Process for producing in-situ foam

Patent metadata

Field	Value
Publication number	US-10808116-B2
Application number	US-201615769101-A
Country	US
Kind code	B2
Filing date	Oct 6, 2016
Priority date	Oct 20, 2015
Publication date	Oct 20, 2020
Grant date	Oct 20, 2020

Abstract

A process for producing an in-situ foam comprising the following mixing 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 %.

First claim

We claim:

1. A process producing an in-situ foam comprising the following mixing components: comprising mixing components comprising:
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 %; and
foaming with a gas or gas mixture under superatmospheric pressure and applying mechanical forces for producing an in-situ foam;
wherein components B) and D) are stored separately and mixed together on site to produce the in-situ foam.

2. The process according to claim 1 comprising an alkali metal alkylsiliconate as cell regulator E).

3. The process according to claim 1 wherein polymer B) has a solubility in water of at least 5 wt % under standard conditions (20° C., 101.3 kPa) at pH 7.

4. The process according to claim 1 comprising a polyvinylamine or a poly(vinylamine-vinylformamide) copolymer as cationic polymer B).

5. The process according to claim 1 comprising a terpolymer comprising vinylamine, vinylformamide and sodium acrylate units as amphoteric polymer B).

6. The process according to claim 1 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).

7. The process according to claim 1 comprising by way of surfactant C) at least one surfactant based on natural proteinaceous raw materials.

8. The process according to claim 1 comprising a dialdehyde as crosslinker D).

9. The process according to claim 1 wherein components B), C), and D) are employed in the form of aqueous solutions.

10. The process according to claim 1 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 %.

11. The process according to claim 10 wherein compressed air having a pressure in the range from 100 to 2000 kPa is introduced in step (a).

12. The process according to claim 10 wherein the aqueous solution or suspension in the last mixing element has a solids content in the range from 5 to 50 wt %.

13. The process according to claim 1 , wherein the in-situ foam has a density in the range from 10 to 50 kg/m 3 .

14. The process according to claim 1 wherein the in-situ foam has a heat of combustion below 3.0 MJ/kg, determined according to DIN 51900 part 3.

15. The process according to claim 1 wherein the in-situ foam is a foam for use in thermal insulation.

16. The process according to claim 1 , further comprising filling cavities and hollow bodies with the in-situ foam.

17. The process according to claim 1 wherein the in-situ foam is a form for use as a fire barrier or as part of a fire barrier.

18. The process according to claim 1 , wherein the components comprise from 1 to 10 wt. % of the one or more additives F), wherein the one or more additives F) are selected from the group consisting of starch, modified celluloses, guar bean flour ether, polyvinyl alcohol, functionalized alkyldioxysilanes or alkyltrioxysilanes, and combinations thereof.

Assignees

• Basf Se

Inventors

• Longo-Schedel Daniela
• Hähnle Hans-Joachim
• Von Benten Rebekka
• Reuter Frank

Classifications

• C04B26/04 Primary

  obtained by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• C08J9/009

  Use of pretreated compounding ingredients · CPC title

• C08J9/30

  by mixing gases into liquid compositions or plastisols, e.g. frothing with air · CPC title

• C08K5/07

  Aldehydes; Ketones · CPC title

• C08J9/0095 Primary

  Mixtures of at least two compounding ingredients belonging to different one-dot groups · CPC title