Continuous method for producing functional material, raw material for functional material and functional material

Abstract

A method for producing a functional material is proposed, wherein in at least one mixing step (14), pulverized rigid foam (16) and at least one adhesive (18) are mixed into a raw material, and wherein in at least one pressing step (22), the raw material is pressed into the functional material, wherein the method is carried out continuously at least from the mixing step (14) up to and including the pressing step (22).

Description

Technical Field

[0001] The present invention relates to a method for producing a functional material, a raw material produced therefor, and a functional material produced thereby. Background Art

[0002] From "Recycling von Polyurethan-Kunststoffen (Recycling of Polyurethane Plastics)" by W. Raβhofer (Heidelberg: Hüthig GmbH, 1994, pp. 386-390, ISBN 3-929471-08-6), it is known to produce a functional material consisting of rigid polyurethane foam and a binder by a discontinuous process. In particular, the raw material is pressed by means of a press, wherein the raw material remains in a stationary press for a settling time until it hardens into the functional material.

[0003] EP 3371250 B1 describes a functional material produced in this way, which is produced, in particular, from comminuted PUR rigid foam (polyurethane rigid foam) and / or comminuted PIR rigid foam (polyisocyanurate rigid foam) and a binder.

[0004] Due to the flow characteristics of bulk goods made of shredded PUR / PIR rigid foam and the bulk goods height, the required quality of the functional material can only be ensured by relatively wide trimming, because at the beginning and end of the plate made of functional material and at the edge when pressure is applied, the bulk goods flow outwards and produce so-called soft areas, which must be removed afterwards. Such soft areas can be avoided by using a device that closes the pressed goods through the frame and moves the press into the frame with a precise fit. However, this would be very complicated and would require a lot of time due to the difficulty in demoulding and would be uneconomical.

[0005] A continuous pressing method for fiber composite panels is known from WO 2019 / 229007 A1. Usually, so-called continuous hot presses are used in continuous processes for compacting the material by means of pressure and temperature. For decades, such presses have played an important role in the wood industry and can produce a wide variety of single-layer and multi-layer wood particle boards with or without surface coating and with a firm and loose structure.

[0006] However, the materials to be pressed, the formulation of the raw materials made from these materials and their adaptation to the pressing process are decisive for the successful production and realization of the desired technical product properties of the functional materials. Summary of the invention

[0007] The object of the invention is in particular to provide a universal method with improved properties with respect to the necessary production time of the functional material and with respect to the quality of the functional material produced thereby. According to the invention, this object is achieved by the features of claim 1, while advantageous embodiments and improvements of the invention can be gathered from the dependent claims.

[0008] A method for producing a functional material is proposed, wherein in at least one mixing step, pulverized rigid foam and at least one binder, which is liquid in particular at room temperature and standard pressure, are mixed to form a raw material, and wherein in at least one pressing step, the raw material is pressed to form the functional material, wherein the method is carried out continuously at least from the mixing step up to and including the pressing step. The functional material can be used, for example, as a thermal insulation material and / or as a material in particular for housing, furniture, the construction industry, buildings, building interiors, vehicle interiors, etc. Particularly preferably, the functional material is also designed as a structural material in addition to the thermal insulation function. In particular, the functional material has a thermal conductivity of at most 0.10 W / (m·K), preferably less than 0.07 W / (m·K), in accordance with EN 12667. The functional material has in particular a thermal conductivity of more than 150 kg / m 3 , preferably greater than 300kg / m 3 , especially preferably greater than 450kg / m 3 Preferably, the functional material has a compressive stress according to DIN EN 826 of greater than 1 MPa, preferably greater than 3 MPa, particularly preferably greater than 6 MPa.

[0009] Optionally, the method comprises a comminution step, in which an object containing hard foam and / or at least substantially formed by hard foam is mechanically comminuted. An object "substantially formed by one material" should be understood in particular as at least 50%, preferably greater than 75%, particularly preferably greater than 90% of the total volume and / or total mass of the object being formed by the material. Preferably, the hard foam is separated from other components of the object, especially before the comminution step, during the comminution step and / or after the comminution step. In particular, the hard foam is pulverized in the comminution step, for example by grinding, shredding and / or chopping. Alternatively, the hard foam is already provided in a pulverized form. The pulverized hard foam is especially at least substantially formed by hard foam particles, especially these hard foam particles each have the cell structure of hard foam. Each individual hard foam particle of at least most of the hard foam particles of the pulverized hard foam has a maximum spatial extension of at least substantially the same size in each direction. Two values ​​"substantially the same size" should be understood in particular as the larger of the two formable quotients of the value being less than 5, preferably less than 3, particularly preferably less than 2. The maximum spatial extension of different rigid foam particles can be at least essentially the same size or be designed to be different sizes. Preferably, the pulverized rigid foam has a flour-like consistency. In particular, the average particle size of the pulverized rigid foam is less than 5 mm, preferably less than 1 mm, particularly preferably less than 500 μm. Preferably, the average particle size is at least greater than 500 nm, in particular greater than 1 μm, particularly preferably greater than 100 μm. The method preferably includes a rigid foam metering step, in which the pulverized rigid foam is transferred from a powder silo or directly from a comminution device for pulverizing rigid foam to a continuous conveyor. The continuous conveyor can be designed as a mechanical conveyor, a gravity conveyor or a flow conveyor. In the rigid foam metering step, the pulverized rigid foam is continuously transferred to the continuous conveyor, especially at a settable rigid foam rate.

[0010] The adhesive is preferably in liquid form before the adhesive hardens, especially under laboratory conditions. Preferably, the adhesive is organic, alternatively inorganic. Preferably, the adhesive comprises an isocyanate. Particularly preferably, the adhesive comprises at least one methylene diphenyl isocyanate (MDI). Alternatively or additionally, the adhesive comprises toluene-2,4-diisocyanate (TDI), urea or water glass. The method comprises, in particular, an adhesive metering step, in which the adhesive is added to the pulverized rigid foam. In the adhesive metering step, in particular, the adhesive is continuously added to the pulverized rigid foam at a settable adhesive ratio.

[0011] In the mixing step, the pulverized rigid foam and the adhesive are mixed continuously, in particular by means of a continuous mixer, particularly preferably by means of a screw extruder. Preferably, a continuous conveyor continuously feeds the pulverized rigid foam to the continuous mixer. Preferably, the adhesive is added to, in particular sprayed into, the pulverized rigid foam in the continuous mixer. In particular, the raw material is continuously generated in the mixing step. The continuous mixer, in particular at the end of the mixing step, continuously outputs the raw material and conveys it, in particular, continuously to another continuous conveyor, in particular a belt conveyor and / or a chain conveyor. In particular, the continuous mixer generates an endless belt of raw material, which is continuously conveyed from another continuous conveyor to a continuous press, in particular a continuous hot press, in particular, which is operated continuously.

[0012] Preferably, the method comprises at least one pre-pressing step, in which the raw material is pre-compacted by means of a continuous device. Optionally, the method comprises at least one layering step, in which a further layer of the raw material or a further layer of another raw material comprising a rigid foam of a different quality than the raw material and / or a rigid foam different from the raw material is applied to the, in particular, pre-compacted raw material.

[0013] In the pressing step, the in particular precompacted raw material, in particular if present, is pressed continuously together with the further layers.

[0014] Preferably, a temperature is applied to the raw material during the pressing step, in particular in order to accelerate the chemical reaction of the binder, in particular polyaddition and / or polycondensation. Particularly preferably, during the pressing step, the raw material is continuously fed to a continuous press, the raw material is continuously pressed from the continuous press, and the functional material is continuously discharged from the continuous press, in particular in contrast to a continuous device or laminator operating in a cycle. The continuous press converts the raw material, in particular, into an endless belt of functional material, which is continuously conveyed to an assembly station by a further continuous conveyor. Preferably, the method comprises an assembly step, in which a subsection is separated from the endless belt of functional material.

[0015] The continuously operable manufacturing plant for functional materials comprises in particular a continuous conveyor, a continuous mixer, another continuous conveyor, a continuous press for pressing, a continuous device for pre-compacting, an assembly station, an adhesive tank and an adhesive metering device, a powder silo and a metering device for pulverized rigid foam, and / or a pulverizing device and optionally at least one storage and metering device for optional fillers and / or for optional covering layers. The method is particularly performed during the effective normal operating state of the manufacturing plant, in particular after the manufacturing plant is started. In particular, unlike discontinuous start-stop operations, "continuously" should be understood as preferably continuously, in particular without interruption, for the duration of the method. The method is particularly terminated by manually or automatically terminating the normal operating state of the manufacturing plant at the latest, for example by shutting down the manufacturing plant, by triggering a fault state and / or maintenance state of the manufacturing plant, etc. In particular, at least the rigid foam metering step, the adhesive metering step, the mixing step, the pre-pressing step and / or the pressing step are performed simultaneously at different positions of the circulating belt of the raw material or the precursor of the raw material. Preferably, the method, in particular in contrast to the discontinuous method, is carried out in an automated manner, in particular without operator intervention, at least from the mixing step, particularly preferably at least from the rigid foam metering step, optionally from the comminution step, up to and including at least the pressing step, preferably up to and including the assembly step. In particular, the control unit of the production plant controls or regulates the production plant during the method, in particular during the rigid foam metering step, the adhesive metering step, the mixing step, the pre-pressing step, the pressing step and / or the assembly step, preferably fully automatically. A "control unit" is to be understood in particular as a unit having at least one control electronics. A "control electronics" is to be understood in particular as a unit having a processor unit and a memory unit and having an operating program stored in the memory unit. In particular, the control unit controls or regulates the production plant without operator intervention, in particular at least after a presetting of the production plant or after the operator has entered process parameters into the operating program.

[0016] By the design scheme according to the present invention, the trimming required due to the flow characteristics of the raw material can be advantageously kept very small. In particular, the trimming perpendicular to the conveying direction of the raw material can be omitted, which trimming especially specifies the size of the plate. In particular, the soft zone that occurs at the edge of the pressing area can be advantageously kept small. In particular, expensive and / or time-consuming measures to limit the soft zone can be omitted, such as a frame structure for the raw material that cooperates accurately with the discontinuous press. In particular, a high-quality cover layer with advantageously few scraps can already be applied to the raw material, thereby advantageously and cost-effectively providing a high-quality cover layer for the functional material. In particular, a separate working step for applying the cover layer to a pre-cut plate made of, in particular, a functional material can be omitted. In addition, even in the case of a functional material with a high material thickness, in particular greater than 20 mm and requiring a large amount of steam for hardening, the steam pressure in the raw material and the functional material can be advantageously kept low, and in particular, a sudden pressure drop can be avoided when the discontinuous press is opened. Thus, the risk of crack formation in the functional material can be advantageously kept low after the pressing step. In particular, in the case of functional materials with low material thickness, in particular less than 10 mm, the duration required for the pressing step can advantageously be kept short, in particular shorter than the duration required for preparing the raw material. As a result, an advantageously high production capacity can be achieved. In particular, the functional material can advantageously be produced quickly. In addition, a cooling press can advantageously be omitted. In addition, the length of the plate produced from the production material can advantageously be selected arbitrarily and is in particular not limited by the size of the continuous press. In particular, it is possible to dispense with refitting the production equipment to change the length of the plate.

[0017] It is also proposed that in at least one method step, the pulverized rigid foam is made of a polyurethane rigid foam, referred to as PUR, a polyisocyanurate rigid foam, referred to as PIR, and / or a phenolic rigid foam. The rigid foam is in particular at least substantially pressure-resistant. “At least substantially pressure-resistant” is to be understood, in particular according to the EN 826 standard and advantageously as withstanding a pressure of greater than 100 kPa, preferably greater than 120 kPa. In particular, “PUR” is to be understood as a rigid foam that complies with DIN EN 13165 and / or EN 14308. In particular, “PIR” is to be understood as a rigid foam that complies with EN 14308 and / or ASTM C 1289. In particular, the pulverized rigid foam is at least substantially formed of a thermosetting plastic. Before comminution, the rigid foam preferably has a thermal conductivity of less than 0.037 W / Km, in particular in accordance with EN 12667. Preferably, the rigid foam has a thermal conductivity of less than 0.03 W / Km, particularly preferably less than 0.025 W / Km, in accordance with EN 12667 before pulverization. The rigid foam particles are obtained in particular by mechanical pulverization, so that the cell structure of the rigid foam is at least partially retained in the rigid foam particles. In particular, the thermal conductivity of a single rigid foam particle is at least substantially the same as the thermal conductivity of the rigid foam before pulverization. In particular, the pulverized rigid foam limits the heat conduction in the raw material. Preferably, water, in particular an aqueous solution, is added to the adhesive in the mixing step and / or in the adhesive mixing step before the mixing step. In particular, the water is evaporated in the pressing step. Preferably, the evaporated water is at least mostly enclosed in the raw material in the pressing step for a hardening duration, which corresponds in particular to a continuous duration by continuous pressing. Optionally, the evaporated water from the raw material and / or from the functional material is partially released during the hardening duration and preferably at least mostly, in particular continuously, after the pressing step. "Most of the time" is to be understood in particular as at least 50%, preferably at least 75%, particularly preferably at least 90% of the total volume and / or total mass. In particular, the evaporated water is provided for heat exchange within the raw material and in particular for uniform hardening of the adhesive. "Provided" is to be understood in particular as being specially designed and / or specially equipped. Providing an object for a specific function is to be understood in particular as the object performing and / or implementing the specific function in at least one application state and / or operating state. By means of the design according to the invention, functional materials can be advantageously manufactured in a resource-saving manner, in particular from industrial residues and / or scraps.

[0018] It is also proposed that in at least one method step, activated water with a mass fraction of up to 3% of the activator is added to the adhesive. The activated water is in particular the water already mentioned for evaporation, which is also doped with the activator. The mass fraction of the activator is in particular related to the total mass of the aqueous solution composed of water and the activator. In particular, in the adhesive premixing step, the activator is dissolved in water to provide an aqueous solution. As an activator, for example, potassium acetate, potassium octoate, amine activator and / or another activator considered meaningful by a person skilled in the art are added. Preferably, the activator comprises a mass fraction of less than 2%, particularly preferably less than 1%. Preferably, the activator comprises a mass fraction of at least 0.01%, particularly preferably at least 0.05%. The water can have the quality of domestic water, filtered water, distilled water, completely demineralized water or ultrapure water before adding the activator, or the water, in particular water without the activator, is added to the adhesive. In particular, the curing duration of the raw material is predetermined in particular by the ratio of the amount of water and the activator to the material thickness of the raw material and / or the functional material. By means of the design according to the invention, the required amount of water can be advantageously kept low with the same hardening duration and / or the hardening duration can be advantageously kept short with the same amount of water. In particular, when using a smaller amount of water, the steam pressure in the continuous press can be advantageously kept low and / or an advantageously high temperature can be applied to the raw material, thereby achieving the same steam pressure with less water. In particular, an advantageously reliable hardening of the adhesive can be achieved. In particular, an advantageously rapid hardening of the adhesive can be achieved. In particular, the manufacturing capacity can be further improved. In addition, the risk of crack formation due to a sudden drop in steam pressure at the output end of the continuous press, especially despite faster hardening, can be advantageously kept low.

[0019] It is further proposed that, in the mixing step, a binder having a mass fraction of less than 10% relative to the total mass of the functional material is added to the pulverized rigid foam. Preferably, the mass fraction of the binder in the functional material is less than 9%, particularly preferably less than 8%. Optionally, a binder having a mass fraction of at least 5%, in particular greater than 6%, of the functional material is added to the pulverized rigid foam. Preferably, the pulverized rigid foam forms a mass fraction of greater than 60%, preferably greater than 75%, particularly preferably greater than 85% of the functional material. Optionally, the method comprises a further mixing step, which in particular replaces the mixing step in at least one setting of the production plant, in particular for producing a rigid foam having a mass fraction of greater than 500 kg / m 3 and / or greater than 600kg / m 3A functional material having a bulk density of 1000 g / cm2 is prepared, to which a binder is added in a mass fraction greater than 10%, in particular up to 12%, preferably up to 15%, and particularly preferably up to 18%, relative to the total mass of the functional material. The design according to the invention makes it possible to produce a functional material having an advantageously low thermal conductivity. In particular, the components of the raw materials that are harmful to health can be advantageously kept low. In particular, the functional material can advantageously be produced at low cost.

[0020] It is further proposed that, in at least one method step, at least one organic and / or inorganic filler is added to the raw material, the pulverized rigid foam and / or the adhesive. Preferably, the filler is supplied before and / or during the mixing step. Particularly preferably, the filler is supplied to the pulverized rigid foam before the mixing step, in particular to a continuous mixer together with the pulverized rigid foam. The filler is preferably formed as a solid substance, which is added to the pulverized rigid foam and / or the adhesive in the form of a powder or granules. Alternatively, the filler or another filler is formed as a fiber material, which is at least substantially formed by mineral fibers or non-mineral fibers such as glass fibers, carbon fibers, ceramic fibers or basalt fibers. The filler preferably has a mass fraction of less than 20% of the total mass of the functional material. The filler preferably has a mass fraction of more than 1%, in particular more than 2%, of the total mass of the functional material. Through the design according to the present invention, the functional material can be advantageously provided with additional properties according to the application, in particular, advantageously low, in particular negative damage to the mechanical and thermal properties of the functional material.

[0021] It is also proposed that the filler forms the functional material in a flame-retardant manner according to combustion reaction class C in accordance with DIN 13501-1. The filler preferably has an expansion behavior when temperature is applied, as a result of which the bulk density of the filler changes when the temperature of the functional material exceeds the activation temperature of the additive. In the basic state, the filler has a density of, in particular, less than 5 g / cm 3 Preferably, the bulk density of the filler is between 1 g / cm 3 and 3g / cm 3 The filler preferably has at least 30cm 3 / g expansion rate, especially in standard atmosphere. Preferably, the expansion rate of the filler is greater than 100cm 3 / g and preferably at 250cm 3 / g and 400cm 3 / g range, especially in standard atmosphere. When the functional material is heated to a temperature greater than the activation temperature of the additive, the expansion behavior of the filler, especially in standard atmosphere, increases the volume of the filler preferably by at least 10 times. The filler especially has an activation temperature of at least 90 degrees Celsius. Preferably, the activation temperature is higher than 120 degrees Celsius. In particular, a temperature lower than the activation temperature is applied to the raw material in the pressing step. If the functional material with the filler is heated to the activation temperature of the filler, the filler preferably expands. When the temperature of the functional material becomes higher than the activation temperature of the filler, the volume fraction of the filler changes. The filler has a carbon content of preferably at least 85%, but in principle it can also be lower. The filler preferably includes graphite. The filler is particularly preferably formed as expanded graphite. The filler especially has acid molecules embedded between graphite layers. If the filler is heated above the activation temperature, the layer especially expands and the volume increases. The functional material preferably has a combustion performance corresponding to the building material grade B1 in accordance with DIN4102-1. According to the design of the present invention, an advantageously safe functional material can be manufactured, which can be used in an advantageously wide range of application fields, especially permitted to be used.

[0022] It is further proposed that in the pressing step, when at least the continuous press is set, the raw material is pressed by the continuous press into a plate with a material thickness of less than 8 mm, in particular without subsequent grinding. The other continuous conveyor particularly comprises a conveying direction from the continuous mixer, in particular through the continuous device to the continuous press and in particular through the continuous press to the assembly station. The conveying direction is preferably parallel to the straight line. Alternatively, the conveying direction comprises at least one curve, a deflection point, etc. The continuous conveyor comprises a maximum conveying width perpendicular to the conveying direction, on which the raw material is distributed in the raw material metering step by means of a stacking device of the conveying device arranged at the continuous mixer, and the maximum conveying width preferably has a constant value along the conveying direction. In particular, the stacking device applies the raw material to the other continuous conveyor with a maximum width parallel to the conveying width of the other continuous conveyor of at least 50 cm, preferably greater than 80 cm, particularly preferably greater than 1.1 m. In particular, the raw material extends uninterruptedly from the stacking point of the other continuous conveyor to the continuous press parallel to the conveying direction of the other continuous conveyor during the execution of the method, in particular extending over several meters. The material thickness of the raw material and the functional material is particularly perpendicular to the conveying direction and extends perpendicular to the conveying width. In particular, the continuous press reduces the material thickness of the raw material to the material thickness of the functional material. In particular, the continuous press is set in at least one method step so that the material thickness of the functional material less than 8mm, especially less than 7mm, preferably less than 6mm, and particularly preferably less than 5mm is produced. Optionally, the continuous press can also be set for a material thickness greater than 8mm. In particular, in at least one method step, the raw material is pressed into a functional material having a material thickness greater than 10mm, especially greater than 40mm, preferably greater than 70mm, and particularly preferably up to 100mm. In particular, the assembly station separates the plate with a settable length parallel to the conveying direction from the circulating belt of the functional material coming out of the continuous press. The assembly station is particularly arranged to separate the plate when the maximum length parallel to the conveying direction is greater than 1m, preferably greater than 5m, and particularly preferably greater than 20m, and in particular the separated plate is supplied to the transport, packaging and / or storage device individually or multiple plates are stacked. Through the design according to the present invention, a thin functional material with a particularly high insulation effect can be manufactured. In particular, functional materials can also be used in applications with little available installation space.

[0023] It is further proposed that in the pressing step, the raw material is pressed into a plate with a material thickness having a maximum permissible tolerance of at most 1 mm, in particular without subsequent grinding. The method optionally comprises a grinding step in order to improve the surface quality of the functional material after the pressing step, wherein the maximum permissible tolerance of the material thickness has already been reached by the pressing step. The grinding step is preferably omitted, so that the plate has an advantageously high adhesion for the subsequent application of a covering layer, for example a functional layer and / or a decorative layer. By means of the design according to the invention, material losses for straightening the functional material can be advantageously kept low.

[0024] It is also proposed that in at least one method step, the functional material is pulverized and the pulverized hard foam is at least partially replaced by the pulverized functional material. In particular, the functional material and the objects made of the functional material can be recycled within the scope of the method. Preferably, the functional material is pulverized in the comminution step, in particular together with the hard foam or separately. Optionally, the adhesive residues of the functional material are filtered out from the pulverized functional material, in particular in a quality-related and / or density-related manner. Alternatively, the adhesive residues are retained in the pulverized functional material. The pulverized functional material is preferably mixed with, in particular, purer pulverized hard foam in a mixing step or in a comminution step. Alternatively, the pulverized hard foam is completely replaced by the pulverized functional material. By the design according to the present invention, a closed loop can be advantageously established for the hard foam. In particular, the functional material can be advantageously manufactured in a resource-saving manner and in an environmentally friendly manner.

[0025] It is also proposed that in at least one method step, the open time of the raw material is set depending on the characteristics of the functional material to be produced. The open time refers in particular to the duration from the adhesive metering step to the pressing step. In particular, the set open time is longer than the minimum open time, which is necessary for the adhesive and activated water to penetrate the powdered hard foam and for the uniform distribution of the adhesive and activated water in the powdered hard foam. In particular, the set open time is shorter than the maximum open time to keep the drying of the raw material, the chemical reaction in the raw material, especially the premature addition and / or polycondensation of the adhesive as little as possible. The open time can be set by the operator or by the control unit depending on the characteristics of the functional material to be produced. In particular, the open time is determined by the conveying speed of the continuous mixer and / or another continuous conveyor.

[0026] The characteristics of the functional material to be produced, on which the open time, in particular the minimum and maximum open times, depend, include, for example, the density of the functional material, the material thickness of the functional material, the number of layers in the functional material. In particular, the higher the open time is set, the denser, thicker and / or more layers of the functional material to be produced. In particular, the lower the open time is set, the smaller and / or thinner the density of the functional material to be produced, and / or the fewer layers it has. By means of the design according to the present invention, the characteristics of the functional material can be advantageously flexibly adapted. In particular, the same manufacturing equipment can advantageously manufacture functional materials of various designs, in particular without modification. In particular, various functional materials can advantageously be manufactured quickly and with advantageously reliable quality.

[0027] It is also proposed that, in the raw material metering step, the raw material is applied to a separation layer, especially at least temporarily arranged at the functional material, and the separation layer is removed from the functional material after the pressing process. Preferably, the separation layer is constituted as a separation paper or a separation film, such as a Teflon film or a nonwoven fabric. In particular, before or at the beginning of the raw material metering step, the separation layer is pulled onto another continuous conveyor. Particularly preferably, after the raw material metering step or at the end of the raw material metering step, especially before the pressing step, another separation layer is arranged on the side of the raw material away from the separation layer. In particular, the separation layer, the raw material and the other separation layer form a sandwich structure before the pressing step. Particularly preferably, the separation layer and / or the other separation layer are peeled off from the functional material after the pressing step or after the assembly step, and are instead worn off. Through the design according to the present invention, the continuous press can be advantageously operated with very little wear. In particular, the deposits in the continuous press and / or the continuous conveyor can be advantageously kept small. In particular, the pressing step can be advantageously performed maintenance-free for a long time. Furthermore, by stripping off the separating layer, an advantageously roughened surface of the functional material can be produced, to which a subsequently applied coating advantageously adheres reliably.

[0028] It is also proposed that in the raw material metering step, the raw material is applied to the covering layer, which is connected with the hardened raw material in a material-matching manner after the pressing process. The covering layer is arranged on a separating layer or on another continuous conveyor before or at the beginning of the raw material metering step. Optionally, after the raw material metering step or at the end of the raw material metering step, especially before the pressing step, another covering layer is arranged on the side of the raw material away from the covering layer. In particular, the covering layer, the raw material and the another covering layer form a sandwich structure before the pressing step. The covering layer and the another covering layer can be made of the same or different materials. The covering layer and / or the another covering layer can be at least substantially formed by organic materials such as melamine resin and / or polyvinyl chloride (PVC) or inorganic materials such as aluminum. Particularly preferably, the separating layer and / or the another separating layer, if present, is peeled off from the covering layer after the pressing step or after the assembly step, and is instead worn off. Through the design according to the present invention, the functional material can be advantageously equipped with additional properties according to the application. For example, the covering layer can be designed as a moisture barrier, an antimicrobial protective layer, a weathering barrier, a sound insulation layer, a high-quality decorative layer, etc. In particular, a subsequent application step for applying the covering layer to the functional material can be omitted, so that the functional material with the covering layer can be produced advantageously quickly and advantageously cost-effectively.

[0029] In addition, a raw material for manufacturing a functional material by means of the method according to the present invention is proposed. The raw material preferably comprises at least a powdered hard foam and / or a powdered functional material. The raw material particularly comprises a liquid adhesive. The raw material preferably comprises activated water or water, and in particular does not contain an activator. Preferably, the activated water or water has a mass fraction of at least 0.5%, preferably greater than 1%, and particularly preferably greater than 2% of the raw material. Preferably, the mass fraction of the active water or water in the raw material is less than 7.5%, preferably less than 5%, and particularly preferably less than 3%. The raw material preferably comprises a filler. Preferably, the powdered hard foam and / or the powdered functional material, the adhesive, optionally the filler and the activated water or water are uniformly distributed in the raw material, wherein, in particular in the case of multiple layers, the distribution is uniform at least in a layered manner. By means of the design according to the present invention, a raw material for a functional material can be provided, which can be advantageously processed continuously and advantageously quickly.

[0030] Furthermore, a functional material produced by the method according to the invention is proposed. The functional material has in particular a thermal conductivity of at most 0.10 W / (m·K), preferably less than 0.07 W / (m·K), in accordance with EN 12667. The functional material has in particular a thermal conductivity of more than 150 kg / m 3 , preferably greater than 300kg / m 3 , especially preferably greater than 450kg / m 3and in particular has a compressive stress of greater than 1 MPa, preferably greater than 3 MPa, particularly preferably greater than 6 MPa according to DIN EN 826. The functional material is preferably corrosion-resistant and non-corrosive. The functional material is preferably resistant to mineral oils, solvents and diluted alkalis and acids. Preferably, the functional material has a flexural strength of greater than 1 MPa, preferably greater than 2 MPa, particularly preferably greater than 4 MPa in accordance with DIN EN 12089. Preferably, the functional material has a shear strength of greater than 250 kPa, preferably greater than 500 kPa, particularly preferably greater than 1 MPa in accordance with DIN EN 12090. The functional material has a shear strength of particularly greater than 250 kPa, preferably greater than 500 kPa, particularly preferably greater than 1 MPa in accordance with DIN EN 12090. In addition, the functional material preferably has a surface pull-out resistance of at least 4.5 N / mm in accordance with DIN EN 14358 for wood screws 6×60. 2 , preferably greater than 6N / mm 2 , especially preferably greater than 7.5N / mm 2 The basic components of the functional material, which are formed only from pulverized rigid foam and adhesive, have in particular a combustion behavior corresponding to combustion reaction class E according to DIN EN 13501-1 and building material class B2 according to DIN 4102-1. The functional material has, through the filler, a combustion behavior corresponding to at least one combustion reaction class C according to DIN EN 13501-1 and at least one building material class B1 according to DIN 4102-1. By means of the design according to the invention, an advantageously stable and at the same time advantageously thermally insulating functional material can be provided, which can be produced advantageously cost-effectively, advantageously in a resource-saving manner, advantageously quickly and / or with advantageously low fluctuations in properties, in particular fluctuations in bulk density.

[0031] The method according to the invention, the raw material according to the invention and / or the functional material according to the invention should not be limited to the above-mentioned applications and embodiments. In particular, the method according to the invention, the raw material according to the invention and / or the functional material according to the invention can have a number different from the number of individual elements, components and units and method steps mentioned in this article to achieve the functional mode described in this article. In addition, in the case of a numerical range specified in the present disclosure, the numerical values ​​within the specified range should also be regarded as public and can be used arbitrarily. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Further advantages emerge from the following description of the drawings. Embodiments of the invention are shown in the drawings. The drawings, the description and the claims contain many combined features. A person skilled in the art will also appropriately consider the features individually and combine them into meaningful further combinations. In the drawings:

[0033] Figure 1 a schematic diagram showing a method according to the present invention; and

[0034] Figure 2 A schematic diagram of a functional material according to the present invention is shown. DETAILED DESCRIPTION

[0035] Figure 1 The flow chart of the method 10 for manufacturing the functional material 12 is shown. The functional material 12 is made of at least one rigid foam 16 and a binder 18. The rigid foam 16 is powdered, mixed with the binder 18 and pressed into the functional material 12.

[0036] The method 10 comprises in particular a comminution step 46. The method 10 comprises a rigid foam metering step 30. The method 10 optionally comprises a moisture measurement step 32. The method 10 preferably comprises a filler metering step 34. The method 10 preferably comprises a binder premixing step 36. The method 10 comprises a binder metering step 38. The method 10 comprises a mixing step 14. The method 10 preferably comprises a raw material mass metering step 50. The method 10 comprises in particular a pre-pressing step 40. The method 10 comprises a pressing step 22. The method 10 preferably comprises an assembly step 42. The method 10 is carried out continuously at least from the mixing step 14 up to and including the pressing step 22. Particularly preferably, the method 10 is carried out continuously from the rigid foam metering step 30 up to and including the pressing step 22. In particular, the rigid foam metering step 30, the filler metering step 34, optionally the binder premixing step 36, the binder metering step 38, the mixing step 14, the pre-pressing step 40 and the pressing step 22 are carried out continuously and in particular in time parallel to one another. The moisture measurement step 32 can be performed continuously, regularly or randomly. The assembly step 42 is performed discontinuously, in particular triggered by a time measurement and / or length measurement of the functional material 12. The comminution step 46 can be performed continuously or discontinuously. Preferably, the comminution step 46 is performed independently of the other method steps of the method 10.

[0037] The rigid foam 16 has a thermal conductivity of less than 0.037 W / Km before pulverization. In the pulverizing step 46, the pulverized rigid foam 16 is made of a polyurethane rigid foam, referred to as PUR, a polyisocyanurate rigid foam, referred to as PIR, and / or a phenolic rigid foam. In the pulverizing step 46, the rigid foam 16 is mechanically pulverized, in particular pulverized. Preferably, the pulverized rigid foam 16 is temporarily stored in a powder silo. In the rigid foam metering step 30, the pulverized rigid foam 16 is continuously applied to a continuous conveyor. The continuous conveyor conveys the pulverized rigid foam 16 to a continuous mixer. In the moisture measurement step 32, the moisture content of the pulverized rigid foam 16 is preferably determined, for example by means of a moisture measuring device or by weighing a fixed volume of the pulverized rigid foam 16 and comparing it with a reference value of known moisture, in particular in the absence of moisture. The moisture measurement step 32 can be performed before or after the rigid foam metering step 30.

[0038] In a filler metering step 34, at least one organic and / or inorganic filler 26 is added to the pulverized rigid foam 16. The filler 26 constitutes a functional material in a flame-retardant manner according to combustion reaction class C in accordance with DIN 13501-1. The filler 26 is in particular formed as expanded graphite. The filler metering step 34 is preferably carried out after the moisture measurement step 32 and in particular before the mixing step 14. Particularly preferably, in the filler metering step 34, the filler 26 is continuously applied to the pulverized rigid foam 16 and in particular is fed together with the pulverized rigid foam 16 by a continuous conveyor to a continuous mixer.

[0039] In the binder premixing step 36, activated water 24 with a mass fraction of at most 3% of the activator is added to the binder 18. Preferably, the control unit controls or regulates the amount of activated water 24 added depending on the moisture measurement step 32 and in particular on the density to be achieved and the material thickness 48 of the functional material 12 (see Figure 2 ). In the binder metering step 38, the binder 18 is mixed with the activated water 24 and continuously added to the pulverized rigid foam 16, especially in a continuous mixer. Alternatively, the binder 18 and the activated water 24 are introduced separately from each other, especially sprayed into the continuous mixer.

[0040] In the mixing step 14, the pulverized rigid foam 16 and the binder 18 are mixed, in particular together with the filler 26 and the activated water 24, to form the raw material 20. In the mixing step 14, the binder 18 is added to the pulverized rigid foam 16 in a mass fraction of less than 10% relative to the total mass of the functional material 12. In the raw material metering step 50, the stacking device arranged at the continuous mixer continuously conveys the raw material 20 to another continuous conveyor, in particular a conveyor belt. In the raw material metering step 50, the raw material 20 is optionally applied to a covering layer, which is connected to the hardened raw material in a material-matching manner after the pressing process 22. In the raw material metering step 50, the raw material 20 is applied to a separation layer, which is removed from the functional material after the pressing process 22. When the functional material 12 is to include a covering layer, the separation layer is applied to another continuous conveyor, the covering layer is applied to the separation layer and the raw material 20 is applied to the covering layer. The open time of the raw material 20 is set depending on the characteristics of the functional material 12 to be produced. In particular, the conveying speed of the further continuous conveyor is set or regulated by the control unit as a function of the properties of the functional material 12 to be produced.

[0041] In the pre-pressing step 40, the raw material 20 is pre-compacted by means of a continuous device. Optionally, the raw material 20 or at least one further layer of another raw material 20 is applied to the pre-compacted raw material 20 and then pre-compacted. In the pressing step 22, the raw material 20, in particular the pre-compacted, is pressed into the functional material 12. In particular, the continuous press applies pressure and temperature to the raw material 20 in the pressing step 22. Preferably, the temperature caused by the continuous press is below the activation temperature of the filler 26, at which the filler 26 preferably has an expansion behavior. The continuous press evaporates the activation water 24 in the pressing step 22. The continuous press seals the evaporated water 24 in the raw material 20 for the most part during the pressing step 22, in particular until the binder 18 hardens. In particular, at the outlet of the continuous press for the functional material 12, the functional material 12 continuously releases the evaporated water 24 from the continuous press. In the pressing step 22, the raw material 20 is pressed by the continuous press into a plate 28 with a material thickness of less than 8 mm, in particular without subsequent grinding, when at least the continuous press is set. The plate 28 made of the functional material 12 is exemplarily Figure 2. In a pressing step 22, the raw material 20 is pressed into a plate 28 with a material thickness 48 having a maximum permissible tolerance of at most 1 mm, in particular without subsequent grinding. In an assembly step 42, the plate 28 is separated from the functional material 12 that emerges continuously from the continuous press, in particular cut and / or sawed off. The plate 28 made of the functional material 12 is applied 44, for example, as a thermal insulation material and / or a building material. The plate 28 made of the functional material 12 can be recycled, in particular after the application 44, by means of the method 10. In particular, scraps of the plate 28 that occur before or during the application 44 can be recycled. The functional material 12 is pulverized so that the pulverized hard foam can be at least partially replaced by the pulverized functional material.

[0042] Description of reference numerals:

[0043] 10 Methods

[0044] 12 Functional Materials

[0045] 14 Mixing Steps

[0046] 16 Rigid foam

[0047] 18 Adhesive

[0048] 20 Raw Materials

[0049] 22 Pressing steps

[0050] 24 Activated Water

[0051] 26 Filling

[0052] 28 Plates

[0053] 30 Rigid Foam Metering Procedure

[0054] 32 Moisture Measurement Steps

[0055] 34 Filler metering steps

[0056] 36 Adhesive Premixing Step

[0057] 38 Adhesive Metering Procedure

[0058] 40 Pre-pressing step

[0059] 42 Assembly steps

[0060] 44 Applications

[0061] 46 Crushing Steps

[0062] 48 Material thickness

[0063] 50 Raw material measurement steps

Claims

1. A method for producing a functional material having a thermal conductivity of at most 0.10 W / (m·K) in accordance with EN 12667, a load greater than 450 kg / m 3 Bulk density and compressive stress greater than 1 MPa according to DIN EN 826, where In at least one mixing step (14), pulverized rigid foam (16) and at least one binder (18) are mixed into a raw material, wherein the average particle size of the pulverized rigid foam is less than 5 mm, wherein water is mixed into the binder in the mixing step and / or in a binder mixing step before the mixing step, wherein the mass fraction of water in the raw material is less than 7.5%, wherein in at least one pressing step (22), the raw material is pressed into the functional material, and wherein the water is evaporated in the pressing step, wherein the method is carried out continuously from at least the mixing step (14) to and including the pressing step (22), wherein in the pressing step, the raw material is continuously supplied to a continuous press, the raw material is continuously pressed by the continuous press, and the functional material is continuously discharged from the continuous press, wherein the evaporated water is at least mostly enclosed in the raw material for a hardening duration corresponding to the continuous duration of the continuous pressing, and the functional material continuously releases the evaporated water from the continuous press via an outlet of the continuous press for the functional material.

2. The method according to claim 1, characterized in that In at least one method step, the pulverized rigid foam (16) is produced from a polyurethane rigid foam, referred to as PUR for short, a polyisocyanurate rigid foam, referred to as PIR for short, and / or a phenolic rigid foam.

3. The method according to claim 1 or 2, characterized in that: In at least one method step, activated water (24) with a mass fraction of at most 3% of the activator is added to the adhesive (18).

4. The method according to claim 1, characterized in that In the mixing step (14), the binder (18) is added to the powdered rigid foam (16) in a mass fraction less than 10% relative to the total mass of the functional material.

5. The method according to claim 1, characterized in that In at least one method step, at least one organic and / or inorganic filler (26) is added to the raw material, the pulverized rigid foam (16) and / or the binder (18).

6. The method according to claim 5, characterized in that The filler (26) forms the functional material in a flame-retardant manner according to combustion reaction class C in accordance with DIN 13501-1.

7. The method according to claim 1, characterized in that In the pressing step (22), when at least the continuous press is set, the raw material is pressed by the continuous press into a plate (28) having a material thickness of less than 8 mm.

8. The method according to claim 7, characterized in that No subsequent grinding.

9. The method according to claim 1, characterized in that: In the pressing step (22), the raw material is pressed into a plate (28) having a material thickness with a maximum allowable tolerance of at most 1 mm.

10. The method according to claim 9, characterized in that No subsequent grinding.

11. The method according to claim 1, characterized in that: In at least one method step, the functional material is pulverized and the pulverized rigid foam (16) is at least partially replaced by the pulverized functional material.

12. The method according to claim 1, characterized in that In at least one method step, the open time of the raw material is set as a function of the properties of the functional material to be produced.

13. The method according to claim 1, characterized in that In a raw material metering step (50), the raw material is applied to a separating layer, which is removed from the functional material after the pressing process (22).

14. The method according to claim 1, characterized in that In a raw material metering step (50), the raw material is applied to a covering layer which, after the pressing process (22), is integrally connected to the hardened raw material.

15. A functional material produced by the method according to any one of claims 1 to 14.

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