FIELD OF THE INVENTION

[0001 ] The present invention relates to a process of preparing cyclic phosphonate esters. More particularly, the invention relates to a process of reacting 1 ,3-diol with at least one of phosphonic acid and phosphinic acid to produce a cyclic phosphonate ester, and the use of such cyclic phosphonate ester{s) as flame-retardant additive(s) in industrial applications such as electronic components, polyurethane foam and textiles, inter alia.

BACKGROUND OF THE INVENTION

[0002] Flame-retardant additives are often used to reduce the risk and severity of combustion. A wide variety of flame retardants are known and commercially available for this purpose. However, there are often considerable technical problems and concerns restricting the use of these flame retardants.

[0003] Neopentyleneglycol-H-phosphonate is one example of a flame retardant that has been made by various methods that include a base and halogenated compounds and which methods use expensive compounds and/or generate high levels of waste.

[0004] The desire, however, for a process which uses more affordable materials and/or has reduced levels of waste still remains.

SUMMARY OF THE INVENTION

[0005] The present invention relates to a process for preparing cyclic phosphonate ester of the general formula (I):

wherein R and R~ are each independently selected from linear or branched alkyl groups containing up to about 10 carbon atoms, optionally containing one or more heteroatom substituents, the process comprising:

reacting a glycol of the general formula (II):

wherein R ^A and R ^B are each independently H or a linear or branched alkyl group containing up to about 10 carbon atoms, optionally containing one or more heteroatom substituents with at least one of phosphonic acid and phosphinic acid in the presence of a solvent, wherein if phosphonic acid is used, cyclic phosphonate ester of the general formula (I) is formed, and if phosphinic acid is used a cyclic phosphonite ester of the general formula (III):

is formed,

wherein R ¹ and R ² are as defined, and wherein any cyclic phosphonite ester of the general formula (III) is further exposed to air to produce cyclic phosphonate ester of the general formula (I). DETAILED DESCRIPTION OF THE INVENTION

[0006] In accordance with the present invention, it has unexpectedly been found that the inventive process, as described herein, is capable of being used to produce a cyclic phosphonate ester, such as the non-limiting example of neopentyleneglycol-H- phosphonate, which avoids the above-noted problems.

[0007] The cyclic phosphonate esters produced by the process of the invention herein are compounds of the general formula (I) as described above, and are useful as flame retardants in various industrial applications.

[0008] In one embodiment herein R ¹ and R ² of general formula (I) are each independently selected from linear or branched alkyl groups containing up to about 8 carbon atoms, more specifically up to about 6 carbon atoms, even more specifically up to about 4 carbon atoms, each said range optionally containing one or more heteroatom substituents.

[0009] Some non-limiting examples of R ¹ and R ² of general formula (I) include linear alkyl groups such as methyl, ethyl, n-propyl, n-butyl _t n-pentyl, n-hexyl, and branched alkyl groups such as iso-propyl, iso-butyl, sec-butyl, tert-butyl, iso-pentyl, tert- pentyl, neo-pentyl, iso-hexyl, and the like. In one embodiment herein, R ¹ and R ² are both linear alkyl groups having from 1 to 9 carbon atoms, specifically from 1 to 4 carbon atoms, even more specifically wherein R ¹ and R ² are each methyl.

[0010] It will be understood herein that a heteroatom is any one of O, N or S.

[0011 ] In one non-limiting embodiment herein there is also provided a process of making cyclic phosphonate (I) comprising reacting glycol (II) with only phosphonic acid (H3PO3) in the presence of a solvent. [0012] In one embodiment each of R ^A and R ^B in the general formula for glycol

(II) is a linear or branched alkyl group of up to 8 carbon atoms, more specifically up to about 6 carbon atoms and most specifically up to 4 carbon atoms. In one non-limiting embodiment each of R ^A and R ^B are independently methyl or ethyl, more specifically each being methyl.

[0013] In one embodiment glycol (II) is selected from the group consisting of 1,3- propanediol, 1,3-butanediol, 2-methyl-l,3-propanediol, neopentylene glycol, 2-methy]-2- ethyl-1 ,3-propanediol, 2,2-diethyl-l ,3-propanediol, 2-ethyl-2-propyl-l ,3-propanediol,

2.2- dipropyl-l ,3-propanediol, 2,2-dibutyl-l ,3-propanediol, 2,2-dipentyl-l ,3-propanediol,

1.3- octanedioI, and combinations thereof.

[0014] As described above, if phosphinic acid (H3PO2) is employed in the process herein, the product is a cyclic phosphonite ester of the general formula (III) as described above, which is then further exposed to air to produce the cyclic phosphonate ester of general formula (I) described above.

[0015] If only phosphinic acid is employed in the process described herein, the reaction product will be a mixture of components, including a compound of the general formula (III) as well as other byproducts. Further reactions with a compound of the general formula (III) can also be conducted thereafter, such as the reaction with Sg to produce a cyclic thiophosphonate ester of the general formula (IV):

and the reaction with BH3*SMe ₂ to produce a compound of the general formula (V):

(V)

wherein Me is methyl. [0016] It will be understood herein that if a combination of phosphonic acid and phosphinic acid is employed in the process herein that a combination of products, as described herein will be obtained depending on the molar ratio of the respective acid employed.

[0017] In one non-limiting embodiment, the reaction of phosphonic and/or phosphinic acid with glycol (II) will be in an equimolar amount, i.e., there will be an equivalent amount of moles of total phosphonic and/or phosphinic acid to moles of glycol (II). In one embodiment, the reaction may be conducted in a slight excess of either phosphonic/phosphinic acid or glycol (II), e.g., a range of molar ratios of total phosphonic/phosphinic acid to glycol (II) of from about 0.8/1 to 1.2/1, more specifically from about 0.9/1 to about 1.1/1 and even more specifically from about 0.95/1 to about 1.05/1. It will be understood herein that should only phosphonic acid or only phosphinic acid be employed herein, that the above noted ratios apply equally thereto.

[0018] In one specific embodiment herein the process can be conducted in the absence of any base. In another embodiment herein the process can be conducted to produce cyclic phosphonate of the general formula (I) without any byproduct.

[001 ] In one embodiment herein, some non-limiting examples of solvents that may be employed in the process herein are hydrocarbon solvents such as hexane, cyclohexane, heptane, octane, benzene, toluene, xylene, petroleum spirit, etc.; halogen- containing hydrocarbon solvents such as chloroform, carbon tetrachloride, 1,2- dichloroethane, trichloroethane, tetrachloroethane, chlorobenzene, dichlorobenzene, etc.; ether solvents such as diisopropyl ether, dibutyl ether, 1 ,4-dioxane, ethylene glycol diethyl ether, etc.; and the like, among which toluene, 1 ,2-dichloroethane and 1,4-dioxane are more specifically employed, and toluene is most specifically employed.

[0020] The amount of the organic solvent used is not particularly limited, but may preferably be about 35 to 70 wt % with respect to the glycol compound (II). [0021 ] The reaction may preferably be carried out by stirring a mixture of the glycol (II) and the organic solvent and adding at least one of phosphonic acid (H3PO3) and phosphinic acid (H3PO2) to the mixture.

[0022] The reaction temperature is 0 to 100° C, preferably 40 to 80° C. If the reaction temperature is lower than 0° C, it is not preferable because the reaction does not progress sufficiently. If the reaction temperature exceeds 100° C, it is not preferable because the produced product decomposes and colors.

[0023] The reaction time is typically about 3 to 8 hours, though it may be varied depending upon conditions such as the reaction temperature.

[0024] In one non-limiting embodiment herein the reaction (i.e., esterification) of phosphonic and/or phosphinic acid with glycol (II) is conducted by conducting the reaction in a Dean-Stark apparatus. A Dean-Stark apparatus is a well known set of equipment to those skilled in the art. While not wishing to be bound by theory, a Dean- Stark apparatus is designed to collect water produced in a synthetic reaction carried out under reflux. The reaction is carried out under reflux in a solvent which is less dense than water, (e.g., toluene) both immiscible with it, and which forms an azeotrope with the water, so as to enable the water formed in the reaction to be removed as an azeotrope.

[0025] In one non-limiting embodiment a Dean-Stark apparatus can comprise an inverted Claisen adapter, with a condenser at the top and a small graduated test-tube acting as a receiver directly below it. The assembly ensures that as a reaction mixture is boiled, (such as the reaction(s) described herein) the denser water is captured in the test tube, while the lighter solvent (e.g., toluene) overflows and is returned to the still pot. The receiver can be modified to include a tap at the bottom to periodically draw off the water.

[0026] In one non-limiting embodiment, the solvent employed herein may be evaporated under reduced pressure and be recycled to the process. [0027] In one other non-limiting embodiment herein there is provided a cyclic phosphonate ester of the general formula (I) described herein which is produced by the process described herein.

[0028] The cyclic phosphonate ester of the general formula (I) may be used as a flame retardant additive in a flame retardant effective amount in a polymer to provide for flame resistance and/or flame retardancy to the polymer. The flame retardant effective amount of the cyclic phosphonate ester of the general formula (I) blended in the polymer of the present invention may be selected as appropriate depending upon the kind of a cyclic phosphonate ester (I), the kind of polymer, the use of a molded article of the polymer composition and the performance (e.g., flame retardancy, etc.) required of the molded article. In one embodiment herein the expression "effective flame retarding amount" can comprise any amount of cyclic phosphonate ester of the general formula (I) and, that can provide a flame retardant pass of California TB 117 and VSS302.

[0029] In another embodiment, the amount of the cyclic phosphonate ester (I) blended as a flame retardant may typically be 0.05 parts by weight or more, preferably 0.1 to 50 parts by weight, more preferably 5 to 20 parts by weight, with respect to 100 parts by weight of the polymer. If the blend amount of the cyclic phosphonate ester (I) is less than 0.05 parts by weight, it is not preferable because the polymer cannot be provided with sufficient flame retardancy. If the blend amount of the cyclic phosphonate ester (I) is more than 50 parts by weight, it is not preferable because it may cause a decline in properties of the polymer. In the case where the resin is polyurethane, the flame retardant may preferabl be added in the step of producing polyurethane. As regards the blend amount of the flame retardant in this case, the cyclic phosphonate ester (I) may be blended in an amount within the above-mentioned range with respect to 100 parts by weight of the total amount of a polyol and a diisocyanate, which are starting materials.

[0030] As examples of the polymer which may be employed herein, may be mentioned thermoplastic resins such as chlorinated polyethylene, polyethylene, polypropylene, copolymers of polyethylene and polypropylene, polybutadiene, styrene- based resin _t impact-resistant polystyrene, polyvinyl chloride, acrylonitrile-chlorinated polystyrene-styrene (ACS) resin, acrylonitrile-styrene (AS) resin, ABS resin, polyphenylene ether, modified polyphenylene ether, polymethacrylate, polyamide, polyester, polycarbonate, etc., and thermosetting resins such as polyurethane, phenolic resin, epoxy resin, melamine resin, unsaturated polyester, and the like. These polymers may be used as a mixture of two or more thereof.

[0031 ] Among the above-mentioned resins, those not containing a halogen may be more specifically employed.

[0032] Further, the cyclic phosphonate ester of the general formula (I) of the present invention can be automatically added at a constant addition rate to a polymer material or during preparation of a polymer composition for molding.

[0033] Other additives for polymers may be blended, if necessary, in the polymer composition of the present invention so long as the blending of the additives does not impair the properties of the polymer to which the flame retardancy should be given.

[0034] As such additives for polymer, may be mentioned other flame retardants than the cyclic phosphonate ester of the general formula (I), antioxidants, inorganic fillers, antistatics, ultraviolet absorbers, lubricants and the like.

[0035] The other flame retardants other than the cyclic phosphonate ester (I) which can be present in the polymer (composition) can be any liquid flame retardant which is different from that described in formula (I) but, preferably, is selected from the group consisting of, but not limited to phosphorous-based flame retardants, preferably non-halogenated phosphorous-based flame retardants, such as those selected from the group consisting of alkyl phosphates, aryl phosphates, alkyl aryl phosphates, alkaryl phosphates, aromatic bisphosphates, oligomeric phosphates, phosphonates; nitrogen- containing compounds such as melamine, ammonium polyphosphate and ammonium pyrophosphate; metal compounds such as aluminum hydroxide, magnesium hydroxide, zinc borate; and, combinations thereof.

[0036] Preferably the at least one different liquid flame retardant is selected from the group consisting of triethyl phosphate, diethyl ethylphosphonate, tris(2-butoxyethyl) phosphate, dibutyl phenyl phosphate, butyl diphenyl phosphate, 2-ethylhexyl diphenyl phosphate, isodecyl diphenyl phosphate, cresyl diphenyl phosphate, triphenyl phosphate, tricresyl phosphate, butylated or isopropylated triphenyl phosphate and combinations thereof.

[0037] In addition to, or alternatively to, the different liquid non-halogenated flame retardant described above, the incorporation of different liquid halogenated flame retardant can also or alternatively be used, e.g., tris(chloropropyl) phosphate,

tris(dichloroisopropyl) phosphate and 2,2-bis(chloromethyl)trimethylene bis(bis(2- chloroethyl) phosphate), and the like, and mixtures thereof.

[0038] The polymer of the present invention preferably comprises at least one non halogen-containing cyclic phosphonate ester of the general formula (I) herein. The ratio of weight percents in the polymer herein of cyclic phosphonate ester of the general formula (I) to total different liquid flame retardaiit(s) can vary, and can range from about 5/95 to about 95/5, respectively, and preferably from about 20/80 to about 80/20, respectively, and most preferably from about 25/75 to about 75/25, respectively.

[0039] As the antioxidants, may be mentioned phosphorus compounds such as trivalent phosphorous compounds including triphenyl phosphite,

tris(nonylphenyl)phosphite, diphenyl isodecyl phosphite, bis(2,4-di-tert- butylphenyl)pentaerythritol diphosphite, tetrakis(2,4-di-tert-butylphenyl)-4,4-diphenylene phosphonite, etc.; hydroquinone compounds such as hydroquinone, 2,5-di-tert- butylh droquinone, octylhydroquinone, 2,5-tert-amylhydroquinone, etc.; phenol compounds; amine compounds; sulfur compounds; and the like. [0040] As the inorganic fillers, may be mentioned mica, talc, alumina and the like.

[0041] As the antistatics, may be mentioned cationic surfactants, non-ionic surfactants and the like.

[0042] As the ultraviolet absorbers, may be mentioned benzophenone

compounds, salicylate compounds, benzotriazole compounds and the like.

[0043] As the lubricants, may be mentioned fatty acid compounds, fatty amide compounds, ester compounds, alcohol compounds and the like.

[0044] For producing the polymer composition of the present invention, there is no particular limitation on the order or method of blending the respective components. For example, the polymer composition may be produced by mixing, melting and kneading the flame retardant, the polymer and other additives for polymer, as required, using known methods. For mixing, melting and kneading, general-use apparatus such as a single- screw extruder, a double-screw extruder, a Banbury mixer, a kneader mixer and the like may be used singly or in combination.

[0045] If the polymer is produced by bulk polymerization, the flame retardant may be added at the feeding of a monomer, at the last stage of bulk polymerization reaction or at the molding of the resulting polymer.

[0046] The obtained polymer (composition) can be further molded by a known method to obtain a molded product in a desired form, for example,, a plate, sheet or film form.

[0047] The cyclic phosphonate ester of the general formula (I) of the present invention may contain minor levels of impurities derived from by-products and unreacted materials during production, but may be used as flame retardants without being further purified so long as the impurities do not affect the flame retardancy of the polymer made from the inventive composition(s) herein. Such impurity level is below about 2wt%, preferably less than 1 wt,% and most preferably less than 0.5 wt% with an optional lower endpoint to such ranges of 0.001 wt.%. In one embodiment herein the cyclic phosphonate ester of the general formula (I) made by the process herein can have an absence of any impurity.

[0048] The polymer of the present invention can include one or more species of cyclic phosphonate ester of the general formula (I).

[0049] There is also provided herein an electrical component comprising a flame retardant effective amount of the cyclic phosphonate ester made by the process described herein.

[0050] Further, there is also provided at least one of a cable insulation, cable jacket and tubing comprising a flame retardant effective amount of the cyclic phosphonate ester made by the process described herein.

[0051] Still further, there is also provided a polyurethane foam comprising a flame retardant effective amount of the cyclic phosphonate ester made by the process described herein.

[0052] Still even further, there is also provided an automotive application comprising a flame retardant effective amount of the cyclic phosphonate ester made by the process described herein.

[0053] Yet even further, there is also provided a textile comprising a flame retardant effective amount of the cyclic phosphonate ester made by the process described herein. In one non-limiting embodiment, the textile can be used in at least one of a padding, a rug, an upholstery, a drapery and insulation. EXAMPLE

[0054] To a solution of phosphorous acid H ₃ PO ₃ (50%, 114.8 g, 700 mmol) in toluene (1.4 L) neopentylglycol (73.64 g, 700 mmol) was added. The reflux system was equipped with a Dean-Stark trap prefilled with toluene. The reaction mixture was refluxed for 18h. The reaction mixture was allowed to cool down to room temperature. The solution was concentrated under high vacuum to give the expected cyclic neopentylglycol phosphonate ester at 100% yield . Phosphorus NMR ³¹ P showed a single peak at 2.99 ppm (d),

[00 5] While the process of the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the process of the invention but that the invention will include all embodiments falling within the scope of the appended claims.