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DE-102019000786-B4 - Method for producing a hybrid polymer material and hybrid polymer material produced according to this method

DE102019000786B4DE 102019000786 B4DE102019000786 B4DE 102019000786B4DE-102019000786-B4

Abstract

A process for producing a hybrid polymer material based on a reactive polymer resin and one or more Si compounds from the group comprising silanes, siloxanes, silazanes and silicone resins, wherein, firstly, recycled plastic material as a quartz-free filler in combination with the reactive polymer resin and one or more Si compounds as well as additives forms a raw material, wherein the raw material further contains at least one alcoholate of zirconium, aluminum or titanium, and wherein the raw material is compacted and subsequently reacted and cured, wherein the proportion of the solid is 40 to 97 wt.% of the total mass of the raw material.

Inventors

  • Jan Interwies

Assignees

  • N-TEC GMBH

Dates

Publication Date
20260513
Application Date
20190204

Claims (9)

  1. A process for producing a hybrid polymer material based on a reactive polymer resin and one or more Si compounds from the group comprising silanes, siloxanes, silazanes and silicone resins, wherein, firstly, recycled plastic material as a quartz-free filler in combination with the reactive polymer resin and one or more Si compounds as well as additives forms a raw material, wherein the raw material further contains at least one alcoholate of zirconium, aluminum or titanium, and wherein the raw material is compacted and subsequently reacted and cured, wherein the proportion of the solid is 40 to 97 wt.% of the total mass of the raw material.
  2. Procedure according to Claim 1 , characterized in that at least one second solid of a different type is introduced into the raw mass.
  3. Procedure according to Claim 1 or 2 characterized in that the solid is/are used in a mixture of fractions of different sizes and/or a mixture of different types and sizes.
  4. Method according to one of the preceding claims, characterized in that the solid is used simultaneously in three fractions of different sizes.
  5. Method according to one of the preceding claims, characterized in that the solid comprises particles with a particle size in the range of 0.01 µm to 10 mm, in particular coarse fractions with a particle size of 1 mm to 10 mm, medium fractions with a particle size in the range of 250 µm to 1 mm and/or fine fractions with a particle size in the range of 0.01 µm to 250 µm.
  6. Method according to one of the preceding claims, characterized in that the ratio of the first solid to the second, differently characterized solid is from 200:1 to 1:200.
  7. Method according to one of the preceding claims, characterized in that the alcoholate of zirconium, aluminium or titanium is an ethoxide, propoxide or butoxide and is preferably selected from titanium isopropoxide, titanium tetrabutanoate, zirconium n-propoxide and aluminium isopropoxide.
  8. Hybrid polymer material, in particular artificial stone, obtainable by a method according to one of the preceding claims.
  9. Hybrid polymer material according to Claim 8 in the form of a slab, tile, slabs, a 3D molded part and in particular in the form of a kitchen worktop, floor tile, a washbasin or sink, a shower tray, a wall or facade element, an insulation element or a drywall element.

Description

The present invention relates to a method for producing a hybrid polymer material and to a hybrid polymer material produced according to this method. Hybrid polymers are polymeric materials that combine structural units from different material classes at the molecular level and possess special properties and functionalities due to their composition. Such materials are frequently produced using the sol-gel process. Because of the unique properties of these materials, which often represent a combination of properties of the starting materials not readily available elsewhere, there is great interest in such hybrid polymeric materials and corresponding production processes, which should be as simple and easily adaptable as possible. DE 10 2017 107 591 A1 describes a process for producing a hybrid polymer material in the form of an artificial stone by reacting a polymer resin with at least one Si compound selected from silanes, siloxanes, silazanes and silicone resins, as well as an inorganic solid and auxiliary materials to form a raw mass, which is then compacted and hardened. WO 97/39043 A1 This mostly concerns foamed polyester polyurethanes used in the production of lightweight components. The polymer contains a high proportion of fillers, which are surface-treated with a liquid reactive component in a preliminary step. JP 2008-163252 A This describes a curable composition for the production of non-reflective coatings for displays. The composition can include various fine particles as fillers, each produced in independent process steps and pretreated differently to ensure its integration into the polymer matrix of the composition. It is therefore an object of the present invention to provide a method for producing a hybrid polymer material which is based on the use of inexpensive starting materials and is as easy to carry out as possible and leads to new hybrid polymer materials with advantageous properties. The present problem is solved by a method according to the attached claim 1. A hybrid polymer material according to claim 8 is also the subject of the present invention. Advantageous embodiments of the invention are the subject of the directly or indirectly referenced claims. It should be noted that this description uses references to commercially available products whose composition is generally not disclosed in detail by the manufacturer, as these compositions are considered trade secrets. Furthermore, singular and plural forms of a term are used interchangeably in the description and the claims, and the mention of the singular, e.g., "solid," includes the plural, e.g., "solids," and vice versa, since the solid contained in the manufactured raw material can, for example, be named in its entirety, but may in fact be composed of various solids differing in type and/or size. Within the scope of the present invention, a "solid of a different type" refers to a solid that differs from another solid in terms of structure and/or material class; for example, a polymeric solid is a solid of a different type compared to a mineral solid or a rock. In the inventive process for producing a hybrid polymer material, the components mentioned in claim 1 form a raw material, which is compacted and subsequently reacted and cured. Curing is carried out, for example, by heat treatment at a temperature in the range of room temperature to 350 °C, by a radical chain reaction, or by UV irradiation. The reaction generally takes place within the raw material during curing. In the presence of metals, autocatalytic or metal-catalyzed, and at least partially exothermic, reactions also occur. During the investigations carried out within the scope of the present invention, it was unexpectedly found that the solid can be integrated or incorporated into the hybrid polymer material according to the invention and, depending on the particle size and/or quantity used, can exert special effects in a controllable manner. In addition to recycled plastics, which are used in a proportion of 40 to 97 wt.% of the total mass of the raw material, a wide variety of materials can be used as solids according to the invention, in particular particulate plastics selected from the group comprising thermoplastics, thermosets, elastomers and mixtures of the same, powder resins, particulate fluoropolymers, fibers of all kinds, minerals, rocks, ores, metal oxides, metals, borides, carbides, nitrides, soapstone, calcined soapstone and vegetable solids, wherein the total amount of all solids in the raw material is a maximum of 97 wt.%. The aforementioned groups of solids are grouped according to their origin or material type, or according to their influence on the properties of the available process products, and may therefore include overlaps or duplicate entries. Particulate plastics, which include in particular thermoplastics, thermosets, and elastomers, are commonly available commercially and can generally be used in their pure form or in any mixtures. Thes