Synthetic mineral polymer compound of the silicoaluminates famil

Details Synthetic mineral polymer compound of the silicoaluminates famil Synthetic mineral polymer compound of the silicoaluminates famil

1982-04-29

1984-09-18

Meros, Edward J.

Compositions: coating or plastic

Coating or plastic compositions

Metal-depositing composition or substrate-sensitizing...

106 84, 1062862, 1062865, 264319, 264333, 423328, 423329, 501153, C04B 700, C01B 3326

Patent

active

044721994

DESCRIPTION:

BRIEF SUMMARY
This invention relates to a mineral polycondensation process for making cast or molded products at temperatures generally up to about 120.degree. C. This process is related to processes for making zeolites or molecular sieves.
The products of such processes, however, have characteristic three-dimensional frameworks which are successions of tetrahedrons TO.sub.4, where T is silicon, aluminum, gallium, phosphorous or the like. Those products form channels or voids of regular dimensions. The voids are molecular in size. Accordingly, the mineral frameworks can be used to separate organic molecules of different molecular sizes. Those structures also exhibit ion exchange properties. Moreover, those products catalyze several different organic polymerization systems.
Numerous patents and other references describe methods for making those synthetic minerals, zeolitics and molecular sieves. D. W. Breck's book entitled, "Zeolite Molecular Sieves," published by Interscience in 1974, is a good reference. Generally, those methods are hydrothermal syntheses of silico-aluminate gels in strong, highly concentrated aqueous alkali. The reactant mixture, containing a large excess of water, is sealed in a container at constant pressure and temperature. Preferably, the pressure is atmospheric, and the temperature is in the range of about 25 C. to about 125.degree. C. The reaction continues over more than ten hours until crystallization of the products occurs. The chemical formula for the resulting synthetic zeolites and molecular sieves may be written as follows: been made in such hydrothermal syntheses. However, these products are very porous and have poor mechanical properties, even when agglomerated with a binder. I have discovered that when reaction conditions do not favor crystallization or crystal formation, I obtain novel products.
An object of this invention is to provide synthetic mineral products with such properties as hard surfaces (5-7 on the Mohs scale), thermal stability and high surface smoothness and precision. Such products are useful for tooling, and for molding art objects, ceramics and the like, and building materials.
The main object is to provide a novel mineral polymer, more precisely a novel mineral polymer compound, and to provide a method of making a new mineral polymer compound.
Other objects such as use of this mineral polymer compound as a binder are apparent from this specification and claims.
The names for these novel three-dimensional polymers are set forth in the following publications: "IUPAC International Symposium on Macromolecules," Stockholm, 1976, Topic III; and "PACTEC IV,", Society of Plastic Engineers, U.S.A., preprint page 151. These mineral polymers are called polysialates and have this empirical formula: sodium, and "n" is the degree of polycondensation. Where "z" is 1, the mineral polymer has this formula: ##STR2## and is called polysialate or PS for short.
Our new polymer is of the K--PS polymer compound type where "M" is potassium.
A suitable method for distinguishing our new polymers from known polymers is through their X-ray powder diffraction pattern. K--PS polymer compound has the characteristic x-ray powder diffraction pattern given in Table A below. To obtain this data, we used the Debye-Scherrer method. The radiation used was the K-Alpha doublet of copper.
The X-ray pattern of K--PS is related to that of natural kaliophilite (KAlSiO.sub.4), which corresponds to the general formula of polysialate. This natural mineral is not a zeolite, but an anhydrous feldspathoid with the formula: ##STR3## where "w" is a value in the range of 0 to 1.
This distinction is very important. Mineral polymers containing zeolitic water must be dehydroxylated at a temperature up to about 400.degree. C. if they are to be used without damage at higher temperature. On the contrary, mineral polymers of the kaliophilite type will resist thermal shock. Thermal shock resistance is a fast test for distinguishing a zeolitic framework from a feldspathoidic one.
Mineral polymer polysialates K--PS have this c

REFERENCES:
patent: 2972516 (1961-02-01), Barrer et al.
patent: 3012853 (1961-12-01), Milton
patent: 3056654 (1962-10-01), Barrer et al.
patent: 4349386 (1982-09-01), Davidovits
"IUPAC International Symposium on MacroMolecules", Stockholm 1976, Topic III.
"PACTECIV", Society of Plastic Engineers, U.S.A. preprint pp. 151-154.
Chemical Abstract 86:19049v, Synthetic Kaliophilite, Zhukova, R. S.; Begletsov, V. V., (USSR), Khim Tekrol, (Kiev), 1976, (3), 63-4.
Barrer, R. M. "Some Researches on Silicates: Mineral Syntheses and Metamorphoses", Transactions of the British Ceramic Soc., vol. 56, No. 4, pp. 155-173, 1957.

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