SYSTEM AND METHOD FOR PRODUCING AN IN-SITU PUR FOAM

Abstract

A system for producing an in-situ foam, which comprises the components from 50 to 98% by weight of one or more inorganic fillers A), from 1 to 48% by weight of one or more water-soluble, cationic polymers B), from 0.5 to 48% by weight of one or more surfactants C), from 0.01 to 5% by weight of one or more crosslinkers D) which are capable of reacting with the polymers B), from 0 to 20% by weight of one or more additives E),
where the percentages by weight of the components A) to E) are based on the nonaqueous fraction and the sum of A) to E) is 100% by weight, process for producing an in-situ foam using the components of the system and foaming by means of a gas or a gas mixture and use for thermal insulation and filling of hollow spaces and hollow bodies.

Claims

1-16. (canceled)

17. A process for producing an in-situ foam, the process comprising providing a system, the system comprising the following components: from 50 to 98% by weight of one or more inorganic fillers as component A, from 1 to 48% by weight of one or more water-soluble, cationic polymers as component B, from 0.5 to 48% by weight of one or more surfactants as component C, from 0.01 to 5% by weight of one or more crosslinkers as component D, which are capable of reacting with the cationic polymers, from 0 to 20% by weight of one or more additives as component E, where the percentages by weight of the components A to E are based on the nonaqueous fraction and the sum of components A to E is 100% by weight. and introducing a gas, or a gas mixture, to the system components to produce the in-situ foam.

18. The process according to claim 17, wherein the one or more cationic polymers includes polyvinylamine or a poly(vinylamine-vinylformamide) copolymer.

19. The process according to claim 17, wherein the one or more surfactants includes a mixture of anionic and nonionic surfactants.

20. The process according to claim 17, wherein the one or more crosslinkers includes a dialdehyde crosslinker.

21. The process according to claim 17, wherein the one or more inorganic fillers are selected from calcium sulfate, aluminum silicates, or mixtures thereof

22. The process according to claim 17, wherein the providing of the system components comprises preparing an aqueous suspension having a solids content in the range from 30 to 50% by weight prepared from the components A to D, and introducing compressed air having a pressure in the range from 100 to 2000 kPa in to the aqueous suspension.

23. The process according to claim 17, wherein the introducing of the gas, or the gas mixture, comprises the introduction into an aqueous solution or suspension comprising at least the one or more components C, followed by adding components A, B and D, and optionally the component E, either together or separately, with one or more mixing elements to the aqueous solution or suspension, foaming the aqueous solution or suspension comprising at least the components A to D, and drying to a water content below 0.5% by weight.

24. The process according to claim 23, wherein the introducing of the gas or gas mixture is the introduction of compressed air having a pressure in the range from 100 to 2000 kPa, and the aqueous solution or suspension has a solids content in the range from 30 to 50% by weight.

25. The process according to claim 17, wherein the introducing of the gas, or the gas mixture, comprises the introduction into an aqueous solution or suspension comprising at least the one or more components C, followed by adding the components A and B, and optionally the component E, either together or separately, with one or more mixing elements to the aqueous solution or suspension, foaming the aqueous solution or suspension comprising at least the components A to C, and optionally the component E, adding the component D, and drying to a water content below 0.5% by weight.

26. The process according to claim 25, wherein the introducing of the gas or gas mixture is the introduction of compressed air having a pressure in the range from 100 to 2000 kPa, and the aqueous solution or suspension has a solids content in the range from 30 to 50% by weight.

27. The process according to claim 17, wherein the in-situ foam is firm in air at 20 C. within a period in the range from 5 to 50 seconds after foaming.

28. The process according to claim 17, wherein the in-situ foam has a density in the range from 10 to 300 kg/m.sup.3.

30. The in-situ foam according to claim 28 which has a heat of combustion of less than 3.0 MJ/kg.

31. Thermal insulation comprising the in-situ foam according to claim 28.

32. The in-situ foam according to claim 28 as a fire barrier or part of a fire barrier.

Description

EXAMPLES

[0061] Starting Materials:

[0062] Component A1 FGD gypsum (from a flue gas desulfurization plant), CaSO.sub.4.2H.sub.2O, calcium sulfate dihydrate

[0063] Component A2.1 kaolin (from Fluka, uncalcined aluminum silicate, Al.sub.2Si.sub.2O.sub.5(OH).sub.4, pharmaceutical grade)

[0064] Component A2.2 Ansilex 93 (calcined kaolin, not surface-treated, average particle size 0.9 m)

[0065] Component B1.1 Lupamin 9050 (copolymer of vinylformamide and vinylamine (1:1) having a high molecular weight; 10% strength solution in water, pH about 8, with chloride as counterion)

[0066] Component B1.2 Lupamin 9070 (copolymer of vinylformamide and vinylamine (3:7) having a high molecular weight; 10% strength solution in water, pH about 8, with chloride as counterion)

[0067] Component B1.3 Lupamin 9050 (copolymer of vinylformamide and vinylamine (1:1) having a high molecular weight; 10% strength solution in water, pH about 8, with benzoic+amidosulfonic acid (1:1) as counterion)

[0068] Component C1 surfactant mixture of anionic and nonionic surfactant: Disponil FES 32 (sodium lauryl polyether sulfate) and Lutensol AT/30 (fatty acid ethoxylate) in a weight ratio of 1:3;

[0069] Component C2 AmphosolCS-50 (cocamidopropyl hydroxysultaine)

[0070] Component D1 Glyoxal (ethanedial, oxalaldehyde)

[0071] Component D2 Waterpoxy 1422 (epoxy resin dispersion in water, 53-57%, 2-6 Pa.$)

[0072] Component E1 Durapox NT (two-component reactive resin system with epoxide as resin component and a mixture of isophoronediamine and N-(3-aminopropyl)-N-dodecylpropane-1,3-diamine as hardener component)

[0073] Component E2 Acronal 5044 (aqueous self-crosslinkable dispersion of a copolymer of an acrylic ester and styrene, solids content 55% by weight, film formation temperature Tg 15 C., particle size 400 nm, pH 6.5-8.5, viscosity 10-100 mPas

[0074] Component E3 Fixapret NF: dimethyldihydroxyethylurea

[0075] Component E4 melamine (pure, powder)

Examples 1-10

[0076] For examples 1-10, an aqueous solution of the component C was foamed by means of compressed air (2000 kPa) in the first mixing element SM 1 of a set-up as per FIG. 1 having three static mixing elements (SM 1, SM 2, SM 3) having diameters in the range from 5 to 10 mm. A mixture of the components A1, A2, B and E and optionally additional water to set the solids content of the suspension was subsequently added via the second mixing element SM 2 Finally, the component D was introduced in the third mixing element SM 3 and homogeneously mixed in. The foam is conveyed through the further mixing elements to the exit nozzle by the introduction of compressed air into the set-up before the first mixing element. Drying was carried out at 20 C. in air.

Examples 11-16

[0077] In examples 11 and 16, the components A) to D) and optionally additional water for setting the solids content of the suspension were foamed together by means of compressed air in an apparatus as per FIG. 2 having a static mixing element (SM 1) having a diameter of 25 mm at an operating pressure of 500 kPa. Drying was carried out at 20 C. in air.

[0078] Tables 1 and 2 show the components A to E for producing the in-situ foams in percent by weight, in each case based on the nonaqueous fraction, and the properties of the dried in-situ foam. The solids content (nonaqueous fraction) in percent by weight is based on the mixture of the components before foaming (examples 11 and 16).

[0079] The density of the foam specimen was determined by weighing and measurement of length, width and height. The heat of combustion was determined in accordance with DIN 51900 part 3. To determine the water absorption (% by weight), the foam specimens were stored in a controlled temperature and humidity chamber at 85% humidity until the weight was constant. The cutting solidity after foaming was determined by means of a knife and a chronometer. A specimen is considered to be cutting-solid when a piece of the specimen can be cut off by means of the knife and lifted away without this piece losing its shape. To determine the shrinkage, the foam specimens were stored in a control temperature and humidity chamber at 85% humidity until the weight was constant and the dimensional changes were measured.

TABLE-US-00001 TABLE 1 Starting materials for the in-situ foams of examples 1-10 in percent by weight, based on the nonaqueous fraction of the components, and properties of the dried in-situ foams Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Component 1 2 3 4 5 6 7 8 9 10 A1 55.7 32.6 58.7 58.7 62.2 58.7 58.9 60.1 59.6 59.8 A2.1 27.8 16.3 29.4 29.4 31 29.3 30.0 29.7 29.8 A2.2 29.4 B1.1 8.3 4.9 8.8 8.8 5 8.8 4.7 7.5 3.1 9 B1.2 B1.3 C1 7.6 45.8 2.5 2.5 1.4 2.5 1.3 1.3 1.3 1.3 C2 D1 0.6 0.3 0.6 0.6 0.2 0.6 0.1 0.2 0.2 0.01 D2 E1 0.9 E2 6.1 E3 0.3 E4 5.6 Solids content of 40 26 34 30 45 30 47 41 48 43 suspension [% by weight] Properties of in-situ foam Density [kg/m.sup.3] 240.9 40.2 172.3 95.2 50.7 95.6 94.2 97.1 95.2 95.2 Heat of combustion [MJ/kg] >3 >3 <3 <3 <3 <3 <3 <3 <3 <3 Water absorption 32 33 32 31 33 32 20 15 8 14 [% by weight] Cutting-solid [sec] 20 22 21 21 22 20 21 19 22 208 Shrinkage [%] 8 7 7 8 2 1 7 8 7 7 Thermal cond. [mW/m*K] 40

TABLE-US-00002 TABLE 2 Starting materials for the in-situ foams of examples 11-16 in percent by weight, based on the nonaqueous fraction of the components, and properties of the dried in-situ foams Ex. Ex. Ex. Ex. Ex. Ex. Component 11 12 13 14 15 16 A1 62.4 62.4 62.4 62.4 62.4 62.4 A2.1 31.1 31.1 31.1 31.1 31.1 31.1 A2.2 B1.1 5 5 5 5 B1.2 5 B1.3 5 C1 1.4 1.4 1.4 1.4 1.4 C2 1.4 D1 0.2 0.2 0.2 0.2 0.2 D2 0.2 E1 E2 E3 E4 Solids content of 45 32 32 32 32 32 suspension [% by weight] Properties of in-situ foam Density [kg/m.sup.3] 35.2 26.9 36.1 32.7 25.8 35.9 Heat of combustion [MJ/kg] <3 <3 <3 <3 <3 <3 Water absorption 16 9 33 17 33 25 [% by weight] Cutting-solid [sec] 18 21 830 22 20 21 Shrinkage [%] 7 8 9 8 7 9 Thermal cond. [mW/m*K] 36