Insulation Material and a Method for its Production

Abstract

An insulating material, in particular a permeable fire-proof sound insulating material comprising water glass and rubber, in particular recycled rubber, consisting of a harden-able mixture which contains 47 to 61 wt % of rubber granulate, 30 to 50 wt % of aqueous sodium silicate, 0.1 to 0.5 wt % water glass stabiliser, 0.4 to 1.5 wt % water glass hardener, and 2 to 6 wt % of aluminium hydroxide, the surface of the rubber granulate being provided with carbon black, the carbon black constituting 0.1 to 1 wt % of total weight. A method for the production of insulating material, according to which firstly the rubber granules are mixed with an aqueous solution of carbon black so as to coat their entire surface, then is added to the aqueous sodium silicate solution aluminium hydroxide and the whole is mixed so as to form an insulating mixture, and then a water glass stabiliser is added to the aqueous sodium silicate solution, and then to this solution is mixed water glass hardener, with this solution being further stirred for 1 to 10 minutes to form a binder solution, and the insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is then poured into the application site.

Claims

1. A permeable fire-proof sound-insulating material comprising water glass and rubber, comprising a harden-able mixture comprising 47 to 61 wt % of rubber granulate, 30 to 50 wt % of aqueous sodium silicate, 0.1 to 0.5 wt % water glass stabilizer, 0.4 to 1.5 wt % water glass hardener, and 2 to 6 wt % of aluminum hydroxide, the surface of the rubber granulate being provided with carbon black, the carbon black constituting 0.1 to 1 wt % of the total weight.

2. The insulating material according to claim 1, wherein the rubber granulate is recycled.

3. The insulating material according to claim 1, wherein the water glass stabilizers are hydrophilic alkoxy alkyl-ammonium salts.

4. The insulating material according to claim 1, wherein the aqueous sodium silicate solution has a density in the range from 1370 to 1400 kg/m.sup.3.

5. The insulating material according to claim 1, wherein the aqueous sodium silicate solution has a molar ratio of Si0.sub.2 to Na.sub.20 in the range from 3.2 to 3.4.

6. A method for the production of the permeable tire-proof sound-insulating material of claim 1, wherein in a first step the rubber granules are mixed with an aqueous solution of carbon black so as to coat their entire surface, then is added to the aqueous sodium silicate solution aluminum hydroxide and the whole is mixed so as to form an insulating mixture, and then in a second step, a water glass stabilizer is added to the aqueous sodium silicate solution, and then to this solution is mixed water glass hardener, with this solution being further stirred for 1 to 10 minutes to form a binder solution, and the insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is then poured into the application site.

7. The method for producing insulating material according to claim 6, wherein before the insulation mixture is added, the binder solution is preheated to a temperature of 65° C.

8. The method for producing insulating material according to claim 7, wherein the resulting mixture is poured into the application site, which is a mould, and further, from the resulting mixture such an amount of binder solution is extruded by means of a press so that the desired ratio of insulating mixture and binder solution is obtained.

9. The method for producing insulating material, according to any one of claims 6 and 7, wherein the resulting mixture is left undisturbed until hardened.

Description

EXAMPLES OF THE PERFORMANCE OF THE INVENTION

Example 1

[0021] The permeable fire-proof sound-insulating material is composed of a harden-able mixture which contains 54 wt % of recycled rubber granulate, 40 wt % of aqueous sodium silicate, 0.3 wt % water glass stabiliser, 4 wt % of aluminium hydroxide, and 1.2 wt % water glass hardener.

[0022] The surface of the rubber granulate is provided with carbon black, the carbon black making up 0.5 wt % of total weight.

[0023] The water glass stabilisers are hydrophilic alkoxy alkyl-ammonium salts, in the form of a 98% aqueous solution of N,N,N′,N′-Tetrakis (2-hydroxypropyl) ethylenediamine.

[0024] The aqueous sodium silicate solution has a density in the range of 1380 kg/m.sup.3 and a molar ratio of SiO.sub.2 to Na.sub.2O in the range of 3.3.

[0025] The water glass hardener is a mixture of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume parts, with a concentration of 3 wt % to pure water glass.

[0026] According to the method of manufacturing a breathable fire-retardant sound-insulating material, the rubber granules are first mixed with an aqueous solution with a concentration of 25 wt % carbon black so that their entire surface is coated with carbon black, aluminium hydroxide is added and the whole is mixed to form an insulating mixture, and a water glass stabiliser is added to the sodium silicate solution, and then a water glass hardener is mixed into the solution, this solution is then stirred for 3 minutes to form a binder solution, which is preheated to 65° C., and the insulating mixture is further mixed into the binder solution, and the resulting mixture is further poured into a silicone mould, and the resulting mixture is further pressed from a press extrudes such an amount of binder solution to produce the desired ratio of insulating mixture to binder solution.

[0027] The resulting product is an insulation board or insulation fitting.

Example 2

[0028] The permeable fire-proof sound-insulating material is composed of a harden-able mixture which contains 61 wt % of recycled rubber granulate, 30 wt % of aqueous sodium silicate, 0.1 wt % water glass stabiliser, 6 wt % of aluminium hydroxide, and 1.5 wt % water glass hardener.

[0029] The surface of the rubber granulate is provided with carbon black, the carbon black making up 1 wt % of total weight.

[0030] The water glass stabilisers are hydrophilic alkoxy alkyl-ammonium salts, in the form of a 98% aqueous solution of N,N,N′,N′-Tetrakis (2-hydroxypropyl) ethylenediamine.

[0031] The aqueous sodium silicate solution has a density in the range of 1400 kg/m.sup.3 and a molar ratio of SiO.sub.2 to Na.sub.2O in the range of 3.4.

[0032] The water glass hardener is a mixture of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume parts, with a concentration of 5 wt % to pure water glass.

[0033] According to the method of manufacturing a breathable fire-retardant sound-insulating material, the rubber granules are first mixed with an aqueous solution with a concentration of 25 wt % carbon black so that their entire surface is coated with carbon black, aluminium hydroxide is added and the whole is mixed to form an insulating mixture, and a water glass stabiliser is added to the sodium silicate solution, and then a water glass hardener is mixed into the solution, this solution is then stirred for 10 minutes to form a binder solution, which is preheated to 65° C., and the insulating mixture is further mixed into the binder solution, and the resulting mixture is further poured into a silicone mould, and the resulting mixture is further pressed from a press extrudes such an amount of binder solution to produce the desired ratio of insulating mixture to binder solution.

[0034] Finally, the resulting mixture is left undisturbed until hardened.

[0035] The resulting product is an insulating fitting.

Example 3

[0036] The permeable fire-proof sound-insulating material is composed of a harden-able mixture which contains 47 wt % of recycled rubber granulate, 50 wt % of aqueous sodium silicate, 0.5 wt % water glass stabiliser, 2 wt % of aluminium hydroxide, and 0.4 wt % water glass hardener.

[0037] The surface of the rubber granulate is provided with carbon black, the carbon black constituting 0.1 wt % of total weight.

[0038] The water glass stabilisers are hydrophilic alkoxy alkyl-ammonium salts, in the form of a 98% aqueous solution of N,N,N′,N′-Tetrakis (2-hydroxypropyl) ethylenediamine.

[0039] The aqueous sodium silicate solution has a density in the range of 1370 kg/m.sup.3 and a molar ratio of SiO.sub.2 to Na.sub.2O in the range of 3.2.

[0040] The water glass hardener is a mixture of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume, with a concentration of 0.8 wt % to pure water glass.

[0041] According to the method of manufacturing a breathable fire-retardant sound-insulating material, the rubber granules are first mixed with an aqueous solution with a concentration of 25 wt % carbon black so that their entire surface is coated with carbon black, aluminium hydroxide is added and the whole is mixed to form an insulating mixture, and a water glass stabiliser is added to the sodium silicate solution, and then a water glass hardener is mixed into the solution, this solution is then stirred for 1 minute to form a binder solution, which is preheated to 65° C., and the insulating mixture is further mixed into the binder solution, and the resulting mixture is further poured into an application site which is a flat divided attic space, spread, surface-treated and left undisturbed until hardened.

INDUSTRIAL APPLICATION

[0042] The insulating material according to the invention can in particular be used to create a permeable fire-proof sound-insulating system in the building industry.