JPS5950698B2 - binding composition - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to relatively low density expanded inorganic fillers such as vermiculite, perlite and monocular clays.

It relates to a method for producing a foam containing. This filling material is
Although extremely bulky when in an unconstrained dry state, when wetted with a liquid resin binder to form a flowable mixture, it tends to pack tightly, thus leading to a loss of very large bulk volume when dry. . This is a disadvantage since it increases the density of the resin bonded product. British Patent Specification No. 13
No. 42090 discloses the production of certain moldings from particles or fibers of non-combustible filler (e.g. monocular clay) embedded in a matrix of open-void rigid phenolic or urea foam resin. is disclosed, the matrix comprising vegetable oil and/or mineral oil, and the molding comprising a liquid phenolic or urea resin, a blowing agent thereof, a hardening agent, and a mixture of vegetable oil and/or mineral oil in a non-flammable manner. The plastic filler particles or fibers are poured into a mold, the mold is closed, and the resin is poured under the action of a blowing agent to embed the particles or fibers in a matrix of foamed rigid resin. It is produced by foaming and curing between particles or fibers.

The invention consists of mechanically mixing and foaming an expanded inorganic filler in a solution of a synthetic thermosetting resin binder in the presence of a surfactant, such that binder:surfactant It relates to a method for producing a foam, characterized in that the weight ratio of .

The resin binder in the present invention contains vegetable oil and/or
Substantially free of mineral oil. According to the present invention, by mechanically mixing and significantly foaming the binder solution, the tendency of the filler to clump when mixed with the binder is reduced, yet facilitates handling. The desired flow state is maintained.

The binder may be pre-foamed before mixing with the filler, or it may be foamed during the mixing process itself. By carefully controlling the amount of surfactant in the binder and controlling the degree of foaming, it is possible to retain most, if not all, of the initial unconstrained dry volume of the filler and improve the compressive strength of the filler itself. It becomes possible to produce foams that exhibit a pressure strength comparable to that of . That is, according to the present invention, it is possible to provide a foamed and cured synthetic resin product reinforced with an expanded inorganic filler, and the volume of the product is equal to the same amount of filler used in the product. is not essentially smaller than its dry volume in the uncompressed state.

However, be aware that when too much surfactant is included, the result is a foam with a volume greater than the volume occupied by the filler used to create the resin-bonded foam in its unconstrained dry state. This is very important.

Such "overfoamed" products usually exhibit low fire resistance, since the filler can no longer support itself when the binder is destroyed. The best combination of density, compressive strength, and thermal insulation is found when the amount of binder and its surfactant content are equal to the volume of filler in the final volume of the foam. The volume should be adjusted to be between the volume in an unconstrained dry state and the volume in a tightly packed state when wet. Generally, the weight ratio of binder to surfactant is between 1:0.005 and 1:0.1.
More preferably, urine may be used as a binder.
1:0.01 when formaldehyde resin is used
The ratio may be between 1:0.05 and 1:0.05. The binders we prefer to use are urea formaldehyde resins (including mixtures thereof with melamine formaldehyde or phenol formaldehyde), melamine formaldehyde resins, ketone formaldehyde resins, furan formaldehyde resins or Water-Extended resins.
) Polyester resin.

The resin-bonded foams of the present invention are extremely easy to handle while in the wet state, i.e. before the binder has hardened, and can be poured, troweled or molded as desired.

They also exhibit little or no shrinkage upon drying, especially when the binder/surfactant weight is adjusted as described above. When dried, the composition exhibits excellent thermal properties including resistance to flame attack;
Therefore, it is useful as a female combustion core material for various architectural elements. Panels and other structural elements cast from this composition are extremely strong and have good screw retention; they can be worked with ordinary woodworking tools. Our invention also includes a method of making a bonded foam composition that includes the steps of mixing a surfactant with a solution of a synthetic resin binder and mechanically subjecting the resulting solution to the expanded inorganic filler prior to mixing with the expanded inorganic filler. The method consists of either pre-foaming the binder solution, or mixing the binder solution and filler with stirring to foam the binder solution.

It will be appreciated that the present invention does not rely on the use of blowing agents other than surfactants.

In order to better understand the invention, it will now be described by way of example with reference to the following examples, where "parts" are by weight unless otherwise indicated. Example 1 Using a pearlite aggregate having a dry weight of about 1281 yen in a tightly packed state and a dry weight of about 100 kg/M3 in an unbound state; 3 parts of 'Z-lite in an unbound state. 2.8 parts of formaldehyde resin containing 68% solids by weight, 0.9 parts of water, "T-Ball" (RJM
．． ) Create a bonded foam by mixing with 0.056 parts of surfactant solution and 0.2 parts of ammonium thiocyanate solution.

Ammonium thiocyanate solution is as a curing agent for this resin. The mixing is carried out in a laboratory mixer;
The mixture was cast as one mass. This mass has a volume slightly smaller than that of the original unconstrained pearlite used to make it, and this reduction in volume is approximately 1,500 parts by volume compared to the original approximately 21 parts by volume. It is. The product has a density of 240k9/M3,
In other words, the effective density of pearlite
The strength was about 120k9/M3 due to the presence of resin which amounted to almost 50% of the composition. Example 2 The above example was repeated using a different surfactant, dodecylbenzenesulfonic acid, as both the blowing agent as well as the hardening agent for the resin.

"Ammonium thiocyanate and 1T ball" is "Nansa SSA" 0.028t! IV) and water were set at 0.2559. The mass is cast as before from this mixture,
It had the same habitat as the mass in Example 1. Example 3 Perlite [Bulk Density 91 Bond/Cu. Feet (144 kg/Frost 3)] l Tourea Honoremanoge Human Resin (Adhesive Grade) 1 part AO. 44 parts T-Ball 514 (Mixed Ano V Lelearyl 7J sulfate)
0.016 parts 15% NH4CNS dissolved enemy
Example 1 was repeated using 0.032 parts.

When mechanically mixed, the compressive strength of this mixture V) is 50p.
si (1 cubic foot (344,74 KN/m)
0.0283 m3) of foam was obtained. Example 4 Example 3 was repeated, replacing the pearlite with cenospheres (hollow ceramic spheres from power plant fly ash) on an equal volume basis.

The total weight of the foam product was increased because the cenospheres had a higher bulk density of 27 bonds/cubic foot (433 kg/M3), but the volume of the product was the same as in Example 1. The compressive strength was however higher, 300 ps1 (2068.4 KN/M2). Example 5 The same volume of pearlite with a bulk specific gravity of 5 bonds/cubic foot (
Example 3 was repeated, substituting lightweight vermiculite of 80.14 kg/M3).

In this case, the product still has the same final volume as the product of Example 3, but the compressive strength is approximately 10 psi (69 KN/
M2). Example 6 2.8 parts of urea formaldehyde adhesive resin and 0.9 parts of water were replaced by 2.8 parts of melamine formaldehyde lamination resin with a solids content of 60% by weight, and 0.2 parts of ammonium thiocyanate solution was replaced with 30 parts of ammonium thiocyanate solution. Example 1 was repeated with the substitution of 0.2 part of % phosphoric acid solution.

The results were the same as those obtained in Example 1. Example 72.8 parts of urea formaldehyde adhesive resin and 0
．． 9 parts of water were replaced by 2.8 parts of acetone noformaldehyde resin with a solids content of 60% by weight, and 0.2 parts of ammonium thiocyanate solution was replaced by 0.2 parts of caustic soda solution.
Example 1 was repeated, substituting

The results were the same here as those obtained in Example 1. Since this product is alkali-cured, it can be used in alkaline environments, e.g.
Can be used as a core between cement sheets. Comparative Example A similar mass made from the same ingredients used in Example 1 but omitting the surfactant weighed 400 kg/M.
It has a density of 3 or more and occupies only half the volume.

Another sample of the mixture of Example 1 was prepared using two frame members and 6
The mixture was spread to fill the 3CTIL deep cavities between the panels.

After the resin was cured, it was tested by applying a flame from a burner supplied under pressure with a gas/air mixture. Even after 45 minutes of tenoning, the flame had not penetrated the panel, and considerable erosion and charring had occurred around the flame application point, while the opposite side of the panel remained cool and completely unaffected. . The above examples demonstrate that the compressive strength of foam products made according to the present invention depends primarily on the compressive strength of the filler used in this type of product.

Claims (1)

[Claims] 1 consisting of mechanically mixing and foaming an expanded inorganic filler into a solution of a synthetic thermosetting resin binder substantially free of vegetable and mineral oils in the presence of a surfactant, thus forming a bond. The weight ratio of agent:surfactant is 1:0.00
A method for producing a foam, characterized in that the ratio is 5 to 1:0.1.