Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
  • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
  • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
  • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like

Definitions

• the invention relates to an insulating element, in particular for the thermal and acoustic insulation of flat or inclined roofs, consisting of mineral fibers bound with binders, in particular glass and / or stone fibers and with a first large surface facing a surface to be insulated and a parallel surface running parallel to it and a spaced-apart second large surface, the large surfaces being connected to one another via side surfaces, which side surfaces are essentially at right angles to one another and to the large surfaces, and with at least one coating arranged on one surface.
• binders in particular glass and / or stone fibers
• Insulation materials made from mineral fibers are known from the prior art, which are offered on the market, for example, under the name "rock wool” and are distinguished by high thermal resilience. These insulating materials have a melting point> 1000 0 C according to DIN 4102 part 17 and are made from melts, whose stones include slags and other residues. The raw materials are melted in cupola or trough furnaces and the melts are shaped on different fiberizing machines. When using conventional shredding machines, mineral fibers and non-fibrous particles are created. Coarser, non-fibrous particles can largely be removed from the continuously formed mineral fiber stream. 5 to approx. 10% by mass of particles> 63 ⁇ m and approx.
• Organic binders in particular mixtures of thermosetting phenol, formaldehyde and urea resins, are usually used.
• the proportions of organic binders are generally less than 4.5% by mass, for stone wool insulation materials manufactured according to the nozzle-blowing process to less than limited to approx. 8 mass%.
• Stone wool insulation materials are also produced using the methods commonly used for the production of glass wool. Such a manufacturing process is characterized in particular by the fact that no or only very small amounts of non-fibrous particles are formed.
• the mineral fibers formed are impregnated with additives that have a water-repellent effect and, due to the changed interface properties of the mineral fibers, develop low adhesive forces that can hold fragments of the finest mineral fibers to a small extent.
• High-boiling mineral oils, oil-in-water emulsions, and more rarely silicone oils or resins are often used for this. The proportions are approx. 0.2 to approx. 0.4 mass%.
• Insulation materials made of stone wool are predominantly produced by cascade fiberizing machines. These fiberizing machines allow that Processing earthenware glasses with very narrow processing areas. However, only very short mineral fibers are formed, which are also deformed by the high air velocities required for the removal of the mineral fibers formed.
• the fiberizing machine is arranged at the entrance of a horizontally directed collecting chamber, in which the mineral fiber flow formed is continuously guided with the aid of an air flow onto an air-permeable conveying device arranged at the end of the collecting chamber. The coarser non-fibrous particles are separated on the way to this conveyor.
• the mineral fiber stream consists of the mineral fibers impregnated with binding agents and additives and the non-fibrous particles. Mineral fibers that are not impregnated with binders are also transported.
• the cohesion and the deformation behavior of the fiber mass formed from the mineral fibers is very significantly influenced by the blowing in of production waste in the form of ground insulation particles or fibers and deteriorates regularly with larger quantities.
• These insulating materials which have been processed by shredding, do not get into the actual binder flow and are therefore only caught by the shape of the newly formed fiber flakes.
• the solidified binders they contain carry additional flammable organic substances into the fiber mass and thus into insulation materials to be produced from the fiber mass.
• the air-permeable conveying device has a filter effect.
• the mineral fibers are deposited in the form of an impregnated primary fiber web on the conveyor with a thickness that is dependent on the performance of the defibration machine and the conveying speed of the conveyor.
• Low grammages of the primary fibrous web are usually sought in order to avoid premature solidification of the binders despite minimal amounts of coolant, such as water.
• the primary fiber web is then placed transversely and obliquely overlapping one another on a third slow-running conveyor device with the aid of an oscillating second conveyor device.
• the described way of forming a sufficiently thick impregnated fiber web is referred to as indirect collection.
• Impregnated mineral fibers possibly including the non-fibrous particles, the binder-free fibers and the fine recycled fine insulation flakes with the help of a chute or by deflecting them from the horizontal in a correspondingly high collecting chamber up to the desired height or the required weight per unit area on a slow-moving one Conveyor device are stored.
• This gentler type of collection means that the mineral fibers are stacked flat on top of each other without any preferred direction.
• the endless impregnated fibrous web formed in the indirect and direct collection can then be compressed to the desired thickness and then compressed in a hardening furnace, whereby after this predominant vertical compression between the hardening furnace has two pressure-transmitting conveyor belts arranged one above the other.
• the two conveyor belts of the hardening furnace consist of U-shaped elements, which are attached to all-round tension members and thus form an endless belt. There are oblong and round holes in the pressure-transmitting surfaces of the lamellar elements, through which hot air is sucked in the vertical direction through the endless fiber web.
• the mineral fibers in particular are pressed into these, for example, 5 to 7 mm wide elongated holes and into the joints between the individual elements, which leads to characteristic profiling of the two large surfaces due to the solidification of the binders in an endless insulation web converted fiber web leads.
• the insulation web can be divided into slab-shaped bodies by rip and cross saws, and if necessary also by horizontal saws into thinner panels.
• the non-combustible insulating materials made of mineral fibers, in particular rock wool, are used on a large scale to insulate particularly light flat roof constructions.
• roof structures with an inclination of the roof area of ⁇ 10 ° are called flat.
• These lightweight flat roof constructions often have wide-span and thin profile sheets as a load-bearing roof shell. Extremely profiled sheets have clear widths between the edges of the top chords of up to approx. 172 mm. Occasionally, the profiled sheets are also installed in a negative position, so that the wider upper chords are now directed downwards, which increases the clear width between the lower chords now on top.
• the lightweight flat roof constructions bend under their own load and later under the weight of water and snow.
• the insulation panels are usually laid out in the form of large-format panels with dimensions of, for example, 2 m length x 1, 2 m width on the load-bearing roof shell or the vapor-retardant airtight layer in the dressing.
• These large-format panels thus form multi-span girders that have a much higher load capacity than narrower panels or even the small format panels that used to be common, with dimensions of, for example, 1 m length x 625 mm width. In all cases, however, cantilevered plate ends should be avoided. Since the spacing of the top chords does not match the usual dimensions of the insulation panels, the insulation panels must be cut so that the panel joints are always in the middle of an top chord. In order to avoid complex cutting work, pressure-resistant, form-fitting bead fillers can be inserted above the lower chords in the profiles on which the board joints of adjacent insulation boards rest.
• Roof waterproofing membranes are then glued or laid onto the insulation layer formed from the insulation panels.
• the roof sealing sheets or foils, as well as the insulation panels, are connected to the profile sheets with screws.
• Pressure-distributing plates or rails are screwed together with the screws to ensure that the force is applied to both materials.
• Stone wool insulation materials have the advantage that they do not react chemically with the different sealing materials.
• the insulation boards made from these insulation materials do not have any thermal changes in dimensions, their edges are also relatively soft, both of which are prevented mechanical influences on the sealing materials.
• the insulation materials are also open to diffusion, which enables an unhindered passage of water vapor and, if sufficient energy is available, a drying of possibly damp roof structures.
• the flat roof constructions described above are considered unusable roof constructions, which should only be used occasionally for maintenance work after the construction phase.
• Subareas to be regulated regularly, such as walkways, are protected by pressure-distributing layers on the sealing sheets or foils as well as constructions mounted on them.
• the stone wool insulation boards are primarily designed for high compressive strength, with the general aim being to maintain a thermal conductivity of ⁇ 0.040 W / m K.
• Insulation boards under seals should have a minimum compressive stress CS (10Y) 60, ie at 10% compression> 60 kPa, for the medium pressure loads that occur on unused roofs according to DIN EN 13162.
• the insulation boards In order to achieve such compressive stress values, the insulation boards must either have a high bulk density and / or high binder contents.
• the insulation boards for use in the flat roof area are unfolded so that the mineral fibers are aligned in a steep bearing to the large surfaces.
• the forces for unfolding the impregnated fiber web are introduced over the large surfaces of the primary fiber web. Since forces of a similar size and direction act on the fiber web via the conveyor belts in the hardening furnace, mineral fibers in and below the two large surfaces of the fiber web and the fabricated from them are oriented relatively flat or at least flatter to the large surfaces than in an area between the two large ones Surfaces of the insulation board. The same applies to the insulation panels made from the insulation sheet.
• the insulating material web is divided horizontally into one or more layers, at least one of the large surface of a partial web obtained in this way lies in an area of the insulating material web that has low strength.
• insulation boards are offered that have a high layer on one surface.
• This layer usually has bulk densities of approx. 150 to approx. 170 kg / m 2 , so that the insulating boards formed in this way have raw densities of approx. 180 to approx. 220 kg / m 3 .
• a further improvement in the load-bearing capacity of an insulation layer is achieved in that two with highly compressed layers are arranged one above the other in such a way that a highly compressed layer rests on top and another one rests on the load-bearing roof shell or the vapor-retarding and air-blocking layer. Since the sandwich-like insulation panels are not non-positively connected to each other, the load-bearing capacity of such a multi-layer insulation layer designed in this way does not increase, or only insignificantly.
• the strength of the insulation layer decreases over time due to relaxation effects, i.e. H. by reducing the stresses induced by compression and folding. These effects are accelerated and increased by repeated mechanical loads.
• the hydromechanical mechanisms of action triggered thereby can lead to extensive loss of strength as a result of the breakdown of the structure.
• the top layer For the effectiveness of the top layer, an intensive connection with the mineral fibers of the insulation layer is advantageous.
• bonding with organic synthetic resins has proven to be a solution, but this leads to a reduction in the building material class of the insulation boards.
• plastic-modified inorganic adhesives are known, but they are often brittle and are difficult to incorporate at a sufficient depth in the insulating layer made of mineral fibers, which acts like a fine filter, so that only thin layers are formed. Thin layers below 20 mm, for example, are too fragile to be effective here. On the other hand, the thicknesses of these layers cannot be increased arbitrarily due to thermal bridge effects. Proceeding from this prior art, the invention is based on the task of improving a generic insulation element with regard to its static properties, in particular its flexural rigidity and also with regard to its processability.
• the coating consists of at least one reaction product made from weakly burned magnesia (MgO) with at least one concentrated magnesia chloride solution.
• the essence of the invention is therefore to form insulation elements known per se, in particular roof insulation panels, on at least one surface with a rigid layer which is non-positively connected to the surface.
• the coating preferably consists of a Sorel cement, where appropriate inorganic additives, finely ground glass fibers and / or waste mineral wool insulation materials are added. Additionally or alternatively, plastic short fibers, wood and / or cellulose fibers can also be used for the reinforcement.
• Sorel cement is an acid-base cement.
• An aqueous magnesium chloride solution acts as the acid, and caustic magnesite (magnesium oxide) acts as the base.
• caustic magnesite magnesium oxide
• the mixture hardens within minutes or even after hours.
• the coating can be adjusted in such a way that it cures variably within the manufacturing process of such insulating elements, so that quick or late curing is selected depending on the manufacturing process. For example, this can make sense in subsequent processing steps in which the coating either has to be cured or does not yet have to be cured.
• the stoichiometric formula of the reaction is:
• the coating has reinforcement.
• the reinforcement preferably consists of at least one, in particular perforated, flat element, in particular of at least one fiberglass nonwoven, fiberglass or cellulose fabric and / or fiberglass staple fibers.
• the number of reinforcement layers is at least one and a maximum of seven layers.
• the thickness of the reinforcement or coating is varied between 2 and 10 mm. In particular, layer thicknesses of approximately 3 and approximately 7 mm are built up.
• the coating can have recesses distributed over the surface in order to improve the water vapor diffusion through the insulation element.
• a contact layer made of a thin roof insulation board made of mineral fibers, in particular stone fibers, is arranged on the coating.
• This contact layer preferably has a layer thickness between 5 and 40 mm, in particular between 15 and 25 mm, it having proven advantageous to glue the contact layer to the coating.
• a further development of this embodiment provides that the adhesive bond between the contact layer and the coating is brought about by the adhesive effect of the uncured coating.
• the contact layer establishes contact between the coating and roof sealing materials, for example bitumen membranes, installed on the insulation elements in the area.
• the contact layer also serves as a water vapor pressure compensation layer.
• an insulation element according to the invention is thus constructed at least in three layers in the form of a sandwich element, the coating being connected both to the mineral fiber body of the insulation element and to the contact layer.
• the adhesive effect of the applied coating is used before it solidifies. If the contact layer is only applied after the coating has set, an unreinforced thin Sorelzement layer can be used for this purpose forms a connection between the contact layer and the coating on the mineral fiber core of the insulating element.
• the above-described contact layer made of a relatively thin mineral fiber plate has a relatively low strength and serves as a powder layer.
• the thickness of this contact layer is selected such that, on the one hand, mechanical fastening elements, in particular fastening plates resting on the insulating element, cannot penetrate so deeply into the insulating element that troughs form, in which surface water may collect.
• this contact layer also provides heat insulation and at least protects the Sorel cement coating underneath the contact layer from the effects of low temperatures, which can lead to frost.
• the coating is treated and in particular covered with impregnation and / or water repellent agents and / or diffusion open paints, in particular silicate and / or emulsion paint system.
• impregnation and / or water repellent agents and / or diffusion open paints in particular silicate and / or emulsion paint system.
• diffusion-permeable impregnation and / or hydrophobizing agents and / or diffusion-open paints reduce the effect of the condensation water that often precipitates on the back of the roof sealing elements.
• the insulating element is designed as an insulating plate with rectangular or triangular surfaces or through an embodiment as a molded body, in particular with semi-cylindrical, spherical or any curved surfaces.
• Fig. 1 shows a first embodiment of an insulation element in the form of an insulation board and 2 shows a second embodiment of an insulation element in the form of an insulation plate.
• the insulating element consists of a mineral fiber body 2, which has two large surfaces 3, which are aligned spaced parallel to each other.
• the mineral fiber body 2 has four side surfaces 4 at right angles to the large surfaces 3, two side surfaces 4 of which are shown in FIG. 1.
• the side surfaces 4 run at right angles to the large surfaces and to each other.
• the insulation element 1 On the upper surface 3 shown in FIG. 1, the insulation element 1 has a coating 5 made of Sorel cement.
• the coating has a reinforcement 6, such as a flat element in the form of a glass fiber random fleece, which is perforated.
• the coating 5 has two circular recesses 7 which penetrate the entire coating 5 in the direction of the surface normal of the large surface 3.
• the coating 5 has a layer thickness of 5 mm.
• the insulation element is designed as an insulation board.
• FIG. 2 A second embodiment of an insulation element 1 is shown in FIG. 2.
• the embodiment according to FIG. 2 compared to the embodiment of the insulating element according to FIG. 1 supplemented by a contact layer 8 which is connected to the coating 5, namely is glued.
• the contact layer 8 consists of a thin roof insulation panel made of mineral fibers and has a layer thickness of 20 mm.
• the bond between the contact layer 8 and the coating 5 is carried out with a layer of Sorel cement, not shown, which is applied to the previously hardened coating 5 without reinforcements.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Building Environments (AREA)
• Roof Covering Using Slabs Or Stiff Sheets (AREA)

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Related Child Applications (1)

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• 2006
  • 2006-09-05 DE DE102006041560A patent/DE102006041560A1/de not_active Withdrawn
  • 2006-10-07 UA UAA200805285A patent/UA93521C2/ru unknown
  • 2006-10-07 EA EA200800910A patent/EA013044B1/ru not_active IP Right Cessation
  • 2006-10-07 CN CN2006800372991A patent/CN101287881B/zh not_active Expired - Fee Related
  • 2006-10-07 EP EP06792397A patent/EP1931838A1/de not_active Withdrawn
  • 2006-10-07 EP EP18187249.0A patent/EP3418464A1/de not_active Withdrawn
  • 2006-10-07 MY MYPI20081010A patent/MY157895A/en unknown
  • 2006-10-07 WO PCT/EP2006/009708 patent/WO2007042232A1/de active Application Filing

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