Compositions – Magnetic – With wax – bitumen – resin – or gum
Patent
1995-12-18
1997-11-04
Bonner, Melissa
Compositions
Magnetic
With wax, bitumen, resin, or gum
252 6256, 252 6251R, 252478, 524 5, 524423, 524788, 106786, 106779, 106772, 106782, 106640, 501 74, C08K 300, C08L 6706
Patent
active
056836163
DESCRIPTION:
BRIEF SUMMARY
The present invention relates to a process for preparing ceramic-like materials and the ceramic-like materials produced thereby. Such materials are suitable for manufacturing articles with magnetic properties products which absorb hard and x-radiations, and goods with insulating properties useful particularly in the building industry due to their very low moisture absorbability.
There are known various processes of binding inorganic fillers, including phosphogypsum, with synthetic polymers in aqueous systems, as is shown in Polish patent specifications 113 573 and 147 599, to prepare compositions to be used as flooring or raw materials for making stuccoes. The drawback of these processes is that the resultant products are rather brittle and porous and therefore possess a high water imbibition. On the other hand, the polymerization process involved proceeds rather slowly, which exclude the use of extrusion or injection moulding methods. There is also known from Polish application no. P. 283 240 a process for manufacturing ceramic-like plastics by binding a waste phosphogypsum with polyester resin in non-aqueous systems containing an accelerant, a curing agent and, in case of need, acetone. The resultant material is suitable for processing into various articles by extrusion or injection moulding and is characterized by good mechanical strength as well as low water and oil absorbabilities.
It has unexpectedly turned out that the use of a composite inorganic filler consisting of a waste phosphogypsum, especially apatite derived phosphogypsum, and other inorganic compounds such as metal oxides or salts, in the form of physically homogenized composition with a grain size not exceeding 25 .mu.m, and binding this filler with unsaturated polyester resins in a non-aqueous system, makes it possible to prepare ceramic-like materials with specific properties, which can be easily moulded, also by casting, and machine processed. It has also turned out that by adding a CO.sub.2 producing substance to the composition of waste phosphogypsum and an unsaturated polyester resin, one can prepare an expanded ceramic-like material.
The process for preparing a ceramic-like materials with magnetic properties by binding an inorganic filler with a synthetic resin in a non-aqueous system, according to the present invention consists in carrying out the process in several stages. At the first stage, a physically homogenized dry composition with a grain size of up to 25 .mu.m is prepared from waste phosphogypsum and magnetite in volume proportion 1:0.66-1.52. The phosphogypsum for this stage is previously heated for at least one hour at a temperature not lower than 177.degree. C. Next, the prepared dry composition in an amount of 100 volume parts is added on continuous stirring for 0.2-4.8 hours to 50-240 volume parts of an unsaturated polyester resin containing up to 8% by volume of an accelerant, such as cobalt naphthenate, after which up to 23 volume parts of an organic dilutant, such as acetone or styrene, is added to maintain the composition viscosity at a level of not higher than 4230 mPa.circle-solid.s. If the polyester resin does not contain an accelerant itself, then such resin is used in the amount of 46-220 volume parts per 100 volume parts of dry composition, and an accelerant in an amount up to 8% by volume or, equivalently, of 4-20 volume parts is added. Then, 3-20 volume parts of a curing agent is added, preferably in the form of a solution with a concentration of 20-40 % by volume of cyclohexanone peroxide or benzoyl peroxide in dibutyl phthalate, to obtain, after the termination of the polymerization, a ceramic-like material with magnetic properties.
The ceramic-like material with magnetic properties, containing an inorganic filler, a synthetic resin according to the present invention, after curing per every 50 volume parts of phosphogypsum contains 33-76 volume parts of magnetite, 46-220 volume parts of an unsaturated polyester resin and up to 46 volume parts of acetone or styrene.
The process for preparing a ceramic-li
REFERENCES:
patent: 3873492 (1975-03-01), Takehisa et al.
patent: 4153470 (1979-05-01), Stahl et al.
patent: 5344490 (1994-09-01), Roosen et al.
Chemical Abstracts, vol. 110, No. 11, 29 May 1989, Columbus, Ohio U.S.A. Abstract No. 198189z, W.F. Chang et al. "Stabilization of Phosphogypsum With Epoxy" p. 344; see abstract & Proceedings Of The International Conference on Phosphogypsum No. 2, 1988, China pp. 287-300 XP57029 no month.
Chemical Abstracts, vol. 101, No. 12, 17 Sep. 1984, Columbus, Ohio, US; abstract No. 96679f, "Foamed Gypsum Boards" p. 345; see abstract & JP,A,5954 658 (AIN Engineering KK) 29 Mar. 1984.
Database WPI Week 8716, Derwent Publications Ltd., London, GB; AN 87-112152 & JP,A,62 057 456 (Showa) see abstract & Patent Abstracts of Japan, vol. II, No. 251 (C-440) 14 Aug. 1987 & JP,A.62 057 456 (Showa) 13 Mar. 1987 see abstract.
Cyrkiewicz Marceli
Herling Erwin
Kleszczewski Jacek
Bednarek Michael D.
Bonner Melissa
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