Process for the production of polyisocyanate organic silicate solid/cellular solid product

Claim 2

A process for producing polyisocyanate organic silicate cellular solid products by the following steps: (a) mixing component (B), an organic polyisocyanate or polyisothiocyanate, with component (A), an oxidated silicon; (b) agitating the mixture at 20° to 60° C. for 10 to 30 minutes thereby producing a polyisocyanate silicate prepolymer; (c) admixing component (C), an organic additive, and component (D), a curing agent with the polisocyanate silicate prepolymer, and allowing the resultant mixture to react, wherein said organic additive contains from 1 to 9 carbon atoms, has a molecular weight of from 32 to 400 and is selected from the group consisting of monoalcohols, monothioalcohols, monophenols, monothiophenols, halomethyl group containing compounds, nitriles, esters, ethers, thioethers, ketones, nitro-group containing compounds, monocarboxylic acid chlorides, monocarboxylic acid bromides, monosulphonic acids or salts thereof, monocarboxylic acids or salts thereof, and aldehydes, with the proviso that when said organic additive is a monoalcohol, monothioalcohol, monophenol, monothiophenol or monocarboxylic acid, said mixing of (C) and (D) into (A and B) takes place substantially simultaneously.

Claim 3

The process of claim 1 wherein the oxidated silicon compound is selected from the group consisting of silicoformic acid, natural occurring oxidated silicon compounds with free silicic acid groups and silica sol.

Claim 4

The process of claim 1 wherein said organic additive is selected from the group consisting of monoalcohols, monocarboxylic acids or salts thereof and monosulphonic acids or salts thereof.

Claim 5

The process of claim 1 wherein the curing agent is selected from the group consisting of water, water containing 10% to 70% by weight of an alkali metal silicate, water containing 20% to 70% by weight silica sol, water containing 5% to 40% by weight of magnesium oxide in the form of a colloidal dispersion, alkali metal metasilicate pentahydrate selected from the group consisting of sodium metasilicate pentahydrate, potassium metasilicate pentahydrate, lithium metasilicate pentahydrate, and mixtures thereof.

Claim 6

The process of claim 1 wherein component (C) is a compound or radical containing a functional group corresponding to one of the following general formulae: ROH, RSH, RCH 2 Cl, RCH 2 I, RCN, RNO 2 , RCOCl, RCOBr, RSO 2 Cl, RCOOH, RSO 3 H, RCOO - , RSO 3 - , ROR, RCOOR or ##STR2## wherein R is CH 3 --, C 2 H 5 -- or C 3 H 7 --.

Claim 7

The process of claim 1, wherein said organic additive is selected from the group consisting of methanol, ethanol, propanol, isopropanol, butanol, isobutanol, t-butyl alcohol and the isomeric pentanols, hexanols and heptanols, cyclohexanol, methylcyclohexanol, methallyl alcohol, allyl alcohol, cyclohexano-methanol, benzyl alcohol, butylmercaptan, phenols, thiophenol and thiocresols; formaldehyde, acetaldehyde, propionaldehyde, butyl aldehyde, pentanals, hexanals, heptanals, octanals and the corresponding semi-acetals and full acetals; formic acid, acetic acid, propionic acid, butyric acid, isobutyric acid, pentanoic acid, hexane carboxylic acid, heptane carboxylic acid, cyclohexane carboxylic acid, benzoic acid, toluic acid; acetyl chloride, propionic acid chloride, acetyl bromide, acid chloride of C 4 -C 6 monocarboxylic acids, methane sulphonic acid chloride, benzenesulphonic acid chloride, p-toluene sulphochloride, o-toluene sulphochloride, carbamic acid chlorides, phenylcarbamic chloride; methyl acetate, ethyl acetate, propyl acetate, butyl acetate, amyl acetate, the methyl and ethyl esters of propionic, butyric, pentanoic, hexanoic, and heptanoic and the corresponding isomeric compounds; methyl ethyl ether, cyclohexyl methyl ether, methyl butyl ether, phenol methyl ether, thiophenol methyl ether, cresol methyl ether, tetrahydrofuranomethyl-methyl ether; ethyl chloride, ethyl bromide, ethyl iodide, n-propyl chloride, n-propyl bromide, n-propyl iodide, isopropyl chloride, isopropyl bromide, isopropyl iodide, butyl chloride, butyl bromide, butyl iodide, benzyl halides, hexahydrobenzyl halides, cyclohexanomethyl chloride, epichlorohydrin, 2-ethyl-2-chloromethyl-oxetane, and 2-ethyl-2-chloromethyloxetane; methyl ether ketone, methyl-isopropyl ketone, methyl-isobutyl ketone, methyl-isoamyl ketone, methyl-n-propyl ketone, methyl-n-butyl ketone, methyl-t-butyl ketone, methyl-furanyl ketone, methyl-tetrahydrofuranyl ketone, methyl-heptyl ketone, ethylhexyl ketone, acetophonone, ω-chloroacetophenone and propiophenone; acetonitrile, propionitrile, butyronitrile, tolunitrile, hexahydrobenzonitrile, acrylonitrile, allylnitrile, methallylnitrile and methacrylonitrile; nitromethane, nitroethane, nitrohexane, nitrobenzene, chlorinated nitrobenzynes, nitrocyclohexanes, brominated nitrobenzenes, benzyl nitrate and nitrotoluene; methanesulphonic acid, ethanesulphonic acid, butanesulphonic acid, benzenesulphonic acid, 2-toluenesulphonic acid, 4-toluenesulphonic acid, chlorsulphonic acid esters and sulphonic acid esters; trimethylphosphite, trimethylphosphate, triethylphosphite and triethylphosphate; calcium lignosulfonate, lignosulfonic acid sodium salts, and lignin sulfate produced by alkali process and mixtures thereof.

Claim 8

The process of claim 1 wherein methanol is the organic additive of component (C).

Claim 9

The process of claim 1 wherein the proportion by weight of component (B), (polyisocyanate), to component (D), (curing agent) is from 70:1 to 20:80.

Claim 10

The process of claim 1 wherein the proportion by mols of component (B), (polyisocyanate), to component (A), (oxidated silicon compound) is fron 2:1 to 1:2.

Claim 11

The process of claim 1 wherein component (C) (organic additive), is used in a quantity of from 1% to 30% by weight, based on component (B), (polyisocyanate).

Claim 12

The process of claim 1 wherein up to 50% by weight, based on the reaction mixture, of a chemically inert blowing agent boiling within the range of from -25° to 80° C. is added.

Claim 13

The process of claim 11 wherein the reaction is accompanied by foaming.

Claim 14

The process of claim 1 wherein the mixture contains from 0.001 to 10% by weight, based on the reaction mixture, of an activator selected from the group consisting of tertiary amines, organo-tin compounds and silaamines.

Claim 15

The process of claim 1, wherein the mixture contains up to 20% by weight, based on the reaction mixture, of a foam stabilizer.

Claim 16

The process of claim 1 wherein the mixture contains up to 20% by weight, based on the reaction mixture, of an emulsifying agent.

Claim 17

The process of claim 1 wherein inorganic or organic particulate or pulverulent materials are added to the reaction mixture.

Claim 18

The product of the process of claim 1.

Claim 19

The process of claim 1 wherein the oxidated silicon compound of component (A) is reacted chemically with a polyol, selected from the group consisting of glycerol, ethylene glycol, propylene glycol, butylene glycol, trimethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol, diethylene glycol, dipropylene glycol, polypropylene glycol, tetraethylene glycol, ether glycols, Bisphenol A, resorcinol, bis (beta-hydroxyethyl) terephthalate, 2-ethyl-2-(hydroxymethyl)-1,3-propanediol, pentaerythritol, quinitol, mannitol, sorbitol, methylglucoside, glucose, starches, fructose, cane sugar, dextrines, dibutylene glycol, polybutylene glycol, polyester resins with free hydroxyl groups, polybutadienes which contain free hydroxyl groups, polycarbonates which contain free hydroxyl groups, trimethylol ethane, trimethylol propane, hexane-1,2,6-triol, polyestor silicates containing free hydroxyl groups, butane-1,2,4-triol, 1,8-octanediol and mixtures thereof, to produce a polyol silicate and in the amount of 1 mol of oxidated silicon compound to 0.5 to 2 mols of the polyol and then reacted with the polyisocyanate in step (a) of claim 1 as component A.

Claim 20

The process of claim 1, wherein an alkali catalyst, selected from the group consisting of sodium hydroxide, sodium carbonate, potassium hydroxide, potassium carbonate, sodium silicate and other alkali metal salts of weak acids, and added in the amount of 1% to 10% by weight, based on the oxidated silicon compound, in step (a) of claim 1.

Claim 21

The product of the process of claim 18.

Claim 22

The process of claim 1 wherein up to 93% by weight, based on weight of the mixture, of a water-binding component is added and wherein the water-binding component is a hydraulic cement, synthetic anhydrite, gypsum or burnt lime.

Claim 23

The product of the process of claim 21.

Claim 24

The process of claim 1 wherein a dry granular alkali metal silicate, selected from the group consisting of sodium metasilicate pentahydrate and potassium metasilicate pentahydrate in the amount of up to 50% by weight, based on the weight of the oxidated silicon compound (component A) is added with the oxidated silicon compound in step (a) of claim 1.

Claim 25

The process of claim 1 wherein an additional step is taken wherein the polyisocyanate (component B) is treated with sulfur trioxide thereby producing a polyisocyanate which contains sulphonic acid and/or suphonate groups.

Claim 26

The product of the process of claim 24.

Claim 27

A polyisocyanate organic silicate plastic, having high strength, elasticity, dimensional stability with increase in temperature and flame resistance, is prepared by the process which comprises substantially simultaneously mixing and reacting an organic polyisocyanate or polyisothiocyanate, an hydrated silica an organic additive selected from the group consisting of monoalcohols, monothioalcohols, monophenols, and monothiophenols, said organic additive having a molecular weight of up to about 400, and a curing agent selected from the group consisting of water, water containing polyols, and water containing an alkali metal silicate, said polyisocyanate organic silicate plastic being the solid/cellular solid product.

Claim 28

A polyisocyanate organic silicate plastic, having high strength, elasticity, dimensional stability with increase in temperature and flame resistance, is prepared by the process which comprises substantially simultaneously mixing and reacting an organic polyisocyanate or polyisothiocyanate, an hydrated silica an organic additive selected from the group consisting of monoalcohols, monothioalcohols, monophenols, and monothiophenols, said organic additive having a molecular weight of up to about 400, and a curing agent selected from the group consisting of water, water containing polyols, and water containing an alkali metal silicate, said polyisocyanate organic silicate plastic being the solid/cellular solid product.

Claim 29

The process of claim 1 wherein the components (A), (B), (C) and (D) are substantially simultaneously mixed.

Claim 30

The product of the process of claim 27.

Claim 31

The process of claim 1 wherein the polyisocyanate (component B) is selected from the group consisting of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate or mixtures thereof.

Claim 32

The process of claim 1 wherein an additional step is taken wherein the organic polyisocyanate is reacted with a polyol to produce a liquid isocyanate-terminated polyurethane prepolymer and used as component (B); the polyol is added in the ratio of 1 to 50 mols to 5 to 99 mols of the polyisocyanate.

Claim 33

The process of claim 1 wherein a polyol is added to component (D) in the ratio of 1 to 50 mols to 50 to 99 mols of component (B).

Claim 34

The process of claim 1 wherein an additional step is taken wherein 10% to 50% by weight of a dry granular alkali metal silicate, selected from the group consisting of potassium metasilicate pentahydrate, and commercial sodium silicate, percentage based on weight of Component A, and is added in step (a) of claim 1.