US 4,940,844 AGrant
Polyol-Alkali Metal Silicate Emulsion
Issue Date:1990-07-10
•22 Claims
Abstract
A stable polyol-alkali metal silicate emulsion is produced by mixing and emulsifying an aqueous alkali metal solution, a polyol and an organic compound that will cause the aqueous alkali metal silicate solution to solidify. The polyol-alkali metal silicate emulsion may be used to react with compounds containing at least two isocyanate radicals to produce polyurethane silicate solid or foamed products which may be used for thermal and sound insulation, coating agents, adhesives, caulking agents and molded objects.
Metadata
Inventor
- David H. Blunt
Application Information
Application Number:US 1771868
Filing Date:1988-04-04
Priority Date:1987-10-19
Art Unit:188
Classifications
IPC:
C08T 306C08K 300C08L 8202C08L 300
Field of Search:
10652452152852574;75492;741;376;377;789;44;46;501;791;846;858;869116;122;154;54;137;138;90744;76447
Patent Drawings
This patent does not have any drawings.
Description
Example 1
About 50 parts by weight of an aqueous solution containing 40% by weight of sodium silicate with a SiO.sub.2 :Na.sub.2 O ratio of 3.25:1 is mixed with 50 parts by weight of a polyol selected from the list below and 1 part by weight of an emulsifier sodium doctyl sulfosuccinate mixed. The aqueous sodium silicate solidifies or coagulates and the mixtures is thoroughly agitated for 10 to 120 minutes to produce a polyol-alkali metal silicate emulsion.
(a) ethylene glycol (mol. wt. 600)
(b) propylene glycol (mol. wt. 500)
(c) propylene glycol (mol wt. 1200)
(d) amine sucrose polyether polyol (hydroxyl no. 350)
(e) sucrose polyether polyol (hydroxyl no. 360)
(f) phenyl amine polyol (hydroxyl no. 530)
(g) propylene polyether triol (hydroxyl no. 650)
(h) caprolactone diol (hydroxyl no. 212)
(i) amine polyol (hydroxyl no. 475)
(j) aromatic polyol (hydroxyl no. 375)
(k) sorbitol-based polyol (hydroxyl no. 490)
(l) polyester polyol (hydroxyl no. 210)
(m) polyurea-filled polyether polyol (hydroxyl no. 28)
(n) castor oil
(o) phenolic polyol (hydroxyl no. 450)
(p) sucrose polyol (hydroxyl no. 480)
(q) polypropylene polyether triol (hydroxyl no. 225)
(r) polypropylene polyether triol (hydroxyl no. 645)
(s) mixtures of the above
Example 2
About 40 parts by weight of an aqueous solution containing 45% by weight of sodium silicate with a SiO.sub.2 :Na.sub.2 O ratio of 3.25:1, 50 parts by weight of a polypropylene triol (hydroxyl no. 56 and mol. wt. 3000), 0.5 part by weight of foam stabilizer (DOW 193 by DOW) and component (c) selected from the list below are mixed and thoroughly agitated for 10 minutes to 120 minutes thereby producing a polyol-alkali metal silicate emulsion with the water attached to the alkali metal silicate.
(a) methanol, 5 parts by weight
(b) ethanol, 5 parts by weight
(c) isopropanol, 5 parts by weight
(d) aqueous formaldehyde (35%), 5 parts by weight
(e) urea powder, 10 parts by weight
(f) propylene oxide, 5 parts by weight
(g) propylamine, 2 parts by weight
(h) diethylenetriamine, 2 parts by weight
(i) acetaldehyde, 5 parts by weight
(j) acetonitrile, 5 parts by weight
(k) thiophenol, 5 parts by weight
(l) amine polyol (hydroxyl no. 475), 5 parts by weight
(m) furfurol, 5 parts by weight
(n) acetone, 10 parts by weight
(o) allyl alcohol, 10 parts by weight
(p) triethylamine, 1 part by weight
(q) ethanolamine, 3 parts by weight
(r) methyl ethyl ketone, 3 parts by weight
(s) diethamolamine, 5 parts by weight
(t) N-methyl morpholine, 3 parts by weight
(u) tributylamine, 2 parts by weight
(v) N,N-dimethylcyclohexylamine, 1 part by weight
(w) furfuryl alcohol, 10 parts by weight
(x) tetrahydrofuran, 10 parts by weight
(y) cyclohexanol, 10 parts by weight
(z) mixtures of the above
Example 3
About 50 parts by weight of an aqueous solution containing about 32% sodium silicate with a SiO.sub.2 :Na.sub.2 O ratio of 3.75:1 is mixed with 5 parts by weight of one of the Components (c) listed in Example 2 thereby produced a solidified or coagulated sodium silicate which is broken into fine particles and thoroughly mixed and emulsified with 100 parts by weight of a polyol selected from the list in Example 1 thereby producing a polyol-alkali metal emulsion with the water attached to the alkali metal silicate.
Example 4
About 50 parts by weight of an aqueous suspension containing about 30% sodium silicate with a SiO.sub.2 :Na.sub.2 O ratio of 3.22 and 10% polysilicic acid is mixed with 75 parts by weight of a polypropylene triol (OH no. 56 and mol. wt. 3000) containing 1 part by weight of a foam stabilizer (DOW 193 by DOW) then thoroughly agitated. To this mixture 5 parts by weight of ethylene glycol and 1 part by weight of triethyleneamine are added and the mixture is emulsified thereby producing a polyol-alkali metal silicate emulsion with the water attached to the alkali metal silicate.
Example 5
Example 4 is modified wherein another alkali metal silicate is used in place of sodium silicate and selected from the list below:
(a) potassium silicate
(b) lithium silicate
(c) mixtures of the above
Example 6
Example 4 is modified wherein 20 parts by weight of an aqueous emulsion or suspension containing 40% by weight of an organic polymer selected from the list below is added with the polyol.
(a) polyvinyl acetate
(b) polyvinyl alcohol
(c) polyvinyl chloride
(d) poly (methyl methacrylate)
(e) poly (sodium methacrylate)
(f) poly (sodium acrylate)
(g) poly (vinylidene chloride)
(h) polyisoprene
(i) polychloroprene
(j) poly (butadeine-acrylonitrile) copolymer
(k) poly (butadeine-styrene) copolymer
(l) poly (vinyl formal) polymer
(m) poly (vinyl chloride-vinyl acetate) copolymer
(n) mixtures of the above
Example 7
Example 1 is modified wherein 10 parts by weight of an polymerizeable organic compound selected from the list below, 0.5 parts by weight of sodium dactyl sulfosuccinate, 0.5 parts by weight of triethylenediamine, 0.05 parts by weight of cobalt naphthanate, 0.05 parts by weight of tin octoate, 0.1 part by weight of potassium persulfate, 0.1 part by weight of potassium persulfate, 0.1 part by weight of benzoyl peroxide, 0.05 parts by weight of N,N-dimethyl aniline and 0.005 parts by weight of cupric sulfate are mixed with the polyol of Example 1 and then mixed with the aqueous alkali metal silicate solution thereby producing on organic polymerpolyol-alkali metal silicate emulsion with the water attached to the alkali metal silicate.
(a) styrene
(b) acrylonitrile
(c) methyl methacrylate
(d) vinyl acetate
(e) N-vinyl carbazole
(f) vinylidene chloride
(g) vinyl pyrovidone
(h) methacrylonitrile
(i) ethyl acrylate
(j) methyl acrylate
(k) allyl methacrylate
(l) vinyl toluene
(m) chloroprene
(n) isoprene
(o) vinyl chloride under pressure to liquify
(p) butadiene under pressure 45 to 60 p.s.i.g. in a closed system
(q) mixtures of the above
Example 8
Example 1 is modified wherein 1 part by weight of a salt forming compound selected from the list below is added and thoroughly mixed with the polyol-alkali metal silicate emulsion of example:
(a) aqueous solution containing 20% phosphoric acid
(b) sodium dihydrogen phosphate
(c) sodium hydrogen sulfate
(d) adipic acid
(e) acetic acid
(f) maleic anhydride
(g) fumaric acid
(h) chloroacetic acid
(i) acetyl chloride
(j) ethyl acetate
(k) ethanesulphonic acid
(l) ethylene chlorohydrin
(m) mixtures of the above
Example 9
Example 1 is modified wherein 5 parts by weight of a dispersion stabilizer selected from the list below is added to the polyol-alkali metal silicate emulsion of Example 1:
(a) starch
(b) casein
(c) bentonite
(d) sulfonated polyisoprene resin
(e) sulfonated phenol-formaldehyde resin
(f) sodium salt of polymethacrylic acid
(g) polymaleic acid
(h) polysilicic acid
(i) sodium salt of polyacrylic acid
(j) polyvinyl alcohol
(k) plant gum
(l) methyl cellulose
Example 10
About 50 parts by weight of an aqueous solution containing 40% by weight of sodium silicate with a SiO.sub.2 :Na.sub.2 O ratio of 3.22:1, 50 parts by weight of a polypropylene triol with hydroxyl no. 56 and mol. wt. 3000and 5 parts by weight of propylene glycol are thoroughly mixed to produce a polyolalkali metal silicate emulsion with the water attached to the alkali metal silicate. The emulsion is then mixed with 50 parts by weight of a compound containing at lease 2 isocyanate groups and selected from the list below thereby producing a tough solid or microcellular polyurethane silicate product.
(a) Diphenylmethane Diisocyanate
(b) Hexamethylene diisocyanate
(c) Polymethylene polyphenyl isocyanate (MONDUR MR by MOBAY)
(d) Polymethylene polyphenyl isocyanate (PAPI 27 by UPJOHN)
(e) Polymeric isocyanate (MONDUR E-512 by MOBAY)
(f) 1,5 naphthalene isocyanate (MONDUR N-15 by MOBAY)
(g) tolylene diisocyanate reacted with castor oil to produce a prepolymer having 22% NCO groups
(h) methylene bis-phenyl diisocyanate reacted with a liquid polyepichlorohydrin to produce a prepolymer of about 24% NCO content
Example 11
About 30 parts by weight of each of the polyol-alkali metal silicate emulsions of Example 1 are mixed with 0.25 parts by weight of an amine polyurethane catalyst (DABCO -R 80 20 by AIR PRODUCTS), 0.25 parts by weight of a foam stabilizer (DOW 190 by DOW), 5 parts by weight of monofluorotrichloromethane and 20 parts by weight of polymeric MDI (MONDUR MR by MOBAY) are thoroughly mixed and reacted thereby producing foamed polyurethane silicate products.
Example 12
About 40 parts by weight of each of the polyol-alkali metal silicate emulsions of Example 2 are mixed with 0.25 parts by weight of an amine polyurethane catalyst (DABCO-R8020 by AIR PRODUCTS), 0.25 parts by weight of a foam stabilizer (DOW 190 by DOW), 3 parts by weight of monofluorotrichloromethane and 30 parts by weight of polymeric MDI (MONDUR MR by MOBAY) are thoroughly mixed and reacted thereby producing a strong flexible polyurethane silicate foam which weights abuout 1 to 2 lb./cu.ft. and is flame retardant.
Example 11
Example 1 is modified by admixing 10 parts by weight of a powdered water-binding agent to the polyol-alkali metal silicate emulsion which is selected from the list below:
(a) burnt lime
(b) gypsum
(c) hydroulic cement (Portland cement)
(d) synthetic anhydride
(e) sodium silicate glass (SiO.sub.2 :Na.sub.2 O ratio of 3.22:1)
Example 12
Example 1 is modified by admixing 25 parts by weight of a powdered oxidated silicon selected from the list below to the aqueous alkali metal silicate solution:
(a) silica
(b) polysilicic acid
(c) fumed silica
(d) precipitated silica
(e) hydrated silica
(f) talc
(g) clay
(h) calcium silicate
(i) magnesium silicate
(j) alumino silicate
(k) zeolite
(l) mixtures of the above
Although specific material and conditions were set forth in the above examples, these were merely illustrative of preferred embodiment of my invention. Various other compositions, such as the typical materials listed above may be used where suitable. The reactive mixtures and products of my invention may have other agents added thereto to enhance or otherwise modify the reaction and products.
Other modifications of my invention will occur to those skilled in the art upon reading my disclosure. These are intended to be included within the scope of my invention as defined in the appended claims.
Claims
I claim:
1. The process for the production of polyol-alkali metal silicate emulsion which consist of mixing the following components: (a) aqueous alkali metal silicate solution, 1 to 50 parts by weight; (b) a polyol, 25 to 100 parts by weight; (c) an effective amount up to 25 parts by weight of an organic compound that will solidify the aqueous alkali metal silicate solution but not react with the alkali metal oxide and is selected from the group consisting of alcohols, polyalcohols, aldehydes, ketones, nitriles, epoxides, amines, amino compounds and mixtures thereof.
2. The product produced by the process of claim 1.
3. The process of claim 1 wherein the alkali metal silicate is selected from the group consisting of sodium silicate, potassium silicate, lithium silicate and mixtures thereof.
4. The process of claim 1 wherein up to 20% by weight of an emulsifying agent is added to the Components (a), (b) and (c), percentage based on weight of Components (a), (b) and (c).
5. The process of claim 1 wherein up to 20% by weight of a foam stabilizer, percentage based on Components (a), (b) and (c), is added with Components (a), (b) and (c).
6. The process of claim 1 wherein up to 10% by weight of a salt-forming compound is added to Components (a), (b) and (c), percentage based on Components (a), (b) and (c).
7. The process of claim 1 wherein up to 20% by weight of a dispersion stabilizer is added to Components (a), (b) and (c), percentage based on Components (a), (b) and (c).
8. The process of claim 1 wherein up to 50 parts by weight of a vinyl monomer and a catalytic amount of a free-radical initiator is added to Components (a), (b) and (c).
9. The process of claim 1 wherein up to 100% by weight of an oxidated silicon compound is added to Components (a), (b) and (c), percentage based on Components (a), (b) and (c), and selected from the group consisting of silica, polysilicic acid, natural silicates, precipitated silica and mixtures thereof.
10. The process of claim 1 wherein up to 20% by weight of a water-binding agent is added to Components (a), (b) and (c), percentage based on Components (a), (b) and (c).
11. The process of claim 1 wherein up to 50 parts by weight of an organic polymer in a fluid state is added to Components (a), (b) and (c).
12. The process of claim 1 wherein up to 100 parts by weight of an inert filler is added to Components (a), (b) and (c).
13. The process of claim 1 wherein up to 50 parts by weight of an organic diene and a catalytic amount of a free-radical initiator is added to Components (a), (b) and (c).
14. The process of claim 1 wherein additional step is taken wherein 1 to 100 parts by weight of a compound containing at least two isocyanate radicals are admixed with 1 to 50 parts by weight of the polyol-alkali metal silicate emulsion produced in claim 1 thereby producing a polyurethane silicate product.
15. The product produced by the process of claim 14.
16. The process of claim 14 wherein up to 50% by weight, percentage based on the weight of Components (a), (b) and (c), of a blowing agent, boiling within the range from 25.degree. C. to 80.degree. C., is added with the polyisocyanate or with the polyolalkali metal silicate emulsion thereby producing a foamed polyurethane silicate product.
17. The product produced by the process of claim 16.
18. The process of claim 14 wherein the compound containing at least two isocyanate radicals is selected from the group consisting of aliphatic, cycloaliphatic, araliphatic, aromatic and heterocyclic polyisocyanates and mixtures thereof.
19. The process of claim 14 wherein the compound containing at least two isocyanate radicals is a phosgenation product of aniline-form aldehyde condensation and mixtures thereof.
20. The process of claim 1 wherein Compound (c) is a compound or radical containing a functional group corresponding to one of the following general formulae: ROH, RSH, RNH.sub.2, NH.sub.2 RNH.sub.2, ##STR2## RCN, wherein R is H, CH.sub.3 --, C.sub.2 H.sub.5 -- or C.sub.3 H.sub.7 --
21. The process of claim 1 wherein Compound (c) is a tertiary amine.