DE202011050486U1 - insulating element - Google Patents

Abstract

Insulating element (1) with two spaced-apart surface substrates (5, 15), comprising a support structure (4) distributed between the inside and transmitting in area with at least one cavity (2), and an articulated gas-permeable heat and / or sound insulating material filled therein Insulating material (21) with dissected gaps and inner surface / s and one / s in dissected spaces befinds / s gas / gas mixture, characterized in that the gas-permeable insulating material (21) filled with a thermally optimized optimized gas filling or formed fillable and substantially gas-tight is.

Description

The invention relates to an insulating element with the features mentioned in the preamble of the independent claim 1.

It is known to perform the thermal and / or acoustic insulation with the help of insulation materials such as perlite, glass wool, rock wool, cellulose, polystyrene beads, etc. For this purpose, the insulation materials can be filled in a loose arrangement as bulk material in cavities of walls or in the form of cut or cut to size solidified formed plates, for example. As rock wool mats between saving and / or saving a roof insulation can be arranged. These insulation materials have a thermal conductivity of approx. 0.035 to 0.04 W / mK, which is valid for a normally dry product. With an insulation thickness of approx. 45 cm, the Central European passive house standard can be achieved. Likewise sleeping bags and blankets as well as garments are known which have between two layers of fabric a filler of down, plastic fleece or foam, which is filled with air. When changing the temperatures, a storage of humidity takes place, which can then be dried out badly or only tedious. Consequently, the insulation performance decreases and it can develop mold and bacterial cultures in the insulating material, which lead to the further deterioration of the insulating material and harmful particles in the indoor air of the environment. As a means, however, in roof insulation, an interior vapor barrier made of a gas-tight film, such as an aluminized plastic film or of a PET, PP, PE or PVC film attached. It should prevent the entry of moisture from the inside. The side of the insulation facing outwards is left without vapor barrier for ventilation, so that the stored water can escape to the outside during a longer drying time. Nevertheless, it can be, because it depends on weather and climate, that the insulation material is already unusable after a few years. For clothing and sleeping bags, the wrapper is deliberately left waterproof, but permeable to water vapor, making it hydrophobic and ventilating it extensively after use.

On the other hand foamed insulation materials are known from plastics or resins, such as Styrofoam, XPS, rigid polyurethane foam and Resol, which can achieve a lower thermal conductivity of about 0.020-0.028 W / mK by a stored in their closed pore cells heat-insulating gas such as CO ₂ . These insulating materials must also be protected against moisture. Their other disadvantages are known by their high energy production costs and their chemical nature, since they often remain undecomposed in nature for an extremely long time and can emit harmful substances. In case of fire, toxic gases can cause suffocation or poisoning of humans. Furthermore, they are significantly more expensive than the insulation materials described above such as perlite or glass wool, but it lacks insulation performance. With an insulation thickness of approx. 25 cm, the central European passive house standard can be achieved with Resol or PUR rigid foam. Even if the insulating materials such as rigid polyurethane foam are arranged between metal sheets, the insulating performance through water retention and chemical changes and the consequences of the temperature cycles decrease significantly over the years.

In DE 199 32 366 B4 insulation boards are disclosed with a force-bearing honeycomb cell structure in which a powder-like insulation material such as fumed silica is filled. Cell-like insulator filled with insulation materials for thermal and / or acoustic insulation are in DE 36 07 047 C2 . DE 34 28 285 A1 . US 3,964,527 . US 4,330,494 and DE 29 42 087 A1 disclosed. The cell structure ensures on the one hand for high mechanical strength, rigidity and dimensional stability of an insulating board and on the other hand serves to hold the insulating material in cells in vertical arrangements. It can be achieved with such insulation elements when using glass / rock wool or perlite thermal conductivity of these insulating materials of about 0.04 W / mK and when using rigid polyurethane foams or Resol about 0.021-0.028 W / mK. Use of rigid polyurethane foams or Resol is, as described above, associated with environmental and health-related side effects.

For mobile applications in transport structures such as truck coolers, but also ships, boats and aircraft slimmer walls are needed - with about 5 to 10 cm, so that a further increase in insulation performance is highly desirable. This can be achieved, for example, with vacuum insulation panels, but they are much more expensive and prone to leaks.

The present invention has for its object to provide a mechanically rigid forces transmitting insulating element or a Dämmanordnung, with a significant insulation performance increase at the same time low cost and extended service life and under favorable environmental and fire protection relevant aspects can be realized.

The present invention is based on an insulating element with two spaced surface substrates comprising an internally arranged forces-transmitting surface-distributed support structure with at least one cavity, and an infill structural gas-permeable heat and / or sound insulating insulation material with fragmented spaces and inner surface filled therein. n and one in dissected intervals located gas / gas mixture. Such insulating elements are known for example on the basis of honeycomb or multi-wall sheets.

The objects according to the invention are achieved in that the gas-permeable insulating material is filled or filled with a heat-optimized, optimized gas filling and is sealed substantially gas-tight. The gas filling and insulating material according to the invention are prepared in such a way that the thermal conductivity of the insulating material comes close to that of the gas filling, the gas filling permeating the gas-permeable insulating material.

Here, divided by dissected spaces, it is meant that the inner surface interstices occupy a substantial volume fraction of the total volume of the insulative material and their inner surfaces are many times greater in terms of the surfaces of the insulative member, such as porous, powdered or fiber based or fragmented insulants for example, with a ratio of 1: 1000 to 1:10 million applies.

The gas filling can also be optimized in a preferred embodiments sound-absorbing. Optimized means experimentally determined or calculated according to algorithms. The gas filling is preferably formed from a gas or gas mixture with a lower thermal conductivity than air.

The gas filling ensures an exclusion of condensed water and water vapor and may itself preferably have a lower thermal conductivity than air. The shape, thickness and volume of the insulating element and its mechanical properties are essentially predetermined by the support structure. The support structure and thus the insulating element can be flat or 2 or 3-dimensionally curved and very dimensionally stable. A honeycomb core structure can be easily formed in one direction and, if the cell walls are provided with slits, also form two directions. Thus, for example, conventional tube-like or half-shell insulating elements and spherical-spherical insulating elements for container insulation can be formed.

According to a preferred embodiment of the present invention, the gas filling is for this purpose free of water vapor and in particular of a gas or gas mixture having a lower thermal conductivity than air. The gas filling may preferably comprise at least one of the incompletely listed gases such as argon Ar, carbon dioxide CO ₂ , krypton Kr, xenon Xe, sulfur hexafluoride SF ₆ , chlorine Cl, butane or dry air.

The water vapor increases its thermal conductivity by adsorption in the insulating material. According to the invention can therefore be achieved by dry air as a gas filling significantly better thermal insulation. The insulating gas filling is itself free of water vapor and ensures an exclusion of the condensed water and water vapor and according to the invention even has a lower thermal conductivity than air. As a result, thermal conductivity values can be achieved which are smaller by a maximum of the difference of, for example, 0.009 W / mK between the thermal conductivity of the air of 0.026 W / mK and the selected gas such as argon of approximately 0.017 W / mK and thus to the resulting thermal conductivity of approximately 0.040-0.009 = 0.031 W / mK.

Additional advantages achieved by this can be seen in the achievable higher fire protection and exclusion of bacterial and mold formation without chemical additives due to the exclusion of oxygen (with the exception of the dry air), resulting in a longer life of the insulating material. Argon and krypton are also known from glass pane applications for their good sound insulation properties, so that when slimmer becoming more efficient inventive insulation, the sound insulation is compensated according to the invention.

A particular increase in performance is achievable in that the inner surfaces of the gas-permeable insulating material are substantially free of adsorbed or adsorbable air gas layers and / or oil layers and / or in particular free of water molecules / water skins, whereby substantially only the gas molecules of the heat-insulating gas filling on the inner Surfaces of the gas-permeable insulating material are adsorbed or adsorbable. The heat flow caused by the water hides considered so far no insulation materials concerned scientific research and data sheets, which he has remained unrecognized. The oil layers often used in glass wool also contribute a heat flow and must be eliminated according to the invention.

Such liberation of water skins requires a preliminary process step, in which the insulating material is brought, for example, directly from a high-temperature production or a heating phase in the insulating gas filling or in the meantime in another inert gas or in vacuum before contact with the ambient air can take place. A mere drying of the insulation materials at temperatures of around 100 ° C is not sufficient. Especially on glass surfaces, as they also occur on glass fibers or pearlite granules, the adsorbed water molecules adhere very persistently due to high adsorption, so this invention means and Provided by sufficiently high heating temperature, and / or vacuum drying and / or freeze-drying to apply the required desorption energy. In addition, according to the invention, this eliminates the heat of the skin stream transmitted through a water membrane, which proportionally increases the thermal conductivity of a conventional insulating material by about 0.010-0.014 W / mK to 0.04 W / mK.

By desorption, other air gases such as nitrogen and oxygen are removed from the surfaces of the structured insulation materials. This too is a useful effect, even if their thermal conductivities are of the order of magnitude of air, and their gas-skin heat conduction is less than that of water-skin but not zero.

The inner surfaces of the dissected spaces of the insulating material are preferably at least 50%, more preferably 90%, more preferably 95%, even more preferably 97%, even more preferably 98%, even more preferably 99%, even more preferably 99.5%. more preferably 99.9%, more preferably 99.99% free of water-skin or adsorbed water molecules. The finely porous insulating materials in vacuum insulation, for example, also have such freedom from water skin.

Since the insulating materials themselves, measured in a vacuum at heated water skins, achieve very low thermal conductivity, such as glass wool / glass fibers, perlite with 0.001 W / mK, remaining as the resulting thermal conductivity essentially only the gas filling remains, so that according to the invention thermal conductivity of fumigated insulation from to 0.026 W / mK in dry air, 0.017-0.018 W / mK in argon and CO ₂ , 0.009-0.010 W / mK in krypton and 0.005-0.007 W / mK with very expensive xenon. By any gas composition and all intermediate thermal conductivity can be adjusted so that the application both cost and Dämmleistungsanpassung can be implemented without major changes in the production. The achievable insulation performance of 0.017-0.018 W / mK for argon and CO ₂ is able to offer products that outperform Resol and PUR rigid foam in insulation performance and convince through better environmental balance, better fire protection and evaporation-proof indoor use.

With a resulting thermal conductivity of 0.017 W / mK, the central European passive house standard of 0.13 W / m ² K can already be achieved with approx. 13 cm and at 0.01 W / mK with 7.7 cm insulation thickness. This allows a very slim wall construction and even for mobile transport structures the passive house standard. However, there is still a small surcharge for the then instead of the removed skin effectively adsorbed gas skin. For a CO ₂ gas skin, this surcharge is up to 0.003 W / mK. Gases such as sulfur hexafluoride SF ₆ , chlorine Cl, butane are listed here only by way of example and hardly usable because of their environmental or fire hazards.

In preferred embodiments, the insulating material and insulating element according to the invention achieves a resulting thermal conductivity of less than 0.03 W / mK, more preferably less than 0.026 W / mK, even more preferably less than 0.020 W / mK, even more preferably less than 0.018 W / mK, even more preferably less than 0.010 W / mK, more preferably below 0.006 W / mK.

An insulating element according to the invention can retain its high insulating properties particularly in the long term if the gas-permeable insulating material is enclosed by a sufficiently gastight envelope, its gas-tightness having a predetermined permeation rate which is sufficient to substantially free the insulating material and the gas filling over a given useful life the air environment penetrating air gases and water vapor to get.

The gas-tight envelope may include or form the spaced-apart surface substrates. The spaced-apart surface substrates may be connected at the edge of the insulating element with a gas-tight edge hull element or the edge seal with extended surface substrate (s). The gas-tight envelope may be integrally formed or composed of sections gas-tight. The useful life of the insulating element may be formed by a predetermined gas tightness for many years and decades.

The gas-tight envelope, in particular on edge regions or surface substrates, can be equipped with at least one second opening which is suitable for the inflow or outflow of the gas. This allows an optional filling of the shell with the insulating gas by merely displacing the air without having to use evacuation.

In preferred embodiments, the insulating element has a gas-permeable insulating material comprising at least one of an incomplete listing of porous or dissected materials such as mineral fibers or wool, glass, stone, basalt wool, organic wool, down, sheep wool, cellulose, shredded paper, reed or straw chips, wood chips, bloated perlite or vermiculite, fumed silica or airgel, oven-porous hard or soft foam, crushed polyurethane or other closed-cell plastic foam, crushed cork, dried sawdust, plastic fleece, synthetic, aramid, glass fiber fabric, roving or -schnitzel, Parabeam ^® structure, hollow fibers, micro hollow beads, glass or Synthetic hollow spheres, or styrofoam beads or similar fine-porous insulating materials. The constituents of the insulating materials may be coated with radiation suppression agents such as carbon or have buried metallic or metal oxide powder. Hollow spheres or bodies have gas-permeable walls or are perforated so that gas can penetrate into their interior spaces.

The degree of compaction of the insulating material is further optimized in a thermally insulating optimally designed embodiments, wherein the insulation-specific Verdichtungsgradabhängigkeit and / or the application temperatures and application-specific temperature differences are evaluated thermal radiation technology and taken into account. The degree of density of a particular insulating material has a direct relationship with the achievable thermal conductivity, which may be linear or non-linear. With higher compression, it may increase, on the other hand, it may rise again when it falls below a certain substance-related density value, because the radiation protection is weakened. According to the invention, the optimum is determined experimentally individually for each insulating material or calculated on the basis of insulation-specific data by means of extrapolation or approximation algorithms.

The gas-tight envelope may be formed from an incomplete list of flexible or rigid materials or any of their compositions: paper / paperboard, plastic film (PVC, PET, PE, PP, PA, polyimide) with or without metallic or ceramic coating, metallic foil or sheet , Wood press boards (MDF, HDF), plywood, woven fabric, plastic sheets, an elastomer, composite fiber material, metal sheets, glass or ceramic sheets, rigid foam sheets, glass foam sheets, Resol, PUR rigid foam sheets, XPS or polystyrene sheets or the like.

Further, the gas-tight envelope having at least one gas-tightness-enhancing layer or film may be an incomplete list of suitable materials such as a metal such as aluminum, lead, tin, bismuth, steel, stainless steel, titanium, copper, brass, a plastic, bitumen, paraffin, lacquer / Paint, adhesive or a synthetic resin. The layer may be applied or impregnated or bonded to it as a laminate in the material of the envelope or directly on or in outer layers of the insulating material. The shell is preferably made of frost-proof and plasticizer-free materials, so that the dew and long service life can lead to any embrittlement and leakage.

The edge of the insulating element is in this case preferably formed with a heat-insulating optimized shell material, for example, a metallic vapor-tight layer has a minimized layer thickness to form a smaller heat margin. It may for example be ensured by aluminum foils in the thickness of about 5 to 30 microns or even less heat conductive by vapor-deposited / sputtered aluminum layer / s in the thickness order of 20 to 100 nm on a plastic film. It can also be done entirely without a metallic layer, if other sealing, coating or covering materials apply sufficient water vapor gas tightness. The sealing of the gas-tight envelope is preferably carried out by cohesive welding, gluing or by a sealing edge closure.

The metallic layer thickness of a gas-tight coating of the sheath elements can be, for example, between 10 and 100 nm, more preferably between 15 and 50 nm, even more preferably between 20 and 30 nm.

Usually, aluminum-coated films or papers as produced for food packaging are usable, with preference given to durable and frost-resistant carrier materials such as PP, PE, PET, PVC and the like. Especially at the edge of the insulating element thinner and less heat-conducting substances and shell sections are preferably used to allow no large edge heat losses, while in the area much thicker shell sections are easily used.

Since the pressure outside and inside the shell is approximately equal to the ambient pressure, little to no gas exchange takes place, so that the caged insulating gas filling for a long useful life fulfills its function. At the same time, the shell protects against the ingress of atmospheric moisture. The filled amount of gas can be set so that the shell receives a tension as an air mattress or the shell loosely applied to the support core and insulation material and compresses it easily.

According to a particularly preferred embodiment of the present invention, an adsorber and / or absorber means for adsorbing and / or absorbing the water vapor / water and / or oxygen and / or nitrogen is disposed within the insulating material. Of course, the latter two oxygen and nitrogen only, if it is not dry air as a gas filling. In this case, the adsorber and / or absorber agent has preferably been previously activated so that it has sufficient gas and / or water absorption capacity. The amount of adsorber / absorber agent can be specified so that a desired period of use of the insulation can be achieved. The Adsorber and / or absorber agent preferably comprises a zeolite, activated carbon, and / or absorber unslaked lime CaO, iron oxide, other metal oxide or any composition thereof.

When using adsorbers or absorbers, care must be taken to ensure that they do not adsorb or absorb the filling gas used, which may occur, for example, in the case of CO ₂ , because otherwise there would be a pressure reduction within the insulating element and capacity utilization of the adsorber absorber agent more can be available for water absorption. So that no negative pressure in the casing and a continuous shrinkage of the insulating element can take place by adsorption or absorption of water vapor, in preferred embodiments, the gas filling may have been filled with a slight overpressure. As a result, the gas diffusion direction is specified from the inside out, so that water vapor can not or less penetrate. The adsorber and / or absorber agent may be arranged as a granulate or in rod or tablet form in the insulating material or as a coating on a portion of the insulating material or on the inner surfaces of the gas-tight envelope or support core. Furthermore, plate-like adsorber elements can preferably be arranged directly adjacent to the shell, where they can immediately absorb the penetrating air gases and water vapor before they can get into the insulating material.

In preferred embodiments, the insulating material and the insulating element have a thermal conductivity of less than 0.03 W / mK, more preferably less than 0.026 W / mK, even more preferably less than 0.020 W / mK, even more preferably less than 0.018 W / mK, even more preferably less than 0.010 W / mK , more preferably below 0.006 W / mK.

The gas-permeable insulation material is loaded depending on the application by external forces, unloaded or partially loaded within the support structure filled, so that the support structure mainly transmits the forces acting on the insulating element forces.

The support structure is preferably formed as a honeycomb cell structure of any cell geometry, a perpendicular to the main propagation plane of the insulating element or surface substrates, inclined or horizontal wave structure, a web structure or formed with a plurality of individually distributed arranged support elements. Individually standing support elements may be, for example, sleeve elements which have a perforation for the purpose of immobilization. The plurality of stand-alone support elements may further be integrally formed in the form of a shaped support structure.

In this case, the support structure is preferably substantially free of adsorbed air gases, in particular of water retention. The support structure may further be formed in more than one layer, each with a arranged between the layers, preferably non-positively connected clamping sheet, it being particularly advantageous if the individual layers of the support structure are arranged offset from one another. Then the cells of the superimposed support structures are offset with their cell walls offset from each other and the conductive heat transfer path through the support structure is longer, whereby the thermal resistance increases. Thus, conductive insulation performance increases of about 20-40% are conceivable. As a honeycomb structure of any cell geometry here is meant a structure of sleeve-like elements with a round, oval, hexagonal or arbitrary polygonal cross-section which are arranged supporting one another. Such structures may be formed of endless strip material or of individual sleeves, which are non-positively connected to each other in particular by a bond or thermoplastic connection. The support structure, for example, as well as insulating material in a baking process of adsorbed in their material and surfaces air gases, especially water released and then preferably with the proposed insulating gas or other only temporarily used noble gas to admit no humidity in the insulation. The support structure is preferably to handle gapless until the completion of the insulating element in the insulating gas or a noble gas used in the meantime.

The cross-section of the support structure in the plane of the surface substrates is further optimized thermally insulating, for which purpose the load capacity of the support structure by the cell width and thickness of the cell walls and material used and the design strength is adapted to the particular application. As a result, the heat transfer along the support structure can be minimized and at the same time the power transmission required for the application can be ensured. The support structure may optionally be designed only for a force transmission of compressive forces and / or tensile forces between the surface substrates or also have a required torsional rigidity. In many applications, the insulating elements fulfill a constructive role. For a given application, the load bearing capacity of the support structure can be optimally designed for the forces that occur so that an unnecessary cross-sectional portion is eliminated. This can be done both experimentally and by calculation methods, in particular CAD-based simulations.

The support structure can be made, for example, from cardboard, pressboard, resin-impregnated cardboard, Plastic, Nomex ^TM paper, ceramics, wood or a wood press, glass or sheet metal / foil be formed.

The cell walls of adjacent cells of the support structure are in preferred embodiments equipped with connection openings or slots for exchanging gas for insulating gas filling. In the manufacturing process, the air or water-vapor-loaded gases can be sucked off via these connecting openings or slits, and dry gas filling can be filled faster over the entire extent of the support structure, since the substances of the support structure allow the gases to pass through relatively poorly. For the filling of the dry gas filling then still unclosed edge regions of the support structure can be used, even if the surface substrates are already connected to the support structure.

The connection of the surface substrates with the support structure is preferably frictionally perform by gluing or thermoplastic welding, if a high torsional rigidity is required and force transmission must also cover the tensile forces pulling the surface of each other from each other. In applications where it is not necessary, at least one of the surface substrates without a non-positive connection on the support structure can only be placed or connected in only a few places.

The addition of germ inhibiting agents in the insulation material can be done, but can also be completely absent, since inventive insulating gases can ensure sterility through their dryness and especially lack of oxygen.

The gas-permeable insulating material has in preferred embodiments in the absence of air own thermal conductivity below 0.04 W / mK, more preferably below 0.01 W / mK, more preferably below 0.005 W / mK, even more preferably below 0.001 W / mK. The own thermal conductivity of the gas-permeable insulating material is measured, for example, in a vacuum without load.

The insulating materials used are particularly effective if they are used free of additives that could outgas, in a purified version. Thus, powdery substances such as perlite, vermiculite or mineral fiber wools such as glass / rock wool can be previously heated and thus freed of adsorbed therein amounts of water and air gases. Accompanying extraction of outgassing can improve and accelerate this cleaning process.

In applications, it may be of particular importance to optimize the degree of compression of the insulating material in a heat-insulating manner. As the degree of density increases, in general, the coefficient of thermal conductivity increases, but when it falls below a level of density, it increases again because the heat radiation is poorly suppressed. Adjustments of the degree of density to the conditions of use, in particular to the occurring temperature differences, are also advantageous.

If necessary, opacifiers may also be added to the insulating material to more effectively and effectively suppress the heat radiation to a level required for a given application. As opacifiers, for example, graphite, metal oxides, metal powders and others are known.

The sealing of the gas-tight envelope can be carried out by thermoplastic welding or by gluing or by a clamp closure. The pressure fluctuations of the ambient air of up to 5-10% are compensated by the shell and insulating material by their volume changes when the shell is flexible. In case of stiff shell or surface substrates, these bear the pressure differential forces occurring.

The insulating gas filling can be filled in a particularly preferred embodiments with a predetermined overpressure, wherein the support structure holds it by their non-positive connection with the gas-tight envelope and prevents it from bloating. If the gas-tight envelope is made of a stiff fabric, then it remains flat in the face and if it is a flexible wrap, then there will be little local swelling, for example over the honeycomb cells. The overpressure on the one hand ensures a predetermined gas permeation from the inside to the outside, whereby the penetration of water vapor and nitrogen and oxygen from the environment is counteracted. On the other hand, this also absorbs the atmospheric pressure fluctuations.

The insulating element may also be equipped with an evacuation and / or filling means, via which it can be evacuated and filled with the insulating gas filling. The evacuation and / or filling means makes it possible, without introducing ambient air into the interior of the shell, to fill the insulating element in a simple manner with an insulating gas selected by the user. In the simplest case, it is an opening in the shell, which is glued gas-tight with an adhesive strip. Also, an evacuation and gas filling via an opening or a still unclosed shell portion is executable in further embodiments. Such an opening can be made by means of an adhesive or thermoplastic be sealed to be laminated sealing element.

The insulating elements according to the invention can be designed as the stiffest plates, rectangular block cubes for stacking or filling of cavities, or as the stiffest shell or tube elements.

It may be the insulating material a binder, for example, for fibrous materials such as wool buried in order to achieve their dimensional stability, despite the incombustible gases or when using dry air, it may be necessary to add germ inhibiting agent in the insulation or treat it.

It can be buried the insulation material, but also the shell material further fire retardants such as boron salt, soda or similar, especially if the insulation material is combustible such as cellulose, paper or plastic fibers. The insulating gas, with the exception of the dry air or flammable gases, significantly improves the fire protection properties, as it would suffocate any fire at the exit point regardless of its nature.

The insulation elements according to the invention can be used in all applications. An incomplete listing gives an approximate idea of it: insulation panels and shell elements for exterior and / or interior building insulation or transportation structure insulation in land, water and air vehicles, refrigerators, ovens, crucibles, tubes, containers, cooking pots / boilers, heat storage, district heating pipes. For example, as Zwischenensparen- and / or Aufsparendämmung of roof walls, with dimensions in standard sizes, as an unencumbered insulation between double walls in stand construction or as load-bearing underbody panel insulation. In particular, applications which require structural rigid insulating elements and shear, shear and compressive and tensile forces must be transmitted, can benefit from advantages of the invention.

The attachment can be carried out in a variety of ways.

Reflective films or metal layers for radiation suppression may also be provided on insides of the envelope and / or parallel to them between multilayer support cores.

According to a further aspect of the invention, the objects of the invention are achieved by a method for producing an insulating element according to one of the previously described preferred embodiment, characterized in that the following method steps are carried out in any order: a) the air in the cavity of the support structure against a heat-insulating and / or replaced sound-absorbing optimized gas filling and b) the support structure is sealed gas-tight. For this purpose, an opening can be used or the envelope can be closed gas-tight directly with gas filling, for example under the desired insulating gas environment.

• a1) Ausheizung oder Trocknung des Dämmstoffs, sodass der Dämmstoff von den an seinen inneren Oberflächen adsorbierten Luftgasschichten, insbesondere von Wassermolekülen/Wasserhäuten befreit wird,
• a11) Ausheizung oder Trocknung der Stützstruktur und/oder der Flächensubstrate;
• a2) Befüllung des Dämmstoffs mit einem dämmenden Gas durch Evakuierung und nachfolgende Gaseinlassung oder durch eine ausreichende Gasdurchspülung, sodass die Zwischenräume des Dämmstoffs im Wesentlichen nur dämmendes Gas enthalten, a2) Befüllung der Hohlräume der wenigstens von einer Seite offenen Stützstruktur mit Dämmstoff;
• a21) Schließung der offenen Stützstrukturseite mit Flächensubstrat und/oder Hülle,
• a3) Evakuierung der Hohlräume der Stützstruktur über eine Gasbefüllungsöffnung oder in einer Vakuumkammer über offene Hohlräume; und Befüllung mit einer wärmedämmend und/oder schalldämmend optimierten Gasfüllung;
• a4) oder eine Durchspüllung der Hohlräume der Stützstruktur mit einer wärmedämmend und/oder schalldämmend optimierten Gasfüllung;

wobei der Dämmstoff bei allen Verfahrensschritten lückenlos gegen Eindringen von Luft insbesondere Wasserdämpfen geschützt wird.Furthermore, at least one of the following optional method steps may be carried out prior to step b):

• a1) heating or drying of the insulating material so that the insulating material is freed from the air gas layers adsorbed on its inner surfaces, in particular from water molecules / water skins,
• a11) heating or drying of the support structure and / or the surface substrates;
• a2) filling the insulating material with an insulating gas by evacuation and subsequent gas injection or by a sufficient gas flushing, so that the interstices of the insulating material substantially contain only insulating gas, a2) filling the cavities of the at least one side open support structure with insulating material;
• a21) closure of the open support structure side with surface substrate and / or shell,
• a3) evacuation of the cavities of the support structure via a gas filling opening or in a vacuum chamber via open cavities; and filling with a heat-insulating and / or sound-insulating optimized gas filling;
• a4) or a through-flushing of the cavities of the support structure with a heat-insulating and / or sound-insulating optimized gas filling;

wherein the insulating material is completely protected in all process steps against the ingress of air, in particular water vapor.

The liberation of the inner surfaces of the gas-permeable insulating material of adsorbed air-gas layers, in particular of water molecules / water skins is preferably carried out directly in the production process of the respective insulating material before contamination with water vapor or ambient air by already introducing the insulating gas or temporarily another noble gas in a suitable process phase , This eliminates the energy needed to heat the insulation. For example, silica, aerogels, perlites and vermiculites, when expanded at 900-1000 ° C and glass or stone wool directly from the melt at 1100-1400 ° C, can be considered to be completely free of adsorbed water skins.

Alternatively, the insulating material applied with water skins is subjected to a subsequent bake-out process, in that it is preferably purged with insulating gas or temporarily with another noble gas and heated up to a predetermined temperature limit. Preferably, the gas is constantly replaced by fresh, thereby flushing out the evaporating water vapor and unwanted other gases from the interstices of the insulating material. In a preferred embodiment of the invention, the insulating material is freed of surfaces of glass fibers in wool or pores in porous powder materials such as perlite, silica adsorbed water molecule layers by a desorption process. For this purpose, the insulation may be subjected to a heating at a maximum allowable for the insulation temperature. Thus, temperature-resistant insulation materials such as perlite, vermiculite, silica, aerogels and mineral wools, such as glass wool, rock wool, basalt wool before other vegetable such as cellulose, sheep wool, flax, etc. have the advantage. In addition, in energy-saving and cost-saving processes, the insulation material in question can simply be removed directly from a still high-temperature phase in the process of its manufacture and brought into contact with the insulating gas instead of the ambient air and sealed airtight. As a result, no heat and effort would be incurred for the desorption of water layers. For example, perlite has a temperature of approx. 900 ° C during expansion, and glass or rock wool is even produced from the melt.

The mineral insulation materials are clearly in the advantage, since they endure higher temperatures, for example, from 300-400 ° C and more. Vegetable and organic insulating materials can often only be heated to a maximum of 70-150 ° C, which makes their removal from water skins more difficult. Here, additionally, a time-effective drying in a vacuum can be helpful. Even drying by freezing and evaporation of the water skins from the solid ice phase can promise success. Other alternatives include chemical processes that are capable of binding the water by a chemical reaction, such as CaO unquenched lime, followed by mechanical separation of the insulating material from the chemical reagent. Of course, all alternative methods can also be combined in order to be able to implement the economically optimum for every insulating material. Also, ion bombardment techniques can be used under vacuum.

Further preferred embodiments of the invention will become apparent from the remaining, mentioned in the dependent claims characteristics.

The invention will be explained below in embodiments with reference to the accompanying drawings. Show it:

1 a schematic cross-sectional view of a preferred embodiment of the insulation element according to the invention with honeycomb core; and

2 a schematic cross-sectional view of another preferred embodiment of the insulation element according to the invention with a wave plate.

1 shows an exploded perspective view of an insulating element according to the invention in the form of a flat plate 1 ,

A structural support structure with support elements 4 in the form of a hexagonally shaped honeycomb structure is with its cell wall edges perpendicular to surface substrates 5 and 15 preferably frictionally z. B. by gluing with an adhesive or thermoplastic welding arranged. As a result, the support structure can on the one hand achieve higher load capacity values and rigidity and, on the other hand, can also absorb pulling forces which, for example, in particular embodiments as a result of gas overpressure in the cells 2 may occur or between the spaced-apart surface substrates 5 and 15 tearing to transfer.

The frictional connection of the support elements 4 with each other is made either by gluing individual elements or in one piece by extrusion from an extrusion or pultrusionsfähigen material. The honeycombs can in this case have any polygonal or round / oval cross sections. Cardboard honeycombs are formed, for example, by staggered bonding of entire paper tapes and subsequent cutting to the desired honeycomb height and subsequent expansion, ie pulling the honeycomb structure apart. Depending on the width of the honeycomb, the available cardboard honeycomb can reach between 8 and 45 mm compressive strength between 50 kPa and 1000 kPa and can be produced even more resiliently by the thickness of the paper used and by reducing the honeycomb width.

The support structure is preferably from all sides with side wall panels or sheets 3 . 6 . 7 and a fourth not shown opposite side wall 7 enclosed side wall plate, so that an enclosed component or plate is formed. From above, an upper clamping sheet or pressure distribution plate as a surface substrate 15 preferably also frictionally z. B. by gluing with an adhesive or thermoplastic welding arranged. Both surface substrates 5 and 15 may in other embodiments, only on the support structure 4 Be up and just on the edge with the side walls 3 . 6 . 7 be connected.

The cavities 2 The honeycomb cells may be filled in preferred embodiments with a heat insulating material, on the one hand prevents the air convection and on the other hand, more importantly, the heat radiation between the outer surface substrates 5 and 15 suppressed. The insulating materials can also serve the sound insulation and reducing the risk of fire. For example, mineral insulating materials such as perlite, vermiculite, rockwool, aerogels, etc. are incombustible and even make a honeycomb structure made of paper extremely fireproof, since inside there is no free air for burning. Furthermore, an insulating material can also be filled partially pressed and thereby exerts an all-round pressure on the cell walls which supports the supporting structures, as a result of which the load-bearing capacity of the supporting structure can be increased.

According to the invention is in the cavities 2 filled a heat-insulating and / or sound-absorbing gas filling. This gas filling may be filled in addition to the insulating material, which is gas permeable thereto, or in empty cavities. However, the preferred embodiments with both gas filling and insulating material achieve lower thermal conductivity, since gases alone can not suppress the heat radiation so.

The support structure 4 is freed according to the invention by a bake-out process and / or a vacuum drying substantially of water stored in its substance. Likewise, the gas-permeable insulating material used according to the invention is freed by a heating process and / or a vacuum drying substantially of adhering to its inner surfaces adsorbed water layers called water skins.

The side walls 6 . 7 . 3 and an unillustrated side and / or the surface substrates 5 and 15 may be formed of a suitable material such as cardboard, corrugated cardboard, plastic or sheet metal, glass sheets, cement, gypsum, Keramiklplatte or similar. Cement, lime or gypsum based cladding may preferably be done by overmolding in a mold. They are preferably gas-tight, which is why metallic coatings, water vapor-tight coatings of Kunstsofffie, bitumen, paraffins, paints, resins are applied underneath.

The surface substrates 5 and 15 may also be reflective coated inside to reduce the radiation exchange between inside.

2 shows a partial sectional plan view of another inventive insulating element or plate 1 ,

Since cardboard honeycomb structures are becoming increasingly difficult to expand with decreasing honeycomb width and large cell wall height, it is possible to achieve a simpler production of highly loadable support structures by vertical arrangement of corrugated cardboard corrugated sheets. The corrugated board is available in different sizes, which are marked with letters from A to G and different paper grades. For higher load capacity, non-recycled or recycled paper such as kraftliner or kraft paper may be preferred. Their load capacity in the vertical direction can be compared with the cardboard honeycomb corresponding honeycomb width.

A corrugated sheet usually consists of a corrugated layer, which serves as a supporting structure 4 serves and a so-called tension or cover sheet 9 , The orientation of the cover sheets 9 is in the present preferred embodiment parallel to the outer side walls 3 and 6 specified. For example only, sections a and b show a different arrangement of the wave structures.

The cavities 2 The wave plate structures can also be filled with a heat-insulating material as described above for honeycomb structures.

The arrangement of the waves can be offset as indicated in section a or above each other as shown in section b. Even their mixed use as here can have advantages. Likewise, corrugated sheets of different shaft dimensions can be used in combination with cardboard honeycombs. This allows, for example, more effective thermal insulation values and resilience and rigidity set. Even three-dimensionally formed wave plates can be used and have the advantage that they are also laterally resilient than the straight waves formed.

The upper and lower surface substrates, not shown 5 and 15 are to be mounted similar to honeycomb panels in previous figure.

For the production of such ausgestalteter insulation elements are also the mentioned extrusion or pultrusion process by using thermoplastic or thermosetting, fiber-reinforced plastics. However, the most economical method of production is corrugated since paper is a renewable and inexpensive material. Corrugated sheets of meter-wide dimensions can be bonded by gluing with inexpensive glue / glues or directly in multi-layered design be obtained. In more northern regions a doubling to 20-30 cm plate thickness could be sufficient. Composite corrugated sheets of this type can be cut very economically into predetermined sheets and further processed by filling with insulating material and attaching pressure distribution plates / means and side walls.

In order to eliminate or considerably reduce the moisture contents and the gas-related conduction and convective heat conduction, according to the invention, a heating with a thermally insulating gas such as CO ₂ , krypton, argon, xenon or dry air with sealing of the outer walls is carried out.

In further preferred embodiments, insulating elements can also with horizontally oriented d. H. lying lying wave, web or honeycomb structures have used, if the pressure capacity does not have to be quite so high. For Central European climate insulation elements according to the invention with plate thicknesses between 10 and 20 cm already sufficient to reach the passive house standard.

It should be noted that the illustrated embodiments can not describe the entire scope of the present invention, but it is possible for one of ordinary skill in the art to create further embodiments of the invention, which are covered by the scope defined in the claims, without being inventive step got to.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 19932366 B4 [0004]
• DE 3607047 C2 [0004]
• DE 3428285 A1 [0004]
• US 3964527 [0004]
• US 4330494 [0004]
• DE 2942087 A1 [0004]

Claims (11)

Insulating element ( 1 ) with two spaced-apart surface substrates ( 5 . 15 ), comprising an internally arranged, force-transmitting in-area distributed support structure ( 4 ) with at least one cavity ( 2 ), and a structured gas-permeable heat and / or sound insulating material ( 21 ) with dissected interstices and inner surface / s and a decomposed interstitial gas / gas mixture, characterized in that the gas-permeable insulating material ( 21 ) filled with a thermally optimized optimized gas filling or formed fillable and is substantially closed gas-tight. Insulating element according to claim 1, characterized in that the gas filling is formed free of water vapor and in particular of a gas or gas mixture with lower thermal conductivity (λ) than air, and / or the gas filling has at least one of the incompletely listed gases such as: argon (Ar) , Carbon dioxide (CO ₂ ), krypton (Kr), xenon (Xe), sulfur hexafluoride (SF ₆ ), chlorine (Cl), butane or dry air. Insulating element according to claim 1 or 2, characterized in that the inner dissected surfaces of the gas-permeable insulating material substantially free of adsorbed or adsorbable air gas layers, and / or oil layers, and / or in particular free of water molecules / water skins, whereby substantially only the gas molecules of heat-insulating gas filling adsorbed or adsorbable to the inner surfaces of the gas-permeable insulating material. Insulating element according to one of the preceding claims, characterized in that the insulating element with a sufficiently gastight envelope ( 5 . 15 . 3 . 7 . 6 ), wherein its gas-tightness has a permeation rate which is sufficient to obtain the insulating material and the gas filling over a given useful life substantially free of air from the air environment penetrating air gases and water vapor. Insulating element according to one of the preceding claims, characterized in that the gas-permeable insulating material ( 21 At least one of an incomplete list of porous materials such as mineral fibers or wool, glass, stone, basalt wool, organic wool, down, sheep wool, cellulose, shredded or straw, wood chips, bloated perlite or vermiculite, fumed silica or Airgel, oven-porous hard or soft foam, crushed polyurethane or other closed-cell plastic foam, crushed cork, dried sawdust, nonwoven plastic, synthetic, aramid, glass fiber fabric, roving or -schnitzel, Parabeam ^® structure, hollow fibers, micro hollow beads, glass - Or hollow plastic balls, or styrofoam beads or similar fine-porous insulating materials. Insulating element according to one of the preceding claims, characterized in that the degree of compaction of the insulating material ( 21 ) is optimized thermally insulating, wherein the insulation-specific Verdichtungsgradabhängigkeit and / or the application temperatures and application-specific temperature differences are evaluated thermal radiation technology and taken into account. Insulating element according to claim 4, characterized in that the gas-tight envelope ( 5 . 15 . 3 . 7 . 6 ) can be formed from an incomplete list of flexible or rigid materials or their arbitrary compositions: paper / cardboard, plastic film (PVC, PET, PE, PP, PA, polyimide) with or without metallic or ceramic coating, metallic foil or sheet metal, wood pressure plates (MDF, HDF), plywood, woven fabric, plastic sheets, an elastomer, composite fiber material, metal sheets, glass or ceramic sheets, rigid foam sheets, glass foam sheets, Resol, PUR rigid foam sheets, XPS or polystyrene sheets or the like. Insulating element according to one of the preceding claims, characterized in that within the insulating material ( 21 ) an adsorber and / or absorber means for adsorbing and / or absorbing the water vapor / water and / or oxygen and / or nitrogen is arranged. Insulating element according to claim 8, characterized in that the adsorber and / or absorber has a zeolite, activated carbon, and / or absorber means undeliminated lime (CaO), iron oxide, other metal oxide or any composition. Insulating element according to any preceding claim, characterized in that the supporting structure ( 4 ) as a honeycomb cell structure ( 4 ) of any cell geometry, one to the main propagation plane of the insulating element or surface substrates ( 5 . 15 ) vertical, inclined or horizontal wave ( 4 ) or web structure or with a plurality of individually distributed arranged support elements is formed. Insulating element according to claim 10, characterized in that the cross section of the support structure ( 4 ) in the plane of the surface substrates ( 5 . 15 ) is optimized thermally insulating, in which case the Loading capacity of the support structure ( 4 ) is adapted to the particular application by the cell width and thickness of the cell walls and material used.

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