Porous molded body in the form of an insulating plaster layer or an insulating panel

Abstract

Insulating plasters and insulated molded panels produced by molding without input of heat contain closed or open celled light weight bodies or mixtures thereof, and at least one binder composed of composite particles containing both an organic polymer and from 15 to 50 weight percent of inorganic solid.

Claims

1. A porous molded body in the form of a flexible insulating plaster layer or a flexible insulating panel, comprising: closed-celled or open-celled or mixed-celled hollow bodies composed of inorganic materials and a binder, wherein composite particles are present as the binder in an amount of 5-20% by weight, the composite particles comprising at least one organic polymer and at least one inorganic solid in a proportion by weight of from 15 to 50% by weight, based on the total weight of organic polymer and inorganic solid in the composite particle, and wherein the porous molded body in the form of the insulating panel is obtained by curing without heat input, and one or more oxides of titanium, zirconium, aluminum, barium, magnesium or iron, or silicon dioxide are present as the inorganic solid.

2. The porous molded body of claim 1, wherein the organic polymer comprises one or more polymers of ethylenically unsaturated monomers selected from the group consisting of vinyl esters of unbranched or branched alkylcarboxylic acids having from 1 to 15 carbon atoms, methacrylic esters and acrylic esters of alcohols having from 1 to 15 carbon atoms, vinylaromatics, olefins, dienes, vinyl halides and mixtures thereof; the one or more polymers optionally also containing from 0.05 to 20% by weight, based on the total weight of all monomers, of one or more functional comonomers selected from the group consisting of ethylenically unsaturated monocarboxylic and dicarboxylic acids; and silicon-functional comonomers.

3. The porous molded body of claim 1, wherein the closed-celled, open-celled, or mixed-celled hollow bodies composed of inorganic materials contain one or more members selected from the group consisting of aerogels composed of silicate, expanded silica sand, expanded perlite, and hollow glass spheres.

4. A method for producing a porous molded body in the form of a flexible insulating plaster layer, comprising: producing a mortar composition by mixing from 10 to 50% by weight of closed-celled, open-celled, or mixed-celled hollow bodies composed of inorganic materials, from 5 to 20% by weight of composite particles, from 40 to 80% by weight of fillers, from 0 to 20% by weight of mineral binders and/or polymeric binders and optionally from 0.1 to 10% by weight of further additives, the percents by weight based on the total weight of the composition without water, and total 100% by weight, with water, wherein the composite particles are present as a binder and comprise at least one organic polymer and at least one inorganic solid in a proportion by weight of from 15 to 50% by weight based on the total weight of organic polymer and inorganic solid in the composite particle, where one or more oxides of titanium, zirconium, aluminum, barium, magnesium, or iron, or silicon dioxide are present as the inorganic solid, and applying the mortar composition to a support material.

5. A method for producing a porous molded body in the form of a flexible insulating panel, comprising: preparing an aqueous molding composition by mixing water with a composition comprising from 10 to 80% by weight of closed-celled, open-celled, or mixed-celled hollow bodies composed of inorganic materials, from 5 to 20% by weight of composite particles, from 10 to 40% by weight of fillers, from 0 to 20% by weight of mineral binders and/or polymeric binders and optionally from 0.1 to 10% by weight of further additives, the weight percentages based on the total weight of the composition without water, wherein the figures in % by weight in each case add up to 100% by weight, wherein the composite particles are present as a binder and comprise at least one organic polymer and at least one inorganic solid in a proportion by weight of from 15 to 50% by weight based on the total weight of organic polymer and inorganic solid in the composite particle, where one or more oxides of titanium, zirconium, aluminum, barium, magnesium, or iron, or silicon dioxide are present as the inorganic solid; molding the aqueous molding composition; and curing without heat input to form the insulating panel.

Description

The Following Examples Serve to Illustrate the Invention

Production of the (Comparative) Dispersions

Comparative Dispersion Without Silica (Comparative Dispersion 1)

(1) 1.0 g of deionized water, 4.6 g of sodium lauryl sulfate and 1.4 g of potassium peroxodisulfate were placed in a nitrogen atmosphere in a reactor having a volume of 3 liters and heated to 40 C. while stirring. At this temperature, a mixture having the following composition was introduced into the reactor:

(2) TABLE-US-00001 Vinyltriethoxysilane 0.8 g Methacrylic acid 8.5 g Butyl acrylate 100.8 g Dodecyl mercaptan 0.3 g Methyl methacrylate 40.7 g Styrene 18.7 g

(3) The temperature was subsequently increased to 80 C., and after this temperature had been reached, the initiator solution (1.4 g of potassium, peroxodisulfate in 86.8 g of water) was fed in over a period of 3 hours, while at the same time a solution having the following composition was introduced separately over a period of 2.5 hours into the reactor:

(4) TABLE-US-00002 Vinyltriethoxysilane: 3.7 g Methacrylic acid: 37.1 g Butyl acrylate: 440.8 g Dodecyl mercaptan: 1.48 g Methyl methacrylate: 177.8 g Styrene 81.5 g

(5) After the metered additions were complete, the mixture was stirred for 2 hours at 80 C. and 1 hour at 85 C.

(6) The polymer dispersion was subsequently diluted with water and the pH was set to 9 by means of an aqueous ammonia solution (12.5% strength). A polymer solution having a solids content (DIN EN ISO 3251) of 43.0% by weight was obtained. The minimum film formation temperature (DIN ISO 2115) was 5 C.

Composite Dispersion With 10% by Weight of Silica (Comparative Dispersion 2)

(7) 1000 g of the 43% strength, aqueous comparative dispersion 1 were placed in a double-wall reactor at 50 C. while stirring and 120 g of an aqueous silica sol (solids content 40%, Bindzil 2040 from Akzo Nobel) were added.

(8) The solution obtained in this way had a solids content of 42.7% and a silica content of 10% by weight, based on the total solids content.

Composite Dispersion With 30% by Weight of Silica (Composite Dispersion 3)

(9) 1000 g of the 43% strength, aqueous comparative dispersion 1 were placed in a double-wall reactor at 50 C. while stirring and 460 g of silica sol (solids content 40%, Bindzil 2040 from Akzo Nobel) were added. The solution obtained in this way had a solids content of 42.1% and a silica content of 30% by weight, based on the total solids content.

Composite Dispersion With 45% by Weight of Silica (Composite Dispersion 4)

(10) 1000 g of the 43% strength, aqueous comparative dispersion 1 were placed in a double-wall reactor at 50 C. while stirring and 880 g of silica sol (solids content 40%, Bindzil 2040 from Akzo Nobel) were added. The solution obtained in this way had a solids content of 41.6% and a silica content of 45% by weight, based on the total solids content.

Production of the Insulating Panels

(11) To produce the insulating panels, the formulations from Table 1 were used. The raw materials were combined and poured into a mold (1.5 cm thick, 2 cm wide and 12 cm long). After a drying time of one week, the insulating panels (test specimens) were taken from the mold.

(12) TABLE-US-00003 TABLE 1 Comp. Comp. Raw materials ex. 1 ex. 2 Ex. 3 Ex. 4 Water 186 117 115.6 114.9 Dispersant (Dispex N 40, BASF) 2 2 2 2 Rheological additive (Bentone 40 40 40 40 EW, Elementis, 5% strength in H.sub.2O) Thickener (Tylose MB 10000KG4, 50 50 50 50 ShinEtsu, 2% strength in H.sub.2O) TiO.sub.2 pigment (Kronos 2190, 20 20 20 20 Kronos) Comparative dispersion 1 151 without silica Comparative dispersion 2 with 10% of silica Composite dispersion 3 152.4 with 30% of silica Composite dispersion 4 153.1 with 45% of silica White cement 80 Perlite filler (0.1-0.3 mm, 220 220 220 220 ADT) Air pore former (Hostapur OSB, 2 Clariant) CaCO.sub.3 filler (Calcilit 100, 275 275 275 275 alpha calcite filler) CaCO.sub.3 filler (Calcilit 500, 125 125 125 125 alpha calcite filler) Total 1000 g 1000 g 1000 g 1000 g

Burning Test

(13) For the burning test, the test specimens were positioned horizontally and a Tirill burner flame (h=20 mm) was applied for a time of at least 60 s. Whether ignition and burning occur was determined. Furthermore, the stability and the change in the plates after application of the flame were assessed. The results of the burning test are summarized in Table 2.

Deformation Test (Fracture Displacement)

(14) The determination of the deformation was carried out in accordance with DIN EN 12002. Here, the fracture displacement was determined in the 3-point bending test in accordance with DIN EN 12002.

(15) To produce the insulating panels, the formulations from Table 1 were used. The raw materials were combined and poured into a mold (1.5 cm thick, 4.5 cm wide and 28 cm long). After a drying time of one week, the insulating panels (test specimens) were taken from the mold. Before the deformation test, the specimens were stored for another 3 days under standard conditions (DIN 50014, 23 C. and 50% rel. atmospheric humidity) and for 2 days at 50 C.

(16) The results of the deformation test are summarized in Table 2:

(17) TABLE-US-00004 Flame Burning Change Fracture application time in the displacement Experiments time [sec] [sec] plate [mm] Comp. example 1 >600 0 stable 0.18* Comp. example 2 60 >40 broken 15.8** Example 3 >600 0 stable 10.2** Example 4 >600 0 stable 2.9** *Storage: 3 days at 90% atmospheric humidity and 2 days under standard conditions. **Storage: 3 days under standard conditions and 2 days at 50 C..

(18) The results show that the plates bonded by means of the composite dispersions of the invention (examples 3 and 4) have good fire protection and satisfactory deformability compared to the inorganically bonded (comparative example 1) and organically bonded plates (comparative example 2).