Foamed insulation and process for producing the same

Details Foamed insulation and process for producing the same Foamed insulation and process for producing the same

1984-04-26

1987-02-17

Anderson, Philip

Synthetic resins or natural rubbers -- part of the class 520 ser

Synthetic resins

Cellular products or processes of preparing a cellular...

5230911, 52743, 118 24, 118303, 264 31, 264 464, 264 465, 264123, 264DIG7, 422133, 425817R, 521 54, 521 55, 521136, 521139, 521141, 523218, 523219, C08J 930, C08J 932, B29C 3910, E04B 234

Patent

active

046440143

DESCRIPTION:

BRIEF SUMMARY
BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates to foams which are useful for insulating cavities and structures, such as spaces between walls in houses. The inventive foam compositions are typically prepared in three separate portions, namely (A) cement, (B) foam, (C) catalyst or hardener. More particularly, in some embodiments the present invention is directed to an insulating foam, which is produced by mechanically mixing and foaming a first alkyl sulfate component, adding a second magnesium oxide component to the first component, and adding a third component which is an aqueous solution of at least one of aluminum chloride, magnesium sulfate, magnesium chloride, zinc chloride, sulfamic acid, sulfonic acid, citric acid, resorcinol, sodium silicate, zinc oxide, barium metaborate, vinyl alcohol, magnesium carbonate, calcium chloride and vinyl acetate. A sodium salt of carboxylate polyelectrolyte, for example, that known as Tamol 731, a Registered Trademark of Rohm and Haas, can be used instead of the alkyl sulfate. In other embodiments, two basic components may be used. In all embodiments air is added initially to foam one of the components or a mixture of components. The present application is also related to application Ser. No. 412,371, filed Aug. 27, 1983 and now abandoned.
2. Description of the Prior Art
In the past, it has been known to use an ureaformaldehyde foam for insulating cavities and structures. However, use of this foam has been prohibited because of alleged health hazards to occupants of structures in which this foam has been used.
It has also been known to use a reaction of magnesium oxide with magnesium chloride or magnesium sulfate to produce an oxychloride or oxysulfate cement.


SUMMARY OF THE INVENTION

It is an object of this invention to provide a foam which can be used for insulating structures.
It is another object of this invention to provide a foam-cement mixture wherein the foam maintains sufficient integrity to maintain its shape and volume until the inter-mixed cement sets or hardens to fix the composition in place.
It is a further object to provide a foam which is made from materials which are not irritating to occupants of structures in which the foam is used.
It is a still further object of this invention to provide a process for making the foam discussed in the previous two objects.
It is a still further object of this invention to provide a foam and a process for making a foam which can be easily used to install the foam in a structure.
The above objects and others are obtained by providing a foam which is made by combining two or three separate component mixtures. In a first embodiment, the first component is an aqueous solution of an alkyl sulfate, styrene maleic anhydride resin and an acrylic resin, which is mechanically foamed. A sodium salt of a carboxylate polyelectrolyte may be used instead of the alkyl sulfate. Maleic anhydride resin may or may not be used with the polyelectrolyte. To the mechanically airfoamed first component is added a second component, which is an aqueous solution of magnesium oxide, dispersants, acrylic resin, perlite and/or precipitated calcium carbonate. A third component is added to these components. The third component is an aqueous solution of aluminum chloride, magnesium sulfate, magnesium chloride, zinc chloride, sulfamic acid, sulfonic acid, citric acid, resorcinol, sodium silicate, zinc oxide, barium metaborate, vinyl alcohol, magnesium carbonate, calcium chloride or vinyl acetate.
In a second, preferred embodiment, the composition may comprise two portions, plus air, in which the initially foamed portion comprises an aqueous solution of polyvinyl acetate and a dispersant, and the second, cementitious portion comprises an aqueous solution or suspension of magnesium oxide and barium metaborate. The foam obtained provides a good insulation "R" value and has properties including flame resistance, low shrinkage, fast set up time, lack of odor and nontoxicity.


BRIEF DESCRIPTION OF THE DRAWINGS

FIG

REFERENCES:
patent: Re25564 (1964-04-01), Alford et al.
patent: 2806509 (1957-09-01), Bozzacco et al.
patent: 3957501 (1976-05-01), Matsuda et al.
patent: 4272935 (1981-06-01), Lukas et al.

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