WO2010043511A1 - Binder composition which can be foamed and use thereof - Google Patents

Abstract

The invention relates to a dry building material mixture which can be foamed under the influence of water and which is suitable particularly for producing a building material foam which can be cured, wherein the dry building material mixture contains (a) at least one calcium aluminate cement, (b) at least one solid oxygen carrier which releases gaseous oxygen under the influence of water, and (c) at least one catalyst which activates and/or accelerates the release of oxygen from the oxygen carrier and which is selected from transition metals and tetraacetylethylenediamine.

Description

 Foamable binder composition and its use

The present invention relates to the field of foamable, especially under the influence of water automatically foaming binder-containing Baustofftrockenmischungen.

In particular, the present invention relates to a self-foaming dry product ("dry mix product"), in particular a frothable building material dry mixture or binder composition, which is particularly suitable for producing a curable building material foam, in particular cement foam, and its use.

Furthermore, the present invention also relates to the building material foam obtainable from the foamable building material dry mixture or binder composition according to the present invention by the action of water or mixing with water, and to the use thereof.

Cement foam products known from the prior art are either produced by the action of pressure and / or temperature, in particular in an autoclave, or they require the addition of liquid and thus not readily manageable and storable hydrogen peroxide solutions, as below executed.

By contrast, the polyurethane-based foams known from the prior art are toxicologically problematic, in particular because of their monomers, in particular methylene diphenyl diisocyanate (MDI). Also for fire protection considerations, they do not always meet the existing requirements when they are used.

Self-leveling masses, on the other hand, can compensate for unevenness of up to a few centimeters (for example, up to approx. 4 cm), but have disadvantages, for example due to their mass. For example, they lead to an excessively high ceiling load in the context of old building renovation in particular, and are often unacceptable there.

In the context of so-called Wärmed_ämmyerbundsystemen (ETICS), synonymously also referred to as E-TICS or E_xternal Thermal Isolation Composite Systems, plate-shaped materials with up to 70% polystyrene are nowadays used in particular. This polystyrene however, they are very voluminous, which is disadvantageous during transport and storage, mechanically unstable and not available in unusual shapes (eg bent).

JP 2006-027937 A describes cement compositions as cementing or grouting compositions, in particular for application to soils, the cement compositions described therein containing not only a binder but also sulfate-based setting accelerators and polyether-based water reducers and coagulation stabilizers based on organic acids. In the case of cementitious systems, moreover, a gas-forming substance may be present.

EP 0 485 814 A1 relates to a dry mortar for an increased pore content, wherein the dry substance is a peroxo compound with 0.1 to 2.0 wt .-%, preferably 0.3 to 0.8 wt .-%, is added, the oxygen cleavage is triggered immediately after the addition of water or steam, wherein the peroxy compound may be a metal peroxide, a carbamide peroxide, a persulfate, a peroxyacetic acid or a percarbonate.

GB-PS 363 192 and GB-PS 399 367 relate to methods for producing porous masses using liquid hydrogen peroxide together with manganese compounds as activators, such as. For example, manganese dioxide or manganese sulfate.

Furthermore, US Pat. No. 6,786,966 B1 relates to pulverulent ash compositions as portland cement substitute for improving cement products.

Finally, US Pat. No. 6,162,839 A describes compositions for producing a light plaster based on a gypsum foam.

The present invention is therefore based on the object to provide a foamable under the action of water Baustofftrockenmischung or binder composition, which are particularly suitable for producing a thermosetting building material foam and the disadvantages of the prior art previously described at least largely avoid or at least mitigate.

In order to solve the above-described problem, the present invention proposes a building material dry mixture or binder composition that can be foamed under the action of water. according to claim 1 before; Further, advantageous embodiments are the subject of the relevant subclaims.

Another object of the present invention is the use of the building material dry mixture according to the invention for producing a curable building material foam.

Furthermore, the subject of the present invention is a building material foam ("binder foam" or "cement foam"), as it is obtainable by exposure to water or with water with respect to a building material dry mixture according to the present invention.

It goes without saying that hereinafter statements which are made to avoid unnecessary repetition only to a single aspect of the invention or object of the present invention, also apply to the other aspects of the invention or articles, without this requiring a separate mention.

Furthermore, it goes without saying that in the context of the present invention, all quantities and quantity ranges listed below are not restrictive. Rather, if necessary, the person skilled in the art will be able to deviate from the quantity ranges and quantities given below, depending on the application or on a case-by-case basis, without departing from the scope of the present invention.

It should also be noted that in the case of the following percentages, in particular weight percentages, this information or the relevant components or ingredients are to be combined in such a way that the sum of all percentages always equals 100%.

The subject matter of the present invention is therefore a building material dry mixture or binder composition which is foamable under the action of water (that is, a self-foaming under chemical reaction), which is particularly suitable for producing a hardenable building material foam, the building material dry mixture

(a) at least one inorganic binder selected from calcium aluminate cements,

together (B) with at least one solid, under the action of water gaseous oxygen releasing oxygen carrier and

(c) with at least one catalyst which activates and / or accelerates the release of oxygen from the oxygen carrier, selected from transition metals and tetraacetylethylenediamine (TAED),

contains.

There are a number of advantages associated with the present invention, some of which are listed below, by way of non-limiting example, without, however, being exhaustive:

Thus, the building material dry mixtures according to the invention and the building material foams available therefrom are not flammable and therefore completely harmless in terms of fire protection, so that they are superior to the polyurethane foams known from the prior art.

In particular, the building material dry mixtures according to the invention and the building material foams which can be produced therefrom are also completely harmless in terms of toxicology.

Furthermore, starting from the building material dry mixtures according to the invention, it is readily possible to produce curable building material foams by the action of water. The production can be carried out easily on site, in particular, no special devices are needed for this. For example, a complicated production under the action of pressure and / or temperature in an autoclave is avoided in an efficient manner. The use of sometimes difficult to handle and storage-stable hydrogen peroxide solutions is avoided.

With the building material foams available starting from the building material dry mixtures according to the invention, any shapes can be foamed with suitable shuttering. For example, extraordinary shapes can also be obtained. These building material foams have a sufficient mechanical stability, but show sufficient flexibility, ie no embrittlement. By producing the building material foam directly on site, a complex transport and a complex storage are avoided.

Compared with conventional mortar products, the building material foams obtainable from the building material dry mixtures according to the invention have a significantly lower density, which predestines them, for example, for use in old building renovation as self-leveling ground leveling compounds, since they do not lead to excessive ceiling loads.

Furthermore, the building material foams obtainable from the building material dry mixtures according to the invention have a high mechanical stability coupled with good flexibility and good adhesion.

Furthermore, a good shelf life is achieved by the exclusive use of solid components. In addition, the product according to the invention can hereby be provided as ready-to-use one-component dry mix (1 K dry mix) in which all constituents are already present in a coordinated and correct dosage, so that possible mixing errors are efficiently ruled out.

Further advantages of the present invention will be readily apparent to those skilled in the art upon reading the following description, and thus the foregoing performance of the advantages of the present invention is not exhaustive.

The term building materials, as used in the context of the present invention, is to be understood very comprehensively and refers in particular to a collective name for all building materials, mostly inorganic materials. For further details on the concept of building materials can be referenced, for example, Römpp Chemielexikon, 10th edition, Georg Thieme Verlag, Stuttgart / New York, 1996, Volume 1, page 370, keyword: "building materials", as well as the literature reviewed there.

In general, the building material dry mixture according to the invention is formed in powder form.

In particular, it is preferred if all constituents of the building material dry mixture according to the invention, in particular components (a), (b) and (c) and optionally also further ingredients, are in particulate form. It is particularly preferred that at least 90% by weight, in particular at least 95% by weight, preferably at least

99 wt .-%, the particles of the building material dry mixture particle sizes below 1,000 microns, especially below 750 microns, preferably below 500 microns have.

Usually, the building material dry mixture according to the invention has a bulk density in the range of 450 to 1200 g / cm ³ , in particular 500 to 1000 g / cm ³ , on.

As stated above, the building material dry mixture according to the invention contains as component (a) an inorganic binder selected from calcium aluminate cements. Of course, the inorganic binder may also contain mixtures of different calcium aluminate cements and / or other inorganic binders in addition to the calcium aluminate cements. Within the scope of the present invention, the term "binder" is to be understood very comprehensively, this term in the context of the present invention referring in particular to hydraulic, latent-hydraulic and pozzolanic binders and mixtures thereof. Such binders that cure only in air (so-called "air binder", such as gypsum, Sorelzement, anhydrite, magnesia binder, whitewash, etc.) are non-hydraulic binder, while hydraulic lime and cements are referred to as hydraulic binders, which set even under water , If this setting only takes place by the action of additives or exciters, then one speaks of latent hydraulic binders, as in the case of blast furnace slags.

If the inorganic binder (a) contains at least one further inorganic binder in addition to at least one calcium aluminate cement, the latter is preferably selected from hydraulic, latent hydraulic and pozzolanic binders and mixtures thereof, in particular hydraulic binders, preferably cements, more preferably from the group of calcium sulfoaluminate cements, Portland cements, Portland composites, blast furnace cements and mixtures thereof.

According to a particular embodiment of the present invention, the inorganic binder (a) used may be a mixture of calcium aluminate cement, such as alumina cement, with Portland cement and / or Portland composite cement. This results in foaming under the action of water with subsequent curing of the resulting foam to particularly good results. As regards the term used in the context of the present invention, the term cements, this term is used extensively in the context of the present invention and refers in particular finely ground hydraulic binders, ie those mineral substances that harden underwater uptake in air and even under water stone-like and after Curing water resistant. Cements consist predominantly of calcium silicates, calcium aluminates and calcium ferrites, ie of CaO with SiO ₂ , AIO ₂ and / or Fe ₂ O ₃ in different proportions, which during "burning" of the raw materials (eg limestone, clay, limestone marl , Tonmergel etc.) at temperatures up to about 1,500 ⁰ C in clinker arise. The essential properties of the cements depend on the composition of the raw materials, the proportion of the components to be ground and the fineness of the grinding. The designation of the cements is generally in accordance with DIN 1 164-1: 1994-10. Then the types of cement can be subdivided into three main types, namely Portland cement or CEM I, Portland composite cement or CEM II and blast furnace cement or CEM III.

The amount of inorganic binder (a) in the building material dry mixture according to the invention can vary within wide ranges. In general, the building material dry mixture according to the invention contains the inorganic binder (s) (a) in amounts of 20 to 98 wt .-%, in particular 30 to 95 wt .-%, preferably 50 to 90 wt .-%, based on the building material dry mixture. Nevertheless, it may be necessary on a case-by-case or application-related basis to deviate from the abovementioned values without departing from the scope of the present invention.

As regards component (b), this is a solid, under the action of water gaseous oxygen releasing oxygen carrier. The term "solid" refers to the fact that the oxygen carrier (b) under normal conditions, ie under normal conditions (temperatures of 20 ⁰ C and atmospheric pressure (1013 hPa)) in the solid state, which the handling compared to the state of the Technically known systems with liquid hydrogen peroxide significantly simplified and also contributes to increased shelf life, even a shelf life in the dry state and as a 1 K system in the first place.

Usually, the oxygen carrier (b) is designed such that it liberates the gaseous oxygen under alkaline conditions, in particular at pH values above 7. In general, the release of the gaseous oxygen takes place with decomposition of the oxygen carrier (b).

In accordance with the invention preferably the oxygen carrier (b) is selected from the group of percarbonates, perborates and persulfates and mixtures thereof, preferably percarbonates, in particular alkali and / or Erdalkalipercarbonaten. Particularly preferred according to the invention is sodium percarbonate.

The amount of oxygen carrier (s) (b) in the building material dry mixture according to the invention can vary within wide ranges. In general, the building material dry mixture according to the invention contains the oxygen carrier (b) in amounts of from 0.1 to 20% by weight, in particular from 0.5 to 10% by weight, preferably from 2.5 to 9% by weight, more preferably 3, 5 to 8.5 wt .-%, most preferably 3 to 8 wt .-%, based on the building material dry mixture.

Preferably, the oxygen carrier (b) is present wholly or partly in coated ("coated") or encapsulated form, preferably based on a water-soluble coating ("coating") or encapsulation. In other words, according to this particular embodiment of the present invention, the particles forming the component (b) are wholly or partly provided with a coating or encapsulation which is in particular water-soluble. This embodiment has the particular advantage that on the one hand premature reaction or gas release is prevented and on the other hand, the storage stability is increased as a result of preventing premature decomposition of the oxygen carrier. Furthermore, the coating or the encapsulation of the oxygen carrier (b) results in a release of the gas or oxygen and thus foaming in a controlled manner when mixed with water; This achieves a particularly good controllable foaming. For the latter effect, it may be advantageous to coat or encapsulate only a portion of the particles forming component (b).

As far as the coating or encapsulation of component (b) is concerned, it is usually water-soluble, so that upon exposure to water after dissolution of the coating or encapsulation, the oxygen carrier (b) can release oxygen gas, usually with decomposition. The coating or encapsulation may consist of a water-soluble inorganic material, in particular salt. It has proven particularly useful in the context of the present invention if the material forming the coating or the encapsulation Alkali or alkaline earth sulfates, silicates, borates or carbonates, or mixtures of or consisting of at least two of these compounds. Particularly good results are obtained on the basis of coatings of at least two of the abovementioned materials, very particularly preferably in the case of coatings based on a combination of sodium silicate and sodium borate.

It can be provided that the material forming the coating or the encapsulation contains or consists of the catalyst (c); This has the advantage that no separate, spatially separated catalyst component is required and the catalyst is already present directly at the site of action. It is also possible to incorporate only a portion of the total amount of catalyst used in the coating or encapsulation and add the remaining amount of catalyst to the mixture.

The oxygen carrier (b), d. H. the particles forming component (b) may be in bimodal particle size distribution. The use of particles of component (b) with bimodal particle size distribution has the particular advantage that uses a time-prolonged and generally more controllable foam formation, which can be explained by first the finely divided oxygen carrier (b) are decomposed under oxygen gas formation, while the coarse-grained particles are only offset in time or later decomposed to this. According to this particular embodiment, the oxygen carrier (b) or the component (b) forming particles on the one hand a fine-grained fraction having an average particle size, in particular determined as D50 value, in the range of 0.05 to 20 microns, preferably 0.15 to 15 microns, and on the other hand, a coarse fraction having an average particle size, in particular determined as D50 value, in the range of 10 to 1500 microns, preferably 80 to 500 microns; The weight-related ratio of fine-grained fraction to coarse-grained fraction may vary within the range from 95: 5 to 5:95, in particular from 80:20 to 20:80, particularly preferably from 70:30 to 30:70.

The building material dry mixture according to the invention comprises at least one catalyst or activator (c) activating and / or accelerating the release of oxygen from the oxygen carrier (b), selected from transition metals and tetraacetylethylenediamine (TAED). The content of catalyst (c) in the building material dry mixture according to the invention can vary within wide ranges; In general, the building material dry mixture contains the catalyst (c) in amounts of 0.02 to 15 wt .-%, in particular 0.6 to 13 wt .-%, preferably 1, 75 to 11 wt .-%, particularly preferably 2.5 to 8 wt .-%, based on the building material dry mixture.

What component (c), d. H. As far as the catalyst is concerned, particularly good results are obtained when mixtures or combinations of at least one transition metal with TAED or else mixtures or combinations of at least two different transition metals, optionally together with TAED, are used.

For the purposes of the present invention, transition metal is to be understood as meaning the transition metal as such, for example as a corresponding metal powder, but preferably the transition metal in the form of its compounds and / or salts. Amounts of amounts of transition metal, unless otherwise indicated, are to be understood as referring to the transition metal as such, even if transition metal compounds and / or transition metal salts are used.

The use of TAED in combination with transition metal (s) as common catalysts has the advantage that the content of transition metals in the building material dry mixture according to the invention can be reduced, and secondly that TAED on the one hand and transition metal (s) on the other hand the decomposition reaction of the oxygen carrier (b) catalyze different degrees or fast, so that a more controllable and / or time-prolonged, in particular more uniform, foaming is achieved.

Preferably, the catalyst (c) is selected from the transition metals iron and / or manganese, preferably in the form of Fe (II), Mn (II) and Mn (IV), more preferably as manganese or iron salts, and / or TAED and Mixtures or combinations of these transition metals optionally together with TAED or else mixtures or combinations of at least one of these transition metals with TAED. Examples of particularly suitable iron and manganese compounds according to the invention are MnO ^" ₂ , MnSO ₄ , MnCO ^" 3, MnC ^ and / or FeSO ₄ and mixtures thereof, optionally together with TAED.

In the event that a combination of TAED with at least one transition metal, in particular iron and / or manganese, is used as catalyst (c), the dry building material mixture generally contains TAED in amounts of from 0.01 to 10% by weight, in particular 0 , 5 to 9 wt .-%, preferably 1, 5 to 8 wt .-%, particularly preferably 2 to 6 wt .-%, based on the dry building material mixture, and the transition metal, in particular iron and / or manganese, preferably in the form of Fe (II), Mn (II) and Mn (IV), in amounts of 0.01 to 5 wt .-%, in particular 0, 1 to 4 wt .-%, preferably 0.25 to 3 wt .-%, particularly preferably 0.5 to 2 wt .-%, based on the building material dry mixture and calculated as the transition metal. TAED and transition metal are preferably used in a weight ratio of TAED / transition metal in the range of 500: 1 to 1:10, in particular 200: 1 to 1: 1, preferably 100: 1 to 1: 1, particularly preferably 50: 1 to 1: 1, used.

Furthermore, it can be provided that the building material dry mixture according to the invention contains further ingredients and / or additives or additives. Such ingredients and / or additives or additives may be selected in particular from the group of plasticizers, rheology modifiers, retarders, accelerators, stabilizers, stabilizers, surfactants, sealants, swelling agents and fillers and mixtures of two or more of these compounds.

According to a particularly advantageous embodiment of the present invention, the building material dry mixture according to the invention may contain a redispersible powder, in particular a redispersion powder based on at least one organic polymer, preferably an ethylene vinyl acetate-based redispersion powder. The amount of redispersible powder can vary within wide limits; In general, the redispersion powder is used in amounts of from 0.01 to 8% by weight, preferably from 2 to 7% by weight, particularly preferably from 2.5 to 5% by weight, based on the building material dry mixture. The use of a redispersion powder in particular has the advantage that the flexibility and adhesion of the building material foam obtainable under the action of water increases and its brittleness is correspondingly reduced.

Furthermore, it can be provided that the building material dry mixture according to the invention contains at least one cellulose derivative, in particular at least one cellulose ether. Usually, the building material dry mixture according to the invention contains the cellulose derivative in amounts of 0.01 to 5 wt .-%, preferably 0.1 to 2 wt .-%, particularly preferably 0.3 to 1, 5 wt .-%, based on the building material dry mixture. The use of cellulose derivatives is of particular advantage in terms of water retention capacity. Furthermore, it may be advantageous according to the invention if the building material dry mixture according to the invention contains at least one setting accelerator, preferably Li ₂ CO ₂ . The amount of setting accelerators can vary widely; In general, the building material dry mixture according to the invention contains the setting accelerator in amounts of 0.01 to 5 wt .-%, in particular 0.05 to 3 wt .-%, particularly preferably 0.1 to 2 wt .-%, based on the building material dry mixture. Setting accelerators used according to the invention may be selected, in particular, from the group of alkali metal and / or alkaline earth metal carbonates, nitrates, nitrites, formates, aluminates, basic sulfates, silicates, hydroxides and oxides and also their mixtures and / or combinations. Particularly preferred according to the invention is Li ₂ CO ₃ . The use of the abovementioned setting accelerators leads to an early hardening and solidification of the building material foams obtainable after exposure to water.

Furthermore, it can be advantageous for positively influencing the properties, in particular the mechanical properties, of the building material foams obtainable by the action of water, if the building material dry mixture according to the invention contains at least one filler. As a result, in particular the mechanical properties of the resulting building material foams can be improved. Fillers which are suitable according to the invention can be selected from the group of flyashes, sands (for example quartz sands or granulated slags), silicon dioxide (for example microsilica), hollow glass spheres, fibers (for example mineral fibers, plastic fibers, steel fibers etc.), perlites, vermiculites, expanded clay and mixtures of two or more of the aforementioned fillers. The total amount of filler can vary within wide ranges; In general, the total amount of filler, based on the building material dry mixture, 0.01 to 60 wt .-%, in particular 5 to 55 wt .-%, particularly preferably 10 to 50 wt .-%.

Furthermore, it may be advantageous if the building material dry mixture according to the invention contains gypsum. The amount of gypsum can vary within wide ranges; In general, the amount of gypsum, based on the building material dry mixture, 0.01 to 10 wt .-%, preferably 0.5 to 5 wt .-%, particularly preferably 0.75 to 3 wt .-%.

Furthermore, there is the possibility of incorporation of a swelling agent, preferably polyacrylamide (PAA), in particular in amounts of 0.01 to 5 wt .-%, preferably 0.5 to 3 wt .-%, particularly preferably 0.5 to 2 wt. -%, based on the building material dry mixture. In principle, the building material dry mixture according to the invention can be formulated either as a 1K system or as a 2K system. Preferably, the building material dry mixture according to the invention is formulated as a 1 K system, ie all constituents are present within a single ready-to-use mixture. For the inventively less preferred case of formulation as a 2K system, it may be provided that either inorganic binder (a) on the one hand and oxygen carrier (b) on the other hand in separate components or that oxygen carrier (b) on the one hand and catalyst (c) on the other hand in separate components are present.

Similarly, it may be provided according to the invention to introduce the building material dry mixture according to the invention in a container suitable for foaming, which - spatially separated from the building material dry mixture - equally contains water, directly in the application, the water can then be brought into contact with the building material dry mixture according to the invention. Such an embodiment may be provided in particular when only relatively small amounts of building material foam to be produced starting from the building material dry mixture according to the invention, for. For home improvement applications.

Another object of the present invention is the use of the building material dry mixture according to the invention for producing a curable building material foam (synonymously also referred to as "binder foam" or "cement foam"). In other words, the present invention according to this aspect of the invention relates to a method for producing a building material foam.

For this purpose, the above-described building material dry mixture according to the present invention is mixed with water or offset. The amount of water can vary within wide ranges; In particular, the mixing water can be used in amounts such that the volume ratio of building material dry mixture / H ₂ O in the range from 2: 1 to 1: 1, in particular 5: 1 to 1: 1, preferably 4: 1 to 1, 5: 1, 1 varies.

According to the invention, preference is given in this aspect of the invention to the water / binder value or water / cement value (w / c value) in the range from 0.2 to 0.9, in particular 0.35 to 0.85, preferably 0.4 to 0.8, is set. After mixing with or the action of water, the building material foam is usually allowed to cure. The result is a cured building material foam having a density usually in the range of 200 to 800 g / l, in particular 250 to 750 g / l, more preferably 250 to 450 g / l, which is associated with the above-mentioned advantages.

For further details of this aspect of the invention, reference may be made to the above statements concerning the building material dry mixture according to the invention, which apply correspondingly in relation to this aspect of the invention.

Yet another subject of the present invention is a building material foam, in particular a cured building material foam, which is obtainable by the action of water on the above-described building material dry mixture according to the present invention, in particular with subsequent curing. For further details on this aspect of the invention, reference may be made to the above statements regarding the other two aspects of the invention, which apply correspondingly in relation to this aspect of the invention.

The building material dry mixtures according to the invention and the building material foams obtainable therefrom can be used in many ways.

Thus, the building material dry mixture according to the invention or the building material foam available therefrom can be used to foam cavities in an efficient manner and mechanically stable and in particular fire-resistant. For example, the building material dry mixture or the building material foam obtainable therefrom can be used to replace or substitute polyurethane foams of the prior art.

Furthermore, the building material dry mixture or the building material foam obtainable therefrom can be used for purposes of fire protection (eg for filling or foaming cable ducts, fire doors, fire protection door frames, etc.).

Furthermore, the building material dry mixture according to the invention or the building material foam obtainable therefrom can also be used as floor covering compound, in particular to compensate for unevenness units. Furthermore, the building material dry mixture according to the invention or the building material foam obtainable therefrom can also be used as plaster (eg exterior plaster, adhesive plaster, thermal insulation plaster, etc.) or as a spray mortar.

Likewise, the building material dry mixture according to the invention or the building material foam obtainable therefrom can also be used for purposes of insulation, in particular thermal insulation.

Furthermore, it is possible to use the building material dry mixture according to the invention or the building material foam available therefrom for the production of components, in particular thermally insulated components, such. B. for stones, such as bricks, masonry, walls or the like.

It is also possible to use the building material dry mixture or the building material foam obtainable therefrom not for the production of complete components, but for the production of large components, in particular masonry and walls, smaller units, such as bricks, bricks or the like, using the Baustoffftrockenmischung or the invention From this building material foam available to connect with each other, in particular to glue.

Finally, it is possible to use the building material dry mixture according to the invention or the building material foam obtainable therefrom as filling foam, in particular for windows, doors, door frames or the like.

The present invention thus efficiently provides an easily handled, generally storable building material dry mixture, which is foamable under the action of water and thus suitable for producing a curable building material foam.

Due to the simple handling and the preparation without further aids simple handling and direct production on site is readily possible.

As a result of their versatility or the building material dry mixture according to the invention or the building material foam available therefrom offers universal applications, as described above. Further embodiments, refinements, modifications and variations of the present invention will be readily apparent to and realizable by those skilled in the art upon reading the present application without departing from the scope of the present invention.

The present invention will be illustrated by the following embodiments, which by no means limit the present invention.

WORKING EXAMPLES

Embodiments Part I:

Example 1: Preparation of dry-mix mixtures of the following composition (in% by weight)

Subsequently, various building material dry mixtures "Mix 1" to "Mix 5" are produced. The ingredients of the mixtures are weighed in each case and homogenized for 15 minutes in a tumble mixer. Mix 1 and Mix 2 are building material dry mixes according to the present invention. Mix 3 to Mix 5 are for comparison purposes.

Example 2 Foaming Behavior of the Mixtures from Example 1

50 g of the mixtures from Example 1 are mixed with 25 g of water in the beaker and carefully homogenized.

The results show that only building material dry mixtures containing as inorganic binder calcium aluminate cement and also a catalyst to be used according to the invention (Mix 1 and Mix 2), when mixed with water have a high volume increase and at the same time good stability of the resulting building material foam. If the addition of the catalyst is omitted (Mix 3) or used as an inorganic binder instead of calcium aluminate cement Portland limestone cement / Portlandkompositzement (Mix 4 and Mix 5), the volume increase, ie the foaming, significantly lower or can only get unstable building material foams. Example 3 Use of Fillers in the Production of the Powder Mixtures (Data in% by Weight)

Used fillers:

Mix 6: fly ash (EFA filler)

Mix 7: sand (quartz sand H33)

Mix 8: sand (quartz sand BSC 412)

Mix 9: hollow glass spheres (Omega-Sil M20)

Mix 10: hollow glass spheres (Poraver 0,25-0,5 mm)

The mixtures are weighed and homogenized for 15 minutes in a tumble mixer.

Example 4 Foaming Behavior of the Mixtures from Example 3

50 g of the mixtures from Example 3 are mixed with 25 g of water in the beaker and carefully homogenized.

Exemplary embodiments Part II: Overview

I. Foaming with liquid H ₂ O ₂ (prior art)

II. Foamable mixture as dry mortar (sodium percarbonate as foaming agent)

III. Foamable dry mortar with percarbonates and activator (s)

III. a) Percarbonate and TAED as activator

III. b) percarbonate and MnO ₂ as activator

III. c) percarbonate and TAED and MnO ₂ as activator (combination)

Foamable mixtures with further activators and combinations

III. d) Percarbonate, Mn (II) compounds and / or TAED as activator

III. e) Percarbonate, Fe (II) compounds and / or TAED as activator

III. f) percarbonate (coated), Mn and Fe compound (s) and / or TAED activator

IV. Storage stabilities of the foamable dry mortar

IV. A) Use of uncoated (uncoated) percarbonates IV. B) Use of coated (coated) percarbonates

V. Use of different fillers I. Foaming with liquid H ₂ O ₂ (prior art)

Example 1 (comparison)

w/z = Wasser/Zement AB-Mix 1

w / z = water / cement AB mix 1

w / z = 0.4

Experiment 1: 25 g AB mix 1 + 9.25 g H ₂ O + 0.75 g H ₂ O ₂

Experiment 2: 25 g AB mix 1 + 1 O g H ₂ O in both mixtures no foaming formation of solidification after about 5 min.

w / z = 1

Experiment 1: 25 g AB mix 1 + 23.5 g H ₂ O + 1, 5 g H ₂ O ₂ slight foaming

Height: approx. 0.5 cm

AB mix 2

w / z = 0.4

Experiment 1: 25 g AB mix 2 + 9.25 g H ₂ O + 0.75 g H ₂ O ₂

Experiment 2: 25 g AB mix 2 + 1 O g H ₂ O in both mixtures no foaming

Start of solidification:> 5 hrs.

w / z = 1

Experiment 1: 25 g AB mixture 2 + 23.5 g H ₂ O + 1, 5 g H ₂ O ₂ creeping foam formation foam height: 1 cm (after about 2 hours)

AB mix 3

w / z = 0.4

Experiment 1: 25 g AB mix 3 + 9.25 g H ₂ O + 0.75 g H ₂ O ₂

Experiment 2: 25 g AB mix 3 + 1 O g H ₂ O in both mixtures no foaming Experiment 1: start of solidification> 60 min. - Experiment 2: start of solidification <5 min. w / z = 0.8

Experiment 1: 75 g AB mix 3 + 57 g H ₂ O + 4.5 g H ₂ O ₂ creeping foaming approx. 5 hours 80% volume increase after solidification stable and firm

w / z = 1

Experiment 1: 75 g AB mix 3 + 70.5 g H ₂ O + 4.5 g H ₂ O ₂ creeping foaming approx. 5 hours 80% volume increase after solidification stable and firm

AB mix 4

w / z = 0.4

Experiment 1: 25 g AB mix 4 + 9.25 g H ₂ O + 0.75 g H ₂ O ₂

Experiment 2: 25 g AB mix 4 + 10 g H ₂ O no foaming

Solidification while stirring

Heat development after mixing

w / z = 0.8

Experiment 1: 25 g AB mix 4 + 18.5 g H ₂ O + 1, 5 g H ₂ O ₂ slight foaming fast solidification

Heat development after mixing weak strength AB mix 6

w / z = 1

Experiment 1: 25 g AB mix 6 + 23.5 g H ₂ O + 1, 5 g H ₂ O ₂ slight foaming

Foam height 1 cm

Solidification beginning after approx. 2 min. - evolution of heat after mixing (35 ^° C.)

AB Mix 6a

w / z = 1

Experiment 1: 25g AB-Mix 6a + 23.5g H ₂ O + 1, 5g H ₂ O ₂ slight foaming

Foam height 1 cm

Solidification beginning after approx. 5 min. slight heat development after mixing

AB Mix 6b

w / z = 1

Experiment 1: 25 g AB mix 6b + 23.5 g H ₂ O + 1, 5 g H ₂ O ₂ slight foaming

Foam height 1 cm

Solidification beginning after approx. 5 min. slight heat development after mixing

Foamable mixture as dry mortar (sodium percarbonate as foaming agent): Example 2 (comparison)

w/z = Wasser/Zement

w / z = water / cement

AB-Mix 3b

w / z = 0.8

Experiment 1: 25 g AB mix 3b + 20 g H ₂ O no foaming

Solidification during stirring - Heat development after mixing

The sodium percarbonate can not be sufficiently activated by the formulation. However, there is an accelerated solidification. Foamable dry mortar with percarbonates and activator (s)

a) Percarbonate and TAED as activator

Example 3

w/z = Wasser/Zement

w / z = water / cement

AB Mix 19a_1

Trial 1: with w / z = 0.5

Foaming with about 200% volume increase, which partially collapses after about 1 hour.

AB Mix 19a_3

Trial 1: with w / z = 0.5 Foaming with about 150% volume increase within 30 min. slight foam shrinkage on hardening.

AB mix 22a_1

Experiment 1: with w / z = 0.8

Foaming with approx. 320% volume increase within 35 min.

- Density: 250 g / l

AB mix 22a_2

Experiment 1: with w / z = 0.6

Foaming with approx. 300% volume increase within 35 min.

- Density 270 g / l

AB mix 22a_3

Trial 1: with w / z = 0.5

Foaming with approx. 300% volume increase within 25 min. Mechanically stable

The comparative compositions without calcium aluminate cement (AB mix 19a_1 and AB mix 19a_3) show significantly less foaming than the inventive building material dry mixtures AB mix 22a_1, AB mix 22a_2 and AB mix 22a_3.

IN THE. b) percarbonate and MnO ₂ as activator Example 4

w/z = Wasser/Zement

w / z = water / cement

AB Mix 19b_1

Trial 1: with w / z = 0.5

Foaming with about 160% volume increase within 25 min.

AB Mix 19b_3

Trial 1: with w / z = 0.5

Foaming with about 140% volume increase within 20 min. AB Mix 19b_5

Trial 1: with w / z = 0.5

Foaming with about 130% volume increase within 20 min.

AB mix 22a_4

Experiment 1: with w / z = 0.5 rapid foaming with about 250% volume increase within 10 min. Solidification beginning after approx. 30 min. - Density 350 g / l Mechanically stable

Even when MnO _{2 is used} as catalyst, the comparative compositions without calcium aluminate cement (AB mix 19b_1, AB mix 19b_3 and AB mix 19b_5) show significantly less foaming than the building material dry mixture according to the invention (AB mix 22a_4).

IN THE. c) percarbonate and TAED and MnO ₂ as activator (combination)

Example 5

w/z = Wasser/Zement

w / z = water / cement

TZ-Mix 22a_7

Trial 1: with w / z = 0.5

Very even volume increase without cracks, moderate stability.

763-AB-0092

Experiment 1 with w / c = 0.5 good foaming to 7 min. Solidification beginning after approx. 7 min.

- Volume increase: 150% mechanical stability: 4

- Density: 510 g / l

Foamable mixtures with further activators and combinations:

IN THE. d) percarbonate with Mn (II) compounds and / or TAED as activator (s)

Example 6

763-AB-0094

Trial 1 with w / z = 0.5

Foaming immediately after mixing solidification beginning after 5 min.

763-AB-0097

Experiment 1 with w / c = 0.5 good foaming to 10 min.

- Start of solidification> 3 hours volume increase: 220% mechanical stability: 5

- Density: 375 g / l

763-AB-0098

Trial 1 with w / z = 0.5

Foaming immediately after mixing Start of solidification after 10 min. mechanical stability: 4

763-AB-0065

Trial 1 with w / z = 0.5

Foaming immediately after addition of water solidification begins after approx. 3 min. I. e) Percarbonate with Fe (II) Compounds and / or TAED as Activator (s)

Example 7

w/z = Wasser/Zement

w / z = water / cement

763-AB-0052

Trial 1 with w / z = 0.5

Foaming up to 15 min. Solidification beginning after approx. 25 min. - Density approx. 450 g / l mechanically stable (4)

763-AB-0053

Trial 1 with w / z = 0.5

Foaming until 10 min. Solidification beginning after approx. 10 min. - Density approx. 500 g / l mechanically stable (3)

763-AB-0055

Trial 1 with w / z = 0.5

Foaming until 7 min. Solidification beginning after 7 min.

- Density approx. 650 g / l

763-AB-0056

Trial 1 with w / z = 0.5

Foaming up to 15 min. Solidification beginning after approx. 50 min.

- Density approx. 430 g / l mechanically stable (4)

763-AB-0057

Trial 1 with w / z = 0.55

Foaming until 10 min. Start of solidification after 10 min.

- Density approx. 500 g / l

I. f) percarbonate (coated) as well as Mn and Fe compound and / or TAED as activator)

Example 8: Percarbonate coated with sodium silicate / borate

w/z = Wasser/Zement

w / z = water / cement

763-TZ-0180

Trial 1 with w / z = 0.6

Foaming until 45 min. Solidification begins after approx. 45 min.

- volume increase: 150%

- Density approx. 487 g / l mechanically stable (5)

763-TZ-0181

Trial 1 with w / z = 0.6

Foaming until 50 min. Solidification begins after approx. 60 min. Volume increase: 205%

- Density approx. 380 g / l mechanically stable (5)

763-TZ-0182

Trial 1 with w / z = 0.6

Foaming until 50 min. Solidification beginning after approx. 50 min. Volume increase: 167%

- Density approx. 389 g / l mechanically stable (5)

763-TZ-0183

Trial 1 with w / z = 0.6

Foaming up to 40 min. Solidification begins after approx. 35 min.

- volume increase: 170%

- Density approx. 375 g / l mechanically stable (4) 763-AB-0116

Experiment 1 with w / c = 0.5 good foaming to 10 min. Solidification beginning after approx. 30 min. Volume increase: 100% mechanical stability: 5

- Density: 780 g / l

763-AB-0119

Experiment 1 with w / c = 0.5 good foaming to 10 min. Solidification beginning after approx. 10 min.

- Volume increase: 190% mechanical stability: 3-4

- Density: 400 g / l

IV. Storage stabilities of the foamable dry mortar: Advantages of the coating

IV. A) Use of uncoated percarbonate

Examples 2 to 7 above

IV. B) Use of coated percarbonates

Example 8 above.

Example 9: Percarbonate coated with sodium sulphate

w / z = water / cement 763-TZ-0162

Trial 1 with w / z = 0.6

Solidification begins after approx. 45 min. Volume increase: 130%

- density approx. 528 g / l mechanically stable (5)

763-TZ-0163

Trial 1 with w / z = 0.6

Solidification begins after approx. 45 min. Volume increase: 125%

- Density approx. 471 g / l mechanically stable (4)

763-TZ-0165

Trial 1 with w / z = 0.6

Solidification beginning after approx. 40 min.

- volume increase: 95%

- Density approx. 509 g / l mechanically stable (5)

IV. C) Results of storage stability

The following types of percarbonate are considered:

1. Uncoated Percarbonate (Examples 2 to 7)

2. Percarbonate coated with sodium silicate / borate (Example 8)

3. Sodium sulfate-coated percarbonate (Example 9)

4. Sodium sulfate / carbonate coated percarbonate (Example 10)

5. Sodium sulfate / silicate coated percarbonate (Example 11)

The uncoated percarbonate decomposes significantly faster in the dry mortar mix than coated percarbonate. Coated percarbonate below 3. decomposes faster than the below 2nd, 4th and 5th mentioned percarbonates with mixed coatings. Coatings with coated percarbonate below 2 are most stable and foam even after 6 months.

V. Use of different fillers

w/z = Wasser/Zement

w / z = water / cement

763-AB-0013

Experiment 1: with w / z = 0.7

Foaming up to 13 min. Volume increase approx. 120%

- density 390 g / l start of solidification> 60 min. Mechanically stable

763-AB-0020

Trial 1: with w / z = 0.5

Foaming up to 13 min.

- Volume increase approx. 1 15%.

- Density 400 g / l

Solidification begins after approx. 45 min. Mechanically unstable

763-AB-0021

Trial 1: with w / z = 0.5

Foaming until 10 min.

- Volume increase approx. 200%

- Density 420 g / l

Solidification beginning after approx. 30 - 40 min. Mechanically unstable

763-AB-0106

Trial 1 with w / z = 0.6

Foaming up to 5 min. Solidification beginning after approx. 15 min.

- Volume increase: 125% mechanical stability: 3

- Density: 440 g / l 763-AB-0107

Trial 1 with w / z = 0.5

Foaming up to 5 min. Solidification beginning after approx. 5 min. Volume increase: 75% Mechanical stability: 5 - Density: 580 g / l

The experiments show that the use of various fillers in building material dry mixtures according to the invention is possible. However, the addition of very high amounts of filler (formulation 763-AB-0020 and 763-AB-0021) is at the expense of the stability of the cured building material foams.

Claims

claims: 1. Under the action of water foamable Baustofftrockenmischung, wherein the Baustoffftrockenmischung (a) at least one inorganic binder selected from calcium aluminate cements, together (B) with at least one solid, under the action of water gaseous oxygen releasing oxygen carrier and (c) at least one catalyst which activates and / or accelerates the release of oxygen from the oxygen carrier (b), selected from transition metals and tetraacetylethylenediamine (TAED), contains. 2. Building material dry mixture according to claim 1, characterized • that the building material dry mixture is powdered and / or That all components of the building material dry mixture are present in particulate form, and / or • the dry building material mixture has a bulk density in the range of 450 to 1200 g / cm ³ . 3. Building material dry mixture according to claim 1 or 2, characterized in that the inorganic binder (a) comprises a mixture of at least one calcium aluminate cement and at least one of them different hydraulic binder. 4. Building material dry mixture according to one of the preceding claims, characterized in that the building material dry mixture, the inorganic binder (a) in quantities from 20 to 98 wt .-%, in particular 30 to 95 wt .-%, preferably 50 to 90 wt .-%, based on the building material dry mixture containing. 5. Building material dry mixture according to one of the preceding claims, characterized in that That the oxygen carrier (b) is designed to release the gaseous oxygen under alkaline conditions and / or • that the oxygen carrier (b) is formed releasing the gaseous oxygen with decomposition and / or • that the oxygen carrier (b) is selected from the group of percarbonates, perborates and persulfates and mixtures thereof, preferably percarbonates, in particular alkali and / or alkaline earth metal percarbonates, more preferably sodium percarbonate. 6. Building material dry mixture according to one of the preceding claims, characterized in that the building material dry mixture, the oxygen carrier (b) in amounts of 0.1 to 20 wt .-%, in particular 0.5 to 10 wt .-%, preferably 2.5 to 9 Wt .-%, particularly preferably 3.5 to 8.5 wt .-%, most preferably 3 to 8 wt .-%, based on the building material dry mixture containing. 7. Building material dry mixture according to one of the preceding claims, characterized in that the oxygen carrier (b) wholly or partially in coated or encapsulated form and / or that the component (b) forming particles wholly or partially provided with a coating or encapsulation are. 8. Building material dry mixture according to claim 7, characterized in that the oxygen carrier (b) and / or the component (b) forming particles on the one hand a fine-grained fraction having an average particle size, in particular determined as D50 value, in the range of 0.05 to 20 microns, preferably 0.15 to 15 microns, and on the other hand, a coarse-grained fraction having an average particle size, in particular determined as D50 value, in the range of 10 to 1500 microns, preferably 80 to 500 microns, in particular in particular, wherein the weight-related ratio of fine-grained fraction to coarse-grained fraction varies in the range of 95: 5 to 5:95, in particular 80:20 to 20:80, preferably 70:30 to 30:70. 9. Building material dry mixture according to one of the preceding claims, characterized in that the building material dry mixture, the catalyst (c) in amounts of 0.02 to 15 wt .-%, in particular 0.6 to 13 wt .-%, preferably 1, 75 to 1 1 wt .-%, particularly preferably 2.5 to 8 wt .-%, based on the building material dry mixture containing. 10. Building material dry mixture according to one of the preceding claims, characterized in that the catalyst (c) is selected from mixtures and / or combinations of at least one transition metal with TAED and mixtures and / or combinations of at least two mutually different transition metals. 11. Building material dry mixture according to one of the preceding claims, characterized in that the catalyst (c) is selected from the transition metals iron and / or manganese, and / or TAED and mixtures and / or combinations of these transition metals optionally together with TAED. 12. Building material dry mixture according to one of the preceding claims, characterized in that the building material dry mixture TAED in amounts of 0.01 to 10 wt .-%, in particular 0.5 to 9 wt .-%, preferably 1, 5 to 8 wt .-% , particularly preferably 2 to 6 wt .-%, based on the building material dry mixture, and / or that the building material dry mixture, the transition metal in amounts of 0.01 to 5 wt .-%, in particular 0.1 to 4 wt .-%, preferably 0.25 to 3 wt .-%, particularly preferably 0.5 to 2 wt .-%, based on the building material dry mixture and calculated as the transition metal contains. 13. Use of a building material dry mixture according to one of the preceding claims for producing a curable building material foam. 14. Use according to claim 13, characterized in that the building material dry mixture according to one of the preceding claims is mixed with water and / or added, in particular wherein water is used in amounts such that the product lumenverhältnis Building material dry mixture / H ₂ O in the range of 2: 1 to 1: 1, in particular 5: 1 to 1: 1, preferably 4: 1 to 1, 5: 1, 1, varies, and / or in particular wherein the water / Binder value, in particular w / c value, in the range of 0.2 to 0.95, in particular 0.35 to 0.85, preferably 0.4 to 0.8, is set. 15. A building material foam, obtainable by the action of water on a building material dry mixture according to one of the preceding claims, in particular followed by a curing.