# US 8,784,709 B2 · 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 > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,784,709 B2 - Document ID: US8784709B2 - Status: Granted - Kind: B2 - Application number: 13/478,926 - Filed: 2012-05-23 - Published: 2012-11-29 - Granted: 2014-07-22 - Earliest claimed: 2011-05-27 - Assignees: Sto SE & Co. Kgaa - Applicants: Martin Hitzler; Andreas Weier; Eva Kohler; Silke Leingruber - Inventors: Martin Hitzler; Andreas Weier; Eva Kohler; Silke Leingruber - Web page: https://patentgrep.com/patent/US8784709B2 ## CPC - E04B 1/88: Insulating elements for both heat and sound - B29C 44/3461: {Making or treating expandable particles} - C08J 9/232: by sintering expandable particles - C08J 9/236: using binding agents - B29K 2025/00: Use of polymers of vinyl-aromatic compounds {or derivatives thereof} as moulding material - B29K 2995/0015: Insulating - C08J 2201/038: Use of an inorganic compound to impregnate, bind or coat a foam, e.g. waterglass - C08J 2325/06: Polystyrene - C08J 2463/00: Characterised by the use of epoxy resins; Derivatives of epoxy resins - C08J 2475/00: Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers - Y10T 428/1372: Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes - Y10T 428/249921: Web or sheet containing structurally defined element or component - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The invention pertains to a method for manufacturing a formed body with a cavity structure for the sound and/or heat insulation of buildings. According to the invention, pre-foamed polystyrene particles are compressed into a formed body in a mold or on a conveyor belt system under the influence of heat and/or pressure, wherein the degree of compression amounts to 0.2-0.8, preferably 0.3 to 0.7, particularly 0.4 to 0.6, such that a communicating cavity volume is preserved in the formed body. The invention furthermore pertains to a formed body for the sound and/or heat insulation of buildings. ## Claims ### Claim 1 A method for manufacturing a formed body with a cavity structure for the sound and/or heat insulation of buildings, wherein pre-foamed 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, comprising: coating at least part of the pre-foamed polystyrene particles with an organic or inorganic binder prior to the compression in a mould or on a conveyor belt system, wherein the compression takes place prior to the complete curing of the binder, and wherein the degree of compression amounts to 0.2-0.8, such that a communicating cavity volume is preserved in the formed body. ### Claim 2 (depends on 1) The method of claim 1, wherein dispersion binders or water-based reactive binders are used as binders. ### Claim 3 (depends on 1) The method of claim 1, wherein pigments and/or fillers are added to a binder prior to the coating of the pre-foamed polystyrene particles with the binder. ### Claim 4 (depends on 1) The method of claim 1, wherein additives are added to the binder prior to the coating of the pre-foamed polystyrene particles with the binder. ### Claim 5 (depends on 4) The method of claim 4, wherein the additives comprise one or more additives selected from the group consisting of thickeners, wetting agents, stabilizers, antifoaming agents, flame retardants and rheological additives. ### Claim 6 (depends on 1) The method of claim 1, wherein pre-foamed polystyrene particles that are coated with an organic or inorganic binder and uncoated pre-foamed polystyrene particles are used, 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. ### Claim 7 (depends on 1) The method of claim 1, wherein pre-foamed polystyrene particles are with an average particle size of 2 to 10 mm are used and/or that pre-foamed polystyrene particles doped with an athermal material are used. ### Claim 8 (depends on 2) The method of claim 2, wherein the dispersion binders comprise at least one of pure acrylates and styrene acrylates. ### Claim 9 (depends on 2) The method of claim 2, wherein the water-based reactive binders comprise at least one of epoxy resins and polyurethane.