Search

KR-20260066834-A - Flame retardant composition for manufacturing polyurethane foam with excellent flame retardant retardancy and storage stability and polyurethane foam comprising the same

KR20260066834AKR 20260066834 AKR20260066834 AKR 20260066834AKR-20260066834-A

Abstract

A flame-retardant composition for manufacturing polyurethane foam comprising a polyester polyol, a polymer-coated red phosphate, and an organic phosphate ester is disclosed, wherein the properties of the polymer-coated red phosphate are improved to enhance viscosity characteristics and storage stability when manufacturing a slurry-type flame-retardant composition, and the reaction rate is improved when foaming a polyurethane foam using the same, and the flame-retardant composition for manufacturing polyurethane foam satisfies semi-flame-retardant performance. A polyurethane foam comprising the same is disclosed. The present invention provides a flame-retardant composition for manufacturing polyurethane foam comprising a polyester polyol, a red phosphorus coated with a polymer, and an organic phosphate ester, wherein the red phosphorus coated with the polymer is a red phosphorus coated with a melamine resin having a red phosphorus content of 80 to 95 weight%, and the carbon (C) component content measured according to the SEM/EDS (scanning electron microscope/energy dispersive spectroscopy) mapping elemental analysis method of the red phosphorus coated with the melamine resin is 10 to 20 weight% and the oxygen (O) component content is 0.1 to 1 weight%.

Inventors

  • 우인섭
  • 현용빈

Assignees

  • 롯데케미칼 주식회사

Dates

Publication Date
20260512
Application Date
20241105

Claims (8)

  1. A flame-retardant composition for manufacturing polyurethane foam comprising a polyester polyol, a polymer-coated red phosphate ester, and an organic phosphate ester, The red chromium coated with the above polymer is a red chromium coated with a melamine resin having a red chromium content of 80 to 95 weight%, and A flame-retardant composition for manufacturing polyurethane foam, characterized in that the carbon (C) component content measured according to the SEM/EDS (Scanning Electron Microscope/Energy Dispersive Spectroscopy) mapping elemental analysis method of the red chromium coated with the above-mentioned melamine resin is 10 to 20 weight% and the oxygen (O) component content is 0.1 to 1 weight%.
  2. In paragraph 1, A flame-retardant composition for manufacturing polyurethane foam, characterized in that the polyester polyol comprises a reaction product of an acid component containing 40 to 80 mol% of isophthalic acid (purified isophthalic acid, PIA); and an alcohol component represented by the following chemical formula 1, wherein the molar ratio of the acid component and the alcohol component is 1:1 to 1:2: [Chemical Formula 1] HO-X-OH In Chemical Formula 1, X is a straight or branched alkylene group having 2 to 6 carbon atoms substituted or unsubstituted with a hydroxyl group; or a straight or branched ether group having 2 to 6 carbon atoms substituted or unsubstituted with a hydroxyl group.
  3. In paragraph 2, A flame-retardant composition for manufacturing polyurethane foam, characterized in that the acid component other than the isophthalic acid is phthalic anhydride (PA) or adipic acid (AA), and the alcohol component is one or more selected from the group consisting of ethylene glycol (EG), diethylene glycol (DEG), triethylene glycol, neopentyl glycol (NPG), MPO (2-methyl-1,3-propanediol), MPD (3-methyl-1,5-pentanediol), butanediol, and hexanediol.
  4. In paragraph 1, A flame-retardant composition for manufacturing polyurethane foam, characterized in that the above-mentioned organic phosphate ester is one or more selected from the group consisting of triphenyl phosphate, tricresyl phosphate, tri(2,6-dimethylphenyl)phosphate, tri(2,4,6-trimethylphenyl)phosphate, tris(isopropylphenyl)phosphate, melamine phosphate, tris(1-chloro-2-propyl)phosphate, tris(2-chloro-ethyl)phosphate, tetraphenyl resorcinol diphosphate, tetraphenylbisphenol A diphosphate, polyphosphate compounds, phosphonate compounds, and phosphinate compounds.
  5. In paragraph 1, A flame-retardant composition for manufacturing polyurethane foam, characterized by comprising 30 to 60 parts by weight of the polyester polyol, 20 to 40 parts by weight of the red phosphorus coated with the polymer, and 20 to 40 parts by weight of the organic phosphate ester.
  6. In paragraph 1, The flame-retardant composition for manufacturing polyurethane foam is characterized by having a viscosity of 1,000 to 3,000 cPs as measured according to the following method, and having no sedimentation of solid particles and no aggregation when evaluated for storage stability according to the following method: [Viscosity Measurement Method] The viscosity of the sample was measured at 25°C using a Brookfield viscometer (spindle 64) in accordance with ASTM D4878 standard; [Storage Stability Evaluation Method] After storing the sample at 25℃ for 3 weeks, the precipitation and aggregation of solid particles were observed.
  7. Polyurethane foam comprising a flame-retardant composition according to any one of claims 1 to 6.
  8. In Paragraph 7, The above polyurethane foam is a polyurethane foam characterized by having a total heat output of 8 MJ/㎡ or less as measured according to the following method: [measurement method] The total heat output was measured by heating for 10 minutes under a heat flux of 50 kW/ m² using a cone calorimeter in accordance with ISO 5660-1 standards.

Description

Flame retardant composition for manufacturing polyurethane foam with excellent flame retardant retardancy and storage stability and polyurethane foam comprising the same The present invention relates to a flame-retardant composition for manufacturing polyurethane foam and a polyurethane foam containing the same, and more specifically, to a flame-retardant composition for manufacturing semi-flame-retardant polyurethane foam having excellent flame retardancy and storage stability and a polyurethane foam containing the same. One of the causes recently identified for major fire accidents in Korea is the installation of building exterior walls using insulation materials that lack flame-retardant or non-combustible performance; this accelerates the spread of fire, leading to greater casualties and property damage. Polyurethane foam has been developed into polyisocyanurate foam (PIR foam) by adding raw materials such as isocyanate and trimerization catalysts to enhance the flame retardant performance of the material itself, thereby increasing the content of isocyanurate, an aromatic structure with excellent heat resistance. Although this has improved flame retardant performance, it does not satisfy the semi-flame retardant performance (total heat output of 8.0 MJ/m² or less for 10 minutes from the start of heating when heated at a heat flux of 50 kW/ m² ) in the heat generation test method specified in ISO 5660-1 , which is one of the semi-flame retardant standards. To address these issues, conventional methods have met the thermal heat generation standards for semi-non-combustible performance by laminating a flame-retardant sheet or panel onto one side of polyurethane foam. However, since this is not a method that fundamentally imparts flame retardancy to the polyurethane foam, the flame-retardant effect is limited, and the complex manufacturing process increases manufacturing costs. Furthermore, following the amendment to the domestic Building Act in December 2021, performance standards are now applied to each material for exterior wall finishing materials made of two or more materials. Consequently, as performance must be secured solely from the core material, it has become necessary to improve the semi-non-combustible performance of the polyurethane core material itself, rather than enhancing flame-retardant performance through the lamination of sheets and panels. Meanwhile, among the polyols that are essential components of polyurethane, polyether polyols and polyester polyols are known to be the most common. These polyols have a significant impact on the properties of the polyurethane or polyurethane foam to be manufactured. As organic compounds, these polyurethane foams are flammable and can cause uncontrollable combustion upon ignition. Therefore, research has been conducted to introduce flame-retardant technology into polyurethane foams, and some products formed from polyurethane foam are legally required to be flame-retardant. In the case of polyurethane resins, particularly polyurethane foam, the required performance is different and special compared to other resin products, so flame retardants applied to general resins are not suitable. Halogen-based flame retardants are widely used as flame retardants for polyurethane foam. However, while halogen-based flame retardants provide excellent performance in polyurethane foam, there is a major problem in that harmful environmentally harmful substances such as hydrogen halides and halogenated dioxins are generated when polyurethane foam products are discarded and incinerated. In response to the need to develop a polyurethane resin composition that minimizes the emission of such toxic substances and satisfies semi-non-combustible performance in the event of a fire, Korean Patent Publication No. 10-2023-0080668 disclosed a polyurethane resin composition using red phosphorus coated with melamine resin. However, depending on the condition of the red chromium coated with melamine resin added to the flame retardant composition containing polyester polyol, there is a problem in that the viscosity characteristics and storage stability are reduced when preparing a slurry-type flame retardant composition, and furthermore, the reaction rate is reduced when foaming polyurethane foam using it. Figure 1 is a diagram showing SEM images of B3 and B5 among the coated red ones used in the examples and comparative examples. Figure 2 is a diagram showing the results of elemental analysis through SEM/EDS mapping for B3 and B5 among the coated reddish-reddish used in the examples and comparative examples. Preferred embodiments of the present invention are described in detail below. In describing the present invention, detailed descriptions of related prior art are omitted if it is determined that such detailed descriptions may obscure the essence of the present invention. Throughout the specification, when a part is described as "comprising" a certain component, this means that, u