EP4339390A1 - Multi-layer insulation system - Google Patents

Abstract

The present invention relates to a multi-layer insulation system (10) for providing a support structure (12) on a surface to be insulated, with at least a first insulation layer (14), which is located closer to the support structure (12), and a second insulation layer (16). , which is located further away from the support structure (12), the at least first insulating layer (14) and second insulating layer (16) having different properties from one another. In order to overcome the disadvantages of insulation systems known from the prior art, such as the time required to set them up or the complicated separation of the components for disposal, the at least first insulation layer (14) and second insulation layer (16) are each formed from foam concrete. Furthermore, the Invention a method for producing such an insulation system (10) as well as a building wall, floor slab or ceiling or a component of a building with such an insulation system (10).

Description

The present invention relates to a multi-layer insulation system formed on a surface of a support structure to be insulated, with at least a first insulation layer, which is located closer to the support structure, and a second insulation layer, which is located further away from the support structure, the at least first insulation layer and second insulation layer have different properties from each other. The invention further relates to a method for producing such an insulation system as well as a building wall, floor slab or ceiling or a component of a building with such an insulation system.

Such a system is provided by the EP 0 056 220 A1 taught. This system includes a comparatively thick plate-like element having a first density and a comparatively thin plate-like element having a second density disposed on one or both sides of the comparatively thick plate-like element. The plate-like elements are cut out of dimensionally stable but not hardened blocks of aerated concrete and stacked, with a hydraulic binder being provided between the plate-like elements. The sandwich component formed in this way is fed into an autoclave and steam-hardened there.

The EP 2 681 171 B1 discloses a mineral multilayer board and a process for its production. The former consists of two layers of the same material, comprising a sulfate and a hydraulically setting binder made of sulfate-aluminate cement, but with different levels of porosity. To produce it, flowable, self-hardening masses are poured one after the other and one above the other in the same mold and allowed to harden together.

Insulation systems serve the purpose, particularly in the case of building walls and building floor panels, but also building ceilings and components of a building, to prevent or at least slow down heat transfer between an inside and an outside of the building or a surrounding soil as much as possible. When the outside temperature is high, heating up the inside of the building should be avoided; when the outside temperature is low, heat loss from the inside of the building to the surroundings or the ground is undesirable.

A distinction must be made between the insulation of an existing building that is to be renovated and/or modernized and new buildings. For the latter, minimum legal requirements for insulation properties usually have to be taken into account. In addition, cheap loans for a builder, for example, are often linked to the fulfillment of minimum standards for thermal insulation.

Nowadays, solid materials such as rigid polyurethane foam (PUR/PIR), stone or mineral wool and extruded or expanded polystyrene rigid foam (XPS or EPS) are often used as insulation materials in new buildings as well as for retrofitting.

Some of these materials pose a significant fire risk, which is why complex measures such as treatment with fire retardants or the use of fire barriers are necessary for approval for use in residential buildings, for example. A major problem also arises from the fact that the aforementioned materials sometimes have a negative influence on the vapor diffusion openness. Due to temperature differences between day and night, as well as prolonged rainfall, there are sometimes large differences in humidity between the inside and outside of building parts. The natural diffusion of moisture is hindered by some of the aforementioned materials. The resulting condensation poses a significant risk of mold formation, including the resulting health risks. In addition, disposal after demolition or dismantling represents a particular challenge, as conventional insulation materials, whether organic or inorganic, are very time-consuming and costly Process must be separated from the concrete. Even mineral foam panels have to be disposed of separately due to their chemical composition. The use of fire retardants may also require separate disposal.

A factor that should not be underestimated when insulating parts of a building is the time required to assemble or erect the insulation layer. As a guideline, for example, an installation speed of around 15 minutes per square meter of wall or floor area is assumed for XPS or EPS. In addition to the pure material costs, high personnel costs quickly arise.

The high transport costs should not be underestimated. The aforementioned insulation materials are transported to the construction site as finished insulation elements. Due to their very large volume, they cause increased transport effort, which has a negative impact on transport costs.

Functionally, all of the aforementioned insulation materials have the disadvantage that when the insulation layer is erected, joints are created in the transition areas between adjacent insulation panels, which act as thermal bridges and thus disadvantageously increase the thermal insulation value λ and can be perceived as an aesthetic impairment of the facade.

The object of the present invention is therefore to describe an insulation system that can be individually adapted to the conditions prevailing in individual cases, which eliminates the aforementioned disadvantages of the prior art and can be used both in the modernization of existing buildings and in new buildings. A further aspect of the present invention is the production of such an insulation system and the description of a building wall, floor slab or ceiling or a component of a building with such an insulation system.

This task is achieved by a multi-layer insulation system according to claim 1 and its production according to claim 12. A building wall, floor slab or ceiling or a component of a building with such an insulation system The subject of claim 14. Advantageous further developments result from the respective dependent claims.

If the support structure is oriented essentially vertically, the insulation system according to the invention can be provided on at least one of the two sides of the support structure. If the support structure is a floor plate with a substantially horizontal orientation, the insulation system according to the invention can be arranged both above and below it. The same applies if the supporting structure is a building ceiling.

The insulation system according to the invention is characterized by at least two insulation layers which have different properties from one another. This makes it possible to optimally fulfill different tasks in the area of building insulation using different insulation layers. A first insulation layer can have a comparatively low density, which ensures optimal thermal insulation. A second insulation layer can have a higher density compared to the first insulation layer, which means that it has less optimal thermal insulation properties, but is more resistant to mechanical influences or weather influences. It is also possible for the second and/or a further insulation layer to have a comparatively high density, with which tasks of the supporting building structure can be at least partially taken over.

A preferred embodiment of the insulation system according to the invention is characterized in that the at least two insulation layers have the same components or starting materials. By adjusting the proportions of the starting materials and possibly different (post-)treatment, the desired, different properties can be achieved despite the use of the same starting materials. It is also possible to add certain additives to individual layers in order to give the respective layer(s) desired properties, such as hydrophobic behavior.

According to the invention, the at least two insulation layers are formed from foam concrete. Foam concrete is a collective term for fresh concrete, which, in addition to binders, fillers and water, also contains added foam or foam generated by an in situ reaction and, if necessary, additives. Classic binders are cement and lime. Due to the grain size of the filler - often gravel, limestone or quartz - which is usually less than 2 mm, it is actually foam mortar by definition. However, since it is used outdoors and in some cases also for load-bearing elements, it is called foam concrete. By using the foam or the in situ foaming agent, a light, porous material is created that has excellent thermal insulation properties. This makes it ideal for use, for example, as a filling material for cavities or for light, heat-insulating leveling layers. At the same time, foam concrete is more sustainable than conventional concrete or mortar because its lower density means that the use of other components such as gravel and sand can be reduced.

In the present invention, the foam concrete is formed according to a preferred embodiment by mixing a mortar slurry with a foam-forming reactant. The procedures that may be used for this are, for example, the EP 3 483 131 B1 or the previously unpublished application DE 10 2021 128 804.5 of a company economically affiliated with the applicant. The method of the last-mentioned document is characterized in particular by the fact that the foam-forming reaction only begins upon contact and mixing of an in situ foam-forming reactant with the mortar slurry. This is used for this purpose DE 10 2021 128 804.5 a device consisting of a mixing device, a slurry line for supplying the mortar slurry to the mixing device, a reactant line for supplying the in situ foam-forming reactant to the mixing device and a reaction and delivery line connected to the mixing device. The reaction and delivery line is designed to mix and convey the mortar slurry and the in situ foam-forming reactant. At the same time, it represents the place where the expansion reaction between the mortar slurry and the in situ foam-forming reaction partner merges into one Foam concrete takes place. What is characteristic of this device is that the line length of the reaction and delivery line is designed as a function of the ambient temperature and/or the composition of the mortar slurry and/or the in situ foam-forming reactant in such a way that the material volume of the foamed concrete is at the outlet end of the reaction opposite the mixing device. and delivery line almost corresponds to the final material volume of the foam concrete.

For this purpose, it is advantageous if a gas-releasing substance is used as the in situ foam-forming reactant. Due to the viscous properties of the mortar slurry, the gas released during the chemical reaction cannot escape into the environment. Instead, it remains in the mortar slurry and forms a large number of small gas bubbles. As a result of the mixing, these gas bubbles are distributed homogeneously in the mortar slurry and form small pores which, after hardening, ensure the good thermal insulation properties of the foam concrete thus formed.

A peroxide, a peroxo compound, a peroxy compound or a solution of one of these, in particular hydrogen peroxide (H ₂ O ₂ ), or any mixture thereof, have proven to be particularly suitable for use as a gas-releasing substance. Hydrogen peroxide in particular has the advantage that, when diluted appropriately, it can also be transported to a construction site without stricter safety requirements, and that it can be stored and conveyed using conventional and common devices. In addition, hydrogen peroxide has advantageous properties as an in situ foam-forming reactant for a mortar slurry, as the resulting foamed concrete is rich in pores and dimensionally stable.

Instead of an in situ foam-forming reactant, according to a further embodiment it is also possible to mix the mortar slurry with a separately produced foam in order to obtain a foam concrete. This can be a surfactant-based, for example a protein-based foam.

According to an advantageous embodiment, the different properties mentioned of the at least two insulation layers are of a physical and/or chemical nature. For example, the aim can be for the foam concrete of the first insulation layer to have a different density than the foam concrete of the second insulation layer and/or the foam concrete of one or more further insulation layers.

If one of the methods described above is used, in which the foam concrete is formed by mixing a mortar slurry with an in situ foam-forming reactant, the different densities of the foam concretes of the at least two insulation layers can be achieved by different mixing ratios of mortar slurry and in situ foam-forming reactant. Within the physical limits of the in situ foam-forming reaction, a higher proportion of the in situ foam-forming reactant leads to increased gas release and thus to increased pore formation. The foam concrete produced in this way has a lower material density due to the higher pore density and therefore better thermal insulation properties. Conversely, a smaller proportion of the in situ foam-forming reactant leads to limited gas release, which also results in fewer pores. The foam concrete obtained after hardening is comparatively less suitable for thermal insulation, but is statically more resilient and less susceptible to mechanical influences and/or environmental influences.

In an analogous manner, according to a further embodiment, in the case of foam concrete, which was formed by mixing a mortar slurry with a separately produced foam, the density and other physical and/or chemical properties can be individually adjusted by varying the mixing ratio of mortar slurry and foam.

The combination of several insulation layers made of foam concrete with different physical and/or chemical properties makes it possible to distribute different tasks of an insulation system to different layers and thus achieve greater efficiency.

Regardless of the manufacturing process of the insulation system according to the invention, which will be discussed below, the insulation system must be attached to a support structure. This can be, for example, an already existing masonry, a load-bearing wall structure that has already been built, a grouted floor to form a floor slab, a building ceiling, or, in the case of a prefabricated concrete part, a concrete layer that has already been cast into a formwork. To improve adhesion, the insulation system according to the invention comprises, according to a further embodiment, an adhesion promoter which promotes adhesion between a first insulation layer and a support structure. By definition, adhesion promoters are characterized by the fact that they create a physical and/or chemical bond in the interface between two layers. In the context of the present disclosure, the term adhesion promoter also includes substances and mixtures that fulfill this function without this being their primary task. Polyolefinic adhesion promoters and silane adhesion promoters should be mentioned as examples and not exhaustively, but within the scope of the present disclosure, materials such as mortar, bitumen or other common building materials also come into consideration.

Alternatively or in addition to the adhesion promoter, this function can also be fulfilled by an additional insulation layer. It is also advisable to also provide this additional insulation layer made of foam concrete. In order to achieve the desired properties, its physical and/or chemical properties should differ from the physical and/or chemical properties of the foam concrete of the first insulation layer.

In addition, additional insulation layers can also be provided. The decision is made on a case-by-case basis and depending on the individual circumstances. These general conditions include, among other things, the climatic conditions and the space available.

In order to stabilize the structure of the several insulation layers described above, in accordance with an advantageous embodiment, the insulation systems run essentially vertically after all construction work has been completed Invention provided on the outside of a second insulation layer or an outermost insulation layer a fabric. This can also be provided with dowels, which ensure that the layers penetrated by them are connected to one another not only adhesively, but also through positive connection and/or material connection. This can effectively prevent loosening, shifting or slipping of individual or multiple layers. Furthermore, an insulation system constructed in this way is able to withstand high wind suction forces.

Furthermore, the insulation system according to the invention can include a reinforcing mortar. This has a high tensile strength and gives the insulation system a high level of resistance to structural loads, especially in conjunction with a fabric incorporated into the reinforcing mortar.

Although reinforcing mortars have a high tensile strength, they are susceptible to weather influences and often do not meet decorative requirements. Therefore, according to a further preferred embodiment, it is advisable to provide the insulation system according to the invention with a top plaster and/or at least one layer of paint. Both are particularly characterized by their high mechanical resilience. They are therefore suitable as the outermost layer of the insulation system according to the invention, since the layers underneath are optimally protected from the effects of the weather.

A method according to the invention for producing one of the insulation systems explained above is characterized in that each of the at least two insulation layers is formed by applying the foam concrete to a support structure, a pressed floor functioning as a support structure or to a previously applied layer of foam concrete. The foam concrete adheres to the support structure or the previously applied layer of foam concrete or to the pressed soil that acts as a support structure.

According to a preferred embodiment of the manufacturing method according to the invention, the insulation system receives further layers and/or layers which have the effect that the insulation system achieves the desired properties in terms of insulation effect, longevity, resistance to mechanical and/or environmental influences and appearance. For this purpose, at least one further insulation layer and/or an adhesion promoter and/or at least one fabric and/or dowels and/or reinforcing mortar and/or a top plaster and/or at least one layer of paint are added to the insulation system. The selection and execution depends on the individual specifications and requirements for the respective application.

For insulation systems that run essentially vertically after all construction work has been completed, the method described above can be carried out directly on a construction site. In this case it is possible that the support structure is formed from a load-bearing segment. On the other hand, it is also conceivable and practical to carry out the process at a location where (somewhat) standardized conditions prevail. For this purpose, the support structure can, for example, initially be aligned horizontally, whereupon the various layers and layers are successively applied or arranged thereon, also spreading horizontally. A component produced in this way can then be transported to a construction site and erected there.

Fig. 1

eine erste Ausführungsform des erfindungsgemäßen Dämmungssystems, und

Fig. 2

eine zweite Ausführungsform des erfindungsgemäßen Dämmungssystems.

The insulation system according to the invention is explained below with reference to the drawings. Show in it:

Fig. 1

a first embodiment of the insulation system according to the invention, and

Fig. 2

a second embodiment of the insulation system according to the invention.

Fig. 1 shows a first embodiment of the insulation system 10 according to the invention. This serves for the (thermal) insulation of a substantially vertical building structure. The component delimiting the direction of the building interior is a support structure 12, which is aligned essentially vertically. As a rule, it acts The support structure 12 is a load-bearing building wall. The components of the insulation system 10 described below are on the side of the support structure 12 facing away from the interior of the building Fig. 1 to the right of it, arranged. A first insulating layer 14 is provided next to the support structure 12. This is formed from a foam concrete and has a dry bulk density of less than 180 kg/m ³ , preferably less than 150 kg/m ³ , particularly preferably less than 120 kg/m ³ . As the density decreases, the thermal insulation properties of foam concrete improve. At the same time, susceptibility to physical and environmental influences increases. However, since the first insulation layer 14 is protected from environmental influences by at least one further layer, this is accepted.

In the execution form according to Fig. 1 an adhesion promoter 18 is additionally provided between the support structure 12 and the first insulating layer 14. This is used if the adhesion between the support structure 12 and the foam concrete of the first insulation layer 14 is not sufficient to attach the latter to the support structure 12 in a process-safe manner.

A second insulation layer 16 is provided on the side of the first insulation layer 14 facing the outside of the building. The second insulation layer 16 is also formed from foam concrete. This consists of the same starting materials as the foam concrete of the first insulation layer 14, but these were mixed in a different ratio. As a result, the dry bulk density of the foam concrete of the second insulation layer 16 is between 150 kg/m ³ and 800 kg/m ³ , preferably between 200 kg/m ³ and 500 kg/m ³ , particularly preferably between 350 kg/m ³ and 450 kg/m ³ . With such a density, the second insulation layer 16 reinforces the thermal insulation properties of the first insulation layer 14, but is less susceptible to physical influences and environmental influences.

This is followed by a fabric 22, which according to in Fig. 1 illustrated embodiment of the insulation system 10 is provided with dowels 24. These connect the adjacent layers to the support structure in a form-fitting and/or material-locking manner. One On the one hand, such a measure counteracts the sliding of individual layers and, on the other hand, it represents a highly effective means of preventing wind suction damage.

Following the fabric 22 with dowels 24, another fabric 26 is provided. In combination with the subsequent reinforcing mortar 28, the fabric 26 gives the layers following the insulation layers 14, 16 a high tensile strength, which can effectively prevent cracking.

While the reinforcing mortar 28, especially in combination with the fabric 26, has a high tensile strength, it is comparatively susceptible to physical stress and environmental influences. For this reason, a top plaster 30 follows as the outermost layer of the insulation system 10. Although this has a low tensile strength, it is extremely resistant to physical stress and environmental influences. Damage to one or more layers of the insulation system 10 can thus be avoided. The penetration of (rain) water into the insulation system 10 is also prevented, which is of great importance both for its longevity and for the functionality of the insulation layers 14, 16.

A second embodiment of the insulation system 10 according to the invention, shown in Fig. 2 , differs from that in Fig. 1 illustrated embodiment by replacing the adhesion promoter 18. Instead, an additional insulation layer 20 is provided on the corresponding surface between the support structure 12 and the first insulation layer 14. With this, the thermal insulation properties of the insulation system 10 can be further improved. If the special requirements for the insulation system 10 require it or the general conditions at the construction site allow it, the same foam concrete can be used for the additional insulation layer 20 as for the second insulation layer 16. In this case, the second insulation layer 16 and the additional insulation layer have 20 the same dry bulk density. In this way, the logistical effort in particular can be significantly reduced, since only two different foam concretes have to be formed for three insulation layers 14, 16, 20.

Reference symbol list

10

Insulation system

12

Support structure

14

First layer of insulation

16

Second layer of insulation

18

Bonding agent

20

Additional insulation layer

22

tissue

24

dowel

26

tissue

28

Reinforcing mortar

30

Cover plaster

Claims (14)

Multi-layer insulation system (10) formed on a surface of a support structure (12) to be insulated, with at least a first insulation layer (14), which is closer to the support structure (12), and a second insulation layer (16), which is further away from the Support structure (12) is located away, the at least first insulating layer (14) and second insulating layer (16) having different properties from one another, characterized in that the at least first insulating layer (14) and second insulating layer (16) are each formed from foam concrete. Multi-layer insulation system (10) according to claim 1, characterized in that the foam concretes of the at least first insulation layer (14) and second insulation layer (16) are formed from the same starting materials. Multi-layer insulation system (10) according to claim 1 or 2, characterized in that the foam concretes of the at least first insulation layer (14) and second insulation layer (16) are formed by mixing a mortar slurry with an in situ foam-forming reactant. Multi-layer insulation system (10) according to claim 1 or 2, characterized in that the foam concretes of the at least first insulation layer (14) and second insulation layer (16) are formed by mixing a mortar slurry with a separately produced foam. Multi-layer insulation system (10) according to claim 3 or 4, characterized in that due to different mixing ratios of the mortar slurry with the in situ foam-forming reactant or the separately produced foam, the foam concrete of the first insulation layer (14) has different physical and / or chemical properties than the foam concrete the second insulation layer (16) and / or the foam concrete of one or more further insulation layers. Multi-layer insulation system (10) according to one of claims 1 to 5, characterized in that an adhesion promoter (18) and/or an additional insulation layer (20) is provided between the support structure (12) and the first insulation layer (14), the additional Insulating layer (20) is formed from a foam concrete, the physical and / or chemical properties of which are different from those of the foam concrete of the first insulating layer (14). Multi-layer insulation system (10) according to one of claims 1 to 6, characterized in that on one side of the first insulation layer (14) or the second insulation layer (16), or if the insulation system (10) has more than two insulation layers (14, 16 ) comprises, on at least one side of at least one of the insulating layers (14, 16, 20), a fabric (22) is provided. Multi-layer insulation system (10) according to claim 7, characterized in that the fabric (22) comprises dowels (24). Multi-layer insulation system (10) according to one of claims 1 to 8, characterized in that the insulation system (10) contains a reinforcing mortar (28). Multi-layer insulation system (10) according to claim 9, characterized in that a fabric (26) is incorporated into the reinforcing mortar (28). Multi-layer insulation system (10) according to one of claims 1 to 10, characterized in that the insulation system (10) is completed by a top plaster (30) and/or at least one layer of paint. Method for producing an insulation system (10) according to one of claims 1 to 11, characterized in that each of a first insulation layer (14) and a second insulation layer (16) is formed in that a foam concrete, produced by mixing a mortar slurry with a in situ foam-forming reactant or a separately produced foam, is applied to a surface of a support structure (12) or a previously applied layer of foam concrete and adheres to the surface of the support structure (12) or the previously applied layer of foam concrete. Method for producing an insulation system (10) according to claim 12, characterized in that the insulation system (10) has at least one further insulation layer (20) and/or an adhesion promoter (18) and/or at least one fabric (22) and/or dowels ( 24) and/or a reinforcing mortar (28) and/or a finishing plaster (30) and/or at least one layer of paint can be added. Building wall, floor slab or ceiling or component of a building with an insulation system (10) according to one of claims 1 to 11.

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