Insulating fill materials, as well as insulating fill layers made from them and ceiling structures with the insulating fill layers

Abstract

Loose insulating fill for producing a loose, unconsolidated insulating fill layer, wherein the loose insulating fill comprises a pumice insulating granulate made of unbroken pumice granules, characterized in that the loose insulating fill a) a continuous grain distribution, b) a maximum grain size ≤ 8 mm, and c) has a proportion of granules with a grain size > 4 mm, wherein the proportion of granules with a grain size > 4 mm in the insulation fill is 5 to 15 wt.%, preferably 10 to 15 wt.%.

Description

[0001] The present invention relates to a loose insulating fill for producing an insulating fill layer, as well as a loose, unconsolidated insulating fill layer produced from the insulating fill, and a ceiling structure with the loose, unconsolidated insulating fill layer.

[0002] Furthermore, the invention relates to a bonded insulating fill for the production of a bonded, solidified insulating fill layer, as well as a bonded, solidified insulating fill layer produced therefrom and a ceiling structure with the bonded, solidified insulating fill layer.

[0003] Loose fill materials are conglomerates of granular material. Insulating loose fills contain at least one insulating granule and are used for both thermal and acoustic insulation. Furthermore, loose fills, once installed, compensate for unevenness in the ground and are often used for this purpose (leveling fills). Examples of insulating granules include expanded clay, expanded glass, expanded shale, aerated concrete, or perlite.

[0004] Furthermore, a distinction is made between loose and bound fill materials.

[0005] Loose fill is applied to the respective substrate and only compacted slightly if necessary. The individual granules of the material are not bonded together.

[0006] A bonded fill contains at least one binder, e.g., a mineral or hydraulic binder. The hydraulic binder preferably consists of Portland cement. The fill is then mixed with water to form a ready-mixed compound, applied to the respective substrate, compacted and / or leveled as necessary, and subsequently allowed to harden. This process bonds the individual granules together and solidifies the fill. However, since the binder content is very low, the granules—unlike, for example, in a lightweight concrete formwork—are not embedded in a continuous binder matrix, but are only bonded to each other at specific points.

[0007] The binder can also be a polymer dispersion.

[0008] Also well-known on the market is the fermacell® honeycomb insulation system, particularly for timber joist ceilings. The fermacell® honeycomb insulation system consists of a cardboard honeycomb panel with open honeycomb cells and a loose fill of limestone granules. The honeycomb panels are laid on the substrate, and the fill is poured into the cells. The fill is then leveled, for example with a straightedge, to create a flat surface. A dry screed element, for instance, is then laid on top of the insulation system.

[0009] DE 41 03 833 A1 discloses the use of a dry mixture of 10 to 40 wt.% of a hydrophobized, mineral bulk material from the group consisting of expanded perlite, pumice, foam glass, lava, expanded clay and / or expanded vermiculite with a bulk density between 60 and 250 kg / m³ 3in a particle size fraction < 10 mm and 60 to 90 wt.% of a calcium sulfate carrier, in particular in the form of gypsum plaster and / or alpha hemihydrate, for the production of a leveling layer (after spraying water onto the previously applied dry mix) under screeds, especially self-leveling screeds. The leveling layer hardens after being sprayed with water.

[0010] DE 199 39 470 A1 discloses a floor construction for covering a substrate, in particular for the floor or ceiling of a room, with a first layer arranged above the substrate for sound insulation, wherein the first layer consists essentially of a first bulk material. Above the first layer, a second layer is arranged for thermal insulation, which consists essentially of a second bulk material, wherein the first bulk material has a higher specific density than the second bulk material in order to promote layer formation through the different specific densities of the two bulk materials. The first bulk material can consist essentially of expanded clay, expanded shale, basalt, shale, or a mixture thereof, and the second bulk material can consist essentially of pumice.

[0011] The object of the present invention is to provide a loose insulating material for the production of a loose, unconsolidated insulating layer with good sound insulation and strength properties.

[0012] Further tasks include providing a loose insulating layer produced from it and a ceiling structure with such an insulating layer.

[0013] A further object of the present invention is the provision of a bonded insulating fill for the production of a bonded, solidified insulating fill layer with good sound insulation and strength properties.

[0014] Further tasks include providing a bonded, solidified insulating loose-fill layer produced from it and a ceiling structure with such an insulating loose-fill layer.

[0015] These problems are solved by a loose insulating fill with the features of claim 1, a bonded insulating fill with the features of claim 12, an unconsolidated insulating fill layer with the features of claim 13, a consolidated insulating fill layer with the features of claim 14, and a ceiling assembly with the features of claim 17. Advantageous embodiments of the invention are characterized in the respective dependent claims.

[0016] The loose insulating material according to the invention serves to produce a loose insulating layer and comprises pumice insulating granules made of unbroken pumice granules. According to the invention, the loose insulating material has a continuous grain distribution and a maximum grain size ≤ 8 mm. Furthermore, according to the invention, the loose insulating material has a proportion of granules with a grain size > 4 mm, wherein the proportion of granules with a grain size > 4 mm in the loose insulating material is 5 to 15 wt.%, preferably 10 to 15 wt.%.

[0017] Unless otherwise specified, the particle size within the scope of the invention is determined by sieving in accordance with DIN 933-1:2012-03.

[0018] The loose insulating material according to the invention preferably consists of at least 80% by mass, preferably at least 90% by mass, preferably at least 95% by mass, and particularly preferably at least 100% by mass of the pumice insulating granules.

[0019] Pumice, also known as natural pumice or pumice stone, is a porous (vesicularly loosened) glassy volcanic rock whose chemical composition is similar to obsidian. In particular, pumice granules exhibit a high open porosity. Since pumice is a granular ejecta, the granules do not need to be crushed and are used uncrushed according to the invention. Furthermore, the pumice granules preferably have a rounded, cubic shape with a rough surface structure according to DIN EN ISO 14688-1:2020-11. The rounded shape results from minimal abrasion during flight and sedimentation.The described grain shape gives the loose insulating fill according to the invention good stability and strength, since the individual granules cannot slip off each other as easily as is the case, for example, with known round granules made of expanded glass or expanded clay.

[0020] As already explained, the granules consist of pumice; they are therefore not hydrophobic or otherwise treated.

[0021] The continuous grain distribution according to the invention ensures good compaction of the insulation material during application without the need for further compaction. Settling of the insulation layer during subsequent use is also minimized.

[0022] Limiting the maximum particle size of the loose insulation to 8 mm ensures that no grooves form when the insulation is leveled after application. This is because grooves can occur if the granules are too large. For this reason, the proportion of granules with a particle size > 6.3 mm in the loose insulation is preferably only 0 to 10% by mass, and more preferably 0 to 5% by mass.

[0023] The fact that the loose insulation material also contains granules with a grain size > 4 mm ensures that it has a low bulk density and therefore good thermal insulation. This is because it increases the void volume between the individual granules.

[0024] Preferably, the loose insulating fill has a bulk density of 400 to 600 kg / m³. 3 preferably 450 to 550 kg / m² 3 , determined according to DIN EN 1097-3:1998-06.

[0025] Furthermore, the loose insulating material preferably has a thermal conductivity of 0.080 to 0.120 (W·m) / K, preferably 0.085 to 0.110 kg / m³. 3 , particularly preferably from 0.090 to 0.100 (W·m) / K, determined according to EN 12667:2001.

[0026] Preferably, the loose insulation material also contains only a small proportion of granules with a grain size ≤ 0.5 mm. This reduces dust levels. In particular, the loose insulation material contains a proportion of granules with a grain size ≤ 0.5 mm of 0 to 10 wt.%, preferably 0 to 5 wt.%.

[0027] And the proportion of granules with a grain size of > 0.5 mm to 1 mm is preferably 3 to 30 wt.%, preferably 5 to 25 wt.%.

[0028] Furthermore, the proportion of granules with a grain size of > 1 mm to 2 mm is preferably 15 to 45 wt.%, preferably 25 to 40 wt.%.

[0029] Furthermore, the proportion of granules with a grain size of > 2 mm to 4 mm is preferably 5 to 25 wt.%, preferably 10 to 20 wt.%.

[0030] Preferably, the loose insulation material also has a moisture content of < 6.0 wt.%, preferably < 2 wt.%, according to DIN EN 1097-5:2008-06. This ensures that, for example, no moisture migrates into the floor structure.

[0031] After extraction, pumice typically has a higher moisture content. For this reason, the extracted pumice granules are preferably dried to the residual moisture content specified above.

[0032] The loose insulating material according to the invention is preferably packaged in a container, preferably a sack or big bag. The container does not need to be airtight. Furthermore, the container preferably has a filling volume of 40 to 1200 liters, more preferably 40 to 1000 liters. Preferably, the sack has a filling volume of 40 to 80 liters, more preferably 50 to 60 liters. And the big bag preferably has a filling volume of 800 to 1200 liters, more preferably 900 to 1000 liters.

[0033] Preferably, the loose insulating material according to the invention is used to produce a loose, unconsolidated insulating layer for a ceiling structure, in particular a timber beam ceiling, a vaulted ceiling, or a solid ceiling. For this purpose, the loose insulating material is poured onto the respective substrate, compacted if necessary, and leveled with a screed. Optionally, wall insulation strips can be installed beforehand in a manner known per se, and the insulating material is placed between the wall insulation strips.

[0034] The height of the insulating fill layer is preferably 5 to 250 mm, preferably 10 to 200 mm.

[0035] A layer of drywall panels, preferably made of gypsum fiberboard or cement-bonded drywall panels, is preferably laid on top of the insulating fill layer.

[0036] An insulating layer, preferably made of mineral wool, is preferably laid on top of the drywall panel layer.

[0037] Dry screed elements are preferably laid on the insulation layer. These dry screed elements are preferably gypsum fiber screed elements (e.g., fermacell screed element), in particular consisting of at least one gypsum fiberboard, or screed elements made of cement-bonded lightweight concrete panels (e.g., fermacell Powerpanel TE).

[0038] The dry screed layer forms the level substrate for the floor covering in a manner that is known per se.

[0039] However, it could also be a conventional screed layer made from screed mortar.

[0040] As already explained, the invention also relates to a bonded loose-fill insulation material. The bonded loose-fill insulation material comprises the loose loose-fill insulation material and at least one binder. This binder can be a mineral, preferably hydraulic, binder, a polymer dispersion, or a mixture thereof. The binder can therefore be solid or liquid. Furthermore, it can be mixed with the loose loose-fill insulation material (in the case of a dry binder) or packaged separately from it (in the case of a dry or liquid binder).

[0041] To produce a solidified loose-fill insulation layer, the loose insulation material is mixed with the appropriate amount of binder and, if necessary, water until a homogeneous fresh mixture is obtained. Mixing can be done, for example, using a hand mixer, a screed pump, or a forced-action mixer.

[0042] The loose-fill compound is then poured onto the respective substrate and leveled using a screed. If necessary, wall insulation strips can be installed beforehand, and the loose-fill compound is then applied between the strips.

[0043] The binder mixture is then allowed to harden. After hardening, the insulating fill is present in the form of a dimensionally stable layer, preferably a leveling layer for compensating for unevenness in the substrate.

[0044] The height of the insulating fill layer is also preferably 5 to 250 mm, preferably 10 to 200 mm.

[0045] In addition, the bonded, solidified loose-fill insulation layer is covered with a layer of drywall panels, just as described above for the loose-fill insulation layer.

[0046] Finally, it should be noted that all the aforementioned, in particular claimed, features of the insulating material fillings and the ceiling structures are particularly advantageous on their own and in any combination and are the subject of the present invention.

[0047] Furthermore, according to the invention, the upper and lower limits specified for each range can all be combined with one another. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 41 03 833 A1

[0009] DE 199 39 470 A1

[0010] Cited non-patent literature

[0000] DIN EN 1097-5:2008-06

[0030]

Claims

[1] Loose insulation fill for producing a loose, unconsolidated insulation fill layer, wherein the loose insulation fill comprises pumice insulation granules made of unbroken granules of pumice, characterized by that the loose insulation fill a) a constant grain distribution, b) a maximum grain size ≤ 8 mm, and c) has a proportion of granules with a grain size > 4 mm, wherein the proportion of granules with a grain size > 4 mm in the insulating material filling is 5 to 15 mass%, preferably 10 to 15 mass%. [2] Loose insulation filling according to claim 1, characterized by that the loose insulation fill consists of at least 80 mass%, preferably at least 90 mass%, more preferably at least 95 mass%, particularly preferably 100 mass% of the pumice insulation granulate. [3] Loose insulation filling according to claim 1 or 2, characterized bythat the loose insulation fill has a proportion of granules with a grain size > 6.3 mm of 0 to 10 mass%, preferably 0 to 5 mass%. [4] Loose insulation filling according to one of the preceding claims, characterized by that the loose insulation fill has a proportion of granules with a grain size ≤ 0.5 mm of 0 to 10 mass%, preferably 0 to 5 mass%. [5] Loose insulation filling according to one of the preceding claims, characterized by that the loose insulation fill has a proportion of granules with a grain size of > 1 mm to 2 mm of 15 to 45 mass%, preferably 25 to 40 mass%. [6] Loose insulation filling according to one of the preceding claims, characterized by that the loose insulation fill has a proportion of granules with a grain size of > 2 mm to 4 mm of 5 to 25 mass%, preferably 10 to 20 mass%. [7] Loose insulation filling according to one of the preceding claims, characterized by that the insulation fill has a bulk density of 400 to 600 kg / m 3 , preferably 450 to 550 kg / m 3 , determined according to DIN EN 1097-3:1998-06. [8] Loose insulation filling according to one of the preceding claims, characterized by that the insulation fill has a thermal conductivity of 0.080 to 0.120 (W·m) / K, preferably 0.085 to 0.110 kg / m 3 , particularly preferably from 0.090 to 0.100 (W·m) / K, determined according to EN 12667:2001. [9] Loose insulation filling according to one of the preceding claims, characterized by that the insulation fill has a moisture content of < 6.0 M%, preferably < 2 M%, according to DIN 1097-5:2008-06. [10] Loose insulation filling according to one of the preceding claims, characterized by that the pumice granules have a rounded, cubic grain shape with a rough surface structure according to DIN EN ISO 14688-1:2020-11. [11] Loose insulation filling according to one of the preceding claims, characterized by that the loose insulation material is packed in a container, preferably a sack or big bag, wherein the container preferably has a filling quantity of 40 to 1200 liters, preferably 50 to 1000 liters. [12] Bound, pourable insulation fill for the production of a bound, solidified insulation fill layer, characterized by that the bound insulation fill comprises the loose insulation fill according to one of the preceding claims and at least one binder. [13] Unconsolidated layer of insulation material arranged on a substrate, characterized by that the insulating fill layer is made of a loose insulating fill according to one of claims 1 to 12. [14] Solidified, bound, dimensionally stable insulating layer arranged on a substrate, characterized bythat the insulating fill layer is made of a bound insulating fill according to claim 12. [15] Unconsolidated or consolidated insulating fill layer according to claim 13 or 14, characterized by that the insulation layer is a leveling layer to compensate for unevenness in the substrate. [16] Unconsolidated or consolidated insulating fill layer according to claim 13, 14 or 15, characterized by that the insulation layer has a height of 5 to 250 mm, preferably 10 to 200 mm. [17] Ceiling construction, in particular a wooden beam ceiling or a vaulted ceiling or a solid ceiling, characterized by that the ceiling structure has an unconsolidated or a consolidated insulating layer according to one of claims 14 to 16. [18] Ceiling structure according to claim 17, characterized by , that the ceiling structure a) a layer of drywall boards arranged directly on the insulation layer, preferably made of gypsum fibreboard or cement-bonded drywall boards, and / or b) an insulating layer, preferably made of mineral wool, preferably arranged on the drywall layer, and / or c) a screed layer, preferably arranged on the insulation layer, preferably a dry screed layer made of dry screed elements, has. [19] Ceiling structure according to claim 18, characterized by that the dry screed elements are gypsum fibre screed elements, in particular consisting of at least one gypsum fibre board, or cement-bonded lightweight concrete boards.