CZ299916B6 - Product from coated mineral wool and process for producing thereof - Google Patents

Abstract

The present invention relates to a coated mineral wool product such as acoustically transparent ceiling panels or facade insulation boards having on at least one side a coating (2) based on siliceous material containing organic plastic. A fiber mat (3) is provided between the coating (2) and the surface of the mineral wool product (1). There is also disclosed a process for manufacturing a mineral wool product (1) being characterized in that a foamed coating (2) based on siliceous material is applied to a fiber mat (3) wherein foam blisters of the applied coating (2) are caused to burst by drying.

Description

Technical field

The present invention relates to a coated mineral wool product, such as an acoustically iranarpine-based mandrel, and an insulating board according to the preamble of claim 1, to the manufacture of such an insulating board. The mineral wool product of claim 8.

The present state of these niches io

Mainly in acoustics and architectural acoustics, sound absorbing wall and ceiling structures are used for two purposes. On the one hand, it reduces the sound level in the room in order to suppress noise in workplaces and living areas, and on the other hand, improves the acoustic conditions by correcting the echo interval. A sound absorber effective for both applications must have a sufficiently high flow resistance to obtain high friction losses, while having a porous structure to allow better sound wave penetration. For the absorption of sound, for example, mineral absorbent sound absorbing fillers have been used in the prior art. Sound attenuation (sound absorption) essentially refers to the conversion of sound energy into heat. Mineral wool, which is a porous, open cell material, is particularly suitable for sound absorption purposes. In principle, energy conversion occurs as a result of friction processes within the absorbent material.

Open mineral wool products such as mineral wool boards are not suitable for acoustic insulation of interiors, for aesthetic reasons.

Therefore, mineral wool insulating boards provided with at least one side of a resin-bonded glass fiber mat having a weight per unit area of between 20 and 150 g / m 2 were used to absorb sound in a visible plain. for aesthetic reasons, the glass fibers were provided with various decorative coatings.

In addition to acoustic and aesthetic properties, sound absorbing or acoustic transparent materials are generally expected to be non-flammable within the meaning of German standard DIN 4102 part 1 for building materials of class Λ.

In order to meet the requirements of Class A building materials, prior art has been sought

5? a low binder content in the fibrous material used as liner for the insulating boards, so that they are relatively brittle and achieve only a low impact strength. This prior art had to be compensated for by the increased density of the mineral wool body. resulting in higher energy costs and starting materials.

However, in relation to sound insulation, the basis weight and sound absorption are diametrically opposed to one another:

High basis weight values result in better impact penetration toughness, while lower basis weight values result in better sound absorption characteristics.

To produce the above-mentioned insulation boards laminated with fiber mats, the glass fiber mats were applied to the uncured mineral wool mat with the aid of a suitable adhesive and rolled in a tunnel furnace. After curing, mechanical shaping into formats of the appropriate size was carried out by means of a forming machine and finally by packaging. However, a considerable amount of fibrous material is released as a result of this post-treatment, resulting in contamination of the surface which is associated with the need for cleaning.

As a result, some fill waste is caused by soiling and deformation of the fiber mat surface inside the tunnel furnace.

- 1 GB 299916 B6

Although the sound absorbing mineral wool insulating boards thus produced already provided good sound absorbing properties, handling at the construction site was due to the low impact penetration toughness of the glass wool mat. often associated with damage and subsequent replacement of mineral wool products.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide coated mineral wool products having a higher impact penetration toughness at a lower cost, which are suitable, for example, for both acoustically transparent ceiling panels and facade insulating panels that are subjected to higher mechanical stress than ceiling panels. panels.

This object is achieved by the characteristic features of claim 1.

With regard to manufacturing technology, this object is solved by the features of claim 8.

Surprisingly, it has been found that when a mineral wool product laminated with a fiber mat according to the invention is coated on at least one side with a silica-based coating containing organic plastic, it acquires a membrane-type property, i.e., relieves pressure and its original shape, thereby greatly enhancing its impact penetration toughness,

By combining the membrane-type property and the increased impact penetration toughness, the mineral wool surface of the present invention becomes considerably more resistant to any possible accidental destruction that may occur at the construction site.

Another advantage of the mineral wool product according to the invention is. coatings can be provided with color pigment admixtures as needed to meet interior design requirements.

The mineral wool products of the invention provide a high degree of sound absorption compared to conventional coated mineral wool products.

The process according to the invention provides products having an impeccable, clean surface, especially given the fact that the coating composition is applied only after the so-called tunnel furnace, i.e. when the body / mineral wool is already in the cured state. In addition, it is essential that the coating composition is applied to the glass fiber mat in the form of a foam. so that the coating composition can be put into the fiber mat and the adjacent body surface, so to speak. This can be realized, for example, by means of an elastic roller 40, whereby the tight connection between the fiber mat surfaces and the underlying mineral wool is achieved by a capillary effect. In principle, however, the coating may also be carried out by immersion, spraying, glazing or gravel. As long as the surface is wet, it remains closed. The real acoustic transparent open-pored surface is only obtained by subsequent drying of the surface of the foam-coated body in an oven, for example under intense infrared heating. As a result of this drying, the macroscopic air bubbles burst before the coating composition cures, releasing the pores of the mat. Due to the adhesion forces, both the mat fibers and the mineral wool fibers are coated with a coating composition which is confirmed on them.

The assembly of fiberglass mat with mineral wool varnish allows for optimum spatial

5 the force distribution in the event of an impact stress, which is further supported by the elasticizing components in the mixture.

The coating composition according to the invention has the following compositions:

% to 40 wt. silica sol (40 wt.% solid SiCK), up to 25 wt. a plastic dispersion; i.

% to 5 wt. 0.5 to 2 wt. 0.05 to 1% by weight residue or aluminum hydroxide foaming agent.

foam stabilizer.

water, and a non-flammable treatment agent and / or other additives.

Although a similar coating composition is known from EP 728 124 Bi. on the one hand, it contains a maximum of 10 wt. the plastic dispersion, while according to the invention the plastic dispersion is present in an amount of at least 10% by weight, and on the other hand the coating is used here solely for the purpose of mechanically stabilizing the respective mineral wool products.

The prior art according to EP 728 124-1 particularly emphasizes the importance of preventing the penetration of bitumen through the coating material into the roof insulating boards formed therefrom, or, when used as so-called base plaster fillers, ensuring their affinity for the plaster mixture.

The coating composition of EP 728 124 B1 is pressed deep into the mineral wool surface, forming web-type web bridges of coating material between the fibers.

In contrast to the prior art of EP 728 124 B1, the coating composition according to the invention is applied to a mineral wool product laminated with a fiber mat, as a rule a mineral wool board; resulting in the surprising properties of the mineral wool product according to the invention.

An embodiment with a preferred coating composition is claim 2, wherein the organic matter content is irrelevant from the point of view of flammability.

The use of the mineral wool products with the lamination of glass wool mats according to claim 3 has the advantage that it is possible to use a cheap standard fiber mat which does not have to be separately manufactured for the mineral wool product.

(I) The mineral wool product according to claim 4 has the advantage that if the layer or coating is made electrically and / or magnetically effective, the mineral wool product can be used, for example, as a microwave absorber, or more generally in the case of so-called electrosmog.

Preferred coating materials for the purpose of absorbing radar radiation are captured in claim 5,

The mineral wool products may be coated preferably comprising further, according to claim

6. foam coating agents, in particular expanded graphite, pentaerythritol or the like, which cause thermal insulation properties in the event of fire.

Advantageous basis weight values of the mat are set forth in claim 7.

For the purposes of the present invention, the foam coating composition is preferably applied in an amount of 100 to 500 g / m 2. preferably about 300 g / m 2 according to claim 9.

In the production of the foam coating composition, a foam density of 100 to 400 g / l is preferably used. preferably about 250 g / L according to claim 10.

The mineral wool product coating of the invention is preferably dried in an oven at a temperature of about 260 ° C. At this temperature, macroscopic air bubbles inside the coating have been found to burst before curing the coating composition, resulting in an open pore assembly. through which sound waves can penetrate inside the mineral wool product and be absorbed therein. At the same time, the coating takes on the character of a membrane type coating. so it has mechanical strength.

Overview of the drawings

Further advantages and features of the present invention will become apparent from the description of the exemplary embodiment and the drawings in which FIG. 1 is a cross-sectional view of a mineral wool product according to the invention, and FIG. at the indentation depth.

DETAILED DESCRIPTION OF THE INVENTION

The mineral wool product 1 shown in section in FIG. 1 has a coating 2 of a suitable fiberglass mat 3 closely connected to the surface of the mineral wool body 4.

In the case of this example, the glass fiber mat is applied to the body 4 during curing inside the tunnel furnace, namely by means of an organic binder which gives the shape of the body. The glass mat 3 adhered to the mineral wool body 4 has a basis weight of approximately 60 g / nf.

is for the production of mineral wool product 1. such as ceiling insulation boards, the following composition was used:

44.7 wt.% 20 wt.

% wt.

% wt.

2.1 wt. 0.3 wt. silica sol sol (40 wt% solid SiO 2). plastic dispersion based on Bayceram weave semi- ^polyurethane , aluminum hydroxide, colorant, foaming agent, foam stabilizer.

water.

The plastic dispersion used in this embodiment was the BAYER re-dispersion after Ivester-Polymer. AG. with a water content of 50%, under the trade name Bayceram ^iKl . However, any plastic dispersion which is both water and light resistant and, in particular, provides good elasticity can be used. It is also possible to use, for example, latex dispersions.

W 53 from Zschimmer & Schwarz was used as a foaming agent, and PSI foam stabilizer, also from Zschimmer & Schwarz, was used as an example.

The coating mixture was foamed with a mixer to approximately 6 times the non-foaming volume. The bulk density of the foam was approximately 250 g / l. The foamed coating composition was applied to the surface of the fiber mat 3 by means of an elastic roller. By means of absorbent foam into the surface which was obtained by means of an elastic roller and the capillary action of the underlying mineral wool, a tight fusion was achieved while the surface was still closed.

The coated blank was exemplary dried in an oven under vigorous infrared heating at approximately 260 ° C. In this drying process, the macroscopic air bubbles burst before the coating composition has cured and form open pores 5 in the coating 2, which at least partially communicate with the pores 6 of the glass fiber mat 3 and thus with the mineral wool body 4.

As a result of this open pore coating 2, sound waves can freely penetrate into the mineral wool body 4 where they are absorbed. On the other hand, for example, when used as a ceiling panel, the open pores are virtually invisible and the viewer has the impression of a smooth, closed surface. By means of adhesive forces, both the mat fibers and the mineral fibers are coated with a coating composition which cures on the fibers.

The ceiling insulating boards 1 produced in this way have on the coated side a membrane-like behavior, given by the elastic-elastic properties of the coating assembly 2, the glass fiber mat 3 and the mineral wool body 4.

-4GB 299916 B6

The ceiling panels 1 thus produced further have a high degree of sound absorption and have an attractive surface with a considerably increased impact penetration toughness compared to conventional mineral wool products lined with fiber mats.

In Fig. 2, which shows the impact penetration strength plotted against the indentation depth, it is clear that the impact penetration toughness of the mineral wine product of the invention is approximately three times that of non-foamed glass fiber mats.

The mineral wool products 1 according to the invention are excellent for insertion into a ceiling structure of a suspended ceiling. Further, due to their high impact penetration toughness, they are well suited for use as facade insulation boards to allow their specific gravity to be reduced.

Claims (12)

PATENT CLAIMS 1. A mineral wool product, such as a ceiling or facade insulating sheet, having at least one side of a silica-based coating (2) containing at least one organic plastic, characterized in that between said coating (2) and the surface of said The mineral wool product (1) is provided with a fiber mat (3). The mineral wool product according to claim 1, characterized in that. that it is formed by applying a foam coating composition to a mineral wool product (I) laminated with a fiber mat (3) and then drying, the coating composition having the following composition: 20 to 40% by weight. 10 to 25 wt. 1 to 5 wt. 0.5 to 2 wt. 0.05 to 1 wt.% Residue or silica sol, 40 wt. solid Si ()>. plastic dispersion, aluminum hydroxide; foaming agent, foam stabilizer. water, and a flammable treatment agent and / or other additives. The mineral wool product according to claim 1 or 2, characterized by. wherein said fiber mat (3) is a glass wool mat. The mineral wool product according to any one of claims 1 to 3, characterized in that said coating (2) is electrically and / or magnetically effective. Product / mineral wool according to claim 4, characterized in that. The coating (2) further comprises electrically conductive and / or magnetically attenuating substances such as carbon, in particular pulverized carbon, carbon fibers, graphite, in particular expanded graphite, mu-metal. 45 carbon monoxide, metal whisker, iron carbonyl. The mineral wool product according to any one of claims 1 to 5, characterized in that said coating (2) additionally comprises foam-forming agents. in particular expanded graphite or pentaerythritol. A mineral wool product according to any one of claims 1 to 6, characterized in that. wherein the basis weight of said fiber mat (3) is 20 to 150 g / nr. preferably 40 to 80 g / m ² , preferably about 60 g / m 2. - with CZ 299916 Bo Method for producing a product (1) / mineral wool according to any one of claims 1 to 7, characterized by. 2. The method according to claim 1, wherein a siliceous binder-based foam coating (2) is applied to the fiber mat (3) by which the mineral wool product is laminated, the bubbles of which are allowed to burst upon drying. A method according to claim 8, characterized in that. wherein the sc foam coating composition is applied in an amount of 100 to 500 g / m < 3 >, preferably about 300 g / m < 3 >. The method according to claim 8 or 9, characterized in that the bulk density of the foam α is 100 to 400 g / l, preferably about 250 g / l. Method according to any one of claims 8 to 10, characterized in that said coating (2) is dried in a tunnel dryer at a temperature of approximately 260 ° C. Method according to one of Claims 8 to 11, characterized in. that the coating composition has the following composition: 20 to 40% Ίιπκ> Ιη. 10 to 25% by weight, 1 to 5 wt. 0.5 to 2 wt. 0.05 to 1 wt. % residue or silica sol, 40 wt. solid Si (1) _; , plastic dispersion. aluminum hydroxide. foaming agent. a foam stabilizer, water, and a flame retardant and / or other additives.