The method of producing foam

IPC classes for russian patent The method of producing foam (RU 2039768):

C08J9/30 - by mixing gases into liquid compositions or plastisols, e.g. frothing with air

C08J9/06 - by a chemical blowing agent

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/ 2323235

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(57) Abstract:

Usage: for thermal insulation of building structures, pipelines. The essence of the invention: method of producing foam before foaming an aqueous solution of urea-formaldehyde resin defend before the deposition of the insoluble part, decanted water-soluble portion of the resin and foamed it in the presence of surfactants, and the resulting foam before conditioning mixed with insoluble part resin and hardener. The insoluble part of the resin used in the form of a suspension with finely dispersed solid filler. 1 C.p. f-crystals, 3 tables.

The invention relates to methods for producing foams based on urea-formaldehyde resin and can be used for thermal insulation of building structures, pipelines, etc.

A method of obtaining urea foams by foaming compressed air to aqueous solutions of acids and surfactants (surfactant) followed by enter in the foam formed urea resin, curing in the foam and drying the obtained material [1]
The disadvantage of this method is the low mechanical strength macavinta exclusively in the channels of the Plateau-Gibbs, what causes brittleness of the final product.

A method of obtaining urea foam by foaming compressed air of aqueous solutions of urea resin and surfactant, followed by curing the resulting foam acid [2]
Using this method allows you to increase 1.2-1.3 times the strength of the final product by distributing the main mass of the urea-formaldehyde resin foam films, however, this increase is clearly not enough to solve the problem of strength of materials of this type.

Closest to the invention to the technical essence and the achieved result is a method for urea foam including a foaming solution of urea-formaldehyde resin in the presence of surfactants, conditioning the resulting foam with hardener in a separate chamber equipped with a rapidly rotating stirrer, curing and molding [3]
This method allows in 2-2,5 times to increase the strength of the foams. Another advantage of this method is the possibility of entering into the process at the conditioning stage foam suspension solid visokovci the deposits of materials, take the load of higher than 1.2 kg/cm²requires a relatively large consumption of urea resin, which increases the cost of the material and its toxicity. In addition, these materials are low elasticity. As special studies, the reason for this is the presence of urea-alkyd resin water-insoluble oligomers, which violates the stability of foam films.

The aim of the invention is to obtain foams with improved strength characteristics while reducing their bulk density and toxicity.

To solve this purpose, the method of obtaining a foam including a foaming aqueous solution of urea-formaldehyde resin in the presence of surfactants, conditioning the resulting foam with hardener in a separate chamber equipped with a rapidly rotating stirrer, curing and molding before foaming an aqueous solution of urea-formaldehyde resin defend before the deposition of the insoluble part, decanted water-soluble portion of the resin and foamed it in the presence of surfactants. The insoluble part of the resin left over from the original on who and molded. The remainder of the original volume of the insoluble part of the resin injected in the form of a suspension after dispersion in her fine particulate filler, pumping it into the foam formed from soluble resin parts, then mixed with hardener and mold.

The invention consists in the following.

Polymer matrix urea foams formed the hard core relationships that occur in the place of the channels of the Plateau-Gibbs in the original liquid foam, and films, partially destroyed during curing of the bubbles. First determine the fragility of the foam, the latter, on the contrary, give it some elasticity. When defending urea-formaldehyde resin is the violation of the equilibrium stabilization of insoluble part (methylinosine), conglomeration, and precipitation. The removal of the insoluble part of the process of foaming the resin provides the ability to get more high and stable foam with a thin homogeneous foam films, resulting in improved mechanical strength and elasticity of the foam.

The insoluble part of the resin consisting of methylinosine, is not involved in the reaction of polycondensation resin, so it via. Introduction as insoluble as filler or in the foam or in the form of a suspension with finely dispersed filler in the foam, does not destroy the formed foam film, maintaining their elasticity. When this suspension fills the channels of the Plateau-Gibbs, thereby increasing the strength of the foam.

The interface between the resin solution and the suspension of its insoluble parts may vary as depending on the batch of resin, and depending on its concentration in the solution, which varies in different technological processes (for example, in the case of light casting foams the resin content in the solution is 18-25% and when receiving a strong enough plates 30-35%). When diluted resin to 18-25% of the boundary, usually located at the level 78-80% of the initial volume of solution, and when diluted up to 30-35% at the level of 72-78% As indicated above, it is also possible fluctuations in the transition from one batch of resin to another. Because in real production conditions, precise determination of the boundaries is difficult, it is recommended for solutions containing more than 25% of the resin to take the border at 75% of the original volume, and for solutions below 25% Natalino, do not exceed 10% and the possibility of partial penetration of the suspension into the chamber of the foaming or, on the contrary, the solution in the chamber conditioning did not significantly affect the final result.

P R I m e R 1. 30 wt.h. urea resin brand CFG (can also be used: UKS, KF-MT, CP-MH) was dissolved in 70 wt.h. water and the resulting mixture was divided into 2 equal parts, using one of them to obtain the foam by a known method. The second part after thorough mixing defended within 12 hours After decantation layer of transparent resin solution, which accounted for 75% of the original volume of the solution. To separate thus soluble portion of the resin was added to 0.15 wt. including surfactants (sulfonic acid may also be a foam containing the active alphagroup, for example, Volgoneft, alkylsulfate sodium and others) and after complete dissolution was wspanialy it with compressed air to obtain a stable foam, which was sent to the air conditioning in the mixer, representing the flow-through unit, equipped with a rapidly rotating stirrer (mixer), which gave the remaining 25% insoluble and 1.5 wt.h. phosphoric acid in the form of a 40% aqueous solution (may be the acid). The resulting foam was molded, dried and samples of foam were investigated on bulk density, strength, elasticity and migration of formaldehyde. In the process of obtaining foam compressed air flow rate was varied to obtain samples of the foam in the range of the bulk density of from 10 to 40 kg/m³. Similar wspanialy control solution, giving his all in the camera foaming, and in the mixer only solution of orthophosphoric acid.

The results of the experiments are presented in table. 1, show that the proposed solution leads to the achievement of this goal. So, from the above data it is seen that at the same bulk density, the strength of the foam obtained according to the invention, increases several times, increasing the strength reduces primeramente, because the necessary strength characteristics are achieved with a lower bulk density of the material, and this leads to reduced toxicity.

P R I m m e R 2. 22 wt.h. urea resin KF-MT was dissolved in 78 wt. including water, the resulting mixture was divided into 2 equal parts, using one for the control experiments (by known means), and the second advocated for 6 h and after atopalm analogously to example 1. The results of the experiments are presented in table.2 and confirm the conclusions of example 1.

P R I m e R 3. 20 wt.h. urea resin KF-G was dissolved in 80 wt.h. water, the resulting mixture was divided into 2 equal parts, using one to control (by known means), and the second to verify the technical solutions with the introduction of solids finely dispersed filler. This part of the resin solution advocated for 8 h and decantation soluble part, which amounted to 77.5% of the original volume. The soluble portion of the resin was wspanialy according to example 1, and the suspension of the insoluble part, premixed with 5 wt. including fly ash CHP and 6 wt.h. resin brand CFG, filed for conditioning in the mixer, analogously to example 1.

In the control experiment was wspanialy the entire solution, and in the mixer filed a suspension of 6 wt. including resin and 5 wt.h. fly ash CHP. The results presented in table.3, show that this solution can significantly improve the properties of composite filled foams differ significantly less Toxicological hazard.

Composite foam obtained by a known method, compressive strength of 0.58-0.60 kg/cm²³and consequently the migration of formaldehyde 0.26 mg/m³h

Thus, the assertion of an aqueous solution of the resin before the deposition of the insoluble part and use it as a filler and then connecting with soluble foamed part allow to increase firmness and elasticity, reduce bulk density and toxicity of foam.

1. A method of OBTAINING a FOAM including a foaming aqueous solution of urea-formaldehyde resin in the presence of surfactants, conditioning the resulting foam with hardener in a separate chamber equipped with a rapidly rotating stirrer, curing and molding, characterized in that before the foaming aqueous solution of urea-formaldehyde resin defend before the deposition of the insoluble part, decanted water-soluble portion of the resin and foamed it in the presence of surfactants, and the resulting foam before conditioning mixed with insoluble part resin and hardener.

2. The method according to p. 1, characterized in that the insoluble portion of the resin used in the form of a suspension with finely dispersed solid filler.