WO2009087610A2 - Composite material and process for the preparation thereof - Google Patents
Composite material and process for the preparation thereof Download PDFInfo
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- WO2009087610A2 WO2009087610A2 PCT/IB2009/050119 IB2009050119W WO2009087610A2 WO 2009087610 A2 WO2009087610 A2 WO 2009087610A2 IB 2009050119 W IB2009050119 W IB 2009050119W WO 2009087610 A2 WO2009087610 A2 WO 2009087610A2
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- Prior art keywords
- porous material
- composite material
- composite
- process according
- thermoset
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Classifications
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- 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
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
-
- 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
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/10—Coating or impregnating
- C04B20/1018—Coating or impregnating with organic materials
- C04B20/1029—Macromolecular compounds
- C04B20/1037—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
-
- 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
- C04B30/00—Compositions for artificial stone, not containing binders
-
- 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
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
-
- 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
- C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
- C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density
Definitions
- the present invention relates to composite materials, particularly to composite materials comprising solid particulate porous materials and thermoset polymers.
- thermoset polymers such as polyurethane
- U.S. Patent No. 5,723,506 describes a combination of thermoset foams with porous materials, thus obtaining a composite of low density.
- foamed polymers are extremely weak and do not provide a suitable composite where mechanical strength is required.
- the problems associated with the toxicity and flammability of polyurethanes limit the applicability of said patent.
- thermoset polymer which comprises a thermoset polymer and a porous material which is of low density and improved mechanical strength.
- process for preparing a composite material which comprises a thermoset polymer and a porous material wherein said process can be employed by simple means and which does not require highly developed skills in polymer production .
- thermoset polymers with porous materials with the ability to control the absorption of said thermoset polymer into the pores of said porous material.
- thermoset polymer a thermoset polymer and a porous material, wherein the penetration of said thermoset polymer into the pores of the porous material is minimized.
- the present invention provides a composite material comprising 80%-95% by volume of a solid porous material and 5%-20% by weight of a thermoset polymer, wherein the density of said composite material is 0.11 - 0.85 gr/ml. Further provided by the present invention is a process for the preparation of a low density composite material comprising applying a thermoset polymer to a solid porous material, wherein said applying by mixing and/or spraying .
- thermoset polymers are combined with solid porous materials.
- the combining of the solid porous material with said thermoset polymer is preferably carried out in a manner in which said polymer coats the porous material and blocks the pores of the solid porous material, hence minimizing the absorption of said polymer into the pores of said porous material .
- This phenomenon is hereinafter referred to as a "coating effect”. It has further been unexpectedly found that when the thermoset polymer is applied to the porous material, said unexpected coating effect is obtained and the density of the composite material is low while the mechanical strength is relatively high in comparison to the density and composition of said composite material.
- thermoset polymer and porous material are combined in a manner in which the porous material is mixed in to the polymer, said coating effect is affected and a relatively larger amount of polymer is absorbed into the pores of the porous material, thus obtaining a composite of higher density.
- the manner in which the the components are mixed is an essential feature for obtaining the composite of the present invention.
- the present invention provides a composite material comprising a solid porous material and a thermoset polymer, wherein the density of said composite material is lower than the composites obtained from thermoset and solid porous materials according to the prior art methods.
- thermoset polymer is applied to the solid porous material.
- the composite material of the present invention comprises 80% - 95% by volume of a solid porous material and 5% - 20% by weight of a thermoset polymer, wherein the density of said composite material is 0.11 - 0.85 gr/ml.
- Suitable solid porous materials for the composite materials of the present invention include mineral porous materials, preferably in fine particulate form. Such materials are available commercially.
- suitable solid porous materials include: alumina, carbon, ceramsite, mica, silica, expanded attapulgite, perlite, expanded perlite, pumice, vermiculite, zeolites, and mixtures thereof, or other expanded minerals preferably, expanded perlite and vermiculite .
- thermo-set polymers suitable for use according to the preset invention include: polyesters, vinylesters, epoxies, phenol resins, poly acetals, polyvinyl alcohols (PVA) , alkyd resins, polyimides and mixtures thereof.
- the composite material further comprises one or more flame retardant additives.
- Suitable flame retardants are selected from among flame retardants which are compatible with the thermoset polymer used in preparing the composites of the present invention.
- Non-limiting examples of such flame retardant (FR) additives are aluminum polyhydrate, titanium oxide, calcite, brominated FR agents, phosphate FRs and carbonate FRs .
- the composite of the present invention demonstrate properties which render said composite as suitable replacements for composites comprising foamed polyurethane based composites which have similar densities (0.04 - 0.50 gr/ml) .
- the present invention further provides a process for the preparation of the composite material comprising applying a thermoset polymer to a solid porous material.
- Said application may be carried out in various methods as may be appreciated by the skilled artisan.
- the polymer be applied onto the solid particles of the porous material .
- a thermoset resin is sprayed onto the particles of the solid porous material.
- the solid porous material is mobilized on a conveyer belt which passes under a device which sprays the thermoset resin in fine atomized form onto the porous material.
- the rate at which the conveyer belt moves and the rate of spraying the thermoset resin may be adjusted according to the density and mechanical strength desired. Such an adjustment is within the expertise of the skilled artisan.
- the process of the present invention requires intensive mixing of the two phases (the thermoset polymer and the porous material) to achieve a homogenous composite.
- the composite may be formed into different shapes. According to an optional embodiment of the process said composite can be pressed to the final volume required which results in the required density of final product. Pressure may be applied by mechanical and/or manual means as may be appreciated by the skilled artisan.
- the process of applying the thermoset polymer to the solid porous material may further be carried out by adding a thermoset polymer to the solid porous material while stirring.
- the rate of stirring may vary according to several different parameters, such as the curing time and the quantity of the accelerating agent. According to a particular embodiment of the invention, the stirring is carried out at a rate of 100-250 rpm and stirring together the pre-formed mix of the accelerating agents with a prepared small quantity of porous ingredient.
- a thermoset resin is slowly added during mixing onto the porous solid material and the homogeneous mixture is then cured in accordance with known techniques .
- Such curing processes include cold curing, hot curing and the addition of a hardening agent.
- the rate of curing may be controlled to correlate to the rate of addition of said resin to the porous solid material.
- a composite material is prepared by adding a thermoset resin selected from among a group comprising polyester, vinylester, epoxy, phenol resins, poly acetals, polyvinyl alcohols (PVA) , alkyd resins, polyimides and mixtures thereof, to a solid particulate porous material selected from among a group comprising perlite, expanded perlite, vermiculite, zeolites, mica, carbon, alumina, silica, expanded attapulgite, ceramsite expanded minerals, pumice and mixtures thereof, wherein the weight to volume ratio between said resin and said porous material is 1/20 w/v to 1/5 w/v. Said resin is added in a manner to create the coating effect.
- a thermoset resin selected from among a group comprising polyester, vinylester, epoxy, phenol resins, poly acetals, polyvinyl alcohols (PVA) , alkyd resins, polyimides and mixtures thereof
- PVA polyvinyl alcohols
- the rate of adding of ingredients has no effect on the equal spreading of resin on porous material.
- the mixture obtained is cured by adding a hardener and mixing.
- the curing agent and/or hardening agent are added to the resin before said resin is added to the porous material .
- initiators are well known in the art and include, without limitation, benzyl peroxide, methyl ethyl ketone peroxides, cumene hydroperoxide, lauroyl peroxide, t-butyl peroctoate, benzoyl peroctoate, t-butyl perbenzoate, di-t-butyl peroxide, and dicumyl peroxide. Mixtures of initiators may also be used. Suitable initiators are chosen depending on the reactivity desired. For example, benzoyl peroxide may be used to initiate crosslinking at a temperature from 0-25 0 C, while dicumyl peroxide is active over a temperature range of about 130-175° C.
- Accelerators may also be used in the thermoset resins of the invention.
- a non-limiting example of a suitable accelerator is cobalt naphthenate.
- an inhibitor may be used.
- Many inhibitors are known from the prior art and the amount employed can be determined by the skilled artisan and is dependent upon the desired delay.
- Additives such as hardening agents, curing agents, inhibitors and accelerators may be added in the process to the resin before coating the porous material or at any stage in the process. It is within the knowledge of the skilled artisan to determine at which stage to add said additives. The amount of additive (s) can be adjusted to the work conditions and is within the skilled artisan's common practice to determine such amounts .
- the porous material and thermoset polymer or mixtures are selected according to the desired density and properties. Selection of appropriate ingredients compatible with said process depends on the application of the final required product properties, e.g. use of the composite for indoor or outdoor applications.
- the present invention can be widely employed in various fields of industry and for various purposes .
- the composite material of the present invention may be employed in the manufacture of cementitious compositions by adding the composite material to a cementitious composition and curing the composite thereafter.
- said composite material may be employed as a filler in the preparation of light construction elements such as sheet rock, wall panels, acoustic and decorative ceilings, indoor and outdoor panels, tiles (e.g. roof tiles), walls and door insulation (thermal and sound) .
- the composite material of the present invention may be used in order to fill cavities and spaces where there is need for light weight filling, for example internal filling between wall panels and filling for doors.
- the composite material obtained according to the present invention has improved properties in terms of low density, they also display improved properties in terms of thermal and sound insulation when considering the density of said material.
- the present example describes the preparation of panesl which may be employed in construction wherein said panels contain a layer of the composite material of the present invention.
- a mold of desired size and shape is sprayed with a first layer of 0.5 Kg jell coat.
- Said jell coat is prepared before spraying by mixing the jell coat with 0.2% by weight the accelerator.
- a second layer is applied wherein said second layer is a reinforcement layer comprising a fiberglass sheet and polyester.
- Said second layer is prepared by mixing 1 Kg of the polyester resin with 0.2% by weight (i.e. 2g) accelerator and 2% (i.e. 2Og) by weight hardening agent and spreading said mixture over the fiberglass sheet which is layered on top of the jell coat.
- the third layer is the layer of the composite material of the present invention which is prepared by loading 20 liters of porous material e.g.
- polyester resin is mixed with 2% by weight of a hardening agent and optionally if needed with an inhibitor. Said resin mixture is stirred well to homogenously disperse the hardening agent and inhibitor. Thereafter, said polyester resin mixture is added slowly to the perlite or vermiculite in order to coat the porous material. This is carried out by spraying the polyester resin onto the porous material. Upon completing the coating of the porous material, said coated porous material is poured into the mold to coat said second layer. A final and fourth layer of similar composition to said second layer is applied to said third layer and the layered panel is pressed to achieve the desired density. The panel is allowed to complete the hardening process and is then ready for use.
- the present example is similar to example 1 in its procedure.
- the panel in this example has seven separate layers.
- the important layer which is the layer of the composite of the present invention, is prepared by mixing 6 kg of polyester resin with 0.2% by weight accelerator, 1% by weight inhibitor, 7% by weight of antimony oxide, 7% by weight para-dibromodiphenyl and 2% by weight hardening agent . Said mixing is carried out until the resin mixture is homogenous. It is then added to 86 liters of porous material, by spraying the resin mixture onto the porous material.
- Example 3 Preparing Filling for Doors
- said filling is prepared by mixing 9 liters of polyester resin with 0.2% by weight accelerator, 1% by weight inhibitor, 7% by weight of antimony oxide, 7% by weight para-dibromodiphenyl and 2% by weight hardening agent. Said mixing is carried out until the resin mixture is homogenous; typically about five minutes. The mixture is then added (applied to) 180 liters of porous material, by spraying the resin mixture onto the porous material.
- the porous material is preferably perlite or vermiculite having a preferred particle size of 2-4 mm.
- the filling is then poured into the door which is supported in a press in order to prevent the door from deforming during the process of adding the filling and the hardening and curing thereof.
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Abstract
A composite material comprising 80%-95% by volume of a solid porous material and 5%-20% by weight of a thermoset polymer, wherein the density of the composite material is 0.11 - 0.85 gr/ml.
Description
COMPOSITE MATERIAL AND PROCESS FOR THE PREPARATION THEREOF
FIELD OF THE INVENTION The present invention relates to composite materials, particularly to composite materials comprising solid particulate porous materials and thermoset polymers.
BACKGROUND OF THE INVENTION The combination of porous solid materials with polymers is known to be an effective method for obtaining relatively low density composites of sufficient mechanical strength. In the preparation of composites with polymers and porous materials, the polymer penetrates the pores of the material and fills said pores, thus increasing the density of the porous material. In particular this problem exists when thermoset polymers are employed. Said problem also exists when thermoplastic polymers are employed. In order to control the penetration of the polymer into said pores, several methods have been developed. U.S. Patent No. 4,234,659 describes a method for regulating the penetration into the pores of a porous material by controlling the polymerization process of a polyolefin. Said process requires highly developed skills in polymerization processes and is not recommended for use by people who are not polymer producers. In the case where thermoset polymers are employed the problem of absorption into the pores of the porous material can be overcome by employing a foamed thermoset polymer such as polyurethane . U.S. Patent No. 5,723,506 describes a combination of thermoset foams with porous materials, thus obtaining a composite of low density. However, foamed polymers are extremely weak and do not provide a
suitable composite where mechanical strength is required. Furthermore, the problems associated with the toxicity and flammability of polyurethanes limit the applicability of said patent. Thus, there is a long felt need for a composite material which comprises a thermoset polymer and a porous material which is of low density and improved mechanical strength. There is a further need for a process for preparing a composite material which comprises a thermoset polymer and a porous material wherein said process can be employed by simple means and which does not require highly developed skills in polymer production .
It is therefore an objective of the present invention to provide a process which combines thermoset polymers with porous materials with the ability to control the absorption of said thermoset polymer into the pores of said porous material.
It is further an objective of the present invention to provide a composite material comprising a thermoset polymer and a porous material, wherein the penetration of said thermoset polymer into the pores of the porous material is minimized.
Other objectives of the invention shall become apparent as the description proceeds.
SUMMARY OF THE INVENTION
The present invention provides a composite material comprising 80%-95% by volume of a solid porous material and 5%-20% by weight of a thermoset polymer, wherein the density of said composite material is 0.11 - 0.85 gr/ml.
Further provided by the present invention is a process for the preparation of a low density composite material comprising applying a thermoset polymer to a solid porous material, wherein said applying by mixing and/or spraying .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The following description is illustrative of embodiments of the invention. The following description is not to be construed as limiting, it being understood that a skilled person may carry out many obvious variations to the invention.
It has unexpectedly been found that the manner in which thermoset polymers are combined with solid porous materials is critical in determining the density of the composite thereby obtained. In order to obtain such a composite material with a low density, the combining of the solid porous material with said thermoset polymer is preferably carried out in a manner in which said polymer coats the porous material and blocks the pores of the solid porous material, hence minimizing the absorption of said polymer into the pores of said porous material . This phenomenon is hereinafter referred to as a "coating effect". It has further been unexpectedly found that when the thermoset polymer is applied to the porous material, said unexpected coating effect is obtained and the density of the composite material is low while the mechanical strength is relatively high in comparison to the density and composition of said composite material. In contrast to the present invention it has been found that when the thermoset polymer and porous material are
combined in a manner in which the porous material is mixed in to the polymer, said coating effect is affected and a relatively larger amount of polymer is absorbed into the pores of the porous material, thus obtaining a composite of higher density. Thus, the manner in which the the components are mixed is an essential feature for obtaining the composite of the present invention.
According to one aspect, the present invention provides a composite material comprising a solid porous material and a thermoset polymer, wherein the density of said composite material is lower than the composites obtained from thermoset and solid porous materials according to the prior art methods.
In accordance with another aspect of the present invention, a method for preparing the composite material of the present invention is provided wherein a thermoset polymer is applied to the solid porous material.
The composite material of the present invention comprises 80% - 95% by volume of a solid porous material and 5% - 20% by weight of a thermoset polymer, wherein the density of said composite material is 0.11 - 0.85 gr/ml. Suitable solid porous materials for the composite materials of the present invention include mineral porous materials, preferably in fine particulate form. Such materials are available commercially. Non-limiting examples of suitable solid porous materials include: alumina, carbon, ceramsite, mica, silica, expanded attapulgite, perlite, expanded perlite, pumice, vermiculite, zeolites, and mixtures thereof, or other expanded minerals preferably, expanded perlite and vermiculite .
Non-limiting examples of thermo-set polymers suitable for use according to the preset invention include: polyesters, vinylesters, epoxies, phenol resins, poly acetals, polyvinyl alcohols (PVA) , alkyd resins, polyimides and mixtures thereof.
According to another embodiment of the present invention, the composite material further comprises one or more flame retardant additives. Suitable flame retardants are selected from among flame retardants which are compatible with the thermoset polymer used in preparing the composites of the present invention. Non-limiting examples of such flame retardant (FR) additives are aluminum polyhydrate, titanium oxide, calcite, brominated FR agents, phosphate FRs and carbonate FRs .
The composite of the present invention demonstrate properties which render said composite as suitable replacements for composites comprising foamed polyurethane based composites which have similar densities (0.04 - 0.50 gr/ml) .
The present invention further provides a process for the preparation of the composite material comprising applying a thermoset polymer to a solid porous material. Said application may be carried out in various methods as may be appreciated by the skilled artisan. However, it is a key feature of the present invention that the polymer be applied onto the solid particles of the porous material .
According to a specific embodiment of the invention, a thermoset resin is sprayed onto the particles of the solid porous material. In one particular embodiment the solid porous material is mobilized on a conveyer belt which passes under a device which sprays the thermoset resin in fine atomized form onto the porous material. The rate at which the conveyer belt moves and the rate of spraying the thermoset resin may be adjusted according to the density and mechanical strength desired. Such an adjustment is within the expertise of the skilled artisan.
The process of the present invention requires intensive mixing of the two phases (the thermoset polymer and the porous material) to achieve a homogenous composite. The composite may be formed into different shapes. According to an optional embodiment of the process said composite can be pressed to the final volume required which results in the required density of final product. Pressure may be applied by mechanical and/or manual means as may be appreciated by the skilled artisan.
The process of applying the thermoset polymer to the solid porous material may further be carried out by adding a thermoset polymer to the solid porous material while stirring. The rate of stirring may vary according to several different parameters, such as the curing time and the quantity of the accelerating agent. According to a particular embodiment of the invention, the stirring is carried out at a rate of 100-250 rpm and stirring together the pre-formed mix of the accelerating agents with a prepared small quantity of porous ingredient.
In a particular mode of carrying out the invention, a thermoset resin is slowly added during mixing onto the porous solid material and the homogeneous mixture is then cured in accordance with known techniques . Such curing processes include cold curing, hot curing and the addition of a hardening agent. The rate of curing may be controlled to correlate to the rate of addition of said resin to the porous solid material.
According to a specific embodiment of the process, a composite material is prepared by adding a thermoset resin selected from among a group comprising polyester, vinylester, epoxy, phenol resins, poly acetals, polyvinyl alcohols (PVA) , alkyd resins, polyimides and mixtures thereof, to a solid particulate porous material selected from among a group comprising perlite, expanded perlite, vermiculite, zeolites, mica, carbon, alumina, silica, expanded attapulgite, ceramsite expanded minerals, pumice and mixtures thereof, wherein the weight to volume ratio between said resin and said porous material is 1/20 w/v to 1/5 w/v. Said resin is added in a manner to create the coating effect. The rate of adding of ingredients has no effect on the equal spreading of resin on porous material. Upon completing the addition of said resin, the mixture obtained is cured by adding a hardener and mixing. According to a further embodiment, the curing agent and/or hardening agent are added to the resin before said resin is added to the porous material .
Hardening or curing of the resin can be carried out in the presence of initiators. Suitable initiators are well known in the art and include, without limitation, benzyl peroxide, methyl ethyl ketone peroxides, cumene
hydroperoxide, lauroyl peroxide, t-butyl peroctoate, benzoyl peroctoate, t-butyl perbenzoate, di-t-butyl peroxide, and dicumyl peroxide. Mixtures of initiators may also be used. Suitable initiators are chosen depending on the reactivity desired. For example, benzoyl peroxide may be used to initiate crosslinking at a temperature from 0-250C, while dicumyl peroxide is active over a temperature range of about 130-175° C.
Accelerators may also be used in the thermoset resins of the invention. A non-limiting example of a suitable accelerator is cobalt naphthenate. Under certain working conditions there may be a need to delay the hardening and/or curing of the thermoset resin. For this purpose an inhibitor may be used. Many inhibitors are known from the prior art and the amount employed can be determined by the skilled artisan and is dependent upon the desired delay. Additives such as hardening agents, curing agents, inhibitors and accelerators may be added in the process to the resin before coating the porous material or at any stage in the process. It is within the knowledge of the skilled artisan to determine at which stage to add said additives. The amount of additive (s) can be adjusted to the work conditions and is within the skilled artisan's common practice to determine such amounts .
The porous material and thermoset polymer or mixtures are selected according to the desired density and properties. Selection of appropriate ingredients compatible with said process depends on the application of the final required product properties, e.g. use of the composite for indoor or outdoor applications.
The present invention can be widely employed in various fields of industry and for various purposes . The composite material of the present invention may be employed in the manufacture of cementitious compositions by adding the composite material to a cementitious composition and curing the composite thereafter. Similarly, said composite material may be employed as a filler in the preparation of light construction elements such as sheet rock, wall panels, acoustic and decorative ceilings, indoor and outdoor panels, tiles (e.g. roof tiles), walls and door insulation (thermal and sound) . Additionally, the composite material of the present invention may be used in order to fill cavities and spaces where there is need for light weight filling, for example internal filling between wall panels and filling for doors.
While the composite material obtained according to the present invention has improved properties in terms of low density, they also display improved properties in terms of thermal and sound insulation when considering the density of said material.
EXAMPLES
EXAMPLE 1 - Preparation of a Panel
The present example describes the preparation of panesl which may be employed in construction wherein said panels contain a layer of the composite material of the present invention.
A mold of desired size and shape is sprayed with a first layer of 0.5 Kg jell coat. Said jell coat is prepared
before spraying by mixing the jell coat with 0.2% by weight the accelerator. After said first layer dries, a second layer is applied wherein said second layer is a reinforcement layer comprising a fiberglass sheet and polyester. Said second layer is prepared by mixing 1 Kg of the polyester resin with 0.2% by weight (i.e. 2g) accelerator and 2% (i.e. 2Og) by weight hardening agent and spreading said mixture over the fiberglass sheet which is layered on top of the jell coat. The third layer is the layer of the composite material of the present invention which is prepared by loading 20 liters of porous material e.g. expanded perlite or vermiculite, having a particle size of 2-4 mm into a mixing vessel. Separately, 2 liters of polyester resin is mixed with 2% by weight of a hardening agent and optionally if needed with an inhibitor. Said resin mixture is stirred well to homogenously disperse the hardening agent and inhibitor. Thereafter, said polyester resin mixture is added slowly to the perlite or vermiculite in order to coat the porous material. This is carried out by spraying the polyester resin onto the porous material. Upon completing the coating of the porous material, said coated porous material is poured into the mold to coat said second layer. A final and fourth layer of similar composition to said second layer is applied to said third layer and the layered panel is pressed to achieve the desired density. The panel is allowed to complete the hardening process and is then ready for use.
Example 2 - Preparation of a composite Panel
The present example is similar to example 1 in its procedure. However, the panel in this example has seven separate layers. The important layer, which is the layer of the composite of the present invention, is prepared
by mixing 6 kg of polyester resin with 0.2% by weight accelerator, 1% by weight inhibitor, 7% by weight of antimony oxide, 7% by weight para-dibromodiphenyl and 2% by weight hardening agent . Said mixing is carried out until the resin mixture is homogenous. It is then added to 86 liters of porous material, by spraying the resin mixture onto the porous material.
Example 3 - Preparing Filling for Doors The present example describes the preparation of a composite material according to the present invention wherein said composite material is used as filling in doors, thus providing thermal and acoustic insulation without significantly adding to the weight of the door. Accordingly, said filling is prepared by mixing 9 liters of polyester resin with 0.2% by weight accelerator, 1% by weight inhibitor, 7% by weight of antimony oxide, 7% by weight para-dibromodiphenyl and 2% by weight hardening agent. Said mixing is carried out until the resin mixture is homogenous; typically about five minutes. The mixture is then added (applied to) 180 liters of porous material, by spraying the resin mixture onto the porous material. The porous material is preferably perlite or vermiculite having a preferred particle size of 2-4 mm. The filling is then poured into the door which is supported in a press in order to prevent the door from deforming during the process of adding the filling and the hardening and curing thereof.
While embodiments of the invention have been described by way of illustration, it will be apparent that the invention may be carried out with many modifications, variations and adaptations, without departing from the scope of the claims.
It should be understood that some modification, alteration and substitution is anticipated and expected from those skilled in the art without departing from the teachings of the invention. Accordingly, it is appropriate that the following claims be construed broadly and in a manner consistent with the scope of the invention .
Claims
1. A composite material comprising 80%-95% by volume of a solid porous material and 5%-20% by weight of a thermoset polymer, wherein the density of said composite material is 0.11 - 0.85 gr/ml.
2. A composite material according to claim 1 wherein said thermoset polymer is selected from among polyester, vinylester, epoxy, phenol resins, poly acetals, polyvinyl alcohols, alkyd resins, polyimides and mixtures thereof.
3. A composite material according to claim 1 wherein said solid porous material is selected from among a group comprising perlite, expanded perlite, vermiculite, zeolites, mica, carbon, alumina, silica, expanded attapulgite, ceramsite expanded minerals, pumice and mixtures thereof.
4. A composite material according to any one of claims 1 to 3 wherein the weight to weight ratio between said resin and said porous material is 1/20 w/v to l/5w/vol.
5. A composite material according to any one of claims 1 to 3 further comprising one or more flame retardant additives .
6. A composite material according to claim 5 wherein said flame retardants are selected from among aluminum polyhydrate, titanium oxide, calcite, brominated flame retardants, phosphate flame retardants and Carbonate flame retardants.
7. A process for the preparation of a composite material comprising applying a thermoset polymer to a solid porous material.
8. A process according to claim 7 wherein said applying is by mixing, spraying, or by means of pressurized and packed material applying vibration equipment .
9. A process according to either one of claims 7 or 8 wherein said thermoset polymer is selected from among polyester, vinylester, epoxy, phenol resins, poly acetals, polyvinyl alcohols, alkyd resins, polyimides and mixtures thereof.
10. A process according to either one of claims 7 or 8 wherein said solid porous material is selected from among a group comprising perlite, expanded perlite, vermiculite, zeolites, mica, carbon, alumina, silica, expanded attapulgite, ceramsite expanded minerals, pumice and mixtures thereof.
11. A process according to claim 7 wherein a thermoset resin is sprayed onto said solid porous material.
12. A process according to claim 11 wherein said solid porous material is mobilized on a conveyer belt which passes under a device which sprays said thermoset resin in fine atomized form onto said porous material.
13. A process according to claim 7 further comprising forming and/or molding the composite into a desired shape .
14. A process according to claim 7 wherein said composite is pressed to a final volume.
15. A process according to claim 7 wherein the weight to volume ratio between said resin and said porous material is 1/20 w/v to l/5w/vol.
16. A process according to claim 7 wherein the thermoset resin is coated onto said solid porous material by adding said thermoset resin to the porous solid material and stirring to obtain an homogenous composite .
17. A process according to claim 7 wherein said thermoset resin is cured or hardened.
18. An article of manufacture comprising a composite material comprising 80%-95% by volume of a solid porous material and 5%-20% by weight of a thermoset polymer, wherein the density of said composite material is 0.11 - 0.85 gr/ml.
19. An article of manufacture according to claim 18 wherein said article is selected from among a group comprising light construction elements including sheet rock, wall panels, acoustic and decorative ceilings, indoor and outdoor panels, tiles, thermal and/or sound insulated walls and doors.
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IL188740 | 2008-01-13 | ||
IL188740A IL188740A0 (en) | 2008-01-13 | 2008-01-13 | Composite material and process for the preparation thereof |
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Cited By (12)
Publication number | Priority date | Publication date | Assignee | Title |
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CN102206091A (en) * | 2010-03-10 | 2011-10-05 | 东南大学 | Method for making ceramsite by using sludge |
CN102249600A (en) * | 2011-06-09 | 2011-11-23 | 郭长有 | Flame retardant and waterproof insulation board and preparation method thereof |
WO2012019578A3 (en) * | 2010-05-26 | 2012-04-26 | Kerapor Gmbh | Fire-retarding materials mixture |
CN102500160A (en) * | 2011-11-10 | 2012-06-20 | 许庆华 | Cylindrical attapulgite active carbon ceramsite filter material |
CN103011720A (en) * | 2012-11-16 | 2013-04-03 | 合肥神舟建筑工程有限公司 | Modified nano-attapulgite clay inorganic thermal-insulation mortar coated with plant ash and preparation method thereof |
CN106631118A (en) * | 2016-12-14 | 2017-05-10 | 万杨知为 | Through-hole haydite and production method thereof |
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CN108147787A (en) * | 2017-12-22 | 2018-06-12 | 中建八局第建设有限公司 | A kind of alumina tailing sintering ceramsite and preparation method thereof |
WO2018185770A1 (en) | 2017-04-05 | 2018-10-11 | Setbone Medical Ltd. | Property changing implant |
CN109293371A (en) * | 2018-09-30 | 2019-02-01 | 柳晶(长春)环保科技有限公司 | A kind of technique preparing haydite using building waste |
CN110467383A (en) * | 2019-09-05 | 2019-11-19 | 张建华 | A kind of waterproof thermal-insulated sloping layer and preparation method thereof |
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CN106368133A (en) * | 2016-10-21 | 2017-02-01 | 山西省交通科学研究院 | Polymer-base environment-friendly ceramsite compound sound barrier |
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CN102206091A (en) * | 2010-03-10 | 2011-10-05 | 东南大学 | Method for making ceramsite by using sludge |
WO2012019578A3 (en) * | 2010-05-26 | 2012-04-26 | Kerapor Gmbh | Fire-retarding materials mixture |
CN102249600A (en) * | 2011-06-09 | 2011-11-23 | 郭长有 | Flame retardant and waterproof insulation board and preparation method thereof |
CN102500160A (en) * | 2011-11-10 | 2012-06-20 | 许庆华 | Cylindrical attapulgite active carbon ceramsite filter material |
CN103011720A (en) * | 2012-11-16 | 2013-04-03 | 合肥神舟建筑工程有限公司 | Modified nano-attapulgite clay inorganic thermal-insulation mortar coated with plant ash and preparation method thereof |
CN103011720B (en) * | 2012-11-16 | 2015-03-11 | 合肥神舟建筑工程有限公司 | Modified nano-attapulgite clay inorganic thermal-insulation mortar coated with plant ash and preparation method thereof |
CN106631118A (en) * | 2016-12-14 | 2017-05-10 | 万杨知为 | Through-hole haydite and production method thereof |
CN106631118B (en) * | 2016-12-14 | 2020-01-07 | 万杨知为 | Through-hole ceramsite and production method thereof |
WO2018185770A1 (en) | 2017-04-05 | 2018-10-11 | Setbone Medical Ltd. | Property changing implant |
US11426487B2 (en) | 2017-04-05 | 2022-08-30 | Setbone Medical Ltd. | Property changing implant |
CN107857576A (en) * | 2017-11-03 | 2018-03-30 | 江西鑫陶科技股份有限公司 | A kind of preparation method of aluminum oxide porous proppant |
CN108147787A (en) * | 2017-12-22 | 2018-06-12 | 中建八局第建设有限公司 | A kind of alumina tailing sintering ceramsite and preparation method thereof |
CN109293371A (en) * | 2018-09-30 | 2019-02-01 | 柳晶(长春)环保科技有限公司 | A kind of technique preparing haydite using building waste |
CN110467383A (en) * | 2019-09-05 | 2019-11-19 | 张建华 | A kind of waterproof thermal-insulated sloping layer and preparation method thereof |
CN113650391A (en) * | 2021-07-28 | 2021-11-16 | 颍上县博浩塑业科技有限公司 | Double-layer resin tile with sound insulation function and production device thereof |
Also Published As
Publication number | Publication date |
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IL188740A0 (en) | 2008-12-29 |
WO2009087610A3 (en) | 2009-09-03 |
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