U.S. patent application number 14/430378 was filed with the patent office on 2015-09-10 for system and method for producing an in-situ pur foam.
The applicant listed for this patent is BASF SE. Invention is credited to Jens Assmann, Klaus Hahn, Hans-Joachim Hahnle, Nikolaus Nestle, Kimberly Simancas, Tatiana Ulanova, Rebekka Von Benten.
Application Number | 20150252164 14/430378 |
Document ID | / |
Family ID | 46963559 |
Filed Date | 2015-09-10 |
United States Patent
Application |
20150252164 |
Kind Code |
A1 |
Simancas; Kimberly ; et
al. |
September 10, 2015 |
SYSTEM AND METHOD FOR PRODUCING AN IN-SITU PUR FOAM
Abstract
A system for producing an in-situ foam, which comprises the
components from 50 to 98% by weight of one or more inorganic
fillers A), from 1 to 48% by weight of one or more water-soluble,
cationic polymers B), from 0.5 to 48% by weight of one or more
surfactants C), from 0.01 to 5% by weight of one or more
crosslinkers D) which are capable of reacting with the polymers B),
from 0 to 20% by weight of one or more additives E), where the
percentages by weight of the components A) to E) are based on the
nonaqueous fraction and the sum of A) to E) is 100% by weight,
process for producing an in-situ foam using the components of the
system and foaming by means of a gas or a gas mixture and use for
thermal insulation and filling of hollow spaces and hollow
bodies.
Inventors: |
Simancas; Kimberly;
(Stuttgart, DE) ; Von Benten; Rebekka; (Mannheim,
DE) ; Hahnle; Hans-Joachim; (Neustadt, DE) ;
Hahn; Klaus; (Kirchheim, DE) ; Nestle; Nikolaus;
(Heidelberg, DE) ; Ulanova; Tatiana;
(Ludwigshafen, DE) ; Assmann; Jens; (Mannheim,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BASF SE |
Ludwigshafen |
|
DE |
|
|
Family ID: |
46963559 |
Appl. No.: |
14/430378 |
Filed: |
September 13, 2013 |
PCT Filed: |
September 13, 2013 |
PCT NO: |
PCT/EP2013/068996 |
371 Date: |
March 23, 2015 |
Current U.S.
Class: |
521/87 ; 252/62;
521/149 |
Current CPC
Class: |
C04B 2103/40 20130101;
C04B 26/12 20130101; C08J 9/0066 20130101; C04B 2111/28 20130101;
F16L 59/028 20130101; C08J 9/0033 20130101; C04B 2103/0062
20130101; C08J 9/30 20130101; C04B 26/16 20130101; C04B 38/10
20130101; C08J 2333/24 20130101; C08J 9/122 20130101; C08J 2339/02
20130101; C04B 26/16 20130101; C04B 14/106 20130101; C04B 14/365
20130101; C04B 38/10 20130101; C04B 38/10 20130101; C04B 14/106
20130101; C04B 14/365 20130101; C04B 24/2652 20130101 |
International
Class: |
C08J 9/12 20060101
C08J009/12; C08J 9/00 20060101 C08J009/00; F16L 59/02 20060101
F16L059/02 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 24, 2012 |
EP |
12185665.2 |
Claims
1-16. (canceled)
17. A system for producing an in-situ foam, the system comprising
the following components: from 50 to 98% by weight of one or more
inorganic fillers as component A, from 1 to 48% by weight of one or
more water-soluble, cationic polymers as component B, from 0.5 to
48% by weight of one or more surfactants as component C, from 0.01
to 5% by weight of one or more crosslinkers as component D, which
are capable of reacting with the cationic polymers, from 0 to 20%
by weight of one or more additives as component E, where the
percentages by weight of the components A to E are based on the
nonaqueous fraction and the sum of components A to E is 100% by
weight.
18. The system according to claim 17, wherein the one or more
cationic polymers includes polyvinylamine or a
poly(vinylamine-vinylformamide) copolymer.
19. The system according to claim 17, wherein the one or more
surfactants includes a mixture of anionic and nonionic
surfactants.
20. The system according to claim 17, wherein the one or more
crosslinkers includes a dialdehyde crosslinker.
21. The system according to claim 17, wherein the one or more
inorganic fillers are selected from calcium sulfate, aluminum
silicates, or mixtures thereof
22. A process for producing an in-situ foam, the process comprising
providing the system components according to claim 17, and
introducing a gas, or a gas mixture, to the system components to
produce the in-situ foam.
23. The process according to claim 22, wherein the providing of the
system components comprises preparing an aqueous suspension having
a solids content in the range from 30 to 50% by weight prepared
from the components A to D, and introducing compressed air having a
pressure in the range from 100 to 2000 kPa in to the aqueous
suspension.
24. The process according to claim 22, wherein the introducing of
the gas, or the gas mixture, comprises the introduction into an
aqueous solution or suspension comprising at least the one or more
components C, followed by adding components A, B and D, and
optionally the component E, either together or separately, with one
or more mixing elements to the aqueous solution or suspension,
foaming the aqueous solution or suspension comprising at least the
components A to D, and drying to a water content below 0.5% by
weight.
25. The process according to claim 24, wherein the introducing of
the gas or gas mixture is the introduction of compressed air having
a pressure in the range from 100 to 2000 kPa, and the aqueous
solution or suspension has a solids content in the range from 30 to
50% by weight.
26. The process according to claim 22, wherein the introducing of
the gas, or the gas mixture, comprises the introduction into an
aqueous solution or suspension comprising at least the one or more
components C, followed by adding the components A and B, and
optionally the component E, either together or separately, with one
or more mixing elements to the aqueous solution or suspension,
foaming the aqueous solution or suspension comprising at least the
components A to C, and optionally the component E, adding the
component D, and drying to a water content below 0.5% by
weight.
27. The process according to claim 26, wherein the introducing of
the gas or gas mixture is the introduction of compressed air having
a pressure in the range from 100 to 2000 kPa, and the aqueous
solution or suspension has a solids content in the range from 30 to
50% by weight.
28. An in-situ foam that is firm in air at 20.degree. C. within a
period in the range from 5 to 50 seconds after foaming and is
obtained by the process according to claim 22.
29. The in-situ foam according to claim 28 which has a density in
the range from 10 to 300 kg/m.sup.3.
30. The in-situ foam according to claim 28 which has a heat of
combustion of less than 3.0 MJ/kg.
31. Thermal insulation comprising the in-situ foam according to
claim 28.
32. The in-situ foam according to claim 28 as a fire barrier or
part of a fire barrier.
Description
[0001] The present invention relates to a system and a process for
producing an in-situ foam and also its use.
[0002] In-situ foams based on urethanes, curable aminoplastic
condensates or phenolic resins have been known for a long time. A
disadvantage is that they are flammable and shrink on drying. DE 25
42 471 describes a process for producing low-shrinkage foams from
curable aminoplastic condensates in the presence of shrinkage- and
flammability-reducing reaction products of orthoboric acid and
polyhydric alcohols or polyalkylene glycol ethers of polyhydric
alcohols.
[0003] WO 2011/051170 describes a process for producing an elastic
inorganic-organic hybrid foam having good heat and sound absorption
properties. The foam is obtained by foaming a mixture of gypsum or
kaolin, an aqueous polyvinylamine solution, a volatile organic
compound as blowing agent, an emulsifier and crosslinker. Owing to
the blowing agents used, flush filling of hollow spaces with foam
is not possible.
[0004] WO 2009/109537 describes a process for producing a foam
having a high flame resistance and low density by curing a
mechanical or blown foam composed of an aqueous composition
comprising alkali metal silicates, surfactants and an aqueous
polymer dispersion. Film formation by drying of the polymer
dispersion is too slow for use as in-situ foam.
[0005] JP-A 11-27931 describes a flame-resistant spray foam based
on polyurethanes which is obtained by mixing an aqueous phosphoric
acid solution and optionally inorganic fillers with a mixture of
urethane prepolymers comprising NCO groups and calcium carbonate
under superatmospheric pressure.
[0006] DE 199 12 988 C1 discloses filler-comprising foams based on
polyurethanes and their suitability as thermal insulation and
insulating materials and also as fire retardant foams.
[0007] WO 2008/007187 describes a hybrid foam based on
polyurethanes and inorganic fillers having good thermal and
acoustic insulation properties, permeability and flame protection
and also good adhesion to concrete.
[0008] If in-situ foams based on polyurethanes are used for filling
virtually closed hollow spaces, the formation of CO.sub.2 in the
reaction of the components can lead to a high pressure buildup in
the hollow spaces, so that the walls burst.
[0009] It was an object of the present invention to remedy the
abovementioned disadvantages and provide a system and a process for
producing an in-situ foam which displays low shrinkage and low
emissions and is sufficiently solid to be cut within a short time.
Furthermore, it should also allow flush filling of even irregular
and/or virtually closed hollow spaces with foam and, for fire
protection, have a low heat of combustion, preferably less than 3.0
MJ/kg, very low smoke formation and no dripping of burning
material.
[0010] The object is achieved by a system for producing an in-situ
foam, which comprises the components [0011] from 50 to 98% by
weight, preferably from 85 to 95% by weight, of one or more
inorganic fillers A), [0012] from 1 to 48% by weight, preferably
from 2 to 10% by weight, of one or more water-soluble, cationic
polymers B), [0013] from 0.5 to 48% by weight, preferably from 1 to
10% by weight, of one or more surfactants C), [0014] from 0.01 to
5% by weight, preferably from 0.1 to 1% by weight, of one or more
crosslinkers D) which are capable of reacting with the polymers B),
[0015] from 0 to 20% by weight, preferably from 1 to 10% by weight,
of one or more additives E), [0016] where the percentages by weight
of the components A) to E) are based on solids or the nonaqueous
fraction and the sum of A) to E) is 100% by weight.
[0017] Component A)
[0018] As component A), the system comprises one or more inorganic
fillers, in particular minerals, for example colloidal silica,
silicates such as aluminum silicates, in particular kaolin
Al.sub.2O.sub.3*2SiO.sub.3*2 H.sub.2O or kaolinite
Al.sub.4[(OH).sub.8Si.sub.4O.sub.10], sulfates such as calcium
sulfate, in particular water-containing sulfates Ca[SO.sub.4]n
H.sub.2O where n=1/2, 2 (gypsum), or mixtures thereof. Particular
preference is given to using calcium sulfate, FGD gypsum from flue
gas desulfurization plants, aluminum silicates, in particular
kaolin, or mixtures thereof.
[0019] The component A is preferably used as naturally occurring
mineral and has preferably not been surface-treated. The average
particle diameter of the component A) is preferably in the range
from 0.1 to 10 .mu.m. The density of the component A) is preferably
in the range from 2 to 3 kg/m.sup.3.
[0020] Component B)
[0021] As component B), the system comprises one or more cationic
polymers. Preference is given to ones which bear primary or
secondary amino groups. The polymer B) is water-soluble, i.e. the
solubility in water is at least 5% by weight, preferably at least
10% by weight, under standard conditions (20.degree. C., 101.3 kPa)
at pH 7. It is used in the form of an aqueous solution, preferably
in a concentration of at least 50 g/l, in particular at least 100
g/l.
[0022] Examples of cationic polymers B are polymers obtained by
polymerization of one or more monomers selected from among
vinylamine, allylamine, ethylenimine, vinylimidazole,
N-alkyl-aminoethyl acrylate, N-alkylaminoethyl methacrylate,
N-alkylaminopropylacrylamide, N-alkyl-aminopropylacrylamide,
N,N-dialkylaminoethyl acrylate, N,N-dialkylaminoethyl methacrylate,
N,N-dialkylaminopropylacrylamide,
N,N-dialkylaminopropylacrylamide.
[0023] It is likewise possible to use polymers which bear primary
or secondary amino groups and are based on renewable raw materials
such as saccharides, e.g. chitosan.
[0024] The polymers comprising vinylamide units described in WO
2010/145956 or the copolymers which can be obtained by subsequent
partial or complete removal of formyl groups from the
N-vinylformamide copolymerized in the polymer to form amino
groups.
[0025] Preference is given to polymers which are obtained by
complete or partial hydrolysis of polymers which can be obtained by
polymerization of at least one monomer of the formula
##STR00001##
[0026] where R.sup.1, R.sup.2.dbd.H or C.sub.1-C.sub.6-alkyl.
Preferred monomers of the formula (I) are N-vinylformamide,
N-vinyl-N-methylformamide, N-vinylacetamide,
N-vinyl-N-methylacetamide, N-vinyl-N-ethyl-acetamide,
N-vinyl-N-methylpropionamide and N-vinylpropionamide.
[0027] Particular preference is given to polyvinylamine or
poly(vinylamine-vinylformamide) copolymers.
[0028] The charge densities of the cationic polymers B (without
counterions) are generally in the range from 1 to 23 meq/g,
preferably in the range from 3 to 14 meq/g, particularly preferably
in the range from 4 to 11 meq/g. The weight average molecular
weights are usually in the range from 50 000 to 2 000 000,
preferably in the range from 100 000 to 1 000 000, particularly
preferably in the range from 300 000 to 500 000. Particular
preference is given to polyvinylamines and copolymers thereof which
are marketed under the trade name Lupamin.RTM.. Examples are
Lupamin.RTM. 9030, Lupamin.RTM. 9050, Lupamin.RTM. 9095.
[0029] Component C)
[0030] As component C), the system comprises one or more
surfactants which are used for forming and stabilizing the foam. It
is possible to use anionic, cationic, nonionic or amphoteric
surfactants as surfactants.
[0031] Suitable anionic surfactants are diphenylene oxide
sulfonates, alkanesfulonates and alkylbenzenesulfonates,
alkylnaphthalenesulfonates, olefin sulfonates, alkyl ether
sulfonates, alkylsulfates, alkyl ether sulfates, alpha-sulfofatty
acid esters, acylaminoalkanesulfonates, acylisethionates, alkyl
ether carboxylates, N-acylsarcosinates, alkylphosphates and alkyl
ether phosphates. Nonionic surfactants which can be used are
alkylphenol polyglycol ethers, fatty alcohol polyglycol ethers,
fatty acid polyglycol ethers, fatty acid alkanolamides, EO/PO block
copolymers, amine oxides, glyceryl esters of fatty acids, sorbitan
esters and alkyl polyglucosides. Cationic surfactants used are
alkyltriammonium salts, alkylbenzyldimethylammonium salts and
alkylpyridinium salts.
[0032] Particular preference is given to using mixtures of anionic
and nonionic surfactants.
[0033] Component D)
[0034] As component D), the system comprises one or more
crosslinkers D) which can react with the component B). Preference
is given to using aldehydes, isocyanates, epoxides, acrylates,
acrylamides, esters, divinylsulfonates, particularly preferably
ethanedial, as crosslinkers D).
[0035] Component E)
[0036] As component E), the system can comprise one or more
additives. Possible additives are, in particular, compounds which
reduce the shrinkage or the water absorption of the in-situ foam.
To reduce the shrinkage, it is possible to use, for example,
dimethyldihydrophyethylurea. The water absorption can, for example,
be reduced by means of self-crosslinking styrene-acrylate
dispersions.
[0037] To improve the foamability, it is possible to add
viscosity-increasing additives, e.g. starch, modified celluloses or
polyvinyl alcohol.
[0038] The system does not comprise any volatile organic blowing
agents such as low-boiling C.sub.4-C.sub.8-hydrocarbons, alcohol,
ethers, ketones and esters.
[0039] To achieve good fire protection, the proportion of organic
constituents in the in-situ foam should be very low. Preference is
given to using a system in which the proportion of organic
constituents is so low that the in-situ foams pass the burning test
A2 in accordance with DIN 4102 and have a fire resistance F30 at a
thickness of 50 mm and F60 at a thickness of 100 mm. The sum of the
solids (nonaqueous fractions) of the components B), C), D) and E)
is therefore preferably in the range from 2 to 15% by weight,
particularly preferably in the range from 5 to 11% by weight, based
on the in-situ foam.
[0040] The invention also provides a process for producing an
in-situ foam using the above-described components A) to E) of the
system and foaming by means of a gas or a gas mixture. The in-situ
foam can be obtained by mixing and foaming an aqueous composition
composed of the components A) to E) with a gas or a gas mixture
under superatmospheric pressure and action of mechanical forces
such as stirring or shearing by means of static mixers. It is also
possible to foam the aqueous composition by dispersing an inert gas
in the form of fine gas bubbles in it. The introduction of gas
bubbles into the aqueous composition can be effected by means of
beating, shaking, stirring, whip-stator or rotor apparatuses.
Preference is given to using mixtures having stator and/or rotor
elements.
[0041] As gas or gas mixture, preference is given to using inert
gases such as nitrogen, argon, carbon dioxide or oxygen. Particular
preference is given to using air.
[0042] In order to produce the in-situ foam, an aqueous suspension
with a solids content in the range from 30 to 50% by weight is
preferably prepared from the components A) to D) and foamed by
introducing compressed air having a pressure in the range from 100
to 2000 kPa.
[0043] The process preferably comprises the steps [0044] (a)
introduction of a gas or a gas mixture into an aqueous solution or
suspension comprising at least the components C), [0045] (b)
optionally mixing-in of further components A) to E) either together
or separately by means of one or more mixing elements, [0046] (c)
foaming of the aqueous suspension comprising at least the
components A) to C), [0047] (d) optionally addition of the
component D), [0048] (e) drying to a water content below 0.5% by
weight.
[0049] In step (a), preference is given to introducing compressed
air having a pressure in the range from 100 to 2000 kPa.
[0050] The mixing-in of the components A) to E) can be carried out
either together or separately by means of one or more mixing
elements. The components B) and D) of the system or the premixes
comprising these components are preferably stored separately and
mixed only on site to produce the in-situ foam. The introduction is
preferably carried out via different points of introduction on the
apparatus.
[0051] The in-situ foam can be produced in commercial foaming
apparatuses for in-situ foams. Suitable apparatuses for producing
the in-situ foam (F) are shown schematically in FIGS. 1-3.
[0052] The apparatus as shown in FIG. 1 comprises three static
mixers (SM 1, SM 2 and SM 3) having three metering devices (D1, D2
and D3). The components C) and the gas or the gas mixture are
preferably introduced via the metering device (D1), the components
A), B) and E) are preferably introduced together via the metering
device (D2) and the component D) is preferably introduced via the
metering device (D3).
[0053] The apparatus as shown in FIG. 2 comprises only one static
mixer (SM 1) with the metering device (D1) for introduction of the
aqueous composition composed of components A) to E).
[0054] The apparatus as shown in FIG. 3 corresponds to the
apparatus shown in FIG. 2 with an additional metering device (D2).
Here, the components A), B), C) and optionally E) can be introduced
together via the metering device D1 and the component D) can be
introduced separately therefrom via the metering device D2.
[0055] In general, the components B)-D) are used in the form of
aqueous solutions. To adapt the viscosity, further water can be
added to individual components or mixtures of components. The
aqueous suspension in step (c) preferably has a solids content in
the range from 5 to 50% by weight, particularly preferably from 10
to 30% by weight.
[0056] The invention also provides an in-situ foam which can be
obtained by the process of the invention. The density can be set
within a wide range as a function of the foaming apparatus used,
the number of mixing elements and the setting of the pressure. The
in-situ foam preferably has a density in the range from 10 to 300
kg/m.sup.3.
[0057] In general, the in-situ foam which can be obtained by the
process of the invention has a lower average pore diameter and a
narrower pore size distribution compared to a blown foam having the
same composition and blown by means of blowing agents. The more
homogeneous foam structure of the in-situ foam is also reflected in
a lower thermal conductivity. The in-situ foam of the invention
preferably has an average pore diameter below 1 mm. The
distribution of the pore diameters is preferably in the range 0.2-1
mm. In comparison, the average pore diameter in the blown foam is
in the range 1-5 mm and the distribution of the pore diameters is
in the range 1-4 mm.
[0058] The in-situ foam preferably has a combustion energy,
determined in accordance with DIN 51900 part 3, of less than 3.0
MJ/kg, preferably in the range from 0.1 to 2.9 MJ/kg.
[0059] The water absorption after storage of the foam specimens in
a controlled temperature and humidity chamber at 85% humidity to
constant weight is preferably from 1 to 35% by weight, particularly
preferably from 5 to 20% by weight.
[0060] The shrinkage after storage of the foam specimens in a
controlled temperature and humidity chamber at 85% humidity to
constant weight is preferably from 0.1 to 10%, particularly
preferably from 1 to 7%.
[0061] The in-situ foam is preferably firm in air at 20.degree. C.
within a period in the range from 5 to 50 seconds, particularly
preferably in the range from 10 to 25 seconds, after foaming. The
in-situ foam is suitable for thermal insulation and for filling
hollow spaces and hollow bodies, in particular for insulating
hollow spaces in building constructions, for example by filling
double masonry walls. Furthermore, the in-situ foam is suitable for
the interior insulation of building constructions, in particular
walls, ceilings, ceilings having a crawl space and roofs, for
filling hollow blocks with foam to improve the insulation
performance, for insulating pipes and engineering components, for
the fire-resistant closure of openings through masonry walls for,
for example, lead-throughs for lines and also for filling fire
doors, doors and window profiles. The in-situ foam is also suitable
as fire barrier or part of a fire barrier in buildings or for
filling hollow spaces and hollow bodies.
[0062] The in-situ foam can be used either alone or in combination
with one or more other insulation materials in the form of boards
or flocs for these and other applications. Suitable insulation
materials are foamed polymers such as expanded foams composed of
white or gray, expandable polystyrene (EPS, Styropor.RTM.,
Neopor.RTM.) or extruded styrene foams (XPS, Styrodur.RTM.) or
polyurethane foams (PUR), foamed elastomers based on neoprene
rubber or EPDM, inorganic insulation materials such as mineral
fibers, rockwool, glass wool, granulated glass foam, foamed glass,
expanded perlite or silicate foams, natural insulation materials
such as sheep's wool, flax, soft wood fiber boards, lightweight
wood wool construction panels, cork, coconut fiber mats or
cellulose. The in-situ foam according to the invention can
preferably be used together with mineral wool.
EXAMPLES
[0063] Starting Materials
[0064] Component A1 FGD gypsum (from a flue gas desulfurization
plant), CaSO.sub.4.2H.sub.2O, calcium sulfate dihydrate
[0065] Component A2.1 kaolin (from Fluka, uncalcined aluminum
silicate, Al.sub.2Si.sub.2O.sub.5(OH).sub.4, pharmaceutical
grade)
[0066] Component A2.2 Ansilex.RTM. 93 (calcined kaolin, not
surface-treated, average particle size 0.9 .mu.m) Component B1.1
Lupamin.RTM. 9050 (copolymer of vinylformamide and vinylamine (1:1)
having a high molecular weight; 10% strength solution in water, pH
about 8, with chloride as counterion)
[0067] Component B1.2 Lupamin.RTM. 9070 (copolymer of
vinylformamide and vinylamine (3:7) having a high molecular weight;
10% strength solution in water, pH about 8, with chloride as
counterion)
[0068] Component B1.3 Lupamin.RTM. 9050 (copolymer of
vinylformamide and vinylamine (1:1) having a high molecular weight;
10% strength solution in water, pH about 8, with
benzoic+amidosulfonic acid (1:1) as counterion)
[0069] Component C1 surfactant mixture of anionic and nonionic
surfactant: Disponil FES 32 (sodium lauryl polyether sulfate) and
Lutensol AT80 (fatty acid ethoxylate) in a weight ratio of 1:3;
[0070] Component C2 AmphosolCS-50 (cocamidopropyl
hydroxysultaine)
[0071] Component D1 Glyoxal (ethanedial, oxalaldehyde)
[0072] Component D2 Waterpoxy.RTM. 1422 (epoxy resin dispersion in
water, 53-57%, 2-6 Pas)
[0073] Component E1 Durapox.RTM. NT (two-component reactive resin
system with epoxide as resin component and a mixture of
isophoronediamine and
N-(3-aminopropyl)-N-dodecylpropane-1,3-diamine as hardener
component)
[0074] Component E2 Acronal.RTM. 5044 (aqueous self-crosslinkable
dispersion of a copolymer of an acrylic ester and styrene, solids
content 55% by weight, film formation temperature Tg -15.degree.
C., particle size .about.400 nm, pH 6.5-8.5, viscosity 10-100
mPas
[0075] Component E3 Fixapret.RTM. NF:
dimethyldihydroxyethylurea
[0076] Component E4 melamine (pure, powder)
Examples 1-10
[0077] For examples 1-10, an aqueous solution of the component C
was foamed by means of compressed air (2000 kPa) in the first
mixing element SM 1 of a set-up as per FIG. 1 having three static
mixing elements (SM 1, SM 2, SM 3) having diameters in the range
from 5 to 10 mm. A mixture of the components A1, A2, B and E and
optionally additional water to set the solids content of the
suspension was subsequently added via the second mixing element SM
2. Finally, the component D was introduced in the third mixing
element SM 3 and homogeneously mixed in. The foam is conveyed
through the further mixing elements to the exit nozzle by the
introduction of compressed air into the set-up before the first
mixing element. Drying was carried out at 20.degree. C. in air.
Examples 11-16
[0078] In examples 11 and 16, the components A) to D) and
optionally additional water for setting the solids content of the
suspension were foamed together by means of compressed air in an
apparatus as per FIG. 2 having a static mixing element (SM 1)
having a diameter of 25 mm at an operating pressure of 500 kPa.
Drying was carried out at 20.degree. C. in air.
[0079] Tables 1 and 2 show the components A to E for producing the
in-situ foams in percent by weight, in each case based on the
nonaqueous fraction, and the properties of the dried in-situ foam.
The solids content (nonaqueous fraction) in percent by weight is
based on the mixture of the components before foaming (examples 11
and 16).
[0080] The density of the foam specimen was determined by weighing
and measurement of length, width and height. The heat of combustion
was determined in accordance with DIN 51900 part 3. To determine
the water absorption (% by weight), the foam specimens were stored
in a controlled temperature and humidity chamber at 85% humidity
until the weight was constant. The cutting solidity after foaming
was determined by means of a knife and a chronometer. A specimen is
considered to be cutting-solid when a piece of the specimen can be
cut off by means of the knife and lifted away without this piece
losing its shape. To determine the shrinkage, the foam specimens
were stored in a control temperature and humidity chamber at 85%
humidity until the weight was constant and the dimensional changes
were measured.
TABLE-US-00001 TABLE 1 Starting materials for the in-situ foams of
examples 1-10 in percent by weight, based on the nonaqueous
fraction of the components, and properties of the dried in-situ
foams Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Ex. Component 1 2 3 4 5 6
7 8 9 10 A1 55.7 32.6 58.7 58.7 62.2 58.7 58.9 60.1 59.6 59.8 A2.1
27.8 16.3 29.4 29.4 31 29.3 30.0 29.7 29.8 A2.2 29.4 B1.1 8.3 4.9
8.8 8.8 5 8.8 4.7 7.5 3.1 9 B1.2 B1.3 C1 7.6 45.8 2.5 2.5 1.4 2.5
1.3 1.3 1.3 1.3 C2 D1 0.6 0.3 0.6 0.6 0.2 0.6 0.1 0.2 0.2 0.01 D2
E1 0.9 E2 6.1 E3 0.3 E4 5.6 Solids content of suspension 40 26 34
30 45 30 47 41 48 43 [% by weight] Properties of in-situ foam
Density [kg/m.sup.3] 240.9 40.2 172.3 95.2 50.7 95.6 94.2 97.1 95.2
95.2 Heat of combustion [MJ/kg] >3 >3 <3 <3 <3 <3
<3 <3 <3 <3 Water absorption 32 33 32 31 33 32 20 15 8
14 [% by weight] Cutting-solid [sec] 20 22 21 21 22 20 21 19 22 208
Shrinkage [%] 8 7 7 8 2 1 7 8 7 7 Thermal cond. .lamda. [mW/m*K]
40
TABLE-US-00002 TABLE 2 Starting materials for the in-situ foams of
examples 11-16 in percent by weight, based on the nonaqueous
fraction of the components, and properties of the dried in-situ
foams Ex. Ex. Ex. Ex. Ex. Ex. Component 11 12 13 14 15 16 A1 62.4
62.4 62.4 62.4 62.4 62.4 A2.1 31.1 31.1 31.1 31.1 31.1 31.1 A2.2
B1.1 5 5 5 5 B1.2 5 B1.3 5 C1 1.4 1.4 1.4 1.4 1.4 C2 1.4 D1 0.2 0.2
0.2 0.2 0.2 D2 0.2 E1 E2 E3 E4 Solids content of suspension 45 32
32 32 32 32 [% by weight] Properties of in-situ foam Density
[kg/m.sup.3] 35.2 26.9 36.1 32.7 25.8 35.9 Heat of combustion
[MJ/kg] <3 <3 <3 <3 <3 <3 Water absorption 16 9
33 17 33 25 [% by weight] Cutting-solid [sec] 18 21 830 22 20 21
Shrinkage [%] 7 8 9 8 7 9 Thermal cond. .lamda. [mW/m*K] 36
* * * * *