Phyllosilicate-impregnated melamine-formaldehyde foam

Patent metadata

Field	Value
Publication number	US-11236212-B2
Application number	US-201816646643-A
Country	US
Kind code	B2
Filing date	Aug 30, 2018
Priority date	Sep 12, 2017
Publication date	Feb 1, 2022
Grant date	Feb 1, 2022

Abstract

A melamine/formaldehyde foam having an open-cell foam structure, with an impregnation applied to the foam structure that comprises at least one particulate phyllosilicate surface-modified with aminosilane and at least one anionically- and/or nonionically-stabilized polyurethane dispersion.

First claim

The invention claimed is:

1. An impregnated melamine/formaldehyde foam having an open-cell foam structure, wherein the impregnated melamine/formaldehyde foam is formed by impregnating an unimpregnated melamine/formaldehyde foam with a composition comprising at least one particulate phyllosilicate surface-modified with aminosilane and at least one anionically- and/or nonionically-stabilized polyurethane dispersion, wherein the composition which is impregnated into the foam structure may be dried.

2. The impregnated melamine/formaldehyde foam according to claim 1 , wherein the particulate phyllo silicate surface-modified with amino silane has a mean particle diameter in the range from 0.2 to 10 μm (Z mean, determined by light scattering, Malvern, Fraunhofer diffraction).

3. The impregnated melamine/formaldehyde foam according to claim 1 , wherein the at least one particulate phyllosilicate surface-modified with aminosilane is applied to the foam structure in an amount of 50 to 350 parts by weight based on 100 parts by weight of unimpregnated melamine/formaldehyde foam.

4. The impregnated melamine/formaldehyde foam according to claim 1 , wherein the at least one anionically- and/or nonionically-stabilized polyurethane dispersion is used in an amount of 0.5% to 10% by weight based on the impregnation dry mass.

5. The impregnated melamine/formaldehyde foam according to claim 1 , wherein the unimpregnated melamine/formaldehyde foam has a density in the range from 5 to 12 g/l.

6. The impregnated melamine/formaldehyde foam according to claim 1 , wherein the density of the impregnated melamine/formaldehyde foam is at least 3 g/l higher than the density of the unimpregnated melamine/formaldehyde foam.

7. The impregnated melamine/formaldehyde foam according to claim 1 , wherein the melamine/formaldehyde foam has a molar ratio of formaldehyde to melamine in the range from 5:1 to 1.3:1.

8. The impregnated melamine/formaldehyde foam according to claim 1 , wherein the at least one anionically- and/or nonionically-stabilized polyurethane dispersion is an aqueous dispersion of a polyurethane comprising carbodiimide structural units of the formula —N═C═N—.

9. The impregnated melamine/formaldehyde foam according to claim 8 , wherein the carbodiimide structural units of the formula —N═C═N— are introduced into the polyurethane via tetramethylxylylene diisocyanate (TMXDI).

10. The impregnated melamine/formaldehyde foam according to claim 8 , wherein the content of carbodiimide structural units of the formula —N═C═N— is 5 to 200 ml/kg based on the polyurethane.

11. The impregnated melamine/formaldehyde foam according to claim 1 , wherein the composition additionally comprises hydrophobizing and/or oleophobizing agents and/or dispersing agents.

12. The impregnated melamine/formaldehyde foam according to claim 1 , wherein an outer surface thereof is at least partially laminated with flat glass-fiber nonwovens, mineral-fiber nonwovens, carbon-fiber nonwovens, carbon-fiber woven fabrics, glass-fiber woven fabrics, mineral-fiber woven fabrics or metal foils.

13. A process for producing an impregnated melamine/formaldehyde foam according to claim 1 , comprising the steps of:
(a) mixing the at least one particulate phyllo silicate surface-modified with aminosilane with the at least one anionically- and/or nonionically-stabilized polyurethane dispersion and optionally the dispersing agent and the hydrophobizing/oleophobizing agent,
(b) applying the mixture from step (a) to the foam,
(c) subsequently impregnating the mixture into the pores of the foam to form an impregnated melamine/formaldehyde foam, optionally by compressing the foam, and
(d) drying the foam.

14. The process according to claim 13 , wherein step d) is carried out at temperatures in the range from 40 to 200° C.

Assignees

• Basf Se

Inventors

• Weisse Sebastian Alexander
• Steinke Tobias Heinz
• Vath Bernhard
• Lenz Werner

Classifications

• C08J9/40 Primary

  Impregnation · CPC title

• C08J9/0066

  Use of inorganic compounding ingredients · CPC title

• C08J2361/28

  with melamine · CPC title

• C08J2201/038

  Use of an inorganic compound to impregnate, bind or coat a foam, e.g. waterglass · CPC title

• C08K9/06

  with silicon-containing compounds · CPC title