Continuous process for producing a functional material, a raw material for a functional material and a functional material

Description

State of the art

[0001] The invention relates to a method for producing a functional material and the functional material produced thereby.

[0002] The production of a functional material from rigid polyurethane foam and a binder in a discontinuous process is known from "Recycling von Polyurethan-Kunststoffen" by W. Raßhofer, Heidelberg: Hüthig GmbH, 1994, pages 386-390, ISBN 3-929471-08-6. In particular, a raw material is pressed using a press, with the raw material remaining in the stationary press for a molding time until it hardens into the functional material.

[0003] EP 3 371 250 B1 describes a functional material produced in this way, which is made, among other things, from shredded PUR rigid foam (polyurethane rigid foam) and / or shredded PIR rigid foam (polyisocyanurate rigid foam) and a binder.

[0004] Due to the flow behavior of bulk material made of shredded PUR / PIR rigid foam and the bulk material's height, the required qualities of the functional material can only be ensured with relatively wide trims. This is because, at the beginning and end of a sheet made of the functional material and at the edges, the bulk material flows outward when pressure is applied, creating so-called soft zones that must be subsequently removed. Such soft zones could be avoided by using a device that encloses the pressed material in a frame and precisely inserts the press into the frame. However, this would be very complex and time-consuming due to the difficulty of demolding, and would be uneconomical.

[0005] WO 2019 / 229007 A1 describes a continuous pressing process for fiber composite panels. Continuous processes in which materials are to be compacted using pressure and temperature typically use so-called continuous heating presses. Such presses have been of great importance for many decades in the wood industry, which produces numerous types of single- and multi-layer particle boards, with and without surface coatings, and with both rigid and loose structures.

[0006] EP 0 245 544 A2 and EP 2 366 532 A1 disclose continuous processes for producing a functional material from a binder and polyurethane residues in the form of pellets or beads. The pellets or beads are treated with steam through a perforated conveyor belt to cure the binder.

[0007] US 3 726 624 A discloses a continuous process for producing a functional material from binder and polyurethane residues, which are crushed by an impact mill to a size of up to 5 / 16 inch 2<.

[0008] However, the decisive factors for successful production and achieving the desired technical product properties of the functional material are the materials to be pressed, a recipe for a raw mass made from the materials and its adaptation to a pressing process.

[0009] The object of the invention is, in particular, to provide a generic method with improved properties with regard to the required production time for the functional material and with regard to the quality of the functional material produced thereby. This object is achieved according to the invention by the features of claim 1, while advantageous embodiments and further developments of the invention can be found in the subclaims. Advantages of the invention

[0010] The invention is based on a method for producing a functional material, wherein in at least one mixing step a rigid foam and at least one binder, in particular one which is liquid at room temperature and standard pressure, are mixed to form a raw mass and wherein in at least one pressing step the raw mass is pressed to form the functional material, wherein the method runs continuously at least from the mixing step up to and including the pressing step, wherein in the pressing step the raw mass is continuously fed to a continuous press, the raw mass is continuously pressed by the continuous press and the functional material is continuously output from the continuous press.

[0011] It is proposed that the rigid foam is pulverized in the at least one mixing step, is formed at least substantially from a thermoset and has an average particle size of less than 5 mm. The functional material can be used, for example, as a thermal insulation material and / or as a material, in particular for housings, furniture, construction, buildings, building interiors, vehicle interiors or the like. Particularly preferably, the functional material is additionally designed as a structural material, in particular in addition to a thermal insulation function. In particular, the functional material has a thermal conductivity according to EN 12667 of at most 0.10 W / (m•K), preferably of less than 0.07 W / (m•K). The functional material has, in particular, a bulk density of greater than 150 kg / m 3< , preferably greater than 300 kg / m 3< , particularly preferably greater than 450 kg / m 3< .Preferably, the functional material has a compressive stress according to DIN EN 826 greater than 1 MPa, preferably greater than 3 MPa, particularly preferably greater than 6 MPa.

[0012] Optionally, the method comprises a comminution step in which objects containing the rigid foam and / or at least substantially formed from the rigid foam are mechanically comminuted. The term "essentially formed from a material" is understood to mean, in particular, that at least 50%, preferably more than 75%, particularly preferably more than 90%, of a total volume and / or a total mass of the object is formed from the material. Preferably, the rigid foam is separated from other components of the objects, in particular before the comminution step, during the comminution step, and / or after the comminution step. In particular, the rigid foam is pulverized in the comminution step, for example, by grinding, shredding, and / or chopping. Alternatively, the rigid foam is already in pulverized form.The pulverized rigid foam is, in particular, formed at least substantially from rigid foam particles, each of which has a cellular structure of the rigid foam. Each individual rigid foam particle of at least a majority of the rigid foam particles of the pulverized rigid foam has a maximum spatial extent of at least substantially the same size in every direction. The term "substantially equal" refers, in particular, to the fact that a larger of the two achievable quotients of the values ​​is less than 5, preferably less than 3, particularly preferably less than 2. Maximum spatial extents of different rigid foam particles can be at least substantially the same size or of different sizes. The pulverized rigid foam preferably has a flour-like consistency.In particular, an average particle size of the pulverized rigid foam is less than 1 mm, particularly preferably less than 500 µm. Preferably, an 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 comprises a rigid foam dosing step in which the pulverized rigid foam is transferred from a powder silo or directly from a comminution system to a continuous conveyor for pulverizing the rigid foam. The continuous conveyor can be designed as a mechanical conveyor, a gravity conveyor, or a flow conveyor. In the rigid foam dosing step, the pulverized rigid foam is transferred to the continuous conveyor, in particular continuously at an adjustable rigid foam rate.

[0013] The binder is preferably present as a liquid, particularly under laboratory conditions, before the binder cures. The binder is preferably organic, alternatively inorganic. The binder preferably comprises an isocyanate. More preferably, the binder comprises at least one methylene diphenyl isocyanate (MDI). Alternatively or additionally, the binder comprises toluene-2,4-diisocyanate (TDI), urea, or waterglass. The process comprises, in particular, a binder dosing step in which the binder is added to the pulverized rigid foam. In the binder dosing step, the binder is added, in particular, continuously to the pulverized rigid foam at an adjustable binder rate.

[0014] In the mixing step, the pulverized rigid foam and the binder are continuously mixed, in particular by means of a continuous mixer, particularly preferably by means of a screw extruder. Preferably, the continuous conveyor continuously feeds the pulverized rigid foam to the continuous mixer. Preferably, the binder is added, in particular sprayed, to the pulverized rigid foam within the continuous mixer. In particular, the raw material is continuously produced in the mixing step. The continuous mixer continuously discharges the raw material, in particular at the end of the mixing step, and transfers it, in particular continuously, to another continuous conveyor, in particular to a belt conveyor and / or a link belt conveyor.In particular, the continuous mixer creates an endless belt of raw material, which is continuously conveyed by the further continuous conveyor to a continuous press, in particular a continuously operated continuous press.

[0015] The method preferably 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 of another raw material, which in particular comprises a different grade of rigid foam and / or a different rigid foam than the raw material, is applied to the pre-compacted raw material.

[0016] In the pressing step, the raw mass, in particular the pre-compacted one, is continuously pressed, in particular if present together with the other layers.

[0017] Preferably, the raw material is subjected to a temperature in the pressing step, in particular to accelerate a chemical reaction, in particular a polyaddition and / or polycondensation, of the binder. In the pressing step, in particular in contrast to a cyclically operated continuous device or multi-stage press, the raw material is continuously fed to the continuous press, the raw material is continuously pressed by the continuous press, and the functional material is continuously discharged from the continuous press. The continuous press converts the raw material, in particular, into an endless belt of the functional material, which is continuously conveyed by the further continuous conveyor to a finishing station. Preferably, the method comprises a finishing step in which a section is separated from the endless bath of the functional material.

[0018] A continuously operable production plant for the functional material comprises, in particular, the continuous conveyor, the continuous mixer, the additional continuous conveyor, the continuous press for compression, the continuous device for pre-compaction, the assembly station, a binder tank and a binder dosing device, the powder silo and a dosing device for the pulverized rigid foam and / or the comminution system, as well as optionally at least one storage and dosing device each for an optional filler and / or for an optional covering layer. The process is carried out, in particular, during an active, regular operating state of the production plant, in particular after startup of the production plant. "Continuous" should be understood to mean continuously, in particular without interruption, for the duration of the process, particularly in contrast to discontinuous start-stop operation.The method is terminated, in particular, at the latest by manually or automatically terminating the regular operating state of the production plant, for example, by shutting down the production plant, triggering an error state and / or a maintenance state of the production plant, or the like. In particular, at least the rigid foam dosing step, the binder dosing step, the mixing step, the pre-pressing step, and / or the pressing step are performed simultaneously at different points on the endless belt of raw material or a precursor of the raw material.Preferably, the process, particularly in contrast to a discontinuous process, runs automatically, in particular without operator intervention, at least from the mixing step, particularly preferably at least from the rigid foam dosing step, optionally from the comminution step, up to and including the pressing step, preferably up to and including the finishing step. In particular, a control unit of the production plant controls or regulates the production plant during the process, particularly during the rigid foam dosing step, the binder dosing step, the mixing step, the pre-pressing step, the pressing step, and / or the finishing step, preferably fully automatically. A "control unit" is to be understood in particular as a unit with at least one control electronics unit."Control electronics" is understood, in particular, to mean a unit comprising a processor unit and a memory unit, as well as an operating program stored in the memory unit. In particular, the control unit controls or regulates the production plant without operator intervention, particularly at least after presetting the production plant or after an operator has entered process parameters into the operating program.

[0019] The design according to the invention advantageously allows trimming required due to the flow behavior of the raw material to be kept to a minimum. In particular, trimming perpendicular to a conveying direction of the raw material, which in particular determines the dimensions of a sheet, can be dispensed with. In particular, a soft zone that arises at an edge of a pressing area can be advantageously kept small. In particular, waste required to remove the soft zone from the functional material with the desired properties can be advantageously kept to a minimum. In particular, costly and / or time-consuming measures to delimit the soft zone, for example a frame construction for the raw material that is precisely tailored to a discontinuous press, can be dispensed with.In particular, high-quality cover layers can be applied to the raw material with advantageously little waste, so that the functional material can be provided with high-quality cover layers in a beneficial and cost-effective manner. In particular, a separate work step for applying the cover layers to the, in particular, pre-cut sheets of the functional material can be dispensed with. Furthermore, even with a functional material with a high material thickness, in particular of more than 20 mm, for which a large amount of steam is necessary for complete hardening, the steam pressure within the raw material and the functional material can be advantageously kept low and, in particular, a sudden pressure reduction when opening the discontinuous press can be avoided. In this way, the risk of cracking in the functional material after the pressing step can be advantageously kept low.In particular, for a functional material with a low material thickness, in particular less than 10 mm, the required duration of the pressing step can advantageously be kept short, in particular shorter than the time required for preparing the raw material. This makes it possible to achieve an advantageously high production capacity. In particular, the functional material can advantageously be produced quickly. Furthermore, a cooling press can advantageously be dispensed with. Furthermore, the length of a plate made of the production material can advantageously be selected arbitrarily and is in particular not limited by the dimensions of the continuous press. In particular, there is no need to convert the production plant to change the length of the plate.

[0020] It is further proposed that, in at least one process step, the pulverized rigid foam be produced from polyurethane rigid foam (PUR for short), polyisocyanurate rigid foam (PIR for short), and / or phenolic rigid foam. The rigid foam is, in particular, at least substantially pressure-resistant. "At least substantially pressure-resistant" is understood to mean, in particular, according to standard EN 826 and advantageously, withstanding a pressure of more than 100 kPa, preferably more than 120 kPa. In particular, "PUR" is understood to mean a rigid foam according to DIN EN 13165 and / or EN 14308. In particular, "PIR" is understood to mean a rigid foam according to EN 14308 and / or ASTM C 1289. Before pulverization, the rigid foam preferably has a thermal conductivity, in particular according to EN 12667, of less than 0.037 W / Km.Before pulverization, the rigid foam preferably has a thermal conductivity according to EN 12667 of less than 0.03 W / Km, particularly preferably less than 0.025 W / Km. The rigid foam particles are obtained in particular by mechanical comminution, so that the cell structure of the rigid foam in the rigid foam particles is at least partially retained. In particular, the thermal conductivity of the individual rigid foam particles is at least substantially equal to the thermal conductivity of the rigid foam before comminution. In particular, the comminuted rigid foam limits heat conduction within the raw mass. Water, in particular an aqueous solution, is preferably added to the binder in the mixing step and / or in a binder mixing step preceding the mixing step. In particular, the water is evaporated in the pressing step.Preferably, the evaporated water is at least largely enclosed in the raw material during the pressing step for a curing time, which in particular corresponds to a passage time through the continuous press. Optionally, the evaporated water is released from the raw material and / or the functional material partially during the curing time and preferably at least largely after the pressing step, in particular continuously. "Largely" is understood to mean at least 50%, preferably at least 75%, particularly preferably at least 90%, of a total volume and / or total mass. In particular, the evaporated water is intended for heat exchange within the raw material and, in particular, for uniform curing of the binder. "Provided" is understood to mean, in particular, specially designed and / or specially equipped.The fact that an object is intended for a specific function should be understood in particular to mean that the object fulfills and / or performs this specific function in at least one application and / or operating state. The design according to the invention allows the functional material to be produced in a resource-efficient manner, particularly from industrial waste and / or offcuts.

[0021] It is further proposed that, in at least one process step, activated water with an activator mass fraction of no more than 3% is added to the binder. The activated water is, in particular, the aforementioned water intended for evaporation, to which the activator is additionally added. The mass fraction of the activator relates, in particular, to a total mass of an aqueous solution comprising the water and the activator. In particular, in the binder premixing step, the activator is dissolved in the water to produce the aqueous solution. For example, potassium acetate, potassium octoate, an amine activator, and / or another activator deemed appropriate by a person skilled in the art is added as the activator. The activator preferably comprises a mass fraction of less than 2%, particularly preferably less than 1%. The activator preferably comprises a mass fraction of at least 0.01%, particularly preferably at least 0.05%.Before the activator is added, the water can have a quality of process water, filtered water, distilled water, demineralized water, or ultrapure water. Alternatively, the water, in particular without activator, is added to the binder. In particular, a curing time of the raw material is predetermined, among other things, by a ratio of the amount of water and activator to a material thickness of the raw material and / or the functional material. Due to the design according to the invention, the required amount of water can be advantageously kept low for the same curing time and / or the curing time can be advantageously kept short for the same amount of water. In particular, with a smaller amount of water used, a steam pressure within the continuous press can be advantageously kept low and / or the raw material can be subjected to an advantageously high temperature, so that the same steam pressure is achieved with less water.In particular, an advantageously reliable curing of the binder can be achieved. In particular, an advantageously rapid curing of the binder can be achieved. In particular, production capacity can be further increased. Furthermore, the risk of cracking, especially despite faster curing, due to a sudden drop in steam pressure at an output of the continuous press can be advantageously kept low.

[0022] Furthermore, it is proposed that the binder be added to the powdered rigid foam in the mixing step at a mass fraction of less than 10% based on the total mass of the functional material. Preferably, the mass fraction of the binder in the functional material is less than 9%, particularly preferably less than 8%. Optionally, the binder is added to the powdered rigid foam at a mass fraction of the functional material of at least 5%, in particular more than 6%. The powdered rigid foam preferably forms a mass fraction of the functional material of more than 60%, preferably more than 75%, particularly preferably more than 85%.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 the functional material with a bulk density of more than 500 kg / m 3< and / or more than 600 kg / m 3<, in which the binder is added at a mass fraction of more than 10%, in particular up to 12%, preferably up to 15%, particularly preferably up to 18%, based on a total mass of the functional material. Due to the design according to the invention, the functional material can be produced with an advantageously low thermal conductivity. In particular, components of the raw material that are hazardous to health can advantageously be kept low. In particular, the functional material can advantageously be produced cost-effectively.

[0023] Furthermore, it is proposed that, in at least one process step, the raw mass, the pulverized rigid foam, and / or the binder be mixed with at least one organic and / or inorganic filler. The filler is preferably added before and / or during the mixing step. Particularly preferably, the filler is added to the pulverized rigid foam before the mixing step, in particular to the continuous mixer together with the pulverized rigid foam. The filler is preferably in the form of a solid that is added to the pulverized rigid foam and / or the binder in the form of a powder or granulate. Alternatively, the filler or a further filler is in the form of a fiber material that is formed at least substantially from 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. Preferably, the filler has a mass fraction of more than 1%, in particular more than 2%, of the total mass of the functional material. The inventive design allows the functional material to be advantageously provided with additional properties depending on the application, in particular with an advantageously low, particularly negative, impairment of the mechanical and thermal properties of the functional material.

[0024] It is further proposed that the filler makes the functional material flame-retardant according to fire reaction class C according to DIN 13501-1. When exposed to temperature, the filler preferably exhibits an expanding behavior through which a bulk density of the filler changes when a temperature of the functional material exceeds an activation temperature of the additive. In a basic state, the filler has a bulk density which is in particular less than 5 g / cm 3 . The bulk density of the filler is preferably between 1 g / cm 3 and 3 g / cm 3 . The filler preferably has an expansion rate of at least 30 cm 3 / g, in particular under standard atmosphere. The expansion rate of the filler is preferably greater than 100 cm 3 / g and is preferably in a range between 250 cm 3 / g and 400 cm 3 / g, in particular under standard atmosphere.The expansion behavior of the filler causes, particularly under standard atmospheres, an increase in volume of the filler by a factor of preferably at least 10 when the functional material is heated to a temperature greater than the activation temperature of the additive. The filler, in particular, has an activation temperature of at least 90 degrees Celsius. Preferably, the activation temperature is above 120 degrees Celsius. In particular, the raw material is subjected to a temperature below the activation temperature during the pressing step. If the functional material with the filler is heated to the activation temperature of the filler, the filler preferably expands. A volume fraction of the filler changes when a temperature of the functional material exceeds the activation temperature of the filler.The filler has a carbon content that is preferably at least 85%, but can in principle also be lower. The filler preferably comprises graphite. The filler is particularly preferably in the form of expandable graphite. The filler in particular comprises molecules of an acid that are embedded between layers of the graphite. If the filler is heated above the activation temperature, the layers in particular expand and the volume increases. The functional material preferably has fire behavior corresponding to building material class B1 according to DIN 4102-1. The design according to the invention makes it possible to produce an advantageously safe functional material that can be used, and in particular is capable of approval, in a particularly advantageously wide range of applications.

[0025] Furthermore, it is proposed that in the pressing step, in at least one setting of the continuous press, 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 further continuous conveyor comprises, in particular, a conveying direction from the continuous mixer, in particular through the continuous device, to the continuous press, and in particular through the continuous press further to the assembly station. The conveying direction is preferably parallel to a straight line. Alternatively, the conveying direction comprises at least one curve, a deflection point, or the like.The continuous conveyor comprises a maximum conveying width perpendicular to the conveying direction, over which the raw material is distributed in a raw material dosing step by means of a filling device of the conveyor system arranged on the continuous mixer, and which preferably has a constant value along the conveying direction. In particular, the filling device applies the raw material to the further continuous conveyor with a maximum width parallel to the conveying width of the further continuous conveyor of at least 50 cm, preferably of more than 80 cm, particularly preferably of more than 1.1 m. In particular, during the ongoing process, the raw material extends continuously, in particular over several meters, parallel to the conveying direction of the further continuous conveyor from a filling point of the further continuous conveyor to the continuous press.A material thickness of the raw mass and the functional material extends in particular perpendicular to the conveying direction and perpendicular to the conveying width. In particular, the continuous press reduces the material thickness of the raw mass to the material thickness of the functional material. In particular, the continuous press is adjusted in at least one method step so that the material thickness of the functional material is less than 8 mm, in particular less than 7 mm, preferably less than 6 mm, particularly preferably less than 5 mm. Optionally, the continuous press is also adjustable for material thicknesses greater than 8 mm. In particular, in at least one method step, the raw mass is pressed into the functional material with a material thickness of more than 10 mm, in particular more than 40 mm, preferably more than 70 mm, particularly preferably up to 100 mm.In particular, the assembly station separates the plate with an adjustable length parallel to the conveying direction from the endless belt of functional material emerging from the continuous press. The assembly station is particularly designed to separate the plate with a maximum length parallel to the conveying direction of more than 1 m, preferably more than 5 m, particularly preferably more than 20 m, and in particular to feed the separated plate individually or several plates in stacks to a transport, packaging and / or storage device. The design according to the invention makes it possible to produce an advantageously thin functional material with a particularly high insulating effect. In particular, the functional material can also be used in applications that have little available installation space.

[0026] Furthermore, it is proposed that in the pressing step the raw material is pressed into a plate with a material thickness whose maximum permissible tolerance is at most 1 mm, in particular without subsequent grinding. The method optionally comprises a grinding step in order to increase the surface quality of the functional material after the pressing step, wherein the maximum permissible tolerance of the material thickness is already achieved by the pressing step. Preferably, the grinding step is omitted, whereby the plate in particular has advantageously high adhesion for the subsequent application of a cover layer, for example a functional layer and / or decorative layer. Due to the design according to the invention, material loss for straightening the functional material can be advantageously kept low.

[0027] It is further proposed that in at least one process step, the functional material is pulverized and the pulverized rigid foam is at least partially replaced by the pulverized functional material. In particular, the functional material and objects produced from the functional material are / are recyclable within the scope of the process. Preferably, the functional material is pulverized in the comminution step, in particular together with or separately from the rigid foam. Optionally, binder residues of the functional material are filtered out of the pulverized functional material, in particular depending on their mass and / or density. Alternatively, the binder residues are left in the pulverized functional material. The pulverized functional material is preferably mixed with, in particular purer, pulverized rigid foam in the mixing step or in the comminution step.Alternatively, the powdered rigid foam is completely replaced by the powdered functional material. The inventive design advantageously allows for the establishment of a closed cycle for the rigid foam. In particular, the functional material can be produced in a resource-saving and environmentally friendly manner.

[0028] Furthermore, it is proposed that in at least one process step of the method, an open time of the raw mass be set depending on the properties of the functional material to be produced. The open time refers in particular to the time period from the binder dosing step to the pressing step. In particular, the set open time is longer than a minimum open time, which is necessary in particular for the binder and activated water to penetrate the powdered rigid foam and for the binder and activated water to be distributed as homogeneously as possible in the pulverized rigid foam. In particular, the set open time is shorter than a maximum open time in order to minimize drying out of the raw mass, chemical reactions within the raw mass, in particular premature polyaddition and / or polycondensation of the binder, or the like.The open time can be set by an operator or by the control unit depending on the nature of the functional material to be produced. In particular, the open time is determined via a conveying speed of the continuous mixer and / or the further continuous conveyor. The nature of the functional material to be produced, on which the open time, in particular the minimum and maximum open time, depends, includes, for example, a density of the functional material, the material thickness of the functional material, and a number of layers in the functional material. In particular, the open time is set to be higher the denser, the thicker, and / or the more layered the functional material to be produced is to be. In particular, the open time is set to be lower the less dense and / or the thinner the functional material to be produced is and / or the fewer layers it has.The inventive design advantageously allows the properties of the functional material to be flexibly adapted. In particular, the same production facility can advantageously produce differently designed functional materials, particularly without retooling. In particular, different functional materials can advantageously be produced quickly and with advantageously reliable quality.

[0029] It is further proposed that the raw material be applied to a separating layer, in particular arranged at least temporarily on the functional material, in the raw material dosing step, which is then removed from the functional material after the pressing process. The separating layer is preferably formed as a separating paper or a separating film, for example as a Teflon film or a nonwoven. In particular, the separating layer is drawn onto the further continuous conveyor before or at the beginning of the raw material dosing step. Particularly preferably, a further separating layer is subsequently arranged on a side of the raw material facing away from the separating layer at or at the end of the raw material dosing step, in particular before the pressing step.

[0030] In particular, the separating layer, the raw material, and the further separating layer form a sandwich structure before the pressing step. Particularly preferably, the separating layer and / or the further separating layer are / are removed from the functional material after the pressing step or after the finishing step, or alternatively, ground off. The inventive design advantageously allows the continuous press to be operated with low wear. In particular, deposits within the continuous press and / or the continuous conveyor can be advantageously kept to a minimum. In particular, the pressing step can advantageously be operated maintenance-free for a long time. Furthermore, by removing the separating layer, an advantageously rough surface of the functional material can be produced, to which a subsequently applied coating advantageously adheres reliably.

[0031] It is further proposed that the raw mass be applied to a cover layer in the raw mass dosing step, which is bonded to the cured raw mass after the pressing process. The cover layer is arranged on the separating layer or on the additional continuous conveyor before or at the beginning of the raw mass dosing step. Optionally, a further cover layer is then arranged on a side of the raw mass facing away from the cover layer at or at the end of the raw mass dosing step, in particular before the pressing step. In particular, the cover layer, the raw mass, and the additional cover layer form a sandwich structure before the pressing step. The cover layer and the additional cover layer can be made of the same or different materials.The cover layer and / or the further cover layer can be formed at least substantially from an organic material, for example melamine resin and / or polyvinyl chloride (PVC), or an inorganic material, for example aluminum. Particularly preferably, the separating layer and / or the further separating layer, if present, are removed from the cover layers after the pressing step or after the assembly step, or alternatively, are ground off. The inventive design allows the functional material to be advantageously equipped with additional properties depending on the application. For example, cover layers can be designed as a moisture barrier, as an antimicrobiological protective layer, as weather protection, as sound insulation, as high-quality decoration, or the like.In particular, a subsequent application step for applying the cover layers to the functional material can be dispensed with, so that a functional material with cover layers can be produced advantageously quickly and advantageously cost-effectively.

[0032] The raw mass preferably comprises at least the powdered rigid foam and / or powdered functional material. The raw mass particularly comprises the liquid binder. The raw mass preferably comprises the activated water or water, particularly without an activator. The activated water or water preferably has a mass fraction of the raw mass of at least 0.5%, preferably more than 1%, particularly preferably more than 2%. The mass fraction of the activated water or water in the raw mass is preferably less than 7.5%, preferably less than 5%, particularly preferably less than 3%. The raw mass preferably comprises the filler. The powdered rigid foam and / or the powdered functional material, the binder, optionally the filler, and the activated water or water are preferably homogeneously distributed in the raw mass, wherein, particularly in the case of multiple layers, the distribution is homogeneous at least layer by layer.The design makes it possible to provide a raw mass for the functional material that can advantageously be processed continuously and advantageously quickly.

[0033] Furthermore, a functional material produced by a method according to the invention is proposed. The functional material has, in particular, a thermal conductivity according to EN 12667 of at most 0.10 W / (m•K), preferably less than 0.07 W / (m•K). The functional material has a bulk density of, in particular, more than 150 kg / m 3 , preferably more than 300 kg / m 3 , particularly preferably more than 450 kg / m 3 , and in particular a compressive stress according to DIN EN 826 of greater than 1 MPa, preferably greater than 3 MPa, particularly preferably more than 6 MPa. The functional material is preferably rot-resistant and non-decomposable. The functional material is preferably resistant to mineral oils, solvents, and diluted alkalis and acids. Preferably, the functional material has a flexural strength according to DIN EN 12089 greater than 1 MPa, preferably greater than 2 MPa, particularly preferably more than 4 MPa.The functional material preferably has a shear strength according to DIN EN 12090 of greater than 250 kPa, preferably of more than 500 kPa, particularly preferably of more than 1 MPa. The functional material has a shear strength according to DIN EN 12090 of in particular more than 250 kPa, preferably of more than 500 kPa, particularly preferably of more than 1 MPa. In addition, the functional material preferably has a screw extraction strength according to DIN EN 14358 of at least 4.5 N / mm 2< , preferably more than 6 N / mm 2< , particularly preferably more than 7.5 N / mm 2< , for a surface extraction of a 6 x 60 wood screw. A basic composition of the functional material, which is formed solely from the powdered rigid foam and the binder, has in particular a fire behavior that corresponds to a fire reaction class E according to DIN EN 13501-1 and a building material class B2 according to DIN 4102-1.Due to the filler, the functional material exhibits fire behavior that corresponds to at least a fire reaction class C according to DIN EN 13501-1 and at least a building material class B1 according to DIN 4102-1. The design according to the invention makes it possible to provide an advantageously stable and simultaneously advantageously thermally insulating functional material that can be produced advantageously cost-effectively, advantageously in a resource-saving manner, advantageously quickly, and / or with advantageously low fluctuations in properties, in particular in bulk density.

[0034] The method according to the invention and / or the functional material according to the invention should not be limited to the application and embodiment described above. In particular, the method according to the invention and / or the functional material according to the invention can have a number of individual elements, components, units, and method steps that differs from the number stated herein to fulfill a function described herein. Furthermore, in the value ranges specified in this disclosure, values ​​within the stated limits are also to be considered disclosed and can be used arbitrarily. Drawings

[0035] Further advantages will become apparent from the following description of the drawings. The drawings illustrate an exemplary embodiment of the invention. The drawings, the description, and the claims contain numerous features in combination. Those skilled in the art will also expediently consider the features individually and combine them into useful further combinations.

[0036] They show: Fig. 1 is a schematic representation of a method according to the invention and Fig. 2 is a schematic representation of a functional material according to the invention. Description of the embodiment

[0037] The Figure 1 shows a process sequence 10 for producing a functional material 12. The functional material 12 is produced from at least one rigid foam 16 and a binder 18. The rigid foam 16 is pulverized, mixed with the binder 18, and pressed to form the functional material 12.

[0038] The method 10 comprises, in particular, a comminution step 46. The method 10 comprises a rigid foam dosing step 30. The method 10 optionally comprises a moisture measurement step 32. The method 10 preferably comprises a filler dosing step 34. The method 10 preferably comprises a binder premixing step 36. The method 10 comprises a binder dosing step 38. The method 10 comprises a mixing step 14. The method 10 preferably comprises a raw material dosing 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 a finishing step 42. The method 10 runs continuously at least from the mixing step 14 up to and including the pressing step 22. The method 10 particularly preferably runs continuously from the rigid foam dosing step 30 up to and including the pressing step 22.In particular, the rigid foam dosing step 30, the filler dosing step 34, optionally the binder premixing step 36, the binder dosing step 38, the mixing step 14, the pre-pressing step 40, and the pressing step 22 are carried out continuously and, in particular, in parallel with one another. The moisture measurement step 32 can be carried out continuously, regularly, or randomly. The finishing step 42 is carried out discontinuously, in particular triggered by a time measurement and / or length measurement on the functional material 12. The comminution step 46 can be carried out continuously or discontinuously. Preferably, the comminution step 46 is carried out independently of the other process steps of the process 10.

[0039] Before pulverization, the rigid foam 16 has a thermal conductivity of less than 0.037 W / Km. In the comminution step 46, the pulverized rigid foam 16 is produced from polyurethane rigid foam (PUR for short), polyisocyanurate rigid foam (PIR for short), and / or phenolic rigid foam. In the comminution step 46, the rigid foam 16 is mechanically comminuted, in particular pulverized. Preferably, the pulverized rigid foam 16 is temporarily stored in a powder silo. In the rigid foam dosing step 30, the pulverized rigid foam 16 is continuously applied to a continuous conveyor. The continuous conveyor transports the pulverized rigid foam 16 to a continuous mixer.In the moisture measurement step 32, a moisture content of the pulverized rigid foam 16 is preferably determined, for example, using a moisture meter or by weighing a fixed volume of the pulverized rigid foam 16 and comparing it with a reference of known moisture content, in particular without moisture. The moisture measurement step 32 can take place before or after the rigid foam dosing step 30.

[0040] In the filler dosing step 34, the pulverized rigid foam 16 is mixed with at least one organic and / or inorganic filler 26. The filler 26 makes the functional material 12 flame-resistant according to fire reaction class C according to DIN 13501-1. The filler 26 is in particular formed as expandable graphite. The filler dosing step 34 preferably takes place after the moisture measurement step 32 and in particular before the mixing step 14. Particularly preferably, the filler 26 is continuously applied to the pulverized rigid foam 16 in the filler dosing step 34 and, in particular, is fed together with the foam by the continuous conveyor to the continuous mixer.

[0041] In the binder premixing step 36, activated water 24 with an activator mass fraction of no more than 3% is added to the binder 18. Preferably, a control unit controls or regulates the amount of activated water 24 added as a function of the moisture measurement step 32 and, in particular, as a function of the desired density and material thickness 48 of the functional material 12 (cf. Fig. 2 ). In the binder dosing step 38, the binder 18 is mixed with the activated water 24 and continuously added to the powdered rigid foam 16, particularly within the continuous mixer. Alternatively, the binder 18 and the activated water 24 are introduced into the continuous mixer separately, particularly by spraying.

[0042] In the mixing step 14, the powdered rigid foam 16 and the binder 18, in particular together with the filler 26 and the activated water 24, are blended to form a raw material 20. In the mixing step 14, the binder 18 is added to the powdered rigid foam 16 at a mass fraction of less than 10% based on the total mass of the functional material 12. In the raw material dosing step 50, a filling device arranged on the continuous mixer continuously transfers the raw material 20 to another continuous conveyor, in particular to a conveyor belt. In the raw material dosing step 50, the raw material 20 is optionally applied to a cover layer, which, after the pressing process 22, is integrally bonded to the cured raw material. In the raw mass dosing step 50, the raw mass 20 is optionally applied to a separating layer, which is removed from the functional material 12 after the pressing process 22.If the functional material 12 is to include a cover layer, the separating layer is applied to the additional continuous conveyor, the cover layer is applied to the separating layer, and the raw material 20 is applied to the cover layer. An open time of the raw material 20 is adjusted depending on the properties of the functional material 12 to be produced. In particular, a conveying speed of the additional continuous conveyor is adjusted or regulated by the control unit depending on the properties of the functional material 12 to be produced.

[0043] In the pre-pressing step 40, the raw mass 20 is pre-compacted by means of a continuous device. Optionally, at least one further layer of the raw mass 20 or of a further raw mass 20 is applied to the pre-compacted raw mass 20 and then pre-compacted. In the pressing step 22, the, in particular pre-compacted, raw mass 20 is pressed to form the functional material 12. In particular, a continuous press applies pressure and temperature to the raw mass 20 in the pressing step 22. The temperature caused by the continuous press is preferably lower than an activation temperature of the filler 26, at which temperature the filler preferably exhibits an expanding behavior. The continuous press evaporates the activated water 24 in the pressing step 22. The continuous press largely encloses the evaporated water 24 in the raw mass 20 during the pressing step 22, in particular until the binder 18 has cured.In particular, at an outlet of the continuous press for the functional material 12, the functional material 12 continuously releases the evaporated water 24. In the pressing step 22, with at least one setting of the continuous press, the raw material 20 is pressed by the continuous press into a plate 28 with a material thickness 48 of less than 8 mm, in particular without subsequent grinding. The plate 28 made of the functional material 12 is shown by way of example in . Figure 2 shown. In the pressing step 22, the raw material 20 is pressed into the plate 28 with a material thickness of 48, the maximum permissible tolerance of which is 1 mm, particularly without subsequent grinding. In the finishing step 42, the plate 28 is separated, in particular cut and / or sawed, from the functional material 12 continuously emerging from the continuous press.

[0044] The panel 28 made of the functional material 12 is used, for example, as thermal insulation and / or as a construction material. The panel 28 made of the functional material 12 is particularly recyclable after use 44 by means of the method 10. In particular, any offcuts of the panel 28 generated before or during use 44 are recyclable. The functional material 12 is pulverized, so that the pulverized rigid foam can be at least partially replaced by the pulverized functional material. Reference symbol

[0045] 10Process 12Functional material 14Mixing step 16Rigid foam 18Binder 20Raw mass 22Pressing step 24Activated water 26Filler 28Plate 30Rigid foam dosing step 32Moisture measurement step 34Filler dosing step 36Binder premixing step 38Binder dosing step 40Pre-pressing step 42Assembly step 44Use 46Crushing step 48Material thickness 50Raw mass dosing step

Claims

1. A method for producing a functional material, wherein in at least one mixing step (14) a rigid foam (16) and at least one binding agent (18) are mixed to form a raw mass, and wherein in at least one pressing step (22) the raw mass is pressed to form the functional material, the method proceeding in a continuous manner at least from the mixing step (14) up to and including the pressing step (22), wherein in the pressing step (22) the raw mass is fed to a throughput press, the raw mass is continuously pressed by the throughput press and the functional material is continuously outputted by the throughput press, characterized in that in the at least one mixing step (14) the rigid foam (16) is in a pulverized state, is at least substantially made of a thermoset and has an average particle size less than 5 mm.

2. The method according to claim 1, characterized in that in at least one method step the pulverized rigid foam (16) is produced from polyurethane rigid foam, PUR for short, from polyisocyanurate rigid foam, PIR for short, and / or from 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 an activator of maximally 3% is mixed into the binding agent (18).

4. The method according to any one of the preceding claims, characterized in that in the mixing step (14) the binding agent (18) is mixed into the pulverized rigid foam (16) with a mass fraction of less than 10% relative to a total mass of the functional material.

5. The method according to any one of the preceding claims, characterized in that in at least one method step at least one organic and / or inorganic filling material (26) is added to the raw mass, the pulverized rigid foam (16) and / or the binding agent (18).

6. The method according to claim 5, characterized in that the filling material (26) makes the functional material difficult to ignite according to combustibility class C of DIN 13501-1.

7. The method according to any one of the preceding claims, characterized in that in the pressing step (22), in at least one setting of the throughput press, the raw mass is pressed by the throughput press to form a panel (28) with a material thickness of less than 8 mm, in particular without subsequent grinding.

8. The method according to any one of the preceding claims, characterized in that in the pressing step (22) the raw mass is pressed to form a panel (28) with a material thickness whose maximally admissible tolerance is at most 1 mm, in particular without subsequent grinding.

9. The method according to any one of the preceding claims, characterized in that in at least one method step the functional material is pulverized and the pulverized rigid foam (16) is substituted at least partially by the pulverized functional material.

10. The method according to any one of the preceding claims, characterized in that in at least one method step an open time of the raw mass is set depending on properties of the functional material that is to be produced.

11. The method according to any one of the preceding claims, characterized in that in a raw mass metering step (50) the raw mass is applied onto a separating layer, which is removed from the functional material after the pressing step (22).

12. The method according to any one of the preceding claims, characterized in that in a raw mass metering step (50) the raw mass is applied onto a cover layer, which is after the pressing step (22) connected to the cured raw mass by substance-to-substance bond.

13. A functional material produced by a method according to any one of claims 1 to 12.