US4613661A — Epoxy phosphate compositions

Claim 1

Independent Claim 159 words

A process for preparing a phosphate ester which contains at least one terminal epoxide moiety, the process comprising contacting under reaction conditions, optionally in the presence of water, at least one phosphoric acid ester with an amount of an epoxide having an epoxy equivalent greater than one, said amount being sufficient to substantially neutralize the phosphoric acid functionality of the phosphoric acid ester, the contacting being such that there is formed a composition comprising a phosphate ester containing terminal epoxide functionality and corresponding to the formula: ##STR9## wherein R' is a glycidyl ether of the general formula: ##STR10## wherein R is a difunctional remnant of a dihydroxy compound formed by removal of the hydroxyl groups thereof; R" is a group as defined by R"' or R'; R"' is an organic group of up to about 20 carbons; and n is a positive number less than about 20 and is equal to the number of repeating units in the compound.

Claim 2

Dependent Claim 159 words

A process for preparing a phosphate ester which contains at least one terminal epoxide moiety, the process comprising contacting under reaction conditions, optionally in the presence of water, at least one phosphoric acid ester with an amount of an epoxide having an epoxy equivalent greater than one, said amount being sufficient to substantially neutralize the phosphoric acid functionality of the phosphoric acid ester, the contacting being such that there is formed a composition comprising a phosphate ester containing terminal epoxide functionality and corresponding to the formula: ##STR9## wherein R' is a glycidyl ether of the general formula: ##STR10## wherein R is a difunctional remnant of a dihydroxy compound formed by removal of the hydroxyl groups thereof; R" is a group as defined by R"' or R'; R"' is an organic group of up to about 20 carbons; and n is a positive number less than about 20 and is equal to the number of repeating units in the compound.

Claim 3

Dependent Claim 110 words

A process for preparing a phosphate ester which contains at least one terminal epoxide moiety, the process comprising: (1) forming an organic-soluble pyrophosphate diester corresponding to the formula: ##STR11## wherein R a is an organic group of up to about carbon atoms, in an organic solvent; (2) contacting the organic-soluble pyrophosphate diester with from about 1 to about 16 moles of water per mole of pyrophosphate diester to form the corresponding phosphoric acid monoesters; and (3) contacting at least one phosphoric acid ester of step (2) with an amount of an epoxy having an epoxy equivalent greater than one, said amount being sufficient to substantially neutralize the phosphoric acid functionality.

Claim 4

Dependent Claim 110 words

A process for preparing a phosphate ester which contains at least one terminal epoxide moiety, the process comprising: (1) forming an organic-soluble pyrophosphate diester corresponding to the formula: ##STR11## wherein R a is an organic group of up to about carbon atoms, in an organic solvent; (2) contacting the organic-soluble pyrophosphate diester with from about 1 to about 16 moles of water per mole of pyrophosphate diester to form the corresponding phosphoric acid monoesters; and (3) contacting at least one phosphoric acid ester of step (2) with an amount of an epoxy having an epoxy equivalent greater than one, said amount being sufficient to substantially neutralize the phosphoric acid functionality.

Claim 5

Dependent Claim 95 words

A process according to claim 2 for preparing a composition comprising a phosphate ester containing terminal epoxide functionality corresponding to the formula: ##STR12## wherein R' is a glycidyl ether of the general formula ##STR13## wherein R is a difunctional remnant of a dihydroxy compound formed by removal of the hydroxyl groups thereof; R" is a group as defined by R"' or R'; R"' is an organic group of up to about 20 carbons; and n is a positive number less than about 20 and is equal to the number of repeating units in the compound.

Claim 6

Dependent Claim 12 words

A process according to claim 3 wherein R"' is alkyl or alkoxyalkyl.

Claim 7

Dependent Claim 11 words

A process according to claim 3 wherein R"' is 2-n-butoxy ethyl.

Claim 8

Dependent Claim 22 words

A process according to claim 2 wherein in step (2) the molar ratio of diester:water is from about 1:2 to about 1:12.

Claim 9

Dependent Claim 22 words

A process according to claim 6 wherein in step (2) the molar ratio of diester:water is from about 1:4 to about 1:10.

Claim 10

Dependent Claim 26 words

A process according to claim 2 wherein in step (3) the equivalent ratio of epoxy equivalent to acid equivalent is from about 4:1 to about 20:1.

Claim 11

Dependent Claim 26 words

A process according to claim 8 wherein in step (3) the equivalent ratio of epoxy equivalent to acid equivalent is from about 6:1 to about 12:1.

Claim 12

Dependent Claim 18 words

A process according to claim 2 wherein in step (3) the reaction is conducted at an elevated temperature.

Claim 13

Dependent Claim 24 words

A process according to claim 10 wherein in step (3) the reaction is conducted at an elevated temperature of up to about 80° C.

Claim 14

Dependent Claim 19 words

A process according to claim 2 wherein in step (2) the addition temperature is about ambient temperature or lower.

Claim 15

Dependent Claim 10 words

A composition prepared according to the process of claim 2.

Claim 16

Dependent Claim 89 words

A composition of matter comprising a phosphate ester containing terminal epoxide functionality corresponding to the formula: ##STR14## wherein R' is a glycidyl ether of the general formula ##STR15## wherein R is a difunctional remnant of a dihydroxy compound formed by removal of the hydroxyl groups thereof; R" is a group as defined by R"' or R'; R"' is an organic group of up to about 20 carbons; and n is a positive number less than about 20 and is equal to the number of repeating units in the compound.

Claim 17

Dependent Claim 89 words

A composition of matter comprising a phosphate ester containing terminal epoxide functionality corresponding to the formula: ##STR14## wherein R' is a glycidyl ether of the general formula ##STR15## wherein R is a difunctional remnant of a dihydroxy compound formed by removal of the hydroxyl groups thereof; R" is a group as defined by R"' or R'; R"' is an organic group of up to about 20 carbons; and n is a positive number less than about 20 and is equal to the number of repeating units in the compound.

Claim 18

Dependent Claim 21 words

A composition according to claim 14 further characterized as comprising from about 0.5 percent to about 2.6 percent phosphorus by weight.

Claim 19

Dependent Claim 21 words

A composition according to claim 15 wherein the phosphorus content is from 0.75 percent to about 1.5 percent phosphorus by weight.

Claim 20

Dependent Claim 23 words

A composition according to claim 14 further characterized by possessing an epoxide content from about 5 percent to about 20 percent by weight.

Claim 21

Dependent Claim 36 words

A composition according to claim 17 characterized in that the epoxide content after storage at 30° C. for 30 days in the presence of air is from about 4.5 percent to about 18 percent by weight.

Claim 22

Dependent Claim 12 words

A composition according to claim 14 wherein R"' is alkyl or alkoxyalkyl.

Claim 23

Dependent Claim 10 words

A composition according to claim 14 wherein R"' is 2-n-butoxyethyl.

Claim 24

Dependent Claim 16 words

A coating composition having intumescent properties prepared using a composition of matter according to claim 14.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1989-09-22	1990-03-24	1990-09-23	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1993-09-22	1994-03-24	1994-09-23	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1997-09-22	1998-03-24	1998-09-23	$7700.00	Window Closed / Lapsed

Epoxy phosphate compositions

Abstract

Inventors

Bibliographic Details

Claims Analysis

References Cited (Backward Citations)

USPTO Annuity & Maintenance Windows

Assigned Categories & Tags

Assign Category Tag