Process for the production of poly (polyisocyanate-polyol-alkali metal silicate) solid or foamed products

Claim 2

The improved process for the production of poly(polyisocyanate-polyol-alkali metal silicate) foamed products by mixing and reacting the following components: (a) the improvement comprises of producing an emulsion of a polyol and alkali metal silicate, which contains only water molecules that are attached to the alkali metal silicate, (b) an organic polyisocyanate or polyisothiocyanate.

Claim 3

The process of claim 1 wherein the alkali metal silicate is sodium metasilicate pentahydrate.

Claim 4

The process of claim 1 wherein the polyol is selected from the group consisting of polyhydric alcohols, castor oil and polyester resins, polycarbonates, polybutadeines, polythioethers, polycarbonates, which contain 2 or more hydroxyl groups and mixtures thereof.

Claim 5

The process of claim 1 wherein the polyisocyanate is selected from the group consisting of aliphatic, cycloaliphatic, araliphatic, aromatic and heterocyclic polyiscyanates and mixtures thereof.

Claim 6

The process of claim 1 wherein the polyisocyanate is a phosgenation product of aniline-formaldehyde condensation and mixtures thereof.

Claim 7

The process of claim 1 wherein 0.001% to 10% by weight of an initiator, percentage is based on the weight of component (a) and (b), is added to the emulsion of alkali metal silicate in a polyol.

Claim 8

The process of claim 6 wherein the initiator is selected from the group consisting of tertiary amine, silaamines, organic-tin compounds and mixtures thereof.

Claim 9

The process of claim 1, wherein up to 10% by weight, percentage based on the reaction mixture, of a curing agent is added with component (a).

Claim 10

The process of claim 1, wherein up to 50% by weight, percentage based on the weight of the reaction mixture, of a blowing agent, boiling within the range from 25° to 80° C., is added with the polyisocyanate or with the emulsion of alkali metal silicate in a polyol.

Claim 11

The process of claim 1, wherein up to 20% by weight, percentage based on the weight of the reaction mixture, of an emulsifying agent is added to the emulsion of an alkali metal in a polyol.

Claim 12

The process of claim 1, wherein up to 20% by weight, percentage based on the weight of the reaction mixture, of a foam stabilizer is added with the emulsion of alkali metal silicate in a polyol.

Claim 13

The process of claim 1, wherein organic or inorganic particulate or pulverulent materials are added to the reactive mixtures in the amount up to 50% by weight, percentage based on the weight of the reaction mixture, is added to the components.

Claim 14

The product produced by the process of claim 1.

Claim 15

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

Claim 16

The process of claim 1 wherein up to 200% by weight of an inorganic water-binding agent, percentage based on the weight of the reaction mixture, selected from the group consisting of hydraulic cement, synthetic anhydride, gypsum or burnt lime and is added with the polyisocyanate, and/or emulsion of an alkali metal silicate in a polyol.

Claim 17

The product produced by the process of claim 15.

Claim 18

The process of claim 1 wherein an isocyanate-terminated polyurethane prepolymer is utilized in place of the organic polyisocyanate.

Claim 19

The process of claim 1 wherein and isocyanate-terminated polyurethane prepolymer is selected from the group consisting of an isocyanate-terminated polyester, isocyanate-terminated polyether, isocyanate-terminated polybutadiene, isocyanate-terminated polysulfide and mixtures thereof.

Claim 20

The product produced by the process of claim 17.

Claim 21

The process of claim 1 wherein the reactants are added in the following proportions: Component (a) 10 to 99 parts by weight of an alkali metal silicate and 50 to 99 parts by weight of a polyol. Component (b) 50 to 99 parts by weight of a polyisocyanate or polyisothiocyanate.

Claim 22

The process of claim 1 wherein a polyisocyanate silicate prepolymer produced by reacting an organic polyisocyanate with hydrated silica in the ratio of 50 parts by weight of the polyisocyanate to 5 to 20 parts by weight of hydrated silica, is used in place of the organic polyisocyanate or polyisothiocyanate.

Claim 23

The product produced by the process of claim 21.

Claim 24

The improved process of claim 1 wherein a poly(polyisocyanate-polyol-alkali metal silicate) prepolymer is produced by mixing and reacting 1 to 20 parts by weight of component (a) with 99 parts by weight of component (b) at a temperature below 40° C. thereby producing a poly(polyisocyanate-polyol-alkali metal silicate) prepolymer which is cured by mixing and reacting up to 178 parts by weight of component (a) thereby producing a poly(polyisocyanate-polyol-alkali metal silicate) foamed product.

Claim 25

The product produced by the process of claim 23.

Claim 26

The process of claim 23 wherein the reaction is accompanied by foaming.

Claim 27

The process of claim 1 wherein up to 20% by weight of a salt forming compound is added and reacted with the alkali metal silicate thereby stabilizing the emulsion.