Process for the production of alkali metal silicate-organic plastics

Claim 2

The process for the production of foamed polyurethane silicate product by mixing and reacting the following components: (a) an aqueous alkali metal silicate solution in the amount of 100 parts by weight; (b) a polymerizable unsaturated organic compound in the amount of 5 to 100 parts by weight; (c) a mono or polycarboxylic acid salt-forming compound in the amount of 1 to 10 parts by weight; (d) an initiator in a catalytic amount; (e) 50 to 200 parts by weight of a polyisocyanate, up to 10% by weight of a polyisocyanate initiator, up to 20% by weight of an emulsifier, up to 50% by weight of a blowing agent, up to 20% by weight of a regulator, and 1 to 150 parts by weight of a polyol are mixed with the emulsive mixture of Components (a), (b), (c) and (d), thereby producing a foamed polyurethane silicate product; percentages are based on weight of the Components (a), (b), (c) and (d).

Claim 3

The product produced by the process of claim 1.

Claim 4

The process for the production of foamed polyurethane silicate products by mixing and reacting the following components: (a) an aqueous alkali metal silicate solution in the amount of 100 parts by weight; (b) a polymerizable unsaturated organic compound in the amount of 5 to 100 parts by weight; (c) a mono or polycarboxylic acid salt-forming compound in the amount of 1 to 10 parts by weight and consisting of organic acid; (d) an initiator in a catalytic amount; then Components (a), (b), (c) and (d) are mixed and reacted, thereby producing an alkali metal silicate-organic plastic emulsion, then (e) 50 to 200 parts by weight of an organic polyisocyanate, up to 10% by weight of a polyisocyanate initiator, up to 20% by weight of an emulsifier, up to 50% by weight of a blowing agent and 1 to 150 parts by weight of a polyol are added to and mixed with the alkali metal silicate-organic plastic emulsion and allowed to react, thereby producing a foamed polyurethane silicate product; percentages are based on the weight of Components (a), (b), (c) and (d).

Claim 5

The process for the production of foamed polyurethane silicate products by mixing and reacting the following components: (a) an aqueous alkali metal silicate solution in the amount of 100 parts by weight; (b) a polymerizable unsaturated organic compound in the amount of 5 to 100 parts by weight; (c) a mono or polycarboxylic acid salt-forming compound in the amount of 1 to 10 parts by weight and consisting of organic acid; (d) an initiator in a catalytic amount; then Components (a), (b), (c) and (d) are mixed and reacted, thereby producing an alkali metal silicate-organic plastic emulsion, then (e) 50 to 200 parts by weight of an organic polyisocyanate, up to 10% by weight of a polyisocyanate initiator, up to 20% by weight of an emulsifier, up to 50% by weight of a blowing agent and 1 to 150 parts by weight of a polyol are added to and mixed with the alkali metal silicate-organic plastic emulsion and allowed to react, thereby producing a foamed polyurethane silicate product; percentages are based on the weight of Components (a), (b), (c) and (d).

Claim 6

The product produced by the process of claim 3.

Claim 7

The process for the production of foamed polyurethane silicate products by mixing and reacting the following components: (a) an aqueous alkali metal silicate solution in the amount of 100 parts by weight, (b) a polymerizable unsaturated organic compound in the amount of 5 to 100 parts by weight; (c) a mono or polycarboxylic acid salt-forming compound in the amount of 1 to 100 parts by weight and consisting of organic acid; (d) an initiator in a catalytic amount; (e) 50 to 200 parts by weight of an organic polyisocyanate, up to 10% by weight of a polyisocyanate initiator, up to 20% by weight of an emulsifier, up to 50% by weight of a blowing agent, 1 to 150 parts by weight of a polyol, up to 20% by weight of a foam regulator, 1 to 300 parts by weight of a water-binding agent selected from the group consisting of hydraulic cement, gypsum, burnt lime, synthetic anhydrite and mixtures thereof.

Claim 8

The process for the production of foamed polyurethane silicate products by mixing and reacting the following components: (a) an aqueous alkali metal silicate solution in the amount of 100 parts by weight, (b) a polymerizable unsaturated organic compound in the amount of 5 to 100 parts by weight; (c) a mono or polycarboxylic acid salt-forming compound in the amount of 1 to 100 parts by weight and consisting of organic acid; (d) an initiator in a catalytic amount; (e) 50 to 200 parts by weight of an organic polyisocyanate, up to 10% by weight of a polyisocyanate initiator, up to 20% by weight of an emulsifier, up to 50% by weight of a blowing agent, 1 to 150 parts by weight of a polyol, up to 20% by weight of a foam regulator, 1 to 300 parts by weight of a water-binding agent selected from the group consisting of hydraulic cement, gypsum, burnt lime, synthetic anhydrite and mixtures thereof.

Claim 9

The product produced by the process of claim 5.

Claim 10

The process for the production of foamed polyurethane silicate product by mixing and reacting the following components: (a) an aqueous alkali metal silicate solution in the amount of 100 parts by weight; (b) a polymerizable unsaturated organic compound in the amount of 5 to 100 parts by weight; (c) a mono or polycarboxylic acid salt-forming compound in the amount of 1 to 10 parts by weight and consisting of organic acids; (d) an initiator, in a catalytic amount, components (a), (b), (c) and (d) are mixed and reacted, thereby producing an alkali metal silicate-organic plastic emulsion; then add component (e) 50 to 200 parts by weight of an organic polyisocyanate, up to 10% by weight of an initiator, up to 10% by weight of an emulsifier, up to 20% by weight of a foam regulator, 1 to 150 parts by weight of a polyol, up to 50% by weight of a blowing agent, 1 to 300 parts by weight of a water-binding agent selected from the group consisting of hydraulic cement, gypsum, burnt lime, synthetic anhydrite, and mixtures thereof are added to, and mixed with, the alkali metal silicate-organic plastic emulsion and allowed to react, thereby producing a foamed polyurethane silicate concrete; percentages are based on the weight of Components (a), (b), (c) and (d).

Claim 11

The process for the production of foamed polyurethane silicate product by mixing and reacting the following components: (a) an aqueous alkali metal silicate solution in the amount of 100 parts by weight; (b) a polymerizable unsaturated organic compound in the amount of 5 to 100 parts by weight; (c) a mono or polycarboxylic acid salt-forming compound in the amount of 1 to 10 parts by weight and consisting of organic acids; (d) an initiator, in a catalytic amount, components (a), (b), (c) and (d) are mixed and reacted, thereby producing an alkali metal silicate-organic plastic emulsion; then add component (e) 50 to 200 parts by weight of an organic polyisocyanate, up to 10% by weight of an initiator, up to 10% by weight of an emulsifier, up to 20% by weight of a foam regulator, 1 to 150 parts by weight of a polyol, up to 50% by weight of a blowing agent, 1 to 300 parts by weight of a water-binding agent selected from the group consisting of hydraulic cement, gypsum, burnt lime, synthetic anhydrite, and mixtures thereof are added to, and mixed with, the alkali metal silicate-organic plastic emulsion and allowed to react, thereby producing a foamed polyurethane silicate concrete; percentages are based on the weight of Components (a), (b), (c) and (d).

Claim 12

The product produced by the process of claim 7.

Claim 13

The process of claim 1 wherein the alkali metal silicate is selected from the group consisting of sodium silicate, potassium silicate and mixtures thereof.

Claim 14

The process of claim 1 wherein the polymerizable unsaturated organic compound is selected from the group consisting of vinyl monomers, organic dienes, allyl compounds, unsaturated aliphatic hydrocarbons and mixtures thereof.

Claim 15

The process of claim 1 wherein the mono or polycarboxylic acid salt-forming compound is selected from the group consisting of aliphatic monocarboxylic acid, aliphatic polycarboxylic acid, cycloaliphatic carboxylic acid, cycloaliphatic polycarboxylic acid, heterocyclic polycarboxylic acid, aromatic carboxylic acid, aromatic polycarboxylic acid, aliphatic carboxylic acid anhydrides, aromatic carboxylic acid anhydride and mixtures thereof.

Claim 16

The process of claim 1 wherein the organic acid is adipic acid.

Claim 17

The process of claim 1 wherein the initiator is selected from the group consisting of organic peroxide, inorganic peroxide, alkali metal persulfate, ammonium persulfate, a redox system and a peroxide with a metal catalyst.

Claim 18

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

Claim 19

The process of claim 10 wherein the vinyl monomer is selected from the group consisting of acrylate compounds, styrene, vinyl acetate, vinyl chloride, vinylidene chloride, acrylonitrite, vinyl toluenes, N-vinyl carbazole, vinyl pyrovidone, vinylidene cyanide, alkyl vinyl ketones, aryl vinyl ketones, methacrylonitrile, and mixtures thereof.

Claim 20

The process of claim 10 wherein the organic diene is selected from the group consisting of isoprene, chloroprene, butadiene and mixtures thereof.

Claim 21

The process of claim 10 wherein the allyl compound is selected from the group consisting of allyl alcohol, 3-chloropropene, 3-bromopropene, methallyl chloride and mixtures thereof.

Claim 22

The process of claim 10 wherein the unsaturated aliphatic hydrocarbon is selected from the group consisting of ethylene, propylene and mixtures thereof.

Claim 23

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

Claim 24

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

Claim 25

The process of claim 1 wherein the polyisocyanate initiator is selected from the group consisting of a tertiary amine, organic tin compound, silaamine and mixtures thereof.

Claim 26

The process of claim 11 wherein the salt-forming compound is adipic acid.

Claim 27

The process of claim 3 wherein inorganic or organic particulates or pulverulent materials are added to the reaction mixtures.

Claim 28

The process of claim 5 wherein inorganic or organic particulates or pulverulent materials are added to the reactive mixture.

Claim 29

The process of claim 7 wherein inorganic or organic particulates or pulverulent materials are added to the reaction mixture.