Patent GB-716495-A (GB)
Title: Improvements in or relating to the manufacture of cellular materials
Inventor: COOPER ALFRED
IPC: C08J9/00
Filed: 1951-06-13
Abstract: A process for the production of a cellular material consisting predominantly of bitumen comprises incorporating together a bitumen, e.g. Gilsonite or similar hard colloidal pitch-like materials which soften when heated and which are derived from coal tar or obtained as a residue from petroleum distillates, a synthetic resinous material, e.g. a cellulose ether or polyvinyl chloride, a blowing agent, and sufficient plasticizing solvent to form a plastic dough, the solvent being removable by heating to the temperature at which the blowing agent forms a gas, heating the mixture to that temperature under sufficient pressure to prevent the gas from fully expanding the dough, cooling the dough, releasing the pressure, re-heating to a temperature at which the embryo gas bubbles expand the material, and holding the material at such temperature until the solvent has been removed.  In an example a mixture of 100 parts of bituminous material sold under the Trade Name "Carbitum Pitch", 15 parts of a , a -azo-bis (iso-butyronitrile) and 25 parts of ethyl cellulose, is ball milled, transferred to a mixer and mixed with 12 parts of a 50/50 mixture of isopropyl acetate and styrene (which is subsequently polymerized), the latter being inhibited with 0.1 per cent. parabenzoquinone, until a smooth paste is obtained which is heated in a press and expanded, giving a product having a density of 10 lbs. per cubic foot and a compression strength of about 150 lbs. per square inch.ALSO:A process for the production of a cellular material consisting predominantly of bitumen comprises incorporating together a bitumen, e.g. Gilsonite, and similar hard colloidal pitch-like material which soften when heated and which are derived from coal tar and obtained as a residue from petroleum distillates a synthetic resin, e.g. an ethenoid plastic such a polyvinyl chloride, a blowing agent, and sufficient plasticizing solvent for example one removable by volatilization during the hardening by heat such as a monomer, polymerized during the hardening by heat as described in Specification 716,366, [Group IV (a)], to form a plastic dough, the solvent being removable by heating to the temperature which the blowing agent forms a gas, heating the mixture to the temperature under sufficient pressure to prevent the gas from fully expanding the dough, cooling the dough, releasing the pressure, and finally re-heating to a temperature at which the embryo gas bubbles expand the material, and holding the material at such temperature until the solvent has been removed.  In a modification instead of incorporating with the bitumen and blowing agent, a synthetic resin and a plasticizer, a monomeric or low polymer liquid is employed as plasticizer which subsequently is polymerized by heat and forms the synthetic resin in situ.  In an example a mixture of a 100 parts of bituminous material sold under the Registered Trade Mark "Iranolin" 80 and 25 parts of x, a -azo-bis (isobutyronitrile) is ball milled together and the fine powder obtained transferred to a dough mixer to which 10 parts of monomeric styrene (which subsequently becomes polymerized) inhibited with 0.10 per cent. catechol are added and the mixture mixed until a smooth dough is obtained, which is discharged into a mould until it fills a cavity therein over which is placed a metal plate designed to be gas-tight and the mould then placed an a steam heated press maintained at a temperature of 320 DEG F. and the mould closed with a hydraulic load sufficient to maintain a pressure of 1 ton per square inch.  After 8 minutes the press and mould are cooled, the hydraulic pressure released and the blank removed from the mould and placed in an oven at 220 DEG F. for days during which time the blank expands to a density of approximately 5lbs. per cubic foot and has a compression strength of about 30 to 35lbs. per square inch.  In another example a mixture of 100 parts of Norwegian Pitch, 20 pars of diazoamino benzene, 40 parts P.V.C. and 10 parts of lead stearate was ball milled, transferred to a mixer, and 20 parts of toluene added to give a smooth paste which was transferred to a mould having therein a cavity and heated as already described for 22 minutes at 320 DEG F. and then cooled, the blank removed, and expansion and drying done in an oven at 220 DEG F. for three days.  A product having a density of about 4lbs. per cubic foot and a compression strength of about 40lbs. per square inch was obtained. In another example a mixture of 100 parts of bituminous material sold under the Trade Name Carbitum Pitch, 15 parts of a , a ,zo-bis (iso-butyro-nitrile), and 25 parts of ethyl cellulose, was ball milled as already described, transferred to a mixer and mixed with 12 parts of a 50/50 mixture of isopropyl acetate and styrene (which is subsequently polymerized), the latter being inhibited with 0.1 per cent. parabenzoquinone, until a smooth paste was obtained which was heated in a press and expanded as above described giving a product having a density of 10lbs. per cubic foot and a compression strength of about 150lbs. per square inch.