Disclose

Foamable composition for building purposes

KURZTEXT

This disclosure relates to a foamable composition, in particular for the field of construction like filling joints or cavities or for connecting construction elements, the composition comprising a foamable aqueous phase and a volatile propellant, the aqueous phase and the propellant are capable of forming a foam when mixed with one another and dispensed under pressure release of the propellant upon release from a pressurized canister through a dispensing tube or nozzle through, wherein the aqueous phase comprises at least one film forming organic polymer and dispersed inorganic components, wherein preferably the composition is essentially free of isocyanate-components, and wherein the dispensed composition upon drying yields a cured foam.

Such foams for building purposes which are produced by dispensing said foam composition at an arbitrary site of construction should altogether meet a complex profile of requirements. For example, they should have a foam stability which is sufficient for filling joints, preferably including vertical joints, for instance joints between doors and windows or other con­struc­ti­onal parts. Especially sealing of joints between constructional parts movable with respect to each other is desired, so that the sealing foam is carrying a dynamic load and should show appropriate physical properties like elasticity and tensile strength in the cured state. Furthermore, said foam preferably only shows reduced or little shrinkage during curing or drying. Furthermore, said foam should provide particularly good adhesion to the respective substrate, including mineral building materials such as brick or concrete, wood, metal or plastic material or the like. Furthermore, the foam composition preferably should meet environmental requirements, namely should contain essentially no hazardous or polluting components such as isocyanates. Further, the foamable composition shall be suitable for application as canned foam, preferably one-component foam, and to be applied with no special equipment. Accordingly, the canned formulation should have sufficient or improved shelf life and lack of mixing problems of the components.

The said foams often are applied outdoors, so that the freshly dispensed, uncured foam may be directly exposed to weather, especially water or rain. This establishes the goal that the fresh, uncured foam, more specifically the foam skin being formed after a certain drying period which still is within the open time of the formulation so that the bulk volume of the foam still is uncured, should show sufficient stability against rain being applied to the skin. As a further desire, the fresh (uncured) foam should not be washed out of the joint by rain or water application, so that good joint fill after water application should be given, preferably in combination with the desired properties as discussed above.

As another aspect, if appropriate, the said foam also may be used as a gluing foam, especially  when it is designed as a collapsible foam, e.g. by supplementation of a cell opening agent and/or adjustment of the rigidity of the foamed composition, for instance by using a plasticizer and/or an appropriate propellant or foaming agent like dimethylether.

In fact a foam and/or respective foaming composition should fulfill at least one or a certain combination of the above captioned desired features or most preferably should fulfill all of the above captioned desired features in combination.

More precisely, it is the desire to provide a foamable composition which can be utilized particularly as construction foam for filling joints showing certain elasticity in cured state to be used in non-rigid joints, which preferably is not hazardous and which especially, when freshly foamed, has improved water resistance, especially joint fill after water application and/or rain water resistance. Preferably, one or more of the further objects as stated above are solved by the foamable composition as described here as well, independent from its canned state.

To achieve the above captioned object a foamable composition is provided comprising dispersed inorganic components and wherein the dispensed composition upon drying yields a cured foam as described below in detail. Preferably the composition is essentially free of isocyanate-components. The total content of the dispersed inorganic component may be ≥ 0.5 % by weight or especially ≥ 1.5 % by weight based on the total foamable composition including propellant, respectively.  The disclosure also covers a joint of building elements being sealed by the respective cured foam or a joint of building elements being glued by the respective cured foam.

 

Especially, the dispersed inorganic material is water insoluble, so that preferably 75 wt.-% or more preferably ≥ 85 wt.-% or ≥ 90 wt.-% or most preferably ≥ 95 wt.-% or ≥ 99 wt.-% of the said inorganic material is dispersed in particulate form in the foamable composition. Especially, the dispersed inorganic material may be an ionic material, so that the inorganic material particles preferably have a hydrophobic surface.

Surprisingly, the foamable composition which is based on an aqueous phase comprising organic film forming polymers, in particular a latex composition, can be improved by the presence of an dispersed inorganic component. Especially, the composition can be stabilized in its freshly foamed state by the presence of an dispersed inorganic component to show improved resistance to water, especially against water (rain) being directly applied to the fresh foam for instance with some water pressure or under application of flowing air. This is given due to a formation of a sufficiently resistant skin (i.e. the skin formed on the fresh foam after a certain drying time being much lower than the curing time of the foam), so that the skin is not significantly deteriorated by the applied rain. Independent thereof or in combination the fresh foam shows enhanced joint fill properties after application of water or rain to it, so that the sealing properties of the foam are increased. The term “fresh foam” means that the dispensed or sprayed foam still is in an uncured state (despite the formed thin skin at the foam surface) and still can be reversibly reshaped by a tool like a spatula. These effects are related to increased skin persistency and decreased water solubility and therefore enhanced resistance against water wash out of the fresh foam. So in fact the dispensed foam on one hand provides a quite stable skin within a fairly short time, e.g. within 4 hours, on the other hand the skin shows appropriate water vapor permeability so that the foam can dry within a reasonable time period to avoid undue change of the cell structure, e.g. by building large cells or voids in the foam. The shrinkage of the foam during curing by drying is reduced, especially after water application to the foam. This manifests and enlarges the possibility to use the foam in outdoor applications in the field of construction. Furthermore, the foamable composition comprising the dispersed inorganic component in the aqueous phase of organic film forming polymers shows good sprayability, i.e. homogenous spraying without interruptions of foam dispense. Furthermore, the dispensed foam composition also is sufficiently stable so that even vertical joints or overhead joints in ceilings can be filled with foam without sagging of the freshly foamed composition and the dispensed foam shows a favorable curing time to sufficiently enable smoothing and planning of the sprayed foam with a tool without detrimental effects to the surface of the foam bead like due to adhesion of the foam at the tool. The adhesion to constructional parts in general, especially as mentioned above, is quite good. Furthermore, the cured foam shows a quite homogeneous structure with relatively small cells. Furthermore, the cured foam has high elasticity, wherein in some cases even a semi-rigid foam ca be achieved.  The canned foamable composition shows good storage stability (shelf life) even as a one-component composition.

In summary, the foamable composition as described here may have the following formulation or properties:

Foamable composition, in particular for the field of construction like filling joints or cavities or for connecting construction elements, the composition comprising a foamable aqueous phase and a volatile propellant, the aqueous phase and the propellant are capable of forming foam when mixed with one another and dispensed under pressure release of the propellant through a dispensing tube, wherein the aqueous phase comprises at least one film forming organic polymer and dispersed inorganic components, wherein preferably the composition is essentially free of isocyanate-components, and wherein the dispensed composition upon drying yields a cured foam,
wherein the total content of the dispersed inorganic component is ≥ 0.5 % by weight based on the total foamable composition including propellant.

The foamable composition is described in more details in the specification as enclosed.

 

LANGTEXT

This disclosure relates to a foamable composition, in particular for the field of construction like filling joints or cavities or for connecting construction elements, the composition comprising a foamable aqueous phase and a volatile propellant, the aqueous phase and the propellant are capable of forming a foam when mixed with one another and dispensed under pressure release of the propellant upon release from a pressurized canister through a dispensing tube or nozzle through, wherein the aqueous phase comprises at least one film forming organic polymer and dispersed inorganic components, wherein preferably the composition is essentially free of isocyanate-components, and wherein the dispensed composition upon drying yields a cured foam.

Such foams for building purposes which are produced by dispensing said foam composition at an arbitrary site of construction should altogether meet a complex profile of requirements. For example, they should have a foam stability which is sufficient for filling joints, preferably including vertical joints, for instance joints between doors and windows or other constructional parts. Especially sealing of joints between constructional parts movable with respect to each other is desired, so that the sealing foam is carrying a dynamic load and should show appropriate physical properties like elasticity and tensile strength in the cured state. Furthermore, said foam preferably only shows reduced or little shrinkage during curing or drying. Furthermore, said foam should provide particularly good adhesion to the respective substrate, including mineral building materials such as brick or concrete, wood, metal or plastic material or the like. Furthermore, the foam composition preferably should meet environmental requirements, namely should contain essentially no hazardous or polluting components such as isocyanates. Further, the foamable composition shall be suitable for application as canned foam, preferably one-component foam, and to be applied with no special equipment. Accordingly, the canned formulation should have sufficient or improved shelf life and lack of mixing problems of the components.

The said foams often are applied outdoors, so that the freshly dispensed, uncured foam may be directly exposed to weather, especially water or rain. This establishes the goal that the fresh, uncured foam, more specifically the foam skin being formed after a certain drying period which still is within the open time of the formulation so that the bulk volume of the foam still is uncured, should show sufficient stability against rain being applied to the skin. As a further desire, the fresh (uncured) foam should not be washed out of the joint by rain or water application, so that good joint fill after water application should be given, preferably in combination with the desired properties as discussed above.

As another aspect, if appropriate, the said foam also may be used as a gluing foam, especially  when it is designed as a collapsible foam, e.g. by supplementation of a cell opening agent and/or adjustment of the rigidity of the foamed composition, for instance by using a plasticizer and/or an appropriate propellant or foaming agent like dimethylether.

In fact a foam and/or respective foaming composition should fulfill at least one or a certain combination of the above captioned desired features or most preferably should fulfill all of the above captioned desired features in combination.

More precisely, it is the desire to provide a foamable composition which can be utilized particularly as construction foam for filling joints showing certain elasticity in cured state to be used in non-rigid joints, which preferably is not hazardous and which especially, when freshly foamed, has improved water resistance, especially joint fill after water application and/or rain water resistance. Preferably, one or more of the further objects as stated above are solved by the foamable composition as described here as well, independent from its canned state.

To achieve the above captioned object a foamable composition is provided comprising dispersed inorganic components and wherein the dispensed composition upon drying yields a cured foam as described below in detail. Preferably the composition is essentially free of isocyanate-components. The total content of the dispersed inorganic component may be ≥ 0.5 % by weight or especially ≥ 1.5 % by weight based on the total foamable composition including propellant, respectively.  The disclosure also covers a joint of building elements being sealed by the respective cured foam or a joint of building elements being glued by the respective cured foam.

Especially, the dispersed inorganic material is water insoluble, so that preferably 75 wt.-% or more preferably ≥ 85 wt.-% or ≥ 90 wt.-% or most preferably ≥ 95 wt.-% or ≥ 99 wt.-% of the said inorganic material is dispersed in particulate form in the foamable composition. Especially, the dispersed inorganic material may be an ionic material, so that the inorganic material particles preferably have a hydrophobic surface.

Surprisingly, the foamable composition which is based on an aqueous phase comprising organic film forming polymers, in particular a latex composition, can be improved by the presence of an dispersed inorganic component. Especially, the composition can be stabilized in its freshly foamed state by the presence of an dispersed inorganic component to show improved resistance to water, especially against water (rain) being directly applied to the fresh foam for instance with some water pressure or under application of flowing air. This is given due to a formation of a sufficiently resistant skin (i.e. the skin formed on the fresh foam after a certain drying time being much lower than the curing time of the foam), so that the skin is not significantly deteriorated by the applied rain. Independent thereof or in combination the fresh foam shows enhanced joint fill properties after application of water or rain to it, so that the sealing properties of the foam are increased. The term “fresh foam” means that the dispensed or sprayed foam still is in an uncured state (despite the formed thin skin at the foam surface) and still can be reversibly reshaped by a tool like a spatula. These effects are related to increased skin persistency and decreased water solubility and therefore enhanced resistance against water wash out of the fresh foam. So in fact the dispensed foam on one hand provides a quite stable skin within a fairly short time, e.g. within 4 hours, on the other hand the skin shows appropriate water vapor permeability so that the foam can dry within a reasonable time period to avoid undue change of the cell structure, e.g. by building large cells or voids in the foam. The shrinkage of the foam during curing by drying is reduced, especially after water application to the foam. This manifests and enlarges the possibility to use the foam in outdoor applications in the field of construction. Furthermore, the foamable composition comprising the dispersed inorganic component in the aqueous phase of organic film forming polymers shows good sprayability, i.e. homogenous spraying without interruptions of foam dispense. Furthermore, the dispensed foam composition also is sufficiently stable so that even vertical joints or overhead joints in ceilings can be filled with foam without sagging of the freshly foamed composition and the dispensed foam shows a favorable curing time to sufficiently enable smoothing and planning of the sprayed foam with a tool without detrimental effects to the surface of the foam bead like due to adhesion of the foam at the tool. The adhesion to constructional parts in general, especially as mentioned above, is quite good. Furthermore, the cured foam shows a quite homogeneous structure with relatively small cells. Furthermore, the cured foam has high elasticity, wherein in some cases even a semi-rigid foam ca be achieved.  The canned foamable composition shows good storage stability (shelf life) even as a one-component composition.

In summary, the foamable composition as described here may have the following formulation or properties:

(1)       Foamable composition, in particular for the field of construction like filling joints or cavities or for connecting construction elements, the composition comprising a foamable aqueous phase and a volatile propellant, the aqueous phase and the propellant are capable of forming foam when mixed with one another and dispensed under pressure release of the propellant through a dispensing tube, wherein the aqueous phase comprises at least one film forming organic polymer and dispersed inorganic components, wherein preferably the composition is essentially free of isocyanate-components, and wherein the dispensed composition upon drying yields a cured foam, wherein the total content of the dispersed inorganic component is ≥ 0.5 % by weight based on the total foamable composition including propellant.

(2)       Composition according to (1), wherein the total content of the dispersed inorganic component is ≥ 1.5 % by weight based on the total foamable composition including propellant.

(3)       Composition according to (1) or (2), wherein  the dispersed inorganic component is selected form the group of silicates,  borates, sulphates, graphite, oxides or oxygen salts, hydroxides, carbonates, phosphates or mixtures thereof.

(4)                   Composition according to (3), wherein the silicate is a nesosilicate (e.g. olivine type), sorosilicate (e.g. epidote, melilite group), cyclosilicate (e.g. tourmaline group),  inosilicates (single chain silicate anions and/or double chain silicate anions, e.g. pyroxene group, amphibole group), phyllosilicate ( e.g. micas, kaolin and clays) or tectosilicate ( e.g. quartz, feldspars, zeolites), or mixtures thereof.

(5)       Composition according to (3) or (4), wherein the silicate is present in calcined form.

(6)       Composition according to any of (1) to (5), wherein the foamable composition comprises aluminium trihydroxide.

(7)       Composition according to (6), wherein aluminium trihydroxide is present in an amount of 0.5 to 30 % by weight based on the total foamable composition.

(8)                   Composition according to any of (1) to (7), wherein the total of dispersed inorganic components is present in the composition in an amount of up to 35 % by weight or up to 50 % by weight based on the total foamable composition , including propellant.

(9)       Composition according to any of (1) to (8) the preceding claims, characterized in that the film forming organic polymer is an elastomeric polymer in the cured foam.

(10)     Composition according to (9), wherein the film forming organic polymer is a type R rubber material or a type M rubber material or a combination of both, including mixtures, blends and copolymers.

(11)     Composition according to any of (1) to (10), wherein the film forming organic polymer is present in the composition in an amount of 10 to 60 % by weight based on the total foamable composition.

(12)     Composition according to any of (1) to (11), wherein the weight ratio between film forming organic polymer and the total of the dispersed inorganic component is in the range from 20:1 to 1:5 or from 10:1 to 1:2.

(13)     Composition according to any of (1) to (12), wherein the foamable composition further comprises a water soluble phosphate.

(14)     Composition of (13), wherein the water soluble phosphate is a lower polyphosphate, preferably comprising up to 10 phosphor atoms, respectively, e.g. a linear or cyclic polyphosphate.

(15)     Composition according to any of (1) to (14), wherein the foamable composition further comprises a water soluble silicate.

(16)     Composition according to any of (1) to (15), wherein the foamable composition further comprises an organic chelating agent.

(17)     Composition according to (16), wherein the chelating agent comprises chelating carboxy and/or amino groups, e.g. is EDTA or NTA or a combination of both.

(18)     Composition according to any of (13) to (17), wherein one or more of the components water soluble phosphate, water soluble silicate and organic chelating agent is present in the composition in an amount of 0.25 to 15 % by weight based on the total foamable composition, with respect to each of the given present component.

(19)     Composition according to any of (13) to (18), wherein the total of the components selected from the group of water soluble phosphate, water soluble silicate and organic chelating agent or combinations of them is present in the composition in an amount of 0.25 to 30 % by weight based on the total foamable composition.

(20)                 Composition according to any of (1) to (19), wherein the composition consists of
        a) 5 – 65 % by weight of organic film forming polymer,
        b) 1.5 - 50 % by weight of total content of dispersed inorganic materials
        c) 0-50 % by weight further components such as flame retardants, stabilizers, cell regulating agents etc,
        d) 2-25 % by weight volatile propellants,
        e) balance to 100% by weight water, at least 15 % by weight of water.

(21)                 Composition according to any of (1) to (20), wherein the composition consists of
a) 5 – 65 % by weight of organic film forming polymer,
b) 1.5 - 50 % by weight of total content of dispersed inorganic materials, optionally comprising aluminium trihydroxide,
c) 0.25 - 30 % by weight of components selected from the group consisting of water soluble phosphates, water soluble silicates, organic chelating components in total
d) 0-50 % by weight further components such as flame retardants, fillers, stabilizers etc,
e) 2-25 % by weight volatile propellants,
f) balance to 100% by weight water, at least 15 % by weight of water.

(22)     Composition according to any of (1) to (21), wherein the content of the film-forming organic polymer and the content of the dispersed inorganic material calcined sheet silicate of the composition are adjusted to provide a foamable composition which, when dispensed to form a bead having a width of 2 cm and a height of 2 cm, after a pre-curing time of the dispensed foam composition of 3 hours at 23°C and 50 % rel. humidity, and after having been sprayed with  water through a nozzle, is withstanding the applied water without visible foam loss, preferably for at least 3 hours,

(23)     Composition according to any of (1) to (22), wherein the content of the film-forming organic polymer and the content of the calcined sheet silicate of the composition are adjusted to provide a foamable composition which, when dispensed to homogeneously fill a joint having a width of 4 cm, after a pre-curing time of the dispensed joint filling foam composition of 3 hours at 23°C and 50 % rel. humidity, and after having been sprayed with  water through a nozzle, is withstanding the applied water achieving a joint fill of ≥ 25 vol.-%.

(24)     Composition according to any of (1) to (23), wherein the composition is a one-component-composition.

(25)     Building elements being arranged to form a joint between each other, wherein the joint is sealed by means of a cured foam composition or wherein two structural parts are glued together by means of an adhesive, wherein the foam composition is a dispensed foamable composition according to any of (1) to (24).

Notwithstanding, if applicable, the foam composition of the present disclosure also can be used for other purposes than joint filling, e.g. can be used as a gluing foam.

The dried foam composition according to the present disclosure preferably yields a soft foam or in some cases a semi-rigid foam.

Curing of the dispensed foam may be achieved, as generally according to the present disclosure, by drying, e.g drying at 23°C, 50% relative humidity and 1013 hPa up to weight constancy. Curing of the dispensed (sprayed) foam preferably can be effected by drying under these conditions without further impacts like radiation, reaction with oxygen or other gaseous components or the like.

In general, the term “foam composition” is related to the dispensed foamable composition.

In case it is stated that a respective component “is” a certain component of a specific generic term of components like an “organic polymer”, “silicate”, “aluminosilicate”, “sheet silicate”, “calcined silicate”, “calcined aluminosilicate”, “calcined sheet silicate”, “borate”, “sulphate”, “oxide” or “oxygen salt”, “hydroxide”, “carbonate”, “phosphate” etc  than it is to be understood that the component preferably is just a specific component of the respective group or also may be a mixtures of components of the respective group.

In case it is stated the component is of a specific type like “of olivine type” than the component characterizing this specific type also is disclosed for its own, for instance the component “olivine”. On the other hand, in case a specific component is used as for instance “olivine”, it is evident that structurally equal or similar components like other components of olivine type structure can be used as well.

As the dispersed inorganic material preferably silicates are applied, which especially may be aluminosilicates, sheet silicates, calcined silicates, calcined aluminosilicates, calcined sheet silicates.

The dispersed silicates preferably are selected from the group of nesosilicates (e.g. olivine), sorosilicates (e.g. epidote, melilite group), cyclosilicates ([SinO3n]2n anions, e.g. tourmaline group),  inosilicates - single chain silicate anions (e.g. pyroxene group), inosilicates - double chain silicate anions (e.g. amphibole group), phyllosilicates (sheet silicates, e.g. [Si2nO5n]2nanions,  e.g. micas and clays) or tectosilicates (3D framework silicate anions like especially [AlxSiyO2x+2y)]x, e.g. quartz, feldspars, zeolites).

The nesosilicates (orthosilicates) being applied as dispersed inorganic material may be selected from the phenakite group (e.g. willemite - Zn2SiO4), from the olivine group (e.g. forsterite - Mg2SiO4, fayalite - Fe2SiO4, tephroite - Mn2SiO4), from the  garnet group (e.g. pyrope - Mg3Al2(SiO4)3, almandine - Fe3Al2(SiO4)3, spessartine - Mn3Al2(SiO4)3, grossular - Ca3Al2(SiO4)3, andradite - Ca3Fe2(SiO4)3, uvarovite - Ca3Cr2(SiO4)3, hydrogrossular - Ca3Al2Si2O8(SiO4)3-m(OH)4m)) from the zircon group (e.g. zircon - ZrSiO4), from the Al2SiO5 group (e.g. andalusite - Al2SiO5, kyanite - Al2SiO5, sillimanite - Al2SiO5, dumortierite - Al6.5-7BO3(SiO4)3(O,OH)3, topaz - Al2SiO4(F,OH)2, staurolite - Fe2Al9(SiO4)4(O,OH)2), from the humite group – (e.g. (Mg,Fe)7(SiO4)3(F,OH)2 , norbergite - Mg3(SiO4)(F,OH)2, chondrodite - Mg5(SiO4)2(F,OH)2, humite - Mg7(SiO4)3(F,OH)2, clinohumite - Mg9(SiO4)4(F,OH)2), from the datolite – group (e.g. CaBSiO4(OH)), from the titanite – group (e.g. CaTiSiO5), from the chloritoid – group (e.g. (Fe,Mg,Mn)2Al4Si2O10(OH)4), from the mullite-group (e.g. aka porcelainite) - Al6Si2O13.

The sorosilicates being applied as dispersed inorganic material may be selected from the hemimorphite (calamine) type (e.g. Zn4(Si2O7)(OH)2·H2O), lawsonite – type (e.g. CaAl2(Si2O7)(OH)2·H2O), ilvaite – type (e.g. CaFe2+2Fe3+O(Si2O7)(OH)), epidote group (e.g. epidote - Ca2(Al,Fe)3O(SiO4)(Si2O7)(OH), zoisite - Ca2Al3O(SiO4)(Si2O7)(OH), clinozoisite - Ca2Al3O(SiO4)(Si2O7)(OH), tanzanite - Ca2Al3O(SiO4)(Si2O7)(OH), allanite - Ca(Ce,La,Y,Ca)Al2(Fe2+,Fe3+)O(SiO4)(Si2O7)(OH), dollaseite-(Ce) - CaCeMg2AlSi3O11F(OH), vesuvianite (idocrase) - Ca10(Mg,Fe)2Al4(SiO4)5 (Si2O7)2 (OH)4) or structurally related components, respectively.

The cyclosilicates (having linked tetrahedra with (TxO3x)2x− anions) being applied as dispersed inorganic material may be selected from the silicates having 3-member ring silicate ions like benitoite – type BaTi(Si3O9) or having 6-member ring silicate ions like e.g. axinite – type (Ca,Fe,Mn)3Al2(BO3)(Si4O12)(OH), beryl/emeralde – type Be3Al2(Si6O18), sugilite – type KNa2(Fe,Mn,Al)2Li3Si12O30, cordierite – type (Mg,Fe)2Al3(Si5AlO18), tourmaline – type (Na,Ca)(Al,Li,Mg)3(Al,Fe,Mn)6 (Si6O18(BO3)3(OH)4 or milarite type. In fact, also cyclosilicates having 4-membered [Si4O12] single rings  like  papagoite or 9-membered ring [Si9O27]-rings like eudialyte may be applied. Structurally related components may be applied as well.

The inosilicates being applied as dispersed inorganic material may be selected from the single chain type (SiO3 – type anions) or from the double chain type. (Si4O11- type anions).

Applied single chain inosilicates may be selected from pyroxene group, e.g. enstatite - orthoferrosilite series like enstatite - MgSiO3 or ferrosilite - FeSiO3) ; pigeonite – type like - Ca0.25(Mg,Fe)1.75Si2O6), from diopside - hedenbergite series (like diopside – type (e.g. CaMgSi2O6 ), hedenbergite – type like CaFeSi2O6, augite – type ( e.g. (Ca,Na)(Mg,Fe,Al)(Si,Al)2O6), from sodium pyroxene series like of jadeite – type (e.g.NaAlSi2O6), aegirine – type (e.g. NaFe3+Si2O6), spodumene – type (e.g. LiAlSi2O6), or  from pyroxenoid group silicates like  wollastonite – type (e.g. CaSiO3), rhodonite – type (e.g. MnSiO3), pectolite – type (e.g. NaCa2(Si3O8)(OH)).

Applied double chain inosilicates may be selected from  amphibole group like of anthophyllite – type (e.g. (Mg,Fe)7Si8O22(OH)2), cumingtonite series like e.g. cummingtonite - Fe2Mg5Si8O22(OH)2 or grunerite - Fe7Si8O22(OH)2, of tremolite series like  tremolite – type (e.g. Ca2Mg5Si8O22(OH)2), actinolite – type like e.g. Ca2(Mg,Fe)5Si8O22(OH)2, hornblende – type like (Ca,Na)2-3(Mg,Fe,Al)5Si6 (Al,Si)2O22(OH)2, from sodium amphibole group like glaucophane – type (e.g. Na2Mg3Al2Si8O22(OH)2), riebeckite (asbestos) – type (e.g. Na2Fe2+3Fe3+2 Si8O22(OH)2) or arfvedsonite – type (like e.g. Na3(Fe,Mg)4FeSi8O22(OH)2).

Applied inosilicate may have 2-periodic single chain (Si2O6) (e.g. pyroxene family like diopside), 2-periodic double chains (Si4O11) (clinoamphibole family, e.g. tremolite), unbranched 3-periodic single chain (e.g. wollastonite), 5-periodic single chain (e.g. rhodonite), cyclic branched 8-periodic chain (e.g. pellyite).

Preferably phyllosilicates or sheet silicates are applied as dispersed inorganic material,  which may be selected from serpentine group (e.g. antigorite - Mg3Si2O5(OH)4, chrysotile - Mg3Si2O5(OH)4, lizardite - Mg3Si2O5(OH)4)), from clay mineral group (e.g. halloysite - Al2Si2O5(OH)4, kaolinite - Al2Si2O5(OH)4, illite - (K,H3O) (Al,Mg,Fe)2 (Si,Al)4O10[(OH)2,(H2O)], montmorillonite - (Na,Ca)0.33(Al,Mg)2 Si4O10(OH)2·nH2O, vermiculite - (MgFe,Al)3(Al,Si)4O10(OH)2·4H2O, talc - Mg3Si4O10(OH)2, sepiolite - Mg4Si6O15(OH)2·6H2O, palygorskite (or attapulgit)- (Mg,Al)2Si4O10(OH)·4(H2O), pyrophyllite - Al2Si4O10(OH)2), from mica group (e.g. biotite - K(Mg,Fe)3(AlSi3)O10 (OH)2, muscovite - KAl2(AlSi3)O10(OH)2, phlogopite - KMg3(AlSi3)O10(OH)2, lepidolite - K(Li,Al)2-3(AlSi3)O10(OH)2, margarite - CaAl2(Al2Si2)O10(OH)2, glauconite - (K,Na)(Al,Mg,Fe)2 (Si,Al)4O10(OH)2, including  muscovite-celadonit group like e.g. aluminoceladonite, celadonit, ferro-alumino celadonit and/or ferroceladonit, or ganterite,  respectively) or brittle mica like clintonite or interlayer deficient micas like hydro-muscovite, phengite etc.). The applied  mica group components specifically may be of dioctahedral or trioctahedral type, or from chlorite group (e.g. chlorite - (Mg,Fe)3(Si,Al)4O10 (OH)2•(Mg,Fe)3(OH)6) or may be bentonite. For instance, the applied  phyllosilicate may have a  single net of tetrahedra with 4-membered rings like apophyllite-(KF)-apophyllite-(KOH) series, a single tetrahedral nets of 6-membered rings like pyrosmalite-(Fe)-pyrosmalite-(Mn) series, a single tetrahedral nets of 6-membered rings like zeophyllite or a double nets with 4- and 6-membered rings like carletonite.

In general, in the phyllosilicate anion layers, especially comprising aluminium, the anion  layers can be saturated according to their valence by hydroxy groups and/or other anions, in particular halogen ions as fluoride,

The phyllosilicates utilized according to the present disclosure especially may be 1:1 clay minerals (two layer clay minerals) such as kaolinite or if so also chrysotile, optionally 2:1 clay minerals (three layer clay minerals) or 2:1:1 clay minerals (four layer clay minerals).

Phyllosilicates are considered to be of “dioctahedral type” also in case of intermediate phases – intermediate from the “dioctahedral type” to “trioctahedral type” - in case 2 to 2,49 of a group of three of the octahedral cites are occupied by cations, preferably 2 to 2,3 or 2 to 2,2 cites of 3 given octahedral cites, more preferably 2 to 2,1 or 2 to 2,05 cites of 3 given octahedral cites. Especially, the “intermediate phases” may be solid solutions wherein the diaoctahedral component or the trioctahedral component is a border component of this solid solution region. As an example for an intermediate phase (Alx,Mgy)2(OH)4[Si2O5] is given, wherein (2x+2y=6 with y > 0). In case more than 2,49 cites of a group of three octahedral cites are occupied by cations, these phyllosilicates are considered to be “trioctahedral type”, for example if in (Alx,Mgy)2(OH)4[Si2O5] the Mg content is much higher than the Al-content (based on atomic ratio). So for instance  muscovite-paragonite-solid solutions, bentonite or the like are covered, without being restricted thereto.

In the calcined sheet silicates the ratio of silicon to aluminium, here expressed as molar ratio SiO2 to Al2O3, may be in the range from 3:1 to 1:3, preferably in the range from 2:1 to 1:2, especially in the range from 1,5:1 to 1:1,5, without being restricted thereto.

Preferably, the dioctahedral phyllosilicates are not of smectite type (expanding silicate including water between the T-O-T- layers (tetrahedra-octahedra-tetrahedra layers)), which however is not excluded from the disclosure per se.  

Furthermore, the applied dispersed silicates may be tectosilicates. The tectosilicates may be selected from quartz group. Preferred tectosilicates are from feldspar family  (e.g. alkali-feldspars (especially potassium-feldspars) like e.g. microcline - KAlSi3O8, orthoclase - KAlSi3O8, anorthoclase - (Na,K)AlSi3O8, sanidine - KAlSi3O8, aabite - NaAlSi3O8, ) may be plagioclase feldspars (like e.g.  albite - NaAlSi3O8, oligoclase - (Na,Ca)(Si,Al)4O8 (Na:Ca 4:1), andesine - (Na,Ca)(Si,Al)4O8 (Na:Ca 3:2), labradorite - (Ca,Na)(Si,Al)4O8 (Na:Ca 2:3), bytownite - (Ca,Na)(Si,Al)4O8 (Na:Ca 1:4), anorthite - CaAl2Si2O8), may be feldspathoid family (e.g. , nosean - Na8Al6Si6O24(SO4), cancrinite - Na6Ca2(CO3,Al6Si6O24).2H2O, leucite - KAlSi2O6, nepheline - (Na,K)AlSiO4, sodalite - Na8(AlSiO4)6Cl2 ), petalite - LiAlSi4O10, from scapolite group  (e.g. marialite - Na4(AlSi3O8)3(Cl2,CO3,SO4), meionite - Ca4(Al2Si2O8)3(Cl2CO3,SO4)), from analcime – type (e.g. NaAlSi2O6•H2O) or from zeolite family  (e.g. natrolite - Na2Al2Si3O10•2H2O, erionite - (Na2,K2,Ca)2Al4Si14O36·15H2O, , stilbite - NaCa2Al5Si13O36•17H2O,  scolecite - CaAl2Si3O10.3H2O or mordenite - (Ca,Na2,K2)Al2Si10O24•7H2O).

In fact, inosilicates and phyllosilicates are preferred as dispersed silicates. The silicates may be aluminosilicates (aluminium being arranged between the silicate anion layer or wherein the aluminium atoms are part of the anionic SiO4-tetrahedra network), especially alumino phyllosilicates. Present aluminosilicates may comprise further kation layers, e.g. of 12-fold coordinated alkali metal atoms.

In some fields of application Fe-containing components are not preferred.

In general, if at least one or more of the above captioned silicates, including aluminosilicates, is present in the composition, one or more of the respective silicate may be present in calcined form. This especially may be given with respect to a nesosilicate (e.g. olivine type), sorosilicate (e.g. epidote, melilite group), cyclosilicate (e.g. tourmaline group),  inosilicates (single chain silicate anions and/or double chain silicate anions, e.g. pyroxene group, amphibole group), phyllosilicate ( e.g. micas, kaolin and clays), especially phyllosilicates of dioctahedral or of trioctahedral type,  or tectosilicate ( e.g. quartz, feldspars, zeolites). In calcined alumino silicates the aluminium atoms may be arranged between the silicate anion layers or the aluminium atoms may be part of the anionic SiO4-tetrahedra network, respectively, wherein further kation layers like layers of coordinated alkali metal atoms (e.g. 12-fold coordinated) may be present).

Especially, each of the above captioned specific silicates may be present in the foamable composition in calcined form. In fact, according to specific embodiments, all of the dispersed silicates being present in the foamable composition may be of calcined form, or a combination of dispersed calcined and non-calcined dispersed silicates is given. As it is evident from the disclosure above, in some embodiments all of the dispersed silicates in the foamable composition may be of non-calcined form (unless explicitly stated, a given “dispersed silicate” is in non-calcined form).

In the meaning of the disclosure the term „calcination“ in general shall be understood that dehydroxylation and/or dehydration of the respective sheet silicate occurs by heat treatment, for example under elimination of crystal water and/or in particular under a elimination of water from the hydroxy groups of the component which is calcinated. Calcination of the respective silicates according to the disclosure may be carried out for example at a temperature of ≥ 500°C or ≥ 530°C or at a temperature of ≥ 550°C or ≥ 600°C or optionally ≥ 700°C, preferably at a temperature of ≤ 900°C or ≤ 800°C, especially ≤ 750°C. Thus calcination is to be distinguished from drying of the respective components, which is carried out at significantly lower temperature. Furthermore, calcination preferably is carried out not at too high temperatures to avoid sintering of the calcined component.

Preferably the calcined silicates have a puzzolane-index (according to Chapelle-test) of ≥ 200 mg Ca(OH)2/g or ≥ 500 mg Ca(OH)2/g, for example about 1400 mg Ca(OH)2/g to achieve improved activation of the calcined silicate, especially to improve rain water resistance. The puzzolane-index may amount to ≤ 5000 or ≤ 3000 mg Ca(OH)2/g. According to the Chapelle-test the total fraction of bound calcium hydroxide is measured, in particular according to the French standard NF P 18-513, attachment A.

In general, the dispersed inorganic component may by crystalline, amorphous or partially amorphous, i.e. comprising crystallographic long range ordered or crystalline structure portions. Especially, the dispersed inorganic component may by crystalline, unless contrary statements are given. The applied calcined silicate especially may be in at least partly amorphous, so that it shows some crystallographic long range order or still some crystalline structure portions, what may be given with respect to all of the disclosed silicates, respectively.

Preferably the calcined silicate exist at least partly or at least almost completely in the form of lamellar particles, especially calcined phyllosilicates. Thus calcination was not carried out at such high temperatures, where the components employed more or less completely lose their morphology or crystallographic long-range order. This seems to improve foam stability, joint fill properties after water application, rain water resistance and other properties as discussed above. Calcined silicates may be used where the lamellar structure of the particles (preferably primary particles) can be recognized by microscopy like light microscopy, especially using visible light with wavelength between 380 and 780 nm.

As dispersed inorganic components borates may be applied. This covers orthoborates, metaborates and hydroxyborates. Preferably, the borates are selected form earth alkaline metal borates, especially Mg and Ca borates or mixed Mg/Ca-borates, including mixed alkaline metal earth alkaline metal borates, respectively, wherein the alkaline atom especially may be sodium and/or potassium. Furthermore aluminium borates may be applied, which may comprise alkaline metals and/or alkaline earth metal ions. Especially borates comprising B4O72- anions, B3O4(OH) 32- anions or [B5O6(OH)6]-anions may be applied. For instances, the borates may be selected from a calcium borate like Ca3(BO3)2, CaB3O4(OH)3·H2O, and NaCa[B5O6(OH)6] • 5 H2O, borocalcite, pandermit, colemanite, ulexite or boracite.

As dispersed inorganic components sulphates may be applied. This especially covers main group sulphates like earth alkaline sulphates (e.g. magnesium sulphate, calcium sulphate, especially CaSO4 . 2 H2O), strontium sulphate, barium sulphate, aluminium sulphate,  subgroup metal sulphates like e.g. zinc sulphate, Ti(III)sulphate or Ti(IV)sulphate, including mixed sulphates like mixed main group sulphates (e.g. magnesium calcium sulphate, earth alkaline aluminium sulphate like magnesium aluminium sulphate or calcium aluminium sulphate), mixed subgroup sulphates or mixed main group subgroup sulphates like earth alkaline subgroup sulphates (for instance earth alkaline iron sulphate or earth alkaline titanium sulphate, wherein earth alkaline metal especially may be magnesium or calcium or a combination of both).

As dispersed inorganic component graphite may be used.

As dispersed inorganic component oxides or oxygen salts may be used. This especially covers main group oxides (like e.g. aluminium oxide, tin oxide), subgroup metal oxides (like e.g. zinc oxide, titanium oxide (e.g. Ti(IV)oxide), iron oxides (like e.g. FeO, Fe2O3, Fe3O4) etc, including mixed oxides like mixed main group oxides, mixed subgroup oxides or mixed main group-subgroup oxides. Mixed main group oxides may be earth alkaline aluminium oxides, especially magnesium or calcium or calcium magnesium aluminium oxides. As mixed main group – subgroup oxides earth alkaline ferrous oxides, especially magnesium or calcium or calcium magnesium ferrous oxides may be used (e.g. calcium or magnesium ferrate or calcium or magnesium aluminium ferrate), or earth alkaline titanium oxides, especially magnesium or calcium or  calcium magnesium titanium oxides may be used (e.g. calcium or magnesium titanate or calcium or magnesium aluminium titanate). In general, the oxides may comprise further anions like hydroxyl groups (like e.g. AlO(OH)), halogen ions (e.g. Cl) etc, specifically, they a pure oxides.  The said oxides may comprise further cations like alkaline metal cations, especially sodium or potassium or both, preferably alkaline metal cations are not present, or only as impurities.

As dispersed inorganic component hydroxides may be used. This especially covers main group hydroxides (like e.g. aluminium hydroxide, zinc hydroxide), subgroup metal hydroxides (like e.g. iron hydroxides etc), including mixed hydroxides like mixed main group hydroxides, mixed subgroup hydroxides or mixed main group-subgroup hydroxides. Mixed main group hydroxides may be earth alkaline aluminium hydroxides, especially magnesium or calcium or calcium magnesium aluminium hydroxides. As mixed main group – subgroup hydroxides earth alkaline ferrous hydroxides, especially magnesium or calcium or calcium magnesium ferrous hydroxides may be used (e.g. calcium or magnesium ferrous hydroxide or calcium or magnesium aluminium ferrous hydroxide). In general, the hydroxides may comprise further anions like oxide anions, halogen ions (e.g. Cl) etc, specifically, they a pure hydroxides.  The said hydroxides may comprise further cations like alkaline metal cations, especially sodium or potassium or both, preferably alkaline metal cations are not present, or only as impurities.

As dispersed inorganic component carbonates may be used. This especially covers main group carbonates (like e.g. earth alkaline metal carbonates like magnesium carbonate, calcium carbonate(e.g. chalk or calcite), magnesium calcium carbonate like dolomite, barium carbonate etc), zinc carbonate hydroxide), subgroup metal carbonates (like e.g. iron carbonates), including mixed carbonates like mixed main group carbonates, mixed subgroup carbonates or mixed main group-subgroup carbonates like earth alkaline metal carbonates (e.g. magnesium or calcium or calcium magnesium ferrous carbonates). In general, the carbonates may comprise further anions like oxide anions, hydroxid anions, halogen ions (e.g. Cl) etc, specifically, they a pure carbonates.

As dispersed inorganic component phosphates may be used. This especially covers main group phosphates (like e.g. earth alkaline metal phosphates, especially magnesium phosphate, calcium phosphate, magnesium calcium phosphates, barium phosphate etc.), subgroup metal phosphates (like e.g. zinc phosphate, iron phosphates like vivianite, wavellite, pseudo wavelitte etc.), including mixed phosphates like mixed main group phosphates (e.g. earth alkaline metal aluminium phosphates like magnesium aluminium phosphate, calcium aluminium phosphate, magnesium calcium aluminium phosphates), mixed subgroup phosphates or mixed main group-subgroup phosphates like earth alkaline ferrous metal phosphates (e.g. magnesium or calcium or calcium magnesium ferrous phosphates), earth alkaline zinc metal phosphates (e.g. magnesium or calcium or calcium magnesium zinc phosphates) ets. In general, the phosphates may comprise further anions like oxide anions, halogen ions (e.g. Cl) etc, specifically, they a pure phosphates. Especially hydroxid posphates may be applied, e.g. apatites like calcium hydroxy apatite, fluoro apatite, phosphorite etc. The above captioned phosphates preferably are orthophosphates (PO43- ions). However, the above captioned phosphates also may be hydrogen phosphates (HPO42- ions) mixed phosphates comprising orthophosphate and hydrogen phosphate ions. However, the above captioned phosphates also may pyrophosphates (P2O74- ions). Furthermore, the above captioned phosphates may be polyphopsphates or metaphosphates, wherein the number of phosphor atoms in the anions may be ≤ 3 or ≤ 4 or ≤ 6, but also ≤ 10 or higher, respectively. The respective phosphate may comprise halogen ions, especially fluoro ions, carbonate ions or other, especially as impurities or as solid solutions.

In general, the dispersed inorganic component may be a synthetic component or from natural origin.

The dispersed inorganic component may be a surface modified by a surface modification agent, for instance  to change the hydrophilic or hydrophobic surface properties of the dispersed inorganic particles, their chemical reactivity, dispersion stability, agglomeration properties of the particles, UV-stability of the cured foam, adhesive properties with the organic film forming  polymer or other properties. Surface modification may be achieved by siloxane groups, ester groups, ether groups or others. Of course, in general non-surface modified dispersed inorganic components may be used.

The dispersed inorganic component as applied in the foamable composition preferably has a grain size distribution in which at least 30 % by weight, preferably at least 50% by weight or particularly preferred at least 80% by weight or about 100 % by weight has a grain size of   ≤ 400 µm, ≤ 250 µm or preferably ≤ 200 µm or ≤ 50 µm, or even ≤ 25 µm or ≤ 10 µm or also ≤ 5 µm or ≤ 1 µm. Hereby on one hand the foam composition can be dispensed trouble-free through a spray nozzle, even if supplied as canned foam, on the other hand the foam stability and size water resistance of a freshly dispensed foam can be especially advantageously improved.  Too coarse grain size has to be avoided to avoid inhomogeneous formulations, e.g. due to sedimentation of the dispersed inorganic material on the bottom of the respective can or canister. On the other hand, too fine grain size has to be avoided what may result in enhancement of aggregation of the dispersed inorganic components or reaction thereof with other components of the composition. Accordingly, the dispersed inorganic component as applied in the foamable composition preferably has a grain size distribution in which at least 30 % by weight, preferably at least 50% by weight or particularly preferred at least 80% by weight or about 100 % by weight has a grain size of ≥ 0,1 µm, ≥ 0,5 µm or  more preferably ≥ 1 µm or ≥ 5µm , especially ≥ 10 µm or ≥ 25 µm or ≥ 50 µm or even ≥ 100 µm or ≥ 150 µm.

In case the dispersed inorganic component has a sheet like particle shape as given especially in phyllosilicates or grahite, the dispersed inorganic component particles preferably have an aspect ratio (ratio of width to height of the particles) of  ≥ 3or ≥ 5, especially ≥ 10 or ≥ 25, for instance ≥ 40 or ≥ 75. The aspect ratio of the particles may be ≤ 200 or ≤ 150, for instance ≤ 100 or ≤ 80 or even ≤ 50. The grain size of the particles may be as described above, without being restricted thereto.

The dispersed inorganic component, especially calcined silicate,  may have a specific surface (BET) of ≥ 0.1 m²/g  or ≥ 0.5 m²/g, especially  ≥ 1 m²/g or  ≥ 3 m²/g or ≥ 5 m²/g, for instance ≥ 10 m²/g or even ≥ 15 m²/g. Hereby the dispersed inorganic component can exhibit a good effect with respect to promotion of foam stability and to improve rain resistance, however these specific surfaces of the dispersed inorganic component are not essential in any case. The specific surface (BET) of the dispersed inorganic component may be up to 100 m²/g or even higher, especially ≤ 75 m²/g or ≤ 50 m²/g, for instance 30 m²/g or 20 m²/g.

The total amount of dispersed inorganic component in the foamable composition may be ≥ 0.5 % by weight or ≥ 1.0 % by weight, preferably is ≥ 1.5 % by weight or ≥ 2% by weight or ≥ 3 % by weight or, especially ≥ 6% by weight or ≥ 8% by weight. In some formulations ≥ 10% by weight or ≥ 16% by weight or ≥ 20% or ≥ 25% may be applicable as the said content. The total amount of dispersed inorganic component in the foamable composition can in particular be ≤ 50% by weight or ≤ 35% by weight or ≤ 30% by weight or ≤ 25% by weight, or especially ≤ 17% by weight.

According to the disclosure in general, unless stated otherwise, the term “foamable composition” also includes the propellant.

The amount of each above captioned specific dispersed inorganic component in the foamable composition may be ≥ 0.5 % by weight or ≥ 1.0 % by weight, preferably is ≥ 1.5 % by weight or ≥ 2% by weight or ≥ 3 % by weight or, especially ≥ 6% by weight or ≥ 8% by weight. In some formulations ≥ 10% by weight or ≥ 16% by weight or ≥ 20% or ≥ 25% may be applicable as the said content of the respective specific dispersed inorganic component. The amount of each respective specific dispersed inorganic component in the foamable composition can in particular be ≤ 50% by weight or ≤ 35% by weight or ≤ 30% by weight or ≤ 25% by weight, or especially ≤ 17% by weight. This especially may be given in combination with the above captioned total amount of dispersed inorganic component in the foamable composition or in some cases independent thereof.

According to the present disclosure the “film forming organic polymer” especially is an organic polymer which is film-forming when drying the dispensed foamable composition or an respective aqueous phase comprising the polymer in a form and content as present in the foamable composition (based on weight percent of the composition), specifically when drying to constant weight to form a film. Especially a coherent film may be formed. Drying may be achieved by spreading the foam composition (preferably without propellant) or named respective aqueous phase comprising the polymer on a planar substrate and allowing the composition to dry under the given conditions until reaching constant weight, to achieve the polymer film . Thus in the cured foam composition the film forming organic polymer preferably provides the “skeleton” or cell walls of the foam structure and co-determines or provides elasticity of the cured foam. The film forming organic polymer is preferably dispersed or emulsified in the aqueous phase of the foamable composition (or respective aqueous phase) or may be dissolved therein, preferably is present in the form of a latex (emulsion or dispersion of natural or synthetic rubber). The term “organic polymer” is to be understood in the meaning that a C-atom comprising backbone structure or a C-atom backbone structure is present (so that e.g. siloxane polymers having a Si-O-backbone structure are not covered by this term). The C-atom backbone structure of the organic polymer may comprise further functional groups like ether groups, ester groups, amide groups etc.. However, preferably, the C-atom backbone of the organic polymer is free from ether groups, ester groups, amide groups or isocyanate groups etc.. Preferably, the  C-atom backbone of the organic polymer is a pure C-atom skeleton.

In principle, in the foamable composition the organic film forming polymer might be present in the form of precursors, building the polymer during curing of the composition.

Preferably the film forming organic polymer of the foamable composition is an elastomer (in cured state of the foam), particularly preferred is a rubber component. Accordingly, the film forming organic polymer may be a co-polymer having rubber like properties when cured. Especially, the film forming organic polymer may be R type rubber material or M type rubber material or a copolymer or blend (mixture) thereof. The term “copolymer” also may include terpolymers and the like. Due to the elastomeric polymer the cured foam can show significant or comparatively high elasticity enabling the foam to seal dynamic joints, shows stress equalization even in the case of shrinkage of the foam due to a water loss during curing and thus prevent cracks in the cell structure resulting in comparatively low air permeability or a high service life also at considerable temperature changes.

In general, R type rubber material is a rubber material predominantly or completely with a continuous C-C backbone of the polymer and unsaturated C-C double bonds in the backbone. M type rubber material is a rubber material predominantly or completely having a continuous C-C backbone (continuous polymethylene chain backbone) of the polymer and without unsaturated C-C double bonds in the backbone. The term “predominantly” means that the elastomeric properties of the polymer and the rain water resistance of the dispensed fresh foam only are slightly influenced by the difference with respect to the totally continuous C-C backbone of the elastomer. The polymer backbone therefore preferably has no groups prone to hydrolysis, such as ether groups or amide groups or ester groups or combinations thereof.

As rubber materials at least of natural rubber, isoprene rubber, butadiene rubber, chloroprene rubber, styrene butadiene rubber, nitrile butadiene rubber, hydrated nitrile butadiene rubber (HNBR), nitrile chloroprene rubber, butyl rubber, isoprene styrene, ethylene rubber, EPDM rubber (ethylene propylene diene), EPM rubber (ethylene propylene), CM rubber (chlorinated PE rubber), FKM rubber (fluoro rubber), FFKM rubber (perfluoro rubber), FPM rubber (polypropylene tetrafluoroethylene copolymer) can be used or combinations of them, for instance in the form of blends of copolymers. Especially isoprene rubber, butadiene rubber, chloroprene rubber, styrene butadiene rubber, nitrile butadiene rubber, hydrated nitrile butadiene rubber (HNBR), or blends or co-polymers thereof may be used. The above captioned rubber materials may form the film forming organic polymer of the foamable composition.

If applicable, in any case the above captioned rubber materials may comprise further monomer units in the polymer structure, though not preferred.

Functionalized rubber materials may be used like carboxylated rubber polymers. This may be given with respect to any of the above captioned rubber materials, disclosed independently with respect to each of them.

The film forming organic polymer may have a glass transition temperature of ≤ 15°C or ≤ 10° C or preferably ≤ 5°C or ≤ 0° C. The film formation of the film forming organic polymer when being spread on substrate and dried as described above may be given at temperatures equal to or below 23°C, for instance ≤ 15°C or ≤ 10° C or ≤ 5° C.

The foamable composition especially may comprise ≥ 5% by weight or ≥ 10% by weight of the film forming organic polymer, particularly preferred ≥ 15% by weight or ≥ 20% by weight or ≥ 25% by weight or especially ≥ 28% by weight ≥ 30% by weight or ≥ 40% by weight or even ≥ 50% by weight or ≥ 65% by weight. The cured composition becomes increasingly water repellent and also exhibits improved elastic properties with increase of the content of organic film forming polymer. Shrinkage, joint fill after water application and rain water resistance may be improved. The content of the organic film forming polymer (solids content) in the foamable composition may be ≤ 65% by weight or ≤ 60% by weight or ≤ 55% by weight or ≤ 50% by weight or preferably ≤ 45% by weight or ≤ 40% by weight, without being limited thereto. Accordingly, the content of the organic film forming polymer (solids content) in the foamable composition may be ≤ 30% by weight or ≤ 20% by weight or ≤ 15% by weight or even ≤ 10% by weight or in some cases ≤ 5% by weight or ≤ 3 by weight.

The content of organic film forming polymer according to the disclosure in any case is related to the solid content of the polymer, especially in case it is applied as an aqueous phase like latex.

If applicable, the foamable composition additionally may comprise further components (additives) being non-film forming organic polymers, for instance thermoplastic polymers, which can for example act as fillers, without being limited thereto. These non-film forming organic polymers may be present in the foamable composition to an amount of ≤ 25 % by weight or ≤ 15 % by weight or ≤ 10 % by weight, for instance ≤ 5 % by weight without being restricted thereto. Preferably, the content of these further polymers in the composition is lower than the content of the film forming organic polymer.

The weight ratio of the film forming organic polymer or especially of the elastomeric film forming organic polymer (in each case relating  to the solids content of the polymer), to the total content of dispersed inorganic component of the foamable composition preferably is in the range from 40:1 to 1:10 or from 20:1 to 1:5 or 10:1 to 1:2, more preferably in the range from 8:1 to 1:1.5 or 6:1 to 1:1.5,  particularly preferred in the range from 6:1 to 1:1 or especially in the range from 5:1 to 1:1 or 4:1 to 1.5:1, without being restricted thereto. Accordingly, the said ratio may be about 3:1 or 2:1. A foam composition having high foam stability in the not yet cured state, in particular in a freshly expanded state, namely with respect to low shrinkage during curing and good rain water resistance, is obtained by utilizing the weight ratios given above, wherein also good properties in the cured state, especially good elongation to fracture, are achieved.

For further improvement, the foamable composition may comprises at least a component selected form chelating agent, water soluble phosphate, water soluble silicate or a combination thereof. Especially, the foamable composition may comprises at least one chelating agent in combination with a water soluble phosphate. Especially, the foamable composition may comprises at least one chelating agent in combination with a water soluble silicate. Especially, the foamable composition may comprise at least one water soluble silicate in combination with a water soluble phosphate. More specifically, the foamable composition may comprise at least a component selected form chelating agent in combination with at least one water soluble phosphate and at least one water soluble silicate. These components turned out to be particularly suitable in increasing joint fill after water application to the fresh foam. Elasticity of the cured foam may be improved. Shrinkage of the foam during curing may be decreased. Rain water resistance of the fresh foam is not deteriorated or is improved.  Furthermore, these components turned out to be particularly suitable for producing a stable fresh foam which after having been foamed into a joint fills that joint without or with only little sagging prior to curing. The term “sagging” according to the disclosure means that the foam substantially keeps its total volume, but loses its shape while the foam bead spreads by flowing. The capability of filling the joint is thus improved. Additionally a more uniform cell structure of the foam may be achieved. Shelf live of the foamable composition may be increased. The above captioned foam properties especially are improved in combination with said dispersed inorganic material, wherein any of said above captioned dispersed inorganic material may be used in combination.

The water soluble phosphate may be an ionic phosphate, especially an inorganic phosphate; more specifically may be a water-soluble oligophosphate or polyphosphate or mixtures thereof. In the ionic phosphate, the cation may include ammonium (NH4) or alkylammonium, which each also may be excluded. Preferably, the cation of the water soluble phosphate is sodium. The oligo- or polyphosphate preferably has 2, 3, 4, 5 or 6 or up to 10, up to 15 or up to 20 or more condensated phosphorus atoms (linked via oxygen atoms) or more, for example 3 or more than 3. Metaphosphates may be applied as water soluble phosphate, however non-cyclic oligo- or polyphosphates are preferred. If applicable, water soluble orthophosphates may be used, though not preferred or are absent from the foamable composition. Especially, alkaline  tripolyphosphate (particularly pentasodium tripolyphosphate), alkaline pyrophosphate (particularly tetrasodium salt or tetrapotassium salt), alkaline hexametaphosphate or mixtures thereof turned out to be particularly preferable, in each case most  preferred alkaline being sodium or potassium or combinations of both, especially sodium . In particular, soluble tripolyphosphates, particularly of the sodium or potassium or both, turned out to be preferable, most preferably STPP (sodium tripolyphosphate Na5P3O10).   The water soluble phosphate may comprise one or a combination of the above mentioned specific phosphates or may be one of the above mentioned specific phosphates.

The water-soluble silicate which is used can particularly constitute alkali metal silicate or be in the form of water glass and/or in the form of a dissolved salt. The alkali metal silicate can be sodium silicate, where appropriate in combination with potassium and/or lithium ions. Potassium silicate (potassium water glass) can also be used as alkali silicate, where appropriate in combination with sodium and/or lithium ions. The sodium content (in atomic percent) can be higher than the potassium and/or lithium content of the water glass, e.g. Na content ≥ 50-60 at.% or ≥ 70-80 at.%, based on the atomic content of the alkalis of the water glass or of the aqueous phase, where appropriate also ≥ 90-95 at.% or practically 100 at.%.

The water glass which is used can have an alkali metal silicone atomic ratio of 1.5 to 6 or 2 to 4, preferably 2.5 to 3.5, particularly preferably 2.75 to 3.25, for example approx 3. The silicate solution or the water glass which is used can have a solid content in the range of 20-75% by weight or 30-60% by weight. The pH of the aqueous silicate solution which is used (e.g. as water glass) can be in the range of 9-3, preferably 10 to 12.5, for example 12, whereby good compatibility with the organic polymer or the utilized aqueous polymer dispersion without functional groups with active hydrogen atoms is given, which influences the storage stability of the composition and also its film-forming properties, sprayability from the can, and its curing properties.

The chelating agent may comprises chelating carboxy and/or amino groups, e.g. may be EDTA (ethylendiaminetetraaceticacid) or NTA (tris(carboxymethyl)amin) or a combination of both.

The total of the components selected from the group of water soluble phosphate, water soluble silicate and organic chelating agent or combinations of them may be present in the composition in an amount of ≥ 0.25% by weight or ≥ 0.5% by weight, especially ≥ 1% by weight or ≥ 2% by weight for instance ≥ 3.5% by weight, or ≥ 5.0 % by weight, even ≥ 7.5% by weight or ≥ 10% by weight or also ≥ 15% by weight or ≥ 20 by weight or ≥ 25% by weight or ≥ 30% by weight.  The said total content may be ≤ 35% by weight or ≤ 30% by weight or ≤ 25% by weight, especially ≤ 20% by weight or ≤ 15% by weight, for instance ≤ 10% by weight or ≤ 7.5% by weight or also ≤ 5% by weight or ≤ 3% by weight or ≤ 2 by weight.

The content of the components selected from the group of water soluble phosphate, water soluble silicate and organic chelating agent, respectively (i.e. content of components of each  selected group -  independent from each other), in the foamable composition may be ≥ 0.25% by weight or ≥ 0.5% by weight, especially ≥ 1% by weight or ≥ 2% by weight for instance ≥ 3.5% by weight, or ≥ 5.0 % by weight, even ≥ 7.5% by weight or ≥ 10% by weight or also ≥ 15% by weight or ≥ 20 by weight or ≥ 25% by weight or ≥ 30% by weight .  The said content of respective component (independent from each other) may be ≤ 35% by weight or ≤ 30% by weight or ≤ 25% by weight, especially ≤ 20% by weight or ≤ 15% by weight, for instance ≤ 10% by weight or ≤ 7.5% by weight or also ≤ 5% by weight or ≤ 3% by weight or ≤ 2 by weight. Said contents especially may be given with respect to any of the components named specifically with respect to each of the said groups.

In case water-soluble silicates are present, the content of the water-soluble silicate in foamable composition may be up to 40% by weight or even up to 50% by weight or up to 66% by weight, so that said total content of the components selected from the group of water soluble phosphate, water soluble silicate and organic chelating agent or combinations of them may be up to the given limit, or in some instances may be higher.

The weight ratio of dispersed inorganic components (total content) to water soluble phosphates in the foamable composition may be within the range of 50:1 to 1:1 or 40:1 to 1.5:1 or preferably within the range of 30:1 to 2:1 or 30:1 to 3:1, especially about 25:1 or about 20:1 or about 15:1 or more specifically about 10:1 or about 7.5:1 or even about 6:1 or about 4:1.

The weight ratio of dispersed inorganic components (total content) to water soluble silicates  in the foamable composition may be within the range of 50:1 to 1:10 or 40:1 to 1:5 or 40:1 to 1:1 preferably within the range of 30:1 to 1:1 or 30:1 to 3:1 or 30:1 to 1:1, especially about 25:1 or about 20:1 or about 15:1 or more specifically about 10:1 or about 7.5:1 or even about 6:1 or about 4:1. The said ratio also may be 1:2 or 1:3 or 1:4.

The weight ratio of dispersed inorganic components (total content) to organic chelating components in the foamable composition may be within the range of 50:1 to 1:1 or 40:1 to 1.5:1 or preferably within the range of 30:1 to 2:1 or 30:1 to 3:1, especially about 25:1 or about 20:1 or about 15:1 or more specifically about 10:1 or about 7.5:1 or even about 6:1 or about 4:1.

Aluminium trihydroxide may be present in the foamable composition as an dispersed inorganic material, especially in an amount of ≤ 30 % by weight  or ≤ 25 % by weight or ≤ 20% by weight or ≤ 15 by weight or for example ≤ 10 % by weight. Aluminium trihydroxide may be present in the composition in an amount of ≥ 0.5 % by weight or ≥ 1 % by weight or ≥ 2.5 % by weight or especially ≥ 5% by weight or even ≥ 7 % by weight or ≥ 10% by weight.

Aluminium trihydroxide (ATH) within the present disclosure may be used in crystalline state, especially in the form of hydrargillite, or in amorphous state. It has been shown that aluminium trihydroxide has beneficial effects in enhancing foam properties (especially of the uncured foam) besides any effects as a flame retardant component.

The weight ratio of dispersed inorganic components in total (other dispersed inorganic components than aluminiumtrihydroxide) to aluminium trihydroxide in the foamable composition may be within the range of 30:1 to 1:3 or 20:1 to 1:3 or 10:1 to 1:2 or preferably within the range of 6:1 to 1:2 or 5:1 to 1;2, most preferably within the range of 4:1 to 1:1.5 or 3:1 to 1:1.5.

The foamable composition of the present disclosure comprises a volatile propellant which is effective for spraying or dispensing the composition by pressure release of the pressurized foamable composition, especially being pressurized by the gas pressure of the volatile propellant. The volatile propellant is from of at least one or a combination of compressed components, each of these components of the volatile propellant is gaseous at room temperature (23°C) and normal pressure (1013 hPa). Preferred examples of propellants are hydrocarbons (including mixtures of hydrocarbons), like lower alkanes up to and including butane (including n- and/or iso-butane), for example propane/butane mixtures, including propane/isobutane, or ethers like dimethyl ether or combinations of them. Hydrocarbons or dimethyl ether or combinations of them preferably are the predominant component(s) of the propellant (in total ≥ 50 wt.-% or ≥ 75 wt.-% or ≥ 85 wt.-% or ≥ 85 wt.-% of the propellant) or are the only propellant components.  If appropriate, other propellants like halogenated hydrocarbons may be used. Preferably, the propellant does not have chemical reactive properties with respect to a component of the foamable composition (especially to the film forming organic polymer) like agglomerating effects to the film forming organic polymer. Especially, the CO2 content of the propellant may be ≤ 25 % by weight or ≤ 10 % by weight or ≤ 5 % by weight or preferably or ≤ 2 % by weight or ≤ 1 % by weight or at least essentially no CO2 is present. The low CO2 content has been found to be favourable with respect to the foaming properties, resulting rain water resistance and joint fill after water application and shelf life of the composition.

The volatile propellant preferably is present in the foamable composition in an amount of ≥ 2 wt.-% or ≥ 3 wt.-% or ≥ 4 wt.-% or ≥ 5 wt.-%. The content of the volatile propellant in the foamable composition may be ≤ 25 wt.-% or ≤ 20 wt.-% or ≤ 15 wt.-% or ≤ 12 wt.-% or ≤ 9 wt.-%, based on the total weight of the composition.

The total content of solids in the foamable composition, including dispersed or emulsified film forming organic polymer, can be up to 70 % by weight or up to 75 % by weight or in some cases may be up to 80 % by weight, it may be ≥ 25 % by weight or ≥ 30 % by weight, preferably ≥ 35 % by weight or ≥ 40 % by weight or more preferably ≥ 45 % by weight. Excessive shrinking of the foam during its drying is prevented while affording good dispensing properties of the foam, particularly as canned foam.

The water content of the foamable composition is preferably ≥ 25% by weight, particularly preferred ≥ 30% by weight, yet further preferred ≥ 35% by weight. Preferably the water content of the foamable composition is ≤ 70 % by weight, preferably ≤ 60% by weight, particularly preferred ≤ 50% by weight. It is to be understood that at excessive water content provides low foam stability of the fresh sprayed foam, generating sagging of the foam or the like, whereas at too low water contents the foamable composition is difficult to dispense.

The total content of alkaline earth metals in the foamable composition may be ≤ 15% by weight or ≤ 10% by weight, particularly preferred ≤ 5 by weight or ≤ 2 by weight or ≤ 1 by weight, relating to the total weight of the foamable composition. The total content of alkaline metals in the foamable composition may be ≤ 15 % by weight or ≤ 10 % by weight or ≤ 5 % by weight or even ≤ 2 % by weight or ≤ 1 % by weight. This also may establish good results with respect to the properties of the cured and uncured foam, avoiding presence of hydrophilic components in too high amount.

The pH of the aqueous phase of the foamable composition (without propellant) can be ≥ 7 or ≥ 7.5 or ≥ 8, for example in the range of 8-12 or 9-12, without being limited thereto.

The foamable compositions are balanced to 100% by weight water, at least 15 % by weight water content.

The foamable composition may contain further components (especially see component (c) or (e) according to general formulas (20) or (21), page 4), the “further components” being different from the above captioned components, such as auxiliary agents, foam stabilizers, flame retardant components (other than above captioned components like aluminium trihydroxide or said dispersed inorganic components), like e.g. phophonates or organic flame retardant components like phosphor or nitrogen comprising components, filler materials (others than said dispersed inorganic components) like water insoluble poly hydroxycarbon compounds like cellulose, intumescent materials, UV absorbing agents,  thixotropic agents, gelling agents or other viscosity adjusting agents, rheological active agents, surfactants like anionic or cationic or neutral surfactant, preferably anionic surfactant, or waxes, cell regulating agents, cell opening agents, preserving agents, herbicides, fungicides, or other auxiliary agents as known in the art to adjust certain properties of the foamable composition or the fresh or cured foam. For some applications, certain auxiliary agents like cell opening agents and/or cell regulating agents may be specifically absent from the composition. Where appropriate, the total content of the further components in the foamable composition can amount ≤ 50% by weight or ≤ 40% by weight, preferably ≤ 30% by weight or ≤ 20% by weight, even ≤ 15% by weight or ≤ 10 % by weight, without being restricted thereto.

The aqueous phase of the foamable composition (including all components except propellant) can exhibit viscosity in the range of 1.000-100.000 mPa.s, preferably in the range of 5.000-75.000 mPa.s, more preferably ≤ 60.000 mPa.s or ≤ 50.000 mPa.s. Such aqueous phase used together with a propellant turned out to be foamable particularly well and uniformly. Especially, the viscosity may be ≥  10.000 mPa.s, more specifically ≥ 15.000 mPa.s or ≥ 20.000 mPa.s, wherein it became evident in course of the disclosure that the respective foam compositions (when dispensed with the propellant) show good foam stability and low shrinkage. The viscosities within the scope of the disclosure each relate to a measuring temperature of 23°C, determined using a Brookfield DV-E Viscometer, spindle LV-2 and speed 0.3 rpm, wherein the can containing the measured liquid has an inner diameter of 48 mm.

The foamable composition preferably contains essentially no isocyanate components having free isocyanate groups like MDI and/or polyurethane components. Especially, independent from one another, the content of isocyanates or polyurethane components in the total formulation may be ≤ 2 % by weight or ≤ 1 % by weight or ≤ 0,5 % by weight or preferably ≤ 0,1 % by weight or even ≤ 0,05 % by weight, respectively, based on the total composition. Most preferably the composition is at least essentially free from isocyanates or polyurethane components or both to avoid hazardous effects of the composition. However, in certain cases, isocyanate components or polyurethane components may be present.

The foamable composition may have the following formulation (general formula I), which has been found to be favourable in many fields of application:

General Formula I
     a) 5 – 65 % by weight of organic film forming polymer,
     b) 1.5 - 35 % by weight of total content of dispersed inorganic materials
     c) 0 - 30 % by weight of components selected from the group consisting of water soluble phosphates, water soluble silicates, organic chelating components in total
     d) 0 -30 % by weight of aluminium trihydroxide
     e) 0-50 % by weight further components such as flame retardants, fillers, stabilizers etc,
     f) 2-25 % by weight volatile propellants,
     g) balance to 100% by weight water, at least 15 % by weight of water.

Preferably, the foamable composition may have the following specific formulation (general formla II

General Formula II
     a) 10 – 60 % by weight of organic film forming polymer,
     b) 3 - 35 % by weight of total content of dispersed inorganic materials
     c) 0 - 10 % by weight of components selected from the group consisting of water soluble phosphates, water soluble silicates, organic chelating components in total
     d) 0 -30 % by weight of aluminium trihydroxide
     e) 0-35 % by weight further components such as flame retardants, fillers, stabilizers etc,
     f) 3-20 % by weight volatile propellants,
     g) balance to 100% by weight water, at least 15 % by weight of water.

More preferred, the foamable composition may have the following more specific formulation (general formla III)

General Formula III
     a) 20 – 55 % by weight of organic film forming polymer,
     b) 3.5 - 30 % by weight of total content of dispersed inorganic materials
     c) 0.5 - 10 % by weight of components selected from the group consisting of water soluble phosphates, water soluble silicates, organic chelating components in total
     d) 0 -30 % by weight of aluminium trihydroxide
     e) 0-35 % by weight further components such as flame retardants, fillers, stabilizers etc,
     f) 3-15 % by weight volatile propellants,
     g) balance to 100% by weight water, at least 15 % by weight of water.

As a further preferred example, the foamable composition may have the following more specific formulation (general formla IV)

General Formula IV
     a) 25 – 50 % by weight of organic film forming polymer,
     b) 10 - 20 % by weight of total content of dispersed inorganic materials
     c) 0 - 5 % by weight of components selected from the group consisting of water soluble phosphates, water soluble silicates, organic chelating components in total
     d) 0 -30 % by weight of aluminium trihydroxide, especially about 10 % by weight
     e) 3-20 % by weight further components such as flame retardants, fillers, stabilizers etc,
     f) 3-15 % by weight volatile propellants,
     g) balance to 100% by weight water, at least 15 % by weight of water.

It is to be understood that any disclosure with respect to the type or content of the components or both of the foamable composition in respect to the present disclosure also is disclosed in combination with the above captioned composition of general formula I to IV.

Preferably, the foamable composition of the disclosure is a one-component composition, all components being provided in one chamber of a container or can. If appropriate, the foamable composition also may be a two-component composition. All components as described in the present disclosure may be present in the same chamber of a two-component composition, without being mandatory.

The foamable composition according to the disclosure can be manufactured by mixing all of the components and homogenization. Homogenization may be achieved in a container, e.g. a can, from which the foamable composition is dispensed. The propellant may be supplied to the container before or after homogenization. Mixing and homogenization can be done at room temperature (23°C) or at other suitable temperatures. The foamable composition may be stockpiled pressurized with the propellant in a container like a can, the pressure in the container at 55°C can be in the range of 6 to 25 bar, especially between 8 and 15 bar. Said container may be adapted for manual handling and shaking, whereby the composition can be sufficiently homogenized for dispensing, and particularly the aqueous phase can be mixed with the propellant so as to be dispensed homogenously by pressure release of the propellant, even after an storage period of several months at 23°C.

The dispensed foam according to the disclosure is characterized by sufficient foam stability and viscosity, low shrinkage during curing, excellent adhesion to the substrate, in particular a mineral substrate or plastic material, well-balanced setting time, high storage stability, also as one-component canned foam, good flexibility, environmental harmlessness and good properties in a rain water resistance test and/or in a joint fill after solubility test.

In a “rain water resistance test” the water resistance of fresh foam, being prepared by dispensing the foamable composition of the present disclosure by pressure release of a pressurized container, is evaluated. In this test finely divided water droplets like water spray is applied to foam beads to simulate the impact of rain and to evaluate whether the foam is washed out by the applied water. A foamable composition according to the present disclosure is dispensed to make a bead having width of 2 cm and height of 2 cm, after a pre-curing time of the dispensed foam composition of 3 hours at 23°C and 50 % rel. humidity. Subsequently, the foam bead is sprayed with water (e.g. through a nozzle with a rate of 3 liter per hour, water temperature 20°C, and a distance of the nozzle to the joint of 7 cm, the nozzle having a diameter so that at a distance 7 cm a circular target surface having a diameter a 9 cm is homogenously applied with the sprayed water). The foam may withstand the applied water without visible foam loss, including without draining water being turbid due to dissolved foam composition. The foam bead may withstand a time period of least 3 hours or least 4 hours, even of at least 5 hours or at least 6 hours of water application under the given conditions without visible foam loss, when having a visual inspection of the bead.

In a “joint fill after solubility test” the solubility of the foam is evaluated by measuring the foam volume present in the joint after water application to a skin of the foam being formed after only a short period of time, wherein the foam just behind the thin skin still is uncured, so that water penetrating the skin tends to wash out the uncured foam arranged behind the skin. A foamable composition according to the present disclosure is dispensed to homogeneously fill a joint having a width of 4 cm, after a pre-curing time of the dispensed joint filling foam composition of 3 hours at 23°C and 50 % rel. humidity. Subsequently, the joint is sprayed with water through a nozzle (e.g. with a rate of 3 liter per hour, water temperature 20°C, and a distance of the nozzle to the joint of 7 cm, the nozzle having a diameter so that at a distance 7 cm a circular target surface having a diameter a 9 cm is homogenously applied with the sprayed water).  The nozzle is directed to the respective bead so that the top of the vertically arranged beads are applied with water and the full diameter of the water spray is in coincidence with the respective bead so that the same amount of water is applied to both lateral sides of said bead. After 4 hours of water application as described, the joint with the still present foam is kept for 2h at stationary atmosphere (23°C, 50% rel. humidity, 1013 hPa) to allow water drain and drying of the foam. Subsequently, after the foam sample is cured for appropriate time, especially for at least 1 week, the volume-% of foam being still present in the joint is determined (100 % reference: foam volume of the completely filled joint).  A foam as applied above withstands the applied water achieving a joint fill of ≥ 10 vol.-% or ≥ 20 vol.-%, preferably of ≥ 25 vol.-% or ≥ 50 vol.-%, more preferably of ≥ 70 vol.-% or ≥ 80 vol.-% or especially ≥ 85 vol.-% or ≥ 90 vol.-%. In fact, the joint fill may be ≥ 95 vol.-% or at least essentially 100 % (as reference: 100 vol.-% joint fill means that the joint is completely filled with foam). This feature of the foam may be given in combination with the rain water resistance as discussed above.

The disclosure also relates to building elements being sealed by a foam composition according to the present disclosure or being related to construction parts being glued by the respective foam.

In the following, the disclosure will be described by way of several illustrative embodiments.

EXPERIMENTAL SECTION

In the tests the film forming organic polymer of the foamable composition is applied in the form of a latex emulsion, wherein the emulsified organic polymer preferably is an elastomeric polymer and is a film forming at room temperature. The content of the film forming organic polymer in the latex emulsion is 50 % by weight. The applied propellant especially may be propane/isobutane (40/60 in % by weight) or dimethylether, preferably the first one. In case a water soluble silicate like a water glass is used, it may be applied as an aqueous solution having a content of about 50 wt.-% of the water soluble silicate.

For preparation, the components of the composition besides the propellant are filled into a can, than the propellant is added under pressure and the can is closed. The pressure of the filled can at 23°C may be about 5 bar, without being restricted thereto. Before dispensing the foam, the can is shaken for at least 10 times to homogenize the can content, more preferably for at least 20 times, to achieve homogeneity of the can content.

Elasticity and Tensile Strength

Elasticity (elongation at break) and tensile strength are determined at samples being oriented perpendicular to the surfaces of the cured foam according to DIN 53455, EN 1607 and ISO 946 (last valid version of the respective standard norm). The joint width is 12 mm. The samples are cured for 7 days in a climate room (23°C, 50% RH, 1013 hPa) before testing. The maximal tensile strength and the elongation at break of five samples are determined and the mean value of these data is given as test result.

Sprayability

The test results are judged by a panel of 3 persons having great experience in the field of developing and application of spray foams.

10:     perfect sprayability, namely homogenous spraying without interruptions of foam dispense; the dispensed foam has optimum fluidity also for application at vertical and overhead joints, namely does not spread when applied to a horizontal substrate and is not sagging in a vertical joint; the pressure of the dispensed is at optimum, namely is steady and uniformly dispensed without splatter

7:       medium rate properties

5:       acceptable in practice only to a very limited extend, dispensed foam may be very thin fluid; no steady and uniform dispensed foam; foam is dispensed with high pressure resulting in considerable splatter

≤ 4:   not acceptable

Shrinkage

Shrinkage is given as a measure of the foam stability. Two foam beads are manually dispensed onto a horizontal substrate surface with constant traverse speed and dispensing rate,   the bead having a width and a height of about 2.5 cm, respectively. The height of the foam bead is measured instantaneously after spraying at two different points being representative for the height and width of the bead, the mean value of these 4 measurement being 100 % reference value. The height of the foam bead was measured again after 24 hours at the same points and the shrinkage measured in terms of a percentage in relation to the reference value.

Joint Fill after Solubility Test and Rain Water Resistance Test

To evaluate the water resistance of fresh foam, being prepared by dispensing the foamable composition of the present disclosure by pressure release of a pressurized container, joint fill after solubility tests and rain water resistance tests  may be conducted as described above. The tests are conducted at a room temperature of 23°C, 50% relative humidity.

Test results

The foamable compositions according to this disclosure show moderate to good or even very good properties with respect to elasticity and tensile Strength (cured foam) , sprayability and shrinkage and in a rain water resistance test and in a joint fill after solubility test.

EMBODIMENTS OF THE FOAMABLE COMPOSITION

In the following tables I to V specific compositions according to the present disclosure are given for example.

ffop: film forming organic polymer (solid content), applied as latex emulsion comprising about 50 % by weight of the film forming organic polymer (especially, the film forming organic polymer is an elastic polymer in cured stated of the composition, more specifically a rubber latex)

dis.in.mat.: dispersed inorganic material, especially this material may be any of the dispersed inorganic materials according to this disclosure, more specifically any of the materials of the groups of silicates,  borates, sulphates, graphite, oxides or oxygen salts, hydroxides, carbonates, phosphates or mixtures thereof, wherein especially the silicate may be a nesosilicate (e.g. olivine type), sorosilicate (e.g. epidote, melilite group), cyclosilicate (e.g. tourmaline group),  inosilicates (single chain silicate anions and/or double chain silicate anions, e.g. pyroxene group, amphibole group), phyllosilicate ( e.g. micas, kaolin and clays) or tectosilicate ( e.g. quartz, feldspars, zeolites), or mixtures thereof, especially the above captioned silicate may be present in calcined form. In case aluminiumtrihydroxide is named specifically as a separate component in the composition, the said dispersed inorganic material is different from aluminiumtrihydroxide.

STPP:  sodium tripolyphosphate, wherein the component may be replaced by any water soluble phosphates as disclosed in this document

WSS: water soluble silicate (solid content), applied as sodium water glass with about 50 wt.-% of the sodium silicate in the aqueous solution. Alternatively, the water soluble silicate may be applied in solid form and is solved in the aqueous phase, either separately from the other components or in presence with some or all of the other components, for instance during homogenization.

EDTA: wherein this component may be replaced by NTA or any other organic chelating agent

ATH: aluminium trihydroxyde

Propellant: propane/isobutane (40/60 in % by weight), wherein this propellant may be partially or totally replaced by dimethylether

The residue of the composition to a total of 100 weight parts is water, in each case.

TABLE I
No. ffop dis.in.mat. STPP WSS EDTA ATH Propellant
1 14 4         7
2 16 9         5
3 15 15         9
4 15 20         8
5 14 25         7
6 16 30         8
7 20 4         7
8 22 9         5
9 18 15         9
10 21 20         8
11 20 25         7
12 22 30         8
13 25 4         7
14 27 9         5
15 24 15         9
16 26 20         8
17 25 25         7
18 26 30         8
19 30 4         7
20 32 9         5
21 29 15         9
22 31 20         8
23 29 25         7
24 31 30         8
25 35 4         7
26 37 9         5
27 36 15         9
28 35 20         8
29 34 25         7
30 33 28         6
31 40 2         12
32 41 6         7
33 39 9         8
34 41 12         8
35 39 16         5
36 36 20         8
 
TABLE II
No. ffop dis.in.mat. STPP WSS EDTA ATH Propellant
1 14 4 1.5       7
2 16 9 2       5
3 15 15 1.5       9
4 15 20 3       8
5 14 25 4       7
6 16 30 2.5       8
7 20 4 2.5       7
8 22 9 2       5
9 18 15 3       9
10 21 20 1       8
11 20 25 4       7
12 22 30 6       8
13 25 4 1.5       7
14 27 9 2       5
15 24 15 3       9
16 26 20 1.5       8
17 25 25 6       7
18 26 30 4       8
19 30 4 2.5       7
20 32 9 2       5
21 29 15 3       9
22 31 20 1       8
23 29 25 4       7
24 31 30 6       8
25 35 4 1.5       7
26 37 9 2       5
27 36 15 3       9
28 35 20 1.5       8
29 31 22 6       6
30 32 25 4       5
31 40 2 1.5       12
32 41 6 2       7
33 39 9 1.5       8
34 37 12 3       7
35 34 15 6       5
36 36 18.5 2.5       7
 
TABLE III
No. ffop dis.in.mat. STPP WSS EDTA ATH Propellant
1 14 4       17 7
2 16 9       3 5
3 15 15       7.5 9
4 15 20       2.5 8
5 14 25       10 7
6 16 30       5 8
7 20 4       27 7
8 22 9       7 5
9 18 15       5 9
10 21 20       22 8
11 20 25       3 7
12 22 30       12 8
13 25 4       7 7
14 27 9       3 5
15 24 15       12 9
16 26 20       5 8
17 25 25       17 7
18 26 30       9 8
19 30 4       3 7
20 32 9       5 5
21 29 15       12 9
22 31 20       9 8
23 29 25       7 7
24 31 12       16 8
25 33 4       22 7
26 37 9       3 5
27 33 14       12 7
28 33 18       7 8
29 34 5       17 7
30 33 20       3 8
31 38 4       11 7
32 41 9       2 5
33 38 2       14 7
34 37 14       5 6
35 38 7       9 7
36 41 5       4 8
 
TABLE IV
No. ffop dis.in.mat. STPP WSS EDTA ATH Propellant
1 14 4 1.5 25     7
2 16 9 2   5   5
3 15 15 1.5 20 3   9
4 15 20 3 17 1   8
5 14 25 4   5   7
6 15 28 2.5 15 1   8
7 20 4 2.5   2   7
8 22 9 2   12   5
9 18 12 2.5 20     9
10 21 20 1   12   8
11 20 25 4   6   7
12 18 27 3 12 2   7
13 19 4 1.5 22 3   7
14 27 9 2 7 8   5
15 18 15 3 18     7
16 26 20 1.5 4 1   8
17 25 25 6   8   7
18 23 30 4 5     8
19 27 4 2.5 15 2   7
20 31 8 2 10     6
21 26 14 3 7 8   7
22 31 20 1   2   8
23 29 25 4   4   7
24 23 18 6 8 6   6
25 35 4 1.5 3     7
26 34 9 2 7     5
27 24 12 1,5 14 0,5   6
28 32 20 2.5   4   8
29 28 14.5 3,5 8 2   6
30 30 24 4   5   6
31 34 4 1.5 10     7
32 37 8 2 4 2,5   5
33 36 15 1.5   4   7
34 35 10 2 5 0.5   7
35 30 12 2,5 7 3   7
36 34 17 1.5 37     6
 
TABLE V
No. ffop dis.in.mat. STPP WSS EDTA ATH Propellant
1 14 4 1.5 5   25 7
2 16 9 2 23 1 3 5
3 15 15 1.5 3 3 7.5 9
4 15 20 3   10 25 8
5 14 25 4   5 10 7
6 14 28 1.5 10   14 8
7 20 4 2.5   2 1 7
8 22 9 2   12 27 5
9 18 15 3 7   5 9
10 19 20 1   12 20 8
11 19 24 4   4 22 7
12 19 27 6 4 2 10 7
13 24 4 1.5 15 3 5 7
14 27 9 2 7 8 3 5
15 27 15 3     12 9
16 26 20 1.5 4 1 5 8
17 23 24 4   4 15 6
18 26 18 3.5 3   12 8
19 30 4 2.5 1 2 3 7
20 28 8 2 10   5 6
21 27 15 3 2 5 10 7
22 31 20 1   2 7 6
23 27 25 2,5   4 7 7
26 34 8 2 6   3 5
28 30 19 1.5   4 7 8
32 38 7 2 3 1,5 2 5

 

Abstract

This publication  is directed to a foamable composition, in particular for the field of construction like filling joints or cavities or for connecting construction elements, the composition comprising a foamable aqueous phase and a volatile propellant, the aqueous phase and the propellant are capable of forming foam when mixed with one another and dispensed under pressure release of the propellant through a dispensing tube, wherein the aqueous phase comprises at least one film forming organic polymer and dispersed inorganic components and wherein the dispensed composition upon drying yields a cured foam. Preferably the composition is essentially free of isocyanate-components. The total content of the dispersed inorganic component may be ≥ 0.5 % by weight or especially ≥ 1.5 % by weight based on the total foamable composition including propellant, respectively. Preferably, the film forming organic polymer is an elastomeric polymer in the cured foam. Preferably, the film forming organic polymer is a type R rubber material or a type M rubber material or a combination of both. The dispersed inorganic component may be selected form a broad range of components including silicates, aluminosilicates, sheet silicates, calcined silicates, borates, sulphates, graphite, oxides or oxygen salts, hydroxides, carbonates, phosphates or mixtures thereof. Furthermore, water soluble inorganic components like water soluble silicates and/or water soluble phosphates and/or organic chelating agents like EDTA may be present alone or in combination with dispersed inorganic components. Building elements being arranged to form a joint between each other may be provided, wherein the joint is sealed by means of a cured foam composition or wherein two components are glued together by means of an adhesive, wherein the foam composition is a dispensed foamable composition as described herewith.

 

Invention Disclosure

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