Insulation Material and a Method for its Production

Abstract

An insulating material, in particular a permeable fire-proof insulating material comprising water glass and which is composed of a air harden-able compound which contains 2 to 40 wt % of plastic balls, 55 to 95.0 wt % of aqueous sodium silicate solution, 2 to 6 wt % of aluminium hydroxide, and 0.1 to 0.5 wt % water glass stabiliser. A method for the production of insulating material, in particular a method for the production of permeable fire-proof insulating material comprising water glass and plastic balls, according to which firstly the plastic balls 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 insulating material, comprising water glass a harden-able compound comprising 2 to 40 wt % of plastic balls, 55 to 95.0 wt % of aqueous sodium silicate solution, 2 to 6 wt % of aluminum hydroxide, and 0.1 to 0.5 wt % water glass stabilizer.

2. The insulating material according to claim 1, wherein the plastic balls are hollow plastic balls.

3. The insulating material according to claim 1, wherein the plastic balls have a diameter of 1 to 50 mm.

4. The insulating material according to claim 1, wherein the material of the plastic spheres is polypropylene.

5. The insulating material according to claim 1, wherein the material of the plastic spheres is polyethylene or polyurethane or polymethyl methacrylate or polyamide or polyvinyl chloride or polyester or phenoplast or aminoplast or Teflon.

6. The insulating material according to claim 1, wherein the surface of the plastic balls is provided with carbon black, the carbon black constituting 0.1 to 1 wt % of total weight.

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

8. 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.

9. 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.

10. The insulating material according to claim 1, wherein the insulating material further comprises a water glass hardener.

11. A method for producing a breathable fire insulation material comprising water glass and plastic balls according to claim 1, wherein in a first step the plastic balls are mixed with an aqueous solution of carbon black so as to coat their entire surface, the resulting plastic balls are then 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 a water glass hardener, with this solution being further stirred for 1 to 10 minutes to form a binder solution, after which 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.

12. The method for producing insulating material according to claim 11, 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 a desired ratio of insulating mixture and binder solution is obtained.

13. The method for producing insulating material according to claim 11, after the resulting mixture is poured into the application site, it is left undisturbed to harden.

Description

EXAMPLES OF THE PERFORMANCE OF THE INVENTION

Example 1

[0021] The permeable fire-proof insulating material is composed of an air-hardening compound which contains 12 wt % hollow plastic balls, which are polypropylene balls with a diameter of 5 to 10 mm, 81.0 wt % of aqueous sodium silicate solution, 4 wt % of aluminium hydroxide, 0.3 wt % water glass stabiliser and 2.3 wt % hardeners.

[0022] The surface of the hollow plastic balls is provided with carbon black, the carbon black constituting 0.4 wt % of total weight.

[0023] Alternatively, the material of the hollow plastic beads may be polyethylene or polyurethane or polymethyl methacrylate or polyamide or polyvinyl chloride or polyester or phenoplast or aminoplast or Teflon.

[0024] 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.

[0025] The aqueous sodium silicate solution has a density in the range of 1390 kg/m.sup.3 and a molar ratio of SiO.sub.2 to Na.sub.2O of 3.3.

[0026] The water glass hardener is a compound of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume, with a concentration of 2.8 wt % to clear water glass.

[0027] According to the method of manufacturing the insulating material, the hollow plastic balls 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 compound, then added to an aqueous solution of sodium silicate is a water glass stabiliser, followed by a water glass hardener being added to the solution, this solution being mixed for 5 minutes to form a binder solution, and then the insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is poured into an application site which is a silicone 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.

[0028] Finally, the resulting mixture is left undisturbed until hardened. The resulting product is an insulating board, or an insulating layer arranged on an OSB board, more precisely between two OSB boards.

Example 2

[0029] The permeable fire-proof insulating material is composed of an air-hardening compound which contains 2 wt % of hollow plastic balls, which are polypropylene spheres with a diameter of 1 to 5 mm, 95.0 wt % of aqueous sodium silicate solution, 2 wt % of aluminium hydroxide, 0.1 wt % water glass stabiliser and 0.8 wt % hardeners.

[0030] The surface of the hollow plastic balls is provided with carbon black, the carbon black being 0.1 wt % of total weight.

[0031] Alternatively, the material of the hollow plastic balls may be polyethylene or polyurethane or polymethyl methacrylate or polyamide or polyvinyl chloride or polyester or phenoplast or aminoplast or Teflon.

[0032] 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.

[0033] An aqueous solution of sodium silicate having 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.

[0034] The water glass hardener is a compound of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume, with a concentration of 0.8 wt % to clear water glass.

[0035] According to the method for producing the insulating material, firstly the hollow plastic balls are mixed with an aqueous solution with a concentration of 25 wt % of carbon black so that their entire surface is coated with carbon black, then aluminium hydroxide is added and the whole is mixed to form an insulating mixture, then added to an aqueous solution of sodium silicate is a water glass stabiliser, followed by a water glass hardener being added to the solution, this solution being mixed for 1 minute to form a binder solution, and then the insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is poured into a flat, divided attic space, spread, surface-treated and left undisturbed to harden.

Example 3

[0036] The permeable fire-proof insulating material is composed of an air-hardening compound which contains 39 wt % of hollow plastic balls with a diameter of 10 to 50 mm, 55 wt % of aqueous sodium silicate solution, 2.5 wt % of aluminium hydroxide, 0.5 wt % water glass stabiliser and 2 wt % hardeners.

[0037] The material of the hollow plastic balls is polypropylene.

[0038] Alternatively, the material of the hollow plastic beads may be polyethylene or polyurethane or polymethyl methacrylate or polyamide or polyvinyl chloride or polyester or phenoplast or aminoplast or Teflon.

[0039] The surface of the hollow plastic balls is provided with carbon black, the carbon black constituting 1 wt % of total weight.

[0040] 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.

[0041] An aqueous solution of sodium silicate having 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.

[0042] The water glass hardener is a compound of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume, with a concentration of 4.5 wt % to clear water glass.

[0043] According to the method for producing the insulating material, firstly the hollow plastic balls are mixed with an aqueous solution with a concentration of 25 wt % of carbon black so that their entire surface is coated with carbon black, then aluminium hydroxide is added and the whole is mixed to form an insulating mixture, then added to an aqueous solution of sodium silicate is a water glass stabiliser, followed by a water glass hardener being added to the solution, this solution being mixed for 10 minutes to form a binder solution, and then the insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is then poured onto the outer wall of a building provided with formwork with a silicone surface and finally, the resulting mixture is left undisturbed to harden, after which the formwork is removed.

Example 4

[0044] The permeable fire-proof insulating material is composed of an air-hardening compound which contains 12 wt % of plastic balls, which are polypropylene balls with a diameter of 5 to 10 mm, 81.0 wt % of aqueous sodium silicate solution, 4 wt % of aluminium hydroxide, 0.3 wt % water glass stabiliser and 2.3 wt % hardeners.

[0045] The surface of the plastic balls is provided with carbon black, the carbon black constituting 0.4 wt % of total weight.

[0046] Alternatively, the material of the plastic spheres may be polyethylene or polyurethane or polymethyl methacrylate or polyamide or polyvinyl chloride or polyester or phenoplast or aminoplast or Teflon.

[0047] 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.

[0048] The aqueous sodium silicate solution has a density in the range of 1390 kg/m.sup.3 and a molar ratio of SiO.sub.2 to Na.sub.2O of 3.3.

[0049] The water glass hardener is a compound of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume, with a concentration of 2.8 wt % to clear water glass.

[0050] According to the method for producing the insulating material, firstly the plastic balls are mixed with an aqueous solution with a concentration of 25 wt % of carbon black so that their entire surface is coated with carbon black, then aluminium hydroxide is added and the whole is mixed to form an insulating mixture, then added to an aqueous solution of sodium silicate is a water glass stabiliser, followed by a water glass hardener being added to the solution, this solution being mixed for 5 minutes to form a binder solution, and then 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 an application site which is a silicone 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.

[0051] Finally, the resulting mixture is left undisturbed until hardened. The resulting product is an insulating board, or an insulating layer arranged on an OSB board, more precisely between two OSB boards.

Example 5

[0052] The permeable fire-proof insulating material is composed of an air-hardening compound which contains 2 wt % of plastic balls, which are polypropylene balls with a diameter of 1 to 5 mm, 95.0 wt % of aqueous sodium silicate solution, 2 wt % of aluminium hydroxide, 0.1 wt % water glass stabiliser and 0.8 wt % hardeners.

[0053] The surface of the plastic balls is provided with carbon black, the carbon black constituting 0.1 wt % of total weight.

[0054] Alternatively, the material of the plastic spheres may be polyethylene or polyurethane or polymethyl methacrylate or polyamide or polyvinyl chloride or polyester or phenoplast or aminoplast or Teflon.

[0055] 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.

[0056] An aqueous solution of sodium silicate having 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.

[0057] The water glass hardener is a compound of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume, with a concentration of 0.8 wt % to clear water glass.

[0058] According to the method for producing the insulating material, firstly the plastic balls are mixed with an aqueous solution with a concentration of 25 wt % of carbon black so that their entire surface is coated with carbon black, then aluminium hydroxide is added and the whole is mixed to form an insulating mixture, then added to an aqueous solution of sodium silicate is a water glass stabiliser, followed by a water glass hardener being added to the solution, this solution being mixed for 1 minute to form a binder solution, and then the insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is poured into a flat, divided attic space, spread, surface-treated and left undisturbed to harden.

Example 6

[0059] The permeable fire-proof insulating material is composed of an air-hardening compound which contains 39 wt % of plastic balls with a diameter of 10 to 50 mm, 55 wt % of aqueous sodium silicate solution, 2.5 wt % of aluminium hydroxide, 0.5 wt % water glass stabiliser and 2 wt % hardeners.

[0060] The material of the plastic balls is polypropylene.

[0061] Alternatively, the material of the plastic spheres may be polyethylene or polyurethane or polymethyl methacrylate or polyamide or polyvinyl chloride or polyester or phenoplast or aminoplast or Teflon.

[0062] The surface of the plastic balls is provided with carbon black, the carbon black constituting 1 wt % of total weight.

[0063] 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.

[0064] An aqueous solution of sodium silicate having 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.

[0065] The water glass hardener is a compound of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume, with a concentration of 4.5 wt % to clear water glass.

[0066] According to the method for producing the insulating material, firstly the plastic balls are mixed with an aqueous solution with a concentration of 25 wt % of carbon black so that their entire surface is coated with carbon black, then aluminium hydroxide is added and the whole is mixed to form an insulating mixture, then added to an aqueous solution of sodium silicate is a water glass stabiliser, followed by a water glass hardener being added to the solution, this solution being mixed for 10 minutes to form a binder solution, and then the insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is then poured onto the outer wall of a building provided with formwork with a silicone surface and finally, the resulting mixture is left undisturbed to harden, after which the formwork is removed.

INDUSTRIAL APPLICATION

[0067] The insulating material according to the invention can in particular be used to create a permeable fire-proof insulating system in the building industry.