SYSTEM AND METHOD FOR PRODUCING IN-SITU FOAM

Abstract

An in-situ foam system and process comprises the components one or more inorganic fillers A) at from 50 to 98 wt %, one or more cationic or amphoteric polymers B) at from 1 to 48 wt %, one or more surfactants C) at from 0.5 to 48 wt %, one or more crosslinkers D) capable of reacting with said polymers B) at from 0.01 to 5 wt %, one or more cell regulators E), selected from silicones, siliconates and carbon, at from 0.5 to 10 wt %, one or more additives F) at from 0 to 20 wt %, wherein the weight percentages of said components A) to F) are based on the nonaqueous fractions and the sum total of A) to F) adds up to 100 wt %.

Claims

1.-19. (canceled)

20. A system for producing an in-situ foam, said system comprising the components 50 to 98 wt % of one or more inorganic fillers A), 1 to 48 wt % of one or more cationic or amphoteric polymers B), 0.5 to 48 wt % of one or more surfactants C), 0.01 to 5 wt %, of one or more crosslinkers D) capable of reacting with said polymers B), 0.5 to 10 wt % of one or more cell regulators E), selected from the group consisting of silicones, siliconates and carbon, 0 to 20 wt % of one or more additives F), wherein the weight percentages of said components A) to F) are based on the nonaqueous fractions and the sum total of A) to F) does not exceed 100 wt %.

21. The system according to claim 20 comprising an alkali metal alkylsiliconate as cell regulator E).

22. The system according to claim 20 wherein polymer B) has a solubility in water of at least 5 wt % under standard conditions (20 C., 101.3 kPa) at pH 7.

23. The system according to claim 20 comprising a polyvinylamine or a poly(vinylamine-vinylformamide) copolymer as cationic polymer B).

24. The system according to claim 20 comprising a terpolymer comprising vinylamine, vinylformamide and sodium acrylate units as amphoteric polymer B).

25. The system according to claim 20 comprising calcium sulfate surface modified with amino, carboxyl and/or hydroxyl groups, aluminum silicates surface modified with amino, carboxyl and/or hydroxyl groups, or mixtures thereof as inorganic fillers A).

26. The system according to claim 20 comprising by way of surfactant C) at least one surfactant based on natural proteinaceous raw materials.

27. The system according to claim 20 comprising a dialdehyde as crosslinker D).

28. The system according to claim 20 wherein components B), C), and D) are employed in the form of aqueous solutions.

29. A process for producing an in-situ foam by using the components of the system according to claim 20 and foaming with a gas or gas mixture.

30. The process according to claim 29 comprising the steps of (a) introducing a gas or gas mixture into an aqueous solution or suspension comprising at least said component C), (b) foaming the aqueous solution or suspension via one or more mixing elements (c) adding components A), B), D), E) and F) together or separately before or after step (b) via one or more mixing elements, (d) drying to a water content below 5 wt %.

31. The process according to claim 30 wherein compressed air having a pressure in the range from 100 to 2000 kPa is introduced in step (a).

32. The process according to claim 30 wherein the aqueous solution or suspension in the last mixing element has a solids content in the range from 5 to 50 wt %.

33. An in-situ foam obtained by the process according to claim 29.

34. The in-situ foam according to claim 33 having a density in the range from 10 to 50 kg/m.sup.3.

35. The in-situ foam according to claim 33 having a heat of combustion below 3.0 MJ/kg, determined according to DIN 51900 part 3.

36. A method comprising utilizing the in-situ foam according to claim 33 for thermal insulation.

37. A method comprising filling cavities and hollow bodies with the in-situ foam according to claim 33.

38. A method comprising utilizing the in-situ foam according to claim 33 as a fire barrier or as part of a fire barrier.

Description

EXAMPLES

Materials Used:

[0066] Component A1 Translink 445 (surface-modified kaolin having an average particle size of 1.4 m) [0067] Component A2 FGD gypsum (from a flue gas desulfurizer), CaSO.sub.4.2H.sub.2O. Calcium sulfate dihydrate [0068] Component A3 Ansilex 93 (calcined kaolin, not surface treated, average particle size 0.9 m) [0069] Component B1 Lupamin 4570 (copolymer of vinylamine, vinylformamide (7:3 molar) having a medium molecular weight, solids content 31%) [0070] Component B2 Xelorex F3000 (terpolymer of vinylamine, vinylformamide and sodium acrylate (35:35:30 molar), amphoteric, having a high molecular weight, solids content 10-12 wt %) [0071] Component B3 Lupamin 9050 (copolymer of vinylformamide and vinylamine (1:1 molar) of high molecular weight; solids content 16.5%), [0072] Component C1 Schaumgeist Omega % (alcohol-resistant protein-type foaming agent based on natural proteinaceous raw materials, foam stabilizers and antifreeze, Dr. Sthamer, Hamburg) [0073] Component C2 surfactant mixture of an anionic surfactant and a nonionic surfactant: Disponil FES 32 (sodium lauryl polyether sulfate) and Lutensol AT80 (fatty acid ethoxylate) in a weight ratio of 1:3; [0074] Component C3 Schaumgeist 6% (protein-type foaming agent based on natural proteinaceous raw materials, foam stabilizers and antifreeze, Dr. Sthamer, Hamburg) [0075] Component D1 glyoxal (ethanedial, oxalaldehyde) [0076] Component E1 aqueous solution of potassium methylsiliconate [0077] Component E2 UF995 graphite [0078] Component F1 3-aminopropyltriethoxysilane

Methods of Measurement:

[0079] The density of the foam sample was determined by weighing and measuring the length, width and height.

[0080] The heat of combustion was determined according to DIN 51900 Part 3.

[0081] To determine water imbibition (wt %) the foam samples were conditioned at 80% humidity and 23 C. to constant weight.

[0082] Sliceability after foaming was determined using a knife and a chronometer. A sample is deemed sliceable when a piece of the sample can be cut off and lifted without losing its shape.

[0083] To determine shrinkage, the foam samples were conditioned at 80% humidity and 23 C. to constant weight and measured for dimensional changes.

[0084] Thermal conductivity was determined by measuring the heat flow in the single plate apparatus of DIN EN 12667 (May 2001). Thermal conductivity A, moist was determined after conditioning at 85% humidity and 23 C. to constant weight.

Examples 1-7

[0085] A setup as per FIG. 1 having two static mixing elements (SM 1, SM 2) with diameters between 20 and 50 mm was used to foam an aqueous solution of components C) and D) and E1 with compressed air (500 kPa) in the first mixing element SM 1 for Examples 1-7. A mixture of components A), B) and F) and, in the case of Example 7, E2 and optionally additional water to adjust the solids content of the suspension was then admixed via feedpoint Dos2 and sent to the second mixing element SM2. As a result of the setup being pressurized with compressed air upstream of the first mixing element, the foam is transported through the further mixing elements to the outlet nozzle. Drying took place in air at 20 C.

Comparative Tests V1 and V2

[0086] A setup as per FIG. 1 having three static mixing elements (SM 1, SM 2 and SM 3) with diameters between 5 and 10 mm was used to foam an aqueous solution of component C with compressed air (2000 kPa) in the first mixing element SM 1. A mixture of components A2, A3, B3 and optionally F1 and optionally additional water to adjust the solids content of the suspension was then admixed via the second mixing element SM 2. This was finally followed in the third mixing element SM 3 by metered addition of component D1 and homogenization. As a result of the setup being pressurized with compressed air upstream of the first mixing element, the foam is transported through the further mixing elements to the outlet nozzle. Drying took place in air at 20 C.

Comparative Test V3

[0087] Comparative Test V3 was prepared in accordance with Examples 1-7 as per FIG. 4.

[0088] Table 1 shows components A to F for producing the in-situ foams in weight percent, each based on the nonaqueous fraction. The solids content (nonaqueous fraction) in weight percent is based on the mixture of all components downstream of the last feedpoint.

[0089] Table 2 shows the properties of the dried in-situ foams. Thermoconductivity , moist was determined after conditioning at 80% humidity and 23 C. to constant weight.

TABLE-US-00001 TABLE 1 Materials used for in-situ foams of Examples B1 to B7 and Comparative Tests V1 to V3 in weight percent based on the nonaqueous fraction of the components Component Units B1 B2 B3 B4 B5 B6 B7 V1 V2 V3 A1 [weight %] 86.5 86.3 86.0 84.5 84.8 84.6 82.2 87.6 A2 [weight %] 62.2 62.4 A3 [weight %] 31.0 31.1 B1 [weight %] 8.7 8.6 8.6 10.2 B2 [weight %] 8.5 8.5 8.5 8.2 B3 [weight %] 5.0 5.0 C1 [weight %] 2.3 2.4 2.6 3.5 3.3 3.3 3.6 1.2 C2 [weight %] 1.4 1.4 D1 [weight %] 0.3 0.3 0.3 0.4 0.4 0.4 0.4 0.2 0.2 0.14 E1 [weight %] 1.5 1.5 1.7 2.3 2.2 2.3 2.4 E2 [weight %] 2.5 F1 [weight %] 0.9 0.9 0.9 0.8 0.8 0.8 0.8 0.3 0.9

TABLE-US-00002 TABLE 2 Properties of dried in-situ foams of Comparative Tests V1 to V3 and of Examples B1 to B7 Property Units B1 B2 B3 B4 B5 B6 B7 V1 V2 V3 Density [kg/m.sup.3] 47 38.3 41.3 25.5 26.7 36.2 27.3 50.7 26.9 46.1 Thermal cond. , (dry) [mW/m*K] 33.3 33.2 33.6 33.1 33.5 33.8 31.9 40 36 38.7 Thermal cond. , (moist) [mW/m*K] 40.6 38.9 35.2 37.2 37.4 36.1 42.1