Melamine resin foam with inorganic filling material

Patent metadata

Field	Value
Publication number	US-9242397-B2
Application number	US-201113286370-A
Country	US
Kind code	B2
Filing date	Nov 1, 2011
Priority date	Nov 5, 2010
Publication date	Jan 26, 2016
Grant date	Jan 26, 2016

Abstract

Melamine-formaldehyde foams comprise from 80% to 98% by weight of an inorganic filling material, wherein the % by weight are based on the total weight of inorganic filling material plus melamine-formaldehyde precondensate used for foam production.

First claim

We claim:

1. A melamine-formaldehyde foam comprising from 80% to 98% by weight of an inorganic filling material, wherein the % by weight are based on the total weight of inorganic filling material plus melamine-formaldehyde precondensate used for foam production and wherein the inorganic filling materials have average particle diameters in the range from 0.03 mm to 3 mm and wherein the melamine-formaldehyde foam passes DIN EN 13501-1 for Class A2.

2. The melamine-formaldehyde foam according to claim 1 comprising from 80% to 95% by weight of an inorganic filling material, wherein the % by weight are based on the total weight of inorganic filling material plus melamine-formaldehyde precondensate used for foam production.

3. The melamine-formaldehyde foam according to claim 1 wherein the inorganic filling material used comprises quartz, olivine, basalt, glass spheres, glass fibers, ceramic spheres, clay minerals, sulfates, carbonates, kieselguhr, silicates, colloidal silica or mixtures thereof.

4. The melamine-formaldehyde foam according to claim 1 wherein the inorganic filling materials are particles with a ratio of a long axis to a short axis in the range from 4:1 to 1:1.

5. The melamine-formaldehyde foam according to claim 1 wherein the inorganic filling materials are embedded into the pore structure of the foam and the average particle diameter corresponds to the average pore diameter of the foam structure.

6. The melamine-formaldehyde foam according to claim 1 wherein the density of the melamine-formaldehyde foam is less than 100 g/l.

7. A process for producing the melamine-formaldehyde foam according to claim 1 , said process comprising:
foaming a melamine-formaldehyde precondensate in a solvent with an acid, a dispersant, a blowing agent and inorganic filling material at temperatures above the boiling temperature of the blowing agent; and
subsequently drying the foam.

8. A thermal or acoustic insulation in building construction, automobile, ship and track vehicle construction, spacecraft construction, or upholstery, said insulation comprising the melamine-formaldehyde foam according to claim 1 .

9. The melamine-formaldehyde foam according to claim 1 , wherein the inorganic filling materials have average particle diameters in the range from 0.05 mm to 2 mm.

10. The melamine-formaldehyde foam according to claim 1 exhibiting a tearing force in the range of 1.6 N to 22.5 N.

11. The melamine-formaldehyde foam according to claim 1 , wherein the inorganic filling materials have average particle diameters in the range from 0.1 mm to 0.5 mm.

Assignees

• Steinke Tobias Heinz
• Ulanova Tatiana
• Hahn Klaus
• Baumgartl Horst
• Möck Christof
• Vath Bernhard
• Nessel Peter
• Schierholz Jens-Uwe
• Wester Bettina
• Quadbeck-Seeger Hans-Jürgen
• Basf Se

Inventors

• Steinke Tobias Heinz
• Ulanova Tatiana
• Hahn Klaus
• Baumgartl Horst
• Möck Christof
• Vath Bernhard
• Nessel Peter
• Schierholz Jens-Uwe
• Wester Bettina
• Quadbeck-Seeger Hans-Jürgen

Classifications

• C08J9/0085

  Use of fibrous compounding ingredients (C08J9/0076 takes precedence) · CPC title

• B29L2031/10

  Building elements, e.g. bricks, blocks, tiles, panels, posts, beams {(frameless domes B29L2025/00, doors B29L2031/724)} · CPC title

• C08G18/32

  Polyhydroxy compounds; Polyamines; Hydroxyamines · CPC title

• B29C2035/0855

  using microwave · CPC title

• C08J9/141

  Hydrocarbons · CPC title