DE19701858A1 - Open porous expanded glass granular material - Google Patents

Abstract

A shape-stable, fire resistant, pressure resistant and open porous expanded glass granular material additionally contains amorphous silica and (poly)phosphates of multivalent metals and is consolidated with alkali metal silicate (waterglass). When used for moulded parts, the above material contains (a) 70-95 (preferably 80-90) wt.% especially round expanded glass granules of 0.25-16.0 mm size; (b) 1-10 (preferably 4-8) wt.% amorphous silica of less than 5 mu particle size; (c) 0-6 wt.% powdery phosphates and/or polyphosphates of Ca(II), Mg(II), Al(III), Zn(II), Fe(II) and Fe(III), preferably aluminium polyphosphate; and (d) quartz sand, ground blast furnace slag and/or mineral pigment replacing up to \}50% of the expanded glass granules. Also claimed are (i) production of expanded glass granule mouldings by intimately mixing the above components (a) to (d), uniformly distributing silicate solution within the mixture and setting in a mould; (ii) production of expanded glass granular material and mouldings in combination with glass and/or textile fibres, nonwoven materials, woven fabrics and matting; and (iii) production of expanded glass granular material and mouldings in combination with rock wool and/or rock wool matting.

Description

The invention relates to a new construction, design and Sa nation system based on expanded glass granules, whose egg property values with regard to thermal, mechanical and chemical stability and thermal insulation in total previous systems of this type are superior. It takes place preferred application in the construction industry, but can also as a carrier material in catalyst technology, biotechno logic and use in horticulture. The manufacture is neither complicated nor time consuming, so this either can be done directly on-site or on-site.

The use of expanded glass granulate in the construction industry as a light aggregate for mortar and concrete is already known:
Light aggregate "PORAVER expanded glass granules"; Approval notice Z-3, 2.2-3 dated December 20, 1991; Institute for Building Technology, Berlin.

Light masonry mortar using Dennert expanded glass granulate as a light supplement (L6); Admission letter Z17.1-296 dated November 29, 1982.

Dennert lightweight wall mortar L9; Admission letter Z17, 1-396 from May 16, 1986; Institute for Building Technology Berlin.

According to a company brochure from Dennert Poraver GmbH a well-known manufacturer of paints, plasters and heating bundle systems also using a PORAVER synthetic resin mixture the development of light and weatherproof facade professionals len and plates succeeded in the restoration facades can be used and reconstructed.

The previously known usage descriptions be  act on expanded glass granules of various grain sizes at Production of components always as an aggregate. This means tet that both the processing and the product cha characteristics of the respective building material largely stay. With increasing porosity and associated with it which surface enlargement are also the among the various atmospheric and spatial Be aging and disintegration processes progress faster.

The object of the invention was therefore to provide refractory, breathable ve and open-pore construction, design and renovation elements with high pressure stability and good thermal insulation based of expanded glass granules in weatherproof and solvent to provide resistant quality.

This task is solved with expanded glass granulate fillings, characterized in that this additionally amorphous Kie silica and phosphates and / or polyphosphates more polyvalent Contain metals and by means of alkali silicate (water glass) are solidified. The flameproof, three-dimensional formed len structures show no pore closure like the traditional materials based on mortar, cement or synthetic resin and are therefore particularly breathable.

The expanded glass granules can be in the grain sizes from 0.25 to 16 mm are used, with "round grain granules" particularly suitable is. The share of the total fill is moving between 70 and 95% by weight, preferably between 80 and 90 % By weight, depending on the grain size and the required pressure stability.

It is possible to through up to 50% of the expanded glass granules Quartz sand, ground blast furnace slag and / or mineral To replace dyes, but with an increase in  specific weight is connected.

The amorphous silica with a preferred particle size of <5 µm (max. 1% above 5 µm) is in the bed Contain 1 to 10 wt .-%, preferably 2 to 5 wt .-%.

Powdery phosphate and / or polyphosphate of a multi-person metal takes up a share of 0 to 6% by weight. The following can be used: phosphates and poly phosphates of calcium (II), magnesium (II), aluminum (III), Zinc (II) and iron (II / III). Aluminum (III) is preferred. Phosphate / polyphosphate.

The alkali silicate used as an aqueous alkaline solution is the granulate / powder mixture subsequently in an amount from 2 to 6% by weight (based on silica content) and evenly distributed. During drying and curing device connects this component with the other components components to a solid mass throughout. Can be used are sodium and potassium silicate solutions. Ka is preferred lium silicate.

The products of the invention can be in any desired Mold are made and are subsequently handcrafted easy to continue with various design elements work. They have a very low weight (150 to 400 Kg / mˆ3) and a high indifference to air humidity and solvent vapors. Also against acid to neutra len aqueous solutions and organic solvents keep yourself resistant. Because of their low temperature Multiple freezing effects are also not visible survived any damage.  

Of particular note are the usage properties:
the thermal insulation value of <0.1 W / mK, the pressure stability from 5.4 to 6.0 N / mmˆ2 and the classification as a non-combustible building material of fire class A1 according to DIN 4102.

Drop tests with a 50 kg weight (linen bag with glass balls) from a height of 60 cm onto a plate according to the invention 100 mm thickness did not produce any visible breaks.

Additional benefits arise when two or more bulk combinations of different grain sizes and quality are produced together. So weight can be saved and improve the surface structure if excluded Lich for the later visible part of fine granules with high Bulk density is used. It is also possible to and improve tensile stability by using the fill Glass fibers or textile fleeces, fabrics or mats (also Stone wool) can be connected in a sheet-like manner. With the latter sound insulation could be achieved at the same time.

For the operational stationary production would also be the one working of glass / stone melting fibers in the granulate rubble not an obstacle.

The products made according to the invention are for everyone Construction work, which is based on low weight, thermal insulation mung, mechanical stability, weather resistance, breathability activity and fire protection arrives, ideally suited.

These are:
Roof construction, roof covering, facade design and renovation, truss renewal, screed laying, floor leveling and covering (e.g. in old buildings) as well as garden house and makeshift dormitory construction.

Other possible uses are in the areas:
Insulation of heat containers, erection of cooling or heating chambers and heat insulation of wet room cells, swimming pools and saunas.

Through their open pore structure and their indifference to over acid to neutral aqueous solutions as well as opposite The products according to the invention can be solvents also as a carrier material for catalytic and enzymatic use processes.

example 1

There was a mixture (bed) of the following components produced:

17,000 g expanded glass round granulate (2-4 mm grain) (Poraver from DENNERT PORAVER GmbH)
1400 g amorphous silica (Elkem Microsilica, Grade 940)
800 g aluminum polyphosphate.

After thorough mixing,

3400 g of potassium water glass solution (25% silica) evenly distributed and the mass in a prepared form poured, in which it hardened overnight.

After that it was walkable and showed a pressure stability of 6.0 N / mmˆ2. The manufactured component subsided can be cut to any desired shape using a saw work. It was dimensionally stable against water and organic Solvent (alcohol, gasoline) and also showed opposite Fire no changes.  

Example 2

There were the components

2000 g expanded glass round granulate (2-4 mm grain) (Poraver as above)
200 g amorphous silica (Elkem Kicrosilica, Grade 940)
100 g aluminum polyphosphate

put together and after thorough mixing with 400 g of potassium water glass solution (25% silica) poured into a mold in which a glass fiber fleece is laid out was. Above it was a 2nd mix of the following components ten laid

15,000 g expanded glass round granulate (8-16 mm grain)
1200 g amorphous silica (Elkem Microsilica, Grade 940)
700 g aluminum polyphosphate,

together with 3000 g of potassium water glass solution (25% silica).

After standing overnight, the hardened mass was removed from the Form removed and over two wooden beams at a distance of 1.20 m. She could be weighted by a man of 90 kg without breaking. This construction too element was easy to machine with a saw and bring it into any desired shape.  

Example 3

A mixture was prepared as in Example 1 and with Aluminum polyphosphate solution treated with the difference that instead of 8500 g expanded glass round granulate the same Amount of ground high and sieved to 2 to 4 mm grain furnace slag kicked.

The cured mass had a pressure stability of 5.6 N / mmˆ2 and also showed solvent and fire he made no changes.

Claims (10)

1. Dimensionally stable, fire-resistant, pressure-resistant and open-pore expanded glass granules, characterized in that they additionally contain amorphous silica and phosphates and / or polyphosphates of polyvalent metals and are strengthened by means of alkali silicate (water glass). 2. expanded glass granulate fillings for molded parts according to claim 1, characterized in that these

• a) Expanded glass granules, preferably expanded glass round-grain granules, with a grain size of 0.25 to 16.0 mm, with a proportion of 70 to 95% by weight, preferably 80 to 90% by weight.
• b) amorphous silica with a particle size of <5 microns and a proportion of 1 to 10 wt .-%, preferably from 4 to 8 wt .-%.
• c) powdered phosphate and / or polyphosphate of calcium (II), magnesium (II), aluminum (III)) zinc (II) and iron (II- / III), preferably aluminum polyphosphate with a proportion of 0 to 6% by weight contain.
• d) instead of expanded glass granules to contain a maximum of 50% quartz sand, ground blast furnace slag and / or mineral dyes.

3. Dimensionally stable expanded glass granulate fillings according to the An sayings 1 and 2, characterized in that these with 1 to 10 wt .-%, preferably with 2 to 6 wt .-% sodium silicate Kat and / or potassium silicate solution (based on silica content) are solidified.   4. Production of expanded glass granulate molded parts, thereby characterized in that the components according to claims 2a to 2d are mixed intimately, then silicate solution in the mixture evenly distributed and the total mixture is then brought into a mold for curing. 5. Production of expanded glass granules and form share in combination with glass / textile fibers and / or Glass / textile fleeces, fabrics and mats. 6. Production of expanded glass granules and form share in combination with rock wool and / or rock wool mats. 7. Use of the dimensionally stable fill according to the An Proverbs 1 to 6 as construction, design and renovation elements for loft conversions, roofing, facade design and renovation, truss renewal, screed laying, flooring compensation and coverage as well as garden shed and makeshift living home building. 8. Use of the dimensionally stable fill according to the claims Chen 1 to 6 for building insulation, insulation of heat / cold over support pipes, insulation of heat containers, errich cooling and heating chambers and for the thermal insulation of Wet room cells, swimming pools and saunas. 9. Use of the dimensionally stable fill according to the claims Chen 1 to 6 as filter material, for the production of dia phrases, for catalytic and enzymatic processes. 10. Use of the dimensionally stable fillings for horticulture in wetlands and lakes.