DE2308340B2 - Building material made from porous inorganic material and organic binding agent - Google Patents

Description

Building materials made from porous fillers held together with a binder are well known. It has already been proposed and tried to use both inorganic and organic porous materials to be processed with organic (synthetic resin) or inorganic (cement) binders to form moldings.

So z. B. in the French Patent specification 15 20 239 proposed to bind a granulate of foamed polystyrene with cement, sand and optionally synthetic resin, and it is also proposed to use relatively heavy inorganic foamed materials, such as. B. to add pumice or expanded clay, which are known to have bulk weights above 250, mostly 500 to 1000 kg / m ^J. The granulate made of foamed polystyrene only acts as a pore-forming agent in the concrete matrix, without contributing anything to the strength. Building materials with concrete as a binding agent are relatively heavy, even when porous inorganic materials are added which, however, have the aforementioned, relatively high bulk weights for lightweight aggregates. In addition, polystyrene is only sparsely wetted by the binder mixture during the production of the concrete, and must therefore be coated with a suitable material, e.g. B. of organic silicon compounds are provided.

Efforts have now been made to eliminate these disadvantages. For example, in the French Patent 14 21400 proposed perlite, a very light porous inorganic material, optionally mixed with particles of expanded polystyrene, with the aid of an organic Binders, such as. B. phenolic resin to be processed into moldings. The very important question of the proportions of the quantities The individual components of the mixture are treated very generally, however, in that namely preferably 70 to 97.5% by weight of the mixture of perlite (including optionally the Artificial foam particles).

According to the invention, however, a building material is now proposed which consists of

A) 5 to 60, preferably 10 to 30% by weight of a first porous inorganic material with a bulk density below 0.25, preferably below 0.15 g / cm ³ , and a grain size below 10 mm, preferably below 8 mm, and

B) a) 15 to 80, preferably 20 to 50% by weight of one

second porous inorganic material with a bulk density above 0.25, preferably above 0.50 g / cm ³ and / or

^{> 0} b) 0.5 to 10, preferably 1 to 5% by weight of one

Plastic foam with a density of about 8 to about 100, preferably 10 to 4 g / l, as well as, if applicable

C) up to 40% by weight of rubber granulate, preferably mixed with textile thread

and the organic binder.

As the first porous inorganic material with a bulk density below 0.25 g / cm ⁵ , aggregate

materials such as perlite, vermiculite, or foam glass waste Proven to be useful. As can be seen, it has been found that with smaller amounts this light, inorganic expanded material will suffice than has been the case up to now

b5 can. Because building material mixtures are made from perlite alone with an organic binder, and therefore very high perlite content for various reasons as have not proven very expedient, will - how

apparent - proposed according to the invention the combination with a second foamed aggregate.

As such an aggregate, either a second porous inorganic material with a bulk density of more than 0.25, preferably more than 0.50 g / cm ³ , such as e.g. B. pumice, expanded clay, foam cement waste od. Like., Especially if you want greater stability and fire resistance of the building material. On the other hand, granulated plastic foam can also be used as a second aggregate, especially when the demands for lighter and therefore better insulating elements are paramount. Here, however, the quantitative ratio of the additives has again proven to be particularly important.

The first lightweight porous inorganic material as an essential component for well insulating and yet relatively stable and also heat-resistant elements should not be used in an amount below about 5, it is better not to use less than 10% by weight, since otherwise these desired effects are hardly worth mentioning Dimensions can occur. On the other hand, it has been shown that light inorganic aggregates in quantities above about 60, yes in most Cases above 30% by weight lead to either the bond is insufficient, or the better properties that result from the addition of plastic foam particles and / or something heavier inorganic porous material should not be achieved are realizable. Similar conditions apply to the specified proportions of the second heavier and therefore stronger porous inorganic material. Has proven to be particularly cheap an expanded clay with a grain size between 3 and 20 mm, preferably between about 7-15 mm.

Ultimately, however, the crowd in particular has increased of the foam plastic particles proved significant, with the technical and economic effectiveness the addition of foam plastic particles for smaller amounts than 0.5, and in most cases also is no longer guaranteed even at amounts below 1% by weight of the total mixture. On the other hand takes place such a rapid decrease with additional amounts of more than 10, mostly with amounts of more than 5% by weight of such building materials generally required property level that is outside these limits Horizontal building material compositions have proven extremely inexpedient.

For example, polyurethane, preferably a rigid polyurethane foam, is used as the foam plastic Use. Polyurethane foams are chemically and thermally very resistant, so that a building material, the polyurethane foam contains, can be subjected to higher stresses without thereby the building material is destroyed. Foamed polystyrene particles will then be used if the building material is not subjected to any major thermal stress.

As mentioned, the building material can contain up to 40% by weight of rubber granulate, preferably as a further additive mixed with textile thread, e.g. B. contained in the form of crushed tires. By aggregates this Art, in particular, the sound insulation is increased, with an additional one if textile thread is present mechanical reinforcement is achieved. As an organic binder! for example latex, polyester, Phenolic resins, melamine resins, polyimides, polyurethanes or the like. In question.

A particularly advantageous embodiment of the building material according to the invention is that the ) Mixture contains 8-50% by weight, preferably 12-40% by weight, of an organic binder. A building material this composition has the advantage of higher mechanical strength, while being excellent Properties in sound insulation can be achieved κι. However, the thermal insulation is also at to address such a high proportion of the binder as good.

If the perlite is surrounded on all sides by the binder, a particularly favorable small structure is created > element, obtained so that high strengths can be obtained.

If the organic binder is in unfoamed form, the individual components of the The building material is particularly strongly bound to one another and at the same time the building material can be produced easily, since no complex devices are required.

If the organic binder is a urea-formaldehyde resin, particularly good wetting of the ) -> enables individual components, thereby creating the building material can be produced particularly easily and at the same time has high strengths.

In order to increase the mechanical strength of the building material, reinforcement inserts can be provided in the mixture, whereby fibers, preferably of an inorganic nature, are used as reinforcement inserts. B. od glass, asbestos. Like. But also fleeces, fabrics and grids have proven to be particularly suitable.

The invention is now explained below with reference to r> Examples explained in more detail.

Example 1: Perlite, polystyrene and expanded clay were mixed dry according to the recipe below, after which an intimate mixing was carried out with the resin and the hardener. This mixture was then placed in a suitable mold and heated at about _{120.degree. C. for about 2V for 2 hours.} The building material was then shaped. The determination of the resistance to fire and heat was carried out in accordance with DlN 4102 and 4108.

Wt%

Perlite 5.61 13.38

^{Γ) ()} grain size up to 6 mm

Polystyrene 1.31 0.99

Grain size 2-6 mm

Expanded clay 5.61 58.66

Grain size 7-12 mm

Urea formaldehyde resin 0.751 16.60
Water 8.54

Ammonium chloride 15 g 0.40

_b0 water 60 g 1.57

Heating time 2.5 hours

Volume weight, g / cm ^{3 0.300}

Fire resistance 150 ⁰ C

Compressive Strength, kp / cm ² 8.1

The following building materials were manufactured analogously to Example 1.

5 2.5! Ow .-% ⁰ C 0.338 Wt% 23 3 08 340 8th I. Wt% 13th 2.5 Wt% Λ - Wt% 0.536 9 ^U C 14th 2.5 Wt% 5 - Weight% 0.478 10 C. I. Wt% 15th i ° C 6th Wt% 152 11 Wt% 16 2, Wt% Examples 11.72 150 33.5 29.4 16.65 11.06 150 10.82 10.55 150 ' 28.0 9.19 150'C 25.2 11.34 2 i ° C 5.61 11.01 5.21 5.01 ll, f 11.01 5.01 4.41 10.6 11.01 5.01 4.41 10.01 5.51 0.76 Examples 4.29 2.7 2.44 1.53 2.19 2.52 1.5 Wt% 2.21 4.45 1.06 5.61 Wt% 12th 1.3 1 Wt% 3.01 2.61 2.5 1 3.01 Wt% 2.61 3.81 1.51 2.61 9.54 3.81 4.51 1.3 5 Perlite 51.78 34.3 10.40 49.22 24.4 45.68 40.38 Grain size up to 6 mm 1.31 9.11 - 5.61 41.4 55.8 5.01 48.20 4.31 43.1 1.83 4.31 42.9 50.40 Polystyrc! 21.80 3.8 0.60 1.81 5.21 23.30 2.41 2.43 5.01 25.40 1.81 5.01 29.70 1.81 5.51 Grain size 2-6 mm 5.61 3.01 38.11 1.5 1 21.42 17.8 1.121 23.70 1.131 22.1 1.51 22.2 22.80 Expanded clay 11.34 46.20 0.98 0.781 12.04 1.171 12.82 1.02 1.81 40.00 15.40 1.02 1.171 Grain size 7-12 mm 1.121 0.53 38.1 19.6 36 g 4.1 9.16 0.50 48 g 44.4 12.24 0.61 36 g 4.28 0.70 36 g 4.22 11.70 Urea- 2.12 - 0.92 30 g 26.20 150g 0.436 0.43 23 g 2.22 192 g 0.58 23 g 2.42 150 g 0.486 30.20 30 g 2.78 150 g 0.479 0.55 Formaldehyde resin Hours. 19.6 3.58 120 g 16g 1.72 91g 23.3 24 g 2.27 91g 150 31 E. 120 g 150 ⁰ C 24 g 2.15 water 23 g 0.545 0.9 1.11 _ 2.5! 13.56 64 g Hours. 1.17 94 g Hours. 124 g 15.70 - 94 g .5 hours Ammonium chloride 91g 150 ' 3.5 0.61 4.3 2.5 0.62 0.5 water 21 2.46 0.540 2.48 Heating time Examples 22 g Hours. Hours. Volume weight, g / cm ³ 7th 88 g 0.630 Fire resistance _ Compressive strength, kp / cm ² 10.01 27.5 3.01 Perlite Grain size 0-6 mm 1.201 Polyurethane hard foam granulate Grain size 5-15 mm 24 g Urea- 95 g Formaldehyde resin water Ammonium chloride water Volume weight, g / cm ³ Fire resistance Perlite Grain size up to 6 mm Polyurethane hard foam granulate Grain size 5-15 mm Expanded clay Grain size 7-12 mm Urea- Formaldehyde resin water Harder water Heating time

continuation

Examples Wt% 13th Wt% 14th Wt% 15th Wt% 16 Wt% 12th

weight

Volume weight, g / cm ³ Fire resistance Compressive strength, kp / cm ²

0.355 8.01
3944 g
0.495 7.661
3851g
0.499 7.451
4775 g
0.640 7.741
4410 g
0.570 150 ⁰ C 150 ⁰ C
8.1 150 ⁰ C
21.9 150 ° C
27.5 10.6

Examples Wt% 18th Wt% 19th Wt% 20th Wt% 21 Wt% 17th

Perlite

Grain size up to 6 mm rigid polyurethane foam granulate grain size 5-15 mm Expanded clay

Grain size 7-12 mm urea formaldehyde resin water

Harder

water

Heating time

weight

Volume weight, g / cm ³ Fire resistance Compressive strength, kp / cm ²

5.01 11.22 5.01 9.36 6.41 4.01 3.50 4.01 2.88

15.27 6.41 13.49 6.41 12.1

4.51 44.90 4.51 37.10 5.51 58.40 5.51 51.34 5.51 46.0

1.171 24.6 12.82

2.5 hours

6.851

3919g

0.577

150 ⁰ C

10

1.81

31.40 0.721 16.10 1.081 21.40 1.44 1 25.5

16.20

8.34

11.05

24 g 0.59 31g 6.64 15 g 0.40 22 g 0.52 29 g 94 g 2.36 124 g 2.52 58 g 1.53 87 g

2.5 hours 7.251 4631 g 0.639 150 ⁰ C resin outflow

2.5 hours

7.451

3608 g

0.485

150 ° C

8.7

2.31 116 g 2.43 2.5 hours 2.5 hours 7.151 7.451 3884 g 4219 g 0.542 0.566 150 ⁰ C 150 ° C 11.9 19.9

Examples Wt% 23 Wt% 24 Wt% 22nd

Perlite 8.01

Grain size up to 6 mm

Expanded clay 4.01

Grain size 7-15 mm

Urea formaldehyde resin 1.081

water

Hardener 22 g

Water 87 g

Heating time

Volume weight, g / cm ³ fire resistance

18.6 9.01 23.2 9.01 20.3 41.8 3.01 34.2 3.01 30.0 24.0 1.081 26.1 1.441 30.5 12.32 13.4 15.5 0.57 22 g 0.63 29 g 0.75 2.81 87 g 2.47 116g 2.92 2.5 hours 2.5 hours 2.5 hours 3331g 3541g 3715g 0.443 0.503 0.489 over 150'C over 150-C over 150'C 809 513/217

9 Wt% 26th Wt% 10 Wt% Examples 25th 27

Perlite 12.01 1086g 48.32 12.01 1086g 34.28 12.01 1086g 26.2 Grain size up to 6 mm

Polystyrene 1.41 35 g 1.66 1.41 35 g 1.14 1.41 35 g 1.97 Grain size 2-6 mm

Urea 0.821 695 g 30.80 1.481 1256 g 39.60 2.16.1 1930 g 44.2 Formaldehyde resin

Water 355 g 15.84 646 g 20.20 940 g 22.7

Hardener 17 g 17 g 0.80 30 g 30 g 0.95 43 g 43 g 1.06

Water 66 g 66 g 2.55 118 g 118 g 3.73 172 g 172 g 4.34

Heating time 2.5 hours 2.5 hours 2.5 hours

Volume weight, g / cm ³ 0.222 0.390 0.434

Compressive Strength, kg / cm ² 12.5 18.8

Fire resistance 120C 150 "C

Examples Wt% 29 Wt% 30th Wt% 28

31.58

2.19

40.60

Perlite 10.81

Grain size up to 6 mm

Polystyrene 2.71

Grain size 2-6 mm

Urea 1.481

Formaldehyde resin

water

Hardener 30 g

Water 118 g

Heating time

Volume weight, g / cm ³

Compressive strength, kp / cm ²

Fire resistance

The building materials according to the invention have a particularly high frost resistance. All the above mentioned materials were subjected to the following test: The so-building material was immersed in water, and after a complete wetting has occurred, away from the water and stored for 3 days at -20 ^0C. The building material was then quickly ^{heated to 60 °} C. and dried. The mechanical properties corresponded to those of the components that were not subjected to a frost test

9.51
4.11
1.481

28.51

3.42

41.60

9.51 4.11 2.161

21.68

2.63

46.40

20.90 30 g 21.31 43 g 23.90 0.96 120 g 1.41 172 g 1.69 3.81 3.90 4.34 2.5 hours 2.5 hours 2.5 hours 6.821 6,981 7.651 0.417 0.382 0.412 18th 16 17th 150 ^{above sea level} 150 "C 150-C

were subjected.

Despite the high frost resistance, however, it may be desirable at the same time or after manufacture of the building material this with an outer layer, z. B. made of hard PVC or plaster, for example with an organic binder such as melamine resin, polyvinyl alcohol, phenolic resin, polyester or the like.

Claims (7)

Patent claims: 1. Building material made of porous inorganic material and possibly plastic foam, both in lumpy form, which with an organic binder, in particular urea-formaldehyde resin, are held together, characterized in that the mixture of A) 5 to 60, preferably 10 to 30% by weight of a first porous inorganic material, such as perlite, vermiculite, foam glass waste, with a bulk density below 0.25, preferably below 0.15 g / cm ³ , and a grain size below 10 mm, preferably less than 8 mm, and B) a) 15 to 80, preferably 20 to 50% by weight a second porous inorganic material, such as pumice, expanded clay, foam cement waste, with a bulk density of more than 0.25, preferably more than 0.50 g / cm ^J and / or b) 0.5 to 5, preferably 1 to 5% by weight of a plastic foam with a volume weight from about 8 to about 100, preferably from 10 to 4-0 g / l, and optionally C) up to 40 wt .-% rubber granulate, preferably mixed with textile thread and the organic binder. 2. Building material according to claim 1, characterized in that the foamed plastic is polyurethane foam, is preferably rigid polyurethane foam. 3. Building material according to claim 1 or 2, characterized in that the second inorganic material Expanded clay with a grain size of over 2 minutes, preferably between 7 and 15 mm, is provided 4. Building material according to one of claims 1 to 3, characterized in that the mixture is 8-50 Contains% by weight, preferably 12-40% by weight, of an organic binder. 5. Building material according to one of claims 1 -4, characterized in that the perlite on all sides Binder is surrounded. 6. Building material according to one of claims 1 -5, characterized in that the organic binder is in unfoamed form 7. Building material according to one of claims 1 -6, characterized in that reinforcement inserts in the mixture are embedded.