Modular green wall elements with improved thermal insulation properties

Abstract

The present invention relates to a modular greenwall element (1) comprising a casing (2) having first and second compartments (6, 6'), the first compartment (6) being arranged to accommodate growing material for plants and the second compartment (6') being at least partially filled with a foam material to provide the element (1) with improved thermal insulation properties.

Description

[Technical field]

[0001] The present invention relates to the field of greenwall elements, in particular to modular prefabricated greenwall elements having improved thermal insulation properties. [Background technology]

[0002] The exterior of buildings must be protected from environmental forces such as wind and rain. Buildings must also be insulated to prevent unnecessary flow of thermal energy from the interior of the building to the exterior or vice versa. Furthermore, for ecological reasons, it is highly desirable to cover building facades with green (vegetated) wall systems. This improves the urban microclimate, provides some insulation and enhances aesthetics. Green wall systems in particular play an important role as urban climate buffers, not only by carbon dioxide sequestration, but also by mitigating the heat island effect, improving general air quality, sound and heat insulation, as well as saving energy and water, improving urban biodiversity and the well-being of urban residents. As a result, modular green wall elements are becoming increasingly important.

[0003] Modular systems for providing greenwalls have been commercially available for some time. However, currently available greenwall modules are "add-on" systems that are installed on the exterior surface of the building envelope and must be glued on top of the existing insulation layer. To ensure sufficient bond strength, metal fasteners that penetrate the insulation layer are typically used to fasten the greenwall elements to the building structure. This has the significant drawback of creating thermal bridges connecting the underside of the insulation layer with the exterior of the building. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, modular greenwall elements with integrated insulation are highly desirable because, when installed, they can cover substantially the entire facade area and avoid the formation of thermal bridges between the interior and exterior sides of the building envelope. The greenwall elements are preferably lightweight and have good fire resistance. [Means for solving the problem]

[0005] The object of the present invention is to provide a modular greenwall element with integrated insulation, which can be used to provide a greenwall covering the entire outer surface of a facade without forming a thermal bridge between the inside and outside of the building envelope.

[0006] Another object of the present invention is to provide a modular greenwall element that is lightweight and fire resistant.

[0007] The subject of the invention is a modular greenwall element as defined in claim 1.

[0008] Surprisingly, it turned out that the object could be achieved by the features of claim 1.

[0009] One of the advantages of the present invention is that the entire facade can be covered with greenwall elements without adversely affecting the insulating properties of the building envelope.

[0010] The core of the invention is a modular greenwall element comprising a casing having at least two cavities (compartments), the first cavity being capable of being filled with a growing material for plants such as soil and the second cavity being at least partially filled with a foamed organic or inorganic material to improve the thermal insulation properties of the element.

[0011] Further objects of the invention are set forth in the other independent claims. Preferred embodiments of the invention are set forth in the dependent claims. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 shows a greenwall element (1) comprising a casing (2) having first and second sections (6, 6'), the interior space of the second section (6') being partially filled with a foam material. [Diagram 2] FIG. 2 shows a casing (2) of a greenwall element comprising a front and a rear wall (3, 3') connected by two longitudinal side walls (4, 4'), a bottom wall (7) and an intermediate wall (5) dividing the interior space formed between the front wall, the rear wall and the longitudinal side walls (3, 3', 4, 4') into first and second compartments (6, 6'). [Diagram 3] Figure 3 shows a casing (2) of a greenwall element comprising a front and rear wall (3, 3') connected by two longitudinal side walls (4, 4'), a bottom wall (7), an intermediate wall (5) dividing the internal space formed between the front wall, rear wall and longitudinal side walls (3, 3', 4, 4') into first and second compartments (6, 6') and a further intermediate wall (5') dividing the internal space of the first compartment (6) into first and second sub-compartments (6a, 6b). [Figure 4] Figure 4 shows a greenwall comprising a substrate (8) and a number of modular greenwall elements attached to a surface of the substrate (8) such that each element (1) is connected to the surface of the substrate (8) via the exterior surface of its back wall (3'). Adjacent elements are attached to each other via the exterior surfaces of their opposing longitudinal side walls (4, 4'). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The subject of the present invention is a modular greenwall element (1) comprising a casing (2) having a first and a second compartment (6, 6'), the first compartment (6) being arranged to contain growing material for plants, such as soil, and the second compartment (6') being at least partially filled with a foam material.

[0014] Substance names beginning with "poly" refer to substances that formally contain more than one functional group per molecule. For example, a polyol refers to a compound that has at least two hydroxyl groups. A polyether refers to a compound that has at least two ether groups.

[0015] The term "polymer" refers to a collection of chemically homogeneous macromolecules resulting from multiple reactions (polymerization, polyaddition, polycondensation) that differ in terms of degree of polymerization, molecular weight and chain length. The term also includes derivatives of said collection of macromolecules resulting from multiple reactions, i.e. compounds obtained by reactions, for example addition or substitution, of functional groups in a given macromolecule, and that may be chemically homogeneous or chemically heterogeneous.

[0016] In this disclosure, the term "copolymer" refers to a polymer derived from two or more types of monomers ("structural units"). The polymerization of monomers into a copolymer is called copolymerization. Copolymers obtained by copolymerization of two monomer types are known as bipolymers, while those obtained from three and four monomer types are called terpolymers and quaternary polymers, respectively.

[0017] The term "rubber" refers to a polymer or polymer blend that can recover from large deformations and can be or has been modified to a state that is essentially insoluble (but swellable) in boiling solvents, especially xylene. A typical rubber can be stretched or deformed to at least 200% of its original dimensions when subjected to an external force, and will return to substantially its original dimensions after the external force is released, with only small permanent deformations (typically about 20% or less). The term "rubber" can be used interchangeably with the term "elastomer."

[0018] "Melting temperature (T mThe term "melting point" refers to the melting point determined as the maximum of the curve determined by differential scanning calorimetry (DSC) using the measurement method defined in the ISO 11357-3:2018 standard and with a heating rate of 2 °C / min. The measurement can be carried out with a Mettler Toledo DSC 3+ instrument and the T is calculated from the DSC-curve measured with the aid of the DSC-software. m If the measured DSC curve shows multiple peak temperatures, the first peak temperature coming from the low temperature side of the thermogram is determined as the melting temperature (T m )

[0019] The "amount or content of at least one component X" in a composition, such as the "amount of at least one synthetic polymer," refers to the sum of the individual amounts of all synthetic polymers contained in the composition. For example, if a composition contains 20% by weight of at least one synthetic polymer, then the sum of the amounts of all synthetic polymers contained in the composition is equal to 20% by weight.

[0020] The term "normal room temperature" refers to 23°C.

[0021] The greenwall elements are preferably preformed. The term "preformed" or "prefabricated" is understood to mean that the element is shaped before being applied to the surface to be covered by the element. In particular, the term "preformed" refers to elements that are not shaped in situ, i.e. not shaped on the surface of the substrate to be covered by the element. Preformed greenwall elements are typically, but not necessarily, manufactured at a location away from the construction site, transported to the site and placed on the surface of the substrate to be covered by the element.

[0022] The term "foam material" refers to a material having numerous distinct voids formed therein. Foam materials suitable for use in the greenwall elements of the present invention include closed-cell, semi-closed (semi-open) cell, and open-cell synthetic organic and inorganic foams. Closed-cell and semi-closed cell foams may be preferred to minimize the ability of the foam material to absorb liquids, especially water.

[0023] Preferably, the foam material has a compressibility of 500 kg / m 3 (g / l) or less, more preferably 300 kg / m 3 (g / l) or less, more preferably 250 kg / m 3 (g / l) or less, more preferably 200 kg / m 3 (g / l) or less, e.g. 15-250kg / m 3 (g / l), preferably 25 to 150 kg / m 3 (g / l).

[0024] The density of the foamed material is preferably measured gravimetrically, for example, by using the following procedure: First, a sample cube having dimensions of 10×10×10 cm is cut from the foamed material and dried in an oven at a temperature of 70° C. until the weight of the material is constant. Then, the weight of the sample cube is measured, and the density of the material is obtained based on the measured weight and the volume of the cube.

[0025] According to one or more embodiments, the foam material is a synthetic organic foam material, preferably selected from the group consisting of polystyrene, polyurethane, polyisocyanurate, and polyolefin foams, and expanded rubber.

[0026] Polyolefin foams and expanded rubbers are usually produced by adding chemical blowing agents to polyolefin melts or curable rubber compositions. Polystyrene-based foams, such as expanded polystyrene (EPS) and expanded extruded polystyrene (XPS), are obtained by expanding the starting composition with a blowing agent such as pentane or by forcing the molten composition through the nozzle of an extruder, where a reduction in pressure causes the expansion of the liquid material.

[0027] Polyurethane (PUR) and polyisocyanurate (PIR) foams are formed by reacting isocyanates and polyols. During the expansion process, the closed pores are filled with an expansion gas such as carbon dioxide or hexane.

[0028] According to one or more embodiments, the synthetic organic foam material is selected from the group consisting of polystyrene, polyurethane, polyisocyanurate, and polyolefin foams.

[0029] According to one or more preferred embodiments, the foam material comprises: a) at least one mineral binder B, and b) optionally at least one synthetic organic polymer SP It is a foamed inorganic material comprising:

[0030] Compared with foamed organic materials, foamed inorganic materials have a great advantage in that they have excellent fire resistance.

[0031] Suitable mineral binders include hydraulic binders such as cement and hydraulic lime, air-setting binders such as calcium sulfate, non-hydraulic lime, latent hydraulic binders and pozzolanic binder materials.

[0032] Hydraulic binders are inorganic materials or blends that become paste-like when mixed with water and harden through a series of hydration reactions to form solid mineral hydrates or hydrate phases that are insoluble or have very low water solubility. Hydraulic binders, such as Portland cement, can harden and retain strength even when exposed to water, for example, under water or under conditions of high humidity. The term "non-hydraulic binders" refers to materials that harden by reaction with carbon dioxide and do not harden in wet conditions or under water.

[0033] Examples of suitable non-hydraulic binders include air slaked lime (non-hydraulic lime) and calcium sulfate. The term "calcium sulfate" is understood to include calcium sulfate anhydrite (CaSO4), calcium sulfate hemihydrate (CaSO4·1 / 2H2O) and calcium sulfate dihydrate (CaSO4·2H2O). Furthermore, the term "calcium sulfate hemihydrate" is understood to include both alpha and beta calcium sulfate hemihydrate. Preferred calcium sulfates include those derived from REA gypsum, phosphogypsum and natural gypsum. The term "REA gypsum" here refers to gypsum obtained in so-called flue gas desulfurization plants.

[0034] The term "latent hydraulic binder material" refers to type II concrete additives with "latent hydraulicity" as defined in the DIN EN 206-1:2000 standard. These types of mineral binders are calcium aluminosilicates that do not set directly or are slow to set when mixed with water. In the presence of an alkali activator, the setting is accelerated by breaking the chemical bonds of the amorphous (or glassy) phase of the binder, promoting the dissolution of ionic species and the formation of calcium aluminosilicate hydrate phases. Examples of latent hydraulic binders include granulated blast furnace slag, which is typically made by quenching molten iron slag from a blast furnace with water or steam to form a glassy granular product that is then dried and ground to a fine powder.

[0035] The term "pozzolanic binder material" refers to type II concrete additives with "pozzolanic properties" as defined in the DIN EN 206-1:2000 standard. These types of mineral binders are silica or aluminosilicate compounds that react with water and calcium hydroxide to form calcium silicate hydrate or calcium aluminosilicate hydrate phases. Examples of pozzolanic binders include natural pozzolans such as tulace, and artificial pozzolans such as fly ash and silica fume. The term "fly ash" refers to the finely ground ash residue resulting from the combustion of pulverized coal, which is obtained with the gases exhausted from the coal-burning furnace. The term "silica fume" refers to amorphous, particulate silicon. Silica fume is usually obtained as a by-product of the processing of silica ores, such as the smelting of quartz in silica smelters, resulting in the formation of silicon monoxide gas, which further oxidizes on exposure to air to produce small particles of amorphous silica.

[0036] Preferably, the at least one mineral binder B constitutes at least 35% by weight, preferably at least 50% by weight, more preferably at least 65% by weight, even more preferably at least 75% by weight of the total weight of the foamed inorganic material.

[0037] Preferably, the at least one mineral binder B is selected from the group consisting of Portland cements, calcium aluminate cements, calcium sulphoaluminate cements, latent hydraulic binder materials, pozzolanic binder materials, calcium sulphate and hydrated lime.

[0038] According to one or more preferred embodiments, the at least one mineral binder B comprises at least one hydraulic binder B1, preferably selected from the group consisting of Portland cements, calcium aluminate cements and calcium sulphoaluminate cements.

[0039] In general, the expression "at least one component X comprises at least one component XN", e.g. "at least one mineral binder B comprises at least one hydraulic binder B1", is understood in the context of the present disclosure to mean that the composition comprises one or more hydraulic binders B1 as representatives of the at least one mineral binder B.

[0040] As used herein, the term "Portland cement" includes cements that are normally understood to be "Portland cements", in particular those described in European Standard EN-197. Portland cements consist mainly of tricalcium silicate (arite) (C3S) and dicalcium silicate (berite) (C2S). Preferred Portland cements include the types CEM I, CEM II, CEM III, CEM IV and CEM V compositions of European Standard EN197-1:2018-11. However, all other Portland cements manufactured according to other standards, such as ASTM, British (BSI), Indian or Chinese standards, are also suitable.

[0041] As used herein, the term "aluminate cement" is intended to include cementitious materials that contain hydraulic calcium aluminate, preferably monocalcium aluminate CA (CaO-Al2O3), as the main component (phase). Different types of aluminate cement include CA2, C3A and C 12 Other calcium aluminates such as A7 may be present. Preferred aluminate cements also include other components such as belite (C2S), alite (C3S), ferrite (C2F, C2AF, C4AF), and ternesite (C5S2S). Some aluminate cements also contain calcium carbonate.

[0042] The most preferred aluminate cements for use as the at least one hydraulic binder B1 include calcium aluminate cements (CAC) that meet the standard requirements of EN4647 ("Calcium Aluminate Cement"). Suitable calcium aluminate cements are commercially available, for example, from Imerys Aluminates and Royal White Cement.

[0043] The term "calcium sulfoaluminate cement (CSA)" is intended to include cementitious materials containing as the main component (phase) C4(A3-xFx)3S(4CaO 3-xAl2O3 xFe2O3 CaSO4), where x has a value of 0, 1, 2 or 3. Typically, calcium sulfoaluminate cements contain aluminates (CA, C3A, C4A, C5A, C6A, C7A, C8A, C9A, C10A, C11A, C12A, C13A, C14A, C15A, C16A, C17A, C18A, C29A, C28A, C39A, C40A, C41A, C42A, C43A, C44A, C45A, C46A, C47A, C48A, C49A, C51A, C52A, C53A, C54A, C55A, C56A, C57A, C58A, C69A, C69A, C70A, C71A, C72A, C73A, C74A, C75A, C76A, C77A, C78A, C79A, C81A, C73A, C74A, C75A, C76A, C77A, C78A, C79A, C82A, C73A, C74A, C75A, C76A, C77A, C78A, C79A, C83A, C74A, C75A, C76A, C77A, C78A, C79A, C83A, C75A, C76A, C77A, C78A, C79A, C79A, C84A, C79A, C79A, C85A, C7 12 A7), belite (C2S), ferrite (C2F, C2AF, C4AF), ternesite (C5S2S) and other components such as calcium sulfate. A preferred calcium sulfoaluminate cement for use as the at least one hydraulic binder B1 contains 20-80% by weight of eelimite (C4A3S), 0-10% by weight of calcium aluminate (CA), 0-70% by weight of belite (C2S), 0-35% by weight of ferrite, preferably tetracalcium aluminoferrite (C4AF), and 0-20% by weight of ternesite (C5S2S), based on the total weight of the calcium sulfoaluminate cement. Suitable calcium aluminate cements (CAS) are commercially available, for example, from Heidelberg Cement AG, Vicat SA and Caltra BV.

[0044] Preferably, the at least one hydraulic binder B1 constitutes at least 50% by weight, more preferably at least 65% by weight, even more preferably at least 75% by weight of the total weight of the at least one mineral binder B. According to one or more embodiments, the at least one mineral binder B is preferably a hydraulic binder selected from the group consisting of Portland cement, calcium aluminate cement and calcium sulphoaluminate cement, preferably Portland cement.

[0045] According to one or more embodiments, the weight ratio of the amount of at least one mineral binder B to the amount of at least one synthetic polymer SP in the foamed inorganic material is from 100:0 to 70:30, preferably from 100:0 to 80:20.

[0046] According to one or more embodiments, the proportion of the at least one synthetic polymer SP is between 1 and 25% by weight, preferably between 5 and 15% by weight, more preferably between 8 and 12% by weight, relative to the weight of the at least one mineral binder B in the foamed inorganic material.

[0047] At least one synthetic organic polymer SP may be used to improve the mechanical properties of the foamed inorganic material, in particular the compressive strength and / or flexural strength. The type of synthetic polymer SP is not particularly limited. Suitable organic synthetic polymers include, for example, polyurethane polymers and homopolymers and copolymers obtained from the free radical polymerization of one or more monomers selected from the group consisting of ethylene, propylene butylene, isoprene, butadiene, styrene, acrylonitrile, (meth)acrylic acid, (meth)acrylates, vinyl esters, vinyl neodecanoate, vinyl alcohol, and vinyl chloride. "(Meth)acrylate" refers to acrylate and methacrylate, and "(meth)acrylic" refers to acrylic and methacrylic.

[0048] The term "polyurethane polymer" refers to polymers prepared by the so-called diisocyanate polyaddition process, including polymers that are largely or completely free of urethane groups. Examples of suitable polyurethane polymers include polyether polyurethanes, polyester polyurethanes, polyether polyureas, polyureas, polyester polyureas, polyisocyanurates, and polycarbodiimides.

[0049] According to one or more embodiments, the at least one synthetic organic polymer SP is a polyurethane polymer, preferably based on at least one polyisocyanate and at least one polyol and / or polyamine monomer.

[0050] Suitable polyisocyanates include monomeric polyisocyanates, as well as oligomers, polymers and derivatives of monomeric polyisocyanates, and mixtures thereof.

[0051] Suitable monomeric polyisocyanates for the polyurethane polymer include at least aromatic di- and trifunctional isocyanates such as 2,4- and 2,6-toluylene diisocyanate and mixtures of its isomers (TDI), 4,4'-, 2,4'- and 2,2'-diphenylmethane diisocyanate and mixtures of its isomers (MDI), 1,3- and 1,4-phenylene diisocyanate, 2,3,5,6-tetramethyl-1,4-diisocyanatobenzene, naphthalene-1,5-diisocyanate (NDI), 3,3'-dimethyl-4,4'-diisocyanatodiphenyl (TODI), dianisidine diisocyanate (DADI), 1,3,5-tris-(isocyanatomethyl)benzene, tris-(4-isocyanatophenyl)methane and tris-(4-isocyanatophenyl)thiophosphate.

[0052] Further suitable monomeric polyisocyanates for polyurethane polymers include aliphatic di- and trifunctional isocyanates, such as 1,4-tetramethylene diisocyanate, 2-methylpentamethylene-1,5-diisocyanate, 1,6-hexamethylene diisocyanate (HDI), 2,2,4- and 2,4,4-trimethyl-1,6-hexamethylene diisocyanate (TMDI), 1,10-decamethylene diisocyanate, 1,12-dodecamethylene diisocyanate, lysine and lysine ester diisocyanate, cyclohexane-1,3- and -1,4-diisocyanate, 1-methyl-2,4- and -2,6-diisocyanatocyclohexane and mixtures of its isomers (HTDI or H6TDI), 1-isocyanato-3,3,5-trimethyl-5-iso-cyanatomethyl-cyclohexane (=isophorone diisocyanate), diisocyanate or IPDI), perhydro-2,4'- and -4,4'-diphenylmethane diisocyanate (HMDI or H12MDI), 1,4-diisocyanato-2,2,6-trimethylcyclohexane (TMCDI), 1,3- and 1,4-bis-(isocyanatomethyl)cyclohexane, m- and p-xylylene diisocyanate (m- and p-XDI), m- and p-tetramethyl-1,3- and -1,4- Xylylene diisocyanate (m- and p-TMXDI), bis-(1-isocyanato-1-methyl-ethyl)naphthalene, dimeric and trimeric fatty acid isocyanates such as 3,6-bis-(9-isocyanatononyl)-4,5-di-(1-heptenyl)cyclohexene (dimeryl diisocyanate) and α,α,α',α'',α''-hexamethyl-1,3,5-mesitylene triisocyanate.

[0053] Polyols that are particularly suitable for polyurethane polymers include polyether polyols, polyester polyols, polycarbonate polyols, poly(meth)acrylate polyols, and hydrocarbon polyols such as polybutadiene polyols, polyhydroxy-functional oils and fats, polyhydroxy-functional acrylonitrile-butadiene copolymers.

[0054] Particularly suitable polyether polyols include the polymerization products of polyoxyalkylene diols and / or polyoxyalkylene triols, in particular ethylene oxide or 1,2-propylene oxide or 1,2- or 2,3-butylene oxide or oxetane or tetrahydrofuran or mixtures thereof, which can be easily reacted with starter molecules having two or three active hydrogens, in particular one active hydrogen, such as water, ammonia, or compounds having several OH or NH groups, such as 1,2-ethanediol, 1,2- or 1,3-propanediol, neopentane, ethylenediamine, ethylenediaminetetraacetate ... In particular, the polymerization can be carried out using ethylene glycol, diethylene glycol, triethylene glycol, the isomeric dipropylene glycols or tripropylene glycols, the isomeric butanediols, pentanediols, hexanediols, heptanediols, octanediols, nonanediols, decanediols, undecanediols, 1,3- or 1,4-cyclohexanedimethanol, bisphenol A, hydrogenated bisphenol A, 1,1,1-trimethylolethane, 1,1,1-trimethylolpropane, glycerol or aniline, or mixtures of the aforementioned compounds.

[0055] Suitable polyester polyols include liquid polyester polyols, as well as amorphous, partially crystalline, and crystalline polyester polyols that are solid at a temperature of 25° C. These include polyester polyols that are dihydric and trihydric, preferably dihydric, alcohols such as 1,2-ethanediol, diethylene glycol, triethylene glycol, 1,2-propanediol, 1,3-propanediol, dipropylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, dimer fatty alcohols, neopentyl glycol, glycerol, 1,1,1-trimethylolpropane, or mixtures of the aforementioned alcohols, in the form of an organic dicarboxylic acid. With an acid or tricarboxylic acid, preferably a dicarboxylic acid, or an anhydride or ester thereof, such as succinic acid, glutaric acid, 3,3-dimethylglutaric acid, adipic acid, suberic acid, sebacic acid, undecanedioic acid, dodecanedicarboxylic acid, azelaic acid, maleic acid, fumaric acid, phthalic acid, dimer fatty acid, isophthalic acid, terephthalic acid, hexahydrophthalic acid, or a mixture of the aforementioned acids, the polyester polyols can also be obtained by reacting with lactones, such as, for example, ε-caprolactone, also known as polycaprolactone.

[0056] Suitable polyamine monomers are compounds that have two or more isocyanate-reactive amine groups.Examples of usable polyamine monomers are diethyltolylenediamine, methylbis(methylthio)phenylenediamine, adipic dihydrazide, ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine, dipropylenetriamine, hexamethylenediamine, hydrazine, isophoronediamine, N-(2-aminoethyl)-2-aminoethanol, polyoxyalkyleneamine, the adduct of 2-acrylamido-2-methylpropane-1-sulfonic acid (AMPS) and the salt of ethylenediamine, the adduct of (meth)acrylic acid and the salt of ethylenediamine, the adduct of 1,3-propanesulfone and ethylenediamine, or any combination of these polyamines.

[0057] According to one or more preferred embodiments, the at least one synthetic organic polymer SP is selected from the group consisting of polyacrylates, styrene-acrylate copolymers, polyvinyl esters, ethylene-vinyl acetate copolymers, ethylene-vinyl alcohol copolymers, styrene-butadiene copolymers, vinyl acetate-vinyl neodecanoate (VeoVa) copolymers, and polyurethane polymers.

[0058] According to one or more preferred embodiments, the at least one synthetic organic polymer SP comprises at least one ethylene-vinyl acetate copolymer and / or at least one terpolymer of ethylene, vinyl acetate and vinyl ester monomers.

[0059] Particularly suitable ethylene-vinyl acetate copolymers for use as the at least one synthetic organic polymer SP have a content of structural units derived from vinyl acetate of less than or equal to 40% by weight, preferably less than or equal to 30% by weight, more preferably less than or equal to 20% by weight, even more preferably less than or equal to 15% by weight, based on the weight of the copolymer.

[0060] According to one or more embodiments, the foamed inorganic material further comprises at least one surfactant S. The term "surfactant" herein refers to a substance that reduces surface tension, and is typically an organic compound that contains both hydrophobic and hydrophilic groups.

[0061] Surfactants can be used in preparing the foamed inorganic material to stabilize the foamed structure.

[0062] Surfactants are well known to the expert and are described, for example, in "Surfactants and Polymers in aqueous solutions" (Wiley-VCH, K. Holmbergetal, 2002). ndThe classification of surfactants is summarized in the International Publication No. 2007 (Imprint Edition, 2007). Suitable surfactants include at least nonionic surfactants, cationic surfactants, anionic surfactants, and amphoteric surfactants. Amphoteric (zwitterionic) surfactants have both cationic and anionic centers bound in the same molecule.

[0063] Non-ionic surfactants are particularly advantageous to use since they have a low tendency to be absorbed into the cement phase, but it is also possible to use cationic, anionic or amphoteric (zwitterionic) surfactants.

[0064] Suitable surfactants for the present invention include lipids such as cholates, glycocholates, fatty acid salts, glycerides, glycolipids and phospholipids. These may be naturally occurring or synthetically produced. In certain embodiments, non-ionic lipids are preferred.

[0065] Suitable anionic surfactants include compounds containing carboxylate, sulfate, phosphate, or sulfonate groups, such as organosulfates, alkyl ether carboxylates, alkyl sulfates, alkyl ether sulfates, fatty alcohol sulfates, alkyl sulfosuccinates, alkylphenol ethoxylates, olefin sulfonates, alkyl phosphates, alkyl ether phosphates, and alkylbenzene sulfonates.

[0066] Suitable nonionic surfactants include, in particular, fatty acid alkoxylates, alkoxylated alcohols, in particular fatty acid alcohol alkoxylates and alkoxylates of glycerol and pentaerythritol, alkylphenol alkoxylates, alkoxylated polysaccharides, alkoxylated polycondensates, fatty acid amide alkoxylates, ethanolamides, esters of fatty acids, in particular methanol, fatty acid esters of sorbitan, sorbitan, glycerol or pentaerythritol, alkoxylated alkylamines with alkyl groups of 6 to 20 carbon atoms, alkyl glycosides, alkyl glucamides, esters of fatty acids and sugars, polysiloxanes, and also alkoxylated sorbitan, copolymers of ethylene oxide and propylene oxide, lauryl ether sulfonates, naphthalene sulfonates, hydrophobized starch, hydrophobized cellulose or surfactants based on siloxanes. Preferred alkoxylates in this context are, in particular, ethoxylates.

[0067] Suitable cationic surfactants include, in particular, ammonium groups or quaternary nitrogen atoms, and have at least one long-chain alkyl group.Suitable examples of cationic surfactants are quaternary ammonium compounds having at least one alkyl group, phosphonium compounds, such as tetraalkylammonium salts, imidazoline compounds, such as N,N-dialkylimidazoline compounds, dimethyl distearyl ammonium compounds, N-alkylpyridine compounds, ammonium chlorides, and amine N-oxides.For example, cationic surfactants can be selected from tetradecyl trimethyl ammonium bromide (TTAB), cetyl trimethyl ammonium bromide (CTAB), and dodecyl trimethyl ammonium bromide (DTAB).

[0068] According to one or more embodiments, the at least one surfactant S comprises or consists of at least one Gemini surfactant.

[0069] Gemini surfactants contain two hydrophilic head groups and two hydrophobic tails separated by a spacer at or near the head groups. If both hydrophobic tails are identical and the hydrophilic groups are identical, the gemini surfactant is said to have a symmetric structure. The substituents of gemini surfactants play a major role in the behavior of these compounds in solution and their potential applications. In particular, gemini surfactants may contain quaternary nitrogen atoms, which are usually present in acyclic systems. However, gemini surfactants containing nitrogen in saturated and unsaturated rings also exist. The spacer tends to be rigid or flexible and hydrophobic or hydrophilic. The special properties of gemini surfactants can be influenced by optimizing the hydrophilic-lipophilic balance (HLB value). This can be done, for example, by introducing balanced polar or hydrophobic groups into both the head groups, the tail groups or the spacer. Examples of preferred gemini surfactants are in particular alkoxylated acetyl diols, or gemini surfactants as described in EP 0 884 298.

[0070] According to one or more further embodiments, the at least one surfactant S comprises a mixture of anionic and / or nonionic surfactants, preferably anionic and / or nonionic surfactants.

[0071] According to one or more further embodiments, at least one surfactant S is an amphoteric surfactant, preferably selected from aminocarboxylic acids and betaines, in particular fatty acid amidoalkyl betaines, in particular cocamidopropyl betaine.Betaines are neutral compounds that have a positively charged cationic functional group that does not have a hydrogen atom, such as a quaternary ammonium or phosphonium cation, and a negatively charged functional group that may not be adjacent to the cationic site, such as a carboxylate group.Betaines are therefore a special type of zwitterion.This type of surfactant has been found to be very beneficial in the context of the present invention, since it is highly compatible with the further components that are usually present in foamed inorganic materials.

[0072] According to one or more embodiments, the casing (2) comprises: a front and a rear wall (3, 3') connected by two longitudinal side walls (4, 4'), an intermediate wall (5) dividing the interior space formed between the front wall, the rear wall and the longitudinal side walls (3, 3', 4, 4') into first and second compartments (6, 6'), and -Bottom wall (7) has.

[0073] Preferably, the intermediate wall (5) extends transversely to the direction of the longitudinal side walls (4, 4'). In this case, the first compartment (6) is defined by the front wall, the intermediate wall and the longitudinal side walls (3, 5, 4, 4') and the second compartment (6') is defined by the rear wall, the intermediate wall and the longitudinal side walls (3', 5, 4, 4') as shown in figures 1 and 2.

[0074] It is also possible, but not necessarily preferred, that the casing (2) comprises further intermediate walls dividing the internal space of the first and / or second compartments (6, 6') into further sub-compartments. According to one or more embodiments, the casing (2) comprises a further intermediate wall (5') dividing the internal space of the first compartment (6) into first and second sub-compartments (6a, 6b), as shown in FIG.

[0075] According to one or more embodiments, the rear wall (3') and the intermediate wall (5) have substantially the same height and / or the height of the front wall (3) is at least 10%, preferably at least 25%, more preferably at least 35% less than the height of the rear wall (3'). The expression "substantially the same height" is understood to mean that the difference in height between the rear wall and the intermediate wall (3',5) is negligible, such as less than 1.5%, preferably less than 1%, more preferably less than 0.5% of the sum of the heights of the rear wall and the intermediate wall (3',5).

[0076] According to one or more embodiments, the depth of the second compartment (6') measured in the direction of the longitudinal side walls (4, 4') is at least 10% less, preferably at least 25% less, more preferably at least 35% less than the depth of the first compartment (6) measured in the direction of the longitudinal side walls (4, 4').

[0077] Preferably, the greenwall element is arranged so as to be attached, via the outer face of the rear wall (3') facing away from the intermediate wall (5), to a surface of a substrate, in particular to architectural elements such as walls and facades of buildings.

[0078] Once attached to the substrate, the outer surface of the rear wall (3') and the surface of the substrate can be indirectly or directly connected to each other. The expression "directly connected" is understood in the context of the present invention to mean that the opposing surfaces of the layers are directly bonded to each other or adhered to each other, without any further layers or substances being present between the layers. In the transition area between the two layers, the materials of the layers can also be present mixed with each other. The opposing surfaces can be indirectly connected to each other via a connecting layer, such as a layer of adhesive.

[0079] The angle formed between the plane of the rear wall (3') and the plane of the bottom wall (7), and / or between the plane of the intermediate wall (5) and the plane of the bottom wall (7), and / or between the plane of the front wall (3) and the plane of the bottom wall (7), and / or between the plane of the longitudinal side walls (4, 4') and the plane of the bottom wall (7) is preferably in the range of 85 to 95°, more preferably 87.5 to 92.5°, and even more preferably 88.5 to 91.5°.

[0080] Also, when the element is mounted via the rear wall (3') of the casing (2) to a vertical surface of a substrate such as a wall or facade of a building, it is preferred that the front wall, rear wall, intermediate wall and longitudinal side walls (3, 3', 5, 4, 4') extend substantially vertically.

[0081] Furthermore, if the element is to be mounted via the rear wall (3') of the casing (2) to a vertical surface of a substrate such as a wall, facade or building, it is preferred that the bottom wall (7) extends substantially horizontally.

[0082] The thickness of the walls of the casing (2) may or may not be constant over the length and / or width of each wall. According to one or more embodiments, the thickness of the front wall, rear wall, longitudinal side walls, intermediate wall and bottom wall (3, 3', 4, 4', 5, 7) is substantially constant over the length and / or width of each wall.

[0083] Preferably, the thickness of the walls (3, 3', 4, 4', 5, 7) is equal to or less than 25 mm, more preferably equal to or less than 15 mm, even more preferably equal to or less than 10 mm. According to one or more embodiments, the walls (3, 3', 4, 4', 5, 7) of the casing (2) have a thickness of 0.1 to 5 mm, preferably 0.25 to 3.5 mm, more preferably 0.35 to 2.5 mm. Casings with wall thicknesses falling within the above ranges can be easily manufactured using conventional processing techniques of thermoplastic materials, such as extrusion, injection molding, additive manufacturing techniques, etc.

[0084] The preferred dimensions of the greenwall elements depend on the application requirements. Preferably, the elements may have a width and / or length of 15-300 cm, more preferably 25-250 cm, even more preferably 35-200 cm.

[0085] The casing of the greenwall element is preferably constructed from a polymeric material. As used herein, the term "polymeric" refers to a material having one or more polymers as a major component.

[0086] Suitable polymers for use in the casing of the greenwall elements include, for example, polyvinyl chloride, polyolefins, halogenated polyolefins, ethylene ketone esters, thermoplastic polyesters, polyamides, and acrylonitrile butadiene styrene, rubber.

[0087] Suitable polyolefins include ethylene-based polyolefins, such as polyethylene, and ethylene copolymers, such as copolymers of ethylene and one or more α-olefins, copolymers of ethylene and vinyl acetate, and copolymers of ethylene and acrylic acid esters.Further suitable polyolefins include propylene-based polyolefins, such as polypropylene, and propylene copolymers, such as copolymers of propylene and one or more α-olefins.Suitable thermoplastic polyesters include, for example, polyethylene terephthalate and polybutylene terephthalate.

[0088] Suitable rubbers include butyl rubber, halogenated butyl rubber, ethylene-propylene-diene monomer rubber, natural rubber, chloroprene rubber, synthetic 1,4-cis-polyisoprene, polybutadiene, ethylene-propylene rubber, styrene-butadiene copolymer, isoprene-butadiene copolymer, styrene-isoprene-butadiene rubber, methyl methacrylate-butadiene copolymer, methyl methacrylate-isoprene copolymer, acrylonitrile-isoprene copolymer, and acrylonitrile-butadiene copolymer.

[0089] According to one or more embodiments, the polymeric material of the casing comprises at least one polymer P selected from the group consisting of polyvinyl chloride, polyethylene, ethylene α-olefin copolymers, ethylene acrylic ester copolymers, ethylene vinyl acetate copolymers, polypropylene, and propylene α-olefin copolymers.

[0090] Suitable polyethylenes for use as the at least one polymer P include, for example, very low density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, high density polyethylene, and ultra-high molecular weight polyethylene, in particular low density polyethylene, linear low density polyethylene, medium density polyethylene, and high density polyethylene.

[0091] Suitable ethylene-α-olefin copolymers include those containing ethylene and one or more C3-C 20 Random and block copolymers with one or more of α-olefin monomers, particularly propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene and 1-hexadodecene, preferably containing at least 60% by weight, more preferably at least 65% by weight, of units derived from ethylene, based on the weight of the copolymer.

[0092] Suitable ethylene random copolymers include, for example, Affinity® trade names such as Affinity® EG 8100G, Affinity® EG 8200G, Affinity® SL 8110G, Affinity® KC 8852G, Affinity® VP 8770G, and Affinity® PF 1140G (all manufactured by Dow Chemical Company); Exact® trade names such as Exact® 3024, Exact® 3027, Exact® 3128, Exact® 3131, Exact® 4049, Exact® 4053, Exact® 5371, and Exact® 8203 (all manufactured by Exxon Mobil); and Queo® (Borealis EG) and ethylene-based polyolefin elastomers (POE) commercially available under the trade name Engage®, such as, for example, Engage® 7256, Engage® 7467, Engage® 7447, Engage® 8003, Engage® 8100, Engage® 8480, Engage® 8540, Engage® 8440, Engage® 8450, Engage® 8452, Engage® 8200, and Engage® 8414 (all from Dow Chemical Company).

[0093] Suitable ethylene-α-olefin block copolymers include ethylene-based olefin block copolymers (OBC) commercially available under the Infuse® trade name, such as Infuse® 9100, Infuse® 9107, Infuse® 9500, Infuse® 9507, and Infuse® 9530 (all manufactured by Dow Chemical Company).

[0094] Suitable copolymers of ethylene and vinyl acetate for use as the at least one polymer P include those having a content of structural units derived from vinyl acetate ranging from 4 to 95% by weight, preferably from 6 to 90% by weight, more preferably from 8 to 90% by weight, based on the weight of the copolymer. Suitable ethylene-vinyl acetate bipolymers and terpolymers, such as ethylene vinyl acetate carbon monoxide terpolymers, are commercially available, for example, under the trade names Escorene® (from ExxonMobil), Primeva® (from Repsol Quimica SA), Evatane® (from Arkema Functional Polyolefins), Greenflex® (from Eni versalis SpA), and Levapren® (from Arlanxeo GmbH), and Elvaloy® (from Dupont).

[0095] Suitable polypropylenes for use as the at least one polymer P include, for example, isotactic polypropylene (iPP), syndiotactic polypropylene (sPP) and homopolymer polypropylene (hPP).

[0096] Suitable propylene copolymers include propylene-ethylene random and block copolymers, as well as copolymers of propylene and one or more C4-C 20 Random and block copolymers with one or more of α-olefin monomers, particularly 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene and 1-hexadodecene, preferably containing at least 60% by weight, more preferably at least 65% by weight, of propylene-derived units, based on the weight of the copolymer.

[0097] Suitable propylene random and block copolymers are commercially available, for example, under the trade names Intune® and Versify (Dow Chemical Company), and Vistamaxx® (Exxon Mobil).

[0098] Further suitable propylene copolymers for use as the at least one polymer P include heterophasic propylene copolymers. These are heterophasic polymer systems that contain a highly crystalline base polyolefin and a less crystalline or amorphous polyolefin modifier. The heterophasic morphology consists of a matrix phase that is mainly composed of the base polyolefin and a dispersed phase that is mainly composed of the polyolefin modifier. Suitable commercially available heterophasic propylene copolymers include reactor blends of the base polyolefin and the polyolefin modifier, also called "in-situ TPO" or "reactor TPO" or "impact copolymers (ICP)", which are typically produced in a sequential polymerization process, in which the components of the matrix phase are produced in a first reactor and transferred to a second reactor, where the components of the dispersed phase are produced and incorporated as domains in the matrix phase. Heterophasic propylene copolymers that contain a polypropylene homopolymer as the base polymer are often referred to as "heterophasic propylene copolymers (HECO)" and heterophasic propylene copolymers that contain a polypropylene random copolymer as the base polymer are often referred to as "heterophasic propylene random copolymers (RAHECO)". The term "heterophasic propylene copolymer" in this disclosure encompasses both the HECO and RAHECO types of heterophasic propylene copolymers.

[0099] Depending on the amount of polyolefin modifier, commercially available heterophasic propylene copolymers are typically characterized as "impact copolymers" (ICPs), or as "reactor-TPOs", or as "soft-TPOs". The main difference between these types of heterophasic propylene copolymers is that the amount of polyolefin modifier is typically less in ICPs than in reactor-TPOs and soft-TPOs, for example 40% by weight or less, in particular 35% by weight or less. As a result, typical ICPs tend to have a lower xylene cold soluble (XCS) content, determined according to the ISO 161522005 standard, and a higher flexural modulus, determined according to the ISO 178:2010 standard, compared to reactor-TPOs and soft-TPOs.

[0100] Suitable heterophasic propylene copolymers include reactor TPO and soft TPO produced by the Catalloy process technology of LyondellBasell, which are commercially available under the trade names Adflex®, Adsyl®, Clyrell®, Hiflex®, Softell® and Hifax®, such as Hifax® CA10A, Hifax® CA12A, and Hifax® CA60A, and Hifax CA212A. Further suitable heterophasic propylene copolymers are commercially available under the trade name Borsoft® (manufactured by Borealis Polymers), such as Borsoft® SD233CF.

[0101] When a foamed inorganic material is used, it is generally preferred that the inner surface of the casing, and in particular the inner surface of the second compartment which contains the foamed material, operates to form a bond with the foamed inorganic material.

[0102] Some polymeric materials are inherently operable to form bonds with mineral binder compositions, while others may require one or more pretreatment steps of the surface of the material using reactive or non-reactive primers, or using flame ("flaming"), oxofluorination, plasma, corona, or similar techniques. Adhesion of the foamed inorganic material to the inner casing surface can also be improved by using a contact layer based on an adhesive composition or a porous material, e.g., a nonwoven or woven fabric.

[0103] According to one or more embodiments, the polymeric material of the casing comprises, all in proportions based on the total weight of the polymer: A) at least 35% by weight, preferably at least 50% by weight, more preferably at least 55% by weight, even more preferably at least 60% by weight, still more preferably at least 65% by weight of at least one polymer P, B) 1.5 to 65% by weight, preferably 2.5 to 50% by weight, more preferably 5 to 45% by weight, even more preferably 10 to 40% by weight, and still more preferably 15 to 35% by weight of at least one inorganic filler F Includes.

[0104] According to one or more embodiments, the at least one polymer P comprises at least one ethylene-vinyl acetate copolymer P1. Preferably, the at least one ethylene-vinyl acetate copolymer P1 has a content of structural units derived from vinyl acetate of at least 5% by weight, more preferably at least 15% by weight, even more preferably at least 25% by weight, still more preferably at least 35% by weight and most preferably at least 45% by weight, based on the weight of the copolymer.

[0105] According to one or more embodiments, the at least one ethylene vinyl acetate copolymer P1 has a content of structural units derived from vinyl acetate of 5 to 95% by weight, preferably 15 to 90% by weight, more preferably 25 to 90% by weight, even more preferably 35 to 90% by weight, even more preferably 45 to 90% by weight, based on the weight of the copolymer.

[0106] According to one or more preferred embodiments, the at least one ethylene-vinyl acetate copolymer P1 has a content of structural units derived from vinyl acetate of 35 to 95% by weight, preferably 45 to 95% by weight, more preferably 55 to 90% by weight, even more preferably 65 to 90% by weight, even more preferably 70 to 90% by weight, based on the weight of the copolymer.

[0107] Ethylene vinyl acetate copolymers having a content of structural units derived from vinyl acetate in the above ranges are particularly suitable for use in the casing polymer as they have been found to enhance the ability of the casing to form bonds with foamed inorganic materials.

[0108] According to one or more embodiments, the at least one ethylene-vinyl acetate copolymer P1 constitutes at least 15% by weight, preferably at least 25% by weight, more preferably at least 35% by weight, even more preferably at least 50% by weight of the total weight of the at least one polymer P.

[0109] Suitable compounds for use as the at least one inorganic filler F include inert mineral fillers and mineral binders.

[0110] The term "inert mineral filler" as used herein refers to a mineral filler that is substantially insoluble in water and does not undergo hydration in the presence of water, unlike mineral binders. Suitable inert mineral fillers include, for example, sand, granite, calcium carbonate, magnesium carbonate, clay, expanded clay, diatomaceous earth, pumice, mica, kaolin, dolomite, xonotlite, perlite, vermiculite, wollastonite, barite, cristobalite, silica, fumed silica, fused silica, glass beads, hollow glass spheres, ceramic spheres, bauxite, crushed concrete, and zeolites.

[0111] Suitable mineral binders for use as the at least one inorganic filler F include hydraulic binders such as cement and hydraulic lime, air-setting binders such as calcium sulfate hemihydrate, anhydrous lime, non-hydraulic lime, latent hydraulic binders and / or pozzolanic binders.

[0112] According to one or more embodiments, the at least one inorganic filler F comprises or consists of at least one inert mineral filler and / or at least one mineral binder, where the at least one inert mineral filler is preferably selected from the group consisting of sand, granite, calcium carbonate, magnesium carbonate, clay, expanded clay, diatomaceous earth, pumice, mica, kaolin, dolomite, xonotlite, perlite, vermiculite, wollastonite, barite, cristobalite, silica, fumed silica, fused silica, glass beads, hollow glass spheres, ceramic spheres, bauxite, crushed concrete, and zeolites, and the at least one mineral binder is preferably selected from the group consisting of portland cement, calcium aluminate cement, calcium sulfoaluminate cement, hydraulic lime, calcium sulfate hemihydrate, anhydrous lime, non-hydraulic lime, latent hydraulic binder materials, and pozzolanic binder materials.

[0113] The at least one inorganic filler F is preferably present in the thermoplastic material in the form of finely divided particles, preferably with a median particle d of less than 500 μm, more preferably less than 250 μm, even more preferably less than 100 μm. 50 The term "particle size" refers to the area-equivalent spherical diameter of a particle.

[0114] Median particle size d 50 The term refers to particles that are less than 50% by volume of all particles. 50 The particle size distribution can be determined by sieve analysis according to the method described in ASTM C136 / C136M-14 ("Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates").

[0115] According to one or more embodiments, the at least one inorganic filler F has a median particle d of 0.1 to 100 μm, preferably 0.1 to 50 μm, more preferably 0.1 to 25 μm, even more preferably 0.1 to 10 μm, and even more preferably 0.1 to 5 μm. 50 It has a diameter.

[0116] The preferences given above for the at least one mineral binder B, the at least one synthetic organic polymer SP, the at least one surfactant S, the at least one polymer P and the at least one inorganic filler F apply equally to all other subjects of the invention, unless otherwise indicated.

[0117] Another subject of the invention is a method for the manufacture of a greenwall element (1) according to the invention, comprising: I) providing a casing (2) having first and second compartments (6, 6') as defined above; II) providing a foam composition; III) at least partially filling the second compartment (6') of the casing (2) with a foaming composition; IV) curing the foam composition; The method includes:

[0118] Preferably, the foam composition has a viscosity of 500 kg / m 3 (g / l) or less, preferably 300 kg / m 3 (g / l) or less, more preferably 250 kg / m 3 (g / l) or less, more preferably 200 kg / m 3 (g / l) or less, e.g. 15-250kg / m 3 (g / l), preferably 25 to 150 kg / m 3 (g / l).

[0119] Step II) of the method of providing the foam composition can be performed prior to or simultaneously with step III) of filling the second compartment of the casing with the foam composition. According to one or more embodiments, step II) is performed prior to step III).

[0120] According to one or more embodiments, the foamed composition is a foamed synthetic organic composition, preferably selected from the group consisting of polystyrene, polyurethane, polyisocyanurate, and polyolefin foamed compositions, and foamed rubber compositions, more preferably selected from the group consisting of polystyrene, polyurethane, polyisocyanurate, and polyolefin foamed compositions.

[0121] According to one or more embodiments, the foam composition comprises: a) at least one mineral binder B; b) optionally at least one synthetic organic polymer SP, c) optionally at least one surfactant S, and d) water The foamed inorganic composition comprises:

[0122] Preferably, the at least one mineral binder B constitutes at least 35% by weight, preferably at least 50% by weight, more preferably at least 65% by weight, even more preferably at least 75% by weight of the total weight of the foamed mineral composition.

[0123] According to one or more embodiments, the weight ratio of the amount of at least one mineral binder B to the amount of at least one synthetic polymer SP in the foamed inorganic composition is from 100:0 to 70:30, preferably from 100:0 to 80:20.

[0124] According to one or more embodiments, the proportion of the at least one synthetic polymer SP is between 1 and 25% by weight, preferably between 5 and 15% by weight, more preferably between 8 and 12% by weight, relative to the weight of the at least one mineral binder B in the foamed inorganic composition.

[0125] According to one or more embodiments, step II) comprises: - providing separately an aqueous foam and an aqueous slurry comprising at least one mineral binder B and optionally at least one synthetic organic polymer SP; - mixing the aqueous foam with an aqueous slurry to obtain a foamed inorganic composition; Includes.

[0126] At least one synthetic organic polymer SP, when used, is preferably present in the aqueous slurry as a dispersed polymer.

[0127] The aqueous slurry can be obtained by providing at least one synthetic organic polymer SP in the form of an aqueous polymer dispersion and / or in the form of a redispersible polymer powder and mixing the aqueous polymer dispersion and / or the redispersible polymer powder with at least one mineral binder B and, optionally, with an additional amount of water, using any conventional mixing technique.

[0128] Aqueous polymer dispersions of at least one synthetic organic polymer SP can be prepared, for example, by free radical polymerization using materials, solution, suspension or emulsion polymerization techniques known to those skilled in the art, or by mixing a redispersible polymer powder with water. Aqueous polymer dispersions comprising two or more different synthetic organic polymers SP can be readily prepared by using mixtures of commercially available aqueous polymer dispersions and / or redispersible polymers.

[0129] Suitable aqueous polymer dispersions are, for example, From Synthomer (UK) limited, products under the Lipaton® trade name, such as Lipaton® SB 2540, Lipaton® SB 3040, and Lipaton® SB 2740 (styrene butadiene copolymers), and Plextol® trade names, such as Plextol E 303 and Plextol X 4002 (pure acrylic); From Celanese, the Mowilith® trade name, such as Mowilith® LDM 7978 (acrylic) and Mowilith® LDM 7651 (styrene acrylic); From BASF, Acronal® trade names, such as Acronal® V 278 (acrylate), Acronal® V 212 (acrylate), Acronal® 81 D (acrylate), Acronal® 4 F (acrylate), Acronal® DS 5017 (pure acrylate), and Acronal® A 107 (pure acrylate); From Airproducts, products under the Airflex® trade name, such as Airflex® EF811 (vinyl acrylic copolymer); From Arkema, Encor® trade names such as Encor® flex 187 (acrylic), Encor® 123 (styrene acrylic), Encor® flex 192 (styrene acrylic), and Encor® 9176 (styrene acrylic); From Wacker Chemie, products under the Vinnapas® trade name, for example Vinnapas® EAF 60 and Vinnapas® EAF 67 (vinyl acetate / ethylene / acrylate polymer); and From Dow Chemicals, Primal® trade names, such as Primal® CA-162 and Primal® CA-172 (acrylic) Available at.

[0130] To obtain the aqueous slurry, at least one synthetic organic polymer SP may preferably be used in the form of a redispersible polymer powder. The redispersible polymer powder is generally produced by spray drying techniques from an aqueous polymer dispersion. The redispersible polymer powder may further comprise one or more compounds selected from colloidal stabilizers and antiblocking agents. Examples of redispersible polymer powders and methods for their production are disclosed, for example, in patent application US 2005 / 0014881 A1.

[0131] Suitable redispersible polymer powders are, for example: From Wacker Chemie, the Vinnapas® trade name, for example, the Vinnapas® 2000 series, the Vinnapas® 3000 series, the Vinnapas® 4000 series, the Vinnapas® 5000 series, the Vinnapas® 7000 series, and the Vinnapas® 8000 series; and Synthomer offers Axilat® trade names such as the Axilat® HP8000 series, Axilat® UP series, Axilat® PSB150 (styrene butadiene copolymer), and Axilat® PAV series (vinyl acetate versatate copolymer). Available at.

[0132] Aqueous foams contain or consist of gas bubbles surrounded by liquid walls. The gas in the bubbles can be any type of gas, such as air, nitrogen, carbon dioxide, a noble gas, or mixtures thereof, preferably air.

[0133] The aqueous foam is preferably prepared by mechanical foaming of the aqueous mixture in the presence of a gas, in particular air, nitrogen and / or carbon dioxide and / or a noble gas. Mechanical foaming refers to a method in which gas bubbles are introduced into the water of the aqueous foam by mixing the gas with water without carrying out a chemical reaction that generates gas.

[0134] According to one or more embodiments, foaming is carried out in the absence of chemically acting pore formers and / or chemically acting blowing agents. In the absence of chemically acting pore formers and / or chemically acting blowing agents means that the proportion of chemically acting pore formers and / or chemically acting blowing agents is less than 0.1% by weight, in particular less than 0.01% by weight, in particular less than 0.001% by weight, based on the weight of water in the aqueous foam. Most preferably, no chemically acting pore formers and / or chemically acting blowing agents are present.

[0135] According to one or more embodiments, the aqueous foam is obtained by mechanically foaming the aqueous mixture with a gas, preferably air.

[0136] Preferably, the aqueous foam comprises at least one surfactant S, preferably an anionic surfactant and / or a nonionic surfactant. The surfactant helps to stabilize the foam structure of the aqueous foam. Suitable types of surfactants have already been mentioned above. It may further be preferred that at least one surfactant S is provided in the aqueous mixture before foaming.

[0137] The at least one surfactant S preferably constitutes 0.001 to 10% by weight, more preferably 1 to 4% by weight, even more preferably 2 to 3% by weight, relative to the total weight of the aqueous foam.

[0138] According to one or more embodiments, the aqueous slurry further comprises at least one solid filler SF. Suitable compounds for use as the at least one solid filler SF include inorganic materials, organic materials, and synthetic organic materials that do not undergo hydration reactions in the presence of water and are substantially insoluble in water. In particular, the at least one solid filler SF is chemically and / or physically distinct from the other constituents of the foamed inorganic composition.

[0139] Preferably, the at least one solid filler SF has a water solubility of less than 0.1 g / 100 g water, more preferably less than 0.05 g / 100 g water, even more preferably less than 0.01 g / 100 g water at a temperature of 20° C. The solubility of a compound in water can be measured as the saturation concentration, at which further addition of compound does not increase the concentration of the solution, i.e., excess material begins to precipitate. The measurement of the aqueous solubility of a compound in water can be carried out using the standard "shake flask" method defined in OECD Test Guideline 105 (adopted 27 July 1995).

[0140] The particle size of the at least one solid filler SF is not particularly limited, with submicron-sized particles, micrometer-sized particles, millimeter-sized particles, and even centimeter-sized particles being all suitable.

[0141] Preferably, the at least one solid filler SF has a maximum particle size of less than or equal to 20 mm, more preferably less than or equal to 5 mm, even more preferably less than or equal to 2.5 mm, even more preferably less than or equal to 1.5 mm.

[0142] According to one or more embodiments, the at least one solid filler SF is selected from the group consisting of sand, limestone, artificial stone, quartz flour, quartz sand, barite, talc, dolomite, wollastonite, mica, perlite, pumice, vermiculite, norite, fly ash, microsilica, kaolin, metakaolin, silica fume, fumed silica, granulated blast furnace slag, foamed blast furnace slag, volcanic slag, expanded clay, expanded shale, expanded slate, foamed glass, pozzolana, diatomaceous earth, ceramic particles, ceramic spheres, and porous silica.

[0143] Preferably, the proportion of the at least one solid filler SF is 0.001 to 25% by weight, more preferably 0.001 to 10% by weight, and even more preferably 0.001 to 5% by weight, based on the total weight of the at least one mineral binder B in the aqueous slurry.

[0144] According to one or more embodiments, the aqueous slurry further comprises at least one plasticizer PL. Suitable plasticizers are liquid inert organic substances having a low vapor pressure, preferably with a boiling point above 200° C. measured at a pressure of 1 bar.

[0145] According to one or more embodiments, the at least one plasticizer PL is selected from the group consisting of lignosulfonates, gluconates, naphthalenesulfonates, melamine sulfonates, vinyl copolymers, polycarbonate ethers, adipic and sebacic acid plasticizers, phosphoric acid plasticizers, citric acid plasticizers, fatty acid esters and epoxidized fatty acid esters, benzoates, phthalates, and esters of 1,2-dicarboxycyclohexane. Preferred plasticizers include polycarboxylate ethers. In particular, the at least one plasticizer PL is chemically different from the at least one synthetic organic polymer SP.

[0146] The proportion of the at least one plasticizer PL, in particular the polycarboxylate ether, is preferably 0.001 to 5% by weight, more preferably 0.01 to 1% by weight, based on the total weight of the at least one mineral binder B in the aqueous slurry.

[0147] Additionally, other additives may be added to the aqueous foam and / or the aqueous slurry.

[0148] Such additives include thickeners, tackifiers, accelerators, set retarders, color pigments, hollow glass beads, film formers, hydrophobic or de-soiling agents such as zeolites or titanium dioxide, latex, organic or mineral fibers, mineral additives or mixtures thereof. Preferably, the additive does not include any defoamers.

[0149] The term "thickening agent" is generally understood to mean any compound that makes it possible to maintain heterogeneous physical phases in equilibrium or to promote this equilibrium. Suitable thickening agents are preferably gums, cellulose or its derivatives, such as cellulose ethers or carboxymethylcellulose, starch or its derivatives, gelatin, agar, carrageenan and / or bentonite clay.

[0150] Accelerators for hydraulic binders are well known, and any setting and hardening accelerator can be used in the present invention. For example, the accelerator can be selected from aluminum hydroxide, aluminum sulfate, carboxylic acid, metal oxide, metal hydroxide, inorganic acid, alkali hydroxide, alkali metal silicate nitrate, and / or nitrite. Particularly advantageous accelerators include aluminum-containing accelerators, such as aluminum sulfate.

[0151] Preferably, the accelerator, in particular the aluminum compound, may be used in an amount of 0.15 to 5% by weight, preferably 0.25 to 3% by weight, in particular 0.5 to 2.5% by weight, based on the total weight of the at least one mineral binder B in the aqueous slurry.

[0152] The aqueous foam and the aqueous slurry of mineral binder B are preferably mixed together under overpressure conditions, preferably at an overpressure of 1 to 15 bar, in particular 2 to 5 bar, relative to the ambient pressure, which allows the density of the foamed mineral binder composition to be easily adjusted within a wide range.

[0153] Most preferably, mixing is performed using a static mixer, whereby preferably the aqueous slurry of aqueous foam and mineral binder B is driven by pressurized air through the static mixer. Preferably, the pressurized air has a pressure of 1 to 15 bar, in particular 6 to 10 bar, higher than the ambient air pressure. Thereby a stable foamed mineral binder composition is obtained in a reliable manner. The aqueous foam can be mixed with the slurry either batchwise or continuously.

[0154] The weight ratio of water to the at least one mineral binder B in the aqueous slurry is preferably 0.2 to 0.7, more preferably 0.25 to 0.5, and further preferably 0.3 to 0.4.

[0155] Another subject of the invention is a greenwall comprising a substrate (8) and one or more modular greenwall elements (1) according to the invention attached to the surface of the substrate.

[0156] Each greenwall element is preferably attached to the surface of the substrate via the outer surface of its rear wall (3').

[0157] According to one or more embodiments, adjacent greenwall elements are attached to each other via the outer faces of their opposing longitudinal side walls (4, 4').

[0158] The substrate (8) is preferably a construction element, in particular a wall or a facade of a building.

[0159] The greenwall elements can be arranged in any pattern on the surface of the substrate (8), for example, as shown in FIG. 4, with the elements lined up in rows or with offsets between rows.

[0160] Yet another subject of the invention is a method for providing a green wall, comprising the steps of: I. Providing one or more modular green wall elements according to the invention; II. attaching the elements to a surface of a substrate (8) such that each element (1) is directly or indirectly connected to the surface of the substrate via the outer surface of the rear wall (3'); III. Optionally, attaching adjacent elements to each other via the outer surfaces of the opposing longitudinal side walls (4, 4'); A method for providing a green wall comprising:

[0161] The substrate (8) is preferably a construction element, in particular a wall or a facade of a building.

[0162] The greenwall elements may be attached to the surface of the substrate and / or to each other using any conventional means, such as by using mechanical fastenings or adhesive or thermal bonding means.

[0163] Suitable mechanical fastening means for attaching the greenwall elements to the substrate surface and / or to each other include metal rods, screws, nails, clevis bolts, wire mesh elements, and fastening brackets.

[0164] Suitable adhesives for attaching the greenwall elements to the surface of the substrate and / or to each other include, for example, one-component and multi-component reactive and non-reactive polyurethane, acrylic and epoxide adhesives. Suitable adhesives include pressure sensitive adhesives, contact adhesives and structural adhesives.

[0165] The term "thermal bonding means" refers to a process in which a bond is formed between layers without the use of adhesives by applying thermal energy to at least partially melt a composition of at least one substrate, followed by contacting opposing surfaces of the substrates with one another, preferably under the influence of pressure, and cooling the substrates.

[0166] According to one or more embodiments, at least 50%, preferably at least 75%, more preferably at least 85% of the outer surface of the rear wall (3') of each element is directly or indirectly connected to the surface of the substrate (8). It is also preferred that the rear wall (3') of each element is directly or indirectly connected to the surface of the substrate (8) over substantially its entire outer surface. The expression "substantially the entire surface" is understood to mean at least 95%, preferably at least 97.5%, more preferably at least 99% of the respective surface.

Claims

1. A modular greenwall element (1) comprising a casing (2) having first and second compartments (6, 6'), the first compartment (6) being arranged to contain growing material for plants and the second compartment (6') being at least partially filled with a foam material.

2. The foam material has a strength of 500 kg / m ３ (g / l) or less, preferably 300 kg / m ３ 10. The element of claim 1 having a density of less than or equal to 10 ...

3. 3. An element according to claim 1 or 2, wherein the foam material is a foamed synthetic organic or inorganic material.

4. The foam material is a) at least one mineral binder B, and b) optionally at least one synthetic organic polymer SP 3. The element according to claim 1, which is a foamed inorganic material comprising:

5. 5. An element according to claim 4, wherein said at least one mineral binder B constitutes at least 35% by weight, preferably at least 50% by weight, of the total weight of said expanded inorganic material.

6. 5. The element of claim 4, wherein the at least one mineral binder B is selected from the group consisting of portland cement, calcium aluminate cement, calcium sulfoaluminate cement, latent hydraulic binder materials, pozzolanic binder materials, calcium sulfate, and hydrated lime.

7. 5. The element according to claim 4, wherein the weight ratio of the amount of said at least one mineral binder B to the amount of said at least one synthetic polymer SP in said foamed inorganic material is from 100:0 to 70:30, preferably from 100:0 to 80:

20.

8. The casing (2) a front and rear wall (3, 3') connected by two longitudinal side walls (4, 4'), an intermediate wall (5) dividing the interior space formed between said front, rear and longitudinal side walls (3, 3', 4, 4') into said first and second compartments (6, 6'); - bottom wall (7) 3. The element according to claim 1 or 2, having

9. 9. An element according to claim 8, wherein the intermediate walls (5) extend transversely to the direction of the longitudinal side walls (4, 4').

10. 9. An element according to claim 8, wherein the depth of the second compartment (6') measured in the direction of the longitudinal side walls (4, 4') is at least 10% less, preferably at least 25% less, than the depth of the first compartment (6) measured in the direction of the longitudinal side walls (4, 4').

11. 3. An element according to claim 1 or 2, wherein the element is arranged to be attached to the surface of a substrate via the outer surface of the rear wall (3') facing away from the intermediate wall (5).

12. Element according to claim 1 or 2, wherein the casing (2) is made of a polymer material.

13. I) providing a casing (2) having first and second compartments (6, 6'); II) providing a foam composition; III) at least partially filling the second compartment (6') with the foam composition; and IV) Curing the foam composition 3. A method for manufacturing a modular green wall element (1) according to claim 1 or 2, comprising:

14. The foaming composition has a viscosity of 500 kg / m ３ (g / l) or less, preferably 300 kg / m ３ 14. The method of claim 13, wherein the granules have a density of less than or equal to 10 ...

15. The foaming composition comprises: a) at least one mineral binder B, b) optionally at least one synthetic organic polymer SP, c) optionally at least one surfactant S, and d) water The method of claim 13, wherein the foamed inorganic composition comprises:

16. 16. The method according to claim 15, wherein said at least one mineral binder B constitutes at least 35% by weight, preferably at least 50% by weight, of the total weight of said foamed mineral composition.

17. Step II) - providing separately an aqueous foam and an aqueous slurry comprising said at least one mineral binder B and optionally said at least one synthetic organic polymer SP; and - mixing the aqueous foam with the aqueous slurry to obtain the foamed inorganic composition; 16. The method of claim 15, comprising:

18. I. Providing one or more modular green wall elements (1) according to claim 1 or 2, II. Attaching the one or more elements (1) to the surface of the substrate (8) such that each element (1) is directly or indirectly connected to the surface of the substrate (8) via the outer surface of the rear wall (3'); III. Optionally, attaching adjacent elements to each other via the outer surfaces of the opposing longitudinal side walls (4, 4'). How to provide a green wall, including:

19. 19. The method according to claim 18, wherein the substrate (8) is a construction element, preferably a wall or a facade of a building.

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