Cementitious magnesia compositions containing salts of organo-silanols

Claim 2

A moldable, castable or sprayable cementitious composition, comprising: (a) magnesium oxide; (b) a magnesium salt having at least moderate solubility in water; (c) at least one water-soluble organo-silanol salt, characterized in having attached to the silicon atom (i) at least one group comprising a water-soluble salt having the general formula: O.sup.- A.sup.+ where A + is a monovalent cation or one equivalent of a polyvalent cation and (ii) at least one group comprising an organo moiety attached to the silicon atom through a substantially non-hydrolyzable silicon-carbon bond with the organo moiety further characterized in having a working parameter of solubility, δ wp , in the range of about 6.2 to about 8.0 (cal./c.c.) 1/2 , with ##EQU3## wherein: F i =the molar attraction constant of an individual functional group of said moiety expressed in (cal. c.c.) 1/2 per mole, and V i =the molar volume constant of an individual group of said moiety expressed in c.c. per mole; and (d) a liquid phase comprising water; wherein the mole ratio of the magnesium oxide to the magnesium salt ranges from 3:1 to 10:1, the level or organo-silanol salt ranges from about 0.5 percent to about 10 percent by weight of the magnesium oxide and the level of water is in an amount effective to cause reaction of at least a portion of said magnesium oxide and at least a portion of said magnesium salt to form a matrix curable to a hardened state.

Claim 3

The cementitious composition of claim 1, wherein said magnesium salt is selected from the group consisting of magnesium chloride, hydrated magnesium chloride, magnesium sulphate, hydrated magnesium sulphate, hydrated magnesium nitrate, hydrated magnesium acetate, magnesium bromide and hydrated magnesium bromide.

Claim 4

The cementitious composition of claim 1, wherein said monovalent cation is selected from the group consisting of tertiary sulphonium, ammonium, substituted ammonium, quaternary ammonium and quaternary phosphonium.

Claim 5

The cementitious composition of claim 1, wherein said monovalent cation is selected from the group consisting of Group IA alkali metal cations.

Claim 6

The cementitious composition of claim 1, wherein said organo-silanol is a hydrolyzate of an organo-silicon compound, said organo-silicon compound characterized in having attached to its silicon atom one or two groups having a hydrolyzable bond with the silicon atom and selected from the group consisting of alkoxyl, aryloxyl, substituted aryloxyl, aralkoxy, substituted aralkoxyl, alylamino, substituted alkylamino, silylamino, substituted silylamino, mercapto and substituted mercapto.

Claim 7

The cementitious composition of claims 1 or 5, wherein said organo moiety comprises alkyl or oxalkyl group which may be substituted with one or more groups selected from the group consisting of alkyl, alkoxy, aryl, aryloxy, substituted aryloxy, acrylyl, substituted acrylyl, carboxy, carboalkoxy, amino, amido, ureido, oxiranyl and sulphur.

Claim 8

The cementitious composition of claim 5, wherein said organo-silicon compound is a reaction product of a compound containing acrylyl or substituted acrylyl groups and a silane having an organo moiety comprising an amino group containing at least one active hydrogen.

Claim 9

The cementitious composition of claim 5, wherein said organo-silicon compound is a reaction product of an amino-compound having at least one active hydrogen and a silane having an organo moiety comprising acrylyl or substituted acrylyl groups.

Claim 10

The cementitious composition of claim 5, wherein said organo-silicon compound is a reaction product of an silane having an organo moiety containing an epoxy group and a compound containing a chemical group selected from the group consisting of amino, amide, ureido, urea, urethane, thiol and hydroxyl, each having at least one active hydrogen atom.

Claim 11

The cementitious composition of claim 5, wherein said organo-silicon compound is a reaction product of an epoxy-containing compound and a silane having an organo moiety comprising one or more chemical groups selected from the group consisting of primary amino, secondary amino, amide, urea, urethane and thiol, each having at least one active hydrogen atom.

Claim 12

The cementitious composition of claim 10, wherein said epoxycontaining compound is an aliphatic epoxide and said silane is an aminoalkylsilane.

Claim 13

The cementitious composition of claim 11, wherein said aliphatic epoxide is 1,2-butylene oxide and said aminoalkylsilane is γ-aminopropyltriethoxysilane.

Claim 14

The cementitious composition of claim 11, wherein said aliphatic epoxide is 1,2-butylene oxide and said aminoalkylsilane is N-β-aminoethyl-γ-aminopropyltrimethoxysilane.

Claim 15

The cementitious composition of claim 10, wherein said epoxy-containing compound is 1,2-butylene oxide and said silane is ureidopropyltriethoxysilane.

Claim 16

The cementitious composition of claim 10, wherein said epoxy-containing compound is an aliphatic epoxide and said silane is a thioalkyl silane.

Claim 17

The cementitious composition of claim 15, wherein said aliphatic epoxide is 1,2-butylene oxide and said thioalkyl silane is mercaptoethyltriethoxysilane.

Claim 18

The cementitious composition of claim 10, wherein said epoxy-containing compound is an aliphatic polyepoxide and said silane is an aminoalkylsilane.

Claim 19

The cementitious composition of claim 17, wherein said aliphatic polyepoxide is 1,4-butanediol di-glycidyl ether and said aminoalkylsilane is γ-aminopropyltriethoxysilane.

Claim 20

The cementitious composition of claim 5, wherein said organo-silicon compound has the structure: ##STR29##

Claim 21

The cementitious composition of claim 5, wherein said organo-silicon compound has the structure: ##STR30##

Claim 22

The cementitious composition of claim 5, wherein said organo-silicon compound has the structure: ##STR31##

Claim 23

The cementitious composition of claim 5, wherein said organo-silicon compound has the structure: ##STR32##

Claim 24

The cementitious composition of claim 1, wherein said organo-silanol salt has the structure: ##STR33##

Claim 25

The cementitious composition of claim 1, wherein said organo-silanol salt has the structure: ##STR34##

Claim 26

The cementitious composition of claim 1 further comprising a material selected from the group consisting of fibrous glass, sisal, mica, mineral wool and cotton.

Claim 27

The cementitious composition of claim 1 further comprising a thickening agent selected from the group consisting of hydroxyethyl cellulose, hydroxypropyl cellulose, polyethylene oxide and polyvinyl alcohol.

Claim 28

The cementitious composition of claim 1 wherein the mole ratio of magnesium oxide to the magnesium salt ranges from 6:1 to 7.5:1 and the level of organo-silanol salt in the composition ranges from about 2 percent to about 5 percent by weight of the magnesium oxide.

Claim 29

A process for forming an article from a curable cementitious composition, comprising: (a) mixing together in the presence of a liquid phase having water sufficient to produce a moldable, curable slurry composition, the components of: (1) magnesium oxide; (2) at least one magnesium salt having moderate solubility in water; and (3) at least one water-soluble organo-silanol salt, characterized in having attached to the silicon atom (i) at least one group comprising a water-soluble salt having the general formula: O-A.sup.+ where A + is a monovalent cation or one equivalent of a polyvalent cation and (ii) at least one group comprising an organo moiety attached to the silicon atom through a substantially non-hydrolyzable silicon-carbon bond with the organo moiety further characterized in having a working parameter of solubility, δ wp , in the range of about 6.2 to about 8.0 (cal.c.c.) 1/2 , with ##EQU4## wherein: F i =the molar attraction constant of an individual functional group of said moiety expressed in (cal.c.c.) 1/2 per mole, and V i =the molar volume constant of an individual group of said moiety expressed in c.c. per mole; and wherein the mole ratio of the magnesium oxide to the magnesium salt ranges from 3:1 to 10:1, the level of organo-silanol salt ranges from about 0.5 percent to about 10 percent by weight of the magnesium oxide (b) placing said slurry composition in a mold form; and (c) allowing said composition to cure sufficiently such that said article may be removed from the mold form without substantially adversely affecting the integrity of the molded article.

Claim 30

A process for forming an article from a curable cementitious composition, comprising: (a) mixing together in the presence of a liquid phase having water sufficient to produce a moldable, curable slurry composition, the components of: (1) magnesium oxide; (2) at least one magnesium salt having moderate solubility in water; and (3) at least one water-soluble organo-silanol salt, characterized in having attached to the silicon atom (i) at least one group comprising a water-soluble salt having the general formula: O-A.sup.+ where A + is a monovalent cation or one equivalent of a polyvalent cation and (ii) at least one group comprising an organo moiety attached to the silicon atom through a substantially non-hydrolyzable silicon-carbon bond with the organo moiety further characterized in having a working parameter of solubility, δ wp , in the range of about 6.2 to about 8.0 (cal.c.c.) 1/2 , with ##EQU4## wherein: F i =the molar attraction constant of an individual functional group of said moiety expressed in (cal.c.c.) 1/2 per mole, and V i =the molar volume constant of an individual group of said moiety expressed in c.c. per mole; and wherein the mole ratio of the magnesium oxide to the magnesium salt ranges from 3:1 to 10:1, the level of organo-silanol salt ranges from about 0.5 percent to about 10 percent by weight of the magnesium oxide (b) placing said slurry composition in a mold form; and (c) allowing said composition to cure sufficiently such that said article may be removed from the mold form without substantially adversely affecting the integrity of the molded article.

Claim 31

The process of claim 28, wherein said components are mixed together by (a) firstly, preparing a blend of said magnesium oxide and said organo-silanol salt; and (b) subsequently mixing said blend with said magnesium salt in the presence of said water.

Claim 32

The process of claim 28 further comprising introducing into said slurry composition a material selected from the group consisting of fibrous glass, sisal, silicas, mica, mineral wool and cotton.

Claim 33

The process of claim 28 further comprising forming said article with the aid of compression force of heat, or both.

Claim 34

The process of claim 28, wherein said magnesium salt is selected from the group consisting of mangesium chloride, hydrated magnesium chloride, magnesium sulphate, hydrated magnesium sulphate, hydrated magnesium nitrate, hydrated magnesium acetate, magnesium bromide and hydrated magnesium bromide.

Claim 35

The process of claim 28, wherein said monovalent cation is selected from the group consisting of tertiary sulphonium, ammonium, substituted ammonium, quaternary ammonium, quaternary phosphonium and Group IA alkali metal cations.

Claim 36

The process of claim 28, wherein said organo moiety of said organo-silanol comprises alkyl group which may be substituted with one or more groups selected from the group consisting of alkyl or alkoxyl groups of one to about eight carbon atoms, primary amino group and secondary amino group.

Claim 37

The process of claim 28, wherein said organosilanol is a hydrolyzate of an organo-silicon compound, said organo-silicon compound characterized in having attached to its silicon atom one or two groups having a hydrolyzable bond with the silicon atom and selected from the group consisting of alkoxyl, aryloxyl, substituted aryloxyl, aralkoxyl, substituted aralkoxyl, alkylamino, substituted alkylamino, silylamino, substituted silylamino, mercapto and substituted mercapto.

Claim 38

The process of claims 28 or 35 wherein said organo moiety comprises alkyl or oxalkyl group which may be substituted with one or more groups selected from the group consisting of alkyl, alkoxy, aryl, aryloxy, substituted aryloxy, acrylyl, substituted acrylyl, carboxy, carboalkoxy, amino, amido, ureido, oxiranyl and sulphur.

Claim 39

The process of claim 35, wherein said organo-silicon compound is a reaction product of a compound containing acrylyl or substituted acrylyl groups and a silane having an organo moiety comprising an amino group containing at least one active hydrogen.

Claim 40

The process of claim 35, wherein said organo-silicon compound is a reaction product of an amino-compound having at least one active hydrogen and a silane having an organo moiety comprising acrylyl or substituted acrylyl groups.

Claim 41

The process of claim 35, wherein said organo-silicon compound is a reaction product of a silane having an organo moiety containing an epoxy group and a compound containing a chemical group selected from the group consisting of amino, amide, ureido, urea, urethane, thiol and hydroxyl, each having at least one active hydrogen.

Claim 42

The process of claim 35, wherein said organo-silicon compound is a reaction product of an epoxy-containing compound and a silane having an organo moiety comprising one or more chemical groups selected from the group consisting of primary amino, secondary amino, amide, urea, urethane and thiol, each having at least one active hydrogen atom.

Claim 43

The process of claim 40, wherein said epoxy-containing compound is an aliphatic epoxide and said silane is an aminoalkylsilane.

Claim 44

The process of claim 35, wherein said organo-silicon compound is selected from the group consisting of compounds illustrated by the formulae: ##STR35##

Claim 45

The process of claim 35, wherein said organo-silicon compound is seleced from the group consisting of (a) a reaction product of 1,2-butylene oxide and γ-aminopropyltriethoxysilane; (b) a reaction product of 1,2-butylene oxide and ureidopropyltriethoxysilane; (c) a reaction product of 1,2-butylene oxide and mercaptoethyltriethoxysilane; and (d) a reaction product of 1,4-butanediol diglycidyl ether and γ-aminopropyltriethoxysilane.

Claim 46

The process of claim 28, wherein said organo-silanol salt has the structure: ##STR36##

Claim 47

The process of claim 28, wherein said organo-silanol salt has the structure: ##STR37##

Claim 48

The process of claim 28 wherein the level of the magnesium oxide to the magnesium salt ranges from 6:1 to 7.5:1 and the level of the organo-silanol salt ranges from about 2 percent to about 5 percent by weight of the magnesium oxide.

Claim 49

A product produced by the process of claim 28.

Claim 50

A storage stable two-package system for forming in the presence of water a moldable, castable or sprayable cementitious material when a first composition is mixed with a second composition, comprising: (a) said first composition including at least one magnesium salt having at least moderate solubility in water; and (b) said second composition prepared from mixing together (1) magnesium oxide; and (2) at least one water-soluble organo-silanol salt, characterized in having attached to the silicon atom (i) at least one group comprising a water-soluble salt having the general formula: O.sup.- A.sup.+ where A + is a monovalent cation or one equivalent of a polyvalent cation and (ii) at least one group comprising an organo moiety attached to the silicon atom through a substantially nonhydrolyzable silicon-carbon bond with the organo moiety further characterized in having a working parameter of solubility, δ wp , in the range of about 6.2 to about 8.0 (cal./c.c.) 1/2 , with ##EQU5## wherein: F i =the molar attraction constant of an individual functional group of said moiety expressed in (cal. c.c.) 1/2 per mole, and V i =the molar volume constant of an individual group of said moiety expressed in c.c. per mole; with the organo-silicon compound at a level ranging from about 0.5 percent to about 10 percent by weight of the magnesium oxide; said compositions being mixed at time of use at levels to provide a mole ratio of the magnesium oxide to the magnesium salt of from about 3:1 to about 10:1.

Claim 51

A storage stable two-package system for forming in the presence of water a moldable, castable or sprayable cementitious material when a first composition is mixed with a second composition, comprising: (a) said first composition including at least one magnesium salt having at least moderate solubility in water; and (b) said second composition prepared from mixing together (1) magnesium oxide; and (2) at least one water-soluble organo-silanol salt, characterized in having attached to the silicon atom (i) at least one group comprising a water-soluble salt having the general formula: O.sup.- A.sup.+ where A + is a monovalent cation or one equivalent of a polyvalent cation and (ii) at least one group comprising an organo moiety attached to the silicon atom through a substantially nonhydrolyzable silicon-carbon bond with the organo moiety further characterized in having a working parameter of solubility, δ wp , in the range of about 6.2 to about 8.0 (cal./c.c.) 1/2 , with ##EQU5## wherein: F i =the molar attraction constant of an individual functional group of said moiety expressed in (cal. c.c.) 1/2 per mole, and V i =the molar volume constant of an individual group of said moiety expressed in c.c. per mole; with the organo-silicon compound at a level ranging from about 0.5 percent to about 10 percent by weight of the magnesium oxide; said compositions being mixed at time of use at levels to provide a mole ratio of the magnesium oxide to the magnesium salt of from about 3:1 to about 10:1.

Claim 52

The two-package system of claim 48, wherein said first composition further comprises water in an amount effective to form a saturated or nearly saturated solution with said magnesium salt.

Claim 53

The two-package system of claim 48, wherein said magnesium salt is selected from the group consisting of magnesium chloride, hydrated magnesium chloride, magnesium sulphate, hydrated magnesium sulphate, hydrated magnesium nitrate, hydrated magnesium acetate, magnesium bromide and hydrated magnesium bromide.

Claim 54

The two-package system of claim 48, wherein said monovalent cation is selected from the group consisting of tertiary sulphonium, ammonium, substituted ammonium, quaternary ammonium, quaternary phosphonium and Group IA alkali metal cations.

Claim 55

The two-package system of claim 48, wherein said organo moiety comprises alkyl group which may be substituted with one or more groups selected from the group consisting of alkyl of one to about eight carbon atoms, primary amino and secondary amino.

Claim 56

The two-package system of claim 48, wherein said organo-silanol is a hydrolyzate of an organo-silicon compound, said organo-silicon compound characterized in having attached to its silicon atom one or two groups having a hydrolyzable bond with the silicon atom and selected from the group consisting of alkoxyl, aryloxyl, substituted aryloxyl, aralkoxyl, substituted aralkoxyl, alkylamino, substituted alkylamino, silylamino, substituted silylamino, mercapto and substituted mercapto.

Claim 57

The two-package system of claims 48 or 53, wherein said organo moiety comprises alkyl or oxalkyl group which may be substituted with one or more groups selected from the group consisting of alkyl, alkoxy, aryl, aryloxy, substituted aryloxy, acrylyl, substituted acrylyl, carboxy, carboalkoxy, amino, amido, ureido, epoxy and sulphur.

Claim 58

The two-package system of claim 53, wherein said organo-silicon compound is a reaction product of a compound containing acrylyl or substituted acrylyl groups and a silane having an organo moiety comprising an amino group containing at least one active hydrogen.

Claim 59

The two-package system of claim 53, wherein said organo-silicon compound is a reaction product of an amino-compound having at least one active hydrogen and a silane having an organo moiety comprising acrylyl or substituted acrylyl groups.

Claim 60

The two-package system of claim 53, wherein said organo-silicon compound is a reaction product of a silane having an organo moiety containing an epoxy group and a compound containing a chemical group selected from the group consisting of amino, amide, ureido, urea, urethane, thiol and hydroxyl, each having at least one active hydrogen atom.

Claim 61

The two-package system of claim 53, wherein said organo-silicon compound is a reaction product of an epoxy-containing compound and a silane having an organo moiety comprising one or more chemical groups selected from the group consisting of primary amino, secondary amino, amide, urea, urethane and thiol, each having at least one active hydrogen atom.

Claim 62

The two-package system of claim 58, wherein said epoxy-containing compound is an aliphatic epoxide and said silane is an aminoalkylsilane.

Claim 63

The two-package system of claim 53, wherein said organo-silicon compound is selected from the group consisting of compounds illustrated by the formulae: ##STR38##

Claim 64

The two-package system of claim 53, wherein said organo-silicon compound is selected from the group consisting of (a) a reaction product of 1,2-butylene oxide and γ-aminopropyltriethoxysilane; (b) a reaction product of 1,2-butylene oxide and ureidopropyltriethoxysilane; (c) a reaction product of 1,2-butylene oxide and mercaptoethyltriethoxysilane; and (d) a reaction product of 1,4-butanediol diglycidyl ether and γ-aminopropyltriethoxysilane.

Claim 65

The two-package system of claim 48, wherein said organosilanol salt has the structure: ##STR39##

Claim 66

The two-package system of claim 48, wherein said organosilanol salt has the structure: ##STR40##

Claim 67

The two-package system of claim 48, wherein at least one of said compositions further comprises a material selected from the group consisting of fibrous glass, sisal, silica, mica, mineral wool and cotton.

Claim 68

The two-package system of claim 48, wherein at least one of said compositions further comprises a thickening agent selected from the group consisting of hydroxyethyl cellulose, hydroxypropyl cellulose, polyethylene oxide and polyvinyl alcohol.

Claim 69

The two-package system of claim 48 wherein the level of the organo-silanol salt ranges from about 2 percent to about 5 percent by weight of the magnesium oxide.