WO2008003150A2

WO2008003150A2 - Composition of an insulating material and a method for manifacturing articles made of it

Info

Publication number: WO2008003150A2
Application number: PCT/BG2007/000014
Authority: WO
Inventors: Veselin Stefanov Vasilev; Anna Borislavovna Marinova
Original assignee: Vai Ltd
Priority date: 2006-07-07
Filing date: 2007-07-04
Publication date: 2008-01-10
Also published as: WO2008003150A3

Abstract

The material will find application in the buildings for heat insulation. It is environmentally clean; do not emit harmful substances when it is exposed to direct fire. It is recyclable and has high insulating efficiency. The composition includes the following components (in volume %) : - granulous heat-insulating material (perlite and/or expanded-clay aggregate) : (3 - 73), fibrous material (mineral wool and/or fibers) : (5 - 15), heat-resistant clay : (5 - 20); kaolin : (5 - 15), adhesive : (5 - 10); alumina : (2 - 70). It also comprises light cement (5-50) %. The method includes mixing of the components until a homogenous mass has been obtained. Simultaneously water is added, in the quantity of (5-17) (in volume %). The resulting mass is poured into molds, whereupon it is pressed and dried in a microwave oven. The finished products are taken out.

Description

COMPOSITION OF AN INSULATING MATERIAL AND A METHOD FOR MANUFACTURING ARTICLES MADE OF IT

FIELD OF THE INVENTION

The invention relates to an insulating material, which will find application mainly in the building industry, and wherever it is necessary to provide heat or noise insulation, for the construction of internal partition walls as well.

BACKGROUND OF THE INVENTION

An insulating material, consisting of expanded polystyrene, is known from the practice. It is usually made in the form of plates. Its characteristics are determined and vary subject to its density, resulting from the expansion. It usually has:

- Heat conductivity coefficient - 0.30 W;

- Density - 25 kg/m³;

- Combustibility - self-extinguishing, i.e. hardly combustible and emitting harmful toxic substances.

An insulating material, comprising vibrated expanded polystyrene, cement and sand, is also known from the practice. The conductivity coefficient of that material is 0.92 W, i.e. the insulating efficiency is 8%, which means that one almost cannot count on that material as insulating material. As a matter of fact nearly all known building structural materials own similar insulating qualities, such as bricks, concrete blocks and other partition materials as well as the ones made of wood. In this case it is relied only on the thickness of the partition or boarding that is made from the product which thickness determinates the insulating qualities of each layer. The maximum temperature difference attainable between the two layers is 8%. The material has a thickness of 400 g/cm³, high water-absorbing capacity, combustibility class Rai 120, i.e. of the class of non-combustible ones, but due to its low insulation indicators, it cannot be used when it is necessary to achieve high insulating capacity of the project under way. The material is manufactured by mixing its components until a homogenous mass has been obtained after adding water. It is poured into forms and is left to harden, whereupon a reaction of cement setting runs. It is usually produced in the form of facing bricks or panels.

The known insulating materials have the disadvantage of being with a relatively high density, something that renders installation difficult and further increases the load on the bearing structures. Despite the fact that most of them are barely combustible, should a fire arise, harmful substances emanate, which impede or make impossible the rescue operations. They have unsatisfactory insulating capacity, emit toxic products at contact with flame, cannot be recycled, cannot stand moisture. Their life is relatively short.

SUMMARY OF THE INVENTION

It is an object of the present invention to create an insulating material which will be non-combustible, with low density and with a low heat conductivity coefficient, 100% recyclable, environmentally clean, with a long life and easy to install, making possible the use of predominantly waste products, in order to obtain a low cost price at its manufacture.

The task has been solved by a composition of an insulating material, which includes, according to the invention, the following components (in volume %):

- granulous heat insulating material 3 - 73

- fibrous material 5 - 15 - heat-resistant clay 5 - 20

- kaolin 5 - 15

- adhesive 5 - 10

- alumina 2 - 70.

It is appropriate for the composition to include further light cement 5 - 50 (in volume %), which allows to vary the characteristics of the end product, related to its bearing capacity.

Perlite and/or expanded-clay aggregate are suitable to be used as granulous heat-insulating material.

The fibrous material has been selected from the type of mineral wool and/or fibers.

The method of production of articles made from the composition, according to the invention, includes mixing of the components and the mixture is being stirred until a uniform, homogenous mass has been obtained. While the components are being mixed, water is added at a rate of 5-17 (in volume %), and the resulting homogenous mass is poured into molds. The mixture in the molds is pressed until the superfluous mechanical moisture has been eliminated, whereupon it is dried in a microwave oven and the finished articles are taken out.

Pressing, according to the method, can be canned out by a 50 t to 15O t hydraulic press.

According to the method, the articles undergo additional treatment, such as painting and/or impregnation, when it is necessary, and subject to the insulating materials application.

The invention advantages consist in the following: the insulating material is environmentally clean, because the used materials do not emit harmful substances when they are exposed to direct fire. The material has slow aging, which is due to its main ingredients. It protects against the UV rays the rooms that are lined with it. It is non-combustible and has a high heat-insulating and noise-insulating capacity. It is 100% recyclable because of the kind of materials used in the composition. Its heat-insulating efficiency is 30%, i.e. it is able to insulate up to 70% of the temperature the material was exposed to, with its layer thickness of 45 mm. And then the use of the material in the building industry will lead to electric power saving. The material can withstand heating of up to 1000⁰C, and at temperatures higher than that it melts, but it does not burn and does not emit harmful substances in contact with the fire.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding, the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Fig. 1 is a perspective view of insulating plates at their installation, as per an embodiment of a product made from the insulating material composition;

Fig. 2 is a view of a structural member of the kind of a construction block, made from the insulating material, in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The insulating material includes generally 90-95 in volume % inorganic substances, and 5-10 in volume % organic substances,.

Example 1: In accordance with the present invention, the composition of an insulating material comprises in volume units:

- granulous heat insulating material (perlite) 73

- fibrous material (mineral wool) 10

- heat-resistant clay 5

- kaolin 5

- adhesive 5

- alumina 2

In the beginning the composition components are mixed and the mixture is stirred until a uniform homogenous mass has been obtained. Preferably the adhesive used is of the type of aqueous dispersion adhesives. While mixing the components, water is added at a quantity 5-17 (in volume %), which serves for a better homogenization, and it does not take part in the final product composition, as no chemical reaction runs. The resulting homogenous mass is then poured into a mold, corresponding to the shape in which the insulating material is going to be carried out in practice. It can be employed as plates, bricks, and any other type of products suitable for implementation of buildings insulation, as is illustrated in figures 1 to 2. After being poured into the mold, the material is pressed, for instance by a 150-ton hydraulic press during 3-7 min. until the superfluous mechanical moisture has been eliminated, and is dried in a microwave oven, for instance during 1 hour. The finished product is taken out and can be applied immediately for insulation needs. The stay in the microwave oven may last also for 1.5 hours, in the event that the residual moisture of the pressed mixture is high.

Example 2: According to a preferred embodiment of the invention, the following composition is used (in volume %): Perlite 60

Expanded-clay aggregate 3

Mineral wool 5

Clay 15

Kaolin 5

Adhesive 5

Alumina 2

Light cement 5

This composition is treated in a way analogous to that described in example 1. In this example the resulting heat insulating material has the following properties: heat conduction coefficient 0.029W, density 300-320 kg/m³, compressive strength 4.75 kg/sm², water-absorbing capacity 5%, it is non-combustible and has an elasticity coefficient of 0.7 N/mm . Example 3: According to another embodiment of the invention, was used the following composition (in volume %): Perlite 5

Expanded-clay aggregate 60

Mineral wool 5

Clay 13

Kaolin 5

Adhesive 5

Alumina 2

Light cement 5

The mixture preparation and its treatment take place in compliance with the method described in Example 1. In this example the insulating material has a slightly lower insulating capacity, but provides a better decorative effect, because of the higher content of expanded-clay aggregate, produced usually in two colors, black and white.

Example 4: In still another embodiment was used the following composition (in volume %): Perlite 54

Expanded-clay aggregate 3

Mineral wool 5

Clay 15

Kaolin 5

Adhesive 6

Alumina 2

Light cement 10

This composition is treated in a way analogous to that described in example 1. With this embodiment the material bearing capacity is considerably enhanced, so it could be used for the production of structural members, too. In such a case, and also if appropriate, when making heat-insulating products with the compositions according to examples 1 through 3, additional processing may be applied, e.g. painting or laying special primer for waterproofing or water- tightness. Such operations are carried out at the end of the treatment cycle, prior to the preparation for packing.

The method of producing the insulating material, as defined in the described examples, consists in the following:

In the beginning the components are mixed and the mixture is stirred until a uniform, homogenous mass has been obtained. Water is added while stirring the components, in quantities of 5-17 (in volume %). The resulting homogenous mass is thereafter poured into molds (special forms), subject to the shape the product will adopt for the practical use. It is possible for the material to be employed as plates, bricks or any other type of articles appropriate for the implementation of the buildings insulation, as it is illustrated in Fig. 1 and Fig. 2. The shapes of the articles themselves do not differ from those used traditionally in the building industry. The indicated embodiments do not in any way limit the forms in which articles can be produced from the material, which is made in accordance with the present invention, neither do they limit the qualities of the final heat-insulating product, obtained in such forms. After being poured into the relevant forms, the material is pressed, for instance for 3-7 minutes until the superfluous mechanical moisture has been eliminated, and is dried in a microwave oven, for instance for 1 to 1.5 hours. The usage of microwave increases the adhesion between the components of the composition. Pressing is preferably conducted by means of a 50 1 to 150 t hydraulic press. The press choice does not affect the end result, if that pressing is carried out until the superfluous mechanical moisture has been eliminated from the mixture pressed thereby. The finished products are taken out, then packing of the produced articles and their marketing follow. Should additional processing be needed, such as painting or laying special primer for waterproofing or water-tightness, those operations are carried out at the end of the treatment cycle, prior to the preparation for packing.

As the adduced examples show, the products made from the heat- insulating material, in accordance with the present invention, can take the shape of rectangular plates 1. Appropriate dimensions are 0.40 m width, by 0.60 m height, by 25-50 mm thickness. Preferably there should be on both parallel sides of the plates a rectangular slot 2, measuring for instance 10 mm by 12.5 to 25 mm depth, enabling the matching of the two plates 1 until they are linked into a sole plane, as is shown in Fig. 1. It is possible, in order to provide greater fixing strength, to provide in the middle of the plate, on both sides, 2 to 4 holes for fixing by dowels to the building. The well known cement adhesives offered on the market, can be used for sticking to the facades, applied preferably with a 20- 30 mm thickness. If necessary, the products can be further shaped as requested, and depending on the specific place of application, since the material, in accordance with the present invention, is subject to shaping by a saw.

APPLICATION OF THE INVENTION

The heat-insulating material, made in the shape of products different in type, such as bricks, boards, liner plates, panels, is intended for heat and noise insulation of rooms. It can be used for both external and internal insulation.

The material is environmentally clean, made up predominantly of 90-95% inorganic matter. The organic adhesives at the ratio provided in the composition, are harmless.

The heat-insulating material products are fixed to the wall surfaces by means of sticking with cement adhesive of the known types, or through mechanical links, employed usually for securing, e.g. dowels or other cement based mortar adhesives. When the lining is required to be waterproof and watertight, the application of additional treatment is desirable, to achieve thereby the qualities sought, for example by acrylic resins, which are absorbed into the plate up to 2 mm and render it further to water-resisting, also resistant to mildews and bacteria.

The insulation products made of the insulating material, in accordance with the present invention, are adequate for direct installation and possible finishing operations, such as puttying and painting. They are easy to shape and their industrial coloration can be done in thousands of tonalities. When manufactured as lining plates, the appropriate dimensions for an easy work are: width 40mm/50mm/60mm, and dimensions of the plate 600/400mm; 500/300mm; 400/300mm.

In the cases of block production 3 they should preferably have the dimensions of 120/600/250, 100/500/250, or 50/500/200, which do not limit the material application to the production of blocks having these dimensions alone.

When additional treatment and waterproof coating are done, the insulating material can be used in more difficult conditions, as well. It may be used, further to linings, also as a structural member for internal partition walls.

Claims

1. A composition of an insulating material, characterized in that it includes the following components (in volume %):

- granulous heat-insulating material 3 - 73

- fibrous material 5 - 15

- heat-resistant clay 5 - 20

- kaolin 5 - 15 - adhesive 5 - 10

- alumina 2 - 70.

2. The composition of an insulating material according to claim 1, characterized in that it further comprises light cement 5-50(in volume %).

3. The composition according to claims 1 or 2, characterized in that the granulous heat-insulating material is perlite and/or expanded-clay aggregate.

4. The composition according to claims 1, 2 or 3, characterized in that the fibrous material is of the type of mineral wool and/or fibers.

5. A method for manufacture of products made of the composition of an insulating material, according to claims 1 to 4, including mixing of the components and the mixture is stirred until a uniform homogenous mass has been obtained, characterized in that while the components are being mixed water is added, in the quantity of 5-17 (in volume %), and the resulting homogenous mass is poured into molds, whereupon it is pressed until the superfluous mechanical moisture has been eliminated, and thereafter it is dried in a microwave oven and the finished products are taken out.

6. The method according to claim 5, characterized in that the pressing is carried out by a 50 1 to 150 t hydraulic press.

7. The method according to claims 5 or 6, characterized in that the products undergo further processing, such as painting and/or impregnation.