EP4373793A1

EP4373793A1 - Insulating and construction elements based on renewable raw materials

Info

Publication number: EP4373793A1
Application number: EP23757226.8A
Authority: EP
Inventors: Henning Sand; Uwe Kaiser; Thomas Bachon
Original assignee: Ewald Doerken AG
Current assignee: Ewald Doerken AG
Priority date: 2022-08-10
Filing date: 2023-08-10
Publication date: 2024-05-29
Also published as: WO2024033496A1; DE102022120176A1

Abstract

The invention relates to a foam material comprising a natural, renewable raw material and a particulate additive, and to its use as an insulating and/or construction means.

Description

Insulation and construction elements based on renewable raw materials

The present invention relates to the technical field of construction, in particular the thermal insulation or supply of buildings.

In particular, the present invention relates to a foam material and its use as an insulating and/or construction material.

Furthermore, the present invention relates to a molded body made of the foam material, in particular a construction or installation board, in particular for use in a floor structure or for use as an insulating board.

In addition, the present invention relates to a particulate foam material in bulk for use as an insulating agent, in particular as blown-in insulation, preferably for heat and/or sound insulation.

The present invention further relates to a composite element which has the foam material according to the invention for use as an insulating and/or construction material

In addition, the present invention relates to the use of a composite element, in particular according to the invention, for thermal and/or sound insulation, in particular of buildings and/or roofs, as well as in the installation of heating and/or supply systems, in particular in floors and/or walls buildings.

The present invention further relates to an underfloor heating element and thermal insulation for use in the thermal insulation of walls and/or roofs of buildings and to impact sound insulation and/or acoustic absorbers for use in the sound insulation of walls and/or floors of buildings.

The present invention also relates to an in-situ foam.

In September 2015, the heads of state and government of the member states of the United Nations set goals at the UN Sustainability Summit in New York for more sustainable development. One aspect of these goals is, among other things, the sustainable design of economic production and consumption as well as the protection of the environment. Sustainable development and design equally includes ecological, economic and social aspects as well as the goal of being able to leave an intact environment and equal life opportunities to future generations.

Construction is traditionally a resource-intensive industry, especially in terms of the need and use of material and monetary resources. Likewise, in the construction sector, long-term measures are usually pursued or implemented, the results of which shape the surrounding environment, sometimes over several decades and sometimes even centuries.

Based on this, there are increasing efforts and initiatives, particularly in the construction industry and the construction sector, to search for and develop sustainable or more sustainable solutions and applications that make it possible to achieve the above-mentioned overarching goal of overall sustainable development, for example with regard to planning , to realize the construction, inventory management and operation of buildings.

In this context, the development and use of alternatives to known building materials that are viewed as positive from an ecological point of view represent an important aspect, for which, among other things, a generally optimized use of building materials and building products, a minimization of energy and water consumption, especially within the framework the production of building materials and products, as well as an overall minimization of environmental impact on a local and global level.

Likewise, in the context of sustainable construction projects, economic aspects must be taken into account, such as, in particular, the subsequent construction and building usage costs that go beyond the acquisition or construction costs and which arise in connection with a newly built as well as a renovated or modernized existing building. The energy efficiency of buildings is particularly relevant here. The building sector is - at least in Germany - one of the largest energy consumers, with energy primarily needed for temperature regulation, ie for heating and possibly also cooling buildings. For example, the installation of a suitable thermal insulation system can make an important contribution to increasing and securing the energy efficiency of a building. The thermal insulation is mainly carried out through so-called external or facade insulation, which means that the outside of the building is usually equipped with thermal insulation. However, particularly in the case of existing buildings, internal insulation can also be an option, especially for subsequent insulation of roofs or attics.

Thermal insulation systems made from petrochemical-based materials, such as polyurethane foams or expanded polystyrene, are often used. Such thermal insulation has excellent insulating properties under ideal conditions, but has the disadvantage that it is flammable and can only be used at limited temperatures.

Furthermore, these insulation systems form a vapor barrier so that moisture from the masonry cannot be released into the environment, which can subsequently lead to the formation of mold and algae on and in the building facade. With regard to the sustainability aspect, insulation made of polyurethane or polystyrene is also considered disadvantageous in that the materials are produced from non-renewable raw materials in an energy-intensive manner and cannot be disposed of in a particularly environmentally friendly manner.

Another option is to use mineral-based insulation materials or systems. These are usually dimensionally stable, open to diffusion and non-flammable. However, in comparison with polymeric insulation materials, for example, they have the disadvantage that they have a high density, so that insulation systems with a high weight are obtained. These systems are also behind plastic-based systems in terms of thermal insulation properties. In addition, mineral materials, like petrochemical raw materials, are fossil raw materials that are not renewable. Finally, the production of mineral-based insulation materials, such as rock wool and glass wool, takes place in ovens at temperatures of around 1500 °C. Considering the CO2 balance of production in addition to the disadvantages mentioned above, these materials are therefore not a sustainable option. Alternatively, insulation systems based on mineral wool or natural organic fibers such as wood, cork, hemp and reed fibers are also used to a small extent. However, these systems often lack the necessary mechanical stability and structural integrity, meaning they are not dimensionally stable but must be specifically reinforced or supported. Mention should be made here, for example, of wood fiber insulation boards or soft wood fiber boards, which can only inadequately withstand pressure loads, especially at specific points. There is also still potential for development with regard to the insulating effect of the materials mentioned. However, from an economic and ecological perspective, the fact that materials from natural and renewable raw material sources are used is positive.

Particularly when taking an integral look at the sustainability of existing thermal insulation systems, it appears overall that there is still a great need for development with regard to thermal insulation that both achieves a high insulating effect and can be produced or produced in a largely sustainable manner. In this context, the choice of materials used in the appropriate insulation is of central importance.

Wood and woody plants are among the oldest raw materials used, especially in the construction sector. Accordingly, there are a variety of concepts and products that address uses in the construction sector, such as the softwood fiberboard mentioned above.

However, in the area of insulation materials and especially with regard to practical, efficient and user-friendly insulation applications, there is still a considerable need for products that provide good insulation performance as well as being durable and resilient and can be used without concerns in terms of health aspects. For example, many wood-based products still have chemicals added, such as binding agents, which may evaporate and release harmful substances such as formaldehyde.

Accordingly, there has been no lack of attempts in the prior art to develop solutions that overcome these disadvantages. For example, DE 10 2010 008 525 A1 relates to lignocellulose-containing moldings which are free of binders and are produced using an enzymatic wet process and an enzymatic dry process. As part of these processes, special mediators or catalysts as well as phenol-oxidizing enzymes are used, which are intended to produce the bond in the shaped body. However, enzymatic-based processes are usually very complex to carry out and prone to failure. The scalability of enzymatic processes is also often limited, making large-scale use unattractive.

WO 02/055722 A1 also relates to a method for producing a porous material based on wood. Here, wood chips are subjected to a fermentation process, from which a malleable mass is obtained, which is then dried using radio wave radiation. However, fermentation processes usually require a certain amount of time, so that the proposed process is quite lengthy overall and also quite complex in terms of drying using microwave radiation.

Against this background, there is a continuing need for innovative materials and components that are suitable for use in construction and in particular for user-friendly and efficient insulation of buildings, and which can also be assessed as positive in terms of sustainability.

The present invention is therefore based on the object of providing a material for insulation and/or construction or building elements, whereby the problems and disadvantages described above that arise in connection with the prior art should at least largely be avoided or at least mitigated.

In particular, it is an object of the present invention to provide a material for insulation and/or construction elements that can be produced sustainably and is also characterized by good application properties, i.e. reliable insulation properties, efficient handling and excellent mechanical properties.

The previously set task is carried out according to the invention by a

Foam material dissolved according to claim 1; further advantageous further training and Refinements of the method according to the invention are the subject of the relevant subclaims.

A further subject of the present invention according to a second aspect of the present invention is the use of a foam material according to claim 11; Further advantageous developments and refinements of the method according to the invention are the subject of the relevant subclaim.

Further subject matter of the present invention according to a third aspect of the present invention is a shaped body according to claim 13; Further advantageous developments and refinements of the method according to the invention are the subject of the relevant subclaims.

Furthermore, the subject of the present invention according to a fourth aspect of the present invention is a particulate foam material according to claim 18.

Yet another subject matter of the present invention according to a fifth aspect of the present invention is a composite element according to claim 19; Further advantageous developments and refinements of the method according to the invention are the subject of the relevant subclaims.

Another subject of the present invention according to a sixth aspect of the present invention is a use of a composite element, in particular according to the invention, for thermal and/or sound insulation, in particular of buildings and/or roofs, preferably of floors, walls and roofs, according to claim 27.

Yet another subject of the present invention according to a seventh aspect of the present invention is a use of a composite element, in particular according to the invention, in the installation of heating and/or supply systems, in particular in floors and/or walls of buildings, preferably of underfloor heating systems, according to claim 28 . Furthermore, the subject of the present invention according to an eighth aspect of the present invention is an underfloor heating element according to claim 29.

Yet another subject of the present invention according to a ninth aspect of the present invention is a thermal insulation for use in the thermal insulation of walls and / or roofs of buildings according to claim 30.

Furthermore, the subject of the present invention according to a tenth aspect of the present invention is an impact sound insulation and/or an acoustic absorber for use in the sound insulation of walls and/or floors of buildings according to claim 31.

Furthermore, the subject of the present invention according to an eleventh aspect of the present invention is an in-situ foam for use as an insulating and/or construction material, in particular for heat and/or sound insulation according to claim 32.

It goes without saying that special features, features, refinements and embodiments as well as advantages or the like, which are explained below - for the purpose of avoiding unnecessary repetitions - only in relation to one aspect of the invention, of course apply accordingly in relation to the other aspects of the invention, without it requires explicit mention.

In addition, all values or parameter information or the like mentioned below can in principle be determined using standardized or explicitly stated determination methods or using determination methods that are familiar to those skilled in this field.

Furthermore, it goes without saying that all weight or quantity-related percentages are selected by the expert in such a way that the total results in 100%.

Having said this, the present invention will be described in more detail below. The subject of the present invention - according to a first aspect of the present invention - is therefore a foam material comprising a natural, renewable raw material based on woody and/or woody plants, the foam material being at least one particulate additive selected from the group of expandable graphite, expanded perlite, expanded vermiculite, silica, aerogels, zeolites and mixtures thereof, in amounts of 5 to 20% by weight, based on the foam material.

Because, as the applicant has discovered, by adding particles to a foam material based on a natural, renewable raw material, in particular based on wood or lignocellulose-containing fibers, the mechanical properties of the foam material made from a natural, renewable raw material can be significantly improved . This is all the more surprising because not only is the strength of the resulting foam material increased, but the elastic deformability is also significantly improved. The present invention thus provides a foam material which is ideally suited for the production of molded bodies and composite elements, in particular conception and installation panels, which can be used in the construction sector for construction purposes and at the same time have excellent heat and sound insulating properties. In this way, molded bodies or composite elements made from the foam material according to the invention can replace both conventional construction and installation panels as well as the heat and sound-insulating materials commonly used. The foam material according to the invention thus combines the properties of different building materials, which were previously used separately, in a single material.

In the context of the present invention, a foam material is to be understood in particular as a solid foam. Foams are structures made up of gas-filled, spherical or polyhedral cells, which are delimited by liquid, semi-liquid, highly viscous or solid cell bars. The cell webs, connected via so-called nodes, form a coherent framework. The foam lamellae are stretched between the cell bars in a closed-cell foam. If the foam lamellae are destroyed or if they flow back into the cell bars at the end of foam formation, you get an open cell Foam. To produce foams, gas is blown into suitable liquids or foam formation is achieved by violently beating, shaking, spraying or stirring the liquid in the relevant gas atmosphere, provided that the liquids contain suitable surfactants or other surface-active substances, so-called foaming agents, which except Interfacial activity also has a certain film-forming ability. In other cases, foam formation is based on chemical reactions that result in gas evolution. Examples of solid foams are, in particular, cork, vermiculite, pumice stone or aerated concrete.

In the context of the present invention, the foam material is usually an open-cell foam.

In the context of the present invention, a particulate additive means particles which are added to the foam material before or during foaming. Additives whose particle sizes and material properties or chemical compositions meet the requirements of the particulate additive used in the foam material according to the invention and whose particle shape is retained in the foam material are also added to the particulate additives.

In particular, the foam material according to the invention can be used to obtain molded bodies and composite elements which have significantly improved mechanical properties compared to molded bodies and composite elements of the prior art based on renewable raw materials. In addition, the molded bodies and composite elements produced with the foam material according to the invention have significantly increased strength, in particular against pressure loads, as well as improved thermal insulation properties and sound-insulating properties. In this context, it is particularly advantageous that the foam material according to the invention retains its insulating properties even when the foam material or moldings or composite elements made from it are exposed to increased amounts of moisture.

Insulating materials based on natural raw materials in particular usually lose their insulating properties when they are exposed to high amounts of moisture, for example in the form of water vapor and especially liquid water. The Loss of function is not reversible, so the corresponding insulation has to be replaced and replaced at great expense. This problem is particularly pronounced with conventional soft wood fiber boards, which, as insulating elements, are irreversibly damaged and fail when moisture absorption exceeds 30%, based on the soft wood fiber content of the boards.

The foam material according to the invention or molded bodies or composite elements made from it do not show this disadvantageous behavior and retain their insulating effect even in the presence or after absorption of moisture. Furthermore, it is also possible for the foam material according to the invention to regenerate completely after absorbing increased or particularly high amounts of water or water vapor, for example as a result of water ingress or damage, without the fear of permanent losses in performance as a result. In addition, in contrast to comparable materials based on, for example, soft wood fiber material, the foam material according to the invention is characterized by a particularly high dimensional stability and only has a swelling of less than 1% in the presence of moisture, in particular even without hydrophobization.

The foam material according to the invention is characterized by high mechanical strength and high structural integrity compared to fiber or wool materials known from the prior art or bodies made from these based on renewable raw materials. These properties are based in particular on the stable and durable foam structure of the foam material according to the invention based on a natural, renewable raw material.

The foam material according to the invention achieves these advantageous properties in particular on the basis of the high degree of crosslinking of the foam material in conjunction with advantageous gas retention properties, which result in a preferably open-pored, highly stable and durable foam structure.

Furthermore, based on this advantageous structure or nature of the foam material according to the invention, excellent insulating properties are achieved, which have not previously been available with comparable or alternative insulating materials based on renewable raw materials. In particular, the foam material is characterized by an advantageous porosity ratio to the amount or mass of material, which is reflected in densities and weights per unit area that are consistently positive. On the basis of the foam material according to the invention, weight-optimized moldings or weight-optimized composite elements can also be obtained, which are characterized by a balanced ratio of their own weight to the achieved insulation performance. Particularly in the area of insulating the roofs of buildings, this aspect is of crucial importance for both over-rafter and between- or under-rafter insulation, especially since any additional weight must be compensated for by the building walls and foundation.

With the present invention, moldings and composite elements can now be made available for the first time, which consist of a foam material or comprise a foam layer, the foam material of which has a natural, renewable raw material, and the moldings and composite elements provided are preferably reliably weather and in particular moisture resistant , highly mechanically resilient as well as effective and, last but not least, weight-optimized in relation to a variety of applications in a building.

Furthermore, the composite elements obtainable with the foam material according to the invention are characterized by particularly excellent composite adhesion and a correspondingly high level of durability and resistance.

The molded bodies and composite elements obtainable with the foam material according to the invention are - particularly depending on the specific design or configuration - ideally suited for use in all types of insulation, ie both for the external and internal insulation of buildings as well as for the insulation of roofs. In addition, molded bodies and composite elements available with the foam material according to the invention can also be designed as sound-absorbing construction elements, which can be used, for example, for impact sound insulation in a floor structure. Shaped bodies and composite elements in the form of prefabricated components or walls available with the foam material according to the invention can also be used as part of a quick and efficient construction and expansion of buildings. In this respect, the one according to the invention is suitable Foam material is advantageous for a wide range of applications and can therefore be designed and configured in a highly variable manner.

In addition to these application-oriented advantages, a significant further advantage of the present invention remains that the foam material according to the invention, which can be used in a variety of ways and flexibly, and the molded bodies and composite elements available with it can be viewed to a high degree or extent as a sustainable solution for the construction sector, especially in comparison to standard ones insulation or construction elements used.

Particularly good results are obtained in the context of the present invention if the foam material contains the particulate additive in amounts of 5 to 15% by weight, in particular 5 to 10% by weight, preferably 6 to 10% by weight, preferably 6 to 9 % by weight, based on the foam material. With the aforementioned amounts of particulate additive in the foam material according to the invention, molded bodies and composite elements that are particularly mechanically resistant and at the same time elastic can be obtained.

A variety of suitable additives can be selected as particulate additives. In the context of the present invention it is provided that the particulate additive is selected from mineral particles. In particular, from the perspective of sustainability, it is not preferred in the context of the present invention if particles based on petrochemically produced polymers are used. In addition, for reasons of fire protection, it is preferred that mineral or at least inorganic particles are used. In the context of the present invention, it is therefore provided that the particulate additive is selected from the group of expandable graphite, expanded pearlite, expanded vermiculite, silica, in particular pyrogenic silica, aerogels, in particular silica aerogels, zeolites and mixtures thereof. In this context, it has proven useful if the particulate additive is selected from the group of expandable graphite, expanded pearlite, expanded vermiculite and mixtures thereof. In the context of the present invention, it is particularly preferred if the particulate additive is expanded graphite. By using expandable graphite, not only can the mechanical properties of the foam material according to the invention be improved, but the fire resistance is also significantly improved. In addition, it has been shown that, in addition to the chemical composition of the additive, the particle size is often important in the context of the present invention. It has proven to be advantageous if the particulate additive has average particle sizes in the range from 10 pm to 2 mm, in particular 20 pm to 1.5 mm, preferably 50 pm to 1 mm, preferably 70 pm to 800 pm, particularly preferably 80 pm to 700 pm. The mechanical properties of the foam material according to the invention can be specifically improved with additives which have particle sizes in the aforementioned ranges.

The average particle size corresponds to the D50 value. D50 means that 50% of the particles have a particle size smaller than the specified value. The particle sizes or particle size distribution can be determined in particular using laser diffraction.

Preferably, the foam material and moldings made from it have fire class C, preferably B, according to DIN EN 13 501-1. Particularly when using inorganic particulate additives, in particular expandable graphite, in amounts of at least 5% by weight, based on the foam material, the foam material or shaped bodies made from it have fire class B and are considered flame retardant. Without the addition of flame retardants, the foam material has fire class E according to DIN EN 13501-1 and is therefore highly flammable, as is to be expected for foams based on renewable raw materials, especially wood foams.

As already stated above, the foam material according to the invention has improved mechanical properties due to the particulate additive. For example, with a bulk density of 70 to 80 kg/m ³ , the foam material according to the invention has a transverse tensile strength according to DIN EN 1607 of 10 to 40 kPa, in particular 10 to 30 kPa, preferably 10 to 25 kPa.

With a bulk density of 100 to 120 kg/m ³ , the foam material according to the invention preferably has a transverse tensile strength according to DIN EN 1607 of 25 to 75 kPa, in particular 30 to 70 kPa, preferably 30 to 60 kPa, preferably 30 to 50 kPa.

At a bulk density of 130 to 150 kg/m ^3, the inventive

Foam material preferably has a transverse tensile strength according to DIN EN 1607 of 40 to 120 kPa, in particular 40 to 100 kPa, preferably 50 to 100 kPa, preferably 50 to 90 kPa.

The foam material according to the invention preferably has an improved transverse tensile strength, determined according to DIN EN 1607, in the range of 4 to 25%, in particular 5 to 20%, compared to a corresponding foam material without particulate additives or with an amount of particulate additives of less than 5% by weight .-%, based on the foam material.

Furthermore, the foam material according to the invention, for example with a bulk density of 70 to 80 kg/m ³ , has a compressive strength at 10% compression according to DIN EN 826 of 40 to 120 kPa, in particular 40 to 100 kPa, preferably 40 to 80 kPa, preferably 40 to 70 kPa , on.

With a bulk density of 100 to 120 kg/m ³ , the foam material according to the invention preferably has a compressive strength at 10% compression according to DIN EN 826 of 80 to 300 kPa, in particular 80 to 250 kPa, preferably 80 to 200 kPa, preferably 100 to 150 kPa, on.

With a bulk density of 130 to 150 kg/m ³ , the foam material according to the invention preferably has a compressive strength at 10% compression according to DIN EN 826 of 250 to 450 kPa, in particular 250 to 400 kPa, preferably 270 to 380 kPa, preferably 270 to 350 kPa, on.

The foam material according to the invention preferably has an improved compressive strength at 10% compression, determined according to DIN EN 1607, in the range of 10 to 50%, in particular 10 to 30%, compared to a corresponding foam material without particulate additives or with an amount of particulate additives less than 5% by weight, based on the foam material.

In addition, the foam material according to the invention, for example with a bulk density of 70 to 80 kg/m ³ , has a pressure modulus, determined according to DIN EN 826, of 500 to 3,000 kPa, in particular 600 to 2,700 kPa, preferably 700 to 2,500 kPa. With a bulk density of 100 to 120 kg/m ^3, the foam material according to the invention preferably has a pressure modulus, determined according to DIN EN 826, of

I .500 to 7,000 kPa, in particular 1,600 to 6,500 kPa, preferably 1,800 to 6,000 kPa.

With a bulk density of 130 to 150 kg/m ³ , the foam material according to the invention preferably has a pressure modulus, determined according to DIN EN 826, of 8,000 to 12,000 kPa, in particular 9,000 to 11,500 kPa, preferably 10,000 to

I I ,000 kPa, on.

The foam material according to the invention preferably has an improved pressure modulus, determined according to DIN EN 826, in the range of 20 to 80%, in particular 30 to 60%, compared to a corresponding foam material without particulate additive or with an amount of particulate additive of less than 5% by weight .-%, based on the foam material.

In the context of the present invention, a natural or, in particular, renewable raw material is understood to mean organic raw materials that come from agricultural and forestry production and are used specifically for further applications outside of the food and feed sector. In the context of the present invention, valuable materials or production by-products and/or materials from reusable or reusable sources that are originally based on a renewable raw material are also considered raw materials.

In the context of the present invention, natural, renewable raw materials based on woody and/or woody plants are used. The natural, renewable raw material is preferably wood. The natural, renewable, plant-based raw material therefore preferably comprises lignin- and/or lignocellulose-based raw materials or, in particular, plants.

Within the scope of the present invention, almost all types of wood or components of woody plants, ie lignin and/or lignocellulose-based plants, can advantageously be used. The natural, renewable plant raw material can accordingly preferably be selected from the group of hardwood, coniferous wood, bark, root material, thinning wood, woody annual plants and mixtures thereof. It is also possible that the natural, renewable plant raw material is obtained from sawing by-products, waste wood, wood-containing waste products and/or recyclable or recycled wood-containing products.

Accordingly, a particular advantage of the present invention is that the foam material can be obtained from a variety of potential starting materials or raw material sources. In particular, with regard to the starting materials or raw material sources of the foam material according to the invention, it is primarily crucial that they are obtained from raw materials or corresponding sources that are based on woody and/or woody plants.

The natural, renewable, plant-based raw material preferably has a particulate, in particular fibrous, shape and/or structure. Furthermore, it is very particularly preferred in the context of the present invention if the natural, renewable, plant-based raw material is in the form of particles, preferably containing lignocellulose, in particular fibers.

Lignocellulose forms the cell wall of woody or woody plants and serves as their structural framework. Hemicelluloses and especially cellulose initially form a framework into which lignin is subsequently incorporated during the process of lignification (lignification), which ultimately results in lignocellulose.

In the context of the present invention, a particulate material based on a natural, renewable, plant-based raw material, preferably based on wood or components of woody plants, is preferably used for the foam material. It is particularly preferred if the wood or components of softwoods are used, in particular fresh softwoods are even more preferred. This particular preference for softwoods, especially fresh ones, can be attributed to the comparatively high lignin content, which has a positive effect on the foam material of the foam layer.

As explained above, the source of raw materials can vary widely. According to a further advantage of the present invention, this aspect allows a particularly variable or flexible design of the manufacturing process of the foam material according to the invention. In particular, the foam material according to the invention is designed to be so flexible in its production that it depends little or hardly on a specific raw material source or quality, which allows both cost-effective and adaptable production of composite elements according to the raw material supply. In particular, in the context of the present invention, essentially all materials that have a lignin or a lignocellulose content can be considered as suitable raw materials, such as - in addition to the aforementioned raw material sources - wood wool, wood fibers, jute, flax, among others as well as vegetable waste from the agricultural industry.

With regard to the nature of the renewable raw material, as already mentioned, it is preferred if it has a particulate, in particular fibrous, shape. It has proven particularly useful if the particles or in particular fibers of the raw material have particle sizes and/or fiber lengths in a range from 100 pm to 50 mm, in particular 200 pm to 10 mm, preferably 250 pm to 5 mm, preferably 300 pm to 2. 5 mm, based on the renewable raw material in its initial state.

Such small particles or in particular short fibers of the natural, renewable raw material can be obtained, for example, from refiner processes or grinding processes. It has proven to be advantageous to carry out two grinding processes, in particular where a comparatively coarser grinding stage is selected first and then a finer grinding stage. As part of this procedure, it is therefore particularly possible to adjust the particle size or fiber length specifically and depending on the application requirements or purpose, for which the geometry of the grinding tools used, the distance between the grinding plates and/or the number of grinding cycles are particularly important.

An advantage of the fibers with small fiber sizes that are preferably used according to the invention is that the material can be easily returned to the process. In addition, no adhesive is required to produce the foam material in the context of the present invention, so that the reusability of the foam material is significantly improved. Offcuts or production leftovers can therefore be reused, in contrast to soft wood fiber boards (HWF boards) produced using the dry process, where any production leftovers must be disposed of. The The foam material used according to the invention is therefore significantly more sustainable and resource-saving than materials previously used.

As part of the refiner processes or grinding processes, fiber suspensions are preferably obtained which are particularly highly viscous and serve as the starting composition for the foam material used according to the invention.

Properties of the foam material, such as its density or strength, can be adjusted variably when fiber suspensions are mixed with raw material fibers or particles of different lengths or sizes. The viscosity of the suspension can also be adjusted by, for example, decanting excess liquid, in particular in the form of water, or by adding liquid or a solvent, in particular water, to the ground mass if a lower-viscosity suspension is desired. The suspensions used are characterized in particular by good gas holding properties, which is particularly advantageous for foam formation.

As far as the composition of the foam material is concerned, this can vary or be varied depending on the application or intended use. According to the invention, it is preferred if the natural, renewable raw material in the foam material has a proportion of more than 75% by weight, in particular 77% by weight, preferably 80% by weight, preferably 82% by weight, very particularly preferred 85% by weight, based on the total composition of the foam material.

It has also proven useful in the context of the present invention if the natural, renewable raw material in the foam material contains a proportion of 75 to 95% by weight, in particular 77 to 94% by weight, preferably 80 to 93% by weight. %, preferably 82 to 92% by weight, very particularly preferably 85 to 91% by weight, based on the total composition of the foam material.

In the context of the present invention, it is preferably provided that the foam material is formed predominantly from renewable raw materials, which is particularly positive from the point of view of sustainability. It should also be mentioned as advantageous in this context that in the context of the present invention not only raw materials, in particular wood or woody plants, from agricultural or forestry production or production can be used, but also such substances can serve as starting materials or raw materials , which arise as by-products or waste products, for example in recycling processes or further production processes.

The foam material can, for example, also be obtained at least essentially exclusively from production waste or recycling sources.

In this sense, within the scope of the present invention, value-adding further processing of already processed materials based on natural raw materials is also possible. This advantageously allows natural resources to be conserved as well as sensible and valuable use of process by-products or supposed waste. In the context of the present invention, this can have an overall positive influence on the value creation cycles of renewable raw materials and thus provide a product that can be assessed as environmentally friendly and sustainable.

However, depending on the application or intended use, it may be advisable within the scope of the present invention to modify the properties of the foam material. In this context, it can prove to be advantageous if the foam material comprises one or more additives. The one or more additives are preferably selected from the group of hydrophobing agents, flame retardants, corona inhibitors, fungicides, oxidizing agents, blowing agents, thickeners, crosslinkers, gelling agents, emulsifiers, pH regulators, plasticizers, binders and/or mixtures thereof.

Suitable water repellents include synthetic or natural oils, paraffins, waxes or organosilicon compounds. Advantageously, the addition of hydrophobic agents makes it possible to reduce the ability or tendency of the foam material to absorb water, which has a particularly positive effect on the long-term stability of the foam and thus of the composite element according to the invention. In the context of the present invention, paraffins and waxes are preferably used as water repellents because they represent environmentally friendly materials and contribute to the excellent ecological properties of the products obtained.

Pearlite, vermiculite and/or expanded graphite, in particular expanded graphite, are preferably used as flame retardants or corona inhibitors. In the context of the present invention, particulate flame or corona retardants are preferably used, which - as already stated above - have a positive effect on the mechanical properties of the foam material. In particular, if the foam material according to the invention is to be used for insulating facades or for cladding exterior building walls, the use of the aforementioned flame or corona retardants has proven to be advantageous. What is particularly advantageous about the flame or corona retardants mentioned is that they are natural and environmentally friendly materials, so that ecologically valuable and sustainable products can be obtained.

The addition of oxidizing agents, in particular hydrogen peroxide, has proven particularly useful in influencing or specifically adjusting the porosity of the foam material. Advantageously, the addition of an oxidizing agent, in particular hydrogen peroxide, also brings about a chemical modification, in particular of the fiber components, of the natural raw material used, from which a higher degree of crosslinking and a permanent, stable crosslinking of the raw material contained in the foam material is ultimately achieved. Likewise, stabilization of the foam structure and a uniform formation of foam pores can be achieved, which in turn is advantageous for both the mechanical and physical properties of the foam material.

The binding or crosslinking of the natural raw material or in particular the corresponding fiber components can also be improved by using acrylates, urea, melamine, glyoxal and/or glyoxylic acid as additives, in particular during the refining process or grinding process.

The foam structure of the foam material can also be advantageously influenced by the addition of blowing agents. Organic blowing agents in the form of azobisisobutyronitrile, azodicarbonamide, in particular activated azodicarbonamide, dinitropentamethylenetetramine, hydrazodicarbonamide, oxibissulfohydrazide, are particularly suitable here. Oxybisbenzenesulfohydrazide, 5-phenyltetrazole, para-toluenesulfonylsemicarbazide, toluene/benzene sulfohydrazide and their salts, in particular alkali and alkaline earth metal salts. Likewise, inorganic blowing agents such as ammonium carbonate, sodium hydrogen carbonate, preferably in a mixture with potassium hydrogen carbonate and an acid carrier, in particular disodium dihydrogen diphosphate, calcium dihydrogen phosphate or calcium citrate, as well as aluminum powder can be used in both acidic and basic environments.

Suitable thickeners and/or gelling agents include sulfite or sulfate pulp waste liquor, turpentine oil, gelling agents, alginates, flour or starch from grain, potatoes, corn, peas or rice. Crosslinkers are preferably selected based on methylcellulose or glutin.

Flour or starch from grain, potatoes, corn, peas or rice can also be used as a binding agent, as can proteins or lignin sulfonate. Proteins can also be used as emulsifiers.

Alums and synthetic additives, in particular isocyanates and polymers, in particular polyvinyl alcohol, polyethylene glycol and polyvinyl acetate, can also be used advantageously as pH regulators and as plasticizers or structure modifiers.

Particularly good results are obtained in this context if the one or more additives in the foam material have a proportion of less than 17% by weight, in particular 12% by weight, preferably 9% by weight, preferably 7% by weight. , very particularly preferably 6% by weight, based on the total composition of the foam material.

It is very particularly preferred that the one or more additives in the foam material have a proportion in a range of 0 to 17% by weight, in particular 0 to 12% by weight, preferably 0.5 to 9% by weight. , preferably 1 to 7% by weight, very particularly preferably 2 to 6% by weight, based on the total composition of the foam material. When using particulate additives, the particle shape of which is retained in the finished foam material, their amount is also added to the particulate additives, so that the total amount of particulate additives is not is exceeded. This applies in particular if additives with specific particle sizes are used to produce the foam material. Additives that remain as particles in the resulting foam material and have corresponding particle sizes are also added quantitatively to the particulate additives in this case.

As far as the production of the foam material is concerned, this is advantageously based on a substantially uncomplicated or uncomplicated process.

The starting point is the already mentioned, particularly highly viscous, fiber suspension, which can be obtained from the renewable raw material. The renewable raw material is advantageously subjected to at least one, preferably at least two, refiner processes or grinding processes. From this, the particularly highly viscous fiber suspension is obtained.

It has been shown that no chemically induced digestions and no additional synthetic binders are required to stabilize the foam material or molded bodies made from it, in particular fibers containing lignocellulose. The particularly highly viscous fiber suspension is preferably obtained from materials containing lignocellulose. Preferably, comminuted, lignocellulose-containing fiber materials are processed at temperatures between 120 ° C and 180 ° C at a pressure of 2 to 8 bar, optionally together with water, to form a fiber suspension. The procedure is preferably such that the fiber suspension has between 5 and 50% of fibers with a fiber length of between 1,000 pm and 2,500 pm.

According to a further preferred modification of the method, further comminution of the fibers is carried out in a thermomechanical process, preferably an atmospheric refiner without excess pressure at room temperature, whereby the fiber length can be adjusted between 200 and 800 pm.

Depending on the intended application, one or more additives, in particular those mentioned above, can be added to the fiber suspension. Particularly preferred is the addition of hydrogen peroxide, which has a positive effect on the foam formation and also the connection of the fibers to form a stable, solid foam. The formation of foam can be induced both physically and chemically, for example by foaming the fiber suspension through intensive stirring or by providing it with chemical blowing agents that release volatile components. Both variants can preferably also be combined.

The, in particular foamed, fiber suspension based on renewable raw materials and, if necessary, additives can subsequently be placed in a shape, which can vary depending on the geometry of the composite element to be produced. In this sense, rectangular and square shapes are particularly conceivable, but prefabricated, tailor-made shapes can also be used for special applications. Preferably, the mold can be formed from a renewable raw material or a valuable material based on renewable raw materials, i.e. in particular, for example, from wood or wood-like fibers, waste paper, waste cardboard and / or cast fiber.

In addition, it has proven useful if the fiber suspension is converted into a highly viscous suspension with a solids-water ratio of 1:2 to 1:20, preferably from 1:5 to 1:0, before being introduced into the mold or applied to a support. 10, is transferred. Dewatering can be done by decanting or other mechanical dewatering.

For the final production of the foam material from the high-viscosity fiber suspension, it has proven useful if the high-viscosity fiber suspension is subjected to a thermal treatment, for example in a temperature range between 100 ° C and 200 ° C. As part of this thermal treatment, the liquid or solvent component, in particular the water component, is first removed from the fiber suspension. Chemical blowing agents can also be activated and the foam material can be foamed or further foamed. Last but not least, the thermal treatment also achieves crosslinking of the fibers of the foam material, in particular by condensing fiber components such as lignocellulose and forming a closely linked network.

Accordingly, in particular at least essentially, the further addition of binders to the foam material or the fiber suspension can be dispensed with, which has an overall positive effect Sustainability aspect affects the foam material according to the invention or the molded body made from it.

After the thermal treatment has been completed, a particularly strong, self-supporting and rigid foam is preferably obtained in the form of a shaped body.

According to a specific example, the foam material can be obtained as follows:

Wood fibers, in particular for example from beech or pine wood, are converted in a first grinding process into a suspension, in particular a highly viscous suspension, for example with a solids content of 7%, and subsequently further defiberized with the addition of water in an atmospheric refiner at room temperature. The highly viscous wood fiber suspension is then freed of excess water using a sieve and a solids content of 10 to 15% is adjusted. Subsequently, hydrogen peroxide (35% in water) is added to the highly viscous suspension in amounts ranging from 5 to 35% by weight and the resulting mass is stirred in an intensive mixer for a maximum of 4 minutes at room temperature. On the one hand, the mass is physically or mechanically foamed, and on the other hand, chemical foaming and a modification of the fiber structure that positively influences the gas-holding properties of the suspension are achieved. The homogeneous, flowable mass obtained is transferred into a mold, preferably perforated on all sides, and dried in an oven at 130 ° C for a period ranging from 6 to 20 hours. The resulting foam material or the foam layer comprising the foam material has bulk densities in a range from 20 to 300 kg/m ³ .

For further details on the production of wood foams that are suitable as a basis for the foam material according to the invention, reference can also be made to EP 3 406 793 A1, the content of which is hereby expressly referred to and the subject matter of which is included in the present invention. The foam material according to the invention is preferably produced in a corresponding manner, but has a proportion of 5 to 20% by weight of particulate additives, based on the foam material. As far as the structure or nature and properties of the foam material are concerned, it is preferred in the context of the present invention if the foam material has an open-pore foam structure.

Furthermore, it is preferred if the foam material has a density of at most 300 kg/m ³ , in particular 275 kg/m ³ , preferably 250 kg/m ³ , and/or at least 20 kg/m ³ , in particular 40 kg/m ³ , preferably 50 kg/m ³ . The foam material therefore advantageously has a density in a range of 20 to 300 kg/m ³ , in particular 40 to 275 kg/m ³ , preferably 50 to 250 kg/m ³ .

If the foam material is designed as a plate for intermediate rafter insulation, in particular as a clamping plate, or is used in a plate for intermediate rafter insulation, the foam material preferably has a density of at most 80 kg/m ³ , in particular at most 60 kg/m ³ , preferably at most 50 kg/m ³ , and/or at least 20 kg/m ³ , in particular at least 30 kg/m ³ , preferably at least 40 kg/m ³ . Advantageously, the foam material according to this embodiment therefore has a density in a range of 20 to 80 kg/m ³ , in particular 30 to 60 kg/m ³ , preferably 40 to 50 kg/m ³ . Due to the low densities and the associated lower compressive strengths, it is possible to fasten the plate, in particular the laying plate or clamping plate, by clamping it between the rafters.

The figure representations show according to

Fig. 1 shows a cross section through a molded body according to the invention and an enlarged section of the same

Fig. 2 is a cross-sectional view of a composite element according to the invention;

3 shows a perspective view of a composite element according to the invention, comprising a foam layer and a functional and/or reinforcing layer designed as a functional film;

4A is a perspective view of a shaped body according to the invention;

4B shows a perspective view of a composite element according to the invention, comprising a foam layer arranged between two functional and/or reinforcing layers designed in the form of reinforcing plates; 5 shows a perspective view of a shaped body according to the invention designed as a studded plate with round studs;

6 shows a plan view of a molded body according to the invention designed as a knob plate with round knobs;

7 shows a side view of a composite element according to the invention designed as a studded plate with round studs;

8 is a perspective view of a shaped body according to the invention designed as a studded plate with square studs;

9 shows a side view of a shaped body according to the invention designed as an underfloor heating element in the form of a studded plate with angular studs;

10 shows a perspective view of a thermal insulation composite system comprising a composite element according to the invention;

11 shows a perspective view of wall insulation based on an in-situ foam according to the invention;

12 shows a perspective view of wall insulation based on insulation according to the invention in the form of a particulate foam material;

13 shows a perspective view of a shaped body according to the invention designed as a laying plate with recesses;

14 shows a side view of a composite element according to the invention designed as a laying plate with recesses;

15 shows a side view of a composite element according to the invention designed as an underfloor heating element in the form of a laying plate with recesses;

Fig. 16 shows a side view of a composite element according to the invention designed as an underfloor heating element in the form of a laying plate with recesses with a heat-conducting layer

Fig. 17 shows a further representation of a composite element according to the invention designed as an underfloor heating element in the form of a laying plate with recesses with a heat-conducting layer in a side view A further subject of the present invention - according to a second aspect of the present invention - is the use of an aforementioned foam material in or as an insulation and/or construction material, in particular for heat and/or sound insulation and/or for the installation of heating and/or supply systems .

In this context, it can be provided that the foam material is designed in the form of shaped bodies or in the form of particles.

As already stated above, the foam material according to the invention is ideally suited for the production of insulation and/or construction materials. The foam material according to the invention can, on the one hand, take on the function of construction and installation panels and, on the other hand, also the function of heat or sound insulation, which is usually applied separately. The foam material according to the invention thus combines the positive properties of various materials that previously had to be used separately or as a composite in the prior art. The use of just a single material, which can take on a variety of functions and replace composite materials, makes it easier to produce the respective building materials and also makes recycling easier, since composites do not have to be separated at great expense.

For further details on this aspect of the invention, reference can be made to the previous statements on the foam material described above, which apply accordingly with regard to the use according to the invention.

Yet another subject of the present invention - according to a third aspect of the present invention - is a shaped body comprising an aforementioned foam material.

In the context of the present invention, it is preferably provided that the shaped body consists of the foam material.

As already stated above, the foam material according to the invention is usually produced in the form of shaped bodies. The moldings obtained in this way can either be shaped directly during production or through subsequent processing, for example by sawing and / or milling, can be obtained specifically and easily for their respective application.

According to a preferred embodiment of the present invention, the shaped body is designed in the form of a construction or installation panel.

According to another preferred embodiment of the present invention, the construction or installation board is intended for use in a floor structure or as an insulation board, preferably for insulation between rafters.

Molded bodies according to the invention or construction or installation panels made from the molded body according to the invention have excellent mechanical properties and at the same time excellent sound and heat-insulating properties, which comparable products from the prior art have not yet achieved. Particularly with regard to compressive strength and dimensional stability, moldings according to the invention stand out in a positive way compared to products from the prior art.

In particular, shaped bodies or construction or installation panels according to the invention are suitable for use in a floor structure, in particular, for example, as a dry coated panel, as a floor insulation panel and/or as a substructure or underlay panel for a floor covering to be applied thereon. The molded bodies or construction or installation panels are characterized by good pressure resistance, especially under point pressure loads. In addition, the panels are particularly dimensionally stable, especially in the presence of moisture, for example.

With regard to the mechanical or physical properties of the moldings or construction or installation panels or the underlying foam material, it is preferred if the foam material has a density of at most 300 kg/m ³ , in particular 275 kg/m ³ , preferably 250 kg/m ³ , and/or at least 20 kg/m ³ , in particular 40 kg/m ³ , preferably 50 kg/m ³ . The foam material therefore advantageously has a density in a range of 20 to 300 kg/m ³ , in particular 40 to 275 kg/m ³ , preferably 50 to 250 kg/m ³ .

As far as the nature or design of the molded body or construction or installation panel according to the invention is concerned, it is preferred It is provided that the shaped body or the construction or installation panel has a three-dimensionally formed or embossed structure, in particular surface structure, at least on one surface, in particular surface.

Such a three-dimensionally formed or embossed structure is preferably in the form of depressions or elevations, in particular in the form of knobs, channels, or the like. In this context, it can further be provided that the three-dimensionally formed or embossed structure has undercuts. In this way, objects, such as underfloor heating lines, can be easily attached, in particular clamped, to the molded body or the construction or installation panel.

A further variant of three-dimensionally designed or embossed structures are designed in the form of indentations and/or bulges in relation to the side surfaces or edges of the molded body or the construction or installation panel, in particular in the form of plug-in connections, tongue-and-groove connections. systems or puzzle systems. Shaped bodies or construction or installation panels with edges designed as plug-in connections, tongue-and-groove systems and/or puzzle systems are particularly suitable for applications in which uncomplicated and time-efficient installation or connection of the panels is desired, which is particularly true for floor structures that are in are to be relocated within a short period of time is advantageous.

According to a further preferred embodiment of the present invention, the shaped body or the construction or installation plate can be designed as an underfloor heating element, in particular as a dimpled sheet and/or dimpled mat and/or dimpled plate or as a laying plate with recesses. In this case, the underfloor heating element is preferably only designed as a single layer, i.e. preferably consists only of the shaped body or the foam material.

According to a further preferred embodiment, the construction or installation plate is designed as a plate for insulation between rafters, in particular as a clamping plate. If the construction or installation board is designed as a board for insulation between the rafters, the foam material preferably has a density of at most 80 kg/m ³ , in particular 60 kg/m ³ , preferably 50 kg/m ³ , and/or at least 20 kg/m ³ , in particular 30 kg/m ³ , preferably 40 kg/m ³ . According to this embodiment, the foam material advantageously has a density in a range of 20 to 80 kg/m ³ , in particular 30 to 60 kg/m ³ , preferably 40 to 50 kg/m ³ . Due to the lower densities and the associated lower compressive strengths, it is possible to attach the construction or installation panel by clamping it between the rafters.

For further details on this aspect of the invention, reference can be made to the previous statements on the previously described foam material and its use, which apply accordingly with regard to the moldings according to the invention.

Furthermore, the subject of the present invention - according to a fourth aspect of the present invention - is an aforementioned foam material in particle form, in particular for use as an insulating material, preferably in the form of a blown-in fill, for heat and/or sound insulation.

Preferably the particulate foam material is present in bulk.

In the context of this aspect of the present invention, it has proven useful if the previously described foam material is used for the particulate foam material, in particular in the form of a, in particular dry, pourable composition or mass. In this sense, it is preferably provided that the foam material described is used in the hardened, foamed state in the form of coarse particles.

These coarse particles can be obtained, for example, by crushing a shaped body from the hardened foam material. Likewise, offcuts or the like of the foam material can also be used for the particulate foam material.

In this respect, the composition of the particulate foam material according to the invention corresponds in particular at least essentially to the composition of the foam material according to the invention. Advantageously, the particulate foam material according to the invention - just like the foam material described above - is characterized by particularly good heat and sound insulation properties. Accordingly, in a similar way to the previously described foam material, it is ideally suited for insulation, in particular thermal insulation and sound insulation, preferably thermal insulation, of buildings and/or roofs, preferably floors, walls and roofs. The particulate foam material is preferably used as blown-in fill or blown-in insulation.

Because the particulate foam material is in the form of a preferably coarsely particulate loose fill, it is advantageously suitable for insulating areas of the building envelope or roof that have particularly demanding geometries and therefore require flexible, applicable insulation solutions.

The particulate foam material preferably has a density in the range of 20 to 40 kg/m ³ , preferably 20 to 30 kg/m ³ .

Due to the advantageously high or, in particular, exclusive proportion of renewable raw materials, the particulate foam material according to the invention also represents a particularly sustainable and environmentally friendly alternative to conventional insulation materials.

For further details on this aspect of the invention, reference can be made to the previous statements on the foam material described above as well as on the other aspects of the present invention, which apply accordingly with regard to the particulate foam material.

Furthermore, the subject of the present invention - according to a fifth aspect of the present invention - is a composite element for use as an insulation and/or construction material, in particular for heat and/or sound insulation and/or for the installation of heating and/or supply systems, having an at least two-layer structure, wherein at least one layer of the composite element is in the form of a foam layer, and wherein the foam layer has an aforementioned foam material. Furthermore, in the context of the present invention, a layer is to be understood as meaning a substantially two-dimensional flat structure, ie such flat structures have two relevant areas or in particular surfaces. The layer thickness or the corresponding side edges or surfaces of the layer are significantly smaller compared to the extent of the (surface) surfaces.

Preferably the foam layer consists of the foam material.

According to a preferred embodiment of the present invention, the foam layer is a previously described shaped body according to the invention.

In the context of the present invention, it is preferably provided that the foam layer is designed as an insulating layer, in particular as a thermal insulation layer and/or sound insulation layer.

If the foam layer is designed as an insulating layer, in particular as a thermal insulation layer, it is preferred in the context of the present invention if the foam layer has a thermal conductivity in the range of 0.015 to 0.085 W/mK, in particular 0.018 to 0.07 W/mK, preferably 0 .02 to 0.055 W/mK, preferably 0.021 to 0.045 W/mK, particularly preferably 0.030 to 0.040 W/mK. The thermal conductivity of the foam material is determined in accordance with DIN 4108-4-2020-11.

As far as the further nature of the composite element according to the invention or its foam layer is concerned, it can be provided within the scope of the present invention that the foam layer has a three-dimensionally formed or impressed structure, in particular surface structure, at least on one surface, in particular surface. In this sense, with reference to the composite element according to the invention, at least one surface of the composite element can have a three-dimensionally formed or embossed structure, in particular a surface structure.

Such a three-dimensionally formed or embossed structure is preferably in the form of depressions or elevations, in particular in the form of knobs. A composite element with a knob-like surface structure is suitable, for example, for use in the installation of Underfloor heating as a so-called studded plate or mat, in which case the composite element is preferably designed in such a way that the heating pipes of the underfloor heating can be clamped between the studs.

In the event that the composite element has a knob-like structure on at least one surface or in particular surface, it may be further preferred that the knobs are round or square, in particular round or polygonal. It can also be provided that the arrangement of the knobs is regular or irregular, with a regular arrangement of the knobs, i.e. a uniform or uniform spacing of the knobs from one another, being preferred.

With regard to the knob itself, it can also be provided that it has further structural elements, such as a protruding or overhanging or even overhanging design of the upper edge of the knob or undercuts. For example, narrowed areas can be formed between the knobs, particularly in the area of the upper end of the knob. This can in turn be advantageous if the composite element is used as a studded plate or mat for underfloor heating, since the heating pipes can be fixed between the studs and are secured against slipping out or similar.

Alternatively or additionally, the heating pipes of an underfloor heating system can also be fastened to the composite element using stapler systems, in particular, for example, with stapler needles that enclose the pipes and thus fix or staple them to the composite element.

It can also be provided that the foam layer has depressions, in particular depressions that are suitable for receiving pipes and lines, preferably underfloor heating.

Furthermore, a variant of a three-dimensionally designed or embossed structure can be designed in the form of indentations and/or bulges with respect to the side surfaces or edges of the foam layer, in particular in the form of plug-in connections, tongue-and-groove systems or puzzle systems. Following on from this, it is also possible within the scope of the present invention for one of the edge surfaces or side surfaces of the composite element to have a three-dimensional surface structure, which is designed or formed in particular depending on the intended use. For example, the edge sides can be designed in the form of plug-in connections, such as tongue-and-groove systems or puzzle systems, preferably puzzle systems. Composite elements with edges designed as plug-in connections, tongue-and-groove systems and/or puzzle systems are particularly suitable for applications in which uncomplicated and time-efficient laying or connecting of the composite elements is desired. This can be the case, for example, for uses of the composite elements according to the invention as insulating elements or as construction elements, in particular for interior construction.

With regard to the further design of the composite element according to the invention, it can be provided within the scope of a further preferred embodiment of the present invention that the composite element has at least one further layer in the form of a functional and/or reinforcing layer.

In this case, it has proven useful if the functional and/or reinforcing layer is arranged indirectly, in particular directly, on the foam layer, in particular on at least one surface of the foam layer, preferably on both surfaces of the foam layer.

Accordingly, within the scope of a particularly preferred embodiment of the present invention, it can be provided that the foam layer is arranged between two functional and/or reinforcing layers.

The functional and/or reinforcing layer is advantageously designed as a functional film and/or reinforcing plate.

In the event that the functional and/or reinforcing layer is designed as a functional film, it has proven useful if the functional film is designed as an undercover membrane, formwork membrane, vapor barrier, fleece layer or aluminum cover layer, in particular as a subcoverage membrane, fleece layer or aluminum cover layer. In this sense, the foam layer can be laminated with a functional film configured as a functional and/or reinforcing layer, or the functional film can also be laminated onto the foam layer or, in particular, extruded onto it.

If an adhesion promoter layer is provided to further strengthen or improve the adhesion between the foam layer and the functional film, adhesion promoters or adhesives are preferably used, and it has proven useful if they contain a plastic and/or a synthetic resin, preferably a polyurethane. Preferably, a polyurethane hot melt adhesive can be used within the scope of the invention.

If the composite element according to the invention has a functional film as a functional or reinforcing layer, the composite elements according to the invention are particularly advantageous for use in the insulation of roofs, in particular as over-rafter, between-rafter or under-rafter insulation. In particular, the composite elements according to the invention configured as described are advantageously characterized by the fact that they are easy to handle and uncomplicated to install as prefabricated, directly installable elements.

According to an advantageous development of the present invention, for composite elements according to the invention which have a functional film as a functional or reinforcing layer, it can be provided that the functional film has at least one longitudinal edge-side adhesive zone on the top and/or the bottom. On the longitudinal edge, this means in particular an arrangement of the adhesive zone along an edge region or side edge of the functional film.

In this case, it is then preferably additionally provided that the functional film and foam layer are arranged in such a way that at least one area, in particular edge area, preferably several areas, in particular edge areas, results in which the film is not covered by the foam layer is so that the adhesive zone can be arranged in these. In this sense, it is correspondingly preferred if the foam layer has a smaller surface area than the functional film, based on a central arrangement of the foam layer and film relative to one another, so that free film edge areas result in which adhesive zones can be arranged. These adhesive zones can be spaced from the longitudinal edge of the film and/or strip-shaped, possibly as interrupted stripes, and, for example, have a width of between 2 and 10 cm. The installation of such adhesive zones can, in particular, significantly facilitate the laying of composite elements according to the invention and enable a particularly durable and resilient connection of the individual composite elements.

If the functional and/or reinforcing layer is designed as a reinforcing plate, it has proven to be advantageous in the context of the present invention for the composite element according to the invention if the reinforcing plate is made of wood board, chipboard, OSB board, fiberboard, in particular made of pressed fiber materials, plasterboard -Board, gypsum fiber board, dry screed board, concrete board, plastic board, wood foam board or their composites. If the reinforcing plate is designed as a fiberboard made of pressed, preferably natural, fiber materials, it is preferred if the fiber material is selected from the group of straw, hemp, coconut, bast, bamboo and mixtures thereof.

In particular, in the context of a particularly preferred embodiment of the present invention, it can be provided that the reinforcing plate designed as a functional and/or reinforcing layer is formed by a further foam layer as described above, i.e. the reinforcing plate can advantageously also be designed as a foam layer or wood foam board, comprising a foam material comprising a natural, renewable raw material. The foam material preferably has the properties and special features already described above.

If the reinforcing plate is formed on the basis of a foam layer, it is further preferred if the foam material of the foam layer and the foam material of the reinforcing layer designed as a foam layer are different from one another, in particular with regard to the properties and / or compositions of the foam material or the foam material thereof obtained foam layer. In particular, the foam layer designed as a reinforcing plate can, for example, have a higher compressive strength and a correspondingly higher density, while the actual one Foam layer has a lower density and also a lower thermal conductivity.

These different properties can advantageously be attributed to a different composition of the foam material, in particular, for example, to a different proportion of additives and/or to differences in relation to the particulate substrate, such as the raw material contained therein and/or its nature. However, this does not require that the respective foam layers always clearly differ from one another optically or visually; rather, it may be that an optical or visual distinction between the foam layers is only possible based on marginal deviations from one another.

Furthermore, within the scope of this embodiment of the present invention, it may be preferred if the foam layer is arranged between two functional and/or reinforcing layers designed as reinforcing plates. A corresponding composite element is characterized by a sandwich arrangement, which can be particularly advantageous in the area of interior design. For example, corresponding composite elements can be used as prefabricated components.

Composite elements according to the invention, which have a configuration as described above, are particularly advantageous for use in interior construction or in the thermal insulation of interior and exterior walls of buildings. The composite elements according to the invention can be used particularly advantageously in the form of prefabricated components for installation, i.e. for example as a sub-deck panel or formwork panel, as well as as facade elements for external insulation or as flat roof insulation panels, in or on the house. It can also be used as a laying or clamping plate for insulation between rafters.

As part of an alternative preferred embodiment of the present invention, it can be provided that the reinforcing layer is designed in the form of a reinforcement. If the foam layer has a reinforcement, this is preferably in the form of a, in particular reinforcing, plate and/or a panel, a, in particular supporting, woven and/or knitted fabric, a membrane and/or a film. Composite elements according to the invention, which comprise a foam layer and a reinforcement arranged thereon, are particularly suitable for use in thermal insulation composite systems. This aspect once again underlines the diverse possible uses of composite elements according to the invention, which, depending on the requirements and specific design, can ultimately be used in all areas of construction and expansion of buildings.

When used as a thermal insulation composite system, the composite element according to the invention represents a particularly sustainable and therefore positive alternative to conventional building materials. Likewise, the composite element according to the invention is characterized by such good mechanical and physical properties, particularly with regard to the insulating performance of the composite element No compromises have to be made compared to comparable products from the prior art.

As already mentioned in connection with the functional and/or reinforcing layer designed as a functional film, it is usually preferred in the context of the present invention if the foam layer and the at least one functional and/or reinforcing layer are firmly, in particular cohesively, connected to one another, preferably are glued together.

Here, bonding of the foam layer and the at least one functional and/or reinforcing layer is both thermally possible, in particular in the event that the functional and/or reinforcing layer is designed as a functional film. The use of adhesion promoters is also proven in the context of the present invention and is particularly preferred if the functional and/or reinforcing layer is designed as a reinforcing plate. In particular, in this context it can be provided that an adhesion promoter layer is provided between the foam layer and the functional and/or reinforcing layer. The adhesion promoter layer preferably comprises an adhesion promoter or adhesive, which contains plastic and/or a synthetic resin, preferably a polyurethane. Preferably, a polyurethane hot melt adhesive can be used within the scope of the invention.

Furthermore, within the scope of the present invention, depending on the application or requirements for the composite element according to the invention, it can be advantageous if the foam layer and/or the functional and/or reinforcing layer are formed in a single layer or in multiple layers. The foam layer is preferably designed in multiple layers.

A multi-layer structure of the foam layer is to be understood in particular as meaning that the foam layer is made up of several layers, with the layers having different foam materials from layer to layer. Differences between the foam materials can exist with regard to the composition of the foam materials, for example with regard to the content of additives or the nature and/or type of natural raw material used. Likewise, the layers can have different mechanical or physical properties, i.e., for example, different foam density or strength.

By comprising composite elements according to the invention foam layers which have a multi-layer structure, the range of properties and applications of the composite element can in particular be expanded. For example, a multi-layer structure of the foam layer is possible when using the composite element as a studded panel or mat or as an installation panel with recesses for underfloor heating. In particular, in this case, the studded panel or the installation panel with recesses, the impact sound insulation underneath and the floor thermal insulation can be combined in a foam layer that has a corresponding multi-layer structure, so that based on the composite element according to the invention, overall there is only a combination construction or - Component can be provided for the installation of underfloor heating.

It is also possible to realize the above-mentioned, usually three-part, floor structure consisting of floor thermal insulation, impact sound insulation and studded panel or installation panel with recesses in a composite element, which is designed in one layer, in particular in relation to the foam layer, i.e. in the form of a single-layer foam layer Property profile corresponds to all of the aforementioned requirements or functions.

It is therefore possible on the basis of the composite element according to the invention to have the three different functions of impact sound insulation, thermal insulation and studded plate or installation plate with recesses, which are usually provided by three different building materials are met, to be combined in one product, ie the composite element according to the invention. In this way, significant material savings and in particular a reduction in the proportion of plastic in the floor structure can be achieved. Also, on the basis of the composite element according to the invention, the foam layer of which, as described above, is designed as a multi- or single-layer dimpled sheet or laying panel with recesses, the laying work for a floor covering or the related one can be significantly simplified. Substructure can be achieved, in particular if the functional and / or reinforcing layer of the composite element is designed, for example, as a reinforcing plate in the form of a dry screed plate or, for example, in particular in the form of a further foam layer.

In particular, with the composite element according to the invention, only one structural element has to be laid instead of usually at least three different building materials. According to a preferred embodiment of the present invention, the composite element according to the invention in the form of a dimpled membrane and/or dimpled panel and/or installation panel with recesses replaces the impact sound insulation, thermal insulation, dimpled membrane or installation panel and the screed in a floor structure for underfloor heating, that is, there is direct Reception of the top covering by the dimpled sheet and/or dimpled plate or installation plate with recesses. If the composite element is designed as a laying plate with recesses for underfloor heating, in particular as an underfloor heating element, it has proven useful if the laying plate has a heat-conducting layer, preferably a heat-conducting plate, on its top side, in particular as an upper layer. The heat-conducting layer is preferably not provided in the recesses of the laying plate. The heat-conducting layer usually consists of a metal, in particular selected from the group of iron, copper, aluminum and their alloys, preferably steel. It can also be provided here that the heat-conducting plate has a coating, in particular an anti-corrosion coating. When the installation panel is installed, in particular when the underfloor heating element is installed, the heat-conducting layer passes on the heat given off by the heating pipes in the recesses over a large area to the floor covering, so that it is heated evenly. A multi-layer structure of the foam layer can also be suitable if the foam layer is arranged between two functional and/or reinforcing layers designed as reinforcement plates. Such sandwich arrangements, which are particularly suitable, for example, for composite elements in the form of prefabricated components, can have an advantageous property profile that is superior to conventional prefabricated components based on a multi-layer design of the foam layer, for example comprising a layer for thermal insulation and a further layer for sound insulation by combining two different functions in an uncomplicated way in one component.

For further details on this aspect of the invention, reference can be made to the previous statements on the foam material according to the invention as well as on the other aspects of the present invention, which apply accordingly with regard to the composite element according to the invention.

A further subject of the present invention - according to a sixth aspect of the present invention - is a use of a composite element, in particular previously described, for thermal and/or sound insulation, in particular of buildings and/or roofs, preferably of floors, walls and roofs.

In particular, it has proven useful if the composite element, in particular previously described, is preferably in the form of insulation panels, preferably laminated rafter insulation panels, intermediate rafter insulation panels, in particular clamping panels, under-rafter insulation panels, flat roof insulation panels, and/or facade elements, preferably underlay panels, formwork panels, and/or dry screed and/or or prefabricated components or facing elements for interior construction, for insulation and/or for the expansion of the building shell and/or roof, in particular both outdoors and indoors.

For further details on this aspect of the invention, reference can be made to the previous statements on the foam material according to the invention as well as on the other aspects of the present invention, which apply accordingly with regard to the use according to the invention. A further subject of the present invention - according to a seventh aspect of the present invention - is a use of a composite element, in particular previously described, in the installation of heating and/or supply systems, in particular in floors and/or walls of buildings, preferably of underfloor heating.

In this context, it can be provided that the composite element replaces the impact sound insulation and thermal insulation, preferably impact sound insulation, thermal insulation and screed, in a floor structure. In this case, the top covering is picked up directly by the composite element according to the invention.

For further details on this aspect of the invention, reference can be made to the previous statements on the foam material according to the invention as well as on the other aspects of the present invention, which apply accordingly with regard to the use according to the invention.

Another subject of the present invention - according to an eighth aspect of the present invention - is an underfloor heating element, in particular a dimpled sheet and / or dimpled mat and / or dimpled plate or a laying plate with recesses, having a previously described shaped body or obtainable from a previously described composite element.

It can be provided here that the dimpled sheet and/or dimpled mat and/or dimpled plate or the installation plate has the impact sound insulation, thermal insulation and dimpled membrane or installation plate with recesses, preferably impact sound insulation, thermal insulation, dimpled membrane or installation plate with recesses and screed, in a floor structure for replaced with underfloor heating. In this case, the top covering is picked up directly by the dimpled sheet and/or dimpled mat and/or dimpled plate or the installation plate.

As stated above, the underfloor heating element can be designed as a laying plate with recesses. In this case, the depressions are preferably designed as pipe or line guides for the underfloor heating lines. It is also possible for the depressions to have undercuts. The underfloor heating element receives the recesses especially a relief-like surface. The depressions can be introduced into the laying plate in any suitable way, for example by shaping during production or subsequently, for example by milling. A subsequent introduction of the depressions is usually preferred.

As already stated above, the underfloor heating element, if it is designed as a laying plate with recesses, has a heat-conducting layer, in particular a heat-conducting plate. Preferably, the heat-conducting layer is not provided in the recesses of the laying plate.

For further details on this aspect of the invention, reference can be made to the previous statements on the foam material according to the invention and on the other aspects of the present invention, which apply accordingly in relation to the dimpled sheet and / or dimpled mat and / or dimpled plate according to the invention.

Furthermore, the subject of the present invention - according to a ninth aspect of the present invention - is a thermal insulation, comprising a previously described shaped body or obtainable from a previously described composite element, for use in the thermal insulation of walls and / or roofs.

Composite elements, in particular those described above, are particularly preferably suitable for use in on-roof insulation, intermediate rafter insulation, under-roof insulation, facade insulation, floor insulation and, in particular, for use in thermal insulation composite systems.

For further details on this aspect of the invention, reference can be made to the previous statements on the foam material according to the invention as well as on the other aspects of the present invention, which apply accordingly with regard to the thermal insulation according to the invention.

A further subject of the present invention - according to a tenth aspect of the present invention - is an impact sound insulation and / or an acoustic absorber, having a previously described shaped body or available from a previously described composite element, for use in the sound insulation of walls and/or floors of buildings.

For further details on this aspect of the invention, reference can be made to the previous statements on the foam material according to the invention and on the other aspects of the present invention, which apply accordingly in relation to the impact sound insulation according to the invention or the acoustic absorber according to the invention.

Finally, a further subject of the present invention - according to an eleventh aspect of the present invention - is an in-situ foam for use as an insulating and/or construction material, in particular for heat and/or sound insulation, comprising a foam material, the foam material being a natural, renewable raw material Base of woody and/or woody plants and a particulate additive selected from the group of expandable graphite, expanded perlite, expanded vermiculite, silica, aerogels, zeolites and mixtures thereof, in amounts of 5 to 20% by weight, based on the foam material , includes. Preferred amounts and configurations of the particulate additive correspond to the amounts and embodiments of the foam material described above.

In the context of this aspect of the present invention, it has proven useful if the foam material according to the invention is used for the in-situ foam according to the invention, in particular in the form of a foamable and sprayable mass. In particular, it is understood that with regard to the foam material for the in-situ foam, we are talking about a non-cured or still curable composition or mass, unless otherwise stated. In this sense, it is preferably provided that the foam material is designed in the form of a curable, freely shapeable and/or freely distributeable mass, in particular wherein the mass is further foamable and can preferably be applied by spray application.

In particular, the composition of the in-situ foam according to the invention corresponds at least essentially to the composition of the foam material according to the invention in the uncured state. This means that the in-situ foam - analogous to the foam material according to the invention in the uncured state - preferably in the form of, in particular highly viscous fiber suspension is present. The foam material advantageously contains at least a small amount of a solvent. The solvent is preferably water.

With regard to the renewable raw material, it is preferred according to the invention if the foam material comprises a natural, renewable raw material, as described above in connection with the foam material according to the invention. In this respect, reference is made in this context to the comments on the foam material according to the invention.

In addition, it is preferably provided that the in-situ foam comprises one or more additives, in particular blowing agents. The blowing agents are preferably selected from organic blowing agents, in particular azobisisobutyronitrile, azodicarbonamide, preferably activated azodicarbonamide, dinitropentamethylenetetramine, hydrazodicarbonamide, oxibissulfohydrazide, oxybisbenzenesulfohydrazide, 5-phenyltetrazole, para-toluenesulfonylsemicarbazide, toluene/benzene sulfohydrazide and their salt e, preferably alkali and alkaline earth metal salts. Likewise, inorganic blowing agents from the group of ammonium carbonate, sodium hydrogen carbonate, preferably in a mixture with potassium hydrogen carbonate and an acid carrier, in particular disodium dihydrogen diphosphate, calcium dihydrogen phosphate or calcium citrate, as well as aluminum powder can be used. With regard to the blowing agent, the only decisive factor is that the blowing agent causes expansion or foam formation at low temperatures, in particular at room temperature.

In this context, it is also advantageous to add oxidizing agents, preferably hydrogen peroxide, in particular as an additional blowing agent. The addition of hydrogen peroxide can advantageously allow the porosity of the foam material to be specifically adjusted.

Furthermore, it has proven useful if the in-situ foam comprises a reactive crosslinker or a reactive binder. According to the invention, preference is therefore given to binders or crosslinkers which crosslink quickly and completely during or immediately following the application of the in-situ foam and cause the foam material or the in-situ foam to harden. The reactive binder can be selected from silanes, polysilanes, silane hydrolysates, polysiloxanes, siliconates, titanates, polytitanates, zirconates, isocyanates, polyisocyanates, reactive polyurethanes and mixtures thereof, in particular silanes, polysilanes, silane hydrolysates, polysiloxanes, siliconates, polyisocyanates, reactive polyurethanes and their mixtures. In this sense, in the context of the present invention, particular preference is given to reactive binders or crosslinkers which crosslink in particular independently of temperature influences and/or specifically in the presence of moisture, in particular in the form of atmospheric moisture and/or also liquid water.

Alternatively, reactive acrylates, in particular cyanoacrylates, have also proven to be suitable binders or crosslinkers in the context of the present invention.

The foam material of the in-situ foam preferably hardens at room temperature and/or in the presence of moisture. In addition, it is preferred according to the invention if the foam material hardens within a short time, in particular within a few minutes, preferably less than 15 minutes, preferably less than 10 minutes.

With regard to the formulation of the in-situ foam, this can vary depending on the application or usage requirements. According to the invention, it is accordingly possible for the in-situ foam to be designed as a one-component or two-component formulation. A two-component formulation of the in-situ foam has proven to be suitable, particularly with regard to the preferred binders or crosslinkers.

If the in-situ foam is designed as a two-component formulation, it has proven useful if the first component comprises the renewable raw material, in particular in the form of a fiber suspension, and one or more blowing agents. The second component preferably comprises the binder or the crosslinker. As part of the application of the in-situ foam, the components are then preferably mixed immediately at the moment of application. In particular, it is provided here that the blowing agent preferably causes instantaneous foaming of the foam material and that the crosslinker immediately begins to crosslink and harden. Because the first component, in particular the fiber suspension contained therein, has at least small amounts of a solvent, in particular water, the crosslinking or hardening of the in-situ foam can be additionally positively influenced, especially in the event that moisture-curing binders or crosslinkers are contained in the in-situ foam .

In this way, within the scope of the present invention, a particularly stable and also advantageously porous foam can be obtained based on the in-situ foam according to the invention, which advantageously matches the foam material according to the invention in terms of its nature and physical and mechanical properties. The main advantage of the in-situ foam according to the invention is the flexible applicability of the foam and the possibility of effectively insulating even geometrically complex or difficult-to-access areas of a building shell or roof.

For further details on this aspect of the invention, reference can be made to the previous statements on the previously described foam material as well as on the other aspects of the present invention, which apply accordingly with regard to the in-situ foam according to the invention.

Further advantages, properties, aspects and features of the present invention result from the following description of embodiments of the present invention which are preferred according to the invention and shown in the drawings.

1 shows a cross section through a molded body 1 according to the invention made from a foam material 2 according to the invention.

The foam material 2 is based on a natural, renewable raw material 4 in the form of a plant raw material based on woody and/or woody plants, preferably wood. Advantageously, within the scope of the present invention, almost all types of wood or components of woody plants can be used, such as, among others, hardwood, coniferous wood, bark, root material, thinning wood, woody annual plants and mixtures thereof.

Likewise, according to a further advantage of the present invention, it is also possible for the renewable plant raw material 4 to be made from sawing by-products, Waste wood, wood-containing waste products and/or recyclable or recycled wood-containing products is selected. The natural, renewable plant raw material therefore preferably comprises 4 lignin and/or lignocellulose-based raw materials or in particular plants.

The natural, renewable plant-based raw material 4 is preferably present in the foam material 2 in the form of particles, in particular fibers. It has proven useful here if the particles or in particular fibers of the natural, renewable raw material have 5 particle sizes and/or fiber lengths in a range from 100 pm to 50 mm, in particular 200 pm to 10 mm, preferably 250 pm to 5 mm, preferably 300 pm to 2.5 mm, based on the renewable raw material in its initial state.

The foam material 2 according to the invention is advantageously characterized by a high proportion of renewable raw material and thus represents a particularly sustainable embodiment of a composite element. The foam material 2 preferably has a proportion of the renewable raw material 5 of more than 75% by weight, in particular 79% by weight. -%, preferably 82% by weight, preferably 84% by weight, very particularly preferably 85% by weight, based on the total composition of the foam material.

The foam material 2 also has a particulate additive in amounts of 5 to 20% by weight, based on the foam material. It is preferred if the foam material 2 contains the particulate additive in amounts of 5 to 15% by weight, in particular 5 to 10% by weight, preferably 6 to 10% by weight, preferably 6 to 9% by weight, based on the foam material. The particulate additive can be selected from a variety of substances or materials. However, it has proven useful that the particulate additive is selected from inorganic or mineral materials. With inorganic or mineral materials, not only can the mechanical properties of the foam material 2 be positively influenced, but the fire and flame resistance is also significantly increased. The particulate additive is selected from the group of expandable graphite, expanded pearlite, expanded vermiculite, silica, in particular pyrogenic silica, aerogels, in particular silica aerogels, zeolites and mixtures thereof. Particularly good results are obtained when the particulate additive is selected from expandable graphite, expanded perlite, expanded vermiculite and their mixtures. The particulate additive is preferably expandable graphite.

The particulate additive preferably has an average particle size D50 in the range from 10 pm to 2 mm, in particular 20 pm to 1.5 mm, preferably 50 pm to 1 mm, preferably 70 pm to 800 pm, particularly preferably 80 pm to 700 pm .

Depending on the application or intended use, it can also be provided within the scope of the present invention that the foam material 2 has one or more additives, the one or more additives preferably being selected from the group of hydrophobing agents, flame retardants, corona inhibitors, fungicides, Oxidizing agents, blowing agents, thickeners, crosslinkers, gelling agents, pH regulators, plasticizers and/or mixtures thereof. In this regard, it has proven to be suitable if the one or more additives in the foam material 2 have a proportion of less than 17% by weight, in particular 12% by weight, preferably 9% by weight, preferably 7% by weight, very particularly preferably 6% by weight, based on the total composition of the foam material. Particulate additives, whose particle shape is retained in the foam material 2, are also added to the particulate additive in terms of quantity if they meet the requirements for the particulate additive, i.e. they are evaluated as additives on the one hand, but also as particulate additives on the other.

With regard to the structure of the foam material 2, it is preferred if the foam material 2 has an open-pore foam structure 3.

The foam material 2 advantageously achieves densities of less than 300 kg/m ³ , in particular less than 275 kg/m ³ , preferably less than 250 kg/m ³ , and/or more than 20 kg/m ³ , in particular more than 40 kg/m 3 m ³ , preferably more than 50 kg/m ³ . In addition, the foam material 2 also achieves advantageous strengths, in particular of more than 20 kPa and/or up to 600 kPa, in particular 400 kPa, preferably 250 kPa, at 10% compression. The foam material therefore advantageously has a compressive strength in a range of 20 to 600 kPa, in particular 30 to 400 kPa, preferably 40 to 250 kPa, at 10% compression in accordance with DIN EN 826. As part of a preferred embodiment of the molded body 1 according to the invention, it is provided that the foam material 2 is designed as an insulating layer, in particular as a thermal insulation layer and/or sound insulation layer.

The foam material 2 then preferably has a thermal conductivity in a range of 0.015 to 0.085 W/mK, in particular 0.018 to 0.07 W/mK, preferably 0.02 to 0.055 W/mK, preferably 0.021 to 0.045 W/mK, particularly preferably 0.030 up to 0.040 W/mK. Accordingly, the foam material 2 according to the invention is particularly suitable for use as thermal and sound insulation, in particular for thermal insulation, of buildings and / or roofs, preferably floors, walls and roofs.

2 shows a preferred use of a shaped body 1 according to the invention in a composite element 5. According to the embodiment shown in FIG. 2, the composite element 5 has a two-layer structure, wherein the composite element 5 comprises a layer of the foam material 2.

According to the preferred embodiment of the present invention, which is shown in FIG. 2, the composite element 5 according to the invention further comprises a functional and/or reinforcing layer 6.

With regard to the functional and/or reinforcing layer 6, it can be provided that it is designed as a functional film 7 and/or as a reinforcing plate. If the functional and/or reinforcing layer is designed as a functional film 7, it has proven useful in the context of the present invention if the functional film 7 is designed as a base layer, formwork membrane, vapor barrier, fleece layer or aluminum cover layer. The functional film 7 is particularly preferably in the form of a base layer, fleece layer or aluminum cover layer.

A preferred embodiment of the composite element 5 according to the invention designed in this way can be seen in FIG. Here, the composite element 2 according to the invention has a layer made of a foam material 2 and a functional film 7 designed as a functional and/or reinforcing layer. As part of a preferred development, the composite element 5 has on the top and/or the bottom of the film 7, according to the embodiment in FIG. at least one adhesive zone 8 on the longitudinal edge.

The adhesive zones 8 are preferably spaced from the longitudinal edge of the film 7 and are strip-shaped. For example, the adhesive zones 8 can have a width of between 2 and 10 cm.

Composite elements 5, which are designed as shown in FIG. 3, are particularly suitable for use in insulating roofs. Based on the advantageous configuration of the composite element 5, a particularly user-friendly or uncomplicated installation of the composite element 5 can be made possible and, in particular, a stable and resistant connection of individual composite elements 5 based on the adhesive zones 8 can be achieved.

In general, it can be provided that the molded body 1 has a three-dimensionally formed or embossed structure with respect to the side surfaces or edges of the foam material 2 and/or the molded body 1 as a whole. By way of example, these structures can be designed in the form of indentations and/or bulges, in particular in the form of plug-in connections, tongue-and-groove systems or puzzle systems, with the preferred molded body 1 shown in FIG. 4A being equipped with a tongue-and-groove system .

As part of a further preferred embodiment of the present invention, which is shown in FIG. 4B, it can be provided that the functional and/or reinforcing layer 6 of a composite element 5 according to the invention is designed as a reinforcing plate. If the functional and/or reinforcing layer 6 is in the form of a reinforcing board, it is preferred in the context of the present invention if the reinforcing board is made of wood board, chipboard, OSB board, gypsum board, gypsum fiber board, fiber board, in particular made of pressed fiber materials, preferably pressed natural fiber materials, wood foam board, dry screed board, concrete board, plastic board or their composites. If the reinforcing plate is designed as a fiberboard made of pressed natural fiber materials, it will It is preferred if the fiber material is selected from the group of straw, hemp, coconut, bast, bamboo and mixtures thereof. In the context of the present invention, it can also be provided that the reinforcing plate is a wood foam board, in particular a wood foam board with increased density compared to the foam material 2 or the shaped body 1.

Furthermore, it can be provided for composite elements 5 according to the invention that the foam material 2, in particular in the form of a shaped body 1, is arranged between two functional and/or reinforcing layers 6, as shown in FIG. 4B. Composite elements 5 with corresponding sandwich arrangements or configurations are particularly suitable for use as prefabricated components and can therefore be used in particular in the interior design of buildings.

Furthermore, it can advantageously be provided within the scope of the present invention that composite elements 5 according to the invention - as well as shaped bodies 1 - have a three-dimensionally formed or embossed structure with respect to the side surfaces or edges of the foam material 2 and / or the composite element 5 as a whole. By way of example, these structures can be designed in the form of indentations and/or bulges, in particular in the form of plug-in connections, tongue-and-groove systems or puzzle systems, with the preferred composite element shown in FIG. 4B being equipped with a tongue-and-groove system.

As shown in Fig. 5, within the scope of the present invention it can preferably be provided that the foam material 2 has a three-dimensionally formed or embossed structure, in particular surface structure, at least on one surface, in particular surface, in particular such a structure, for example. can be in the form of depressions or elevations, in particular in the form of knobs 10.

A correspondingly designed molded body 1 or a composite element 5 in the form of a studded plate 9 can, for example, have round studs 10. Furthermore, it has proven useful if the arrangement of the knobs 10 is regular, that is, there is a uniform or evenly dimensioned spacing of the knobs 10 from one another (see FIGS. 5 and 6). 7 also shows a side view in the form of a schematic section through a studded plate 9 in Form of a composite element 5 shown, the section running along a line VV, as shown in Fig. 6. However, it is easily possible to form the studded plate 9 in one layer, ie in the form of a molded body 1 according to the invention.

A shaped body according to the invention configured in accordance with Figures 5 and 6

I or a composite element 5 according to the invention configured in accordance with Figures 5 to 7 in the form of a studded plate 9 is particularly suitable for use for installing underfloor heating. In particular, the molded body 1 according to the invention or the composite element 5 according to the invention is configured in the form of the preferred embodiment as a studded plate 9 in such a way that the heating pipes of an underfloor heating system can be arranged and laid between the studs 10, the heating pipes also being able to be fixed between the studs 10. Alternatively or additionally, shaped bodies 1 according to the invention or composite elements 5 according to the invention can also be combined with stapler systems, in particular where the heating pipes of the underfloor heating are fixed with stapler needles. The studded plate 9 is preferably an underfloor heating element 12. The underfloor heating element 12 is designed in particular in such a way that it can be used as a laying plate for underfloor heating, wherein the pipes or lines of the underfloor heating can preferably be arranged within the underfloor heating element 12 or from these can be included.

As an alternative to the design of the knob plate 9 according to FIGS. 5 to 7, it is also possible for the knobs to be angular, in particular polygonal. A corresponding knob plate 9 is shown in FIG. 8, in particular where the knobs

I I the knob plate 9 is polygonal. Furthermore, it is also possible for the knobs to have undercuts. In this way, better fixation of underfloor heating pipes, for example, is possible.

Furthermore, within the scope of the present invention, it can be provided that the layer made of the foam material 2 and/or the functional and/or reinforcing layer 6 are designed in multiple layers, with the layer made of the foam material 2 preferably being designed in multiple layers. A correspondingly configured composite element 5 in the form of an underfloor heating element 12 is shown in FIG. According to this embodiment of the present invention, a preferred underfloor heating element 12 has a functional and/or reinforcing layer 6 and three layers of foam materials 2. Here, layer A of the foam material is designed in the form of a studded plate or mat and has corresponding studs 10. The underlying layer B of the foam material can in particular be configured as impact sound insulation and advantageously has a foam material that is different from layer A. There may be differences between the foam materials of layers A and B, for example with regard to the composition of the foam material, ie the content of additives or also the nature and/or type of natural raw material used. Likewise, the foam materials of layers A and B can also have different mechanical and/or physical properties, that is, for example, a foam density or strength that differs from one another. The same applies to the layer C of the foam material, which is preferably designed as floor thermal insulation as part of the design of the composite element 5 according to the invention according to FIG.

Based on the molded body 1 according to the invention or the composite element 5 according to the invention, new types of insulation and construction elements can be provided which, compared to conventional insulation or floor structures, are both more sustainable and material-saving and can be installed in a more user-friendly manner.

As part of a further preferred embodiment of the composite element 5 according to the invention, it can be provided that the reinforcing layer is designed in the form of a reinforcement 15, in particular with the foam material 2 then being arranged directly on the reinforcement 15. Exemplary reinforcements 15 can in particular be designed in the form of a, preferably reinforcing, plate and/or a panel, a, preferably supporting, woven and/or knitted fabric, a membrane and/or a film.

Correspondingly configured composite elements 5 are, as shown in FIG. 10, advantageously suitable for use in thermal insulation composite systems. An exemplary thermal insulation composite system, as shown in FIG. 10, further comprises, in addition to the composite element 5 according to the invention, in particular one Adhesive layer 14 and a plaster 16 applied to the reinforcement 15 of the composite element. The composite element 5 is connected to the wall 13 to be insulated via the adhesive layer 14, preferably via a layer of the foam material 2.

Thus, based on the composite element 5 according to the invention, a variety of applications for the construction sector, in particular the construction and/or expansion of buildings, can be provided, which can fulfill a wide variety of purposes. In particular, composite elements 5 according to the invention are suitable for use as insulating materials, in particular for heat and/or sound insulation, with the majority of applications of composite elements according to the invention also being associated with a significantly easier, more user-friendly and more efficient installation of the composite element according to the invention in comparison to comparable prefabricated components of the prior art accompanied.

In addition to the composite element 5 according to the invention, which is characterized significantly by the foam material 2 contained therein, in particular with regard to the mechanical or physical properties of the composite element 5, the use of an in-situ foam 17 in the area of insulation can also be used within the scope of the present invention. in particular the thermal insulation and/or impact sound insulation of buildings and/or roofs. A corresponding application of an in-situ foam 17 can be seen in FIG. 11, according to which the in-situ foam 17 is arranged between a wall 13 and a functional and/or reinforcing layer 6, here in particular in the form of a pre-wall construction based on a reinforcing plate, in particular where the in-situ foam 17 is particularly suitable for use on geometrically demanding detailed designs.

In the context of the present invention, it has proven useful if the foam material 2 provided for the foam layer of the composite element 5 according to the invention is used for the in-situ foam 17 according to the invention, in particular in the form of a foamable and sprayable mass. Advantageously, the composition of the in-situ foam 17 according to the invention therefore corresponds at least essentially to a composition of the foam material 2 according to the invention, in particular in the non-hardened or hardened state. In addition to the renewable raw material 4, which is contained in the foam material of the in-situ foam 17, the in-situ foam 17 can also comprise one or more additives, in particular blowing agents, and preferably a reactive crosslinker or a reactive binder. Based on this composition, both uniform foaming or foaming and rapid hardening of the in-situ foam 17 can be achieved.

Here, the composition or formulation of the in-situ foam 17, for example in the form of a one-component or a two-component formulation, is preferably selected such that the in-situ foam or the foaming agent contained therein, preferably comprising a renewable raw material, a blowing agent and a reactive crosslinker or a reactive binder, which foams or expands during the application or immediately afterwards and also begins to crosslink and harden.

Since the in-situ foam 17 is preferably in the form of a sprayable and free-formable foam material, the foam is particularly suitable for insulating geometrically demanding or difficult-to-access areas. The foam material can in particular be in the form of the highly viscous fiber suspension, which is also used as a starting material for producing the foam layers of composite elements 5 according to the invention.

Finally, another aspect of the present invention is a particulate foam material 18 as shown in Figure 12. Here, the particulate foam material 18 has decayed between a wall 13 and a functional and/or reinforcing layer, here in particular in the form of a pre-wall construction based on a reinforcing plate.

In this regard, it is preferred within the scope of the present invention if the particulate foam material 18 is in the form of a, in particular dry, pourable and/or inflatable composition or mass, which preferably corresponds to the composition of the foam material 2, molded bodies 1 according to the invention and composite elements 5 according to the invention. In particular, the particulate foam material 18 can be obtained from the, in particular hardened, foam material 2, for example as part of a further Manufacturing step is shredded or in the form of, for example, cuttings.

13 shows a representation of a shaped body 1 according to the invention in the form of a laying plate 19. According to the embodiment shown in the figure representation, the laying plate 19 has recesses 20, which are particularly suitable for receiving pipes and lines, for example from underfloor heating. The recesses 20 give the laying plate 19 a particularly relief-like surface. The depressions 20 can be created in particular by shaping during the production of the laying plate 19 or by processing the laying plate 18 after its production, for example by milling. The depressions 20 are preferably arranged on the laying plate 19 in such a way that pipes or lines can be laid over several laying plates 19 that are lined up and/or connected to one another.

In addition to one or more foam materials 2, the laying plate 19 can also have one or more functional or reinforcing layers 6 and can then be in the form of a composite element 5. According to the embodiment shown in Fig. 14, the laying panel 19 is a composite element 5 with a layer of a foam material 2 and a functional or reinforcing layer 6.

According to a preferred embodiment, the laying plate 19, in particular the laying plate 19 with recesses 20, is designed as an underfloor heating element 12. In addition to one or more layers of foam materials 2, the underfloor heating element 12 can also have one or more functional or reinforcing layers 6. In particular, within the scope of the present invention it can be provided that the foam layer 2 and/or the functional and/or reinforcing layer 6 are designed in multiple layers, with the foam layer 2 preferably being designed in multiple layers. A correspondingly configured composite element 5 in the form of an underfloor heating element 12 is shown in FIG. 15.

According to a further preferred embodiment of the invention, the composite element 5 as an underfloor heating element 12 in the form of a laying plate 19 with depressions 20 and a heat-conducting layer 21. Corresponding composite elements 5 are in the figure representations according to Figures 16 and 17 shown. 16 shows a composite system 5 designed as an underfloor heating element 12 in the form of a laying plate 19 with depressions 20. A further layer, namely a heat-conducting layer 21, is applied to the foam material 2. The heat-conducting layer 21 is preferably a heat-conducting plate and consists in particular of a metal, preferably selected from the group of iron, copper, aluminum and their alloys. In this context, it is preferred if the heat-conducting layer 21, in particular the heat-conducting plate, consists of steel. The heat-conducting plate can in turn be coated, for example with an anti-corrosion coating. The heat-conducting layer 21 is preferably applied over the entire surface to the foam material 2, in particular by means of gluing, the heat-conducting layer 21 preferably having recesses in the area of the depressions 20 and in the area of fastening sections, such as tongue and groove systems.

17 shows a further embodiment of the composite element 5 as an underfloor heating element 12 in the form of a laying plate 19 with depressions 20. According to FIG. 17, the foam material 2 has a multi-layer structure with the layer sequence ABC, as already described above. The embodiment shown in FIG. 17 also has a heat-conducting layer 21.

List of reference symbols:

1 molded body

2 foam material

3 open-pore foam structure

4 renewable raw material

5 composite element

6 functional and/or reinforcing layer

7 functional film

8 adhesive zones

9 stud plate

10 round studs

11 square nubs

12 underfloor heating element

13 wall

14 adhesive layer

15 reinforcement

16 plaster

17 in-situ foam

18 particulate foam material

19 laying plate

20 deepening

21 heat-conducting layer

A foam layer layer A

B foam layer layer B

C foam layer layer C

Claims

Patent claims:

1. Foam material, comprising a natural, renewable raw material based on woody and / or woody plants, characterized in that the foam material contains at least one particulate additive selected from the group of expanded graphite, expanded perlite, expanded vermiculite, silica, aerogels, zeolites and the like Mixtures in amounts of 5 to 20% by weight, based on the foam material.

2. Foam material according to claim 1, characterized in that foam material contains the particulate additive in amounts of 5 to 15% by weight, in particular 5 to 10% by weight, preferably 6 to 10% by weight, preferably 6 to 9% by weight. -%, based on the foam material.

3. Foam material according to claim 1 or 2, characterized in that the particulate additive is selected from the group of expanded graphite, expanded pearlite, expanded vermiculite, fumed silica, silica aerogels, zeolites and mixtures thereof, in particular expanded graphite, expanded pearlite, expanded vermiculite and mixtures thereof, preferably expanded graphite.

4. Foam material according to one of the preceding claims, characterized in that the particulate additive has average particle sizes in the range from 10 pm to 2 mm, in particular 20 pm to 1.5 mm, preferably 50 pm to 1 mm, preferably 70 pm to 800 pm, particularly preferably 80 pm to 700 pm.

5. Foam material according to one of the preceding claims, characterized in that the natural, renewable raw material is wood.

6. Foam material according to one of the preceding claims, characterized in that the natural, renewable raw material makes up more than 75% by weight of the foam material, in particular 79% by weight, preferably 82% by weight, preferably 84% by weight. -%, very particularly preferred 85% by weight, based on the total composition of the foam material. Foam material according to one of the preceding claims, characterized in that the foam material contains one or more additives, in particular selected from the group of hydrophobing agents, flame retardants, corona inhibitors, fungicides, oxidizing agents, blowing agents, thickeners, crosslinkers, gelling agents, emulsifiers, pH regulators, plasticizers, Binders and/or a mixture thereof. Foam material according to one of the preceding claims, characterized in that the foam material has fire class C, preferably B, according to DIN EN 13 501-1. Foam material according to one of the preceding claims, characterized in that the foam material has a density of less than 300 kg/m ³ , in particular less than 275 kg/m ³ , preferably less than 250 kg/m ³ , and/or more than 20 kg/ m ³ , in particular more than 40 kg/m ³ , preferably more than 50 kg/m ³ . Foam material according to one of the preceding claims, characterized in that the foam material has a thermal conductivity in a range of 0.015 to 0.085 W/mK, in particular 0.018 to 0.07 W/mK, preferably 0.02 to 0.055 W/mK, preferably 0.021 to 0.045 W/mK, particularly preferably 0.030 to 0.040 W/mK. Use of a foam material according to one of claims 1 to 10 in or as an insulation and/or construction material, in particular for heat and/or sound insulation and/or for the installation of heating and/or supply systems. Use according to claim 11, characterized in that the foam material is in the form of shaped bodies or in the form of particles. Shaped body comprising a foam material according to one of claims 1 to 14. Shaped body according to claim 13, characterized in that the shaped body consists of the foam material.

15. Shaped body according to claim 13 or 14, characterized in that the shaped body is designed in the form of a construction or installation board, in particular for use in a floor structure or as an insulation board, preferably for insulation between rafters.

16. Shaped body according to claim 15, characterized in that the construction or installation plate is designed as an underfloor heating element, in particular dimpled sheet and/or dimpled mat and/or dimpled plate or installation plate with recesses.

17. Shaped body according to claim 15, characterized in that the construction or installation plate is designed as a plate, in particular a clamping plate, for the insulation between rafters.

18. Particulate foam material in bulk, in particular for use as an insulating material, preferably in the form of a blown-in fill, for heat and/or sound insulation, made from a foam material according to one of claims 1 to 10.

19. Composite element for use as an insulating and/or construction material, in particular for heat and/or sound insulation and/or for installing heating and/or supply systems, having an at least two-layer structure, with at least one layer of the composite element in the form of a foam layer is formed and wherein the foam layer comprises a foam material according to one of claims 1 to 10.

20. Composite element according to claim 19, characterized in that the foam layer is formed from a shaped body according to one of claims 13 to 16.

21. Composite element according to claim 19 or 20, characterized in that the foam layer is designed as an insulating layer, in particular as a thermal insulation layer and / or sound insulation layer. 22. Composite element according to one of claims 19 to 21, characterized in that the foam layer has a three-dimensionally formed or impressed structure, in particular surface structure, at least on one surface, in particular surface.

23. Composite element according to one of claims 19 to 22, characterized in that the composite element has at least one further layer in the form of a functional and / or reinforcing layer.

24. Composite element according to claim 23, characterized in that the functional and / or reinforcing layer is designed as a functional film and / or reinforcing plate.

25. Composite element according to claim 24, characterized in that the functional film is designed as an undercover membrane, formwork membrane, vapor barrier, fleece layer or aluminum cover layer, in particular as an undercover membrane, fleece layer or aluminum cover layer.

26. Composite element according to claim 24 or 25, characterized in that the reinforcing plate is designed as a wooden board, chipboard, OSB board, gypsum board, fiberboard, in particular made of pressed fiber materials, gypsum fiber board, dry screed board, concrete board, plastic board, wood foam board or their composites.

27. Use of a composite element, in particular according to one of claims 19 to 26, for thermal and / or sound insulation, in particular of buildings and / or roofs, preferably of floors, walls and roofs.

28. Use of a composite element, in particular according to one of claims 19 to 26, in the installation of heating and / or supply systems, in particular in floors and / or walls of buildings, preferably of underfloor heating.

29. Underfloor heating element, in particular dimpled sheet and/or dimpled mat and/or dimpled plate or installation plate with recesses, comprising a shaped body according to claim 13 or 14 or obtained from one Composite element according to one of claims 19 to 26, for use in underfloor heating. Thermal insulation, comprising a shaped body according to claim 13 or 14 or obtained from a composite element according to one of claims 19 to 26, for use in the thermal insulation of walls and / or roofs of buildings. Impact sound insulation and/or acoustic absorber, comprising a shaped body according to claim 13 or 14 or obtained from a composite element according to one of claims 19 to 26, for use in the sound insulation of walls and/or floors of buildings. In-situ foam for use as an insulating and/or construction material, in particular for heat and/or sound insulation, comprising a foam material, characterized in that the foam material is a natural, renewable raw material based on woody and/or woody plants and at least one particulate additive, selected from the group of expandable graphite, expanded pearlite, expanded vermiculite, silica, aerogels, zeolites and mixtures thereof, in amounts of 5 to 20% by weight, based on the foam material.