DE4428613A1 - Multilayer heat and sound-insulating material - Google Patents

Abstract

A process for the prodn. of multilayer, fibrous heat and sound-insulating material (I) which is bonded with hot air at fixed distance; and consists of at least two complementary layers of fibre of different construction and/or compsn., mainly of mixts. of fibre of different type, thickness, length and crimping, with binding fibres and mainly recycled synthetic and/or natural fibres and/or fibrous formations to produce artificial, irregular absorbent and/or reflecting barriers inside at least one of the layers comprises: (a) having different densities in the individual layers; and/or (b) prodn. of textile sheets by different fibre lay-up techniques; and/or (c) textile and non-textile fillers in part or all of the fibre layers; and/or (d) between the layers and/or on the surface of at least one layer; and/or (e) combining with smooth and/or regular or irregular formable or preformed textile spacers, e.g. honeycomb or nap structures or spacer webs between and/or on the surface of layer(s); and/or (f) combining with non-textile, smooth and/or regular or irregular preformed spacers and also 3-dimensional open or closed textile sheet between and/or on the surface of layer(s).

Description

As insulation materials, especially for construction, packaging, Mechanical engineering, cooling systems, but also e.g. B. the vehicle rich, are predominantly inorganic mineral fiber Insulation materials, foams and natural fiber materials known of their property profile, preferably for certain Property profiles, such as thermal or acoustic insulation, constructed as rolls or as sheets, and thus for this section are particularly suitable. Because these two Requirements "heat and sound" differ from the design contradict her often because z. B. for good thermal insulation Fiber materials mainly the density and fiber fineness plays a role, but precisely because of the sound area the solid-state conductivity and the flexural strength frequently has negative effects, the task was to construct new tion - also from an ecological point of view (if possible can be used several times in the cycle) - to find that by Long-term use will help reduce heat consumption reduce, save fossil fuels, and, if they are not burned for a long period of time, especially a positive one with natural fibers Oxygen balance benefit the earth.

It also applies to the 70% of the textile waste material to save rials that are currently still burned or dumped become, and to a meaningful use, and Materials suspected of causing disease, to be avoided as far as possible.  

Solved for the areas of sound and thermal insulation - including the goals of the 2nd Thermal protection ordinance - was this through material, Material and process combinations, especially for flexible, predominantly rollable mats made of at least two main fiber layers and mostly recycled Chemical fiber residues and / or recycled Natural fibers, such as wool, coconut, but mainly germinate leafy plants with high levels of parenchyma due to the foam-like structure, like bagasse, Corn stalks, Chinese reed, etc., in thicknesses of approx. 3 to approx. 200 mm for a single one fixed at a distance Main fiber layer. The weights are between approx. 10 kg m³ and 300 kg m³.

Here, the smooth, curved or curled Fa , lying or standing within the fiber layers any other geometry (e.g. herringbone) mostly thermal, but also by a mixture of thermal and mechanical hardening (e.g. calender) bound and at least finally at a distance be fixed to particular volume at low To represent density, with narrow thickness tolerances, and the possibility of protective equipment also via fluids horizontally and / or vertically through the layers bring.

For adapting to the most diverse heat and Sound requirements also help different design possibilities of these nonwovens, e.g. B. different proportions Binding fibers within a main fiber layer, folds after the struto process, but in particular also multi-layer Layers, e.g. B. same or compatible adhesive fibers in the main layers or adhesive aids in between associated with mostly differently made Nonwoven fabrics, the orientation of a fiber layer also in different angular geometry to other fiber layers can stand, also using z. B. the under different property pictures at Naßvliesen, Spinnvlie  sen, hydroentangled nonwovens, binder fleeces, over acted nonwovens etc., with constructable flow resistance stands for the sensitive sound range, e.g. B. Binder, fillers and fiber thickness combinations and / or especially for thermal insulation, e.g. B. layers with Soft foam chips with and without textile components, Foam granules, foam beads, textile surface (e.g. Fabrics) and shapes (e.g. spheres), fibrous Forms (e.g. ribbons, fibrillated foils), fibers with integrated microcapsules (heat), fibers with ex panding natural or synthetic substances (Superabsorbers for e.g. moisture absorption, volume and for sealing), carbonized fibers, textile chips, Particles reflecting heat rays, e.g. B. mica, Cube structures (wood chips), lattice structures or honeycomb profiles made from a wide variety of materials (e.g. Cardboards, compact plastics, foams, papers) and the like, between the fiber layers of individual layers or one or more times between the main fiber layers and also on at least one surface of complete layers as well as mixtures of all of these options depending on Requirements profile of the end product. It's also about Insulation by damping and in certain areas of application e.g. B. also about airtightness and To achieve watertightness, for example in flat roofs, Facades, partition or pitched roof area for the different roof pitch angles.

Multi-layer combinations are also used to insulate Secondary sound paths (e.g. between the upper edge of the wall and Concrete ceiling) ideal as an intermediate layer.

Through fiber combination and sufficient layer thickness in different but connected fiber layers (Bottom PP / PES top and as an application e.g. in Flat roof area) can be next to the Heat / sound applications also otherwise incompatible  Materials such as B. polyester, concrete (alkaline), avoid the good properties of the polyester, e.g. B. to bitumen.

The equipment (e.g. phosphorus-containing substances, boron compound dung, water glass) against pests, fungus, moisture, Flammability etc., especially for the proportion of special natural fibers to be protected for a long-term ge resistance to consumption, can already be used during processing (e.g. tearing) of the fibers / recycled fibers, alone or with other aids, e.g. B. consolidation, in or on the same are applied, or z. B. by impregnation the mat in the production run (Fullard), or also in afterwards with rolls, sheets or molded parts e.g. B. high pressure impregnation of the protective agent in Autoclaves over liquid or gaseous media, or a Mixture thereof (solvent, CO₂, butane, etc. - by Compression and liquefaction even possible in the circuit), vertically and / or horizontally through the laminates. The latter is particularly interesting, especially since Multi-layer products are said to be predominantly hydrophobic, but largely capable of water vapor diffusion, but often also one-sided - mainly on the room side of the building Insulation - are diffusion shut-off.

While it is existing as fiber insulation developed materials mainly around one or two plants material combinations deals with fibers of a geometry, possibly additional, differently dimensioned binding fibers (e.g. Wool or cotton, thermoplastic bound with Hot melt adhesive powders or melt fibers, or in the case of glass, Rock wool or tear cotton to solidify with resins, such as phenol or melamine), with thin predominantly optically conditional covers are claimed in the Development consciously and because of the existing in it desired properties, recycled materials the entire amount of yarn and fibers used with their un  various forms, such as B. also multifilament fibers, extruded tapes, endless and also flocked yarns various shapes and thicknesses and different lengths in order to achieve the to be able to dispose of the entire textile market, and the needed, if possible in height and width of the Main layers, irregularly desired artificial, absorbent (e.g. flocked fibers) or reflective Barriers (e.g. fibrillated foils), alone or in Connection with the other materials listed in to form the fiber mats. Due to the predominantly thermal Bond, about z. B. circulating air and belt dryer, should required narrow thickness tolerances achieved and largely no other chemical materials, at least however their share will be reduced.

The use of non-textile materials within the Fiber layers, such as B. fibrillated foils, Foam chips, papers, etc., is for example for the Elasticity or electrical conductivity u. a. m. next to the additional insulation effects make sense and are feasible.

In order to improve the properties (e.g. rigidity, Shear strength) can be between or at the Surfaces of the individual layers for reinforcement, for example also multi-dimensional lattice structures, organic, as well as inorganic materials (mesh, nets, Braids, stretched polymer grids etc., also for one low-resistance flow), or one or more layered thermoplastic films, filled heavy layered foils, aluminum-steamed or aluminum-coated Thermopla ste, aluminum foil and the like can be introduced. The Nonwovens or layered insulation materials can be further z. B. Quilting and knitting techniques are still mechanically consolidated will.  

Smooth, but because of the much wanted water vapor permeability predominantly openwork structures; about e.g. B. Embossing also preformed fabrics, but also e.g. B. foils with air bubbles to form distances; distance-forming structures from z. B. the thermoplastic sheets area, the non-woven or the knitting area (Spacer fabrics); Honeycomb structures, regular and / or un regular, open and / or closed, in different shapes and materials, often three dimensions regional deformed, also as a cavity labyrinth with acoustic effective cavities to z. B. interference resistances, density and to influence the volume, partially or completely, expand the design options, so that it z. B. also suitable as core material for vacuum insulation technology is.

By high compression of the total layer thickness or of Partial layers are also produced plat structures that are often no longer able to roll. However, these can also be used e.g. B. by a cut or by sawing vertically to the running direction through a part the layers so that rollability is given again is.

In the predominantly through fleece forming, pouring, laminating, Precoat and press technology produced multilayer As listed, insulation materials should be at least two-layer composite materials fixed at a distance with predominantly at least one main layer Recycled mixed fibers or at least portions Recycled fibers plus binding fibers act entirely or in Sub-areas also progressive (e.g. needled on one side, or made with a film as a melting Vapor barrier caused by water vapor and the previously heal resulting pressure precompacts the fiber layer and then is resolved) are built with different Density thereby, the bulk techniques for example  serve to cut fiber chips, fiber balls or torn Textile chips or torn foil-fiber combinations etc. to be covered on fiber mats, if necessary, and these thermally with through-air dryers, mainly Cover belt dryers, calenders and / or heater systems (IR, HF etc.) and / or presses at a distance, or mechanically, or by gluing (e.g. by Exploiting the residual heat after a dryer) in one or but also downstream operations with the others To connect fiber or material layers or to the Equip surfaces (e.g. self-adhesive equipment). Loose is also important for the soundproofing area only punctiform surface layers.

For the long-term connection of the fibers - also to avoid formation of trickle problems - for thermal solidification, as for a partial and full area, with certain Applications (e.g. molded parts, vehicle area) desired Concealment (HF, ultrasound, heat pulse etc.), as before gend thermoplastic binding fibers and / or thermoplastic Powder, in particular made of polyolefins, polyamide and Polyesters (polymers and / or copolymers) are used arrive, thermoplastic and / or duro plastic systems (e.g. resins), sometimes also foamable fiber applications or mass fractions in the Mat as a binder and / or protective equipment (e.g. Epoxy resins, latex, TPE), alone or filled with equipment substances, which are used directly or react reactively (e.g. CO₂, water vapor, emitters), but also natural binders, such as B. those made of starch and protein or combination (lignins, pectins and gelatin etc. also modified towards alkaline), which as Binder, but also as part of the protective equipment (e.g. water-repellent).

The thermal fiber consolidation can, except e.g. B. lamination, additionally on calenders, plates or  appropriately designed, large-format sieve-like Cover bands, also embossing surface structures, in order, for. B. To get contours on the surfaces. A cutting too or milling such surfaces - with the same goal, increasing the surface - is doable.

To achieve further standard regulations - also according to the 2. Heat protection regulation - are for example for the Er target the flammability standards alongside liquid or Powder equipments also combinations with flame-retardant Fibers, e.g. B. based on melamine resin, with fibrous structure the z. B. fibrillated aluminum foil or aluminum vapor ten or aluminum-coated, thermoplastic films, conceivable; or lamination between the layers or on the Surface, at the same time or in a re-designed area beitsgang, with flame-retardant materials such. Belly for pressings (calenders, plates, molds, etc.) as stabilizers on the surface to achieve a Sandwich effects with plates, rolls, or partially compacted or fully compressed molded parts, with one or double-sided use. This also includes waiters surface techniques, such as B. painting, priming, wallpaper or spraying on fibers or powders (e.g. glass, Metal), such as ceramic or mineral materials, e.g. B. Mica for optical and / or technical reasons.

Below are some examples of the various items being considered developments:

• 1) For a production hall, thermal and acoustic insulation pose a parallel task. For the task of thermal insulation, therefore, the multi-layer fiber combination according to claim 1a offers itself, with high proportions of different wool recycling fibers and mixed with a crimped thermoplastic PP fine fiber as adhesive fiber, since suitable densities of 150-250 kg m are mixed with wool and over the crimped fine fibers ³ (claim 1a) and thus also good thermal insulation values can be achieved. The material is compressed to about 50 mm using calenders and / or belts. In a further operation or in the case of possible combinations with two separate fleece-forming systems, the second layer is added for the predominantly sound-absorbing task. This is primarily a mixture of coarse recycled mixed fibers with a mat thickness of 50 mm, but only approx. 80 kg cbm density (claim 1a), standing (claim 1b) compared to the predominantly horizontal fibers of the first fiber layer due to the low flow resistance, also bound via polypropylene binding fibers. Between the two layers, a poly propylene adhesive fleece 20 g / m² is used for better connection. The composite is now fixed to the total thickness of approx. 100 mm at a distance using a shroud dryer.
• 2) An example of non-textile filling materials, claim 1c, is a thermal and acoustic insulation for the automotive sector, where it is a matter of displaying the floor assembly under the carpet with a mixture of regenerated fiber materials, foam chips and mainly thermoplastic fiber materials in several layers for the dimensionally stable deformation, the insulation and the elasticity.
  To achieve a well-deformable and dimensionally stable nonwoven material, a mixture of predominantly thermoplastic materials with 50% polypropylene fibers, alternatively (polyester bicomponent fibers) and 30% cotton, the rest various recycling fibers in the weight range 500 g m² with 10 mm thickness is used as the carrier layer. This material runs together with a 1,400 g and 30 mm regrind fiber mixture with a share of 40 volume percent foam chips and approx. 30% PP binding fibers (alternatively PES bikofibers) in combination. The foam chips are used to increase sound, heat and vibration insulation, but also to show elasticity between the carpet and the floor panel. The high proportions of thermoplastic binding fibers are intended to ensure the dimensionally stable deformation and the connection between the layers and to counteract delamination.
• 3) For covering flat roofs in industrial Trapezoidal sheets are often used in this area. These will here, according to predominantly claim 1d, heat and soundproof covered with a recycling Fiber mixing combination with high density to z. Belly To show tread resistance between the profile sheets. A 100 mm RG 200 kg m³ regenerated nonwoven fabric is used for this manufactured where at a distance of 10 mm from the top to further stabilization a coarse mesh PES mesh fabric, to increase tear resistance and penetration resistance, is introduced. This material is now being reduced To have flow resistances for the sound and for Ab fuse surface because of the desired Bitumen compatibility or z. B. to avoid Film softener hikes with a 10 mm fleece layer made from recycled polyester fibers RG 50 kg m³. Around Making the material rollable becomes the more compact Regenerate fiber mat on the back approx. 70 mm vertically Sawed the direction of travel so that it is inside Tissue still at a safe layer height located.
• 4) For partitions in the prefabricated house area, but also e.g. B. in the office area, inherently rigid compact elements are required. These are said to have firmness, but also to have a sound-absorbing effect, and often, because they are textile-covered, also have a cushioning effect. Here is according to claim 1e a combination with different compressed and at a distance cushion effect and low flow resistance on the outside, strength and concealability inside, compared to z. B. a cardboard honeycomb core to represent the torsional rigidity.
  The structure looks like this; 10 mm regenerated fiber mat, density 70 kg m³; 20 mm regenerated fibreboard RG 150 kg m³; honeycomb core 20 mm covered on both sides; and on the other side again the same structure with first 20 mm RG 150 kg m³; and outwards again 10 mm with 70 kg m³.
• 5) Not as an example for further use textile materials, according to claim 1f, is one Facade insulation board mentioned from a 100 mm thick Regenerate fiber mat - density 180 kg m³. On the Outside for applying thin layers Spraying of z. B. cleaning material and / or decorative material it has a thin 5 mm thick layer with high Flow resistance, thus high reflection uniform fibers with the greatest possible thickness and length, in order to rub plaster or spray on other reflective materials, such as. B. mica, to present a surface that is as smooth as possible. At the 100 mm thick goods is further for better stability Another mesh on the front and one on the back thermoplastic spacer mat of 20 mm, covered with a 100 g fleece to allow air circulation as a multi-layer plate applied behind the insulation to allow.

Claims (4)

1.Process for the production of a multi-layered, essentially thermally bonded with air and fixed at a distance fiber insulation material with sound and heat insulation properties from at least two differently constructed and / or composed, complementary fiber layers, mainly from mixtures of fibers, which with respect are different in type, thickness, length and ripples; from binding fibers and mainly recycled chemical fibers and / or natural fibers and / or fibrous structures to create artificial, irregularly existing absorbent and / or reflective barriers within at least one of the fiber layers, characterized by a) different densities within the individual fiber layers; and / or b) different textile surface-forming fiber laying techniques; and / or c) textile and non-textile filling materials, partially or over the entire area within the fiber layers; and / or d) textile and non-textile filler materials, partially or completely between the fiber layers and / or on the surfaces of at least one of the fiber layers; and / or e) combination with textile, smooth and / or regularly or irregularly shaped and / or preformed, distance-forming structures, eg. B. honeycomb, knobbed structures or spacer fabrics, also three-dimensionally, partially or over the entire area between fiber layers and / or on the surfaces of at least one of the fiber layers; and / or f) combination with non-textile, smooth and / or regularly or irregularly pre-formed distance-forming, also three-dimensionally deformed, openwork or closed flat structures, partially or over the entire area between the fiber layers and / or on the surfaces of at least one of the fiber layers. 2. Process for the production of multilayer sound and thermal insulation materials, according to claim 1, characterized there through that the required protective equipment, especially for the natural fiber shares against z. B. pests, fungal attack, Moisture and flammability as a melt in Processing fed to, sprinkled on or is sprayed on during the fiber surface formation process, or by dipping, or mainly with plates, rolls, Molded parts also via liquid or gaseous substances as a transport medium under excess pressure, horizontally and / or vertically in and / or on the fibers or layers Insulation is applied. 3. Process for the production of multilayer sound and thermal insulation materials according to claim 1 and 2, characterized by the fact that for reinforcement and stabilization thermally bound and fixed at a distance Main fiber layers and the other layers, thermoplastic and / or thermosetting, reactive and / or also foaming systems on the fibers and / or Proportionally introduced into the laminates to the To give composite additional stability, being in this Systems all or part of the substances of the protective equipment are already integrated. 4. Use of the insulation materials according to one of claims 1-3 as rolls, plates, stamped parts, such as for molded parts in Area of the construction, machine and vehicle industry.