Layered silicates and water-resistant articles made therefrom

• US 5,049,237 A
• Filed: 10/30/1989
• Issued: 09/17/1991
• Est. Priority Date: 03/25/1985
• Status: Expired due to Fees

• Current Assignee: Armacell Enterprise GmbH & Company KG (Armacell International SA)
• Original Assignee: Armstrong World Industries Incorporated
• Inventors: Ko, Kenneth K., Hosfeld, Lewis K., Brubaker, Richard A., Bohrn, Walter J., Garman, Shelly N., Tymon, Thomas M.
• Primary Examiner(s): CANNON, JAMES
• Application Number:
  US07/428,725
• Time in Patent Office: 687 Days
• Field of Search: 106/416, 106/417, 106/DIG. 3, 162/157.2, 162/164.3, 162/181.8, 252/315.2, 252/378 R, 428/283, 428/324, 428/331
• US Class Current: 162/157.2
• CPC Class Codes: C01B 33/44 Products obtained from layered base-exchange silicates by ion-exchange with organic compounds such as ammonium, phosphonium or sulfonium compounds or by intercalation of organic compounds, e.g. organoclay material
• CPC Class Codes: C01B 35/08 Compounds containing boron and nitrogen, phosphorus, oxygen, sulfur, selenium or tellurium
• CPC Class Codes: C01B 35/10 Compounds containing boron and oxygen C01B35/06 takes precedence
• CPC Class Codes: C04B 14/206 Mica or vermiculite modified by cation-exchange; chemically exfoliated vermiculate
• CPC Class Codes: C04B 35/6224 Fibres based on silica
• CPC Class Codes: C04B 41/00 After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone conditioning of the materials prior to shaping C04B40/00; applying liquids or other fluent materials to surfaces, in general B05; grinding or polishing B24; apparatus or processes for treating or working shaped articles of clay or other ceramic compositions, slag or mixtures containing cementitious material B28B11/00; working stone or stone-like materials B28D; glazes, other than cold glazes, C03C8/00; etching, surface-brightening or pickling compositions C09K13/00
• CPC Class Codes: D21H 13/44 Flakes, e.g. mica, vermiculite
• CPC Class Codes: Y10S 106/03 Mica
• CPC Class Codes: Y10S 277/934 Seal swells when wet
• CPC Class Codes: Y10S 428/902 High modulus filament or fiber
• CPC Class Codes: Y10S 428/92 Fire or heat protection feature
• CPC Class Codes: Y10T 428/251 Mica
• CPC Class Codes: Y10T 428/259 Silicic material
• CPC Class Codes: Y10T 428/31721 Of polyimide
• CPC Class Codes: Y10T 442/2992 Coated or impregnated glass fiber fabric
• CPC Class Codes: Y10T 442/699 Including particulate material other than strand or fiber material

Abstract

Disclosed are flocced mineral materials which may be utilized to prepare high temperature resistant, water resistant articles. These materials are prepared by utilizing, as a starting material, a gellable layered swelled silicate that has an average charge per structural unit that ranges from about -0.4 to -1 and which contains interstitial cations which promote swelling with a source of at least one species of multiamine derived cations.

Claims

1. A flocced, 2:

1 layered silicate composition which comprises a swelled layered silicate floc, the said silicate being selected from mica and vermiculite and having an average charge per structural unit that ranges from about -0.4 to about -1, said silicate containing at least some interstitial cations that consist essentially of;

a cationic diamine compound.

2. A composition as described in claim 1 wherein the cationic diamine compound has the formula:

space="preserve" listing-type="equation">(R.sup.3).sub.3 N-(CX.sub.2).sub.n -N(R.sup.3).sub.3.sup.+2

wherein (1) each R is independently selected from hydrogen, a C₁ -C₈ saturated or unsaturated, straight or branched, chain alkyl group, or an aryl group, with the proviso that there be no more than one aryl group on each nitrogen, (2) each X is independently selected from hydrogen, an alkyl group or an aryl group and (3) n represents an integer from 2 to 15, with the option that, when n is 3 or more, the CX₂ groups may form ringed moieties which may be aromatic.

3. The composition of claim 1 prepared with a dispersion of a swelled layered silicate which contained exchangeable interstitial ions, and was contacted with the cationic diamine to exchange at least some of the exchangeable interstitial ions with the cationic diamine to thereby flocculate the silicate.

4. The composition of claim 1 wherein the silicate is vermiculite.

5. A composition as described in claim 1 which also contains polybenzimidazole fiber.

6. A composition as described in claim 1 wherein the layered silicate is a mica.

7. The composition of claim 1 which is paper.

8. The composition of claim 1 which is a dried film.

9. A composition as described in claim 1 also containing fiber.

10. A composition as described in claim 9 wherein the fiber includes polybenzimidazole fiber.

11. A composition as described in claim 1 wherein the cationic diamine compound has the formula:

##STR2## wherein (1) each R¹ can independently be either hydrogen or a C₁ -C₈ saturated or unsaturated, straight or branched, chain alkyl group, and (2) R² is a saturated, or unsaturated linear or branched hydrocarbon moiety.

12. A composition as described in claim 11 wherein each R¹ is hydrogen, and R² has from 1 to 6 carbon atoms.

13. A composition as described in claim 11 wherein each R¹ is hydrogen and R² has from 6 to 18 carbon atoms.