Insulating Material and Method for its Production

Abstract

An insulating material, in particular a permeable fire-proof insulating material comprising water glass and polystyrene, consisting of a hardening mixture which contains 1 to 32.4 wt % of expanded polystyrene, 57.5 to 96.0 wt % of aqueous sodium silicate solution, 2 to 6 wt % of aluminium hydroxide, 0.8 to 2.6 wt % water glass hardener and 0.1 to 0.5 wt % of water glass stabilizer, while the surface of the expanded polystyrene is provided with carbon black, the carbon black making up 0.1 to 1 wt % of total weight. 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 polystyrene, according to which firstly the polystyrene beads 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 stabilizer 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 and polystyrene, comprising a hardening mixture comprising 1 to 32.4 wt % of expanded polystyrene, 57.5 to 96.0 wt % of aqueous sodium silicate solution, 2 to 6 wt % of aluminum hydroxide, 0.8 to 2.6 wt % water glass hardener and 0.1 to 0.5 wt % of water glass stabilizer, and the surface of the expanded polystyrene is provided with carbon black, the carbon black making up 0.1 to 1 wt % of total weight.

2. The insulating material according to claim 1, wherein the expanded polystyrene is spheres with a diameter of 3 to 6 mm.

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

4. 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.

5. 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 of 3.2 to 3.4.

6. A method for the production of the permeable fire-proof insulating material of claim 1, wherein in a first step the polystyrene beads 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 aluminum hydroxide and the whole is mixed so as to form an insulating mixture, and in a second step, the water glass stabilizer 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.

7. The method for producing insulating material according to claim 6, 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 the desired ratio of insulating mixture and binder solution is obtained.

8. The method for producing insulating material, according to 7, wherein the resulting mixture is left undisturbed to harden.

Description

EXAMPLES OF THE PERFORMANCE OF THE INVENTION

Example 1

[0017] The permeable fire-proof insulating material is composed an air-hardening mixture which contains 10 wt % of expanded polystyrene, which are spheres with a diameter of 3 to 6 mm, 83.0 wt % of aqueous sodium silicate solution, 4 wt % of aluminium hydroxide, 0.3 wt % water glass stabilizer and 2.3 wt % hardeners.

[0018] The surface of the expanded polystyrene is provided with carbon black, the carbon black making up 0.4 wt % of total weight.

[0019] The water glass stabilizers are hydrophilic alkoxy alkyl-ammonium salts, in the form of a 98% aqueous solution of N,N,N′,N′-Tetrakis (2-hydroxypropyl) ethylenediamine.

[0020] 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.

[0021] The water glass hardener is a mixture of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume parts, with a concentration of 2.8 wt % to pure water glass.

[0022] According to the method for producing the insulating material, firstly the polystyrene beads 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 stabilizer, 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.

[0023] 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

[0024] The permeable fire-proof insulating material is composed of an air-hardening mixture which contains 1 wt % of expanded polystyrene, which are spheres with a diameter of 3 to 6 mm, 96.0 wt % of aqueous sodium silicate solution, 2 wt % of aluminium hydroxide, 0.1 wt % water glass stabilizer and 0.8 wt % hardeners.

[0025] The surface of the expanded polystyrene is provided with carbon black, the carbon black making up 0.1 wt % of total weight.

[0026] The water glass stabilizers are hydrophilic alkoxy alkyl-ammonium salts, in the form of a 98% aqueous solution of N,N,N′,N′-Tetrakis (2-hydroxypropyl) ethylenediamine.

[0027] 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.

[0028] The water glass hardener is a mixture of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume parts, with a concentration of 0.8 wt % to pure water glass.

[0029] According to the method for producing the insulating material, firstly the polystyrene beads 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 stabilizer, 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

[0030] The permeable fire-proof insulating material is composed of an air-hardening mixture which contains 32.4 wt % of expanded polystyrene, which are spheres with a diameter of 3 to 6 mm, 57.5 wt % of aqueous sodium silicate solution, 6 wt % of aluminium hydroxide, 0.5 wt % water glass stabilizer and 2.6 wt % hardener.

[0031] The surface of the expanded polystyrene is provided with carbon black, the carbon black making up 1 wt % of total weight.

[0032] The water glass stabilizers 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 1400 kg/m.sup.3 and a molar ratio of SiO.sub.2 to Na.sub.2O in the range of 3.4.

[0034] The water glass hardener is a mixture of pure glycerol diacetate/triacetate in a ratio of 7:3 by volume parts, with a concentration of 4.5 wt % to pure water glass.

[0035] According to the method for producing the insulating material, firstly the polystyrene beads 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 stabilizer, 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

[0036] The insulating material according to the invention can in particular be used to create a permeable fire-proof insulating system in the building industry.