Process for the production of polyisocyanate silicate solid or cellular solid products

Claim 2

The process for the production of a polyisocyanate silicate resinous product by the following steps: (a) adding a silicon halide to a polyol while agitating at ambient temperature and pressure, thereby producing a polyol silicate resinous product; (b) adding a polyisocyanate to said polyol silicate resinous product while agitating for 10 to 60 minutes and in the amount sufficient to produce an isocyanate-terminated polyisocyanate silicate prepolymer, thereby (c) producing an isocyanate-terminated polyisocyanate silicate prepolymer, (d) adding a curing agent to the isocyanate-terminated polyisocyanate silicate prepolymer and mixing thoroughly, thereby (e) producing a polyisocyanate silicate resinous product.

Claim 3

The process of claim 1 wherein the silicon halide is silicon tetrachloride.

Claim 4

The process of claim 1 wherein the polyol is selected from the group of polyhydric alcohols, polyester polymers with at least 2 hydroxyl groups per mol, polyethers with at least 2 hydroxyl groups per mol, castor oil, polybutadiene polymer and copolymers with free hydroxyl groups, polyacetal polymers with at least 2 hydroxyl groups per mol, polycarbonates with at least 2 hydroxyl groups per mol and mixtures thereof.

Claim 5

The process of claim 1 wherein the polyisocyanate is selected from the group consisting of arylene polyisocyanates, and alkylene polyisocyanates.

Claim 6

The process of claim 1 wherein the polyisocyanate is toluene 1,4-diisocyanate, toluene 1,6-diisocyanate and mixtures thereof.

Claim 7

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 of 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, dry granular commercial sodium and potassium silicate, water containing 0.001 to 10% by weight of an activator, selected from the group consisting of a tertiary amine and a tin salt of carboxylic acid, and mixtures thereof.

Claim 8

The process of claim 1 wherein the curing agent is added in the amount of 3% to 200% by weight, based on the weight of the polyisocyanate silicate prepolymer.

Claim 9

The process of claim 1, wherein the reaction is accompanied by foaming.

Claim 10

The process of claim 1, wherein the mixture contains from 0 to 20% by weight, based on the reaction mixture, of a foam stabilizer.

Claim 11

The process of claim 1 wherein from 0% to 50% by weight, based on the reaction mixture, of a chemically inert blowing agent, boiling within the range of from -25° C. to 80° C., is added to the isocyanate-terminated polyisocyanate silicate prepolymer in step (d) of claim 1 before adding the curing agent.

Claim 12

The process of claim 1 wherein the mixture contains from 0 to 20% by weight, based on the reaction mixture, of an emulsifying agent.

Claim 13

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

Claim 14

The process of claim 1 wherein 0 to 95% by weight, based on the weight of the reacton 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 15

The process of claim 1 wherein about 0% to 50% by weight, based on the weight of the isocyanate-terminated polyisocyanate silicate prepolymer, of a resin extender selected from the mineral oil, coal tar and poly-alpha-methyl-styrene is added to the isocyanate-terminated polyisocyanate silicate prepolymer in step (d) of claim 1 before the curing agent is added.

Claim 16

The process of claim 1 wherein from 0% to 50%, based on the weight of the polyisocyanate silicate prepolymer, of a high-boiling aromatic ester plasticizer, selected from the group consisting of benzoate ester, a phthalate ester and a polyester benzoate is added to the polyisocyanate silicate prepolymer in step (d) of claim 1 before the curing agent is added.

Claim 17

The process of claim 1 wherein an additional step is taken wherein about 1 part by weight of a dry, fine, granular hydrated silica is added in step (a) of claim 1, and mixed with 1 to 2 parts by weight of the silicon halide, then agitated at ambient temperature and pressure for 1 to 4 hours, and the reaction is complete in 6 to 12 hours, thereby producing a white, fine granular mixture of halosilicon acids.

Claim 18

The product produced by the process of claim 1.

Claim 19

The product produced by the process of claim 13.

Claim 20

The process of claim 1 wherein the silicon halide is added in the ratio of 1 mol to 1 to 4 mols of the polyol.

Claim 21

The product produced by the process of claim 16.