WO1998033748A1 - Production of aluminium hydroxide coated glass microspheres - Google Patents

Production of aluminium hydroxide coated glass microspheres Download PDF

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Publication number
WO1998033748A1
WO1998033748A1 PCT/EP1998/000452 EP9800452W WO9833748A1 WO 1998033748 A1 WO1998033748 A1 WO 1998033748A1 EP 9800452 W EP9800452 W EP 9800452W WO 9833748 A1 WO9833748 A1 WO 9833748A1
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WO
WIPO (PCT)
Prior art keywords
glass microspheres
process according
aluminium
solution
aluminium hydroxide
Prior art date
Application number
PCT/EP1998/000452
Other languages
French (fr)
Inventor
Neil Brown
Original Assignee
Martinswerk Gmbh Für Chemische Und Metallurgische Produktion
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Martinswerk Gmbh Für Chemische Und Metallurgische Produktion filed Critical Martinswerk Gmbh Für Chemische Und Metallurgische Produktion
Priority to US09/341,995 priority Critical patent/US6171651B1/en
Priority to AU62140/98A priority patent/AU6214098A/en
Priority to EP98904155A priority patent/EP0968141B1/en
Priority to DE69814602T priority patent/DE69814602T2/en
Priority to AT98904155T priority patent/ATE240276T1/en
Publication of WO1998033748A1 publication Critical patent/WO1998033748A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
    • C03C17/22—Surface treatment of glass, not in the form of fibres or filaments, by coating with other inorganic material
    • C03C17/23—Oxides
    • C03C17/25—Oxides by deposition from the liquid phase
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2217/00—Coatings on glass
    • C03C2217/20—Materials for coating a single layer on glass
    • C03C2217/21—Oxides
    • C03C2217/214—Al2O3
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2218/00—Methods for coating glass
    • C03C2218/10—Deposition methods
    • C03C2218/11—Deposition methods from solutions or suspensions

Definitions

  • the present invention provides a method for the coating of glass microspheres with an aluminium hydroxide.
  • Applications for aluminium hydroxide coated glass microspheres are for example in the production of light weight glass-reinforced plastic composite materials for use in mass transportation.
  • Aluminium hydroxide is well-established in the plastics industry as a halogen-free filler which is used to impart fire retardant and smoke suppressing properties to synthetic thermosetting resin systems. Moreover, the trend towards stricter requirements on the burning behaviour of plastics means an increasing demand for aluminium hydroxides which can be incorporated in plastics at ever higher filling levels. In glass-reinforced unsaturated polyester composites for example it is not uncommon for the aluminium hydroxide content of the composite material to be >50 wt.%.
  • Aluminium hydroxide (Al(OH) 3 ) has a density of 2.42 g/cm 3 which is considerably higher than the ca 1.1 g/cm 3 of a synthetic resin.
  • the glass fibres used for structural composites contribute further to increased weight due to the even higher density of ca 2.6 g/cm 3 .
  • microspheres of aluminium silicate or borosilicate glass are available in particle sizes which are similar to those of aluminium hydroxide but they have densities in the range of 0.1- 1.0 g/cm , so that their incorporation in even relatively small amounts can provide a significant reduction in weight of the end composite.
  • the problem when using hollow glass microspheres is the need to maintain acceptable mechanical properties of the end composite. This is particularly important for structural plastic composite materials.
  • the well-rounded, smooth surfaces of the hollow glass microspheres militate against an effective "bond" between the inorganic filler and the organic resin so that the use of hollow of glass microspheres is generally accompanied by a deterioration in physical properties of the composite material.
  • Objective of the present invention therefore is to avoid the problems associated with the methods known in the art and to develop a method for applying an aluminum hydroxide directly onto the surface of hollow glass microspheres.
  • the objective of the invention is achieved with the process according to claim 1, comprising the steps of a) adding an organic complexing agent to an aqueous solution of an acidic aluminium salt b) raising the pH of the solution to a value of > 9, c) adding a predetermined amount of said glass microspheres to said solution to form a suspension d) hydrothermally treating said suspension in an oxidising atmosphere at about 150 °C to 350 °C and e) separating the aluminium hydroxide coated glass microspheres from the suspension.
  • a glass microsphere coated following the process of claim 1 provides uniform aluminium hydroxide coating which remains firmly attached to the underlying glass microsphere surface during further processing thereby allowing the incorporation into synthetic resin of aluminium hydroxide coated glass microspheres with their associated fire retardant properties and providing a substrate for using conventional additives which increase compatibility and strengthen the "bond" between the inorganic and organic phases.
  • Figure 1 shows a scanning electron micrograph of a typical appearance of the aluminium hydroxide coated glass microspheres.
  • Preferred aluminium hydroxide applied is the boehmite type aluminium hydroxide (A1OOH) which crystallizes out under the conditions used in the process of the present invention and firmly adheres on the substrate i.e. the glass microspheres.
  • A1OOH boehmite type aluminium hydroxide
  • hollow microspheres of an aluminum silicate glass or a soda lime boro silicate glass are used.
  • hollow glass microspheres the FG- 200-7 glass microspheres (aluminium silicate glass) of the Fillite Company and the K20 Scotchlite Glass Bubbles of the 3M Company (boro silicate glass) can be mentioned.
  • the preferred starting solution is an aqueous solution of an acidic aluminium salt, expediently selected from the group consisting of aluminium sulfate, aluminium nitrate and aluminum chloride in which the hydrated Al + -ions are according to step a) of claim 1 initially complexed and stabilized in solution by the addition of an organic complexing agent.
  • organic acids such as for example gluconic acid, tartaric acid, citric acid and oxalic acid are applied, usually before raising the pH of the solution into the alkaline range.
  • step b) of claim 1 the pH of the solution is then raised to a value of > 9, preferably to about 11 by addition of an inorganic base, preferably selected from the group consisting of sodium hydroxide, potassium hydroxide or of an aqueous solution of ammonia.
  • an inorganic base preferably selected from the group consisting of sodium hydroxide, potassium hydroxide or of an aqueous solution of ammonia.
  • step c) of claim 1 a pretermined amount of the glass microspheres is added to form a suspension.
  • a pretermined amount of the glass microspheres is added so that a concentration of 50 to 100 g/1 is reached.
  • the hydrothermal treatment according to step d) of claim 1 is then usually accomplished in an autoclave.
  • this hydrothermal treatment performed at temperatures of about 150 °C to 350 °C, preferably at 250 °C, the complex of the organic complexing agent with the hydrated Al -ions oxidatively degrades.
  • oxygen or an oxygen containing gas is preferably added during the hydrothermal reaction.
  • the Al 3+ -complexes break down, the aluminium ions released crystallize out of solution in the form of boehmite at the same elevated temperature.
  • the crystalline boehmite is deposited directly on the surfaces of the glass microspheres.
  • the aluminium concentration, the nature of the complexing agent and /or the amount of oxygen used influence can be exercised on the particle size of the boehmite and hence thickness of the coating. While all four parameters can affect boehmite particle size, only the amount of oxygen is of major significance, i.e., when oxygen is used.
  • increasing the amount of oxygen used as a rule decreases the average size of the boehmite particle because of the faster initial release of aluminium ions for crystallization.
  • decreasing the amount of oxygen as a rule increases the average size of the boehmite particles.
  • step e) of claim 1 Separation of the aluminium hydroxide coated glass microspheres from the suspension according to step e) of claim 1 can be effected by methods known to those skilled in the art.
  • the coating can be varied in its thickness and adheres firmly to the underlying surface during subsequent handling and processing in synthetic resins.
  • the aluminium hydroxide coating imparts fire retardant properties to the glass microspheres in addition to providing a substrate for effective bridge-building between the filler and the organic resin system
  • a stock solution (21) of 0.45 M aluminium sulfate was prepared at room temperature by dissolving 600 g of Al 2 (SO 4 ) 3 .18H 2 O in deionized water.
  • 500 ml of the stock solution in a 2 litre capacity glass beaker was added 500 ml of 1.5 M tartaric acid with agitation using a magnetic stirrer.
  • Into the vortex created by the stirrer was run 10 M NaOH until the pH of the resulting solution reached 11.2.
  • To a 1 litre aliquot of this solution was added 80 g of glass microspheres (FG-200-7 grade; Fillite) and the whole transferred to a 3 litre capacity Inconel autoclave fitted with an internal coil for rapid heating and cooling.
  • the glass microspheres had a density of ca. 0.5 g/cm and ranged in particle size up to a maximum of ca. 150 ⁇ m.
  • the suspension On cooling back to conditions of atmospheric pressure and temperature, the suspension was removed from the autoclave and the solids filtered, washed with hot deionized water and dried at 110 °C.
  • the pH of the liquor filtrate was ca. 7.9 and was composed primarily of sodium sulphate (ca. 45 g/1 sulphate) and the sodium salts of the organic carbon degradation products.
  • the dried product was boehmite coated glass microspheres and weighed 100.1 g.
  • the density of the aluminium hydroxide composite hollow glass microspheres was 1.00 g/cm .
  • X-ray diffraction confirmed that the crystalline aluminium hydroxide coating was boehmite.
  • the increase in average particle size indicated a boehmite layer thickness of ca 1 ⁇ m.
  • the boehmite coating is highly polycrystalline in nature with the boehmite crystals intergrown and randomly oriented on the surfaces of the microsphere surfaces.
  • the adherence of the boehmite to the underlying microsphere surfaces was strong enough to survive a heat treatment at 1000 °C for 60 min in which the boehmite was calcined to aluminium oxide of density ca. 3.95 g/cm 3 .
  • Example 2 The experimental procedure of Example 1 was repeated with the difference that the system was seeded with borosilicate hollow glass microspheres (K20, scotchlite glass bubbles, 3M) which had a density of 0.20 g/cm and ranged in particle size up to a maximum of ca. 90 ⁇ m.
  • the dried product was boehmite coated glass microspheres and weighed 100.2 g.
  • the density of these aluminium hydroxide composite hollow glass microspheres was 0.76 g/cm 3 .

Abstract

A process for the coating of glass microspheres with an aluminium hydroxide is described which comprises the hydrothermal treatment of a suspension of complexed Al3+-ions with glass microspheres. The aluminium hydroxide coated glass microspheres can be applied in the production of light weight glass-reinforced plastic materials e.g. for use in mass transportation.

Description

Production of aluminium hydroxide coated glass microspheres
The present invention provides a method for the coating of glass microspheres with an aluminium hydroxide. Applications for aluminium hydroxide coated glass microspheres are for example in the production of light weight glass-reinforced plastic composite materials for use in mass transportation.
Aluminium hydroxide is well-established in the plastics industry as a halogen-free filler which is used to impart fire retardant and smoke suppressing properties to synthetic thermosetting resin systems. Moreover, the trend towards stricter requirements on the burning behaviour of plastics means an increasing demand for aluminium hydroxides which can be incorporated in plastics at ever higher filling levels. In glass-reinforced unsaturated polyester composites for example it is not uncommon for the aluminium hydroxide content of the composite material to be >50 wt.%.
In mass transportation for instance, it is possible to achieve the strict fire requirements on composite materials by using aluminium hydroxide alone as fire retardant filler. At the same time, however, the long term trend in composite materials is towards lighter weight composites which reduce energy costs. In the railways, for example, less weight means an increased pay-load for high speed trains and less wear and tear on the tracks.
Aluminium hydroxide (Al(OH)3) has a density of 2.42 g/cm3 which is considerably higher than the ca 1.1 g/cm3 of a synthetic resin. The use of aluminium hydroxide by itself therefore raises the density and hence overall weight of the end-composite. In addition, the glass fibres used for structural composites contribute further to increased weight due to the even higher density of ca 2.6 g/cm3.
Well-established in the art is the incorporation of hollow microspheres of aluminium silicate or borosilicate glass to decrease the overall weight of plastic composite materials and enhance their thermal insulation characteristics . Such microspheres are available in particle sizes which are similar to those of aluminium hydroxide but they have densities in the range of 0.1- 1.0 g/cm , so that their incorporation in even relatively small amounts can provide a significant reduction in weight of the end composite. The problem when using hollow glass microspheres however is the need to maintain acceptable mechanical properties of the end composite. This is particularly important for structural plastic composite materials. However, the well-rounded, smooth surfaces of the hollow glass microspheres militate against an effective "bond" between the inorganic filler and the organic resin so that the use of hollow of glass microspheres is generally accompanied by a deterioration in physical properties of the composite material.
Objective of the present invention therefore is to avoid the problems associated with the methods known in the art and to develop a method for applying an aluminum hydroxide directly onto the surface of hollow glass microspheres.
The objective of the invention is achieved with the process according to claim 1, comprising the steps of a) adding an organic complexing agent to an aqueous solution of an acidic aluminium salt b) raising the pH of the solution to a value of > 9, c) adding a predetermined amount of said glass microspheres to said solution to form a suspension d) hydrothermally treating said suspension in an oxidising atmosphere at about 150 °C to 350 °C and e) separating the aluminium hydroxide coated glass microspheres from the suspension.
It has been surprisingly discovered that a glass microsphere coated following the process of claim 1 provides uniform aluminium hydroxide coating which remains firmly attached to the underlying glass microsphere surface during further processing thereby allowing the incorporation into synthetic resin of aluminium hydroxide coated glass microspheres with their associated fire retardant properties and providing a substrate for using conventional additives which increase compatibility and strengthen the "bond" between the inorganic and organic phases. Figure 1 shows a scanning electron micrograph of a typical appearance of the aluminium hydroxide coated glass microspheres.
Preferred aluminium hydroxide applied is the boehmite type aluminium hydroxide (A1OOH) which crystallizes out under the conditions used in the process of the present invention and firmly adheres on the substrate i.e. the glass microspheres.
Expediently, hollow microspheres of an aluminum silicate glass or a soda lime boro silicate glass are used. As preferred but non-limiting examples of hollow glass microspheres the FG- 200-7 glass microspheres (aluminium silicate glass) of the Fillite Company and the K20 Scotchlite Glass Bubbles of the 3M Company (boro silicate glass) can be mentioned.
The preferred starting solution is an aqueous solution of an acidic aluminium salt, expediently selected from the group consisting of aluminium sulfate, aluminium nitrate and aluminum chloride in which the hydrated Al +-ions are according to step a) of claim 1 initially complexed and stabilized in solution by the addition of an organic complexing agent. Preferably organic acids, such as for example gluconic acid, tartaric acid, citric acid and oxalic acid are applied, usually before raising the pH of the solution into the alkaline range.
According to step b) of claim 1 the pH of the solution is then raised to a value of > 9, preferably to about 11 by addition of an inorganic base, preferably selected from the group consisting of sodium hydroxide, potassium hydroxide or of an aqueous solution of ammonia.
Subsequently according to step c) of claim 1 a pretermined amount of the glass microspheres is added to form a suspension. As a rule such an amount is added so that a concentration of 50 to 100 g/1 is reached.
The hydrothermal treatment according to step d) of claim 1, is then usually accomplished in an autoclave. Within this hydrothermal treatment, performed at temperatures of about 150 °C to 350 °C, preferably at 250 °C, the complex of the organic complexing agent with the hydrated Al -ions oxidatively degrades. To support this oxidative degradation, oxygen or an oxygen containing gas is preferably added during the hydrothermal reaction. As the Al3+-complexes break down, the aluminium ions released crystallize out of solution in the form of boehmite at the same elevated temperature. The crystalline boehmite is deposited directly on the surfaces of the glass microspheres.
By varying the pH of the crystallizing solution, as a rule in the range of 10 to 12, the aluminium concentration, the nature of the complexing agent and /or the amount of oxygen used, influence can be exercised on the particle size of the boehmite and hence thickness of the coating. While all four parameters can affect boehmite particle size, only the amount of oxygen is of major significance, i.e., when oxygen is used. At a predetermined pH, operating temperature and complexing agent, increasing the amount of oxygen used as a rule decreases the average size of the boehmite particle because of the faster initial release of aluminium ions for crystallization. Conversely, decreasing the amount of oxygen as a rule increases the average size of the boehmite particles.
Separation of the aluminium hydroxide coated glass microspheres from the suspension according to step e) of claim 1 can be effected by methods known to those skilled in the art.
The coating can be varied in its thickness and adheres firmly to the underlying surface during subsequent handling and processing in synthetic resins. The aluminium hydroxide coating imparts fire retardant properties to the glass microspheres in addition to providing a substrate for effective bridge-building between the filler and the organic resin system
The present invention will now be illustrated in detail with reference to the following examples, which however are not to be interpreted as limiting the scope of the invention. Examples:
Example 1
A stock solution (21) of 0.45 M aluminium sulfate was prepared at room temperature by dissolving 600 g of Al2(SO4)3.18H2O in deionized water. To 500 ml of the stock solution in a 2 litre capacity glass beaker was added 500 ml of 1.5 M tartaric acid with agitation using a magnetic stirrer. Into the vortex created by the stirrer was run 10 M NaOH until the pH of the resulting solution reached 11.2. To a 1 litre aliquot of this solution was added 80 g of glass microspheres (FG-200-7 grade; Fillite) and the whole transferred to a 3 litre capacity Inconel autoclave fitted with an internal coil for rapid heating and cooling. The glass microspheres had a density of ca. 0.5 g/cm and ranged in particle size up to a maximum of ca. 150 μm.
Agitation of the autoclave contents was provided by a permanent magnetic stirrer fitted with a six-blade turbine and operated at 330 rpm. The autoclave was then closed and oxygen gas introduced at 25 °C to a partial pressure of lOx 10 Pa. The autoclave and contents were heated to 250 °C and maintained at this temperature for 60 min.
On cooling back to conditions of atmospheric pressure and temperature, the suspension was removed from the autoclave and the solids filtered, washed with hot deionized water and dried at 110 °C. The pH of the liquor filtrate was ca. 7.9 and was composed primarily of sodium sulphate (ca. 45 g/1 sulphate) and the sodium salts of the organic carbon degradation products.
The dried product was boehmite coated glass microspheres and weighed 100.1 g. The density of the aluminium hydroxide composite hollow glass microspheres was 1.00 g/cm . X-ray diffraction confirmed that the crystalline aluminium hydroxide coating was boehmite. The increase in average particle size indicated a boehmite layer thickness of ca 1 μm. Scanning electron microscope and ED AX analyses indicated that the boehmite is deposited uniformly over the microsphere surfaces. The boehmite coating is highly polycrystalline in nature with the boehmite crystals intergrown and randomly oriented on the surfaces of the microsphere surfaces. The adherence of the boehmite to the underlying microsphere surfaces was strong enough to survive a heat treatment at 1000 °C for 60 min in which the boehmite was calcined to aluminium oxide of density ca. 3.95 g/cm3.
Example 2
The experimental procedure of Example 1 was repeated with the difference that the system was seeded with borosilicate hollow glass microspheres (K20, scotchlite glass bubbles, 3M) which had a density of 0.20 g/cm and ranged in particle size up to a maximum of ca. 90 μm. The dried product was boehmite coated glass microspheres and weighed 100.2 g. The density of these aluminium hydroxide composite hollow glass microspheres was 0.76 g/cm3. Particle size analysis indicated that the thickness of the boehmite coating was of the order of 0.1 - 1.0 μm.

Claims

Claims:
1) Process for the coating of glass microspheres with an aluminum hydroxide comprising the steps of a) adding an organic complexing agent to an aqueous solution of an acidic aluminium salt b) raising the pH of the solution to a value of > 9, c) adding an amount of said glass microspheres to said solution to form a suspension d) hydrothermally treating said suspension at about 150 °C to 350 °C and e) separating the aluminium hydroxide coated glass microspheres from the suspension.
2) Process according to claim 1 characterized in that the aluminum hydroxide applied is a boehmite-type aluminium hydroxide.
3) Process according to claims 1 or 2 characterized in that hollow microspheres of an aluminium silicate glass or a boro silicate glass are used.
4) Process according to one of claims 1 to 3 characterized in that the acidic aluminium salt is selected from the group consisting of aluminium sulfate, aluminium nitrate and aluminum chloride.
5) Process according to one of claims 1 to 4 characterized in that the organic complexing agent is an organic acid.
6) Process according to claim 5 characterized in that the organic acid is selected from the group consisting of gluconic acid, tartatric acid, citric acid and oxalic acid.
7) Process according to one of claims 1 to 6 characterized in that raising the pH in step b) is effected by adding to said solution an inorganic base. 8) Process according to claim 7 characterized in that the inorganic base is selected from the group consisting of sodium hydroxide, potassium hydroxide or of an aqueous solution of ammonia.
9) Process according to one of claims 1 to 7 characterized in that the glass microspheres are added in such an amount to said solution that a concentration of 50 to 100 g/1 is reached.
10) Process according to one of claims 1 to 8 characterized in that the hydrothermal treatment in step d) is effected in the presence of oxygen or an oxygen containing gas.
11) Aluminiumhydroxide coated glass microspheres obtainable according to the claims 1 to
PCT/EP1998/000452 1997-01-30 1998-01-28 Production of aluminium hydroxide coated glass microspheres WO1998033748A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US09/341,995 US6171651B1 (en) 1997-01-30 1998-01-28 Production of aluminium hydroxide coated glass microspheres
AU62140/98A AU6214098A (en) 1997-01-30 1998-01-28 Production of aluminium hydroxide coated glass microspheres
EP98904155A EP0968141B1 (en) 1997-01-30 1998-01-28 Production of aluminium hydroxide coated glass microspheres
DE69814602T DE69814602T2 (en) 1997-01-30 1998-01-28 MICRO-HOLLOW GLASS BALLS COATED WITH ALUMINUM HYDROXIDE
AT98904155T ATE240276T1 (en) 1997-01-30 1998-01-28 MICRO HOLLOW GLASS BALLS COATED WITH ALUMINUM HYDROXIDE

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB9702171.1A GB9702171D0 (en) 1997-01-30 1997-01-30 Aluminium hydroxide composite glass microspheres
GB9702171.1 1997-01-30

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WO1998033748A1 true WO1998033748A1 (en) 1998-08-06

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PCT/EP1998/000452 WO1998033748A1 (en) 1997-01-30 1998-01-28 Production of aluminium hydroxide coated glass microspheres

Country Status (8)

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US (1) US6171651B1 (en)
EP (1) EP0968141B1 (en)
AT (1) ATE240276T1 (en)
AU (1) AU6214098A (en)
DE (1) DE69814602T2 (en)
ES (1) ES2200312T3 (en)
GB (1) GB9702171D0 (en)
WO (1) WO1998033748A1 (en)

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DE69814602T2 (en) 2004-03-25
EP0968141A1 (en) 2000-01-05
ES2200312T3 (en) 2004-03-01
EP0968141B1 (en) 2003-05-14
AU6214098A (en) 1998-08-25
DE69814602D1 (en) 2003-06-18
US6171651B1 (en) 2001-01-09
ATE240276T1 (en) 2003-05-15
GB9702171D0 (en) 1997-03-26

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