WO2007023118A2 - Offenzelliger schaumstoff mit brandhemmenden und oleophoben/hydrophoben eigenschaften und verfahren zu seiner herstellung - Google Patents
Offenzelliger schaumstoff mit brandhemmenden und oleophoben/hydrophoben eigenschaften und verfahren zu seiner herstellung Download PDFInfo
- Publication number
- WO2007023118A2 WO2007023118A2 PCT/EP2006/065343 EP2006065343W WO2007023118A2 WO 2007023118 A2 WO2007023118 A2 WO 2007023118A2 EP 2006065343 W EP2006065343 W EP 2006065343W WO 2007023118 A2 WO2007023118 A2 WO 2007023118A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- foam
- fire
- resin
- retardant substance
- mixture
- Prior art date
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Classifications
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- 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
- C08J9/36—After-treatment
- C08J9/40—Impregnation
- C08J9/42—Impregnation with macromolecular compounds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/56—After-treatment of articles, e.g. for altering the shape
- B29C44/5618—Impregnating foam articles
-
- 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
- C08J9/22—After-treatment of expandable particles; Forming foamed products
-
- 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
- C08J9/35—Composite foams, i.e. continuous macromolecular foams containing discontinuous cellular particles or fragments
-
- 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
- C08J2201/00—Foams characterised by the foaming process
- C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
- C08J2201/038—Use of an inorganic compound to impregnate, bind or coat a foam, e.g. waterglass
-
- 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
- C08J2205/00—Foams characterised by their properties
- C08J2205/04—Foams characterised by their properties characterised by the foam pores
- C08J2205/05—Open cells, i.e. more than 50% of the pores are open
-
- 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
- C08J2361/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
- C08J2361/22—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with acyclic or carbocyclic compounds
-
- 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
- C08J2427/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249987—With nonvoid component of specified composition
- Y10T428/249991—Synthetic resin or natural rubbers
Definitions
- the invention relates to a foam of a foam matrix with substantially open cells and with an applied to the foam matrix impregnation of substantially fluorocarbon resin and / or silicone resin having improved fire retardant properties. Furthermore, the invention relates to a method for producing such a foam.
- Open-cell foams made of different materials are used, for example, in the thermal or acoustic insulation of buildings and vehicles. Furthermore, open-cell foams are used for the acoustic and thermal insulation of plants and plant components in mechanical engineering.
- a method by which a melamine resin foam can be impregnated is known, for example, from EP-A 0 451 535.
- a binder is first applied to the surface of the melamine resin foam and this then performed with the binder through a nip of two oppositely moving rollers, wherein the nip is set smaller than the uninfluenced thickness of the melamine resin foam.
- the binder may be added to the oleophobic and / or hydrophobic adjustment.
- the object of the present invention is to provide an open-celled foam with hydrophobic and / or oleophobic finish, which has improved fire retardant properties.
- a foam made of a foam matrix having substantially open cells and having a matrix applied to the foam impregnation of substantially fluorocarbon resin and / or silicone resin, wherein the impregnation additionally contains at least one fire-retardant substance.
- Suitable foams in the context of the present invention are, for example, those in which the foam matrix is composed of a melamine / formaldehyde polycondensate.
- Other suitable foams are those in which the foam matrix is a urea / formaldehyde polycondensate and those in which the foam matrix is an open cell polyurethane foam.
- the foam matrix is composed of a melamine / formaldehyde polycondensate.
- the ratio of melamine to formaldehyde for producing the foam matrix is 1: 1.2 to 1: 4.
- Such melamine / formaldehyde foams are known, for example, from EP-B 0 071 672. Accordingly, the foams are prepared by foaming an aqueous solution of a melamine / formaldehyde condensation product, the solution containing an emulsifier, an acidic curing agent and a blowing agent, preferably a C 5 to C 7 hydrocarbon. Subsequently, the melamine / formaldehyde condensate is cured at elevated temperature.
- the foam In order to render the foam hydrophobic and / or oleophobic, it is treated with commercially available impregnating agents of fluorocarbon resins or silicone resins. This prevents the foam from being completely saturated with liquid water or oil.
- the fluorocarbon or silicone resin is preferably in the form of emulsified droplets in water or volatile organic solvents, e.g. Methanol, ethanol, acetone or pentane, before.
- water is preferred as the emulsifier.
- this is additionally impregnated with at least one fire retardant substance.
- the foam is preferably impregnated with a mixture of the at least one flame retardant and the fluorocarbon resin and / or silicone resin.
- Flame retardants are generally used as fire-retardant substances. Flame retardants are chemical compounds that are added to combustible materials to better protect them from fire. Flame retardants increase the risk of fire caused by an ignition source of low intensity of, for example, a cigarette, candle or an electrical defect minimized. When the flame retardant material ignites, the flame retardant slows down the burning process and often prevents the fire from spreading to other parts.
- flame retardants The delay or prevention of the combustion process by flame retardants is due to chemical or physical action. Chemically acting flame retardants generally disrupt the radical chain reaction of combustion in the gas phase or build up a charred layer which protects the material against oxygen and forms a barrier to the heat source (intumisence).
- the physical effect of flame retardants occurs by cooling by cooling energy consuming processes initiated by additives and / or chemical release of water to a temperature below the temperature necessary to maintain the combustion process.
- the physical effect may also occur by dilution, with inert substances and additives that emit non-combustible gases, lowering the oxygen concentration in the combustion gases above the foam so far that the combustion is interrupted.
- flame retardants are classified into halogen compounds (bromine and chlorine compounds), phosphorus compounds, nitrogen compounds, intumescent systems, mineral substances (based on aluminum and magnesium) as well as borax, Sb 2 O 3 and nanocomposite.
- halogen compounds bromine and chlorine compounds
- phosphorus compounds phosphorus compounds
- nitrogen compounds based on aluminum and magnesium
- intumescent systems mineral substances (based on aluminum and magnesium) as well as borax, Sb 2 O 3 and nanocomposite.
- borax Sb 2 O 3 and nanocomposite.
- borax Sb 2 O 3 and nanocomposite.
- Suitable flame retardants known to the person skilled in the art are described, for example, in the brochure "Flame retardants, frequently asked questions" of the European Flame Retardants Association, January 2004.
- Fire-retardant substances which are suitable according to the invention are, for example, flame retardants based on silicates, borates, hydroxides and phosphates of the metals of I. to IM. Main group, zinc and ammonium.
- the metal of the I. to IM. Main group is preferably sodium, potassium, calcium, magnesium or aluminum.
- the fire-retardant substance is particularly preferably selected from sodium silicates, potassium silicates, magnesium hydroxide, aluminum hydroxide, sodium borate, potassium borate, magnesium borate, zinc borate, ammonium (poly) phosphates, NaM. (poly) phosphates, potassium (poly) phosphates, calcium (poly) phosphates and aluminum (poly) phosphates.
- the impregnation is composed of a mixture containing the fire-retardant substance and the fluorocarbon resin or silicone resin.
- the impregnation is composed of a mixture containing the fire-retardant substance and the fluorocarbon resin or silicone resin.
- the foam is then impregnated with this mixture.
- at least one polymer dispersion may be present as binder in the mixture. The addition of a binder fixes the fire retardant substance on the cell webs of the foam and thus prevents the release of dust in the further processing of the impregnated foam after drying.
- thermosetting acrylate binders such as those sold by BASF under the trade name Aerodur®. Due to the thermosetting (crosslinking) properties of these binders, the flame-retardant, hydro- and oleophobicized foam blanks can be permanently deformed in a molding press or a deep-drawing tool. The acoustic properties (sound damping) of the open-cell foam blanks are not impaired by the binder, the hydrophobic and oleophobicizing components and the fire-retardant substance but, on the contrary, in most cases even improved.
- foam blanks can be covered and compressed with air-permeable nonwovens made of non-woven or cotton fiber nonwovens.
- This form of further processing is used in particular in the production of sound-absorbing molded parts for the automotive industry.
- the drying temperatures of the foam blanks must not exceed 100 to 150 0 C.
- the pressing or embossing to the molding in the molding press or a deep-drawing tool is carried out at 150 to 240 0 C, preferably at 170 to 230 0 C.
- thermosetting acrylate binders consists essentially of acid and alcohol components which crosslink on heating in an esterification reaction. The much higher crosslink density is responsible for the thermoset character of the thermoformed foam components.
- Preferred solutions or disposals of thermosetting acrylate binders contain no harmful components, so that there are also occupational hygiene advantages over binders based on epoxides, phenolic resins and urea-formaldehyde resins.
- thermosetting acrylate binder eg Aerodur® dispersions as Binders also have other advantages: The molded parts produced with them have a greater elasticity and a partially hydrophobic character compared to moldings which were produced with solutions of thermosetting acrylate binders, eg Aerodur® solutions.
- the impregnation takes place in two stages.
- the foam matrix is impregnated with the fire retardant substances and the binder.
- a layer of fluorocarbon resin and / or silicone resin for hydrophobization / oleophobization is then applied to the cell webs.
- the foam is impregnated in a single impregnation step with a mixture of fluorocarbon resin or silicone resin, the binder and the fire retardant substances.
- the mixture generally contains from 1 to 30% by weight of fluorocarbon resin or silicone resin and from 10 to 70% by weight of fire retardant substances.
- the remaining parts by weight consist essentially of binder and water or volatile organic substances.
- Particularly preferred are mixtures with low levels of Fluorcarbon valued. Silicone resins and high levels of fire retardant substances to achieve a high fire protection effect.
- Impregnation increases the density of open-cell foams by 10 to 2000%. Density increases in the range of 100 to 1000% are particularly preferred. With melamine resin foams having a bulk density of about 10 g / l, densities of the impregnated foam in the range from 20 to 100 g / l are particularly preferred.
- the preparation of the foam according to the invention in which the impregnation is composed of a mixture containing the fire retardant substance and fluorocarbon resin or silicone resin, is carried out by a process comprising the following steps:
- steps (b) and (c) are performed sequentially, first step (b), then step (c).
- the application of the mixture to the foam and the pressing of the foam can be carried out, for example, as described in EP-A 0 451 535.
- the foam is passed between two rollers rotating in opposite directions, wherein the distance of the rollers is selected so that the foam is compressed in this case.
- the mixture which impregnates the foam is applied to the horizontal juxtaposed rolls so that a liquid pool is formed at the location where the foam is moved through the rolls. Due to the rotational movement of the rollers and the pressing of the foam, the mixture, which is contained in the liquid pool, is pressed into the foam. The mixture settles around the webs of the foam and forms after curing a closed surface.
- the thus impregnated foam is preferably dried in a drying oven at a temperature in the range of 40 to 200 ° C.
- the foam impregnated in a first stage may also be subjected to the impregnation process several times by the same method. As a result, the thickness of the layer enveloping the webs and thus the density is increased in each step.
- the process for producing a foam according to the invention comprises the following steps:
- step (c) pressing or padding the foam to uniformly distribute the resin in the foam of step (a) loaded with the at least one fire retardant substance.
- the foam is also possible to impregnate the foam with the substance with which this is to be impregnated, and then to press.
- the foam is pulled, for example, by a bath containing the at least one substance with which the foam is to be impregnated.
- any further method known to the person skilled in the art with which the foam can be impregnated is also conceivable any further method known to the person skilled in the art with which the foam can be impregnated.
- the pressing is preferably carried out in each case as described in EP-A 0 451 535, by passing the foam through a defined gap between two counter-rotating rollers aligned in parallel.
- the impregnated foam is transported on a conveyor belt and a roller which rotates at the same peripheral speed, with the Foam is moved, pressing on the foam.
- the pressure on the foam can be exerted by the fact that the foam is placed for example in a press in which a stamp presses on the foam. In this case, however, a continuous pressing is not possible.
- the pressing can also be carried out by any further device known to the person skilled in the art.
- the resin with which the foam is impregnated is preferably present in both embodiments as an emulsion in a highly volatile solvent.
- suitable Solvents are, for example, water or volatiles such as methanol or ethanol.
- the resin is in aqueous emulsion.
- thermoacoustic components in security-related construction sectors in the form of wall or ceiling panels, which may be structured and planar, in particular the latter also in combination with non-combustible covers, e.g. of metal, plasterboard, carbon fiber or glass fiber webs and fabrics u. a ..
- Non-combustible core elements can also be used for fireproof door elements, in particular in combination with fire protection boards or strips, e.g. from Palusol® from BASF AG, which are preferably bonded together with a core of the impregnated foam according to the invention, where necessary in combination with non-combustible frame constructions made of preferably metallic materials or wooden frames.
- the foam impregnated according to the above process can also contribute to increasing fire safety as a core material for glass or carbon fiber curtains.
- Such curtains with increased fire safety are preferably used to darken rooms that are used for presentation or demonstration purposes.
- With the fire class A2 according to DIN 4102, such curtains can also make a fire safety contribution in public buildings, e.g. Hospitals, theaters, cinemas, multifunctional rooms etc.
- An open-cell melamine / formaldehyde foam is impregnated with a mixture of a 5% by weight fluorocarbon resin emulsion and a 30% by weight sodium silicate-containing adhesive and dried at 90 ° C. The density increase after drying is 150%. The thus impregnated foam meets the requirements of fire class A 2 according to DIN 4102 and floats on water.
Abstract
Description
Claims
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/063,946 US20080280126A1 (en) | 2005-08-22 | 2006-08-16 | Open-Celled Foam Having Flam-Retardant and Oleophobic/Hydrophobic Properties and a Process for Producing It |
DE200650006265 DE502006006265D1 (de) | 2005-08-22 | 2006-08-16 | Offenzelliger schaumstoff mit brandhemmenden und oleophoben/hydrophoben eigenschaften und verfahren zu seiner herstellung |
EP20060792830 EP1919992B1 (de) | 2005-08-22 | 2006-08-16 | Offenzelliger schaumstoff mit brandhemmenden und oleophoben/hydrophoben eigenschaften und verfahren zu seiner herstellung |
JP2008527443A JP5005694B2 (ja) | 2005-08-22 | 2006-08-16 | 難燃性及び疎油性/疎水性特性を有する連続気泡フォーム及びその製造方法 |
CN2006800308232A CN101248124B (zh) | 2005-08-22 | 2006-08-16 | 具有阻燃和疏油/疏水性能的开孔泡沫及其生产方法 |
AT06792830T ATE458777T1 (de) | 2005-08-22 | 2006-08-16 | Offenzelliger schaumstoff mit brandhemmenden und oleophoben/hydrophoben eigenschaften und verfahren zu seiner herstellung |
BRPI0614938-3A BRPI0614938A2 (pt) | 2005-08-22 | 2006-08-16 | espuma processo para a produção da mesma, e, uso da espuma |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102005039625.9 | 2005-08-22 | ||
DE102005039625A DE102005039625A1 (de) | 2005-08-22 | 2005-08-22 | Offenzelliger Schaumstoff mit brandhemmenden und oleophoben/hydrophoben Eigenschaften und Verfahren zu seiner Herstellung |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2007023118A2 true WO2007023118A2 (de) | 2007-03-01 |
WO2007023118A3 WO2007023118A3 (de) | 2007-04-19 |
Family
ID=37685204
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2006/065343 WO2007023118A2 (de) | 2005-08-22 | 2006-08-16 | Offenzelliger schaumstoff mit brandhemmenden und oleophoben/hydrophoben eigenschaften und verfahren zu seiner herstellung |
Country Status (10)
Country | Link |
---|---|
US (1) | US20080280126A1 (de) |
EP (1) | EP1919992B1 (de) |
JP (1) | JP5005694B2 (de) |
KR (1) | KR20080047360A (de) |
CN (1) | CN101248124B (de) |
AT (1) | ATE458777T1 (de) |
BR (1) | BRPI0614938A2 (de) |
DE (2) | DE102005039625A1 (de) |
ES (1) | ES2340523T3 (de) |
WO (1) | WO2007023118A2 (de) |
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Also Published As
Publication number | Publication date |
---|---|
US20080280126A1 (en) | 2008-11-13 |
EP1919992B1 (de) | 2010-02-24 |
ES2340523T3 (es) | 2010-06-04 |
WO2007023118A3 (de) | 2007-04-19 |
JP5005694B2 (ja) | 2012-08-22 |
EP1919992A2 (de) | 2008-05-14 |
BRPI0614938A2 (pt) | 2013-01-01 |
CN101248124A (zh) | 2008-08-20 |
DE502006006265D1 (de) | 2010-04-08 |
CN101248124B (zh) | 2012-05-16 |
ATE458777T1 (de) | 2010-03-15 |
DE102005039625A1 (de) | 2007-03-01 |
JP2009504893A (ja) | 2009-02-05 |
KR20080047360A (ko) | 2008-05-28 |
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