Imperial Chemical Industries Limited

Desmond W Osmond

Maurice W Skinner

Edmund J West

David G Dawson

Frederick A Waite

Stephen Barry Downing

Peter G Osborn

Norman Douglas Smith

Barrie J Thorpe

Morice W Thompson

Stable, fluid, mouldable and curable compositions are described from which may be fabricated composite materials, of improved mechanical properties, comprising an organic polymer matrix and a particulate inorganic reinforcing phase dispersed in and bonded to the matrix. The fluid compositions comprise (A) a polymerizable organic liquid having a viscosity not greater than 50 poise at the moulding temperature, (B) inorganic filler particles of defined size constituting at least 20% by volume, and optionally up to 90% by volume, of the total composition, and (C) a defined polymeric dispersant whereby the filler particles are stably dispersed in the polymerizable liquid. The generally low viscosity of the curable compositions enables them to be cast by simple techniques and polymerization of the component (A) yields the above-described composite materials.

Inorganic reinforcing phase dispersed and bonded to polymer matrix

Cementitious compositions having a modulus of rupture greater than 20 MN/m.sup.2 are prepared by subjecting a mixture of hydraulic cement, fine aggregate, a selected water-dispersible polymer and water to a homogenization process (in order to very substantially reduce voidage in the product) and by thereafter curing and drying the product. The aggregate improves the modulus of rupture and resists any loss in this strength property due to moisture uptake and loss.

Cementitious compositions

In U.S. Pat. No. 4,070,199 we have described cured polymer-containing cementitious compositions of high modulus of rupture. The cured compositions are made by curing the product of subjecting to a homogenization process comprising high shear mixing (e.g. extrusion or calendering) the ingredients hydraulic cement, water and a selected water-dispersible polymer. The polymer is selected by a test which determines thermally its effect on the cement hydration reaction. The present invention describes the use in similar compositions of a class of water-dispersible acidic polymer, not selected by the above-mentioned test, which contains a specified proportion of carboxyl groups. Shaped products comprised of the new cured compositions of high modulus of rupture are useful, for example, in building applications where previously it was necessary to employ asbestos in admixture with the cement.

Stable, fluid, moldable and curable compositions are described from which may be fabricated composite materials, of improved mechanical properties, comprising an organic polymer matrix and a particulate inorganic reinforcing phase dispersed in and bonded to the matrix. The fluid compositions comprise (A) a polymerizable organic liquid having a viscosity not greater than 50 poise at the molding temperature, (B) inorganic filler particles of defined size constituting at least 20% by volume, and optionally up to 90% by volume, of the total composition, and (C) a defined polymeric dispersant whereby the filler particles are stably dispersed in the polymerizable liquid. The generally low viscosity of the curable compositions enables them to be cast by simple techniques and polymerization of the component (A) yields the above-described composite materials.

Composite materials

Cured cementitious compositions having a modulus of rupture of greater than 15 MN/m.sup.2 are prepared by curing and drying a homogeneous uncured cementitious composition which comprises in defined proportions hydraulic cement, water and a selected water-dispersible polymer.

The dissemination of gas turbine engine aviation fuels under shock conditions, particularly by forming mist particles, and the accompanying fire hazard, are reduced by dissolving in the fuel a soluble polymer of molecular weight greater than 10.sup.6 in such concentration that there is molecular overlap of the dissolved polymer in the fuel, the dissolved polymer being one containing polar groups which form bonds with each other when the fuel is subjected to shock.

Polymer solution

A polymer is dissolved in a liquid hydrocarbon fuel which has a flash point of at least 90.degree. F and is of a type suitable for gas turbine aircraft engines in order to reduce the tendency of the fuel to particulate dissemination when the fuel is subjected to shock. The polymer has a viscosity average molecular weight greater than 10.sup.6 or an intrinsic viscosity greater than 2.5 dls./gm. and the amount of polymer is sufficient that there is molecular overlap of polymer molecules in the liquid.

Aviation fuel containing dissolved polymer and having reduced tendency

A stable dispersion of polymer in a non-solvent organic liquid is made from a monomer which is both solid and not completely soluble in the organic liquid at the polymerisation temperature, optionally in conjunction with other monomers which are appreciably soluble in the liquid medium at that temperature. The process comprises dispersing the solid monomer in the organic liquid in the presence of a specified monomer-stabilising agent so as to produce a stable dispersion of particles of mean diameter not greater than 50.mu., and then heating the dispersion of solid monomer together with the other monomers, if any, at the polymerisation temperature in the presence of a specified polymer-stabilising agent. A single stabilising agent combining the functions of monomer-stabiliser and polymer-stabiliser may be employed. The process is applicable to the production of both addition polymers and condensation polymers.

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Windsor, United Kingdom

Desmond W Osmond