Akzo America Inc.

Akzo Nobel N.v.

Stauffer Chemical Company

Akzo N.v.

Ripplewood Phosphorus U.S. LLC

Alan M Aaronson

John Tomko

Danielle A Bright

Fred Jaffe

Jeffrey E Telschow

Andrzej M Piotrowski

Jagadish C Goswami

Ki-Soo Kim

Danielle Angrand Bright

Sophia Dashevsky

Gerald Fesman

Johst H Burk

Ronald L Pirrelli

Johannes Hermanus Boelee

Gurudus D Sinai-Zingde

Robert L Protzmann

Alkylene-bridged diphosphate compounds can be used to modify, namely, reduce, the viscosity of fluid flame retardants (polybrominated aryl oxides, oligomeric phosphate esters, etc.) which are useful in flame retarding polyurethane and thermoplastic compositions.

Viscosity modification of high viscosity flame retardants

A process for the synthesis of a hydrocarbylvinyl-1-phosphonic acid hydrocarbyl ester, such as a 1-phenylvinylphosphonic acid dialkyl ester, which utilizes: (a) the base catalyzed addition (preferably using a nonnucleophilic strong organic base) of a hydrocarbyl phosphite, such as a dialkyl phosphite containing no more than about eight carbon atoms in either of its alkyl groups, to an aldehyde or methyl ketone, such as a phenyl ketone, as exemplified by acetophenone, to form a hydrocarbyl 1-hydroxy-1-hydrocarbylphosphonate, such as a dialkyl 1-hydroxy-1-phenylalkylphosphonate compound; (b) the acid-catalyzed esterification (preferably acetylation) of the compound from (a) with an acid anhydride to form an acylated intermediate; and (c) the removal of carboxylic acid (preferably at a temperature of from about 50&deg; C. to about 215&deg; C. under reduced or atmospheric pressure) from the intermediate from (b) to form the desired hydrocarbylvinylphosphonic acid hydrocarbyl ester, such as a 1-phenylvinylphosphonic acid dialkyl ester.

Synthesis of a hydrocarbylvinylphosphonic acid hydrocarbyl ester

The disclosure teaches a blend of a predominant amount of a polyphosphate flame retardant and an effective amount of a liquid crystalline additive for viscosity reduction and compatibilization when blended with a thermoplastic polymer, as compared to use of just the polyphosphate flame retardant alone. The polyphosphate can comprise resorcinol bis(diphenyl phosphate) and/or its higher oligomers. The liquid can be a liquid crystalline segmented block copolymer or a liquid crystalline oligomer.

Blend of polyphosphate flame retardant and liquid crystalline additive

A flame retardant mixture, suitable for use in polyurethane foams, comprises a polybrominated diphenyl oxide (e.g., pentabromodiphenyl oxide) and an organic diphosphate (e.g., an aromatic diphosphate). A small amount of triaryl phosphate can also be present for viscosity reduction purposes.

Flame retardant mixture of polybrominated diphenyl oxide and organic

Phenolphthalein bis(dihydrocarbyl phosphates), optionally substituted with chloro or bromo atoms, can be used as fire retardant additives for polymers.

Phenolphthalein bis (dihydrocarbyl phosphate) compounds

Glycol bisphosphate compounds are formed by first hydrolytically condensing a dihydrocarbylhalophosphate to form a tetrahydrocarbyl pyrophosphate and then reacting the pyrophosphate with a cyclic ether to form the glycol bisphosphate.

Formation of tetraarylpyrophosphate

Polyvinyl chloride resin can be plasticized with a carbon monoxide-propylene copolymer. Since the copolymer is soluble in organic solvent, it and the polyvinyl chloride can be dissolved in an organic solvent and then cast to form a film. The copolymer can be a liquid, relatively low molecular weight material, which can be heat blended with the resin along with a smaller amount of a conventional external plasticizer for the resin.

Plasticization of polyvinyl chloride with carbon monoxide-propylene

Glycol bisphosphate compounds are formed by first hydrolytically condensing a dihydrocarbylhalophosphate to form a tetrahyrocarbyl pyrophosphate and then reacting the pyrophosphate with a cyclic ether to form the glycol bisphosphate.

Formation of glycol bisphosphate compounds

Melamine pyrophosphate is made by the direction reaction of pyrophosphoric acid and melamine in an aqueous reaction medium at a temperature of from about 0.degree. C. to about 60.degree. C., preferably from about 0.degree. C. to about 20.degree. C.

Process for manufacture of melamine pyrophosphate

Diaryl sulfones are formed in a two-stage procedure. The first involves the reaction of an aryl sulfonic acid with an aryl reagent containing active hydrogen while by-product water is removed azeotropically. In the second stage, which contains unreacted sulfonic acid, is treated with a sulfone condensing agent and additional aryl reagent to react additional, unreacted aryl sulfonic acid from the first stage.

Preparation of diaryl sulfones

Liquid mixed triaryl thiophosphate mixtures can be prepared by forming a mixture of phenol and substituted phenols, forming a phosphite from that mixture and sulfurizing the phosphite, washing the thiophosphate with aqueous base, and drying the so washed thiophosphate under mild conditions. The products are liquid while containing at least 25 percent symmetrical triaryl thiophosphate. Colorless and odorless products are prepared.

Process for preparing liquid triaryl thiophosphate mixtures

A composition comprises polyurethane, a two-component flame retardant system consisting of an additive first flame retardant containing organophosphorus, and a second flame retardant containing organochlorine or organobromine. The composition of the invention may be employed for polyurethane foams, especially rigid foams. Diminished combustibility for rigid foam is measured by a flame-spread index less than 75 and a smoke developed index less than 450 when subjected to ASTM Test E-84, Surface Burning Characteristics of Building Materials. Dimethyl methylphosphonate is a representative additive organophosphorus first flame retardant. Trichloroisopropyl alcohol is a representative second flame retardant containing organochlorine.

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Flushing Meadows, NY, United States of America

Alan M Aaronson