Melamine-formaldehyde foams comprising hollow microspheres

Patent metadata

Field	Value
Publication number	US-9353232-B2
Application number	US-201213471557-A
Country	US
Kind code	B2
Filing date	May 15, 2012
Priority date	May 16, 2011
Publication date	May 31, 2016
Grant date	May 31, 2016

Abstract

The present invention relates to melamine-formaldehyde foams comprising hollow microspheres wherein said hollow microspheres have a median particle diameter (D 50 , volume averaged, Malvern, Fraunhofer diffraction) in the range from 260 μm to 490 μm, and also processes for producing these melamine-formaldehyde foams and their uses.

First claim

We claim:

1. A melamine-formaldehyde foam comprising hollow microspheres, wherein said hollow microspheres have a median particle diameter (D 50 , volume averaged, Malvern, Fraunhofer diffraction) in the range from 260 μm to 490 μm, wherein the melamine-formaldehyde foam has an open-cell foam scaffold comprising a multiplicity of interconnected, three-dimensionally branched struts and open cell-pores.

2. The melamine-formaldehyde foam according to claim 1 , wherein the hollow microsphere content is in the range from 0.1% to 60% by weight, wherein the percentages by weight are based on the total weight of hollow microspheres and melamine-formaldehyde precondensate used for foam production.

3. The melamine-formaldehyde foam according to claim 1 , wherein the hollow microspheres are embedded into the open-cell pores.

4. The melamine-formaldehyde foam according to claim 1 , wherein the hollow microsphere walls comprise a polymer or an inorganic material.

5. The melamine-formaldehyde foam according to claim 1 , wherein the hollow microsphere walls comprise glass.

6. The melamine-formaldehyde foam according to claim 1 , wherein the hollow microsphere interiors are at least partly filled with a substance which is released by destruction of the hollow microsphere walls to develop its specific activity for a particular desired use.

7. The melamine-formaldehyde foam according to claim 2 , wherein the hollow microspheres are embedded into the open-cell pores.

8. The melamine-formaldehyde foam according to claim 7 , wherein the hollow microsphere walls consist of a polymer or of an inorganic material.

9. The melamine-formaldehyde foam according to claim 7 , wherein the hollow microsphere walls comprise glass.

10. The melamine-formaldehyde foam according to claim 9 , wherein the hollow microsphere interiors are at least partly filled with a substance which is released by destruction of the hollow microsphere walls to develop its specific activity for a particular desired use.

11. A process for producing the melamine-formaldehyde foam comprising hollow microspheres according to claim 1 wherein the consecutive process steps a) and b) are carried out:
a) heating to foam up and crosslink a mixture comprising a melamine-formaldehyde precondensate having a molar ratio of melamine:formaldehyde in the range from 1:1.3 to 1:5, hollow microspheres having a median particle diameter (D 50 , volume averaged, Malvern, Fraunhofer diffraction) in the range from 260 μm to 490 μm, curatives, dispersants and blowing agents, and
b) drying the foam obtained in process step a).

12. A cushioning which comprises the melamine-formaldehyde foam comprising hollow microspheres according to claim 1 .

Assignees

• Steinke Tobias Heinz
• Nessel Peter
• Hahn Klaus
• Baumgartl Horst
• Möck Christof
• Vath Bernhard
• Wester Bettina
• Schierholz Jens-Uwe
• Pung Dave
• Basf Se

Inventors

• Steinke Tobias Heinz
• Nessel Peter
• Hahn Klaus
• Baumgartl Horst
• Möck Christof
• Vath Bernhard
• Wester Bettina
• Schierholz Jens-Uwe
• Pung Dave

Classifications

• C08J2205/05

  Open cells, i.e. more than 50% of the pores are open · CPC title

• C08J9/141

  Hydrocarbons · CPC title

• C08J2361/28

  with melamine · CPC title

• C08J9/32

  from compositions containing microballoons, e.g. syntactic foams · CPC title

• E04B2001/742

  Use of special materials; Materials having special structures or shape · CPC title