POROUS MOLDED BODY IN THE FORM OF AN INSULATING PLASTER LAYER OR AN INSULATING PANEL

Abstract

The invention relates to a porous molded body in the form of an insulating plaster layer or an insulating panel, comprising closed-cell or open-cell or mixed-cell hollow bodies made of inorganic materials and comprising a binder, characterized in that composite particles are contained as the binder, wherein the composite particles contain at least one organic polymer and at least one inorganic solid, wherein the weight percentage of inorganic solid is 15 to 50 wt %, with respect to the total weight of organic polymer and inorganic solid in the composite particle.

Claims

1. A porous molded body in the form of an insulating plaster layer or an 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 binder, wherein the composite particles contain at least one organic polymer and at least one inorganic solid and the proportion by weight of inorganic solid is 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 an insulating panel is obtained by curing without heat input.

2. The porous molded body as claimed in claim 1, wherein one or more oxides of titanium, zirconium, aluminum, barium, magnesium or iron or silicon dioxide are present as inorganic solid.

3. The porous molded body as claimed in claim 2, wherein 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 and vinyl halides; and optionally from 0.05 to 20% by weight, based on the total weight of the monomers, of one or more functional comonomers selected from the group consisting of ethylenically unsaturated monocarboxylic and dicarboxylic acids; and silicon-functional comonomers are present as organic polymer.

4. The porous molded body as claimed in claim 3, wherein the formulation for producing the molded body contains from 5 to 20% by weight of composite particles, based on the total weight of the dry composition without water.

5. The porous molded body as claimed in claim 4, wherein one or more members selected from the group consisting of aerogels composed of silicate, expanded silica sand, expanded perlite, and hollow glass spheres are present as closed-celled or open-celled or mixed-celled hollow bodies composed of inorganic materials.

6. A method for producing porous molded bodies as claimed in claim 5 in the form of an insulating plaster layer comprising: mixing from 10 to 50% by weight of closed-celled or 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, in each case based on the total weight of the dry composition without water, where the figures in % by weight in each case add up to 100% by weight with water; and applying to a support material.

7. A method for producing porous molded bodies as claimed in claim 5 in the form of an insulating panel comprising: mixing from 10 to 80% by weight of closed-celled or 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, in each case based on the total weight of the dry composition without water, where the figures in % by weight in each case add up to 100% by weight with water; molding; and curing without heat input.

8. (canceled)

Description

The Following Examples Serve to Illustrate the Invention

Production of the (Comparative) Dispersions

Comparative Dispersion Without Silica (Comparative Dispersion 1)

[0040] 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:

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

[0041] 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:

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

[0042] After the metered additions were complete, the mixture was stirred for 2 hours at 80 C. and 1 hour at 85 C.

[0043] 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)

[0044] 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.

[0045] 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)

[0046] 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)

[0047] 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

[0048] 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.

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

[0049] 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)

[0050] 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.

[0051] 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.

[0052] The results of the deformation test are summarized in Table 2:

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..

[0053] 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).