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

Claim 2

A cellular polyisocyanate organic silicate plastic, having high strength, elasticity, flame resistance and dimentional stability with increase in temperature, is prepared by the process which comprises substantially simultaneously mixing and reacting an organic polyisocyanate or polyisothiocyanate, an alkali metal cellulose silicate polymer selected from the group consisting of sodium cellulose silicate polymer and potassium cellulose silicate polymer, 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 an activator, water, water containing polyols, and water containing an alkali metal silicate, said polyisocyanate silicate plastic being the cellular solid product.

Claim 3

A process for producing foamed 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 4

A process for producing foamed 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 5

The process of claim 2 wherein Component C is a compound of 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 - .

Claim 6

The process of claim 2 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, benzoic acid, toluic acid; acetyl chloride, propionic acid chloride, acetyl bromide, acid chloride of C 4 -C 6 monocarboxylic acids, methane sulphonic acid chloride, benzene-sulphonic acid chloride, p-toluene sulphochloride, otoluene 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, cyclohexano-methyl chloride, epichlorohydrin, 2-ethyl-2-chloromethyloxetane; methyl ethyl ketone, methyl-isopropyl ketone, methyl-isobutyl ketone, methylisoamyl 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, ω-chloroacetophenone and propiophenone; acetonitrile, propionitrile, butyronitrile, tolunitrile, hexahydrobenzonitrile, acrylonitrile, allylnitrile, methallylnitrile and methacrylonitrile; nitromethane, nitroethane, nitrohexane, nitrobenzene, 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 7

The process of claim 2 wherein methanol is the organic additive of Component C.

Claim 8

The process of claim 2 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 9

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

Claim 10

The process of claim 2 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 ad dry granular commercial sodium and potassium silicate, and mixtures thereof.

Claim 11

The process of claim 2 wherein up to 50% by weight, based on the reaction mixture, of a chemically inert blowing agent, boiling within the range of -25° C. to 80° C., is added.

Claim 12

The process of claim 2 wherein the reaction is accompanied by foaming.

Claim 13

The process of claim 2 wherein the mixture contains up to 20% by weight, based on the reaction mixture, of a foam stabilizer.

Claim 14

The process of claim 2 wherein the mixture contains up to 20% by weight, based on the reaction mixture, of an emulsifying agent.

Claim 15

The process of claim 2 wherein inorganic or organic particulate or pulverulent materials are added to the reaction mixture.

Claim 16

The product of the process of claim 2.

Claim 17

The process of claim 2 wherein up to 200% by weight, based on the weight of the mixture, of a water-binding agent is added and wherein the water-binding agent is a hydraulic cement, synthetic anhydrite, gypsum or burnt lime.

Claim 18

The product of the process of claim 15.

Claim 19

The process of claim 2 wherein the Components A, B, C and D are substantially simultaneously mixed.

Claim 20

The product of the process of claim 17.

Claim 21

The process of claim 2 wherein an additional step is taken wherein the organic polyisocyanate is reacted with a polyol to produce a liquid isocyanate-terminated polyurethane prepolymer and is used as Component B, and the polyol is added in the ratio of 1 to 50 mols to from 50 to 99 mols of the polyisocyanate.

Claim 22

The process of claim 2 wherein a polyol is added to Component C in the ratio of 1 to 50 mols to from 50 to 99 mols of Component B.

Claim 23

The process of claim 2 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.