DE4415406A1 - Heat and/or noise insulation panel mfr. and insulating panel - Google Patents

Abstract

In a process for prodn. of heat and noise insulation plates or components using recycled materials quantities of rubberized hair granules, mineral fillers, a binder and pieces of foamed material are mixed together in various ratios and in different particle sizes and pressed into plates (7) or blocks when hot. The claimed insulating plates (7) have surfaces (6) with various profiled patterns e.g. naps (9), recesses which engage with each in tongue and groove style to hold two plates (7) together on the faces.

Description

The invention relates to a method of manufacture treatment of insulation boards and molded parts for sound and / or Thermal insulation by pressing under the influence of heat from shredded, mixed with binder recycling and / or new materials, sometimes with the addition of minera filler are generated, as well as their special Training and uses.

It is known from shredded recycling material Foam sheets mixed with a binder to produce means, but it is disadvantageous that these products, since they are not fibrous, at low and medium density to achieve a desired kick and airborne sound insulation value do not have good compressive strength zen, d. H. they sit down too hard and under load are therefore not to be used as a base for a corresponding load, such as B. with a screed to use.

The so-called rubber hair consists of natural fiber materials, such as coconut fibers, animal hair or a mixture thereof, these materials sprayed with latex and under heat exposure to drying. This one here Fiber structure forms the starting material for the manufacturer a precursor of pressed recyclable upholstery molded parts, e.g. B. for automobile seats, upholstered furniture  and the like. In the further processing steps, it becomes Mats folded and in molds that the desired correspond to the contours of the upholstery parts, the molded parts under the influence of pressure and heat desired form, as far as it is feasible. The vulcanization process is followed by a necessary dimensional stability achieved.

In the manufacture of these molded rubber hair pieces fall due to the often required additions of material Achievement of the required final outer contours, he considerable residual amounts of rubber hair since the final External contours and any openings required or the like. By cutting or machining operations be put. In addition to these remaining quantities, Pressed parts that are not due to faulty production are use. There are also disposal issues of upholstery parts and the like from rubber hair further quantities of this material, with such waste quantities going forward must be disposed of in an environmentally friendly manner.

These remarkable residual and recycling amounts from rubber hair must still be stored in landfills for disposal today the, because none yet work economically and reliably known process for reusing these substances are. Landing them involves considerable costs, cannot be unlimited due to lack of suitable storage in the future and also creates a burden for the environment.

In the production of parts from artificial and natural Chen foams, e.g. B. flexible polyurethane foam or La tex foam, there are also large amounts of recycling material,  so it is inevitable that at leaks the Foam mold emerge from plastic foam residues and it arises also increase waste by trimming Precast parts or by reject parts during production as well as the scrapping of facilities that just if there are foam residues, as is the case with seats and other other devices, which must also be disposed of conditions and in the sense of a reduced environmental impact are to be used for other purposes.

The invention specified in claim 1 is Underlying problem, insulation boards or insulation board combinations ons with high air, impact, structure-borne noise as well To generate insulation, which is incurred for disposal ne recycling materials made of rubber hair or rubber hair and Foams or corresponding new raw materials are use.

This problem is solved by the in claim 1 Features solved by recycling rubber hair as well as this with appropriate amounts of foam substances as a mixture for the production of sound and heat medämmplatten, insulation board combinations or insulation molding le are to be processed as it is particularly cheap proved. To ensure secure manufacturing Capacities of the same quality are available when quantities are missing corresponding recycling materials similar Neuwerk easy to use fabrics.

The advantages achieved with the invention are in particular special in that now also recycling quantities from rubber hair can be disposed of economically and by certain  Mixing ratios of shredded recycling quantities made of rubber hair granules as well as mineral fillers and Binders or rubber hair granules, foam flakes, mineral fillers and binders added, given if necessary by the required quantities of new materials of the same type Kind, by a hot pressing process, high quality insulation panels or molded parts for sound and / or Thermal insulation in the qualitative requirements matched physically different properties can be put. This is an environmentally friendly Disposal, both of residual amounts of rubber hair and from Foam ensures savings as well Raw materials achieved, the end products the known Insulation materials opposite for the relevant application gen surprisingly improved, good on the requirements have fit properties, and the after Parts produced relatively low in invention Price lies, with similar effectiveness known insulation fabrics compared to smaller dimensions allow what also cheaper to combine with the insulation boards renal parts such. B. doors.

An advantageous production of larger plates or blocks according to claim 2, offers a less expensive production of semi-finished products, from which, depending on the order intake, under various, desired plate sizes or molded parts short to be generated in good time by mechanical separation, for what stockpiling of these semi-finished products is particularly important which has a favorable effect, both for the manufacturer of the semi-finished products ge as well as at branches or dealers, ins especially if they are at great distances or abroad have their seat.  

The feature of claim 3 allows, except for the given recycling materials for disposal also in loading may process new materials of the same type.

The grain to be used differently according to claim 4 or flake size of the components used allowed a further adjustment of the mix to the respective ge set quality requirements for the finished product.

An advantageous embodiment of the invention is in Pa claim 5 indicated by the surface special Requirements or desires is customizable, such as. B. to Achieve increased slip resistance, special design, he generation of air spaces between two merged plat ten, increase the insulation effect against sound and / or heat transition, protection against absorption of moisture and the like

The embodiment according to claim 6 enables the products produced according to the invention to be used when a surface with special properties, such as a denser or more wear-resistant or different colored surface and the like is required.
According to the features of claim 7 further combinations with different materials are possible.

The content of claim 8 ensures that a surprisingly high soundproofing effect when folded insulation boards with different physical properties existing.

The insulation panels or Insulation board combinations and molded parts are to be used:

• - for insulation inlays in door leaves and as sound insulation Intermediate layers for walls, preferably as loose de double plates,
• - As a sound-absorbing material under floor or wall tiles sen,
• - for footfall sound insulation and thermal insulation for people construction height as a base for floor screed,
• - to achieve intermediate air layers with insulation board door constructions,
• - as a base for machine foundations for noise insulation mung,
• - As semi-finished insulation boards for the production of floor tiles when coating them with PVC or the like,
• - as semi-finished insulation boards for the production of with PVC, Ready-made insulation boards coated with PUR,
• - As sound or thermal insulation molded parts for installation in Ma machines and / or facilities for plant construction and the like

Embodiments of the invention are in the drawing shown in perspective and are described in more detail below described.

Show it:

Fig. 1 chenseite a portion of an insulating panel having longitudinal and transverse corrugations on a Oberflä,

Fig. 2 surface side of a portion of an insulating panel provided with longitudinal and transverse directions in dots on an upper, said relatively thin insulation panel verbun with another sheet of Other pe gem suitable or desired material is the,

Fig. 3 is a partial region of an insulating board extending in the longitudinal or transverse direction grooves,

Fig. 4 shows a portion of an insulation board with glued on one side of thin plastic plate,

Fig. 5 is a combination of two insulating plates, one plate is provided with strip-shaped springs in which a surface which come to fit in the grooves of the other,

Fig. 6 shows a detail of a component for door leaves, partitions or the like. With two internal inlaid insulation panels of different physical properties as well as thickness,

Fig. 7 is a molded part of an insulating material according to the invention.

An insulation board 1 according to FIG. 1 has on a surface side 2 longitudinal and transverse corrugations 3 and 4 with cross-section-like cross-sections, the distances between which can be chosen differently. Such corrugations 3 and 4 can also be provided in only one direction. By such corrugations 3 and 4 are in the system on straight surfaces without elevations Lufträu me to increase the sound and / or heat insulation before a higher grip or pattern of the upper surface is achieved.

A surface side 6 of an insulation board 7 of a combinated insulation board 8 according to FIG. 2 is provided with flattened spherical cap 9 to increase the surface grip or to reduce its contact surface or to create air spaces, these knobs 9 can also be used as surface patterns in Come into consideration.

A plate 11 is connected to the insulation board 7 by gluing. It can consist of an insulation board according to the invention, with the same or different physical properties of the insulation board 7 or from another suitable material such as plastic, chipboard material, wood or the like.

Fig. 3 shows a homogeneous insulation board 14 with Längenril len 15 a surface side 16 , which may be at different distances from each other, also to achieve air spaces or increased air flow.

In a combination plate 18 according to FIG. 4, a thin plastic plate 20 is connected by adhesive with an insulating plate 19 according to the invention. The plastic plate 20 can also be made of a veneer plate 21 made of wood, cardboard or a metal plate 22 , e.g. B. made of copper sheet to be replaced.

An insulation board combination 24 according to FIG. 5 is equipped with an insulation board 25 , in which a surface side 26 is provided with springs 27 , which lie in grooves 29 of an upper surface side 28 , whereby in the direction of the springs 27 and grooves 29, a secure assignment of both plates ten is reached.

A door leaf 31 according to FIG. 6 consists essentially of outer plates 34 between which there are two inner mutually loosely laid insulation boards 32 and 33 , which can be made in different thicknesses 36 and 37 . The outer panels 34 are conventional door panels made of solid wood, veneered wood panels or chipboard, exterior veneered or plastic-coated or the like, and the inner insulation panels each consist of a material according to the invention with different physical properties, which has proven to be particularly sound-absorbing. So the insulation board 32 can be made of 75% rubber hair granules, 5% binder and 20% mineral filler in a density of 800 to 1000 kg / m³ and the insulation board 33 made of 63% rubber hair granules and 32% pressed foam flakes and 5% binder in one Density range from 400 to 600 kg / m³
It was found that such a sound-absorbing door leaf through the mutually placed insulation panels 32 and 33 has a significantly higher sound and heat insulation than be known door leaves of the same thickness or that a thinner overall construction of a sound-insulating door or wall allows for a similarly required degree of damping is light, the total thickness 35 35 45 mm, whereas it had to be 65 mm in the previously known design with the same insulation effect, which means a further simplification and cheaper, since the entire door structure has a smaller width and weight, it It is advantageous to make a loose juxtaposition of the insulation panels 32 and 33 .

A further increase in sound and heat insulation can be achieved by training adjacent surface surfaces of the insulation boards and / or their outer sides with knobs 9 or corrugations 3 , 4 .

A molded part 39 as shown in FIG. 7 can be machined from a corresponding insulating board semi-finished product in the case of a corresponding number of pieces as a finished pressing part or in single or small series production. If there is a matching design in the case of molded parts 39 in most of the molds, to which designs with smaller differences to be achieved by removal are required, these can be produced by additional machining.

Depending on the qualities of the insulation panels to be achieved or molded parts becomes the structure of each inventory parts and the composition of the homogeneous mixture of Molding compound determined. It is the grain size of the shredded rubber hair granules or the flake size the foam proportions, the ratio of rubber hair granules to Foam flakes and the percentage of bin medium and that of the mineral filler. The introduced mixture in the mold is more appropriate example under a pressure of about 120 N / cm² Heating of approx. 130 ° pressed.

A higher input of binders in the mixture and the reduction in the grain size of the rubber hair and the Flakes of the foam increase the density and the sta table strength of the insulation material, so that this good machining is also possible.  

The expedient percentage of the Binder also depends on the required density of the manufactured part or plate. With higher you percent less binder is used than never lower density. All suitable for this purpose can be used as binders known adhesives are added, e.g. B. more elastic Polyurethane binder or a natural binder, e.g. B. La tex. A higher percentage of the added bin moreover, the durability of the plates or the shaped articles is increased by.

The following examples shed light on some of them Invention to be achieved qualities of the insulation boards or Insulation molded parts.

example 1

Combination of two pressed insulation boards 1 and 2 with a material thickness of 16 mm, z. B. for door and wall insulation.

Plate 1 consists of: 74% ground rubber hair, grain size about 3 mm,
20% mineral filler, e.g. B. chalk,
6% binder.

The sealing range is set to 800-1000 kg / m³.

Plate 2 consists of: 62% ground rubber hair, grain size about 3 mm, with about 50% latex,
33% flocked foam, e.g. B. flexible polyurethane foam, floc size 3 mm,
6% binder.

All quantities are percentages by weight, based on the finished mixture. The sealing area is set to 400 up to 600 kg / m³.

The combination of the two loosely folded plates, the outside each with a glued 5 mm thick wood chipboard can be provided, measured in the fen test bench, 1.9 m², a noise reduction of 46 dB in Frequency range 35.5 to 8000 H₂.

Example 2

An insulation board with a thickness of about 20 mm is produced by pressing at 100 to 130 ° from a mixture of the following composition:
32% ground rubber hair, grain size about 4 mm,
62% foam (e.g. flexible polyurethane foam),
6% binder, e.g. B. elastic polyurethane binder.

This insulation board with a density of 300 kg / m³ exhibits dynamic stiffness according to DIN 29052 of 30 MN / m³ on, resulting in a sound reduction of 26 dB in the step rich is achieved. Permanent settlement according to DIN 18 165, Part 2 is 1 mm.

Claims (8)

1. A process for the production of insulating boards and molded parts for sound and / or heat insulation by pressing under the action of heat, whereby shredded foam recycling material can also be used, characterized in that percentage components of the homogeneous press mixture are obtained in order to achieve their physical properties Rubber hair granulate, mineral filler and binder or rubber hair granulate, mineral filler, binder and foam flakes, both in different proportions and in different grain sizes or flocculations, which are used as finished plate products ( 1 , 7 , 14 , 19 , 25 , 32 , 33 ) or as semi-finished products in blocks or as molded parts ( 39 ). 2. The method according to claim 1, characterized in that end products ( 1 , 7 , 14 , 19 , 25 , 32 , 33 ) or semi-finished products in blocks from which mechanical separation, such as splitting, sawing, cutting, milling, insulation create plates ( 19 , 32 , 33 ) with smooth surfaces. 3. The method according to claim 1 and 2, characterized records that the components from gum hair nulate and foam flakes by crushing Recycling materials, if necessary through use of appropriate new materials.   4. The method according to claim 1 and 3, characterized records that the grain sizes or flake sizes of Granules or flake masses of Re cycling and / or new materials can be selected between 0.1 to 8 mm. 5. Insulation panels produced by the method according to claims 1 to 4, characterized in that at least one of their surface side ( 2 , 6 , 16 , 26 ) be special shapes, such as corrugations ( 3 , 4 ), knobs ( 9 ), grooves ( 15 ) and recesses or in pairs a matching tongue and groove design ( 27 , 29 ). 6. Insulation boards produced by the method according to claims 1 to 4 and executed according to claim 5, characterized in that at least one of its outer surface is coated with a plastic plate ( 20 ). 7. Insulating panels produced by the method according to claims 1 to 4, characterized in that at least one of their outer surfaces ( 29 ) with veneer panels ( 21 ) or cardboard or pressed wood ( 22 ) or chipboard ( 23 ) or metal plates ( 24 ) through Gluing are connected. 8. Insulation boards produced by the method according to claims 1 to 4, characterized in that preferably two for insulation inlays in doors, walls or the like. Two insulation boards ( 32 , 33 ) with different physical properties and, as desired, different thicknesses ( 36 , 37 ) placed against each other for installation, with at least one of the mutually adjacent surface side having a special surface configuration, such as with corrugations ( 3 , 4 ), knobs ( 29 ), grooves ( 15 ), can be formed.