DE102010028914A1 - Sprayable and trowelable mass for filling cavities, comprises foam particles, aqueous polymer dispersion related to solid, foaming agent, thickener, filler, flame protective agent, water, and super absorber - Google Patents

Abstract

The sprayable and trowelable mass comprises foam particles, 20-50 weight portions of aqueous polymer dispersion related to solid, 0.1-3 weight portions of foaming agent, 0.1-3 weight portions of thickener, 1-50 weight portions of filler, 5-10 weight portions of flame protective agent, 10-300 weight portions of water, and 0.5-5 weight portions of super absorber, where the weight portions are related to 100 weight portions of foam particles. The foam particles have average particle diameter of 2-10 mm. The sprayable and trowelable mass contains foamed expandable polystyrene as foam particles. The sprayable and trowelable mass comprises foam particles, 20-50 weight portions of aqueous polymer dispersion related to solid, 0.1-3 weight portions of foaming agent, 0.1-3 weight portions of thickener, 1-50 weight portions of filler, 5-10 weight portions of flame protective agent, 10-300 weight portions of water, and 0.5-5 weight portions of super absorber, where the weight portions are related to 100 weight portions of foam particles. The foam particles have an average particle diameter of 2-10 mm. The sprayable and trowelable mass contains foamed expandable polystyrene as foam particles, where the foamed expandable polystyrene contains 0.1-10 wt.% of athermanous particles. The foam particles contain 1-6 wt.% of an organic bromo compound and 0.1-0.5 wt.% of dicumyl or peroxide. A mixture of hard dispersion, which has a glass transition temperature of 15-25[deg] C after filming, and soft dispersion, which has a glass transition temperature of 5-10[deg] C after filming, is used as aqueous dispersion. The flame protective agent is aluminum hydroxide. An independent claim is included for a method for filling cavities.

Description

The Invention relates to sprayable and fillable masses Base of foam particles and aqueous polymer dispersions, and methods for filling cavities.

water-soluble Polymer dispersions are on a large scale available. They serve as a starting material of various Formulations in the construction sector. Aqueous polymer dispersions based on acrylates, styrene / acrylates, vinyl acetates (Vac), Ethyl vinyl acetates (EVA) or styrene / butadiene make up the largest Area dar.

Thermal insulation materials EPS are now steam-foamed and the individual EPS beads stick together.

to Thermal insulation in construction will be common Foam sheets of expandable polystyrene used. These can be used on both the inner and outer wall be applied as a thermal insulation composite system.

For An economical construction method will also be special hollow block building blocks used, their chambers with prefoamed foam particles filled and then punctiform with steam be welded.

to Backfilling of columns and spaces within ETICS systems Today PU foams are mineral wool or specially shaped EPS cuttings used, the handling is complicated.

The Fill cavities in bricks for optimization The thermal conductivity is also today with carried out the measures described above.

today ETICS boards or moldings are made either with cementitious, pasty or PU foam adhesives attached. Join this repeatedly gaps or gaps in the ETICS system on, the laborious must be closed (eg in the window / door area or at bump edges). Z. Zt. Come here PU foams or Cuttings are used. High workload and high raw material prices Forcing processors to cheaper alternatives to search. Here could EPS-foamed beads (eg Neopor), which simply adds water-based dispersion be an alternative.

By The high requirements of the new energy regulation are brick manufacturers forced the cavities in the stones with insulation material to provide the required thermal conductivity values to reach. Currently these cavities are either with EPS moldings (Cuttings), mineral wool or PU foams filled. Forcing high workload and sometimes very high material costs brick makers looking for alternatives.

For complicated moldings made of EPS materials that are expensive with steam could be foamed a mass made of EPS beads, which is mixed with dispersion one Alternative pose. Due to the possibility of sprayable Formulations could handle even complicated forms without great effort to be produced.

packings for thermal insulation or soundproofing purposes, with appropriate formulation setting, be fixed and thus prevent the risk of drowning. Fields of application would be z. B. also in the range of wooden floor or floorboard filling to see.

The EP-A 1 634 911 describes the use of polymer foam particles and polymer binders for the production of soil leveling fillers and a free-flowing mixture of polymer foam particles, cement, lime cement or gypsum and redispersible polymer particles.

The EP-A 1 854 620 describes a method for filling cavities with foam particles, in which the cavity is filled with foam particles, which have been wetted with an aqueous dispersion and then the aqueous polymer dispersion is coagulated and solidified with a coagulant, for example a carboxylic acid.

From the DE-A 10 2007 012 626 is a method for the production of water-absorbing coated particles of prefoamed polystyrene known. The prefoamed polystyrene particles are here mixed with a polymer dispersion and a superabsorbent.

For Different processors is the speed of curing the fillers crucial. Mainly the Surface hardening is crucial because filled Materials partly after a short time (within 5-10 min) must be transportable.

task The object of the present invention was to provide a rapidly solidifying injection molding or to find fillable mass, in particular as Soundproof and heat-insulating material for filling gaps in thermal insulation systems is suitable and a simple and inexpensive process for filling cavities with foam particles allows.

• A) Schaumstoffpartikel,
• B) 5 bis 100 Gewichtsteile, bezogen auf Feststoff, wässrige Polymerdispersion,
• C) 0 bis 5 Gewichtsteile eines Schäumungsmittel,
• D) 0 bis 5 Gewichtsteile eines Verdickers,
• E) 0 bis 100 Gewichtsteile eines Füllstoffes,
• F) 0 bis 20 Gewichtsteile eines Flammschutzmittels,
• G) 10 bis 300 Gewichtsteile Wasser,
• H) 0,1 bis 10 Gewichtsteile eines Superabsorbers,

wobei sich die Gewichtsteile jeweils auf 100 Gewichtsteile Schaumstoffpartikel beziehen, gefunden.Accordingly, a sprayable and trowelable composition comprising

• A) foam particles,
• B) 5 to 100 parts by weight, based on solids, of aqueous polymer dispersion,
• C) 0 to 5 parts by weight of a foaming agent,
• D) 0 to 5 parts by weight of a thickener,
• E) 0 to 100 parts by weight of a filler,
• F) 0 to 20 parts by weight of a flame retardant,
• G) 10 to 300 parts by weight of water,
• H) 0.1 to 10 parts by weight of a superabsorbent,

wherein the parts by weight each refer to 100 parts by weight of foam particles found.

• A) Schaumstoffpartikel,
• B) 20 bis 50 Gewichtsteile, bezogen auf Feststoff, wässrige Polymerdispersion,
• C) 0,1 bis 3 Gewichtsteile eines Schäumungsmittel,
• D) 0,1 bis 3 Gewichtsteile eines Verdickers,
• E) 1 bis 50 Gewichtsteile eines Füllstoffes,
• F) 5 bis 10 Gewichtsteile eines Flammschutzmittels,
• G) 10 bis 300 Gewichtsteile Wasser,
• H) 0,5 bis 5 Gewichtsteile eines Superabsorbers,

wobei sich die Gewichtsteile jeweils auf 100 Gewichtsteile Schaumstoffpartikel beziehen.A preferred sprayable and fillable mass consisting of

• A) foam particles,
• B) 20 to 50 parts by weight, based on solids, of aqueous polymer dispersion,
• C) 0.1 to 3 parts by weight of a foaming agent,
• D) 0.1 to 3 parts by weight of a thickener,
• E) 1 to 50 parts by weight of a filler,
• F) 5 to 10 parts by weight of a flame retardant,
• G) 10 to 300 parts by weight of water,
• H) 0.5 to 5 parts by weight of a superabsorbent,

wherein the parts by weight each refer to 100 parts by weight of foam particles.

Component A)

When Foamed particles can be polymer foam particles of thermoplastic Polymers are used.

Prefers are prefoamed, expandable as polymer foam particles Styrene polymers (EPS) or polyolefin foam particles, such as expanded Polypropylene (EPP) used. The polymer foam particles have usually a mean particle diameter in the range of 2 to 10 mm and a bulk density in the range of 5 to 20 g / l, preferably in the range of 8 to 16 g / l.

Polymer foam particles based on styrene polymers can by pre-foaming EPS with hot air or steam in a prefoamer to the desired density. By one or repeated prefoaming in a printing or continuous Prefoamers can in this case final bulk densities below 10 g / l.

sets One value on a particularly good sound insulation, so used if possible, polymer foam particles with a large average particle diameter and the narrowest possible particle size distribution. For a particularly high thermal insulation it is expedient to use polymer foam particles with higher density.

Because of their high thermal insulation capability, it is particularly preferable to use prefoamed, expandable styrene polymers containing athermanous solids, such as carbon black, aluminum or graphite, in particular graphite having an average particle size in the range from 1 to 50 μm particle diameter in amounts of from 0.1 to 10% by weight, in particular 2 to 8 wt .-%, based on EPS, and for example EP-B 981 574 and EP-B 981 575 are known.

The Polymer foam particles are especially equipped with flame retardants. You can, for example, 1 to 6 wt .-% of an organic Bromine compound, such as hexabromodylcodecane (HBCD) and optionally additionally 0.1 to 0.5% by weight of dicumyl or of a peroxide contain.

Component B)

When Component B) are 5 to 100 parts by weight, preferably 20 to 30 Parts by weight, based on solids, of an aqueous polymer dispersion used. Usually the solids content is 10 to 60 wt .-%, preferably 20 to 50 wt .-%.

In the process according to the invention, as component B) of the aqueous composition, preference is given to using an aqueous polymer dispersion which, after drying, becomes a dried polymer film having a glass transition temperature in the range from -60 to + 100 ° C., preferably in the range from -30 ° to + 80 ° C, more preferably in the range of -10 ° to + 60 ° C leads. The glass transition temperature can be determined by differential scanning calorimetry (DSC). In general, the glass transition temperature with DSC after ISO 11357-2 determined at a heating rate of 20 K / min.

It may also be dispersions of block copolymers or mixtures different polymer dispersions are used, the two or more glass transition temperatures. hereby For example, a combination of low film-forming temperature with increased mechanical stability, better Compatibility or increased hydrophobicity possible be.

As component B) are suitable, for example, polymers based on monomers such as vinylaromatic monomers, such as α-methylstyrene, p-methylstyrene, ethylstyrene, tert-butylstyrene, vinylstyrene, vinyltoluene, 1,2-diphenylethylene, 1,1-diphenylethylene, alkenes, such as ethylene or propylene, dienes, such as 1,3-butadiene, 1,3-pentadiene, 1,3-hexadiene, 2,3-dimethylbutadiene, isoprene, piperylene or isoprene, α, β-unsaturated carboxylic acids, such as acrylic acid and methacrylic acid, their esters, in particular alkyl esters, such as C _1-10 -alkyl esters of acrylic acid, in particular the butyl esters, preferably n-butyl acrylate, and the C _1-10 -alkyl esters of methacrylic acid, in particular methyl methacrylate (MMA), or carboxamides, for example acrylamide and methacrylamide.

The Optionally, polymers may contain from 1 to 5% by weight of comonomers, such as (meth) acrylonitrile, (meth) acrylamide, ureido (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 3-hydroxypropyl (meth) acrylate, acrylamidopropanesulfonic acid, Methylolacrylamide or the sodium salt of vinylsulfonic acid contain.

The polymers are preferably composed of one or more of the monomers styrene, butadiene, acrylic acid, methacrylic acid, C _1-4 -alkyl acrylates, C _1-4 -alkyl methacrylates, acrylamide, methacrylamide and methylolacrylamide.

Particularly suitable polymers are acrylate resins which are used according to the invention as aqueous polymer dispersions, if appropriate additionally with hydraulic binders based on cement, lime cement or gypsum. Suitable polymer dispersions are, for example, by free-radical emulsion polymerization of ethylenically unsaturated monomers, such as styrene, acrylates or methacrylates, as in WO 00/50480 described, available.

Especially Preference is given to pure acrylates or styrene-acrylates, which from the Monomeric styrene, n-butyl acrylate, methyl methacrylate (MMA), methacrylic acid, Acrylamide or methylolacrylamide.

The Preparation of the polymer dispersion is carried out in a conventional manner, for example by emulsion, suspension or dispersion polymerization, preferably in the aqueous phase. You can also pass the polymer through Prepare solution or bulk polymerization, split if necessary and the polymer particles then in water in conventional Disperse way. In the polymerization, the for the respective polymerization process customary initiators, Emulsifiers or suspension aids, regulators or other auxiliaries concomitantly; and polymerized continuously or discontinuously at the usual temperatures for the respective process and printing in common reactors.

Suitable aqueous polymer dispersions are, for example, those in WO 03/106365 described polymer dispersions. Preference is given to using acrylate dispersions, styrene-acrylate dispersion, styrene-butadiene dispersions and vinyl acetate dispersions.

Furthermore, polyurethane dispersions are suitable, as used, for example, in US Pat DE-A 19 708 451 are described. These can be obtained by preparing prepolymers from monomeric or polymeric diols, for example polyester diols, polycarbonate diols or polyether diols such as polytetrahydrofuran with isocyanates, in particular hexamethylene diisocyanate (HDI), dicyclohexylmethane diisocyanate (HMDI), isophorone diamine (IPDA) or isophorone diisocyanate (IPDI). Subsequently, the dispersion can be prepared after neutralization, for example with an amine or sodium hydroxide and subsequent addition of water.

By the combination of two dispersions with different glass transition temperatures can improve the adhesion to the material to be filled become. Similarly, the internal cohesion of the improves sprayable and trowelable mass, making it possible is, filled bricks easily on site to cut.

Especially is preferred as an aqueous dispersion, a mixture of hard dispersion, which after filming a glass transition temperature in the range of 15 to 25 ° C, and a soft Dispersion, which after filming a glass transition temperature in the range of 5 to 10 ° C, can be used.

at suitable choice of the mixing ratio of hard dispersion too soft dispersion can be processed even at low temperatures up to approx. + 5 ° C without additional film-forming aids be ensured. A mixture of hard to soft dispersion in the weight ratio 1: 1 to 3: 1, preferably 2: 1 has this proved to be optimal.

Component C)

It is advantageous for the production and stabilization of the polymer dispersion generated foam as component C) 0 to 5 parts by weight, preferably 0.1 to 3 parts by weight of a foaming agent, for example a surfactant or combinations of several surfactants to use.

The Surfactant system should be compatible with the polymer dispersion be. Particularly advantageous are surfactant systems that are used to produce and stabilization of aqueous foams in alkaline Media and at high electrolyte concentrations are suitable.

When Surfactants may be anionic, cationic, nonionic or ambivalent surfactants or mixtures thereof are used. It can Both low molecular weight and polymeric surfactants are used.

nonionic Surfactants are, for example, addition products of alkylene oxides, in particular ethylene oxide, propylene oxide and / or butylene oxide with alcohols, Amines, phenols, naphthols or carboxylic acids. Advantageous are used as surfactants addition products of ethylene oxide and / or Propylene oxide containing at least 10 carbon atoms alcohols wherein the addition products per mole of alcohol are from 3 to 200 moles of ethylene oxide and / or propylene oxide attached. The addition products contain the alkylene oxide units in the form of blocks or in statistical distribution. Examples of nonionic Surfactants are the addition products of% mol of ethylene oxide to 1 mol Tallow fatty alcohol, reaction products of 9 moles of ethylene oxide with 1 mole Tallow fatty alcohol and addition products of 80 moles of ethylene oxide with 1 mole of tallow fatty alcohol.

Further Commercially available nonionic surfactants consist of reaction products of oxo alcohols or Ziegler alcohols with 5 to 12 moles of ethylene oxide per mole of alcohol, especially with 7 moles of ethylene oxide. Other commercial Nonionic surfactants are obtained by ethoxylation of castor oil receive. Per mole of castor oil, for example 12 to 80 mol of ethylene oxide attached. Other commercial products are, for example, the reaction products of 18 moles of ethylene oxide with 1 mole of tallow fatty alcohol, the addition products of 10 moles of ethylene oxide to 1 mole of a C "/ C" oxo alcohol, or the reaction products from 7 to 8 moles of ethylene oxide to 1 mole of a C "/ C" oxo alcohol.

Further suitable nonionic surfactants are phenol alkoxylates such as p-tert-butylphenol reacted with 9 moles of ethylene oxide, or Methyl ethers of reaction products of 1 mole of a C "-C" alcohol and 7.5 moles of ethylene oxide.

Further suitable nonionic surfactants are alkoxylated, preferably ethoxylated silicones. Preference is given here to water-soluble silicone surfactants which are obtained by reacting short-chain silicones (Diemthicone) be obtained with a high molar proportion of ethylene oxide.

The Surfactants described above can, for example, by Esterification with sulfuric acid in the corresponding sulfuric acid half ester converted become. The sulfuric acid semiesters are in the form of the alkali metal or ammonium salts used as anionic surfactants. As anionic Surfactants are, for example, alkali metal or ammonium salts of sulfuric acid half-esters of addition products of ethylene oxide and / or propylene oxide with fatty alcohols, alkali metal or ammonium salts of alkylbenzenesulfonic acid or alkylphenol ether sulfates. Products of the type mentioned are commercially available.

Also cationic surfactants are suitable. examples for this are the dimethylsulfate quaternary reaction products of 6.5 moles of ethylene oxide with 1 mole of oleylamine, distearyldimethylammonium chloride, Lauryltrimethylammonium chloride, Cetylpyridiniumbromid and with dimethyl sulfate quaternary reaction products of triethanolamine stearate. Due to interactions with anionic silicates are exclusive cationic surfactants are often not used for foam stabilization suitable. The combination of cationic surfactants with anionic stabilized polymer latex can destabilize the dispersion to lead.

The Surfactants are preferred in the aqueous composition in an amount in a range of 0.1 to 15 parts by weight, especially preferably in a range of 1 to 10 parts by weight, respectively based on the weight of the aqueous composition, contain.

Component D)

When Excipients may be in the inventive Stabilizers, thickeners, or mixtures thereof used become. It may be advantageous to use additional thixotropic agents to use, the z. As a control of the viscosity of allow foaming binder. These Additives can be organic or inorganic Be nature. Frequently used additives are z. B. phyllosilicates, polyphosphates, polyvinyl alcohol, polyvinylpyrolidone, etc. It is an advantage if these additives are not negative Have effects with regard to the fire properties.

thickener For example, to optimize the foam structure and the Improved foam stability used. As a thickener come all known natural and synthetic polymers that account for the viscosity greatly increase an aqueous system. in this connection it can be water-swellable or water-soluble synthetic or natural polymers.

Component E)

When Fillers are preferably chalks, concreteites, talc, Gypsum, cement, silica or silica, activated carbons, Graphites, calcium oxide, zinc oxide, aluminophosphates, boron phosphates, pigments, such as titanium dioxide and iron oxide or mixtures thereof are used. It can also intumescent additives, for. B. Expanded graphite or carbohydrates, are used. structural reinforcements by adding lightweight fillers with low thermal conductivities (eg expanded glass, poraver, expanded clay, perlite, etc.) are possible. Inserts made of non-woven fabrics are also possible and strengthen the system structure additionally.

Component F)

Preferably, the foam particles used as component A) already contain halogenated or halogen-free flame retardants. However, especially at high levels of the aqueous dispersion used as component B), the flammability can be increased again. Therefore, flame retardants are additionally preferably added to the sprayable and spreadable composition. Preference is given to using halogen-free flame retardants, for example aluminum oxide, aluminum hydroxides, boric acid and bristles. Aluminum hydroxide (Al (OH) ₃ ) is particularly preferably used. Such flame retardants are commercially available, for example, under the name Apyral.

Next the flame retardancy, aluminum hydroxide can also be a faster Drying the sprayable and spatula-capable mass effect. The mass shows excellent stability during processing. An addition of about 20 parts by weight of flame retardants is this suffice.

Component H)

To accelerate the hardening of the sprayable or fillable composition according to the invention Water reducing agent (superabsorber) used.

Of the Superabsorber used according to the invention a common superabsorbent, which is a multiple of its own weight Absorb on water and retain under some pressure can. In general, he has a CRC ("Centrifuge Retention Capacity ") of at least 5 g / g, preferably at least 10 g / g and in a particularly preferred form at least 15 g / g. Preferably, the superabsorbent is a crosslinked polymer based partially neutralized acrylic acid, and most preferably Form he is surface postcrosslinked. A superabsorbent can also be a mixture of materially different individual superabsorbers its, it comes here less on the material composition than on the superabsorbent properties.

method for the production of superabsorbents, also surface postcrosslinked Superabsorbents, are known.

In In a preferred embodiment this is at least one superabsorbent polymer is a homo- or copolymer which is unsaturated Contains mono- or dicarboxylic acids.

When Superabsorbents are acid group-bearing polymers, in particular crosslinked or partially crosslinked polyacrylic acid, Polymethacrylic acid or a copolymer based on acrylic acid, whose acid groups are neutralized to 10 to 90 mol%. Be particularly preferred 35 to 80, in particular 40 to 75 mol% of Neutralized acid groups. The superabsorbents are in the general in finely divided form with an average particle size in the range of 1 to 100 microns and a water absorption capacity in the range of 10 to 360 g / g, in particular in the range of 20 to 250 g / g used.

Especially A superabsorbent polymer based on a crosslinked polymer is preferred Acrylic acid.

• a) mindestens ein ethylenisch ungesättigtes, säuregruppentragendes Monomer, beispielsweise Acrylsäure oder Methacrylsäure und deren Natrium-Salze
• b) mindestens einen Vernetzer, beispielsweise Triacrylate des 3- bis 5-fach ethoxylierten und/oder propoxylierten Glycerins.
• c) wahlweise mindestens ein mit dem Monomeren a) copolymerisierbares ethylenisch und/oder allylisch ungesättigtes Monomer, beispielsweise Acrylamid, Methacrylamid, Crotonsäureamid, Dimethylaminoethylmethacrylat, Dimethylaminoethylacrylat, Dimethylaminopropylacrylat, Diethylaminopropylacrylat, Dimethylaminobutylacrylat, Dimethylaminoethylmethacrylat, Diethylaminoethylmethacrylat, Dimethylaminoneopentylacrylat und Dimethylaminoneopentylmethacrylat und
• d) wahlweise mindestens ein oder mehrere wasserlösliche Polymere, auf die die Monomere a), b) und gegebenenfalls c) zumindest teilweise aufgepfropft werden können, beispielsweise Polyvinylalkohol und Stärke,

erhalten.Synthetic superabsorbents are obtained, for example, by polymerization of a monomer solution containing

• a) at least one ethylenically unsaturated, acid group-carrying monomer, for example acrylic acid or methacrylic acid and their sodium salts
• b) at least one crosslinker, for example triacrylates of the 3- to 5-fold ethoxylated and / or propoxylated glycerol.
• c) optionally at least one ethylenically and / or allylically unsaturated monomer copolymerizable with the monomer a), for example acrylamide, methacrylamide, crotonic acid amide, dimethylaminoethyl methacrylate, dimethylaminoethyl acrylate, dimethylaminopropyl acrylate, diethylaminopropyl acrylate, dimethylaminobutyl acrylate, dimethylaminoethyl methacrylate, diethylaminoethyl methacrylate, dimethylaminoneopentyl acrylate and dimethylaminoneopentyl methacrylate and
• d) optionally at least one or more water-soluble polymers to which the monomers a), b) and optionally c) can be at least partially grafted, for example polyvinyl alcohol and starch,

receive.

superabsorbent are usually by polymerization of an aqueous Monomer solution and optionally a subsequent Comminution of the hydrogel obtained. Suitable manufacturing method are described in the literature.

The dried hydrogel is preferably ground and sieved, wherein For grinding usually roller mills, pin mills, Hammer mills, cutting mills or vibrating mills can be used. The particle size (Screen cut) of the sieved, dry superabsorber is preferably in the range of 1 to 500 microns, more preferably in the range from 10 to 150 μm. The particle size is used in accordance with the procedure defined by EDANA (European Disposables and Nonwovens Association) recommended test method No. 420.2-02 "Particle size distribution ".

The Thus prepared dry superabsorbent polymers are preferably subsequently surface postcrosslinked. The surface postcrosslinking can in a conventional manner with dried, ground and sieved polymer particles happen. For this purpose, compounds, those with the functional groups of the base polymer with crosslinking can react, mostly in the form of a solution applied the surface of the base polymer particles. suitable Post-crosslinking agents are, for example, di- or polyglycidyl compounds such as ethylene glycol diglycidyl ether, the reaction products of polyamidoamines with epichlorohydrin, 2-oxazolidinone and N-hydroxyethyl-2-oxazolidinone.

Of Further, additional coagulants be used for faster solidification. As a coagulant are salts of monovalent or polyvalent cations, among others such as calcium nitrate, calcium chloride, aluminum sulfate, magnesium nitrate or zinc nitrate, which preferably has good water solubility and Bronsted acids, in particular strong acids such as formic acid, acetic acid, citric acid or lactic acid. Also, mixtures of such coagulants is being brought up for consideration. In the inventive Methods are preferred for 100 parts by weight of foam particles 0.1 to 10 parts by weight, in particular 1 to 5 parts by weight of the aqueous Polymer dispersion, based on solids used. The solids content of the aqueous polymer dispersion is usually 30 to 80 wt .-%, in particular 45 to 75 wt .-%.

Of the Dehydration from the sprayable or leveling compound can additionally with the help of water binders such. As cements, perlite, gypsum, sawdust done When not using hydraulically setting materials (cement) However, the thermal conductivity values are significantly better.

According to the invention the sprayable or fillable mass of the components A) and B), and optionally the components C), D), E), F) G) and H) filled in the cavity. The mentioned are preferred Components with a paddle mixer at low rpm premixed. The paddle mixer serves to elevated Air entry in the formulation. The foaming dispersion is supported by component C). component D) contributes to foam stabilization. The mass will be after one Stirring time of approx. 5 min via a suitable filling aid (large syringe or hopper with rammer) in filled the cavity. By adding the superabsorbent and optionally coagulants, rapid setting takes place after filling the cavity. Preference is given to superabsorbents added at the end of the mixing process and then the hollow stones immediately, preferably within 1 minute, filled. The delayed Digestion time of the superabsorbent ensures that the Dehydration then takes place only in the hollow stone and to the desired Stiffen the mixture leads.

According to the invention the solidification of the aqueous polymer dispersion with a Superabsorber in the cavity filled with foam particles. Here, the aqueous polymer dispersion with the foam particles and the superabsorbent are simultaneously introduced into the cavity. This has the advantage of having a fast film formation on top the cavity, for example a hollow block, takes place and the bed solidifies quickly.

Alternatively, it is also possible to introduce the aqueous dispersion and foam particles into the cavity, and then solidify, for example, by sprinkling the superabsorbent. The spreading can be done by means of a fine sieve with a preferred mesh size in the range of 0.25 to 0.5 mm. The order quantity is between 0.1-1 g / cm ² .

The Introduction of a cell gas in the spritz- or spatula-capable Mass can be done in different ways.

The Foaming of the aqueous composition takes place preferably by mechanical effects, in particular shear, particularly preferably by vigorous stirring or mixing under Mixing with air. The foams can be very easy by simple stirring using known mixing technologies be generated (eg with the help of manual mixers or Cleaning machines). However, it is also according to the invention possible, the composition by dispersing a inert gas to foam in the form of fine gas bubbles. The introduction of gas bubbles into the aqueous composition For example, with the help of beating, shaking, Stirring or lashing devices.

Further it is also possible to foam the composition by that gases from a liquid-filled opening outflow or by the exploitation of turbulence phenomena in currents. Furthermore, the training of Slats on wires or sieves for this purpose be used. These different methods can also be combined if necessary. As inert gases For example, nitrogen, carbon dioxide, helium, neon are suitable and argon.

to Preparation of the whipped foam is in the aqueous composition, if necessary with additives and before the introduction of Polymer foam particles, a gas, preferably air, registered. This can be done, for example, by a suitable mixer, dispenser or a porous membrane. In the formed foam then thermoplastic foam particles, For example, prefoamed EPS particles are registered and foamed in a mold or optionally pressed become. The pressing is recommended especially at higher Proportions of foam particles.

The binder can also be supplied under pressure, a gaseous substance as a physical blowing agent, which leads to an increase in volume at a relaxation to atmospheric pressure. It can also be used a liquid which is converted by changes in pressure or temperature in the gaseous state of matter. The substance can be present homogeneously dissolved in the substantially aqueous binder (eg methanol, ethanol, isopropanol, CO ₂ , methyl formate or ethyl formate or form separate phases, eg pentane, etc. In multiphase systems, the use is a dispersant advantageous.

It Chemical blowing agents can also be used z. B. form a gas due to chemical decomposition processes; for example Carbonates, azides, hydrazides, hydroxides or peroxides. The release of the gas may be by reaction of one, two or more components done and by changing the environmental conditions, eg. As the temperature can be initiated. Further examples are acids or acid anhydrides in combination with carbonates or Isocyanates in combination with water.

to Solidification of the sprayable and trowelable mass can the superabsorbent be incorporated into the mass or on the Surface of the filled cavity scattered become.

A in particular, it is possible to obtain a fillable mass if you incorporate the entire amount of superabsorber in the mass.

• i) Herstellung eines Schlag- oder Treibschaumes aus einer wässrigen Zusammensetzung, enthaltend
• A) Schaumstoffpartikel,
• B) 5 bis 100 Gewichtsteile, bezogen auf Feststoff, einer wässrigen Polymerdispersion,
• C) 0 bis 5 Gewichtsteile Schäumungsmittel,
• D) 0 bis 5 Gewichtsteile Verdicker,
• E) 0 bis 100 Gewichtsteile Füllstoffe,
• F) 0,1 bis 10 Gewichtsteile Superabsorber,
• G) 0 bis 20 Gewichtsteile Flammschutzmittel,
• H) 10 bis 300 Gewichtsteile Wasser, wobei sich die Gewichtsteile jeweils auf 100 Gewichtsteile Schaumstoffpartikel beziehen.
• ii) Befüllen des Hohlraumes mit dem Schlag- oder Treibschaum.

A method for filling a cavity comprises the steps

• i) Preparation of a blowing foam from an aqueous composition containing
• A) foam particles,
• B) 5 to 100 parts by weight, based on solids, of an aqueous polymer dispersion,
• C) 0 to 5 parts by weight of foaming agent,
• D) 0 to 5 parts by weight of thickener,
• E) 0 to 100 parts by weight of fillers,
• F) 0.1 to 10 parts by weight of superabsorbent,
• G) 0 to 20 parts by weight of flame retardant,
• H) 10 to 300 parts by weight of water, wherein the parts by weight each refer to 100 parts by weight of foam particles.
• ii) filling the cavity with the blowing or foaming foam.

alternative you can have a sprayable mass without or with low Produce portions of superabsorbent, enter them into the cavity and then by sprinkling the mass with superabsorbent solidify.

• i) Herstellung eines Schlag- oder Treibschaumes aus einer wässrigen Zusammensetzung, enthaltend
• A) Schaumstoffpartikel,
• B) 5 bis 100 Gewichtsteile, bezogen auf Feststoff, wässrige Polymerdispersion,
• C) 0 bis 5 Gewichtsteile Schäumungsmittels,
• D) 0 bis 5 Gewichtsteile Verdicker,
• E) 0 bis 100 Gewichtsteile Füllstoffe,
• F) 0 bis 5 Gewichtsteile Superabsorber,
• G) 0 bis 20 Gewichtsteile Flammschutzmittel,.
• H) 10 bis 300 Gewichtsteile Wasser, wobei sich die Gewichtsteile jeweils auf 100 Gewichtsteile Schaumstoffpartikel beziehen,
• ii) Befüllen des Hohlraumes mit dem Schlag- oder Treibschaum
• iii) Verfestigung der Oberfläche des befüllten Hohlraumes durch Bestreuen des Schlag oder Treibschaums mit 0,1 bis 1 Gewichtsteilen Superabsorber F pro cm².

An alternative method of filling voids comprises the steps

• i) Preparation of a blowing foam from an aqueous composition containing
• A) foam particles,
• B) 5 to 100 parts by weight, based on solids, of aqueous polymer dispersion,
• C) 0 to 5 parts by weight foaming agent,
• D) 0 to 5 parts by weight of thickener,
• E) 0 to 100 parts by weight of fillers,
• F) 0 to 5 parts by weight of superabsorbent,
• G) 0 to 20 parts by weight of flame retardant.
• H) 10 to 300 parts by weight of water, wherein the parts by weight each refer to 100 parts by weight of foam particles,
• ii) filling the cavity with the blowing or foaming foam
• iii) solidification of the surface of the filled cavity by sprinkling the impact or foaming foam with 0.1 to 1 parts by weight of superabsorbent F per cm ² .

The inventive method is particularly suitable for filling chambers in hollow blocks with foam particles. As hollow blocks, for example, those made of clay with one or more hollow chambers can be used. Furthermore, hollow blocks made of lightweight concrete, which consist of reducing the density of the component, for example, from an aqueous cement mortar mixture and a lightweight aggregate, such as pumice, hüttenbims, perlite, expanded clay, expanded glass or expanded slate and as in WO 03/106365 described, can be produced.

By using different concentrations of the wet component (dispersion + Additi ven), a wide variety of textures can be created in combination with the EPS beads (from foam structure to trowelable systems, fixed fillings to self-leveling masses). This allows a very flexible application latitude.

The new foam formulations are without blowing agents, as is the case with PU foams can be used.

The Foams have no increase in volume, which in the case of backfilling in non-dimensionally stable materials is advantageous (eg backfilling in still soft, not hardened bricks) with larger Applications may rely on familiar machine-based technologies such as silo processing are used (EPS beads in silo, dispersion component is made directly from IPC's in the silo screw mixed) When filling of bricks, the spatula can or foam-like formulation without high mechanical engineering Effort to be filled. Steam lances for foaming The insulation material is not necessary.

By The use of water-based dispersion is the cleaning of the Working tools, as well as the disposal of waste easily and easily possible.

Examples

Starting Materials:

Component A)

Graphite-containing, expandable polystyrene (Neopor ^® N 2400 with average diameter about 2 mm or Neopor ^® N 2200 with a mean diameter of about 5 mm from BASF SE) was pre-foamed to a continuous prefoamer to a density of about 10 g / l ,

Component B)

• Acronal ^® 290 D (styrene-acrylic dispersion, solids content 50 wt .-%, Tg approximately 22 ° C) Acronal ^® S 400 (Tg about 8 ° C)

Component C)

• Comperlan ^® KD (foaming agent, fatty acid diethanolamide from Cognis)

Component D)

• Latekoll ^® DS 6269 X (thickener)

Component E)

• Poraver ^® (expanded glass, grain size 0.2 mm, Fa. Dennert)

Component F)

• Apyral ^® 16 (flame retardants, aluminum hydroxide Fa. Nabaltec AG)

Component G)

• deionized water

Component H)

• Superabsorbent VP PWS 3002

example 1

• a) bonding of Neopor ^® -Schaumstoffkügelchen with dispersion: In the first experiment the basic possibility of bonding of Neopor ^® -Schaumstoffkügelchen with aqueous dispersion was checked. For this purpose, a commercially available styrene / acrylate dispersion (Acronal 290D). The dispersion has a solids content of 50%. After diluting the dispersion with water (1: 5) was added to this solution Neopor ^® -Schaumstoffkügelchen grit 2400 (fine about 1.8 mm diameter). The mixing ratio is about 1: 3. The mixture was then filled into styrofoam shapes measuring 50 × 220 × 80 mm. After drying, the samples were de-activated and tested for strength. The test specimens show adequate book and abrasion resistance.

Formulation: Wet component: 30 g Acronal ^® 290D 160 g of water Mixture: 100 g neoprene balls 2400 290 g wet component

• b) Generation of sprayable mixtures: The mixture described under a) was additionally mixed by means of a suitable stirrer, which introduces a large amount of air into the mixture, thereby producing a foam-like structure. In order to stabilize the foam and to increase the foam yield a conventional foaming agent (Comperlan ^® KD) and a thickener Latekoll ^® DS was used 6269x. The foam was hand-filled into a large syringe and injected into the molds already described above. After drying, the samples were switched off again and tested for strength. The strengths and the abrasion behavior corresponded to the sample from experiment a)

formulation the mixture: 100 g neoprene balls 2400 30 g Acronal ^® 290D 160 g of water 1 g of Comperlan ^® KD 0.6 g Latekoll ^® DS 6269x

• The density of the generated foam is about 53 g / l.
• c) Addition of light fillers to improve the structure: When adding light filler type Poraver ^® blown glass, it is possible to formulate a spreadable mass which, after drying, has a higher strength than the mixture without light filler. In addition, a second dispersion of Acronal S400 is used to increase the flexibility of the final formulation.

• d) Beschleunigung der Erhärtung der Formulierungen durch Koagulation Zur Trockenzeitreduzierung wurde im ersten Versuch Untersuchungen der Koagulierung verschiedener Dispersionen durchgeführt. Die Koagulierung mit Zitronensäure zeigte bei der Dispersion Acronal^® 290 D die größten Effekte. Das Besprühen der Oberfläche der Formulierung aus Versuch b) mit Zitronensäure zeigt eine schnelle Oberflächenverfestigung innerhalb von 1–5 min. Nachteilig hierbei ist, dass durch die hohe Glasstemperatur der Dispersion (+22°C) die Koagulation bei niedrigen Temperaturen (< +5°C) unzureichend ist. Um den Einsatz von zusätzlichen Weichmachern zu verhindern wurde der unter e) beschriebene Weg untersucht
• e) Beschleunigung der Oberflächenerhärtung der Formulierung durch Wasserentzug Ausgangspunkt ist der Gedanke, durch geeignete Hilfsmittel nur das Wasser aus der Formulierung zu ziehen, ohne dass die Dispersionspartikel mit absorbiert werden. Durch den Wasserentzug verfilmt die Dispersion sehr schnell. Der natürliche Verdunstungseffekt des Wassers wird durch geeignete Additive stark beschleunigt. Im Test wurde die Oberfläche der unter Versuch b beschriebene Formulierung mit den Additiven bestreut und nach ca. 5–10 min der Festigkeitszustand geprüft. Die Versuche wurden bei +5°C durchgeführt.

Tabelle 1: Additiv Beschleunigung der Oberflächenerhärtung innerhalb 5–10 min nach Auftrag Zement Mangelhaft Gips Mangelhaft Sägespäne, fein Mangelhaft Pangel S9 Nicht ausreichend Standard Superabsorber BASF Nicht ausreichend Superabsorber Typ VP PWS 3002 (Mahlfeinheit < 50 µm; Standard BASF Superabsorber fein gemahlen) Gut Superabsorber Typ VP PWS 1000F (Mahlfeinheit < 175 µm; salzstabil aus Trostberg) Gut Superabsorber Typ VP PWS 1000F (Mahlfeinheit < 125 µm; salzstabil aus Trostberg) Sehr gut

• f) Beschleunigung der Erhärtung der Gesamtformulierung durch Verwendung von Superabsorbern Ausgehend von den guten Ergebnissen aus Versuch e wurde die Gesamtformulierung mit Superabsorber versetzt. Als Einsatzmenge dienten hierbei ca. 20 l des formulierten Schaums aus Versuch b). Bereits bei Zusatz von ca. 50 g Superabsorber Typ VP PWS 1000F findet eine starke Versteifung des Schaums statt. Die Masse ist nicht mehr spritzfähig, jedoch wesentlich schneller erhärtend.
• g) Im Gegensatz zu dem Standard BASF Superabsorber gibt der Superabsorber aus Trostberg das Wasser schneller wieder ab, was zu einer deutlich schnelleren Durchhärtung der Gesamtformulierung aus f) führt.

Formulation of the mixture: 100 g Neopor ^® 2400 -Schaumstofffkugeln 33 g Poraver ^® grain size 0.2 mm 25 g Acronal ^® 290D 25 g Acronal ^® S400 200 g of water 1.7 g Comperlan® ^® KD 1.3 g Latekoll ^® DS 6269x

• d) Accelerating the Curing of the Formulations by Coagulation In the first experiment, coagulation tests of various dispersions were carried out to reduce dry-time. Coagulation with citric acid showed the largest effects in the dispersion Acronal ^® 290 D. Spraying the surface of the formulation of experiment b) with citric acid shows rapid surface solidification within 1-5 min. The disadvantage here is that the coagulation at low temperatures (<+ 5 ° C) is insufficient due to the high glass temperature of the dispersion (+ 22 ° C). In order to prevent the use of additional plasticizers, the route described under e) was investigated
• e) Accelerating the Surface Hardening of the Formulation by Dehydration The starting point is the idea of using suitable aids only to draw the water from the formulation without the dispersion particles being absorbed. Due to the removal of water, the dispersion films very quickly. The natural evaporation effect of the water is greatly accelerated by suitable additives. In the test, the surface of the formulation described under test b was sprinkled with the additives and the strength state was checked after about 5-10 min. The experiments were carried out at + 5 ° C.

Table 1: additive Acceleration of surface hardening within 5-10 minutes after application cement Inadequate plaster Inadequate Sawdust, fine Inadequate Pangel S9 Unsatisfactory Standard superabsorbent BASF Unsatisfactory Superabsorber type VP PWS 3002 (grinding fineness <50 μm, standard BASF superabsorber finely ground) Well Superabsorber type VP PWS 1000F (grinding fineness <175 μm, salt stable from Trostberg) Well Superabsorber type VP PWS 1000F (grinding fineness <125 μm, salt-stable from Trostberg) Very well

• f) Accelerating the hardening of the overall formulation by using superabsorbents Based on the good results from experiment e, the overall formulation was mixed with superabsorbent. About 20 l of the formulated foam from experiment b) were used as the feedstock. Already with the addition of approx. 50 g Superabsorber Type VP PWS 1000F, a strong stiffening of the foam takes place. The mass is no longer sprayable, but hardening much faster.
• g) In contrast to the standard BASF superabsorber, the Superabsorber from Trostberg releases the water more quickly, resulting in a significantly faster curing of the overall formulation from f).

Example 2 (sprayable formulation)

The sprayable formulations of Examples 2a, 2b and 2c were analogously to Example 1b using Apyral 16 as a flame retardant as a sprayable formulation according to the prepared in Table 2 composition.

Example 3 (trowelable formulation)

The trowelable formulations of Examples 3a, 3b, 3c) and 3d) were analogously to Example 1b using Apyral 16 as a flame retardant sprayable formulation according to the prepared in Table 2 composition.

Example 4

Sprayable materials (4b) and putties (4a, 4c) were prepared analogously to Example 1c and solidified as described under 1e) with superabsorbent VP PWS to test plates having a thickness of about 50 mm. For this purpose, a mold made of styrodur was ^® (XPS) with an edge length of 1 × 1 m and a depth of 50 mm. In this then the mass was filled in and smoothed slightly on the surface with a commercial trowel and lightly steamed. The test plates were after about 7 days. Drying time off and dried for a further 21 days at standard climate (23 ° C / 50% relative humidity). Before measuring the heat The plates were again conditioned at 40 ° C for 24 h to eliminate any residual moisture.

The thermal conductivity was according to DIN 52612 measured at a Einplattenapparatur EP500 at 10 ° C. The thickness of the test plates was about 50 mm. The lambda values given in Table 3 are not thick-corrected. Table 3: example foam particles Density of the plate [kg / m ³ ] Plate thickness [mm] Lambda 10 ° C [mW / m · K] 4a Neopor ^® N 2200 / N2400 25.7 49.9 31.9 4b Neopor ^® N 2200 / N2400 27.0 52.9 32.6 4c Neopor ^® N N2400 29.6 55.0 31.5

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - EP 1634911 A [0012]
• EP 1854620A [0013]
• DE 102007012626 A [0014]
• - EP 981574 B [0023]
• EP 981575 B [0023]
• WO 00/50480 [0031]
• WO 03/106365 [0034, 0080]
• - DE 19708451 A [0035]

Cited non-patent literature

• - ISO 11357-2 [0026]
• - DIN 52612 [0092]

Claims (10)

Sprayable and fillable composition containing A) Foam particles, B) 5 to 100 parts by weight, based on Solid, aqueous polymer dispersion, C) 0 to 5 Parts by weight of a foaming agent, D) 0 to 5 parts by weight a thickener, E) 0 to 100 parts by weight of a filler, F) 0 to 20 parts by weight of a flame retardant, G) 10 to 300 parts by weight of water H) 0.1 to 10 parts by weight of a Superabsorbents, where the parts by weight each to 100 Parts by weight of foam particles. Sprayable and fillable mass according to claim 1, consisting of A) foam particles, B) 20 to 50 Parts by weight, based on solid, of aqueous polymer dispersion, C) 0.1 to 3 parts by weight of a foaming agent, D) 0.1 to 3 parts by weight of a thickener, E) 1 to 50 parts by weight a filler, F) 5 to 10 parts by weight of a Flame retardant, G) 10 to 300 parts by weight of water, H) 0.5 to 5 parts by weight of a superabsorbent, where the Parts by weight per 100 parts by weight of foam particles Respectively. Sprayable and fillable mass according to claim 1 or 2, characterized in that the foam particles have a average particle diameter in the range of 2 to 10 mm. Sprayable and spreadable mass after one of claims 1 to 3, characterized in that they as Foam particles prefoamed, expandable polystyrene (EPS). Sprayable and fillable mass according to claim 4, characterized in that the prefoamed, expandable Polystyrene (EPS) contains 0.1 to 10% by weight of athermanous particles. Sprayable and spreadable mass after one of claims 1 to 5, characterized in that the foam particles 1 to 6 wt .-% of an organic bromine compound and 0.1 to 0.5 Wt .-% dicumyl or a peroxide. Sprayable and spreadable mass after one of claims 1 to 6, characterized in that as aqueous Dispersion a mixture of a hard dispersion, which after filming a glass transition temperature in the range of 15 to 25 ° C and a soft dispersion which after filming a Glass transition temperature in the range of 5 to 10 ° C has to be used. Sprayable and spreadable mass after one of claims 1 to 7, characterized in that as a flame retardant Aluminum hydroxide is used. Method for filling cavities, comprising the steps i) production of a blowing or foaming foam from an aqueous composition containing A) Foam particles, B) 5 to 100 parts by weight, based on Solid, an aqueous polymer dispersion, C) 0 to 5 parts by weight of foaming agent, D) 0 to 5 parts by weight Thickeners, E) 0 to 100 parts by weight of fillers, F) 0 to 20 parts by weight of flame retardant, G) 10 to 300 parts by weight Water, H) 0.1 to 10 parts by weight of superabsorbent, in which the parts by weight each to 100 parts by weight of foam particles Respectively. ii) filling the cavity with the impact or driftwood. A method of filling cavities, comprising the steps of: i) producing a blowing or blowing foam from an aqueous composition containing A) foam particles, B) 5 to 100 parts by weight, based on solids, aqueous polymer dispersion, C) 0 to 5 parts by weight foaming agent, D) 0 to 5 parts by weight thickener, E) 0 to 100 parts by weight fillers, F) 0 to 20 parts by weight flame retardant G ) 10 to 300 parts by weight of water, H) 0 to 5 parts by weight of superabsorbent, wherein the parts by weight each refer to 100 parts by weight of foam particles, ii) filling the cavity with the impact or foaming foam, iii) solidifying the surface of the filled cavity by sprinkling the impact or blowing foam with 0.1 to 10 parts by weight of superabsorbent F).