EP0947637B1 - Thermal and/or sound insulating element and treatment process, especially coating of insulating materials - Google Patents

Abstract

The device (10) for treating, in particular, for coating insulation plates for purposes of glueing them at least partially with cover layers comprises a carrier element (11) of a plurality of pins or needles (12, 13) of which at least some (13) are hollow for delivery of a low-viscosity glue.

Description

The invention relates to a method for the treatment, in particular coating of insulation materials with a coating for at least partially bonding a heat insulation board made of the insulating material with cover layers or supporting surfaces, wherein the thermal insulation panel consists in particular of mineral fibers, preferably glass or Steinwollfasem or polystyrene foam and the coating is applied to at least one large surface of the thermal insulation panel and the thermal insulation panel is perforated, in particular needled, prior to and / or during the application of the coating, at least in the area of the surface to be coated. Moreover, this invention relates to an insulating element for heat and / or sound insulation purposes, especially in conjunction with thermal insulation systems consisting of a thermal insulation board, in particular of mineral fibers, preferably glass or rock wool fibers, or polystyrene foam, and applied at least on a large surface Coating for at least partial bonding of the thermal insulation panel with cover layers or supporting surfaces, wherein the thermal insulation panel is perforated at least in the area of the large surface or surfaces having the coating and has a plurality of apertures open for coating and the coating forms protrusions formed in engage the holes so that the cured coating has a nail-like structure anchored in the thermal barrier panel

In many applications of insulation elements for thermal and / or acoustic insulation, a non-positive bond to the supporting surfaces on the one hand and / or cover layers on the other hand is required. For example, flat roof constructions are known in which the insulating elements are glued to supporting concrete or profile sheet surfaces and on the even a water-dissipating layer of bitumen membranes or plastic films is glued. In pitched roof insulation, water vapor permeable, but water-repellent films are bonded to the thermal insulation material by partial bonding. In both cases, the wind suction acts permanently or only during the construction phase of the pitched roof on the composite of the insulating element and the cover.

In external thermal insulation systems, the thermal insulation panels are glued to a substrate, such as an external facade and optionally applied to the exposed surfaces of the insulating elements plaster layers or ceramic plates frictionally. In these cases, the dead load in conjunction with the wind suction acts on the thermal insulation composite system.

On the other hand, it is known to bond shear-resistant insulating elements, for example made of non-combustible mineral wool, on both sides with smooth or profiled surfaces. These elements are used as separation and / or outer walls and / or ceilings and as bulkheads on ships, etc.

Moreover, it is known to glue insulating elements of the type in question with nonwovens or fabrics made of glass and other inorganic and organic fibers. Such covered thermal insulation panels are used as ceiling cladding, silencer backdrops, noise barriers, facade insulation panels and so on.

In these areas, mineral wool insulation materials, polystyrene rigid foams, rigid polyurethane foams, rigid polyisocyanurate foams and phenolic foams are the most commonly used as insulating materials. In addition, it is also known to produce insulating elements made of cellulose fibers and / or other organic fibers. These insulating elements exist in terms of their insulating properties and their applicability Advantages and disadvantages that are known per se and should not be discussed further here.

Mineral fiber insulation elements consist of glassy solidified fibers with different chemical compositions. These fibers are bonded with relatively brittle binders such as thermosetting phenolic resins, ormocers or the like. Here, a distinction is made between glass wool and rock wool insulating materials, with the rock wool insulating materials generally having a higher apparent density compared to the glass wool insulating materials. Glass wool insulating materials and rock wool insulation materials are summarized under the term mineral wool insulating materials, the fibers have average diameter of about three to six microns, different lengths and smooth or curved in the insulating element are arranged. The fibers are mostly parallel or at a very shallow angle to the two large surfaces of the insulating element. But there are also known as lamella plates, in which the Einzelfasem are arranged steeply to perpendicular to the large, usually provided with adhesives surfaces. The tensile and compressive strength of these lamellar plates is significantly increased in comparison to the insulating elements with parallel to the large surfaces extending fibers. The anisotropy of the strength properties is utilized, for example, in so-called lamellar mats. Here relatively narrow slats are glued to a carrier foil. The lamellae are resistant to pressure perpendicular to the large surfaces and compressible in the horizontal direction, so that the mats can be rolled up relatively easily and at the same time have a sufficiently high compressive strength when applying these lamellar mats to a surface.

The fibers horizontally or flat against the large surfaces to which an adhesive is to be applied form excellent fine filters, so that only true solutions, particles of nanometer size or up to a few micrometers in diameter even penetrate into the surface can. In order to allow a greater penetration of the adhesive in the large surfaces, it is known to incorporate the adhesive or a corresponding coating under pressure in the surfaces of the insulating element. However, it has been shown that the filter effect is increased by the reduction of the distances between the fibers by this pressure. For solvent-free adhesives but can not be waived this pressure to overcome the hydrophobicity of the fibers. The hydrophobicity could also be overcome by the addition of surfactants. It would then be possible to do without the pressure. However, the use of surfactants usually prohibits, since neither in the factory application but certainly can not be ensured in an application on the site that not residues of surfactants remain in the insulation. These Tensidereste would relatively quickly wetting the entire insulation or large parts thereof cause, so that the desired processing qualities are unreachable. In insulating elements with fibers arranged at right angles or steeply to the surfaces, it is in principle easier to press adhesive particles between the fibers. The reason for this is that the fibers are naturally stiffer in the axial direction and can dodge on the other hand when pressing the adhesive particles relative to each other. In addition, the distances between the individual fibers or tufts can be increased by a bulging of the surface.

Another special feature of the insulating elements made of mineral fibers is that not all fibers are fixed evenly with binders. There are thus not inconsiderable proportions of unbound fibers within the insulating element. By these unbound fibers, the transverse tensile strength of the insulating element is significantly reduced, especially as the unbound fibers are often stored due to production in the vicinity of the large surfaces. In addition, the recycling fibers introduced to an increasing extent in the production of insulating elements made of mineral fibers also have an effect on strength. These recycled fibers are injected in the usual manufacturing process of insulating elements of mineral fibers in a collection chamber, but can not be integrated into the fiber mass to the same extent as the fibers in statu nascendi. In principle, such insulating elements are made of mineral fibers in the way that natural or artificial stones are melted in a cupola and the melt is then fed to a fiberizing device. In this fiberizing apparatus, the melt is fibrillated into microfine fibers, which are then wetted at least with binders and deposited on a continuous conveyor. On this continuous conveyor then forms an endless mineral fiber layer, which is further processed depending on the desired end product, ie, for example, compressed and horizontal and vertical cut. Other processing or processing stages are also known.

In addition, insulation elements made of polystyrene rigid foams are provided for the above applications. The surfaces of polystyrene hard foam expanded as a strip or block foam inherently have a good adhesive strength, inter alia, to commercially available construction adhesives or plastic-doped plasters. In the sawn or cut surfaces of slab foam boards is added that the surface tears scaly by the mechanical stress on a microscopic scale. Furthermore, the specific surface area increases due to the concave arched membranes of the individual foam spheres. The gussets between the foamed balls remain sublime, so that the adhesive or plastic-doped plasters can be connected to the webs from both sides or anchored to the micro scales. These effects lead to normally sufficient adhesive tensile strengths. In thermal insulation systems, the insulation boards glued to the load-bearing surface can normally take over the forces resulting from dead load and wind suction. However, if it comes to a long-lasting moisture penetration of the insulation boards, so decreases the transverse tensile strength of the connection. The demolition the adhesive or plaster layer is predominantly on the surface of the insulation board.

The insulation elements described above are usually painted on the construction site with the appropriate coatings, such as adhesive mortars and / or plastic dispersions before the insulation elements are glued on the building side or the final plaster is applied. However, it is also known to provide the coatings of the insulating elements already at the factory, so that the insulating elements can be provided on site with a cured coating. Both the application of a factory coating and the application of an on-site coating, i. At the construction site, the above-described disadvantages with regard to the processability of the insulating elements may have.

From DE 38 26 913 A1 a method for producing a building board is known, in which a mineral base layer is applied over an entire surface to an elastic base layer, for example of mineral wool, artificial foam or the like, which is anchored point by point with the base layer by depressions. For this purpose, uniform depressions (blind holes) are provided in a large surface area. The mineral plaster base layer consists of plastic, preferably mineral mortar.

Furthermore, FR 2 094 104 A1 discloses a prefabricated self-supporting sound and heat insulating composite element, which consists of an insulating material layer and liquid coatings arranged on both sides, in particular CaSo ₄ binding building materials (gypsum) and plastics. The insulation material has on both sides staggered non-continuous holes that are punched, drilled or pressed. These holes are filled with the liquid coating, so that an improved bond between the coating and the insulating material is made.

However, the previously known from this prior art composite elements are not suitable for use in the facade area. Rather, these are self-supporting sound and heat insulating composite elements whose coating is designed such that it provides the carrying capacity of the composite element. Consequently, this coating must be completely cured, which in turn results in a surface which, when placed against the intended application by means of an adhesive mortar in the area of the façade, does not have the necessary strength properties. On the contrary, the design of the composite element with the self-supporting properties ensuring coatings leads to a very high weight of this composite element, so that a not inconsiderable shear stress in the area of the adhesive mortar arises when such composite elements are installed as Fassadendämmelemente. The stability of such a facade insulation would be more than questionable, so that the person working in this field will not consider such a design in the field of facade insulation elements.

Starting from this prior art, the invention has for its object to provide an insulating element of the generic type with a coating which is improved in which the connection between the coating and the insulating element. It is another object of the invention to provide a method for coating an insulating element of the generic type, with which or with which an improved insulating element can be produced in a simple and economical manner.

The solution to this problem provides for a generic insulation element, that the coating consists of a relatively thin adhesive in the holes and a relatively granular adhesive mortar on the surface.

According to the invention, the insulating element thus consists of a thermal insulation board, for example of mineral fibers or polystyrene foam, and a coating which is arranged at least on a surface of the thermal insulation board. The thermal barrier panel has a plurality of apertures extending at right angles to the large surface to be coated, in particular holes into which the coating to be applied may penetrate to provide a deep anchorage in the thermal barrier panel. As a result, a much better adhesion, in particular solvent-free dispersion adhesive or on the basis of hydraulically hardening binders built adhesive or combinations thereof is achieved. In the case of thermal insulation panels made of polystyrene rigid foam, it has been found that the more intensive toothing of the thermal insulation panel with the coating counteracts any possible breakage of the adhesive or plaster layer on the surface of the insulation panel, so that an insulation element designed in this way has a significantly increased transverse tensile strength.

The thermal insulation board is preferably needled. It has proved to be advantageous that the thermal insulation board has 5 to 20 holes per cm ² , in particular 8 to 10 holes per cm ² in fibrous thermal insulation panels or 10 to 16 holes per cm ² in rigid foam thermal insulation panels. This number of holes is sufficient to achieve an intimate connection between the thermal insulation panel and the coating over the entire surface of the insulating element, wherein the thermal insulation panel is not significantly weakened.

According to a further feature of the invention it is provided that the holes depending on their dense arrangement in the large surface of the thermal insulation board, at least in the region of the large surface diameter of 1 to 5 mm, preferably 2 to 3 mm. In this embodiment, the holes is to be considered that the insulating properties of the insulating element not by too large nail-shaped anchors Coating be adversely affected. On the other hand, the nail-shaped protrusions of the coating must be sufficiently stably sized to avoid shearing the coating from its nail-shaped protrusions. However, even with coarser punctures and a correspondingly lower number of punctures or impressions per cm ² good results can be achieved. Essential in the design of the number of punctures and the material thickness of engaging in the recesses nail-shaped projections of the coating is the structure of the insulating element. These include the fiber orientation, the bulk density, the binder contents and the elasticity of the fibers.

For mineral fibers that are substantially parallel to the large surfaces, the holes are preferably tapered and / or frusto-conical, so that each hole terminates in a point.

In insulating elements whose mineral fibers extend substantially at right angles or inclined to the large surfaces, the holes are preferably cylindrical, conical and / or frusto-conical and / or truncated pyramid shaped with each dome-shaped or spherical segment-shaped ends. In any case, the holes are formed depending on the bulk density of the insulating materials to be treated, so that a safe introduction of the coating in the holes is possible.

Of course, it is also possible to form the insulating element of a double-coated thermal insulation board. In this case, it has proven to be advantageous to offset the holes in both large surfaces of the thermal insulation board to each other, so that a connection of the holes of both surfaces does not exist. Such a compound would possibly result in the application of the coating composition to thermal bridges, which are to be prevented in such insulation elements. On the other hand, by staggering the holes in both large surfaces, there is also the possibility of deep anchoring to achieve such insulation elements, which have only a small material thickness, so that each anchorage of the coating can be formed greater than half the material thickness of the insulating element.

In rigid foam thermal insulation panels, it has proven to be advantageous to form the holes with an axial length of less than or equal to 5 mm, since then already the above-described problems regarding the demolition of the adhesive or plaster layers on the surface of the insulation board are substantially reduced.

On the part of the method according to the invention is provided to solve the problem that as a coating, a relatively low-viscosity adhesive injected specifically into the perforation and relatively granular adhesive mortar or the like are arranged on the surface.

In this case, 5 to 20 holes per cm ² , in particular 8 to 10 holes per cm ² in fibrous thermal insulation panels or 10 to 16 holes per cm ^{2 are introduced} in rigid foam thermal insulation panels in the large surface to be coated.

Preferably, both large surfaces of the thermal insulation panels are perforated, in particular needled and then coated, wherein the holes in the opposite surfaces are arranged offset from one another.

It has proven to be advantageous to apply the coating at the factory. Here, the coating can be incorporated both manually and mechanically in the surface of the thermal insulation board.

In order to achieve an intimate bond of the coating with the thermal insulation panel, it is advantageous to apply the coating under pressure to the surface of the thermal insulation panel and to press it into the perforation.

In the case of thermal insulation materials, polyurethane injections have proven to be suitable as coatings, whereas injections with filled silica sol, ormocers, waterglass, phosphate binders or the like are of advantage for heat-resistant thermal insulation materials. Finally, according to the method, it is advantageous to apply a second coating after the first factory coating.

Figur 1

eine Wärmedämmplatte für ein Dämmstoffelement in perspektivischer Ansicht;

Figur 2

ein Abschnitt eines Dämmstoffelementes im Querschnitt;

Figur 3

eine zweite Ausführungsform eines Dämmstoffelementes im Querschnitt;

Figur 4

eine dritte Ausführungsform eines Dämmstoffelementes im Querschnitt und

Figur 5

einen Abschnitt einer Vorrichtung zur Beschichtung von Dämmstoffen in Seitenansicht.

Further features and advantages of the invention will become apparent from the following description of the accompanying drawings in which preferred embodiments of an insulating element according to the invention are shown. In the drawing show:

FIG. 1

a thermal insulation panel for an insulating element in a perspective view;

FIG. 2

a section of an insulating element in cross section;

FIG. 3

a second embodiment of an insulating element in cross section;

FIG. 4

a third embodiment of an insulating element in cross section and

FIG. 5

a section of a device for coating insulating materials in side view.

A thermal insulation panel 1 shown in FIG. 1 has an upper, large surface 2, a lower, large surface 3, narrow sides 4 and longitudinal sides 5. The thermal insulation panel 1 is cuboid, so that the surfaces 2, 3 are arranged in each case at right angles to the narrow sides 4 and the longitudinal sides 5.

The large surface 2 is provided in a uniform pattern with holes 6 open to the surface 1. The thus formed thermal insulation board 1 is prepared for receiving a coating, such as an adhesive mortar or a plastic dispersion, wherein the coating not shown in Figure 1 is applied to the surface 2 and penetrates into the holes 6 to enter into an intimate anchoring with the thermal insulation board 1 ,

In the figures 2 to 4 different embodiments of insulating elements are shown, each consisting of a thermal insulation board 1 and a coating 8.

In Figure 2 it can be seen that the holes 6 are cylindrical in the predominant part and conical in their closed end. When applying the coating 8 on the surface 2 of the thermal insulation board 1, the coating 8 penetrates into the holes 6 and fills them completely. In this case, the coating can also undergo an anchoring, aligned parallel to the large surfaces 2, 3, with the fibers 9 of the thermal insulation board 1. It can also be seen in FIG. 2 that the coating 8 is arranged in a region of the thermal insulation board 1 which is near the surface.

In contrast, Figure 3 shows a section of an insulating element 7, wherein the coating 8 penetrates the thermal insulation board 1 over its entire material thickness. The holes 6 are cylindrical in this embodiment.

In contrast, FIG. 4 shows an insulating element 7 which is provided with a coating 8 on both surfaces 2 and 3. Also in this embodiment, the thermal insulation element 1 at right angles to its surfaces 2 and 3 arranged holes 6, the pyramidal formed and filled after application of the coatings 8 with coating material.

In order to avoid thermal bridges in the insulating element 7 in this embodiment, the holes of the two surfaces 2, 3 are arranged offset to one another, so that a connection between the reaching into the thermal insulation board 1 wedges of adhesive mass does not exist.

Finally, FIG. 5 shows a device 10 for the treatment, in particular coating of insulating elements. This device 10 consists of a carrier 11 which is linearly movable via linear motors 12 in a direction not shown insulating material to or from this Dämmstofflage.

The carrier 11 has a plurality of needles 12, which are substantially cylindrical and have a conical tip. These needles 12 penetrate into the thermal insulation board 1 and perforate the thermal insulation board 1, for example, with a pattern, as shown in Figure 1.

A part of the needles is designed as hollow needles 13, wherein each hollow needle 13 has an axially extending, centrally arranged channel 14, which channel 14 is connected to a supply line 15. Adhesive material is fed to the hollow needle 13 via the supply line 15, which is injected into the thermal insulation panel 1 when the support 11 is lowered and needles 12 or 13 penetrate into the thermal insulation panel 1. But it is also conceivable that all needles 12 are formed according to the hollow needles 13.

With the device described above, a thermal insulation board 1 is perforated before a coating 8 is applied to the perforated large surface of the thermal insulation board to form an insulating element 7. The liquid coating 8 penetrates at least into the holes 6 of the perforation and preferably also in the vicinity of these holes 6 between the fibers 9, so that the coating 8 not only adheres to the surface of the thermal insulation board 1, but also in the interior of the thermal insulation board first is anchored.

After curing of the coating 8, it is possible to apply a further coating, so that insulation elements 7 are produced, which are highly resilient and can be provided, for example in thermal insulation composite systems with a clinker clothing. The second coating can also be factory or on-site, i. be applied to the construction site. It must be ensured that the second coating forms an intimate connection with the first coating.

Claims (16)

1. Process of treating, especially coating insulating materials with a coating for at least partially pasting together a thermal insulation board produced from said insulating material with cover layers or supporting surfaces, wherein said thermal insulation board particularly consists of mineral fibres, preferably glass or rock wool fibres or of solid polystyrene foam and wherein said coating is applied to at least one major surface of said thermal insulation board and said thermal insulation board is perforated, especially needled at least in the region of the surface to be coated, prior to and/or during applying said coating,
   characterized in
   that as a coating (8) a relatively liquid bonding agent is purposefully injected in said perforation and that an adhesive mortar or the like which are relatively granular compared thereto are arranged on said surface (2)
2. Process according to claim 1,
   characterized in
   that in the major surface (2) to be coated there are made 5 to 20 holes per cm², particularly 8 to 10 holes per cm² in the case of fibrous thermal insulation boards (1) or 10 to 16 holes per cm² in the case of solid foam thermal insulation boards (1).
3. Process according to claim 1,
   characterized in
   that said two major surfaces (2, 3) of the thermal insulation board (1) are perforated, especially needled and thereafter coated, with the holes (6) in the opposite surfaces (2, 3) being arranged in a mutually offset fashion.
4. Process according to claim 1,
   characterized in
   that said coating (8) is applied in the factory.
5. Process according to claim 1,
   characterized in
   that said coating (8) is worked in the surface (2) of the thermal insulation board (1) manually and/or by machine.
6. Process according to claim 1,
   characterized in
   that said coating (8) is applied to the surface (2) of the thermal insulation board (1) under pressure and is pressed into the perforation.
7. Process according to claim 1,
   characterized in
   that after the first coating in the factory a second coating is applied.
8. Insulating element produced in the process according to one of the claims 1 to 7 and intended for thermal and/or sound insulation purposes, especially in connection with composite thermal insulation systems, consisting of a thermal insulation board, especially from mineral fibres, preferably from glass and/or rock wool fibres, or solid polystyrene foam, and a coating that is applied to at least on major surface for partially bonding together said thermal insulation board (1) with cover layers or supporting surfaces, wherein said thermal insulation board (1) is formed in a perforated fashion at least in the region of said major surface (2) or surfaces (2, 3) having said coating (8) and includes a plurality of holes (6) open towards said coating (8), and wherein said coating (8) forms protrusions which penetrate in said holes (6), so that the cured coating
   characterized in
   that said coating (8) consists of a relatively liquid bonding agent in the holes (6) and of an adhesive mortar on the surface (2), which adhesive mortar is relatively granular compared to said liquid bonding agent.
9. Insulating element according to claim 8,
   characterized in
   that said thermal insulation board (1) is needled.
10. Insulating element according to claim 8,
    characterized in
    that said thermal insulation board (1) includes 5 to 20 holes (6) per cm², particularly 8 to 10 holes (6) per cm² in the case of fibrous thermal insulation boards or 10 to 16 holes (6) in the case of solid foam thermal insulation boards (1).
11. Insulating element according to claim 8,
    characterized in
    that said holes (6) have a diameter of 1 to 5 mm, preferably of 2 to 3 mm at least in the region of said major surface (2), in dependence of their close arrangement in the major surface (2) of the thermal insulation board (1).
12. Insulating element according to claim 8,
    characterized in
    that said mineral fibres run substantially parallel to the major surfaces (2, 3) and that said holes (6) are formed conically and/or in the form of a truncated cone.
13. Insulating element according to claim 8,
    characterized in that said mineral fibres run substantially at right angles or inclined to the major surfaces (2, 4) and that said holes (6) are formed cylindrically, conically and/or as a truncated cone with calotte-shaped or spherical segment-shaped ends, respectively.
14. Insulating element according to claim 8,
    characterized in
    that said holes (6) are oriented substantially at right angles to the major surfaces (2, 3) of the thermal insulation board (1).
15. Insulating element according to claim 8,
    characterized in
    that said holes (6) in said two major surfaces (2, 3) of the thermal insulation board (1) are arranged in a mutually offset fashion.
16. Insulating element according to claim 8,
    characterized in
    that said holes (6) have an axial length equal to or less than 5 mm in the case of solid foam thermal insulation boards.

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