Process for the production of polyisocyanate silicate plastics utilizing an alkali metal cellulose silicate condensation product

Claim 2

A process for producing polyisocyanate silicate plastics by the following steps: (a) mixing Component B, an organic polyisocyanate, or polyisothiocyanate with Component A, an alkali metal cellulose silicate condensation product; (b) agitating the mixture at 20° C. to 60° C. for 10 to 30 minutes, thereby producing a polyisocyanate silicate prepolymer; (c) admixing Component C, an organic additive, and, optionally, Component D, a curing agent, with the polyisocyanate silicate prepolymer and allowing the resultant mixture to react, wherein said organic additive contains 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 acid 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 Components C and D into the polyisocyanate silicate prepolymer takes place substantially simultaneously.

Claim 3

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, ROR, RCOOR OR ##STR2## wherein R is CH 3 - , C 2 H 5 - or C 3 H 7 -1 .

Claim 4

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, butylmercaptain, phenol, cresols, 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, benzoil 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, propy 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, cyclohexano-methyl chloride, epichlorohydrin, 2-ethyl-2-chloromethyloxetane, and 2-ethyl-2-chloromethyloxetane; methyl ethyl 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, acetophenone, W-chloroacetophenone and propionphenone; acetonitrile, propionitrile, butyronitrile, tolunitrile, hexahydrobenzonitrile, acrylonitrile, allylnitrile, methallynitrile and methacrylonitrile; nitromethane, nitroethane, nitrohexane, nitribenzene, chlorinated nitrobenzenes, 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 5

The process of claim 1 wherein methanol is the organic additive of Component C.

Claim 6

The process of claim 1 wherein the components are added in the following ratio. (a) 2 parts by weight of Component A to 1 to 10 parts by weight of Component B; (b) 1% to 30% by weight of Component C, based on weight of Component B; (c) Optionally, 1 to 80 parts by weight of Component D to 70 to 80 parts by weight of Component B.

Claim 7

The process of claim 1 wherein the polyisocyanate compound is selected from the group consisting of 2,4-toluene diisocyanate, 2-6-toluene diisocyanate, polyphenyl-polymethylene-isocyanates obtained by aniline-formaldehyde condensation followed by phosgenation mixtures thereof.

Claim 8

The process of claim 1 wherein Component D 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 silicate selected from the group consisting of sodium silicate, potassium silicate, lithium silicate and dry granular commercial sodium and potassium silicate, and mixtures thereof.

Claim 9

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 -25° to 80° C., is added.

Claim 10

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

Claim 11

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

Claim 12

The product of the process of claim 1.

Claim 13

The process of claim 1 wherein up to 200% by weight, based on the weight of the mixture, of a water-binding agent is added and wherein the waterbinding agent is a hydraulic cement, synthetic anhydrite, gypsum or burnt lime.

Claim 14

The product of the process of claim 12.

Claim 15

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

Claim 16

The product of the process of claim 14.

Claim 17

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, and the polyol is added in the ratio of 1 to 50 mols to 50 to 99 mols of the polyisocyanate.

Claim 18

The process of claim 1 wherein a polyol is added to Component C in the ratio of 1 to 50 mols to 50 to 99 mols of Component B.

Claim 19

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.