US20010041753A1 - Melamine resin foam - Google Patents

Melamine resin foam Download PDF

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Publication number
US20010041753A1
US20010041753A1 US09/826,167 US82616701A US2001041753A1 US 20010041753 A1 US20010041753 A1 US 20010041753A1 US 82616701 A US82616701 A US 82616701A US 2001041753 A1 US2001041753 A1 US 2001041753A1
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US
United States
Prior art keywords
foam
ammonium salt
fire
ammonium
weight
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
US09/826,167
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US6350511B2 (en
Inventor
Arnd Thom
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BASF SE
Original Assignee
BASF SE
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Filing date
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Assigned to BASF AKTIENGESELLSCHAFT reassignment BASF AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: THOM, ARND
Publication of US20010041753A1 publication Critical patent/US20010041753A1/en
Application granted granted Critical
Publication of US6350511B2 publication Critical patent/US6350511B2/en
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/36—After-treatment
    • C08J9/365—Coating
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2361/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
    • C08J2361/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
    • C08J2361/26—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds
    • C08J2361/28—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds with melamine
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2201/00—Properties
    • C08L2201/08—Stabilised against heat, light or radiation or oxydation
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
    • C08L61/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
    • C08L61/26—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds
    • C08L61/28—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds with melamine
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249955—Void-containing component partially impregnated with adjacent component
    • Y10T428/249958—Void-containing component is synthetic resin or natural rubbers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249987—With nonvoid component of specified composition
    • Y10T428/249991—Synthetic resin or natural rubbers

Definitions

  • the invention relates to an open-celled melamine resin foam (MF foam) with improved fire performance.
  • MF foams have low density, good mechanical workability and especially outstanding sound absorption.
  • a commercially available product of this type is BASOTECT® from BASF Aktiengesellschaft, which is increasingly used in the construction sector, but also for internal vehicle parts.
  • MF foams give them advantageous fire performance. For example, they achieve fire class B1 to DIN 4102. Recently, stricter requirements have been placed on the fire performance of foams in the construction sector, in particular in Scandinavian countries, and the known MF foams do not, for example, achieve fire class A to Nordtest NT Fire 004.
  • MF foams whose cell-structure surface has been to some extent or entirely coated with an ammonium salt, preferably using from 0.1 to 20% by weight, in particular from 1 to 10% by weight.
  • an ammonium salt preferably using from 0.1 to 20% by weight, in particular from 1 to 10% by weight.
  • the depth of penetration of the ammonium salt into the foam should be at least 1 mm, preferably 2 to 20 mm.
  • Preferred flame retardants are the salts of phosphoric acid, in particular ammonium orthophosphate and ammonium polyphosphate.
  • the ammonium salt is used as an aqueous solution, preferably of from 1 to 50% strength by weight, in particular of from 5 to 30% strength by weight.
  • MF foams are known per se, for example from EP-B 71 672.
  • EP-B 17 671 they are produced by foaming an aqueous solution of an MF condensation procuct which comprises an emulsifier, an acidic curing agent, and a blowing agent, preferably a C 5 -C 7 hydrocarbon, and curing the MF condensate at an elevated temperature.
  • an aqueous solution of the ammonium salt is now used to coat, spray or saturate these foams, excess liquid is squeezed out if appropriate, and the foam is dried.
  • the MF foams according to the invention can be used in shipbuilding for the thermal and sound insulation of engine-rooms, where they comply with the marine standard IMO A. 635.

Abstract

The invention relates to open-celled melamine foams which have improved fire performance and whose cell-structure surface has been to some extent or entirely coated with an ammonium salt.

Description

  • The invention relates to an open-celled melamine resin foam (MF foam) with improved fire performance. [0001]
  • MF foams have low density, good mechanical workability and especially outstanding sound absorption. A commercially available product of this type is BASOTECT® from BASF Aktiengesellschaft, which is increasingly used in the construction sector, but also for internal vehicle parts. [0002]
  • The chemical composition of MF foams gives them advantageous fire performance. For example, they achieve fire class B1 to DIN 4102. Recently, stricter requirements have been placed on the fire performance of foams in the construction sector, in particular in Scandinavian countries, and the known MF foams do not, for example, achieve fire class A to Nordtest NT Fire 004. [0003]
  • It is an object of the present invention, therefore, to provide a further improvement in the fire performance of MF foams. [0004]
  • We have found that this object is achieved by using MF foams whose cell-structure surface has been to some extent or entirely coated with an ammonium salt, preferably using from 0.1 to 20% by weight, in particular from 1 to 10% by weight. To give an adequate extent of fire resistance, the depth of penetration of the ammonium salt into the foam should be at least 1 mm, preferably 2 to 20 mm. [0005]
  • Preferred flame retardants are the salts of phosphoric acid, in particular ammonium orthophosphate and ammonium polyphosphate. The ammonium salt is used as an aqueous solution, preferably of from 1 to 50% strength by weight, in particular of from 5 to 30% strength by weight. [0006]
  • MF foams are known per se, for example from EP-B 71 672. According to EP-B 17 671, they are produced by foaming an aqueous solution of an MF condensation procuct which comprises an emulsifier, an acidic curing agent, and a blowing agent, preferably a C[0007] 5-C7 hydrocarbon, and curing the MF condensate at an elevated temperature. According to the invention, an aqueous solution of the ammonium salt is now used to coat, spray or saturate these foams, excess liquid is squeezed out if appropriate, and the foam is dried.
  • This can be done at an elevated temperature by using hot air or circulating air, or in drying ovens, or by treating with microwaves or with infrared radiation, but preferably simply by storage at room temperature in free contact with the atmosphere for a number of hours. [0008]
  • In the case of relatively large moldings it is useful to treat the entire surface with the ammonium salt solution, and the depth of penetration of the solution here should be at least 1 mm. Relatively small moldings can be completely immersed into the solution. In the case of sheets, it is frequently sufficient for these to be coated or sprayed on just one side with the ammonium salt solution. The amounts to be applied are then preferably within the range from 20 to 200 g of a 20% strength solution per m[0009] 2 of surface.
  • The good properties of the MF foam, such as mechanical workability and sound absorption, are not impaired by coating according to the invention with the ammonium salt, but fire performance is considerably improved. [0010]
  • In addition to the application in the construction sector and in the automotive industry, the MF foams according to the invention can be used in shipbuilding for the thermal and sound insulation of engine-rooms, where they comply with the marine standard IMO A. 635.[0011]
    • EXAMPLE
  • One side of a sheet of MF foam of dimensions 23×23×1 cm and of density 0.01 g/cm[0012] 3 (BASOTECT 2011) was sprayed with a 20% strength by weight solution of ammonium orthophosphate. The amount applied was about 50 g of solution per m2. The sheet was dried overnight in free contact with the atmosphere. It then comprised about 0.5 g, i.e. 10% by weight, of ammonium salt. It achieved fire class A in the NT Fire 004 fire test.

Claims (7)

We claim:
1. An open-celled melamine-resin foam (MF foam), whose cell-structure surface has been to some extent or entirely coated with an ammonium salt.
2. An MF foam as claimed in
claim 1
, wherein the ammonium salt content is from 0.1 to 20% by weight.
3. An MF foam as claimed in
claim 1
, wherein the depth of penetration of the ammonium salt into the surface of the foam is at least 1 mm.
4. An MF foam as claimed in
claim 1
, wherein the ammonium salt is a salt of phosphoric acid, in particular ammonium phosphate or ammonium polyphosphate.
5. A process for producing the MF foam as claimed in
claim 1
, which comprises using an aqueous solution of the ammonium salt to coat, spray or saturate the foam, squeezing out excess liquid if appropriate, and drying the foam.
6. A process as claimed in
claim 5
, wherein the strength of the solution is from 1 to 50% by weight.
7. An open-celled MF foam which achieves fire class A in the NT Fire 004 fire test.
US09/826,167 2000-04-15 2001-04-05 Melamine resin foam Expired - Fee Related US6350511B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE2000118768 DE10018768A1 (en) 2000-04-15 2000-04-15 Melamine resin foam
DE10018768 2000-04-15
DE10018768.4 2000-04-15

Publications (2)

Publication Number Publication Date
US20010041753A1 true US20010041753A1 (en) 2001-11-15
US6350511B2 US6350511B2 (en) 2002-02-26

Family

ID=7638892

Family Applications (1)

Application Number Title Priority Date Filing Date
US09/826,167 Expired - Fee Related US6350511B2 (en) 2000-04-15 2001-04-05 Melamine resin foam

Country Status (8)

Country Link
US (1) US6350511B2 (en)
EP (1) EP1146070A3 (en)
JP (1) JP2002003638A (en)
KR (1) KR20010098612A (en)
CN (1) CN1187186C (en)
CA (1) CA2343347A1 (en)
DE (1) DE10018768A1 (en)
ZA (1) ZA200103051B (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050211838A1 (en) * 2004-03-29 2005-09-29 The Boeing Company Foam composite insulation for aircraft
US20070136923A1 (en) * 2005-12-20 2007-06-21 Donald Aldridge Garment with padding
US20100178826A1 (en) * 2006-08-11 2010-07-15 Basf Se Patents, Trademarks And Licenses Padding material with increased fire safety for seats in the transport sector and furniture sector
US8662448B2 (en) 2011-06-06 2014-03-04 The Boeing Company System and method for insulating frame member
US8822557B2 (en) 2009-10-27 2014-09-02 Basf Se Elastic inorganic-organic hybrid foam
US8937106B2 (en) 2010-12-07 2015-01-20 Basf Se Melamine resin foams with nanoporous fillers
US9242397B2 (en) 2010-11-05 2016-01-26 Basf Se Melamine resin foam with inorganic filling material

Families Citing this family (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030113496A1 (en) 2001-12-17 2003-06-19 Harris Michael G. Polyethylene melt blends for high density polyethylene applications
FR2836470B1 (en) * 2002-02-25 2004-07-09 J S O MELANIN FOAM MATTRESS AND APPLICATIONS THEREOF
US6822051B2 (en) 2002-03-29 2004-11-23 Media Plus, Inc. High density polyethylene melt blends for improved stress crack resistance in pipe
GB2405112B (en) * 2002-06-03 2006-03-01 Chong Hak Tay A fire resistant insulation material
US7629043B2 (en) 2003-12-22 2009-12-08 Kimberly-Clark Worldwide, Inc. Multi purpose cleaning product including a foam and a web
US7504439B2 (en) * 2004-11-01 2009-03-17 Polymer Technologies, Inc. Hydrophobation of melamine foam
US20060229229A1 (en) * 2005-04-11 2006-10-12 Kimberly-Clark Worldwide, Inc. Cleaning composite
US20070166488A1 (en) * 2006-01-19 2007-07-19 Trefethren Susan M Cleaning composite comprising lines of frangibility
US20090274892A1 (en) * 2006-06-14 2009-11-05 Feng Qin Hydrophobic open celled foam and method of making the same
EP2063757A1 (en) 2006-09-15 2009-06-03 Reckitt Benckiser Inc. Cleaning article comprising melamine foam sponge
US7930790B2 (en) 2007-04-26 2011-04-26 The Procter & Gamble Company Fabric exfoliation method and articles
JP5732384B2 (en) 2008-04-29 2015-06-10 ビーエーエスエフ ソシエタス・ヨーロピアＢａｓｆ Ｓｅ Flexible silica-containing foam
US9347004B2 (en) * 2009-06-16 2016-05-24 The Boeing Company Flame propagation resistant foam and method
US20110318564A1 (en) * 2010-06-29 2011-12-29 Feng Qin Aircraft insulating foam
KR101226752B1 (en) * 2010-09-02 2013-01-25 동화홀딩스 주식회사 process for preparing fire retardant melamine resin and fire retardant melamine sheet using the same
CN103210026B (en) 2010-11-05 2014-08-20 巴斯夫欧洲公司 Melamine resin foam material having an inorganic filler
KR101903203B1 (en) 2010-12-07 2018-10-01 바스프 에스이 Melamine resin foams comprising nanoporous fillers
EP2678379B1 (en) 2011-02-24 2016-04-20 Basf Se Melamine resin foam having particulate filler
US20150210817A1 (en) 2012-09-12 2015-07-30 Basf Se Melamine resin foam material comprising an anorganic filler material having a high density
CN103408789B (en) * 2013-05-13 2015-03-11 四川大学 High-efficiency flame-retardant modified melamino-formaldehyde foams and preparation method thereof
KR101684694B1 (en) 2014-10-20 2016-12-08 한국신발피혁연구원 Method producing of low specific gravity noninflammable composite material
US9433854B1 (en) 2015-02-13 2016-09-06 Andre D'Alessandro Device and method for removing scratch-off coatings
CN112795053B (en) * 2021-02-01 2022-03-18 河南大学 Method for recycling melamine formaldehyde resin foam waste and flame retardant prepared by method
WO2023052389A1 (en) 2021-10-01 2023-04-06 Basf Se Open-celled melamine resin foams comprising halogen-free flame retardants

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DE2917064A1 (en) * 1979-04-27 1980-11-13 Basf Ag Reducing formaldehyde evolution from aminoplast foams - by treating foam surface with formaldehyde binding agent esp. urea
EP0071672A1 (en) 1981-08-07 1983-02-16 Cadbury Schweppes Transport Services Limited Fuel supply system for an internal combustion engine
JPS59100144A (en) * 1982-12-01 1984-06-09 Bridgestone Corp Fire-resistant phenolic resin foam
JP3354220B2 (en) * 1993-07-09 2002-12-09 日清紡績株式会社 Melamine resin foam
DE19600877A1 (en) * 1996-01-12 1997-07-17 Budenheim Rud A Oetker Chemie Ammonium phosphate-based flameproofing agent free of afterglow

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050211838A1 (en) * 2004-03-29 2005-09-29 The Boeing Company Foam composite insulation for aircraft
US7040575B2 (en) * 2004-03-29 2006-05-09 The Boeing Company Foam composite insulation for aircraft
EP1735210B2 (en) † 2004-03-29 2011-08-10 The Boeing Company Foam composite insulation for aircraft
WO2007075306A2 (en) * 2005-12-20 2007-07-05 Lion Apparel, Inc. Garment with padding
WO2007075306A3 (en) * 2005-12-20 2007-09-20 Lion Apparel Inc Garment with padding
GB2446555A (en) * 2005-12-20 2008-08-13 Lion Apparel Inc Garment with padding
GB2446555B (en) * 2005-12-20 2010-06-16 Lion Apparel Inc Garment with padding
US7913322B2 (en) 2005-12-20 2011-03-29 Lion Apparel, Inc. Garment with padding
US20070136923A1 (en) * 2005-12-20 2007-06-21 Donald Aldridge Garment with padding
US20100178826A1 (en) * 2006-08-11 2010-07-15 Basf Se Patents, Trademarks And Licenses Padding material with increased fire safety for seats in the transport sector and furniture sector
US8822557B2 (en) 2009-10-27 2014-09-02 Basf Se Elastic inorganic-organic hybrid foam
US9242397B2 (en) 2010-11-05 2016-01-26 Basf Se Melamine resin foam with inorganic filling material
US8937106B2 (en) 2010-12-07 2015-01-20 Basf Se Melamine resin foams with nanoporous fillers
US8662448B2 (en) 2011-06-06 2014-03-04 The Boeing Company System and method for insulating frame member

Also Published As

Publication number Publication date
CN1318464A (en) 2001-10-24
ZA200103051B (en) 2002-10-14
KR20010098612A (en) 2001-11-08
EP1146070A3 (en) 2002-01-09
DE10018768A1 (en) 2001-10-18
CA2343347A1 (en) 2001-10-15
EP1146070A2 (en) 2001-10-17
CN1187186C (en) 2005-02-02
US6350511B2 (en) 2002-02-26
JP2002003638A (en) 2002-01-09

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Owner name: BASF AKTIENGESELLSCHAFT, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:THOM, ARND;REEL/FRAME:011950/0151

Effective date: 20010420

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STCH Information on status: patent discontinuation

Free format text: PATENT EXPIRED DUE TO NONPAYMENT OF MAINTENANCE FEES UNDER 37 CFR 1.362

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Effective date: 20060226