Fiber-free shaped parts

1. A fiber-free molding composition comprising:

(a) a binder selected from the group consisting of an epoxide, a polyisocyanate, a furane-resin-free phenolic resin, and mixtures thereof; and

(b) a filler mixture containing:

(i) from about 20 to 90% by weight, based on the weight of the filler mixture, of an inorganic high-temperature-resistant filler;

(ii) a heat activatable swelling agent;

(iii) an adhesive; and

(iv) a micropore-forming, high-temperature-resistant filler.

2. The composition of claim 1 wherein the filler mixture further comprises:

(iii) an adhesive;

(iv) a micropore-forming, high-temperature-resistant filler; and

(v) a grinding and/or anticaking agent.

3. The composition of claim 1 wherein the filler mixture has a pH of up to 7.5.

4. The composition of claim 2 wherein the filler mixture contains;

(i) from 20 to 90% by weight of the inorganic high-temperature-resistant filler;

(ii) from 1 to 30% by weight of the heat-activatable swelling agent;

(iii) from 0.1 to 35% by weight of the adhesive;

(iv) from 2 to 40% by weight of the micropore-forming, high-temperature-resistant filler; and

(v) from 0.01 to 10% by weight of the grinding and/or anticaking agent, all weights being based on the total weight of the molding.

5. The composition of claim 1 further comprising a hardener.

6. The composition of claim 1 further comprising a blowing agent.

7. The composition of claim 1 wherein the molding has a density of from 100 to 300 kg/m 3 .

8. A process for making a fiber-free molding composition comprising:

(a) providing a binder selected from the group consisting of an epoxide, a polyisocyanate, a furane-resin-free phenolic resin, and mixtures thereof;

(b) providing a thermosetting hardener;

(c) providing a filler mixture containing:

(i) an inorganic high-temperature-resistant filler;

(ii) a heat-activatablle swelling agent;

(iii) an adhesive;

(iv) a micropore-forming, high-temperature-resistant filler; and

(v) a grinding and/or anticaking agent; and

(d) combining (a)–(c) to form the fiber-free molding composition.

9. The process of claim 8 further comprising mixing an emulsifier with the binder.

10. The process of claim 8 further comprising providing a blowing agent.

11. The process of claim 8 wherein the filler mixture has a pH of up to 7.5.

12. The process of claim 8 further comprising introducing the molding mixture into a mold to form a solid, fiber-free foam form.

13. The product of the process of claim 8 .

14. The product of the process of claim 9 .

15. The product of the process of claim 10 .

16. The product of the process of claim 11 .

17. The product of the process of claim 12 .