DE2348476A1 - RIGID FOAM MADE FROM RESIN SYSTEMS AND VARIOUS FILLING AGENTS AND PROCESSES FOR THEIR PRODUCTION - Google Patents

Description

Patenfanwalf Karl A. Brose

Dip! - i * ng.

D-8023 Munich - p _u | f _ach WiiB «slr. 2, T. Mdlfl. 7 «3 05 70.793 f 712

1 / au Munich-Pullach, September 26, 1973

MELAMINA ULTRA 3 / A. - Industria Quimica, Rua dos Algibebes, 6 - sala 304 - Caixa Postal, 1616, Salvador, Brazil and COORDENACAO DOS PROCtRAMAS DE POS-GRADUACAO DE ENGEiJHARIA DA UNIVF.RRIDA.DE FEDERAL DO RIO DE JANEIRO J- COPPE / UFRJ, Centro de Tecnologia, Bloco G Ilha do Fundao - Caixa Postal 1191, ZC-OO Rio de Janeiro, Guanabara, Brazil

Rigid foams made from synthetic resin systems and various Fillers and processes for their production.

The invention relates to rigid foams made from synthetic resin systems and various fillers and a method for their production.

The invention is to the manufacture of solids present Materials of various densities directed, based on melamine resin foams and various inorganic ones Fillers that are flame-retardant and that after being added to the foam and after hardening of the same lead to painterials, which in the broadest Dimensions in the construction industry in the form of partition walls, suspended ceilings and linings, as brickworks for erection of inner and outer walls, as a basement coating and covers as well as for the production of decorative coatings and covers can be used, as they are in addition to a

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have excellent acoustic and thermal insulation properties due to their comparatively high mechanical strength.

The products currently available on the market for achieving the above-mentioned tick have various disadvantages on, one of the major drawbacks being the flammability of such products. The products provided according to the invention, which are subjected to carbonization under the action of a direct flame are self-extinguishing, i.e. the Combustion reaction stops immediately when the direct flame is removed from the material. Also own they show the characteristics of nitrided materials which, when decomposed, lead to the formation of nitrogen and other nitrated compounds which slow down the oxidation reaction of the material. This reaction is further caused by the formation of a coked or carbonized! material layer on the surface, which is reached by the flame, which consequently acts as an insulating material against the progress of the flame. Because of this fact does not undergo any appreciable decrease in the structural strength of the material.

The inorganic fillers can be according to the intended one Purpose of the material made of plaster of paris, asbestos, glass, and polymer material fibrous materials, metal powder, magnesite, stone, wool, diatomite, stone powder, sand, talc and the organic ones Fillers can consist of piassava fibers, coconut fibers and sisal fibers and sugarcane bagasse. These fillers can have different states of agglomeration and fiber lengths and can be added alone or in appropriate proportions to two or more such materials.

The melamine formaldehyde monomer and the curable compositions based on the melamine resin with various fillers

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BATH ORIGINAL

v / earth is achieved in the following manner.

The melamine formaldehyde monomer, which is the basis of the melamine foam is manufactured according to the following formulation and working conditions:

Formaldehyde in a 37% solution is heated to about 78 ί 1 ° C heated in a reactor equipped with a constant agitation and temperature control. The one with a 10-something (Weight / volume) HaOH solution becomes neutralized formaldehyde then melamine was added and the reactor temperature was increased to 87-1 ° C increased over a period of about 30 minutes and held at that value, with the reaction under reflux is carried out. The degree of prepolymerization of the monomer is determined by turbidity tests frequently carried out during work controlled and the melamine formaldehyde monomer solution given below at the end of the reaction is characterized by the turbidity ratio to distilled water of 1: 1. The solution is then quickly cooled to room temperature and the product stored for later use.

The physical characteristics of the monomer solution obtained are as follows: Clear solution which over time becomes cloudy becomes cloudy and hardened; pH = 9.0; Density = 1.25 g / cm; Viscosity = 1.2 g / cm / sec, each measured at 30-0.1 C; Solids content about 60%. The molar ratio of the reagents is as follows: 11 MbI formaldehyde; 8.63 moles of melamine; 0.165 Moles of NaOHο

In the turbidity test, a certain weight of the monomer is determined and water is slowly added until it becomes permanent Turbidity of the mixture is achieved. The weight ratio of what is required to produce this turbidity or cloudiness

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chen water to the monomer must be 1: 1.

To produce rigid melamine resin foam, the water in the blowing agent, which in the present case is an anionic acid detergent, is added to a previously measured amount and the mixture is stirred vigorously for about 10 minutes, after which it takes on the consistency of a light foam. Instead of that the mixture is subjected to vigorous stirring, a gas can be bubbled through the mixture so that the same lightweight foam is achieved. This gas can be supplied from an external source or in situ by means of a chemical Reaction or an organic solvent with a low boiling point can be used.

The monomer solution then becomes the foam previously obtained without interruption the stirring or the introduction of the gas is added. When using a volatile organic solvent the polymerization reaction is sufficiently exothermic to cause blowing, foaming or expansion the reaction mixture takes place. The acidic catalyst can now be added to the monomer solution or subsequently in can be added to a third step without stopping the agitation, which is continued for a sufficient time must to ensure that the reaction mixture obtained is homogeneous.

Finally, the filler is added to the foam, taking care that the stirring is continuous to achieve a homogeneous mixture, which can then be poured into the desired shape.

If a pure melamine-formaldehyde foam is to be produced, this last step is not carried out.

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The properties or relative amounts of resin, water, blowing agent, Acid catalyst and filler, for example an inert mineral powder as used in the present invention are given in Table 1 below:

Table 1

Components by weight

Kelamin resin "100

Blowing agent (anionic detergent) 2-10

Haters 100-800

Acid catalyst 0-2.5

Fillers 0 - 200

The properties of the obtained from the above procedure Materials are as follows:

a) The color of the material depends on the filler added. If the foam has no added filler, the color is white. The product shows a low density, the brittleness of the material decreases with a decrease its density, but even with low-density formulations, the material withstands pressure and tension, how they can be applied by hand.

b) The product is resistant to water and corrosive effects Agents and is not subjected to modifications of its properties in long contact with such agents.

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c) The density of the material achieved is in the range between 0.05 g / cm ^J up to densities of about 1.00 g / cm " ³ , depending on the amount of water and foaming agent used in the formulation.

b) The compression resistance from 5.0 kgf / cm to 80 kgf / cm
increases linearly with density.

e) The material shows an internal alveolar or cellular
Structure consisting of closed cells, which means that it has excellent thermal and acoustic insulation properties. Its outer surface, however, shows an attractive appearance with a glossy resin layer without interruptions.

f) The material is not flammable.

g) The surface of the material can be painted using conventional methods and products or even with materials available on the market, such as wallpaper, metal foils and wood foils and other types of coatings
laminated plastic material.

All of the technical details mentioned in the description are important for the invention.

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Claims (5)

PATENT CLAIMS 1. Rigid foam made from synthetic resin systems and various fillers, characterized in that the rigid foam consists of a mixture of melamine resins and an acidic blowing agent with or without an acidic polymerization reaction catalyst and an amount of "free" water, and variable proportions are more inert May contain fillers. 2. Rigid foams according to claim 1, characterized in that the relative proportions of the various components for each 100 parts by weight of the melamine resin in the range between 2 to 10 parts of blowing agent, 100 to 800 parts of water, 0 to 2.5 parts acid catalyst and 0 to 200 parts of inert filler. Process for the production of rigid melamine resin foams for production of products of low density, excellent mechanical strength (compressive stress), alveolar internal structure (closed cells) for use as a material with excellent acoustic and thermal insulation properties with using the compositions according to claim 1 or 2, characterized in that the mixture of water and blowing agent foamed or a gas is generated in situ or a gas is introduced into the mixture of water and blowing agent and that then, with continued stirring, a melamine resin monomer is introduced into the foam and optionally an acid catalyst is added and that then the resin is cured, which curing can be carried out at room temperature or above room temperature. 4. The method according to claim 3, characterized in that the mixture of water, blowing agent and melamine resin monomer 5098U / 0973 volatile organic solvent is added, with the progress of the polymerization reaction caused by the reaction The heat released is sufficient to cause the mixture to foam. 5. The method according to claim 3 or 4, characterized in that a mixture of aqueous foam, which is a detergent or a Contains blowing agent, cured with melamine resin with or without an acidic catalyst at room temperature or above room temperature is, which inert fillers may be included. 509814/0973