Process for producing profiled elements

Abstract

The present invention relates to composite elements comprising a profile and an insulating core enclosed at least to some extent by the profile, where the insulating core is composed of an organic porous material which has a thermal conductivity in the range from 13 to 30 mW/m*K, determined in accordance with DIN 12667, and a compressive strength of more than 0.20 N/mm.sup.2, determined in accordance with DIN 53421, processes for producing composite elements of this type, and the use of a composite element of this type for producing windows, doors, refrigerators, and chest freezers, or elements for facade construction.

Claims

1. A composite element, comprising: an insulating core consisting of an organic porous material; and a profile at least to some extent enclosing the insulating core; wherein a thermal conductivity of the organic porous material is from 13 to 30 mW/m*K, determined in accordance with DIN 12667, and a compressive strength of the organic porous material is more than 0.20 N/mm.sup.2, determined in accordance with DIN 53421; and the organic porous material is at least one selected from the group consisting of an organic xerogel based on a polyurethane having at least 50 mol % of the linkages of the monomer units in the form of urethane linkages, an organic xerogel based on a polyisocyanurate having at least 50 mol % of the linkages of the monomer units in the form of isocyanurate linkages, an organic xerogel based on a polyurea having at least 50 mol % of the linkages of the monomer units in the form of urea linkages, an organic aerogel based on a polyurethane having at least 50 mol % of the linkages of the monomer units in the form of urethane linkages, an organic aerogel based on a polyisocyanurate having at least 50 mol % of the linkages of the monomer units in the form of isocyanurate linkages, and an organic aerogel based on a polyurea having at least 50 mol % of the linkages of the monomer units in the form of urea linkages.

2. The composite element according to claim 1, wherein the organic porous material has a density in the range from 70 to 300 kg/m.sup.3.

3. The composite element according to claim 1, wherein the organic porous material has a heat resistance of more than 160 C.

4. The composite element according to claim 1, wherein the profile comprises polyvinyl chloride or aluminum.

5. An insulating material, consisting of: an organic porous material having a thermal conductivity in the range from 13 to 30 mW/m*K, determined in accordance with DIN 12667, and a compressive strength of more than 0.20 N/mm.sup.2, determined in accordance with DIN 53421, wherein the organic porous material is at least one selected from the group consisting of an organic xerogel based on a polyurethane having at least 50 mol % of the linkages of the monomer units in the form of urethane linkages, an organic xerogel based on a polyisocyanurate having at least 50 mol % of the linkages of the monomer units in the form of isocyanurate linkages, an organic xerogel based on a polyurea having at least 50 mol % of the linkages of the monomer units in the form of urea linkages, an organic aerogel based on a polyurethane having at least 50 mol % of the linkages of the monomer units in the form of urethane linkages, an organic aerogel based on a polyisocyanurate having at least 50 mol % of the linkages of the monomer units in the form of isocyanurate linkages, and an organic aerogel based on a polyurea having at least 50 mol % of the linkages of the monomer units in the form of urea linkages.

6. A profile, comprising: said insulating material according to claim 5 as a core.

7. A window, door, refrigerator, freezer, or an element for a facade construction, comprising said profile according to claim 6.

8. A composite element, comprising: a profile and an insulating core enclosed at least to some extent by the profile, wherein the insulating core consists of an organic porous material which has a thermal conductivity in the range from 13 to 30 mW/m*K, determined in accordance with DIN 12667, and a compressive strength of from 0.2 to 0.64 N/mm.sup.2, determined in accordance with DIN 53421; and wherein the organic porous material is at least one selected from the group consisting of an organic xerogel based on a polyurethane having at least 50 mol % of the linkages of the monomer units in the form of urethane linkages, an organic xerogel based on a polyisocyanurate having at least 50 mol % of the linkages of the monomer units in the form of isocyanurate linkages, an organic xerogel based on a polyurea having at least 50 mol % of the linkages of the monomer units in the form of urea linkages, an organic aerogel based on a polyurethane having at least 50 mol % of the linkages of the monomer units in the form of urethane linkages, an organic aerogel based on a polyisocyanurate having at least 50 mol % of the linkages of the monomer units in the form of isocyanurate linkages, and an organic aerogel based on a polyurea having at least 50 mol % of the linkages of the monomer units in the form of urea linkages.

9. A continuous process for producing a composite element according to claim 1, said process comprising: constructing the profile around the insulating core.

10. The process according to claim 9, wherein the profile is continuously constructed around the insulating core by a ring extruder.

11. The process according to claim 9, wherein the profile is constructed from a plurality of parts around the insulating core.

12. The process according to claim 9, wherein the profile comprises polyvinyl chloride.

Description

EXAMPLES

Production Example: Aerogel

1. Starting Materials

(1) The following compounds were used to produce the gels: Component a1: oligomeric MDI (Lupranat M200) with NCO content of 30.9 g per 100 g in accordance with ASTM D5155-96 A, a functionality in the region of three, and a viscosity of 2100 mPa.Math.s at 25 C. in accordance with DIN 53018 (compound M200 below). Component a2: 3,3,5,5-tetraethyl-4,4-diaminodiphenylmethane (MDEA below) Catalysts: butyldiethanolamine, methyldiethanolamine

2. Production Example 1

(2) 80 g of compound M200 were dissolved in 220 g of 2-butanone at 20 C. in a glass beaker, with stirring. 8 g of the compound MDEA and 8 g of butyldiethanolamine, and 1 g of water, were dissolved in 220 g of 2-butanone in a second glass beaker. The two solutions from step (a) were mixed. This gave a clear mixture of low viscosity. The mixture was allowed to stand at room temperature for 24 hours for hardening. The gel was then removed from the glass beaker and dried in an autoclave via solvent extraction using supercritical CO.sub.2.

(3) The gel monolith was removed from the glass beaker and transferred to a 25 l autoclave. >99% acetone was charged to the autoclave in such a way that acetone completely covered the monolith, and the autoclave was then sealed. This method can prevent shrinkage of the monolith due to evaporation of the organic solvent before the monolith comes into contact with supercritical CO.sub.2. The monolith was dried in the CO.sub.2 stream for 24 h. The pressure (in the drying system) was from 115 to 120 bar; the temperature was 40 C. Finally, the pressure within the system was reduced in a controlled manner to atmospheric pressure within a period of about 45 minutes at a temperature of 40 C. The autoclave was opened, and the dried monolith was removed.

(4) The resultant porous material had a density of 150 g/L.

(5) Thermal conductivity was determined in accordance with DIN EN 12667 by using guarded hot plate equipment from Hesto (Lambda Control A50). Thermal conductivity was 20.0 mW/m*K at 10 C.

(6) Tensile strength was determined in accordance with DIN 53292 and was 0.87 N/mm.sup.2.

(7) Modulus of elasticity was determined in accordance with DIN 53292 and was 15.3 N/mm.sup.2.

3. Production Example 2

(8) 80 g of compound M200 were dissolved in 220 g of 2-butanone at 20 C. in a glass beaker, with stirring. 8 g of the compound MDEA and 8 g of butyldiethanolamine, and 2 g of water, were dissolved in 220 g of 2-butanone in a second glass beaker. The two solutions from step (a) were mixed. This gave a clear mixture of low viscosity. The mixture was allowed to stand at room temperature for 24 hours for hardening. The gel was then removed from the glass beaker and dried in an autoclave via solvent extraction using supercritical CO.sub.2.

(9) The gel monolith was removed from the glass beaker and transferred to a 25 l autoclave. >99% acetone was charged to the autoclave in such a way that acetone completely covered the monolith, and the autoclave was then sealed. This method can prevent shrinkage of the monolith due to evaporation of the organic solvent before the monolith comes into contact with supercritical CO.sub.2. The monolith was dried in the CO.sub.2 stream for 24 h. The pressure (in the drying system) was from 115 to 120 bar; the temperature was 40 C. Finally, the pressure within the system was reduced in a controlled manner to atmospheric pressure within a period of about 45 minutes at a temperature of 40 C. The autoclave was opened, and the dried monolith was removed.

(10) The resultant porous material had a density of 153 g/L.

(11) Thermal conductivity A was determined in accordance with DIN EN 12667 by using guarded hot plate equipment from Hesto (Lambda Control A50). Thermal conductivity was 21.0 mW/m*K at 10 C.

(12) Compressive strength was determined in accordance with DIN 53421 and was 0.64 N/mm.sup.2 for 5.3% compression.

(13) Modulus of elasticity was 31 N/mm.sup.2.

4. Production Example 3

(14) 80 g of the compound M200 were dissolved in 250 g of ethyl acetate at 20 C. in a glass beaker, with stirring. 8 g of the compound MDEA and 8 g of methyldiethanolamine were dissolved in 250 g of ethyl acetate in a second glass beaker. The two solutions from step (a) were mixed. This gave a clear mixture of low viscosity. The mixture was allowed to stand at room temperature for 24 hours for hardening. The gel was then removed from the glass beaker and dried in an autoclave via solvent extraction using supercritical CO.sub.2.

(15) The gel monolith was removed from the glass beaker and transferred to a 25 l autoclave. >99% acetone was charged to the autoclave in such a way that acetone completely covered the monolith, and the autoclave was then sealed. This method can prevent shrinkage of the monolith due to evaporation of the organic solvent before the monolith comes into contact with supercritical CO.sub.2. The monolith was dried in the CO.sub.2 stream for 24 h. The pressure (in the drying system) was from 115 to 120 bar; the temperature was 40 C. Finally, the pressure within the system was reduced in a controlled manner to atmospheric pressure within a period of about 45 minutes at a temperature of 40 C. The autoclave was opened, and the dried monolith was removed.

(16) The resultant porous material had a density of 110 g/L.

(17) Thermal conductivity A was determined in accordance with DIN EN 12667 by using guarded hot plate equipment from Hesto (Lambda Control A50). Thermal conductivity was 20.0 mW/m*K at 10 C.

(18) Compressive strength was 0.52 N/mm.sup.2 for 10% compression.