Two-component composition

Abstract

The invention relates to a two-component composition. This composition contains a first component comprising at least one water glass and hollow microspheres filled with propellant gas, said microspheres having a core filled with propellant gas and a polymer material as a shell, and a second component comprising an organic solvent for opening the hollow microspheres, wherein the first component contains silicate fibers.

Description

[0001] Two-component composition

[0002] Description

[0003] The present invention relates to a two-component composition and its use for producing a foam. The foam obtained from the two-component composition can be used, among other things, as fire-resistant foam.

[0004] Another subject of the present application is the fire-resistant foam obtained from the two-component composition, as well as a method for producing fire-resistant materials from the two-component composition. Foam materials used in fire protection are known from the prior art.

[0005] Foam glass products made from liquid water glass, fillers, and peroxides are well-known. The peroxides decompose into oxygen in the alkaline water glass, causing the mixture to foam. Corresponding compositions are described in US Patent 3,095,312. To avoid the use of reactive peroxides, an alternative process is employed in which an acidic hardener is used, which hardens the water glass and simultaneously releases a gas, such as CO2. This gas, along with the addition of surfactants, causes the mixture to foam. The disadvantage of this process is that the gas-releasing reaction leads to a temperature increase of up to 100 °C (US Patent 3,850,650 A). Another process does not require any foaming agent in the water glass composition. Foam glass is produced solely through the rapid heating of the water and the resulting gas bubbles, as described in US Patent 6,497,945 B.

[0006] US Patent 8,822,557 B discloses an elastic foam composed of organic and inorganic components. This results in a mineral foam with improved mechanical properties and water resistance, containing a mineral binder and a polymer dispersion.

[0007] German patent DE 101 41 777 A1 discloses a non-combustible, inorganic foam that is moisture-resistant and elastic. The foam is based on a mixture of an alkali metal silicate, an alkali metal aluminate, and a blowing agent. The process for producing the inorganic foam requires the application of heat.

[0008] DE 32 44 523 A1 discloses the production of a spray foam from water glass and a hardener solution without the application of heat. The two components, water glass and hardener solution, are contained in two pressure vessels; the foam is generated, among other things, by a propellant gas that is liquid under increased pressure at 0 to 50 °C. The spray foam is suitable for the production of, for example, non-combustible filling or insulating material in the construction industry. A carboxylic acid ester can also be used as the hardener. After hardening, the foams are classified as building material class A2 (DIN 4102).

[0009] US 5,194,087 describes a refractory, waterproof and acid-resistant binder consisting essentially of a hardened mixture of about 10 to 90 wt.% of an alkali silicate, about 1 to 40 wt.% of a reactive metal oxide of magnesium or titanium and about 1 to 70 wt.% of a carbonate compound.

[0010] EP 2571 829 discloses a process for producing molded bodies for fire protection materials from compositions consisting of at least two different sodium silicates of specific viscosity. EP 2571 829 further discloses the simultaneous use of blowing gas-filled microcapsules for inflating this composition, the inflation being carried out under the influence of energy. The use of more energy-efficient methods for gas release, as well as the advantage of inflation within a specific temperature range, are not disclosed.

[0011] EP 3 732 147 A discloses a process for producing a solid fire-resistant material, in particular in the form of a fire-resistant board, wherein a first composition containing at least one water glass and propellant-containing microcapsules is provided, and then the microcapsules are ruptured by the addition of propylene carbonate in a second composition. WO 2019 / 110835 A discloses a combination comprising a first composition and a second composition, wherein the first composition contains microhollow spheres and the second composition contains a solvent for rupturing these microhollow spheres, and the first composition and / or the second composition contains an inorganic and / or organic binder, wherein the microhollow spheres have a polymer shell and contain a propellant.

[0012] A disadvantage of these compositions known from the prior art is that the resulting foams do not exhibit satisfactory curing behavior with simultaneous mechanical stability.

[0013] Another disadvantage of the materials known from the prior art is their sometimes high proportion of organic compounds, which leads to poorer fire protection and temperature stability.

[0014] Furthermore, another disadvantage of two-component systems is that the risk of inhomogeneous distributions between the two components must be avoided as much as possible in order to enable a homogeneous and efficient supply of the foam.

[0015] Finally, the state of the art is also disadvantageous with regard to the ratio of overall density and stability of the cured foam, since a large number of cavities are usually introduced into the foam in these foam systems.

[0016] Starting from this state of the art, the object of the present invention is to provide a two-component composition which leads to foam masses which overcome at least one disadvantage of the prior art.

[0017] In particular, a two-component composition for producing a foam should be provided that enables foam formation without an external heat input. The building materials that can be produced using the foam, such as in-situ foams or lightweight panels, should be as fire-resistant as possible and / or exhibit good flexural strength. Good sound and / or thermal insulation of the resulting materials is also particularly advantageous.

[0018] One or more of these problems of the present invention are solved by a two-component composition.

[0019] This problem is solved by a two-component composition comprising a (1) first component comprising at least a water glass and propellant-filled microhollow spheres with a propellant-filled core and a polymer material as a shell, wherein the microcapsules contain at least 20 wt% propellant based on their dry weight; and

[0020] (2) second component comprising an organic solvent for opening these microhollow spheres,

[0021] characterized in that the first component contains silicate fibers with an average fiber length of 2 to 6 mm.

[0022] This task can also be solved by a two-component composition containing a

[0023] (1) First component comprising at least a water glass and propellant-filled micro-hollow spheres with a propellant-filled core and a polymer material as a shell, wherein the microcapsules contain at least 20% by weight of propellant, based on their dry weight; and

[0024] (2) second component comprising an organic solvent for opening these microhollow spheres,

[0025] characterized by the fact that the two-component composition contains a metakaolin.

[0026] Within the scope of the present invention, soundproofing materials are understood to be special building components that dampen, absorb, or prevent noise from passing from one room to another. They are used in both private and commercial settings to improve acoustics and reduce noise pollution. Typical applications for soundproofing materials include, for example, living spaces (to improve sound insulation between rooms), open-plan offices (to reduce noise and improve speech intelligibility), studios, rehearsal rooms, home theaters, industrial halls, machine rooms, schools, daycare centers, and event venues. These soundproofing materials offer the advantages of reduced noise pollution, improved well-being and concentration, and, according to the invention, are flexible in shape, color, and installation (e.g., wall, ceiling, freestanding) and also possess fire protection and thermal insulation properties.Within the scope of the present invention, fire protection materials are understood to be form-flexible protection systems designed to adapt to different geometric shapes, components, and installation situations. They are primarily used where rigid fire protection solutions reach their limits, for example, in the case of irregular contours, pipework, or movable structures. Their flexibility allows for seamless adaptation, enabling even complex areas to be reliably sealed against fire and smoke. Furthermore, the present invention also relates to rigid fire protection materials resulting from the composition provided for in the invention.

[0027] These materials are characterized by high thermal stability, ensuring that their structure and protective properties are maintained even under extreme temperatures. Another essential feature is their ability to delay heat transfer and prevent the penetration of flames or smoke. Many of these products incorporate mechanisms that activate in the event of a fire, such as an intumescent reaction in which the material foams up in a controlled manner, thereby sealing openings. At the same time, they remain permanently flexible, allowing for easy processing and the ability to accommodate structural movement without compromising their protective function. Furthermore, they must be durable over extended periods and maintain their performance even under changing environmental conditions.

[0028] The fire protection properties of such materials are subject to stringent requirements. They must demonstrate, according to recognized testing standards, that they achieve defined fire resistance durations while maintaining their functionality in terms of compartmentation and thermal insulation. Their fire behavior is strictly classified, with low flammability and minimal smoke emission being crucial criteria. Equally important is reproducible behavior in an emergency: intumescent systems must react reliably and consistently without uncontrolled deformation or loss of their protective effect. All properties must be documented by test certificates, approvals, and classification reports that confirm the material's safety and long-term durability.Furthermore, they must not release any substances that are harmful to health or the environment and must be compatible with other common construction and installation products to ensure safe use in various applications. The components of the two-component mixture are described in more detail below, starting with the first component.

[0029] Components of the first component

[0030] Not all of the components of the first component described below are mandatory.

[0031] silicate fibers

[0032] Silicate fibers are a group of fibers based on silicates—mineral compounds consisting mainly of silicon (Si) and oxygen (O). Silicate fibers can be made from natural silicates (such as asbestos) or synthetically produced silicate materials (such as glass or mineral fibers). There are various types of silicate fibers that differ in their chemical composition, manufacturing processes, and specific properties, and which can be used according to the present invention:

[0033] Glass fibers are one of the best-known forms of silicate fibers. They consist of amorphous silicon dioxide (SiO2) and other components such as aluminum oxide (Al2O3), boron trioxide (B2O3), and calcium oxide (CaO). Glass fibers are non-crystalline, meaning they have an irregular atomic structure. They are widely used due to their high strength, flexibility, and resistance to high temperatures and chemicals.

[0034] Mineral fibers, also known as rock wool or mineral wool, consist of a mixture of silicate materials, especially basaltic or diabase materials, which are melted at high temperatures and then processed into fibers.

[0035] Ceramic fibers consist mainly of silicon dioxide and other metal oxides such as aluminum oxide (Al₂O₃) or magnesium oxide (MgO) and have a crystalline structure. They are suitable for applications requiring high temperatures and extreme chemical resistance.

[0036] The aforementioned silicate fibers are characterized by a number of exceptional physical, chemical and mechanical properties that make them particularly suitable for use in the present invention:

[0037] Silicate fibers, especially glass and ceramic fibers, are able to withstand extremely high temperatures without losing their structural integrity. Glass fibers can withstand temperatures up to 1000 °C, while ceramic fibers can withstand even higher temperatures. These fibers also have excellent thermal insulation properties and are stable and resistant to many chemicals. They are particularly resistant to acids and bases, as well as many organic solvents.

[0038] Silicate fibers are also mechanically strong and have high tensile strength, making them suitable for the production of reinforcing fibers in composite materials.

[0039] Silicate fibers are generally non-combustible and therefore offer advantages in the application area of ​​fire protection according to the invention.

[0040] In a first embodiment of the present invention, the silicate fibers are contained in the first component in an amount of at least 0.1 wt.%, preferably at least 0.2 wt.%, more preferably at least 0.3 wt.%, more preferably at least 0.4 wt.%, more preferably at least 0.5 wt.%, in each case based on the total weight of the first component.

[0041] In a second embodiment of the present invention, the silicate fibers are contained in the first component in an amount of at most 10 wt.%, preferably at most 8 wt.%, more preferably at most 6 wt.%, more preferably at most 4 wt.%, more preferably at most 2 wt.%, more preferably at most 1 wt.%, more preferably at most 0.8 wt.%, more preferably at most 0.7 wt.%, in each case based on the total weight of the first component.

[0042] In a particular embodiment of the present invention, the silicate fibers are contained in the first component in an amount of 0.1 to 10 wt.%, preferably 0.1 to 8 wt.%, more preferably 0.2 to 6 wt.%, more preferably 0.2 to 4 wt.%, more preferably 0.3 to 2 wt.%, more preferably 0.3 to 1 wt.%, more preferably 0.4 to 0.8 wt.%, more preferably 0.5 to 0.7 wt.%, each based on the total weight of the first component.

[0043] By adding silicate fibers to the first component, the organic content in the two-component composition according to the invention can be kept low, which offers advantages with regard to fire class, temperature stability, CO2 emissions and waste disposal.

[0044] The mechanical stability of the foam resulting from the two-component composition according to the invention can be improved by adding silicate fibers. Within the scope of the present invention, it has been found that the longer the silicate fibers used, the higher the mechanical stability. In practice, however, two problems arise when using excessively long fibers:

[0045] In practical application, when using a foam based on the two-component composition according to the invention, a so-called static mixer must be screwed onto the commonly used cartridge in which the first and second compositions are stored before mixing. This cartridge is a plastic part with many coils, intended to ensure a homogeneous distribution of the individual components. Long silicate fibers can become entangled in these coils and thus clog them.

[0046] Furthermore, excessively long silicate fibers in mixing containers tend to form "nests". The fibers can become entangled and thus accumulate inhomogeneously or, in extreme cases, knotted together.

[0047] Short fibers are easier to handle and process in production. According to the invention, this results in an average fiber length of the silicate fibers of preferably at most 7 mm, more preferably at most 6 mm, more preferably at most 5 mm, more preferably at most 4 mm, and more preferably at most 3.5 mm.

[0048] According to the invention, this also results in an average fiber length of the silicate fibers of preferably at least 0.5 mm, preferably at least 1 mm, more preferably at least 1.5 mm, more preferably at least 2 mm, more preferably at least 2.5 mm.

[0049] According to the invention, this results in a mean fiber length of the silicate fibers of preferably 0.5 to 7 mm, more preferably 1 to 6 mm, more preferably 1.5 to 6.5 mm, more preferably 2 to 6 mm, more preferably 2 to 4 mm, and more preferably 2.5 to 3.5 mm. A mean fiber length of the silicate fibers in the aforementioned ranges represents a good compromise between the stability, risk of clogging, and risk of nest formation in the resulting composition.

[0050] water glass

[0051] The first component of the two-component composition according to the invention contains at least one water glass. This water glass acts as a binder in the two-component composition according to the invention and in the resulting foam.

[0052] Water glasses are hydrated, amorphous silicon dioxide compounds formed by dissolving silicon dioxide (SiO2) in an alkaline solution. These materials are a special type of silicate that exists in aqueous solutions and have a gel-like, viscous consistency. Water glasses are also known as liquid glasses or liquid silicates.

[0053] Water glass consists mainly of silicon dioxide (SiO2) dissolved in an alkaline solution, typically sodium hydroxide (NaOH) or potassium hydroxide (KOH). The chemical formula for water glass depends on the type of alkali (sodium or potassium) and is generally: Sodium water glass: Na2SiO3

[0054] Potassium silicate: K₂SiO₃

[0055] It is a soluble compound that does not have a crystalline structure like ordinary glass, but rather an amorphous (irregular) structure typical of many silicates. Unlike crystalline glass, water glass lacks an ordered atomic arrangement. It is an amorphous silicate that exists in a gel-like form and is referred to as "liquid glass" due to its viscosity and chemical composition.

[0056] The physical properties of water glass vary depending on the concentration of the solution and the type of alkali used. Typical properties of water glass include:

[0057] Solubility in water (water glass is soluble in water, and depending on the concentration of the solution, it can have a gel-like or liquid consistency), viscosity (water glass has a high viscosity that increases with the concentration of silicon and alkali), alkalinity (water glass has a high pH and is strongly alkaline (basic), which makes it useful in many industrial applications), heat resistance (water glass is able to withstand high temperatures, making it suitable for applications in firefighting and as an insulating material), and low strength compared to crystalline glass (since water glass does not have a solid crystalline structure, its strength is limited; it behaves more like a gel-like substance).

[0058] Water glass has a wide range of applications. It can be used as a flame retardant because it is resistant to high temperatures and fires. Water glass is also suitable for sealing surfaces. Therefore, the two-component composition according to the invention, as well as the resulting foams, can preferably be used as a surface coating in building protection. The production of fire-resistant lightweight panels is particularly preferred.

[0059] According to the invention, suitable water glasses as binders are sodium or potassium silicate (sodium or potassium water glass), particularly with a solids content of 25 to 55%. According to the invention, preferred water glasses as binders are sodium silicate (sodium water glass), particularly with a solids content of 25 to 55%.

[0060] According to the invention, it is particularly preferred if the first component and the two-component composition according to the invention do not contain potassium silicate. While potassium silicate can increase the stability of the cured foam in the solid state in practice, it also reduces the adhesion to other surfaces, which makes its use in the two-component composition according to the invention disadvantageous.

[0061] Within the scope of the present invention, it may be advantageous if the first component of the two-component composition according to the invention contains at least two different water glasses, in particular two different sodium water glasses.

[0062] Sodium silicate glass varies in its solids content (sodium silicate) and also in its chemical microstructure (orthosilicate, disilicate, trisilicate, etc.). In practice, these different sodium silicates manifest themselves in different hardening behaviors.

[0063] Therefore, within the scope of the present invention, it is particularly advantageous if a first sodium silicate is used in the first component of the two-component composition according to the invention, which leads to faster hardening but also to a somewhat reduced mechanical stability.

[0064] According to the invention, this first sodium silicate is then preferably used additionally with at least one second sodium silicate, which is flowable when still moist.

[0065] By appropriately adjusting the proportions of water glass, an optimum of the different properties can be achieved.

[0066] The first sodium silicate is preferably contained in the first component in an amount of at least 20 wt.%, preferably at least 25 wt.%, further preferably at least 30 wt.%, in each case based on the total weight of the first component.

[0067] The first sodium silicate is preferably contained in the first component in an amount of at most 60 wt.%, preferably at most 55 wt.%, further preferably at most 50 wt.%, in each case based on the total weight of the first component.

[0068] The first sodium silicate is preferably present in the first component in an amount of 20 to 60 wt.%, more preferably 25 to 55 wt.%, and further preferably 30 to 50 wt.%. The second sodium silicate is preferably present in the first component in an amount of at least 5 wt.%, more preferably at least 10 wt.%, and further preferably at least 15 wt.%, in each case based on the total weight of the first component.

[0069] The second sodium silicate is preferably contained in the first component in an amount of at most 40 wt.%, preferably at most 35 wt.%, more preferably at most 30 wt.%, in each case based on the total weight of the first component.

[0070] The second sodium silicate is preferably contained in the first component in an amount of 5 to 40 wt.%, preferably 10 to 35 wt.%, more preferably 15 to 30 wt.%, in each case based on the total weight of the first component.

[0071] When using only one glass of sodium silicate solution, it preferably has the following properties:

[0072] (1) Weight ratio of SiO2 to Na2Ü equal to 2.30 to 3.80, preferably 3.00 to 3.60, particularly preferably 3.10 to 3.50

[0073] (2) Density of 1300 to 1600 kg / m³ 3 preferably 1300 to 1500 kg / m² 3 , especially preferred 1340 to 1380 kg / m³ 3 ; and

[0074] (3) Water content of 50 to 70 wt.%, preferably 60 to 65 wt.%, particularly preferably 63.2 to 64.8 wt.%.

[0075] As already explained, the use of two different water glasses proves to be advantageous.

[0076] Preferably, the composition therefore contains at least two different sodium silicates, wherein the first sodium silicate has a viscosity of 1000 to 2400 mPa*s (20 °C) and the second sodium silicate has a viscosity of 75 to 250 mPa*s (20 °C). The first sodium silicate, which has a viscosity of 1000 to 2400 mPa*s (20 °C), preferably has at least one further of the following properties:

[0077] (1) Weight ratio of SiO2 to Na2Ü equal to 2.30 to 2.60, preferably 2.32 to 2.56, particularly preferably 2.34 to 2.54;

[0078] (2) Density of 1500 to 1600 kg / m³ 3 preferably 1520 to 1580 kg / m³ 3 , particularly preferred 1540 to 1565 kg / m³ 3 ; and

[0079] (3) Water content of 50 to 55 wt.%, preferably 51 to 54 wt.%, particularly preferably 51.9 to 53.6 wt.%.

[0080] The viscosity of this glass is preferably from 1200 to 2200 mPa * s (20 °C) and particularly preferably from 1400 to 2000 mPa * s (20 °C).

[0081] The second sodium silicate has a viscosity of 75 to 250 mPa * s (20 °C) and preferably has at least one further of the following properties: (1) weight ratio of SiCh to Na2Ü equal to 2.80 to 3.80, preferably 3.00 to 3.60, particularly preferably 3.10 to 3.50;

[0082] (2) Density of 1300 to 1500 kg / m³ 3 preferably 1330 to 1450 kg / m³ 3 , particularly preferably 1365 to 1375 kg / m³ 3 ; and

[0083] (3) Water content of 55 to 70 wt.%, preferably 60 to 65 wt.%, particularly preferably 63.2 to 64.6 wt.%.

[0084] The viscosity of this glass is preferably from 85 to 225 mPa * s (20 °C) and particularly preferably from 100 to 200 mPa * s (20 °C).

[0085] For example, a sodium water glass with a weight ratio of 2.3 can be used as the first sodium water glass and a sodium water glass with a weight ratio of 3.3 as the second sodium water glass. The ratio of the two water glasses can preferably be between 120-200 parts by weight of a sodium water glass with a weight ratio of 2.3 to 10-50 parts by weight of a sodium water glass with a weight ratio of 3.3, particularly preferably 140-180 parts by weight to 15-40 parts by weight, and especially preferably 155-165 parts by weight to 20-30 parts by weight.

[0086] The composition contains water glasses, in particular sodium water glasses, based on the total mass of the composition, generally 60 to 98 wt.%, preferably 70 to 97 wt.%, more preferably 80 to 96 wt.%.

[0087] The reasons for using water glass in the two-component composition according to the invention are manifold. It can be used as a flame retardant because it is resistant to high temperatures and fires. Water glass is also suitable for sealing surfaces. Therefore, the foams according to the invention can preferably be used as surface coatings for paper, textiles, and in building protection. The production of fire-resistant lightweight panels is particularly preferred.

[0088] Microhollow spheres

[0089] The microhollow spheres in the first component contain a blowing agent and have a polymer shell.

[0090] The microhollow spheres in the first component can be present in an amount of at least 1 wt.%, preferably at least 2 wt.%, further preferably at least 3 wt.%, in each case based on the total weight of the first component.

[0091] The microhollow spheres are preferably contained in the first component in an amount of at most 10 wt.%, preferably at most 8 wt.%, more preferably at most 6 wt.%, in each case based on the total weight of the first component.

[0092] The microhollow spheres are preferably present in the first component in an amount of 1 to 10 wt.%, more preferably 2 to 8 wt.%, and more preferably 3 to 6 wt.%, based on the total weight of the first component. After the addition of the second component, the polymer shell is opened by a solvent, i.e., the polymer shell is at least partially or completely dissolved, so that the blowing agent contained in the microhollow sphere is released. The mixture of the first and second components then foams up.

[0093] The microspheres and the solvent are therefore functionally separated before the two components are combined. They are functionally separated if the polymer shell of the microspheres dissolves or decomposes essentially only after the two components are combined. This is ensured by the microspheres and the solvent existing in different components (first and second component) or by other means of separation.

[0094] The microhollow spheres can have a diameter Dso of 5 to 100 pm, preferably 5 to 50 pm, and even more preferably 10 to 30 pm. In a preferred embodiment, the microhollow spheres have a diameter Dso of 10 to 16 pm. They have a polymer shell and contain a blowing agent. Polymer shells with a low calorific value are preferred. In principle, all polymer shells are suitable that can be opened and dissolved by a solvent, preferably without the application of heat.

[0095] The outer shell of the microcapsules can be formed from any polymer material, as long as the material is able to enclose a suitable propellant gas and expands when energy is supplied or breaks open by the addition of an agent and releases this propellant gas.

[0096] The polymer shell comprises a polymer, for example EVA (ethylene-vinyl acetate copolymer); polyvinylidene chloride and / or acrylonitrile; acrylonitrile, methyl methacrylate and / or methacrylonitrile, or combinations thereof; preferably acrylonitrile and / or methacrylonitrile, most preferably acrylonitrile and methacrylonitrile.

[0097] The propellant is preferably a propellant gas. The choice of propellant is unlimited. Propellants that occupy a larger volume after release are preferred. Therefore, liquid propellants may be preferred over gaseous propellants. Propellants that are non-flammable and chemically inert are advantageous.

[0098] Examples of propellants include liquefied gases (liquid at room temperature and low compression, e.g. < 10 bar) comprising short-chain hydrocarbons selected from methane, ethane, propane, n-butane, isobutane, pentanes such as n-pentane, isopentane and neopentane, or combinations thereof; chlorofluorocarbons such as trichlorofluoromethane and dichlorodifluoromethane; dimethyl ether, air, CO2, nitrogen, CFCs or combinations thereof.

[0099] For example, a mixture of propane and butane can be used. Isobutane is particularly preferred.

[0100] The propellant can be used dry, as a dispersion, or with varying degrees of dryness. In one application, the microcapsule is a dispersion; in another, it is dried or has varying degrees of dryness. In yet another embodiment, the microcapsule is partially dried and partially in a dispersion. Water is used as the dispersion medium. The propellant-containing microcapsules have a propellant content of 2 to 35 wt.%, preferably 5 to 30 wt.%, more preferably 10 to 30 wt.%, and more preferably 20 to 30 wt.%, based on the dried microcapsule. In one embodiment, the dried microcapsules have a propellant content of at least 20 wt.%. The propellant-containing microcapsules generally have a shell material content of 50 to 95 wt.%, preferably 50 to 90 wt.%, based on the dried microcapsule.-%, further preferably 60 to 90 wt.%, further preferably 60 to 80 wt.%.

[0101] The microcapsules equipped with propellant gas may also contain other ingredients in the core and / or shell material, such as magnesium hydroxide and / or silicates.

[0102] The propellant-filled microcapsules contain such additional ingredients, each based on the dried microcapsule, in a content of 0 to 30 wt.%, preferably 0 to 25 wt.%, more preferably 0 to 20 wt.%, more preferably 1 to 5 wt.%.

[0103] The propellant-filled microcapsules can have any desired average particle size. Average particle sizes are, for example, 1 to 90 µm, preferably 1 to 50 µm, more preferably 5 to 20 µm, and more preferably 10 to 16 pm.

[0104] The propellant-filled microcapsules generally have a density of < 20 kg / m³, based on the dried microcapsules. 3 , preferably of < 17 kg / m² 3 , further preferably of < 14 kg / m² 3 , further preferably of < 12 kg / m² 3 on.

[0105] Microhollow spheres are also referred to as microspheres. For example, Expancel® type microhollow spheres from Mouryon can be used, such as Expancel® microhollow spheres of type 461 DU 20, 551 WU 20, 031 30 WUF 40 or 031 DU 40, with type 031 WUF 40 or 031 DU 40 being particularly preferred. Other manufacturers of suitable microhollow spheres include Kureha and Matsumoto.

[0106] The use of micro-hollow spheres results in a very compact microfoam with good thermal insulation properties when foamed. The resulting foam is not as brittle as pure water glass foam produced without the use of such microcapsules. A positive effect on the expansion volume is also often achieved when using these microcapsules.

[0107] According to the invention, the mass ratio between water glass (or water glasses) and the propellant-filled microcapsules is 5.0 to 35.0, preferably 6.0 to 25.0, more preferably 8.0 to 24.0.

[0108] Within the scope of the present invention, the use of other blowing agents, such as azo compounds, which are expensive, problematic to handle, and environmentally problematic, is preferably avoided. The use of expandable graphite can also be omitted within the scope of the present invention. In one embodiment, the composition is free of expandable graphite. In another embodiment, the composition is free of conventional blowing agents such as triazine derivatives. In a preferred embodiment, the composition is free of both expandable graphite and triazine derivatives.

[0109] binder

[0110] In addition to the aforementioned water glass(s), the first component of the two-component composition according to the invention can contain at least one further binder. This binder can be organic or inorganic, with inorganic binders being advantageous in order to keep the organic content in the two-component composition according to the invention low.

[0111] The binder can lead to chemical hardening and / or cross-linking of the resulting foam.

[0112] Organic and / or inorganic binders can harden or crosslink through physical or chemical processes. The binder is therefore preferably hardenable or crosslinkable. In physical hardening, the binder is suspended in a solvent, for example. Hardening then occurs, for example, through the evaporation or drying of the solvent. Examples include polyolefins, vinyl polymers (e.g., polyvinyl acetate, polyvinyl alcohol), styrene-butadiene copolymers, and polyacrylates (acrylic resins). Acrylic resins, for example, are based on polymers or copolymers of acrylic acid, methaacrylic acid, and their esters. They are copolymerized, for example, with other unsaturated monomers such as styrene or acrylonitrile.

[0113] Other possible binders include SBR latex, natural latex, neoprene latex, cement, or gypsum. Examples of possible cement types include:

[0114] The European standard DIN EN 197-1 distinguishes 27 so-called normal cements, which are divided into five categories according to their main components. These are:

[0115] - CEM I: Portland cements

[0116] - CEM II: Portland composite cements

[0117] - CEM III: Blast furnace cements

[0118] - CEM IV: Pozzolanic cements

[0119] - CEM V: Composite elements

[0120] The main types of cement are subdivided according to their main components into the cement types according to DIN EN 197-1 and special cements VLH according to DIN EN 14216:

[0121] - Portland cement CEM I - Portland cement CEM HAS

[0122] - Portland silica fumed cement CEM HAD

[0123] - Portland pozzolanic cement CEM II / -P and CEM II / -Q

[0124] - Portland fly ash cement CEM II / -V and CEM II AW

[0125] - Portland shale cement CEM HAT

[0126] - Portland limestone cement CEM HAL and CEM HALL

[0127] - Portland composite cement CEM HAM

[0128] - Blast furnace cement CEM III / VLH III

[0129] - Pozzolana cement CEM IV / VLH IV

[0130] - Composite cement CEM V / VLH V

[0131] Portland cement is preferred, but other types of cement can also be used. A specialist can select a suitable type of cement depending on the application.

[0132] Examples of gypsum types include:

[0133] - Plaster

[0134] - Plaster

[0135] - Mortar plaster

[0136] - Adhesive plaster

[0137] - Machine-applied gypsum plaster

[0138] - Joint plaster

[0139] - Plaster of Paris

[0140] - Screed plaster

[0141] - Ready-mixed plaster

[0142] - Polymer gypsum

[0143] Adhesive plaster is preferred, especially red band.

[0144] In one embodiment, the inorganic and / or organic binder is a plastic and is in the form of a dispersion. All of the aforementioned plastics are suitable for use as plastic dispersions, in particular styrene-butadiene copolymers (especially styrene-butadiene acrylate), acrylate dispersions, polyvinyl acetate dispersions, SBR latex, natural latex, neoprene latex, polyurethane dispersions, or epoxy resin dispersions. Plastic dispersions that are alkali-resistant or cement-compatible are particularly preferred. Foams with a plastic dispersion exhibit high elasticity and low density. This applies both when the plastic dispersion is used in addition to another binder and when the plastic dispersion is used as the binder itself.

[0145] Liquid plastics are also possible in non-aqueous systems, for example, liquid silicone resin or polyurethane systems. A hardener is preferably added to these to fix the foam structure.

[0146] Chemical hardening or crosslinking may require the addition of a hardener, such as a carboxylic acid ester; a crosslinking agent (e.g., sulfur, peroxides, or metal oxides in the vulcanization of rubber); a catalyst (e.g., acid or driers); or the application of heat or UV radiation. Chemical hardening, particularly the hardening of cement or gypsum, may require the addition of a setting accelerator. Examples of setting accelerators for cement include calcium chloride; alkaline carbonates, such as sodium carbonate, potassium carbonate, and calcium carbonate; aluminates, such as tricalcium aluminate; calcium ammonium nitrate; calcium nitrate; or basic ammonium salts.

[0147] Examples of setting accelerators for gypsum are calcium sulfate dihydrate (preferably finely ground) or potassium sulfate.

[0148] Physical hardening is also conceivable, for example, by removing water. Desiccants or superabsorbents are suitable for this purpose. Removing the water allows the foam to stabilize quickly and prevents collapse. Quicklime is particularly suitable because, in addition to binding the water, it releases a large amount of heat during its reaction. The released heat, combined with the binding of water, leads to accelerated hardening and stabilization of the foam.

[0149] If the binders, such as plastic dispersions, cement or gypsum, cannot react directly with the solvent, for example with 4-methyl-1,3-dioxolan-2-one, hardeners can be used to harden and stabilize the foam.

[0150] Kaolins are particularly preferred binding agents.

[0151] Components of the second component

[0152] Not all of the components of the second component described below are mandatory.

[0153] solvents

[0154] The second component comprises a solvent. The solvent serves to open the polymer shell of the microhollow spheres. For this purpose, it is at least partially dissolved or dissolved. Therefore, according to the invention, any solvent that can partially dissolve or dissolve the polymer shell of the microhollow spheres used is suitable.

[0155] Furthermore, the solvent is preferably selected in such a way that it simultaneously initiates the crystallization of the water glass.

[0156] Solvents that can be used according to the invention are preferably selected from the group consisting of polar solvents such as acetone, nitromethane, or dimethyl sulfoxide, or organic carboxylic acid esters (RI-OC(=O)-O-R2 with Ri, R2 = alkyl, allyl, and / or aryl groups) or a combination thereof; preferably a carboxylic acid ester. The carboxylic acid ester can be selected from the following group: dimethoxyformic anhydride, 1,3-dioxolan-2-one, 4-methyl-1,3-dioxolan-2-one, 4-hydroxymethyl-1,3-dioxolan-2-one, or combinations thereof; and is preferably 1,3-dioxolan-2-one or 4-methyl-1,3-dioxolan-2-one or a combination thereof.

[0157] Polar solvents with a high dipole moment are particularly suitable for rapidly opening the polymer shell of microhollow spheres when the polymer shell contains acrylonitrile and / or methacrylonitrile. For example, acetone (λ = 20) reacts with the polymer shell, but more slowly than 4-methyl-1,3-dioxolan-2-one (λ = 65). Therefore, especially when the polymer shell contains acrylonitrile and / or methacrylonitrile, 1,3-dioxolan-2-one and 4-methyl-1,3-dioxolan-2-one are particularly preferred. Both solvents can rapidly open the polymer shell.

[0158] 4-Methyl-1,3-dioxolan-2-one is particularly preferred as a solvent in the second component.

[0159] Water

[0160] The second component of the two-component composition according to the invention comprises water. This increases the volume of the second component, so that the mixing ratio with the first component can be advantageously adjusted.

[0161] Water may also be included additionally or alternatively in the first component.

[0162] In a preferred embodiment, however, the first component is anhydrous.

[0163] binder

[0164] The second component may also contain a binder.

[0165] The binding agent is primarily metakaolin. Metakaolin is produced from kaolinitic clay and is classified as a synthetic pozzolan (abbreviation for main cement constituents according to DIN EN 197-1: Q).

[0166] Kaolin (also known as china clay) is an unconsolidated, white sedimentary rock (a weathering product of feldspar) belonging to the large group of clays. Kaolin is iron-free. Clay with a high kaolin content is calcined after crushing and thermal drying to produce metakaolin. Metakaolin therefore contains high proportions of reactive silica and thus exhibits pozzolanic properties. Since kaolinitic clays are not available in large quantities and metakaolin is expensive, its use in concrete as an additive and in cement production is strictly limited.

[0167] By adding metakaolin with a high proportion of SiO2 and AlO2O3, the water stability of the cured product, obtainable from the reaction of the first and second components, can be greatly increased.

[0168] Rheology modifiers

[0169] The second component can additionally contain a rheology modifier, which, for example, controls the viscosity of the second component and thus of the two-component composition according to the invention.

[0170] Examples of this are Tafigel® products.

[0171] Wetting agent

[0172] The second component may also contain a wetting agent.

[0173] Examples of this are Metolat® products. The wetting agent first ensures a uniform dispersion, but the addition of a wetting agent also guarantees that the organic solvent is sufficiently water-soluble to open the micro-hollow spheres.

[0174] Two-component composition

[0175] The two-component composition according to the invention is formed by bringing the first and second components into contact.

[0176] In a preferred embodiment, the combination of the first component and the second component can be in a ratio between 10:1 and 1:1, preferably between 5:1 and 1:1, more preferably between 4:1 and 1:1, more preferably between 3:1 and 1:1, more preferably between 2:1 and 1:1, more preferably at approximately 2:1.

[0177] The ratio depends on the desired reaction time. It also depends on the binder used. Furthermore, it depends on the components contained in the first and second components.

[0178] Furthermore, it is preferred if, in relation to the total quantity, the amount of propylene carbonate is at least 1.5 wt%, preferably 3 to 4 wt%, and more preferably less than 5 wt%.

[0179] The following are examples of the mixing ratios that result:

[0180]

[0181] 10:1 16.5 to 55%

[0182]

[0183] Furthermore, the mixing ratio of the components water glass to propylene carbonate should be in the range of 60 to 1 to 2 to 1.

[0184] Furthermore, the mixing ratio of propylene carbonate to microhollow spheres should be in the range of 1 to 15 to 10 to 1.

[0185] In one embodiment of the present invention, the mixing ratio of the components water glass to propylene carbonate is in a range of 60 to 1 to 2 to 1, and at the same time the mixing ratio of propylene carbonate to microhollow spheres is in a range of 1 to 15 to 10 to 1.

[0186] The rate of reaction of the first and second components can be controlled by temperature, water addition, and viscosity adjustment.

[0187] The components of the two-component composition according to the invention, i.e., the components of the first and second components, are preferably selected such that the following properties of the two-component composition result:

[0188] Solids content in wt.%: preferably at least 40%, more preferably at least 45%, more preferably at least 50%, more preferably at least 55%

[0189] preferably at most 80%, more preferably at most 75%, more preferably at most 70%, more preferably at most 65%

[0190] preferably 40 to 80%, more preferably 45 to 75%, more preferably 50 to 70%, more preferably 55 to 65%

[0191] Water content in wt.%: preferably at least 20%, more preferably at least 25%, more preferably at least 30%, more preferably at least 35%

[0192] preferably at most 60%, more preferably at most 55%, more preferably at most 50%, more preferably at most 45%, preferably 20 to 60%, more preferably 25 to 55%

[0193] %, more preferably 30 to 50%, more preferably 35 to 45%

[0194] Organic content in wt.%: preferably at least 2%, more preferably at least 3%, more preferably at least 4%, more preferably at least 5%

[0195] preferably at most 15%, more preferably at most 10%, more preferably at most 9%, more preferably at most 8%

[0196] preferably 2 to 15%, more preferably 3 to 10%, more preferably 4 to 9%, more preferably 5 to 8% proportion of microhollow spheres, preferably at least 0.5%, more preferably min wt%: at least 1%, more preferably at least 1.5%, more preferably at least 2%

[0197] preferably at most 10%, more preferably at most 8%, more preferably at most 6%, more preferably at most 5%

[0198] preferably 0.5 to 10%, more preferably 1 to 8%, more preferably 1.5 to 6%, more preferably 2 to 5%

[0199] Propylene carbonate content preferably at least 0.5%, more preferably at least 0.75% by weight, more preferably at least 1.0% by weight.

[0200] further preferred at least 1.5%

[0201] preferably at most 10%, more preferably at most 8%, more preferably at most 6%, more preferably at most 5%

[0202] preferably 0.5 to 10%, more preferably 0.75 to 8%, more preferably 1.0 to 6%, more preferably 1.5 to 5%

[0203] According to the invention, it is important to note that the two-component composition has a low organic content. By adjusting the formulation, the total organic content (of the two-component composition according to the invention) can be adjusted to the values ​​mentioned above. This can positively influence the fire classification. Furthermore, the environmental aspects are also significantly improved.

[0204] The viscosity and density of the first and second components are preferably adjusted to the following ranges: viscosity, density

[0205] First component preferably 50 to 150 preferably 1.20 to 1.80

[0206] dPas, further preferred g / cm 3 , further preferably 1.25 to 60 to 130 dPas, further 1.75 g / cm² 3 , further preferably 1.30, preferably 70 to 110 to 1.70 g / cm³ 3 , further preferably dPas, further preferably 1.35 to 1.65 g / cm³ 3

[0207] 80 to 100 dPas

[0208] Second component preferably 20 to 100, preferably 0.90 to 1.50

[0209] dPas, further preferred g / cm 3 , further preferably 0.95 to 25 to 90 dPas, further 1.45 g / cm³ 3 , further preferably 1.00 preferably 30 to 80 to 1.40 g / cm³ 3 , further preferably dPas, further preferably 1.05 to 1.35 g / cm³ 3

[0210] 35 to 75 dBas

[0211] The viscosity is measured using a HAAKE VT2plus viscometer, spindle 2, 62.5 RPM. The viscosity can be adjusted by adding fillers within the range described above, ensuring that the components can still be easily pressed using a hand press. At the same time, the viscosity is high enough that the resulting foam maintains good adhesion to walls, even when applied to vertical surfaces. This is achieved with the values ​​given above.

[0212] The two-component composition according to the invention can have further components in either the first or the second component.

[0213] Further components of the two-component composition according to the invention: Within the scope of the present invention, it was surprisingly found that the composition of process step (1) or (1'), which has further components, is advantageous for the fire protection material obtained according to the process according to the invention.

[0214] The ceramicization of the composition at elevated temperatures is a supporting component.

[0215] These components can support the ceramicization of the fire protection material during the temperatures of the inventive process and / or exert this effect in the event of a fire.

[0216] A component that promotes the ceramization of the composition at elevated temperatures is preferably selected from the group consisting of mineral additives, aluminum hydroxide, filter dust, fly ash, ceramic hollow spheres, glass hollow spheres, foam glass granules, slate flour, quartz flour, mica, wollastonite, calcium carbonate, kaolin, vermiculite, and ettringite. The use of aluminum hydroxide, vermiculite, glass hollow spheres, ceramic hollow spheres, and calcium carbonate, as well as mixtures thereof, is particularly preferred.

[0217] The weight fraction of this component, which supports ceramization, is generally 1 to 15 wt.%, preferably 3 to 13 wt.%, and more preferably 6 to 12 wt.%, based on the total mass of the composition.

[0218] Borax / Water glass / Borax hardener

[0219] Another preferred component of the composition is disodium tetraborate decahydrate (borax), wherein the content of disodium tetraborate decahydrate, based on the total mass of the composition, is generally 0.1 to 10 wt.%, preferably 0.25 to 7.5 wt.%, and more preferably 0.5 to 5.0 wt.%.

[0220] The composition may additionally include at least one further component which leads to hardening and / or setting of the composition.

[0221] The other component is generally selected from the group consisting of phosphate-containing water glass hardeners, glyoxal, triacetin, ethylene carbonate, and propylene carbonate. The content of each hardener, based on the total mass of the composition, is generally 0.5 to 10 wt.%, preferably 1.0 to 7.5 wt.%, and more preferably 2.0 to 5.0 wt.%.

[0222] Hygroscopic component

[0223] The composition may additionally include at least one further component that has moisture-retaining and / or hygroscopic properties. By adding such a component, the residual moisture content of the fire protection material can be adjusted and kept constant.

[0224] This additional component is preferably selected from the group consisting of glycerin, Epsom salt (magnesium sulfate), calcium chloride, zeolites, and sugar (also in the form of molasses). The use of Epsom salt is particularly advantageous because its high water of crystallization has especially positive effects on the cooling action in case of fire.

[0225] Other components

[0226] Furthermore, the composition may additionally include at least one silica.

[0227] The composition may also contain other ingredients commonly used in gas-producing compounds.

[0228] The composition generally has a water content of 15 to 65 wt.%, preferably 20 to 55 wt.%, and particularly preferably 25 to 50 wt.%, based on the total mass of the composition. This water content in the composition can be achieved by the specific selection of the individual components or by the addition of water. Higher water contents, for example up to 95 wt.%, can also be achieved by adding further water.

[0229] The water content of the composition can be increased by adding substances with a high water of crystallization content, such as ettringite. Similarly, the drying out of the mass can be reduced or prevented by adding substances with a high vapor pressure, such as glycerin. The addition of such substances also increases the residual moisture content of the fire protection material.

[0230] Furthermore, the two-component composition according to the invention preferably does not include a base, which has the positive effect of making the pH value significantly more tolerable.

[0231] In particular, bases selected from the group consisting of sodium hydroxide and potassium hydroxide are excluded from the composition according to the invention.

[0232] Use of the two-component composition according to the invention

[0233] The two-component composition according to the invention can be used as construction foam, fire protection foam, non-combustible adhesive and / or for the production of fire protection materials.

[0234] Construction foam, also known as assembly foam, insulating foam, filling foam, or insulating foam, is, according to the present invention, a spray foam used in construction for sealing, bonding, and insulating. This process is referred to as "foaming." Prior art construction foams are typically polyurethane-based and are then also called PU foam or PUR foam. These construction foams are used as one-component (1K) or two-component (2K) foams.

[0235] Fire-resistant foam, as defined in the present invention, is a fire-retardant material used to slow down or prevent the spread of fire and smoke. It typically consists of expanding polymers that expand when heated, thereby forming an insulating barrier. In industry and trade, fire-resistant foam is frequently used for sealing cable and pipe penetrations, protecting steel beams, or lining walls and ceilings. It is also used in the electrical engineering, mechanical engineering, automotive, and civil engineering sectors.

[0236] Fire protection materials within the meaning of the present invention refer to materials that are (largely) non-combustible, have a temperature-insulating or heat-insulating effect and thus provide heat or flame protection, and may even contribute to preventing fires, for example by releasing water.

[0237] The gas impermeability of fire-resistant materials can be desirable in specific situations, as it prevents the supply of oxygen to the source of the fire and suppresses the escape of potentially hazardous combustion gases. To facilitate processing and application, fire-resistant materials generally possess not only dimensional stability, which they preferably retain even at elevated temperatures, but also a low density and a certain degree of hardness. The dimensional stability, even at elevated temperatures, enables the fire protection of specific, selected areas. The low density simplifies the transport and attachment of these materials to the desired locations (e.g., on objects). Furthermore, the low density of fire-resistant materials results in a minimal increase in the overall weight of an object after the application of the fire-resistant material.The hardness of fire-resistant materials facilitates processing (for example, cutting them into desired sizes and shapes), transport, storage, and application to objects. In addition to cutting fire-resistant materials to size after installation, manufacturing them directly into the desired shapes is also advantageous, as this eliminates the subsequent cutting step.

[0238] Cutting to size within the meaning of the invention means any form of processing, such as milling, cutting, etching or other methods known to those skilled in the art, to obtain a fire protection material of the desired size and shape.

[0239] Due to the diverse applications of fire protection materials, such as outdoor use, high stability against the prevailing environmental conditions at the point of use, such as temperature fluctuations, direct sunlight, wind, water exposure, and humidity, is essential. The requirements for fire protection materials vary depending on the application and may therefore differ from this description.

[0240] These materials are used in various industries, such as the construction industry, particularly in preventative structural fire protection. However, fire-resistant materials also have a potentially wide range of applications outside of fire protection, especially due to their temperature-insulating properties. The application areas of fire-resistant materials and thermal insulation materials often overlap due to their very similar requirements.

[0241] Application areas with (high) temperature differences (outside of a fire) for which fire-resistant materials can be used include metallurgy and the metalworking industry in general, as well as the thermal insulation of furnaces in particular. The "ordinary" thermal insulation of buildings, such as houses, while simultaneously maintaining the aforementioned fire-resistant properties through the use of fire-resistant materials is also conceivable. Further areas of application are obvious to the expert.

[0242] The development of improved fire protection materials is driven and influenced by both legal requirements and standard market mechanisms. Therefore, the production of fire protection materials possessing the aforementioned properties should be as cost-effective, energy-efficient, and simple as possible. Furthermore, the fire protection materials should be as customizable as possible in terms of shape or easy to process to achieve the desired form. Ideally, they should also be able to be made from safe, readily available, and inexpensive raw materials. The term "foaming" or "expanding"—as used in the context of the present invention—refers to the mode of action of special materials that can be expanded and thereby form an insulating body.A fine, uniform structure of this inflating compound is of particular interest in order to achieve a uniform and high level of protection across the entire area of ​​the inflating compound. Any kind of cracks or larger cavities are undesirable. Furthermore, an increase in volume is necessary, because if this increase is absent or minimal, the resulting bodies generally have an unacceptably high density. Accordingly, within the scope of the present invention, a "poor inflating layer" or "poor inflating behavior" means that the volume increase was insufficient and / or the structure of the inflating body does not have a fine, uniform structure.

[0243] The water resistance and structure of the fire protection materials obtained according to the present invention are optimized, and the swelling behavior of the claimed compositions is optimal.

[0244] The term "solid fire protection material" used in this invention refers, as is also evident from its intended use as a fire protection board, to a solid material. This material is preferably not powdery, whereby the presence of a few powdery residues on the otherwise non-powdery and solid fire protection material is to be understood as a solid material.

[0245] The color of the fire protection material produced using the inventive method is preferably white to light beige.

[0246] The use of the two-component composition according to the invention is achieved, as already explained, by bringing the two components into contact, wherein the solvent of the second component splits the micro-hollow spheres of the first components.

[0247] Breaking down the microcapsules with a solvent is a more energy-efficient method compared to inflating them by energy input. This allows for the use of lower process temperatures, such as room temperature, than with energy-based inflation.

[0248] The rupture of the microcapsules with a propellant can occur in a variety of ways. For example, a chemical reaction between the propellant and the microcapsule, resulting in gas release, or a physical interaction between the propellant and the microcapsule, causing the capsules to swell and thus releasing the propellant gas, are conceivable. Of course, other interactions for rupturing the microcapsules are possible, and a combination of different interactions is also conceivable.

[0249] Preferably, the gas release begins after the addition of the agent within a period of between 20 seconds and 20 minutes, more preferably between 20 seconds and 10 minutes, more preferably between 30 seconds and 5 minutes, and more preferably between 1 minute and 3 minutes.

[0250] The resulting fire-resistant material is essentially dimensionally stable. It generally has a density of less than 0.6 g / cm³. 3 preferably less than 0.5 g / cm³ 3 , especially preferably less than 0.4 g / cm³ 3 , on.

[0251] If the first and second components are provided in a specific mold and subsequently brought into contact, the resulting fire-resistant materials can preferably be removed from this mold easily, essentially without residue, and with their shape stability after hardening. The mold can then be reused without extensive cleaning.

[0252] In contrast to the straightforward removal of fire protection materials from their specific molds, the production of composite materials presents a different challenge. Here, during the initial contact, the two components are in contact with carrier materials, or they contact these carrier materials after expansion. Following expansion, the fire protection material and the carrier materials form a solid composite material (or composite body). The composition thus exhibits sufficient adhesive properties, so that, preferably, no additional adhesives are required in the production of composite materials. This aspect is discussed further in the section on the production of composite materials.

[0253] Use of fire protection materials

[0254] The fire protection materials obtained according to the inventive method are used, for example, in the construction industry, such as in the lining and / or cladding of doors, windows, door frames, window frames, walls, floors, and ceilings, for penetrations, penetrations, and other openings. Besides building construction, and, for example, in the lining of tunnels and pipes, the fire protection materials can also be used in shipbuilding and vehicle construction, such as in railway carriages, or in the transport sector, such as in containers. The protection of cables and other electronics, as well as use in personal protective clothing, are also possible.In particular, the materials described above according to the invention can be used for the manufacture of molded parts for heating installations, molded parts for valves and fittings, fire protection boxes for accumulators and batteries in private households, modular bulkhead boxes, system devices for external fire barriers, plates or boxes for the construction of component reveals, fire protection devices for IT servers, fire protection devices for hazardous material cabinets, for fire protection of automobiles and transport vehicles, in particular for battery protection of electric vehicles, as well as for insulating and fire protection material in the aerospace industry.

[0255] The fire protection materials according to the invention can be used, for example, to protect a "black box" or similarly sensitive electronics. A black box is a computer used, for example, in manned and / or unmanned aircraft, land vehicles, and watercraft. Examples of aircraft include airplanes and helicopters. Examples of land vehicles include trains and cars. Examples of watercraft include ships, boats, and submarines. During operation, the black box records various parameters, such as the vehicle's speed and position, but can also be used to record other parameters, such as sounds like conversations. The recorded data can be read out if necessary. This is particularly important in the event of accidents, such as an airplane crash, and / or near misses, in order to reconstruct the sequence of events and / or the cause of the accident using the recorded data.

[0256] Since accidents often involve extreme conditions, the black box must be protected against such conditions. From an economic perspective, this protection should be as compact and lightweight as possible. These extreme conditions include, for example, high thermal energies, such as those caused by a fire, and high kinetic energies, such as those encountered in a high-speed collision. The black box may also need protection against various chemicals that, particularly in the event of an accident, could contact its electronics and compromise the stored data, preventing or partially retrievable data. Such chemicals include water, which might come into contact with the black box during firefighting or from a leak in a watercraft, as well as other chemicals, such as those used in fire suppression.Chemicals that are released, for example, by the high thermal energies of a fire.

[0257] Composite materials

[0258] The fire protection material produced by the inventive method, starting from the first and second components, can be used in the form of composite materials. A composite material comprises such a fire protection material and at least one carrier material.

[0259] The composition obtained from the first and second components exhibits not only expanding properties but also adhesive properties. Therefore, the composition is particularly suitable for bonding materials.

[0260] Accordingly, the present invention also relates to composite materials comprising a composition of a fire protection material starting from the first and second components and at least one carrier material, wherein the composition is either applied to the carrier material or the carrier material is impregnated with this composition.

[0261] The carrier material is selected from the group consisting of nonwoven materials, in particular nonwoven materials made of glass fibers, polyester, natural fibers, cellulose / pulp or polyamide; woven fabrics made of glass fibers or blended fabrics; nonwoven fabrics made of glass fibers; mineral wool, in particular mineral wool made of glass or rock; cellulose materials such as paper materials and cardboard materials, in particular paper honeycomb, wood fiberboard or honeycomb constructions; plastic materials; metal materials, such as metal foils and sheets, in particular aluminum foils and sheets or stainless steel foils and sheets; glass materials, such as glass foils and glass wool; cotton fabrics; wood materials and wood-based panels such as MDF, HDF and particleboard; foams made of polyurethane, polystyrene, glass or rock foam, PVC or phenol; materials made of extruded polystyrene foam; materials made of polyethylene foam, polypropylene foam, polyurethane foam and polypropylene foam;Films made of polypropylene, polyethylene, polyurethane or silicone and general decorative surfaces such as HPL or CPL. Other suitable materials include materials made of flax, jute, hemp and cellulose fibers, as well as textile materials in general.

[0262] It is preferably selected from the group consisting of: nonwoven materials; paper and cardboard materials, such as paper honeycomb; plastic materials; metal materials, such as metal foils, in particular aluminum foils; glass materials, such as glass foils and glass wool; cotton fabrics; wood materials; mineral wool; materials made of extruded polystyrene foam, polyurethane foam, polyethylene foam and polypropylene foam; materials made of jute, flax, hemp and cellulose fibers; and textile materials.

[0263] It is also possible to use composite structures made of, for example, glass fabric / aluminium or HPL / glass fleece) as a substrate material.

[0264] Furthermore, the carrier materials can be perforated, slit, or structured in other ways for specific applications.

[0265] Within the scope of the present invention, the carrier material can be impregnated with the expanding composition, and subsequently, according to process step (2) or (2'), the composition can be converted into the fire-retardant material. Impregnation of the carrier material is possible by using an immersion bath filled with the composition and immersing the carrier material into the immersion bath. Impregnation of suitable carrier materials, in particular paper or cardboard materials such as paper or cardboard honeycomb, leads to the penetration of the composition between the fibers of the carrier material, so that even cutting such impregnated carrier materials does not result in a loss of fire-retardant properties. Impregnation of the composition into suitable carrier materials can also be improved by the use of surfactants. Process step (2) or (2')(2') can be carried out before or after cutting the impregnated materials. If paper honeycomb is impregnated with the composition, non-combustible composite materials are obtained after applying process step (2) or (2'), from which, for example, walls, ceilings or other building elements can be manufactured.

[0266] The fire protection effect of these composite materials can be further increased by the following measures:

[0267] 1. The paper used for the paper honeycomb is perforated beforehand. This reduces the percentage of flammable material and improves the absorption of the composition. Furthermore, the composition also fills the perforated cavities, increasing its concentration.

[0268] 2. Glass, paper, or plastic fleece impregnated with a specific composition is used as a cover layer for the paper honeycomb. This cover layer increases both the mechanical stability of the paper honeycomb and its fire-resistant properties. The amount of fire-resistant compound applied can be varied as required. 3. The process step (2) or (2') according to the invention then follows.

[0269] Instead of nonwoven fabric, top layers made of perforated paper and paper perforated with fire-resistant compound can also be used.

[0270] Furthermore, the resulting surface layers can also be coated with aluminum foil, which improves heat reflection and reduces water vapor diffusion. Sandwich structure

[0271] A further object of the present invention is a composite body comprising a carrier material according to the above definition, which has been provided with the composition of fire protection material starting from the first and second components, and at least one further layer, which is formed by an aluminum foil, a glass fleece or a paper or cardboard material and which is applied to the carrier material.

[0272] The substrate material can preferably be a paper or cardboard honeycomb.

[0273] The next layer can be formed, for example, by a perforated paper fleece, a perforated cardboard material, or glass fleece.

[0274] This additional layer, formed by a perforated paper fleece or a perforated cardboard material, may also preferably be impregnated with the composition.

[0275] After providing such a sandwich structure, a fire-resistant material is obtained which has the structure described above. Composite bodies with such a structure are also referred to as sandwich structures within the scope of the present invention. These sandwich structures not only exhibit excellent fire-retardant properties, but are also sufficiently strongly bonded due to the adhesive properties of the composition, without the need for an additional adhesive.

[0276] In particular, when using cardboard honeycomb as a second layer, covering the cardboard honeycomb with the fire protection material produced by the inventive method prevents heat transfer by convection and simultaneously (for example in case of fire) achieves a cooling effect by evaporating the water from the fire protection mass.

[0277] In the event of a fire, the resulting sandwich structures remain intact and individual layers do not break off from the sandwich.

[0278] The sandwich structures according to the invention comprise the following structure:

[0279] (1) a first layer of aluminium foil, glass fleece, paper or cardboard material or a combination thereof;

[0280] (2) a second layer of nonwoven material; paper or cardboard material, such as a paper honeycomb; plastic material; metal material, such as a metal foil, in particular aluminum foil; glass material, such as glass foil or glass wool; cotton material, wood material or mineral wool material; polyethylene foam materials; extruded polystyrene foam materials; polyurethane foam materials; polypropylene foam materials; flax, jute, hemp and cellulose materials;

[0281] (3) a third layer consisting of aluminium foil, glass fleece, paper or cardboard material or a combination thereof;

[0282] wherein the composite material is structured such that the first layer is provided on one side of the second layer and the third layer is provided on the other side of the second layer and the fire protection material from the composition according to the inventive method has been applied on one side or on both sides.

[0283] The two-component composition according to the invention is preferably used in a cartridge with two separate compartments, wherein the first component is located in the first compartment and the second component is located in the second compartment. A two-component cartridge is an innovative packaging system specifically designed for products consisting of two separate components that react and harden upon application. This type of cartridge is widely used in the construction and repair industries, the automotive sector, and the arts and crafts sector.

[0284] The cartridge is typically made of robust plastic, ensuring safe storage and handling of the two components. The cartridge is divided into two compartments, each containing one of the components. The two compartments are preferably arranged coaxially.

[0285] During application, the cartridge is inserted into a suitable cartridge gun. Pressing the trigger applies pressure to the cartridge, forcing both components simultaneously through the mixing nozzle. Once mixed, a chemical reaction begins between the solvent and the microspheres, resulting in hardening. The curing time is described above.

[0286] The cartridge allows for precise dosing of the two components, resulting in a consistent quality of the final product.

[0287] Because the components are stored separately, the durability of the materials is maintained for longer without them reacting prematurely.

[0288] Using a cartridge gun makes the application simple and clean, without the need for additional mixing tools.

[0289] The two components in the two-component cartridge are mixed by a special mixing mechanism integrated into the mixing nozzle. The mixing nozzle is a crucial element that ensures uniform mixing. The mixing ratio is determined by the pipe diameter of the compartments. The nozzle contains special flow paths or mixing elements that guarantee thorough blending of the two components. One example of this is the use of a static mixer. This process ensures that the two components react optimally with each other, resulting in high quality and strength of the final product.

[0290] Example 1

[0291] The present invention will be explained in more detail with reference to the following exemplary embodiment.

[0292] A two-component composition is manufactured from the following components of the first and second components. Both components are provided separately in a two-compartment cartridge:

[0293] Recipe: Mixing ratio (mass ratio in %)

[0294] First component

[0295] Water glass 1 25%

[0296] Water glass 2 40%

[0297] Micro hollow sphere 5%

[0298] Silicate fiber 3 mm 0.7%

[0299] Fillers 29.3%

[0300] Total mass: 100%

[0301] Second component

[0302] Water 40%

[0303] Additional additives 5%

[0304] Propylene carbonate 10%

[0305] Meta-Kaolin 10%

[0306] Fillers 35%

[0307] Total mass: 100%

[0308] The first and second components are supplied in a two-compartment cartridge and dispensed from the cartridge at a mixing ratio of 2:1. The dispensed product, before complete curing, exhibits the following properties: Composition of components:

[0309] >

[0310]

[0311] Density and viscosity

[0312]

[0313] Example 2

[0314] Exemplary embodiment 2 illustrates the technical effect attributable to the presence of metakaolin in the composition according to the invention. For this purpose, two compositions are provided which differ solely in the presence of metakaolin. All other components are identical in both compositions.

[0315] The two compositions have the following chemical structure, where composition V1 does not contain metakaolin (comparison), while composition V2 includes metakaolin (mixing ratio (mass ratio in %)).

[0316]

[0317]

[0318] Foam samples are added to 100 ml of water and left to stand for 4 days, after which the samples are visually evaluated. The results are summarized in the table below:

[0319] Table of Results - Resolution Behavior

[0320]

[0321] The results shown in the table above demonstrate that the addition of metakaolin with a high proportion of SiC>2 and Al2O3 greatly increases the water stability of the cured product obtainable from the reaction of the first and second components.

[0322] Example 3

[0323] Exemplary embodiment 3 shows the temperature resistance of a composition according to the invention comprising silicate fibers, compared to a system with the same composition but without the presence of silicate fibers (polypropylene fibers were used instead of silicate fibers in the comparison example). For this purpose, two compositions are provided which differ solely in the presence of silicate / polypropylene fibers. All other components are identical in both compositions.

[0324] The two compositions have the following chemical structure (mixing ratio (mass ratio in %)):

[0325]

[0326]

[0327]

[0328] The foamed compositions are stored as molded parts at 1000 °C for 2 hours and then visually evaluated. The results are summarized in the table below:

[0329] Table of Results - Temperature Behavior

[0330]

[0331]

[0332] The results shown in the table above demonstrate that the addition of silicate fibers greatly increases the temperature stability of the cured product obtained from the reaction of the first and second components.

[0333] Example 4

[0334] Exemplary embodiment 4 demonstrates the effects of the mean fiber length of the silicate fibers on potential clogging and nesting of two-component cartridges. For this purpose, the composition from exemplary embodiment 3, which contains silicate fibers, is used, and the mean length of the silicate fibers is varied. The results are as follows:

[0335]

[0336] Stability:

[0337] + low stability

[0338] ++ Medium, still acceptable stability +++ High stability

[0339] Constipation:

[0340] + low risk of blockage

[0341] ++ moderate, still acceptable risk of blockage

[0342] +++ high risk of blockage

[0343] Nest formation:

[0344] + low nesting

[0345] ++ moderate, still acceptable nest formation

[0346] +++ high nest formation

[0347] A mean fiber length of 2 to 6 mm for the silicate fibers represents a good compromise between stability, risk of clogging and risk of nest formation, considering the properties examined above.

[0348] Within the scope of the present invention, the aforementioned properties are determined as follows:

[0349] Stability:

[0350] The stability / fracture strength of the cured foam product is assessed. This can be done either manually by breaking off the manufactured components or as a 3-point bending test on a tensile-compression testing machine. Both measurement methods yield identical ratings, where + indicates low stability, ++ indicates moderate, still acceptable stability, and +++ indicates high stability.

[0351] Blockage of the two-component cartridge:

[0352] A filled cartridge with an attached static mixer is squeezed, and it is examined whether this results in no blockage (+), small blockages that can be squeezed out by stronger pressure (++), or a complete blockage of the static mixer / cartridge outlet (+++).

[0353] Nest formation:

[0354] Nest formation is assessed by observing the formation of fiber nests when the fiber-containing component is mixed. Analysis is carried out by filtering a sample after mixing the mass (not in cartridges) and evaluating the formed nests / “fiber clumps” in such a way that + represents low nest formation, ++ represents medium, still acceptable nest formation, and +++ represents high nest formation.

Claims

Patent claims 1. Two-component composition, containing (1) a first component comprising at least a water glass and propellant-filled micro-hollow spheres with a propellant-filled core and a polymer material as a shell; and (2) a second component comprising an organic solvent for opening these micro-hollow spheres, characterized in that the first component contains silicate fibers with an average fiber length of 2 to 6 mm.

2. Two-component composition, containing (1) a first component comprising at least a water glass and propellant-filled micro-hollow spheres with a propellant-filled core and a polymer material as a shell; and (2) a second component comprising an organic solvent for opening these micro-hollow spheres, characterized by the fact that the two-component composition contains a metakaolin.

3. Two-component composition according to claim 2, characterized in that the first component contains silicate fibers.

4. A two-component composition according to any one of claims 1 to 3, characterized in that the silicate fibers are contained in the first component in an amount of 0.1 to 10 wt.%, preferably 0.1 to 8 wt.%, more preferably 0.2 to 6 wt.%, more preferably 0.2 to 4 wt.%, more preferably 0.3 to 2 wt.%, more preferably 0.3 to 1 wt.%, more preferably 0.4 to 0.8 wt.%, more preferably 0.5 to 0.7 wt.%, in each case based on the total weight of the first component.

5. A two-component composition according to any one of claims 1 to 4, characterized in that the silicate fibers have an average fiber length of 2 to 4 mm, more preferably 2.5 to 3.5 mm.

6. Two-component composition according to one of claims 1 to 5, characterized in that the first component contains at least two different water glasses.

7. Two-component composition according to one of claims 1 to 6, characterized in that the first component contains at least two different sodium water glasses.

8. Two-component composition according to one of claims 1 to 7, characterized in that the first component does not contain potassium silicate.

9. Two-component composition according to one of claims 1 to 8, characterized in that the proportion of organic components in the first and second component is at most 15 wt.%, more preferably at most 10 wt.%, more preferably at most 9 wt.%, more preferably at most 8 wt.%, in each case based on the total weight of the first and second component.

10. Two-component composition according to one of claims 1 to 9, characterized in that the increase in volume from liquid to foam upon contact of the first and second components is a factor of 1.5 to 8, more preferably 2 to 6, more preferably 2.5 to 5.

11. Two-component composition according to one of claims 1 or 3 to 10, characterized in that the two-component composition contains a metakaolin, 12. Cartridge comprising at least two compartments, wherein the first compartment contains a first component and the second compartment contains a second component, characterized in that the first and second components are configured according to any one of claims 1 to 11.

13. Use of the two-component composition according to any one of claims 1 to 11 or of the cartridge according to claim 12 as construction foam or fire-resistant foam.

14. Use of the two-component composition according to any one of claims 1 to 11 or of the cartridge according to claim 12 for the manufacture of fire protection materials.

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