Binder composition suitable to produce a foamed molded body

Abstract

5 The present invention relates to a binder composition suitable to produce a foamed molded body. In particular, the present invention relates to binder compositions comprising (a) an inorganic binder, (b) a foaming agent, (c) a dispersant and (d) an antifoaming agent selected from a specific phosphoric ester, wherein the phosphoric ester can also be 0 covalently bound to the dispersant (c). The present invention further relates to a hardened foamed molded body obtainable from a binder composition according to the invention. Further a composition comprising the antifoaming agent in combination with the dispersant and the use of the antifoaming agent to enhance the compressive strength of the hardened foamed molded body is disclosed.

Description

[0001] BASF SE 240544W001

[0002] 1

[0003] Binder composition suitable to produce a foamed molded body

[0004] The present invention relates to a binder composition suitable to produce a foamed molded body. In particular, the present invention relates to binder compositions comprising (a) an inorganic binder, (b) a foaming agent, (c) a dispersant and (d) an antifoaming agent selected from a specific phosphoric ester, wherein the phosphoric ester can also be covalently bound to the dispersant (c). The present invention also relates to a hardened foamed molded body obtainable from a binder composition according to the invention. Further, the antifoaming agent in combination with the dispersant and the use of the antifoaming agent to enhance the compressive strength of the hardened foamed molded body is disclosed.

[0005] Calcium sulfate hemihydrate is an important building material used for the preparation of mortars, screeds, casting molds, and particularly gypsum boards and wallboards, also termed sheetrock or drywall. Due to technical requirements, considerably varying properties are demanded of calcium sulfate binders. Particularly if a binder composition with high fluidity is desired, dispersants are indispensable.

[0006] Gypsum board is the generic name for a family of panel products that consist of a noncombustible core, composed primarily of gypsum, and a paper surfacing on the face, back and optionally along the edges. Gypsum board is the umbrella term describing one of several building materials and is also called drywall, wallboard, plasterboard, sheetrock or dryrock. All gypsum boards contain gypsum cores; however, they can be faced with a variety of different materials, including but not limited to paper, fabric, fiberglass mats and other materials.

[0007] To produce gypsum board, the calcined gypsum is mixed with water and additives to form a slurry that is fed between continuous layers of sheet, such as paper, on a board machine. The term gypsum slurry as used herein refers to pastes, mortars or grouts with a certain water content that typically contain gypsum in its various forms, fine aggregates or fillers like usually sand or limestone, in some cases setting materials selected form cement, latent cement, pozzolanes and other formulation additives to the aqueous gypsum slurry selected from retarders, accelerators, foaming and / or anti-foaming agents, non-shrink agents, workability agents, pigments, stabilizers, hydrophobizing agents, rheology modifiers etc. As the board moves down a conveyer line, the calcium sulfate recrystallizes or rehydrates, chemically combining with the water that was removed during calcination and reverts to its original rock state. The sheet paper becomes chemically and mechanically bonded to the core. The board is then cut to length and conveyed through dryers to remove any free moisture. Such gypsum boards are used on a large scale in the building industry in particular for interior walls, ceilings, and roofs.

[0008] Of significance is the acceleration of setting in the production of gypsum slabs and the reduction of matrix material to reduce weight for ease of handling, especially of gypsum board. At present, more than 8,000 million m2of gypsum board per year are produced globally. The production of gypsum board has long been known. It is described, for example, BASF SE 240544W001

[0009] 2 in US Patent 4,009,062. The settable gypsum slurry composed of calcium sulfate hemihydrate and water used is typically produced in a flow mixer at high speed and as explained above, applied continuously to a cardboard sheet and covered with a second piece of cardboard sheet. The two cardboard sheets are referred to as the front and back sheets. The line of boards then moves along what is called a setting belt and an almost complete conversion of the settable calcium sulfate phases to calcium sulfate dihydrate must have taken place at the end of the setting belt. After this hardening, the sheet is individualized into boards and the water still present in the boards is removed in heated multistage dryers.

[0010] In order to meet rising demand and to minimize production costs, efforts are constantly being made to improve the production process. Modern plants for fabrication of gypsum slabs can reach manufacturing rates of up to 180 meters per minute. The greatest possible exploitation of the plant capacity is possible only through the use of high-efficiency additives. The setting time of the calcium sulfate hemihydrate determines the time until the gypsum plasterboard can be cut and hence the length and the speed of the conveyor belt, and ultimately the production rate. In addition, the hydration has to be complete before the boards are exposed to high temperatures in the dryer. Otherwise, the strength potential of the binder is inadequately utilized and the risk of volume expansion arises as a result of post-hydration on ingress of moisture.

[0011] One method of controlling the density of the product is by the addition of a soap-based foam to the liquid slurry. Conventionally, pre-generated foam is added to gypsum slurry in the manufacturing process of gypsum boards to prepare light-weight wallboards thereby reducing the amount of gypsum and substantially reducing material costs (WO 2012 / 122102; US 2006 / 0162839). The stucco then sets around the foam bubbles, creating voids in the gypsum matrix. It is important to control the size of the bubbles to avoid undesirable properties in the panels. If the bubbles are too small, a large number of small bubbles are needed to effect the change in density. Where there are lots of bubbles in a confined space, the resulting gypsum matrix has a low compressive strength. Bubbles that are too large tend to blister and thus are not able to keep air in the product to reduce gypsum product density. Moreover, blisters lead to surface defects. Thus, it has been found that if the gypsum is formed having not too small and homogeneous void sizes, it is possible to produce a building panel that is both strong and free of surface defects (cf.

[0012] US 5,643,510 A, US 5,085,929 A).

[0013] US8344084 relates to a liquid admixture composition for a calcium sulfate binder system containing composition comprising an aqueous composition comprising a) a copolymeric dispersing component, b) an antifoaming agent component, c) a surfactant component, and d) water. However, US8344084 is not related to foamed products at all.

[0014] US6139623 disclose an emulsion admixture for use in hydraulic cement compositions formed by emulsifying an antifoaming agent being selected from the group consisting of (i) a phosphate ester having the formula P(O)(O-R)3wherein P represents phosphorus, O represents oxygen, and R represents a C2-C20alkyl group; (ii) a borate ester; and (iii) a BASF SE 240544W001

[0015] 3 polyoxyalkylene copolymer having defoaming properties, a surfactant, said surfactant comprising (i) an esterified fatty acid ester of a carbohydrate selected from the group consisting of a sugar, sorbitan, a disaccharide, and a polysaccharide; (ii) a C2-C20alcohol having polyoxyalkylene groups; or (iii) a mixture thereof and a comb polymer having a carbon-containing backbone to which are attached cement-anchoring members and oxyalkylene groups. A method of making a stable emulsion admixture comprising the comb polymer, as well as a hydraulic cement composition comprising the admixture, are also described. US6139623 is not related to foamed products at all.

[0016] WO 2012 / 049077 also published as EP 2 627 708 Bl discloses a formulation containing at least one component having dispersing properties and selected from the group consisting of a compound at least containing a branched comb polymer having polyether side chains, a naphthalene sulfonate-formaldehyde condensate (“NSF") and a melamine sulfonateformaldehyde condensate (“MSF"), and b) a polycondensation product containing (I) at least one structural unit with an aromatic or heteroaromatic sub-unit and at least one polyether side chain, and (II) at least one phosphatized structural unit with an aromatic or heteroaromatic sub-unit, and (III) at least one structural unit with an aromatic or heteroaromatic sub-unit, the formulation being suitable as admixture for a hydraulic binder and preferably a calcium sulfate binder system containing composition. In one embodiment the composition further comprises an antifoaming agent selected from trialkyl phosphate, polyoxypropylene copolymer and / or glycerol / alcohol acetate, and more preferably triisobutylphosphate. In a further embodiment, the antifoaming agent is a phosphoric ester having the formula P(O)(O-R8)8.X(O-R9)Xwherein P represents phosphorus, O represents oxygen, and R8and R9are independently a C2-C20alkyl or an aryl group, and x = 0, 1, 2, whereby an alkyl group with C2-C8is preferred. Since R8and R9exclusively represent alkyl or aryl groups, WO 2012 / 049077 only discloses trialkyl phosphates.

[0017] US2014 / 0073711 discloses a gypsum slurry comprising calcium sulfate, a dispersant, a foaming agent, a polycondensation product containing (I) at least one structural unit with an aromatic or heteroaromatic sub-unit and at least one polyether side chain, and (II) at least one phosphatized structural unit with an aromatic or heteroaromatic sub-unit, and (III) at least one structural unit with an aromatic or heteroaromatic sub-unit. In one embodiment the composition further comprises a antifoaming agent, wherein also a phosphoric ester having the formula P(O)(O-R8)8.X(O-R9)Xwherein P represents phosphorus, O represents oxygen, and R8and R9are independently a C2-C20alkyl or an aryl group, and x = 0, 1, 2, whereby an alkyl group with C2-C8is preferred. Since R8and R9exclusively represent alkyl or aryl groups, US2014 / 0073711 only discloses trialkyl phosphates.

[0018] One object of the present invention is to provide a binder composition that is suitable to form foamed slurries with coarse pore structure by using state-of-the-art foaming agents and dispersants and thereby provide a hardened foamed molded body having improved compressive strength.

[0019] It has been surprisingly found that the above-mentioned object can be solved by a binder composition suitable to produce a foamed molded body, comprising: BASF SE 240544W001

[0020] (a) an inorganic binder;

[0021] (b) a foaming agent;

[0022] (c) a dispersant;

[0023] (d) an antifoaming agent selected from a phosphoric ester

[0024] (i) having the formula (IX)

[0025] O=P(O-R1)3.X(O-R2)X(IX) wherein

[0026] P represents phosphorus,

[0027] 0 represents oxygen,

[0028] R1is selected from linear or branched C5-C20alkyl or an aryl group,

[0029] R2is H and x = 1 or 2, or

[0030] (ii) having the formula (X)

[0031] O=P(O-R1)(O-R2)(O-R3) (X) wherein

[0032] P represents phosphorus,

[0033] 0 represents oxygen,

[0034] R1is H or is selected from a linear or branched C5-C20alkyl or an aryl group, R2is H,

[0035] R3selected from linear or branched C5-C20alkylene or an arylene group, and wherein the antifoaming agent of formula (X) is covalently bound to the dispersant (c) via R3.

[0036] The inventors surprisingly found that a binder composition according to the invention overcomes the problem of the prior art systems applying state-of-the-art dispersants in foamed gypsum slurries. The binder composition according to the invention provides a coarse pore geometry, wherein the antifoaming agent according to the invention leads to more desired pores. Further, it was surprisingly found that the antifoaming agent further improves the dispersing effect of the state-of-the-art dispersants.

[0037] Brief description of the drawings

[0038] Figure 1 shows a picture of the air pore structures of hardened gypsum mixtures of Example 1 (Inventive Example 1 (bottom picture, D2EH PA sample, large pores) and Reference 1 (top picture, small pores))

[0039] Figure 2 shows a picture of the air pore structures of hardened gypsum mixtures of Example 2 (Comparative Example 2 (top picture, TiBP sample, smaller pores) and Inventive Example 2 (bottom picture, D2EHPA sample, larger pores)) BASF SE 240544W001

[0040] 5

[0041] Figure 3 shows a picture of the air pore structures of hardened gypsum mixtures of Example 3 (Reference 3 (top picture, small pores) and Inventive Example 3 (bottom picture, M2EHPA sample, larger pores))

[0042] Figure 4 shows a picture of the air pore structures of hardened gypsum mixtures of Example 4 (Comparative Example 4 (top picture, TiBP sample, small pores) and Inventive Example 3 (bottom picture, D2EHPA sample, larger pores))

[0043] Figure 5 shows a picture of the air pore structures of hardened gypsum mixtures of Example 5 (Reference 5 (top picture, large pores) and

[0044] Inventive Example 5 (bottom picture, D2PEHA sample, very large pores))

[0045] Figure 6 shows a picture of the air pore structures of hardened gypsum mixtures of Example 6 (Reference 6 (top picture, small pores) and Inventive Example 6 (bottom picture, M2EHPA sample, larger pores than reference))

[0046] Figure 7 shows a picture of the air pore structures of hardened gypsum mixtures of Example 7 (Reference 7 (top picture, small to medium pores) and Inventive Example 7 (bottom picture, D2PEHA sample, large pores))

[0047] Figure 8 shows a picture of the air pore structures of hardened gypsum mixtures of Reference 9

[0048] Figure 9 shows a picture of the air pore structures of hardened gypsum mixtures of Example 9

[0049] Figure 10 shows a picture of the air pore structures of hardened gypsum mixtures of Inventive Example 9

[0050] Figure 11 shows a picture of the air pore structures of hardened gypsum mixtures of Reference 10

[0051] Figure 12 shows a picture of the air pore structures of hardened gypsum mixtures of Inventive Example 10

[0052] In a preferred embodiment, the inorganic binder (a) is selected from the group consisting of gypsum, cement and mixtures thereof.

[0053] In the context of the present invention, the term “gypsum” relates to the compound calcium sulfate in its anhydrous or hydrated form, for example gypsum rock, consisting of this compound in crystalline form, and the corresponding building material such as calcium sulfate hemihydrate, dihydrate, or anhydrite of the formula CaSO4x H2O where x is 0, 2 or 2, or mixtures of these.

[0054] In a preferred embodiment, the gypsum is selected from the group consisting of natural gypsum, calcium sulfate, calcined gypsum, calcium sulfate hemihydrate, calcium sulfate anhydrite, plaster of Paris, synthetic gypsum, preferably formed as a by-product of flue gas desulfurization, or recycled gypsum.

[0055] In the context of the present invention, the term “recycled gypsum” relates to gypsum that has already been used in the production of gypsum-containing articles and has been recovered from said articles. BASF SE 240544W001

[0056] 6

[0057] In one embodiment, the recycled gypsum is recycled from at least one compound selected from the group consisting of stucco gypsums, mortar gypsums, machine gypsum plasters, plastering gypsums, bonding gypsums, jointing gypsums, filling gypsums, insulating gypsums, flooring gypsums, ready-mixed plaster gypsums, imitation marbles and gypsumcontaining ready-made structural components. Additionally, the recycled gypsum may comprise siloxanes, wax emulsions, or combinations thereof.

[0058] Recycled gypsum generally comprises the additives present in the gypsum-containing articles that are integrated into the production process. For example, hydrophobized gypsum plasterboard panels that are used for wet room finishing including siloxanes or wax emulsions.

[0059] The term “cement” as used herein denotes a cement in accordance with the CEM classification as set forth for example in DIN EN 197-1. A preferred cement is ordinary Portland cement (OPC) according to DIN EN 197-1, which may either contain calcium sulfate (< 7 wt.-%) or is essentially free of calcium sulfate (< 1 wt.-%). Another preferred cement is sulfoaluminate cement (calcium sulfoaluminate cement, CSA) or high alumina cement (HAC) according to DI N EN 14647 or a mixture of ordinary Portland cement and aluminate cement, in particular a mixture of ordinary Portland cement and high alumina cement or a mixture of ordinary Portland cement and sulfoaluminate cement or a mixture of ordinary Portland cement, high alumina cement, and sulfoaluminate cement.

[0060] In a preferred embodiment, the foaming agent (b) comprises at least one compound selected from the group consisting of an alkyl sulfate, an alkyl ether sulfate, alkyl polyglycoside, a betaine, a glutamate, a sulfo ketone, an alkyl aryl, an alkyl ether, an alkyl aryl ether, an alkyl ether an isethionate, a N-acylamino acid compound, a sulfoacetate, a sulfonate, a sulfosuccinate, a taurate, an alkanolamide, an amine oxide, a carboxylate, a cationic polymer, a silicone, an alcohol, a protein derivative, and mixtures thereof.

[0061] In a particularly preferred embodiment, the foaming agent (b) comprises at least one compound selected from the group consisting of an alkyl sulfate, an alkyl ether sulfate, olefin sulfonate, alkylbenzene sulfonates, alkyl polyglycoside, alkylamido betaines, alkyl ethoxylates, protein hydrolysates, and mixtures thereof.

[0062] Preferred alkyl polyglycosides are compounds according to formula (I I).

[0063] R5-O- [G]P(II) where R5is a linear or branched alkyl and / or alkylene radical having 8 to 18 carbon atoms, G is a sugar residue having 5 or 6 carbon atoms, preferably G is glucose, and p is numbers from 1 to 10.

[0064] Preferred betaines are alkylamido betaines according to formula (I II).

[0065] R6-CO-N H-(CH2)y-N+(CH3)2-CH2-COO_(I II) BASF SE 240544W001

[0066] 7 where R6is a linear or branched alkyl or alkylene radical having 7 to 19 carbon atoms and y is an integer in the range of 2 to 4.

[0067] Also preferably carboxylates are alkyl ethoxylates.

[0068] Preferably, the alkyl ether is selected from the group consisting of poly(ethyleneoxide) alkyl ether, poly(oxypropylene) alkyl ether, (poly(ethylen-neoxide) alkyl ether, and poly(propyleneoxide) alkyl ether.

[0069] N-acylamino acid compounds are preferably N-acylglutamic acid compounds according to formula (IV).

[0070] M1OOC-CH2-CH2-CH(N H-CO-R7)-COOM2(IV) where R7is a linear or branched alkyl or alkylene radical having 7 to 19 carbon atoms and the M1and M2radicals are independently selected from the group consisting of H, Li, Na, K, Ca / 2, Mg / 2, ammonium and alkanolamines.

[0071] Protein derivatives are preferably protein hydrolysates.

[0072] Alkyl sulfates comprise linear or branched alkyl sulfates. Linear or branched alkyl sulfate are known in the art.

[0073] Exemplary embodiments of linear or branched alkyl sulfate are compounds of the formula (V):

[0074] R8-OSO3'M+(V) where R8is a linear and / or branched hydrocarbon moiety having a maximum molecular weight of 253, preferably a linear or branched alkyl group containing 2 to 20 carbon atoms, more preferably 6 to 18 carbon atoms; and M is a monovalent cation including at least one selected from sodium, potassium, lithium, magnesium ammonium and mixture thereof.

[0075] Preferably, the alkyl sulfate is an alpha-sulfo fatty acid disalt. More preferably, the alphasulfo fatty acid disalt is a compound of the formula (VI)

[0076] R9CH(SO3M8)COOM4(VI) where R9is a linear or branched alkyl or alkylene radical having 6 to 16 carbon atoms and M8and M4are independently H, Li, Na, K, Ca / 2, Mg / 2, ammonium or alkanolamine. Particularly preferred alkanolamines here are monoethanolamine, diethanolamine, triethanolamine and monoisopropanolamine.

[0077] A further proviso applicable is that the alpha-sulfo fatty acid disalt comprises 3 wt.-% or less based on the total weight of the alpha-sulfo fatty acid salt of a compound according to formula (VI), in which the R9radical is an alkylene radical.

[0078] Preferably, R9is a saturated linear alkyl radical having 8 to 16 carbon atoms, more preferably 9 to 16 carbon atoms, especially preferably 10 to 12 carbon atoms.

[0079] More preferably, the proviso is applicable that the alpha-sulfo fatty acid disalt comprises 90% by weight or more, based on the total weight of the alpha-sulfo fatty acid salt of a compound according to formula (VI), in which the R9radical is a decyl and / or dodecyl radical. BASF SE 240544W001

[0080] 8

[0081] More preferably, M3and M4are Na.

[0082] Accordingly, the alpha-sulfo fatty acid disalt is especially preferably the disodium salt of 2- sulfododecanoic acid, the disodium salt of 2-sulfotetradecanoic acid, or a mixture thereof. Most preferably, the alpha-sulfo fatty acid disalt is a mixture of the disodium salt of 2- sulfododecanoic acid and the disodium salt of 2-sulfotetradecanoic acid.

[0083] The compounds of the formula (VI) can be prepared by any relevant methods known to those skilled in the art. An especially preferred method of preparation is the sulfonation of the corresponding carboxylic acids. Such a preparation method involves reacting the corresponding carboxylic acid, especially the corresponding fatty acid, with gaseous sulfur trioxide, preferably in a molar ratio of SO3to fatty acid in the range of from 1.0:1 to 1.1:1. The crude products thus obtained, which are acidic sulfonation products, are then partially or fully neutralized, preferably fully neutralized with aqueous NaOH.

[0084] In a preferred embodiment, the foaming agent (b) comprises at least 50 wt.-% with respect to the total weight of the foaming agent (b), preferably 60 wt.-%, and more preferably 70 wt.-%, of a compound selected from the group consisting of an alkyl sulfate, an alkyl polyglycoside, and a mixture thereof.

[0085] In a preferred embodiment, the antifoaming agent (d)(i) and the foaming agent (b) are present in the composition in a ratio ((d) (i):(b)) in the range of from 1:1000 to 2:1, preferably in a range of from 1:500 to 1:1, more preferably in a range of from 1:200 to 1:2, even more preferably in a range of from 1:150 to 1:3, and particularly preferably in a range of from 1:10 to 1:5.

[0086] In one embodiment, the composition further comprises a surfactant (e) selected from the group consisting of a styrene / maleic acid copolymer, an alcohol alkoxylate, an acetylenic diol, a monoalkylpolyalkylene, an alkylethersulfonate, and an alkyl ether carboxylate. Preferably, the alcohol alkoxylate is an alcohol ethoxylate R10-(EO)-H with R10being an aliphatic hydrocarbon group having from 1 to 25 carbon atoms or, an ethoxylated nonylphenol.

[0087] Preferably, the surfactant (e) is present in an amount of 0.00002 to 0.20 wt.-%, more preferably 0.0001 to 0.10 wt.-% based on the total weight of the binder composition.

[0088] When the surfactant (e) is present in the binder composition of the invention, the air bubble size of the binder composition can be further advantageously adjusted. Furthermore, the antifoaming agent is stabilized by the presence of the surfactant (e).

[0089] The dispersant (c) according to the invention is preferably selected from

[0090] (i) polyaryl ether polymers,

[0091] (ii) polycarboxylate ether polymers,

[0092] (iii) polyphosphate ether polymers or polyphosphonate ether polymers, and

[0093] (iv) sulfonate group containing polymers.

[0094] The dispersant (c) according to the invention preferably comprises at least two monomer units. It may also, however, be advantageous to use copolymers having three or more monomer units. BASF SE 240544W001

[0095] 9

[0096] In one preferred embodiment, the ether-group of the dispersant (c) are selected from (i), (ii) or (iii) are represented by the structural unit (I),

[0097] *-U-(C(O))k-X-(AlkO)n-W (I) where

[0098] * indicates the bonding site to the polymer,

[0099] U is a chemical bond or an alkylene group having 1 to 16 carbon atoms,

[0100] X is oxygen, sulfur or a group N R1, k is 0 or 1, n is an integer whose average value based on the polymer is in the range from 3 to 300,

[0101] Aik is C2-C4alkylene, it being possible for Aik to be identical or different within the group

[0102] (Alk-O)n,

[0103] W is a hydrogen, a Cj-Ce alkyl or an aryl radical or is the group Y-F, where

[0104] Y is a linear or branched alkylene group having 2 to 8 carbon atoms and may carry a phenyl ring,

[0105] F is a 5- to 10-membered nitrogen heterocycle which is bonded via nitrogen and which as ring members, besides the nitrogen atom and besides carbon atoms, may have 1, 2 or 3 additional heteroatoms, selected from oxygen, nitrogen, and sulfur, it being possible for the nitrogen ring members to have a group R2, and for 1 or 2 carbon ring members to be present in the form of a carbonyl group,

[0106] R1is hydrogen, Cx-C4alkyl or benzyl, and

[0107] R2is hydrogen, Cj-C4alkyl or benzyl.

[0108] With particular preference, the dispersant c) of the invention comprises at least one group from the series of carboxyester, carboxyl, phosphono, sulfino, sulfo, sulfamido, sulfoxy, sulfoalkyloxy, sulfinoalkyloxy, and phosphonooxy group.

[0109] With more particular preference, the water-soluble polymeric dispersant of the invention comprises an acid group.

[0110] The term “acid group” is understood in the present specification to refer both to the free acid and to the salts thereof. The acid may preferably be at least one from the series of carboxyl, phosphono, sulfino, sulfo, sulfamido, sulfoxy, sulfoalkyloxy, sulfinoalkyloxy, and phosphonooxy group. Particularly preferred are carboxyl and phosphonooxy groups.

[0111] In one particularly preferred embodiment, at least one dispersant (c) (i) represents a polycondensation product comprising

[0112] (II) a structural unit comprising an aromatic or heteroaromatic group and the polyether group, and

[0113] (III) a phosphated structural unit comprising an aromatic or heteroaromatic group. BASF SE 240544W001

[0114] 10

[0115] The structural units (II) and (III) are preferably represented by the following general formulae

[0116] (II) A-U-(C(O))k-X-(AlkO)n-W where

[0117] A is identical or different and is represented by a substituted or unsubstituted, aromatic or heteroaromatic compound having 5 to 10 carbons in the aromatic system, the other radicals possessing the definition stated for structural unit (I);

[0118] (III) where

[0119] D is identical or different and is represented by a substituted or unsubstituted, aromatic or heteroaromatic compound having 5 to 10 carbons in the aromatic system.

[0120] Furthermore, E is identical or different and is represented by N, NH or O, m = 2 if E = N and m = 1 if E = N H or O.

[0121] R3and R4independently of one another are identical or different and are represented by a branched or unbranched Cxto C10alkyl radical, C5to C8cycloalkyl radical, aryl radical, heteroaryl radical or H, preferably by H, methyl, ethyl or phenyl, more preferably by H or methyl, and especially preferably by H. Furthermore, b is identical or different and is represented by an integer from 0 to 300. If b = 0, E = O. More preferably D = phenyl, E = 0, R3and R4= H, and b = 1.

[0122] The polycondensation product preferably comprises a further structural unit (IV) which is represented by the following formula

[0123] (IV) where

[0124] Y independently at each occurrence is identical or different and is represented by (II), (III) or further constituents of the polycondensation product. BASF SE 240544W001

[0125] 11

[0126] R5and R6are preferably identical or different and represented by H, CH3, COOH or a substituted or unsubstituted, aromatic or heteroaromatic compound having 5 to 10 carbons. R5and R6here in structural unit (IV) are independently of one another preferably represented by H, COOH and / or methyl.

[0127] In one particular preferred embodiment, R5and R6are represented by H.

[0128] The molar ratio of the structural units (II), (III), and (IV) in the phosphated polycondensation product of the invention may be varied within wide ranges. It has proven useful for the molar ratio of the structural units [(II) + (III)]: (IV) to be 1:0.8 to 3, preferably 1:0.9 to 2, and more preferably 1:0.95 to 1.2.

[0129] The molar ratio of the structural units (II): (III) is normally 1:10 to 10:1, preferably 1:7 to 5:1, and more preferably 1:5 to 3:1.

[0130] The groups A and D in the structural units (II) and (III) in the polycondensation product are usually represented by phenyl, 2-hydroxyphenyl, 3-hydroxyphenyl, 4-hydroxyphenyl, 2- methoxyphenyl, 3-methoxyphenyl, 4-methoxyphenyl, naphthyl, 2-hydroxynaphthyl, 4-hydroxynaphthyl, 2-methoxynaphthyl, 4-methoxynaphthyl, preferably phenyl, and A and D may be selected independently of one another and may also each consist of a mixture of the stated compounds. The groups X and E are represented independently of one another preferably by O.

[0131] Preferably, n in structural unit (I) is represented by an integer from 5 to 280, more particularly 10 to 160, and very preferably 12 to 120, and b in structural unit (III) is represented by an integer from 0 to 10, preferably 1 to 7, and more preferably 1 to 5. The representative radicals whose length is defined by n and b may consist here of uniform structural groups, though it may also be useful for them to comprise a mixture of different structural groups. Furthermore, the radicals of the structural units (II) and (III) may independently of one another each have the same chain length, with n and b in each case being represented by one number. In general, however, it will be useful for these each to be mixtures having different chain lengths, and so the radicals of the structural units in the polycondensation product have different numerical values for n and, independently for b.

[0132] In one particular embodiment, the present invention further envisages a sodium, potassium, ammonium and / or calcium salt, and preferably a sodium and / or potassium salt, of the phosphated polycondensation product.

[0133] The phosphated polycondensation product of the invention frequently has a weight-average molecular weight of 5000 g / mol to 150 000 g / mol, preferably 10 000 to 100 000 g / mol, and more preferably 20 000 to 75 000 g / mol.

[0134] With regard to the phosphated polycondensation products for preferred use in accordance with the present invention, and to their preparation, reference is additionally made to patent applications WO 2006 / 042709 and WO 2010 / 040612, the content of which is hereby incorporated into the specification. BASF SE 240544W001

[0135] 12

[0136] In a further preferred embodiment, the polycarboxylate ether polymer (c) (ii) is a copolymer which is obtainable by polymerizing a mixture of monomers comprising

[0137] (V) at least one ethylenically unsaturated monomer which comprises at least one radical from the series of carboxylic acid, carboxylic salt, carboxylic ester, carboxylic amide, carboxylic anhydride, and carboxylic imide and

[0138] (VI) at least one ethylenically unsaturated monomer comprising a polyether group, the polyether group being represented preferably by the structural unit (I).

[0139] The copolymers in accordance with the present invention contain at least two monomer units. It may, however, also be advantageous to use copolymers having three or more monomer units.

[0140] In one preferred embodiment, the ethylenically unsaturated monomer (V) is represented by at least one of the following general formulae from the group of (Va), (Vb), and (Vc):

[0141] In the monocarboxylic or dicarboxylic acid derivative (Va) and in the monomer (Vb) present in cyclic form, where Z = 0 (acid anhydride) or NR16(acid imide), R7and R8independently of one another are hydrogen or an aliphatic hydrocarbon radical having 1 to 20 carbons, preferably a methyl group. B is H, -COOMa, -CO-O(CqH2qO)r-R9, -CO-NH-(CqH2qO)r-R9.

[0142] M is hydrogen, a mono- or di- or trivalent metal cation, preferably sodium, potassium, calcium or magnesium ion, or else ammonium or an organic amine radical, and a = 1 / 3, 1 / 2 or 1, according to whether M is a mono-, di- or trivalent cation. Organic amine radicals used are preferably substituted ammonium groups which derive from primary, secondary or tertiary alkylamines, alkanolamines, C5.8cycloalkylamines, and C6.14arylamines. Examples of the corresponding amines are methylamine, dimethylamine, trimethylamine, ethanolamine, diethanolamine, triethanolamine, methyldiethanolamine, cyclohexylamine, dicyclohexylamine, phenylamine, diphenylamine in the protonated (ammonium) form.

[0143] R9is hydrogen, an aliphatic hydrocarbon radical having 1 to 20 carbons, a cycloaliphatic hydrocarbon radical having 5 to 8 carbons, an aryl radical having 6 to 14 carbons, this radical optionally being substituted as well, q = 2, 3 or 4 and r = 0 to 200, preferably 1 to 150. The aliphatic hydrocarbons here may be linear or branched and also saturated or unsaturated. Preferred cycloalkyl radicals are cyclopentyl or cyclohexyl radicals, and preferred aryl radicals are phenyl or naphthyl radicals, which in particular may also be substituted by hydroxyl, carboxyl or sulfonic acid groups. BASF SE 240544W001

[0144] 13

[0145] Furthermore, Z is 0 or NR16, where R16independently of each occurrence is identical or different and is represented by a branched or unbranched Cxto C10alkyl radical, C5to C8cycloalkyl radical, aryl radical, heteroaryl radical or H.

[0146] The following formula represents the monomer (Vc):

[0147] In this formula, R10and R11independently of one another are hydrogen or aliphatic hydrocarbon radical having 1 to 20 carbons, a cycloaliphatic hydrocarbon radical having 5 to 8 carbons, an optionally substituted aryl radical having 6 to 14 carbons.

[0148] Furthermore, R12is identical or different and is represented by (CnH2n)-SO3H with n = 0, 1, 2, 3 or 4, (CnH2n)-OH with n = 0, 1, 2, 3 or 4; (CnH2n)-PO3H2with n = 0, 1, 2, 3 or 4, (CnH2n)- OPO3H2with n= 0, 1, 2, 3 or 4, (C6H4)-SO3H, (C6H4)-PO3H2, (C6H4)-OPO3H2and (CnH2n)-NR14bwith n = 0, 1, 2, 3 or 4 and b by 2 or 3.

[0149] R13is H, -C00Ma, -CO-O(CqH2qO)r-R9, -CO-N H-(CqH2qO)r-R9, where Ma, R9, q and r possess the definitions stated above.

[0150] R14is hydrogen, an aliphatic hydrocarbon radical having 1 to 10 carbons, a cycloaliphatic hydrocarbon radical having 5 to 8 carbons, an optionally substituted aryl radical having 6 to 14 carbons.

[0151] Furthermore, Q is identical or different and is represented by N H, N R15or O, where R15is an aliphatic hydrocarbon radical having 1 to 10 carbons, a cycloaliphatic hydrocarbon radical having 5 to 8 carbons or an optionally substituted aryl radical having 6 to 14 carbons.

[0152] In one particularly preferred embodiment, the ethylenically unsaturated monomer (VI) is represented by the following general formulae (Via) in which all the radicals having the definitions above. BASF SE 240544W001

[0153] 14

[0154] In a further-preferred embodiment, the ethylenically unsaturated monomer (VI) is represented by the following general formulae (Vlb) where

[0155] R1, R2, R3independently of one another, identically or differently, are H, CH3,

[0156] R4is linear or branched C C^ alkylene,

[0157] R5, R6independently of one another, identically or differently, are H, Cj-C^ alkyl, C3- C15cycloalkyl, aryl, -CH^O-C C^ alkyl, CH2-O-C2-C20alkenyl, and R5and R6may also together form a C3-C6alkylene,

[0158] R7independently at each occurrence, identically or differently, is H, C!-C4alkyl,

[0159] O

[0160] 11R

[0161] — C— R8

[0162] R8is Cj-022 alkyl, C2-C22alkenyl, and n independently at each occurrence, is identical or different and is an integer from 2 to 200.

[0163] In particular, the copolymer has an average molar weight (Mw) of between 5,000 and 150,000 g / mol, more preferably 10,000 to 80,000 g / mol, and very preferably 15,000 to 60,000 g / mol, as determined by gel permeation chromatography.

[0164] The polymers are analyzed for average molar mass and conversion by means of size exclusion chromatography (column combinations: Shodex OH-Pak SB 804 HQ and OH-Pak SB 802.5 HQ from Showa Denko, Japan; eluent: 80 vol% aqueous solution of HCO2NH4(0.05 mol / l) and 20 vol-% MeOH; injection volume 100 pl; flow rate 0.5 ml / min).

[0165] The preparation of the comb polymers which comprise the structural units (V) and (VI) is carried out in a conventional way, for example by free-radical polymerization. It is, for example, described in EP0894811, EP1851256, EP2463314, EP0753488.

[0166] In one preferred embodiment, the polyphosphate ether polymers or polyphosphonate ether polymer (c) (iii) is a copolymer which is obtainable by polymerizing a mixture of monomers comprising

[0167] (VII) at least one ethy lenically unsaturated monomer comprising a structural unit of formula (Vila) BASF SE 240544W001 in which

[0168] Z is OM2for polyphosphate ether polymers or H for polyphosphonate ether polymers

[0169] * indicates the bonding site to the ethylenically unsaturated moiety,

[0170] R1is an alkylene group having 2 to 8 carbon atoms,

[0171] Y is 0 or N R2,

[0172] M1and M2each independently of one another are hydrogen, an ammonium compound and a mono-, di- or trivalent metal

[0173] R2is a radical from the group of hydrogen, an alkyl group having 1 to 8 carbon atoms, and formula (Vllb), where Z, R1, M1and M2possess the definitions stated for formula (Vila),

[0174] (VIII) at least one ethylenically unsaturated monomer comprising the structural unit having the polyether side chain.

[0175] In one preferred embodiment monomer (VII) is represented by at least one ethylenically unsaturated monomer comprising a structural unit of formula (Vile) in which

[0176] R1is an alkylene group having 2 to 8 carbon atoms,

[0177] R3is H or Methyl

[0178] M1and M2each independently of one another are hydrogen, an ammonium compound and a mono-, di- or trivalent metal, preferably sodium or hydrogen.

[0179] Y is 0 or NR2,

[0180] R2is a radical from the group of hydrogen, an alkyl group having 1 to 8 carbon atoms, and formula (A), BASF SE 240544W001

[0181] 16

[0182] O i11i

[0183] — R - O- P-QIM

[0184] OM2( ) in which

[0185] R1, M1and M2possess the definitions stated for formula (Vile)

[0186] The polyphosphate ether polymers according to the invention may further comprise monomers of formula (XX) in which R1, R2, Y and M1possess the definitions stated for formula (Vile).

[0187] The monomer (VIII) is preferably represented by formula (Villa) in which

[0188] R3is hydrogen, an aliphatic hydrocarbon radical having 1 to 16 C atoms, a cycloaliphatic radical having 5 to 12 C atoms or an aryl radical having 6 to 14 C atoms, it being possible for the aryl radical to have further substituents, n is identical or different and in each case is an integer from 2 to 4, m is an integer between 3 and 160, in particular between 50 and 140,

[0189] Z is at least one radical a, b, c, d and e, represented by the formulae (a), (b), (c), (d) and

[0190] (e) below:

[0191] BASF SE 240544W001

[0192] 17 lt is further preferred for the group R1both in monomer (Vila) and in monomer (Vile) to be an ethylene group. More particularly monomer (Vile) may be 2-hydroxyethyl acrylate phosphate, 3-hydroxypropyl acrylate phosphate, 2-hydroxyethylacrylamide phosphate or 3-hydroxypropylacrylamide phosphate. Monomer (XX) may preferably be bis[2-hydroxyethyl acrylate] phosphate, bis[3-hydroxypropylacrylate] phosphate, bis[2-hydroxyethylacrylamide] phosphate or bis[3-hydroxypropylacrylamide] phosphate.

[0193] Monomer (VIII) may very preferably be at least one compound from the series of 3-methylbut-3-en-l-ol-polyethylene glycol with a molar mass of 1000 to 3000 g / mol, 3-methylbut-3-en-l-ol-polypropylene glycol with a molar mass of 1000 to 3000 g / mol, methallyl-polyethylene glycol with a molar mass of 1000 to 3000 g / mol, vinyloxybutylpolyethylene glycol with a molar mass of 1000 to 7000 g / mol, vinyloxybutylpolypropylene glycol with a molar mass of 1000 to 7000 g / mol, allylpolyethylene glycol with a molar mass of 1000 to 3000 g / mol and allylpolypropylene glycol with a molar mass of 1000 to 3000 g / mol.

[0194] Besides the monomers (VII), (VIII) and (XX) there may in principle also be other monomers present in the polymer (c) (iii). Suitable more particularly in this context are all radically polymerizable monomers. In one particularly preferred embodiment the polymer (c) (iii) consists of monomers (VII), (VIII) and (XX).

[0195] The copolymer of the invention preferably fulfills the requirements of the industry standard EN 934-2 (February 2002).

[0196] In one particularly preferred embodiment, at least one dispersant (c) (iv) represents a sulfonate group containing polymer selected from the group consisting of a polynaphthalene sulfonate, a ketone resin, a melamine resin, a lignosulfonate, and mixtures thereof, preferably is naphthalene sulfonate-formaldehyde condensate. Preferably, polynapthalene sulfonates are neutralized by calcium ions. BASF SE 240544W001

[0197] 18

[0198] An especially preferred polynaphtalene sulfonate is ^-naphthalene sulfonate formaldehyde (BNS). A commercially available product is Flube CA 40 available by Bozetto (a calcium salt of polymer of naphthalenesulfonic acids condensed with formaldehyde).

[0199] Preferably, the ketone resin is synthetized from cyclohexanone or acetone and / or mixtures thereof, formaldehyde and sulfite, more preferably cyclohexanone, formaldehyde and sulfite (CFS) as the monomers. Preferably, the CFS-based ketone resin has a molecular weight between 10 000 and 40 000 g / mol, more specifically between 15 000 and 25 000 g / mol. The lignosulfonate is preferably a water-soluble anionic polyelectrolyte polymer. Usually, ligonosulfates are understood as byproducts from the production of wood pulp using sulfite pulping and are known to the person skilled in the art.

[0200] Polynapthalene sulfonates are derivatives of sulfonic acid which contain a naphthalene functional unit and are usually used as plasticizers for inorganic binders. They are produced on a large scale by condensation of naphthalenesulfonate or alkylnaphthalenesulfonates with formaldehyde.

[0201] Melamine resins are resins with melamine rings terminated with multiple hydroxyl groups derived from formaldehyde. Preferred melamine resins are melamine sulfonate / formaldehyde condensation products.

[0202] In one further preferred alternative embodiment the dispersant c) according to the invention is selected from

[0203] (i) polyaryl ether polymers,

[0204] (ii) polycarboxylate ether polymers, and

[0205] (iii) polyphosphate ether polymers or polyphosphonate ether polymers.

[0206] In a preferred embodiment, the antifoaming agent (d) is selected from a phosphoric ester (i) having the formula (IX)

[0207] O=P(O-R1)8.X(O-R2)X(IX) wherein

[0208] P represents phosphorus,

[0209] O represents oxygen,

[0210] R1is selected from linear or branched C8-C16alky group, preferably branched C8-C16alky group,

[0211] R2is H and x = 1 or 2, or

[0212] (ii) having the formula (X)

[0213] O=P(O-R1)(O-R2)(O-R3) (X) wherein

[0214] P represents phosphorus,

[0215] O represents oxygen, BASF SE 240544W001

[0216] 19

[0217] R1is H or is selected from linear or branched C8-C16alkyl or an aryl group, preferably branched C8-C16alky group,

[0218] R2is H,

[0219] R3selected from linear or branched C8-C16alkylene group, and wherein the antifoaming agent of formula (X) is covalently bound to the dispersant c) via R3.

[0220] The antifoaming agent (d) present in the binder composition of the invention allows for larger air bubbles in the binder slurry. Furthermore, by addition of antifoaming agent (d) to the binder composition of the invention, the size of air bubbles in a slurry of water and the binder composition can be advantageously adjusted.

[0221] Advantageously the antifoaming agent (d) (ii) is covalently bound to the dispersant (c). The covalent bond can be formed in the synthesis of the dispersant by polymerization. In this case the alkylene group R3in formula (X) is preferably attached to a polymerizable group. In a further embodiment the antifoaming agent (d) (ii) is grafted to the previously synthesized dispersant. Methods of grafting of monomers to polymers is well known to the skilled person in the art.

[0222] Examples are radical grafting: In this method, the polymer is treated with a radical initiator compound to generate active radicals. These radicals initiate the polymerization of the monomer and allow for the attachment of the monomer to the polymer backbone.

[0223] Anionic grafting: This reaction can be used with polymerizable monomers containing anionic groups. By using a strong base catalyst, the polymer is deprotonated, creating active anionic sites. These anions then react with the monomers, facilitating grafting.

[0224] Cationic grafting: Similar to anionic grafting, this method utilizes an appropriate catalyst to generate cationic sites on the polymer. These cationic sites then react with the monomers, resulting in grafting.

[0225] Grafting through reactivity of functional groups: If the polymer already possesses functional groups that can react with the functional groups of the monomer, these groups can be utilized to enable grafting. Examples include reactions such as esterification, amidation, or thiol-ene reactions.

[0226] In a preferred embodiment the alkylene group R3in formula (X) comprises a functional group that can be reacted with a functional group of the dispersant, preferably the reaction is an esterification or amidation.

[0227] In a further preferred embodiment, the antifoaming agent (d) (i) is selected from octyl phosphate, nonyl phosphate, decyl phosphate, undecyl phosphate, dodecyl phosphate, tridecyl phosphate, tetradecyl phosphate, pentadecyl phosphate, hexadecyl phosphate, 2- ethylhexyl phosphate, isodecyl phosphate, isotridecyl phosphate, isopentadecyl phosphate, isotetradecyl phosphate, isooctyl phosphate, bis(octyl) phosphate, bis(nonyl) phosphate, bis(decyl) phosphate, bis(undecyl) phosphate, bis(dodecyl) phosphate, bis(tridecyl) phosphate, bis(tetradecyl) phosphate, bis(pentadecyl) phosphate, bis(hexadecyl) BASF SE 240544W001

[0228] 20 phosphate, bis(2-ethylhexyl) phosphate, bis(isotridecyl) phosphate, bis(isopentadecyl) phosphate, bis(isotetradecyl) phosphate and bis(isooctyl) phosphate.

[0229] With particular preference, the antifoaming agent (d) (i) is selected from 2-ethyl hexyl phosphate and bis(2-ethyl hexyl) phosphate.

[0230] The binder composition of the present invention may further comprise an additive selected from the group consisting of a set accelerator, a set retarder, an anti-sag agent, a bonding agent, a dedusting agent, a reinforcing material, a biocide, and combinations thereof.

[0231] In a further preferred embodiment of the invention the binder composition comprises, based on the dry weight of the binder composition,

[0232] A) 10 - 99.9 wt.-%, more preferably 50 - 99.9 wt.-%, most preferably 95 - 99.9 wt.-% of (a) an inorganic binder;

[0233] B) 0.00001 - 1 wt.-%, more preferably 0.0001 - 0.1 wt.-%, most preferably 0.005 - 0.05 wt.-% of (b) a foaming agent;

[0234] C) 0.001- 1 wt.-%, more preferably 0.005 - 0.5 wt.-%, most preferably 0.03 - 0.3 wt.- % of (c) dispersant and

[0235] D) 0.00002 to 0.20 wt.-%, more preferably 0.0001 - 0.05 wt.-%, most preferably 0.0005 - 0.01 wt.-% of (d) an antifoaming agent selected from a phosphoric ester having the formula (IX).

[0236] The present invention further relates to a hardened foamed molded body obtainable from a binder composition according to the invention.

[0237] The invention also provides a method for producing a hardened foamed molded body, the method comprising the steps of

[0238] (I) mixing water, the inorganic binder (a), and a dispersant (c) yielding a binder slurry;

[0239] (II) providing a foaming agent (b),

[0240] (III) adding an antifoaming agent (d) (i) to the binder slurry of step (I) and / or the foaming agent of step (II);

[0241] (IV) combining the binder slurry obtained in step (I) and the foaming agent of step (II) yielding a foamed binder slurry;

[0242] (V) forming the foamed binder slurry into an article; and

[0243] (VI) allowing the article to set.

[0244] The invention also provides a further preferred method for producing a hardened foamed molded body, the method comprising the steps of

[0245] (la) mixing water, the inorganic binder (a), and a dispersant (c) comprising the antifoaming agent (d) (ii) or (d) (i) yielding a binder slurry;

[0246] (Ila) providing a foaming agent (b),

[0247] (Illa) combining the binder slurry obtained in step (la) and the foaming agent of step (Ila) yielding a foamed binder slurry;

[0248] (IVa) forming the foamed binder slurry into an article; and

[0249] (Va) allowing the article to set. BASF SE 240544W001

[0250] 21

[0251] In a further embodiment of the method the antifoaming agent is added in an amount to adjust the pore size in the foamed binder product to a predetermined size.

[0252] In order to produce the foamed binder slurry according to the invention, water is used in an amount such that a flowable slurry is obtained. The amount of water to be used varies significantly according to the application in which the foamed binder slurry is used, the nature of the dispersant, the properties of the binder (i.e. stucco or cement) and the additives being used. The water to binder ratio (“WSR”) for gypsum wallboard production is preferably about 0.40 to about 1.20 based on the dry weight of the binder. Commonly a WSR of about 0.45 to about 0.90 is preferred.

[0253] Water used to obtain the slurry should be as pure as practical for best control of the properties of both the slurry and the set plaster. Salts and organic compounds are well known to modify the set time of the slurry, varying widely from accelerators to set inhibitors. Some impurities lead to irregularities in the structure as the interlocking matrix of dihydrate crystals forms, reducing the strength of the set product. Product strength and consistency is thus enhanced by the use of water that is as contaminant-free as practical. Preferably, the water is distilled water.

[0254] The foaming agent of the method of the present invention is the foaming agent (b) as described above.

[0255] In a preferred embodiment, in step (II) or (Ila) the foaming agent (b) is provided in the form of a preformed foam. The foam is pre-generated from an aqueous foaming agent solution. One method of making the foam is using a foam generator that mixes the foaming agent solution with air. Any method of mixing can be used to combine the foaming agent with solution air that causes bubbles to be formed, including agitation, turbulent flow or mixing. The amount of water and air are controlled to generate foam of a particular density. Adjustment of the foam volume is used to control the overall dry product weight.

[0256] In a preferred embodiment, the pore size adjusting agent comprises a surfactant. Preferably, the surfactant of the method of the present invention is the surfactant (e) as described above.

[0257] The method of the invention comprises a step (V) or (IVa) of allowing the article to set. This step is known to the person skilled in the art.

[0258] The method of the present invention comprises a step (VI) or (Va) of forming the foamed binder slurry into an article. The forming of an article from a foamed binder slurry is also known to the person skilled in the art.

[0259] Preferably, the determined size of the pore size of the foamed binder product is in the range of 150-2000 pm, more preferably 200-800 pm. The antifoaming agent is preferably added in an amount of 0.00002 to 0.20 wt.-%, more preferably 0.0001 - 0.05 wt.-% based on the dry weight of the binder composition.

[0260] In one preferred embodiment the present invention also provides a composition comprising, based on the dry weight of the composition,

[0261] 30 - 99.9 wt.-%, more preferably 90 - 99.75 wt.-%, most preferably 95 - 99.5 wt.-% of a dispersant and BASF SE 240544W001

[0262] 22

[0263] 0.1 - 15 wt.-%, more preferably 0.25 - 10 wt.-%, most preferably 0.5 - 5 wt.-% of an antifoaming agent selected from a phosphoric ester (i) having the formula (IX)

[0264] O=P(O-R1)3.X(O-R2)X(IX) wherein

[0265] P represents phosphorus,

[0266] O represents oxygen,

[0267] R1is selected from linear or branched C5-C20alkyl, or an aryl group,

[0268] R2is H and x = 1 or 2, or

[0269] 30 - 100.0 wt.-%, more preferably 90 - 99.75 wt.-%, most preferably 95 - 99.5 wt.-% of a dispersant, wherein the antifoaming agent of formula (X) is covalently bound to the dispersant via R3, wherein formula (X) is represented by the following formula

[0270] O=P(O-R1)(O-R2)(O-R3) (X) wherein

[0271] P represents phosphorus,

[0272] O represents oxygen,

[0273] R1is H or is selected from linear or branched C5-C20alkyl or an aryl group,

[0274] R2is H,

[0275] R3selected from linear or branched C5-C20alkylene or an arylene group.

[0276] The dispersant is preferably selected from

[0277] (i) polyaryl ether polymers,

[0278] (ii) polycarboxylate ether polymers,

[0279] (iii) polyphosphate ether polymers or polyphosphonate ether polymers,

[0280] (iv) sulfonate group containing polymers.

[0281] The invention further relates to the use of an antifoaming agent in an aqueous composition comprising a) an inorganic binder, b) a foaming agent and c) a dispersant, wherein the antifoaming agent is selected from a phosphoric ester

[0282] (i) having the formula (IX)

[0283] O=P(O-R1)3.X(O-R2)X(IX) wherein

[0284] P represents phosphorus,

[0285] O represents oxygen, BASF SE 240544W001

[0286] 23

[0287] R1is selected from linear or branched C5-C20alkyl, or an aryl group, R2is H and x = 1 or 2, or

[0288] (ii) having the formula (X)

[0289] O=P(O-R1)(O-R2)(O-R3) (X) wherein

[0290] P represents phosphorus,

[0291] 0 represents oxygen,

[0292] R1is H or is selected from linear or branched C5-C20alkyl or an aryl group,

[0293] R2is H,

[0294] R3selected from linear or branched C5-C20alkylene or an arylene group, and wherein the antifoaming agent of formula (X) is covalently bound to the dispersant (c) via R3, to enhance the compressive strength of the hardened foamed molded body.

[0295] Owing to their inherently hydrophobic nature, defoamers used in dispersant formulations are generally insoluble. As a result, even advanced formulations — despite the inclusion of emulsifiers — frequently encounter storage stability issues. Unexpectedly, it has now been found that the present invention enables the provision of stable aqueous dispersantdefoamer formulations.

[0296] Therefore, in one further preferred embodiment the present invention also provides an aqueous composition comprising a solubilizer, a dispersant, and an antifoaming agent selected from a phosphoric ester (i) having the formula (IX)

[0297] O=P(O-R1)3.X(O-R2)X(IX) wherein

[0298] P represents phosphorus,

[0299] 0 represents oxygen,

[0300] R1is selected from linear or branched C5-C20alkyl, or an aryl group, R2is H and x = 1 or 2, or an aqueous composition comprising a solubilizer and a dispersant, wherein the antifoaming agent of formula (X) is covalently bound to the dispersant via R3, wherein formula (X) is represented by the following formula

[0301] O=P(O-R1)(O-R2)(O-R3) (X) wherein

[0302] P represents phosphorus, 0 represents oxygen, BASF SE 240544W001

[0303] 24

[0304] R1is H or is selected from linear or branched C5-C20alkyl or an aryl group,

[0305] R2is H,

[0306] R3selected from linear or branched C5-C20alkylene or an arylene group.

[0307] Preferably, the aqueous composition comprises, based on the dry weight of the composition,

[0308] 0.1 - 20 wt.-%, more preferably 0.25 - 15 wt.-%, most preferably 1 - 5 wt.-% of a solubilizer,

[0309] 30 - 99.8 wt.-%, more preferably 75 - 99.5 wt.-%, most preferably 90 - 98.5 wt.-% of a dispersant, and

[0310] 0.1 - 15 wt.-%, more preferably 0.25 - 10 wt.-%, most preferably 0.5 - 5 wt.-% of an antifoaming agent selected from a phosphoric ester (i) having the formula (IX)

[0311] O=P(O-R1)3.X(O-R2)X(IX) wherein

[0312] P represents phosphorus,

[0313] O represents oxygen,

[0314] R1is selected from linear or branched C5-C20alkyl, or an aryl group,

[0315] R2is H and x = 1 or 2, or the aqueous composition comprises 0.1 - 20 wt.-%, more preferably 0.25 - 15 wt.-%, most preferably 1 - 5 wt.-% of a solubilizer and

[0316] 30 - 99.9 wt.-%, more preferably 85 - 99.75 wt.-%, most preferably 95 - 99.0 wt.-% dispersant, wherein the antifoaming agent of formula (X) is covalently bound to the dispersant via R3, wherein formula (X) is represented by the following formula

[0317] O=P(O-R1)(O-R2)(O-R3) (X) wherein

[0318] P represents phosphorus,

[0319] O represents oxygen,

[0320] R1is H or is selected from linear or branched C5-C20alkyl or an aryl group,

[0321] R2is H,

[0322] R3selected from linear or branched C5-C20alkylene or an arylene group.

[0323] In a preferred embodiment the solubilizer is selected from the group of fatty alkyl sulphates, olefin sulfonates and alkylbenzene sulfonates. Specifically preferred are C6-C20fatty alkyl sulphates.

[0324] For these aqueous compositions the dispersant is preferably selected from

[0325] (i) polyaryl ether polymers,

[0326] (ii) polycarboxylate ether polymers and

[0327] (iii) polyphosphate ether polymers or polyphosphonate ether polymers. BASF SE 240544W001

[0328] 25

[0329] This procedure results in a clear solution of the aqueous compositions showing superior temperature and storage stability over long periods (1 year and above) of time.

[0330] In a preferred embodiment the antifoaming agent having the formula (IX) is used in an amount of 0.00002 to 0.20 wt.-%, more preferably 0.0001 - 0.05 wt.-%, most preferably 0.0005 - 0.01 wt.-% based on the dry weight of the hardened foamed molded body.

[0331] In an alternative embodiment dispersant (c), wherein the antifoaming agent of formula (X) is covalently bound to the dispersant c) via R3, is used in an amount of 0.001- 1 wt.-%, more preferably 0.005 - 0.5 wt.-%, most preferably 0.03 - 0.3 wt.-% based on the dry weight of the hardened foamed molded body.

[0332] Furthermore, it has been found that the present invention also enables the formulation of stable aqueous compositions comprising a foaming agent and an antifoaming agent. Accordingly, in another preferred embodiment, the present invention provides an aqueous composition comprising a foaming agent and an antifoaming agent selected from a phosphoric ester (i) having the formula (IX):

[0333] O=P(O-R1)3.X(O-R2)X(IX) wherein

[0334] P represents phosphorus,

[0335] O represents oxygen,

[0336] R1is selected from linear or branched C5-C20alkyl, or an aryl group, R2is H and x = 1 or 2.

[0337] Preferably, the aqueous composition comprises, based on the dry weight of the composition,

[0338] 30 - 99.99 wt.-%, more preferably 50 - 99.9 wt.-%, most preferably 75 - 99.8 wt.-% of a foaming agent, and

[0339] 0.01 - 70 wt.-%, more preferably 0.1 - 50 wt.-%, most preferably 0.2 - 25 wt.-% of an antifoaming agent selected from a phosphoric ester (i) having the formula (IX)

[0340] O=P(O-R1)3.X(O-R2)X(IX) wherein

[0341] P represents phosphorus,

[0342] O represents oxygen,

[0343] R1is selected from linear or branched C5-C20alkyl, or an aryl group, R2is H and x = 1 or 2.

[0344] In a preferred embodiment the foaming agent comprises at least one compound selected from the group consisting of an alkyl sulfate, an alkyl ether sulfate, olefin sulfonate, BASF SE 240544W001

[0345] 26 alkylbenzene sulfonates, alkyl polyglycoside, alkylamido betaines, alkyl ethoxylates, protein hydrolysates, and mixtures thereof.

[0346] This procedure results in a defoamer in foaming agent formulation of the aqueous compositions showing good temperature and storage stability over long periods (1 year and above) of time.

[0347] The invention is further illustrated by the appended figures and the examples that follow.

[0348] BASF SE 240544W001

[0349] 27

[0350] Examples mPEG = Poly(ethylenglycol)methylether

[0351] VOBPEG = Vinyloxy butyl polyethy lenglykol

[0352] Phenyl-PEG = Poly(ethylenglycol)phenylether

[0353] HEMA = Hydroxyethylmethacrylat

[0354] Composition of dispersant polymers:

[0355] • Polymer 1, 32 wt.-% aqueous solution of polyaryl ether-based comb-polymer, monomers: Phenyl-PEG 5000, phenoxyethanolphosphate, formaldehyde.

[0356] • Polymer 2, 44 wt.-% aqueous solution of polycarboxylate ether-based comb-polymer, monomers: mPEG 5000, methacrylic anhydride.

[0357] • Polymer 3, 40 wt.-% aqueous solution of polycarboxylate ether-based comb-polymer, monomers: VOBPEG 3000, acrylic acid.

[0358] • Polymer 4, 29 wt.-% aqueous solution of polyphosphate ether-based comb-polymer, monomers: mPEG 5000 methacrylate, phosphated HEMA.

[0359] Preparation of foam:

[0360] A foaming agent solution containing 6 to 7 g / L of Vinapor® / Texapon® foaming agent (based on fatty alkyl sulphate) was filled in a supply tank and routed to a foam generator. By use of a stator rotor system, and by addition of compressed air, the foaming agent solution was transferred into foam. The foam density was adjusted to 75 g / L for all conducted experiments.

[0361] Mixing procedure:

[0362] Mono / di alkyl phosphates (2-ethylhexyl phosphate “M2EHPA”, bis(2-ethylhexyl) phosphate “D2EHPA”), dispersants (Polymer 1 to 4), 400 g stucco (E-hemihydrate from natural source) and accelerator (fine milled dehydrate from ball mill to adjust a setting time of about 2:00 to 2:20 min:s) were interspersed in water. Then the powder had to soak in liquid for 15 seconds. Afterwards, the slurry was mixed with the Hobart mixer at level II (285 rpm) for 30 seconds. Meanwhile the foam was added to the slurry.

[0363] Dispersants were dosed 0.1 wt.-% active related to stucco. Mono / di alkyl phosphate dosage was 0.67 to 2.5 wt.-% related to active dispersant. Water stucco ratio (WSR) was between 0.48 to 0.60 for all experiments.

[0364] Estimation of initial setting:

[0365] Initial setting was determined with the so-called knife-cut method (analogous to DIN EN 13279).

[0366] Estimation of flow:

[0367] After mixing procedure a cylinder 5 cm in diameter and 10 cm in height was filled with the BASF SE 240544W001

[0368] 28 foamed stucco slurry up to the top edge and lifted after 60 seconds relative to the start of the mixing procedure. At the end the patty diameter was measured with a caliper rule on two perpendicular axes.

[0369] Estimation of compressive strength:

[0370] Test specimens (4 x 4 x 16 cm3) were prepared according to DIN 196-1 for investigation of strength development. Before testing compressive strength, all specimens were dried until mass consistency. Dry density was determined by weighing and by volume (256 cm3).

[0371] Example 1:

[0372] In Inventive Example 1 Alabaster Gypsum (Gessi Roccatrada) was used along with fatty alkylsulphate-based foaming agent (Vinapor® GYP 3711, BASF, 36%), polyaryl ether-based dispersant (Polymer 1, 32 wt.-% aqueous solution) and D2EHPA (Baysolvex®, Lanxess, 95%). Soap concentration of the foaming agent solution was 6 g Vinapor® GYP 3711 in 1 liter of deionized water.

[0373] Inventive Example 1 shows, that adding 2.5 wt.-% D2EHPA related to polyaryl ether-based dispersant leads to a mild defoaming behavior of the gypsum foam, compared to reference 1. Dry densities of both samples are similar at 0.84 kg / dm3for Reference 1 and 0.82 kg / dm3for Inventive Example 1. The more desirable pore structure (larger pores) of Inventive Example 1 leads to a higher compressive strength of 7.37 N / mm2compared to reference 1 at 6.61 N / mm2.

[0374] Example 2:

[0375] In Example 2 Gessi Roccastrada natural gypsum was used along with fatty alkylsulphate- based foaming agent (Vinapor® GYP 3711, BASF, 36 wt.-%), polyaryl ether-based dispersant (Polymer 1, 32 wt.-% aqueous solution), D2EHPA (Baysolvex®, Lanxess, 95%) and triisobutyl phosphate (BASF, Degressal SD 40, 100%). Soap concentration of the foaming agent solution was 6 g Vinapor® GYP 3711 in 1 liter of deionized water. BASF SE 240544W001

[0376] 29

[0377] Comparative Example 2 shows, that adding 2.5 wt.-% D2EHPA related to polyaryl ether- based dispersant leads to a better defoaming behavior of the gypsum foam, compared to state of the art TiBP defoamer. Dry densities of both samples are similar at 0.84 kg / dm3for TiBP and 0.85 kg / dm3for D2EHPA. The more desirable pore structure (larger pores) of D2EHPA sample leads to a higher compressive strength of 7.34 N / mm2compared to 6.96 N / mm2for TiBP sample. Comparative Example 2 is also a reference example for EP 2 627 708 and US2014 / 0073711,

[0378] Example 3:

[0379] In Example 3 Alabaster Gypsum (Gessi Roccatrada) was used along with fatty alkyl sulphate-based foaming agent (Vinapor® GYP 3711, BASF, 36%), polycarboxylate ether- based dispersant (Polymer 2, 44 wt.-% aqueous solution) and M2EHPA (Epiphos®, Lanxess, 95%). Soap concentration of the foaming agent solution was 6 g Vinapor® GYP 3711 in 1 liter of deionized water.

[0380] Inventive Example 3 shows, that adding 2.5 wt.-% M2EH PA related to polymer 2 dispersant leads to a more desirable pore structure (larger pores) compared to Reference 3. Dry density of both samples is very comparable at 0.77 kg / dm3for Reference 3 and 0.75 kg / dm3for the Inventive Example 3. Inventive Example 3 exhibits higher compressive strength of 5.93 N / mm2compared to Reference 3 at 5.29 N / mm2. BASF SE 240544W001

[0381] Example 4:

[0382] In Example 4 Alabaster Gypsum (Gessi Roccatrada) was used along with fatty alkyl ether sulphate-based foaming agent (Vinapor® GYP 2680, BASF, 27%), polycarboxylate ether- based dispersant (Polymer 2, 44 wt.-% aqueous solution), D2EHPA (Baysolvex®, Lanxess, 95%) and triisobutyl phosphate (BASF, Degressal SD 40, 100%). Soap concentration of the foaming agent solution was 6 g Vinapor® GYP 2680 in 1 liter of deionized water.

[0383] Comparative Example 4 shows, that adding 1.5 wt.-% D2EHPA related to polymer 2 dispersant leads to a more desirable pore structure (larger pores) compared to 1.5 wt.-% TiBP. Dry density of both samples is identical at 0.79 kg / dm3. D2EHPA sample exhibits higher compressive strength of 5.34 N / mm2compared to TiBP sample at 4.46 N / mm2.

[0384] Example 5:

[0385] In Inventive Example 5 Alabaster Gypsum (Gessi Roccatrada) was used along with fatty alkyl ether sulphate-based foaming agent (Vinapor® GYP 2680, BASF, 27%), polycarboxylate ether-based dispersant (Polymer 3, 40 wt.-% aqueous solution) and D2PEHA (Baysolvex®, Lanxess, 95%). Soap concentration of the foaming agent solution was 6 g Vinapor® GYP 2680 in 1 liter of deionized water.

[0386] Inventive Example 5 shows, that adding 1.5 wt.-% D2EHPA related to polymer 3 leads to a more desirable pore structure (larger pores) compared to Reference 5. Dry density of both samples is very comparable at 0.73 kg / dm3for Reference 5 and 0.74 kg / dm3for Inventive Example 5. Inventive Example 5 exhibits higher compressive strength of 4.77 N / mm2compared to Reference 5 at 4.25 N / mm2. BASF SE 240544W001

[0387] Example 6:

[0388] In Example 6 Alabaster Gypsum (Gessi Roccatrada) was used along with fatty alkyl sulphate-based foaming agent (Texapon® 1030, BASF, 30%), polyaryl ether-based dispersant (polymer 1, 32 wt.-% aqueous solution) and M2EHPA (Epiphos®, Lanxess, 95%). Soap concentration of the foaming agent solution was 7 g Texapon® 1030 in 1 liter of deionized water.

[0389] In Inventive Example 6 adding 0.67 wt.-% M2EHPA related to poly arylether-based dispersant polymer 1 also leads to slightly larger air pores compared to Reference 6. Dry densities of both samples are comparable at 0.83 kg / dm3for Reference 6 and 0.80 kg / dm3for the Inventive Example 6. Inventive Example 6 shows higher compressive strength of 6.29 N / mm2compared to Reference 6 at 5.83 N / mm2.

[0390] Example 7:

[0391] In Example 7 Keramod 125 natural gypsum (Casea) was used along with fatty alkyl sulphate-based foaming agent (Vinapor® GYP 3782, BASF, 37%), polyphosphate ether- based dispersant (Polymer 4, 29 wt.-% aqueous solution) and D2PEHA (Baysolvex®, Lanxess, 95%). Soap concentration of the foaming agent solution was 6 g Vinapor® GYP 3782 in 1 liter of deionized water.

[0392] Inventive Example 7 shows, that adding 1.25% D2EHPA related to polymer 4 leads to a more desirable pore structure (larger pores) compared to Reference 7. Dry density of both samples is very comparable at 0.63 kg / dm3for Reference 7 and 0.64 kg / dm3for Inventive BASF SE 240544W001

[0393] 32

[0394] Example 7. Inventive Example 7 exhibits higher compressive strength of 4.08 N / mm2compared to Reference 7 at 3.68 N / mm2.

[0395] Example 8:

[0396] Foaming agent and defoamer can also be premixed, which results in a homogeneous defoamer in foaming agent formulation.

[0397] In Example 8 di alkyl phosphate (D2EHPA) was not added into the mixing water as described in the experiments above but was added into the foaming agent solution and was filled in the supply tank and was processed through the foam generator.

[0398] In the described example 8 Keramod 125 natural gypsum (Casea) was used along with fatty alkyl sulphate-based foaming agent (Vinapor® GYP 3711, BASF, 36%), polycarboxylate ether-based dispersant (Polymer 2, 44 wt.-% aqueous solution) and D2EHPA (Baysolvex®, Lanxess, 95%). Soap concentration of the foaming agent solution was 6 g Vinapor® GYP 3711 in 1 liter of deionized water. In Inventive Example 8 0.34 g D2EHPA was added into 1 liter of foaming agent solution.

[0399] Inventive Example 8 shows, that adding 2.1 wt.-% D2EHPA related to polymer 2 dispersant into the foaming agent solution also leads to a more desirable pore structure (larger pores) compared to Reference 8. Dry density of both samples is identical at 0.59 kg / dm3for Reference 8 and Inventive Example 8. Inventive Example 8 exhibits higher compressive strength of 2.75 N / mm2compared to Reference 8 at 2.54 N / mm2.

[0400] In Examples 1 to 8 it is shown, that adding only a comb polymer-based dispersant to a foamed gypsum slurry leads to a fine pore structure. By admixing 0.7 to 2.5 wt.-% a mono / di alkyl phosphate (relative to dispersant) a much more preferred coarse pore structure can be achieved, which leads to an increase in compressive strength (compared at similar dry densities of the samples). Mono / di alkyl phosphate can be added into the mixing water along with the dispersant and stucco or can be added into the foaming agent solution, processed through the foam generator and admixed via foam into the stucco slurry.

[0401] Example 9:

[0402] In Example 9 Keramod 125 natural gypsum (Casea) was used along with fatty alkyl sulphate-based foaming agent (Vinapor® GYP 3711, BASF, 36%), Poly Naphthalene Sulphonate (Flube CA 40, Bozzetto, 40%) and Triisobutyl phosphate (Degressal SD 40, BASF SE 240544W001

[0403] BASF, 100%). Soap concentration of the foaming agent solution was 7 g Vinapor® GYP 3711 in 1 liter of deionized water.

[0404] Example 9 shows that adding 1.5 wt.-% Triisobutyl phosphate related to Flube CA 40 leads to a slightly larger pore structure compared to Reference 9, but smaller as for Inventive Example 9. Dry density of samples is at same level for Reference 9 (0.67 kg / dm3) and for Example 9 (0.64 kg / dm3). Example 9 exhibits lower compressive strength of 3.82 N / mm2compared to Reference 9 at 4.23 N / mm2. Inventive Example 9 shows the highest compressive strength at 5.19 N / mm2.

[0405] Example 10:

[0406] Dispersants and defoamers can also be premixed using a solubilizer, which results in a homogeneous defoamer in dispersant formulation.

[0407] For Example 10 dispersant, defoamer and solubilizer were premixed with a rotary mixer at 200 RPM for 10 Minutes resulting in a clear solution. Storage tests for 30 days at 5° C and 60° C do not show any signs of a phase separation or demixing.

[0408] The following table presents mixing ratio of the used substances.

[0409] Dispersant formulation 1.1:

[0410] The above mixture results in a clear solution.

[0411] Mixing procedure: BASF SE 240544W001

[0412] 34

[0413] Dispersant formulation 1.1, 400 g stucco (E-hemihydrate from natural source) and accelerator (fine milled dehydrate from ball mill to adjust a setting time of about 2:00 to 2:30 min:s) were interspersed in water. Then the powder had to soak in liquid for 15 seconds. Afterwards the slurry was mixed with the Hobart mixer at level II (285 rpm) for 30 seconds. Meanwhile the foam was added to the slurry.

[0414] Dispersant was dosed 0.1% active related to stucco.

[0415] In Inventive Example 10 Casea Keramod 125 natural gypsum was used along with fatty alkylsulphate-based foaming agent (Vinapor® GYP 3711, BASF, 36%), polyaryl ether-based dispersant (Polymer 1, 32%), di 2-ethyl hexyl phosphoric acid and fatty alkyl sulphate solubilizer (Texapon® 1030) (Dispersant formulation 1.1). Soap concentration of the foaming agent solution was 6 g Vinapor® GYP 3711 in 1 liter of deionized water. Active dispersant dosage was 0.1% to stucco for both Reference 10 and Inventive Example 10.

[0416] Inventive Example 10 shows, that using Dispersant formulation 1.1 instead of plain polyaryl ether-based dispersant leads to a mild defoaming behavior of the gypsum foam, compared to reference 10. Dry densities of both samples are similar at 0.76 kg / dm3for reference 1 and for inventive example 1. The larger pore structure of inventive example 10 compared to reference 10 is shown in figures 11 and 12. Compressive strength of Inventive Example 10 is 4.15 N / mm2and for Reference 10 it is 3.59 N / mm2.

Claims

BASF SE 240544W00135Claims1. A binder composition suitable to produce a foamed molded body, comprising:(a) an inorganic binder;(b) a foaming agent;(c) a dispersant;(d) an antifoaming agent selected from a phosphoric ester(i) having the formula (IX)O=P(O-R1)3.X(O-R2)X(IX) whereinP represents phosphorus,0 represents oxygen,R1is selected from linear or branched C5-C20alkyl or an aryl group, R2is H and x = 1 or 2, or(ii) having the formula (X)O=P(O-R1)(O-R2)(O-R3) (X) whereinP represents phosphorus,0 represents oxygen,R1is H or is selected from a linear or branched C5-C20alkyl or an aryl group, R2is H,R3selected from linear or branched C5-C20alkylene or an arylene group, and wherein the antifoaming agent of formula (X) is covalently bound to the dispersant c) via R3.

2. The binder composition according to claim 1, wherein the inorganic binder (a) is selected from the group consisting of cement, gypsum, and a mixture thereof.

3. The binder composition according to claims 1 or 2, wherein the foaming agent (b) comprises at least one compound selected from the group consisting of an alkyl sulfate, an alkyl ether sulfate, alkyl polyglycoside, a betaine, a glutamate, a sulfo ketone, an alkyl aryl, an alkyl ether, an alkyl aryl ether, an alkyl ether an isethionate, a N-acylamino acid compound, a sulfoacetate, a sulfonate, a sulfosuccinate, a taurate, an alkanolamide, an amine oxide, a carboxylate, a cationic polymer, a silicone, an alcohol, a protein derivative, and mixtures thereof.

4. The binder composition according to any one of claims 1 to 3, wherein the dispersant (c) is selected from(i) polyaryl ether polymers,BASF SE 240544W00136(ii) polycarboxylate ether polymers,(iii) polyphosphate ether polymers or polyphosphonate ether polymers, and(iv) sulfonate group containing polymers.

5. The binder composition according to claim 4, wherein the ether-group of the dispersant (c) selected from (i), (ii) or (iii) are represented by the structural unit (I),*-U-(C(O))k-X-(AlkO)n-W (I) wherein* indicates the bonding site to the polymer,U is a chemical bond or an alkylene group having 1 to 16 carbon atoms,X is oxygen, sulfur or a group N R1, k is 0 or 1, n is an integer whose average value based on the polymer is in the range from 3 to 300,Aik is C2-C4alkylene, it being possible for Aik to be identical or different within the group (Alk-O)n,W is a hydrogen, a Ci-C6alkyl or an aryl radical or is the group Y-F, whereY is a linear or branched alkylene group having 2 to 8 carbon atoms and may carry a phenyl ring,F is a 5- to 10-membered nitrogen heterocycle which is bonded via nitrogen and which as ring members, besides the nitrogen atom and besides carbon atoms, may have 1, 2 or 3 additional heteroatoms, selected from oxygen, nitrogen, and sulfur, it being possible for the nitrogen ring members to have a group R2, and for 1 or 2 carbon ring members to be present in the form of a carbonyl group,R1is hydrogen, Cj-C4alkyl or benzyl, andR2is hydrogen, Cj-C4alkyl or benzyl.

6. The binder composition according to claim 4 or 5, wherein the at least one dispersant (c) (i) represents a polycondensation product comprising(II) a structural unit comprising an aromatic or heteroaromatic moiety and the polyether group,(III) a phosphated structural unit comprising an aromatic or heteroaromatic moiety.BASF SE 240544W001377. The binder composition according to claims 4 or 5, wherein the polycarboxylate ether polymer (c) (ii) is a copolymer which is obtainable by polymerizing a mixture of monomers comprising(V) at least one ethy lenica lly unsaturated monomer which comprises at least one radical from the series consisting of carboxylic acid, carboxylic salt, carboxylic ester, carboxylic amide, carboxylic anhydride, and carboxylic imide and(VI) at least one ethylenically unsaturated monomer comprising the structural unit having the polyether side chain.

8. The binder composition according to claim 7, wherein the ethylenically unsaturated monomer (V) is represented by at least one of the following general formulae from the group of (Va), (Vb), and (Vc)whereR7and R8independently of one another are hydrogen or an aliphatic hydrocarbon radical having 1 to 20 carbon atomsB is H, -COOM,, -CO-O(CqH2qO)r-R9, -CO-NH-(CqH2qO)r-R9M is hydrogen, a mono-, di- or trivalent metal cation, ammonium ion or an organic amine radical a is 1 / 3, 1 / 2 or 1R9is hydrogen, an aliphatic hydrocarbon radical having 1 to 20 carbon atoms, a cycloaliphatic hydrocarbon radical having 5 to 8 carbon atoms, an optionally substituted aryl radical having 6 to 14 carbon atoms q independently of one another for each (CqH2qO) unit is identical or different and is 2, 3 or 4, and r is 0 to 200Z is O, NR16R16independently at each occurrence is identical or different and is represented by a branched or unbranched C to C10-alkyl radical, C5- to C8cycloalkyl radical, aryl radical, heteroaryl radical or H,BASF SE 240544W00138whereR10and R11independently of one another are hydrogen or an aliphatic hydrocarbon radical having 1 to 20 carbon atoms, a cycloaliphatic hydrocarbon radical having 5 to 8 carbon atoms, an optionally substituted aryl radical having 6 to 14 carbon atomsR12is identical or different and is represented by (CnH2n)-SO3H where n = 0,1, 2, 3 or 4, (CnH2n)-OH where n = 0, 1, 2, 3 or 4; (CnH2n)-PO3H2where n = 0, 1, 2, 3 or 4, (CnH2n)-OPO3H2where n = 0, 1, 2, 3 or 4, (C6H4)-SO3H, (C6H4)-PO3H2, (C6H4)-OPO3H2, and (CnH2n)-N R14bwhere n = 0, 1, 2, 3 or 4 and b = 2 or 3R13is H, -C00Ma, -CO-O(CqH2qO)r-R9, -CO-N H-(CqH2qO)r-R9, where Ma, R9, q, and r possess definitions stated aboveR14is hydrogen, an aliphatic hydrocarbon radical having 1 to 10 carbon atoms, a cycloaliphatic hydrocarbon radical having 5 to 8 carbon atoms, an optionally substituted aryl radical having 6 to 14 carbon atomsQ is identical or different and is represented by N H, N R15or O; where R15is an aliphatic hydrocarbon radical having 1 to 10 carbon atoms, a cycloaliphatic hydrocarbon radical having 5 to 8 carbon atoms, or an optionally substituted aryl radical having 6 to 14 carbon atoms.

9. The binder composition according to claim 4 or 5, wherein the polyphosphate ether polymers or polyphosphonate ether polymer (c) (iii) is a copolymer which is obtainable by polymerizing a mixture of monomers comprising(VI I) at least one ethy lenically unsaturated monomer comprising a structural unit of formula (Vila)BASF SE 240544W00139in whichZ is OM2for polyphosphate ether polymers orH for polyphosphonate ether polymers* indicates the bonding site to the ethylenically unsaturated moiety,R1is an alkylene group having 2 to 8 carbon atoms,Y is 0 or N R2,M1and M2each independently of one another are hydrogen, an ammonium compound and a mono-, di- or trivalent metalR2is a radical from the group of hydrogen, an alkyl group having 1 to 8 carbon atoms, and formula (Vllb), where Z, R1, M1and M2possess the definitions stated for formula (Vila),(VIII) at least one ethylenically unsaturated monomer comprising the structural unit having the polyether side chain.

10. The binder composition according to any one of claims 1 to 9, wherein the antifoaming agent (d) is selected from a phosphoric ester(i) having the formula (IX)O=P(O-R1)3.X(O-R2)X(IX) whereinP represents phosphorus,0 represents oxygen,R1is selected from linear or branched C8-C16alkyl group, preferably branched C8-C16alkyl group, R2is H and x = 1 or 2, or(ii) having the formula (X)O=P(O-R1)(O-R2)(O-R3) (X)BASF SE 240544W00140 whereinP represents phosphorus,0 represents oxygen,R1is H or is selected from linear or branched C8-C16alkyl or an aryl group, preferably branched C8-C16alky group,R2is H,R3selected from linear or branched C8-C16alkylene group, and wherein the antifoaming agent of formula (X) is covalently bound to the dispersant (c) via R3.

11. The binder composition according to claim 10, wherein the antifoaming agent (d) (i) is selected from 2-ethylhexyl phosphate and bis(2-ethy lhexyl) phosphate.

12. Hardened foamed molded body obtainable from a binder composition according to claims 1 to 11.

13. An aqueous composition comprising a foaming agent and an antifoaming agent selected from a phosphoric ester (i) having the formula (IX):O=P(O-R1)8.X(O-R2)X(IX) whereinP represents phosphorus,O represents oxygen,R1is selected from linear or branched C5-C20alkyl, or an aryl group,R2is H and x = 1 or 2.

14. An aqueous composition comprising a solubilizer, a dispersant, and an antifoaming agent selected from a phosphoric ester (i) having the formula (IX)O=P(O-R1)8.X(O-R2)X(IX) whereinP represents phosphorus,O represents oxygen,R1is selected from linear or branched C5-C20alkyl, or an aryl group,R2is H and x = 1 or 2, or an aqueous composition comprising a solubilizer and a dispersant, wherein the antifoaming agent of formula (X) is covalently bound to the dispersant via R3, wherein formula (X) is represented by the following formulaBASF SE 240544W00141O=P(O-R1)(O-R2)(O-R3) (X) whereinP represents phosphorus,0 represents oxygen,R1is H or is selected from linear or branched C5-C20alkyl or an aryl group,R2is H,R3selected from linear or branched C5-C20alkylene or an arylene group.

15. Use of an antifoaming agent in an aqueous composition comprising a) an inorganic binder, b) a foaming agent and c) a dispersant, wherein the antifoaming agent is selected from a phosphoric ester(i) having the formula (IX)O=P(O-R1)3.X(O-R2)X(IX) whereinP represents phosphorus,0 represents oxygen,R1is selected from linear or branched C5-C20alkyl, or an aryl group,R2is H and x = 1 or 2, or(ii) having the formula (X)O=P(O-R1)(O-R2)(O-R3) (X) whereinP represents phosphorus,0 represents oxygen,R1is H or is selected from linear or branched C5-C20alkyl or an aryl group,R2is H,R3selected from linear or branched C5-C20alkylene or an arylene group, and wherein the antifoaming agent of formula (X) is covalently bound to the dispersant (c) via R3, to enhance the compressive strength of the hardened foamed molded body.

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