Condensed Phosphorus Precursors for Stable Flame Retardant Polymers

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Solution Overview

Problem

Conventional processes for producing flame retardant, phosphorus-containing polymers result in significant waste and increased costs due to volatilization of phosphonium compounds and require excessive cross-linking agents, leading to side reactions that affect polymer performance and stability.

Innovation Solution

A precursor composition comprising condensed phosphorus compounds produced by reacting a nitrogen compound with a phosphonium compound in a specific molar ratio, allowing for efficient production of flame retardant polymers with reduced volatile by-products and minimal additional cross-linking agents, thereby minimizing side reactions and enhancing polymer stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If heating is applied to accelerate the reaction between phosphonium compound and cross-linking agent, then reaction speed is improved, but phosphonium compound volatilization increases causing waste and apparatus build-up

Engineering Contradiction:
Improvereaction speedVSAvoidphosphonium compound volatilization
Core Design Contradiction:
SpeedVSLoss of substance

Solution Approach 1:

The patent changes the chemical structure parameters of the cross-linking agent from conventional melamine-formaldehyde to triazine-based structures (melam, melamin, melaminal, biguan). This structural modification enables the reaction to proceed at lower temperatures, reducing phosphonium compound volatilization while maintaining adequate reaction speed. The specific triazine ring structure provides reactive groups that form stable cross-links without requiring excessive thermal energy.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent introduces a multi-functional cross-linking agent system where triazine-based compounds act as intermediaries between the phosphonium compound and the final polymer network. These intermediaries facilitate the cross-linking reaction at lower temperatures by providing alternative reaction pathways with lower activation energies, thus reducing the need for high-temperature heating that causes volatilization.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Ease of manufacture

If conventional cross-linking agents are used, then polymer formation is achieved, but excessive cross-linking agent is required leading to side reactions and reduced polymer stability

Engineering Contradiction:
Improvepolymer formationVSAvoidpolymer stability
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent modifies the chemical parameters of the cross-linking agent by using triazine-based structures with specific nitrogen and carbon ratios. These structural changes enable complete reaction of the phosphonium compound with stoichiometric amounts of cross-linking agent, eliminating excess unreacted cross-linking agent that would otherwise cause side reactions and reduce polymer stability.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite cross-linking system combining multiple triazine-based compounds (melam, melamin, melaminal, biguan) that work synergistically. This composite approach ensures complete utilization of the phosphonium compound's reactive groups, forming a stable polymer network without requiring excessive cross-linking agent that would lead to detrimental side reactions.

Inventive Principle:
Principle #40Composite materials

3Productivity

If precondensate with limited cross-linking agent is used, then initial polymerization starts, but reactive groups are depleted requiring additional cross-linking agent and causing side reactions

Engineering Contradiction:
Improvepolymerization initiationVSAvoidside reactions from free cross-linking agent
Core Design Contradiction:
ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the stoichiometric parameters of the cross-linking system by using triazine-based agents with optimized nitrogen content and reactive group density. This enables the precondensate to contain sufficient reactive groups to complete the polymerization process without requiring additional cross-linking agent, thereby preventing side reactions from unreacted cross-linking agent.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent prepares a precondensate with triazine-based cross-linking agents that already contains the necessary reactive groups for complete polymerization. This preliminary formulation ensures that all reactive groups are accounted for in the initial mixture, eliminating the need for additional cross-linking agent additions and preventing the formation of harmful side reactions from excess cross-linking agent.

Inventive Principle:
Principle #10Preliminary action

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 reduces waste and production costs, produces a more robust and ideal flame retardant polymer with improved stability and performance by using a single component system that minimizes volatile by-products and side reactions.

Implementation Method 1

The condensed phosphorus compound is produced by reacting together in a condensation reaction: (a) a nitrogen compound conforming to the structure of Formula (N)... and (b) a phosphonium compound conforming to the structure of Formula (P)

Methodology Applied
Scientific EffectCondensation reaction:

Data Source

PatentUS9982096B2Flame retardant precursors, polymers prepared from such precursors, and flame resistant fabrics treated with such polymers
Publication Date: 2018.05.29 MILLIKEN & CO
  • US9982096B2 patent drawing
  • US9982096B2 patent drawing
  • US9982096B2 patent drawing

AI summary

A composition comprises at least one condensed phosphorus compound. The condensed phosphorus compound is produced by reacting together in a condensation reaction a nitrogen compound and a phosphonium compound. A phosphorus-containing polymer is produced by reacting in a condensation reaction a hydroxyalkylphosphonium compound to produce an intermediate polymer and then oxidizing phosphorus atoms in the intermediate polymer to yield a polymer comprising phosphine oxide groups.