Treated textile material and process for producing the same

Patent metadata

Field	Value
Publication number	US-9926663-B2
Application number	US-201414460937-A
Country	US
Kind code	B2
Filing date	Aug 15, 2014
Priority date	Aug 19, 2013
Publication date	Mar 27, 2018
Grant date	Mar 27, 2018

Abstract

An article comprises a textile material and a flame retardant, phosphorus-containing polymer. The flame retardant, phosphorus, containing polymer can be present in the form of a plurality of microprotuberances. The flame retardant, phosphorus, containing polymer can contain a relatively low amount of residual hydroxyalkyl groups bonded to the phosphorus atoms in the polymer. A process for producing a treated textile material is also provided.

First claim

What is claimed is:

1. An article comprising:
(a) a textile material, the textile material comprising a plurality of textile fibers, each of the textile fibers having a surface; and
(b) a flame retardant, phosphorus-containing polymer disposed on at least a portion of the surface of at least a portion of the textile fibers, wherein at least a portion of the flame retardant, phosphorus-containing polymer is present in the form of a plurality of microprotuberances protruding from the surface of the textile fibers, wherein each microprotuberance has a diameter of about 10 microns or less.

2. The article of claim 1 , wherein microprotuberances have a primary size of about 100 nm to about 5 microns.

3. The article of claim 1 , wherein at least a portion of the microprotuberances are agglomerated to form agglomerates, and the agglomerates have a diameter of about 100 microns or less.

4. The article of claim 1 , wherein the flame retardant, phosphorous containing polymer is produced by a process comprising the steps of:
(a) providing a phosphonium compound comprising at least one phosphonium moiety, the phosphonium moiety conforming to the structure of Formula (I)

wherein R 1 is selected from the group consisting of hydrogen, C 1 -C 3 alkyl, C 1 -C 3 haloalkyl, C 2 -C 3 alkenyl, and C 2 -C 3 haloalkenyl;
(b) providing a nitrogen-containing cross-linking compound, the nitrogen-containing cross-linking compound comprising two or more nitrogen-hydrogen bonds;
(c) reacting the phosphonium compound and the nitrogen-containing cross-linking compound in a condensation reaction to produce a first intermediate polymer, the first intermediate polymer comprising a plurality of phosphorus atoms; and
(d) oxidizing the first intermediate polymer to convert at least a portion of the phosphorus atoms in the first intermediate polymer to a pentavalent, phosphine oxide state, thereby producing a flame-retardant, phosphorus-containing polymer.

5. The article of claim 4 , wherein the phosphonium compound is selected from the group consisting of:
(a) phosphonium compounds conforming to the structure of Formula (I)

wherein R 1 is selected from the group consisting of hydrogen, C 1 -C 3 alkyl, C 1 -C 3 haloalkyl, C 2 -C 3 alkenyl, and C 2 -C 3 haloalkenyl; X is an anion selected from the group consisting of chloride, sulfate, hydrogen sulfate, phosphate, acetate, carbonate, bicarbonate, borate, and hydroxide; b is the charge of the anion X; and a is equal to (−b);
(b) phosphonium precondensates made by reacting one or more phosphonium compounds conforming to the structure of Formula (I) with a cross-linking compound; and
(c) mixtures thereof.

6. The article of claim 5 , wherein the phosphonium compound is a phosphonium precondensate made by reacting a tetrahydroxymethyl phosphonium salt with urea.

7. The article of claim 4 , wherein the nitrogen-containing cross-linking compound is urea.

8. The article of claim 1 , wherein at least a portion of the textile fibers are cellulosic fibers.

9. The article of claim 8 , wherein about 50% or more of the textile fibers are cellulosic fibers.

10. The article of claim 1 , wherein at least a portion of the textile fibers are thermoplastic synthetic fibers.

11. The article of claim 1 , wherein the textile material is a knit textile material.

12. An article comprising:
(a) a textile material, the textile material comprising a plurality of textile fibers, each of the textile fibers having a surface; and
(b) a flame retardant, phosphorus-containing polymer disposed on at least a portion of the surface of at least a portion of the textile fibers, wherein the flame retardant, phosphorous containing polymer is produced by a process comprising the steps of:
(1) providing a phosphonium compound comprising at least one phosphonium moiety, the phosphonium moiety conforming to the structure of Formula (I)

wherein R 1 is selected from the group consisting of hydrogen, C 1 -C 3 alkyl, C 1 -C 3 haloalkyl, C 2 -C 3 alkenyl, and C 2 -C 3 haloalkenyl;
(2) providing a nitrogen-containing cross-linking compound, the nitrogen-containing cross-linking compound comprising two or more nitrogen-hydrogen bonds;
(3) reacting the phosphonium compound and the nitrogen-containing cross-linking compound in a condensation reaction to produce a first intermediate polymer, the first intermediate polymer comprising a plurality of phosphorus atoms; and
(4) oxidizing the first intermediate polymer to convert at least a portion of the phosphorus atoms in the first intermediate polymer to a pentavalent, phosphine oxide state, thereby producing a flame-retardant, phosphorus-containing polymer comprising a plurality of phosphorus atoms having functional groups attached thereto; and

wherein 10% or less of the functional groups attached to the phosphorus atoms in the flame retardant, phosphorus-containing polymer are hydroxyalkyl groups.

13. The article of claim 12 , wherein about 5% or less of the functional groups attached to the phosphorus atoms in the flame retardant, phosphorus-containing polymer are hydroxyalkyl groups.

14. The article of claim 12 , wherein the phosphonium compound is selected from the group consisting of:
(a) phosphonium compounds conforming to the structure of Formula (I)

wherein R 1 is selected from the group consisting of hydrogen, C 1 -C 3 alkyl, C 1 -C 3 haloalkyl, C 2 -C 3 alkenyl, and C 2 -C 3 haloalkenyl; X is an anion selected from the group consisting of chloride, sulfate, hydrogen sulfate, phosphate, acetate, carbonate, bicarbonate, borate, and hydroxide; b is the charge of the anion X; and a is equal to (−b);
(b) phosphonium precondensates made by reacting one or more phosphonium compounds conforming to the structure of Formula (I) with a cross-linking compound; and
(c) mixtures thereof.

15. The article of claim 14 , wherein the phosphonium compound is a phosphonium precondensate made by reacting a tetrahydroxymethyl phosphonium salt with urea.

16. The article of claim 12 , wherein the nitrogen-containing cross-linking compound is urea.

17. The article of claim 12 , wherein at least a portion of the textile fibers are cellulosic fibers.

18. The article of claim 17 , wherein about 50% or more of the textile fibers are cellulosic fibers.

19. The article of claim 12 , wherein at least a portion of the textile fibers are thermoplastic synthetic fibers.

20. The article of claim 12 , wherein the textile material is a knit textile material.

21. A process for producing a treated textile material, the process comprising the steps of:
(a) providing a textile material, the textile material comprising a plurality of textile fibers, each of the textile fibers having a surface;
(b) providing a treatment composition, the treatment composition comprising:
(i) a phosphonium compound comprising at least one phosphonium moiety, the phosphonium moiety conforming to the structure of Formula (I)

wherein R 1 is selec

Assignees

• Milliken & Co

Inventors

• Valenta Petr
• Mondal Rajib
• Rogers James A
• Moore Michael Todd
• Spruell Jason M
• Keller Keith A
• Gerhardt Warren W
• Emery Nathan B

Classifications

• Y10T442/268

  Phosphorus and nitrogen containing compound · CPC title

• D06M15/687

  containing atoms other than phosphorus, silicon, sulfur, nitrogen, oxygen or carbon in the main chain · CPC title

• Y10T442/2672

  Phosphorus containing · CPC title

• D06M13/285

  Phosphines; Phosphine oxides; Phosphine sulfides; Phosphinic or phosphinous acids or derivatives thereof · CPC title

• D06M2200/30

  Flame or heat resistance, fire retardancy properties · CPC title