Fire-resistant material and process

Abstract

Fire-resistant organic materials including foams, are made by heating at temperatures sufficient to cause polymerization and elimination of nitrogen and sulfur precursor aromatic polymers having sulfonamide linkages and aromatic compounds capable of forming said polymers, e.g. sulfamyl-type aminoaromatic compounds such as sulfanilamide, sulfaguanadine and the like. Preferred compounds are those providing para linkages in the sulfonamide polymer chain, those which are substantially free of oxidizing substituents, for example nitro groups, and those which are not fused-ring aromatic. Preferred foams are the high expansion foams, i.e. those having expansion ratios of at least about 3:1, more preferably at least about 8:1. The precursors of these fire-resistant organic materials can be incorporated into polymers such as polyvinylidene chloride, polyisocyanates, aminoplasts, and the like either physically by mixing or by chemical reaction to give improved fire-resistance. Also inorganic fillers such as titanium dioxide, silica, alumina and the like can be added to the polymers and/or the precursor to give compositions having improved fire resistance.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The field of the invention is fire-proofed compositions including foams and process for making.

2. Description of the Prior Art

In the August-September 1968, Sampe Journal, beginning on page 21, is an article on, "The Use of a Salt of p-Nitroaniline as a Component for Intumescence Coating", by John A. Parker, George M. Fohlen, Paul M. Sawko and Roy N. Griffin, Jr.

U.S. Pat. No. 3,535,130 issued Oct. 20, 1970, on "Intumescence Paints", relates to the same subject matter as the Sampe Journal article.

SUMMARY OF THE INVENTION

Fire-resistant organic materials including foams, are made by heating at temperature sufficient to cause polymerization and elimination of nitrogen and sulfur, precursor aromatic polymers having sulfonamide linkages and aromatic compounds capable of forming said polymers, e.g. sulfamyl-type aminoaromatic compounds such as sulfanilamide, sulfaguanidine and the like. Preferred compounds are those providing para linkage in the sulfonamide polymers chain, those which are substantially free of oxidizing substituents, for example nitro groups, and those which are not fused-ring aromatic. Preferred foams are the high expansion foams, i.e. those having expansion ratios of at least about 3:1, more preferably at least about 8:1. The precursors of these fire-resistant organic materials can be incorporated into polymers such as polyvinylidene chloride, polyisocyanates, aminoplasts, and the like either physically by mixing or by chemical reaction to give improved fire-resistance. Also inorganic fillers such as titanium dioxide, silica, alumina and the like can be added to the polymers and/or the precursor to give composition having improved fire resistance.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Compounds useful in the process of the invention to make fire-resistant materials of the invention are shown in Table I with an asterisk (*) opposite them, and Table I in addition has data on other compounds not of the invention for comparison. These compounds of the invention are merely illustrative of a variety of compounds actually tested in making fire-resistant materials. Polymeric sulfonamides useful in the process of the invention are described in U.S. Pat. No. 2,321,891, for example, para-benzene disulphonyl chloride, page 2, column 1, line 57, can be reacted with paraphenylenediamine, line 72, to give polymeric sulfonamides useful in the process of the invention.

Heating compositions of the invention may be accomplished in air or in inert atmospheres, by whatever method desired, including open flames. Some of the compositions will flame briefly during foam generation, but the flames are quickly extinguished as the reaction progresses. Many compositions melt before the onset of foaming. The liquid range may be shortened, and the temperature at which foaming begins may be reduced by small additions of compounds which react at lower temperatures, such as benzenesulfonhydrazides. The onset of foaming is accompanied by darkening, gas evolution, and formation of a black thermoplastic low expansion foam, which may be cooled to a brittle solid for later activation if desired. On further heating, the thermoplastic foam expands further and sets to a low density fire resistant foam containing most of the carbon of the initial composition in a form which decomposes very slowly under prolonged heating in inert atmospheres at temperatures up to 960.degree. C., and which oxidizes very slowly in diffusion flames.

TABLE I__________________________________________________________________________ Melt Plastic Burning Expansion Yield, Glowing After Stability Compound or Mixture Range, .degree.C. Range, .degree.C. Observed Ratio Wt. % in Flame Glow in__________________________________________________________________________ Flame*Sulfaguanidine 193-320 320-60 none 20:1 45 none none excellent*N-Acetylsulfanilyl chloride none v high 40 none none excellent*Sulfanilamide 165-320 320-60 some 30:1 42 none none excellent*N-Sulfanilylacetamide much high 34 none none excellent*Sulfaguanidine-Sulfanilamide,1:1 mix 165-320 320-60 slight 25:1 47 none none excellent*N-Acetylsulfanilylchloride-sulfanilamide, 1:1 mix 165-320 320-60 slight 20:1 49 none none excellent*Sulfanilamide-Sulfanilic acid,1:1 mix 165-265 285-350 slight 30:1 43 v slight none v good*Sulfanilamide-Sulfanilic acid,1:2 mix none slight 20:1 35 slight slight goodSulfanilic acid none none none none high severe ashes slight4,4'-Sulfonyldianiline 175-300 300-60 much 2:1 low none none v good4,4'-oxybis(benzenedisulfonyl-hydrazide) 195-200 nil much 10:1 low none none v good*2-Amino-4-chlorobenzenesulfona-mide some 10:1 25 some slight good4-Nitroaniline bisulfate 185-95 215-20 slight 10:1 30 some slight fair2-Amino-1-Napthalenesulfonicacid none none some 2:1 some slight fairTaurine (2-aminoethanesulfonicacid) nil slight none 10:1 fair some slight poorTelomers Prepared by Interfacial Condensation*4,4'-biphenyldisulfonylchloride + 4,4'-Sulfonyl- 150-170 290 slight low good none none excellentdianiline*4,4'-biphenyldisulfonylchloride + p-phenylene none none slight none good none none excellentdiamine*m-Benzenedisulfonyl chloride+ m-phenylenediamine 175-80 slight none good some some poor*m-Benzenedisulfonyl chloride+ 4,4'-sulfonyldianiline yes 3:1 good some some poorTwo Component Systems Reacted by Melting Together in a Spatula BeforeBurning Foam Glowing After Stability Aniline or Phenol Acid or Acid Chloride Yield in Flame Glow in__________________________________________________________________________ Flame*4,4'-Sulfonyldianiline 4,4'-Biphenyldisulfonyl chloride 10:1 none none excellent*3,5-Dibromo-4-hydroxyaniline 4,4'-Biphenyldisulfonyl chloride 20:1 none none excellent4,4'-Dihydroxydiphenylsulfone 4,4'-Biphenyldisulfonyl chloride 4:1 slight none v good4,4'-Dihydroxydiphenylsulfone 3,3'-Sulfonylbis(benzenesulfonyl chloride) 2:1 slight none v good4,4'-Dihydroxydiphenylsulfone m-Benzenedisulfonylchloride 1:1 slight none v good*Benzidine Sulfamide 20:1 none none excellent*Benzidine Sulfamic Acid 5:1 none none excellent*Benzidine m-Benzenedisulfonyl Chloride 20:1 slight slight good*Benzidine 3,3'-Sulfonylbis(benzenesulfonyl chloride) 20:1 slight none v good*Sulfanilic Acid Sulfamide 20:1 none none excellent*Metanilic Acid Sulfamide 10:1 severe slight fair*3,3'-Sulfonyldianiline m-Benzenedisulfonyl Chloride 3:1 slight none good__________________________________________________________________________ *Compounds of the invention

Table II contains elemental analysis from experiments of heating sulfanilamide and sulfaguanidine with samples being taken and analyzed at several different stages of foam development.

TABLE II______________________________________ANALYSIS OF FOAMS AND PRECURSORS %C %H %N %S %O______________________________________Sulfanilamide 41.84 4.68 16.27 18.62 18.581st Stage Foam.sup.1 Upper Surface 39.51 3.71 11.03 18.61 27.14Lower Layer 56.35 3.22 13.73 14.25 12.452nd Stage Foam.sup.2 54.40 2.99 12.77 14.85 14.992nd Stage Foam 63.37 1.07 9.34 5.12 21.1(after heating).sup.3Sulfaguanidine 39.24 4.70 26.15 14.97 14.941st Stage Foam.sup.4 45.17 3.87 23.67 13.76 13.532nd Stage Foam.sup.5 49.67 3.03 21.26 12.21 13.83______________________________________ .sup.1 44% weight loss, heated in a beaker on the hotplate to 360.degree. C. .sup.2 After reheating to thermoset stage in flame. 58% weight loss .sup.3 Surface sample after roasting 5 min. in Meeker burner flame. .sup.4 Heating to 360.degree., 31% weight loss. .sup.5 Flame heating of 1st stage, 48% weight loss.

Table III contains foam yields, oxidation rates and thermal stability data obtained using thermogravimetric apparatus on four different compounds useful in process of the invention. This table is a summary of TGA runs on each of the compounds, separate runs for each compound being made in air and in helium atmosphere, at heating rates of 2.7-2.8.degree. C./minute.

TABLE III__________________________________________________________________________FOAM YIELDS AND OxIDATION RATES OF FIRE-RESISTANT FOAMS Final Oxidation of Foams Residue Generated and Heated in Air in He T, Residue When Max. Oxidation OxidationFoams Derived From @ 960.degree. C. Oxidation Began* Rate @ T, .degree.C. Completed__________________________________________________________________________Sulfaguanidine 29.7% 420.degree. C. @ 51% 0.81%/min., 550 660.degree. C.Sulfanilamide 33.9% 350.degree. C. @ 52.5% 0.77%/min., 500 640.degree. C.N-Acetylsulfa- 34% 340.degree. C. @ 56% 0.85%/min., 475 600.degree. C.nilyl ChlorideN-Sulfanilyl- 28.8% 335.degree. C. @ 49% 0.73%/min., 485 630.degree. C.acetamide__________________________________________________________________________ *Weight losses during melting, thermoplastic foaming and thermoset foamin were identical in air and in helium to the temperature and residue shown. The samples in helium then showed a slow, nearly linear weight loss to th 960.degree. C. temperature limit, while the samples in air were consumed by slow oxidation.

Table IV contains elemental analysis of 960.degree. C. residues in helium referred to in Table III. It appears from the analyses that sulfur and nitrogen containing fragments are responsible for the vapor phase which creates the foamed structure.

TABLE IV__________________________________________________________________________ANALYSIS OF 960.degree. C. RESIDUES OF FIRE-RESISTANT FOAMSCompound Used toGenerate the Foam %C %H %O.sup.1 %N %S Ratio__________________________________________________________________________Sulfanilamide 72.89 1.65 13.73 4.36 7.23 C.sub.6 H.sub.1.63 O.sub.0.85 N.sub.0.31 S.sub.0.22Sulfaguanidine 75.80 1.63 9.87 6.86 5.84 C.sub.6 H.sub.1.55 O.sub.0.58 N.sub.0.47 S.sub.0.17N-acetylsulfanilyl 76.33 1.64 12.53 6.44 3.06 C.sub.6 H.sub.1.55 O.sub.0.74 N.sub.0.44 S.sub.0.09ChlorideN-sulfanilylacetamide 80.22 1.50 10.47 5.05 2.76 C.sub.6 H.sub.1.34 O.sub.0.59 N.sub.0.32 S.sub.0.09__________________________________________________________________________ .sup.1 Oxygen determined by difference

Table V reports insulation tests on certain sulfanilamide foams. For these tests 4".times.4" panels of 3/8" plywood were drilled to accept an iron-constantan thermocouple introduced from the center of the unexposed face to position the junction just flush with the exposed face. Fire-resistant foams were then generated on the exposed surfaces by heating the precursor with an open flame. The foams were measured, and evaluated by direct impingement of the 1200.degree. C. flame from a propane torch placed 2" from the surface of the foam. The time for the thermocouple to reach 400.degree. F. was measured, as was the extent of erosion. The initial foam heights ranged from 11/16" l to 11/8", so the heating times were normalized on the basis of the initial foam height (seconds required to reach 400.degree. F. per inch of initial thickness).

TABLE V______________________________________INSULATIVE TESTS ON FOAMS Time to 400.degree. F. Erosion RateFoam Generated From (sec./inch) (mils./sec.)______________________________________Sulfanilamide 267 1.87Sulfaguanidine 309 2.31Sulfanilamide + 10% TiO.sub.2 400 0.22______________________________________

Although the invention has been described in terms of specified embodiments which are set forth in considerable detail, it should be understood that this is by way of illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly modifications are contemplated which can be made without departing from the spirit of the described invention.

Claims

1. A fire-resistant material made

(a) by heating at temperatures sufficient to cause polymerization monomeric aromatic compounds capable of forming aromatic polymers substantially free of oxidizing substitutents having sulfonamide linkages, and heating said aromatic polymers at temperatures greater than about 285.degree. C., which temperatures may be reduced by small additions of benzenesulfonhydrazides which react at lower temperatures, sufficient to cause elimination of nitrogen and sulfur; or

(b) by heating aromatic polymers substantially free of oxidizing substituents having sulfonamide linkages at temperatures greater than about 285.degree. C., which temperatures may be reduced by small additions of benzenesulfonhydrazides which react at lower temperatures sufficient to cause elimination of nitrogen and sulfur.

2. A material of claim 1 wherein said component has para linkages.

3. A material of claim 1 which is a foam having an expansion ratio of at least about 8:1.

4. A material of claim 1 wherein said component is non-fused ring aromatic.

5. A material of claim 1 wherein said component is a sulfanyl-type aminoaromatic compound.

6. A material of claim 1 wherein said component is a polymeric aromatic sulfonamide.

7. A material of claim 1 wherein said component is sulfanilamide.

8. A material of claim 1 wherein said component is sulfaguanidine.

9. A material of claim 1 wherein said component is about an equimolar mix of sulfanilamide and sulfanilic acid.

10. A material of claim 1 wherein said component is about an equimolar mix of 4,4'-biphenyldisulfonyl chloride and p-phenylene diamine.

11. A material of claim 1 wherein said component is about an equimolar mix of 4,4'-sulfonyldianiline and 4,4'-biphenyldisulfonyl chloride.

12. A process for making fire-resistant material comprising

(a) heating at temperatures sufficient to cause polymerization monomeric aromatic compounds capable of forming aromatic polymers substantially free of oxidizing substituents having sulfonamide linkages, and heating said aromatic polymers at temperatures greater than about 285.degree. C., which temperatures may be reduced by small additions of benzenesulfonhydrazides which react at lower temperatures, sufficient to cause elimination of nitrogen and sulfur; or

(b) heating aromatic polymers substantially free of oxidizing substituents having sulfonamide linkages at temperatures greater than about 285.degree. C., which temperatures may be reduced by small additions of benzenesulfonhydrazides which react at lower temperatures, sufficient to cause elimination of nitrogen and sulfur.

13. A process of claim 12 wherein said component has para linkages.

14. A process of claim 12 wherein said material is a foam having an expansion ratio of at least about 8:1.

15. A process of claim 12 wherein said component is non-fused-ring aromatic.

16. A process of claim 12 wherein said component is a sulfanyl-type aminoaromatic compound.

17. A process of claim 12 wherein said component is a polymeric aromatic sulfonamide.

18. A process of claim 12 wherein said component is sulfanilamide.

19. A process of claim 12 wherein said component is sulfaguanidine.

20. A process of claim 12 wherein said component is about an equimolar mixture of sulfanilamide and sulfanilic acid.

21. A process of claim 12 wherein said component is about an equimolar mixture of 4,4'-biphenyldisulfonyl chloride and p-phenylene diamine.

22. A process of claim 12 wherein said component is about an equimolar mixture of 4,4'-sulfonyldianiline and 4,4'-biphenyldisulfonyl chloride.