CH709259A2 - Insulation boards for interior and exterior insulation of buildings, the process for their preparation, their use and thus insulated building. - Google Patents

Abstract

The insulation board is used to insulate building envelopes. It is made on the basis of expanded perlite, a homogeneous mixture which then hardens. Specifically, it consists of a whipped homogenous mixture having a composition of at least 40% by volume of glazed, surface-closed, air-filled spheres of expanded silica sands having a density of only 60 to 150 grams / liter, so as a result the closed-cell, uncut Perlite no measures for a hydrophobization are necessary. The residual volume consists of a mineral binder, which was made with the addition of a foaming agent, so that 20 to 40% of the volume of the finished insulating board due to the foaming of the foaming agent consists of trapped air, and 10 to 20% of the volume of the mineral binder, which Contains foaming agent. These insulation boards are used to create wall structures inside or outside of buildings by the insulation boards (8) are applied to a cleaned, rendered clean with a plaster and then provided with adhesive mortar inner or outer wall of a building. If necessary, they can be mechanically fixed to the building wall, and then a flush (9) can be applied with reinforcing mesh grating (10) based on glass and finally applied a top coat, which is optionally provided with a paint.

Description

This invention relates to special building panels for installation as internal and external insulation of buildings. On the other hand, the invention relates to the method for producing these insulation boards, then their use and finally a building, are insulated on the outer or inner walls so.

Although old buildings are often beautiful - sometimes actual monuments - but they usually have a poorly insulating building shell and are generally difficult to subsequently isolate. The development of efficient insulation systems, such as a well insulating insulating plaster or well insulating insulation boards is therefore a challenge. Today, there are insulating plasters and insulation boards based on airgel, which are twice as good at insulating as usual insulating plaster types. The reference value for the insulation is the heat transfer and this is expressed as lambda value (γ). Airgel insulation plasters have a lambda value of 30 mW / mK, as a pure laboratory value, and insulation boards made of airgel nonwoven one of 12 to 15 mW / mK. These airgel insulation boards are therefore much more efficient. In addition, the airgel insulating plaster, when pumped, partially loses its effect because the airgel is mechanically stressed by the pump.

In Switzerland, as an example, there are about 1.5 million old buildings. With this building substance must be lived, yes one wants to receive it consciously often. But at the same time the energy consumption of the country is increasing. 4.5 million tonnes of light heating oil and 3 million cubic meters of natural gas are imported annually, according to the Swiss Federal Office of Energy. 43 percent of them are burned for heating buildings. In order to be more economical with these energy sources, there is no way around a better isolation of these old houses around.

How to insulate a historic building - be it a barn house, a house from the Art Deco era, or an old town house? Homeland Security does not allow you to simply pack historical façades with modern insulation boards.

To get the look of an old house wall, a plaster is best. The lining of winding staircases, round arches and retaining walls with conventional thick insulation boards is sometimes costly. A cladding made of insulating plaster can be decidedly easier to install, especially on winding areas. In addition, the plaster rests directly on the masonry and leaves no gaps where moisture can condense. In practice, therefore, often resorting to combinations of insulation boards and insulation finishes. Large, flat surfaces are covered with insulation boards, however, angular areas of the building are provided with insulating plaster.

One of the best, if not the very best, insulating material that can be produced industrially is airgel. The material, also known as "frozen smoke" because of its appearance, consists of about 5 percent silicate - the rest is air. Airgel was used to isolate space suits as early as the 1960s and brought it to 15 entries in the Guinness Book of Records, including those for "Best Isolator" and "Lightest Solid". Airgel is already being used in the construction sector, for example as an inflatable insulating material for interstices between walls or in the form of fiber fleece insulation boards. In fact, airgel pellets are extremely light, almost weightless and they can be held between thumb and forefinger. But once you rub your fingers, they crumble. After two or three movements only a fine powder is left. If the powder is gently mixed with water and the plaster thus applied will be applied by hand, good results can be achieved, but if the plaster is pumped through the hose of a professional cleaning machine at a pressure of 5 to 20 bar, the mechanical destroys Stress the airgel and its insulating effect. Airgel should therefore be integrated into the plaster in such a way that its effect is maintained even when mechanically pumping the Dämmputzes. Laboratory samples of this airgel plaster developed by the Federal Materials Testing Institute EMPA in CH-Dübendorf gave a thermal conductivity γ of 30 mW / (mK). Thus, this airgel insulating plaster would be more than twice as good insulating as a conventional insulating plaster and comparable or even better insulating than a sheet of extruded polystyrene (EPS). The conventional insulation plasters have lambda values between 65 and 90 mW / (mK), the worst only a γ value of 110 or 130 mW / (mK). For practical application, the airgel insulating plaster is sprayed onto the masonry with a plastering machine and then smoothed. This soft insulating plaster must then be protected in a further operation with a fabric-embossed investment mortar. However, it has been shown that an airgel applied as a pumped plaster, lets through significantly more heat, especially when the pumping section is long. Due to the mechanical stress of the airgel in the pump its effect collapses and the lambda value increases. With a 30-meter-long pumping line, the heat transfer and thus the lambda value increase from 30 to 40 to 45 mW / mK.

Thermal insulation panels on the other hand suffer by their assembly no deterioration of their γ value. An airgel plate has a γ value of 15 to 20 mW / mK, which is better than an extruded polystyrene plate (EPS plate) with its γ value of 33 mW / mK. Although thermal insulation boards can not be used everywhere, they are ideal in many situations because they offer a low γ value. Airgel panels or airgel insulation plasters are generally very expensive. If it were possible to use a thermal insulation board with comparable γ values at much lower prices, it would be highly interesting for many applications. A thin and lightweight insulation board can always be installed quickly and easily and it can be cut to any size.

The object of this invention is therefore to provide such an insulating board and to provide the method for their preparation, namely for an insulating board that is as light as possible, offers a lower γ value than conventional insulating mats, and which such stability and Durability has proven that it is suitable for building on interior and exterior walls of buildings.

In addition, the insulation board should be inexpensive to manufacture, so that it is also economically competitive compared to the established insulation method such as applying insulation plaster or growing conventional insulation boards, such as extruded polystyrene and other insulating material, can be used. So it is a further object of the invention to provide a method by which such insulation boards can be produced.

Finally, it is an object of the invention to provide the use of such insulation boards to achieve a better thermal insulation of building envelopes and also to create a building, which includes created with such insulation panels wall structures.

This object is achieved by an insulating panel for insulating building envelopes based on expanded perlite, which is characterized in that it consists of a cured homogeneous mixture, with a composition of at least 40% of the volume of glazed, on its surface closed-cell, air-filled balls of expanded silica sands, which have a density of 60 to 150 grams / liter, so that no measures for hydrophobization are necessary due to the closed-cell, unraised Perlite, and the remaining volume consists of a mineral binder, which with addition of a foaming agent, so that 20 to 40% of the volume of the finished insulating board due to the foaming of the foaming agent consist of trapped air, and 10 to 20% of the volume of the mineral binder containing the foaming agent.

The method for producing such insulation boards is characterized by the steps according to claim 9.

The use of the insulation boards produced takes place for the thermal insulation of building envelopes by these insulation boards are applied to a cleaned, leveled with a plaster and then provided with adhesive mortar inner or outer wall of a building, if necessary mechanically fixed to the building wall and afterwards Flush-mounted with a reinforcing mesh grid on glass base is applied and finally a top coat is applied, which is optionally provided with a paint. And a building is characterized in that it has inside or outside at least one wall structure which contains insulation boards according to one of claims 1 to 8, which are produced by one of the methods according to claim 9 to 11.

Based on the drawings, the insulation board and its structure is described in detail as well as their installation on building walls explained.

It shows:

[0015] <Tb> FIG. 1 <SEP> An insulating board of the homogenous mixture of air-filled spheres of expanded silica sand, mineral binder and a foaming agent; <Tb> FIG. 2 <SEP> The construction of a version of the insulating board as a laminate, in a cross section; <Tb> FIG. 3 <SEP> The construction of a sandwich insulation board in a cross section; <Tb> FIG. 4 <SEP> The structure of an insulating board in which a flat side and a narrow side are edged by a reinforcing reinforcing layer or an additional insulating layer; <Tb> FIG. 5 <SEP> The structure of an insulating board having a plurality of plate-like cores connected by dowels, and in which a flat side and all narrow sides are edged by a reinforcing reinforcing layer; <Tb> FIG. 6 <SEP> The first step for insulating a plastered old building wall - removing the old plaster and cleaning; <Tb> FIG. 7 <SEP> The second step for insulating a plastered old building wall - leveling the wall with a plaster; <Tb> FIG. 8 <SEP> The third step for insulating a plastered old building wall - applying an adhesive mortar spread and applying the insulation board to the still-moist adhesive mortar and fix it if necessary; <Tb> FIG. 9 <SEP> The fourth step for insulating a plastered old building wall - applying a flush with integrated reinforcing mesh; <Tb> FIG. 10 <SEP> The fifth step - applying a fine plaster and, if necessary, applying a paint coat.

Raw perlite is a chemically and physically converted volcanic rock (obsidine) with a white, powdery appearance. The crude pearlite contains up to 2% water and has a density of 900-1600 kg / m 3. According to a process with multi-stage annealing to temperatures of about 800 ° C to 1400 ° C perlite inflates to 10-15 times the volume. The density of the inflated product is then only 60-150 kg / m <3>, so has a very exceptionally light weight. The bloating of perlite has been known for years. However, the previous Blähmethode leads to open-cell, torn Perliten. For the present insulation boards, however, a novel perlite, consisting of glazed balls with closed cavities, is used. The process for producing this novel perlite is multi-stage and is described in detail in WO 2013 6/053 635 A1. The perlite sand is first sorted by means of a grading curve into different grain sizes. Each individual grain size is then inflated in a trickle canal with multistage temperature zones of increasing temperatures and thus glazed the surface of the balls. Typical grain sizes produced in this way are: • 0.1 mm to 0.5 mm • 0.5 mm to 0.8 mm • 0.8 mm to 1.0 mm • 1.0mm to 2.0mm So far, perlites have been bloated with traditional ovens. As a consequence of the uncontrolled effect of temperature, the perlites, which have a low bulk density of less than 300 grams / liter in the swelling product, are broken. Basically, insulation boards with a low bulk density have a higher porosity and accordingly always a better insulating effect. Accordingly, open-celled perlites, which naturally have a high water absorption capacity and are correspondingly less suitable for insulating materials, are produced in traditional ovens. If, for example, in the prior art an expanded product with a bulk density of less than 300 grams / liter is used as the insulating material in boards, plasters or fillers, additional measures are required for hydrophobicizing or coating the surface with bitumen. However, these hydrophobing measures make such insulation boards economically less interesting. The method according to WO 2013/053 635 makes it possible to produce closed-cell perlite having a low bulk density of less than about 60 to 150 grams / liter. Basically, the insulating effect is increased when as much air is introduced into the plate. It has been found that the proportion of air in the insulating board can be increased by deliberately introducing a foaming agent when the mineral binder is mixed or mixed. Now, the glazed, closed at their surface, filled with air balls of expanded silica sand with a mineral binder, which is mixed with a foaming agent and was mixed with water, homogeneously mixed and cured in a mold. By foaming it is achieved that the entire plate-like core 1, that is, this homogeneous insulation board in its volume consists of about 30% air and 10% to 20% by weight of mineral binder. This perlite insulation board is stiff and has surprisingly good stability, so that a special reinforcement layer or additional specific insulation layer is not necessary for most applications. Optionally, an airgel powder can optionally be added homogeneously, or in the context of a layer structure, a layer of airgel nonwoven fabric can be inserted into the layer structure of the insulation board.

If particularly rigid insulation boards with increased stability are required, such insulation board may be optionally equipped with additional stabilizing layers in the form of a lattice structure as reinforcing reinforcing layer. Such a reinforcing layer can be applied to one of the flat sides of the insulating board, or on both flat sides. As an intermediate layer into the interior of the insulation board, for example, an airgel nonwoven layer can be installed as an additional insulation layer, so that it has a laminate layer structure. In addition, anchoring systems can be installed as an option, as, for example, anchors extend approximately through the layer structure of the insulating board running transversely to the layers.

These novel, glazed balls have in contrast to broken perlite very low water absorption ability. One based on these balls, mixed with a mineral binder mixed with a foaming agent, creates a stable insulation board that is vapor permeable, which is important for the interior climate of a building. In order to improve open-cell perlites in terms of water absorbency, they have hitherto been coated, for example with bitumen. Another variant is to impregnate open-celled perlites with paraffin, silane or siloxane or to improve them with silicone and to use them for fillings. With the novel method mentioned above, however, no finishing measures and no impregnation are necessary for surface-glazed perlites since the product does not absorb water.

In Fig. 2, the insulation board is provided with a reinforcing layer or airgel-nonwoven layer and shown in cross section. It is used to insulate building envelopes, which of course also goes with bare insulation boards without special reinforcing layer. As a special feature, however, the insulation board shown here has a laminate structure of at least two layers, namely a plate-like core 1 of glazed and thus closed at its surface, filled with air balls, which are formed by expanding silica sand or by puffing of perlite and made with a mineral binder with the addition of a foaming agent to a homogeneous mixture, which then cured. The expanded spheres of different diameters have a specific gravity of only about 60-150 kg / m <3>. So they are extremely light and enormously heat-insulating, with a γ-value of 35 to 45mW / mK, and thus comparable to that of a much more expensive EPS insulation board. Overall, however, the plate thus obtained always remains air or vapor permeable. At least one of the flat sides of the plate-like core 1 is equipped in the example shown with a lattice structure 2 as reinforcing reinforcing layer, or equipped with airgel-fleece layer. This lattice structure 2 can already be connected in the manufacturing process of the gluing by means of a mineral adhesive mixture, for example based on water glass, or lime and / or lime and cement base or by glazing with the resulting core by placing it in the bottom of the box-shaped mold in which the core is solidified, so that it then adheres to this core and reinforces it. This grid structure may be tissue, a scrim, a net-like grid structure or a nonwoven. The material for this reinforcing layer may be, for example, cellulose or glass, or it may be natural or synthetic fibers.

Fig. 3 shows an insulating board, which shows an effective sandwich construction, of three layers, wherein the middle, "clamped" layer is the plate-shaped core 1, which consists of the said inflated beads of pearlite, mixed with mineral binder and foaming agent. The reinforcing layers or airgel nonwoven layers 2 on the two opposite flat sides of this insulation board can be constructed of different materials and structures or even identical. It is understood that even insulation boards with alternately several reinforcing or airgel nonwoven layers 2 and multiple cores 1 can be built. The total thickness of the simplest, two-layer insulation boards measures approx. 10-40mm.

Fig. 4 shows a variant of the insulating board, in which a flat side and all narrow sides are bordered by a reinforcing reinforcing layer 2. This reinforcing layer 2 may for example consist of cellulose glass. Other possibilities provide reinforcing layers 2 of natural fibers or synthetic fibers. Advantageously, such reinforcing layers 2 are mechanically fastened as scrim, knit or nonwoven on the plate-like core or they are laminated on him. Another variant is that the reinforcing layer 2 is incorporated in a lime mortar or cement mortar, which adheres to the reinforced sides of the plate-like core 1.

Fig. 5 shows the structure of an insulating board with a plurality of plate-like cores 1, which are connected by dowels 12, and in which a flat side and all narrow sides are bordered by a reinforcing reinforcing layer 2. The individual plate-like cores 1 may consist of different materials, and they are provided at least on a flat side with a laminated nonwoven fabric 13. The insulating panel shown in Fig. 5 is constructed as follows: First, a box is made of a material which later acts as a reinforcing layer comprising the panel. Then, first, a plate-like core 1 is filled as a homogeneous insulation board, which consists in its volume to about 30% of air and 10% to 20% by weight of mineral binder in the box. Next, a web 13 is placed on this insulation board in the box, and then dowels 12 are inserted through the web 13 in this insulation board, because otherwise no mechanical connection. Then, a second plate-like core 1 is inserted from said homogeneous, cured mixture on this dowel 13 and pressed in the box. Finally, it can be sealed at the top with another reinforcing layer 15. For this purpose, a reinforcing layer 15 made of a lime mortar or a cementitious mortar is suitable.

From Fig. 6 will now be shown how such an insulating board for the insulation of an inner wall 3 is used. The same applies to an outer wall. First, the old plaster 4 of an inner wall 3 is removed from the same, and the substrate 5 is cleaned and dried so that a dust-free surface is present. Then, as shown in Fig. 7, the exposed masonry is leveled with a plaster 6, so that a perfectly flat surface is prepared for the next step and laying the insulation boards. In a next step, as shown in Fig. 8, an adhesive mortar 7 is applied to this plaster base 6. This adhesive mortar 7 may be a lime mortar or a cementitious mortar or cementitious lime mortar. He is just profiled to create a perfectly flat surface for the snug receiving the insulation panels 8. Next, the laying of the insulating panels 8 follows as shown. Ideally, the insulation boards 8 measure approx. 40cm x 60cm, making them easy to handle and transport. They are simply pressed onto the still soft adhesive mortar 7 on the wall and then adhere to the same, because they are so unusually light. It is advantageous started down in a corner, and the insulation panels 8 can then be piled up against the wall piled up. It is ensured that no cavities are formed behind the plates 8 by the pad is prepared as even as possible. If particularly thick or multi-layer insulation panels 8 of, for example, 30 mm thickness or more are used, they can be anchored with additional fastening systems in a known manner in the support base, as has long been practiced for conventional polystyrene insulation panels.

As a next step, as shown in Fig. 9, first flush 9 applied to the lime or cement base on the insulation boards 8, and in these a reinforcing fabric 10 is incorporated on a glass base with alkali-resistant coating. After curing of this flush 9 with the support fabric 10 in the interior, as shown in Fig. 10, a top coat 11 is applied. This can be used afterwards as desired, as a support for wallpapering, or be provided with a structure for the desired room ambience, or even receive an open-pored paint with preferably a silicate color. In any case, the whole structure remains vapor-permeable on the wall. It is thus an exceptionally good thermal insulation produced with excellent γ value.

The primary task of a Dämmputzes is the heat insulation. A traditional thermal insulation plaster based on pearlite or styrofoam has a lambda value of approx. 70-120 mW / mK. However, the thermal insulation board with the presented glazed expanded perlite core has a γ value of almost 35-45 mW / mK. Traditional thermal insulation plasters are usually applied in practice in layer thicknesses of 30 mm to 80 mm as internal or external plasters. In the new system, the overall layer thickness of the wall structure is significantly reduced by means of the laminate or sandwich-type insulation board 8. Add to this the enormous advantage of the super light weight of these insulation boards, which makes their handling and installation a real pleasure. A drying time of about 30 days - as required for conventional wall constructions with insulating plaster of 30 mm thickness - does not have to wait.

Claims (13)

Insulating board for insulating building envelopes based on puffed perlite, characterized in that it consists of a prepared homogenous mixture having a composition of at least 40% of the volume of glazed, surface-closed, air-filled balls of expanded silica sand , which have a density of 60 to 150 grams / liter, so that no measures for a hydrophobization are necessary due to the closed-cell, unraised Perlite, and the remaining volume consists of a mineral binder, which was made with the addition of a foaming agent, so that 20 to 40 % of the volume of the finished insulating board due to the foaming of the foaming agent consist of trapped air, and 10 to 20% of the volume of the mineral binder containing the foaming agent. 2. Insulating board claim 1, characterized in that the mineral binder of lime and / or cement with a foaming agent, stirred with water. 3. Insulating board according to claim 1, characterized in that the mineral binder is a water glass, mixed with a foaming agent and stirred with water. 4. Insulating board according to one of the preceding claims, characterized in that the glazed, closed at its surface, filled with air balls of expanded silica sand up to 10% of its volume fraction airgel are admixed in powder form. 5. insulation board for insulating building envelopes according to one of the preceding claims, characterized in that at least one flat side of the plate-like core (1) with a lattice structure as reinforcing reinforcement layer (2) made of cellulose glass, natural fibers or synthetic fibers or a combination This fabric is equipped, and this mechanically fastened or laminated on as a scrim, knit or nonwoven, or mechanically fastened or laminated on an airgel nonwoven fabric as an insulating layer. 6. Insulating board for insulating building envelopes according to one of the preceding claims, characterized in that it has a layer structure, and each an insulating intermediate layer of airgel-fiber fleece between the superimposed Dämmplattenschichten is laminated, the individual layers are pressed together and secured with them passing dowels , 7. insulation board for insulating building envelopes according to one of the preceding claims, characterized in that at least one layer of the insulating board of a brown light filler (14) made of phenol resin with low water absorption - known as aeroball - whose microballoons have a viscosity of the resin of flowable ( at 10% by weight addition) to pasty (at 30% by weight addition) has. 8. insulation board for insulating building envelopes according to one of claims 5 to 7, characterized in that all its sides are enclosed by a reinforcing layer (2). 9. A method for producing an insulating panel according to any one of claims 1 to 8, characterized in that glazed, closed at its surface, air-filled balls of expanded silica sands having a density of 60 to 150 grams / liter, so as a result of the closed-cell , undetached perlite no measures for a hydrophobing are necessary mixed with a mineral binder, which was made with the addition of a foaming agent, so that after curing of the binder 20 to 40% of the volume of the finished insulation board due to the foaming of the foaming agent consists of trapped air, and 10 to 20% of the volume of the mineral binder containing the foaming agent. 10. The method according to claim 9 for producing an insulating board according to one of claims 1 to 8, characterized in that after curing of the mineral binder at least one flat side of the plate-like core (1) with a lattice structure as reinforcing reinforcing layer (2) made of cellulose glass, from natural fibers or synthetic fibers or a combination of these substances as a scrim, knit or non-woven mechanically attached to the insulation board or laminated on it. 11. The method according to any one of claims 9 to 10 for producing an insulating board according to one of claims 1 to 8, characterized in that blown perlite is used in the form of glazed balls with different diameters, namely in the following composition, by weight: 30-60% with diameter 0.1 mm to 0.5 mm, 20-50% with diameter 0.5 mm to 0.8 mm, 10-30% with diameter 0.8 mm to 1.0 mm, 0 to 10% with diameter 1.0mm to 2.0mm. 12. Use of insulation boards according to one of claims 1 to 8 and produced by one of the methods according to claim 9 to 11, for creating wall structures inside or outside of buildings by the insulation boards (8) on a cleaned, with a plaster (6). Equipped and afterwards with adhesive mortar (7) provided inside or outside wall (3) of a building are applied, if necessary mechanically fixed to the building wall (3) and then a flush (9) with reinforcing mesh grating (10) is applied to glass base and Finally, a top coat (11) is applied, which is optionally provided with a paint. 13. Building, characterized in that it has inside or outside at least one wall structure, which insulation boards (8) according to one of claims 1 to 8, prepared according to one of the methods of claim 9 to 11.