EP1641425A1 - Procede de production d'une charge composite silanisee et procede de production d'un materiau composite - Google Patents

Procede de production d'une charge composite silanisee et procede de production d'un materiau composite

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Publication number
EP1641425A1
EP1641425A1 EP04738972A EP04738972A EP1641425A1 EP 1641425 A1 EP1641425 A1 EP 1641425A1 EP 04738972 A EP04738972 A EP 04738972A EP 04738972 A EP04738972 A EP 04738972A EP 1641425 A1 EP1641425 A1 EP 1641425A1
Authority
EP
European Patent Office
Prior art keywords
weight
silane
core material
coupling agent
filler
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04738972A
Other languages
German (de)
English (en)
Inventor
Joachim KARTHÄUSER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
NANON AS
Original Assignee
NANON AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by NANON AS filed Critical NANON AS
Publication of EP1641425A1 publication Critical patent/EP1641425A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
    • C03C17/28—Surface treatment of glass, not in the form of fibres or filaments, by coating with organic material
    • C03C17/30—Surface treatment of glass, not in the form of fibres or filaments, by coating with organic material with silicon-containing compounds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K6/00—Preparations for dentistry
    • A61K6/70—Preparations for dentistry comprising inorganic additives
    • A61K6/71—Fillers
    • A61K6/76—Fillers comprising silicon-containing compounds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K6/00—Preparations for dentistry
    • A61K6/80—Preparations for artificial teeth, for filling teeth or for capping teeth
    • A61K6/884—Preparations for artificial teeth, for filling teeth or for capping teeth comprising natural or synthetic resins
    • A61K6/887—Compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/40—Organo-silicon compounds

Definitions

  • a method of producing a silanized composite filler and a method of producing a composite material A method of producing a silanized composite filler and a method of producing a composite material.
  • the invention relates to methods of producing a silanized composite filler and a composite material comprising said filler.
  • the composite material produced according to the invention may in principle be used for any applications, but it is in particular useful when high strengths are desired.
  • Composites comprising fillers are common today.
  • the interface between the filler and the polymeric material is of significant importance to the properties of the composite material.
  • the interface adjusts the mechanical resistance of the composite and the amount of filler which may be incorporated into a matrix.
  • thermoplastics or thermosets In order to enhance the compatibility and the adhesion forces of fillers with the surrounding matrix, often thermoplastics or thermosets, it is commonly practiced to treat the surface of the filler.
  • a coupling agent such as phosphorus- based compounds, carboxylic acids, titanates, amines etc.
  • silanes An often used coupling agent is functional silanes (as spray, aqueous or alcoholic solution, or as dry blend).
  • Silanes ensure strong bonding between the filler and the silicium atom of the silane on the one hand, and improved bonding between the chemical groups of the silane and the surrounding matrix on the other hand.
  • These silanes are available in differently reactive forms. As an example, chlorosilanes react fast with water-containing surfaces whilst alkoxysilanes can be employed if a lower reaction speed is preferred. Equally, a range of silane functionalities are available to afford compatibility with different plastic types. Some commercially available silanes or silane functionalities perform merely on the basis of chemical "likeness", others allow reactive cross-linking via e.g. vinyl bonds.
  • US 4,740,538 discloses coated minerals as fillers.
  • the minerals are coated with an alkoxysilane using conventional coating methods e.g. by treatment in a fluidized bed.
  • US 5,332,429 discloses a method of treating fluoroaluminosilicate glass filler with a silanol in an aqueous solution optionally comprising alcohol or ketone solvents.
  • the objective of the present invention is to provide an alternative or even improved method of applying a coupling agent to a filler for a composite material, which method is simple to use and inexpensive, and whereby a good or even improved bonding between filler and composite matrix material can be obtained.
  • silane coupling agents can be applied to the surface of a filler in a simple and effective process.
  • the total composition of the solvent, pre and after treatments and the selection of silane coupling agents may be obtained as it is further described in the following.
  • the method of the invention contributes to the art by providing new alternatives for use giving the user the desired benefits.
  • the method of the invention for producing a silanized composite filler comprises the steps of
  • the filler core material may in principle be of any type of material or combinations of materials which under the treatment conditions are in solid form.
  • Such filler core materials are generally known in the art, and examples hereof are e.g. disclosed in US 2003/0083516, US 5,968,652, US 2001/00366617, US 5,861 ,445 and US 4,740,538.
  • the filler core material may e.g. be selected for adding properties such as mechanical properties e.g. strength, wearing, durability, low-weight, etc. to the final matrix into which is to be incorporated.
  • the core material may also be selected in order to reduce cost, to change surface characteristics or for other reasons.
  • the filler core material is selected from the group of metals such as, aluminum, tin, lead, magnesium, calcium, strontium, barium, titanium, zirconium, vanadium, chromium, manganese, iron, cobalt, nickel, copper and zinc; metal oxides/ hydroxides such as alumina trihydrate, oxides of aluminum, tin, lead, magnesium, calcium, strontium, barium, titanium, zirconium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, antimony and zinc; metal salts, such as phosphates, sulfides, and sulfates; minerals such as spodumene, mica, montmorillonite, kaolinite, bentonite, hectorite, beidellite, attapulgite, chrysolite, garnet, saponite, and hercynite; ceramic materials such as hydrated or anhydrous silicas, silica, silicate glass, quartz
  • the filler core material is selected from the group of silica, fumed silica, silica made by sol-gel chemistry, silicate glass, quartz, barium silicate, barium sulphate, barium molybdate, barium methacrylate, barium yttrium alkoxy, strontium silicate, barium borosilicate, strontium borosilicate, borosilicate, lithium silicate, amorphous silica, calcium phosphate, calcium carbonate, alumina, aluminium zirconia, tinoxide, tantalum oxide, niobium oxide, and titania glass, carbon black, graphite, cristobalite, silica, zircon-silica, calcium metasilicate (e.g. wollastonite), calcium magnesium silicate, and mixtures thereof.
  • sol-gel chemistry silicate glass, quartz, barium silicate, barium sulphate, barium molybdate, barium methacrylate, barium y
  • the filler core material may in one embodiment be porous, such as with pores e.g. as described for the filler disclosed in US 5,968,652.
  • the filler is nonporous particles.
  • the filler may in principle have any shape and size e.g. in the form of particles or fibers or mixtures thereof.
  • the type, the size and the shape of the desired filler depend largely on their intended use e.g. in paints, in dental cements, in insulating materials and e.t.c.
  • the filler core material comprises or preferably is in the form of particles having particle diameters in the range from about 0.001 ⁇ m (1 nm) to about 4 mm, such as for dental cement use 0.001-100 ⁇ m (e.g. between 0.005 and 1.0 ⁇ m), such as 1 mm to 4 mm for use in road marking materials.
  • having particle diameters is meant - unless other is specified - that at least 95 % by weight, preferably at least 98 % by weight of the particles are within the specified ranged as measured using sieving.
  • the particles and/or fibers have a BET surface area of between 0.1 and 1000 m 2 /g, such as between 1 and 500 m 2 /g measured using gaseous nitrogen.
  • the filler core material comprises or preferably is in the form of fibers.
  • a fiber means in this context a unit with a length to diameter aspect ratio of 2 or more.
  • the fibers may be chopped or non- chopped, single crystalline or polycrystalline, single filaments or polyfilaments.
  • the fibers may e.g. have an aspect (length to diameter) ratio of 2 to 1000, such as from 2 to 300, such as from 3 to 200, such as preferably at least 20.
  • the diameter of the fibers may preferably being in the range of up to about 3000 ⁇ m, such as in the range from 0.001 ⁇ m to 100 ⁇ m, such as in the range from 0.01 ⁇ m to 10 ⁇ m.
  • glass fibers are preferred due to their low cost and high strength. Such glass fibers may advantageously be used in a polymer glass fiber matrix as further disclosed below.
  • the filler core material is spherical hollow glasses (bobbles) e.g. with a particle size between 0.01 and 100 ⁇ m.
  • This hollow filler core material may preferably be used in insulating materials e.g. mixed in a ratio of 10-70 % by weight.
  • the covering of filler core material when the filler core material is relatively small such as with a major amount (50 % by weight measured using sieving) of filler with diameter or particle size less than 10 ⁇ m, or even less than 1 ⁇ m
  • the low surface tension of pressurized CO 2 allows diffusion and prevents baking together of the filler core material particles/fibers.
  • Such baking together of filler core material particles/fibers is often seen in prior art methods. This effect may be further improved by using a surfactant as described further below.
  • the filler core material comprises or is in the form of a woven or non-woven fiber unit, such as a fiber mat.
  • silane coupling agent includes silane components as well as silanol compositions e.g. with 1-3 OH-groups.
  • Silanol is hydrolyzed silane (e.g. alkoxy silans and chloro silans).
  • the silane coupling agent is in the form of a monomeric, oligomeric or polymeric alkoxy- or chlorosilane coupling agent such as ethylenically-unsaturated alkoxysilane coupling agent or a combination or mixture thereof.
  • the silane coupling agent comprises at least one of the groups vinyl groups, allyl groups, alkyl groups, styryl groups, aromatic groups, chloromethylaromatic groups, amino groups, isocyanate groups, halogen atoms such as fluorine or chlorine or bromine atoms, epoxide groups, mercapto groups, acrylic groups, metacrylic groups, silazane groups, and azido groups.
  • the method of the invention is highly beneficial when the silane coupling agent includes alkoxysilanes or chlorosilanes in that alkoxysilanes yield alcohols which in prior art methods are difficult to remove upon deposition onto surfaces containing hydroxyl groups, and chlorosilanes yield HCI which is equally difficult to remove and poses HSE risks for operating personnel.
  • HCI needs to be removed quantitatively.
  • These byproducts as well as HCI are easily removed using CO 2 containing medium.
  • water and alcohol as carriers, as well as silanols formed in the reaction of chlorosilane with water or alcohol, which need to be removed as they adversely effect the composite stability, can easily be removed using CO 2 containing medium according to the invention.
  • the silane coupling agent is selected so that it is capable of bonding chemically via ionic and/or covalent bondings to the filler core material.
  • the silane coupling agent is selected so that it is capable of bonding physically to the filler core material e.g. by adhesion, hydrogen bondings or by cross-linking to itself.
  • both chemical and physical bondings will be provided between the silane coupling agent and the filler core material.
  • the silane coupling agent is selected so that it is capable of bonding chemically via ionic and/or covalent bondings to the polymer matrix material. " In another embodiment, the silane coupling agent is selected so that it is capable of bonding physically to the polymer matrix material e.g. by adhesion, hydrogen bondings or by cross-linking to itself. In one embodiment, both chemical and physical bondings will be provided between the silane coupling agent and the polymer matrix material.
  • the silane coupling agent is selected from the group consisting of the following silanes or the corresponding silanols: vinyltrimethoxysilane, vinyltriethoxysilane, vinyltri-(2-methoxyethoxy)-silane, vinylbenzylcationic silane, ⁇ -methacryloxypropyltrimethoxysilane, ⁇ -amino- propyltrimethoxysilane, ⁇ -aminopropyltriethoxysilane, N-( ⁇ -aminoethyl)- ⁇ - aminopropyltrimethoxysilane, ⁇ -(3 4-epoxycyclohexyl)-ethyltrimethoxysilane, ⁇ -gycidoxypropyltrimethoxysilane, ⁇ -mercaptopropyltrimethoxysilane, isocy- anotoethyltrimethoxysilane, isocyanatopropyltrimethoxys
  • silane coupling agent carrying relative large substituents which is difficult or impossible to dissolve in water and organic solvents, and thereby not applicable in practice in the prior art methods, because the treatment proceeds from an emulsion with long reaction times and side reactions competing with the surface treatment as consequence. This is due to the fact that CO 2 has shown to exhibit excellent solubility properties for silane coupling agent under pressure. Furthermore, short reaction times are achieved in general using the CO 2 containing medium according to the invention.
  • the silane coupling agent has a relatively low molecular weight, such as preferably below 500 g/mol, e.g. between 150 and 400 g/mol.
  • a particularly improved silanized composite filler can be obtained. It has thus been found that by using such low molecular silane coupling agent the coating onto the filler core material has shown to become highly homogenous, and with increased bonding strength, which furthermore results in a silanized composite filler which can be bonded with a very high bonding strength to a composite matrix.
  • the silane coupling agent has a surface tension which is less than the surface tension of water (72 dyn/cm at 20 degree C).
  • the treatment medium comprises CO 2 .
  • the amount of CO 2 should preferably be a significant amount, and even more preferred a dominant amount such as at least 50 % by weight, such as at least 75 % by weight, such as at least 85 % by weight, such as at least 90 % by weight, such as at least 95 % by weight, such as essentially pure CO 2 .
  • the remaining part of the treatment medium may in principle be anything that does not prevent the desired reaction between the filler core material and the silane coupling agent.
  • the treatment medium comprises up to 50 % by weight of water, such as up to 25 % by weight of water, such as up to 10 % by weight of water, such as up to 5 % by weight of water, such as up to 1 % by weight of water.
  • silanes e.g. silanetriols with hydrophobic residues are entirely soluble in the treatment medium as well as in water.
  • the limit of the solubility in water is given by 6 carbons in an aliphatic and 7 carbons in an aromatic silane. Longer residues lead to the formation of micelles with a hydrophobic core.
  • the tendency of phase separation increases again when the silanetriol starts to polycondense, because the resulting oligosilanes are more or less insoluble in water.
  • the stability of the silanetriol solutions depends strongly on their pH. A pH-range of 2-4 is most favorable for a maximum stability. (H. R. Kricheldorf, Silicon in Polymer Synthesis, Springer Verlag Berlin, 1996, p.418-421).
  • sc-CO 2 (or liquid CO 2 ) silanetriols with longer carbon chains are soluble. Moreover the pH in sc-CO 2 is between 2.8 and 3.0 in a temperature range of 25 to 70°C and a pressure of 70 to 200 atm. in the presence of small amounts of water.
  • silane coupling agent is soluble in the treatment medium.
  • silane coupling agent having low molecular weight e.g. between 150 and 500 g/mol is preferred.
  • silane coupling agent can be dispersed in the treatment medium.
  • the treatment medium comprises up to 50 % by weight of an organic solvent such as alcohols, ketones, paraffins, ethers, amines, aromatics, such as up to 25 % by weight of organic solvent, such as up to 10 % by weight of organic solvent, such as up to 5 % by of organic solvent.
  • an organic solvent such as alcohols, ketones, paraffins, ethers, amines, aromatics, such as up to 25 % by weight of organic solvent, such as up to 10 % by weight of organic solvent, such as up to 5 % by of organic solvent.
  • the coupling agent is more effective in forming chemical bondings with the filler core material.
  • the treatment medium comprises a surfactant, e.g. up to about 3 %, such as up to about 1 %, such as up to about 0.2 % by weight of surfactants.
  • the surfactants may in principle be any type of surfactant such as anionic, cationic, non-ionic and amphoteric surfactants. It has surprisingly been found that the detergent results in a faster process, which also may provide a larger concentration of silane coupling agents bonded onto the surface of the filler core material. It is believed that the major purpose of the detergent is to modify the surface tension of the filler core material to increase wetting properties with the treatment medium.
  • the wettability of the filler core and the silane coupling agent with the CO 2 treatment medium may be increased and thereby improving the reaction speed.
  • the detergent may preferably be in form of a liquid or in the form of a solution.
  • the detergent should preferably be added to keep the surface tension below a desired level, e.g. 50 dyn/cm, more preferred in the range between 20 and 45 dyn/cm.
  • the CO 2 is in its liquid state during the treatment step. At least part of the silane coupling agent should preferably be dissolved or dispersed in the treatment medium. Thus, in one embodiment the silane coupling agent is partly or preferably totally dissolved or dispersed in the treatment medium containing CO 2 .
  • the CO 2 is in its supercritical state during the treatment step. At least part of the silane coupling agent should preferably be dissolved or dispersed in the treatment medium. Thus, in one embodiment the silane coupling agent is partly or preferably totally dissolved or dispersed in the treatment medium containing CO 2 .
  • the CO 2 may convert from one state to another.
  • the CO 2 is changing from its liquid state/gas state to its supercritical state during the treatment step. This may be performed by changing the pressure and/or the temperature.
  • the treatment may be speeded up. Furthermore this change of state may result in an instant intermixing of the filler core/silane coupling agent and the treatment medium, whereby additional stirring may be superfluous, thereby resulting in a saving in equipment.
  • the amount of silane coupling agent to CO 2 containing medium may vary depending on the filler core material and the silane coupling agent used. In one embodiment, the amount of silane coupling agent to treatment medium is between 0.001 :1 w/w and 1 :1 , preferably in the range of 0.01 :1 w/w and 0.1 :1.
  • the inventor of the present invention has found that particles with relatively small amounts of silane coupling agent when incorporated in a polymeric matrix result in surprisingly good cohesion properties.
  • the amount of silane coupling agent is selected so that the final filler comprises between 0.01 % and 1 %, such as between 0.05 % and 0.5 %, such as between 0.08 % and 0.2 % by weight of the silane coupling agent.
  • the amount of silane coupling agent is selected so that the final filler comprises between 0.01 % and 1 %, such as between 0.05 % and 0.5 %, such as between 0.08 % and 0.2 % by weight of the silane coupling agent
  • the filler core material has a particle size so that the BET surface area measured using N 2 gas is 50 m 2 /g or higher, such as between 100 and 100 m 2 /g.
  • a silanized filler is particularly useful in a dental cement as described further below.
  • the filler core material is in the form of glass fibers having a length to diameter aspect ratio of 20 or more, such as from 25 to 500, such as from 50 to 200.
  • the pH value of the treatment medium may advantageously be adjusted to either 5 or less or 8 or higher to thereby promote hydrolysis of the silane.
  • the added surfactant may e.g. additionally be used for adjusting pH value.
  • the filler core material is subjected to a cleaning step prior to or simultaneously with the silane treatment step.
  • This cleaning step may preferably comprise the step of subjecting the filler core material to a cleaning medium comprising CO 2 .
  • the cleaning medium may have a composition as disclosed above for the treatment medium.
  • the cleaning medium and the treatment medium may be different from each other or they may be equal.
  • the cleaning medium and the treatment medium have essentially equal composition.
  • This embodiment is particularly simple to perform as the cleaning and treatment may be carried out simultaneously or immediately after each other in the same reactor, using the same medium as cleaning medium and treatment medium.
  • the cleaning step is initiated prior to initiation of the treatment step, such as preferably at least one minute prior to initiation of the treatment step, such as preferably at least 5 minutes prior to initiation of the treatment step, such as preferably at least 10 minutes prior to initiation of the treatment step, such as preferably at least 15 minutes prior to initiation of the treatment step.
  • the treatment step may e.g. be initiated simply by adding the silane coupling agent to the reaction chamber.
  • the combined cleaning-treatment method is highly beneficial first of all because of its simplicity, but also because of the improved filler material obtained.
  • the simplicity of the combined cleaning-treatment method is due to the fact that the method may be carried out virtually as a one step method.
  • the filler core material and the cleaning medium are placed in a reactor and the pressure and e.g. temperature are regulated to the desired level, after a certain time, which optimally is at least 5 minutes, the silane coupling agent is added to the reaction chamber optionally together with additional CO 2 or other additional parts of the treatment medium. Simultaneously the temperature and/or pressure may be adjusted to the treatment conditions, and the treatment is performed.
  • the silane treated filler core material may additionally be subjected to an impregnating step comprising depositing additional components to the silane treated filler core material.
  • an impregnation step is well known in the art, and an example hereof is disclosed as the impact modifiers in US 4,740,538.
  • the impregnating step comprises depositing one or more impregnating components in the form of organic components, such as polymer or polymer precursors (including monomers, dimers and oligomers) to the silane treated filler core material, said impregnating components preferably being added from an impregnating medium comprising CO 2 .
  • organic components such as polymer or polymer precursors (including monomers, dimers and oligomers)
  • the impregnating component(s) is/are selected from the group consisting of mono or multifunctional monomers, such as monomers comprising one, two or more ethylenically unsaturated double bonds e.g. including unsaturated amides such as 2-acrylamidoglycolic acid, methylene bis-acrylamide, methylene bis-methacrylamide, 1 ,6-hexamethylene bis- acrylamide, tetra acrylamido glycuril (" TAGU”) and diethylenetriamine tris- acrylamide; linear, branched or cyclic polymer of ethylenically unsaturated monomers, polyester, polyamide, polyether, polyethyleneglycol, polysaccharide, cellulose, polyproplylene, polyacrylonitsile, polyurethane, poly(vinyl chloride), poly(methyl methacrylate), phenol-formaldehyde, melamine-formaldehyde, and urea-formaldehyde; -
  • the impregnating component(s) is/are selected from the group consisting of mono-, di- or polyfunctional acrylates and methacrylates such as methyl acrylate, methyl methacrylate, ethyl acrylate, isopropyl methacrylate, n-hexyl acrylate, styryl acrylate, allyl acrylate, glycerol diacrylate, glycerol triacrylate, ethyleneglycol diacrylate, diethyleneglycol diacrylate, triethyleneglycol dimethacrylate (“TEGDMA"), tetraethyleneglycol dimethacrylate, polyethyleneglycol dimethacrylate (e.g., "PEG200 DMA", “PEG400 DMA” and "PEG600 DMA” with an average of 4.5, 9 and 13.6 ethyleneglycol groups or “units” respectively), 1 ,3-propanediol diacrylate, 1 ,3-propanediol diacryl
  • the impregnating medium may have a composition as disclosed above for the treatment medium.
  • the impregnating medium and the treatment medium may be different from each other or they may be equal.
  • the impregnating medium and the treatment medium have essentially equal composition. This embodiment is particularly simple to perform as the cleaning and treatment may be carried out immediately after each other in the same reactor, using the same medium as impregnating medium and treatment medium.
  • the silane treated filler core material may additionally be subjected to a curing step for further curing of the silane coating and optional impregnation of the coating.
  • the curing step may e.g. include subjecting the silane treated filler core material to increased temperature or radiation or other activating treatments as are generally known in the art.
  • Curing may preferably be performed in the treatment reactor under inert gas atmosphere. Thereby oxidation and degradation risks are minimized.
  • the silane treated filler core material may further be subjected to a final rinsing step for removing soluble products, said rinsing step preferably including subjecting the silane treated filler core material to a flushing with a flushing medium comprising CO 2 , such as at least 50 % by weight, such as up to about 75 % by weight, such as up to about 85 % by weight, such as up to about 90 % by weight, such as up to about 95 % by weight of CO 2 , such as essentially pure CO 2 , the remaining of the flushing medium preferably consisting of water, organic solvents and/or surfactants.
  • the flushing medium may have a composition as disclosed above for the treatment medium.
  • the flushing medium and the treatment medium may be different from each other or they may be equal.
  • the flushing medium and the treatment medium have essentially equal composition. This embodiment is particularly simple to perform as the cleaning and treatment may be carried out immediately after each other in the same reactor, using the same medium as impregnating medium and treatment medium.
  • the treatment medium (or medium if the same is used for all steps) may be recirculated, and extracted components such as reaction by-products (e.g. HCL) may be removed and thereby pollution and HSE risk may be reduced.
  • reaction by-products e.g. HCL
  • the cleaning medium, the treatment medium, the impregnating medium and the flushing medium have essentially the same composition, which provides a very simple method.
  • the final silane treated filler core material may, if necessary, be subjected to a drying step. In most situations this step is not necessary as the final silane treated filler is already dry due to the use of the medium(s).
  • the "solvent" carbon dioxide is completely removed upon depressurizing. Dynamic drying is therefore not needed.
  • the invention also relates to a method of producing a composite material comprising the steps of producing a silanized composite filler using the method as described above and mixing said silanized composite filler with an optionally curable composite matrix material.
  • a method of producing a composite material comprising the steps of producing a silanized composite filler using the method as described above and mixing said silanized composite filler with an optionally curable composite matrix material.
  • the composite matrix material may in principle be any type of polymeric material.
  • the composite matrix material may in one embodiment be selected from the group consisting of -linear, branched or cyclic polymer of monomers such as ethylenically unsaturated monomers or difunctional materials such as diols, diamines, diisocyanates, dicarboxylic acids, the thus derived polymers being selected from the group of polyester, polyamide, polyether, polyethyleneglycol, polysaccharide, cellulose, polyethylene, polyproplylene, polybutylene, polyacrylonitrile, polyurethane, poly(vinyl chloride), poly(methyl methacrylate), polystyrene, polysulfone, polycarbonate, fluoropolymers such as polytetrafluoroethylene, polyvinyldifluoride, synthetic and natural rubber, thermoplastic elastomer, silicone rubber, phenol-formaldehyde, melamine- formaldehyde, and urea-formal
  • the composite matrix material may in one embodiment be selected from the group consisting of mono-, di- or polyfunctional acrylates and methacrylat.es such as methyl acrylate, methyl methacrylate, ethyl acrylate, isopropyl methacrylate, n-hexyl acrylate, styryl acrylate, allyl acrylate, glycerol diacrylate, glycerol triacrylate, ethyleneglycol diacrylate, diethyleneglycol diacrylate, triethyleneglycol dimethacrylate (“TEGDMA”), tetraethyleneglycol dimethacrylate, polyethyleneglycol dimethacrylate (e.g., "PEG200 DMA", “PEG400 DMA” and "PEG600 DMA” with an average of 4.5, 9 and 13.6 ethyleneglycol groups or “units” respectively), 1 ,3-propanediol diacrylate, 1 ,3-propanediol dime
  • the curing between the silanized filler and the composite matrix is afforded by cross linking saturated or unsaturated organic groups attached to both the filler and present in the composite matrix, said cross linking e.g. being provided by applying radiation such as UV-iight or gamma- radiation and/or by activation (decomposition) of previously admixed peroxides or azocompounds such as dicumylperoxide or bis-[t-butylperoxy] compounds or azo-bis-isobutyronitril.
  • the composite material may in principle be for any type of use.
  • the composite material is a composite material for use in the industrial, automotive, aviation and aerospace sector, such as parts which can be produced by injection moulding, extrusion, calendering or moulding.
  • the composite material is a dental cement.
  • the filler core material is selected from the group consisting of crystalline quartz, pyrolytic silica (SiO 2 ), lithium aluminium silicate, glass, boron glass and barium glass. All of these filler core materials have high hardness, chemical inertness and refractive index and opacity close to that of tooth structure.
  • the filler core material is a glass bead, preferably in the form of relatively fine powder, such as a glass bead with a particle size so that the BET surface area measured using N 2 gas is 50 m 2 /g or higher, such as between 100 and 100 m /g.
  • the filler core material is an inorganic material and has a particle size between 0.005 and 1.0 ⁇ m
  • the filler core material for the dental cement may preferably be treated so that the amount of silane coupling agent is selected to provide the glass bead with between 0.01 % and 1 %, such as between 0.05 % and 0.5 %, such as between 0.08 % and 0.2 % by weight of the silane coupling agent.
  • the dental cement should preferably be relatively highly filled with the silanized composite filler (preferably silanized glass beads), such as with a filling degree of at least 10 % by weight, such as between 15 and 90 %, such as between 50 and 80 % by weight of silanized composite filler of the total dental cement.
  • the polymer matrix could in principle be any type of polymer matrixes, but preferably the matrixes which are particularly adapted for dental use include Bisphenol-diglycidol methacrylate (Bis-GMA), Urethane dimethacrylate (UDMA), Triethylenglycol dimetahcrylate (TEGDMA) and Bisphenol A polyethylene glycol diether dimethacrylate (Bis-EMA).
  • Bisphenol-diglycidol methacrylate Bisphenol-diglycidol methacrylate
  • UDMA Urethane dimethacrylate
  • TEGDMA Triethylenglycol dimetahcrylate
  • Bis-EMA Bisphenol A poly
  • the polymer matrix is light curable, and includes a catalyst which is already mixed into the paste, but does not become active until illuminated with a strong light.
  • the dental cements may e.g. further comprise one or more of the following components zinc oxide-eugenol, zinc phosphate, zinc silico-phosphate, zinc- polyacrylate, zinc-polycarboxylate, glass ionomer, colour modifiers and pigments (e.g. titan dioxide and metal oxide pigments).
  • the invention also relates to the use of composite material as a dental cement, as well as the dental material itself.
  • the dental cement according to the invention has been found to have a very high biocompability, and does not result in release of excessive amounts of fluoride which is a common problem of prior art dental cements. Furthermore the dental cement of the invention has a high cohesiveness, comparable or even improved with respect to prior art dental compositions. Yet the dental cement according to the invention can be produced at lower cost than comparable conventional dental cements.
  • the composite material is a paint.
  • the filler core material is mineral fibers or beads e.g. glass beads, preferably in the form of relatively fine powder, such as glass beads with a particle size so that the BET surface area measured using N 2 gas is 50 m 2 /g or higher, such as between 100 and 100 m 2 /g.
  • the glass beads for the paint have a particle size between 0.5 - 100 ⁇ m.
  • the glass beads may preferably be of mineral glass.
  • the filler core material is fibers, such as mineral fibers e.g. glass fibers.
  • the fibers may preferably have a diameter of from 0.5 to 3000 ⁇ m.
  • the aspect ration may e.g. be as disclosed above.
  • the mineral fibers or beads may preferably be treated so that the amount of silane coupling agent is selected to provide the mineral fibers or beads for the paint with between 0.01 % and 2 %, such as between 0.1 % and 1 %, such as about 0.5 % by weight of the silane coupling agent.
  • the filling degree in the paint may vary largely in dependence of the use of the paint, but normally it will be up to about 30 % by weight, such as between 1 and 25 % by weight of the paint in its dilution as recommended for use.
  • the polymer matrix could in principle be any type of polymer matrixes, but preferably the matrixes which are particularly adapted for paints such as epoxy paint.
  • the paint may e.g. further comprise pigments, thinner, dryer and other additives as are normally used in conventional paints
  • the invention also relates to the use of composite material as a paint cement as well as the paint itself.
  • the paint according to the invention has been found to have a desirably high cohesiveness and further it has been found that the silanized glass beads result in a corrosion protection which makes the paint highly useful in e.g. ship paint applications.
  • the composite material is a polymer glass fiber matrix
  • the glass fibers may in this polymer glass fiber matrix preferably have a relatively high length to diameter aspect ratio, such as preferably at least 20 or more, such as from 25 to 500, such as from 50 to 200.
  • the polymer matrix may e.g. be a thermoplast or a non-thermoplast (curable polymer).
  • the polymer matrix may be as disclosed in the general method of the invention above, e.g. PE, PP, PA, epoxy, PET and etc.
  • the silane coupling agent is selected so that the final glass fiber filler comprise between 0.01 % and 1 %, such as between 0.05 % and 0.5 %, such as between 0.08 % and 0.2 % by weight of the silane coupling agent.
  • This polymer glass fiber matrix is particularly useful as material for applications in the automobile and ship industry.
  • the glass fibers e.g. PPG (3310), E-glass, 3-6 mm in length
  • the glass fibers are silanized using octyltriethoxysilan as silane coupling agent and thereafter the silanized glass fibers are mixed with PE.
  • the amount of silane may e.g. be 1 wt% silane or 0.2 wt% silane or anything there between.
  • the glass fiber mat is silanized using 3-(triethoxysilyl)- propylamin as silane coupling agent and thereafter the silanized glass fibers are mixed with PET.
  • the invention also relates to the use of the polymer glass fiber matrix in the automobile and ship industry as well as the polymer glass fiber matrix itself.
  • a polymer glass fiber matrix according to the invention is for use in the pump industry, in particular for cooling wheels for pumps.
  • the glass fibers are silanized using 3-(triethoxysilyl)- propylamin as silane coupling agent and thereafter the silanized glass fibers are mixed with nylon (PA).
  • PA nylon
  • the amount of silane may e.g. be 1 wt% silane or 0.2 wt% silane or anything there between. Examples
  • the treatment steps include at least one of the following processes:
  • a specific embodiment relates to a new material designed for windmill wings.
  • silane-treated glass fiber mats and epoxy resins are employed.
  • glass fiber mats are treated in pressurized gas, especially containing carbon dioxide, and with silanes carrying long alkyl chains, vinyl-, aromatic- and other groups.
  • the glass fibers are thereafter moulded together with polyolefins, polyesters, polyurethanes, silicones and similar thermoplastics. This results in wings with comparable mechanical properties, but with the advantages of (i) lower production and material costs, (ii) recycleability.
  • Example 2 Example 2
  • Glass filler core material fibers or beads
  • silane coupling agent are placed separately in a pressure reactor. They may be positioned in different compartments of the reactor, or the silane coupling agent may be dosed into the reactor at a later stage after pressurizing, and the glass material may optionally be held in gas and liquid permeable bags to ease handling.
  • Carbon dioxide is added to the reactor typically up to a pressure of 40 bars and a temperature of 15 degree C. Higher and lower temperatures and pressures may be applied.
  • the reactor content is agitated, either by rotating the reactor itself (for small scale experiments) or by rotating or moving baskets within the reactor, or by moving and pumping around the dense phase medium (CO2). After 15-30 min, reaction is completed, and products are either post-cured 24 hrs at room temperature, alternatively 2-4 hours at around 100 degree C.
  • silane For very reactive silanes, it is recommendable to dose the silane successively into the reactor and / or to agitate glass fibers or glass beads simultaneously.

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  • Health & Medical Sciences (AREA)
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  • Oral & Maxillofacial Surgery (AREA)
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  • Geochemistry & Mineralogy (AREA)
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  • Pigments, Carbon Blacks, Or Wood Stains (AREA)

Abstract

L'invention concerne un procédé de production d'une charge composite silanisée, ledit procédé consistant: (i) à utiliser un matériau noyau de charge et (ii) à traiter ledit matériau noyau de charge, qui est de préférence un matériau noyau de charge inorganique se présentant par exemple sous forme de fibres ou de billes, à l'aide d'un agent de couplage silane en présence d'un milieu de traitement comprenant du CO2. Le meilleur résultat est obtenu lorsque l'agent de couplage silane est relativement petit, présentant par exemple un poids moléculaire inférieur à 500g/mol. L'invention concerne également un procédé de production d'un matériau composite comprenant la charge composite silanisée, ainsi que les produits obtenus. La charge composite silanisée est simple à produire et présente une bonne adhérence à la matrice polymère d'un matériau composite.
EP04738972A 2003-07-04 2004-07-02 Procede de production d'une charge composite silanisee et procede de production d'un materiau composite Withdrawn EP1641425A1 (fr)

Applications Claiming Priority (2)

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DKPA200301028 2003-07-04
PCT/DK2004/000475 WO2005002530A1 (fr) 2003-07-04 2004-07-02 Procede de production d'une charge composite silanisee et procede de production d'un materiau composite

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