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
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
  • C04B28/26—Silicates of the alkali metals
• • 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
  • C08G18/4825—Polyethers containing two hydroxy groups
• • 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
  • 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
  • C08G2110/00—Foam properties
  • C08G2110/0041—Foam properties having specified density
  • C08G2110/0066—≥ 150kg/m3
• • 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
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

• the present invention relates to siliceous-based polyurea compositions, the process for their manufacture and their use in various areas. More particularly, the present inven- tion relates to siliceous-based polyurea compositions, obtainable by reacting isocy- anates, alkali silicates and hydratable aluminosilicates.
• US-Patent 3,607,794 discloses a process for the production of a silica-containing refractory product which consists essentially of a reaction between an aqueous solution of an alkali metal silicate and an organic polyisocyanate in the presence of an inert material selected from the group consisting of particulate materials, fibrous and mixtures thereof and in the absence of a preformed resin.
• an inert material selected from the group consisting of particulate materials, fibrous and mixtures thereof and in the absence of a preformed resin.
• the use of amine catalysts, foaming agents and foam stabilizing agents is recommended in that US patent publication.
• An emulsion inversion generates materials with properties reflective of the continuous organic matrix, which are then more combustible.
• the isocyanate-containing resin hardens by reaction of -NCO with the basic aqueous solution, carbon dioxide is liberated from the resultant carbamic acid which then transfers to the aqueous phase and causes hydrated silica gel precipitation.
• the liberated amine unit forms polyurea by reaction with isocyanate groups, while further condensation reactions cause silicon dioxide network formation.
• the homogeneity of the biphasic mixture can be improved by incorporating dispersing agents, wetting agents and emulgators.
• US-Patent 4,129,696 describes a process for the production of inorganic-organic plas- tic composites and the resultant products.
• the process generally comprises a reaction of an aqueous alkali metal silicate solution with a liquid organic polyisocyanate having a viscosity at 25 0 C of at least about 0.4 Pa*s, said reaction being conducted in the absence of inorganic water-binding fillers. It is recommended to use catalysts, foaming agents and emulsifying agents.
• a method to provide lightweight foamed PUS hybrid materials derived from a sol-gel reaction is disclosed by combining waterglass-polyisocyanate hybrids, where interpenetrating networks are produced from ionic-modified polyisocyanates (GB 1 ,483,270, GB 1 ,385,605 and DE 22 27 147 A1 ). Lightweight materials were produced by this method using chlorofluorocarbon blowing agents. In the examples listed, elevated processing temperatures of >30 0 C, or slow (over 40 minutes) foam rise are reported.
• the problem underlying the present invention is to mitigate the above identified disadvantages of the prior art.
• materials with a reasona- bly wide spectrum and a good balance of properties are needed, especially lightweight, high mechanical load baring, flame retarding materials.
• Avoiding halogenated and/or phosphorous-containing additives, foam stabilizing agents, catalysts and/or foaming agents would be of further advantage.
• no flame protection on the basis of halogenated and/or phosphorous-containing additives is commonly used as these additives could migrate into the food storage compartment and post toxicological risks.
• Refrigerator insulation is therefore often composed of flammable materials and entails high flame loads. A practical need therefore existed in the art for halogen and/or phos- phorous-free insulation materials with reduced flame loads and reduced flammability.
• the present invention pertains to siliceous-based polyurea compositions, which are obtainable by reacting ingredients comprising a) a polyisocyanate, b) an aqueous silicate, and c) a hydratable aluminosilicate.
• the reaction ingredients further comprise d) a polyol, and/or e) an inert filler.
• the polyisocyanate according to the present invention is an aliphatic isocyanate, an aromatic isocyanate or a combined aliphatic/aromatic isocyanate, having an -NCO functionality of preferably > 2.
• Suitable polyisocyanates include tetramethylene diisocyanate, hexamethylene diisocy- anate (HMDI), dodecamethylene diisocyanate, 3-isocyanatomethyl-3,5,5-trimethyl- cyclohexyl isocyanate, i.e.
• IPDI isophorone diisocyanate
• H12MDI 4,4'-dicyclohexylmethane diisocyanate
• CHDI 1,4-cyclohexane diisocyanate
• TDI 4,4'-diisocyanatodicyclo- hexyl-2,2-propane
• p-phenylene diisocyanate 2,4- and 2,6-toluene diisocyanate
• TDI 2,6-toluene diisocyanate
• MDI tolidine diisocyanate
• MDI 1,2-naphthylene diisocyanate
• xylylene diisocyanate 1, tetramethylxylene diisocyanate
• TXDI tetramethylxylene diisocyanate
• Polyisocyanates containing heteroatoms in the moiety linking the isocyanate groups are also suitable, i.e. polyisocyanates containing urea groups, urethane groups, biuret groups, allophonate groups, uretidinedione groups, isocyanurate groups, imide groups, carbodiimide groups, uretonimine groups and the like.
• polymeric polyisocyanates based upon diphenylmeth- ane diisocyanate isomers (MDI), the so-called MDI-grades, and polymeric MDI (PMDI), having an -NCO functionality of preferably > 2.
• suitable (polymeric) polyisocyanates should possess viscosities of less than 20 Pa « s, preferably less than 10 Pa « s.
• the -NCO content should be in the range 10 - 30 % by weight.
• the aqueous silicate according to the present invention is an alkali silicate or ammonium silicate, preferably ammonium, lithium, sodium or potassium waterglass, or combinations thereof, having a (silica) modulus as defined by its Si ⁇ 2:M2 ⁇ molar ratio of 4.0 - 0.2, preferably 4.0 - 1.0, wherein M stands for a monovalent cation, and having a solids content of 10 - 70 % by weight, preferably 30 - 55 % by weight, and/or a silicate content, calculated as Si ⁇ 2, of 12 - 32 % by weight, preferably 18 - 32 % by weight.
• Sodium and potassium waterglass are particularly preferred. Waterglass-viscosities should be in the range of 0.2 - 1.0 Pa*s; higher viscosities should be lowered by the addition of appropriate aqueous alkali.
• Suitable hydratable aluminosilicates are the dehydrated and/or de hydroxy I ated forms of hydrated aluminosilicates such as antigorite, chrysotile, lizardite; kaolinite, illite, smectite clay, montmorillonite, vermiculite, talc, palygorskite, pyrophyllite, biotite, muscovite, phlogopite, lepidolite, margarite, glauconite; chlorite; and zeolites.
• Preferred hydratable aluminosilicates are selected from the group consisting of dehydrated kaolinite, meta- kaolin, fly ash, pozzolanes, zeolites, and mixtures thereof. These materials do not possess cementitious properties. Metakaolin is particularly preferred. When dehydrated (100 - 200 0 C), aluminosilicate minerals lose most of their physically bound water. At higher temperatures, dehydroxylation takes place, and the interlayer region of these minerals collapse. Kaolinite dehydroxylates between 500 - 800 0 C to form metakaolin.
• the polyol is a polyfunctional alcohol having an -OH functionality of preferably > 2.
• Suitable polyols include, but are not limited to ethylene glycol, 1 ,2- und 1 ,3-propylene glycol, 2-methyl-1 ,3-propanediol, 1 ,2-, 1 ,3-, 1 ,4- and 2,3-butanediol, 1 ,6-hexanediol, 1 ,8-octanediol, neopentylglycol, cyclohexanedimethanol, cyclohexane-1 ,4-diol, 1 ,4-bis- hydroxymethylcyclohexane, 1 ,5-pentanediol, 3-methyl-1 ,5-pentanediol, 1 ,12-dodecane- diol, diethylene glycol, triethylene glycol, tetraethylene glycol, pentaethylene glycol, di- propylene glycol, dibutylene glycol; glycerol,
• a polyisocyanate prepolymer is a polymeric iso- cyanate having an -NCO functionality of preferably > 2.
• Polyisocyanate prepolymers are preferably synthesized from the above mentioned MDI-grades or PMDI.
• inert fillers there can be used the above mentioned hydrated aluminosilicates, ball clay, china clay, barytes, calcium carbonate such as calcite, mica, perlite, pumice, silica such as quartz, dolomite, wollastonite, alumina, iron oxides, non-water binding zeolites or mixtures thereof.
• any other inert fillers known in the art may be employed.
• the mass percentages of ingredients may be varied within a broad range.
• the following percentages apply to polyisocyanates, aqueous silicates, hydratable aluminosilicates and inert fillers:
• Preferred percentages comprise:
• compositions of the present invention possess flame-retarding properties.
• additives such as foam stabilizing agents, wetting agents, dispersing agents, catalysts and/or foaming agents may be used in the compositions of the present invention, these additives can be preferably avoided.
• the siliceous-based polyurea compositions of the present invention are generally prepared by following a staged mixing process, comprising the steps of mixing a hydrat- able aluminosilicate with an aqueous silicate and reacting this mixture with a polyisocyanate and/or a polyisocyanate prepolymer, optionally in the presence of a polyol and/or with the inclusion of an inert filler.
• the materials are then left to mature within suitable supporting containers.
• the reactions are generally carried out at room temperature, and sufficient heat is generated in-situ to cure the reaction contents.
• the process for the manufacture of the composition according to the present invention preferably further comprises slow pressure release of gas formed in the reaction of the polyisocy- anate and/or polyisocyanate prepolymer with water, i.e. pressure-released controlled foaming.
• siliceous-based polyurea compositions of the present invention pertains to the areas of aviation; automotive assemblies, examples include but are not limited to seating, dashboards, interior padding, steering wheels, door panels, storage surrounds and engine space components; construction, examples include but are not limited to sandwich structures, thermally insulating panels, load bearing roofing and flooring systems, bridge and road repair systems; consumer products, examples include but are not limited to stationary and mobile refrigerator units; fire protection, examples include but are not limited to flame sealing materials; furniture components, examples include but are not limited to mattresses and upholstery; and insulation, examples include but are not limited to building panels and exterior insulation finishing systems; shipbuilding and/or windmill construction, examples include but are not limited to high load bearing in-situ filling of double-walled construction elements.
• Prepolymer 1 was obtained by reacting 1000 g commercial grade 4,4'-diphenylmethane diisocyanate (Lupranat ® Ml) with 863 g commercial grade propylene glycol (Desmophen ® 3600 z) having an OH value of 56.0 mg/g KOH.
• the obtained Prepolymer 1 had an -NCO content of 15.6 % by weight and a viscosity at 24 0 C of 709 mPa*s.
• A-Component Metakaolin, Argical M 1000 24.0 g
• Components A and C were mixed for 30 seconds at 1000 rpm.
• Component B was added and mixed for 60 seconds at 600 rpm.
• the density after 7 days storage at room temperature in a Styropor ® mould was 1.380 g/ml.
• A-Component Metakaolin, Argical M 1000 4.19 g
• Components A and C were mixed at 900 rpm for 60 seconds.
• Component B was added and mixed for 60 seconds at 600 rpm.
• the material was poured into a mould, and after 3 days tensile, compressive and flexural strengths values of 1.7 N/mm 2 , 9.4 N/mm 2 and 63.3 N/mm 2 respectively were recorded.
• tensile, compressive and flexural strengths values of 1.7 N/mm 2 , 9.4 N/mm 2 and 63.3 N/mm 2 respectively were recorded.
• During testing the 4 « 4 « 4 cm 3 block demon- strated an exceptional response to compression as it was crushed to within 21 % of its original height under a maximum pressure of 100 ton, yet it re-expanded to over 80% of its original height upon pressure release.
• During flexural strength measurement a 4 « 4 « 16 cm 3 sample was deformed by 46 % and once pressure was released the material returned to its original shape.
• A-Component Metakaolin, Argical M 1000 16.78 g
• Components A and C were mixed at 800 rpm for 60 seconds.
• Component B was added and mixed for 60 seconds at 600 rpm.
• the material was poured into a mould and allowed to set.
• the density after 7 days storage at room temperature in the Styropor ® mould was 0.875 g/ml.
• A-Component Metakaolin, Argical M 1000 13.43 g
• Components A and C were mixed at 800 rpm for 60 seconds.
• Component B was added and mixed for 60 seconds at 600 rpm.
• the material was poured into a mould, and after 3 days tensile, compressive and flexural strengths values of 1.5 N/mm 2 , 5.2 N/mm 2 and 62.5 N/mm 2 respectively were recorded.
• tensile, compressive and flexural strengths values 1.5 N/mm 2 , 5.2 N/mm 2 and 62.5 N/mm 2 respectively were recorded.
• 4 « 4 « 4 cm 3 block demonstrated an exceptional response to compression as it was crushed to within 23 % of its original height under a maximum pressure of 100 ton, yet it re-expanded to over 80% of its original height upon pressure release.
• During flexural strength measurement a 4 « 4 « 16 cm 3 sample was deformed by 48 % and once pressure was released the material returned to its original shape.
• the density after 7 days storage at room temperature in a Styropor ® mould was 0.987 g
• A-Component Metakaolin, Argical M 1000 46.98 g
• component A The ingredients of component A were mixed at 1000 rpm for 60 seconds. Component B was added and mixed for 60 seconds at 600 rpm. The material was poured into a mould, and after 3 days the tensile strength was measured. A maximum tensile strength value of 3.2 N/mm 2 , with 48 % elongation, was recorded. The density after 7 days storage at room temperature in a Styropor ® mould was 0.710 g/ml.
• component B The ingredients of component A were mixed at 1000 rpm for 60 seconds. Component B was added and mixed for 60 seconds at 600 rpm. The material was poured into a mould, and after 3 days the tensile strength was measured. A maximum tensile strength value of 3.2 N/mm 2 , with 48 % elongation, was recorded. The density after 7 days storage at room temperature in a Styropor ® mould was 0.710 g/ml.
• A-Component Metakaolin, Argical M 1000 44.74 g
• component A The ingredients of component A were mixed at 1000 rpm for 60 seconds, added to component B and mixed for a further 60 seconds at 600 rpm.
• the material was poured into a mould, and after 3 days tensile, compressive and flexural strengths values of 1.7 N/mm 2 , 6.6 N/mm 2 and 62.5 N/mm 2 respectively were recorded.
• 4 « 4 « 4 cm 3 block demonstrated an exceptional response to compression as it was crushed to within 29 % of its original height under a maximum pressure of 100 ton, yet it re-expanded to over 80 % of its original height upon pressure release.
• During flexural strength measurement a 4 « 4 « 16 cm 3 sample was deformed by 20 %.
• the density after 7 days storage at room temperature in a Styropor ® mould was 0.969 g/ml.
• the material passed B2 flame testing according to DIN 4102. A maximum flame height of 20 mm was recorded after 20 seconds.
• A-Component Metakaolin, Argical M 1000 40.27 g
• component A The ingredients of component A were mixed at 1000 rpm for 60 seconds, added to component B and mixed for a further 60 seconds at 600 rpm.
• the material was poured into a mould, and after 3 days tensile, compressive and flexural strengths values of 1.7 N/mm 2 , 8.1 N/mm 2 and 66.5 N/mm 2 respectively were recorded.
• 4 « 4 « 4 cm 3 block demonstrated an exceptional response to compression as it was crushed to within 25 % of its original height under a maximum pressure of 100 ton, yet it re-expanded to over 80 % of its original height upon pressure release.
• During flexural strength measurement a 4 « 4 « 16 cm 3 sample was deformed by 25 %, and once pres- sure was released the material returned to its original shape.
• the density after 7 days storage at room temperature in a Styropor ® mould was 0.842 g/ml.
• A-Component Metakaolin, Argical M 1000 35.85 g
• component A The ingredients of component A mixed at 2000 rpm for 60 seconds, component B was added and mixed for 30 seconds at 1000 rpm, and placed in a 500 cm 3 container to allow for a controlled pressure release. 10 seconds after sealing the container foam rise began, and 20 seconds later a controlled pressure release from the container over a 10 second period provided a stable foamed material.
• the density after 7 days storage at room temperature in a Styropor ® mould was 0.294 g/ml.

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