WO2011147885A1

WO2011147885A1 - Coating compound, in particular for ceilings and/or walls

Info

Publication number: WO2011147885A1
Application number: PCT/EP2011/058584
Authority: WO
Inventors: René NEUHAUS
Original assignee: Neuhaus Rene
Priority date: 2010-05-25
Filing date: 2011-05-25
Publication date: 2011-12-01
Also published as: CH703178A1

Abstract

The invention relates to an open-pored curing, non-combustible coating compound, in particular for ceilings and/or walls, comprising the following composition: 20 to 80 parts by volume of an inorganic, granular light-weight filler having a grain diameter of up to 5 mm and a bulk weight of no more than 1,000 kg/m³, 80 to 20 parts by volume of an aqueous phase, comprising: 2 to 40 wt % Ca(OH)₂, 0 to 40 wt % Ca CO₃fine particulate, 0 to 2 wt % auxiliary dispersing agent, 0.1 to 5.0 wt % thickener, the remainder being water, with the stipulation that the weight fraction of Ca(OH)₂ + CaCO₃ is at least 6 wt %. A coating produced therefrom comprises a plurality of heat conducting elements (12) arranged at a distance from each other and extending from the wall or ceiling surface (2) to approximately the side (18) of the coating (16) facing away from said surface.

Description

Coating material, in particular for ceilings and / or walls

Technical area

The invention relates to a coating composition with sound-absorbing and moisture-regulating properties and their processing technology and product cycle. The inorganic, non-combustible, light coating composition with sound-absorbing and moisture-regulating properties is suitable for producing seamless, smooth ceilings and walls and can be applied in a single application in a thickness of up to 70 mm. It is suitable for the production of sound-absorbing structures, such as plates. In combination with vertically integrated heat conductors, the coating compound is especially suitable for the coating of thermoactive ceilings / walls.

State of the art

If, on the part of the architecture of buildings, there is a desire for seamless smooth ceilings or walls, suspended ceilings and / or glued-on acoustic systems consisting of individual panels are used. The panels are mounted on a suspended support structure or directly on the concrete and joined together with grout, adhesive tapes, etc. After assembly of the panels, the surface is smoothed off with a coating compound.

Due to the different flow resistance of the connection points and / or the different flow resistance of the materials used, undesired joint marking can take place over time.

The systems described in the prior art are partly constructed on fiber-containing products or need a fiber-containing plate in order to achieve the listed sound absorption. Mineral fibers may be legal resp. However, health reasons are not used in all indoor countries. Furthermore, the mineral fiber-based absorption system always also contain formaldehyde, which should be avoided according to the current requirements. The preservatives used in aqueous systems are sensitizing and may, among other things, cause skin irritations.

The products used in practice based on lightweight fillers and / or mineral fiber boards are not suitable for sound absorption in buildings with thermoactive component cooling or heating due to their thermal insulation properties. For example, EP 0 652 187 A1 describes a plaster mortar based on foam glass granules, which, however, would be unsuitable for the present application due to its high thermal insulation capacity.

A system used in practice for the sound absorption of thermo-active components is based on quartz gravel. The additional weight must be compensated by expensive measures such as thicker concrete slabs and or reinforced reinforcement, which in turn would result in higher costs and less space. The same applies to the plaster mortar described in EP 0 652 187 A1, which has a dry bulk density of approximately 0.45 g / cm ³ .

The systems described in various publications are based on the absorption of different materials such as absorbent plates based on fiber, perforated or foam boards in combination with microporous coatings and must be separated and disposed of costly and energy-intensive during dismantling.

Various materials mentioned in the literature for achieving smooth ceilings based on marble and quartz granules can not be ground, and therefore, the areas created therefrom partially have insufficient flatness tolerance.

Creating thin, smooth microporous layers based on marble, quartz granules requires high mechanical pressure from the smoothing tools. This has an effect on increased compaction of the surface and therefore leads to a reduction of the sound absorption.

The organic resins used in the prior art are flammable and have at least a high water hazard class, so that products based thereon must be incinerated with high energy expenditure. Furthermore, these often soft polymers promote adhesion by bonding e.g. Fine dust on the surface a rapid surface contamination, which leads to an early, expensive renovation of these systems.

The formulations used according to various publications for sound-absorbing systems are not frost-resistant due to the raw materials used and must be stored and / or transported in winter in a cost and energy-intensive manner.

Cementary sound absorption systems have a limited processing time and started containers / bags must be disposed of.

The processing of dry mixtures, which should give a bright surface, requires clean water. However, this is not always available at the time of installation on the object.

Presentation of the invention

The object of the invention was to develop a sound-absorbing, moisture-regulating coating for walls, ceilings in the interior and exterior with the requirement profiles: Sound-absorbing smooth, bright surfaces;

Fire rating at least A2;

Layer thicknesses from 1 mm to 70 mm by single order

Integration of pipes mounted on the raw floor, piping. - grind surface to plan so that gliding suitable ceilings can be created;

Low basis weight of the system even when used for coating thermoactive components.

When sanding the ceilings, the surface always stays white;

- Suitable for thermoactive ceilings, walls;

Rational, fast, machine processability with long open time; Abandonment in building construction by e.g. the builder caused usual tolerance compensation for walls, ceilings by e.g. Basic plaster, suspended ceiling system;

- Selected raw materials, which take into account ecological requirements and have a good energy balance;

Absolutely formaldehyde-free formulation of an acoustic system;

Easy to clean by removing the dirty layer; - Free from VOCs;

- Possibilities of creating very bright surfaces without the addition of additional white pigments such as titanium oxide, zinc white, zinc sulfide, etc.

Possibility of use without the necessary mineral fiber plates mentioned in some systems for sound absorption;

Abandonment of chemical preservatives;

- Product processing up to 5 ° C room temperature, surface temperature possible.

The above and other objects are achieved by the coating composition defined in claim 1, by the use defined in claim 5 and by the coating defined in claim 6. According to a first aspect of the invention, an open-cell curing, incombustible coating composition is provided, in particular for ceilings and / or walls, which is substantially free of hydraulic binders. The coating composition according to the invention is characterized by the following composition:

20 to 80 parts by volume of an inorganic, granular light filler with a grain diameter of up to 5 mm and a bulk density of at most 1 Ό00 kg / m ³ ,

80 to 20 parts by volume of an aqueous phase comprising:

2 to 40% by weight of Ca (OH) ₂

- 0 to 40 wt .-% CaCO ₃ finely divided,

0 to 2.0% by weight of dispersing assistant,

0.1 to 5.0 wt .-% thickener, and

the rest of the water;

with the proviso that the proportion by weight of Ca (OH) ₂ + CaCO3 is at least 6% by weight.

It has been found that the initial ratio of Ca (OH) ₂ + CaCO 3 can be varied over a wide range without substantially changing the inventive shafts. For example, can be started without CaCO ₃ , in which case a minimum content of 6 wt .-% of Ca (OH) ₂ is to be used.

In general, the composition according to the invention contains from 20 to 80 parts by volume of the inorganic, granular, light filler, with from 25 to 70% by volume and in particular from 55 to 65 parts by volume being used in most cases.

The coating composition of the invention is suitable for applying a sound-absorbing and / or moisture-regulating coating on a wall or ceiling surface. Furthermore, the inventive method coating composition for applying a sound-absorbing and / or moisture-regulating coating on a building, in particular on a plate. Furthermore, the coating composition according to the invention is suitable for producing a plate.

A further aspect of the invention relates to a jointless coating applied to a wall or ceiling surface, formed from an inorganic granular lightweight filler having a grain diameter of up to 5 mm and a bulk density of at most 1 × 100 kg / m ³ , in combination with an inorganic filler. see binders. The binder consists mainly of Ca (OH) ₂ and CaCO ₃ , wherein the content of CaCO ₃ in the final product, ie after virtually complete carbonation of Ca (OH) ₂ about 15 to 80 wt .-% is.

The coating composition according to the invention comprises a solid part and a liquid phase, which are mixed together shortly before processing and can be processed by hand or by machine. However, it is also possible to prepare a ready-to-use finished mixture of all components or to produce finished sound-absorbing bodies from the coating composition.

The solid part is from the bulky, homogeneous lightweight filler such. Perlite, foam glass granules or foamed sand-lime granules with a diameter of up to 5 mm, which can be conveyed on demand and can not be seen during storage or transport.

In the BigBag and in the silo, the solid part can be fed directly from the production plant to the construction site, thus saving energy, environment and costs. The liquid phase contains water, calcium hydroxide, calcium carbonate and the usual additives such as thickener, wetting agent and pigment distributor and has a shelf life of at least 3 months and is frost-resistant. The liquid phase is prepared as follows. The water is presented. With vigorous stirring, the additives are introduced and stirred until a stable mousse is obtained. Thereafter, the binders are added. Obtained is a stable highly viscous mixture, which is characterized by a specific density of less than 1 .2 g / cm ³ .

The liquid phase is now mixed with the light filler e.g. mixed with the expanded glass granules in commercial mixers in the ratio listed below and applied by hand and / or by machine to the surfaces to be coated and smoothed if desired, allowed to dry and, if desired, ground and / or coated with paint and / or with a microporous plaster. So that the blanket can be smoothed, the compressive strength and / or sandability of the solid part must not be greater than the compressive strength and / or sandability of the cured binders. Thus, during grinding, the surface color due to e.g. Whole grain fraction does not change, the white filler used must be homogeneous and can e.g. not merely coated with a bright product, which is removed during grinding and thereby releases a darker surface. Advantages:

The formulation with two components, namely a homogeneous light filler (powdery and giant-shaped) and an aqueous phase of the binder with the additives allows the rational machine processing with silo and commercially available plastering machines. The open porosity of the coating composition is achieved by evaporation of the water used in the formulation. Surfactants and / or a combination of highly swollen additives in the aqueous phase, such as acrylic-based superabsorbents, natural and chemically modified cellulose, starch, and sugar derivatives, can be used to control air entrainment.

After drying the coating composition, the surface can be sanded smoothly with standard grinders to the Streiflichttauglichkeit.

In case of damage to the ceiling / walls, these can be partially repaired due to the selected materialization of the task, without having to coat the entire ceiling again. The addition of organosilicon compounds, photocatalytically active substances and halogenated compounds improves the soiling behavior in particular.

If heavily soiled, the surface can be sanded with little effort and is white again.

Furthermore, the ecological, health claim of the coating composition is characterized by the absence of preservatives and / or volatile organic substances normally required in aqueous systems, such as solvents, plasticizers, etc., and the absence of organic binders and inorganic fibers.

With organic natural additives based on natural or chemically modified natural products (starch derivatives, in particular corn and rice starch), the elongation at break and the crack formation of the system were improved. With this coating mass produced sound absorbing ceilings and or walls must not previously be primed to achieve the tolerances, which in turn results in costs and a time savings in construction. Residues from demolition or opened containers can be recycled to 100%.

Residues from dismantling or opened containers can be disposed of in the same way as concrete or do not need to be incinerated.

Preferred embodiments of the invention are defined in the dependent claims.

Advantageously, the light filler essentially consists of multicellular glass hollow spheres or of a expanded glass granulate. Corresponding products are commercially available, for example, under the name "Omega Bubbles" or "Poraver".

The grain curve of the granular lightweight filler is selected according to the application range (e.g., acoustic properties) in a range of up to 5 mm.

Preferably, the granular lightweight filler has a particle diameter of 0.1 to 1 .0 mm, in particular from 0.5 to 1 .0 mm for comparatively thick Be layers, while with a fine-grained light filler and very thin, only about 1 - 7 mm thick coatings let produce. As a result, it is not only possible to save material for certain applications, but also to realize a particularly compact arrangement. According to a particularly preferred embodiment of the coating composition, it has an open-pore air volume of more in the cured state as 40 vol .-%, a water absorption capacity of more than 1 15 wt .-% and a density of less than 0.4 g / cm ³ on.

The lightweight fillers used offer the possibility of applying thick layers. However, their thermal insulation properties are disadvantageous for the intended application. To provide the required heat conduction, the seamless coating is equipped in an advantageous embodiment with a plurality of mutually spaced-apart heat-conducting elements which extend from the wall or ceiling surface to approximately the side facing away from the coating.

In particular, each thermally conductive element may have a sheet metal strip or an elongate profile filled with a latent heat accumulator, which is aligned substantially perpendicular to the wall or ceiling surface.

In an advantageous embodiment of the jointless coating, each thermally conductive element has at least one fixing element equipped with adjusting means in order to adjust the position of the sheet metal strip relative to the wall or ceiling surface or the side of the coating facing away therefrom. It is particularly preferred if the coating has an open-pore air volume of more than 40% by volume in the region between the individual heat-conducting elements. Without wishing to be bound by any particular theoretical explanation, the combination of the selected binder with the thickener system appears to cause the following: the spherical fillers combine with the calcite crystals to form a rugged, high surface area network. The selected surface structure allows sound waves to be superimposed upon the impact of sound waves and reflection of sound, thereby improving the sound absorption of the surfaces created with the coating composition. This property, which is necessary for the invention, is not achieved with formulations according to EP 0 652 187. Furthermore, the hydraulic binders absorb the water necessary for pore formation, which is no longer available for pore formation and makes the necessary pore volume of greater than 40% impossible.

A pore volume of this order of magnitude is possible with hydraulic binders only in combination with organic binders. However, these are again flammable and do not meet the envisaged goal of incombustibility.

Brief description of the drawings

Exemplary embodiments of the invention are described in greater detail below with reference to the drawings, in which: FIG. 1 shows a first embodiment of a coating applied to a ceiling surface, in a first vertical sectional view;

Fig. 2 shows the coating of Figure 1, in a second vertical sectional view corresponding to the section II-II of Fig. 1.

3 shows a second embodiment of a coating applied to a ceiling surface, in a first vertical sectional view; and

FIG. 4 shows the coating of FIG. 3, in a second vertical sectional view corresponding to the section IV-IV of FIG. 3.

Ways to carry out the invention

In the first exemplary embodiment of a ceiling coating shown in FIGS. 1 and 2, a fixing element 4 is provided on the underside 2 of a raw ceiling attached to an L-shaped profile by means of screws 6. The fixing element 4 is provided with vertically extending oval-hole slots 8, which serve to adjust the height of a by means of screws 10 or alternatively by means of rivets mounted thereon thermally conductive element 12. In the example shown, the heat-conducting element 12 is formed by a sheet metal strip which has a bevelled edge 14 on its underside. In the figures, the already applied coating mass 16 is also shown, which just barely covers the edge 14 of each heat-conducting element 12 and thereby forms the finished ceiling underside 18. The fixing element 4 and the heat-conducting element 12 are formed from a good heat-conducting material, for example made of aluminum sheet. Due to the surface contact between the fixing element 4 and the heat-conducting element 12 screwed thereto, a good heat transfer is ensured. On the existing ceiling soffit the Fixierlelemente 4 are fixed in a specified by the planning distance / grid by means of the mechanical attachment shown above or by gluing. The heat-conducting elements 12 are then attached to the fixing elements 4. The possibility of compensating for tolerances in the construction is achieved by a height adjustability of the fixing elements and / or the heat-conducting elements. In the example shown, the height adjustment is facilitated by the beveled edge 14.

In principle, the heat-conducting elements in the horizontal plane can be connected to one another in both directions.

Finally, the interspaces are filled with the coating material. With a guided example on the heat-conducting elements leveling the excess coating material is removed, the ceiling smoothed and the surface further processed as desired. In the second embodiment shown in Figs. 3 and 4, the ceiling coating is constructed analogous to that of Figs. 1 and 2, and accordingly, the matching components are provided with the same reference numerals as in Figs. 1 and 2. Significant difference from the first embodiment is in the second embodiment, that the fixing element 4a has a wider vertical web, which accommodates a clamping device 20 for fixing a heat-conducting member 12a. The latter is designed as a closed hollow longitudinal profile with an interior, which is filled with a latent heat storage 22, for example, a commercial paraffin wax or a salt hydrate. A rounded longitudinal edge 24 allows the heat-conducting element 12a to be inserted well into the clamping device 20.

In general, working mixtures can be formulated in the range given below.

Decisive for the product properties is always the composition by volume based on the inorganic light filler. Any information in percent by weight refers to a grain density of the light filler from 0.48 to 0.58 g / cm ³ and a bulk density of 260 to 330 g / l. In the case of deviations in the grain density of this value, the composition also shifts in percent by weight.

Inorganic light filler: 20 to 80% by volume, e.g. Glass bubbles, Omega Bubbles 0.5 to 1 .0 mm,

or expanded glass granules, Poraver 0.5 to 1 .0 mm

Aqueous phase: rest

Ca (OH) ₂ 2 - 40% by weight

- CaCO ₃ finely divided max. 100 pm 0-40% by weight

Dispersing agent, 0 - 2.0% by weight Thickener, eg hydroxyethylcellulose (HEC)

Xanthan, methylcellulose 0.1 - 5.0% by weight

Residual water 20 - 50 wt.% As the water does not react chemically with the other constituents, it serves as a means of transport and for air entrainment. Thus, the air content and thus the sound absorption of the different frequencies can be controlled directly with the water content and a suitable surface-active substance such as dispersing aids and / or surfactants and adapted to the different acoustic requirements.

It can be assumed that the comparatively high pH of approx. 12.5 caused by Ca (OH) ₂ promotes the surface activity of the thickener and thereby enables optimum foaming with simultaneous thickening of the aqueous system.

In order to achieve optimum processing properties, it is also possible to use combinations of various commercial organic and inorganic thickeners, for example. Bentonite or silica are used.

The ratio Ca (OH) ₂ to CaCO3 is variable. After carbonation of Ca (OH) ₂ , the CaCO3 content is between 15 and 80% of the dried formulation. Due to the different particle size of the CaCO3 used and the Ca (OH) ₂ , the pore sizes can be influenced and their acoustic effect can be controlled.

Substances which are known from the prior art and can be added thereto, but are not absolutely necessary for the invention, but can in part improve the product properties: Inorganic thickeners, for example bentonite (0.1-2%), can be used in some cases instead of the organic and thus combustible thickeners.

Na salt of a polyacrylic acid (0.1-2%) for the supportive formation of the air pores, which is mainly provided by the aqueous mousse of methylcellulose and the dispersing aid.

Polysilanes - Siloxanes (0.1 - 2%) improve the soiling behavior, and allow the surface to be cleaned with water extraction. - fibers e.g. Cellulose fiber (0.1 - 2%) improves the homogeneous drying, results in a faster carbonation, can contribute to pore formation and reduce cracking.

Substances such as soda, CaC, cationic silicon surfactants, ΤΊΟ2 _, soda (0.1 - 2%), promote the carbonation of the coating and or absorb some bad odors in the room.

Examples of formulations

The data refer to the formulation as applied to the building and are given as weight percentages:

Formulation A

Glass bubbles, Omega Bubbles 0.5 - 1 .0 mm 37%

Aqueous phase, formed from:

- Ca (OH) ₂ 7%

- CaCO ₃ finely divided max. 100 by 14%

Pigment distributor 0.2%

Methylcellulose 1%

- Water 40.8% Formulation B

Glass Bubbles, Omega Bubbles 0.0 - 0.5 mm 38%

Water phase, formed by:

- Ca (OH) ₂ 10%

- CaCO ₃ finely divided max. 100 by 15%

Pigment distributor 0.2%

Methylcellulose 1%

- Water 35.8% characterization of the cured coating composition

Test specimens were prepared from the coating composition according to the above formulations. The cured specimens were weighed in the dry state, then immersed for 12 hours in water at room temperature and then weighed again after draining the water. From this it is possible to determine the water absorption and, via the known or measurable density of the test specimen and the known density of water, also the volume of water absorbed or the filled pore volume. Example of test specimen according to formulation A

- Weight of the test piece in the dry state: 61 g

- Volume of the specimen in the dry state: 184 cm ³

Density of the test piece in the dry state = 61 g / 184 cm ³ 0.331 g / cm ³

- Weight of specimen after water absorption: 159 g - Weight of absorbed water: 98 g

Water absorption = 98 g / 61 g: 160% by weight

- open-pore air volume = 98 ^cm3 / 184 cm ^3: 53 vol .-%

Claims

Open-pore curing, non-combustible coating composition, especially for ceilings and/or walls, which is essentially free of hydraulic binders and is characterized by the following composition:

20 to 80 parts by volume of an inorganic, granular lightweight filler with a grain diameter of up to 5 mm and a bulk density of a maximum of 1 Ό00 kg/m ³ ,

80 to 20 parts by volume of an aqueous phase, comprising:

- 2 to 40% by weight Ca(OH) ₂

- 0 to 40% by weight of CaCO ₃ finely divided,

0 to 2% by weight of dispersing aid,

0.1 to 5.0% by weight of thickener, and

the rest water,

with the proviso that the weight proportion of Ca(OH) ₂ + CaCO3 is at least 6% by weight.

Coating composition according to claim 1, wherein the lightweight filler consists essentially of multicellular hollow glass spheres or expanded glass granules.

Coating composition according to claim 1 or 2, wherein the lightweight filler has a grain diameter of 0.1 to 1.0 mm, in particular 0.5 to 1.0 mm.

Coating composition according to one of claims 1 to 3, characterized in that in the cured state it has an open-pore air volume of more than 40% by volume, a water absorption capacity of more than 1-15% by weight and a density of less than 0.4 g / cm ³ has.

Use of the coating composition according to one of claims 1 to 4 for applying a sound-absorbing and/or moisture-regulating coating to a wall or ceiling surface or to a building, in particular a panel, or for producing a panel.

Seamless coating (16) applied to a wall or ceiling surface, formed from an inorganic, granular lightweight filler with a grain diameter of up to 5 mm and a bulk density of at most 1 Ό00 kg/m ³ , in combination with an inorganic binder, the binder consists mainly of Ca(OH) ₂ and CaCO3 and the CaCO3 content of the end product is approximately 15 to 80% by weight.

Seamless coating according to claim 6, wherein the lightweight filler essentially consists of multicellular hollow glass spheres or expanded glass granules with a grain diameter of preferably 0.1 to 1.0 mm, in particular 0.5 to 1.0 mm.

Seamless coating according to claim 6 or 7, comprising a plurality of spaced-apart heat-conducting elements (12; 12a), which extend from the wall or ceiling surface (2) to approximately the side (18) of the coating (16) facing away from it. extend.

Seamless coating according to claim 8, wherein each heat-conducting element (12) comprises a metal sheet strip which is oriented substantially perpendicular to the wall or ceiling surface.

Seamless coating according to claim 8, wherein each heat-conducting element (12a) has an elongated profile filled with a latent heat storage (22) which is oriented substantially perpendicular to the wall or ceiling surface.

Seamless coating according to claim 7 or 8, wherein each heat-conducting element (12; 12a) has at least one fixing element (4; 4a) equipped with adjustment means (8, 10; 20) in order to adjust the position of the metal sheet strip (12) or the elongated profile (12a) relative to the wall or ceiling surface (2) or the side (18) of the coating (16) facing away from it.

12. Seamless coating according to one of claims 7 to 1 1, with an open-pore air volume of more than 40% by volume.