Material for sound and heat insulation as well as a system for screed renovation

Abstract

Material for sound and heat insulation between a first structural component and a second structural component adjacent to the first structural component, with a material composition suitable and designed to have a flowable processing consistency in a first state and a flow-resistant construction consistency in a second state, characterized in that the material composition comprises a granulate of expanded polystyrene bound in an aqueous polymer matrix and a thixotropic agent, wherein the effect of the thixotropic agent leads to the second state in which the flow-resistant construction consistency is present.

Description

[0001] The invention relates to a material for sound and heat insulation between a first structural element and a second structural element adjacent to the first structural element, comprising a material composition suitable and designed to exhibit a flowable processing consistency in a first state and a flow-resistant construction consistency in a second state. Furthermore, the invention relates to a system for the renovation of a screed in a wall area, wherein an edge strip is installed between the screed and the wall area.

[0002] During screed work, an edge strip is typically installed between the screed and the wall to prevent sound bridges, provide insulation against cold, and accommodate screed movement. However, during renovations, for example following water damage, this edge strip is often removed to ensure thorough drying. Currently, no adequate replacement is provided in such cases, leaving the renovated area without an edge strip for sound decoupling, thermal insulation, and movement absorption. This results in a structural defect or, at the very least, an area where the screed meets the wall that has been inadequately repaired.

[0003] Common materials such as mortar, polyurethane foams, or sealants are either too hard, not elastic enough, difficult to work with, or prone to phase separation. Furthermore, they cannot be reliably applied in narrow perimeter joints.

[0004] The invention is based on the objective of providing a material and a system with which, after a renovation of a structural building element, in particular a screed, a condition can be essentially restored between this and an adjacent structural building element, in particular a wall, as existed before the renovation.

[0005] The object is achieved according to the invention by the material composition comprising a granulate of expanded polystyrene bound in an aqueous polymer matrix and a thixotropic agent, wherein the effect of the thixotropic agent leads to the second state in which the flow-resistant construction consistency is present.

[0006] An advantage of the present invention is that the material can be sold in small volumes, particularly air-dried, and only mixed with water on-site in the required quantity to allow it to be processed, preferably in a paste-like consistency. After processing, it can harden to achieve a flow-resistant, construction-grade consistency. Preferably, however, the material is supplied ready-to-use as a paste in a plastic bucket. At the point of use, the paste-like material can be drawn up with a mortar pump and then applied to a perimeter joint. In this case, adding and mixing on-site is unnecessary.

[0007] A further advantage of the present invention is that the flow-resistant material is elastic. As it hardens to an elastic consistency, the material becomes a fully-fledged replacement for the missing edge strip at the end of the processing and can even exhibit better sound absorption properties.

[0008] It is also an advantage of the present invention that the expanded polystyrene granules comprise grains with a particle size of 0.1 to 2.0 mm. These particle sizes ensure a low density while maintaining an excellent paste-like consistency for processing and an elastic consistency for construction. Initially, rubber granules were tested as an insulating material. However, despite the elastic polymer matrix, the resulting end product was too hard. In contrast, the use of polystyrene beads led to a significantly more elastic mass. Different particle sizes were investigated; smaller particle sizes proved to be particularly easy to process and resulted in a homogeneous, elastic structure.

[0009] A further advantage of the present invention is that the aqueous polymer matrix is ​​based on a vinyl-acrylate copolymer, and in particular a vinyl acetate copolymer. During development, various binder matrices were investigated. PU dispersions proved unsuitable because they become too hard after curing. Acrylate and vinyl acetate dispersions, on the other hand, showed significantly higher elasticity and are also more cost-effective. Therefore, an acrylate dispersion was chosen as the base. However, the invention is not limited to such an acrylate dispersion as the binder matrix. Alternatively, other materials can also be used, especially those based on a vinyl-acrylate or vinyl acetate copolymer.

[0010] Simply mixing acrylate dispersion and polystyrene granules resulted in poor applicability. Adding water created a pumpable slurry that could be easily applied to the perimeter joint between the first structural element, particularly the screed, and the second structural element, particularly the wall. However, phase separation occurred between the water and the granules, which impaired its shelf life. Therefore, a thixotropic agent was added for stabilization.

[0011] A further advantage of the present invention is therefore that the thixotropic agent is produced on the basis of an agent from the group consisting of methylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, guar gum, locust bean gum, tamarind bean gum, gum arabic, tragacanth gum, agar-agar, carrageenan, sodium alginate, xanthum gum, gellan gum, pullulan, potato starch, corn starch, wheat starch, bentonite, attapulgite, and sepiolite.

[0012] Particularly suitable are starches (potato or corn starch) or other thickeners, especially methylcellulose. Increasing the viscosity results in a stable, storable slurry that shows no phase separation in the bucket and is still easy to process.

[0013] After curing, an elastic polystyrene matrix is ​​formed, which is significantly more flexible than conventional polystyrene sheets. A suitable polystyrene according to the invention is commercially available under the brand name Styropor®.

[0014] Further advantages of the present invention result from the additional features of the dependent and subsidiary claims.

[0015] A perimeter joint is formed between one structural element, in particular the screed, and the other structural element, in particular the wall. This joint is located where the edge trim was installed before the renovation. Remnants of the edge trim may be present in the area adjacent to the renovation. The flowable material, preferably in a paste-like consistency, is applied to this perimeter joint and then hardens there to its flowable and elastic consistency. At this consistency, the material fulfills the functions of sound decoupling, thermal insulation, and movement absorption between the wall and screed, thus providing a high-quality solution for renovation projects.

[0016] The expanded polystyrene ensures low density and good thermal and acoustic insulation properties. The aqueous polymer matrix binds the granules and gives the material a stable, elastic structure after curing. The thixotropic agent prevents phase separation and creates a pumpable, easy-to-process consistency.

[0017] According to claim 2, the flow-resistant construction consistency can be elastic, thereby accommodating movements of the screed. According to claim 3, the polystyrene granules comprise particle sizes of 0.1 to 2.0 mm, enabling a homogeneous distribution. According to claims 4 and 5, the polymer matrix can be based on a vinyl acrylate or vinyl acetate copolymer. Claim 6 names suitable thixotropic agents, including cellulose derivatives, natural polysaccharides, and mineral thickeners.

[0018] A particularly suitable composition in the processed state is specified in claim 7 and comprises, among other things, 60-80 wt.% water, 10-30 wt.% acrylate dispersion, and 1-10 wt.% polystyrene granules. The weight percent values ​​refer to the material in its pasty, pre-processed consistency.

[0019] The material, in its paste-like processing consistency, preferably also contains 0.01–0.5 wt% preservatives. In particular, a mixture of 2-methyl-2H-isothiazol-3-one and 1,2-benzisothiazol-3(2H)-one in a ratio of 1:4 to 4:1 is used as the preservative. This product is commercially available.

[0020] Trials were conducted with other weight proportions of the material in the paste-like processing consistency, without achieving results even remotely as good as those with the aforementioned weight proportions.

[0021] The system according to claim 8 provides that an edge joint is formed between a renovated screed and a wall area without edge strips. The material is introduced into this edge joint in its first, flowable state. After hardening, the material is in its second, flow-resistant state and forms an elastic, sound-decoupled edge joint.

[0022] This material is not only suitable for forming edge joints. Due to its elastic, heat-insulating and pumpable properties, it can also be used as a leveling compound when installing underfloor heating, as a joint filler in drywall systems, or as an elastic insulating compound in other construction areas.

[0023] One embodiment comprises a composition according to claim 7. The material is poured or pumped into the perimeter joint and hardens within a few hours to a few days, depending on temperature and humidity. After hardening, the material has an elastic consistency that accommodates movements of the screed and reduces sound transmission.

Claims

[1] Material for sound and heat insulation between a first structural element and a second structural element adjacent to the first structural element, having a material composition suitable and designed to have a flowable processing consistency in a first state and a flow-resistant construction consistency in a second state, characterized by , that the material composition comprises a granulate of expanded polystyrene bound in an aqueous polymer matrix and a thixotropic agent, wherein the action of the thixotropic agent leads to the second state in which the flow-resistant construction consistency is present. [2] Material according to claim 1, characterized by that the flow-resistant construction consistency is elastic. [3] Material according to claim 1 or 2, characterized by , that the expanded polystyrene granules comprise granules with a grain size of 0.1 to 2.0 mm. [4] Material according to any one of claims 1 to 3, characterized by that the aqueous polymer matrix is ​​based on a vinyl acrylate copolymer. [5] Material according to claim 4, characterized by that the aqueous polymer matrix is ​​based on a vinyl acetate copolymer. [6] Material according to any of the preceding claims, characterized by , that the thixotropic agent is based on an agent from the group consisting of methylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, guar gum, locust bean gum, tamarind bean gum, gum arabic, tragacanth gum, agar-agar, carrageenan, sodium alginate, xanthum gum, gellan gum, pullulan, potato starch, corn starch, wheat starch, bentonite, attapulgite, sepiolite. [7] Material according to claim 6, characterized by that the material composition in the first state includes 60-80 wt.% water, 2-8% by weight of cornstarch or potato starch, 10-30 wt.% acrylate dispersion 1-10 wt.% expanded polystyrene granules 0.01-0.5 wt.% preservatives [8] System for the renovation of a screed in a wall area, wherein an edge strip is installed between the screed and the wall area, characterized by , that between the renovated screed and a wall area without edge strips an edge joint is formed into which a material, in particular according to one of claims 1 to 7, is introduced in a first flowable state and hardens until the second flow-resistant state is reached. [9] Containers comprising a container and a material according in particular one of claims 1 to 7, characterized bythat the container comprises a plastic container with a dispensing opening into which the processable, pasty material is filled, wherein the plastic container has a substantially airtight resealable lid for the dispensing opening.