FOAMABLE, MULTICOMPONENT COMPOSITION WHICH FORMS AN INSULATION LAYER AND USE OF SAID COMPOSITION

Abstract

A foamable, insulating-layer-forming multi-component composition has at least one alkyoxysilane-functional polymer, at least one insulating-layer-forming fire-protection additive, a blowing-agent mixture, and a cross-linking agent. The at least one alkoxysilane-functional polymer contains, as terminal groups and/or as side groups along the polymer chain, alkoxy-functional silane groups of a formula Si(R.sup.1).sub.m(OR.sup.2).sub.3-m. In this formula, R.sup.1 stands for a linear or branched C.sub.1-C.sub.16 alkyl moiety, R.sup.2 for a linear or branched C.sub.1-.sub.6 alkyl moiety and m for an integer from 0 to 2. The composition can be a foam-in-place foam or can be used for the manufacture of molded blocks.

Claims

1. A foamable, insulating-layer-forming multi-component composition, comprising at least one alkoxysilane-functional polymer, at least one insulating-layer-forming fire-protection additive, a blowing-agent mixture and a cross-linking agent, wherein the at least one alkoxysilane-functional polymer comprises, as a terminal group and/or as a side group along a chain of the polymer, an alkoxy-functional silane group of the general formula (I)
Si(R.sup.1).sub.m(OR.sup.2).sub.3-m (I), wherein R.sup.1 is a linear or branched C.sub.1-C.sub.16 alkyl moiety, R.sup.2 is a linear or branched C.sub.1-C.sub.6 alkyl moiety and m is an integer from 0 to 2, wherein individual ingredients of the blowing-agent mixture are separated from one another to inhibit reaction prior to mixing, and the cross-linking agent is separated from the alkoxysilane-functional polymer to inhibit reaction prior to mixing.

2. The composition according to claim 1, wherein the blowing-agent mixture comprises compounds that are capable of reacting with one another, if mixed, to form carbon dioxide (CO.sub.2), hydrogen (H.sub.2) or oxygen (O.sub.2).

3. The composition according to claim 2, wherein the blowing-agent mixture comprises an acid and a compound that is reactive with the acid to form carbon dioxide.

4. The composition according to claim 2, wherein the blowing-agent mixture comprises a base and a compound that comprises an Si-bound hydrogen atom.

5. The composition according to claim 1, wherein the polymer comprises a basic backbone, which is selected from the group consisting of an alkyl chain, a polyether, polyester, polyether ester, polyamide, polyurethane, polyester urethane, polyether urethane, polyether ester urethane, polyamide urethane, polyurea, polyamine, polycarbonate, polyvinyl ester, polyacrylate, polyolefin, polyisobutylene, polysulfide, rubber, neoprene, phenol resin, epoxy resin and melamine.

6. The composition according to claim 1, wherein the alkoxysilane-functional polymer comprises at least two alkoxy-functional silane groups.

7. The composition according to claim 1, wherein the cross-linking agent is water or a water-containing ingredient.

8. The composition according to claim 1, wherein the insulating-layer-forming fire-protection additive comprises at least one thermally expandable compound and/or a mixture that comprises at least one dehydrogenation catalyst, at least one gas builder and optionally at least one carbon source.

9. The composition according to claim 8, wherein the fire-protection additive further comprises an ash-crust stabilizer.

10. The composition according to claim 1, wherein the composition further comprises a further cross-linking agent as a co-cross-linking agent.

11. The composition according to claim 1, wherein the composition further comprises a catalyst.

12. The composition according to claim 11, wherein the catalyst is selected from the group consisting of metal compounds, acid compounds, and basic compounds.

13. The composition according to claim 11, wherein the catalyst is an amine compound.

14. The composition according to claim 1, wherein the composition further comprises at least one further ingredient, which is selected from the group consisting of plasticizers, water scavengers, inorganic fillers and further additives.

15. (canceled)

16. A molded block obtained by mixing together components, thereby obtaining the composition according to claim 1, then foaming the composition in a mold.

17. A foaming process, comprising foaming the composition according to claim 1, thereby obtaining a foam providing fire protection: in an opening, a cable penetration, and/or a pipe penetration in a wall, floor, or ceiling; in a joint between a ceiling and a wall part: between masonry openings or construction parts; between a ceiling and a wall; or between an outside wall and a curtain-wall facade of a building.

18. The molded block of claim 16, wherein the molded block has a density of from 160 to 300 g/cm.sup.3.

19. The process of claim 17, wherein the foam has a density of from 160 to 300 g/cm.sup.3.

20. The composition according to claim 1, wherein the composition further comprises a filler.

21. The process of claim 17, wherein the foam is capable of forming an ash crust upon exposure to a fire.

Description

EXEMPLARY EMBODIMENTS

[0092] The individual components listed in Examples 1 and 2 are respectively mixed and homogenized. For use, these mixtures are mechanically mixed with one another in a container until homogeneous intermixing has been achieved and until foaming has begun.

[0093] The fire-protection properties of the compositions obtained in this way were determined by means of macro-thermomechanical analysis with a Makro-TMA 2 apparatus (developed and constructed by Hilti (HEG) & ASG (Analytik-Service Gesellschaft in Augsburg). For this purpose, round specimens with diameter d=45 mm were respectively cut out. The specimens were respectively heated to 650 C. with an imposed load of 100 g and a heating rate of 15 K/min. The stability of ash crust obtained in this way was determined with a Texture Analyzer (CT3 of Brookfield). For this purpose, the specimen was penetrated with a T7 element at a constant speed of 0.5 mm/s. The force applied to this was measured as a function of the penetration depth. The greater the force, the harder the ash crust.

EXAMPLE 1

Foam System Foamed by Evolution of Hydrogen

[0094]

TABLE-US-00001 Ingredient Proportion [wt %] Poly(methyl hydrogen siloxane) .sup.1) 5.9 Tri-(2-chloroisopropyl) phosphate .sup.2) 3.4 Aliphatic silane-terminated prepolymer .sup.3) 58.6 Basic solution .sup.4) 8.8 Expandable graphite .sup.5) 9.4 Ammonium polyphosphate .sup.6) 5.7 Aluminum trihydrate .sup.7) 1.9 Monopentaerythritol .sup.8) 1.5 Iron oxide (Fe.sub.2O.sub.3) .sup.9) 0.9 Calcium carbonate .sup.10) 3.2 Quartz powder .sup.11) 0.5 Fumed silica .sup.12) 0.1 Swellable layer silicate .sup.13) 0.1 .sup.1) Poly(methyl hydrogen siloxane); VWR; Article number 818063 .sup.2) Levagard PP (Lanxess Co.); viscosity at 20 C.: <100 mPas .sup.3) Desmoseal S XP- 2821 (Bayer Co.); .sup.4) From 7.4 wt % tap water and 1.3 wt % sodium hydroxide flakes, wherein the proportions are respectively relative to the total weight of the composition .sup.5) Nord-Min 351 of Nordmann-Rassmann, Hamburg, Germany; .sup.6) Exolit AP 422 of Clairant; average particle size ~15 m .sup.7) ATH HN-434 of J. M. Huber Corporation, Finland) .sup.8) Charmor PM 40 of Perstorp Specialty Chemicals AB; particle size <40 m; water content 0.1% .sup.9) Bayferrox 130 M of Lanxess .sup.10) OMYACARB 5SV of Omya .sup.11) MILLISIL W12 of Quarzsandwerke GmbH; mean particle size 16 m .sup.12) CAB-O-SIL TS-720 of Cabot Corporation .sup.13) OPTIGEL WX of Byk Chemie GmbH

EXAMPLE 2

Foam System Foamed by Carbon Dioxide

[0095]

TABLE-US-00002 Ingredient Proportion Aliphatic silane-terminated prepolymer I .sup.1) 22.0 Aliphatic silane-terminated prepolymer II .sup.2) 22.0 Triethyl phosphate .sup.3) 4.4 Vinyltrimethoxysilane .sup.4) 2.1 Tap water 11.3 Calcium carbonate .sup.5) 5.9 Surfactant .sup.6) 0.5 Citric acid, anhydrous .sup.7) 12.5 Expandable graphite .sup.8) 8.6 Ammonium polyphosphate .sup.9) 5.3 Aluminum trihydrate .sup.10) 1.8 Monopentaerythritol .sup.11) 1.4 Iron oxide (Fe.sub.2O.sub.3) .sup.12) 0.8 Dioctyltin diketanoate .sup.13) 0.3 p-Toluenesulfonic acid .sup.14) 0.5 Xanthan .sup.15) 0.2 Fumed silica .sup.16) 0.4 .sup.1) Desmoseal S XP- 2821 of Bayer AG; .sup.2) Desmoseal S XP-2749 of Bayer AG .sup.3) Levagard TEP-Z of Lanxess; viscosity at 20 C.: <1.7 mPas .sup.4) Geniosil XL 10 of Wacker, dynamic viscosity at 25 C. 0.6 mPas; density at 25 C. 0.97 g/cm3 .sup.5) OMYABOND 520-OM of Omya .sup.6) Glucopon 215 UP of BASF .sup.7) Citric acid anhydride F6000 (CAS no. 77-92-9) of BCD Chemie .sup.8) Nord-Min 351 of Nordmann-Rassmann, Hamburg, Germany; .sup.9) Exolit AP 462 of Clairant; microencapsulated with melamine resin .sup.10) ATH HN-434 of J. M. Huber Corporation, Finland) .sup.11) Charmor PM 40 of Perstorp . . .; particle size <40 m; water content 0.1% .sup.12) Bayferrox 130 M of Lanxess .sup.13) TIB KAT 223 of TIB Chemicals, Mannheim, Germany .sup.14) p-Toluenesulfonic acid monohydrate, CAS number 6192-52-5 of Sigma-Aldrich .sup.15) Xanthan of Kremer Pigmente, Article number 63450 .sup.16) Cab-O-Sil TS-720 of Cabot

Comparison Example

[0096] For comparison, the product CP660 of the Hilti Co. was used. This is a PU-based fire-protection foam.

TABLE-US-00003 TABLE 1 Results of determination of the stability of the ash crust F.sub.max, mN Comparison example 4791 Example 1 6039 Example 2 3266

[0097] As is evident from Table 1, the inventive compositions yield a solid ash crust, wherein the composition foamed with carbon dioxide forms a harder ash crust than that of the commercially available product CP 660.

EXAMPLE 3

Foam System Foamed by Carbon Dioxide: Fire Test

[0098] In order to be able to appraise whether the inventive compositions are suitable as fire protection bulkheading, a composition comprising the ingredients listed in the following was filled into a commercial 2-component cartridge in a mixing ratio of 3:1 and applied via a static mixer for use. In the process, the respective ingredients of the blowing-agent components were kept separate from one another and the co-cross-linking agent was kept separate from the polymers.

[0099] A fire test for cable penetrations was performed according to EN 1366-3 (Annex B). For this purpose, a cellular concrete wail with four openings of 2020 cm and a depth of 15 cm was provided with the following penetrations; type C and E cables and an empty pipe (d=32 cm). The foam to be tested as well as a commercially available product was introduced into the openings and subjected to a 90-minute fire test. On the non-fire side, the temperatures were measured at the foam surface and at the individual cables and the pipe. The time taken for the room temperature to exceed 180 C. (T rating) was written down for individual penetration elements. OK means that T was<180 C. during the entire test.

TABLE-US-00004 Ingredient Proportion Component A Aliphatic silane-terminated prepolymer I .sup.1) 22.6 Aliphatic silane-terminated prepolymer II .sup.2) 22.6 Tri-(2-chloroisopropyl) phosphate .sup.3) 4.3 Silicone-glycol copolymer .sup.4) 0.2 Dioctyltin diketanoate .sup.5) 0.2 Short chopped glass fibers .sup.6) 1.1 Calcium carbonate .sup.7) 3.0 Chalk .sup.8) 0.6 Expandable graphite .sup.9) 9.9 Ammonium polyphosphate .sup.10) 6.1 Aluminum trihydrate .sup.11) 2.1 Monopentaerythritol .sup.12) 1.5 Iron oxide (Fe.sub.2O.sub.3) .sup.13) 0.9 Component B Citric acid, anhydrous .sup.14) 13.8 Tap water 9.2 Apple pectin .sup.15) 0.5 Titanium dioxide .sup.16) 0.3 Monopentaerythritol .sup.12) 0.3 Melamine .sup.17) 0.3 Ammonium polyphosphate .sup.10) 0.5 .sup.1) Desmoseal S XP 2821 of Bayer AG; .sup.2) Desmoseal S XP 2749 of Bayer AG .sup.3) Levagard PP (Lanxess Co.); viscosity at 20 C.: <100 mPas .sup.4) DABCO DC 198 of Air Products .sup.5) TIB KAT 223 of TIB Chemicals, Mannheim, Germany .sup.6) FGCS 70-30/3 of STW .sup.7) Socal 322 of SpecialChem .sup.8) Omyacarb 5-SV .sup.9) Nord-Min 351 of Nordmann-Rassmann, Hamburg, Germany; .sup.10) Exolit AP 422 of Clariant; average particle size ~15 m .sup.11) ATH HN-434 of J. M. Huber Corporation, Finland) .sup.12) Charmor PM 40 of Perstorp . . .; particle size <40 m; water content 0.1% .sup.13) Bayferrox 130 M of Lanxess .sup.14) Of Sigma Aldrich (CAS no. 77-92-9) .sup.15) Pectin of Sigma Aldrich, (CAS no. 9000-69-5) .sup.16) Of Kronos Inc. .sup.17) Melamines of OCI Melamine

TABLE-US-00005 TABLE 2 Results from the fire test Example 3 Comparison example 1. Empty pipe OK OK 2. Type C cable 68 min 63 min 3. Type E cable 73 min 74 min 4. Foam surface OK OK

[0100] From Table 2, it can be inferred that the foam from the inventive composition yields better fire protection than the foam from the commercially available product.

[0101] On the basis of the examples, it has been possible to show that the inventive compositions are eminently suitable as fire-protection foams.