CA2091952C - Foam boards having improved thermal insulation properties, and a process for the production thereof - Google Patents

Foam boards having improved thermal insulation properties, and a process for the production thereof

Info

Publication number
CA2091952C
CA2091952C CA002091952A CA2091952A CA2091952C CA 2091952 C CA2091952 C CA 2091952C CA 002091952 A CA002091952 A CA 002091952A CA 2091952 A CA2091952 A CA 2091952A CA 2091952 C CA2091952 C CA 2091952C
Authority
CA
Canada
Prior art keywords
foam
foam board
compression
boards
foam boards
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA002091952A
Other languages
French (fr)
Other versions
CA2091952A1 (en
Inventor
Karl-Heinz Wassmer
Frieder Hohwiller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BASF SE
Original Assignee
BASF SE
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=6454416&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CA2091952(C) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by BASF SE filed Critical BASF SE
Publication of CA2091952A1 publication Critical patent/CA2091952A1/en
Application granted granted Critical
Publication of CA2091952C publication Critical patent/CA2091952C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34Auxiliary operations
    • B29C44/56After-treatment of articles, e.g. for altering the shape
    • B29C44/5627After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34Auxiliary operations
    • B29C44/35Component parts; Details or accessories
    • B29C44/352Means for giving the foam different characteristics in different directions

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Laminated Bodies (AREA)
  • Molding Of Porous Articles (AREA)
  • Building Environments (AREA)

Abstract

Foam boards having an anistropy such that the cells are compressed in a direction of the board thickness, the boards having a density of from 15 to 45 kg/m3 and the ratio between the long and short axes in the compressed cells being from 1.2 to 1.6, have improved insulation properties.

Description

~ ~ ~ 9 11 9 5 ~

Foam boards having improved thermal insulation propertieS~ and a process ~or the production thereof The present invention relates to a process for the production of foam boards having improved thermal insulation properties. In particular, the present invention relates to foam boards of this type which have an anisotropy of the type that the cells a~e compressed in the direction of the board thickness, and to a process for aftertreating known foam boards by temporary compression.
Foam boards, fo~ example made of polyolefin foams or made from polystyrene extruded or particle foam, have long been employed for thermal and sound insulation.
For sound insulation, in particular impact (footstep) sound insulation, preference is given to foam boards which have been elasticized by temporary compression in the direction of the board thickness.
For example, the use of elasticized EPS (expandable polystyrene) insulating boards for impact sound insulation in accordance with DIN 18164, Part 2, Schaumkunststoffe als Dammstoffe fUr das Bauwesen, is known. Boards of this type must have adequate resilience. The resilience is characterized in DIN 18 164, Part 2, by the dynamic rigidity s' (also known as the impact sound reduction factor) of the insulating layer, including the air trapped in it.
For structural engineering reasons, impact sound insulation boards must have very low dynamic rigidity and relatively restricted deformation under load (difference between the supplied thickness or nominal thickness and the thickness under load, expressed as the (dLdB) value in accordance with DIN 18164, Part 2.
This means that the degree of compression (also known as the degree of elasticization), and thus the deformation, of the foam structure can only be modified to a limited extent.
In the known aftertreatment of foam boards by , 209195~

compression (also known as elasticization), foam boards typically having a density of from 8 to lo kg/m3 are compressed to a maximum extent of 66% of their original thickness, and this is maintained for a certain time (usually less than 60 seconds).
After the pressing is terminated, slight irreversible deformation of the cell structure remains, all the cells having an anisotropy such that the ratio between the long and short axes is from 1.15 to 1.25. The dynamic rigidity values achieved, for example, in a 25 mm thick foam board made from polystyrene particle foam are around 10 N/cm3. The (dLdB) values are from about 1 to 3 mm.
In addition to sound insulation, an important factor for improving the properties of foam boards is, in particular, also the thermal insulation.
It is an object of the present invention to improve the thermal insulation properties of known foam boards by reducing the thermal conductivity, in particular in the direction of the board thickness, and in addition to improve the sound insulation properties.
It has found that, surprisingly, this object is achieved by a process which comprises compressing conventional foam boards having a density of from 11 to 40 kg/m3 to a maximum extent of from 50 to 90% of their original thickness, maintaining this compression for at least 10 seconds, and subsequently releasing the compression. The foam boards obtained by this process have improved thermal insulation properties. They have cells compressed in the direction of the board thickness, and an increased density of from 15 to 45 kg/m3. Their anisotropy is such that the ratio between the long and short axes in the compressed cells being from 1.2 to 1.6, preferably from 1.3 to 1.55, particularly preferably from 1.35 to 1.5.
Conventional foam boards or foam slabs can be employed in the process according to the invention. In general, however, ~,-~ . .

. 20gl9S2 - 3 - o.Z. 0050/43098 foam slabs are employed, from which foam boards are subsequently cut in a suitable size in a conventional and known manner perpendicular to the elasticization direc-tion.
This allows the process according to the invention to be carried out in a very economical manner in one step for a large number of future foam boards. In addition, there are no problems caused by edge effects.
The terms foam slab and foam board are therefore used synonymously-in the description, unless stated otherwise at the point in question.
The foam boards can comprise closed- or open-cell polyolefin foam, phenolic resin foam, polystyrene foam or polyurethane foam. Preference is predom;n~ntly given to closed-cell foams, in particular made from polystyrene, polyurethanes and polyolefins.
The foam boards very particularly preferably comprise polystyrene foam. Preference is given to poly-styrene particle foam as opposed to extruded polystyrene foam.
The preferably isotropic foam slabs on which the foam boards according to the invention are based are produced in a conventional and known manner.
For example, foam slabs are produced from poly-styrene particle foam by expanding blowing agent-contain-ing, expandable polystyrene beads by heating at above their melting point, for example by means of hot air or preferably by means of steam. After cooling and if desired interim storage, the foam particles obtained can be welded together by re-heating in a mold which does not seal in a gas-tight manner to give a foam slab.
Suitable expandable polystyrene beads are des-cribed, for example, in EP-B 106 129, EP-A 383 133 and DE-A 39 15 602.
Preference is given to expandable polystyrene beads having a size of from l to 2 mm.
The freshly produced foam boards are preferably 2049l952 o.z. 0050/43098 stored for at least 2 hours and particularly preferably for at least 6 hours before the process according to the invention is carried out.
The known foam boards or slabs employed in the process according to the invention generally have a density of from 11 to 40 kg/m3.
By comparison, the foam boards or slabs according to the invention generally have a density of from 15 to 45 kg/m3. Rowever, the effect of the invention is par-ticularly pronounced at densities above 20 kg/m3. The density is therefore preferably from 20 to 30 kg/m3.
As a consequence of carrying out the process according to the invention, the density of the foam slabs is permanently increased by up to about 50%, based on the pre-process density.
In the process according to the invention, the foam slabs are generally compressed in the direction of a surface perpendicular to a m~x;mllm extent of from 50 to 90%, preferably from 70 to 85%, particularly preferably from 70 to 80%, of their original thickness. Depending on the compressive set or properties desired, the foam boards can be compressed to a m~x;mll~ extent of 90% using certain programs for the compression rate and subsequent release and if desired for certain hold times.
In general, the compression is carried out by moving two plane-parallel metal plates toward one another at a constant compression rate and without interim hold times to a ~x;mll~ compression. At the m~x;mllm compres-sion, the slabs are held for a certain time, but for at least 10 seconds. The distance between the two metal plates is then increased again, in general likewise at a constant release rate.
The compression rate used is generally from 1 to 150 cm/min, preferably from 30 to 95 cm/min, particularly preferably from 70 to 80 cm/min.
The foam slabs are generally held at the m~; mllm compression for from 10 to 120 seconds, preferably for 2~91g52 - 5 - O.Z. 0050/43098 -from 30 to 90 seconds.
The compression can be carried out in a conven-tional and known manner in presses for EPS. Examples of suitable presses are marketed by Maschinenfabrik Paul Ott in 7050 Waiblingen-Neustadt, Germany.
However, it is also possible to carry out the compression at a rate which varies with time and with interim hold times of various lengths.
For example, it is possible to first compress the slabs to less than the m~;mllm compression and to hold the compression at this value for a certain time.
In addition, it may be advantageous to carry out the pressing with superimposed vibration (vibration pressing).
After complete release, the foam slabs after-treated by the process according to the invention are generally stored under atmospheric conditions for at least 5 hours. This enables the foam slabs to relax to their final dimensions. A storage time of the compressed slabs of from 1 to 2 days has proven particularly ad-vantageous.
Foam boards can then be obtained from these foam slabs by cutting perpendicular to the elasticization direction in a conventional and known manner. These foam boards usually have a cross-sectional area of at least 50 cm2 .
The foam boards according to the invention and the process according to the invention have a number of advantages. Thus, it is possible for thinner insulating layers and thus less material to be used during construction in order to achieve a certain thermal - resistance (see DIN 4108, Part 2), or for the thermal resistance for a prespecified insulating material thickness to be lower than in the case of untreated foam board.
The board thickness is frequently determined by the application. It is a considerable advantage of the 2091gS2 - 6 - o.Z. 0050/43098 foam boards according to the invention that prespecified thermal conductivities can be achieved usinq boards of low density. For example, the thermal conductivity of foam boards according to the invention in which the density is 20 kg/m3 is as low as in conventional foam boards having a density of 28 kg/m3. There is thus a material saving of from 30 to 50%.
A further surprising advantage is that the resilience (s') can be set to the low level of less than or equal to 10 N/cm3 which is necessary for improving the thermal conductivity, independently of the density and board thickness in the density range from 15 to 30 kg/m3 which is conventional for thermal insulation boards in construction applications. The dynamic rigidity in the direction of the board thickness is usually from 4 to 10 Ntcm3 in accordance with the invention.
Since the long-term compressive stress of, for example, EPS boards is affected in a linear manner by the foam density, the small drop in compressive stress caused by the elasticization can be compensated by correspond-ingly increased foam densities, even in pressure-affected applications.
EXAMPLES
In the Examples and Comparative Examples, foam boards made from polystyrene particle foam were employed.
A 300 K 25 press from Maschinenfabrik Paul Ott in 7050 Waiblingen-Neustadt, Germany, was employed for compressing the polystyrene particle foam slabs.
The compression was carried out between two plane-parallel plates at a force of 25 MP and a rate of 75 cm/min. The hold time at m~;ml~m compression was 1 minute in each case. The two plates were then moved away from one another at a rate of 192 cm/min.
The compressed slabs were stored for 2 days under atmospheric conditions after release.
The thermal conductivity was determined in accordance with DIN 52612, Part 1, for the novel foam ~Ogl952 - 7 - o.Z. 0050/430g8 -boards aftertreated by compression and for untreated foam boards.
In addition, the effect of different maximum compressions was investigated for foam boards having different densities.
The anisotropy was determined by evaluating foam sections under an optical microscope. To this end, foam cells were measured and the anisotropy determined as the ratio between the long and short axes.
The experimental results are summarized in the Table.

2~91952 - 8 - O.Z. 0050/43098 ,~, ON O N ~ 7 0 N N ~ O ~ d' O ~ ~ ~

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Claims (7)

1. A process for the production of foam board having improved thermal insulation properties, said process comprising:
(a) providing a conventional foam board having a density of from 11 to 40 kg/m3;
(b) compressing said foam board to a maximum extent of from 50 to go percent of its original thickness;
(c) maintaining the compression for at least 10 seconds; and (d) releasing the compression;
thereby resulting in a foam board having cells compressed in the direction of the board thickness wherein the resultant foam board has an increased density of from 15 to 45 kg/m3 and the ratio of long to short axes of the flattened cells is from about 1.2 to 1.6.
2. A process as defined in claim 1, wherein the ratio of long to short axes of the flattened cells in the resultant foam board is from 1.3 to 1.55.
3. A process as defined in claim 1, wherein the foam board comprises polystyrene particle foam.
4. A process as defined in claim 1, 2 or 3, wherein the resultant foam board has an increased density of from 20 to 30 kg/m3.
5. A process as defined in claim 1, 2 or 3, wherein the process comprises compressing said foam board to a maximum compression of from 70 to 85 percent of its original thickness.
6. A process as defined in claim 1, 2 or 3, wherein the process comprises maintaining the compression for a period of from 30 to 90 seconds.
7. A process as defined in claim 1, 2 or 3, wherein the step of compressing the foam board comprises moving two plane-parallel plates toward one another with said foam board disposed between said parallel plates at a constant compression rate of from 1 to 150 cm/min.
CA002091952A 1992-03-19 1993-03-18 Foam boards having improved thermal insulation properties, and a process for the production thereof Expired - Fee Related CA2091952C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DEP4208759.7 1992-03-19
DE4208759A DE4208759A1 (en) 1992-03-19 1992-03-19 FOAM PANELS WITH IMPROVED THERMAL PROPERTIES AND METHOD FOR THEIR PRODUCTION

Publications (2)

Publication Number Publication Date
CA2091952A1 CA2091952A1 (en) 1993-09-20
CA2091952C true CA2091952C (en) 1997-09-16

Family

ID=6454416

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002091952A Expired - Fee Related CA2091952C (en) 1992-03-19 1993-03-18 Foam boards having improved thermal insulation properties, and a process for the production thereof

Country Status (5)

Country Link
EP (1) EP0561216B2 (en)
JP (1) JPH068348A (en)
CA (1) CA2091952C (en)
DE (2) DE4208759A1 (en)
ES (1) ES2081149T5 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100467523C (en) * 2002-05-31 2009-03-11 欧文斯科宁知识产权资产有限公司 Anisotropic polymer foam

Families Citing this family (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4416852A1 (en) * 1994-05-13 1995-11-16 Basf Ag Expandable styrene polymers
DE4416861A1 (en) * 1994-05-13 1995-11-16 Basf Ag Expandable styrene polymers
DE4416862A1 (en) * 1994-05-13 1996-02-22 Basf Ag Expandable styrene polymers
US5900442A (en) 1995-05-12 1999-05-04 Imperial Chemical Industries Plc Flexible polyurethane foams
US5817704A (en) * 1996-03-08 1998-10-06 The Procter & Gamble Company Heterogeneous foam materials
EP1205501A1 (en) * 2000-11-09 2002-05-15 Huntsman International Llc Process for preparing rigid polyurethane or urethane-modified polyisocyanurate foam and foam thus obtained
US8557884B2 (en) 2002-05-31 2013-10-15 Owens Corning Intellectual Capital, Llc To enhance the thermal insulation of polymeric foam by reducing cell anisotropic ratio and the method for production thereof
WO2006053029A1 (en) * 2004-11-12 2006-05-18 Dow Global Technologies, Inc. Impact-absorbing members for dynamic impact applications
DE102009040203A1 (en) * 2009-09-07 2011-03-10 Puren Gmbh Molded foam element with at least two distinguishable geometry structures
EP2589477B1 (en) * 2011-11-03 2016-03-09 Kamal Mostafa Plastic foam sheet and method for processing of flat plastic foam sheets
DE102011119607A1 (en) 2011-11-29 2013-05-29 Kamal Mostafa Method for processing of planar plastic foam board, involves performing irreversible and reversible compressions of plastic foam board are performed such that compressed thickness of plastic foam board is less than initial thickness
FI20125394L (en) 2012-04-11 2013-10-12 Finnfoam Oy Method and system for producing an expanded polymer insulation block and a polymer insulation block
EP3283560B1 (en) 2015-04-15 2019-11-13 Dow Global Technologies LLC Thermally insulating foam with vertically elongated cells

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2447802A1 (en) * 1979-01-30 1980-08-29 Roth Sa Freres PROCESS FOR MANUFACTURING A SOUND ABSORBING MATERIAL AND MATERIAL THUS OBTAINED
JPS6056096B2 (en) * 1981-04-15 1985-12-09 旭ダウ株式会社 Styrenic resin foam
US4552904A (en) * 1982-01-25 1985-11-12 The Dow Chemical Company Rigid thermoplastic resin foam and process for preparation thereof

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100467523C (en) * 2002-05-31 2009-03-11 欧文斯科宁知识产权资产有限公司 Anisotropic polymer foam

Also Published As

Publication number Publication date
JPH068348A (en) 1994-01-18
EP0561216B1 (en) 1996-01-03
CA2091952A1 (en) 1993-09-20
EP0561216A1 (en) 1993-09-22
DE59301280D1 (en) 1996-02-15
ES2081149T3 (en) 1996-02-16
DE4208759A1 (en) 1993-09-23
EP0561216B2 (en) 1999-01-13
ES2081149T5 (en) 1999-04-01

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