Panel comprising a hardened inorganic foam and a structural reinforcement element, method for producing same and use thereof

Abstract

The present invention relates to a building panel (1) comprising an insulation layer (2) formed of a cured inorganic foam and at least one structural reinforcement element (3) firmly attached to at least one surface of the cured inorganic foam, wherein the at least one structural reinforcement element (3) is a cured mortar, preferably a cured cementitious mortar. The panel of the present invention is useful as a heat insulating and / or sound insulating panel in construction, or as a cover board.

Description

Technical Field

[0001] The present invention relates to a construction panel including an insulation layer formed of a cured inorganic foam and at least one structural reinforcement element firmly attached to at least one surface of the cured inorganic foam. The panel of the present invention is useful as a heat insulating and / or sound insulating panel, or as a construction and / or fireproof cover board.

Background Art

[0002] The facade of a building needs to be protected from environmental loads such as wind and rain. A building must also be insulated to prevent the flow of unnecessary thermal energy from the inside to the outside or vice versa of the building. Also, sound insulation and / or fire protection between a building or compartments in a building are becoming increasingly important. Particularly with respect to building insulation, either external insulation (EIFS) by arranging different layers of insulation panels and decorative materials such as minerals or organic plasters on the outer wall of a building, or internal insulation (ITI) by arranging different layers of insulation panels and decorative materials particularly on the inner wall of a building is known.

[0003] Rigid prefabricated insulation panels including foamed synthetic organic materials such as expanded polystyrene (EPS) foam panels, extruded polystyrene (XPS) foam panels, polyurethane foam panels (PUR), and polyisocyanurate (PIR) are typically used for insulating building structures. Such materials have a very low thermal conductivity, a relatively high compressive strength, and typically a low density of 150 g / l or less, and are thus very suitable for insulation applications. The main drawback of foamed synthetic organic materials is their high flammability. Typically, additional fire-resistant structures such as fire-resistant glass scrim or glass mat must be applied. In some countries, in order to meet fire-resistant requirements, a non-combustible "fire bar" having a melting point of at least 1000 °C must be added between adjacent insulation panels in the facade.

[0004] Soundproof panels can be made of, for example, mineral wool. Fireproof panels can be made of, for example, mineral wool-based sandwich panels, or gypsum boards, or cementitious mortars.

[0005] Foamed cementitious compositions are known and typically provide a combination of lightweight, good thermal insulation and / or soundproof properties combined with excellent fire resistance. Foamed concrete, also known as cellular lightweight concrete (CLC), can be obtained by mixing a gas-generating foaming agent such as hydrogen peroxide or aluminum powder into the concrete slurry, or by separately producing an aqueous foam and then mixing these with the concrete slurry.

[0006] Foamed cementitious compositions have good fire resistance properties, but these are relatively low in compressive strength and / or flexural strength due to the brittleness of the foaming material. Due to the poor strength, it may lead to problems during transportation, storage, handling and installation. To compensate for the drawbacks due to poor mechanical properties, it is possible to provide a "lightweight insulation concrete (LWIC) system" by using foamed cementitious boards in combination with foamed synthetic organic boards, typically EPS boards.

[0007] International Patent Application Pamphlet No. 2021 / 023942 discloses a heat-insulating panel including a heat-insulating layer formed of a cured inorganic foam and at least one flexible reinforcing element in a watermark pattern. However, such composite materials are difficult to recycle.

[0008] European Patent No. 1088800 discloses a soundproof panel having a layer of foamed cementitious material and a backing layer attached thereto, which backing layer can be made of paper, felt, glass fiber mat or mineral fiber board.

[0009] International Patent Application Pamphlet No. 2015 / 144796 discloses a cement-based coating composition suitable for passive fire protection.

[0010] The insulation panel should be lightweight and have excellent fire-resistant properties and sufficient mechanical strength, particularly with regard to compressive strength and flexural strength. The technical problem underlying the present invention is thus to provide a heat-insulating and / or sound-insulating and / or fire-protecting panel that is recyclable, has high fire resistance, and is easy to install. Preferably, the insulation panel has a low environmental impact.

Summary of the Invention

Problems to be Solved by the Invention

[0011] An object of the present invention is to provide a panel that simultaneously has insulation properties, particularly heat-insulating and / or sound-insulating and / or fire-protecting properties, sufficient mechanical strength, and good fire-resistant properties. Preferably, the panel of the present invention is also lightweight, i.e., has a low density.

Means for Solving the Problems

[0012] Surprisingly, it has been found that the panel according to claim 1 is a solution to this object.

[0013] The core of the present invention lies in the discovery that the sufficiently high mechanical strength of a panel containing a cured inorganic foam as an insulation layer can be achieved by firmly attaching at least one structural reinforcement element to the surface of the inorganic foam, where the at least one structural reinforcement element is cured mortar. In particular, the insulation properties such as heat-insulating and / or sound-insulating properties and fire resistance are not impaired. A particularly suitable material for the structural reinforcement element is cured mortar, preferably cured cementitious mortar, in particular cured mortar having the same chemical composition as the cured inorganic foam but a higher density.

[0014] A further aspect of the present invention is the subject matter of further independent claims. Preferred embodiments of the present invention are the subject matter of the dependent claims.

Modes for Carrying Out the Invention

[0015] In a first aspect, the present invention relates to a panel comprising an insulation layer formed of a cured inorganic foam and at least one structural reinforcement element firmly attached to at least one surface of the cured inorganic foam, wherein the at least one structural reinforcement element is a cured mortar, preferably a cured cementitious mortar.

[0016] The panel in this context may have any form or shape. According to a preferred embodiment, the panel is in the form of a rectangular cuboid, in particular in the form of a rectangular plate. However, other shapes and forms are also possible, especially irregular shapes. It is particularly preferred that the panel of the present invention is regularly shaped such that it can completely cover a given surface without overlapping with a thin joint. The dimensions of the panel of the present invention are not particularly limited. However, dimensions suitable for panels installed in buildings are generally preferred.

[0017] The panel can be a prefabricated panel. The panel can also be formed at the work site, for example, it can be a site-formed panel or a site-cast panel.

[0018] The panel of the present invention includes an insulation layer. The insulation layer is a layer having insulation properties, particularly heat insulation and / or sound insulation and / or fire protection properties. In other words, the insulation layer is preferably a heat insulation and / or sound insulation and / or fire protection layer, particularly a heat insulation layer. According to an embodiment, the insulation layer has a thermal conductivity of 0.02 to 0.15 W / m·K, preferably 0.03 to 0.07 W / m·K. The thermal conductivity is measured in accordance with the standard DIN EN 12664:2001.

[0019] The insulation layer is formed of a cured inorganic foam. In other words, the insulation layer consists of a cured inorganic foam. The term "cured inorganic foam" in this context relates to a material based on a cured inorganic binder and having a cellular structure. Preferably, the cellular structure is a closed-cell structure. However, it is also possible to have an open-cell structure.

[0020] According to an embodiment, the density of the insulation layer is 500 g / l or less, preferably 350 g / l or less, more preferably 250 g / l or less, even more preferably 200 g / l or less, preferably within the range of 25 to 250 g / l, more preferably within the range of 35 to 150 g / l.

[0021] Throughout this context, when referring to density or when a density value is stated, such density is measured by weight measurement. The preferred measurement method is as follows: First, a sample cube having dimensions of 10×10×10 cm is cut out from the material, and then it is dried in an oven at a temperature of 70°C until the weight of the material becomes constant. Next, the weight of the sample cube is measured, and the density (g / l) of the material is obtained by dividing the measured weight of the cube by 1 l.

[0022] In this context, the term "low density" means a density of 500 g / l or less.

[0023] According to an embodiment, in the panel of the present invention, at least one structural reinforcement element, particularly all structural reinforcement elements, have a density of at least 1.5 times, preferably at least 2.5 times, the density of the insulation layer. For example, when the density of the insulation layer is 100 g / l, the density of at least one structural reinforcement element is at least 150 g / l, preferably at least 250 g / l.

[0024] In the panel of the present invention, it may also be preferable that the density of at least one structural reinforcement element is at least 150 g / l, more preferably at least 250 g / L.

[0025] According to an embodiment, the overall density of the panel of the present invention is 500 g / l or less, particularly 300 g / l or less, and preferably within the range of 110 to 500 g / l, more preferably 160 to 250 g / l.

[0026] The mechanical strength of the panel described in the present invention and / or the mechanical strength of the material can be measured as the impact resistance of the cured material. The impact resistance can be measured in accordance with the standard EN ISO 7892 and / or the standard EOTA EAD 040083-00-0404 (2019). Another method for measuring the mechanical strength is, for example, to measure the compressive strength in accordance with the standard DIN EN 826:2013. The impact resistance and the compressive strength are correlated with each other. This means that a higher impact resistance always correlates with a higher compressive strength, and vice versa.

[0027] According to an embodiment, the cured inorganic foam of the present invention a) at least one cured inorganic binder B, b) at least one surfactant S and / or particles N, and c) optionally, at least one synthetic organic polymer SP is included.

[0028] Preferably, at least one inorganic binder B is selected from the group consisting of cement, gypsum, lime, latent hydraulic binders, pozzolans, and geopolymers. In particular, the cement can be Portland cement as described in standard EN 197-1:2018-11, calcium aluminate cement as described in standard EN 14647, and / or calcium sulfoaluminate cement. The term "gypsum" means including various forms of CaSO4, especially anhydrous CaSO4, α- and β-hemihydrate CaSO4, and dihydrate CaSO4. The term "lime" means including natural hydraulic lime, formulated lime, hydraulic lime, and air-hardening lime as described in standard EN 459-1:2015. Pozolans and latent hydraulic materials are preferably selected from the group consisting of clay, calcined clay, especially metakaolin, kiln dust, microsilica, fly ash, zeolite, rice husk ash, slag, especially blast furnace slag, calcined shale oil, and natural pozzolans such as pumice and trass. Geopolymers are aluminosilicate polymers. A specific example of a geopolymer is blast furnace slag activated with water glass.

[0029] Preferably, at least one inorganic binder B is selected from Portland cement, calcium aluminate cement, calcium sulfoaluminate cement, latent hydraulic binder materials, pozzolan binder materials, calcium sulfate, and / or slaked lime. In particular, at least one inorganic binder B is selected from Portland cement, calcium aluminate cement, and / or calcium sulfoaluminate cement.

[0030] As used herein, the term "Portland cement" specifically refers to the cement described in European Standard EN-197. Portland cement mainly consists of tricalcium silicate (alite) (C3S) and dicalcium silicate (belite) (C2S). Preferred Portland cements include the types CEM I, CEM II, CEM III, CEM IV, and CEM V of European Standard EN 197-1:2018-11. However, all other Portland cements produced in accordance with other standards, such as ASTM standards, British (BSI) standards, Indian standards, or Chinese standards, are also suitable.

[0031] As used herein, the term "alumina cement" is intended to include cementitious materials that contain calcium aluminate hydrate, preferably monocalcium aluminate CA (CaO·Al2O3), as the main constituent (phase). Depending on the type of alumina cement, other calcium aluminates such as CA2, C3A, and C 12 A7 may also be present. Preferred alumina cements also include other constituents such as belite (C2S), alite (C3S), ferrite (C2F, C2AF, C4AF), and ternesite (C5S2$). Some alumina cements also contain calcium carbonate.

[0032] The most preferred alumina cement for use as at least one inorganic binder B is calcium aluminate cement (CAC) that meets the requirements of Standard EN 4647 ("Calcium Aluminate Cement"). Suitable calcium aluminate cements are commercially available, for example, from Imerys Aluminates and Royal White Cement.

[0033] The term "calcium sulfoaluminate cement (CSA)" has, as the main constituent (phase), C4(A 3-x F x)3$(4CaO·3-xAl2O3·xFe2O3·CaSO4) (where x has a value of 0, 1, 2, or 3) is intended to be included in the cementitious material. Typically, calcium sulfoaluminate cement also includes other components such as aluminate (CA, C3A, C 12 A7), belite (C2S), ferrite (C2F, C2AF, C4AF), tricalcium sulfoaluminate (C5S2$), and calcium sulfate. Preferred calcium sulfoaluminate cement for use as at least one inorganic binder B contains, based on the total weight of the calcium sulfoaluminate cement, 20 - 80 w% of ye'elimite (C4A3$), 0 - 10 w% of calcium aluminate (CA), 0 - 70 w% of belite (C2S), 0 - 35 w% of ferrite, preferably tetracalcium aluminoferrite (C4AF), and 0 - 20 w% of tricalcium sulfoaluminate (C5S2$). Suitable calcium sulfoaluminate cement (CSA) is commercially available, for example, from Heidelberg Cement AG, Vicat SA, and Caltra B.V.

[0034] The hardened inorganic binder B is the reacted, preferably substantially completely reacted, inorganic binder B in the hardening reaction in the presence of water. In particular, the hardening reaction involves the formation of solid hydrates or solid hydrate phases. The term "substantially completely reacted" refers to a substantially complete reaction at 25 °C, 1023 mbar, and 50% r.h.

[0035] According to one or more embodiments, the weight ratio of the amount of at least one inorganic binder B to the amount of at least one synthetic organic polymer SP in the hardened inorganic foam is 100:0 to 70:30, preferably 100:0 to 80:20.

[0036] According to one or more embodiments, at least one synthetic organic polymer is present, and the proportion of at least one synthetic organic polymer SP is 1 - 25 w%, preferably 5 - 15 w%, more preferably 8 - 12 w%, based on the weight of at least one inorganic binder B in the hardened inorganic foam.

[0037] At least one synthetic organic polymer SP can be used to improve the mechanical properties of the cured inorganic foam, particularly the compressive strength and / or flexural strength.

[0038] The type of the synthetic organic polymer SP is not particularly limited. Examples of suitable synthetic organic polymers include, for example, polyurethanepolymers and homopolymers and copolymers obtained from 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)acrylate, vinyl ester, vinyl neodecanoate, vinyl alcohol, and vinyl chloride. The term "(meth)acrylate" refers to acrylate and methacrylate, and the term "(meth)acrylic" refers to acrylic and methacrylic.

[0039] The term "polyurethane polymer" refers to a polymer prepared by a so-called diisocyanate polyaddition process that contains little or no urethane groups. Examples of suitable polyurethane polymers include polyether polyurethanes, polyester polyurethanes, polyether polyureas, polyureas, polyester polyureas, polyisocyanurates, and polycarbodiimides.

[0040] According to one or more embodiments, at least one synthetic organic polymer SP is preferably a polyurethane polymer based on at least one polyisocyanate and at least one polyol and / or polyamine monomer.

[0041] Examples of suitable polyisocyanates include monomeric polyisocyanates, as well as oligomers, polymers, and derivatives of monomeric polyisocyanates, and mixtures thereof.

[0042] Suitable monomeric polyisocyanates for polyurethane polymers include at least aromatic di- and tri-functional 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.

[0043] More suitable monomeric polyisocyanates for polyurethane polymers include 1,4-tetramethylene diisocyanato, 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 diisocyanato, lysine- and lysine ester diisocyanates, cyclohexane-1,3- and -1,4-diisocyanates, 1-methyl-2,4- and -2,6-diisocyanatocyclohexane and mixtures of its isomers (HTDI or H6TDI), 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane (=isophorone 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, 3,6-bis-(9-isocyanatononyl)-4,5-di-(1-heptenyl)cyclohexene (dimeryldiisocyanat) and aliphatic di- and tri-functional isocyanates such as dimer and trimer fatty acid isocyanates such as α,α,α',α',α",α"-hexamethyl-1,3,5-mesitylene triisocyanate and the like.

[0044] Particularly suitable polyols for polyurethane polymers include polyether polyols, polyester polyols, polycarbonate polyols, poly(meth)acrylate polyols, and hydrocarbon polyols such as polybutadiene polyols, polyhydroxy-functional fats and oils, and polyhydroxy-functional acrylonitrile-butadiene copolymers.

[0045] Particularly preferred polyether polyols include polyoxyalkylene diols and / or polyoxyalkylene triols. In particular, they are polymers that can be polymerized using starting molecules having two or three, particularly one, active hydrogens such as water, ammonia or compounds. Ethylene oxide or 1,2-propylene oxide or 1,2- or 2,3-butylene oxide or oxetane or tetrahydrofuran or a mixture thereof, and 1,2-ethanediol, 1,2- or 1,3-propanediol, neopentyl glycol, diethylene glycol, triethylene glycol, isomeric dipropylene glycol or tripropylene glycol, isomeric butanediol, pentanediol, hexanediol, heptanediol, octanediol, nonanediol, decanediol, undecanediol, 1,3- or 1,4-cyclohexanedimethanol, bisphenol A, hydrogenated bisphenol A, 1,1,1-trimethylolethane, 1,1,1-trimethylolpropane, glycerol or aniline, or polymerization products with a number of OH or NH groups such as mixtures of the aforementioned compounds.

[0046] Suitable polyester polyols include liquid polyester polyols and amorphous, partially crystalline and crystalline polyester polyols which are solid at a temperature of 25°C. These are obtained by reacting 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 alcohol, neopentyl glycol, glycerol, 1,1,1-trimethylolpropane, or a mixture of the above alcohols with organic dicarboxylic or tricarboxylic acids 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, and hexahydrophthalic acid, preferably dicarboxylic acids or their anhydrides or esters, or a mixture of the above acids, and also from polyester polyols formed from lactones such as those derived from ε-caprolactone which is also known, for example, as polycaprolactone.

[0047] Suitable polyamine monomers are compounds having two or more isocyanate-reactive amine groups. Examples of polyamine monomers that can be employed include diethyltoluenediamine, methylbis(methylthio)phenylenediamine, adipic dihydrazide, ethylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine, dipropylenetriamine, hexamethylenediamine, hydrazine, isophoronediamine, N-(2-aminoethyl)-2-aminoethanol, polyoxyalkyleneamine, 2-acrylamido-2-methylpropane-1-sulfonic acid (AMPS) and adducts of salts of ethylenediamine, adducts of salts of (meth)acrylic acid and ethylenediamine, adducts of 1,3-propanesulfone and ethylenediamine, or any desired combination of these polyamines.

[0048] According to one or more preferred embodiments, at least one synthetic organic polymer SP is selected from the group consisting of polyacrylate, styrene-acrylate copolymer, polyvinyl ester, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, styrene-butadiene copolymer, vinyl acetate-vinyl neodecanoate (VeoVa) copolymer, and polyurethane polymer.

[0049] According to one or more preferred embodiments, 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 at least one vinyl ester monomer.

[0050] The content of the structural unit derived from vinyl acetate in the ethylene-vinyl acetate copolymer, which is particularly suitable for use as at least one synthetic organic polymer SP, is 40 w% or less, preferably 30 w% or less, more preferably 20 w% or less, and even more preferably 15 w% or less based on the weight of the copolymer.

[0051] According to an embodiment, at least one synthetic organic polymer SP is present in the form of an aqueous polymer dispersion and / or in the form of a redispersible polymer powder. The synthetic organic polymer SP is mixable with the inorganic binder B by using any conventional mixing technique. The synthetic organic polymer may be added to the cement slurry together with the aqueous foam, however, this is not very preferable. The aqueous polymer dispersion of at least one synthetic organic polymer SP can be prepared, for example, by radical polymerization using substances, solutions, suspensions or emulsion polymerization techniques all known to those skilled in the art, or by mixing the redispersible polymer powder with water. An aqueous polymer dispersion containing two or more different synthetic organic polymers SP can be easily prepared by using a commercially available aqueous polymer dispersion and / or a mixture of redispersible polymers.

[0052] The synthetic organic polymer SP may be additionally stabilized. Preferably, the synthetic organic polymer SP is stabilized with polyvinyl alcohol (PVA).

[0053] According to one or more embodiments, the cured inorganic foam further comprises at least one surfactant S. Here, the term "surfactant" refers to a substance that reduces surface tension, which is usually an organic compound containing both a hydrophobic group and a hydrophilic group.

[0054] The surfactant can be used for stabilizing the foam structure during the preparation of the cured inorganic foam. The surfactant S can also form part of the aqueous foam.

[0055] According to one or more embodiments, the proportion of at least one surfactant S is 0.1 to 25 w%, preferably 1 to 15 w%, more preferably 5 to 12 w% based on the total dry weight of the cured inorganic foam.

[0056] Surfactants are well known to those skilled in the art, for example, "Surfactants and Polymers in aqueous solutions" (Wiley-VCH, K. Holmberg et al, 2 ndIt is summarized in (Edition, 2007). Suitable surfactants include at least nonionic surfactants, cationic surfactants, anionic surfactants, and amphoteric surfactants. Amphoteric (zwitterionic) surfactants have both a cationic center and an anionic center that bind to the same molecule.

[0057] Since nonionic surfactants tend to be less absorbed by the cement phase, it can be particularly advantageous to use nonionic surfactants. However, it is also possible to use cationic, anionic, or amphoteric (zwitterionic) surfactants.

[0058] Suitable surfactants in the context of the present invention include lipids such as cholates, glycocholate salts, fatty acid salts, glycerides, glycolipids, and phospholipids. These may be derived from natural sources or may be obtained synthetically. In certain embodiments, nonionic lipids are preferred.

[0059] Suitable anionic surfactants include compounds containing a carboxylate, sulfate, phosphate, or sulfonate group such as alkyl sulfonates, alkyl ether carboxylates, alkyl sulfates, alkyl ether sulfates, aliphatic alcohol sulfates, alkyl sulfosuccinates, alkylphenol ethoxylates, olefin sulfonates, alkyl phosphates, alkyl ether phosphonates, lauryl ether sulfonates, naphthalene sulfonates, and alkyl benzene sulfonates.

[0060] Suitable nonionic surfactants include, in particular, fatty acid alkoxylates, alkoxylated alcohols, especially fatty alcohol alkoxylates and alkoxylates of glycerol and pentaerythritol, alkylphenol alkoxylates, alkoxylated polysaccharides, alkoxylated polycondensates, fatty acid amide alkoxylates, ethanolamides, fatty acid esters, especially fatty acid esters of methanol, sorbitan, glycerol or pentaerythritol, alkoxylated alkylamines having an alkyl group consisting of 6 to 20 carbon atoms, alkyl glycosides, alkyl glucamides, esters of fatty acids and saccharides, polysiloxanes, and copolymers of alkoxylated sorbitan, ethylene oxide and propylene oxide, hydrophobized starch, hydrophobized cellulose, proteins, or siloxane-based surfactants. Preferred alkoxylates in this context are especially ethoxylates.

[0061] In particular, the use of protein surfactants results in a mixture that is sufficiently stable to cure low-density hardened inorganic foams without any further additives.

[0062] Suitable cationic surfactants contain in particular an ammonium group or a quaternary nitrogen atom and have at least one long-chain alkyl group. Examples of suitable cationic surfactants are quaternary ammonium compounds having at least one alkyl group, phosphonium salt compounds, tetraalkylammonium salts, imidazolines such as N,N-dialkylimidazoline compounds, dimethyldistearylammonium compounds, N-alkylpyridine compounds, ammonium chloride and amine N-oxides, etc. For example, the cationic surfactant can be selected from tetradecyltrimethylammonium bromide (TTAB), cetyltrimethylammonium bromide (CTAB) and dodecyltrimethylammonium bromide (DTAB).

[0063] According to one or more embodiments, at least one surfactant S comprises or consists of at least one gemini surfactant. A gemini surfactant contains, at the head group or in the vicinity thereof, two hydrophilic head groups and two hydrophobic tails separated by a spacer. When both of the hydrophobic tails are the same and the hydrophilic groups are equivalent, the gemini surfactant is said to have a symmetric structure. The substituents in the gemini surfactant are highly involved in the behavior of these compounds in solution and their potential uses. In particular, the gemini surfactant may contain a quaternary nitrogen atom, which usually exists in an acyclic form. However, there are also gemini surfactants containing nitrogen in saturated and unsaturated rings. The spacer can be rigid or flexible and tends to be hydrophobic or hydrophilic. The special properties of the gemini surfactant 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, tails or spacers. Examples of preferred gemini surfactants are, in particular, alkoxylated acetyldiols or the gemini surfactants described in European Patent No. 0 884 298.

[0064] According to one or more further embodiments, at least one surfactant S comprises an anionic surfactant and / or a nonionic surfactant, preferably a mixture of an anionic surfactant and / or a nonionic surfactant.

[0065] According to one or more further embodiments, at least one surfactant S is preferably an amphoteric surfactant selected from aminocarboxylic acids and betaines, in particular fatty acid amide alkyl betaines, in particular cocamidopropyl betaine. Betaines are neutral chemical compounds having a positively charged cationic functional group without a hydrogen atom, such as a quaternary ammonium or phosphonium salt cation, and a negatively charged functional group such as a carboxylate group that may not be adjacent to the cationic site. Betaines are therefore a specific type of zwitterion. These types of surfactants have been found to be very beneficial in the context of the present invention because they have a high compatibility with further components typically present in foamed inorganic materials.

[0066] According to an embodiment, particles N are present in the composition of the present invention.

[0067] The particles N of the present invention preferably have a particle size in the range of 10 nm to 500 μm, preferably 20 nm to 300 μm, more preferably 25 nm to 150 μm, even more preferably 30 nm to 100 μm, particularly 30 nm to 1 μm. The particle size can be determined by laser diffraction as described in ISO 13320:2009. In particular, a Mastersizer 2000 instrument equipped with a Hydro 2000G dispersion unit and Mastersizer 2000 software manufactured by Malvern Instruments GmbH (Germany) is used. For example, isopropanol is suitable as the measurement medium. Preferably, the particle size of non-spherical or irregularly shaped particles is represented by the equivalent spherical diameter of a sphere having the same volume. Throughout the present invention, when a range of particle sizes is described, the lower value of the range always represents the D10 value, while the upper value of the range described herein for the particle size represents the D90 value of the respective particle size distribution.

[0068] According to some embodiments, the particles N of the present invention are nanoparticles. This means that the particles N have a particle size within the nanometer range, particularly the particle size D50.

[0069] In particular, the particles N are selected from inorganic particles, in particular, pure and mixed metal oxides, hydroxides, carbides, nitrides, phosphates, carbonates, silicic acids, sulfates. According to an embodiment, the particles N are clay, talc, silica, calcium carbonate, ferrite, gibbsite, titanium oxide, zinc oxide, aluminum oxide, magnesium oxide, zirconium oxide, tin oxide, cerium oxide, spinel, aluminum hydroxide, calcium hydroxide, magnesium hydroxide, silicon carbide, boron carbide, silicon nitride, boron nitride, calcium phosphate, nickel carbonate, calcium carbonate, magnesium carbonate, silica fume, fly ash, quartz, mullite glass, slag, calcium silicate, mullite, cordierite, zeolite, diatomaceous earth, cement, calcium sulfate and / or carbon black particles. In particular, the particles are silica particles.

[0070] According to another preferred embodiment, the particles are selected from organic particles, in particular polymer particles, in particular polystyrene particles and / or poly(methyl methacrylate) particles.

[0071] When present, the proportion of the particles N is, in particular, 1 to 50 vol%, in particular 2 to 20 vol%, in particular 3 to 10 vol% with respect to the total volume of the cured inorganic foam.

[0072] In this context, an aqueous foam is a material containing a gas phase dispersed in water. The gas can be any gas such as air, nitrogen, carbon dioxide, noble gas or a mixture thereof, preferably air. The aqueous foam may further contain additional components, in particular at least one of the above surfactants S. Methods for producing an aqueous foam are known per se to those skilled in the art. For example, it is possible to use a foaming device manufactured by Gertec.

[0073] The aqueous foam is preferably prepared by mechanical foaming of an aqueous mixture in the presence of a gas, in particular air, nitrogen and / or carbon dioxide and / or noble gas. Mechanical foaming refers to a method of introducing gas bubbles into the water of an aqueous foam by mixing a gas and water without performing any gas generation chemical reaction.

[0074] According to one or more embodiments, the aqueous foam is obtained by mechanically foaming an aqueous mixture containing a gas, preferably air.

[0075] According to an embodiment, the cured inorganic foam of the present invention is: a) (i) at least one inorganic binder B, (ii) optionally 1 to 25 w%, preferably 5 to 15 w%, more preferably 8 to 12 w% of at least one synthetic organic polymer SP, based on the dry weight of the inorganic binder B, (iii) optionally 0.01 to 10 w% of a fluidizing agent for the inorganic binder B, based on the dry weight of the inorganic binder B, and (iv) water in an amount such that the weight ratio of water to inorganic binder B is 0.2 to 0.6 to provide a wet mixture containing; b) (i) water, and (ii) a surfactant S and / or particles N in an amount of 0.1 to 25 w%, preferably 1 to 15 w%, more preferably 1 to 10 w%, based on the total weight of the aqueous foam to provide an aqueous foam containing; c) mixing the wet mixture and the aqueous foam of steps a) and b); and d) curing the mixture obtained in step c) obtained by a method comprising.

[0076] According to an embodiment, the cured inorganic foam of the present invention is: a) (i) at least one inorganic binder B, (ii) optionally 1 to 25 w%, preferably 5 to 15 w%, more preferably 8 to 12 w% of at least one synthetic organic polymer SP, based on the dry weight of the inorganic binder B, (iii) optionally 0.01 to 10 w% of a fluidizing agent for the inorganic binder B, based on the dry weight of the inorganic binder B, and (iv) An amount of water such that the weight ratio of water to inorganic binder B is 0.2 to 0.6 providing a wet mixture containing the same; b) (i) water, and (ii) Particles N in an amount of 1 to 50 vol%, particularly 2 to 20 vol%, particularly 3 to 10 vol%, based on the total volume of the aqueous foam providing an aqueous foam containing the same; c) mixing the wet mixture and the aqueous foam of steps a) and b); and d) curing the mixture obtained in step c) obtained by a method comprising the same.

[0077] In such embodiments, the weight ratio of a) and b) depends on the required density. A lower density is achieved by increasing the dosage of b). According to the embodiment, the weight ratio of a) and b) is 10:1 to 1:10.

[0078] According to a further embodiment, the cured inorganic foam of the present invention is: a) (i) at least one cement, (ii) at least one synthetic organic polymer SP in an amount of about 10 w% based on the dry weight of the cement, (iii) a fluidizing agent for said cement in an amount of about 0.2 w% based on the dry weight of the cement, and (iv) an amount of water such that the water-cement weight ratio is 0.4 providing a wet mixture containing the same; b) (i) water, and (ii) a surfactant S in an amount of about 3 w% based on the total weight of the aqueous foam providing an aqueous foam containing the same; c) mixing the wet mixture and the aqueous foam of steps a) and b); and d) curing the mixture obtained in step c) obtained by a method consisting of the same.

[0079] According to the embodiment, the weight ratio of a) and b) is 10:1 to 1:10.

[0080] According to a further embodiment, the cured inorganic foam of the present invention is: a) (i) at least one inorganic binder B, (ii) at least one surfactant S and / or particles N, (iii) optionally 1 to 25 w%, preferably 5 to 15 w%, more preferably 8 to 12 w% of at least one synthetic organic polymer SP, based on the dry weight of the inorganic binder B, (iv) optionally, further additives, and (v) water in an amount such that the weight ratio of water to inorganic binder B is 0.2 to 0.6 providing a suspension containing; b) foaming the suspension provided in step a); and c) curing the foamed mixture obtained in step b) obtained by a method comprising.

[0081] The foaming step can be any process known to those skilled in the art. In particular, the foaming can be carried out by chemical foaming, mechanical foaming and / or physical foaming processes.

[0082] The cured inorganic foam of the present invention may additionally contain further additives common in the concrete or mortar industry. In particular, the inorganic foam of the present invention may contain aggregates, fillers, fluidizing agents, shrinkage reducing agents, air entraining agents, deaerating agents, rheology modifiers, accelerators, retarders, water resistant agents, strength enhancers, fibers, defoaming agents, redispersible polymer powders, chromate reducing agents, pigments, corrosion inhibitors, alkali-aggregate reaction inhibitors, anti-freezing agents, water repellents and / or biocides.

[0083] The hardening of the inorganic foam typically occurs when the inorganic binder B is brought into contact with water and / or when the inorganic binder is reacted at a temperature of 5 to 50 °C and a pressure of 1 atm. Hardening at higher temperatures and / or higher pressures is not preferred in the context of this text. The hardened inorganic foam is obtained when the mechanical strength, especially the impact resistance, flexural strength and / or compressive strength do not increase significantly further over time. Typically, the hardened inorganic foam is obtained after hardening for 28 days at 20 °C and a pressure of 1 atm. It can be advantageous to cover the inorganic foam or panel during hardening. Covering prevents rapid evaporation of water and can result in a higher compressive strength. It is possible to additionally dry the hardened inorganic foam or the panel of the present invention at a high temperature, for example 40 to 90 °C.

[0084] The flexural strength can be measured in accordance with DIN EN 1015-11, and the compressive strength can be measured in accordance with DIN EN 826:2013. The impact resistance can be measured in accordance with the standard EN ISO 7892 and / or the standard EOTA EAD 040083-00-0404 (2019).

[0085] The method for obtaining the hardened inorganic foam of the present invention is known to those skilled in the art and is described, for example, in the pamphlet of International Publication No. WO 2019 / 038105.

[0086] According to an embodiment, the method for producing a hardened inorganic foam is: (i) providing a dry mixture Md1 comprising at least one inorganic binder B and optionally the above further additives; (ii) optionally mixing the dry mixture Md1 with at least one synthetic organic polymer SP; (iii) mixing the mixture obtained in (ii) with an aqueous foam to obtain a wet mixture Mw1, wherein the aqueous foam comprises at least one surfactant S; (iv) optionally shaping the wet mixture Mw1 into any desired form and shape; (v) Curing the wet mixture Mw1 at a temperature of 5 to 50 °C and a pressure of 1 atm comprising.

[0087] The aqueous foam and the mixture of Md1 and optional SP are preferably mixed with each other under overpressure conditions. An overpressure of 1 to 15 bar, in particular 2 to 5 bar, relative to the ambient atmospheric pressure is preferred. This makes it possible to easily adjust the density of the cured inorganic foam over a wide range.

[0088] Most preferably, the mixing is carried out using a static mixer, whereby preferably the aqueous foam and the mixture of Md1 and optional SP are fed through the static mixer by means of pressurized air. Preferably, the pressurized air has a pressure of 1 to 15 bar, in particular 6 to 10 bar, higher than the ambient atmospheric pressure. This makes it possible to reliably obtain a stable foam. The aqueous foam can be mixed with the slurry either batchwise or continuously.

[0089] The weight ratio of water to at least one inorganic binder B in the wet mixture Mw1 is preferably 0.2 to 0.7, more preferably 0.25 to 0.5, even more preferably 0.3 to 0.4.

[0090] According to an alternative embodiment, a method for producing a cured inorganic foam is: (i) providing a dry mixture Md1 comprising at least one inorganic binder B and optionally the above further additives; (ii) optionally, mixing the dry mixture Md1 of step (i) with at least one synthetic organic polymer SP and water to prepare a wet mixture Mw; (iii) mixing the mixture obtained in (ii) with an aqueous foam to obtain a wet mixture Mw1, wherein the aqueous foam comprises at least one surfactant S; (iv) optionally, shaping the wet mixture Mw1 into any desired form and shape; (v) curing the wet mixture Mw1 at a temperature of 5 to 50 °C and a pressure of 1 atm including.

[0091] The aqueous foam and the wet mixture Mw are preferably mixed with each other under overpressure conditions. An overpressure of 1 to 15 bar, particularly 2 to 5 bar, relative to the ambient atmospheric pressure is preferred. This enables the density of the cured inorganic foam to be easily adjusted over a wide range.

[0092] Most preferably, the mixing is carried out using a static mixer, whereby preferably the aqueous foam and the wet mixture Mw are fed through the static mixer by pressurized air. Preferably, the pressurized air has a pressure of 1 to 15 bar, particularly 2 to 5 bar, higher than the ambient atmospheric pressure. This enables a stable foam to be reliably obtained. The aqueous foam can be mixed with the slurry either batchwise or continuously.

[0093] The weight ratio of water to at least one inorganic binder B in the wet mixture Mw is preferably 0.2 to 0.7, more preferably 0.25 to 0.5, and even more preferably 0.3 to 0.4.

[0094] According to an alternative embodiment, the method for producing a cured inorganic foam is: (i) providing a dry mixture Md1 comprising at least one inorganic binder B and optionally the further additives as described above; (ii) mixing at least one surfactant S, water, and optionally at least one synthetic organic polymer SP with the dry mixture Md1 to prepare a wet mixture Mw1; (iii) foaming the wet mixture Mw1 obtained in (ii); (iv) optionally shaping the foamed wet mixture Mw1 into any desired form and shape; (v) curing the foamed wet mixture Mw1 at a temperature of 5 to 50 °C and a pressure of 1 atm including.

[0095] The weight ratio of water to at least one inorganic binder B in the wet mixture Mw1 is preferably from 0.2 to 0.7, more preferably from 0.25 to 0.5, and even more preferably from 0.3 to 0.4.

[0096] Therefore, the cured inorganic foam of the present invention is obtained by providing a dry mixture Md1 containing at least one inorganic binder B and, optionally, the above further additives, and preparing a wet mixture Mw1 from the dry mixture Md1 by adding an aqueous foam, wherein the aqueous foam contains at least one surfactant S and, optionally, at least one synthetic organic polymer SP, and curing the wet mixture Mw1.

[0097] According to an embodiment, the cured inorganic foam has a density of 500 g / l or less, preferably 350 g / l or less, more preferably 250 g / l or less, and even more preferably 200 g / l or less, and is 25 to 250 g / l, preferably 35 to 150 g / l.

[0098] According to an embodiment, the cured inorganic foam has a thermal conductivity of 0.02 to 0.15 W / m·K, preferably 0.03 to 0.07 W / m·K. The thermal conductivity is measured as described in the standard DIN EN 12664:2001.

[0099] The panel according to the present invention is firmly attached to at least one surface of the cured inorganic foam and includes at least one structural reinforcement element that is a cured mortar, preferably a cured cementitious mortar.

[0100] In particular, at least one structural reinforcement element forms the outer surface of the panel of the present invention.

[0101] By "firmly attached", it means that the structural reinforcement element cannot be easily removed from the surface of the cured inorganic foam, and preferably, the structural reinforcement element cannot be removed from the surface without damaging the cured inorganic foam. In other words, preferably, the detachment strength of at least one structural reinforcement element from the said surface is higher than the tensile strength of the cured inorganic foam.

[0102] Very preferably, at least one structural reinforcement element completely covers at least one surface of the cured inorganic foam without overlapping. Panels having such an assembled configuration can be conveniently used to cover surfaces, such as the outer wall of a building, by arranging them adjacent to each other. However, it is also possible that at least one structural reinforcement element covers only a part of one surface of the cured inorganic foam. For example, the structural reinforcement element may cover more than half of one surface of the insulation layer, while the remaining half of the surface of the insulation layer may be covered by an adjacent structural reinforcement element. According to some embodiments, for example, a part of the structural reinforcement element, such as half, covers a part of the surface of the insulation layer, such as half, while another part of the same structural reinforcement element, such as the remaining half, covers a part of another adjacent insulation layer, such as half. By repeating such an assembled configuration, it is possible to cover surfaces, such as the exterior of a building.

[0103] It is particularly preferred that two or more surfaces of the cured inorganic foam, especially two surfaces, are completely covered by the structural reinforcement element. Therefore, according to an embodiment, the panel according to the present invention is characterized in that the first structural reinforcement element is firmly attached to the first surface of the insulation layer, and the second reinforcement element is firmly attached to the second surface of the insulation layer. The first and second structural reinforcement elements may have the same chemical composition and density, or may have different chemical compositions and / or densities. It is particularly preferred that the first surface and the second surface of the insulation layer are opposite surfaces of the insulation layer (surfaces facing each other).

[0104] According to a particularly preferred embodiment, the panel of the present invention includes, or is composed of, a first structural reinforcement element forming the first outer surface of the panel, an insulation layer formed of a cured inorganic foam, and a second structural reinforcement element forming the second outer surface of the panel, and the first and second structural reinforcement elements are disposed on the surfaces opposite to the insulation layer.

[0105] The structural reinforcement element is a cured mortar, preferably a cured cementitious mortar. In particular, the cured mortar of the present invention has almost the same chemical composition as, or substantially the same chemical composition as, the cured inorganic foam, but has a high density. In this regard, the terms "almost the same" and "almost equivalent" mean that 80% by weight, preferably 90% by weight, of the composition is chemically identical. Therefore, according to an embodiment, the insulation layer formed of a cured inorganic foam and each structural reinforcement element have almost equivalent chemical compositions or substantially the same chemical composition, and each structural reinforcement element has a higher density compared to the insulation layer.

[0106] Depending on the density of the cured inorganic foam, the density of the cured mortar can be 200 g / l or more, preferably 250 g / l or more, more preferably 500 g / l or more, even more preferably 1000 g / l or more, particularly 1500 g / l or more or 2000 g / l or more.

[0107] According to an embodiment, the density of the structural reinforcement element, which is a cured mortar, is at least 1.5 times higher, preferably at least 2 times higher, particularly at least 5 times higher, than the density of the cured inorganic foam.

[0108] The preferred cured mortar of the present invention is (in each case, based on the total dry weight of the composition): a) 10 to 90 w%, preferably 15 to 65 w%, more preferably 30 to 55 w% of at least one inorganic binder B; b) 0 to 80 w%, preferably 25 to 75 w%, more preferably 35 to 60 w% of an aggregate, particularly sand; c) 0.01 to 10 w% of other additives; and d) water obtained from

[0109] The amount of water used is sufficient to cure at least one inorganic binder B and impart the desired workability to the dry mixture of mortar, particularly cementitious mortar. Preferably, the amount of water is such that the resulting weight ratio of water to powder is 0.3 to 1.0, more preferably 0.5 to 0.8.

[0110] At least one inorganic binder B is as defined above.

[0111] The other additives are selected from the group consisting of plasticizers, fluidizing agents, rheology modifiers, accelerators, retarders, air entraining agents, deaerating agents, corrosion inhibitors, fibers, redispersible polymer powders, shrinkage reducing agents, pigments, strength enhancers, water resistant agents, alkali-aggregate reaction inhibitors, chromate reducing agents, defoaming agents, steel passivating agents, antifreeze agents and / or biocides.

[0112] The aggregate can be any material that is non-reactive in the hydration reaction of the binder. The aggregate can be any aggregate typically used in construction materials. Typical aggregates are, for example, rock, crushed stone, gravel, sand (especially quartz sand, river sand and / or crushed stone sand), recycled concrete, glass, expanded glass, hollow glass beads, glass ceramics, volcanic rock, pumice, perlite, vermiculite, quarry waste, raw, fired or melted soil or clay, porcelain, electrically melted or fired abrasive, fired support, silica xerogel. The aggregate may be a fine aggregate or filler such as ground limestone, ground dolomite, and / or ground aluminum oxide. The aggregate useful in the present invention can have any shape and size commonly found for such aggregates. A particularly preferred aggregate is sand. Sand is a natural granular material composed of fine rock or mineral particles. It is available in various forms and sizes. Examples of suitable sand are quartz sand, limestone sand, river sand or crushed aggregate. Suitable sand is described, for example, in ASTM C778 or standard EN 196-1.

[0113] According to an embodiment, the aggregate can also be one or more of the following (i) to (v). (i) A bio-derived material, preferably of plant origin, more preferably a bio-derived material of plant origin substantially composed of cellulose and / or lignin, in particular a bio-derived material selected from the group consisting of or consisting of flax, linen, cereal straw, rye, rice, rapeseed, corn, sorghum, flax, thatch, rice husk, sugarcane, sunflower, kenaf, coconut, olive seed, bamboo, wood or a mixture thereof. According to an embodiment, the bio-derived material of plant origin preferably has a defined shape selected from fibers, fibrils, dust, powder, shavings, pith, in particular sunflower pith, corn pith, rapeseed pith and mixtures thereof. (ii) Preferably, a synthetic non-mineral material selected from the group consisting of or consisting of a thermoplastic, a thermosetting plastic, an elastomer, a rubber, a fabric fiber, a plastic material reinforced with glass or carbon fiber. The synthetic non-mineral material may or may not be filled. (iii) Preferably, an inorganic aggregate derived from the demolition of a civil engineering structure or a building structure selected from the group consisting of or consisting of waste concrete, mortar, bricks, natural stone, asphalt, tiles, tiling, foam concrete, clinker, scrap metal. (iv) An organic aggregate derived from the recycling of industrial products, particularly composite materials that are difficult to recycle, particularly recycled insulation materials. Particularly preferred examples are polystyrene, polyurethane, phenolic resin, wood insulation materials and mixtures thereof. (v) Used foundry sand, catalyst carrier, desoda treatment carrier according to the Bayer process, clinker aggregate, filler derived from the treatment of drilling sludge, sewage sludge, slurry, paper waste, paper incineration ash, household waste incineration ash and other non-hazardous granular materials usually scheduled for landfill.

[0114] Most preferably, the aggregate is in particulate form.

[0115] In this context, it is important that the hardened mortar forming the structural reinforcement layer, particularly the hardened cementitious mortar, has a mechanical strength high enough to withstand external loads. For example, the impact resistance classification of the mortar should be Category I or II of EOTA EAD 040083-00-0404 (2019). For example, the compressive strength of the mortar should be 70 kPa or more, preferably 100 kPa or more, more preferably 300 kPa or more.

[0116] The flexural strength can be calculated in accordance with DIN EN 1015-11, and the compressive strength can be calculated in accordance with DIN EN 826:2013. The impact resistance can be calculated in accordance with the standard EN ISO 7892 and / or the standard EOTA EAD 040083-00-0404 (2019).

[0117] Therefore, according to an embodiment, the panel of the present invention has reinforcing elements (in each case, based on the total dry weight of the composition): a) at least one inorganic binder B of 10 to 90 w%, preferably 15 to 65 w%, more preferably 30 to 55 w%; b) aggregates, in particular sand, of 0 to 80 w%, preferably 25 to 75 w%, more preferably 35 to 60 w%; c) other additives of 0.01 to 10 w%; and d) water and is a hardened cementitious mortar obtained from, and is characterized by having an impact resistance classification of Category I or II of EOTA EAD 040083-00-0404 (2019). Alternatively, the mortar has a compressive strength of 70 kPa or more, preferably 100 kPa or more, more preferably 300 kPa or more.

[0118] According to a particularly preferred embodiment of the present invention, the reinforcing element is a hardened cementitious mortar having the same chemical composition as the hardened inorganic foam forming the insulation layer, wherein the hardened cementitious mortar has a higher density compared to the hardened inorganic foam. For example, the density of the hardened inorganic foam forming the insulation layer is 500 g / l or less, preferably 350 g / l or less, more preferably 250 g / l or less, even more preferably 200 g / l or less, and is 25 to 250 g / l, preferably 35 to 150 g / l, etc., and the density of the structural reinforcing element which is a hardened mortar is at least 1.5 times higher, preferably at least 2 times higher, especially at least 5 times higher compared to the density of the hardened inorganic foam.

[0119] The different densities of the hardened cementitious mortar forming the reinforcing layer and the hardened inorganic foam forming the insulation layer are a) an aqueous slurry containing at least one inorganic binder B, optionally at least one synthetic organic polymer SP, and water and b) an aqueous foam containing water and a surfactant S and / or particles N This can be achieved, for example, by mixing different weight ratios of a) to b).

[0120] A high weight ratio of a) to b) results in a higher density, while a low weight ratio results in a lower density.

[0121] These embodiments provide the advantages of a particularly simple manufacturing process and better recyclability.

[0122] The hardened cementitious mortar of the present invention is obtained by the steps of providing a dry mixture Md2 mixture comprising at least one inorganic binder B, other additives, and optionally an aggregate as described above, preparing a wet mixture Mw2 from the dry mixture Md2 by adding water, and curing the wet mixture Mw2.

[0123] According to some particularly useful embodiments, the compositions of the dry mixture Md1 and the dry mixture Md2 have the same composition.

[0124] According to an embodiment, the mortar used as the structural reinforcement element of the present invention, preferably cementitious mortar, is in the form of a flat layer or a flat sheet. Also, the insulation layer can be in the form of a flat layer of a flat sheet. In some embodiments, the mortar used as the structural reinforcement element of the present invention, preferably cementitious mortar, is in the form of a flat layer or a flat sheet, and covers one surface of the insulation layer, preferably the flat sheet of the insulation layer, and has the same dimensions as the said surface of the insulation layer. In other embodiments, the mortar used as the structural reinforcement element, preferably cementitious mortar, covers two or more surfaces of the insulation layer, preferably two surfaces. The mortar, preferably cementitious mortar, can be in the form of a number of flat layers or flat sheets, each sheet being applied to a different surface of the insulation layer, where each sheet has the same dimensions as the surface it covers. Also, in such embodiments, the insulation layer can be in the form of a flat sheet. According to certain embodiments, the panel of the present invention is characterized in that a first flat layer or flat sheet of mortar, particularly cementitious mortar, is firmly attached to one surface of the insulation layer, preferably the flat sheet of the insulation layer, and completely covers the said surface of the insulation layer. Optionally, in such embodiments, a second flat sheet of mortar, particularly cementitious mortar, is firmly attached to a second surface of the insulation layer, particularly the flat sheet of the insulation layer, and completely covers the said second surface of the insulation layer. Preferably, the first and second surfaces thus covered are the opposite surfaces of the insulation layer. More preferably, the insulation layer is in the form of a flat sheet. Very preferably, in such embodiments, the width and length of the layer or sheet of mortar, particularly cementitious mortar, and the width and length of the layer or sheet of the insulation layer are equal.

[0125] The panel of the present invention comprising an insulation layer formed of a hardened inorganic foam and at least one structural reinforcement element which is a cementitious mortar has particularly good fire resistance properties. The panel of the present invention comprising an insulation layer formed of a hardened inorganic foam and at least one structural reinforcement element which is a cementitious mortar particularly has an excellent balance of insulation properties, particularly heat insulation and / or sound insulation properties, fire resistance properties, and strength, particularly compressive strength and / or flexural strength.

[0126] The panel of the present invention can be in any form or shape as described above. According to an embodiment, the panel of the present invention is in the form of a rectangular sheet having a total thickness of 0.2 to 50 cm, preferably 0.5 to 25 cm, more preferably 5 to 25 cm. The total thickness of the panel of the present invention is related to the combination of the thickness of the insulation layer formed of the hardened inorganic foam and the thickness of any at least one structural reinforcement element. In particular, the thickness of the insulation layer formed of the hardened inorganic foam can be adjusted to provide desired insulation properties, particularly heat insulation and / or sound insulation and / or fire protection properties, and the thickness of at least one structural reinforcement element can be adjusted to provide desired strength, particularly compressive strength and / or flexural strength. It is preferably possible that the thickness of the insulation layer formed of the hardened inorganic foam and the thickness of at least one reinforcement element are different.

[0127] According to an embodiment, the panel of the present invention is (i) an insulation layer formed of a hardened inorganic foam having a density in the range of 50 to 200 g / l, said layer having a thickness of 5 to 20 cm, and b) at least one structural reinforcement element firmly attached to at least one surface of the hardened inorganic foam and having a thickness of 2 to 5 cm, said structural reinforcement element being formed of a hardened cementitious mortar having a density at least 1.5 times higher, preferably at least 2 times higher, preferably at least 5 times higher than the density of the hardened inorganic foam comprising / consisting of.

[0128] All of the above embodiments are also relevant to these embodiments.

[0129] According to a second aspect, the present invention relates to a method for forming a panel according to the present invention.

[0130] According to an embodiment, the method comprises: (i) providing an inorganic foam; (ii) providing a cementitious mortar; (iii) bringing the inorganic foam and the cementitious mortar into intimate contact while in an uncured state; and (iii) curing an assembly of the inorganic foam and the cementitious mortar including.

[0131] In step (iii), it is possible to apply a layer of mortar, preferably a cementitious mortar, to at least one surface of the inorganic foam, preferably while the inorganic foam is still wet. Further, it is also possible to apply an additional primer or adhesive material to the inorganic foam and then apply a layer of cementitious mortar.

[0132] Similarly, in step (iii), it is possible to apply the inorganic foam to at least one layer of the cementitious mortar, preferably while the cementitious mortar is still wet. Further, it is also possible to apply an additional primer or adhesive material to the cementitious mortar and then apply a layer of the inorganic foam.

[0133] According to an embodiment, the method of the present invention also a) optionally, filling a mold with a cementitious mortar in a wet state; b) placing an inorganic foam in the mold, which is the same as that used in a) if present; and c) applying a cementitious mortar on top of the inorganic foam in the same mold including.

[0134] According to another embodiment, the method of the present invention also comprises: a) optionally, extruding a layer of cementitious mortar in a wet state; b) extruding a layer of inorganic foam, or, if step a) is present, extruding a layer of inorganic foam onto the wet cementitious mortar; and c) extruding a layer of cementitious mortar onto the inorganic foam and includes.

[0135] The method of the present invention can be a co-extrusion molding method. Therefore, a layer of mortar, preferably a cementitious mortar, can be co-extruded together with the inorganic foam. Alternatively, the inorganic foam can be extruded onto the mortar surface. Another form is a layered deposition of inorganic foam and mortar, preferably a cementitious mortar layer.

[0136] However, especially when the density of the inorganic foam and the density of the cementitious mortar are significantly different in the wet state, for example, when the density of the cementitious mortar in the wet state is 2 times or 5 times higher than the density of the inorganic foam in the wet state, the application of the cementitious mortar onto the inorganic foam can result in the sedimentation of the cementitious mortar into the inorganic foam and / or the collapse of the foam layer. In such cases, therefore, it may be preferable to cure the inorganic foam to at least some extent before applying the cementitious mortar thereon. The term "cure to at least some extent" refers to an effective time sufficient for the inorganic foam to exhibit sufficient mechanical strength to withstand the weight of the cementitious mortar.

[0137] According to some embodiments, the cementitious mortar is applied to the inorganic foam only after the inorganic foam has cured to at least some extent.

[0138] Therefore, according to an embodiment, the method for producing a panel of the present invention is: (i) providing an inorganic foam; (ii) providing a cementitious mortar; (iii) A step of bringing the inorganic foam and the cementitious mortar into close contact when the inorganic foam is at least somewhat cured and the cementitious mortar is still wet; and (iii) A step of curing the assembly of the inorganic foam and the cementitious mortar comprising.

[0139] According to some other embodiments, the inorganic foam is applied to the cementitious mortar only after the cementitious mortar is at least somewhat cured.

[0140] Therefore, according to an embodiment, the method for producing the panel of the present invention is: (i) A step of providing an inorganic foam; (ii) A step of providing a cementitious mortar; (iii) A step of bringing the inorganic foam and the cementitious mortar into close contact when the cementitious mortar is at least somewhat cured and the inorganic foam is still wet; and (iii) A step of curing the assembly of the inorganic foam and the cementitious mortar comprising.

[0141] The mortar, preferably the cementitious mortar, the inorganic foam and the insulation layer are as described above. Therefore, all of the above embodiments and preferred features also apply to this aspect of the present invention.

[0142] Very preferably, the curing step is carried out at a temperature of 5 to 50 °C and a pressure of 1 atm. For example, curing at a higher temperature and / or under pressure in an autoclave is not preferred.

[0143] In particular, according to an embodiment, in the method of the present invention, the inorganic foam and the cementitious mortar have the same chemical composition, and the cementitious mortar has a higher density than the inorganic foam.

[0144] The fact that such a panel can be easily recycled is a particular advantage.

[0145] The method for forming the panel of the present invention can be implemented at a given work site. Therefore, the panel of the present invention can be formed at the work site, for example, at a construction site, or at the site where a system using such a panel is formed. Similarly, the method for forming the panel of the present invention can be implemented at a location other than the site. Therefore, the panel of the present invention may also be prefabricated and transported to the work site for installation, or to the site where the panel will subsequently be used to form a further system.

[0146] In a further aspect, the present invention relates to the use of the above panel or a panel obtained by the above method as a heat-insulating and / or sound-insulating and / or fire-proof panel, or as part of a heat-insulating system, or as part of a sound-insulating system, or as part of a fire-proof system.

[0147] According to an embodiment, the panel has a thermal conductivity of 0.02 to 0.15 W / m·K, preferably 0.03 to 0.07 W / m·K, as measured according to the description of standard DIN EN 12664:2001, a density of 500 g / l or less, preferably 350 g / l or less, more preferably 250 g / l or less, even more preferably 200 g / l or less, and a density of 25 to 250 g / l, preferably 35 to 150 g / l, etc., as measured as described above, and an impact resistance classified as Category I or II according to EOTA EAD 040083-00-0404 (2019). Alternatively, the mortar has a compressive strength of 70 kPa or more, preferably 100 kPa or more, more preferably 300 kPa or more, as calculated in accordance with DIN EN 826:2013.

[0148] According to an embodiment, the heat insulation and / or sound insulation panel of the present invention has fire resistance characteristics or can be used as a fire barrier. In this context, fire resistance characteristics exist when at least one requirement such as the following standards is met: UL 790, UL 1256, FM Approvals 4880, FM Approvals 4882, ASTM E84, ASTM E108, EN 13501-1. Very preferably, the panel of the present invention conforms to Class A1 or A2 according to the standard EN 13501:2019-05.

[0149] In a further aspect, the present invention relates to the use of the above panel or a panel obtained by the above method as a cover board and / or as a passive fire barrier.

[0150] In particular, in the sense of the present invention, the cover board can be used for roof applications. The cover board can be applied under the roof membrane to provide a fire barrier, to add additional heat insulation and / or sound insulation characteristics, and / or to support and reduce the stress of the roof membrane.

[0151] According to an embodiment, the panel has a thermal conductivity of 0.02 to 0.15 W / m·K, preferably 0.03 to 0.07 W / m·K, as measured according to the description of the standard DIN EN 12664:2001, a density of 500 g / l or less, preferably 350 g / l or less, more preferably 250 g / l or less, even more preferably 200 g / l or less, and a density of 25 to 250 g / l, preferably 35 to 150 g / l, etc., and an impact resistance classified as Category I or II according to EOTA EAD 040083-00-0404 (2019). Alternatively, the mortar has a compressive strength of 70 kPa or more, preferably 100 kPa or more, more preferably 300 kPa or more, as calculated according to DIN EN 826:2013.

[0152] According to an embodiment, the keyboard of the present invention has fire-resistant properties or can be used as a passive fire barrier. In this context, fire-resistant properties exist when at least one requirement such as the following standards is met: UL 790, UL 1256, FM Approvals 4880, FM Approvals 4882, ASTM E84, ASTM E108, EN 13501-1. Very preferably, the panel of the present invention conforms to Class A1 or A2 according to EN 13501-1:2019.

Brief Description of the Drawings

[0153]

Fig. 1a

Fig. 1b

Fig. 1c

Fig. 2

Example

[0154] To produce the foamed mineral binder composition, a device of "Foamed Concrete Laboratory Mixer-SBL" manufactured by GERTEC Maschinen-und Anlagenbau GmbH (Germany) was used. Thereby, an aqueous foam having a predetermined density was produced in a first container, and a cement slurry was separately produced in a second container. Then, to obtain the foamed mineral binder composition, i.e., the foamed cement composition, the aqueous foam and the cement slurry were sent by pressurized air into the static mixing unit of this device. Thereby, the target foam density of the foamed cement composition was adjusted by air pressure.

[0155] The cement slurry was prepared from 64 w% of type CEM I Portland cement, 25.6 w% of water, 6.4 w% of one kind of synthetic organic polymer SP (ethylene-vinyl acetate copolymer having Tg 16°C and stabilized with PVA), 3.8 w% of polyurethane polymer (used as a dispersion in water, 3.8% with respect to the polymer content), and the aqueous foam was prepared from 97 w% of water and a mixture of 3 w% of anionic and nonionic surfactants.

[0156] The generation of the foam was initiated with a Gertec SBL apparatus and the foam was generated by placing a layer having a thickness of 14 cm and a target density of 100 - 200 g / l in a mold. The surface of this layer was flattened and each foam was left standing at 23°C / 50% r.h. After 1 day, the foam was demolded and cured for a total of 28 days. The details of the foam thus generated are reported in Table 1 below.

[0157] Also, panels were generated as follows.

[0158] First layers of foam having a thickness of 2 - 4 cm and a target density of 250 - 500 g / l were placed in molds respectively. This first layer was flattened and immediately, a second layer of foam having a thickness of 10 - 12 cm and a target density of 100 g / l was applied on top of the first layer in the mold. The second layer was flattened and each panel was left standing at 23°C / 50% r.h. After 1 day, the panel was demolded and cured for a total of 28 days.

[0159] The details of the panels thus generated are reported in Table 2 below. Type I panels had a first layer with a thickness of 4 cm and a density of 250 g / l and a second layer with a thickness of 10 cm and a density of 100 g / l. Type II panels had a first layer with a thickness of 2 cm and a density of 500 g / l and a second layer with a thickness of 12 cm and a density of 100 g / l.

[0160] The obtained foams and panels were tested for impact resistance in a manner similar to the method described in EN ISO 7892 and EOTA EAD 040083 - 00 - 0404 (2019). For the test, a steel ball with a diameter of 74 mm and a weight of 644 g was dropped onto the respective surfaces of the cured inorganic foam or panel from a height of 47.5 cm as shown in Table 1 or 2 below. The diameter of the impact area is reported in Tables 1 and 2 below.

[0161]

Table 1

[0162]

Table 2

[0163] From the results of Table 1 above, it has been clearly shown that the impact resistance increases with the increase in the density of the material subjected to impact. This increase is not linear because the upper limit of the impact resistance has been reached with the increase in density (see the black line in Figure 2).

[0164] The results of Table 2 above indicate that the panel according to the present invention has a sufficiently high impact resistance and is, therefore, suitable, for example, as a heat-insulating panel for facade applications having an impact resistance category II according to EOTA EAD 040083-00-0404 (2019). The type I panel having an overall density of 143 g / L has a smaller diameter of the impact area and, therefore, has a higher impact resistance on the high-density side compared to a pure foam having the same overall density. The same applies to the type II panel having an overall density of 157 g / L.

[0165] Furthermore, panels were manufactured in the same manner and with the same materials as above, but the layer thicknesses and densities were as shown in Table 3 below. The impact resistance of the panels was measured as above and, therefore, the impact was always applied to the second layer. The thermal conductivity of the material of each individual layer was calculated in accordance with the standard DIN EN 12664:2001, and the R-value of the panel was then calculated. The individual R-values were calculated as the sum of the layer thickness divided by the thermal conductivity of that layer. For example, in panel 3-3, the layer with a density of 100 g / L was measured to have a thermal conductivity of 0.048 W / m K, and the layer with a density of 250 was measured to have a thermal conductivity of 0.071 W / m K. From this, the R-value of panel 3-3 was calculated to be (0.1 / 0.048)+(0.04 / 0.071)=2.6.

[0166]

Table 3

[0167] From the results in Table 3 above, it can be seen that in order to achieve good reinforcement, the density of the reinforcement layer is preferably at least 150 g / L. It can also be seen that in order to achieve good reinforcement, the density of the reinforcement layer is preferably at least 1.5 times higher than the density of the inorganic foam. On the other hand, since the density of the inorganic foam and / or the reinforcement layer or the overall panel density will result in a reduction in the R-value and thus a decrease in the heat insulation performance for a given geometry, it can be seen that they should not be overly large.

[0168] Reinforcement can be confirmed in Figure 2. In Figure 2, the black dots and black lines correspond to the curve of the impact resistance vs. density of the pure foam (the black dots represent the measured values in Table 1). The five black crosses correspond to the diameters of the impact areas of Panels 2-1, 2-3, 3-2, 3-3, and 3-4 plotted against the overall panel density. It can be seen that the black crosses are considerably below the black line. Therefore, Panels 2-1, 2-3, 3-2, 3-3, and 3-4 have higher impact resistance compared to pure foams of the same overall density and are thus reinforced. On the other hand, Panels 2-2, 2-4, and 3-1 indicated by black triangles in Figure 2 do not show improved reinforcement.

[0169] The reference signs in the drawings have the following meanings.

Description of Reference Signs

[0170] 1 Panel 2 Insulation layer 2a First insulation layer 2b Second insulation layer 3 Structural reinforcement element 3a First structural reinforcement element 3b Second structural reinforcement element 4 Surface 4a First surface 4b Second surface

Claims

1. A panel (1) comprising an insulation layer (2) formed of a hardened inorganic foam and at least one structural reinforcing element (3) firmly attached to at least one surface (4) of the hardened inorganic foam (2), wherein the at least one structural reinforcing element (3) is hardened mortar, preferably hardened cementitious mortar.

2. The panel (1) according to claim 1, characterized in that a first structural reinforcing element (3a) is firmly attached to the first surface (4a) of the insulation layer (2), and a second reinforcing element (3b) is firmly attached to the second surface (4b) of the insulation layer (2).

3. The panel (1) according to claim 2, characterized in that the first surface (4a) and the second surface (4b) of the insulation layer (2) are opposite surfaces.

4. The cured inorganic foam is a) At least one type of cured inorganic binder B; b) at least one surfactant S and / or particles N; and c) At least one synthetic organic polymer SP, by optional selection. A panel (1) according to claim 1 or 2, characterized by including the following:

5. The reinforcing element (3) is (based on the total dry weight of the composition): a) At least one inorganic binder B in an amount of 10-90 w%, preferably 15-65 w%, more preferably 30-55 w%; b) Aggregate, particularly sand, in an amount of 0-80 wt%, preferably 25-75 wt%, more preferably 35-60 wt%; c) 0.01 to 10 w% of other additives; and d) water The panel (1) according to claim 1 or 2, characterized in that it is a hardened cementitious mortar obtained from.

6. The panel (1) according to claim 1 or 2, characterized in that the insulation layer (2) and each structural reinforcing element (3), formed from a hardened inorganic foam, have almost equivalent or substantially the same chemical composition, and each structural reinforcing element (3) has a higher density than the insulation layer (2).

7. The panel (1) according to claim 1 or 2, characterized in that the insulation layer (2) has a density of 500 g / l or less, preferably 350 g / l or less, more preferably 250 g / l or less, and even more preferably 200 g / l or less, for example, 25 to 250 g / l, preferably 35 to 150 g / l.

8. The panel (1) according to claim 1 or 2, characterized in that the at least one structural reinforcing element (3) has a density at least 1.5 times, preferably at least 2.5 times, the density of the insulation layer (2).

9. The panel (1) according to claim 1 or 2, characterized in that the overall density of the panel (1) is 500 g / l or less, particularly 300 g / l or less, preferably in the range of 110 to 500 g / l, and more preferably in the range of 160 to 250 g / l.

10. The panel (1) according to claim 1 or 2, characterized in that the insulation layer (2) has a thermal conductivity of 0.02 to 0.15 W / m·K, preferably 0.03 to 0.07 W / m·K.

11. A method for forming a panel (1) according to claim 1 or 2, (i) the step of providing an inorganic foam; (ii) The step of providing cementitious mortar; (iii) The step of adhering the inorganic foam and the cementitious mortar to each other while they are still in an unhardened state; and (iv) A step of curing the assembly of inorganic foam and cementitious mortar. A method that includes this.

12. A method for forming the panel (1) according to claim 11, a) Optionally, a step of filling a mold with cementitious mortar in a wet state; b) the step of placing the inorganic foam in a mold, the mold being the same as the one used in a) if it exists; and c) Preferably, the step of applying cementitious mortar on top of the inorganic foam in a mold that is identical if present. A method characterized by further comprising:

13. A method for forming the panel (1) according to claim 11, a) Optionally, a step of extruding a layer of cementitious mortar in a wet state, b) the step of extruding the inorganic foam layer, or, if step a) is present, the step of extruding the inorganic foam layer onto the wet cementitious mortar; and c) Step of extruding a layer of cementitious mortar onto the inorganic foam. A method characterized by further comprising:

14. A method for forming a panel (1) according to claim 11, characterized in that the inorganic foam and the cementitious mortar have the same chemical composition, and the cementitious mortar has a higher density than the inorganic foam.

15. Use of the panel (1) according to claim 1 or 2 or a panel (1) formed by the method of claim 11, for use as a thermal insulation and / or soundproofing panel, and / or as a fireproofing panel, or as part of a thermal insulation system, or as part of a soundproofing system, or as part of a fireproofing system.

16. Use of a panel (1) according to claim 1 or 2, or a panel (1) formed by the method of claim 11, as a cover board and / or passive fire barrier.

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