EP2164815A1

EP2164815A1 - Heat and footfall insulation material having a low content of hydraulic binder and a high proportion of foamed polystyrene

Info

Publication number: EP2164815A1
Application number: EP08774685A
Authority: EP
Inventors: Michael Jernei
Original assignee: Sika Technology AG
Current assignee: Sika Technology AG
Priority date: 2007-07-03
Filing date: 2008-07-03
Publication date: 2010-03-24
Also published as: WO2009004049A1; EP2014625A1

Abstract

The present invention relates to an insulation material dry mix for producing footfall and heat insulation. These insulation material dry mixes have a low proportion of hydraulic binder, a dispersion polymer and a high proportion of polystyrene in the form of foamed polystyrene beads and foamed polystyrene pellets. The insulation material dry mix or the insulation material composition which have been made up with water are extremely well suited for producing footfall and heat insulations, in particular for floors. They have extremely high heat and footfall insulation properties and also a short time until they can be walked on or sufficiently matured for floor laying.

Description

THERMAL AND THERMAL INSULATION WITH LOW CONTENT OF HYDRAULIC BINDER AND HIGH SHARE OF DAMPED POLYSTYRENE

Technical area

The invention relates to Dämmstoffzusarrinnensetzungen and insulation materials for thermal and impact sound insulation, which are formulated on the basis of foamed polystyrene and hydraulic binders.

State of the art

Thermal and impact sound insulation is very important in modern building construction. It is known that foams have good insulating properties. Foams based on polystyrene or polyurethane, in particular as boards, and rockwool or mineral wool boards are widespread. Usually, these boards are subsequently covered with a cover layer, for example earth-dry processed undercoat mortar, or concrete, ("screed") or flow screeds or slab constructions (wood, etc.), as the base layer under these base courses Two pieces to be processed separately Firstly, a bed of, for example, chippings (bound or unbonded) is level compensated, then panels are very laboriously cut to size, and efforts have therefore been made to develop cement-based jointless foams and foams. However, since the foams have to be solidified by the cement matrix, such an insulating material, which is constructed solely on a cement binder, has a very high cement content and therefore, in addition to a high specific gravity, a se hr poor heat and impact sound insulation. Typically, minimum binder contents of 120 kg of cement per m ^{3 are} necessary in order to achieve sufficient load-bearing capacity. It was therefore tried to reduce the cement content. Thus, it has been found in DE 3345550 A1 that the addition of hydrolyzed silica such a reduction of the cement in a polystyrene containing thermal insulation plaster for the outside of buildings by 25%. However, because of their high binder content, such compositions have very rigid insulations which can not be used as impact sound insulation with dynamic stiffnesses below 70 MN / m ³ .

EP 0 819 662 A1 describes an insulating material for heat and impact sound insulation of a floor which, in addition to a foam granulate and a cementitious binder, has a proportion of amorphous silica of at least 10% by weight, based on the cement. The mode of action is explained here by the pozzolanic effect of the silicic acid used.

These mineral binders of the prior art realistically allow a reduction of the binder content to only 60 kg and more per m ³ Styrofoam granulate. These fillings - carried out sufficiently stable - are relatively rigid and have after hardening a dynamic stiffness before commissioning between 40 and 60 MN / m ³ and therefore show only a medium impact sound reduction. In contrast to the highly cementitious beds (100 kg and more), however, the cementitious bonds between the granules partially break during direct walking before application of the cement screed and the bed settles and softens.

For the determination of the insulation properties, on the one hand the thermal conductivity [W / mK] and on the other hand the impact sound reduction [dB] or, with that, the dynamic stiffness [MN / m ³ ] are determined. Bonded granular beds according to the prior art typically have thermal conductivities of greater than 0.044 W / mK and dynamic stiffness of about 20 MN / m ³ after loading.

It is therefore desirable to have systems which, with significantly improved binding force and improved recovery behavior, have equivalent or better heat and impact sound properties, and are therefore significantly safer to use.

DE 28 36 855 A1 discloses a thermal layer based on organic closed-cell waterproof foam particles with aluminum oxide cement, a dispersion of a copolymehsate and finely divided, swelling-acting drying aids, water-soluble thixotropic agents and instant adhesion and air-pore stabilizers.

DE 200 17 460 U1 discloses a dry mix of polystyrene granules (polystyrene recyclate) and a hydraulic binder, wherein the binder is ground on the granules in order to prevent that takes place during storage, a demixing of polystyrene and binder. However, the dry blends disclosed herein have very high densities, which is due to the high proportion of cement, or on the small proportion of polystyrene granules. Such compositions have to be improved heat and impact sound properties.

DE 29 30 615 A1 discloses a mixture for a fast-curing screed with closed-cell foam particles, a hydraulic binder, diluents, leveling agents, water retention agents and a lubricant. However, these mixtures have a very low proportion of foamed polystyrene, so that such compositions have much to be improved heat and impact sound properties.

WO 2005/021459 A2 discloses an insulation composition with foam granules and a cementitious binder, a water retention agent in an amount between 0.1 and 25 wt .-%, based on the cement, and a ratio of foam granules to cement of 20 wt .-% and 120% by weight.

WO 2005/021460 A2 discloses an insulation composition with foam granules and a cementitious binder, a water retention agent, a dispersion plastic in an amount of 2 to 15 wt .-% dry matter based on the cement and cement in an amount below 100 kg / m ³ of water based insulation composition.

However, it has been found that these systems are still capable of improvement despite improvements in strength / binder ratio and reduction in drying time. Presentation of the invention

Object of the present invention was to develop insulating materials based on a hydraulic binder, which have the highest possible proportion of foamed polystyrene, and after curing with water, a high intrinsic strength and excellent heat and impact sound insulation, especially after mechanical stress, have can be processed well and quickly accessible, or ready to go, are.

Surprisingly, it has been found that this object can be achieved by an inventive insulation-dry composition according to claim 1, or by an insulation composition containing the inventive insulation-dry composition and water. This allows use of hydraulic binder of less than 80% by weight, and of expanded polystyrene of more than 8% by weight, based on the insulation dry composition, while maintaining excellent mechanical strength as well as excellent insulating properties. A significant advantage of these compositions is good processability coupled with rapid accessibility and ready-to-use, as well as excellent strength with further reduced bulk density and thus improved thermal conductivity.

Further aspects of the present invention are uses of an inventive insulation dry composition or an insulation composition in a floor construction for heat-insulating and / or impact sound insulating purposes and a floor construction comprising an insulating material obtained from an inventive dry insulation composition or an insulation composition.

Preferred embodiments of the invention are the subject of the dependent claims.

Brief description of the drawings

In the following, embodiments of the invention will be explained in more detail with reference to the drawings. The same elements are provided in the various figures with the same reference numerals. Fig. 1 a screed floor construction in cross section in the wall area

Fig. 2 is a screed floor construction in cross section with lines

3 shows the measuring arrangement for determining the dynamic rigidity FIG. 4 shows the schematic measuring arrangement according to FIG

Way to carry out the invention

The present invention relates, in a first aspect, to an insulation dry composition for producing impact sound insulation and thermal insulation. This insulation dry composition comprises

a) a hydraulic binder in an amount of less than 80% by weight, based on the insulating dry composition b) at least one dispersion plastic c) at least polystyrene in the form of foamed polystyrene beads d) at least polystyrene in the form of foamed polystyrene granules with a mechanical stress damaged surface. The amount of polystyrene (sum of c) and d)) is more than 8% by weight, based on the insulation dry composition.

The insulation dry composition contains a hydraulic binder (a). For the interpretation of the term "hydraulic binder" applies in this document an expanded definition: in addition to the classically referred to as hydraulic binders

Substances, namely those substances which can be hardened with water even under water ("hydraulic binder 'in CD Römpp Chemie Lexikon - Version 1.0, Stuttgart / New York, Georg Thieme Verlag 1995), are also the latent-hydraulic binder, namely which the binding of additives with water set ('latent hydraulic binder' in CD Römpp Chemie Lexikon - Version 1.0, Stuttgart / New York, Georg Thieme Verlag 1995), as well as such substances which react only in air with water ('nonhydraulisches binder' in CD Römpp Chemie Lexikon - Version 1.0, Stuttgart / New York, Georg Thieme Verlag 1995), referred to as hydraulic binders.

Thus, in addition to cements, especially calcium sulfate, in the form of anhydrite, hemihydrate or dihydrate gypsum, or blast furnace slag, are also referred to as hydraulic binders.

Preferably, the hydraulic binder is or contains at least one cement. In particular, the cement is a cement according to Euronorm EN 197. Preferred cements are Portland cements, sulfoaluminate cements and high-alumina cements, in particular Portland cement. Cements of cements can lead to particularly good properties. Particularly suitable are mixtures of at least one Portland cement with at least one Sulfoaluminatzement or at least one Tonerdeschmelzzement. For quick curing especially cementitious rapid binder are used, preferably at least one alumina cement or other aluminate source, such as aluminate clinker, and optionally calcium sulfate, in the form of anhydrite, hemihydrate or dihydrate gypsum; and / or calcium hydroxide.

The proportion of the hydraulic binder, in particular of the cement, is preferably 40-80% by weight, in particular 50-80% by weight, preferably 50-75% by weight, based on the insulation dry composition. The proportion of the hydraulic binder, in particular of the cement, is in particular limited to 100 kg / m ³ , preferably 80 kg / m ³ , of the water-based insulating dry composition upwards.

The insulating dry composition contains at least one dispersion plastic (b). Under a dispersion plastic is present throughout the

Letters understood an organic copolymer which is present in an aqueous dispersion or as a redispersible powder, for example obtained by a spray drying of a dispersion Such powders are the Professional also known as plastic dispersion powder. This copolymer is in particular a copolymer of at least two, preferably of two, different ethylenically unsaturated monomers, of which at least one comonomer, preferably all comonomers, are selected from the group comprising ethylene, butadiene, methacrylic acid, acrylic acid, methacrylic acid esters, acrylic acid esters , Styrene, vinyl acetate and acrylonitrile.

The copolymers acrylic acid / styrene, methacrylic acid / styrene, styrene / butadiene and vinyl acetate / ethylene have generally been found to be suitable. However, under certain circumstances, it is advantageous to use vinyl acetate-free polymers.

Particularly preferred are acrylic acid / styrene and methacrylic acid / styrene copolymers.

These copolymers are prepared by the usual polymerization processes known to those skilled in the art. The dispersion resin typically has a molecular weight in the range between 30O00 and 10'OOOOOO g / mol, in particular between 100O00 and 5OOO ¹ OOO g / mol. Particular preference is given to molecular weights of between 200,000 and 2,000,000 g / mol.

The particles of the dispersion plastic are in a finely divided aqueous plastic dispersion advantageously between 0.04 to 0.5 .mu.m, in particular between 0.1 to 0.2 .mu.m, or in a coarsely disperse aqueous

Dispersion advantageous between 2 to 5 microns, and as Kunstoffdispersionspulver

0.5 to 10 μm after redispersion.

Surprisingly, it has also been shown that, while the elasticity of the insulation remains constant, higher bond strengths are achieved with dispersion plastics which have a low elastic character, that is to say a high glass transition temperature.

The dispersion plastic is preferably used in an amount of from 0.5 to 25, in particular from 0.5 to 15, preferably from 2 to 12,% by weight, dry matter, based on the hydraulic binder.

The mode of action of the dispersion plastic is essentially explained by the fact that the dispersion plastic particles have the adhesive strength of rigid, set binder hydraulic binder on the elastic foamed polystyrene particles significantly improved. For example, a microscope analysis has shown that the binder layer, which is only about 20-30 μm thick, does not detach on the granules even when the elastic spheres are compressed to a fraction of the original thickness.

The full development of the elastification effect of the dispersion plastic on the insulation-dry composition unfolds above all in interaction with a water retention agent, which is mentioned as a possible existing further constituent of the composition. It is extremely surprising that even a relatively small addition of a dispersion plastic gives the desired effect in the composition.

The insulating dry composition contains at least polystyrene in the form of foamed polystyrene beads (c). Foamed polystyrene beads are foamed in a known manner from expandable polystyrene, ie polystyrene, which contain a blowing agent, by heat treatment, in particular by hot steam. This process is known per se and has long been used for the production of expanded polystyrene rigid foams (EPS), for example Styropor®, in particular in the production of EPS rigid foam boards, as they are mainly used for insulation. The degree of foaming and thus the raw bulk density of the foamed polystyrene beads can be varied by the process parameters in the foaming on demand. The pearls have almost perfect spherical shape and are composed of closed foam cells. The surfaces are intact except for small open pores which are distributed needle-like on the entire spherical surface. In particular, they have no damage caused by mechanical stress. Foamed polystyrene beads, which were merely foamed and not further processed, are also called new polystyrene. A particularly preferred embodiment for foamed polystyrene beads is New Styrofoam®, ie Styrofoam®, which has merely been foamed and not further processed. The insulating dry composition contains at least polystyrene in the form of foamed polystyrene granules with a surface damaged by mechanical stress (d). In contrast to the foamed polystyrene beads mentioned above, these foamed polystyrene granules are not spherical but typically have a polyhedral shape. There are two embodiments which result in such foamed polystyrene granules.

On the one hand, foamed polystyrene granules of foamed polystyrene plates and / or molded parts, in particular of polystyrene packaging, by mechanical comminution, such as milling, can be obtained. In such a comminution, the fused together foam particles are torn apart, so that the surface has cracks, pockets and trailing edges. This type can be obtained in particular from foamed polystyrenes, which are collected as waste, and is also referred to as recycled polystyrene.

On the other hand, it is possible to obtain foamed polystyrene granules having a surface (d) damaged by mechanical stress by mechanical processing, in particular, by rolling or roughening, directly from foamed individual polystyrene beads (c) as described above. In such a mechanical machining cracks and / or cracks in the surface.

Depending on the degree of foaming or density of the starting material used and the type of mechanical processing or its process parameters, different bulk densities can be achieved.

Both the foamed polystyrene granules with a surface damaged by mechanical stress (d) and the foamed polystyrene beads (c) can be screened if necessary and so certain grain size distributions are achieved. Usually, the particle size is between> 0 and 8 mm. The proportion below 1 mm is preferably less than 10% by weight and the proportion above 2 mm is more than 75% by weight, since the binder requirement is additionally increased by smaller particles. The amount of polystyrene in the form of foamed polystyrene beads and the polystyrene in the form of foamed polystyrene granules with a surface damaged by mechanical stress, ie the sum of c) and d), based on the insulation dry composition, is more than 8% by weight , preferably more than 10% by weight. In particular, the proportion of polystyrene (sum of c) and d)) is between 15 and 45

% By weight, in particular between 15 and 40% by weight, preferably between 20 and 40% by weight, based on the insulation dry composition.

Particularly preferably, the polystyrene in the form of foamed polystyrene beads (c) or in the form of foamed polystyrene granules (d) has a bulk density between 8 and 20 kg / m ³ , in particular between 10 and 18 kg / m ³ , preferably between 12 and 18 kg / m ³ , up.

For the essence of the invention, it is essential that the insulating dry composition contains a mixture of polystyrene in the form of foamed polystyrene beads (c) to polystyrene in the form of foamed polystyrene granules (d) having a surface damaged by mechanical stress. The weight ratio of polystyrene in the form of foamed polystyrene beads (c) to polystyrene in the form of foamed polystyrene granules (d) having a surface damaged by mechanical stress is in particular between 0.1 and 5, in particular between 0.2 and 3, preferably between 0.3 and 2.

When only foamed polystyrene beads (c) are used (ie, amount of d) = 0), the insulating composition can not be densified and smoothed by ordinary means, because the beads dodge due to their hardness and spherical shape, thus making densification in a large space impossible , In this compression state, the insulation is difficult to walk. Even if this insulating composition is sufficiently densified in a mold with great skill, the hardened insulation shows a high dynamic rigidity and is therefore unsuitable as impact sound insulation.

When only foamed polystyrene granules having a surface (d) damaged by mechanical stress are used (i.e., amount of c) = 0), the insulation dry composition requires greatly increased mixing water, and therefore the drying time is considerably retarded.

Furthermore, the binder content can not be reduced to the same extent due to the increased w / c value and the lower intrinsic strength of the polystyrene granules, as is the case when working with a mixture of c) and d).

In a particularly preferred embodiment, the insulating dry composition further contains at least one water retention agent. A "water retention agent" is defined throughout this document as follows:

For the purposes of this patent, a water retention agent is a substance which, according to a modified WoIf I I method, as explained below, has a water retention capacity of more than 85% for an organic water retention agent in one

Water / cement ratio (= "w / z") of 0.7

- more than 33% for an inorganic water retention agent at a w / c of 0.4

- more than 85% at a w / c of 0.7 for a mixture of organic and inorganic water retention agents:

It becomes a cellulose filter paper on a flat glass plate

(Schleicher & Schuell, D-37582 Dassel, No. 2294 0 11 cm), then a thin one

Cellulose fleece (Schleicher & Schuell, D-37582 Dassel, No. 0980/1 0 11 cm) and placed on a plastic ring (inner diameter 90 mm and height 15 mm).

The cement paste is prepared by mixing for 3 minutes with a plastic spatula of cement (Milke Cem I 52.5 R Werk Geseke), water, corresponding to a weight-based water / cement ratio (= "w / z") of 0.7, or 0.4, and the substance to be tested in each case as a water retention agent prepared and immediately flush filled with the top edge in the ring (need about 180g cement paste). The dosage of the substance to be tested for this test must be between 0.4% and 5% by weight for an organic water retention agent and between 12% and 15% for an inorganic water retention agent. For a mixture of inorganic and organic water retention agents, for this test the dosage is between 0.4% and 5% by weight for the organic water retention agent and between 12% and 15% for the inorganic water retention agent.

After 3 minutes exposure from ring filling, the water release to the cellulose filter paper is determined by differential weighing of same before and after water absorption and recalculated to 100 g of cement paste. From the thus determined water release m _x for the substance to be tested as water retention agent and m _re / for the zero test, ie cement without substance, the water retention capacity (WRV) is determined according to the following formula.

WRV = - ^ - mref The water retention agent may be an organic or an inorganic compound. Inorganic water retention agents can typically be found in the multilayer silicates such as bentonite, smectite, montomorillonite, or even in calcined kaolins, in particular metakaolin. Metakaolin has proven to be a particularly suitable inorganic water retention agent. Organic water retention agents are typically found in cellulose ethers, methylcelluloses, hydroxypropylmethylcelluloses, hydroxyethylcelluloses, carboxymethylcelluloses, and other cellulose derivatives, starch ethers, welan gum, or synthetic thickeners such as polyacrylic acid or PU acrylates. To be particularly suitable Hydroxyalkylmethylcellulosen, in particular hydroxypropyl methylcelluloses and Hydroxyethylmethylcellulosen shown.

The weight fraction of the sum of all water retention agents used depends strongly on the desired insulating and mechanical properties of the water-cured insulation dry composition and the water retention agent used, and typically ranges between 0.1 and 25% by weight, based on the hydraulic binder.

Inorganic water retention agents are advantageously used in a concentration of between 0.2 and 25% by weight, preferably between 0.5 and 9% by weight.

%, in particular between 0.5 and 3 wt .-%, based on the hydraulic

Binders, in particular based on the cement used. organic

Water retention agents are advantageously used in a concentration between 0.1 and 9 wt .-%, preferably between 0.5 and 5 wt .-%, in particular between 0.7 and 4 wt .-%, based on the hydraulic binder, in particular based on the cement used.

Particularly preferred are organic water retention agents. The use of a water retention agent is advantageous in that it is possible to formulate insulating dry compositions which have a particularly small proportion of hydraulic binders and, above all, small amounts of water for rapid ready-to-use.

The advantageous effect of the water retention agent is explained by the fact that in the insulating materials of the prior art, the water used, which is required for the hydraulic curing of the cement, is usually absorbed by the foamed polystyrene to a considerable extent, so that at the surface of the setting of the hydraulic binder is disturbed, and therefore on the polystyrene foam surface no proper bond is formed. This is all the more pronounced the smaller the proportion of the hydraulic binder relative to the polystyrene and the smaller the amount of mixing water. This is greatly prevented by the use of water retention agents and the hydraulic binder forms after setting with the polystyrene foam surface an excellent bond, even if the proportion of the hydraulic binder is small compared to the polystyrene foam. The use of the water retention agent makes it possible to use a small w / c factor (water / cement weight ratio) and thus a delay in the setting and deterioration of the mechanical properties can be largely prevented.

Optionally, the insulation dry composition additionally comprises at least one filler which is not a foamed polystyrene, no hydraulic binder, no dispersion plastic and no water retention agent and the average particle size is chosen so that the ratio of average particle size of the filler to average particle size of the foamed polystyrene smaller 1, especially between 0.01 and 0.5, in particular between 0.02 and 0.25. Such fillers may be elastic or rigid. However, preferred are elastic fillers. Examples of rigid fillers are glass beads, hollow glass beads, expanded glass beads, sand, quartz powder. As elastic fillers are in particular rubber or rubber, preferably in granular or powder form, into consideration. The use of these fillers is especially advantageous when a

Insulating material with a low proportion of hydraulic binder, typically in the range of between 15 and 30 kg per m ³ of composition, to be achieved.

In the case of larger proportions of hydraulic binders, typically a binder level of more than 25 kg per m ³ of composition, the insulating dry composition may contain special solid particles such as mica platelets, recycled scrap granules, water-absorbent plastic fibers, hydrophobic plastic particles such as Shreds of polyethylene or polypropylene films. These particles can intentionally introduce predetermined breaking points into the insulating material, which leads to lower dynamic stiffnesses, up to 5 MN / m ³ , and thus to better insulating properties, compared with the same compositions without these solid particles, without the mechanical load capacity is reduced too much. The particle size is very much dependent on the individual composition or product requirements and must be determined in each case by the skilled person within the scope of his knowledge, or optimized. The insulation dry composition may further contain other ingredients. Such constituents are, for example, pigments, flame retardants, UV stabilizers, complexing agents, hardening and / or setting accelerators, film-forming aids, hardening and / or setting retarders, corrosion inhibitors, water repellents, air-pore formers, defoamers, dyes, surfactants, odorous substances or biocides.

It may also be advantageous in some circumstances that the insulating dry composition is free of amorphous silica.

One skilled in the art can use his expertise in granulometrics to optimize the insulation dry composition to the particle size of the individual ingredients.

The dry bulk density of the insulating dry composition is preferably less than 110 kg / m ³ , in particular less than 100 kg / m ³ , preferably between 20 and 100 kg / m ³ .

An insulating material based on the technology of the prior art has - especially at lower cement content - a significantly poorer composite in the cured insulation, which means that when its loads, such as those caused by a walk, break the bonds between the granules and in Large quantities of foam granulate particles break out, and consequently the insulating material "crumbles".

The insulation-dry composition can with usual

Be prepared and stored in the absence of water or moisture for a long time packed. However, it is quite possible that the insulation-dry composition before

Place where the application is mixed. The insulating dry composition is mixed with water used. Thus, another aspect of the present invention is an insulation composition obtained from an above-described insulation dry composition and water.

The amount of water used depends strongly on the amount of hydraulic binder. If the hydraulic binder contains or consists of cement, in particular Portland cement, the amount of water is advantageously such that the water / cement ratio is from 0.2 to 3, in particular 0.3 to 2.5, preferably 0.3 to 1.5. The water / cement ratio may thus differ from that which the cement or concrete technologist usually applies.

The wet bulk density, or the density immediately after

Application ('dry mortar raw density') of the insulating composition is preferably less than 140 kg / m ³ , in particular less than 130 kg / m ³ , preferably between 45 and 120 kg / m ³ , most preferably between 45 and 100 kg / m ³ .

The insulation composition can be prepared immediately prior to application from the individual components or semi-finished products or it can be industrially manufactured and / or transported mixed to the location of the application.

The water is mixed with it immediately before application to Dämmstoffzusammensetzung or mixing the individual components thereof.

For this purpose, different variants of the production are suitable.

In a first variant, the hydraulic binder with the

Most, typically about 90%, of the foamed polystyrene are mixed. For this purpose, first the water, then the

Disperse plastic and then the remainder of the polystyrene mixed.

If a plastic dispersion is used, this can be done in advance with the

Mixed water and thus be added simultaneously with the water. If a plastic dispersion powder is used, it can also be mixed with the hydraulic binder, if appropriate with the water retention agent and the foamed polystyrene, before the addition of water. It may prove to be advantageous if the water and the plastic dispersion are added not in one shot but in portions with stirring.

Another variant of the preparation is that the foamed foam granules are submitted, then the water, then the possibly present water retention agent, then the hydraulic binder and then the dispersion plastic, optionally mixed in the form of a dispersion.

In a preferred variant of the preparation, the hydraulic binder is premixed with the possibly existing water retention agent and the dispersion plastic, then the binder is mixed with the water and finally the foamed polystyrene is added. It may also be advantageous here if the components are not added at one go, but in portions with stirring.

A further preferred variant of the preparation consists in first admixing the hydraulic binder, with which any water retention agent is present, some of the water and then this premix to the foamed polystyrene in at least two stages with metered addition of the water. The mixing vessel is first charged with about three quarters of the total amount of polystyrene before the premixed binder content is added with the metered mixing water. Subsequently, or mixed with the mixing water, the dispersion plastic is added. The remaining polystyrene is then filled during the mixing process.

Another embodiment of the preparation is that the foamed polystyrene with the hydraulic binder, possibly present water retention agent and the dispersion plastic are mixed, and then the water is mixed. In all of these described Herstellvahanten the

Mixing advantageously carried out in a designed for compressed air delivery of the mixed mixing vessel. After the mixing process, the mixture can then be discharged by means of compressed air and transported via a hose to the place of introduction.

Another possibility for the production consists in the fact that the individual components in the correct ratio continuously metered and continuously mixed and conveyed in a short mixing section.

For thermal insulation, the insulation composition is placed between two different temperature materials and has the function of preventing the heat energy transfer between them. It is clear that therefore this insulation composition can be used on the one hand for thermal insulation or even for cold insulation. For impact sound insulation, it is important to acoustically decouple the surface, which is typically substantially horizontal, on which the steps are softened, or to acoustically decouple a structure directly connected thereto from the remainder of the building structure by applying an insulation composition therebetween. After the bonding of the insulation compositions described, the insulating materials thus produced have excellent insulating properties even in small layer thicknesses of a few centimeters. Thus, another object of the present invention is an insulating material which is obtained from the previously described insulating dry composition after mixing with water, or from a previously described insulating composition after reaction of the hydraulic binder with water.

The described insulation dry composition, or the described insulation composition, is used in particular in the production of screed floor. In addition, however, it can also be used as filling cavities which are bounded by substantially vertically arranged surfaces. An example of such an application is the isolation between two walls. A screed floor construction typically takes place as shown schematically in FIG. 1 and FIG. On the floor 1 of the building the mixed with water insulation dry composition is applied as Dämmstoffzusammenammmen- set 2 in a usual layer thickness between 5 and 10 cm. Increasingly, layer thicknesses of 15 cm and more are introduced for thermal insulation in comparison with cellar ceilings and roof-terrace apartments. Especially with these increased insulation thicknesses, the drying of insulation of the prior art extends to 3 - 9 weeks.

If necessary, installation tubes 3 are present in the insulating layer. If such pipes are present, care must be taken to ensure that they are well wrapped by the insulation composition 2 so that no bridges for sound or heat energy can form. At the earliest, as soon as the insulating composition has built up sufficient strength so that it can be walked on, a thin release film 6, usually made of polyethylene, and, if appropriate, underfloor heating pipes 4 may optionally be laid. Subsequently, a cement screed 5 is applied. In order to achieve a good thermal and impact sound insulation, it must be ensured that the cement screed 5 or cover slips attached to it are always adequately insulated by further insulating materials 7 such as foam strips passing through the insulating layer 2 through pipes or conduits 9. Such a separation layer with insulating properties is advantageously also in the wall area between wall 8, typically made of concrete or brick, and cement screed 5 to install.

In addition to the insulating function, the insulating layer also has the function of a leveling layer to compensate for unevenness in the floor and facilitates the installation of ducting and installation pipes. This is particularly important in renovation work, where for the insertion of the pipes and pipes of consuming and - especially in a concrete floor tedious step of sharpening or milled along the floor. In addition, the greatly reduced weight, compared to a conventional leveling ground, makes it possible to efficiently block even soils with a small load-bearing capacity. The inventive insulation composition hardens with

Water to a mass in which the foamed polystyrene is interconnected by the matrix of the set hydraulic binder. The

Layer thickness of the cement is small and is typically less than 0.1 mm.

The density of the insulating material after setting and drying, ie after reaching the equilibrium moisture content, is preferably less than 120 kg / m ³ , in particular less than 100 kg / m ³ , preferably between 35 and 90 kg / m ³ .

It is of course also possible by the use of more hydraulic binder, and thus less foamed polystyrene, to increase the strength of the insulating composition, whereby, however, with significant increase in strength, the good insulating properties are largely lost. In cases where the insulating properties are not of primary interest or are not necessary, such a composition may well have interesting applications. For example, within certain limits, the weight of a floor could be significantly reduced for higher loads without any significant loss of strength being expected.

For use as an insulating material, however, the largest possible proportion of foamed polystyrene, as it is still acceptable from the inherent strength of the cured insulation composition forth, strive for. Due to the consistency of the mixed with water insulation dry composition on the one hand, the leveling of the surface is simplified and on the other hand allows mounting on an inclined surface. For example, a flat roof, but also a pitched roof, is possible with the same insulation composition.

It is possible with little effort to create a seamless, and thus perfectly insulating, heat and impact sound insulation layer in large thicknesses, which after a short time already resilient, for example, walk-in. The inventive insulating materials, or the insulating compositions after curing with water, have amazingly good heat and impact sound insulation properties. Thermal insulation properties can be achieved below 0.045 W / mK. Dynamic stiffnesses of less than 20 MN / m ³ , in particular lower than 10 MN / m ³ can be achieved. Experience has shown that such values lead to a subsonic noise reduction of more than 30 dB.

A preferred embodiment in which the insulating composition has an amount of hydraulic binder of 15-35 kg / m ³ , in particular 15-30 kg / m ³ , based on the uncured insulation composition, characterized by very good impact sound and Thermal insulation. This embodiment is mainly used in cases where primarily high to highest impact sound insulation and thermal insulation are required, and the requirements for the mechanical strength of the insulation material are lower. It is possible with insulating compositions of this embodiment Wärmeleitfähigkeiten λi _O ° c, dry (dried, measured at 10 ⁰ C average temperature in accordance with ÖNorm B 6015, Part 1) of <0.038 W / m K possible.

Another preferred embodiment, in which the insulating composition has an amount of hydraulic binder of 35-50 kg / m ³ , in particular 40-50 kg / m ³ , based on the uncured insulation composition, characterized by extremely fast drying and excellent high mechanical strengths. This embodiment is mainly used in cases where primarily highest load capacities and fastest accessibility are required, and the requirements for impact sound and thermal insulation are indeed present and required to a high, but not at the highest level. There are with this embodiment insulation compositions thermal conductivities λio ° C, dry (dried, measured at 10 ⁰ C average temperature based on ÖNorm B 6015, part 1) of <0.043 W / mK possible. In a further preferred embodiment, in which the insulating composition has an amount of hydraulic binder of 30-45 kg / m ³ , in particular 30-40 kg / m ³ , based on the uncured insulating composition, characterized by greatly improved impact sound - And thermal insulation and greatly improved high mechanical strength. This embodiment is mainly used in cases where a good mix of load capacity, fast accessibility and high demands on the impact sound and thermal insulation are required. There are with insulation compositions of this embodiment, heat conduction capabilities .lambda..sub.i _O ° C, dry (dried, measured at 10 ⁰ C average temperature based on ÖNorm B 6015, part 1) possible of <0.040 W / mK.

The insulating materials are already resilient after a short time. The load capacity is usually determined by the accessibility. It can be achieved according to the invention insulating materials, which are already walkable after 1 day, sometimes even after 4 hours.

The insulation compositions are characterized by excellent processability coupled with a short shelf life. The term "ready-to-eat" is understood to mean the time that elapses before an insulating material applied in such a manner can be overcoated, without the excess moisture in the insulating material giving rise to problems. The limit value for the maximum permissible excess moisture for applications under floating floorings in residential and administrative buildings can be considered to be a thickness-independent value of 3 kg / m ² . This excess moisture diffuses slowly through the building materials and caused experience, no damage. Depending on the layer thickness, this surface and non-volume-dependent limit thus requires different residual moisture per unit volume, which can be accepted when occupied. Therefore, higher bulk densities not only dry slower, but also require a higher degree of dryness in order to fall below this excess moisture of 3 kg / m ² . Specifically herein lies the advantage of the inventive insulation dry composition which can be processed with low make-up water contents. It can be with Achieve slip rates of one day for the inventive insulation compositions. With the use of cementitious quick binders even slip tires of 3 to 4 hours can be achieved, which allows completely new applications, especially in the field of roof insulation.

LIST OF REFERENCE NUMBERS

1 floor 8 wall

2 Insulation composition 9 pipes or pipes

3 installation tubes 10 sample, insulation material

4 underfloor heating pipes 11 screed

5 cement screed 12 accelerometer

6 release film 13 impulse hammer

7 insulation materials

Examples

The following examples illustrate the present invention.

Used raw materials

Table 1. Used raw materials. Water retention agents

The substances in Table 2 were, as described, examined at a w / c ratio of 0.7 or 0.4 on the water retention capacity by means of modified WoIf-I I method.

Table 2. Water retention agents.

Insulation Composition and Specimen Preparation

For the preparation of the specimens was as a hydraulic binder a very early high-strength Portland cement (Milke Cem I 52.5 R from the factory

Geseke) ("Cem") or a ternary system ("fast binder")

Fused alumina cement (proportion:> 50% by weight), hemihydrate gypsum (proportion:> 30

Wt .-%) and Portland cement (proportion: <10 wt .-%) used.

The novel compositions (B1, B2) and comparison compositions (/ ef.7 to Ref. 5) were prepared according to Table 3. The amounts of the water-mixed insulation compositions given there are based on kg / m ^{3 of} the uncured wet mix.

Table 3. Insulation Dry Compositions or Insulation Compositions.

* based on insulation composition (i.e., including water) = 100% ** based on insulation dry composition (i.e., excluding water) = 100%

The blends were prepared in a 10 liter Hobart mixer as follows. Foamed Polystyrene Beads (New Polystyrene) ("PSnew") knife 3-6 mm; Bulk density 13 kg / m ³ , for example available from Flatz Verpackungen-Styrofoorm GmbH, Germany) and foamed recycling polystyrene ("PS _re cyi") (diameter 0-8 mm, bulk density 13 kg / m ³ , available for example from JOMA Dämmstoffwerk GmbH, Germany) and the hydraulic binder with water retention agent and dispersion plastic were introduced, and then the water was added during the mixing.The mixture was mixed for 3 minutes, allowed to rest for 10 minutes and then compacted 20 × 20 × 8 cm under light site compaction 3 specimens of the above dimensions were produced and allowed to harden for 28 days.

Test specimens and measuring methods

On each of two of the 8 cm thick insulating specimens (20 x 20 cm cross-section) of the respective insulation compositions from Table 3 were linear with a servo-hydraulic compression testing machine with a feed rate of 1 mm / sec. loaded up to a compression of 10mm (12.5% compression) by means of pressure plate. Here, the load at 5 mm compression ("load at 5 mm compression"), and at 8mm ("load at 10% compression") and the compression at a load of 30 kN / m ² , corresponding to 3058 kg / m ² , determined. All results are the means of the two measurements.

The third sample 10 of each composition of Table 3 was coated with 8 cm of screed 11 and after 28 days the dynamic stiffness before and after 5 mm compression (compressed via servo-hydraulic compression testing machine as described above) was determined by swing-out test by determining the natural frequency of the sample. The measuring arrangement is shown for this purpose in FIG. 3 and FIG. The accelerometer "PSB 302B03" 12 was placed on the screed layer 11. Vibrations were then induced into the insulating material by means of a light impact with an impact hammer 13, which was detected by the accelerometer and recorded in the FFT analyzer "AND AD-3524 FFT Analyzer" 14 were further processed. This made it possible to determine the natural frequency of the insulating material, from which the dynamic stiffness Q [MN / m ³ ] is calculated as follows: _ (2πf) ² md ^~ A with

/ = measured natural frequency in Hz m = oscillating mass (screed) A = contact surface of the samples

The processability is judged qualitatively over a rating of 1 (very good) to 5 (very bad). In the case of poor processing, the composition of the insulating material has no pressure point during application and the foamed polystyrene diffuses and does not undergo the necessary compaction. With good processing, however, a pressure point is present and a leveling by peeling by means of aufgekanteter Metallatte is possible. When grading 5 further deduction by means of Abziehlatte is not possible because no flat and hardened surface is obtained.

As described in ÖNorm B 6550-1 ("Thermal insulation and / or sound insulation in building construction - Tied EPS packings"), the accessibility was determined by placing a point load of 0.2 kN on a round contact surface of 50 cm ² over a period of 120 seconds and a measurement of the deformation checked The walkability is given at the time when the deformation under load is less than 3 mm.

The maturity is given when the excess moisture, which is trapped in the insulation by the application of the screed, resulting in no damage in the floor and ceiling construction. For

Dammschüttungen there is still no generally recognized state of

Technology. Some building physicists usually specify a limit value based on the square meter ceiling construction with 3 kg / m ² excess moisture.

The maturity was therefore determined with 20cm insulation thickness (standard insulation thickness for thermal insulation, which already results in extremely extended drying times with conventional beds) as follows: A Test specimens measuring 20 x 20 x 20 cm were sealed air- and moisture-tight on five sides. This specimen was weighed (m ₀ ) immediately after the preparation and for 3 months in a climatic chamber with 80% rel. Stored humidity and a temperature of 23 ° C and in the first week daily and then at intervals of 3 days (m _x ) weighed. The weight difference to the original weight (m _o -m _χ ) corresponds to the amount of water that has been released by evaporation since the beginning of storage. After 3 months at the latest, the equilibrium moisture content of the bed has reached a constant value m _eq . The amount of excess water on the day x {m _{U x} ), which is relevant for the maturity, is calculated as follows:

The maturity is reached for the first time at the time x, in which the amount of excess water m _{U x} ≤ 120 g (corresponding to <3 kg / m ² ) and is shown in Table 4 as "ready-made" x in days (d).

Table 4. Properties of insulating compositions or insulating materials. Comparative Examples Ref. 1 to Ref. 3 and Ref. 5 use recycled polystyrene only, while Comparative Example Ref. 4 uses only virgin polystyrene.

On the one hand, the results of the experiments from Table 4 show that Reference Examples Ref. 1 to Ref. 3 and Ref. 5 have a very long drying time and a very poor shelf life. Further, Comparative Example Ref. 4 shows such poor processability that practical use for screed construction is out of the question. The comparison of examples ref. 5 and B2 shows that even with the use of quick binders, inventive example B2 shows a great advantage in rapid drying (due to reduced mixing water) and earlier ready-for-sale. It is further shown that despite the greatly reduced content of hydraulic binder of B2 compared to Ref.5 the load capacity is only slightly smaller, the thttschalldämmenden properties expressed in terms of lower dyn. Stiffnesses are improved.

The example B1 shows in comparison to Ref. 2 despite 12.5% lower binder content about 50 to 70% higher load capacity. A further advantage of B1 is the maturity of 1 day instead of 13 days at ref. 2. B1 even exceeds ref. ^, Which contains about 53% more binders in terms of strength and ready-to-use.

Examples B1 and B2 show the potential for improving the strength while maintaining the binder content or the thermal conductivity (over lower binder content) with the same strength and improved sound-absorbing properties and at the same time with greatly reduced drying time.

Claims

claims

An insulation dry composition for producing an impact sound insulation and heat insulation, comprising a) a hydraulic binder in an amount of less than 80% by weight, based on the insulation dry composition b) at least one dispersion plastic c) at least polystyrene in the form of foamed polystyrene beads d) at least polystyrene in the form of foamed polystyrene granules having a surface damaged by mechanical stress, wherein the amount of polystyrene (sum of c) and d)) exceeds 8

% By weight, based on the insulation dry composition.

2. Insulating dry composition according to claim 1, characterized in that the insulating dry composition further contains at least one water retention agent.

3. Insulating dry composition according to claim 1 or 2, characterized in that the insulation dry composition has a dry bulk density of less than 110 kg / m ³ , in particular less than 100 kg / m ³ , preferably between 20 and 100 kg / m ³ , having.

4. Insulating dry composition according to one of the preceding claims, characterized in that the amount of

Polystyrene (sum of c) and d)) is more than 10% by weight, based on the insulation dry composition.

5. Insulating dry composition according to one of the preceding claims, characterized in that the proportion of the hydraulic binder 40-80% by weight, in particular from 50-80% by weight, preferably from 50-75% by weight, based on the Insulation dry composition, amounts.

6. insulating dry composition according to one of the preceding claims, characterized in that the proportion of polystyrene (sum of c) and d)) between 15 and 45% by weight, in particular between 15 and 40% by weight, preferably between 20 and 40 % By weight, based on the insulation dry composition.

7. insulating dry composition according to one of the preceding claims, characterized in that the weight ratio of polystyrene in the form of foamed polystyrene beads (c) to polystyrene in the form of foamed polystyrene granules (d) with a surface damaged by mechanical stress a value between 0.1 and 5 , in particular between 0.2 and 3, preferably between 0.3 and 2.

8. Insulating-drying composition according to one of the preceding claims, characterized in that the polystyrene in the form of foamed polystyrene beads (c) Styrofoam®, which has only been foamed and not further processed.

9. insulating dry composition according to one of the preceding claims, characterized in that the polystyrene in the form of foamed polystyrene granules (d) with a damaged by mechanical stress surface recyling polystyrene, and in particular by grinding polystyrene plates and / or polystyrene packaging is obtained ,

10. insulation-dry composition according to one of claims 1 to 8, characterized in that the polystyrene in the form of foamed polystyrene granules (d) with a mechanical

Strain damaged surface is obtained by a mechanical treatment, in particular by a Walken or roughening, of polystyrene in the form of foamed polystyrene beads (c).

11. Insulating-drying composition according to one of the preceding claims, characterized in that the polystyrene in the form of foamed polystyrene beads (c) or in the form of foamed polystyrene granules (d) has a bulk density between 8 and 20 kg / m ³ , in particular between 10 and 18 kg / m ³ , preferably between 12 and 18 kg / m ³ .

12. Insulating-drying composition according to one of the preceding claims, characterized in that the hydraulic binder cement, in particular Portland cement, contains or consists thereof.

13. Insulating-dry composition according to one of the preceding claims, characterized in that the dispersion plastic in an amount of 0.5 to 25% by weight, in particular from 0.5 to 15

% By weight, preferably from 2 to 12% by weight, dry matter based on the hydraulic binder.

14. Insulating-drying composition according to one of the preceding claims, characterized in that the dispersion plastic is a copolymer of at least two ethylenically unsaturated monomers, in particular selected from the group of ethylene, butadiene, methacrylic acid, acrylic acid, methacrylic acid esters, acrylates, styrene, vinyl acetate and acrylonitrile.

15. An insulation-dry composition according to claim 14, characterized in that the dispersion plastic is a copolymer of acrylic acid / styrene or methacrylic acid / styrene or vinyl acetate / ethylene, in particular a copolymer of acrylic acid / styrene or methacrylic acid / styrene.

16. insulating dry composition according to claim 14 or 15, characterized in that the dispersion plastic a Molecular weight between 30O00 and 10'OOOOOO g / mol, in particular between 100'0OO and 5OOO ¹ 000 g / mol, preferably between 200'0OO and 2'OOOOOO g / mol.

17. insulation-dry composition according to one of claims 2 to 16, characterized in that the weight fraction of the sum of all water retention agents, based on the hydraulic binder between 0.1 wt .-% and 25 wt .-% is.

18. Insulating-drying composition according to one of claims 2 to 17, characterized in that the water retention agent is an organic compound and that the weight fraction of the sum of all organic water retention agents between 0.1 and 9 wt .-%, preferably between 0.5 and 5 wt .-%, in particular between 0.7 and 4 wt .-%, based on the hydraulic binder, is.

19. Insulating-drying composition according to one of claims 2 to 18, characterized in that the water retention agent is a starch ether, cellulose derivative, welan gum or a synthetic thickener, in particular a hydroxyalkylmethylcellulose, preferably a

Hydroxypropylmethylcellulose or a hydroxyethylmethylcellulose.

20. An insulation-dry composition according to any one of claims 2 to 17, characterized in that the water retention agent is an inorganic compound and that the weight fraction of the sum of all inorganic water retention agents between 0.2 and 25 wt .-%, in particular between 0.5 and 9 wt .-% , based on the hydraulic binder, is located.

21. Insulating-drying composition according to one of claims 2 to 17 or 20, characterized in that the water retention agent is a multi-layer silicate or a calcined kaolin, preferably metakaolin.

22. An insulation composition obtained from an insulation dry composition according to any one of claims 1 to 21 and water.

23. Dämmstoffzusannnnensetzung according to claim 22, characterized in that the hydraulic binder cement, in particular Portland cement contains or consists of and that the amount of water is such that the water / cement ratio of 0.2 to 3, in particular 0.3 to 2.5, preferably 0.3 to 1.5, is.

24. Insulating composition according to claim 22 or 23, characterized in that the amount of hydraulic binder 15-35 kg / m ³ , in particular 15-30 kg / m ³ , based on the non-cured insulation composition.

25. Insulating composition according to claim 22 or 23, characterized in that the amount of hydraulic binder 35-50 kg / m ³ , in particular 40-50 kg / m ³ , based on the non-cured insulation composition.

26. An insulating material obtained from an insulation dry composition according to any one of claims 1 to 21 after mixing with water or an insulating composition according to any one of claims 22 to 25 after reaction of the hydraulic binder with water.

27. Use of an insulating dry composition according to any one of claims 1 to 21 after mixing with water or an insulating composition according to any one of claims 22 to 25, characterized in that it is applied to a floor and cured.

28. Use of an insulating dry composition according to any one of claims 1 to 21 or an insulating composition according to one of claims 22 to 25 in a floor structure for heat-insulating and / or thttschalldämmenden purposes.

29. Floor construction comprising an insulating material according to claim 26.