DE2416270A1 - CONSTRUCTION MATERIALS - Google Patents

Description

DR. MÜLLER-BORS Di ^ L.-ING. GROENSNG DIPL.-CHEM. DR. DEUFEL DIPL.-CHEM. DF .. SCHÖN DiPL-PHY-S. HERTEL

PATENT LAWYERS

CASE B 1183

BRITISH INDUSTRIAL PLASTICS LIMITED Manchester / Great Britain

Construction materials

UNION PRIORITY: Great Britain No. 16096/73 of April 4, 1973

4098-3 / 1121

The invention relates to building materials or composite materials. The invention particularly relates to resin-bonded ones Materials or compositions containing expanded inorganic fillers of relatively low density, such as vermiculite, perlite, and puffed clays. These fillers possess in a loose, dry state However, they tend to have a high volume or a low volume weight if they lead to the formation of fluids Mixtures wetted with liquid binders tend to compact, making them a large one Lose part of the contents of the drying room. This is disadvantageous because it reduces the density of the bound product is increased.

The invention now relates to a composite material which contains a surface-active agent in a Mechanically foamed, essentially free of vegetable and / or mineral oil, cured synthetic resin binder containing dispersed expanded inorganic filler.

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3/1121

The invention "also relates to a method of manufacture such foamed composite materials, which is characterized in that one has a surfactant with a solution of a synthetic resin binder and either the resulting solution mechanically prior to mixing pre-foaming with an expanded inorganic filler or mixing the filler with the binder solution, while the latter is stirred for the purpose of frothing.

It has been shown that the foaming of the binder reduces the tendency of the filler when it is mixed with the binder to compact can be substantially reduced, although at the same time that which is desirable for easy handling fluid state is maintained. The binder can or can be pre-expanded before mixing with the filler be foamed while mixing in. By carefully controlling the amount of surfactant in the Binder and thus the degree of foaming, it is possible to produce composite materials that have the largest proportion, if not retain all of the original dry bulk volume of the filler and which have compressive strength, which is comparable to that of the filler as such.

The invention thus effectively permits the creation of a foamed, cured synthetic resin which is formed with is reinforced with an expanded inorganic filler, a unit volume of this product preferably being substantially substantial Contains not less than a unit volume of the dry filler (calculated in the uncompacted state).

It should be noted, however, that adding too large an amount of the surfactant will result in a composite material can, which has a larger volume than by the

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The manufacture used loose, dry filler studded will. These "over-foamed" composite materials usually exhibit reduced fire resistance, as the filler no longer has a hold when the binder is destroyed. It is believed to be the best Combination of density, compressive strength and thermal insulation properties results when the amount of binder and the content of surfactant are adjusted so that the volume of the composite materialβ or the bound composition between the dry loose volume and the wet compacted volume of the used in the manufacture of the filler material. In general, the weight ratio of binder to surfactants range from 1: 0.005 to 1: 0.1, preferably from 1: 0.01 to 1: 0.05, in particular if a urea-formaldehyde resin is used as the binder.

Urea-formaldehyde resins (including Mixtures of these resins with melamine-formaldehyde resins or phenol-formaldehyde resins), melamine-formaldehyde resins, Ketone-formaldehyde resins, furan-formaldehyde resins or water-extended polyester resins are preferred.

The bonded foamed materials or compositions of the invention can be used in the wet state, i. before the binder hardens, can be handled in a simple manner and can be poured with the Trowel applied or shaped. They also show little or no shrinkage on drying, in particular when the ratio of binder to surfactant is adjusted in the manner described above will. When dry, the materials have excellent thermal properties, including a resistance to flame erosion and are

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409843/1121

therefore different as flame retardant cores for building elements most suitable. Panels and other structural elements cast from the materials are relatively stable, show a good screw holding capacity; you can also use usual Woodworking tools are machined.

It goes without saying that according to the invention in addition to the surface-active Agent no blowing or foaming agent is required.

The following examples are intended to explain the invention further without, however, restricting it.

example

A connected foamed material is produced from a Perlitzschllagmaterial, which in the dry, compressed state has a density of about 128 kg / m and in the loose, dry state a density of about 100 kg / nr by adding 3 parts by weight of the loose Perlite with 2.8 parts by weight of a urea-formaldehyde resin with 68% by weight of pesticides, 0.9 parts by weight of water, 0.056 parts by weight of a solution of a surface-active agent ("TEEPOL" RTM) and 0 , 2 parts by weight of an ammonium thiocyanate solution, the latter serving as a hardener for the resin. The mixing process is effected in a laboratory mixer and the mixture is poured into a block. This block has a volume which is slightly larger than that of the loose perlite originally used to produce the block, the reduction in volume being about 1,500 parts by volume for an original volume of about 21,000 parts by volume. The product has a density of 240 kg / m 2, so that the effective density of the perlite is about 120 kg / nr, since the resin makes up about 50% of the composite material.

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Example2

Repeat the previous example, but with another surfactant, namely dodecylbenzenesulfonic acid, used, which serves both as a foaming agent and as a hardener for the resin. The ammonium thiocyanate solution and the surface-active agent ("TBBPOl"] is replaced by 0.028 parts by weight of dodecylbenzenesulfonic acid ("HAFSA SSA", R.T.M.) and 0.255 parts by weight of water.

As in Example 1, the mixture is cast into a block which has the same properties as those obtained in Example 1 having.

example

Example 1 is repeated using the following ingredients:

Perlite,

(Density 144 kg / m) urea-formaldehyde resin (Adhesive quality)

¥ ater

mixed alkyl aryl sulfonate ("TEEPOL 514")

15 # ammonium thiocyanate solution

Mechanical mixing of this mixture gives 0.0283 ffi of a foam with a compressive strength of 344.74

1 , 44 Weight .-Part 1 , 016 Il Il 0 , 032 If 0 η Il 0 Il

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409843/1121

Example 4

Example 3 is repeated, replacing the perlite with an equal volume of hollow ceramic spheres ("cenospheres") made from power plant fly ash. The total weight of the foamed product increases because the hollow ceramic spheres have a larger density (433 kg / nr) and the product has the same volume as that of Example 1. However, the result is a higher compressive strength of 2068.4 kN / m ² .

example

Example 3 is repeated, but replacing the perlite with an equal volume of lightweight vermiculite with a density of 80.14 kg / m 2. The product again has the same final volume as the product of Example 3, but has a compressive strength of only 69 kN / m ² .

example

Example 1 is repeated, the 2.8 parts by weight of the urea-formaldehyde adhesive resin and 0.9 parts by weight of water being passed through 2.8 parts by weight of a melamine-formaldehyde laminating resin with a solids content of 60 wt -.! $> and 0.2 wt .- parts of ammonium thiocyanate replaced by 0.2 parts by weight of a 30 #igen phosphoric acid solution. The results are the same as those obtained in Example 1.

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Example 7

The measures of Example 1 are carried out again, with but instead of 2.8 parts by weight of urea-formaldehyde adhesive resin and 0.9 parts by weight of water 2.8 parts by weight of an Aeeton-formaldehyde resin with a pesticide content of 60 wt .- # used and instead of 0.2 part by weight of ammonium thiocyanate solution, 0.2 part by weight a 20% sodium hydroxide solution. The results are again the same as those obtained in Example 1. Since this product is hardened with alkaline, it can it can be used in alkaline areas, e.g. as a core between asbestos-cement panels.

EXAMPLE OF DISPOSAL

One made from the ingredients of Example 1 but without using the surfactant A similar block has a volume weight of 400 kg / m and only half the volume.

Another sample of the mixture of Example 1 is made to produce a simulated building panel, the consist of two frame parts and 6 mm thick plywood cover plates, the mixture of filling material for the 3 cm gap is used between the panels. After the resin has hardened, the plate is checked, by directing a flame at them from a burner charged with a pressurized gas / air mixture will. Even after 45 minutes, the flame has not yet penetrated the plate, although there has been considerable erosion and charring occurred in the area of the flame impact point. The opposite side of the plate remains cold and completely unaffected.

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409843/1121

The above examples show that the compressive strength of the foamed product produced according to the invention in depends essentially on the compressive strength of the filler used in the material. It is still to be added that a hardened urea-formaldehyde foam with equivalent density not mixed with fillers has a compressive strength from about 1034 to 1379 kN / m.

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Claims (8)

PATENT CLAIMS: 1. Yerbund material containing a surface-active in one Means containing, essentially τοπ vegetable and / or mineral oil free, mechanically foamed, hardened, synthetic resin binder dispersed expanded inorganic filler. 2. Composite material according to claim 1, characterized in that that it contains not less than a unit volume of the dry filler per unit volume. 3. Composite material according to claim 1, characterized in that the content of binder and surface-active Kittel is controlled such that the volume of the material between the loose dry volume and the wet compacted volume of the filler used in the manufacture. 4. Composite material according to one of the preceding claims, characterized in that it is used as a resin binder a urea-formaldehyde resin (or a mixture thereof with a melamine-formaldehyde resin or a Phenol-formaldehyde resin), a melamine-formaldehyde resin, a ketone-formaldehyde resin, a furan-formaldehyde resin or a water-extended polyester resin. - 9 409843/1121 5. Composite material according to one of the preceding claims, characterized in that it is used as a filler Vermiculite, perlite, expanded clay or hollow ceramic spheres made from power plant fly ash contains. β. Yerbund material according to one of the preceding claims, characterized in that the weight ratio of binder to surface-active Mean is 1: 0.005 to 1: 0.10. 7. A method for producing a composite material according to any one of the preceding claims, characterized in that that a surfactant with a solution of a synthetic resin binder mixed and the resulting solution mechanically pre-foamed before it is expanded with an inorganic Filler mixed. 8. A method for producing a composite material according to any one of the preceding claims, characterized in that that a surfactant with a solution of a synthetic resin binder mixed and an expanded inorganic filler mixed with the binder solution while this stirs for the purpose of foaming.