EP2956501A1 - Composition moussage, composite de mousse polymère et procédé de fabrication du composite de mousse polymère - Google Patents

Composition moussage, composite de mousse polymère et procédé de fabrication du composite de mousse polymère

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Publication number
EP2956501A1
EP2956501A1 EP14751379.0A EP14751379A EP2956501A1 EP 2956501 A1 EP2956501 A1 EP 2956501A1 EP 14751379 A EP14751379 A EP 14751379A EP 2956501 A1 EP2956501 A1 EP 2956501A1
Authority
EP
European Patent Office
Prior art keywords
fibres
weight
foam
mixing
length
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Withdrawn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
EP14751379.0A
Other languages
German (de)
English (en)
Inventor
Dorte Bartnik JOHANSSON
Peter Farkas Binderup Hansen
Anders Bach
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.)
Rockwool AS
Original Assignee
Rockwool International 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 Rockwool International AS filed Critical Rockwool International AS
Priority to EP14751379.0A priority Critical patent/EP2956501A1/fr
Publication of EP2956501A1 publication Critical patent/EP2956501A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0085—Use of fibrous compounding ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2361/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
    • C08J2375/04—Polyurethanes

Definitions

  • the invention relates to insulating products for use in buildings in circumstances where a high compressive strength, high compression modulus of elasticity, good dimensional stability and fire resistance are required.
  • roofing boards have also been manufactured in the past in the form of foam boards. Whilst these are less dense than high-density mineral fibre boards, most have the inherent disadvantage of being much more combustible than mineral fibres so must usually be coated or otherwise treated with a suitable thermal barrier. Even when treated, the foam boards still tend to be more combustible than mineral fibre-based boards.
  • Foam boards are also prone to deterioration over time.
  • dimensional stability can be a problem, because foam materials tend to shrink over time, in particular in hot or humid conditions.
  • Composite foam materials comprising fibres are known for use in the building industry.
  • DE1991351 1 A1 describes a method of making synthetic resin polyurethane foam comprising graphite and incombustible fibres.
  • the fibres have a length of 5mm.
  • GB 882296 states that the addition of a fibrous material to liquid foamable materials causes an increase in viscosity of the foamable materials with the result that it is very difficult to stir in more than about 10% by weight of fibres, based on the weight of the foamable material.
  • the inventors of GB 882296 use a special process involving associating a foamable material with a mass of intermeshed mineral fibres, at least partially enclosing a zone around the mass, foaming the material to fill the zone and setting the foamable material.
  • the fibres used are at least about 0.5 inches long.
  • US 2003/0068485 A1 describes the use of chopped or milled fibre glass in foam as a termite repellent.
  • the fibres preferably range in length from 0.396mm to 12.7mm.
  • DE 10 2005 060 744 A1 describes a polymeric foam composite material based on fibrous material and a mixture of a curable resin with unexpanded thermoplastic particles, the particles being expanded after being impregnated in the fibrous material.
  • the proportion of fibres in the finished foam composite material is between 15 and 50 wt/%.
  • WO 94/29375 describes a fire resistant product based on an expanded polymeric foam material comprising a mixture of a foam-forming agent, a resin, fibrous material and an exfoliating material.
  • the fibrous material can comprise man-made mineral fibres and/or inorganic fibres.
  • the total content of exfoliating agent and/or made man mineral fibres is between 1 % and 90% of the total mix of materials.
  • US 4839393 describes polyurethane foams based on reactive pol ols and polyisocyanate containing a filler and modified with an organofunctional silane containing a hydrolysable group and an ethylenically unsaturated linkage.
  • the filler can be glass fibres and the production method involves producing T IB2014/000176
  • the fibre length is from about 0.25 inches to about 1.5 inches.
  • US 4,082,702 discloses a rigid polyurethane foam obtained by mixing an organic polyol, a polyisocyanate, a catalyst, microballoons and a flame retardant.
  • the mixture can also contain flexible fibres such as glass fibres which gan be chopped, preferably to about 6mm in length. There is no disclosure of fibres shorter than 150pm.
  • CN101781395 relates to a hard polyurethane adiabatic heat insulation foam material.
  • the material contains chopped glass fibre powder having a length of 100-500pm.
  • EP1878663 describes a thermal insulation panel for a thin-walled cryogenic tank.
  • the panel is formed from a polyurethane foam that is reinforced with glass fibres.
  • the fibres have an average length greater than 10mm.
  • CN2856234 describes a panel formed by combining polyurethane with glass fibres having a length of 15-150mm.
  • JPH 62210 describes a urethane foam resin embedded with carbon and glass fibres of length 13-50mm.
  • a foam composite having a high fire resistance, high compressive strength, a high compression modulus of elasticity, and a high level of dimensional stability, but with a low density as compared with high-density mineral fibre boards. Furthermore, there remains a need for a foam composite having this combination of properties that can be produced by mixing fibres into a foamable composition without complex .mixing processes to provide a homogeneous distribution of fibres within the composite.
  • the invention provides a foamable composition comprising:
  • first fibres defined as those fibres having a length less than 150pm
  • second fibres defined as those fibres having a length of at least 150pm
  • first fibres by weight are discontinuous man- made vitreous fibres, and wherein at least 60% of the first fibres by weight have a length less than 65pm and at least 30% of the second fibres by weight have a length of at least 250pm.
  • the invention provides a polymeric foam composite comprising:
  • first fibres defined as those fibres having a length less than 150pm
  • second fibres defined as those fibres having a length of at least 150pm
  • first fibres by weight are discontinuous man- made vitreous fibres, and wherein at least 60% of the first fibres by weight have a length less than 65pm and at least 30% of the second fibres by weight have a length of at least 250pm.
  • the invention provides a method for producing a polymeric foam composite according to the invention comprising:
  • first fibres by weight are discontinuous man- made vitreous fibres, and wherein at least 60% of the first fibres by weight have a length less than 65 m and at least 30% of the second fibres by weight have a length of at least 250 ⁇ .
  • the invention provides a method for producing a polymeric foam composite according to the invention comprising:
  • the inventors have found that the length distribution and the types of fibres used plays an important role in providing a composite with a desirable combination of properties.
  • the inventors have found that providing both very short man-made vitreous fibres and a portion of much longer fibres, of any suitable type, provides a foam composite which highly fire resistant, has high compressive strength and a high compression modulus of elasticity.
  • the polymeric foam composite that is produced also has a high level of dimensional stability and can be produced with simple mixing methods.
  • the weight percentage of fibres above or below a given fibre length is measured with a sieving method.
  • a representative sample of the man-made vitreous fibres is placed on a wire mesh screen of a suitable mesh size (the mesh size being the length and width of a square mesh) in a vibrating apparatus.
  • the mesh size can be tested with a scanning electron microscope according to DIN ISO 3310.
  • the upper end of the apparatus is sealed with a lid and vibration is carried out until essentially no further fibres fall through the mesh (approximately 30 mins). If the percentage of fibres above and below a number of different lengths needs to be established, it is possible to place screens with incrementally increasing mesh sizes on top of one another. The fibres remaining on each screen are then weighed.
  • first fibres are defined as those fibres having a length of less than 150 ⁇ .
  • the second fibres are defined as those fibres having a length of at least 150pm.
  • first fibres are first fibres (i.e.
  • the remaining fibres i.e. from 2 to 60% by weight of the fibres, based on the total fibre weight, are second fibres (i.e. fibres having a length of at least 150 ⁇ ).
  • second fibres i.e. fibres having a length of at least 150 ⁇ .
  • first fibres Preferably, of the fibres present in the foamable composition and in the polymeric foam composite, from 5 to 50% by weight, more preferably from 10 to 40% by weight and most preferably from 15 to 30% by weight, based on the total fibre weight, are second fibres.
  • the length distribution of the first and second fibres means that the overall combined length distribution of first and second fibres present in the foamable composition and in the polymeric foam composite is at least bimodal, having a mode below 65 ⁇ and another mode above 250pm.
  • the modes can be determined by separating fractions of the combined first and second fibres by length, at 5pm intervals for example, and weighing each fraction. A mode exists where a fraction contains more fibres by weight than either of the neighbouring length fractions. The possibility of there being more than two modes is not excluded by the phrase "at least bimodal".
  • the length distribution of the first fibres is such that at least 80% or even 85% or 90% of the first fibres have a length less than 125 micrometres.
  • the greatest compressive strength can be achieved when at least 90% by weight of the first fibres, based on the total weight of first fibres, have a length less than 100 micrometers and at least 75% by weight of the first fibres, based on the total weight of first fibres, have a length less than 65 micrometers.
  • first fibres can be included in a foamable composition at a relatively high level without processing difficulties being encountered. Therefore relatively large quantity of first fibres can be included in the foamable composition and, as a result, the compressive strength, fire resistance, and in particular the compression modulus of elasticity of the resulting foam can be improved.
  • ground fibres having such a low length would simply act as a filler, increasing the density of the foam.
  • the inventors have surprisingly found that by using first fibres having the length distribution described above, high levels of fibres can be incorporated into the foam precursor and the resulting foam. The result of this is that significant increases can be achieved in the compressive strength and, in particular, the compression modulus of elasticity of the foam.
  • the first fibres are also able to strengthen the cell walls of the foam, reducing breakage of the cell walls, which in turn reduces degradation in the insulating properties and water impermeability of the foam composite over time.
  • at least 0.5%, more preferably at least 1 % of the first fibres by weight, based on the total weight of first fibres have a length less than 10pm. Including a significant level of very short fibres is believed to assist with the foam formation process as a nucleating agent.
  • at least 50% by weight, based on the total weight of first fibres are discontinuous man-made vitreous fibres.
  • at least 60%, more preferably at least 70%, even more preferably at least 90% and most preferably substantially all of the first fibres, based on the total weight of first fibres, are man-made vitreous fibres.
  • discontinuous man-made vitreous fibres are well understood by those skilled in the art.
  • Discontinuous man-made vitreous fibres are, for example, those produced by internal or external centrifugation, for example with a cascade spinner or a spinning cup.
  • the discontinuous man-made vitreous fibres are preferably stone fibres.
  • stone fibres have a content of oxides as follows:
  • MgO up to 5%, preferably 1 to 8% or 4 to 10%
  • Composites including stone fibres of the above composition have also been found to have improved fire resistance as compared with composites in which the filler used does not contain a significant level of iron.
  • An alternative stone wool composition useful in the invention has oxide contents in the following ranges:
  • the high level of alumina in fibres of this composition can act as a catalyst in the formation of a polyurethane foam.
  • stone fibres are preferred, the use of discontinuous glass fibres and slag fibres as first fibres in the foamable composition and polymeric foam composite of the invention is also possible.
  • the man-made vitreous fibres that must make up at least 50% by weight of the first fibres in the present invention are discontinuous fibres that are preferably produced with a cascade spinner or a spinning cup.
  • the methods of the invention include the step of producing the man-made vitreous fibres with a cascade spinner or a spinning cup.
  • fibres produced by these methods have been used for insulation, whilst continuous glass fibres have been used for reinforcement in composites.
  • Continuous fibres e.g. continuous E glass fibres
  • foam composites comprising short, discontinuous fibres have a compressive strength that is at least comparable with foam composites comprising continuous glass fibres of a similar length. This unexpected level of strength is combined with good fire resistance, a high level of thermal insulation and cost efficient production.
  • the discontinuous man-made vitreous fibres In order to achieve the required length distribution of the first fibres, it will usually be necessary for the discontinuous man-made vitreous fibres to be processed further after the standard production.
  • the further processing will usually involve grinding or milling of the man-made vitreous fibres for a sufficient time for the required length distribution to be achieved.
  • the first fibres have an average diameter of from 1.5 to 7 micrometres, preferably from 2 to 6 or from 3 to 6 micrometers.
  • Thin first fibres as preferred in the invention are believed to provide a higher level of thermal insulation to the composite than thicker fibres, but without a significant reduction in strength as compared with thicker fibres as might be expected.
  • the average fibre diameter is determined for a representative sample by measuring the diameter of at least 200 individual fibres by means of the intercept method and scanning electron microscope or optical microscope (1000x magnification).
  • Any first fibres that are not man-made vitreous fibres can be any other type of suitable fibres.
  • Suitable fibres include cellulose fibres, for example in the form of cellulose pulp, carbon fibres, synthetic fibres such as aramid fibres (e.g. Kevlar), polyester fibres, polyamide fibres, PAN fibres or pre-oxidised PAN fibres, for example in the form of PAN pulp and mixtures thereof.
  • the fibres can be fibrillated fibres.
  • the amount of first fibres that are not man-made vitreous fibres is preferably kept low, however.
  • At least 30%, preferably at least 50% by weight, based on the total weight of second fibres have a length of at least 250pm.
  • at least 95%, preferably at least 97%, more preferably at least 99% of the second fibres by weight have a length of less than 6000pm.
  • Second fibres having these length distributions have been found to provide an excellent level of dimensional stability to the polymeric foam composite of the invention, even when the second fibres are included at a relatively low level. Fibres longer than 6000pm have been found to destroy bubbles during foam formation resulting in an increase in viscosity that hinders foam formation.
  • the second fibres can be any type or types of fibre that can withstand the foaming process. Generally, a certain level of heat resistance and a relatively high melting point are advantageous. For polyurethane foams, for example, it is preferred that the second fibres are stable (i.e. do not melt or degrade) up to at least 150°C.
  • At least 80%, more preferably at least 90% and most preferably substantially all of the second fibres by weight, based on the total weight of second fibres are man- made vitreous fibres, cellulose fibres, for example in the form of cellulose pulp, carbon fibres, synthetic fibres such as aramid fibres (e.g. Kevlar), polyester fibres, polyamide fibres, PAN fibres or pre-oxidised PAN fibres, for example in the form of PAN pulp or a mixture thereof.
  • the fibres can be fibrillated fibres. Most preferred are man-made vitreous fibres, in particular stone fibres.
  • the stone fibres preferably have the composition set out above in relation to the first fibres.
  • man-made vitreous fibres are present as second fibres, they are preferably discontinuous man-made vitreous fibres, more preferably produced by internal or external centrifugation, especially with a cascade spinner or a spinning cup.
  • the second fibres preferably have an average diameter of 3 to 15pm. Second fibres of this average diameter have been found to be advantageous, because thicker fibres can destroy the struts in the foam.
  • the tensile modulus of the second fibres is at least 5GPa.
  • at least 80%, more preferably at least 90%, most preferably essentially all of the second fibres by weight, based on the total weight of second fibres have this property.
  • the foamable composition comprises a combined total of first and second fibres of at least 15%, more preferably at least 20%, most preferably at least 35% by weight, based on the total weight of the composition.
  • the foamable composition comprises a combined total of first and second fibres of less than 85%, preferably less than 80%, more preferably less than 75% by weight, based on the total weight of the composition.
  • the foamable composition comprises a foam precursor.
  • the foam precursor is a material that either polymerises (often with another material) to form a polymeric foam or is a polymer that can be expanded with a blowing agent to form a polymeric foam.
  • the composition can be any composition capable of producing a foam on addition of a further component or upon a further processing step being carried out.
  • Preferred foamable compositions are those capable of producing polyurethane foams.
  • Polyurethane foams are produced by the reaction of a polyol with an isocyanate in the presence of a blowing agent. Therefore, in one embodiment, the foamable composition comprises a polyol as the foam precursor. In another embodiment, the foamable composition comprises an isocyanate as the foam precursor. In another embodiment, the composition comprises a mixture of an isocyanate and a polyol as the foam precursor.
  • foaming can be induced by adding a further component comprising an isocyanate. If the foam precursor is an isocyanate, foam formation can be induced by the addition of a further component comprising a polyol.
  • Suitable polyols for use either as the foam precursor or to be added as a further component to the foamable composition to induce foam formation are commercially available polyol mixtures from, for example, Bayer Material Science, BASF or DOW Chemicals.
  • Commercially available polyol compositions are often supplied as a pre-mixed component that comprises polyol and any or all of catalyst(s), flame retardant(s), surfactants and water, the latter which can act as a chemical blowing agent in the foam formation process. Generally it comprises all of these.
  • Such a pre-formed blend of polyol with additives is commonly known as a pre-polyol.
  • the isocyanate for use either as the foam precursor or to be added as a further component to the foamable composition to induce foam formation is selected on the basis of the density and strength required in the foam composite as well as on the basis of toxicity. It can, for example, be selected from methylene polymethylene polyphenol isocyanates (PMDI), methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI), hexamethylene diisocyanate (HDI) and isophorone diisocyanate (IPDI), PMDI or MDI being preferred.
  • PMDI methylene polymethylene polyphenol isocyanates
  • MDI methylene diphenyl diisocyanate
  • TDI toluene diisocyanate
  • HDI hexamethylene diisocyanate
  • IPDI isophorone diisocyanate
  • PMDI or MDI being preferred.
  • One particularly suitable example is diphenylmethane-4,4'
  • a blowing agent is required.
  • the blowing agent can be a chemical blowing agent or a physical blowing agent.
  • the foamable composition comprises a blowing agent.
  • the blowing agent can be added to the foamable composition together with a further component that induces foam formation.
  • the blowing agent is water. Water acts as a chemical blowing agent, reacting with the isocyanate to form CO 2 , which acts as the blowing gas.
  • the foamable composition comprises water as a blowing agent.
  • the water is usually present in such a foamable composition in an amount from 0.3 to 2 % by weight of the foamable composition.
  • a physical blowing agent such as liquid C0 2 or liquid nitrogen could be included in the foamable composition or added to the foamable composition as part of the further component that induces foam formation.
  • the foamable composition in an alternative embodiment, is suitable for forming a phenolic foam.
  • Phenolic foams are formed by a reaction between a phenol and an aldehyde in the presence of an acid or a base.
  • a surfactant and a blowing agent are generally also present to form the foam. Therefore, the foamable composition of the invention could comprise, in addition to the man- made vitreous fibres, a phenol and an aldehyde (the foam precursor), a blowing agent and a surfactant.
  • the foamable composition could comprise as the foam precursor, a phenol but no aldehyde, or an aldehyde but no phenol.
  • foamable compositions suitable for forming polyurethane or phenolic foams are preferred, the invention also encompasses foamable compositions suitable for forming polyisocyanurate, expanded polystyrene and extruded polystyrene foams.
  • the foam composite is especially a polyisocyanurate foam composite, where the blowing agent is preferably pentane. Pentane has the advantage over other blowing agents that it is more environmentally friendly and cost effective than for instance HFC blowing agents.
  • Pentane can be c-pentane, i-pentane, or n-pentane or a mixture of two or more of these.
  • the choice between c-pentane, i-pentane and n-pentane is dependent on the production method. They are quite different in boiling point, initial thermal conductivity, aged thermal conductivity and price.
  • the preferred pentane in this invention is n-pentane based on the price and aged thermal conductivity.
  • the foamable composition and the foam composite of the invention can contain additives in addition to the foam precursor and the first and second fibres.
  • the additive can be included with a further component that is added to the foamable composition to induce foam formation.
  • the foam precursor or the polymeric foam composite to comprise a fire retardant such as expandable powdered graphite, aluminium trihydrate or magnesium hydroxide.
  • the amount of fire retardant in the foam precursor is preferably from 3 to 20% by weight, more preferably from 5 to 15% by weight and most preferably from 8 to 12 % by weight.
  • the total quantity of fire retardant present in the foam composite is preferably from 1 to 10%, more preferably from 2 to 8% and most preferably from 3 to 7 % by weight.
  • the foamable composition or polymeric foam composite can comprise a flame retardant such as nitrogen- or phosphorus- containing polymers.
  • the first and/or second fibres used in the present invention can be treated with binder, which, as a result, can be included in the composition as an additive if it is chemically compatible with the composition.
  • the binder is usually present in the foamable composition at a level less than 5% based on the total weight of the foamable composition.
  • the foam composite usually contains less than 5% binder, more usually less than 2.5% binder.
  • the first and second fibres used are not treated with binder.
  • the surfactant could, alternatively, be added to the composition as a separate component.
  • the polymeric foam composite of the invention comprises a polymeric foam and first and second fibres as defined above.
  • the polymeric foam composite can be formed from the foamable composition of the invention. It is also possible to form the polymeric foam composite of the invention without using a foamable composition according to the invention, in particular when a foamable composition is used that contains only some of first and second fibres, so that the distribution of fibres is not as required in the foamable composition of the invention. In such a case, the required distribution can be achieved by addition of further fibres as part of a further component that induces foam formation or by the addition of further fibres in a separate stream.
  • the polymeric foam is a polyurethane foam or a phenolic foam.
  • Polyurethane foams are most preferred due to their low curing time.
  • the polymeric foam composite comprises a combined total of first and second fibres of at least 5%, preferably at least 10%, more preferably at least 15% by weight, based on the total weight of the polymeric foam composite.
  • the polymeric foam composite comprises a combined total of first and second fibres of less than 85%, more preferably less than 70%, even more preferably less than 55% by weight, based on the total weight of the polymeric foam composite.
  • the method comprises (i) providing a foam precursor, and (ii) providing from 40 to 98% by weight, based on the total fibre weight, first fibres, defined as those fibres having a length less than 150pm and from 2 to 60% by weight, based on the total fibre weight, second fibres, defined as those fibres having a length of at least 150 ⁇ .
  • the foam precursor and first and second fibres are as discussed above.
  • it is required to provide a further component suitable for inducing foam formation.
  • the first fibres, second fibres, foam precursor and further component are then mixed, which induces foam formation.
  • the invention provides a method for producing a polymeric foam composite according to the invention comprising:
  • first fibres by weight are discontinuous man- made vitreous fibres, and wherein at least 60% of the first fibres by weight have a length less than 65pm and at least 30% of the second fibres by weight have a length of at least 250pm.
  • step (iv) comprises mixing the first fibres and the second fibres into the foam precursor and subsequently mixing the further component with the foam precursor.
  • a foamable composition according to the invention is produced as an intermediate product.
  • the first and second fibres can be mixed with a polyol as the foam precursor, which forms a foamable composition according to the invention.
  • the foamable composition usually also comprises water as a chemical blowing agent. Then foaming can be induced by the addition of an isocyanate.
  • step (iv) comprises mixing a first portion of the fibres provided in step (ii) with the foam precursor, mixing a second portion of the fibres provided in step (ii) with the further component and subsequently mixing the foam precursor with the further component.
  • the first and second portions of the fibres can contain any selection of the first and second fibres.
  • the first portion of the fibres provided in step (ii) comprises at least 70%, more preferably at least 85%, most preferably at least 95% by weight first fibres, based on the weight of the first portion of fibres.
  • the second portion of the fibres provided in step (ii) comprises at least 70%, more preferably at least 85%, most preferably at least 95% by weight second fibres, based on the weight of the second portion of fibres.
  • step (iv) comprises mixing a first portion of the fibres provided in step (ii) with the foam precursor to provide a stream comprising foam precursor and fibres, then mixing, in a single step, the stream comprising foam precursor and fibres, a stream comprising the further component and a stream comprising a second portion of the fibres provided in step (ii), wherein the second portion of fibres is metered directly into a mixing chamber of a mixing head by axial injection.
  • the first and second portions of the fibres can contain any selection of the first and second fibres.
  • the first portion of the fibres provided in step (ii) comprises at least 70%, more preferably at least 85%, most preferably at least 95% by weight first fibres, based on the weight of the first portion of fibres.
  • the second portion of the fibres provided in step (ii) comprises at least 70%, more preferably at least 85%, most preferably at least 95% by weight second fibres, based on the weight of the second portion of fibres.
  • the foam precursor is provided in a first stream of foam precursor and a second stream of foam precursor and step (iv) comprises:
  • the first and second portions of the fibres can contain any selection of the first and second fibres.
  • the first portion of the fibres provided in step (ii) comprises at least 70%, more preferably at least 85%, most preferably at least 95% by weight first fibres, based on the weight of the first portion of fibres.
  • the second portion of the fibres provided in step (ii) comprises at least 70%, more preferably at least 85%, most preferably at least 95% by weight second fibres, based on the weight of the second portion of fibres.
  • At least part of the mixing step (iv) can be carried out with a mechanical mixing method such as use of a rotary mixer or simply by stirring.
  • the mixing step (iv) is carried out at least in part using a visco jet agitator.
  • the method preferably further comprises providing a surfactant and mixing the surfactant with at least one of: the foam precursor;
  • step (ii) are mixed with the foam precursor or the further component.
  • the foam precursor and the further component are mixed using a high pressure mixing head as commercially available.
  • Additives as discussed above can be added to any of the components or added separately in step (iv).
  • surfactant has also been found to be useful for facilitating mixing of the fibres into the foam precursor. Therefore, the method preferably further comprises providing a surfactant and mixing the surfactant with at least one of the foam precursor and the fibres provided in step (ii), before the mixing step (iii).
  • foam formation is induced by carrying out a further processing step.
  • the further processing step depends on the type of foam precursor being used, but could, for example be applying a reduced pressure to the mixture of foam precursor and first and second fibres.
  • a foamable composition was produced by mixing 240g of a commercially available polyol formulation with 60g of mineral wool fibres having an average length determined by the sieving method described herein of 500pm. Mixing was performed in a beaker with slow addition of the fibres and mixing by propellers. The mixing was increasingly difficult as fibers were added, limiting the amount of fibres that could be added.
  • 340 g of a commercially available composition of diphenylmethane-4,4'-diisocyanate and isomers and homologues of higher functionality were mixed by propellers for 20 seconds at 3000 rpm. The material was then transferred into a mold and allowed to foam. The total amount of inorganic, non-combustible, fibers in the foam was 9% of the total mass.
  • a foamable composition was produced by mixing 240g of a commercially available polyol formulation with 90g ground discontinuous stone wool fibres with over 50% having a length less than 64 m. Mixing was easy and a homogeneous suspension was easily obtained. To the mixture, 30g of mineral wool fibres having an average length determined by the sieving method described herein of 50 ⁇ . Mixing was performed in a beaker with slow addition of the fibers and mixing by propellers. Mixing was less difficult than in example 1.
  • the overall distribution of fibres was such that from 40 to 98% by weight of the fibres, based on the total fibre weight, had a length less than 150pm and at least 50% of these fibres had a length less than 65pm and such that from 2 to 60% by weight of the fibres, based on the total fibre weight, had a length of at least 150 m and at least 30% of these fibres had a length of at least 250 ⁇ .
  • 340 g of a commercially available composition of diphenylmethane-4,4'-diisocyanate and isomers and homologues of higher functionality were mixed by propellers for 20 seconds at 3000 rpm. The material was then transferred into a mold and allowed to foam.
  • the total amount of inorganic, non-combustible, fibers in the foam was 17% of the total mass or twice as high as the amount of fibers that could be added in Example 1.

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  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Reinforced Plastic Materials (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

L'invention concerne une composition moussable comprenant : un précurseur de mousse ; 40 à 98 % en poids, sur base du poids total de fibres, de premières fibres, définies comme des fibres présentant une longueur inférieure à 150 μm ; et 2 à 60 % en poids, sur base du poids total de fibres, de deuxièmes fibres, définies comme des fibres présentant une longueur d'au moins 150 μm ; au moins 50 % en poids des premières fibres étant des fibres vitreuses discontinues synthétiques et au moins 60 % en poids des premières fibres présentant une longueur inférieure à 65 µm et au moins 30 % en poids des deuxièmes fibres présentant une longueur d'au moins 250 μm.
EP14751379.0A 2013-02-18 2014-02-18 Composition moussage, composite de mousse polymère et procédé de fabrication du composite de mousse polymère Withdrawn EP2956501A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP14751379.0A EP2956501A1 (fr) 2013-02-18 2014-02-18 Composition moussage, composite de mousse polymère et procédé de fabrication du composite de mousse polymère

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP13155692 2013-02-18
PCT/IB2014/000176 WO2014125367A1 (fr) 2013-02-18 2014-02-18 Composition moussage, composite de mousse polymère et procédé de fabrication du composite de mousse polymère
EP14751379.0A EP2956501A1 (fr) 2013-02-18 2014-02-18 Composition moussage, composite de mousse polymère et procédé de fabrication du composite de mousse polymère

Publications (1)

Publication Number Publication Date
EP2956501A1 true EP2956501A1 (fr) 2015-12-23

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WO (1) WO2014125367A1 (fr)

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ES2658741T3 (es) 2013-10-16 2018-03-12 Rockwool International A/S Fibras vítreas artificiales
ES2732954T3 (es) * 2017-05-16 2019-11-26 Antolin Grupo Ing Sa Guarnición interior de tacto suave para vehículos
BR102017018127A2 (pt) * 2017-08-24 2019-03-26 Odair Salvelino Teixeira Micro-fibra introduzida em espuma rígida composta de poliuretano e poliisocianurato aplicado em produto isolante térmico
CN107686560B (zh) * 2017-09-26 2020-11-06 南京林业大学 一种纤维素阻燃改性复合酚醛泡沫的制备方法
US11401451B2 (en) 2017-11-20 2022-08-02 L&P Property Management Company Fiber reinforced flexible foams
CN116462882A (zh) * 2023-05-17 2023-07-21 东风汽车集团股份有限公司 一种高性能回收聚氨酯泡沫材料、制备方法及其应用

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FR1199550A (fr) * 1957-03-14 1959-12-15 Owens Corning Fiberglass Corp Procédé de fabrication de produits composites de mousse et de fibres
WO1994029375A1 (fr) * 1993-06-16 1994-12-22 Environmental Seals Limited Produits resistant au feu
WO2013010245A1 (fr) * 2011-07-19 2013-01-24 Epic Ventures Inc. Mousse réticulée à alvéoles ouvertes modifiée par des fibres s'étendant à travers et entre les alvéoles de ladite mousse et procédés de préparation de celle-ci
EA027560B1 (ru) * 2011-08-18 2017-08-31 Роквул Интернэшнл А/С Пенообразующая композиция, композитный пеноматериал, способ его изготовления и изделие

Non-Patent Citations (1)

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Also Published As

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