CN101679797A - 用于密封和隔热的喷入型泡沫胶乳 - Google Patents
用于密封和隔热的喷入型泡沫胶乳 Download PDFInfo
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- CN101679797A CN101679797A CN200780048857A CN200780048857A CN101679797A CN 101679797 A CN101679797 A CN 101679797A CN 200780048857 A CN200780048857 A CN 200780048857A CN 200780048857 A CN200780048857 A CN 200780048857A CN 101679797 A CN101679797 A CN 101679797A
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Abstract
提供喷涂泡沫胶乳,其用于填充墙壁空穴以提高建筑物的密封和隔热性能。该喷涂泡沫胶乳包括胶乳体系和气态凝固组分。在至少一个示例性实施方案中,包括二氧化碳作为气态凝固组分。适合用于喷涂泡沫的一种胶乳为聚偏氯乙烯(PVDC),其具有阻燃性和环境耐久性。但是,优选的胶乳是苯乙烯-丁二烯橡胶(SBR)。胶乳体系可还包括触变剂例如LaponiteRD合成粘土。喷涂泡沫胶乳不含聚氨酯。还提供制备喷涂泡沫胶乳的方法,其包括供给胶乳体系和向该胶乳体系添加气态凝固组分。
Description
技术领域
本发明主要涉及泡沫胶乳,更具体地涉及用于填充墙壁空穴以提高建筑物的密封和隔热性能的喷涂泡沫胶乳(spray latex foams,喷发泡沫胶乳)。还提供喷涂泡沫胶乳的制造方法以及使用该喷涂泡沫胶乳填充墙壁空穴的方法。
背景技术
在隔热和结构增强的领域中喷涂泡沫(喷发泡沫)已得到广泛应用。例如,通常将喷涂泡沫用于隔热或赋予物品例如汽车、热水浴盆、冰箱、船艇和建筑物结构体以结构强度。此外,将喷涂泡沫用在用途例如家具和寝具的缓冲、地毯下面的垫料、声学材料、纺织层合物和能量吸收材料。目前,喷涂泡沫,尤其是用作房屋墙壁的隔热体或者密封剂的那些是聚氨酯喷涂泡沫。
聚氨酯喷涂泡沫和它们的制造方法是公知的。典型地,聚氨酯喷涂泡沫由两种分离的组分形成,通常称为“A”侧和“B”侧,当它们彼此接触时反应。第一组分或者“A”侧含有分子上具有高百分比的NCO(氮、碳和氧)官能团的异氰酸酯例如二异氰酸酯或多异氰酸酯。第二组分或者“B”侧含有包括两个或更多个活性氢的多元醇、有机硅类表面活性剂、发泡剂、催化剂和/或其他助剂。含活性氢的化合物通常为多元醇、伯胺和仲胺、和/或水。优选地,使用二醇和三醇的混合物以实现所需的发泡性能。设计总多元醇羟基数以实现1∶1的第一组分与第二组分的比例(A∶B)。
通常通过分开的线路将两种组分传送到喷枪例如撞击式喷枪内。在高压下经过小孔泵送第一和第二组分以形成分开的各组分料流。第一和第二组分的料流相交并在枪内彼此混合并开始反应。反应的热引起第一和第二组分中反应物的温度升高。这种温度上升引起位于第二组分(“B”侧)中的发泡剂蒸发并形成泡沫混合物。当混合物离开喷枪时,该混合物与表面接触,与其粘附,并继续反应直到异氰酸酯基团完全反应。产生的传热阻或者R值可以为4/英寸~8/英寸。
存在与常规聚氨酯喷涂泡沫相关的几个问题。例如,尽管用这样的聚氨酯喷涂泡沫密封建筑物减少了草案并使调节的空气在建筑物内和使外部的空气在建筑物外,但湿气渗入建筑物的能力下降。结果,在这些严密密封的建筑物中湿气和空气污染物的水平上升以致不再允许湿气渗入建筑物内。
与常规聚氨酯喷涂泡沫相关的另一个问题是第一组分(“A”侧)含有高水平的亚甲基二苯基二异氰酸酯(MDI)单体。当喷涂泡沫反应物时,MDI单体形成液滴,如果没有遵循严格的安全预防措施,安装泡沫的工人可能会吸入液滴。即使短暂暴露于异氰酸酯单体也会引起呼吸困难、皮肤刺激、水泡和/或鼻子、咽喉和肺部刺激。这些单体的长时间暴露可导致呼吸道的过敏,其会导致类似哮喘的反应和可能导致死亡。
这样的常规聚氨酯喷涂泡沫的另一个问题是认为未使用的残留聚亚甲基二苯基二异氰酸酯(PMDI)是危险的废物。PMDI通常具有20%的NCO。此外,PMDI能在环境中以液态保持多年。因此,必须遵循专门的程序以确保用许可的填埋土地来正确和安全地处理PMDI废物。这样的预防措施既昂贵又耗时。
这样的常规聚氨酯喷涂泡沫的又一个问题是“A”侧中异氰酸酯和“B”侧中多元醇的反应是“两部分”按比例定量反应,在泡沫的形成和施涂期间其需要复杂的设备。这样的泡沫还存在的问题是它经常引起设备阻塞,导致清理起来耗时。具体地,通常使用的撞击式喷枪以1∶1的相同粘度液体的比例相当好地工作。但是,当较大料流压倒较小料流时,较高比例的混合物往往引起堵塞,使得“A”和“B”侧的组分的反应在孔内发生。一旦这种情况发生,必须拆卸和清理喷枪,这涉及特种化学品。此外,拆卸喷枪会花去保温承包人大量的停工时间,因为其可能要花时间解决堵塞问题。
已经使用现有技术中已知的Talalay法生产泡沫胶乳枕和类似物品。具体地,Talalay法是将轻微发泡的胶乳倒入模具内以将其部分填充的间歇法。在此方法中,将挥发物或产生气体的物质与胶乳混合以生成泡沫。添加剂可以是过氧化氢或低沸点溶剂。然后将未发泡的胶乳放入模具中。闭合模具,胶乳借助真空膨胀以完全填充模具。发泡后,将胶乳冷却到低于水的凝固点以使排水和泡沫崩溃趋势推迟。使二氧化碳气体通过泡沫。然后将温度升至115℃以实现硫化。在二氧化碳添加的期间体系的pH值可从11降到9。在当今更为现代的Talalay法中,将胶乳机械发泡,而该方法的其余部分保持相同。根据这种较新的方法,用压缩空气在模具中制备泡沫并在不同时间将二氧化碳引入模具内。仅有压缩空气不会使胶乳凝结。此外,Talalay法是间歇法,其中将胶乳倒入模具中并且不是喷涂泡沫。
Ko等的美国专利No.7,053,131公开了吸收制品,其包括超临界流体处理的泡沫。具体地,使用超临界二氧化碳以生成泡沫,据称该泡沫具有改善的物理和界面性能。
Taylor的美国专利No.6,414,044教导了发泡填塞和密封剂组合物,其包括胶乳乳液和液体气态推进剂组分。发泡的组合物并不含有气态凝固组分。
Bland等的美国专利No.6,071,580公开了用包括二氧化碳的发泡剂制成的吸收性挤出热塑性泡沫。据称该泡沫能吸收大于等于其理论容量的50%的液体。
Hsu的美国专利No.5,741,823教导了在木基材上制备光滑硬涂层。该涂层由发泡聚合胶乳乳液制成并将其施涂在木基材的表面上。
Natoli等的美国专利No.5,585,412公开了制备不含CFC的柔性聚氨酯泡沫的方法,其使用包封发泡剂。该方法提供具有所需密度的聚氨酯泡沫,其避免了氯氟烃或其他挥发性有机发泡剂的使用。据称该包封发泡剂在由水发泡聚氨酯泡沫的制造中补充了由水提供的主要发泡作用并有利于制备具有所需密度的泡沫。
Cogliano的美国专利No.4,306,548公开了轻质发泡多孔铸件。为了制造该铸件,对膨胀的无孔聚苯乙烯发泡珠粒或其他形状涂覆氯丁橡胶、天然橡胶或其他胶乳的层。然后将涂覆聚苯乙烯埋入多孔封壳中,并将该封壳施加于断裂的肢。在封壳上添加另外的涂覆聚苯乙烯并添加气体凝固剂以使胶乳凝胶,这导致聚苯乙烯珠粒相互粘附并产生均一的刚性结构。
因此,现有技术中存在着对于喷涂泡沫胶乳不仅对工人安全和对环境友好,并且还允许湿气渗透的要求。
发明内容
本发明的目的是提供用于填充墙壁空穴以提高建筑物的密封和隔热性能的喷涂泡沫胶乳。本发明的喷涂泡沫胶乳包括胶乳体系和气态凝固组分。该胶乳体系还可包括触变剂。
本发明的另一目的是提供制备喷涂泡沫胶乳的方法。该制备喷涂泡沫胶乳的方法主要包括供给胶乳体系且向该胶乳体系添加气态凝固组分以制备喷涂泡沫胶乳。该胶乳体系包括胶乳乳液和可任选地包括触变剂。
本发明的另一目的是提供填充墙壁空穴的方法,其包括将喷涂泡沫胶乳喷入空穴内。该喷涂泡沫胶乳包括胶乳体系和气态凝固组分。该胶乳体系包括胶乳乳液并且还可包括触变剂。
本发明的喷涂泡沫胶乳的一个优点是泡沫不含有常规聚氨酯喷涂泡沫中出现的有害化学品,例如MDI单体。因此,本发明的喷涂泡沫胶乳不含有会引起皮肤或肺部过敏或产生有毒废物的有害蒸汽。而且,当喷涂泡沫胶乳时,例如填充墙壁空穴以密封和/或隔热建筑物的包层时,喷涂泡沫胶乳并不向空气中散发有害蒸汽。安装本发明的泡沫对工人是安全的并且因此能用于家装市场和居住的房屋。喷涂泡沫胶乳中缺少有害化学品还意味着能安全地处理它而不用遵循任何严格的危险废物处理预防措施。
喷涂泡沫胶乳的另一优点是可以使用现存的设计用于常规两部分喷涂聚氨酯泡沫体系的喷涂设备在不会阻塞喷涂设备下施涂泡沫。因此,当使用本发明的喷涂泡沫胶乳时,施涂喷枪能反复使用而没有阻塞且不需产生的必要的清洁。
考虑以下的详细说明后,本发明的以上和其他目的、特点和优点将更充分地显现。
附图说明
图1是描述对本发明二氧化碳固化SBR胶乳样品进行的应力-应变试验结果的图示说明。
具体实施方式
除非另有限定,本文中使用的所有技术和科技术语具有与本发明所属技术领域的普通技术人员普遍理解相同的含义。尽管类似或等同于本文中说明的那些的任何方法和材料能够用于本发明的实施或试验,但本文中对优选的方法和材料进行了说明。本文中引用的所有参考文献,包括公布的或者对应的美国或外国专利申请、发行的美国或外国专利以及任何其他参考文献均全文引为参考,包括出现在引用的参考文献中的所有数据、表格、图和正文。
本发明涉及用于填充建筑物的墙壁空穴以改善密封和隔热性能的不含聚氨酯的喷涂泡沫胶乳。本发明的喷涂泡沫胶乳包括胶乳体系和气态凝固组分。另外,该胶乳体系可以包括触变剂。与常规喷涂聚氨酯泡沫不同,本发明的喷涂泡沫胶乳不含异氰酸酯。因此,在本发明的喷涂泡沫胶乳中不存在MDI单体。因为本发明的喷涂泡沫胶乳不含有异氰酸酯,因此在安装泡沫期间无有害化学品放出。
优选地,本发明的喷涂泡沫胶乳及其组分满足某些性能特性或者适用性(“FFU”)标准。具体地,喷涂泡沫胶乳应满足的化学特性FFU包括以下标准:
泡沫应当粘附于各种材料例如木材、金属、混凝土和塑料。
化学成分应当尽可能安全。如果使用危险化学品,不应当将其引入或雾化到能够被吸入的空气中。
通过使用发泡剂能将泡沫化学发泡,或者可以用气体机械发泡。
喷涂泡沫胶乳的安装者在没有任何专门的个人防护设备(“PPE”)例如呼吸装置下应当能用该材料工作,但防护眼镜、防尘面具和手套是可接受的。
泡沫不应适于霉或真菌生长(ASTM C1338)。
泡沫不应含有昆虫或啮齿动物的食物来源。
应当具有12个月的未反应成分的最小保存期限。
还希望本发明的喷涂泡沫胶乳满足某些物理性质FFU。本发明的喷涂泡沫胶乳应当满足的物理性质FFU包括以下内容:
泡沫重量应当为0.5~2.0磅/立方英尺。
泡沫应当是足以在室温下或通过加热而喷涂的流体(在高剪切速率下粘度<10,000cp)。
泡沫在空穴中不应流挂或下落。
泡沫应当将整个空穴填充或者用于用气密层涂覆空穴。
理想地,泡沫应当是闭孔类型,但如果需要开孔类型来实现其他FFU,可以接受开孔类型。
泡沫应当具有至少3.7°Fft2h/BTU每英寸的热阻(R值)。
在失火期间泡沫应当是非流挂和非滴落的(即阻燃剂)。
泡沫不应当腐蚀金属物体例如螺钉、钉子、电器盒等。
空气渗透应当是可忽略的(ASTM E283-04)(具体地,0.4cfm/sqft)。
水蒸汽渗透应当大于1坡莫或5.72×10-8g/Pa-s-m2。
泡沫的颜色应当是红色/粉红。
泡沫应当具有小的气味。
如上所述,本发明的喷涂泡沫胶乳包括胶乳体系。优选地,该胶乳体系是含水胶乳乳液。该胶乳乳液包括通常由乳液聚合制备的胶乳粒子。除了该胶乳粒子以外,该胶乳乳液可包括水、稳定剂例如氨和表面活性剂。
有多种类型的胶乳可以用于该胶乳乳液中。合适的胶乳的非限定性例子包括天然和合成橡胶树脂、以及它们的混合物,包括:热固性橡胶;热塑性橡胶和弹性体,包括例如丁腈橡胶(例如丙烯腈-丁二烯);聚异戊二烯橡胶;氯丁橡胶;聚丁二烯橡胶;丁基橡胶;乙烯-丙烯-二烯单体橡胶(EPDM);聚丙烯-EPDM弹性体;乙烯-丙烯橡胶;苯乙烯-丁二烯共聚物;苯乙烯-异戊二烯共聚物;苯乙烯-丁二烯-苯乙烯橡胶;苯乙烯-异戊二烯-苯乙烯橡胶;苯乙烯-乙烯-丁烯-苯乙烯橡胶;苯乙烯-乙烯-丙烯-苯乙烯橡胶;聚异丁烯橡胶;乙烯-醋酸乙烯酯橡胶;硅橡胶,包括例如聚硅氧烷;甲基丙烯酸酯橡胶;聚丙烯酸酯橡胶,包括例如丙烯酸异辛酯和丙烯酸的共聚物;聚酯;聚醚酯;聚氯乙烯;聚偏氯乙烯;聚乙烯基醚;聚氨酯和共混物;以及它们的组合,包括例如它们的线形、放射形、星形和锥形嵌段共聚物。由于其阻燃性和其环境耐久性,特别关注的一种胶乳是聚偏氯乙烯(PVDC)。用于本发明的优选的胶乳是苯乙烯-丁二烯橡胶(SBR)。
在实现本发明的组合物的条件下,在胶乳乳液中可以使用任何反应性胶乳固体含量。基于乳液的总重量,乳液的反应性胶乳固体含量可以大于30重量%,优选地,大于40重量%,更优选地,大于50重量%。另外,基于乳液的总重量,乳液的反应性胶乳固体含量可以小于80重量%,优选地,小于70重量%,更优选地,小于62重量%。
优选将用于胶乳乳液中的胶乳稳定化。为了实现可接受的稳定性,如上所述胶乳乳液可包括稳定剂。希望该稳定剂为胶乳产生碱性环境。氨是优选的稳定剂。优选地,使用具有pH为8~12、优选为10的碱性氨溶液。能用于稳定胶乳乳液的其他苛性材料包括,例如,氢氧化钾和氢氧化钠。
另外,胶乳乳液可以包括表面活性剂。尽管并不希望被理论束缚,但据认为表面活性剂用远离粒子而面对的带负电的尾部涂覆胶乳(或“点阵”)粒子,以致带正电的乳清产生粒子互相排斥的环境。还认为表面活性剂层与水在粒子周围形成界面膜(即水合层)。只有当该膜是完整时原点阵才稳定。因为点阵粒子在微米范围内,故通过布朗运动使它们进一步稳定。另外,因为点阵粒子是带负电的,所以认为胶乳是阴离子型的。
胶乳乳液以喷涂泡沫胶乳的60~95重量%的量存在。优选地,胶乳乳液以喷涂泡沫胶乳的70~85重量%的量存在。
除了上述胶乳乳液外,胶乳体系可以包括触变剂,尤其对于低密度泡沫(即,小于等于2磅/英尺3)。当泡沫结构固化以防止该结构崩溃时,触变剂“实质上冻结”该结构。本文中使用的短语“实质上冻结”意在表示不是通过将温度降低到水的凝固点以下来实现该结构的冻结。取而代之,“冻结的”意在表示以前流动/粘性材料现在通过内部类似脚手架的结构使其基本上不动,这种情况下由触变剂提供该类似脚手架的结构。优选的触变剂是合成层状硅酸盐例如RD合成粘土。产品属于由Southern Clay ProductsCorporation生产的合成层状硅酸盐系列。本发明中可以使用其他触变剂,只要当胶乳完成凝固和固化时该触变剂将水结构“冻结”。本发明中有用的其他触变剂包括粘土、气相法二氧化硅、炭黑、甲基纤维素和官能化膨润土。如果在添加胶乳体系的任何其他组分前添加触变剂并使其溶胀,则最佳地使用触变剂。触变剂可溶胀并以2%的加料量产生高度触变的凝胶。触变剂可以以喷涂泡沫胶乳的小于等于15重量%的量存在。优选地,基于喷涂泡沫胶乳,触变剂的存在量是1~10重量%。
取决于用于胶乳乳液中的点阵粒子的类型,胶乳体系还可以包括其他任选的附加组分例如泡沫促进剂、乳浊剂、加速剂、泡沫稳定剂和/或发泡剂。如可对本领域技术人员显而易见那样,应意识到材料经常起到多于一种的上述功能,即使在本文中可以主要仅以一种功能的标题讨论该材料。
任选地,在胶乳体系中可以包括一种或多种泡沫促进剂。该泡沫促进剂辅助形成稳定的泡孔结构。该泡沫促进剂可以选自季铵皂类和甜菜碱类、胺类和蛋白质类、羧酸盐皂类例如油酸盐、蓖麻醇酸盐、蓖麻油皂类和松脂酸盐,以及它们的组合。优选的泡沫促进剂是羧酸盐皂。优选的羧酸盐皂是油酸钾。可以以小于等于喷涂泡沫胶乳的3重量%的量使用泡沫促进剂,优选喷涂泡沫胶乳的0.5~2.5重量%。
在胶乳体系中可以使用一种或多种乳浊剂来提高热阻或绝热值(R值)。可用于胶乳体系中的乳浊剂包括,但不限于,碳、氧化铁和石墨例如微米尺寸的石墨和纳米尺寸的石墨。乳浊剂可以以喷涂泡沫胶乳的小于等于10重量%、优选1~4重量%的量存在于胶乳体系中。
任选地,在本发明喷涂泡沫的胶乳体系中还可存在一种或多种加速剂。加速剂的存在有助于凝固过程。凝固是指胶乳粒子聚到一起并且聚合物链彼此联锁的现象。可用于本发明中的加速剂的非限制性例子包括噻唑化合物例如巯基苯并噻唑锌、多官能肟化合物例如对,对′-二苯甲酰醌二肟和二硫代氨基甲酸盐例如二甲基二硫代氨基甲酸锌和二丁基二硫代氨基甲酸钠。如果使用,在胶乳体系中可以以喷涂泡沫胶乳的小于等于10重量%、优选1.5~8重量%的量包括该一种或多种加速剂。
另外,在胶乳体系中可存在一种或多种泡沫稳定剂。泡沫稳定剂倾向于提高在成形和定型过程中泡沫的完整性并可以还起到发泡助剂的作用。泡沫稳定剂的非限制性的例子包括例如氧化锌和氧化镁。如果使用,可以以喷涂泡沫胶乳的小于等于15重量%、优选3~10重量%的量包括该稳定剂。稳定剂的优选量是使泡沫稳定剂当pH变成酸性时变得可溶于乳清中并且使其与脂肪酸皂类(即,泡沫促进剂)一起作用以形成稳定的泡孔结构的量。
此外,胶乳体系可任选地含有一种或多种发泡剂。胶乳体系中可以使用的发泡剂的例子包括低沸点烃例如环戊烷和正戊烷、水、氢氟烃以及惰性气体例如空气、二氧化碳和氮。可用于胶乳体系中的发泡剂的量可以落在喷涂泡沫胶乳的5~30重量%的范围内。合适的氢氟烃发泡剂的具体例子包括HFC236ca(1,1,2,2,3,3-六氟丙烷)、HFC-236ea(1,1,1,2,3,3-六氟丙烷)、HFC-236fa(1,1,1,3,3,3-六氟丙烷)、HFC-245ca(1,1,1,2,2,3-六氟丙烷)、HFC-245ea(1,1,2,3,3-五氟丙烷)、HFC-245eb(1,1,1,2,3-五氟丙烷)、HFC-245fa(1,1,1,3,3-五氟丙烷)、HFC-356mff(1,1,1,4,4,4-六氟丁烷)、HFC-365mfc(1,1,1,3,3-五氟丁烷)和HCFC141b(2-氟-3,3-氯丙烷)。
除了以上详细说明的胶乳体系外,本发明的喷涂泡沫胶乳还包括气态凝固组分,其用于凝固胶乳。本发明中能使用各种气态凝固剂。在优选的实施方案中,气态凝固组分是二氧化碳。二氧化碳起到起泡剂的作用并且还促进喷涂泡沫胶乳的凝固。二氧化碳的存在酸化胶乳的含水基体并且引起胶乳粒子从溶液中析出而凝固。二氧化碳的存在还排除了需要任何烃推进剂,尽管可包括它们作为任选的发泡剂。在本发明中使用的二氧化碳可以是纯二氧化碳气体或者它可以来自在化学反应期间释放二氧化碳的其他来源。用于产生二氧化碳的这样的合适的替代来源包括例如碳酸盐如碳酸铵和碳酸氢盐如碳酸氢钠。
根据本发明的一个示例性实施方案,包括二氧化碳作为气态凝固剂并使其达到高压(例如100~500psi),以致它溶解于乳清(即水)相中。在发明的喷涂泡沫胶乳中,二氧化碳与含水的氨反应以产生氨基甲酸盐。应当指出的是,将二氧化碳与胶乳体系混合在一起以使其凝固并且没有在施涂后使用其来固化胶乳。
本发明的喷涂泡沫胶乳中使用二氧化碳的优点是众多的。例如,胶乳一般需要昂贵的化学品和用于固化的热处理。但是,在喷涂泡沫胶乳中使用的二氧化碳是低成本、相对安全的化学品。根据本发明的至少一个实施方案,使用二氧化碳来发泡并凝固胶乳,由此去除了需要更昂贵的化学品和热处理。昂贵的化学品和热处理的去除降低了与喷涂泡沫胶乳相关的制造成本,由此使本发明的泡沫更成本有效。一般从发电或制造工艺回收二氧化碳的事实使它成为更易得到的资源。
二氧化碳在泡沫胶乳中能迅速发挥作用,因为不像Talalay法那样它不遇到冷冻水。在本发明的喷涂泡沫胶乳中,二氧化碳在某一压力下扩散到水中并形成碳酸,其迅速与氨反应形成氨基甲酸盐。据认为氨基甲酸盐起到交联剂和加速剂的作用以固化泡沫并产生最终泡沫产品。碳酸还将胶乳中的水的pH下移到酸性区域。这种pH的转移将使胶乳粒子失稳并且导致它们凝固(例如,移动到一起并凝聚)。在零剪切下,通过触变剂泡沫中的水将实质上冻结。这种“冻结”将降低或者甚至防止泡沫中的排水和崩溃行为。
在优选的实施方案中,将二氧化碳和压缩空气的组合用于泡沫的凝固和发泡。将二氧化碳与压缩空气混合的一个优点是安全,因为对施涂本发明的喷涂泡沫的个人或人们来说,100%二氧化碳会产生危险的工作条件。另外,在喷涂泡沫胶乳中用100%二氧化碳施涂喷涂泡沫胶乳的住宅内的二氧化碳的水平会迅速增加。另一方面,如果同时使用二氧化碳和压缩空气,可将二氧化碳在混合装置中在空气中引入空气流中,或者在混合装置中引入泡沫自身。优选地,将二氧化碳与压缩空气在混合器中混合以产生泡沫。
根据本发明的至少一个示例性实施方案,胶乳体系的实际发泡能通过混合装置例如连续混合器来实现。可将气态凝固剂和胶乳体系泵入混合器的混合头内。使用连续混合器的一个优点是它强烈地混合而没有产生大量的热,大量的热会导致胶乳过早凝固。此外,可以在连续混合器的出口放置第二混合装置例如静态混合器。多孔圆筒和实心圆柱形壳体可以包围该第二混合器,这可使气态凝固组分均匀引入。或者,可以将气态凝固组分直接引入连续混合器内。可用于本发明中的混合器的例子是Oakes型连续混合器。
除了胶乳体系和气态凝固组分外,可以包括在本发明的喷涂泡沫胶乳中的其他成分包括染料、颜色指示剂、胶凝剂、泡沫稳定剂和促进剂、加速剂、发泡剂。如前指出,材料常常可以起到多于一种的上述功能,如对本领域技术人员显而易见那样,即使在下文中可能主要只以一种功能的标题来讨论该材料。
任选地,还可以使用染料来改变泡沫的颜色。对泡沫优选红色/粉红色。可使用颜色指示剂来提供施涂后泡沫干了的视觉确认。
另外,在喷涂泡沫胶乳的胶乳体系中可任选地包括一种或多种泡沫稳定剂。泡沫稳定剂提高成形和定型过程中泡沫的完整性并且还起到发泡助剂的作用。可用于喷涂泡沫胶乳中的泡沫稳定剂的非限制性的例子包括上述那些,即氧化锌和氧化镁,以及二苯基胍和氯化铵。如果使用,取决于存在的泡沫稳定剂的一种或多种类型,将以喷涂泡沫胶乳的小于等于10重量%的量,优选喷涂泡沫胶乳的0.5~6重量%的量包括该稳定剂。
任选地,在喷涂泡沫胶乳中可以包括一种或多种胶凝剂以有利于半液体粘性泡沫的胶凝并在凝固时形成固体泡孔结构。泡沫的凝胶化可以由相对不可溶的酸形成化学品例如氟硅酸的铵、钠或钾盐的水解引起。泡沫的凝胶化还可由合适的热敏性铵盐例如硫酸铵、硝酸铵、氯化铵、硫氰酸铵、甲酸铵和醋酸铵的分解引起。在将液体泡沫混合并使之起泡后可引入一种或多种胶凝剂。通常,在发泡后但在将泡沫拉成所需形状之前小心将胶凝剂计量到泡沫中。如果使用,使用的一种或多种胶凝剂的量可基于选择的该一种或多种胶凝剂的胶凝能力和使用的胶乳粒子的类型来选择。基于喷涂泡沫胶乳,可以以小于等于15重量%,优选5~13重量%的量包括胶凝剂。应当指出的是,与使乳清的pH移动并且不仅产生凝固而且使胶乳交联的二氧化碳不同,胶凝剂并不将胶乳硫化。
本发明的喷涂泡沫胶乳中还可以包括一种或多种加速剂。可用于本发明中的加速剂的非限制性的例子包括上述那些,以及有机酚类。如果使用,可以以喷涂泡沫胶乳的小于等于10重量%、优选0.5~5重量%的量包括该一种或多种加速剂。
任选地,本发明的喷涂泡沫胶乳可以包括一种或多种另外的发泡稳定剂。发泡稳定剂促进泡沫的形成并且包括材料例如常规表面活性剂。有用的表面活性剂包括阳离子、阴离子、两性和非离子表面活性剂,例如前述的羧酸盐皂类、季铵皂类和甜菜碱类、胺类和蛋白质类、油酸盐类、蓖麻醇酸盐类、蓖麻油皂类和松脂酸盐类,以及烷基硫酸盐类。如果使用,取决于存在的发泡稳定剂的一种或多种类型,可以以喷涂泡沫胶乳的小于等于5重量%、优选0.25~3重量%的量包括该发泡稳定剂。
本发明的喷涂泡沫胶乳中还可以包括发泡剂。可以存在于喷涂泡沫胶乳中的合适的发泡剂包括上述适合用于胶乳体系中的那些,即烃类、水、氢氟烃类和惰性气体。此外还可以在本发明的喷涂泡沫胶乳中使用过氧化氢作为发泡剂。
在分散于胶乳体系内的聚合物或蜡壳中可以将这些任选的组分包封或者不包封。在Owens Corning的题目为“Pseudo One Part Foam”的美国专利申请公开No.2006/0047010中记载了合适的包封方法的一个例子,在本文中将其内容全文引为参考。优选地,为了直到使用喷涂泡沫胶乳时不产生胶乳的凝固,将附加的或者任选的组分包封。
在本发明中,喷涂泡沫胶乳可取地具有低密度。具体地,泡沫的密度应当为0.5~2磅/英尺3。优选0.5磅/英尺3的密度。为了产生具有高热阻系数和低空气渗透性的泡沫胶乳,优选较低的密度,两者均是隔热材料的所需性能。尽管低密度泡沫是希望的,但本发明的方法可以用于制备任何密度的泡沫。通过向混合装置内计量较少的压缩空气将增加泡沫的密度。因此,在本发明的另一个示例性实施方案中,泡沫可以具有高密度(即大于2磅/英尺3)并且可以只用作气密层而不用作隔热材料。
根据一个实施方案,本发明的喷涂泡沫胶乳含有两种分离的组分(即胶乳体系和气态凝固剂),类似于常规的双组分喷涂聚氨酯泡沫(“A”和“B”侧)。使用设计用于常规双组分喷涂聚氨酯泡沫的现有的喷涂设备安装本发明的双组分喷涂泡沫胶乳。
根据另一个示例性实施方案,本发明的喷涂泡沫胶乳是“单组分”的变形。更具体地,喷涂泡沫胶乳可以为喷涂泡沫体系,其将一种或多种反应物包封在分散于胶乳体系内的聚合物或蜡壳中。这种包封使得在没有显著反应的情况下能将反应物混合在一个容器中。当通过施涂枪处理这种混合物/悬浮液时,例如通过加热或剪切将该一种或多种包封的反应物基本上释放并与胶乳体系混合。胶乳组分的比例可以在1∶1到更高比例的范围,例如1∶20,这有助于在蜡/聚合物壳体中的少量成分的包封概念,然后壳体悬浮于主要成分(即胶乳体系)中。
本发明的“单组分”喷涂泡沫胶乳需要并不昂贵或复杂的喷涂设备例如常规、双组分喷涂聚氨酯泡沫所需的类型。“单组分”喷涂泡沫胶乳的喷涂设备可以为简单的喷枪例如简单的隔膜泵或回转泵。这些类型的喷枪不容易阻塞并且维护和清洁也容易得多。
根据本发明的另一个实施方案,还可以将第三化学反应物包封。例如,为了使本发明的方法简单,可有利地将某些成分如氟硅酸钠和/或氧化锌包封,以致通过喷涂过程使它们活化。可以将这些组分包封于在喷涂过程期间熔融的蜡壳中或者在发泡的剪切作用下破裂的壳体中。
根据本发明,可以通过首先供给优选包括胶乳乳液和触变剂的胶乳体系来制造本发明喷涂泡沫胶乳。向该胶乳体系添加气态凝固组分以形成喷涂泡沫胶乳。为了实现所需的较低泡沫密度,也可以使用空气来使泡沫发泡。因此,将空气注入/夹带到胶乳体系以降低密度,接着注入气态凝固组分以向胶乳体系添加更多气体并使该结构凝固。
在使用中,可将本发明的喷涂泡沫胶乳喷涂到开放的空穴内例如在墙柱之间或者闭合的空穴内,在这里喷涂泡沫胶乳膨胀以将任何开放空间密封。可取地施涂为连续喷涂过程。
本发明的喷入型泡沫胶乳可以用于使建筑物例如住宅隔热以免受建筑物包层外部的温度波动。喷涂泡沫胶乳可以起到传导性和对流性隔热体作用。通过填充建筑物屋顶或墙壁的裂纹和/或裂缝,本发明的喷涂泡沫胶乳还可以用作空气渗透的密封剂。
本发明的喷涂泡沫胶乳优选是非结构泡沫。胶乳的软泡沫性质使得容易压实。因此,本发明喷涂泡沫胶乳具有几个优点。例如,对于开放的墙壁空穴,不存在后施涂废物。如果存在空穴超量填充,清水墙(drywall)会简单地将泡沫压回空穴内。本发明的泡沫是柔性的,因此对清水墙不施加显著的压力并且几乎不或者不发生清水墙的弯曲或分离。
本发明的喷涂泡沫胶乳的一个优点是将泡沫安全安装到墙壁空穴内。当施涂或喷涂时该喷涂泡沫胶乳并不向空气中释放任何有害蒸汽。因此,本发明的喷涂泡沫胶乳降低了对用泡沫作业或者位于泡沫附近的个体有害的威胁。此外,施涂喷涂泡沫胶乳对安装者来说更易于控制,因为在安装期间他/她不需要穿戴特殊的呼吸装置。
本发明泡沫的另一优点是它能用于装修市场,以及人类或动物居住的房间。现存常规的喷涂聚氨酯泡沫不能用于这些应用中,因为产生大量游离的异氰酸酯单体,这些单体会对住处的居住者产生不利的影响。如上所述,异氰酸酯单体的暴露可能导致对鼻、咽喉和肺的刺激、呼吸困难、皮肤刺激和/或水泡以及呼吸道过敏。
本发明的另一个优点是可在没有明显反应的情况下将喷涂泡沫胶乳的组分混合并储存在一个容器中直到使用该喷涂泡沫胶乳的时候。这简化了喷涂泡沫的施涂,因为在施涂时不添加其他组分。取而代之,在施涂时使包封的组分活化。
已对本发明进行了概括的说明,通过参考以下例示的某些具体实施例能获得进一步的理解,仅为举例说明而提供实施例并且它们不意在全部包括或限制,除非另有说明。
实施例
以下在实施例1-3中示出根据本发明的喷涂泡沫胶乳组合物的预言性实施例。这些实施例举例说明可用于本发明胶乳体系的不同的点阵粒子。在实施例1-3的每一个中,部分A是指胶乳体系,而部分C是指用于使泡沫发泡和凝固的气态组分。部分B是指可或不可被包封的辅助添加剂。能在热敏或剪切敏感性包封剂例如低熔点石蜡或丙烯酸中将部分B组分包封。然后在低剪切混合下在部分A容器中将部分B添加到部分A。然后可以将双组分(A和B)与计量量的空气泵入混合装置例如高剪切、动态混合器或发泡头中。在靠近发泡头的出口或者在喷涂喷嘴组件(发泡头之后)将二氧化碳计量到泡沫中。整个体系在50-80磅/英寸2的压力下以致二氧化碳将溶解于胶乳的水相中。可以将静态混合器连接于发泡头的端部或者在喷涂喷嘴处以有助于二氧化碳与泡沫的混合。
如果不将部分B组分包封,那么在发泡头(在静态混合器之前)或者在喷涂喷嘴处(在静态混合器之前)可将它们计量到泡沫中。取决于水能从泡沫结构中扩散出的快慢,凝固过程可能要用几个小时才完成。任选地,能在完成凝固后对泡沫结构进行固化过程。固化过程一般需要在烘箱中长时间的加热步骤以使聚合物硫化(交联)。固化步骤赋予泡沫对于某些应用例如座垫或寝具所必需的附加的弹性和强度。
实施例1:苯乙烯丁二烯泡沫胶乳组合物
表1
在此实施例中,胶乳体系包括SBR胶乳乳液。通常氨已经是胶乳乳液的一部分;但是,在此实施例中它作为独立的组分示出。如前面所讨论,使用氨来调节胶乳的pH以产生稳定的胶体。除了SBR胶乳乳液外,此实施例中的胶乳体系还包括触变剂。应当理解尽管此实施例中使用了RD触变性粘土,但在二氧化碳完成胶乳的凝固时粘土将水结构“冻结”的条件下,在此实施例中能使用其他粘土产品。胶乳体系还包括油酸钾作为泡沫促进剂、纳米尺寸的石墨作为乳浊剂和氧化锌作为泡沫稳定剂。使用二氧化碳作为气态凝固剂,和将空气用作发泡剂。
实施例2:聚氯丁二烯泡沫胶乳组合物
表2
在此实施例中,胶乳乳液包括聚氯丁二烯胶乳。除了胶乳乳液外,此实施例中的胶乳体系包括触变剂。胶乳体系还包括氧化锌作为泡沫稳定剂,以及对,对′-二苯甲酰醌和二丁基二硫代氨基甲酸钠作为用于凝固过程的加速剂。邻苯二酚起到胶凝剂和加速剂的作用。泡沫稳定剂可以含有C-鲸蜡基甜菜碱和润湿剂以及烷基硫酸钠。将作为气态凝固剂的二氧化碳和空气计量到混合头内。可将所有的B组分分别或者一起包封。
实施例3:天然橡胶泡沫胶乳组合物
表3
在此实施例中,胶乳体系包括天然橡胶胶乳乳液。胶乳体系还包括RDS触变性粘土作为触变剂。胶乳体系的附加组分是乳浊剂(纳米尺寸的石墨)、泡沫促进剂(油酸钾)和加速剂。在此实施例中,二苯基胍和氯化铵起到泡沫稳定剂的作用。可以对所有的B组分进行或不进行包封。
实施例4:天然橡胶和SBR泡沫胶乳组合物
根据本发明制造胶乳应力应变样品。胶乳乳液包括天然胶乳和SBR的混合物。将用氨稳定的八分之一(1/8)英寸厚的胶乳层(天然胶乳和SBR的混合物)倒入三(3)英寸直径的铝盘。然后将盘放入压力容器的底部并且将容器密封。然后将150psi的二氧化碳引入容器内并在室温下使其与胶乳乳液相互作用五(5)分钟。除了在引入二氧化碳之前将温度升高到50℃外,用相同的方式制造第二组胶乳应力应变样品。然后对容器进行脱气并打开,取出样品。然后将厚胶乳膜从铝盘拉出并用纸巾垫干。使其在环境气氛中静置并连续干燥四(4)天。从这些样品切下条状物,其尺寸大约为1英寸×1英寸。这些条状物用于使用机器测定载荷-伸长率(或者应力-应变)。
图1说明了对本发明的二氧化碳固化的SBR胶乳样品进行的应力-应变试验的结果,这些样品是按照实施例4中所述制造的。图1示出随着应变而增加的应力,其表明是交联材料。图1还示出对具有二氧化碳的混合物施加热看起来使强度增加。无法对具有相同年龄的同等空气干燥的胶乳样品进行试验,因为该同等空气干燥的样品没有完整性(即它们在处理时崩溃)。另一方面,本发明的样品在试验期间没有破裂。取而代之,当本发明的样品从机器的夹具释放时,样品很快恢复到起始长度的两倍。这些结果表明本发明的喷涂泡沫胶乳样品是粘结性弹性材料并且具有作为用于填充空穴的密封/隔热材料应用所需要的性能。另外,样品没有崩溃的事实表明本发明的喷涂泡沫胶乳适当地凝固。否则,样品会崩溃。
以上概括地并针对具体实施方式对本申请的发明进行了说明。尽管以认为优选的实施方案示出发明,在同类公开内容的范围内能够选择对本领域技术人员已知的大量替代变形。除了对以下提出的权利要求的叙述外,对发明并无其他限制。
Claims (20)
1.用于提高建筑物的密封和隔热性能的喷涂泡沫胶乳,该喷涂泡沫胶乳包含:
包括触变剂的胶乳体系;和
气态凝固组分。
2.权利要求1所述的喷涂泡沫胶乳,其中所述胶乳体系包括选自天然橡胶、合成橡胶和它们的混合物的胶乳。
3.权利要求2所述的喷涂泡沫胶乳,其中所述胶乳是苯乙烯-丁二烯橡胶(SBR)。
4.权利要求1所述的喷涂泡沫胶乳,其中所述气态凝固组分包括二氧化碳。
5.权利要求1所述的喷涂泡沫胶乳,其中所述触变剂选自粘土、气相法二氧化硅、炭黑、甲基纤维素、官能化膨润土和合成层状硅酸盐。
6.权利要求5所述的喷涂泡沫胶乳,其中所述触变剂是合成层状硅酸盐。
7.权利要求1所述的喷涂泡沫胶乳,其中所述胶乳体系还包括选自泡沫促进剂、乳浊剂、加速剂、发泡剂和泡沫稳定剂的至少一种成分。
8.权利要求1所述的喷涂泡沫胶乳,其中所述喷涂泡沫胶乳还包括选自染料、颜色指示剂、胶凝剂、泡沫稳定剂、泡沫促进剂、发泡剂和加速剂的至少一种成分。
9.权利要求8所述的喷涂泡沫胶乳,其中将所述染料、颜色指示剂、胶凝剂、泡沫稳定剂、泡沫促进剂、发泡剂和促进剂中的一种或多种包封并分散在所述胶乳体系中。
10.权利要求1所述的喷涂泡沫胶乳,其中所述喷涂泡沫胶乳具有0.5~2磅/英尺3的密度。
11.制备喷涂泡沫胶乳的方法,所述方法包括:
供给胶乳体系,所述胶乳体系包括胶乳乳液和触变剂;和
向该胶乳体系中添加气态凝固组分以形成喷涂泡沫胶乳。
12.权利要求11所述的方法,还包括
向所述胶乳体系添加选自由染料、颜色指示剂、胶凝剂、泡沫稳定剂和促进剂、发泡剂和加速剂组成的组中的至少一种成分。
13.权利要求12所述的方法,其中将所述染料、颜色指示剂、胶凝剂、泡沫稳定剂、泡沫促进剂、发泡剂和加速剂中的一种或多种包封并分散在所述胶乳体系中。
14.权利要求11所述的方法,其中所述胶乳乳液包括选自天然橡胶、合成橡胶和它们的混合物的胶乳。
15.权利要求14所述的方法,其中所述胶乳是苯乙烯-丁二烯橡胶。
16.权利要求11所述的方法,其中所述触变剂选自粘土、气相法二氧化硅、炭黑、甲基纤维素、官能化膨润土和合成层状硅酸盐。
17.权利要求11所述的方法,其中所述气态凝固组分包括二氧化碳。
18.填充墙壁空穴的方法,包括向所述空穴内喷涂喷涂泡沫胶乳,所述喷涂泡沫胶乳包括胶乳体系和气态凝固组分,其中所述胶乳体系包括触变剂。
19.权利要求19所述的方法,其中所述胶乳体系包括选自天然橡胶、合成橡胶和它们的混合物的胶乳。
20.权利要求19所述的方法,其中所述气态凝固组分包括二氧化碳。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US11/647,747 US8779016B2 (en) | 2006-12-29 | 2006-12-29 | Spray-in latex foam for sealing and insulating |
US11/647,747 | 2006-12-29 | ||
PCT/US2007/026433 WO2008082618A1 (en) | 2006-12-29 | 2007-12-28 | Spray-in latex foam for sealing and insulating |
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CN101679797A true CN101679797A (zh) | 2010-03-24 |
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CN200780048857A Pending CN101679797A (zh) | 2006-12-29 | 2007-12-28 | 用于密封和隔热的喷入型泡沫胶乳 |
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US (1) | US8779016B2 (zh) |
EP (1) | EP2121855A1 (zh) |
JP (1) | JP2010514899A (zh) |
KR (1) | KR20090106494A (zh) |
CN (1) | CN101679797A (zh) |
AU (1) | AU2007339243A1 (zh) |
CA (1) | CA2670807A1 (zh) |
MX (1) | MX2009006955A (zh) |
NZ (1) | NZ577570A (zh) |
RU (1) | RU2009128750A (zh) |
WO (1) | WO2008082618A1 (zh) |
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-
2007
- 2007-12-28 KR KR1020097013354A patent/KR20090106494A/ko not_active Application Discontinuation
- 2007-12-28 EP EP07868109A patent/EP2121855A1/en not_active Withdrawn
- 2007-12-28 AU AU2007339243A patent/AU2007339243A1/en not_active Abandoned
- 2007-12-28 JP JP2009544107A patent/JP2010514899A/ja not_active Abandoned
- 2007-12-28 RU RU2009128750/05A patent/RU2009128750A/ru not_active Application Discontinuation
- 2007-12-28 NZ NZ577570A patent/NZ577570A/en unknown
- 2007-12-28 WO PCT/US2007/026433 patent/WO2008082618A1/en active Application Filing
- 2007-12-28 CA CA002670807A patent/CA2670807A1/en not_active Abandoned
- 2007-12-28 CN CN200780048857A patent/CN101679797A/zh active Pending
- 2007-12-28 MX MX2009006955A patent/MX2009006955A/es unknown
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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CN115445879A (zh) * | 2022-10-08 | 2022-12-09 | 常州市第一橡塑设备有限公司 | 一种高强度石油压裂泵壳体制作方法 |
CN115445879B (zh) * | 2022-10-08 | 2023-04-14 | 常州市第一橡塑设备有限公司 | 一种高强度石油压裂泵壳体制作方法 |
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NZ577570A (en) | 2011-03-31 |
CA2670807A1 (en) | 2008-07-10 |
RU2009128750A (ru) | 2011-02-10 |
WO2008082618A1 (en) | 2008-07-10 |
EP2121855A1 (en) | 2009-11-25 |
US8779016B2 (en) | 2014-07-15 |
MX2009006955A (es) | 2009-07-08 |
US20080160203A1 (en) | 2008-07-03 |
AU2007339243A1 (en) | 2008-07-10 |
KR20090106494A (ko) | 2009-10-09 |
JP2010514899A (ja) | 2010-05-06 |
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