Technical Field

The invention relates to a chemical composition providing incombustibility to polyurethane and derivatives thereof by using kaolin clay and various natural mineral additives, and a method for producing the same.

Prior Art

Polyurethane is a polymer consisting of organic units chain joined by carbamate links. Basically, it is formed by the reaction of polyol and isocyanate monomers. A catalyst is used for enhancing the reaction speed. Moreover, said catalyst is used for enhancing the foam structure and can also be used as an additive and a blowing agent.

Nowadays, polyurethanes are used for applications such as flexible foams (sponges), flexible and non-inflatable elastomers, adhesives, coatings, integral products including both elastomer and foam structures, rigid foams (insulation materials), rigid and non-inflatable wood imitations. It is also used commonly for the production of heat, noise and water insulation materials in construction sector (in buildings).

In the state of art, polyether polyols are usually used in polyurethanes in the form of foam. The main components of polyurethane which is a polymer are di- and triisocyanates and polyols. In order to enable the treatment of said polymer or change the features of the polymer, other materials can be added into the main component.

In the Publication No. CN1621429 known in another state of art, a polyisocyanurate (PIR) foam and a polyol combination are described. Said rigid foam has the perfect performance of the ordinary PUR foam and it also has a better dimensional stability, heat resistance, flame penetration resistance and low some emission when the foam burns.

In the patent document with Publication No. MX2019006044 known in another state of art, PUR rigid foams are described which are obtained by reacting an organic polyisocyanate component of a certain viscosity range with a component comprising at least one polyol component which is reactive to isocyanate groups, water, and optionally hydrogen. The patent applications whose brief information are provided above are methods used in the state of art. These applications cannot provide the desired incombustibility resistance and also, they are expensive. For this reason, there is a need for new methods which has a high incombustibility class and reinforcing features and which is also cost-effective.

Brief Description of the Invention

The aim of the invention is to provide a chemical composition providing incombustibility to polyurethane and derivatives thereof by using kaolin clay and various natural mineral additives, and a method for producing the same.

The invention provides safety of life and property in the building by retarding the growth of fire within and around the building by means of fighting the fire in the event of a possible fire thanks to the incombustible PUR filled sandwich panel which improves the incombustibility class of the present PUR foam in a way enhancing the foam form by using kaolin clay which is a natural mineral, and which is also suitable for fire insulation in buildings.

The fire resistance performance of said mineral-doped invention is better than the existing foams as it comprises certain amounts of silicon dioxide, aluminum oxide, iron (III) oxide, calcium oxide, potassium dioxide, titanium dioxide, sodium oxide, magnesium oxide, illite and kaolinite. The mechanical properties thereof are also better than the existing foams.

Thanks to the invention, the market cost of the foam-filled sandwich panels is reduced as the unit price of the mineral additive is cost-effective. The foam form (surface characterization) of the product obtained after the treatment is better than the existing PUR foam form.

Description of the Drawings

Fig. 1 The general view of flow diagram of the method according to the present invention.

Description of the References in the Drawings

For a better understanding of the invention, the definitions of the numerals in the drawings are provided below:

100. Method

Detailed Description of the Invention: The PUR foam which improves the incombustibility class by means of the method (100) according to the invention is produced by the steps given below:

- adding various amounts of kaolin clay into polyol (and derivatives thereof) (101 )

- mixing the polyol and kaolin clay mixture respectively at various revolutions, various temperatures, in various systems and for various periods until it becomes homogenous (102)

- adding various amounts of catalyst (and derivatives thereof), additive (and derivatives thereof) and blowing agent (and derivatives thereof) into the mixture obtained at later stages and mixing it until it becomes homogenous (103) adding various amounts of MDI (Iso) into the obtained mixture, mixing it in various systems and at various revolutions, and starting the reaction by collision via a pump of various pressure values (104)

The kaolin clay rates added in step 101 are between 10 and 80%.

The revolution, temperature, systems and period values in step 102 are respectively 20-10000 rpm, 0-200°C, open, close, under reflux, in pressurized containers and 1 -120 minutes.

The rates of catalyst (and derivatives thereof), additive (and derivatives thereof) and blowing agent (and derivatives thereof) in step 103 are between 0.1 and 20%.

The rate of MDI (Iso), the systems and the revolution values in step 104 are respectively 5- 200%, open, close, under reflux, in pressurized containers and 20-10000 rpm.

Said chemical composition comprises polyol (and derivatives thereof) of 10 to 80% and/or kaolin clay of 10 to 80% and/or catalyst (and derivatives thereof) of 0.1 to 20% and/or additive (and derivatives thereof) of 0.1 to 20% and/or blowing agent (and derivatives thereof) of 0.1 to 20%, and/or MDI (Iso) of 0.06 to 0.09%.

The content of the chemical providing incombustibility to polyurethane and derivatives thereof is provided in Table 1.

Table-1 : The content of the chemical providing incombustibility to polyurethane and derivatives thereof Catalyst (and derivatives thereof) 0.1 -20%

The invention improves the incombustibility class of the existing PUR foam via enhancing the foam form by means of using the kaolin clay which is a natural mineral. Polyol which is an organic compound comprising more than one hydroxyl group is the main monomer of polyurethane foams. For the present invention, these can be polyether - polyester polyol and derivatives thereof; polyethylene oxide and derivatives thereof, polyethylene glycol and derivatives thereof, polypropylene glycol and derivatives thereof, polyoxy alkylene polyol and derivatives thereof, cyclic ether (epoxides) and derivatives thereof, propylene oxide (PO) and derivatives thereof, ethylene oxide (EO) and derivatives thereof, butanediol and derivatives thereof, polyglycolide and derivatives, poly(tetramethylene)oxide and derivatives thereof, polyethylene adipate and derivatives thereof, polycaprolactone and derivatives thereof, bis(hydroxymethyl) butyric acid and derivatives thereof, polylactic acid, diethylene glycol and derivatives thereof, N,N,N',N',N",N"-hexamethyl-1 ,3,5-triazine-1 ,3,5(2H,4H,6H)-tri-n- propylamine and derivatives thereof, 1 ,1 ',1",1"'-ethylenedinitrolotetrapropan-2-ol and derivatives thereof, tris(2-chlorine-1 -methylethyl)phosphate and derivatives thereof, ethylenediamine, propoxylated and derivatives thereof, formic acid and derivatives thereof.

The minerals inside the kaolin clay of the present invention enters into a cross-linked structure completely after the formation of polyurethane foam by forming a complex with the polyol chains, and act as a barrier when subjected to flame. One of the aims of the invention is to enable upgrading the incombustibility level of the foam to a higher class. Additionally, one of the aims of the invention is to provide safety of life and property in the building by retarding the growth of fire within and around the building by means of fighting the fire in the event of a possible fire thanks to the incombustible PUR filled sandwich panel which is also suitable for fire insulation in buildings.

The catalyst used for adjusting the reaction rate of the polyurethane foam formation of the present invention can be N,N-dimethylcyclohexanamine and derivatives thereof, cyclohexyldimethylamine and derivatives thereof, N,N',N"-tris(dimethylamino-propyl)- hexahydrotriazine and derivatives thereof, N,N,N',N'-tetramethyl-2,2'-oxybis(ethylamine) and derivatives thereof, ethyleneglycol and derivatives thereof, dimethylcyclohexylamine, N,N and derivatives thereof. The additive used for providing the desired level of pores during the polyurethane foam formation of the present invention can be diethylene glycol and derivatives thereof and triethyl phosphate and derivatives thereof.

The blowing agent used for providing the intensity related volume during the synthesis of the polyurethane foam of the present invention can be n-pentane and derivatives thereof, carbondioxide and derivatives thereof and nitrogen and derivatives thereof.

MDI (Iso) which is the cross-linker used for the polyurethane foam formation of the present invention can be isophorone, diisocyanate and derivatives thereof, 1 ,6-diisocyanatohexane and derivatives thereof, 1 ,4-diisocyanatobutane and derivatives thereof, dicyclohexylmethane diisocyanate and derivatives thereof, lysine methyl ester diisocyanate and derivatives thereof, 4,4- diphenylmethane diisocyanate and derivatives thereof and toluene diisocyanate and derivatives thereof. This will be more cost-effective for kaolin-doped polyol as the it can be used at lower rates.

Industrial Applicability of the Invention

The PUR foam of the present invention provides safety of life and property in the building by retarding the growth of fire within and around the building by means of fighting the fire in the event of a possible fire thanks to the incombustible PUR filled sandwich panel which is also suitable for fire insulation in buildings. The present invention is useful for insulation materials and construction sector thanks to the feature mentioned above.

The invention is not limited to the exemplary embodiments and other different embodiments can easily be envisaged by a person skilled in the art. These should be deemed in the scope of the protection claimed by the claims of the invention.