HYBRID FOAM

Abstract

The present invention relates to a hybrid foam, to a process for producing a hybrid foam and a hybrid foam obtainable by this process and to the use of the hybrid foam for adhesive bonding, filling and/or insulating.

Claims

1: A hybrid foam, comprising: at least one mineral binder; at least one polymer comprising monomer units derived from at least one ethylenically unsaturated monomer or from a combination of a polyisocyanate and a polyol and/or a polyamine; at least one surface-active substance; at least one thickener; optionally at least one further additive; and water.

2: The hybrid foam of claim 1, wherein the at least one mineral binder is a cement, slaked lime, gypsum or a mixture thereof.

3: The hybrid foam of claim 1, wherein the at least one polymer is selected from the group consisting of a (meth)acrylate copolymer, a styrene-acrylate copolymer, a styrene-methacrylate copolymer, a styrene-butadiene copolymer, a styrene-2-ethylhexyl acrylate copolymer, a styrene-n-butyl acrylate copolymer, a polyurethane, polyvinyl acetate and an ethylene-vinyl acetate copolymer.

4: The hybrid foam of claim 1, wherein the at least one surface-active substance is selected from the group consisting of a C.sub.8-C.sub.18-alkyl sulfate, a C.sub.8-C.sub.18-alkyl ether sulfate, a C.sub.8-C.sub.18-alkyl sulfonate, a C.sub.8-C.sub.18-alkylbenzene sulfonate, a C.sub.8-C.sub.18--olefin sulfonate, a C.sub.8-C.sub.18-sulfosuccinate an -sulfo-C.sub.8-C.sub.18-fatty acids disalt, a C.sub.8-C.sub.18-fatty acid salt, a C.sub.8-C.sub.18-fatty alcohol ethoxylate, a block copolymer of ethylene oxide and propylene oxide, a C.sub.8-C.sub.18-alkyl polyglycoside, a protein and mixtures thereof.

5: The hybrid foam of claim 1, wherein the at least one thickener is selected from the group consisting of a cellulose ether, a starch ether and a polyacrylamide.

6: The hybrid foam of claim 1, wherein the optional at least one further additive is selected from the group consisting of a pH modifier, a filler, an accelerator, a retarder, a rheology modifier, a superplasticizer, a surfactant, a hydrophobizing agent and mixtures thereof.

7: The hybrid foam of claim 1, wherein an amount of the at least one mineral binder is 10% to 98% by weight, based on a total weight of the hybrid foam and an amount of the at least one polymer is 1% to 25% by weight, based on the total weight of the hybrid foam.

8: A process for producing a hybrid foam, the process comprising: (1) producing a mixture comprising at least one mineral binder; at least one polymer comprising monomer units derived from at least one ethylenically unsaturated monomer or from a combination of a diisocyanate and a diol and/or a diamine; optionally at least one additive; and water; (2) mixing the mixture of (1) with an aqueous foam comprising water and at least one surface-active substance, to obtain a hybrid foam; and (3) optionally curing the hybrid foam obtained in (2).

9: The process of claim 8, wherein the at least one mineral binder is a cement, slaked lime, gypsum or a mixture thereof.

10: The process of claim 8, wherein the at least one polymer is selected from the group consisting of a (meth)acrylate copolymer, a styrene-acrylate copolymer, a styrene-methacrylate copolymer, a styrene-butadiene copolymer, a styrene-2-ethylhexyl acrylate copolymer, a styrene-n-butyl acrylate copolymer, a polyurethane, a polyvinyl acetate and an ethylene-vinyl acetate copolymer.

11: The process of claim 8, wherein the at least one surface-active substance is selected from the group consisting of a C.sub.8-C.sub.18-alkyl sulfate, a C.sub.8-C.sub.18-alkyl ether sulfate, a C.sub.8-C.sub.18-alkyl sulfonate, a C.sub.8-C.sub.18-alkylbenzene sulfonate, a C.sub.8-C.sub.18--olefin sulfonate, a C.sub.8-C.sub.18-sulfosuccinate, an -sulfo-C.sub.8-C.sub.18-fatty acid disalt, a C.sub.8-C.sub.18-fatty acid salt, a C.sub.8-C.sub.18-fatty alcohol ethoxylate, a block copolymer of ethylene oxide and propylene oxide, a C.sub.8-C.sub.18-alkyl polyglycoside, a protein and mixtures thereof.

12: The process of claim 8, wherein the aqueous foam further comprises at least one thickener.

13: The process of claim 12, wherein the at least one thickener is selected from the group consisting of a cellulose ether, a starch ether and a polyacrylamide.

14: The process of claim 8, wherein the optional at least one additive is selected from the group consisting of a pH modifier, a filler, an accelerator, a retarder, a rheology modifier, a superplasticizer, a surfactant, a hydrophobizing agent and mixtures thereof.

15: A hybrid foam obtainable by the process of claim 8.

16: A process for bonding, filling and/or insulating, the process comprising obtaining the hybrid foam of claim 1.

17: A process for bonding, filling and/or insulating, the process comprising obtaining the hybrid foam of claim 15.

Description

EXAMPLES

[0166] The production of a hybrid foam according to the invention is described by way of example hereinbelow.

[0167] Cement, limestone flour and cellulose ether are initially charged. Polycarboxylate ether, a polymer dispersion and water are then added to the initially charged dry mixture and mixed with a kitchen mixer for 110 seconds. This is followed by addition of an aqueous foam comprising a surface-active substance to the mixture via a foam generator, wherein the foam is folded into the mixture. The mixture is then again mixed with a kitchen mixer for a further 130 seconds to obtain a hybrid foam according to the invention.

[0168] For the investigations which follow all examples (save for the reference example 1) were produced in the manner described above. In a departure from the manner described above the reference example 1 was produced without foam addition and represents a classical EIFS bonding mortar as used in practice. The composition of the examples is reported in the table which follows. Unless otherwise stated the reported % by weight values relate to the total weight of the hybrid foam.

Composition of Examples Produced

[0169]

TABLE-US-00001 Styrene Styrene Styrene- Polyvinyl acrylate acrylate butadiene acetate copolymer I copolymer II copolymer Polyurethane Cement Limestone flour [% by wt.] [% by wt.] [% by wt.] [% by wt.] [% by wt.] [% by wt.] [% by wt.] Ref. Ex. 1 2 73 24 Ref. Ex. 2 73 24 Ex. 1 3.5 73 24 Ex. 2 7 73 24 Ex. 3 3.5 73 24 Ex. 4 7 73 24 Ex. 5 7 25 75 Ex. 6 7 25 75 Ex. 7 7 50 50 Ex. 8 7 50 50 Ex. 9 3.5 73 24 Ex. 10 3.5 73 24 Ex. 11 3.5 73 24

[0170] The polyvinyl acetate dispersion comprises polyvinylacetate-co-ethylene. The dispersion has a solids content of 100% by weight, i.e. is in the form of a dispersion powder. The polymer has a glass transition temperature of 0 C.

[0171] The styrene-acrylate copolymer dispersion I comprises a styrene-butyl acrylate copolymer having a glass transition temperature of 19 C. As stabilizing auxiliary monomers acrylic acid and acrylamide are each employed in an amount of less than 2% by weight based on the total polymer amount calculated as solid. The dispersion has a solids content of 50% by weight. The polymer has a particle size of 120 nm.

[0172] The styrene-acrylate copolymer dispersion II comprises a styrene-butyl acrylate copolymer. The dispersion has a solids content of 51% by weight. As stabilizing auxiliary monomers acrylic acid and acrylamide are each employed in an amount of less than 2% by weight based on the total polymer amount, calculated as solid. The dispersion further comprises C12/14-fatty alcohol-ethoxylate-30-EO-sulfate in an amount of 3% by weight and C16/18-oxoalcohol-18 EO in an amount of 3% by weight. The polymer has a glass transition temperature of 19 C. and a particle size of 121 nm.

[0173] The styrene-butadiene copolymer dispersion comprises a styrene-butadiene copolymer. The dispersion has a solids content of 50% by weight. As stabilizing auxiliary monomers methacrylic acid and acrylamide are each employed in an amount of less than 2% by weight based on the total polymer amount, calculated as solid. The polymer has a glass transition temperature of 11 C. and a particle size of 175 nm.

[0174] The polyurethane dispersion comprises polyurethane. The dispersion has a solids content of 39.8% by weight. The polymer has a glass transition temperature of 35 C. and a particle size of 100 nm.

[0175] Unless otherwise stated the following ingredients were also added in all examples: [0176] fatty alkyl ether sulfate, Na salt (C12/14+2EO-sulfate, Na salt) (surface-active substance) in an amount of 0.05% by weight based on the total weight of the hybrid foam; [0177] polycarboxylate ether in an amount of 0.14% by weight based on the total weight of the hybrid foam; [0178] cellulose ether in an amount of 0.02% by weight based on the total weight of the hybrid foam.

[0179] The flexural tensile strength and compression strength were determined on a cured prism according to DIN_EN_1015-11 and the curing time according to DIN_EN_1015-18 table 1 was used.

[0180] Tensile bond strength values and failure type were determined according to ETAG 004 6.1.4.1 on concrete slabs.

[0181] Tensile bond strength values on concrete slabs according to ETAG 004 6.1.4.1 [0182] a) conditions: 28 d under standard conditions (23 C./50% rel. humidity) (28d in table): [0183] threshold value according to standard: >=0.25 N/mm.sup.2 [0184] conditions: 28 d under standard conditions (23 C./50% rel. humidity)+48 h immersion in water+2 h, 23 C./50% rel. humidity (28d+2d wet in table) [0185] threshold value according to standard: >=0.08 N/mm.sup.2 [0186] b) conditions: 28 d under standard conditions (23 C./50% rel. humidity)+48 h immersion in water+7 d, 23 C./50% rel. humidity (28d+2d wet in table): [0187] threshold value according to standard: >=0.25 N/mm.sup.2

[0188] The fresh bulk density (also wet density) was determined according to DIN-EN-1015-16. After 29 minutes the mixture was stirred for a further 15 seconds and after a further 45 seconds fresh bulk density was determined at 30 minutes. Dry density was determined according to EN1015-10 determination of dry bulk densities of solid mortars with the exception that establishment of a flow value according to 1015-2 table 2 was eschewed.

Tensile Bond Strength Values on Concrete Slabs According to ETAG 004 6.1.4.1

[0189]

TABLE-US-00002 Tensile Tensile strength Tensile Tensile strength 28 d + Dry strength strength 28 d + 2 d wet + density 7 d 28 d 2 d wet 7 d (kg/L) (N/mm.sup.2) (N/mm.sup.2) (N/mm.sup.2) (N/mm.sup.2) Ref. 1.38 0.621 0.661 0.435 0.832 Ex. 1 Ref. 0.56 (not (not (not (not Ex. 2 measurable) measurable) measurable) measurable) Ex. 1 0.79 0.28 0.334 0.456 0.639 Ex. 2 0.84 0.57 0.646 0.435 0.574 Ex. 3 0.71 0.129 0.132 0.3 0.353 Ex. 4 0.71 0.169 0.189 0.391 0.749

Variation of Cement/Limestone FlourTensile Bond Strength Values on Concrete Slabs According to ETAG 004 6.1.4.1

[0190]

TABLE-US-00003 Tensile Tensile strength Tensile Tensile strength 28 d + Dry strength strength 28 d + 2 d wet + density 7 d 28 d 2 d wet 7 d (kg/L) (N/mm.sup.2) (N/mm.sup.2) (N/mm.sup.2) (N/mm.sup.2) Ref. Ex. 1 1.38 0.621 0.661 0.435 0.832 Ex. 2 0.84 0.57 0.646 0.435 0.574 Ex. 4 0.71 0.169 0.189 0.391 0.749 Ex. 5 0.74 0.459 0.806 0.351 0.944 Ex. 6 0.76 0.453 0.47 0.332 0.746 Ex. 7 0.79 0.663 0.734 0.55 0.866 Ex. 8 0.79 0.343 0.346 0.379 0.639

Failure Type in Tensile Bond Strength Measurements

[0191]

TABLE-US-00004 Tensile Tensile Tensile Tensile strength strength Dry strength strength 28 d + 2 d 28 d + 2 d density 7 d 28 d wet wet + 7 d (kg/L) (N/mm.sup.2) Failure type (N/mm.sup.2) Failure type (N/mm.sup.2) Failure type (N/mm.sup.2) Failure type Ref. Ex. 1 1.38 0.621 adhesive (0%), 0.661 adhesive (0%), 0.435 adhesive (60%), 0.832 adhesive (30%), cohesive (100%) cohesive (100%) cohesive (40%) cohesive (70%) Ref. Ex. 2 0.56 adhesive (%). cohesive (%) Ex. 1 0.79 0.28 adhesive (0%), 0.334 adhesive (0%), 0.456 adhesive (5%), 0.639 adhesive (5%), cohesive (100%) cohesive (100%) cohesive (95%) cohesive (95%) Ex. 2 0.84 0.57 adhesive (0%), 0.646 adhesive (10%), 0.435 adhesive (5%), 0.574 adhesive (8%), cohesive (100%) cohesive (90%) cohesive (95%) cohesive (92%) Ex. 3 0.71 0.129 adhesive (0%), 0.132 adhesive (3%), 0.3 adhesive (10%), 0.353 adhesive (10%), cohesive (100%) cohesive (97%) cohesive (90%) cohesive (90%) Ex. 4 0.71 0.169 adhesive (10%), 0.189 adhesive (0%), 0.391 adhesive (0%), 0.749 adhesive (35%), cohesive (90%) cohesive (100%) cohesive (100%) cohesive (65%) Ex. 5 0.74 0.459 adhesive (15%), 0.806 adhesive (10%), 0.351 adhesive (0%), 0.944 adhesive (0%), cohesive (85%) cohesive (90%) cohesive (100%) cohesive (100%) Ex. 6 0.76 0.453 adhesive (0%), 0.47 adhesive (0%), 0.332 adhesive (0%), 0.746 adhesive (0%), cohesive (100%) cohesive (100%) cohesive (100%) cohesive (100%) Ex. 7 0.79 0.663 adhesive (0%), 0.734 adhesive (0%), 0.55 adhesive (5%), 0.866 adhesive (3%), cohesive (100%) cohesive (100%) cohesive (95%) cohesive (97%) Ex. 8 0.79 0.343 adhesive (4%), 0.346 adhesive (0%), 0.379 adhesive (0%), 0.639 adhesive (5%), cohesive (96%) cohesive (100%) cohesive (100%) cohesive (95%)

Flexural Tensile Strengths and Compressive Strengths of Mortar Prisms (7d) According to DIN EN998-1

[0192]

TABLE-US-00005 Flexural tensile Flexural Compressive strength/ tensile strength compressive strength at at dry strength ratio dry density density of at dry density of 0.6 kg/L 0.6 kg/L of 0.6 kg/L (N/mm.sup.2) (N/mm.sup.2) (N/mm.sup.2) Ref. Ex. 2 0.60 3.15 0.19 Example 9 0.89 2.18 0.41 Example 3 0.83 3.50 0.24 Example 10 1.07 3.79 0.28 Example 1 0.89 3.87 0.23 Example 11 0.78 3.57 0.22 Example 2 1.21 3.99 0.30 Example 4 0.99 4.43 0.22

Flexural Tensile Strengths and Compressive Strengths (28d) of Mortar Prisms According to DIN EN998-1

[0193]

TABLE-US-00006 Flexural tensile Flexural Compressive strength/ tensile strength compressive strength at at dry strength ratio dry density density of at dry density of 0.6 kg/L 0.6 kg/L of 0.6 kg/L (N/mm.sup.2) (N/mm.sup.2) (N/mm.sup.2) Ref. Ex. 2 0.87 2.96 0.29 Example 3 1.28 4.20 0.30 Example 1 1.46 4.28 0.34 Example 2 1.71 5.1 0.34 Example 4 1.85 5.44 0.34