Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/46—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with organic materials
  • C04B41/48—Macromolecular compounds
  • C04B41/488—Other macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds
  • C04B41/4884—Polyurethanes; Polyisocyanates
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/08—Processes
  • C08G18/10—Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/40—High-molecular-weight compounds
  • C08G18/48—Polyethers
  • C08G18/50—Polyethers having heteroatoms other than oxygen
  • C08G18/5021—Polyethers having heteroatoms other than oxygen having nitrogen
  • C08G18/5024—Polyethers having heteroatoms other than oxygen having nitrogen containing primary and/or secondary amino groups
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G18/00—Polymeric products of isocyanates or isothiocyanates
  • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
  • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
  • C08G18/67—Unsaturated compounds having active hydrogen
  • C08G18/671—Unsaturated compounds having only one group containing active hydrogen
  • C08G18/672—Esters of acrylic or alkyl acrylic acid having only one group containing active hydrogen
• • E—FIXED CONSTRUCTIONS
  • E21—EARTH OR ROCK DRILLING; MINING
  • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
  • E21D11/00—Lining tunnels, galleries or other underground cavities, e.g. large underground chambers; Linings therefor; Making such linings in situ, e.g. by assembling
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00724—Uses not provided for elsewhere in C04B2111/00 in mining operations, e.g. for backfilling; in making tunnels or galleries
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2190/00—Compositions for sealing or packing joints

Definitions

• the present invention provides such a method, which comprises providing a liner to at least a portion of at least one surface, the liner comprising the product of reaction of
• the surface comprises at least one inorganic mineral other than a metal or a glass, with the proviso that the surface is a surface other than a trafficable surface (that is, a surface other than a traffic-bearing surface, for example, such as a highway, bicycle path, or sidewalk used for vehicular or pedestrian traffic).
• the surface comprises at least one material selected from the group consisting of rock, stone, concrete, brick, stucco, and the like, and combinations thereof.
• the liner can have a tensile strength, elongation at break, and thickness sufficient to provide support to exposed surfaces in an excavation.
• the liner preferably exhibits a 4-hour Tensile Strength of at least about 1 MPa and/or an elongation at break of at least about 10 percent and/or a thickness of at least about 0.5 mm.
• the reactive diluent is preferably a free-radically polymerizable monomer (more preferably, an acryloyl- or methacryloyl-f unctional monomer) .
• the method of the invention provides a surface with a liner that can exhibit surprising ultimate load-bearing capability (upon complete cure) and, prior to complete cure, generally develops sufficient strength to be useful in a load-bearing capacity (for example in a mining environment) within about 4 hours.
• a wide range of starting liner components can be utilized in the method and can be easily applied to a surface by spraying (even at low temperatures), yet the resulting composition can cure to provide a tough, flexible, relatively thick coating.
• starting liner components of sufficiently low hydrophilicity can be selected so as to provide a liner that is relatively water-resistant and stable to hydrolysis.
• the invention provides a liner comprising the product of reaction of
• kits for producing a liner comprises (a) a first composition comprising
• At least one polymerizable reactive diluent that contains essentially no isocyanate-reactive groups (that is, sufficiently few isocyanate-reactive groups that a liner prepared from the kit exhibits a 4-hour Tensile Strength of at least about IMPa);
• kits comprising at least one polymer bearing isocyanate- reactive groups, which, when combined with the first composition, reacts to form a material suitable for use as a liner; wherein the kit further comprises expandable graphite.
• a second kit comprises
• kit further comprises expandable graphite.
• Isocyanate group-bearing prepolymers suitable for use in the method of the invention include those that are capable of reacting with the isocyanate-reactive groups of component (b) and/or with component (c).
• prepolymers are well-known in the art.
• the preparation of such prepolymers involves the reaction of a polyfunctional active hydrogen-containing compound with a diisocyanate or other polyisocyanate, using an excess of the isocyanate to yield an isocyanate-terminated prepolymer product.
• An extensive description of some of the useful techniques for preparing suitable isocyanate prepolymers can be found in the text by J. H. Saunders and K. C.
• the prepolymers have an average isocyanate functionality of at least about 2 (more preferably, about 2 to about 5; most preferably, about 2 to about 3).
• Suitable polyfunctional active hydrogen-containing compounds for use in preparing the prepolymers include polyols, polyamines, polythiols, and the like, and mixtures thereof. Polyols are generally preferred. Preferably, the compounds exhibit relatively low hydrophilicity.
• Preferred polyols have molecular weights that enable the preparation of liquid prepolymers.
• Polycarbonates, polyethers, and polyesters are generally preferred, with polyethers being more preferred.
• Most preferred are polyethers that exhibit relatively low hydrophilicity (for example, polyethers having fewer than half (more preferably, fewer than one-third; most preferably, fewer than one-fourth) of the total number of ether units being ethyleneoxy units).
• Suitable polyester polyols include those formed from diacids (or their monoester, diester, or anhydride counterparts) and diols or triols.
• Useful diacids include saturated C 4 - C 12 aliphatic acids (including branched, unbranched, or cyclic materials) and/or C 8 -C 1S aromatic acids.
• suitable aliphatic acids include, for example, succinic, glutaric, adipic, castor fatty acid, pimelic, suberic, azelaic, sebacic, 1,12-dodecanedioic, 1,4- cyclohexanedicarboxylic, 2-methylpentanedioic acids, and the like, and mixtures thereof.
• aromatic acids examples include, for example, terephthalic, isophthalic, phthalic, 4,4'-benzophenone dicarboxylic, 4,4'-diphenylamine dicarboxylic acids, and the like, and mixtures thereof.
• useful diols include C 2 -C 12 branched, unbranched, or cyclic aliphatic diols.
• Suitable diols and triols include, for example, ethylene glycol, glycerine, neopentyl glycol, 1,3-propylene glycol, trimethylol propane, 1,2-propylene glycol, 1,4-butanediol, 1,3-butanediol, hexanediols, 2-methyl-2,4- pentanediol, cyclohexane-l,4-dimethanol, 1,12-dodecanediol, and the like, and mixtures thereof.
• Suitable polyether polyols include polyoxy-C 2 -C 6 -alkylene polyols (having branched or unbranched alkylene groups).
• suitable polyether diols include, for example, polyethylene oxide, poly(l,2- and 1,3-propyleneoxide), poly(l,2- butyleneoxide), random or block copolymers of ethylene oxide and 1,2- propylene oxide, polytetramethylene glycols, propylene glycol, neopentyl glycol, hexanediol, butanediol, and the like, and mixtures thereof.
• Suitable acrylic polyols include polyols based on monoethylenically unsaturated monomers such as monoethylenically unsaturated carboxylic acids and esters thereof, styrene, vinyl acetate, vinyl trimethoxysilane, acrylamides, and the like, and mixtures thereof.
• Useful monomers include but are not limited to methyl acrylate, butyl acrylate, ethyl acrylate, 2-ethylhexyl acrylate, hydroxybutyl acrylate, hydroxyethyl acrylate, glycidyl acrylate, lauryl acrylate, acrylic acid, and the like, and mixtures thereof.
• the polymers can be homopolymers or copolymers.
• the copolymers can also contain a significant number of units derived from methacrylate monomers (for example, methyl methacrylate, butyl methacrylate, hydroxyethyl methacrylate, lauryl methacrylate, glycidyl methacrylate, methacrylic acid, and the like, and mixtures thereof).
• Preferred acrylic polyols include hydroxy-functional oligomers prepared by the process described in U.S. Patent No.
• Polyisocyanates that can be used to prepare the prepolymers having isocyanate groups include aliphatic, alicyclic, and aromatic polyisocyanates, and mixtures and combinations thereof.
• Useful polyisocyanates (or isocyanate monomers) have an average isocyanate functionality of at least about 2 (preferably, about 2 to about 5; more preferably, about 2).
• the polyisocyanates are aromatic polyisocyanates (for example, due to greater reactivity rate).
• One of the most useful polyisocyanate compounds that can be used is tolylene diisocyanate (TDI), particularly as a blend of 80 weight percent of tolylene-2,4-diisocyanate and 20 weight percent of tolylene-2,6-diisocyanate.
• TDI tolylene diisocyanate
• a 65:35 blend of the 2,4- and 2,6-isomers can also be used.
• These polyisocyanates are commercially available under the trademark HYLENE , as NACCONATE 80, and as MONDUR TD-80.
• the tolylene diisocyanates can also be used as a mixture with methylene diphenyl diisocyanate.
• polyisocyanate compounds that can be used (alone or in combination) include other isomers of tolylene diisocyanate; hexamethylene diisocyanate (HDI) including, for example, the 1,6 isomer; xylene diisocyanate (XDI); methylene diphenyl diisocyanate (MDI) including, for example, diphenylmethane-4,4 '-diisocyanate; m- or p- phenylene diisocyanate; isophorone diisocyanate (IPDI); 1,5-naphthalene diisocyanate; tetramethylene diisocyanate; 1,4-cyclohexane diisocyanate; hexahydrotolylene diisocyanate; l-methoxy-2,4-phenylene diisocyanate; 2,4-diphenylmethane diisocyanate; 4,4'-biphenylene diisocyanate; 3,3'-d
• Preferred isocyanates include tolylene diisocyanate (TDI), hexamethylene diisocyanate (HDI), methylene diphenyl isocyanate (MDI), xylene diisocyanate (XDI), and the like, and mixtures thereof.
• TDI tolylene diisocyanate
• HDI hexamethylene diisocyanate
• MDI methylene diphenyl isocyanate
• XDI xylene diisocyanate
• the prepolymer bearing isocyanate groups can be prepared, for example, by reacting a polyisocyanate with a copolymer of polyoxyethylene-propylene polyol using an NCO/OH equivalent ratio of about 5:1 to about 1.05:1, preferably a ratio of about 2.0:1 to 2.5:1.
• the preparation of isocyanate-terminated prepolymers is described, for example, in U.S. Patent Nos. 4,315,703 (Gasper) and 4,476,276 (Gasper) and references therein, the descriptions of which are incorporated herein by reference.
• Benzoyl chloride can be added during prepolymer preparation to avoid side reactions of polyisocyanate. Preferably, no solvent is used to dilute the prepolymer.
• prepolymer preparation purification of the prepolymer is preferably carried out to remove unreacted monomeric polyisocyanate. This is preferably accomplished by quenching the unreacted monomeric polyisocyanate with a compound that is reactive to isocyanate groups, so that the prepolymer preferably contains less than about 0.7 weight percent (more preferably, less than about 0.5 weight percent) of unreacted monomeric polyisocyanate.
• the presence of the monomeric polyisocyanate can result in toxicity (for example, during spraying of the liner composition). Also, it has been discovered that by removing or quenching the unreacted monomeric polyisocyanates, preferred liners of superior strength can be produced. Other advantages can include reduced toxicity and lowered heat generation.
• the prepolymer can be purified from unreacted monomeric polyisocyanate by processes and/or methods using, for example, falling film evaporators, wiped film evaporators, distillation techniques, various solvents, molecular sieves, or organic reactive reagents such as benzyl alcohol.
• U.S. Patent No. 4,061,662 (Marans et al.) describes the removal of unreacted tolylene diisocyanate (TDI) from an isocyanate prepolymer by contacting the prepolymer with molecular sieves.
• unreacted preferably monomeric polyisocyanates can be quenched with an amine (preferably, a secondary amine; more preferably, a monofunctional secondary amine) or an alcohol (for example, an arylalkyl alcohol), preferably in the presence of a tertiary amine catalyst (such as, for example, triethylamine) or an alkoxysilane bearing a functional group that is reactive to isocyanate groups (for example, an amine).
• a tertiary amine catalyst such as, for example, triethylamine
• alkoxysilane bearing a functional group that is reactive to isocyanate groups for example, an amine.
• the unreacted polyisocyanates are more preferably reacted with an arylalkyl alcohol, such as benzyl alcohol, used with a tertiary amine.
• the unreacted polyisocyanates are most preferably reacted with an arylalkyl alcohol, such as benzyl alcohol, used in conjunction with an alkoxysilane bearing one secondary amino group.
• the unreacted polyisocyanates can be quenched without substantially affecting the terminal isocyanate groups of the prepolymer.
• arylalkyl alcohol such as benzyl alcohol
• N-alkyl aniline for example, N-methyl or N-ethyl aniline and its derivatives
• diisopropylamine dicyclohexylamine, dibenzylamine, diethylhexylamine, and the like, and mixtures thereof.
• suitable alcohols include arylalkyl alcohols (for example, benzyl alcohol and alkyl-substituted derivatives thereof); free-radically polymerizable, hydroxyl- functional monomers; and the like; and mixtures thereof.
• arylalkyl alcohols for example, benzyl alcohol and alkyl-substituted derivatives thereof
• free-radically polymerizable, hydroxyl- functional monomers and the like; and mixtures thereof.
• silanes examples include DYNASYLAN 1189 (N-(n-butyl)- aminopropyltrimethoxysilane available from Degussa Corporation, NJ, USA), DYNASYLAN 1110 (N-methyl-3-aminopropyltrimethoxysilane available from Degussa Corporation, NJ, USA), SILQUEST A-1170 (bis (trimethoxysilylpropyl)amine available from Osi Specialties, Crompton Corporation, USA), SJLQUEST Y-9669 (N-phenyl)- gamma-aminopropyltrimethoxysilane available from Osi Specialties, Crompton Corporation, USA), and the like, and mixtures thereof.
• DYNASYLAN 1189 N-(n-butyl)- aminopropyltrimethoxysilane available from Degussa Corporation, NJ, USA
• DYNASYLAN 1110 N-methyl-3-aminopropyltrimethoxysilane available from
• reaction time When alcohols are used to quench the unreacted polyisocyanates, the application of heat can be used to reduce the reaction time. Reactions with amines can generally be conducted, however, at ambient temperature for a relatively shorter period of time.
• the amount of unreacted monomelic polyisocyanate present in the reaction mixture comprising the prepolymer following the reaction with the amine, alcohol, or silane is most preferably 0, but preferably can range up to about 0.7 weight percent, more preferably up to about 0.5 weight percent.
• a preferred method of purifying the prepolymer is by the method of U.S. Patent No. 6,664,414 (Tong et al.), the disclosure of which is incorporated herein by reference.
• Isocyanate-reactive polymers suitable for use in the method of the invention include those which bear active hydrogen-containing groups (for example, amino, thio (that is, mercapto), carboxyl, and/or hydroxyl groups).
• Such polymers include, for example, polycarbonates, polyalkadienes, polyethers, polyesters, polyvinyl aromatics, polyacrylics, polyvinyl esters, and the like, and combinations thereof (for example, those having an equivalent weight in the range of about 250 to about 10,000; preferably, from about 400 to about 7,500; more preferably, from about 500 to about 5,000) having an average reactive group functionality of at least about 2.
• Such functional polymers can be prepared by known methods, and a number are commercially available. Liquids are generally preferred, as are polymers that exhibit relatively low hydrophilicity.
• the groups that are reactive to isocyanate groups are preferably hydroxyl (alcohol), primary or secondary amino, and/or carboxyl groups (more preferably, hydroxyl and/or primary or secondary amino groups; most preferably, primary or secondary amino groups), and mixtures thereof.
• the polymer has an average reactive group functionality of at least about 2 (preferably, about 2 to about 20; more preferably, about 2 to about 5).
• polymers that are useful (when functionalized in the foregoing manner) include aliphatic polycarbonates such as aliphatic polycarbonate diols; polyethers such as polyethylene glycol, polypropylene glycol, polybutylene glycol, and polytetrahydrofuran; polyvinyl aromatics such as polystyrene; polyvinyl esters such as polyvinyl acetate; polyacrylics such as hydroxyl-terminated polyacrylics and polyacrylics bearing pendant hydroxyl groups; polyesters such as polycaprolactones, polybutylene adipate, polydiethylene adipate, poly(3-methyl-l,5-pentane) adipate, and poly(neopentyl/l,6-hexane) adipate; and mixtures thereof.
• aliphatic polycarbonates such as aliphatic polycarbonate diols
• polyethers such as polyethylene glycol, polypropylene glycol, polybutylene
• the polymer is preferably hydrophobic in nature to reduce or prevent hydrolysis of its polymeric backbone.
• adipic acid-based polyester polyols are more resistant to hydrolysis than phthalate-based polyester polyols.
• Polyols based on polycarbonate or dimer acid diol generally have higher hydrolytic resistance than polyester-based polyols.
• Polycarbonates, polyethers, and polyesters are generally preferred, with polyethers being more preferred.
• Most preferred are polyethers that exhibit relatively low hydrophilicity (for example, polyethers having fewer than half (more preferably, fewer than one-third; most preferably, fewer than one-fourth) of the total number of ether units being ethyleneoxy units).
• Suitable reactive diluents for use in the method of the invention include those that are polymerizable (for example, acrylates, methacrylates, and epoxides).
• the reactive diluent is a free-radically polymerizable monomer (for example, ethylenically- unsaturated monomers such as acrylates, methacrylates, styrene, vinyl acetate, and the like, and mixtures thereof).
• Suitable monomers include methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, ethyl methacrylate, butyl methacrylate, ethyltriglycol methacrylate, isobornyl acrylate, isobornyl methacrylate, 2- (((butylamino)carbonyl)oxy)ethyl acrylate, acetoacetoxyethyl methacrylate, acetoacetoxyethyl acrylate, acetoacetoxypropyl acrylate, acetoacetoxybutyl acrylate, 2- methyl-2-(3-oxo-butyrylamino)-propyl methacrylate, 2-ethylhexyl acrylate, n-octyl acrylic acetate, decyl acrylate, lauryl acrylate, stearyl
• Preferred monomers include isobornyl acrylate, isobornyl methacrylate, decyl acrylate, lauryl acrylate, stearyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, decyl methacrylate, tetrahydrofurfuryl methacrylate, lauryl methacrylate, stearyl methacrylate, phenylcarbitol acrylate, nonylphenyl carbitol acrylate, nonylphenoxy propyl acrylate, 2-phenoxyethyl methacrylate, 2-phenoxypropyl methacrylate, and the like, and mixtures thereof (with tetrahydrofurfuryl methacrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl methacrylate, 2-phenoxyethyl methacrylate, and 2- phenoxypropyl methacrylate, and mixtures thereof being more preferred). If desired, small amounts
• multifunctional acrylates or methacrylates can be utilized to, for example, effect crosslinking.
• multifunctional monomers include ethylene glycol diacrylate; 1,2-propylene glycol diacrylate; 1,3-butylene glycol diacrylate; 1,6-hexanediol diacrylate; neopentylglycol diacrylate; trimethylolpropane triacrylate; polyoxyalkylene glycol diacrylates such as dipropylene glycol diacrylate, Methylene glycol diacrylates, tetraethylene glycol diacrylates, polyethylene glycol diacrylate; ethylene glycol dimethacrylate; 1,2-propylene glycol dimethacrylate; 1,3-butylene glycol dimethacrylate; 1,6-hexanediol dimethacrylate; neopentylglycol dimethacrylate; bisphenol-A-dimethacryl
• components (a), (b), and (c) can be applied to a surface (preferably, in an order and manner of combination that does not permit the premature reaction of one or more of the components) and the resulting mixture allowed to react to form a liner comprising the product of reaction of the components.
• a surface preferably, in an order and manner of combination that does not permit the premature reaction of one or more of the components
• the resulting mixture allowed to react to form a liner comprising the product of reaction of the components.
• intermediates that are capable of reaction to form one or more of the components (or to form the final product) can be applied to the surface, or the liner can be preformed and then applied to the surface.
• the liner composition further comprises an initiator (more preferably, an initiator and an accelerator), so that initiating species can be relatively rapidly generated.
• an initiator more preferably, an initiator and an accelerator
• the resulting liner can be cured by exposure to ultraviolet (if the composition is only lightly filled) or electron beam radiation, thermal curing is generally preferred.
• one or more photoinitiators for example, benzophenone can be added, if necessary or desired, for example, in amounts ranging from about 0.05 to about 5 weight percent (based upon the total weight of all liner components).
• suitable photoinitiators include 2,2-dimethoxy- 1,2-diphenylethane-l-one, 2-methyl-l-[4-(methylthio)phenyl]-2-morpholinopropanone-l, benzophenone, and the like, and mixtures thereof.
• a curing system comprising a thermally-activatable initiator (and, more preferably, also an accelerator) is utilized (for example, in amounts of from about 0.01 or 0.5 to about 5 or 10 weight percent of each, based upon the total weight of all liner components).
• thermally-activatable initiators include organic peroxides, for example, diacyl peroxides, dialkyl peroxides, hydroperoxides, ketone peroxides, and the like, and mixtures thereof.
• the accelerator of the curing system if an accelerator is used, is generally substantially non-reactive to isocyanate and functions to decompose the initiator through, for example, a redox reaction, thereby facilitating the generation of active radicals. (Alternatively, heat and pressure can be utilized to accelerate reaction.)
• Useful accelerators include metal salts, for example, cobalt naphthenate and vanadium octoate; mercaptans, for example, glycol dimercaptoacetate; tertiary amines, for example, dimethyl-p-toluidine, diisopropoxy-p-toluidine, diethyl-p-toluidine, dimethyl aniline, and aniline butyraldehyde condensate; and the like; and mixtures thereof.
• Preferred accelerators are tertiary amines.
• kits of the invention can comprise two or more compositions, depending upon the nature of the components and the need or desire for component separation.
• the accelerator can be included in a kit composition that does not contain initiator.
• the accelerator can be included in the kit composition that also contains the reactive diluent, with the initiator being included in a kit composition that preferably does not contain reactive diluent.
• the initiator and the reactive diluent can preferably be kept in separate kit compositions and then brought together for the first time just prior to application to a surface.
• the prepolymer and the reactive polymer can also preferably be kept separate until just prior to application.
• the resulting liner is preferably gas-tight and flexible.
• the liner preferably has an elongation at break (measured according to ASTM D-638-97) of from about 10 to about 1000%, more preferably from about 30 to about 800%, even more preferably from about 50 to about 400%, most preferably from about 100 to about 300%.
• the liner is, preferably, a cross-linked mass having a high degree of flexibility.
• the liner does not significantly swell upon contact with water.
• the liner exhibits toughness.
• the liner exhibits a 4-hour Tensile Strength of at least about 1 MPa (more preferably, at least about 2 MPa; even more preferably, at least about 3 MPa; most preferably, at least about 4 MPa).
• the liners produced according to the method of the invention can be used as load- bearable coatings to support, for example, rock surfaces in a mine.
• the liners are preferably thick (at least about 0.5 mm; preferably, up to about 6 mm or even 10 mm or more) when cured completely.
• additive ingredients can be included in the liner.
• viscosity modifiers can be included to increase or decrease the viscosity, depending on the desired application technique.
• Fungicides can be added to prolong the life of the liner and to prevent attack by various fungi.
• active ingredients can be added for various purposes, such as substances to prevent encroachment of plant roots, and the like.
• Other additives that can be included in the liner include, without limitation, rheological additives, emulsifiers, plasticizers, fillers, fire retardants, smoke retardants, defoamers, and coloring agents. Care should be exercised in choosing fillers and other additives to avoid any materials that will have a deleterious effect on the viscosity, the reaction time, the stability of the liner being prepared, and the mechanical strength of the resulting liner.
• the additional filler materials that can be included in the liner can provide a more shrink-resistant, substantially incompressible, and fire retardant liner. Any of a number of filler compositions can be effective.
• Useful fillers include particulate filler material having a particle size of less than about 500 microns, preferably about 1 to 50 microns, and a specific gravity in the range of about 0.1 to 4.0, preferably about 0.5 to 3.0.
• the filler content of the cured liner can be as much as about 10 parts filler per 100 parts by weight cured liner, preferably about 5 parts to about 10 parts per 100.
• useful fillers include expandable graphite (for example, graphite that expands upon application of heat) such as GRAFGUARD 220-80B or GRAFGUARD 160-150B (Graftech, Ohio, USA); silica such as quartz, glass beads, glass bubbles, and glass fibers; silicates such as talc, clays, (montmorillonite) feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, and sodium silicate; metal sulfates such as calcium sulfate, barium sulfate, sodium sulfate, aluminum sodium sulfate, and aluminum sulfate; gypsum; vermiculite; wood flour; aluminum trihydrate; carbon black; aluminum oxide; titanium dioxide; cryolite; chiolite; and metal sulfites such as calcium sulfite.
• expandable graphite for example, graphite that expands upon application of heat
• silica such as quartz, glass beads, glass bubbles
• Preferred fillers include expandable graphite, feldspar, and quartz.
• the filler is most preferably expandable graphite.
• the amount of filler added to the liner can preferably be chosen so that there is no significant effect on elongation or tensile strength of the resulting liner. Such amounts can be determined by routine investigation.
• the resulting liner can also be fire retardant (and, if expandable graphite is the filler, can exhibit some self -extinguishment characteristics).
• at least some preferred embodiments of the liner preferably can meet the fire retardant specifications of CAN/ULC-S102-M88 or ASTM E-84. These tests determine burn rate and the amount of smoke generation.
• the components can be pumped using positive displacement pumps and then mixed in a static mixer before being sprayed onto a surface.
• the mixture can then be sprayed onto a substrate with or without air pressure.
• the mixture can preferably be sprayed without the use of air.
• the efficiency of mixing depends on the length of the static mixer.
• Useful application equipment includes, for example, a pump manufactured by Gusmer Canada, Ontario, Canada, as Model H-20/35, having a 2-part proportioning high pressure spray system that feeds through a heated temperature controlled (for example, 5O 0 C) zone to an air purging impingement mixing spray head gun of, for example, type GAP (Gusmer Air Purge) also manufactured by Gusmer.
• type GAP Gusmer Air Purge
• Liners were prepared by mixing the Part A' and Part B' materials described in the numbered examples below (which were stored in separate cartridges) using an air-powered dispensing gun (3MTM EPXTM Applicator, available from 3M Company, St. Paul, Minnesota) and an 18-element static mixer. The resulting mixture was injected into a poly(tetrafluoroethylene)-lined, stainless steel mold to make a film of 3 x 50 x 200 mm.
• 3MTM EPXTM Applicator available from 3M Company, St. Paul, Minnesota
• the ratio of A':B' was 4: 1. After mixing Parts A' and B' , the resulting mixture gelled in less than 1 minute and was used to form a film.
• the tensile and elongation properties of a dogbone-shaped sample (0.635 cm wide) of the resulting film were tested one hour after mixing, essentially according to test method ASTM D-638-97 (American Society for Testing and Materials, West Conshohocken, Pennsylvania) using a gauge separation of 5.08 cm (2 inches) and a separation rate of 20 cm (7.87 inches) per minute. The results are shown in Table 1 below.
• Example 2 Example 2
• Part A' was a mixture of 102 g of Part B of 3MTM Scotch-WeldTM Low Odor Acrylic Adhesive DP810 (containing no initiator; available from 3M Company, St. Paul, Minnesota) and 9 g of PoIy-SA.
• Part B' was a mixture of 35 g of the trifunctional isocyanate prepolymer described in Example 1 and 1.02 g of cumene hydroperoxide. The ratio of A':B' was 3:1. After mixing Parts A' and B', the resulting mixture gelled in less than 1 minute and was used to form a film.

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• 2005
  • 2005-09-19 WO PCT/US2005/033262 patent/WO2006034082A1/en not_active Ceased
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