Patent Application
20120267562
The subject of the invention is a heat-insulating, fire-proof, water-resistant, permeable-to-air, flexible lightweight concrete with a volume-density below 500 kg/m3, made with polystyrene pearl, which is equally suitable for heat-, and sound-insulation of walls and slabs, as well as decreasing their water permeability or water-absorbing capacity, as well as increasing their resistance to fire at the same time keeping their ability to be permeable to air and humidity, when renovate old buildings or built new buildings.
In the state of the art there are several heat-insulating materials and lightweight concretes. The most common materials among heat-insulating ones are the glass wool, rock wool or basalt wool base solutions of boards or plates, solid polystyrene boards, and among lightweight concretes there is pearlitic concrete, or plaster, respectively the lightweight concrete including polystyrene pearl is known as well, with a volume-density generally above 500 kg/m3. I could not find a lightweight concrete, which is water-resistant and permeable-to-air, made of polystyrene pearl (or from other insulating material) containing nothing else beside binding materials.
The drawback of the heat-insulating materials used earlier is, that they each have deficiencies in certain advantageous properties, such as: the glass wool, rock wool or basalt wool base solutions of boards and plates are not water-resistant, this way moisture can condensate in them, worsening their heat-insulating ability, they are not fire-proof and they can not resist to rodents and insects. The polystyrene boards are not permeable-to-air, so moisture can condensate behind them, worsening their heat-insulating ability and they are not fire-proof Lightweight concretes, plasters with pearlite are not water-resistant and their volume-density is high, resulting in very low heat-insulating capacity.
The volume-density of lightweight concretes containing polystyrene pearl as well is also higher, as they contain different materials, heavier than polystyrene pearl, which are often not water-resistant.
The GB 1333487 patent description makes known a method for the production of lightweight building elements. The lightweight building elements are obtained from a hardened mixture of cement, water and a vinyl latex which mixture is homogenized with expanded polystyrene which has been pretreated with an aqueous dispersion of an epoxy glue, a hardener and an organic solvent. Specified vinyls are the acetate which can be copolymerized with acrylic or methacrylic esters and copolymers of styrene with such acrylic esters. Portland and aluminous cements are used, and the expanded polystyrene has a maximum size of 3 mm. Polyamines are the hardeners, and surfactants, e.g. sulphonates and Et2O condensates with phenols are optional. In the course of the method disclosed in the document the polystyrene particles are pretreated, and the volume-density of the produced lightweight building elements is 200-800 kg/m3.
The GB 1291941 patent description makes known an insulating lightweight cellular concrete, which comprises an aggregate of multicellular glass nodules in a cellular cement matrix. The outer continuous skin of the nodules can be of a different composition from the core. Air entrainers are lignosulphonates, licorice root, Vinsol and Darex (both Trade Marks). A hydroxylated COOH derivative reduces the water requirements for workability. The lightweight building elements made known above are not permeable-to-air and not flexible.
The HU 203 507 patent description filed under No. P 85 02259 makes known a lightweight concrete for heat insulating layer, which contains the mixture of water, soda glass, cement and insulating granular material. The lightweight concrete disclosed in the document contains the mixture of 160-240 l water of drink water quality, 5-20 kg soda glass of technical quality, 30-180 kg cement, 40-170 kg fly ash, 1 m3 granular polystyrene foam of 2-20 mm diameter, and its air-dry body density is 200-400 kg/m3. The lightweight concrete made known in the document is not permeable-to-air.
The HU 174 868 patent description makes known a method for the production of lightweight concrete with additive. With the help of the disclosed method, homogenous lightweight concrete with apparent density of 200-800 kp/m3, from additives of granular polystyrene foam and/or glass foam with cement binding material and with aluminium-hydrosilicate can be produced. The lightweight concrete produced with the said method is applicable for heat insulating purpose in a prefabricated or monolithic way. The advantage of the method is that the granular polystyrene foam and/or glass foam can be mixed in the cement binding material without surface-activation and pressure application. The basis of the production of the lightweight concrete disclosed in the document is the production of the thixotrope binding material paste.
The HU 162 516 patent description makes known a method for the production of gravel consisting of medium layer and cement, and for the production of lightweight concrete binding lyophobic and also lyopylic materials, from porous granular thermoplastic—preferably from expanded polystyrene pearl. In the course of the method the porous granular thermoplastic is mixed with 5-20 volume %, preferably 10 volume % water dispersion counting on its volume, which contains maximum 5% surface-active material and 0.5-5% polyacrylate or ethylene-vinyl-acetate copolymer. In the course of the production of gravel the granular plastic is coating with the water dispersion of the medium material, and the resulting granular material is homogenized with cement. The gravel can be used for the production of lightweight concretes, in 6-30 kg/m3 quantity. The lightweight concretes produced with the above type of gravel have an excellent flexibility and stability. In the course of the method disclosed in the document the polystyrene pearl is pretreated, and the volume density of the resulting lightweight concrete is 200-700 kg/m3.
The KR100788746 patent description makes known a mortar composition for preventing inter-floor noises, which is provided to need no step of adding a separate noise-protecting layer on a concrete slab, and to realize excellent compression strength and impact noise-protecting effect. A mortar composition for preventing inter-floor noises comprises: 100 parts by weight of Portland cement; 10-30 parts by weight of styrene-butadiene synthetic rubber latex containing a mixed surfactant containing an anionic surfactant and a non-ionic surfactant in a weight ratio of 1:9-0:1; 20-400 parts by weight of waste tire powder; and 50-100 parts by weigh of sand, wherein 5-40 wt % of the mixed surfactant is used based on 100 wt % of the solid content of the styrene-butadiene synthetic rubber latex.
The KR100521694 patent description makes known a composition for preventing heat isolation, sound absorption and shock sound using polystyrene waste materials comprising crushed particles, synthetic zeolite, inorganic flame retardant, synthetic filament waste materias, soluble binder, cellulose fattening adhesive and inorganic pigment.
The U.S. Pat. No. 5,482,550 patent description makes known a structural building unit formed from a set solid mixture consisting essentially of about 30% to about 75% by weight portland cement, about 1% to about 25% by weight percent ground expanded cellular polystyrene, about 1% to about 35% by weight ground cellulosic fiber, about 2% to about 15% by weight fly ash, about 1% to about 10% by weight silica fume, about 1% to about 15% by weight bentonite, about 25% to about 50% by weight water, about 0% to about 3% by weight air entrainer, about 0% to about 10% by weight paraffin wax emulsion and about 0% to about 15% by weight rubber emulsion.
The U.S. Pat. No. 3,869,295 patent description makes known uniform lightweight concrete and plaster. They are prepared by a novel method which assures that the aggregate is uniformly admixed with the cementitious material and other relatively heavy ingredients of the concrete and plaster mixes. This is accomplished by wetting the surfaces of the lightweight aggregate particles with an aqueous medium, admixing the wet aggregate particles with dry finely divided cementitious material to form a coating thereon, and thereafter adding additional aqueous medium in an amount to produce a coherent formable uncured concrete or plaster matrix. The uncured concrete or plaster matrix may be formed into a desired configuration, and then is allowed to set in the usual manner. The addition of hydrated lime improves the cohesive properties of an uncured concrete matrix. Increased strength in cured lightweight concrete may be obtained by admixing pozzolan, hydrated lime and/or finely divided inert inorganic fillers such as sand with the uncured concrete matrix. A lightweight aggregate including expanded polystyrene beads is preferred, and further increased strength may be obtained by using, polystyrene beads expanded in hot water.
All in all the task to be solved was the working out of such a heat-insulating material, which is very light, but fire-proof, water-resistant, permeable-to-air and flexible in one. Theoretically the ideal way of it is, if only the gaps between the polystyrene pearls are filled with fire-proof, water-resistant, permeable-to-air and flexible binding material. this way by kind of sticking them together, and so the material resulting from it is fire-proof, water-resistant, permeable-to-air and flexible, and remains light at the same time. However it is not possible to mix polystyrene pearls only with cement and water, as it gets assorted due to the very big difference of volume-density.
This problem was solved, when we realized, that homo-, co-, and terpolymers—which are water-soluble and/or can be dispersed in water, and do not include and do not emit volatile organic hydrocarbons hazardous to the environment—should be used as organic binding material.
The invention is a heat-insulating, fire-proof, water-resistant, permeable-to-air, flexible lightweight concrete with a volume-density below 500 kg/m3, which is equally suitable for heat-, and sound-insulation of walls and slabs, as well as decreasing their water permeability or water-absorbing capacity, as well as increasing their resistance to fire at the same time keeping their ability to be permeable to air and humidity, for renovation old buildings or building new buildings, which is characterized by that it can be easily mixed and its composition is: polystyrene pearl, or recycled polystyrene of1-10 mm diameter particle size, water, cement and organic binding material mixed with cement: such homo-, co-, and terpolymers, which are water-soluble and/or can be dispersed in water, such as vinyl-chloride, vinyl esters of saturated,—unsaturated and aromatic organic acids, vinyl-butirate, ethylene, acrilic acid esters, styrene, alkyl-izocianates, silanes, siloxalates.
In one preferred realization of the solution according to the invention, for the sake of making processing easier, additional organic additives are added, such as polyvinyl-alcohols, cellulose ethers and other protecting colloids, sedimentation blockers, plasticizers.
In an other preferred realization of the solution according to the invention, the cement is mixed, or replaced by gypsum.
In a further preferred realization of the solution according to the invention, polystyrene pearl is mixed or replaced by a material, which is of small volume-density, (max. 400 kg/m3), consists of granules and is water-repellent.
In a further preferred realization of the solution according to the invention, materials used as additives are the following:
as organic binding material any homo-, co-, and terpolymer can be used, which is water soluble and/or can be dispersed in water, in given case the are produced with using vinyl-chloride, vinyl esters of saturated,- unsaturated and aromatic organic acids, vinyl-butirate, ethylene, acrilic acid esters, styrene, alkyl-izocianates, silanes, siloxalates.
and/or
additional organic additives can be polyvinyl-alcohols, cellulose ethers and other protecting colloids, sedimentation blockers, plasticizers,
and/or
as mineral additives rock grist, in given case limestone, dolomite, pigments, in given case iron-oxide, titaiume-dioxide etc., pearlite, mica schist, etc. can be used.
In a further preferred realization of the solution according to the invention, materials used as filling material are the following:
and/or
and/or
and/or
and/or
In a further preferred realization of the solution according to the invention, the size of the filling material is between 0-20 mm, and the filling materials falling in different size-range are preferably used in a fractional in such a way, that the materials fall in the same size-range, or in given case they are used in a non-fractional way.
In a further preferred realization of the solution according to the invention. at the production of the heat-insulating material the components are mixed with a traditional technology, in given case with mixing machine, in the following order, first we feed the water, than cement is added to it, following it the additive is fed, from these three components we mix a material of a dilute sour cream consistence, in the end we add the filling material to the compound at continuous mixing, we mix the total material composition into a homogenous state, and we use the compound produced this way appropriate to the application.
In a further preferred realization of the solution according to the invention, the heat-insulating material is used in bottoming, borders, road concrete elements, building basic units, building elements, and/or in monolithic concrete structures prepared in the place, lattice blind elements, in given case as heat-insulating plaster, heat-insulating panel, permanent lattice blind, wall element, brick, prefabricated building elements, insulation of heat,- gas,- oil,- water lines.
In a further preferred realization of the solution according to the invention, in the case the volume-density of the filling material is bigger than 100-200 kg/m3, it is used as building material instead of concrete, or we produce elements, bricks from it.
In the case of the most general realization of the solution according to the invention, the invention is a heat-insulating, fire-proof, water-resistant, permeable-to-air, flexible lightweight concrete with a volume-density below 500 kg/m3, which is equally suitable for heat-, and sound insulation of walls and slabs, as well as decreasing their water permeability or water-absorbing capacity, as well as increasing their resistance to fire at the same time keeping their ability to be permeable to air and humidity, when renovate old buildings or built new buildings. Its components are materials known in themselves: polystyrene pearl of 1-10 mm diameter, hydraulic inorganic binding material, organic (polymer) binding material, mineral and organic additives, water. We can achieve the optimal properties by choosing their type and proportion.
The refuse of disintegrated used packaging material in suitable size can be preferably used as polysterene pearl, the recycling of the refuse result in solving a considerable environmental protection problem as well.
As hydraulic binding material any type of cement, gypsum and anhydrite type is appropriate, the principle of choice is strength, binding time etc.
As organic binding material any homo-, co-, and terpolymer can be used, which is water soluble and/or can be dispersed in water, does not include and does not emit volatile organic hydrocarbons hazardous to the environment. Such materials are widely known: they are made with the use of vinyl-chloride, vinyl esters of saturated,- unsaturated and aromatic organic acids, vinyl-butirate, ethylene, acrilic acid esters, styrene, alkyl-izocianates, silanes, siloxalates. Their common characteristic is, that even in small quantity they allow the mixture of polystyrene and hydraulic binding materal making the product of excellent strength, adherence and water-proof.
Additional organic additives can be polyvinyl-alcohols, cellulose-ethers and other protecting colloids, sedimentation blockers, plasticizers, making the production process easier. As mineral additives rock grist, (limestone, dolomite) pigments (iron-oxide, titane-dioxide etc.) perlite, mica schist, etc. can be used. The water should be free of contamination, preferably drink water, tap water.
The heat-insulating material produced this way is very light after setting, depending on the quantity of organic binding material and cement, it can be 100 kg/m3, so it is of excellent heat-insulating capacity.
The invention is set forth by the following examples:
The invention can be realized by the simple mixing of the following materials: 1 m3 polystyrene pearl of 1-10 mm particle size or recycled polystyrene of 1-10 mm particle size, 100 l water, 80 kg cement and 10 kg organic (polymer) binding material, which is mixed to the cement. The material prepared such a way, will be of 100-120 kg/m3 volume density, after drying. The quantity of the added cement determines the actual volume density of the ready material, because the mass of other materials altogether are only 20 kg/m3.
The material prepared such a way, will be of appr. 100 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 100 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 200 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 200 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 300 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 300 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 300 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 400 kg/m3 volume density. after drying.
The material prepared such a way, will be of appr. 400 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 400 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 500 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 500 kg/m3 volume density, after drying.
The material prepared such a way, will be of appr. 500 kg/m3 volume density, after drying.
In the course of the preparation of the lightweight concrete according to the invention, in case more cement is used, then the ready-made material will be heavier, so it will have worse heat-insulating capacity and larger compression strength, but the proportion of the organic binding material can be changed opposite the proportion of cement, that is it can be decreased if the proportion of the cement is increased. With the changing of the proportions different heat-insulating materials meeting different demands can be made. The ready-made material can be greased, pumped, cast; board, brick or filling walls can be made of it, and above 300 kg/m3 volume density it can be plastered as well.
The invention can be preferably realized by mixing cement with gypsum or using gypsum instead of cement.
The invention can be preferably realized as well by mixing or replacing polystyrene pearl by a material, which consists of granules and is water-repellent and is of small volume-density (max. 400 kg/m3).
The heat-insulating, fire-proof, water-resistant, permeable-to-air, flexible lightweight concrete with a volume-density below 500 kg/m3, made with polystyrene pearl according to the invention is equally suitable for heat-, and sound-insulation of walls and slabs, as well as decreasing their water permeability or water-absorbing capacity, as well as increasing their resistance to fire at the same time keeping their ability to be permeable-to-air and humidity, for renovation old buildings or building new buildings. Its composition is: polystyrene pearl, or recycled polystyrene of 1-10 mm diameter, water, cement and organic (polymer) binding material mixed with cement: such homo-, co-, and terpolymers—which are water-soluble and/or can be dispersed in water. Resulting from the use of organic (polymer) binding material, the polystyrene pearls can be easily mixed with the inorganic binding material and water.
In the case of preferable specific realization of the lightweight concrete according to the invention the applicable materials are the following:
Material Compound:
The lightweight concrete according to the invention consists of four main components, which are the following: water, cement, additive, filling material.
Materials Used as Additive are the Following:
All homo-, co-, and terpolymers—which are water-soluble and/or can be dispersed in water, and do not include and do not emit volatile organic hydrocarbons hazardous to the environment—should be used as organic binding material. Such materials are widely known: they are prepared with the use of vinyl-chloride, vinyl esters of saturated,- unsaturated and aromatic organic acids, vinyl-butirate, ethylene, acrilic acid esters, styrene, alkyl-izocianates, silanes, siloxalates. Their common feature is that even in small quantity, they make possible the mixing of polystyrene and the hydraulic binding material, the excellent adhesion, strength and water-tightness of the product.
Further organic additives can be the following: polyvinyl alcohols, cellulose-ethers and other protective colloids, sedimentation-inhibitors, plasticizers, which facilitate the processing. As mineral additives ground stones (limestone, dolomite), pigments (iron-oxide, titanium-dioxide, etc.), pearlite, mica schist, etc. can be used, if required. The water is contamination-free, preferably drink water, tap water.
As filling material in the concrete instead of gravel, all materials can be put in, which are preferably the following:
In the case the volume density of the filling material is greater than 100-200 kg/m3, it is not appropriate for heat-insulation, but it is excellent building material, it can be used instead of concrete, or elements (bricks) can be produced from it.
Sizes, Rates
The size of the filling material is between 0-20 mm (it is difficult to mix the powder with gravel, so powder can be utilized only in certain circumstances).
Preferably the raw materials are used in a fractional way: they must be fallen in the same size-range. They can be used also in a non-fractional way.
Conditions of Production, Technology:
We mix with traditional technology. Order of adding of materials is the following: 1.: water, 2.: cement, 3.: additive (among the materials made known above), we mix a material of a dilute sour cream consistence from these three components, and 4.: filling material.
We mix the total into a homogenous state, than we use it appropriate to the application.
It is an essential idea of the invention, that the additive makes possible to mix the filling material into the water+cement compound in a homogenous way.
Applications, utilizations, end-product: heat-insulating plaster, heat-insulating panel, permanent lattice blind, wall element, brick, prefabricated building elements, insulation of heat,- gas,- oil,- water lines, bottoming, borders, road concrete elements, building basic units, building elements, monolithic concrete structures prepared in the place, lattice blind elements.
The loadbearing capacity of the product depends on the strength (compression strength) of the cement and on the compression strength of the filling material. The compression strength of the cement and the filling material determine together the compression strength, statics, heat-transfer coefficient and the possibilities of application of the end-product.
The heat-insulating material produced this way can be even 100 kg/m3, depending on the quantity of the binding materials. The ready-made material can be greased, pumped, cast; board, brick or filling walls can be made of it, and above 300 kg/m3 volume density it can be plastered as well. The cement can be mixed or replaced by gypsum. The polystyrene pearl can be mixed, or replaced by a material, which consists of granules and is water-repellent and is of small volume-density (max. 400 kg/m3).
| Number | Date | Country | Kind |
|---|---|---|---|
| PCT/IB2009/007587 | Nov 2009 | IB | international |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IB10/03001 | 11/24/2010 | WO | 00 | 5/24/2012 |
