DE4415406C2 - Sound and / or heat insulating parts - Google Patents

Description

The invention relates to a method for manufacturing provide sound and / or heat insulating insulation len as semi-finished or finished products by pressing Exposure to heat, including crushed foam can be used, as well as accordingly provided insulation parts.

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 ge low and medium density to achieve a he did not wish good impact and airborne sound insulation values Have compressive strength, d. H. they sit down at the Load too strong and are therefore not a base with appropriate load, such as. B. at an est rich 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 the sea. This is hereafter The fiber structure forms the starting material for the Production of a precursor of pressed recyclable gene upholstery parts, for. B. for automobile seats, upholstery pieces of furniture u. The like. In the further processing steps it is folded into mats and in molds that  correspond to the desired contours of the upholstery parts, introduced, the molded parts under pressure and heat acting on your desired shape as far as practicable is received. Through a final vulcanization the necessary dimensional stability enough.

In the manufacture of these molded rubber parts hair fall due to the often required material gave to achieve the requested final outside contours, considerable residual amounts of rubber hair because the final outer contours and possibly necessary che openings or the like. By cutting or machining processing operations. To these remaining quantities there are still reject-pressed parts that are faulty as a result Production are not to be used. Also revealed from the disposal of upholstery parts and the like Rubber hair further quantities of this material, the waste of this type will be disposed of in an environmentally friendly manner in future Need to become.

These considerable residual and recycling quantities made of rubber Today hair must still be disposed of in landfills be because no economic and reliable casually working procedures for reusing these Substances are known. Landing them causes significant cost, cannot be unlimited due to lack suitable deposits in the future and also represents a burden on the environment.

When manufacturing parts from artificial and natural union foams, e.g. B. flexible polyurethane foam or  Latex foam, even larger amounts of recycled mate fall rial, it is inevitable that leaking stel len the foam mold emerge plastic foam residues, and there are also additional amounts of waste caused by loading cut to finished parts or by rejects at Production and scrapping of equipment gene, which also contain foam residues, as in Sitting and other devices is the case, which one if to be disposed of and in the sense of a reduced order world pollution as possible for other uses are lead.

From DE 34 38 368 A1 is a construction insulating plate be knows, essentially from a rubber waste pressed container mixed with synthetic resins, its cavity with panels consisting of waste or this waste is filled in an uncompressed form.

DE 42 31 097 A1 discloses a method of manufacture len a composite particle body, with plastic layered packaging materials thermally pressed will.

DE 79 12 879 U1 relates to a heat insulating and sound-absorbing faceplate, which the good heat inherent Styrofoam plate shaft and good sound swallowing property of polyester or polyether Have foam mats and also light on the outside and should be easy to clean, what by gluing bond between polystyrene sheet and polyester or Polyether foam mat is reached, the latter after  outside is a knob side coated with polyurethane sits.

DE 89 04 124 U1 finally discloses an aesthetic attractive and easy-care composite element, in which a thin wood-based panel to the top layer hears, whose outer surface to form a decor is provided with a paint application.

The entire state of the art is no indication of that Use of rubber hair. The invention is therefore the basic problem of meaningful reuse use of rubber hair, what is its use for insulation boards with high air, impact, structure-borne and thermal insulation is also proposed in the manner specified in claim 1, that using rubber hair granulate insulation or Components of different composition and density to achieve different physical properties manufactured and combined into insulation parts the. To ensure a secure production box capacity of the same quality are available when quantities are missing corresponding recycling materials similar New easy to use materials.

The advantages achieved with the invention are in particular special in that now also recycling quantities of rubber hair can be disposed of economically and by be agreed mixing ratios of crushed Recycled quantities from rubber hair granules as well as mineral ones Fillers and binders or rubber hair granules, Foam flakes, mineral fillers and bandages medium supplemented, if necessary with necessary men  against new materials of the same type, by a heat standing pressing process, high-quality insulation boards or Insulated molded parts for sound and / or heat insulation in physically adapted to the qualitative requirements different properties can be produced nen. This makes environmentally friendly disposal, both of residual amounts of rubber hair and foam fen also guarantees a saving in raw materials achieved, with the end products the well-known insulation compared to for the applications in question surprisingly improved, easily adaptable to the requirements Have properties, and according to the inven parts produced relatively low in price are known insulation materials with a similar effectiveness towards smaller dimensions allow what is also cheaper to combine with the insulation boards rende parts, such as. B. doors.

To achieve different physical properties can for the individual components different grain sizes or flocculation of the stock parts are chosen, preferably to the stock share at least rubber hair granules, mineral filling fabric and binder and possibly foam flakes belong.

A different grain or flake size to choose the components used allow further adjustment solution of the mix to the respective qualification requirements of the finished product.  

An advantageous production of larger plates or Blocks offers a less complex production of half testify from which, depending on the order intake, made a difference short, desired plate sizes or molded parts are to be generated by mechanical separation, for what these stocks of these semi-finished products are in stock has a particularly favorable effect, both at the manufacturer of the Semi-finished products as well as branches or contracts dealers, especially if they are at great distances or are based abroad.

The surface can have special requirements or wishes be adjusted, such as B. to achieve increased Non-slip, special design, generation of air clear between two folded plates, increase the insulation effect against sound and / or heat transfer, Protection against absorption of moisture and. the like

According to a further feature of the invention, minde at least one of the outer surfaces of the insulating part with a Plastic board or with veneer boards, cardboard or pressed wood, chipboard or metal plates be tet or glued if a surface with special their properties, such as a denser and / or ver more wear-resistant and / or different colored surface or Like. is required.

Combining at least two rubber hair granules ent holding components of different compositions and density results in an insulation part, in particular an insulation panel with a surprisingly high soundproofing effect.  

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

• - for insulation inlays in door leaves and as sound protective liners for walls, preferably as loose adjacent double panels,
• - As a sound-absorbing material under the floor or wall tiles,
• - for impact sound insulation and thermal insulation for Ver reduction in height as a sub-floor for floors screed,
• - to achieve intermediate air layers with insulation plate constructions,
• - as a base for machine foundations for noise insulation,
• - as semi-finished insulation boards for the production of floor tile 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 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:

Figure 1 shows a portion of an insulation board with longitudinal and transverse corrugations on a surface surface.

FIG. 2 shows a portion of an insulating panel provided with longitudinal and transverse directions in nubs on a surface side;

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

Fig. 4 is a partial region of an insulating board with a glued on one side of thin plastic plate;

Figure 5 shows a combination of two components to form an insulation board, in which one surface of an element is provided with strip-shaped springs which engage in grooves in the other;

Figure 6 shows a detail of a component for door leaves, partitions or the like with two internal loaded components of different physical properties as well as thickness..; and

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

An insulation or construction element 1 according to FIG. 1 of an insulation board according to the invention has on its surface side 2 longitudinal and transverse corrugations 3 and 4 with circular section-like cross sections, the distances of which from one another can be chosen as desired. Such corrugations 3 and 4 can also be provided in only one direction. Through such corrugations 3 and 4 are in the system on straight surfaces without surveys air spaces to increase the sound and / or thermal insulation; moreover, a higher grip or patterning of the surface is achieved.

A surface side 6 of an insulation element 7 of a combined insulation board 8 according to FIG. 2 is provided with flattened spherical cap-like knobs 9 to increase the surface surface grip or to reduce their contact surface or to create air spaces, these knobs 9 can also be used as surface patterns in Be come.

A plate 11 is connected to the insulating element 7 by gluing. It consists of an insulation element according to the invention with different physical properties to the insulation element 7 .

Fig. 3 shows a homogeneous insulation element 14 with longitudinal grooves 15 of a surface side 16 , which may be at different distances from each other, chen chen to achieve air spaces or increased air flow.

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

An insulation combination 24 of FIG. 5 has an insulating element 25 whose one surface side 26 countries with Fe 27 is provided, the einliegen a second insulating element, in the grooves 29 of the gegenüberlie constricting surface side 28, thereby in the direction of the springs 27 and Nu th 29 is a secure Allocation of both plates is achieved.

A door leaf 31 according to FIG. 6 consists essentially of outer plates 34 , between which there are two inner mutually loosely laid insulation elements 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 insulation elements of the inner insulation panel each consist of a material with different physical properties, which has proven to be particularly sound-absorbing. So the insulation element 32 can be made of 75% rubber hair granulate, 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 granulate 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 elements 32 and 33 has a significantly higher sound and heat insulation than 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, the total thickness can be 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 cost reduction, since the entire door structure has a smaller width and less weight , It is advantageous to make a loose juxtaposition of the insulation elements 32 and 33 .

A further increase in sound and heat insulation can be achieved by designing adjacent surfaces on the side 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 produced with a corresponding number of pieces as a completely failing pressed part or in the case of single or small series production from a corresponding insulating semi-finished product. If there is a matching design in molded parts 39 in most of the molded areas, 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 at an Er 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 Flaking the foam increases the density and the sta table strength of the insulation material, so that this good machining is also possible.

The appropriate percentage to be added the binder also depends on the density required of the molded part or plate to be produced. At high Percentage less binder is used than at lower density. Everyone can be a binder suitable known adhesives added to this the, e.g. B. elastic polyurethane binder or a natural Licher binder, e.g. B. latex. A higher percentage of the added binder increases the durability of the Plates or the molded body.  

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 elements 1 and 2 with a material thickness of 16 mm, z. B. for door and wall insulation.

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

The density range is set to 800-1000 kg / m³. Element 2 consists of:
62% ground rubber hair, grain size about 3 mm, with about 50% latex,
33% flocked foam, e.g. B. soft polyurethane foam, flake size 3 mm,
6% binder.

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

The combination of the two loosely folded elements te, each outside with a glued 5 mm thick  Wood chipboard can be provided, measured in Window test stand, 1.9 m², a noise reduction of 46 dB in the frequency range 35.5 to 8000 Hz.

Example 2

An insulation element with a thickness of about 20 mm was produced by pressing at 100 to 1300 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 29 052 of 30 MN / m³ on, resulting in a sound reduction of 26 dB in the step area is reached. Permanent settlement according to DIN 18 165, part 2, is 1 mm.

Claims (16)

1. A method for producing sound and / or heat-insulating parts as semi-finished or finished products by pressing under the action of heat, whereby crushed foam can be used, characterized in that using rubber hair granules a size of at least about 3 mm in one proportion of at least 30% as well as a small proportion of binder, components of different composition and density are produced to achieve different physical properties and at least two components are combined to form insulation parts. 2. The method according to claim 1, characterized in that that to achieve different physical Properties for the individual components different grain sizes or flocculations of the Be components can be selected. 3. The method according to claim 1 or 2, characterized records that to the ingredients at least rubber hair granulate, mineral filler and binder like this as may include foam flakes. 4. The method according to any one of claims 1 to 3, characterized characterized in that the constituents by comminution recycled materials. 5. The method according to any one of claims 1 to 4, characterized characterized that the ingredients were crushed New materials are added.   6. The method according to any one of claims 1 to 5, characterized characterized in that the grain sizes or flake size the granules or flakes to be processed of recycling and / or new materials between about 3 to 8 mm can be selected. 7. The method according to any one of claims 1 to 6, characterized in that the two components are put together. 8. The method according to any one of claims 1 to 7, characterized characterized that plate-shaped components ago be put. 9. The method according to any one of claims 1 to 6, characterized characterized that blocks of different physi calic properties that are produced by mechanical separation, such as cutting, splitting, Sawing, milling, in which to combine into insulation parts who disassembled the components with smooth surfaces the. 10. Insulating part, in particular insulating board, characterized by the combination of at least two rubber hair-containing components ( 7 , 11 ; 25 ; 32 , 33 ) of different composition and density. 11. Insulating part according to claim 10, characterized by Components of different thickness. 12. Insulating part according to claim 10 or 11, characterized ge indicates that at least one of its components uneven on at least one of its surfaces is shaped. 13. Insulating part according to claim 12, characterized in that the mutually facing surfaces of the components ( 25 ) are provided with at least one tongue and groove connection ( 27 , 29 ). 14. Insulating part according to one of claims 10 to 13, characterized in that at least one of its outer surfaces is coated with a plastic plate ( 20 ). 15. Insulating part according to one of claims 10 to 14; characterized in that at least one of its outer surfaces ( 29 ) with veneer panels ( 21 ) or cardboard or pressed wood ( 22 ) or chipboard ( 23 ) or Metallplat ten ( 24 ) is connected by gluing. 16. Use of an insulating part according to one of claims 10 to 15 as a located in doors, walls or the like