Flam retardant blends for flexible polyurethane foam

Abstract

A composition is disclosed that comprises an otherwise flammable flexible polyurethane foam and a multi-component flame retardant additive. The flame retardant additive includes an alkyl substituted aryl phosphate and an alkyl phosphate ester wherein the alkyl groups range from C4 to C20 and contain one to six oxygen atoms in the alkyl chain. Optionally, the flame retardant additive includes a halogenated flame retardant containing more than 30 wt. percent of bromine, chlorine, or a mixture thereof.

Description

Claims

1. A flame retardant composition comprising: an alkyl substituted aryl phosphate represented by the general structure

2. The composition of claim 1 wherein said alkyl substituted aryl phosphate is a member selected from the group consisting of t-butylated triphenyl phosphate, i-butylated triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, and mixtures thereof.

3. The composition of claim 1 wherein said alkyl substituted aryl phosphate is butylated triphenyl phosphate including triaryl phosphates with individual rings containing 0, 1, or 2 butyl groups, when said triaryl phosphates are alkylated, said alkylated triaryl phosphates contain between 5.5 to 9 wt. percent phosphorus.

4. The composition of claim 1 wherein said alkyl substituted aryl phosphate is isopropylated triphenyl phosphate including triaryl phosphates with individual rings containing 0, 1, or 2 isopropyl groups, when said triaryl phosphates are alkylated, said alkylated triaryl phosphates contain between 5.5 to 9 wt. percent phosphorus.

5. The composition of claim 1 wherein said alkyl phosphate ester is a heterocycle containing oxygen.

6. The composition of claim 1 wherein the alkyl groups of said alkyl phosphate ester range from C4 to C20 and contain one to six oxygen atoms in the alkyl chain represented by the following formulas:

7. The composition of claim 1 wherein said alkyl phosphate ester is tris(butoxyethyl)phosphate.

8. A flame retardant composition for use with a flexible polyurethane foam comprising: a component A, said component A being an alkyl substituted aryl phosphate represented by the general structure

9. The composition of claim 8 wherein said component A is a member selected from the group consisting of t-butylated triphenyl phosphate, i-butylated triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, and mixtures thereof.

10. The composition of claim 8 wherein said component A is butylated triphenyl phosphate including triaryl phosphates with individual rings containing 0, 1, or 2 butyl groups, when said triaryl phosphates are alkylated, said alkylated triaryl phosphates contain between 5.5 to 9 wt. percent phosphorus.

11. The composition of claim 8 wherein said component A is isopropylated triphenyl phosphate including triaryl phosphates with individual rings containing 0, 1, or 2 isopropyl groups, when said triaryl phosphates are alkylated, said alkylated triaryl phosphates contain between 5.5 to 9 wt. percent phosphorus.

12. The composition of claim 8 wherein said component B additives are a member selected from the group consisting of brominated alkylated aromatics, brominated aromatic ethers, brominated benzoates, and phthalates represented by the general structures

13. The composition of claim 8 wherein said alkyl phosphate ester is a heterocycle containing oxygen.

14. The composition of claim 8 wherein the alkyl groups of said alkyl phosphate ester range from C4 to C20 and contain one to six oxygen atoms in the alkyl chain represented by the following formulas:

15. The composition of claim 8 wherein said alkyl phosphate ester is tris(butoxyethyl)phosphate.

16. The composition of claim 8 wherein said component A and said component B are present in a ratio of about 99:1 to about 5:95 wt. percent of component A to component B.

17. The composition of claim 16 wherein said component A and said component B are present in a ratio from about 70:30 to about 30:70 wt. percent.

18. The composition of claim 17 wherein said component A and said component B are present in a ratio from about 50:50 wt. percent.

19. The composition of claim 8 wherein said component A and said component B are present in a ratio with component C from about 25:75 to about 1:99 wt. percent.

20. The composition of claim 19 wherein component A and component B are present in a ratio with component C from about 15:85 to about 1:99 wt. percent.

21. A flame retardant composition for use with a flexible polyurethane foam comprising: a component A, said component A is an alkyl substituted aryl phosphate selected from the group consisting of butylated triphenyl phosphates and isopropylated triphenyl phosphates;a component B, said component B includes brominated flame retardants containing greater than 30 percent selected from the group consisting of alkylated aromatics, aromatic ethers, benzoates, and phthalates; anda component C, said component C includes a flame retardant additive comprising an alkyl phosphate ester wherein the alkyl groups range from C4 to C20 and contain one to six oxygen atoms in the alkyl chain represented by the following formulas: