THPS-Based Flame Retardant Composition to Reduce Formaldehyde Content
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Solution Overview
Problem
Existing flame-retardant precursors for textiles contain high levels of formaldehyde, making them hazardous during storage, transportation, and handling, and difficult to manage within regulatory limits.
Innovation Solution
Using tetrakis(hydroxyorgano) phosphonium sulfate (THPS) instead of tetrakis(hydroxyorgano) phosphonium chloride (THPC) to form a condensate with urea or thiourea, reacting at temperatures below 100°C to achieve a formaldehyde content of less than 0.1% and reducing odour during application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If THPC is used to form flame-retardant condensate, then flame-retardant properties are achieved, but formaldehyde content becomes high causing toxicity and handling issues
Solution Approach 1:
The patent changes the counterion parameter of the phosphonium salt from chloride (THPC) to sulfate (THPS). This parameter change fundamentally alters the formaldehyde release behavior during condensation reactions, reducing formaldehyde content in the final flame-retardant composition while preserving the essential flame-retardant properties of the phosphonium-based system.
2Productivity
If reaction temperature is increased to improve reaction efficiency, then manufacturing speed increases, but formaldehyde content increases making the product hazardous
Solution Approach 1:
The patent demonstrates that using THPS instead of THPC changes the temperature-formaldehyde relationship. The sulfate-based system allows for effective condensation reactions at lower temperatures without generating excessive formaldehyde, thereby decoupling the trade-off between reaction efficiency and formaldehyde content that exists with chloride-based systems.
3Object-affected harmful factors
If formaldehyde content is reduced to meet regulations, then safety and compliance improve, but flame-retardant effectiveness may be compromised
Solution Approach 1:
The patent shows that changing the counterion from chloride to sulfate in the phosphonium salt enables the system to achieve both low formaldehyde content and effective flame-retardant performance. The sulfate anion appears to stabilize the condensation products or alter the reaction pathway, allowing flame-retardant condensates to form with minimal formaldehyde release.
Solution Approach 2:
The patent creates a composite chemical system combining the phosphonium cation with the sulfate anion (THPS), which exhibits synergistic properties. This composite approach allows the system to simultaneously achieve low formaldehyde content and high flame-retardant effectiveness, as the sulfate component contributes to both reduced formaldehyde release and maintained flame-retardant functionality.
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 THPS-based condensate significantly reduces formaldehyde content and odour, enhancing safety and compliance with regulations while maintaining effective flame-retardant properties.
Implementation Method 1
reaction of: (a) a tetrakis (hydroxyorgano) phosphonium sulfate (herein "THPS"); (b) urea or thiourea (herein "(thio)urea")
Implementation Method 2
comprise a precursor that reacts under ammonia curing to form a polymer, said polymer imparting the sought flame retardant properties
Data Source
AI summary
The instant invention relates to a composition useful as a precursor for imparting flame-retardant properties to textile articles, comprising a condensate of : (a) a tetrakis (hydroxyorgano) phosphonium sulfate THPS; (b) urea, or alternatively thiourea; (c) optionally, and preferably, an aliphatic hydroxyl-reactive compound, such an amine wherein said composition has a very low free formaldehyde content, namely of less than 0,1 %.