Albemarle Corporation

Ethyl Corporation

Albermarle Corporation

Albemarie Corporation

Saadat Hussain

George H Ransford

John C Parks

David H Knoebel

Lawrence M Jenkins

Gary L Bowman, Jr

Arthur G Mack

Raymond B Dawson

Henry J Barda

Burton J Sutker

Amgad S Mossaad

Charles H Kolich

Bonnie G McKinnie

David R Brackenridge

William R Brown

Robert L Davis

Jeffrey Todd Aplin

Mark A Templeton

Gerald L Scymanski

A high assay decabromodiphenylalkane product in which the alkylene group contains in the range of about 1-10 carbon atoms and has an occluded free bromine content of &#x3c;500 ppm is prepared. The process comprises brominating, in a liquid phase reaction mixture, at least one &#x3b1;,&#x3c9;-diphenylalkane having an alkylene group of 1-10 carbon atoms, with a limited excess of bromine, in the presence of an aluminum, aluminum halide or a ferric halide catalyst in which the original halogen atoms of such halides are chlorine atoms, bromine atoms, or both. The limited excess of bromine is such that the maximum excess amount of bromine used in conducting the reaction is about 20 mole % relative to the stoichiometric amount required to convert the amount of &#x3b1;,&#x3c9;-diphenylalkane used to decabromodiphenylalkane. Crude high assay decabromodiphenylalkane product is prepared without use of heat treatment, oven ageing, or grinding or other forms of pulverization.

Preparation of high assay decabromodiphenylalkane product with low occluded free bromine content

High assay, reaction-derived decabromodiphenylethane product is prepared by feeding (i) diphenylethane or (ii) partially brominated diphenylethane having an average bromine number less than about two, or (iii) both of (i) and (ii), into the liquid confines of a reaction mixture. Such reaction mixture is (a) formed from components comprised of excess liquid bromine and aluminum-based Lewis acid bromination catalyst, and (b) maintained at one or more elevated reaction temperatures of from about 45&#xb0;-90&#xb0; C., and at least when elevated pressure is needed to keep a liquid state in the reaction mixture at the temperature(s) used, the reaction mixture is at such an elevated pressure, whereby ar-bromination occurs. The feeding is conducted at a rate slow enough to form high assay reaction-derived decabromodiphenylethane product, which is an effective flame retardant.

Preparation and provision of high assay decabromodiphenylethane

Solid-state highly brominated compounds such as solid brominated flame retardants with bromine contents of at least about 60 wt % often contain occluded bromine. Because of their high bromine contents, such compounds have relatively low solubility in common organic solvents. Despite this low solubility, the content of occluded bromine in such solid brominated compounds is effectively reduced by agitating a concentrated agitated slurry of the compound in an inert solvent at a suitable temperature for at least about 1 hour. Thereafter, solids with reduced content of occluded bromine are isolated or recovered from the slurry. Novel products having substantially reduced or eliminated occluded bromine contents and other very desirable characteristics are also provided.

Processing of solid brominated aromatic organic compounds containing occluded bromine

An additive mixture useful as a flame retardant is described. The mixture is comprised of (i) a poly(bromophenyl)alkane having in the molecule in the range of 13 to 60 carbon atoms and in the range of two to four aryl groups and (ii) a poly(bromophenyl)bromoalkane having in the molecule in the range of 13 to 60 carbon atoms and in the range of two to four aryl groups, said poly(bromophenyl)bromoalkane being in an amount which is greater than 25 wt %, based on the total weight of the additive mixture. A facile process for making the poly(bromophenyl)bromoalkane is also described.

Poly(bromoaryl)alkane additives and methods for their preparation and use

This invention relates to a novel process which comprises feeding a mixture formed from diphenylethane and bromine to a stirrable reaction mass comprised of bromine and a bromination catalyst to yield a decabromodiphenylethane wet cake which can be most economically treated to provide a high quality decabromodiphenylethane product.

Bromination process

Provided are new flame retardants and liquid flame retardant additive compositions of low viscosity for use in flexible polyurethane foams. The new flame retardants are the reaction product of at least one brominated aromatic diester diol with at least one alcohol-reactive agent. Preferred liquid flame retardant additive compositions are capable of minimizing visible scorching of the foam during its production. Flexible flame retardant polyurethane foams and methods for their production are also provided. The flame retardant additive compositions are formed at least from a) at least one reaction product of a brominated aromatic diester diol and an alcohol-reactive agent; b) at least one hindered amine antioxidant; and c) at least one phenolic antioxidant in which the phenolic ring is substituted by an alkanoic acid alkyl ester group in which alkanoic acid moiety has in the range of 2 to about 4 carbon atoms and the alkyl group has in the range of about 6 to about 16 carbon atoms.

Flame retardant, additive compositions, and flame retardant polyurethanes

This invention relates to a novel process which comprises feeding a mixture formed from disphenylethane and bromine to a stirrable reaction mass comprised of bromine and a bromination catalyst to yield a decabromodiphenylethane wet cake which can be most economically treated to provide a high quality decabromodiphenylethane product.

This invention relates to a novel process which comprises feeding a mixture formed from diphenylethane and bromine to a stirrable reaction mass comprised of bromine and a bromination catalyst to yield a decabromodiphenylethane wet cake which can be most economicaly treated to provide a high quality decabromodiphenylethane product.

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Baton Rouge, LA, United States of America

Saadat Hussain