Brominated flame retardant and its application in polyurethane foams

Patent metadata

Field	Value
Publication number	US-11970570-B2
Application number	US-201816625107-A
Country	US
Kind code	B2
Filing date	Jun 26, 2018
Priority date	Sep 28, 2017
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

This invention provides polyurethane foams containing a brominated flame retardant. Also provided are formulations and methods for preparing polyurethane foams containing a brominated flame retardant.

First claim

That which is claimed is:

1. A formulation comprising 2,3-dibromoallyl alcohol, at least one polyol, at least one catalyst, and at least one surfactant.

2. A formulation as in claim 1 wherein the polyol is a polyether polyol and/or a polyester polyol.

3. A formulation as in claim 1 wherein the amount of 2,3-dibromoallyl alcohol is about 1 wt % to about 25 wt %, the amount of polyol is about 40 wt % to about 80 wt %, the amount of surfactant is about 0.1 wt % to about 5 wt %, and/or the amount of catalyst is about 0.25 wt % to about 10 wt %, based on the total weight of the formulation.

4. A formulation as in claim 1 wherein the polyol has a functionality of about 3 to about 7.

5. A formulation as in claim 3 further comprising a blowing agent in the amount of about 0.5 wt % to about 20 wt %.

6. A polyurethane formed from components comprising at least one polyisocyanate and a formulation as in any of claims 1 - 5 .

7. A process for forming a polyurethane, which process comprises
contacting A) at least one isocyanate and/or polyisocyanate and B) a formulation formed from 2,3-dibromoallyl alcohol, at least one polyol, at least one catalyst, and at least one surfactant, to form a mixture; and
allowing the mixture to cure to form a polyurethane.

8. A process as in claim 7 wherein B) further comprises at least one blowing agent.

9. A process as in claim 8 wherein A) and B) are in amounts such that the Isocyanate Index is about 80 to about 200, and wherein a flexible polyurethane foam is formed.

10. A process as in claim 7 wherein A) and B) are in amounts such that the Isocyanate Index is about 85 to about 1000, and wherein a rigid polyurethane foam is formed.

11. A polyurethane formed as in any of claims 7 - 10 .

12. A polyurethane formed from ingredients comprising 2,3-dibromoallyl alcohol, at least one polyol, at least one catalyst, at least one surfactant, and at least one polyisocyanate.

13. A polyurethane as in claim 12 wherein the polyol is an aromatic polyester polyol and either a polyether polyol or at least one sucrose/glycerine polyol; wherein the catalyst is potassium octoate and/or dibutylbis(dodecylthio) stannane; wherein the surfactant is a silicone glycol; and/or wherein the polyisocyanate is diphenylmethane diisocyanate.

14. A polyurethane as in claim 13 wherein the ingredients further comprise a blowing agent selected from water, trans-1-chloro-3,3,3-trifluoropropene, 1,2-bis(trifluoromethyl)ethene or a mixture of any two or more of these.

15. A polyurethane as in claim 13 wherein the amount of 2,3-dibromoallyl alcohol is about 1.5 wt % to about 10 wt %; wherein the amount of polyol is about 25 wt % to about 35 wt %; wherein the amount of catalyst is about 0.5 wt % to about 4 wt %; and/or wherein the amount of surfactant is about 0.25 wt % to about 2.5 wt %, based on the total weight of the polyurethane.

16. A polyurethane as in claim 13 wherein the aromatic polyester polyol has a functionality of about 1.75 to about 2.75 and a hydroxyl number in the range of about 200 to about 350.

Assignees

• Albemarle Corp

Inventors

• Wu Tse-Chong
• Ibay Augusto Caesar
• O'Day Joseph Morgan

Classifications

• C08J9/148

  perfluorinated · CPC title

• C08J9/0023

  containing oxygen · CPC title

• C08J2205/06

  Flexible foams · CPC title

• C08J2203/144

  Perhalogenated saturated hydrocarbons, e.g. F3C-CF3 · CPC title

• C08G2110/0025

  rigid · CPC title