DE29519649U1 - Insulation mat - Google Patents

Description

Insulation mat -

The invention relates to an insulation mat for heat and/or sound insulation, in particular for impact sound insulation of floor separating ceilings in buildings. It consists of a mixture of shredded textile primary waste with a thermoplastic binder, solidified by thermal treatment.

Such insulation mats are used, for example, according to DIN 4109, Table 3, in the renovation of old buildings , but also in new buildings, of floor dividing ceilings in residential buildings, office and administrative buildings and multi-story buildings with apartments and work rooms in order to reduce impact sound.

They are also used for thermal insulation, for example in buildings for building material class B2 requirements. DE-Gbm 69 303 077 describes an insulation mat that is used for cold, heat and sound insulation. It consists of cut and/or torn synthetic fiber waste and is solidified by adding a thermoplastic binding agent and thermal treatment of the fleece. The synthetic fibers used in various waste groups are pure production waste from fiber production, without any admixtures of foreign substances such as wool _, cotton, etc., which form a fleece and can be processed without any problems in the manner described after adding a thermoplastic binding agent in powder form, preferably between 8 and 12% by weight.

The binding agent with a described grain size of 100 pm to 250 um is a new material. Even with a higher use of the new and therefore more complex binding agent, the internal connection of the fiber material in the insulation mat can only be produced within narrow limits. On the other hand, the fiber waste used, unless it is

are hollow fibers themselves, no closed cavities, which have a negative impact on the insulating properties such as sound absorption coefficient ₅ , thermal conductivity and thermal resistance of the insulating mat in panel form. A variable design of the properties of the insulating mats according to the respective application is only possible through the type of starting materials and their proportions.

It has also been described how to shred waste mixtures consisting of synthetic fibres and foreign fibres such as wool, cotton, rayon and artificial silk and to form them between two cover films by applying pressure and heat while melting or dissolving the synthetic fibres into panels or sheets, which are mainly used as chipboard or plywood substitutes. In principle, the same limitations and problems described above apply to these panels or sheets with regard to their suitability as insulation mats with variable insulation properties.

The problem underlying the invention is to create an insulation mat of the type described, which has better properties that can be adjusted to the respective application when using inexpensive starting materials that cannot be used otherwise or can only be used with great effort.

The problem is solved with the insulation mat described in claim 1.

In particular, the raw materials used in the form of flat composite materials can hardly be used in any other way or only at an unacceptably high cost and are therefore available cheaply. By using polyurethane foam in a quantity tailored to the respective application, closed pores are introduced into the insulation mat in the desired manner, which improve the insulation properties in line with requirements.

The top and bottom of the insulation mat form

Essentially no closed surfaces,'which promotes their sound-absorbing function,

According to an advantageous embodiment of the insulating mat according to the invention, its insulating properties can also be varied via the adaptable dimensions of the sections of the textile primary waste used.

By means of another embodiment of the invention, the internal bonds and thus also the properties of the insulation mat can be preferably influenced via the dimensions of the sections of the shredded polyethylene film used.

A further advantageous embodiment of the invention provides for a variable weight proportion of the thermoplastic binder used. This also makes it possible to influence properties of the insulation mat such as its strength as a rigid plate or its flexibility in the case of rollable and adaptable mats. Another advantageous feature of the invention is that relatively inexpensive recycled material, for example in the form of used packaging films, is used as the binder.

Two further embodiments of the insulating mat according to the invention provide for the use of primary textile waste in the form of a flat composite material with at least one layer of polyester and, in another case, of polyamide. The proportion of these synthetic materials also influences the insulating properties and the strength of the insulating mat. Depending on the components of the insulating mat, which vary as described above, the insulating mat is advantageously solidified thermally and under pressure within the set limits according to two further embodiments of the invention. The pressure dimensioning has a significant influence on the properties and physical parameters of the insulating mat.

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The invention will be explained in more detail below using an example embodiment:

With an insulation mat preferably intended for impact sound insulation, 10 mm thick, with a density of 340 kg/m^ and a dimensional stability of 0.89% at room temperature in accordance with DIN 18165, Part 2, an impact sound improvement level of 26 dB is achieved. This hard-hitting insulation mat also has a thermal conductivity of 0.06 W/mk. The intensively mixed components of the insulation mat were solidified at a temperature of 165°C and under pressure of 0.14 bar. The insulation mat consists of 80% primary textile waste and 20% of a thermoplastic binder.

A composite upholstery fabric consisting of three layers is used as primary textile waste, which consists of an outer fabric, an intermediate layer and a lower fabric. The outer fabric consists of polyester with a share of 55% of the composite upholstery fabric, the intermediate layer of polyurethane foam with a share of 17% and the lower fabric of polyamide with a share of 8%. This is cutting waste from the manufacture of car seat covers. In particular, because of the intermediate layer of polyurethane foam, which cannot be separated with reasonable effort, the cutting waste cannot be reused in any other way and would otherwise have to be disposed of in landfills, which is expensive and harmful to the environment.

The cut pieces of the composite upholstery material have been suitably shredded into individual sections with dimensions of 5 mm to 20 mm in length and width. The shredded polyethylene films consist of individual sections of recycled packaging films of 5 mm to 20 mm in length and width. Depending on the intended application, the properties of the insulation mats to be produced can be optimally designed in various ways. The sections of the composite upholstery material and the packaging film can be mixed together in a ratio of a maximum of 50% polyethylene film and a minimum of 50% composite upholstery material. By increasing the proportion of polyurethane

ethane foam also increases the number of closed pores in the insulation mat, which also improves its insulating properties.

On the other hand, the contained sections of the textile primary waste in the form of the flat composite materials form open pores on the top and bottom of the insulation mat as well as between adjacent sections that are partially not connected by the melted sections of the polyethylene films, which have a predominantly sound-absorbing effect.

The size of the sections of the textile primary waste and the thermoplastic binder used also determines the properties of the final product,

The insulation mat is solidified in an appropriate manner after thermal treatment and when pressure is applied. Insulation mats preferably used for thermal insulation are soft and can be rolled up in rolls, whereas those intended for impact sound insulation are hard and plate-shaped. All transitional forms are possible. The conditions can be varied according to the desired properties of the insulation board.

Claims (1)

Expectations I.Insulating mat for heat and/or sound insulation, in particular for impact sound insulation of floor slabs in buildings, consisting of a mixture of shredded textile primary waste solidified by thermal treatment with a thermoplastic binder,
characterized in that - primary textile waste made from flat composites of layers of different materials, of which at least one layer consists of polyurethane foam, and - the thermoplastic binder for solidification under pressure treatment from shredded polyethylene film consist. 2"Insulating mat according to claim 1, characterized in that the textile primary waste consisting of flat composites of layers of different materials consists of sections of 5 mm to 20 mm in length and width. 3"Insulating mat according to claims 1 and 2, characterized in that the thermoplastic binder formed from shredded polyethylene films consists of sections of 5 mm to 20 mm in length and width, 4,Insulating mat according to claims 1 to 3, characterized _in that the thermoplastic binder formed from shredded polyethylene films is contained in weight proportions of 10% to 50 % , &idigr;&iacgr;·; 5. Insulating board according to claims 1 to 4 *"· characterized in that the thermoplastic binder formed from shredded polyethylene foils consists of recycled foils, 6-Insulating mat according to claims 1 to 4, characterized in that the textile primary waste from flat composite materials of layers of different materials, of which at least one layer consists of polyurethane foam, has at least one layer of polyester. 7. Insulating mat according to claims 1 to 4, characterized in that the textile primary waste from flat composites of layers of different materials, of which at least one layer consists of polyurethane foam, has at least one layer of polyamide. S. Insulating mat according to claims 1 to 7, characterized in that the mixture of shredded textile primary waste is solidified with a thermoplastic binder after thermal treatment from 165 ⁰ C to 180 "C. 9.Insulating mat according to claim 8, characterized in that the mixture of shredded textile primary waste is solidified with a thermoplastic binder after pressure treatment of 0.01 bar to 0.8 bar.