A THERMAL INSULATION BOARD COMPRISING AT LEAST ONE AEROGEL COMPOSITE MATERIAL FOR THE THERMAL INSULATION OF BUILDINGS

Abstract

The present invention relates to a thermal insulation board (IB) comprising at least two insulating layers (A) bonded together. At least one of the at least two insulating layers (A) comprises at least one aerogel composite material, wherein the aerogel composite material comprises at least one silica aerogel (a1), at least one polymer foam (a2) and at least one flame retardant (a3). The present invention also relates to a thermal insulation system (IS) comprising the thermal insulation board (IB). Further, it relates to a process for the production of the thermal insulation board (IB) and to the use of the thermal insulation board (IB) and of the thermal insulation system (IS) for the thermal insulation of buildings, parts and/or elements of buildings.

Claims

1. A thermal insulation board (IB) comprising at least two insulating layers (A), wherein the at least two insulating layers (A) are bonded together and wherein at least one of the at least two insulating layers (A) comprises at least one aerogel composite material comprising: (a1) at least one silica aerogel, (a2) at least one polymer foam and (a3) at least one flame retardant, wherein the at least one aerogel composite material comprised in at least one of the at least two insulating layers (A) comprises 10 to 94% by weight of the at least one silica aerogel (a1), 1 to 20% by weight of the at least one polymer foam (a2) and 5 to 70% by weight of the at least one flame retardant (a3), based in each case on a total weight of the at least one aerogel composite material and wherein the thermal insulation board is characterized by thermal properties that include a furnace temperature rise <50° C., a mass loss of <50% and a flame time of <20 s determined according to ISO 1182:2010.

2. The thermal insulation board (IB) according to claim 1, wherein: i) the at least two insulating layers (A) are bonded together by at least one first adhesive (AD1), and/or ii) the at least two insulating layers (A) are bonded together by mechanical fixing (MF), preferably by sewing, clamps, rivets, dowels and/or nails, and/or iii) each of the at least two insulating layers (A) has a thickness of 1 to 500 mm, preferably of 5 to 100 mm, more preferably of 5 to 20 mm.

3. The thermal insulation board (IB) according to claim 2, wherein: i) the at least one first adhesive (AD1) is selected from the group consisting of inorganic adhesives, organic adhesives and inorganic-organic hybrid adhesives, the at least one first adhesive (AD1) preferably being a polyurethane-based one- or two-component adhesive with a calorific value of <40 MJ/kg, optionally filled with inorganic compounds, and/or ii) the at least one first adhesive (AD1) is applied to at least one surface of at least one of the at least two insulating layers (A), preferably with a thickness of 0.01 to 10 mm, more preferably with a thickness of 0.01 to 5 mm, most preferably with a thickness of 0.05 to 2 mm, and/or iii) the at least one first adhesive (AD1) is applied to at least one surface of at least one of the at least two insulating layers (A) with a weight per square meter of 10 to 500 g/m.sup.2, preferably with a weight per square meter of 50 to 250 g/m.sup.2

4. The thermal insulation board (IB) according to claim 1, wherein the at least one aerogel composite material comprised in at least one of the at least two insulating layers (A) has: i) a density of 0.10 to 0.40 g/cm.sup.3, preferably of 0.15 to 0.25 g/cm.sup.3, and/or ii) a thermal conductivity 1 of ≤0.030 W/(mK), preferably of ≤0.020 W/(mK), and/or iii) a liquid water uptake of ≤20% by weight, preferably of ≤10% by weight, more preferably of ≤5% by weight, most preferably of ≤1% by weight, based on the total weight of the at least one aerogel composite material, and/or iv) a heat of combustion of ≤1.5 MJ/kg.

5. The thermal insulation board (IB) according to claim 1, wherein the at least one aerogel composite material comprised in at least one of the at least two insulating layers (A) comprises: i) 20 to 80% by weight, preferably 30 to 70% by weight, of the at least one silica aerogel (a1), based on the total weight of the at least one aerogel composite material, and/or ii) 1 to 15% by weight, preferably 3 to 10% by weight, of the at least one polymer foam (a2), based on the total weight of the at least one aerogel composite material, and/or iii) 19 to 65% by weight, preferably 27 to 60% by weight, of the at least one flame retardant (a3), based on the total weight of the at least one aerogel composite material.

6. The thermal insulation board (IB) according to claim 1, wherein the at least one silica aerogel (a1) comprises in a range from 1 to 25% by weight, preferably in the range from 1 to 10% by weight, of at least one hydrophobic group, based on the total weight of the at least one silica aerogel (a1), wherein the at least one hydrophobic group is bound to at least one silicon atom.

7. The thermal insulation board (IB) according to claim 1, wherein the at least one polymer foam (a2) comprised in the at least one aerogel composite material i) is an open-cell polymer foam, preferably an open-cell melamine-based foam or an open-cell urethane-based foam, more preferably an open-cell melamine-based foam, and/or ii) has a density of 0.002 to 0.025 g/cm.sup.3, preferably of 0.005 to 0.015 g/cm.sup.3.

8. The thermal insulation board (IB) according to claim 1, wherein the at least one flame retardant (a3) comprised in the at least one aerogel composite material is selected from inorganic compounds, preferably from the group consisting of clay minerals, low melting glasses, metal oxides, metal oxide hydroxides, metal hydroxides, carbonates and hydrocarbonates, more preferably from clay minerals, metal oxides, metal oxide hydroxides and metal hydroxides.

9. The thermal insulation board (IB) according to claim 1, wherein the at least one flame retardant (a3) is embedded in the at least one silica aerogel (a1).

10. The thermal insulation board (IB) according to claim 1, wherein the at least one aerogel composite material further comprises at least one infrared absorbing or reflecting opacifier, preferably selected from the group consisting of carbon black, graphite, boron carbide, metal oxides and metal carbides, more preferably from metal oxides.

11. A thermal insulation system (IS) comprising the thermal insulation board (IB) according to claim 1 and a fixing layer (X), wherein the fixing layer (X) affixes the thermal insulation board (IB) on a building wall (BW).

12. The thermal insulation system (IS) according to claim 11, wherein the fixing layer (X): i) comprises at least one second adhesive (AD2) selected from the group consisting of inorganic adhesives and organic adhesives, preferably consists of at least one adhesive selected from the group consisting of inorganic adhesives and organic adhesives, more preferably consists of mortar, and/or ii) has a thickness of 0.5 to 30 mm, preferably of 1 to 10 mm.

13. The thermal insulation system (IS) according to claim 11, wherein the thermal insulation system (IS) further comprises an upper layer (B) which is bonded to the thermal insulation board (IB) such that in the thermal insulation system (IS) there is the thermal insulation board (IB) between the fixing layer (X) and the upper layer (B).

14. The thermal insulation system (IS) according to claim 13, wherein the upper layer (B) i) comprises at least one third adhesive (AD3) selected from the group consisting of inorganic adhesives and organic adhesives, preferably the at least one third adhesive (AD3) comprising mortar, and optionally at least one reinforcing material selected from the group consisting of meshes, fibers, fleeces and fabrics, preferably from meshes and fibres, and/or ii) has a thickness of 0.5 to 30 mm, preferably of 1 to 10 mm.

15. The thermal insulation system (IS) according to claim 13, wherein the thermal insulation system (IS) further comprises a finishing layer (C) bonded to the upper layer (B), wherein: i) the finishing layer (C) comprises plaster or render, and/or ii) the finishing layer (C) has a thickness of 0.5 to 40 mm, preferably of 2 to 20 mm.

16. The thermal insulation system (IS) according to claim 15, wherein the thermal insulation system (IS) further comprises a surface finishing layer (D) bonded to the finishing layer (C), wherein: i) the surface finishing layer (D) comprises a coating, a lamination, a film, a foil or a paint, and/or ii) the surface finishing layer (D) has a thickness of 0.001 to 10 mm, preferably of 0.002 to 2 mm.

17. A process for production of a thermal insulation board (IB) according to claim 1 comprising: a) providing at least two insulating layers (A), wherein at least one of the at least two insulating layers (A) comprises at least one aerogel composite material comprising at least the following components (a1) to (a3) (a1) at least one silica aerogel, (a2) at least one polymer foam and (a3) at least one flame retardant, and b) bonding the at least two insulating layers (A) together, preferably by at least one first adhesive (AD1) and/or by mechanical fixing (MF), to obtain the thermal insulation board (IB).

18. (canceled)

19. A thermal insulation board (IB) comprising: at least two insulating layers (A), wherein at least one of the at least two insulating layers comprises a silica aerogel composite; an adhesive layer between the at least two insulating layers comprising an adhesive having a calorific value of less than <40 MJ/kg; and wherein the thermal insulation board is dimensioned and configured as a thermal protection between automotive electric drive battery cells.

20. The thermal insulation board of claim 19, wherein the silica aerogel composite further comprises a flame retardant and a polymer foam.

21. The thermal insulation board of claim 20, wherein the silica aerogel composite further comprises: 10 to 94% by weight of a silica aerogel; 1 to 20% by weight of a polymer foam; and 5 to 70% by weight of a flame retardant.

22. The thermal insulation board of claim 19, wherein the thermal insulation board is characterized by thermal properties that include a furnace temperature rise <50° C., a mass loss of <50% and a flame time of <20 s determined according to ISO 1182:2010.

Description

EXAMPLES

[0183] Table 1 states the essential parameters of the insulating layers (A) used in the thermal insulation boards (IB) according to inventive examples E1 to E3, and table 2 states the essential parameters of the insulating layers (A*) used in the thermal insulation boards (IB) according to comparative examples C1 to C3.

TABLE-US-00001 TABLE 1 Heat of Perpendicular Composition combustion tensile of the λ per weight Density Thickness strength Layer Material material [W/(mK)] [MJ/kg] [g/cm.sup.3] [mm] [kPa] A1 Aerogel comprises at 0.016 2.9 0.16  5 15 composite least one material silica aerogel, at least one open-cell melamine- based foam and at least one flame retardant A2 Aerogel comprises at 0.016 2.9 0.16 10 15 composite least one material silica aerogel, at least one open-cell melamine- based foam and at least one flame retardant A3 Stone wool 0.035 1.7 0.12 55  5

TABLE-US-00002 TABLE 2 Heat of Perpendicular Composition combustion tensile of the λ per weight Density Thickness strength Layer Material material [W/(mK)] [MJ/kg] [g/L] [mm] [kPa] A*1 Stone wool 0.035 1.7 0.12 100 5 A*2 Stone wool 0.035 1.7 0.12  60 5 A*3 Aerogel Comprises 0.019 2.7 0.21  10 8 composite from 25 to 95 material % by weight of silica aerogel and from 5 to 75 % by weight of inorganic fibers A*4 Aerogel Comprises 0.019 2.7 0.21  5 8 composite from 25 to 95 material % by weight of silica aerogel and from 5 to 75 % by weight of inorganic fibers

[0184] The thermal conductivity λ is determined according to DIN EN 12667:2001-05 and DIN EN 13162.

[0185] The heat of combustion per weight is determined according to DIN EN ISO 1716:2010-11.

[0186] The density is determined according to DIN EN 1602:2013-05.

[0187] The perpendicular tensile strength is determined according to DIN EN 1607:2013-05

[0188] Table 3 states the composition and the overall thickness of the thermal insulation boards (IB) according to inventive examples E1 to E3; table 4 states the composition and the overall thickness of the thermal insulation boards according to comparative examples C1 to C3. In the present case, the composition means the order in which the different layers are bonded together.

TABLE-US-00003 TABLE 3 Example Composition Overall Thickness [mm] E1 4 layers of A2 and one 45 layer of A1 are bonded together by a polyurethane-based adhesive filled with inorganic compounds in the following order: A2 A2 A2 A2 A1 to obtain a board comprising five insulating layers (A) E2 4 layers of A2 and one 49 layer of A1 are bonded together by mortar (mortar thickness: 1 mm) in the following order: A2 A2 A2 A2 A1 to obtain a board comprising five insulating layers (A) E3 one layer of A3 and two 75 layers of A2 are bonded together by a polyurethane-based adhesive filled with inorganic compounds in the following order: A3 A2 A2 to obtain a board comprising three insulating layers (A)

TABLE-US-00004 TABLE 4 Example Composition Overall Thickness [mm] C1 A*1 100 C2 5 layers of A*3 and one 55 layer of A*4 are bonded together by water glass glue in the following order: A*3 A*3 A*3 A*3 A*3 A*4 to obtain a board comprising six insulating layers (A*) C3 one layer of A*2 and 80 two layers of A*3 are bonded together by water glass glue in the following order: A*2 A*3 A*3 to obtain a board comprising three insulating layers (A)

[0189] To obtain a thermal insulation system (IS), the inventive thermal insulation boards (IB) according to examples E1 to E3 and the thermal insulation boards according to comparative examples C1 to C3 are affixed on a building wall (BW) by a mortar (fixing layer (X)). The mortar has a thickness of 5 mm, a thermal conductivity λ of 0.540 W/(mK), a density of 1.2 g/cm.sup.3 in the dried state and a heat of combustion of 0.5 MJ/kg.

[0190] The thermal insulation boards (IB) according to inventive examples E1 and E3, as well as the thermal insulation boards according to comparative examples C2 and C3, are produced before affixing them on the building wall (BW). The thermal insulation board (IB) according to inventive example E2 is produced on site by first affixing a layer A2 on the building wall (BW) by mortar (fixing layer (B)) and then bonding the further three layers A2 and the layer A1 each to the previous layer A2 by mortar.

[0191] After affixing the thermal insulation boards on a building wall (BW) by mortar, a mortar with a reinforcing mesh (upper layer (B)) is bonded to the thermal insulation boards according to inventive examples E1 to E3 and to the thermal insulation boards according to comparative examples C1 to C3 such that in the thermal insulation system there is the thermal insulation board between the fixing layer (X) and the upper layer (B). The upper layer (B) has a thickness of 5 mm.

[0192] In inventive examples E1 and E2, the upper layer (B) is bonded to the layer A1 and in inventive example E3, the upper layer (B) is bonded to layer A2. In comparative example C1, the upper layer (B) is bonded to layer A*1, in comparative example C2, the upper layer (B) is bonded to layer A*4 and in comparative example C3, the upper layer (B) is bonded to layer A*3.

[0193] A finishing layer (C) comprising plaster is bonded to the upper layer (B). The finishing layer (C) has a thickness of 5 mm.

[0194] The properties of the thermal insulation systems according to the inventive examples E1 to E3 and of the thermal insulation systems according to the comparative examples C1 to C3 are shown in table 5. The properties of the insulation boards comprised in the thermal insulation systems according to the inventive examples E1 to E3 and in the thermal insulation systems according to the comparative examples C1 to C3 are shown in table 6.

TABLE-US-00005 TABLE 5 Properties of the thermal insulation systems comprising thermal insulation boards as well as layers (X), (A), (B) and (C) Example E1 E2 E3 C1 C2 C3 Total 60 64 90 115 70 95 thickness [mm] Weight per 25 30 28 30 30 30 m.sup.2 [kg/m.sup.2] Heat of 1.2 1.0 1.0 1.0 1.4 1.1 combustion per weight [MJ/kg] Heat of 30 31 29 29 40 33 combustion per surface area [MJ/m.sup.2] U-Value 0.35 0.35 0.35 0.35 0.34 0.36 [m.sup.2K/W] R-Value 2.8 2.8 2.8 2.9 2.9 2.8 [W/m.sup.2K] Perpendicular 15 15 5 5 8 5 tensile strength [kPa] Workability, Very good Very good Low Low to moderate moderate handling, sectility, sectility, generation moderate generation generation cutting and very low very low of dust generation of dust of dust dust emission generation generation of dust of dust of dust

TABLE-US-00006 TABLE 6 Properties of the thermal insulation boards Example E1 E2 E3 C1 C2 C3 Total 45 49 75 100 55 80 thickness [mm] Weight per 7 12 10 12 12 12 m.sup.2 [kg/m.sup.2] Heat of 2.9 1.8 2.0 1.7 2.7 2.1 combustion per weight [MJ/kg] Heat of 21 22 20 20 31 24 combustion per surface area [MJ/m.sup.2] U-Value 0.36 0.36 0.35 0.35 0.35 0.36 [m.sup.2K/W] R-Value 2.8 2.8 2.8 2.9 2.9 2.8 [W/m.sup.2K] Perpendicular 15 15 5 5 8 5 tensile strength [kPa] Workability, Very good Very good Low Low to moderate moderate handling, sectility, sectility, generation moderate generation generation cutting and very low very low of dust generation of dust of dust dust emission generation generation of dust of dust of dust

[0195] The specific heat of combustion per surface area and per weight is calculated from the individual components of the system by multiplying the respective MJ/kg value with the weight of the component for each component for a 1 m.sup.2 surface area.

[0196] The U- and R-values can be calculated by referring to Klaus Liersch, Normen Langner, “Bauphysik kompakt”, Verlag Bauwerk BBB, 4. Auflage 2011, ISBN 987-3-89932-285-9, Chapter 6 “Wärmedurchgang durch ebene opake Bauteile”).

[0197] As can be seen from table 6, the inventive thermal insulation boards (IB) according to inventive examples E1 to E3 show a reduced heat of combustion, a reduced total thickness and weight as well as a reduced generation of dust compared to the thermal insulation boards according to comparative examples C1 to C3 while providing a similar overall thermal insulation performance (U-/R-value). In addition, the inventive thermal insulation boards (IB) according to inventive examples E1 to E3 show an increased perpendicular tensile strength compared to the thermal insulation boards according to comparative examples C1 to C3.

[0198] The same holds true for the inventive thermal insulation systems: As can be seen from table 5, the inventive thermal insulation systems (IS) according to inventive examples E1 to E3 also show a reduced heat of combustion, a reduced total thickness and weight as well as a reduced generation of dust compared to the thermal insulation systems according to comparative examples C1 to C3 while providing a similar overall thermal insulation performance (U-/R-value). Further, they also show an increased perpendicular tensile strength compared to the thermal insulation systems according to comparative examples C1 to C3.

[0199] The inventive thermal insulation systems (IS) can, for example, be used in a multi-layered external thermal insulation composite system (ETICS).