WO2005066428A1

WO2005066428A1 - Sandwich element for sound and heat insulation

Info

Publication number: WO2005066428A1
Application number: PCT/EP2005/000207
Authority: WO
Inventors: Peter Randel; Manfred Rupprecht; Heinz-Werner Borger; Christoph Adelmann; Norbert Schneider
Original assignee: Porextherm Dämmstoffe GmbH
Priority date: 2004-01-12
Filing date: 2005-01-12
Publication date: 2005-07-21
Also published as: DE102004001673A1

Abstract

The invention relates to a sandwich element for sound and heat insulation, said element being made of a composite of two plates comprising a laminated material, roller material, foamed material, reactive material, and fibrous material, and a vacuum insulation panel which is embedded in a non-positive fit between the plates.

Description

Sandwich element for sound and heat insulation

The invention relates to a sandwich element for sound and heat insulation of floor, wall and roof surfaces and for absorbing traffic loads in direct connection with top coverings.

Known insulation materials only have inadequate compressive and flexural strength, which is why a rigid, load-bearing load distribution layer, usually a mineral screed according to DIN 18560, must be installed above them to distribute the traffic load arising from the use of the rooms.

According to this standard, the soft and therefore easily deformable insulation under the load distribution layer becomes an unavoidable compressibility of ax. 4 mm allowed. This leads to the rigid load distribution layer dropping accordingly. As a result, the floor and tile-laying craft is prevented from completing the connection between the base and the floor, as the sinking of the load distribution layer can take several years. A deficiency status arises for the executing craftsman, which is due to the inadequacy of the recognized rules of technology described here.

In addition, mineral load distribution layers are considerably deformed in the first 4 weeks due to drying out. The resilient insulating materials underneath cannot prevent these changes in shape. -The drying of the mineral load distribution layer takes at least 4 weeks, but if the air humidity is high, it can take months before covering with top coverings. This represents considerable uncertainty for planning the construction time. The thermal conductivity of insulation layers can be significantly reduced if there is a vacuum in the system (for example US 5,950,450 DE 4339435). Inexpensive solutions include microporous thermal insulation layers that are gas-tightly sealed in composite films. be welded. These are used as insulation for cooling devices, buildings or transport containers.

In order to protect such vacuum insulation panels from injuries, it is known to incorporate them into other systems. Products and processes are described in DE 101 34 322 AI and WO 01/66864 AI, in which vacuum insulation panels e.g. are foamed in polystyrene. Likewise, in an application WO 97/12100, modular structures with a vacuum insulation panel have already been described. EP 1 291 300 A2 describes a multi-layer structure with a vacuum insulation panel between temperature-resistant outer layers.

From DE 19950058 it is known to produce fiber insulation layers from PET recycling material and to use them for sound and heat insulation on buildings. PET layers in thicknesses between 1 and 20 mm are mainly used in the floor area. Due to the flat and adhesion-friendly surface, they allow direct covering with top documents such as with tiles, natural stone, carpet and other soft coverings or parquet and other hard coverings. Furthermore, these load-distributing layers have very good impact sound insulation properties.

The present invention relates to a sandwich element for sound and heat insulation consisting of a composite of two plates made of a pressed, rolled, foam, reactive or fiber material with a non-positively embedded vacuum insulation panel between the plates. The pressed, rolled, foam, reactive and fiber materials are, for example, a ze- or calcium sulfate-bound material, metal, wood, wood fiber, wood granulate, wood chips, polyethylene, polypropylene, polystyrene, polyurethane, polyethylene terephthalate (PET), cotton and their blends. The two plates can be the same or different. It is preferably PET sheets, preferably sheets made of PET fibers. For their production, production residues can preferably be prepared from PET nonwovens and preferably mixed with a low-melting binder (see DE 19950058). The mixture is pressed into plates under pressure and temperature. The PET plate preferably has a density of approximately 100-1000 kg / m ³ , a maximum application temperature of 100 ° C. and a mechanical load capacity of 5 kN / m ² (DIN 1055).

The vacuum insulation panel preferably consists of an open-pore organic or inorganic foam or a fiber material or of mixtures as described in DE-A-4432896, DE-A-19618968, US-A-6589488, or in DE-A-10151479 (hereby incorpo rated) by reference) are disclosed. Mixtures with pyrogenic silica are preferred, particularly preferably pyrogenic silica with a BET> 150 m ² / g. The layer density is preferably> 100 kg / m ³ . The materials mentioned are preferably covered by a film which is gas-tight and suitable for vacuum. The film can also be a composite film with an incorporated metal layer (eg aluminum) or several metallised layers, as is known, for example, from DE-A-10320630 or DE-A-10325607.

The vacuum insulation panel is preferably a microporous vacuum insulation panel, as is known from DE-A-10320630 or DE-A-10325607.

The sandwich element is preferably in the form of a three-layer plate.

To produce a sandwich element according to the invention, the three layers are non-positively connected to one another. The non-positive connection is preferably made using an adhesive. The adhesive is preferably selected from reactive resin, plastic dispersion or a thermoplastic. For example, two sheets of pressed, rolled, foam, reactive, and fiber materials are bonded on one side with an adhesive fabric applied. The vacuum insulation panel is positioned in the center of the adhesive bed of one plate and the second plate with the side to which the adhesive is applied is centered or offset by 5 to 20 mm, preferably by 5 to 15 mm, particularly preferably by 5 to 10 mm, to the first plate for training a circumferential rabbet positioned on the vacuum insulation panel.

The production is preferably carried out in such a way that the vacuum insulation panel is undersized all the way around the pressed, rolled, foam, reactive and fiber materials. The undersize is preferably 2 to 15 mm on all sides. This protects the vacuum insulation panel in the sandwich element from all sides.

The sandwich element according to the invention preferably consists of a microporous vacuum insulation panel, which is embedded between two polyethylene terephthalate fiber plates in a force-locking manner.

In a preferred embodiment, the sandwich element consists of two 4 to 20 mm, preferably 4 to 10 mm, particularly preferably 4 to 5 mm thick PET sheets which are non-positively connected to a vacuum insulation panel with a thickness of 10 to 25 mm, preferably 12 to 20 mm, particularly preferably 13 to 15 mm.

The sandwich element according to the invention has excellent thermal and impact sound insulation properties. In the particularly preferred embodiment, an overall thickness of <25 mm is also achieved, which is particularly attractive for the use of the sandwich element in the renovation of old buildings. Such a sandwich element combines excellent thermal and impact sound insulation with a low layer thickness (less than 25mm) and high load transfer of up to 5kN / m ² . In this embodiment, the impact sound improvement with tiles is: ΔL _W = 18 dB. Vacuum insulation panels are often very susceptible to mechanical injuries due to their enveloping composite films, which leads to many failures due to air pulls, especially when used on construction sites. In the sandwich element according to the invention, the vacuum insulation panel of the PET layers is protected by the hard, preferably slightly protruding PET layers on all sides (approx. 2 to 15 mm). The transport and processing properties as well as the mechanical resilience (e.g. through use). and the lifespan of the sandwich elements is improved compared to conventional vacuum insulation panels. The sandwich element according to the invention exceeds the thermal insulation properties of PET layers by a factor of 16 and also the thermal conductivity of λ = 0.03 W / (mK) which is customary in the prior art for thermal insulation materials is far exceeded by the sandwich element, since this has a λ = 0.005

W / (m * K) has reduced thermal conductivity. Compared to polystyrene, which is used very often in this area of application, this thermal insulation is better by a factor of 6. This means that the sandwich element can reduce the height required for thermal insulation above a load-bearing ceiling by 80%.

Due to the density fluctuations of the core insulation material in the vacuum insulation panel, the evacuation leads to dimensional tolerances that can reach up to one percent. These tolerances, which fluctuate from plate to plate, can lead to problems when laying vacuum insulation panels flat, for example on floors. The different sizes lead to gaps that have to be filled in with other less good insulation materials. Microporous vacuum insulation panels are non-positively embedded between two PET layers, which have very tight dimensional tolerances, allowing the sandwich elements to be laid flat without gaps. Dimensional inaccuracies are preferably filled within the sandwich element by means of compression bands.

In a particularly preferred embodiment, the sandwich element according to the invention has a pressure and bending activity that makes it possible to load it with a traffic load of up to 5 kN / m ² (DIN 1055).

This sandwich element represents sound and heat insulation, which, in contrast to all known insulation materials, can be provided directly with top coverings and can be subjected to the traffic load mentioned. In contrast to all known insulation materials, no additional load distribution layer is required for your use.

If the sandwich element is to be laid, as is customary in construction, on pipes and empty pipes fixed on a raw concrete ceiling, the following procedure is preferred: The raw concrete ceiling is made with a bound bed, e.g. made of expanded glass and quick cement, with a uniform thickness, which is based on the thickest pipe , overdrawn. These bound fillings have the advantage that there is no deformation due to drying. After 24 hours, with a compressive strength of the bound bed of> 1.5 N / mm ^2, the sandwich panels on which the invention is based are laid in a half bond. Due to the high inherent stability of the sandwich panel, the change between fill and lines in the ground has no influence on the continuous load distribution.

In addition, the sandwich element with a thickness of <25 mm, in contrast to the construction procedure described above, offers the advantage of an undisturbed and untrimmed uniformly thick layer of insulation with a clearly defined and unrestricted insulation effect. With a thickness of the sandwich panel of 25 mm, a value for U = 0.26 W / (m ² .K) is achieved. This value is 15% better than the value of U> 0.35 W / (m ² .K) required in this situation according to DIN 4108, for which a conventional floor structure of> 100 mm would be required.

If the sandwich element is constructed in such a way that the vacuum insulation panel (3) has an undersize compared to the pressed, rolled, foam, reactive and fiber materials (1), so a compensation tape (2) is preferably placed in the circumferential gap between the pressed, rolled, foam, reactive, and fiber materials in order to minimize thermal bridges where there is no vacuum insulation panel. The flaps of the film of the vacuum insulation panel (4) are preferably folded over on one side (FIG. 4).

After laying, the sandwich element can be directly covered with ceramic and natural stone using the thin bed method according to DIN 18157. Before covering with soft coverings such as Carpet or linoleum according to DIN 18365, it is preferred to first apply a leveling compound. This also applies before laying with solid parquet, prefabricated parquet of any kind and laminate.

The sandwich elements are preferably used wherever dimensional stability and robustness are required with high insulation performance. They are primarily suitable for sound and heat insulation and for simultaneously diverting traffic loads from the top surface to the structure in the floor area. However, it is also possible to use other areas such as e.g. of walls, ceilings or roofs. The invention thus also relates to insulation produced using a sandwich element according to the invention.

1 shows the structure of a sandwich element consisting of a microporous vacuum insulation panel (vacuum insulation panel) between two polyethylene terephthalate fiber layers (PFS).

Fig. 2 shows a wall structure with a sandwich element on an outer wall with a heat transfer coefficient U == 0.26 W / m ² K. The sandwich element for heat and sound insulation has a thermal conductivity λ = 0.005 W / m * K) and a thickness of 21 mm. Fig. 3 shows a floor structure with a sandwich element over a floor ceiling with a heat transfer coefficient U = 0.26 W / m ² K.

1: Bound compensation bed (λ = 0.07 W / m ² K) over bare ceiling and pipes. Thickness eg 50 mm.

2: sandwich element (λ = 0.005 W / m ² K). Thickness 21 mm. 3: piping

Fig. 4: shows the section on a sandwich element: 1: PET layer

2: Compensation band

3: Vacuum insulation panel

4: folded flap of the vacuum insulation panel foil

5: glue

The following examples serve to further explain the invention.

Example 1: Production of a sandwich element

The cut microporous core material is inserted into a three-layer welded multi-layer film bag and sealed under vacuum. The finished size of the vacuum insulation panel is 990mm * 590mm * 15mm. The outer circumferential flap is folded over on one side and fixed with adhesive tape.

Two sheets of PET fibers, size 1000 mm x 60 mm x 4 mm, are applied to one side with an adhesive. The vacuum insulation panel is positioned in the center of the adhesive bed of one plate and the second plate with the adhesive-coated side is offset by 5 to 10 mm to the lower layer to form a circumferential fold on the vacuum insulation panel. The sandwich element is stored temporarily until the adhesive has hardened. The circumferential gap is filled with a compensation tape with a cross section of 10mm * 10mm. Example 2 Processing of the panels from example 1

The sandwich element can either be glued to the substrate or laid floating. Individual elements are to be arranged in a semi-union. When laying on the floor, an edge distance of> 5 mm must be maintained from all rising components such as columns and walls. It is advisable to place an edge insulation strip. The subfloor must be stable (payload> 0.5 kN / m ² ) and even in accordance with DIN 18202. Height compensation on storey ceilings above pipes is preferably made with a lightweight, bound bed. The sandwich element can be laid on top when the bed has reached a compressive strength of at least 1.5 N / mm ² .

Gluing: On the liability-friendly surface, e.g. a plastic-coated thin-bed mortar with a 6 mm notched trowel, in which the sandwich element is immediately inserted. After the laying mortar has hardened, the top covering can be applied in a conventional manner.

Floating installation: The sandwich elements are butted against each other. The butt joints are taped over in the middle with a crepe tape with a minimum width of 50 mm. The top covering can then be applied in a conventional manner.

Example 3: Conventional construction of an insulation and comparison of the properties of the conventional construction with the construction from Example 2 According to the recognized rules of technology for creating floors on load-bearing floor slabs and floors, the required sound and heat insulation is achieved Compared to the outside area or a foreign apartment, the following conventional structure is created:

On a load-bearing component such as a reinforced concrete ceiling (approx. 180mm) was applied as rock wool sound insulation in a thickness of approx. 30mm. It was applied as polystyrene in a thickness of approx. 60mm. Finally, a screed was applied at a height of approx. 45mm as a load distribution layer. This structure, like the structure from example 2, was provided with a ceramic top covering of a height of approx. 10 mm.

Tab. 1 compares the dimensions and properties of the two floor structures

The insulation using the sandwich element is considerably thinner and still has better (thermal insulation, resilience) or equally good (impact sound insulation) properties as conventional insulation.

Claims

claims

1. Sandwich element for sound and heat insulation consisting of a composite of two plates made of a pressed, rolled, foam, reactive or fiber material with a non-positively embedded vacuum insulation panel between the plates.

2. Sandwich element according to claim 1, characterized in that it is in the pressed, rolled, foam, reactive, or fiber material is a cement or calcium sulfate-bound material, metal, wood, wood fiber, wood granules, wood chips, polyethylene, polypropylene , Polystyrene, polyurethane, polyethylene terephthalate (PET), cotton and their blends.

3. Sandwich element according to claim 2, characterized in that it is PET in the pressed, rolled, foam, reactive, or fiber material.

4. Sandwich element according to one of claims 1 to 3, characterized in that the vacuum insulation panel consists of an open-pore organic or inorganic sheeting or a fiber material or of mixtures with pyrogenic silica.

5. Sandwich element according to claim 4, characterized in that the vacuum insulation panel is a microporous vacuum insulation panel.

6. Sandwich element according to one of claims 1 to 5, characterized in that it consists of a microporous vacuum insulation panel which is non-positively embedded between two polyethylene terephthalate fiberboard.

7. Sandwich element according to one of claims 1 to 6, characterized in that it has the shape of a three-layer plate.

8. Sandwich element according to one of claims 1 to 7, characterized in that it has a compressive and flexural strength which makes it possible to load it with a traffic load of up to 5 kN / m ² .

9. Use of a sandwich element according to one of claims 1 to 8 for sound and heat insulation of floor, wall and roof surfaces and for absorbing the traffic loads in direct connection with a top covering.

10. Insulation produced using a sandwich element according to one of claims 1 to 8.