes: at least one polyol, at least one phosphorus based flame retardant having at least one active hydrogen attached to a nitrogen or oxygen atom, at least one of a co-reactant having an equivalent weight of up to 400 and at least one active hydrogen attached to a nitrogen or oxygen atom, at least one catalyst, and at least one polyisocyanate.