Substituted ammonium polyphosphate composition

Claim 2

A substantially water-insoluble substituted ammonium polyphosphate composition having the general formula (I) z.sub.1 --o[--(po.sub.3 nh.sub.4).sub.j --(PO.sub.3 R'N).sub.k --].sub.y Z.sub.2 (I) wherein Z 1 and Z 2 are each selected from --NH 4 and --NR', N is a reactive nitrogen, R' is the residue R, of an organic nitrogenous spumific agent of general formula (II) r(nh.sub.2).sub.p (NH).sub.q (N).sub.r (II) wherein p, q and r are integers from 0 to 6 and (p + q + r) is 1 or more; said spumific agent hving a nitrogen to carbon ratio of 5 : 1 to 0.1 : 1, and a thermal decomposition temperature above 150° C, and wherein j is from 1 to 20, k is 1 to 10 and y is 1 or more.

Claim 3

A composition according to claim 1, wherein p is an integer from 0 to 5, q and r are each integers of 0 to 4 and p + q + r is 2 to 6.

Claim 4

A composition according to claim 1, wherein R contains at least one functional group selected from --OH, --SH, CO, CHO, COOH, NO. NO 2 , NOH, --SO 3 H, CN, CONH 2 .

Claim 5

A composition according to claim 1, wherein R contains at least one heteroatom selected from O, F, Cl, Br, P, S, B and Si.

Claim 6

A composition according to claim 2, wherein said spumific agent contains only elements selected from the group consisting of N, C, O and H.

Claim 7

A composition according to claim 1 wherein said spumific agent is selected from melamine, dicyandiamide, guanidine carbonate and mixtures thereof.

Claim 8

A substantially water-insoluble, substituted ammonium polyphosphate composition having the general formula (I) z.sub.1 --o[--(po.sub.3 nh.sub.4).sub.j --(PO.sub.3 R'N).sub.k --].sub.Y Z.sub.2 (I) wherein Z 1 and Z 2 are each selected from --NH 4 and --NR', N is a reactive nitrogen, R' is the residue R of an organic nitrogenous spumific agent of general formula (II) r(nh.sub.2).sub.p (NH).sub.q (N).sub.r (II) wherein p is an integer of 1 to 3, q is 0 or 1, r is an integer of 0 to 3 and (p + q + r) is 2 to 6; said spumific agent having a nitrogen to carbon ratio of 5 : 1 to 0.1 : 1, and a thermal decomposition temperature above 150° C, said spumific agent having a high degree of unsaturation and being thermally decomposable to gaseous products containing non-combustible gas, and wherein j is from 1 to 20, k is 1 to 10, and y is 1 or more.

Claim 9

A substantially water-insoluble, substituted ammonium polyphosphate composition having the general formula (I) z.sub.1 --o[--(po.sub.3 nh.sub.4).sub.j --(PO.sub.3 R'N).sub.k --].sub.Y Z.sub.2 (I) wherein Z 1 and Z 2 are each selected from --NH 4 and --NR', N is a reactive nitrogen, R' is the residue R of an organic nitrogenous spumific agent of general formula (II) r(nh.sub.2).sub.p (NH).sub.q (N).sub.r (II) wherein p is an integer of 1 to 3, q is 0 or 1, r is an integer of 0 to 3 and (p + q + r) is 2 to 6; said spumific agent having a nitrogen to carbon ratio of 5 : 1 to 0.1 : 1, and a thermal decomposition temperature above 150° C, said spumific agent having a high degree of unsaturation and being thermally decomposable to gaseous products containing non-combustible gas, and wherein j is from 1 to 20, k is 1 to 10, and y is 1 or more.

Claim 10

A composition according to claim 7 wherein said spumific agent is melamine.

Claim 11

A process for preparing a substantially water-insoluble substituted ammonium polyphosphate composition comprising i. condensing together at an elevated temperature a condensed phosphoric acid containing more than 72% P 2 O 5 , by weight, and containing one or more phosphoric acids selected from the group consisting of polyphosphoric acids and metaphosphoric acids, and a spumific agent of general formula (II) r(nh.sub.2).sub.p (NH).sub.q (N).sub.r (II) wherein p, q and r are integers from 0 to 6 and (p + q + r) is 1 or more, and said spumific agent has a nitrogen to carbon ratio of 5 : 1 to 0.1 : 1, and a decomposition temperature above 150° C, to form a solid foam, and ii. crushing the solid foam to form a particulate material.

Claim 12

A process for preparing a substantially water-insoluble substituted ammonium polyphosphate composition comprising i. condensing together at an elevated temperature a condensed phosphoric acid containing more than 72% P 2 O 5 , by weight, and containing one or more phosphoric acids selected from the group consisting of polyphosphoric acids and metaphosphoric acids, and a spumific agent of general formula (II) r(nh.sub.2).sub.p (NH).sub.q (N).sub.r (II) wherein p, q and r are integers from 0 to 6 and (p + q + r) is 1 or more, and said spumific agent has a nitrogen to carbon ratio of 5 : 1 to 0.1 : 1, and a decomposition temperature above 150° C, to form a solid foam, and ii. crushing the solid foam to form a particulate material.

Claim 13

A process according to claim 9, including the further step of curing the particulate material at an elevated temperature under pressure, without substantial weight loss.

Claim 14

A process according to claim 9, wherein urea is included in said condensing step.

Claim 15

A process according to claim 9, wherein p is an integer from 0 to 5, q and r are integers of 0 to 4, and p + q + r is 2 to 6.

Claim 16

A process according to claim 10, wherein said condensing is carried out at a temperature of 150° to 350° C and said curing is carried out at a temperature of 150° to 300° C for 3 to 24 hours at a pressure more than 1 and less than 30 atmospheres.

Claim 17

A process according to claim 9, wherein said condensing is carried out at a temperature of 225 to 300° C for 3 to 20 minutes.

Claim 18

A process according to claim 10, including the step of grinding the cured product to a fine powder having an average particle size of about 25 microns.

Claim 19

A process according to claim 9, wherein in said condensing there is included a few mole % of a polyhydric compound.

Claim 20

A process according to claim 9, wherein said condensing is carried out in a liquid state.

Claim 21

A process according to claim 9, wherein in said condensing there is included a compound of a polyvalent metal.

Claim 22

A process according to claim 9, wherein said spumific agent is selected from melamine, dicyandiamide, guanidine carbonate and mixtures thereof.

Claim 23

A process according to claim 9, wherein p is an integer of 1 to 3, q is 0 or 1 and r is an integer from 0 to 3 and (p + q + r) is 2 to 6; said spumific agent of formula (II), having a high degree of unsaturation and being thermally decomposable to gaseous products containing non-combustible gas.

Claim 24

A process according to claim 20 wherein said spumific agent of formula (II) is melamine.