Insulation board containing at least one aerogel composite for thermal insulation of buildings

Abstract

The present invention relates to an insulating board (IB) comprising at least two insulating layers (A) bonded together. At least one of the at least two insulating layers (A) comprises at least one aerogel composite material, the aerogel composite material comprising at least one silica aerogel (a1), at least one polymer foam (a2), and at least one flame retardant (a3). The present invention also relates to an insulating system (IS) comprising the insulating board (IB). Furthermore, the present invention relates to a method for producing the insulating board (IB) and the use of the insulating board (IB) and the insulating system (IS) for insulating buildings, components, and / or building elements.

Description

[Technical Field]

[0001] The present invention relates to an insulating board (IB) comprising at least two insulating layers (A) bonded together. At least one of the at least two insulating layers (A) comprises at least one aerogel composite material, the aerogel composite material comprising at least one silica aerogel (a1), at least one polymer foam (a2), and at least one flame retardant (a3). The present invention also relates to an insulating system (IS) comprising the insulating board (IB). Furthermore, the present invention relates to a method for producing the insulating board (IB) and the use of the insulating board (IB) and the insulating system (IS) for insulating buildings, components, and / or building elements.

[0002] Energy conservation, particularly through thermal insulation, is an important issue in industrial and building construction. Conventional insulating materials include glass wool, mineral wool, extruded polystyrene, and expanded polystyrene. The insulating capacity of an insulating material is measured by its thermal conductivity. The lower the thermal conductivity value, the less heat the insulating material conducts and the better its insulating ability.

[0003] Aerogels are widely considered to be among the best solid insulation materials available, generally possessing a thermal conductivity λ of ≦20 W / (mK). However, because aerogels are typically obtained in granular form, which poses transportation and handling challenges, they are typically bonded together with a binder to obtain a single block piece, preferably a panel, or embedded in a mechanically stable substrate or carrier material, such as glass fiber mat. However, these approaches have several additional drawbacks. They increase the overall weight and thickness of the insulation material and tend to exhibit dust during handling, machining, and installation. Furthermore, when the granules are bonded together, the insulation material also tends to be mechanically brittle. Therefore, to avoid this undesirable weight and thickness increase and reduce dust, open-cell polymer foams have recently been used as carrier materials. By incorporating aerogels into open-cell polymer foams, an insulation layer comprising aerogel and open-cell polymer foam is obtained.

[0004] The resulting insulation layer is typically bonded to at least one additional insulation layer to form a multi-layer insulation board, which may also contain aerogel. The resulting multi-layer insulation board can then be bonded to at least one additional layer that is not an insulation layer to form a thermal insulation system. Examples of additional layers include adhesives, mortars, reinforcing materials, paints, coatings, and plasters.

[0005] Thermal insulation systems are used, for example, in exterior multi-layer insulation composite systems (ETICS), exterior multi-layer insulation facade systems (EIFS), and interior insulation systems.

[0006] U.S. Patent Application Publication No. 2016 / 0115685 discloses a multi-layer panel including at least one layer consisting essentially of an insulating composite material, the insulating composite material including inorganic aerogel and melamine foam. For example, one or more plaster boards can be bonded to one or both sides of the layer consisting essentially of the insulating composite material.

[0007] European Patent No. 2,347,059 discloses an insulated building wall comprising an exterior thermal insulation composite system (ETICS) attached to the building wall. The exterior thermal insulation composite system includes an insulation subsystem that is either a thermal insulation subsystem including at least a first insulation board containing 20-90% by weight of aerogel and at least a second insulation board containing mineral wool, or a thermal insulation subsystem including at least one composite insulation board containing mineral wool and 20-90% by weight of aerogel. The exterior thermal insulation composite system also includes at least one mechanical fastener and an outer layer that is a system including a mortar layer.

[0008] EP 2,665,876 describes an insulated building wall comprising a composite insulation system and an exterior building wall, the composite insulation system being attached to the side of the building wall facing away from the building, the composite insulation system comprising at least two layers of insulating cladding, each of which contains 25-95% by weight aerogel, 5-75% by weight inorganic fibers, and 0-70% by weight inorganic filler. The layers of insulating cladding are bonded together by an inorganic binder. The aerogel is at least one aerogel based on silicon, aluminum, and / or titanium.

[0009] U.S. Patent Application Publication No. 2018 / 0112134 discloses a fire-resistant material incorporating silica aerogel with an organic foam material, such as one or a combination of melamine and polyurethane.

[0010] US Patent Application Publication No. 2002 / 0094426 describes an aerogel composite comprising an aerogel selected from the group consisting of inorganic and organic gel-forming materials and a reinforcing structure. [Prior art documents] [Patent documents]

[0011] [Patent Document 1] US Patent Application Publication No. 2016 / 0115685 [Patent Document 2] European Patent No. 2,347,059 [Patent Document 3] European Patent No. 2,665,876 [Patent Document 4] US Patent Application Publication No. 2018 / 0112134 [Patent Document 5] US Patent Application Publication No. 2002 / 0094426 Summary of the Invention

[0012] Nevertheless, a problem that still frequently arises from aerogels embedded in open-cell polymer foam is the emission of dust during handling and cutting.

[0013] Additionally, to enable long-term application under humid conditions typically encountered in building and construction applications, aerogels, particularly silica aerogels, can contain hydrophobic groups that impart water repellency to the material and minimize water absorption and retention. However, the inclusion of these hydrophobic groups in aerogels typically increases the heat of combustion of the aerogels, and the classification of insulation boards (IBs) and / or insulation systems containing these aerogels as "non-combustible" is compromised by their failure to achieve certain thresholds for relevant properties such as heat of combustion, flame duration, mass loss, or furnace temperature rise under certain test methods.

[0014] Therefore, the underlying objective of the present invention is to provide an improved insulation board and / or an improved insulation system comprising aerogel, which should be easy to handle and should exhibit minimal heat of combustion. Furthermore, the insulation board and / or the insulation system should exhibit improved mechanical stability against mechanical loads, for example in terms of normal tensile strength.

[0015] This object is achieved by an insulating board (IB) comprising at least two insulating layers (A), which are bonded to one another, and at least one of the at least two insulating layers (A) comprises at least one aerogel composite material comprising at least the following components (a1) to (a3): (a1) at least one silica aerogel; (a2) at least one polymer foam, and (a3) at least one flame retardant;

[0016] Surprisingly, it has been found that the insulation boards (IB) of the present invention exhibit reduced dust emissions compared to the dust emissions of prior art insulation boards with comparable thermal capacity, where "comparable thermal capacity" in the context of the present invention means comparable U-values ​​and R-values. The insulation boards (IB) of the present invention are therefore easier to handle, especially when cutting and installing.

[0017] In the context of the present invention, the term "U-value" is understood to mean the rate of heat transfer through an insulation board (IB) or insulation system (IS), respectively, divided by the difference in temperature across that insulation board (IB) or insulation system (IS). The unit of measurement is W / m 2 K. The better the insulation board (IB) or insulation system (IS), respectively, is insulated, the smaller the U-value. The R-value is the reciprocal of the U-value. The U-value and the R-value are calculated, for example, according to Klaus Liersch, Normen Langner, "Bauphysik kompakt", Verlag Bauwerk BBB, 4th August 2011, ISBN 987-3-89932-285-9, Chapter 6 "Warmedurchgang durch ebene opake Bauteile".

[0018] Furthermore, the insulation board (IB) of the present invention exhibits a lower density compared to the density of state-of-the-art insulation boards with comparable thermal capacity, resulting in a lower weight.

[0019] Furthermore, the insulation board (IB) of the present invention exhibits reduced thermal conductivity compared to that of prior art insulation boards of comparable dimensions and can therefore be used at lower thicknesses to achieve comparable U or R values, which also leads to a lighter weight insulation board (IB).

[0020] Additionally, the insulating board (IB) of the present invention exhibits reduced heat of combustion and therefore can be classified as non-combustible according to various building codes.

[0021] The insulation board (IB) of the present invention also exhibits high mechanical stability, particularly high normal tensile strength, which, when incorporated into an insulation system (IS), reduces the need and number of additional mechanical fixing aids such as dowels.

[0022] It has also surprisingly been found that when the insulation board (IB) of the present invention is integrated into an insulation system (IS), dust emissions during handling, machining and cutting are reduced, and the insulation system (IS) exhibits a lower weight and lower thickness compared to state-of-the-art insulation systems with comparable thermal capacity (U-value or R-value, respectively), resulting in space savings in solving insulation problems.

[0023] The inventive insulation system (IS) comprising the inventive insulation board (IB) also exhibits a reduced heat of combustion, preferably of ≦3.0 MJ / kg, compared to state-of-the-art insulation systems, and can even reach values ​​of ≦1.5 MJ / kg depending on the specific design of the entire insulation system, and can therefore be classified as non-combustible according to various building codes.

[0024] The insulation system (IS) comprising the insulation board (IB) of the present invention also exhibits high mechanical stability and normal tensile strength, so that no or little additional mechanical fixing aids are required for the insulation board (IB) of the present invention and the additional layer (X), and optionally the additional layers (B), (C) and (D).

[0025] In the context of the present invention, the term "aerogel composite" is understood to mean a material comprising at least one aerogel and at least one additional component that is immiscible with the at least one aerogel precursor. In a preferred embodiment, the "aerogel composite" comprises at least 10 wt. %, preferably at least 20 wt. %, and more preferably at least 30 wt. % of at least one aerogel, based on the total weight of the aerogel composite. The additional component can be selected, for example, from fillers, additives, or foams. The aerogel composite according to the present invention comprises at least one silica aerogel (a1) as the at least one aerogel and at least one polymer foam (a2) and at least one flame retardant (a3) ​​as additional components. As described below, the aerogel composite can also comprise additional components, such as infrared-absorbing or reflective opacifiers.

[0026] In the context of the present invention, the term "aerogel" is understood to mean aerogels as well as xerogels. Generally, xerogels are materials produced by a sol-gel process in which the liquid phase is removed from the gel by drying below the critical temperature and above the critical pressure of the liquid phase ("subcritical state"). In contrast, aerogels are generally referred to as aerogels when the liquid phase is removed from the gel during the sol-gel process under "supercritical conditions," forming an open-pore, highly porous structure with air-filled pores. Aerogels can be organic or inorganic. Inorganic aerogels are selected, for example, from silica aerogels, titanium oxide aerogels, manganese oxide aerogels, calcium oxide aerogels, or zirconium oxide aerogels. The aerogel contained in the thermal insulation board (IB) of the present invention is at least one silica aerogel.

[0027] Below are provided definitions that provide further details of the inventive insulating board (IB) and the inventive insulating system (IS) as such, as well as the inventive method for producing said insulating board (IB). Insulation board (IB)

[0028] The insulation board (IB) of the present invention comprises at least two insulating layers (A), and therefore can comprise exactly two insulating layers (A), or three, four, five or more insulating layers (A). The number of layers of the insulation board (IB) itself is determined by the number of insulating layers (A) bonded together. Therefore, for an insulation board (IB) comprising two layers itself, two insulating layers (A) are bonded together. Therefore, for an insulation board (IB) comprising three or four layers itself, it is preferred that three or four insulating layers (A) are bonded together. As long as an insulation board (IB) comprising many more layers is produced, the number of insulating layers (A) bonded together should correspond to the number of layers, for example, if the insulation board (IB) comprises 10 layers, there will be 10 insulating layers (A) as an example.

[0029] For an insulating board (IB) comprising three or more insulating layers (A), the individual insulating layers (A) are preferably assembled in stages. Thus, for an insulating board (IB) comprising three insulating layers (A), the product of the first step is preferably an insulating board (IB) comprising two insulating layers (A), which are then bonded to another insulating layer (A) to obtain an insulating board (IB) comprising three insulating layers (A). The three insulating layers (A) may be identical or different from one another (e.g., with respect to their thickness and composition), and at least one of the three insulating layers (A) comprises at least one aerogel composite material comprising at least components (a1) to (a3).

[0030] The insulating layers (A) used in the bonding method correspond, in terms of their chemical composition, to the insulating boards (IB) themselves produced in the context of the method of the invention (in the case of adhesive bonding, ignoring the adhesive used, and ignoring components optionally applied to the surface, for example).

[0031] Preferably, each insulating layer (A) to be bonded has the same dimensions and / or the same chemical composition. However, if necessary, insulating layers (A) having different dimensions and / or different chemical compositions can be bonded to each other. For example, if three insulating layers (A) are bonded to each other, all of which have the same dimensions and (for example) all of which contain at least one aerogel composite material containing at least components (a1) to (a3), the resulting product is an insulating board (IB) containing three insulating layers (A), all of which contain at least one aerogel composite material containing at least components (a1) to (a3).

[0032] The insulating layers (A) to be bonded together can have any desired dimensions. Regarding their length and width, they can range from centimeters to several meters. Regarding the third dimension (thickness), while any desired dimension is theoretically possible, in practice, the thickness of the insulating layer (A) is preferably 1 to 500 mm, more preferably 5 to 100 mm, and most preferably 5 to 20 mm. Thus, the thickness of the insulating board (IB) produced by the method of the present invention results from the sum of the thicknesses of all the insulating layers (A) used. However, as a possible example, in the case of adhesive bonding, the resulting insulating board (IB) can have an increased thickness compared to the sum of the thicknesses of the insulating layers (A) used, since after applying at least one adhesive, a "layer" containing at least one first adhesive (AD1) with a specific thickness is also formed for each pair of insulating layers (A).

[0033] In the present invention, the thickness is defined as the z-direction, which, together with the x- and y-directions, defines the dimensions of the insulation board (IB) (or each of the layers (A)) of the present invention in a Cartesian coordinate system. In the present invention, the x-direction means the length of the insulation board (IB) (or each of the layers (A)), and the y-direction means the width of the insulation board (IB) (or each of the layers (A)). The length of the insulation board (IB) (or each of the layers (A)) of the present invention is always greater than its width and thickness. In the insulation board (IB) of the present invention (in the layer (A)), it is preferred that the length (x-direction) is greater than the width (y-direction), and similarly the width is greater than the thickness (z-direction).

[0034] In the case of the insulating board (IB) of the present invention, when at least one pair of insulating layers (A) is joined, it is preferable that each of the two insulating layers (A) has a length (x direction) of 500 to 2800 mm, preferably 1000 to 1500 mm, a width (y direction) of 500 to 1250 mm, preferably 500 to 900 mm, and a thickness (z direction) of 1 to 500 mm, preferably 5 to 100 mm, more preferably 5 to 20 mm. In the case of an insulating board (IB) including three or more insulating layers (A), it is even more preferable that each of the insulating layers (A) included therein has the above-mentioned dimensions.

[0035] The heat insulating board (IB) of the present invention is a) providing at least two insulating layers (A), wherein at least one of the at least two insulating layers (A) comprises at least the following components (a1) to (a3): (a1) at least one silica aerogel; (a2) at least one polymer foam, and (a3) providing at least one aerogel composite comprising at least one flame retardant; and b) by a method comprising steps a) and b) of joining at least two insulating layers (A) to one another, preferably by means of at least one adhesive and / or mechanical fastening, to obtain an insulating board (IB).

[0036] The present invention therefore also provides a method for producing an insulating board (IB), comprising the steps of: a) providing at least two insulating layers (A), wherein at least one of the at least two insulating layers (A) comprises at least the following components (a1) to (a3): (a1) at least one silica aerogel; (a2) at least one polymer foam, and (a3) providing at least one aerogel composite comprising at least one flame retardant; and b) produced by a method comprising steps a) and b) of joining at least two insulating layers (A) to one another, preferably by means of at least one first adhesive (AD1) and / or mechanical fixing (MF), to obtain an insulating board (IB).

[0037] If the at least two insulating layers (A) are joined to one another by mechanical fastening (MF), they are preferably joined to one another by sewing, clamps, rivets, dowels and / or nails.

[0038] When the at least two insulating layers (A) are bonded to each other by at least one first adhesive (AD1), the at least one first adhesive (AD1) is selected from the group consisting of inorganic adhesives, organic adhesives and inorganic-organic hybrid adhesives.

[0039] In the context of the present invention, the term "at least one first adhesive (AD1)" is understood to mean exactly one first adhesive (AD1) as well as two or more first adhesives (AD1). In a preferred embodiment, at least two insulating layers (A) are bonded to each other by one first adhesive (AD1).

[0040] However, it is also possible that the at least two insulating layers (A) are joined to one another by means of at least one first adhesive (AD1) and a mechanical fixing (MF).

[0041] The inorganic adhesive preferably contains at least one component selected from the group consisting of water glass, silicate, lime, gypsum, cement, and anhydrite. The organic adhesive preferably contains at least one component selected from the group consisting of polyurethane-based one-component or two-component adhesives, unsaturated polyesters, epoxides, (meth)acrylates, and silicones. The inorganic-organic hybrid adhesive preferably contains an organic adhesive filled with an inorganic compound.

[0042] In a preferred embodiment, the at least one first adhesive (AD1) is a polyurethane-based one- or two-component adhesive, optionally filled with inorganic compounds, with a calorific value of <40 MJ / kg.

[0043] The inorganic, organic, and inorganic-organic hybrid adhesives can be applied using a variety of techniques, such as by spraying, rolling, or brushing the adhesive or its components. Optionally, the adhesive can be applied as a spray adhesive foam, a foam adhesive, or a foam adhesive.

[0044] When at least two insulating layers (A) are bonded to each other by at least one first adhesive (AD1), the at least one first adhesive (AD1) is preferably applied to at least one surface of at least one of the at least two insulating layers (A), preferably to a thickness of 0.01 to 10 mm, more preferably to a thickness of 0.01 to 5 mm, and most preferably to a thickness of 0.05 to 2 mm.

[0045] In a preferred embodiment, the at least one first adhesive (AD1) is applied to at least one surface of at least one of the at least two insulating layers (A) in a density of 10 to 500 g / m 2 Weight per square meter, preferably 50 to 250 g / m 2 It is applied at a weight per square meter of

[0046] Preferably, at least one first adhesive (AD1) is applied to each of the pair of insulating layers (A) to be bonded to only one surface of the two starting insulating layers (A). For example, at least one first adhesive (AD1) can be applied over a large area to the corresponding surface of the insulating layer (A). The first adhesive (AD1) can be applied by a conventional method, such as brushing, spraying, rolling, squeegeeing, or printing. Preferably, at least one first adhesive (AD1) is applied to only one surface of the starting insulating layer (A) to be bonded (to each of the pair of insulating layers (A)), and no first adhesive (AD1) is applied to the second surface to be bonded.

[0047] In a preferred embodiment, the at least one first adhesive (AD1) is applied uniformly in one direction on the surface of the insulating layer (A). In another preferred embodiment of the present invention, the at least one first adhesive (AD1) is applied to at least one surface of the insulating layer (A) in a structured manner, preferably in the form of spots, lines or a grid, more preferably in the form of a grid.

[0048] This embodiment of the present invention is also referred to as a structured bond. The structured bond with the at least one first adhesive (AD1) can be achieved by any structure or structural form. The at least one first adhesive (AD1) can be applied in a structured manner, preferably over 20 to 80%, more preferably over 40 to 80%, and most preferably over 50 to 75% of the surface of each insulating layer (A). [Brief explanation of the drawings]

[0049] (Mode for Carrying Out the Invention) Insulation layer (A)

[0050] The insulating layer itself is known in principle to those skilled in the art and can comprise, for example, extruded polystyrene (XPS) foam, expanded polystyrene (EPS) foam, polyurethane foam, phenolic foam, wood fibers, cellulose fibers, cork, calcium silicate, gypsum, mineral foam, glass foam, mineral wool, stone wool, glass wool, glass fibers, fiberglass, and aerogel.

[0051] In the thermal insulation board (IB) of the present invention, at least one of the at least two insulating layers (A) contains at least one aerogel composite material containing at least the components (a1) to (a3).

[0052] In the context of the present invention, the term "at least one of the at least two insulating layers (A)" is understood to mean exactly one insulating layer (A) as well as two or more insulating layers (A). In a preferred embodiment, each of the at least two insulating layers (A) comprises at least one aerogel composite comprising at least components (a1) to (a3).

[0053] In another preferred embodiment, at least one of the at least two insulating layers (A) consists essentially of at least one aerogel composite material comprising at least the components (a1) to (a3).

[0054] In the context of the present invention, the term "consisting essentially of at least one aerogel composite comprising at least components (a1) to (a3)" is understood to mean that at least one of the at least two insulating layers (A) comprises at least 99.5% by weight, preferably at least 99.9% by weight, of at least one aerogel composite comprising at least components (a1) to (a3). In a more preferred embodiment, each of the at least two insulating layers (A) consists essentially of at least one aerogel composite comprising at least components (a1) to (a3).

[0055] However, it is also possible that only one of the at least two insulating layers (A) comprises at least one aerogel composite material comprising at least components (a1) to (a3), and a further layer of the at least two insulating layers (A) does not comprise at least one aerogel composite material comprising at least components (a1) to (a3), but instead comprises at least one different material selected from the group consisting of extruded polystyrene (XPS) foam, expanded polystyrene (EPS) foam, polyurethane foam, phenolic resin foam, wood fibers, cellulose fibers, cork, calcium silicate, gypsum, mineral foam, glass foam, mineral wool, stone wool, glass wool, glass fibers, and aerogel. Two or more insulating layers (A) may comprise at least one aerogel composite, and a further layer of the at least two insulating layers (A) may not comprise the at least one aerogel composite comprising at least components (a1) to (a3), but may instead comprise at least one different material selected from the group consisting of extruded polystyrene (XPS) foam, expanded polystyrene (EPS) foam, polyurethane foam, phenolic resin foam, wood fiber, cellulose fiber, cork, calcium silicate, gypsum, mineral foam, glass foam, mineral wool, stone wool, glass wool, glass fiber, and aerogel.

[0056] In the context of the present invention, the term "at least one aerogel composite" is understood to mean exactly one aerogel composite, as well as a mixture of two or more aerogel composites. In a preferred embodiment, each of the at least two insulating layers (A) comprises one aerogel composite.

[0057] Furthermore, in the context of the present invention, the term "at least one different material" is understood to mean both exactly one different material and a mixture of two or more different materials. In a preferred embodiment, each insulating layer (A) that does not contain at least one aerogel composite material comprising at least components (a1) to (a3) ​​comprises one different material. In a more preferred embodiment, each insulating layer (A) that does not contain at least one aerogel composite material comprising at least components (a1) to (a3) ​​consists essentially of one different material. aerogel composite materials

[0058] At least one aerogel composite comprises at least the following components (a1) to (a3): (a1) at least one silica aerogel; (a2) at least one polymer foam, and (a3) at least one flame retardant;

[0059] The at least one aerogel composite may comprise at least one silica aerogel (a1), at least one polymer foam (a2), and at least one flame retardant (a3) ​​in any desired amounts.

[0060] Preferably, the at least one aerogel composite comprises at least 10 wt.-%, more preferably at least 20 wt.-%, and most preferably at least 30 wt.-% of component (a1), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0061] The at least one aerogel composite preferably comprises 94 wt.-% or less, more preferably 80 wt.-% or less, most preferably 70 wt.-% or less of component (a1), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0062] In a preferred embodiment, the at least one aerogel composite comprises 10 to 94 wt.-%, preferably 20 to 80 wt.-%, more preferably 30 to 70 wt.-% of component (a1), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0063] Preferably, the at least one aerogel composite comprises at least 1 wt.-%, more preferably at least 3 wt.-%, of component (a2), based in each case on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0064] The at least one aerogel composite preferably comprises no more than 20 wt.-%, more preferably no more than 15 wt.-%, and most preferably no more than 10 wt.-% of component (a2), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0065] In a preferred embodiment, the at least one aerogel composite comprises 1 to 20 wt. %, preferably 1 to 15 wt. %, more preferably 3 to 10 wt. % of component (a2), based in each case on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0066] Preferably, the at least one aerogel composite comprises at least 5 wt.-%, more preferably at least 19 wt.-%, and most preferably at least 27 wt.-% of component (a3), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0067] The at least one aerogel composite preferably comprises 70 wt.-% or less, more preferably 65 wt.-% or less, most preferably 60 wt.-% or less of component (a3), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0068] In a preferred embodiment, the at least one aerogel composite comprises 5 to 70 wt.-%, preferably 19 to 65 wt.-%, more preferably 27 to 60 wt.-% of component (a3), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0069] Thus, it is preferred when the at least one aerogel composite comprises in the range of 10 to 94 wt. % of the at least one silica aerogel (a1), in the range of 1 to 20 wt. % of the at least one polymer foam (a2), and in the range of 5 to 70 wt. % of the at least one flame retardant (a3), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2), and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0070] It is particularly preferred when the at least one aerogel composite comprises in the range of 20 to 80 wt. % of the at least one silica aerogel (a1), in the range of 1 to 15 wt. % of the at least one polymer foam (a2), and in the range of 19 to 65 wt. % of the at least one flame retardant (a3), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2), and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0071] It is particularly preferred when the at least one aerogel composite comprises in the range of 30 to 70 wt. % of the at least one silica aerogel (a1), in the range of 3 to 10 wt. % of the at least one polymer foam (a2), and in the range of 27 to 60 wt. % of the at least one flame retardant (a3), in each case based on the sum of the weight percentages of the at least one silica aerogel (a1), the at least one polymer foam (a2), and the at least one flame retardant (a3), preferably based on the total weight of the at least one aerogel composite.

[0072] Thus, the weight % values ​​of the at least one silica aerogel (a1), the at least one polymer foam (a2) and the at least one flame retardant (a3) ​​typically add up to 100%.

[0073] The at least one aerogel composite may further comprise, in addition to the at least one silica aerogel (a1), the at least one polymer foam (a2), and the at least one flame retardant (a3), at least one infrared absorbing or reflective opacifier.

[0074] In the context of the present invention, "at least one infrared absorbing or reflecting opacifier" should be understood to mean either exactly one infrared absorbing or reflecting opacifier or a mixture of two or more infrared absorbing or reflecting opacifiers.

[0075] The at least one aerogel composite may include, for example, 0.1 to 10 wt. % of at least one infrared absorbing or reflective opacifier, based on the total weight of the at least one aerogel composite. Preferably, the at least one aerogel composite includes 1 to 5 wt. % of at least one infrared absorbing or reflective opacifier, based on the total weight of the at least one aerogel composite.

[0076] It will be understood that if the at least one aerogel composite comprises at least one infrared absorbing or reflective opacifier, the weight % value of the at least one silica aerogel (a1) present in the at least one aerogel composite will be correspondingly reduced so that the sum of the weight % values ​​of the at least one silica aerogel (a1), the at least one polymer foam (a2), the at least one flame retardant (a3) ​​and the at least one infrared absorbing or reflective opacifier adds up to 100%.

[0077] Suitable infrared absorbing or reflecting opacifiers are known per se to those skilled in the art and are preferably selected from the group consisting of carbon black, graphite, boron carbide, metal oxides and metal carbides, more preferably metal oxides.

[0078] Examples of suitable metal oxides are titanium oxide, iron oxide and manganese oxide.

[0079] The at least one aerogel composite preferably has a viscosity of 0.10 to 0.40 g / cm, as measured according to ASTM C167 3 , more preferably 0.15 to 0.25 g / cm 3 It has a density of

[0080] Furthermore, the at least one aerogel composite preferably has a thermal conductivity, determined according to DIN EN 12667:2001-05, of λ≦0.030 W / (mK), more preferably λ≦0.020 W / (mK).

[0081] At least one aerogel composite may be hydrophobic. In a further preferred embodiment, the at least one aerogel composite has a liquid water absorption of ≦20 wt. %, preferably ≦10 wt. %, more preferably ≦5 wt. %, and most preferably ≦1 wt. %, based on the total weight of the at least one aerogel composite. Liquid water absorption is one expression of the hydrophobicity of an aerogel or aerogel composite. Within the context of the present invention, the term "liquid water absorption" refers to a measure of the ability of an aerogel or aerogel composite to absorb or retain liquid water. Liquid water absorption can be expressed as the percentage (by weight or volume) of water absorbed or retained by the aerogel or aerogel composite when exposed to liquid water under specific measurement conditions. The liquid water absorption of an aerogel or aerogel composite can be determined by methods known in the art, including, but not limited to, DIN EN 12087:2013-06, Method 2. An aerogel or aerogel composite having improved liquid absorption relative to another aerogel or aerogel composite has a lower liquid absorption / retention rate relative to the reference aerogel or aerogel composite.

[0082] In another preferred embodiment, the at least one aerogel composite has a heat of combustion of ≦3.0 MJ / kg, preferably determined according to EN ISO 1716:2010-11.

[0083] More preferably, it has an oven temperature rise of ≦50° C., a mass loss of ≦50%, and a flame time of ≦20 seconds, as measured in accordance with ISO 1182:2010.

[0084] In particularly preferred embodiments, the at least one aerogel composite has a liquid water absorption of ≦10 wt. %, a thermal conductivity of ≦0.020 W / (mK) and a heat of combustion of ≦3.0 MJ / kg. Silica aerogel (a1)

[0085] At least one aerogel composite comprises at least one silica aerogel (a1).

[0086] The terms "at least one silica aerogel," "silica aerogel," and "component (a1)" are used interchangeably and have the same meaning in the context of the present invention. Furthermore, in the context of the present invention, the term "at least one silica aerogel" is understood to mean exactly one silica aerogel and mixtures of two or more silica aerogels. In a preferred embodiment, the at least one aerogel composite comprises one silica aerogel.

[0087] Silica aerogels are known in principle to those skilled in the art. They are usually prepared from gel precursors by the sol-gel method.

[0088] Examples of suitable gel precursors are metal silicates such as sodium silicate and potassium silicate, and alkoxysilanes such as tetramethoxysilane (TMOS) and tetraethoxysilane (TEOS).

[0089] However, it is also possible to use a gel precursor containing at least one hydrophobic group to impart or improve certain properties, such as stability or hydrophobicity, in the resulting silica aerogel. It will be apparent to those skilled in the art that the use of a gel precursor containing at least one hydrophobic group will result in the resulting silica aerogel also containing at least one hydrophobic group bonded to at least one silicon atom.

[0090] Suitable gel precursors containing at least one hydrophobic group are alkyl and aryl silanes, such as trimethylmethoxysilane (TMS), dimethyldimethoxysilane (DMS), methyltrimethoxysilane (MTMS), trimethylethoxysilane, dimethyldiethoxysilane (DMDS), methyltriethoxysilane (MTES), ethyltriethoxysilane (ETES), diethyldiethoxysilane, ethyltriethoxysilane, propyltrimethoxysilane, propyltriethoxysilane, phenyltrimethoxysilane, and phenyltriethoxysilane (PhTES).

[0091] In a preferred embodiment, the silica aerogel is prepared from a mixture comprising a gel precursor comprising at least one hydrophobic group and a gel precursor selected from tetramethoxysilane (TMOS) and tetraethoxysilane (TEOS).

[0092] However, the gel can also be treated with a hydrophobizing agent to impart or improve the stability and / or hydrophobicity of the resulting silica aerogel. Hydrophobizing treatment can be carried out by immersing the gel in a mixture containing a hydrophobizing agent and a solvent in which the hydrophobizing agent is soluble and which is miscible with the gel solvent in the wet gel. Suitable solvents include, for example, methanol, ethanol, isopropanol, xylene, toluene, benzene, dimethylform, amides, and hexane. However, hydrophobizing can also be imparted by directly contacting the gel with the hydrophobizing agent in liquid or gas form.

[0093] Examples of hydrophobizing agents include, but are not limited to, trimethylchlorosilane (TMCS), triethylchlorosilane (TECS), triphenylchlorosilane (TPCS), dimethylchlorosilane (DMCS), dimethyldichlorosilane (DMDCS), or generally alkyl or arylalkoxysilanes, or alkyldisilazanes or alkyldisiloxanes, such as hexamethyldisilazane or hexamethyldisiloxane.

[0094] In a preferred embodiment, the at least one silica aerogel (a1) comprises at least one hydrophobic group in a range of 1 to 25 wt. %, preferably in a range of 1 to 10 wt. %, based on the total weight of the at least one silica aerogel (a1), and the at least one hydrophobic group is bonded to at least one silicon atom.

[0095] The at least one silica aerogel (a1) may be a monolithic aerogel, a particulate aerogel, or a combination thereof. Within the context of the present invention, the term "monolithic" means that the majority (by weight) of the aerogel is in the form of a single interconnected aerogel nanostructure. Monolithic aerogels can be initially formed to have an integral interconnected gel or aerogel nanostructure, but can subsequently crack, break, or split into non-integral aerogel nanostructures. Monolithic aerogels are distinguished from granular aerogels. Within the context of the present invention, the term "particulate" means that the majority (by weight) of the aerogel is in the form of particulates, particles, granules, beads, or powders, which may be combined or compressed together but lack interconnected aerogel nanostructures between individual particles. Polymer foam (a2)

[0096] At least one aerogel composite comprises at least one polymer foam (a2).

[0097] The terms "at least one polymer foam," "polymer foam," and "component (a2)" are used interchangeably and have the same meaning in the context of the present invention. Furthermore, in the context of the present invention, the term "at least one polymer foam" is understood to mean exactly one polymer foam and mixtures of two or more polymer foams. In a preferred embodiment, the at least one aerogel composite comprises one polymer foam.

[0098] Polymer foams are known in principle to those skilled in the art.

[0099] The polymer foam may be an open-cell polymer foam or a closed-cell polymer foam. The at least one polymer foam (a2) contained in the at least one aerogel composite is preferably an open-cell polymer foam.

[0100] In the context of the present invention, the term "open-cell polymer foam" is understood to mean a polymer foam comprising a plurality of closely spaced cells having cavities filled, for example, with air and / or another gas, the cavities being interconnected by openings in the walls of the respective cells.

[0101] Cells whose cavities are interconnected by openings in the walls of each cell are also called "open cells." Open-cell polymer foams, preferably those with wettable cell walls, can usually absorb liquids by capillary action. Open-cell polymer foams contain more than 50% open cells (based on the total number of cells in the open-cell polymer foam). Consequently, closed cells may also be present in open-cell polymer foams.

[0102] In the context of the present invention, "closed cells" are cells whose cavities are not interconnected by openings in the walls of the respective cells. In the present invention, an open-cell polymer foam always contains more closed cells than closed cells (based on the total number of cells).

[0103] Preferably, the open-cell polymer foam comprises at least 60%, preferably at least 80%, and more preferably at least 90% open cells, based on the total number of cells in the open-cell polymer foam.

[0104] A "closed-cell polymer foam" contains more than 50% closed cells (based on the total number of cells in the closed-cell polymer foam). As a result, closed cells can also be included in a closed-cell polymer foam. In the context of the present invention, a closed-cell polymer foam always contains more closed cells than closed cells (based on the total number of cells).

[0105] Preferably, the closed-cell polymer foam comprises at least 80%, preferably at least 90%, and more preferably at least 95% closed cells, based on the total number of cells in the closed-cell polymer foam.

[0106] Open-cell or closed-cell polymer foams themselves, as well as their manufacturing methods, are known to those skilled in the art. They can be manufactured, for example, by a foaming process, in which, in a first step, a gas is typically blown into a suitable liquid, preferably a molten polymer or polymer extract, or foam formation is achieved by vigorous beating, shaking, spraying, or stirring of the liquid in a gas atmosphere. The liquid is then typically cured in a second step to obtain an open-cell or closed-cell polymer foam. Whether an open-cell or closed-cell polymer foam is obtained depends, among other things, on the volume of the liquid, mechanical conditions, pressure, and temperature.

[0107] The polymer foam may also be a thermoplastic or thermosetting polymer foam. In the context of the present invention, open-cell thermosetting polymer foams are preferred. In a more preferred embodiment, the at least one polymer foam (a2) contained in the at least one aerogel composite is an open-cell melamine-based foam or an open-cell urethane-based foam, preferably an open-cell melamine-based foam.

[0108] The at least one polymer foam (a2) contained in the at least one aerogel composite has a density of 0.002 to 0.025 g / cm, measured according to EN ISO 845:2009-10. 3 , preferably 0.005 to 0.015 g / cm 3It is more preferred that the density of the polymer is 0.05 to 0.15. Flame retardant (a3)

[0109] At least one aerogel composite includes at least one flame retardant.

[0110] The terms "at least one flame retardant," "flame retardant," and "component (a3)" are used interchangeably and have the same meaning in the context of the present invention. Furthermore, in the context of the present invention, the term "at least one flame retardant" is understood to mean exactly one flame retardant and a mixture of two or more flame retardants. In a preferred embodiment, at least one aerogel composite comprises a mixture of two or more flame retardants.

[0111] Flame retardants are known in principle to those skilled in the art.

[0112] The at least one flame retardant in the context of the present invention is an inorganic compound, preferably selected from the group consisting of clay minerals, low-melting glasses, metal oxides, metal oxide hydroxides, metal hydroxides, carbonates and bicarbonates, more preferably selected from clay minerals, metal oxides, metal oxide hydroxides and metal hydroxides.

[0113] Suitable clay minerals are, for example, aluminum silicate clays, phyllosilicate clays, kaolinite, halloysite, endelite, mica, diaspore, gibbsite, montmorillonite, beidellite, pyrophyllite, nontronite, brabysite, smectite, levlierite, rectorite, celadonite, attapulgite, chloropar, volkonskoite, allophane, racevinite, zillnite, sebelite, miloschite, corosite, simolite and newtonite.

[0114] A suitable low melting glass is, for example, glass beads.

[0115] Suitable metal oxides are, for example, magnesium oxide and titanium oxide.

[0116] Suitable metal hydroxides are, for example, magnesium hydroxide and aluminum hydroxide.

[0117] At least one aerogel composite can be prepared, for example, by the following successive steps a) to d): a) casting a sol containing at least one gel precursor, at least one solvent and at least one flame retardant (a3) ​​into a reactor in which at least one polymer foam (a2) is placed, wherein the at least one gel precursor is a gel precursor for producing at least one aerogel (a1); b) gelling at least one gel precursor in at least one polymer foam (a2) to obtain at least one lyogel, wherein the at least one lyogel comprises the gelled at least one gel precursor, at least one solvent and at least one flame retardant (a3); c) drying the at least one lyogel obtained in step b) to remove at least one solvent from the at least one lyogel and obtain at least one aerogel composite comprising at least one aerogel (a1), at least one polymer foam (a2) and at least one flame retardant (a3); d) removing the at least one aerogel composite obtained in step c) from the reactor.

[0118] However, the at least one flame retardant (a3) ​​may be added at any stage of the process for producing at least one aerogel composite, for example, between steps a), b), c), or d), or between steps a) and b), between steps b) and c), or between steps c) and d), or after step d).

[0119] In a preferred embodiment, at least one flame retardant (a3) ​​is embedded in at least one silica aerogel (a1). Insulation System (IS)

[0120] The present invention also provides an insulation system (IS) comprising an insulation board (IB) and a fixing layer (X), the fixing layer (X) fixing the insulation board (IB) to a building wall (BW).

[0121] In the context of the present invention, the terms "fixed layer" and "layer (X)" are used synonymously and have the same meaning. The building walls (BW) can be external and / or internal building walls (BW), floors, roofs, and / or ceilings.

[0122] It will be clear to those skilled in the art that in an insulation system (IS), a fixing layer (X) fixes the insulation board (IB) to the building wall (BW) such that there is a fixing layer (X) between the building wall (BW) and the insulation board (IB).

[0123] The anchoring layer (X) preferably comprises at least one second adhesive (AD2) selected from the group consisting of inorganic and organic adhesives, more preferably consists of at least one adhesive selected from the group consisting of inorganic and organic adhesives, and most preferably consists of mortar. Suitable mortars can be purchased, for example, from Knauf under the trade names Knauf SM 300 or SM 700.

[0124] The at least one second adhesive (AD2) can be the same as the at least one first adhesive (AD1), but it is also possible that the at least one second adhesive (AD2) is different from the at least one first adhesive (AD1).

[0125] In a preferred embodiment, the fixing layer (X) has a thickness of 0.5 to 30 mm, preferably 1 to 10 mm. The thickness of the fixing layer (X) is preferably greater than the thickness of the at least one first adhesive (AD1) applied to at least one surface of at least two insulating layers (A) in the heat insulating board (IB).

[0126] The insulation system (IS) preferably further comprises an upper layer (B) bonded to the insulating plate (IB), such that the insulating plate (IB) is between the fixed layer (X) and the upper layer (B) in the insulation system (IS).

[0127] In the context of the present invention, the terms "upper layer" and "layer (B)" are used synonymously and have the same meaning.

[0128] Preferably, the top layer (B) comprises at least one third adhesive (AD3) selected from the group consisting of inorganic adhesives and organic adhesives, and optionally at least one reinforcing material selected from the group consisting of meshes, fibers, fleeces and fabrics, preferably selected from the group consisting of meshes and fibers.

[0129] Suitable inorganic adhesives are renders and mortars. Suitable organic adhesives are polymer-based adhesives. Preferably, the top layer (B) comprises mortar.

[0130] The at least one second adhesive (AD3) can be the same as the at least one first adhesive (AD1) and / or the at least one second adhesive (AD2), but it is also possible that the at least one second adhesive (AD2) is different from the at least one first adhesive (AD1) and / or the at least one second adhesive (AD2).

[0131] The thickness of the upper layer (B) is preferably 0.5 to 30 mm, more preferably 1 to 10 mm. It will be clear to those skilled in the art that it is also preferable for the thickness of the upper layer (B) to be thicker than the thickness of at least one first adhesive (AD1) applied to at least one surface of at least one of the at least two insulating layers (A) in the heat insulating board (IB).

[0132] It will be clear to those skilled in the art that the upper layer (B) is fixed to the insulation board (IB) by means of at least one third adhesive (AD3) contained in the upper layer (B).

[0133] In a further preferred embodiment, the insulation system (IS) also comprises a finishing layer (C) bonded to the top layer (B).

[0134] In the context of the present invention, the terms "finishing layer" and "layer (C)" are used synonymously and have the same meaning.

[0135] It will be clear to those skilled in the art that in an insulation system (IS), the finishing layer (C) is bonded to the upper layer (B) so that the upper layer (B) is between the finishing layer (C) and the insulation board (IB).

[0136] The finishing layer (C) preferably comprises a plaster or a rendering. Suitable plasters and renderings may contain inorganic and / or organic components. Examples of suitable inorganic components are gypsum, cement, lime, and silicates. Examples of suitable organic components are polystyrene and polyacrylates.

[0137] The thickness of the finishing layer (C) is preferably from 0.5 to 40 mm, more preferably from 2 to 20 mm.

[0138] It will be clear to those skilled in the art that the finishing layer (C) is attached to the upper layer (B) by means of at least one adhesive contained in the upper layer (B) and / or by means of a plaster or rendering contained in the finishing layer (C).

[0139] In a further preferred embodiment, the insulation system (IS) also comprises a facing layer (D) bonded to the facing layer (C).

[0140] It will be clear to those skilled in the art that in the insulation system (IS), the facing layer (D) is bonded to the facing layer (C) so that the facing layer (C) is between the upper layer (B) and the facing layer (D).

[0141] In the context of the present invention, the terms "surface finish layer" and "layer (D)" are used synonymously and have the same meaning.

[0142] The surface finish layer (D) preferably comprises a coating, laminate, film, foil or paint, preferably an exterior or interior wall paint well known to those skilled in the art, which is preferably applied in the form of a paint based on an aqueous dispersion or emulsion of inorganic pigments and an organic binder such as an acrylic, vinyl, polyurethane, polyester, epoxy or silicone polymer.

[0143] The thickness of the surface finishing layer (D) is preferably from 0.001 to 10 mm, more preferably from 0.002 to 2 mm.

[0144] As will be clear to those skilled in the art, by fixing the insulation board (IB) to the building wall (BW) by the fixing layer (X), the layer (B) optionally bonded to the insulation board (IB), the layer (C) optionally bonded to layer (B), and the layer (D) optionally bonded to layer (C) are also fixed to the building wall (BW), so that the insulation system (IS) as a whole is fixed to the building wall (BW).

[0145] The insulation boards (IB) and / or insulation systems (IS) can be attached to the external and / or internal building walls (BW), floors, roofs and / or ceilings, respectively, by means of the fixing layer (X) only, or they can be additionally attached by mechanical fixings, preferably by dowels, nails, screws and / or rails.

[0146] The inventive insulating board (IB) and / or the inventive insulating system (IS) can be fixed directly to the walls (BW), floors, roofs and / or ceilings of external and / or internal buildings by means of a fixing layer (X), or can be fixed indirectly by pre-installing the inventive insulating board (IB) and / or the inventive insulating system (IS) on a carrier plate, preferably comprising at least one component selected from the group consisting of magnesium oxide, calcium silicate, plaster, plaster, wood, plywood, wood fibres, flakes, particles and chips, and the carrier plate is fixed to the walls (BW), floors, roofs and / or ceilings of external and / or internal buildings by means of a fixing layer (X).

[0147] 1 shows a schematic representation of an embodiment of the inventive insulation board (IB) and the inventive insulation system (IS), in which the inventive insulation board (IB) comprises five insulating layers (A) bonded together by at least one first adhesive (AD1). The inventive insulation board (IB) is attached to the building wall (BW) by a fixing layer (X) to obtain the inventive insulation system (IS). A top layer (B) is bonded to the inventive insulation board (IB) so that the insulation board (IB) is present between the fixing layer (X) and the top layer (B) in the insulation system (IS). A finishing layer (C) is bonded to the top layer (B). A surface finishing layer (D) is bonded to the finishing layer (C).

[0148] 2 shows a schematic representation of another embodiment of the inventive insulation board (IB) and the inventive insulation system (IS), respectively, in which the inventive insulation board (IB) comprises five insulating layers (A) bonded to one another by at least one first adhesive (AD1). The inventive insulation board (IB) is attached to the building wall (BW) by a fixing layer (X) to obtain the inventive insulation system (IS). A top layer (B) is bonded to the insulation board (IB) so that the insulation board (IB) is present between the fixing layer (X) and the top layer (B) in the insulation system (IS). A finishing layer (C) is bonded to the top layer (B). A facing layer (D) is bonded to the finishing layer (C). The insulation board is additionally fixed to the building wall (BW) by mechanical fixings (MF). use

[0149] The present invention therefore also provides the use of an inventive insulating board (IB) or an inventive insulating system (IS) for the thermal insulation of buildings, parts and / or building elements, preferably for the thermal insulation of walls, floors, roofs and / or ceilings of external and / or internal buildings, more preferably for the thermal insulation of walls, floors, roofs and / or ceilings of external and / or internal buildings in a multi-layer external thermal insulation composite system (ETICS), a multi-layer external thermal insulation facade system (EIFS), a ventilated or curtain facade system and / or an internal thermal insulation system.

[0150] For example, the thermal insulation system (IS) of the present invention is used behind a facade system, cladding, facing or covering applied to an external or internal building wall (BW), preferably in a ventilated facade system, behind a rainwater screen or cladding element connected to the external building wall (BW) via a carrier substructure, where the thermal insulation system (IS) is optionally joined to the wall by at least one adhesive or by mechanical fastening, and optionally provided with a finishing fleece, fabric or other coating or lamination.

[0151] Furthermore, the insulation system (IS) of the present invention is used, for example, in facade cassette systems, infill facade panels, framework, frame or panel constructions, post and beam and post and mullion facades, element facades, curtain walls and curtain facades, double skin facades, perforated, pierced or perforated facades, striped facades, component facades, integrated facades and facade components with integrated functions, for example, green facades, integrated photovoltaic devices, ventilated or heated facades.

[0152] The insulation systems (IS) of the present invention may also find beneficial application in other wide range of fields of application, for example in the building and construction segment, for example in thermal bridges and thermal isolation, e.g. facade joints, consoles and anchors, roller shutters or other shading elements, post boxes, cable ducts, shafts for pipes, tubes and conduits, interior or exterior window or door reveals, frames, jambs, jambs, lintels or sills, ETICS dowel covers (rondela) or joint sealing tapes, etc. They may also find use, for example, in the insulation of interior walls, especially in niches, alcoves, recesses, openings or cavities, for example radiator niches or window alcoves, for example in insulation and insulation systems (IS) in drywall constructions, including plasterboard, wallboard, plasterboard, post and beam and framing structures, partition elements, wall stud elements or lining and groove elements.

[0153] The insulation system (IS) of the present invention may also be used, for example, for insulating cavity walls and hollow spaces between walls, insulating roofs, especially sloped and flat roofs, such as inverted roofs, protective membrane roofs, green roofs, ventilated roofs and between, above or below rafters, as well as baffles, attics, jamb wall insulation, floors, raised floors, underfloors, hollow floors, crawl spaces, terraces, balconies, ceilings, basement ceilings, park deck ceilings, soffit insulation, and insulating floor or wall heating or cooling systems. They can also be used, for example, for the insulation of doors, gates, door and gate infills, including sliding, roller or sectional doors and gates, window profiles and frames, and other hollow profiles in buildings and structures, for example inserted into profiles as prefabricated insulating elements or as insulating elements in continuous extrusion or pultrusion processes, for the insulation of fire protection and fire protection systems, and for the insulation of non-combustible, non-burning elements or parts of such applications, such as fire barriers, fire breaks, fire locks, fire stripes, fire doors, gates or curtains, smoke vents or roof domes, residential conduits, ducts, vents and pipes and systems of building services and technical building installations, such as boilers, heaters, hot and cold water supplies, solar power generation, air conditioning and air supply systems, and cold stores and refrigerator rooms.

[0154] Beyond the field of building and construction, the insulation system (IS) of the present invention may also be used in other insulation applications, for example in domestic and commercial appliances, such as refrigerators, coolers, freezers, iceboxes, refrigerated shelves and display cases, vending machines, ovens, as part or component of the insulation of curtains or separating or dividing elements in containers, refrigerators, refrigerated storage, for example, in the insulation of transport and logistics containers and boxes for the transport of medicines, vaccines, medical samples, organs, blood, beverages, food or other perishable goods, in the insulation of electronic devices such as computers, tablet PCs, laptop PCs, displays, screens and monitors, mobile phones and smartphones, sensors, household appliances and wearable electronics, in the insulation of clothing, functional clothing, apparel and sportswear, including cooler bags, tents, sleeping bags, shoes, sports shoes and boots, soles and insoles, jackets, gloves and headwear, in the insulation of powertrains, engine compartments, engine covers, engine compartments, for fuels, liquefied gases, exhaust gas treatment media, such as urea solutions, thermal protection between parts of vehicles with hybrid or electric drive systems, e.g. battery cells, battery modules and casings, power electronics, electric engines, fuel cells, tanks for media such as hydrogen and the respective pipes and lines, and thermal protection between parts of passenger compartments and parts of the vehicle body, e.g. headliners, roof liners, underbody, doors, trim, firewalls, rear walls, etc.; thermal protection between parts of vehicles with hybrid or electric drive systems, e.g. battery cells, battery modules and casings, power electronics, electric engines, fuel cells, tanks for media such as hydrogen and the respective pipes and lines, and thermal protection between parts of passenger compartments and parts of the vehicle body, e.g. headliners, roof liners, underbody, doors, trim, firewalls, rear walls, etc.; thermal protection between parts of commercial utility vehicles and construction machinery, e.g. trucks, dump trucks, tank trucks, asphalt mixers, road pavers, tractors, vans, cranes, tunnel boring machines, mining vehicles and machinery, e.g. respective trailers, containers and structures of such vehicles, e.g. reefers, interior and exterior insulation of buses, trams, trains and the respective coaches, cars and wagons; thermal protection between parts of military and armoured vehicles, e.g. aircraft, helicopters, satellites and other aerospace vehicles and equipment,It may be employed in the insulation of exteriors, cabins or parts, the insulation of interiors, exteriors, cabins or parts of ships, boats or yachts, and the insulation of interiors, exteriors, cabins or caravans, trailer caravans, camper vehicles, mobile homes, including lift and pop-top roofs. [Example]

[0155] The invention is illustrated by reference to the following examples.

[0156] Table 1 shows the essential parameters of the insulating layer (A) used in the insulating boards (IB) according to Examples E1 to E3 of the present invention, and Table 2 shows the essential parameters of the insulating layer (A*) used in the insulating boards (IB) according to Comparative Examples C1 to C3.

[0157] Table 1 JPEG2023504374000001.jpg113170

[0158] Table 2 JPEG2023504374000002.jpg96170

[0159] The thermal conductivity λ is determined in accordance with DIN EN 12667:2001-05 and DIN EN 13162.

[0160] The heat of combustion per weight is determined in accordance with DIN EN ISO 1716:2010-11.

[0161] The density is determined in accordance with DIN EN 1602:2013-05.

[0162] The normal tensile strength is determined according to DIN EN 1607:2013-05

[0163] Table 3 shows the composition and total thickness of the insulating boards (IB) according to Examples E1 to E3 of the present invention, and Table 4 shows the composition and total thickness of the insulating boards according to Comparative Examples C1 to C3, where composition refers to the order in which the different layers are bonded to each other.

[0164] Table 3 JPEG2023504374000003.jpg188170

[0165] Table 4 JPEG2023504374000004.jpg148170

[0166] To obtain an insulation system (IS), the insulation boards (IB) of the present invention according to Examples E1 to E3 and the insulation boards according to Comparative Examples C1 to C3 are attached to the building wall (BW) by a mortar (fixing layer (X)). The mortar has a thickness of 5 mm, a thermal conductivity λ of 0.540 W / (mK), and a dry density of 1.2 g / cm. 3 The heat of combustion is 0.5MJ / kg.

[0167] The insulation boards (IB) according to the inventive examples E1 and E3, and the insulation boards according to the comparative examples C2 and C3, are manufactured before being attached to the building wall (BW). The insulation board (IB) according to the inventive example E2 is manufactured on-site by first fixing the layer A2 to the building wall (BW) with mortar (fixing layer (B)), and then joining three further layers A2 and A1 to the previous layer A2 with mortar, respectively.

[0168] After the insulation boards are fixed to the building wall (BW) with mortar, a mortar with a reinforcing mesh (top layer (B)) is bonded to the insulation boards according to Examples E1 to E3 of the present invention and Comparative Examples C1 to C3 so that the insulation boards are between the fixed layer (X) and the top layer (B) in the insulation system. The thickness of the top layer (B) is 5 mm.

[0169] In inventive examples E1 and E2, the upper layer (B) is bonded to layer A1, and in inventive example E3, the upper layer (B) is bonded to layer A2. In comparative example C1, the upper layer (B) is bonded to layer A*1, in comparative example C2, the upper layer (B) is bonded to layer A*4, and in comparative example C3, the upper layer (B) is bonded to layer A*3.

[0170] A finishing layer (C) containing plaster is glued to the top layer (B). The thickness of the finishing layer (C) is 5 mm.

[0171] The properties of the thermal insulation systems according to Examples E1 to E3 of the present invention and the thermal insulation systems according to Comparative Examples C1 to C3 are shown in Table 5. The properties of the thermal insulation plates included in the thermal insulation systems according to Examples E1 to E3 of the present invention and the thermal insulation systems according to Comparative Examples C1 to C3 are shown in Table 6.

[0172] JPEG2023504374000005.jpg149170

[0173] JPEG2023504374000006.jpg149170

[0174] The specific heat of combustion per surface area and per mass is calculated by multiplying the MJ / kg value by 1m 2 The surface area is calculated from the individual components of the system by multiplying the component weight of each component.

[0175] The U-value and R-value can be calculated by reference to Klaus Liersch, Normen Langner, "Bauphysik kompakt", Verlag Bauwerk BBB, 4th Auflage 2011, ISBN 987-3-89932-285-9, Chapter 6 "Warmedurchgang durch ebene opake Bauteile").

[0176] As can be seen from Table 6, the inventive insulation boards (IB) according to inventive examples E1-E3 exhibit reduced heat of combustion, reduced total thickness and weight, and reduced dust generation compared to the insulation boards according to comparative examples C1-C3, while providing similar overall insulating capacity (U value / R value). Additionally, the inventive insulation boards (IB) according to inventive examples E1-E3 exhibit increased normal tensile strength compared to the insulation boards according to comparative examples C1-C3.

[0177] The same is true for the inventive insulation systems, and as can be seen from Table 5, the inventive insulation systems (IS) according to inventive examples E1-E3 also exhibit reduced heat of combustion, reduced total thickness and weight, and reduced dust generation compared to the insulation systems according to comparative examples C1-C3, while exhibiting similar overall insulating capacity (U / R values). Furthermore, they also exhibit increased normal tensile strength compared to the insulation systems according to comparative examples C1-C3.

[0178] The insulation system (IS) of the present invention can be used, for example, in an exterior multi-layer insulation composite system (ETICS).

Claims

1. A heat insulating plate (IB) comprising at least two insulating layers (A), wherein the at least two insulating layers (A) are joined to each other, and at least one of the at least two insulating layers (A) comprises at least one aerogel composite material comprising at least the following components (a1) to (a3): (a1) at least one silica aerogel constituting 10 to 94% by weight of the aerogel composite material; (a2) at least one polymer foam constituting 1 to 20% by weight of the aerogel composite material; (a3) at least one flame retardant constituting 5 to 70% by weight of the aerogel composite material.

2. i) the at least two insulating layers (A) are joined to each other by at least one first adhesive (AD1), and / or ii) the at least two insulating layers (A) are joined to each other by mechanical fixing (MF), and / or iii) each of the at least two insulating layers (A) has a thickness of 1 to 500 mm, the heat insulating plate (IB) according to Claim 1.

3. The heat insulating plate (IB) according to Claim 2, wherein the at least two insulating layers (A) are joined to each other by sewing, clamping, riveting, doweling and / or nailing.

4. i) the at least one first adhesive (AD1) is selected from the group consisting of inorganic adhesives, organic adhesives and inorganic-organic hybrid adhesives, and / or ii) the at least one first adhesive (AD1) is applied to at least one surface of at least one of the at least two insulating layers (A), and / or iii) The at least one first adhesive (AD1) is applied to at least one surface of at least one of the at least two insulating layers (A) at a weight per square meter of 10 to 500 g / m ２ of the heat insulating plate (IB) according to claim 2.

5. The heat insulating plate (IB) according to Claim 4, wherein the at least one first adhesive (AD1) is a one-component or two-component polyurethane-based adhesive having a calorific value of < 40 MJ / kg.

6. The heat insulating plate (IB) according to Claim 5, wherein the one-component or two-component polyurethane-based adhesive is filled with an inorganic compound.

7. The heat insulating plate (IB) according to any one of Claims 4 to 6, wherein the at least one first adhesive (AD1) is applied to at least one surface of at least one of the at least two insulating layers (A) with a thickness of 0.01 to 10 mm.

8. the at least one aerogel composite material contained in at least one of the at least two insulating layers (A) is i) A density of 0.10 to 0.40 g / cm ３ and / or ii) a thermal conductivity λ of ≤ 0.030 W / (mK), and / or iii) a liquid water absorption of ≤ 20% by weight, based on the total weight of the at least one aerogel composite material, and / or iv) a heat of combustion of ≤ 3.0 MJ / kg, and / or v) a heat insulating plate (IB) according to any one of claims 1 to 7, having a furnace temperature rise of ≤ 50°C, a mass loss of ≤ 50%, and a flame time of ≤ 20 seconds.

9. The at least one aerogel composite material comprised in at least one of the at least two insulating layers (A) is i) 20 to 80% by weight of the at least one silica aerogel (a1), based on the total weight of the at least one aerogel composite material, and / or ii) 1 to 15% by weight of the at least one polymer foam (a2), based on the total weight of the at least one aerogel composite material, and / or iii) 19 to 65% by weight of the at least one flame retardant (a3), based on the total weight of the at least one aerogel composite material, of a heat insulating plate (IB) according to any one of claims 1 to 8.

10. The at least one silica aerogel (a1) contains at least one hydrophobic group in the range of 1 to 25% by weight, based on the total weight of the at least one silica aerogel (a1), and the at least one hydrophobic group is bonded to at least one silicon atom, of a heat insulating plate (IB) according to any one of claims 1 to 9.

11. The at least one polymer foam (a2) comprised in the at least one aerogel composite material is i) a closed-cell polymer foam, and / or ii) The heat insulation plate (IB) according to any one of claims 1 to 10, having a density of 0.002 to 0.025 g / cm ３ .

12. The closed-cell polymer foam is a closed-cell melamine-based foam or a closed-cell urethane-based foam, of a heat insulating plate (IB) according to claim 11.

13. The at least one flame retardant (a3) comprised in the at least one aerogel composite material is selected from inorganic compounds, of a heat insulating plate (IB) according to any one of claims 1 to 12.

14. The at least one flame retardant (a3) is selected from the group consisting of clay minerals, low melting point glasses, metal oxides, metal oxide hydroxides, metal hydroxides, carbonates and bicarbonates, of a heat insulating plate (IB) according to any one of claims 1 to 12.

15. The heat insulation plate (IB) according to any one of claims 1 to 14, wherein the at least one flame retardant (a3) is embedded in the at least one silica aerogel (a1).

16. The heat insulation plate (IB) according to any one of claims 1 to 15, wherein the at least one aerogel composite material further comprises at least one infrared absorbing or reflecting opacifier.

17. The heat insulation plate (IB) according to claim 16, wherein the at least one infrared absorbing or reflecting opacifier is selected from the group consisting of carbon black, graphite, boron carbide, metal oxides and metal carbides, and more preferably is selected from metal oxides.

18. A heat insulation system (IS) comprising the heat insulation plate (IB) according to any one of claims 1 to 17 and a fixing layer (X), wherein the fixing layer (X) fixes the heat insulation plate (IB) to a wall (BW) of a building.

19. The fixing layer (X) is i) includes at least one second adhesive (AD2) selected from the group consisting of inorganic adhesives and organic adhesives, and / or ii) has a thickness of 0.5 to 30 mm, and the heat insulation system (IS) according to claim 18.

20. The heat insulation system (IS) according to claim 19, wherein the fixing layer (X) consists of at least one adhesive selected from the group consisting of inorganic adhesives and organic adhesives.

21. The heat insulation system (IS) according to claim 19, wherein the fixing layer (X) consists of mortar.

22. The heat insulation system (IS) further comprises an upper layer (B) joined to the heat insulation plate (IB), and the heat insulation plate (IB) is present between the fixing layer (X) and the upper layer (B) in the heat insulation system (IS), and the heat insulation system (IS) according to any one of claims 18 to 21.

23. The upper layer (B) is i) includes at least one third adhesive (AD3) selected from the group consisting of inorganic adhesives and organic adhesives, and / or ii) has a thickness of 0.5 to 30 mm, and the heat insulation system (IS) according to claim 22.

24. The third adhesive (AD3) includes mortar, and the heat insulation system (IS) according to claim 23.

25. The heat insulation system (IS) according to any one of claims 22 to 24, wherein the upper layer (B) further comprises at least one reinforcing material selected from the group consisting of mesh, fiber, fleece and fabric.

26. The heat insulation system (IS) further comprises a finishing layer (C) joined to the upper layer (B), i) the finishing layer (C) includes plaster or primer, and / or ii) the finishing layer (C) has a thickness of 0.5 to 40 mm, the heat insulation system (IS) according to any one of claims 22 to 25. **Claim 27** The heat insulation system (IS) further comprises a surface finishing layer (D) joined to the finishing layer (C), i) the surface finishing layer (D) includes a coating, lamination, film, foil or paint, and / or ii) the surface finishing layer (D) has a thickness of 0.001 to 10 mm, the heat insulation system (IS) according to claim 26. **Claim 28** A method for manufacturing a heat insulation board (IB) according to any one of claims 1 to 17, a) a step of providing at least two insulating layers (A), at least one of the at least two insulating layers (A) being at least one aerogel composite material comprising at least the following components (a1) to (a3): (a1) at least one silica aerogel constituting 10 to 94% by weight of the aerogel composite material, (a2) at least one polymer foam constituting 1 to 20% by weight of the aerogel composite material, (a3) at least one flame retardant constituting 5 to 70% by weight of the aerogel composite material including, the step, b) a step of joining the at least two insulating layers (A) to each other to obtain the heat insulation board (IB) A manufacturing method including steps a) and b). **Claim 29** The method according to claim 28, wherein the at least two insulating layers (A) are joined to each other by at least one first adhesive (AD1) and / or mechanical fixing (MF). **Claim 30** Use of the heat insulation board (IB) according to any one of claims 1 to 17 or the heat insulation system (IS) according to any one of claims 18 to 27, for heat insulation of a building, or parts and / or elements of a building. **Claim 31** Use of the heat insulation board (IB) according to any one of claims 1 to 17 or the heat insulation system (IS) according to any one of claims 18 to 27, for heat insulation of external and / or internal building walls (BW), floors, roofs and / or ceilings. Use of the heat-insulating plate (IB) according to any one of claims 1 to 17 or the heat-insulating system (IS) according to any one of claims 18 to 27, for the heat insulation of external and / or internal building walls (BW), floors, roofs and / or ceilings in a multilayer external thermal insulation composite system (ETICS), a multilayer external insulation facade system (EIFS), a ventilation or curtain facade system and / or an internal thermal insulation system.