Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Cellular products or processes of preparing a cellular...
Patent
1992-01-21
1993-03-02
Foelak, Morton
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Cellular products or processes of preparing a cellular...
521117, 521121, 521130, 521187, 521188, 521 88, 521 89, 521 97, C08J 900, C08J 902
Patent
active
051909855
DESCRIPTION:
BRIEF SUMMARY
The invention relates to stable, shrinkage-free, possibly fireproof and/or emission-free aminoplastic cellular foams and the process for manufacturing them from carbamide-formaldehyde resin condensate (subsequently referred to as "amino resin precondensate") and a hardener foaming agent as well as amino resin precondensate constituents and hardener foaming agent constituents for manufacturing such foams.
Aminoplastic resin cellular foams have been in use for decades. However, the use of these cellular foams as, for example, filling material for hollow space in building construction, has been limited thus far due to their instability, heavy shrinkage and undesirable emission of formaldehyde. This is primarily because it has not been possible to transfer the laboratory results achieved thus far to the work site (see, for example, DIN 18159, Part 2, where 4% shrinkage is tolerated). In addition, the conditions for shrinkage, related to the release of formaldehyde, have been unsatisfactorily resolved. Therefore in recent years aminoplastic cellular foams in building construction have been almost totally driven from the market.
As of today polyhydric alcohols, such as, for example, polyethylene glycol, diethylene glycol, sorbitol, etc. are state of the art additives to the resin precondensate solution (see, for example, DE-PS 1.054.232, U.S. Pat. No. 2,542,471). The use of these, presumably molecule chain stabilizing alcohols, is limited by the constituent amounts. A surplus of alcohols reduces the fireproof capability of the foams. In order to maintain this fireproof capability nevertheless, ortho-boric acid transformation products, for example, were added to alcohol surpluses as a counter measure.
By adding boric acid esters it was possible to improve the resin quality or cellular foam quality, but the products were still not completely satisfactory (DE-PS 2.542.471).
Also proposed as formaldehyde binding for the manufacture of low-formaldehyde products is the introduction into the foaming agent of carbamide in concentrated form (DE-PS 32 16 897). Resorcinol is also used for this purpose in the conventional foaming agent solutions. In addition, phosphoric acid is used as a resin (DE-PS 32 16 897).
One object of the invention under consideration is the creation of aminoplastic cellular foams with optimal stability with large volume and low weight. An additional task of the invention under consideration is the creation of low-shrinkage and/or emission-free aminoplastic cellular foams.
The term "stable" refers, in relation to the invention under consideration, to the foam's ability to resist decomposition.
The term "low-shrinkage" means in this case a linear shrinkage, at wood industry standard conditions, of less than 4%, preferably of less than 1% and generally preferred of, at the most, 0,2%.
By "emission-free" the understanding here is of foams that exhibit no detectable smell of formaldehyde during and after hardening.
These objects will be accomplished in accordance with the invention by the composition of the foaming agent hardener constituent on the one hand, and/or the resin precondensate constituents on the other. The aminoplastic cellular foams according to the invention and the process for manufacturing them as well as the foaming agent hardener constituents and resin precondensate constituents for manufacturing such foams are defined in the independent claims. Preferred embodiment foams are to be found in the dependent claims.
For the manufacture of emission-free, low-shrinkage, fireproof aminoplastic cellular foams used for the most part as sound and heat insulation in building construction, although for other purposes as well, a halogen--(preferably bromide)--alkylene-polyol, for example 1,4-dibromide-2-butene-1,4-diol, is added to the resin precondensate solution along with common polyhydric alcohols. The alkylene group of these polyols includes unsaturated olefine groups with one or more double bonds. Although the reaction mechanism has not been completely explained, it is assumed that these com
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Foelak Morton
IDC System AG
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