Flame retardant

Abstract

Flame retardant protection has been demonstrated on cotton and on polyester-cotton materials by the product obtained from the reaction of cyanamide and PCl.sub.5 followed by reaction with anhydrous ammonia in excess of that required to react with the chlorine on the cyanamide and PCl.sub.5 intermediate product. Conveniently the material can be treated with an aqueous solution containing a sufficient amount of the new flame retardant compound and the material dried to make the material self extinguishing. Then the treated and dried material is cured at a sufficient temperature to bond the flame retardant to the material. Alternatively and usually preferably, the drying and curing can be accomplished as a single operation.

Description

BACKGROUND OF THE INVENTION

1. Field of the invention

Fireproofing.

2. Description of the prior art

One of the older patents in this art is U.S. Pat. No. 2,782,133 teaching aminocyclophosphazene as a fireproofing agent for cellulosic fibers such as cotton. A recent patent is U.S. Pat. No. 3,711,542 teaching certain new N-methylol phosphazene compounds as flame retardants on cotton, and this patent under Background of the Invention contains a summary of certain phosphazene prior art on flameproofing.

SUMMARY OF THE INVENTION

Flame retardant protection has been demonstrated on cotton and on polyester-cotton materials by the product obtained from the reaction of cyanamide and PCl.sub.5 followed by reaction with anhydrous ammonia in excess of that required to react with the chlorine on the cyanamide and PCl.sub.5 intermediate product. Conveniently the material can be treated with an aqueous solution containing a sufficient amount of the new flame retardant compound and the material dried to make the material self extinguishing. Then the treated and dried material is cured at a sufficient temperature to bond the flame retardant to the material. Alternatively and usually preferably, the drying and curing can be accomplished as a single operation.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preparation of product

The structure for the product of the reaction of cyanamide with phosphorus pentachloride, then ammonia is believed to be

[(NH.sub.2).sub.3 P.dbd.N--C.tbd.N].sub.n based on the following reaction H.sub.2 NCN + PCl.sub.5 .fwdarw. N.tbd.C--N.dbd.PCl.sub.3 .sup. NH.sbsp.2 N.tbd.C--N.dbd.P(NH.sub.2).sub.3 + 3NH.sub.4 Cl It was hoped that the peraminated compound would be an active monomer analogous to acrylonitrile. ##STR1## However the infrared spectrum of the crude product does not show nitrile absorption but instead indicates something akin to carbodiimide absorption. This indicates at least a dimeric structure ##STR2## or possibly a linear oligomer. The trichloro-precursor and amminated products are both new compositions.

One hundred and twenty-four and a half grams (0.60 m) of PCl.sub.5 were added rapidly to a slurry of 25.0 g (0.60 m) of cyanamide (EKC, practical) in 500 ml of chloroform with stirring. There was immediate reaction with the evolution of hydrogen chloride gas. After the initial reaction had subsided, the mixture was heated to reflux and kept there for 18 hours. The resultant, milky slurry was placed under vacuum to remove dissolved hydrogen chloride. An additional 500 ml of chloroform was added followed by the cautious addition of 500 ml of liquid ammonia. The ammonia was contained by a Dry Ice condenser. The excess ammonia was allowed to evaporate overnight.

Evaporation of a sample of the supernatant liquid left no residue. The slurry was mixed with 131.4 g (1.8 m) of diethylamine and refluxed for 7 hours to remove the ammonium chloride as ammonia and chloroform soluble diethylamine.sup.. hydrochloride. After standing over the weekend, the white solid was filtered from the red solution and washed with 500 ml of chloroform. The material appeared to be hygroscopic, so it was subjected to vacuum to remove the remaining chloroform, weight 85.0 g.

The infrared spectrum of this product showed --NH absorption and had a moderately strong band at 2155 cm.sup.-.sup.1 which suggests cyclization to give a carbodiimide structure. There was also strong absorption at 6.4 and 8.5.mu..

The product, a free-flowing, nonhygroscopic, white powder, was moderately soluble in water yielding a weakly alkaline solution. The material was insoluble in hot cyclohexene, xylene, toluene, THF, DMAC, DMF, pyridine, ethyl acetate, methylene chloride, trichloroethylene, ethanol, nitrobenzene and HMPA. The material shrinks at 93.degree. C. in a melting point tube, softens as 120.degree. C. forming a soft foam, expanding up the tube. The evolution of gas is noted. The crude product had 19.8% phosphorus and contained chlorine. Recrystallization from water raised the phosphorus content to 22% (theoretical 26%) and the chlorine was almost entirely removed.

______________________________________ % Calc'd for CH.sub.6 N.sub.5 P Recrystallized Product______________________________________C 10.10 12.10H 5.04 4.95N 58.80 48.80P 26.10 21.89 Cl 0.00 0.30______________________________________

Treatment of fabrics

A solution containing the desired weight percent of the flame retardant reagent in sufficient water to just saturate the cloth was poured on a weighed piece of cloth lying flat in a plastic bag. The solution was worked over the surface of the cloth, until it was uniformly wet. After standing for about fifteen minutes, the cloth was placed in an oven at the desired temperature and dried and cured. After drying and curing, the cloth was allowed to equilibrate before being weighed.

Cure conditions

Cure was effected at 140.degree. C. using the one operation to also dry the wet sample. Formaldehyde and magnesium chloride catalyst were included as an auxiliary treatment in some instances in an attempt to make the material more durable to washing.

Flammability tests

Samples of cloth 10 in. .times.31/2 in. were clamped in a metal stand and tested according to AATC Test Method 34-1969 using a propane torch in place of the special gas mixture. This flammability test is described in J. Amer. Assoc. Text. Chem. and Colorists 2, (3), 49/19 (1970).

Tabulation of data

The test data are tabulated in the following table. The table is divided into three main sections: Fabric Treatment, Flammability Tests and Miscellaneous Conditions. The following column headings are used. The added notes are for explanation of their meanings where not self explanatory.

______________________________________Column Heading Explanation______________________________________1 Cloth Type2 Reagent * = Cyanamide/PCl.sub.5 /NH.sub.3 product3 Auxiliary material used to bind to cloth such as formaldehyde and catalyst4 % Final Add-On weight percent of product added to the cloth after all processes including laundering if indicated in column 95 Distance this represents the length Burned, in. of the sample that was burned out, charred or scorched from the ignited edge6 Time,Sec. time from ignition to removal of flame even though self extinguishment had already occurred7 SE answers question -- Did the (Self Extinguish) fire self extinguish before burning the entire sample length? Y = yes; N = no8 Cure Temperature temperature at which the wet cloth was dried and cured in a single operation9 Post Treatment indicates treatment of sample after curing but before flammability test. L = laundered, detergent wash and dried; NL = not laundered______________________________________ __________________________________________________________________________ MiscellaneousFabric Treatment Flammability Test Conditions__________________________________________________________________________ % Distance Cure Final Burned, Time, Temp. PostCloth Type Reagent Auxiliary Add-On in. Sec SE .degree. C. Treatment__________________________________________________________________________65/35polyester/cotton * -- 20.8 5 30 Y 140 NL65/35polyester/cotton * -- 12.6 10 N 140 Lcotton * -- 16.8 31/2 30 Y 140 NLcotton * -- 5.78 3 30 Y 140 L65/35polyester/cotton * CH.sub.2 O, MgCl.sub.2 2.8 10 10 N 140 Lcotton * CH.sub.2 O, MgCl.sub.2 3.4 10 10 N 140 L65/35polyester/cotton * -- 5.67 10 15 N 140 L50/50polyester/cotton * -- 10.8 10 20 N 140 L__________________________________________________________________________ *Cyanamide/PCl.sub.5 /NH.sub.3 SE = Self Extinguishing Y = Yes NL = Not Laundered N = No L = Laundered Note: Untreated cotton and cotton/polyester cloths are not self extinguishing in the flammability test.

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 of the disclosure. For example, an auxiliary treatment of the cloth with formaldehyde plus a quaternary base or an aminoplast such as trimethylolamine with or without a quaternary base may be useful in making the material more durable to washing with retention of flame retardant properties. Also, other types of cellulose as well as cotton are made flame retardant by the process of the invention, for example, paper and cellulose sponge. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.

Claims

1. A process for making flame-retardant material of cellulose such as cotton, paper and sponge or polyester-cotton having about 30 to 70% by weight cotton comprising treating said material with an aqueous solution of the product made by reacting cyanamide with PCl.sub.5 followed by reaction with anhydrous ammonia in excess of that required to react with the chlorine on the cyanamide and PCl.sub.5 intermediate product in sufficient amount and curing the treated material at a sufficient temperature to make the treated and cured material self-extinguishing when subjected to a flame-sufficient to ignite and consume the untreated material.

2. A process of claim 1 wherein said material comprises about 65% by weight polyester and 35% by weight cotton.

3. A process of claim 1 wherein said material comprises about 50% by weight polyester and 50% by weight cotton.

4. A process of claim 1 wherein said material comprises cotton.

5. A flame-retardant polyester-cotton material made by the process of claim 1.

6. A flame-retardant cellulose material made by the process of claim 1.

7. A flame-retardant cotton material made by the process of claim 1.