Reactive flame retardant blends for flexible polyurethane foam

Abstract

The present invention provides dialkyl phosphorus-containing compounds, namely reactive mono-hydroxyl-functional dialkyl phosphinates in a blend with a phosphate compound, said blend serving as highly efficient reactive flame retardant blend in flexible polyurethane foam. The invention further provides fire-retarded polyurethane compositions comprising said the reaction product of the flame retardant blend with polyol and isocyanate foam forming components.

1 .- 15 . (canceled) 
     
     
         16 . A flame-retardant blend comprising:
 (A) a phosphorus-containing polyol reaction product of the partial phosphorylation of a polyalcohol, which phosphorus-containing polyol reaction product comprises at least one phosphorus-containing group, of the formula (I-B):   
       
         
           
           
               
               
           
         
         wherein:
 R 1  and R 2  are independently selected from a linear or branched alkyl group containing from 1 to 4 carbon atoms, 
 n 1  is an integer equal to or greater than 1 and n 2  is one, with n 1 +n 2  being equal to or greater than 2, and 
 Z 2  is a moiety derived from a branched polyol which has a valence of n 1 +n 2 , and is of the general formula: 
 
       
       
         
           
           
               
               
           
         
         wherein R is selected from the group consisting of: 
       
       
         
           
           
               
               
           
         
         and where each R 6  independently is H or is an alkyl of from 1 to 4 carbon atoms, x is ≥1, y is 2 or 3; z is an integer of from 2 to 5; and, m≥1; and, 
         (B) a phosphate compound. 
       
     
     
         17 . The flame-retardant blend of  claim 16 , wherein R 1  and R 2  are each an ethyl group. 
     
     
         18 . The flame retardant blend of  claim 16 , wherein the phosphate compound is selected from the group consisting of mixed t-butylphenyl phenyl phosphates, resorcinol bis(diphenyl phosphate), bisphenol A bis(diphenyl phosphate), tris (2-butoxyethylphosphate), and combinations thereof. 
     
     
         19 . The flame retardant blend of  claim 16  further comprising a halogenated phosphate compound selected from the group consisting of tris(1,3-dichloro-2-propyl) phosphate (TDCP); phosphoric acid esters, oxydi-2,1-ethanediyl tetrakis (2-chloro-1-methylethyl) ester; Amgard V6 (2,2-bis(Chloromethyl)-1,3-propanediyl tetrakis(2-chloroethyl) Ester Phosphoric Acid); ELF-800 (2,2-bis(Chloromethyl)-1,3-propanediyl tetrakis(2-chloro-1-methylethyl) Ester Phosphoric Acid); and combinations thereof. 
     
     
         20 . A flame-retarded flexible polyurethane foam comprising the reaction product of a polyol, an isocyanate and a flame retardant-effective amount of the flame-retardant blend of  claim 16 . 
     
     
         21 . An article comprising the polyurethane foam of  claim 20 . 
     
     
         22 . An application comprising the article of  claim 21 , wherein the application is selected from the group consisting of furniture applications, automotive applications, boating applications, bus seating applications, train seating applications, RV seating applications, office furniture seating applications, aviation applications, tractor applications, bicycle applications, engine mount applications, compressor applications, bedding applications, insulation applications, sporting goods applications, shoe applications, carpet cushioning applications, packaging applications, textile applications, buffer cushioning applications, HVAC applications, tent applications, life raft applications, luggage applications, and hand bag applications, which comprises the flexible polyurethane of claim  1 . 
     
     
         23 . The furniture application of  claim 22 , which is upholstered furniture. 
     
     
         24 . The automotive application of  claim 22 , which is selected from the group consisting of automotive seat cushions, head linings and head rests, back cushions for automobiles and trucks, bus seating, vehicle seat bottom and back bolsters, armrests, support rings for run flat tires, and other automobile interior components. 
     
     
         25 . The bedding application of  claim 22  which is selected from the group consisting of mattresses and mattress top applications. 
     
     
         26 . The insulation application of  claim 22 , which is a sound insulation material.