INHERENT FLAME RETARDANT RIGID POLYURETHANE FOAM

Abstract

The present invention provides a kind of inherent flame retardant rigid polyurethane foam. The production formula comprises 100 to 105 pbw of polyether polyol and reactive phosphorus-containing flame retardant, 2.5 to 3.5 pbw of amine catalyst, 0.8 to 2.5 pbw of tertiary amine catalyst, 0.8 to 2.5 pbw of foam stabilizer, 0.5 to 1.5 pbw of blowing agent, 135 to 150 pbw of isocyanates, and 0.05 to 0.1 pbw of organo-metallic catalyst, wherein the reactive phosphorus-containing flame retardant is 9,10-dihydro-9-oxa-10-phosphaphenanthrene-4-hydroxybenzyl alcohol. The active monomers containing flame retarding elements are introduced into main chain and side chain of PU for modification, which permanently improves the flame retardancy of PU without obvious effect on other performance of PU matrix.

Claims

1. An inherent flame retardant rigid polyurethane foam synthesized from raw materials comprising: (A) 100 to 105 pbw of polyether polyol and a reactive phosphorus-containing flame retardant, (B) 2.5 to 3.5 pbw of an amine catalyst, (C) 0.8 to 2.5 pbw of a tertiary amine catalyst, (D) 0.8 to 2.5 pbw of a foam stabilizer, (E) 0.5 to 1.5 pbw of a blowing agent, (F) 135 to 150 pbw of isocyanates, and (G) 0.05 to 0.1 pbw of an organo-metallic catalyst; wherein the reactive phosphorus-containing flame retardant is 9,10-dihydro-9-oxa-10-phosphaphenanthrene-4-hydroxybenzyl alcohol.

2. The inherent flame retardant rigid polyurethane foam according to claim 1, wherein the weight ration of the polyether polyol and the reactive phosphorus-containing flame retardant is 10 to 90:10 to 90.

3. The inherent flame retardant rigid polyurethane foam according to claim 1, wherein the polyether polyol is applicable to rigid polyurethane foam.

4. The inherent flame retardant rigid polyurethane foam according to claim 1, wherein the amine catalyst is triethylenediamine.

5. The inherent flame retardant rigid polyurethane foam according to claim 1, wherein the tertiary amine catalyst is 2,4,6-tris(dimethylaminomethyl)phenol.

6. The inherent flame retardant rigid polyurethane foam according to claim 1, wherein the foam stabilizer is silicon-carbide-bond foam stabilizer.

7. The inherent flame retardant rigid polyurethane foam according to claim 1, wherein the blowing agent is water.

8. The inherent flame retardant rigid polyurethane foam according to claim 1, wherein the viscosity of the isocyanates is 150 to 250 mPa.Math.s, and the isocyanates has a NCO content of 30.0 wt % to 32.0 wt %.

9. The inherent flame retardant rigid polyurethane foam according to claim 1, wherein the organo-metallic catalyst is dibutyltin dilaurate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 illustrates a .sup.1H NMR spectroscopy of reactive phosphorus-containing flame retardant (DOPO-HB) of the present invention.

[0028] FIG. 2 illustrates a .sup.31P NMR spectroscopy of reactive phosphorus-containing flame retardant (DOPO-HB) of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0029] The present invention will be further described with the drawings and the embodiments.

[0030] The .sup.1H and .sup.31P NMR spectroscopy of DOPO-HB of the following embodiments refers to FIG. 1 and FIG. 2 respectively. .sup.1H NMR (ppm, DMSO-d.sub.6), =4.975.18 (1H, H.sup.b), 6.116.27 (1H, H.sup.a), 6.648.22 (12H, ArH), 9.399.43 (1H, if). .sup.31P NMR (ppm, DMSO-d.sub.6), =31.0.

[0031] The polyether polyol applicable to rigid polyurethane foam of the following embodiments is sucrose polyether polyol with a droxyl value of 441 mgKOH/g, and the isocyanates is made of Wanhua Chemical Group Co. Ltd of which the model is PM-100 with viscosity of 150250 mPa.Math.s and NCO content of 30.0 wt %32.0 wt %.

Embodiment 1

[0032] Embodiment 1 is a contrast embodiment without adding reactive phosphorus-containing flame retardant.

[0033] 105 g sucrose polyether polyol, 3.5 g triethylenediamine, 2.5 g silicon-carbide-bond foam stabilizer, 2.5 g 2,4,6-tris(dimethylaminomethyl)phenol and 1.5 g water are mixed together under high-speed stirring to obtain component A. Component B consisting of 150 g PM-100 and 0.1 g dibutyltin dilaurate is added into component A under high-speed stirring for uniform mixing. The mixture is poured into self-made mould for foaming as soon as it turns white. And after the processes of curing for 48 hours and demoulding, the rigid polyurethane foam with an oxygen index of 17.0 according to GB/T 2406.1-2008 standard is obtained.

Embodiment 2

[0034] 90 g sucrose polyether polyol, 10 g DOPO-HB, 2.5 g triethylenediamine, 0.8 g silicon-carbide-bond foam stabilizer, 0.8 g 2,4,6-tris(dimethylaminomethyl)phenol and 0.5 g water are mixed together under high-speed stirring to obtain component A. Component B consisting of 135 g PM-100 and 0.05 g dibutyltin dilaurate is added into component A at room temperature under high-speed stirring of 2500 r/min for uniform mixing. The mixture is poured into self-made mould for foaming as soon as it turns white. And after the processes of curing for 48 hours and demoulding, the rigid polyurethane foam with an oxygen index of 18.0 according to GB/T 2406.1-2008 standard is obtained.

Embodiment 3

[0035] 80 g sucrose polyether polyol, 20 g DOPO-HB, 3.0 g triethylenediamine, 1.7 g silicon-carbide-bond foam stabilizer, 1.7 g 2,4,6-tris(dimethylaminomethyl)phenol and 1.0 g water are mixed together under high-speed stirring to obtain component A. Component B consisting of 142 g PM-100 and 0.08 g dibutyltin dilaurate is added into component A at room temperature under high-speed stirring of 2500 r/min for uniform mixing. The mixture is poured into self-made mould for foaming as soon as it turns white. And after the processes of curing for 48 hours and demoulding, rigid polyurethane foam with an oxygen index of 19.5 according to GB/T 2406.1-2008 standard is obtained.

Embodiment 4 to 10

[0036] The method for preparing inherent flame retardant rigid polyurethane foam of embodiment 4 to 10 is similar to embodiment 1. A series of inherent flame retardant rigid polyurethane foam with different phosphorus content are prepared by changing the dosage proportion of polyether polyol and DOPO-HB, wherein the dosage proportions of polyether polyol and DOPO-HB of embodiment 4 to 10 is presented on the following sheet:

TABLE-US-00001 Sucrose Limiting polyether oxygen polyol DOPO-HB index Embodiment 4 70 g 30 g 21.5 Embodiment 5 60 g 40 g 23.5 Embodiment 6 50 g 50 g 25.5 Embodiment 7 40 g 30 g 27.5 Embodiment 8 30 g 70 g 29.5 Embodiment 9 20 g 80 g 31.5 Embodiment 10 10 g 90 g 33.5

[0037] Although the present invention has been described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the present invention as defined by the appended claims.

INDUSTRIAL APPLICABILITY

[0038] Both DOPO-HB and polyether polyol are hydroxyl-terminated alcohols, so that DOPO-HB is able to realize the functionality of polyether polyol. The flame retarding elements are introduced into the molecular chain between oxhydryl active sites, which makes the resultant compound having both flame retardance of inorganics and plasticity of organics.