Method for manufacturing a formed body with a cavity structure for sound and/or heat insulation and formed body for sound and/or heat insulation

Abstract

A formed body with a cavity structure for the sound and/or heat insulation of buildings. The formed body has a cavity structure and has pre-foamed polystyrene particles compressed in a mould or on a conveyor belt system under the influence of pressure and/or heat. The formed body has a communicating cavity volume and the communicating cavity volume has a volume fraction that amounts to 5 to 30 vol. %, preferably 10 to 25 vol. %, particularly 15 to 20 vol. %, referred to the total volume of the formed body, and comprising at least part of the pre-foamed polystyrene particles firmly enclosed in a cured organic or inorganic binder that is used for coating at least part of the polystyrene particles prior to their compression in a mould or on a conveyor belt system.

What is claimed is: 
     
         1 . A formed body for the sound and/or heat insulation of buildings, wherein the formed body has a cavity structure and consists of pre-foamed polystyrene particles that are compressed in a mould or on a conveyor belt system under the influence of pressure and/or heat, and wherein the formed body has a communicating cavity volume and the communicating cavity volume has a volume fraction that amounts to 5 to 30 vol. %, preferably 10 to 25 vol. %, particularly 15 to 20 vol. %, referred to the total volume of the formed body, comprising:
 at least part of the pre-foamed polystyrene particles firmly enclosed in a cured organic or inorganic binder that is used for coating at least part of the polystyrene particles prior to their compression in a mould or on a conveyor belt system.   
     
     
         2 . The formed body of  claim 1 , wherein the binder content amounts to 2.5 to 30 wt. %, particularly 5 to 15 wt. %, referred to the total weight of the formed body. 
     
     
         3 . The formed body of  claim 1 , wherein the binder is a dispersion binder, such as, for example, pure acrylates, styrene acrylates or the like, preferably with no or only slight solvent content, or a water-based reactive binder such as, for example, epoxy resins, polyurethane or the like. 
     
     
         4 . The formed body of  claim 1 , wherein the binder, prior to the coating, includes pigments and/or fillers. 
     
     
         5 . The formed body of  claim 1 , wherein the binder includes, prior to the coating, additives. 
     
     
         6 . The formed body of  claim 5 , wherein the additives include one or more additives selected from the group consisting of thickeners, wetting agents, stabilizers, antifoaming agents, flame retardants and rheological additives. 
     
     
         7 . The formed body of  claim 1 , comprising pre-foamed polystyrene particles that are coated with an organic or inorganic binder and uncoated pre-foamed polystyrene particles, wherein the coated and uncoated polystyrene particles are compressed into a formed body in a mould or on a conveyor belt system under the influence of pressure and/or heat in a regular or irregular arrangement. 
     
     
         8 . The formed body of  claim 1 , comprising pre-foamed polystyrene particles with an average particle size of 2 to 10 mm, preferably 3 to 8 mm, particularly 4 to 6 mm, and/or pre-foamed polystyrene particles doped with an athermal material.