EP2060690B1 - Method for fixing insulating ballast made of polymer particulate foam granulates - Google Patents

Description

The invention relates to a method for local solidification of a Dämmschüttung of polymer particle foam granules, which for the insulation of a building, etc., in particular a clam wall masonry, is used, wherein the granules expandable polymer particles.

It is known to insulate cavities in exterior walls, ceilings or the like of buildings by pourable or inflatable insulation materials. This is the case, for example, in a so-called core insulation of bivalve masonry, in which the air gap between interior building wall and outer masonry (Verklinkerung) is filled with a granular, foamed insulation. Here are often at least pre-expanded polystyrene particles or beads or other type of expanded polymer particles used, since they have very good thermal insulation properties.

An example of such a pourable or inflatable insulation material is in the DE 20 2006 018 200 U1 described. Here, in addition to end-expanded polystyrene particles, which are present in a spherical shape with a size of, for example, between 2 mm and 6 mm, EPS milled material with a flat chip-like particle size of, for example, 0.5 mm to 4 mm and mixed into the introduced to be insulated hollow or receiving space.

However, it has been found in practice that such Dämmgut-bedding due to their very low bulk density and their mobility are often difficult to retain in the cavities. In particular, they have the desire to leaks, for example in the joint area of components that fill the Delimiting the cavity, or escape at other openings in such walls, etc.

To counter this problem, for example, the DE 31 32 279 A1 and the DE 28 30 914 A1 to provide the polymer particles used here with a binder, which is introduced together with these in the receiving space in the structure to be insulated. As a result, the individual particles adhere to each other in the cavity, so that the trickling of the same at defects etc. is drastically reduced. The binder used here is latex, which is applied, for example, diluted onto the polymer particles. In this way, a kind of composite body or molded body is formed in the receiving space of the structure to be insulated, since the individual polymer particles are connected to each other after the curing of the latex binder.

However, this procedure is also associated with disadvantages: The latex binder impairs the good flow behavior, which can lead to incomplete cavity filling. Furthermore, the latex binder is combustible, so that increases the fire load in the structure to be insulated, which is not desirable in the rule. In addition, the addition of this binder is associated with a considerable procedural and device complexity, which makes the processing more expensive. Furthermore, the binder itself is not a negligible cost factor. Finally, the use of such an additional binder and in particular a binder based on latex for health and environmental reasons is not without problems.

In addition, in practice, the problem is often that in existing structures with existing Dämmschüttungen subsequent breakthroughs, openings, etc., for example, for a line bushing, the subsequent installation of windows or doors, etc. to be created. If the bed is not here by means of a binder, for example, according to DE 31 32 279 A1 or the DE 28 30 914 A1 is solidified, the granules trickles when making the opening due to the gravitational force out, so that it can lead to an impairment of the work processes and to a considerable extent to a deterioration of the insulation effect.

From the US 3,554,934 For example, a method has become known which uses expandable polymer particles as bulk material in order to then subsequently subject them to a second expansion by means of steam in the form of water vapor. This moldings are made in the form of insulation boards. In this process, the polymer particles are first expanded, whereby they stick together so incompletely that free spaces remain between the particles. An aqueous solution of a hardenable resin and ammonium bromide is introduced into these clearances. Subsequently, the structure is subjected to a heat treatment to remove the water and to cure the resin.

Furthermore, from the EP 1 854 620 A1 a method for filling cavities in hollow blocks with foam particles has become known. Specifically, this provides for wetting the foam particles with water, an aqueous solution or aqueous dispersions prior to filling the cavity, and coagulating an aqueous polymer dispersion with a coagulating agent within the cavity.

From the WO 83/00029 A1 Finally, a method and an apparatus for producing an insulating layer in a brick has become known. Here, a Dämmschüttung polymer particles is introduced into at least one receiving space of the brick and solidified therein. The particles are expandable thermoplastic polymer particles such as polystyrene beads, which are end-expanded by means of water vapor in the receiving space and thereby completely bond together. As a result, the insulation layer is reliably fixed in the brick, so that it can be transported to the construction site without damage.

The invention has for its object to provide a method with which on site with little effort trickling out of a Dämmschüttung from a receiving space in a building can be reliably suppressed without disadvantageous additives must be used, which can exert an influence on the flow behavior in particular ,

This object is achieved by the method according to claim 1.

The invention thus provides for the first time to carry out an expansion step of the polymer particles on site at the structure to be insulated within the hollow or receiving space given there. It has surprisingly been found that such expandable polymer particles are solidifiable in the course of such end expansion under the prevailing conditions on construction sites and in conventional constructions, taking into account in particular the economic conditions, so that trickling is effectively suppressed. The solidification is based on such a change in the surface condition of the polymer particles that it comes to a kind of welding between adjacent polymer particles. This is also supported by the limited space available in the receiving space of the structure to be insulated, etc., since the expanding during the expansion step polymer particles each other take away the space and press each other.

In this way, without any addition of an additional binder de facto a shaped body in the region of the receiving space of the structure to be insulated, in which the expansion takes place. Thus, trickling of the granules can be reliably avoided at this point. This is both at initial filling of the receiving space with the granules of the case, since here can close leakage points according to the invention, as well as the subsequent formation of breakthroughs, etc. in the building, where it comes in the course of work to leaks.

Another advantage of the invention lies in the fact that the action on the granules is limited to the relevant points in the Dämmschüttung, while this is wetted in the prior art full volume with binder. This makes it possible according to the invention to keep the processing effort very low.

In addition, the procedure of the invention has the advantage that no additional fire load is introduced by a binder, etc. in the product. Since, according to the invention, no binder is used, there are no additional concerns with regard to ecological or health-endangering aspects of the ingredients of such an insulation.

In this case, it is generally known to subject polystyrene particles or the like to a double expansion. Thus, such polymer particles are prepared by a Vorexpandierschritt means of steam and then used as a raw material for the production of insulation boards. For this purpose, these pre-expanded polymer particles are introduced into a suitable mold and foamed there by means of steam and thus end-expanded, resulting in insulating blocks. These are then cut to standard commercial and standard insulation boards or already have the desired final dimensions, so that no reworking is required. This process takes place at the factory, since here the expansion can be reliably and accurately controlled and, in particular, there is no negative interaction of the water vapor with neighboring components. Alternatively, it is also known to end-expand such pre-expanded polymer particles and to use as bulk material, as it DE 20 2006 018 200 U1 suggests. To solve the known problem of trickling carries the DE 20 2006 018 200 U1 but nothing at all.

Thus, it was already known in practice to subject pre-expanded and thus again expandable polymer particles to a second expansion; However, this step has hitherto been applied exclusively to procedures within manufacturing factories, since it was obviously intended to avoid the introduction of water vapor into voids in structures to be insulated, etc., such as the space in a multi-layered masonry. Furthermore, it seems that the process of end-exporting was considered too complex to be carried out under local conditions at the site. In any case, an indication of a possible implementation of an on-site final expansion at the construction site is not apparent from the prior art and is also unknown in practice. Such a procedure is first proposed by the present invention.

Advantageous developments of the method according to the invention are the subject of the dependent claims 2 to 7.

Thus, the polymer particles can be expanded by means of steam, which has the significant advantage that a medium is used which does not introduce any fire load into the insulation and also contains no active ingredients that would be of concern for health or environmental reasons. In addition, the use of water vapor to assist in the expansion of polymer particles is a well-known and proven measure, so that this process can be carried out reliably.

It is particularly advantageous if the steam is introduced under pressure over a predetermined period of less than 20 seconds in the granules. Practical experiments have shown that such a short exposure period is already sufficient to achieve the desired expansion result. In addition, it is ensured by this temporary supply of water vapor that moisture is introduced into the structure only to a very limited extent. there It has already proven to be effective if the water vapor is introduced into the receiving space of the granules for less than 10 seconds, and usually already about 5 seconds are sufficient to achieve the desired effects, in which case very little moisture is introduced into the receiving space.

The water vapor may e.g. be introduced via existing leaks on the building in the receiving space for the granules; However, it can also be advantageous to improve the process sequence as well as the targeted solidification in the field of intrinsically dense bodies of the structure, for example in the subsequent formation of pipe openings, if in the building at least one access opening for introducing the water vapor into the receiving space for the granules is trained. Then, the expansion can be limited locally targeted and keep the moisture supply in the receiving space low, at the same time a reliable and sufficient expansion in the desired range is achieved.

In practice, it has proven to be particularly advantageous if the polymer particles are first introduced pre-expanded polystyrene beads, since herewith a material with particularly good thermal insulation properties with low weight and good flow behavior is used.

Alternatively, instead of the pre-expanded polystyrene beads and a Regenerat of polymer particles, which as a residue in the factory production of rigid foam insulation, or from the decay of cavity fillings or as a secondary material from the material Rececyling and preparation of foam boards, in particular of EPS insulation materials , and may have properties, in particular an expandability comparable to the polymer beads, in any mixing ratio up to the complete substitution can be used.

In an advantageous embodiment of the invention, the granules further milled material, which from the factory mechanical machining of hard foam Based on EPS, XPS or PUR-based, resulting in a high quality recovery of this waste.

It has been shown that the proportion of milled material can preferably be less than 60 vol.% Of the granules, i. can be used to a considerable extent, without the effect of the invention would be nullified. However, the milled material is preferably used in a proportion of less than 50% by volume and in particular of less than 30% by volume of the granules, since here a greater stability of the adhesive bond can be achieved within the solidified region in the insulating filling.

The polymer beads may be provided with a fire retardant additive. In particular, the flame retardant additive can be a brominated or chlorinated organic compound which has been found to be particularly useful in practice. In this case, the fire retardant additive can be added in a proportion of 0.1 to 10 wt.% Based on the weight of the polymer beads.

According to a further aspect of the present invention, according to claim 8, a use of a Dämmschüttung of polymer particle foam granules with expandable polymer particles, in particular pre-expanded polymer particles, shown, which is used for the insulation of a building, etc., in particular a bivalve masonry, and is arranged there in a receiving space, said Dämmschüttung is used to produce a locally solidified insulation layer by means of a method according to the invention.

Thus, according to the invention, in particular the intermediate material in the production of insulating panels, namely pre-expanded polymer beads, can be used directly in accordance with the invention and can be used to produce a locally consolidated zone in the insulation in a building structure.

The invention will be explained in more detail by means of exemplary embodiments.

In one embodiment, the cavity is subsequently filled in a building with double-shell masonry by means of a Dämmschüttung of polystyrene particle foam granules. The granules have a bead size ≤ 6 mm in diameter and is introduced under low pressure into the receiving space within the wall. There, the polystyrene beads are distributed throughout the available space due to their good flowability. If the receiving space is e.g. However, in the joint area of two components of the outer wall does not produce a tight seal, the polystyrene beads can trickle out of the receiving space in this area.

To prevent this, water vapor is introduced under pressure into the Dämmschüttung according to the invention at the leakage point, whereby the polystyrene beads are subjected to an expansion. This results in a kind of welding of the individual polystyrene beads together in the treated area, so that a solid body of larger dimensions results. This is too big to pass through the leak site. and seals the leakage site, thereby preventing trickling free, unbonded polystyrene beads.

In addition, it is also possible to use e.g. a freely present top of Dämmschüttung be solidified in the wall by the action of water vapor so that trickling or lifting of polystyrene beads thereof, for example, under the influence of wind forces during construction can be prevented.

Furthermore, if the respective leakage point should not be large enough to permit effective evaporation of the granules, it is also possible to provide access openings e.g. formed by a drilling process through which the water vapor can be passed.

In another embodiment, a window is subsequently formed in an existing double-walled masonry with a Dämmschüttung of expandable granules in the core. This requires a corresponding opening in the wall getting produced. According to the invention, a suitable number of access openings, which are located at a predetermined distance from each other, are bored adjacent to the location of the window to be produced, through which steam is then introduced into the insulating filling. The subsequent expansion of the polystyrene beads in the insulation fillet thus solidifies the edge area around the window opening to be created, so that a separating cut can be carried out here without granules emerging from the insulation layer.

In a further embodiment, a passage opening for the passage of a water pipe, e.g. an external connection for the water extraction with Dämmschüttung made. Here, too, is limited locally and introduced through a single access opening water vapor in the Dämmschüttung. This makes it possible to achieve a solidification of the insulating fill in this area, so that subsequently the larger hole for the passage of the water pipe can be formed without this granules would escape from the core area. In this case, for example, the formation of a Zugsangsöffnung with a diameter of 8 to 10 mm to solidify an area with a diameter of more than 100 mm, the solidification effect of the parameters of the vapor deposition as well as the properties of Dämmschüttung depends and therefore depending on Use case may vary.

To provide the water vapor, e.g. As in the practical experiments carried out a conventional steam cleaner can be used. An example of this is the "Kärcher Steam Cleaner 1501 VAPORAPID", which has proven to be suitable for this purpose.

The invention can thus be carried out both with initially introduced expandable polymer beads and with 100% recycled or already incorporated regenerate, with or without an addition of milled material from expanded polymer. Furthermore, with the method according to the invention targeted local areas are solidified in a Dämmschüttung.

Claims (8)

1. A method for the local solidification of a bulk insulation material of polymer particle foam granulate without addition of a binder,
   the bulk insulation material serving for insulation of a solidium etc., in particular double-wall masonry, and being arranged inside a reception space of said solidium, and
   said granulate including expansible polymer particles,
   characterized in that
   a step of expanding the polymer particles on site, at the construction site, in the location to be solidified inside the bulk insulation material is provided so as to prevent granulate from trickling out from a leakage of the reception space,
   wherein the action on the granulate is limited to the relevant location within the bulk insulation material by specifically solidifying a local region inside the bulk insulation material.
2. The method according to claim 1, characterized in that the polymer particles are expanded by means of water vapor.
3. The method according to claim 2, characterized in that the water vapor is introduced into the granulate under pressure over a predetermined time period of less than 20 seconds, preferably less than 10 seconds, and in particular about 5 seconds.
4. The method according to claim 2 or 3, characterized in that at least one access opening for introduction of the water vapor into a reception space for the granulate is formed inside the solidium.
5. The method according to any one of claims 1 to 4, characterized in that the granulate of polymer beads is made up of pre-expanded polystyrene introduced for the first time and/or of reclaim.
6. The method according to any one of claims 1 to 5, characterized in that the granulate further includes milled material.
7. The method according to claim 6, characterized in that the milled material content is less than 60% (vol.), preferably less than 50% (vol.), and in particular less than 30% (vol.) of the granulate.
8. Use of a bulk insulation material of polymer particle foam granulate including expansible polymer particles, in particular pre-expanded polymer particles, which serves for insulation of a solidium etc., in particular double-wall masonry, and is arranged there inside a reception space, in order to produce a locally solidified insulation layer by means of a method according to any one of claims 1 to 7.