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US 20040O82712A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2004/0082712 A1 Blount (43) Pub. Date: Apr. 29, 2004 (54) FLAME RETARDANT UREA-BIOBASED which is a division of application No. 09/149,847, URETHANE COMPOSITIONS filed on Sep. 8, 1998, now Pat. No. 6,258,298. (76) Inventor: David H. Blount, San Diego, CA (US) Publication Classification Correspondence Address: (51) Int. Cl. ................................................... C08K 3/00 David H. Blount (52) U.S. Cl. .............................................................. 524/589 6728 Del Cerro Blvd. San Diego, CA 92120 (US) (57) ABSTRACT (21) Appl. No.: 10/687,899 Flame retardant urethane compositions of this invention are produced by reacting a urea and/or urea condensate, a bio (22) Filed: Oct. 17, 2003 based compound and a polyisocyanate. The urea condensa tion compositions are produced by heating urea or heating Related U.S. Application Data urea to produce isocyanic acid and/or cyanic acid which reacts with urea to form urea condensates. The bio based (60) Continuation-in-part of application No. 09/941,402, compound are environmentally friendly, replaceable com filed on Aug. 30, 2001, which is a continuation-in pound Such as Vegetable oils, molasses, Sugar, lignin and part of application No. 09/532,646, filed on Mar. 22, hemi-cellulose. The urea and/or urea condensation com 2000, now Pat. No. 6,348,526, which is a continua pounds may be mixed with or reacted with carbonization tion-in-part of application No. 08/801,776, filed on auxiliaries. For example, polyurethane foams can be ren Feb. 14, 1997, now Pat. No. 5,788,915, and which is dered leSS flammable with urea and/or urea condensation a continuation-in-part of application No. 08/723,779, compounds and utilized as insulating and Sound proofing filed on Sep. 30, 1996, now Pat. No. 5,854,309, and materials. US 2004/0082712 A1 Apr. 29, 2004 FLAME RETARDANT UREA-BO BASED 0009 under conditions sufficient to prepare the URETHANE COMPOSITIONS flame retarded urethane products. 0001. This patent application is a continuation-in-part of 0010. In another aspect, the invention comprises urea patent application Ser. No. 09/941,402 filed Jul. 30, 2001, and/or urea condensation Salt of phosphorus and/or boron which is a continuation-in-part of No. 09/532,646 filed Mar. containing compound and bio based compounds reacted 22, 2000; which is a continuation-in-part of No. 08/801,776 with polyisocyanates to produce flame retarded urethane and filed Feb. 14, 1997, now U.S. Pat. No. 5,788,915, which is a process to prepare the flame retarded urethane comprising a continuation-in-part of No. 08/723,779 filed Sep. 30, 1996 Serially contacting: now U.S. Pat. No. 5,854,309 and a division of No. 09/149, 847 filed Sep. 8, 1998 now U.S. Pat. No. 6,258,298. 0011 (A) urea and/or urea condensates FIELD 0012 (B) bio based compounds 0013 (E) phosphorus and/or boron containing com 0002 The invention concerns urea compounds and bio based compounds reacted with polyisocyanates to produce pound that will react with urea and/or a urea flame retarded urethane products. The invention also con 0014) condensation compound. cerns their preparation and use. The urea compounds with bio based compounds reacted with polyisocyanates are 0015 (C) polyisocyanate. useful to produce flame retardant urethane plastics. The urea 0016. The flame-retardant compounds of this invention compounds and may be reacted with phosphorus and/or are produced by mixing a urea compound with a bio based boron containing compounds to produce other flame retar compound then adding and mixing with a polyisocyanate at dant compounds. The urea compounds may also be reacted ambient pressure and at ambient or elevated temperature. with aldehydes to produce amino condensation-aldehyde Any Suitable temperature or preSSure may be utilized in this resins for use with bio based compounds a flame retardant process. Upon heating above the melting point urea form a urethanes. very reactive compound isocyanic acid which will react with itself or other organic or inorganic nitrogen containing BACKGROUND compounds especially urea compounds. In order to increase 0003. The urea and urea compounds produced by heating the flame retardant properties and carbonization properties of urea to produce urea condensation compounds, Such as a of the urea condensation compound a carbonization auxil mixture of urea, biuret, cyanuric acid and cyamelide, is iary, Such as, phosphorus Oxyacid compounds, organic phOS known in the arts, but the use of these compounds with bio phorus compounds that will react with a urea compound, based compounds as a flame retardant is novel. The urea boric acid, Sulfuric acid, etc., is added to the urea compounds condensation compounds and their phosphorus and/or boron mixed and/or reacted. Other carbonization auxiliaries may Salts are used as flame retardant compounds in plastics and be mixed with the urea compounds and bio based com natural products. Urea and melamine were utilized as a pounds then reacted with the polyisocyanate to produce the flame retardant compound by FracaloSSi, et al., in U.S. Pat. flame retardant polyurethane. Fillers and carbonization aux No. 4,385,131. Melamine was utilized as flame retardant iliaries may be added to the urea or bio based compounds. compounds in polyurethanes by Yukuta, et al., in U.S. Pat. No. 4,221,875 and by Grinbergs et al., in U.S. Pat. No. Component A 4,745,133. Amino phosphates was utilized by Blount in U.S. 0017 Urea and/or urea condensates such as biuret, cya Pat. No. 5,010,113. nuric acid cyamelide or a mixture of urea, biuret, cyanuric 0004 What is lacking and what is needed are useful acid, ammelide and cyamelide may be utilized as component inexpensive nitrogen containing organic compounds with a A and may be in the form of a powder, crystals, a Solid or plurality of nitrogen moieties to be mixed with bio based and an aqueous Solution. Any Suitable urea may be utilized. compounds then reacted with polyisocyanates to produce Component B novel flame retardant urethane products. What is addition ally lacking are compositions having Such urea compounds 0018. Any suitable bio based compounds may be use in and/or their Salts with bio based compounds employed this invention suitable bio based compounds include but not therein. limited to vegetable oils Such as Soybean oil, cottonSeed oil, Safflower oil, peanut oil, Sun flower oil, peanut oil, canola SUMMARY oil, corn oil, palm oil, rapeseed oil, and mixtures thereof, Soy protein, Soy milk, lignin, Sodium lignin Sulfonate, Sodium 0005. In one aspect, the invention comprises urea and/or cellulose, hemi-cellulose, Sugar, corn Syrup, molasses and urea condensation compounds and their Salts and bio based mixtures thereof. Any oil-containing Seeds nuts and kernels compounds reacted with polyisocyanates to produce flame in which the oil can be removed and produces suitable oil retarded urethanes. Another aspect of the invention is a that can be used in this invention may be obtained from process to prepare flame retarded urethanes by Serially apricot Stones, avocado, bilibary, borage, Stinging nettle, contacting beach nuts, copra, cashew nut, calendula, groundnut, Spurge, rubber Seed, rose hip, hemp, hazelnut, raspberry, elderberry, 0006 (A) urea and/or urea condensates black currant, coffee, coriander, linseed, caraway Seed mac 0007) (B) bio based compounds adamia nut, almonds, melon Seed, poppy, nutmeg, evening primrose, neem Seed, niger Seed, red pepper, brazil nut, 0008 (C) polyisocyanates passion fruit, pecon, pistachio, Sea buckhom, mustard Seed, US 2004/0082712 A1 Apr. 29, 2004 Sesame Seed, tropho plant, tomato Seed, grape Seed, flax hydrogen phosphates, ammonia dihydrogen phosphate, bro Seed, walnut and citrus Seed Soybean oil and modified Soy mated phosphates, alkali metal dihydrogen phosphate and oil are preferred. halogenated phosphate-phosphite and their halides and acids. Organic phosphorus compounds include, but not Component J limited to, alkyl, cyclic, aryl and alkyl-aryl phosphorus 0.019 Any suitable polyisocyanate may be utilized in this compounds, Such as, alkylchlorophosphines, alkyl phos invention. The commercial available polyisocyanate Such as phines, alkyl phosphites, dialkyl hydrogen phosphites, TDI, MDI, PMDI or their prepolymers and mixtures thereof dialkyl alkyl phosphonates, trialkyl phosphites, organic acid are preferred. 44 diphenylmethane diisocyanate, 2,4 diphe phosphates, organic diphosphonate esters, aryl phosphites, nylmethane diisocyanate and modified diphenylmethane aryl hydrogen phosphates, halogenated phosphonates esters dissocyanates may be utilized. and mixtures thereof. Amino condensation borates may be produced by contacting boric acid and amino condensation Component D compound under conditions Sufficient to prepare the amino condensation borates which may also be utilized as a flame 0020 Water or any other suitable blowing agent may be retardant compound. Amino condensation boron-phosphates utilize Such as acetone, methylisobutyl ketone, Freon, may be produced by contacting boron-phosphates and amino mechanical froth air, methyl chloride, carbon dioxide and condensation compounds under conditions Sufficient to pre mixtures thereof maybe used as the blowing agent. pare amino condensation boron-phosphate compounds which may also be utilized as a flame-retardant compound. Component E The Salt forming phosphorus containing compounds will 0021 Urethane catalyst such as tertiary amines and react with the amino condensation compounds to form an organic tin catalyst and other organic metal catalyst may be amino condensation Salt of a phosphorus containing com utilized in this invention. Some of the amine catalyst that pound. may be used are a mixture of 33%. 1,4-diaza-bicyclo-octane and 67% dipropylene glycol, a tertiary amine blowing agent, Component G and n,n',n", dimethylamino-propyl-hexahydrotriazine ter 0025) Any suitable filler may be used in this invention. tiary amine. The fillers that may be utilized in the flame retardant mixture are usually insoluble in the reaction mixtures.