DE4402912A1 - Fibre-reinforced and heat-insulating structural part - Google Patents

Abstract

It is characteristic of the products according to the invention that the main component (1) consists principally of previously known, technically unutilised problem waste, such as foam or cellular plastic (2), which has been reduced to a size suitable for the product, but that new, clean plastic can also be used as such or in a suitable mixture with waste plastic. Admixed with the plastic are the previously described natural fibres (3), which regulate and improve the mechanical properties. The outer layers may also be accordingly reinforced by waste or new fibres, fibres from natural-fibre bags or other natural-fibre materials in suitable lengths, etc. All natural fibres (3) such as reed, straw, sisal, hemp, cotton, coconut fibre, jute, linen, manilla, various types of grass, shredded branches and brushwood, etc. may be admixed, and used as such on their own and also together with other natural fibres in order to reinforce the products according to the invention. In order to bind the fibres and improve the adhesive properties between the fibres (3) and the granules (2), suitable dispersion glue or some other binder may be admixed. These agents are classified as binders (4) or additives (5), according to the amount admixed. In order to avoid rotting of the organic fibres, they may be impregnated with a suitable agent, for example the said sodium silicate. An increase in the ... Original abstract incomplete. <IMAGE>

Description

There are several known, mainly for Construction industry and the builders, heat-insulating and also durable construction parts, load-bearing structures, molds u. Many of these are sandwich or multi-layer constructions from a heat-insulating inner part with the corresponding load-bearing outer layer, or vice versa. Alternatively, they can be made from homogeneous thermal insulation materials without added reinforcing components exist, similar those described in Finnish Patent No. 53339 Form constructions in which the Thermally molded part with a load-bearing Construction layer can be filled.

Construction parts according to the invention heat-insulating component reinforcing natural fiber have been added are from earlier not known.

Known heat-insulating components are u. a. EPS, foamed polystyrene or PUR foam, as well as surfaces of conventional panels from z. B. sheet or plasterboard, or cleaned Surfaces. Even inside can be different there are supporting structures.

With conventional plastics processing processes only new and clean raw material used, possibly to the one small part, but usually at most 10%, accruing from own production and recyclable clean plastic waste is added, which also the quality worsened.

Waste consisting of the edges of EPS Sheets or other dirty plastic waste or used, unsaleable packaging and old PUR foam, can not with the conventional manufacturing methods be recycled.

Destruction or reuse of EPS, SB, PVC, PUR or other cell and foam plastic waste bring environmental, waste disposal and economic problems  with it: until today there were no products or Manufacturing methods that are emerging today Recycle large amounts of plastic waste could.

Plastic waste is a problem waste, that now according to the invention High quality recycled products processed can be.

As has been stated, the exterior the well-known sandwich construction except various panels, also made of glass fiber reinforced Resin. However, fiber is proportionate expensive to manufacture consumes a lot of energy and the environment charged. Glass is also heavy. A manufacture with the fiberglass-like material Asbestos is prohibited.

Alternatively, polymeric fibers, e.g. B. pp fibers, been used. The problem with these fibers is the good chemical resistance of the Olefins, which means they're bad adhere to the binders and thereby deteriorate the desired durability properties. Other plastic fibers are e.g. B. PETP and PA, which are too expensive.

Unstabilized plastic fibers have one poor weather and light resistance, which shortens their useful life.

Steel fibers are an alternative raw material not suitable. If the fibers are too close to the Outside surfaces, they rust. Your price is high, their weight is even greater than that the fiber.

Completely different from the use in the products according to the invention are cellulose "fiber", i.e. H. rough pieces of wood, in load-bearing compact coarse concrete structures used as a replacement for cast steel been. These "wood fibers" are however in Relationship to those used according to the invention Fibers very coarse and because of their structure not suitable for e.g. B. strong but thin Outside surfaces. The offer of suitable There is also fiber of uniform quality low, although the price is low. Such pieces of wood become energy used.  

This invention relates primarily on construction products, some of which already have been enumerated. According to the invention Products can a. Elements, molds Foundations, various supporting and non-supporting Constructions, walls, doors, columns, Floors, beam layers, roof structures, Stairs and slabs, as well as parts from above mentioned products without the Invention in any way only on the limited examples.

Other products according to the invention are e.g. B. cheap one-way transport containers that subsequently a second use as such, or put together in larger units, in z. B. disaster areas as thermal insulation Find makeshift houses.

Areas of use are also z. B. loudspeakers and products of sound reproduction, according to their acoustic properties Desire can be regulated.

Construction and properties of the invention are described in more detail below. The features characteristic of the invention are described in the part claim.

Although this invention, like so many others significant inventions, is simple, was their importance until today neither in the plastics processing still in the construction industry been recognized and inventive products are not yet known.

The advantages of the invention are significant, and the benefits of the whole are greater than the linear sum of Parts, which also for the experts Is surprise.

The numbering used below refers to the picture no .: 1, and is the same as in the part claim is used.

The advantages of the products ( 1 ) according to the invention include great mechanical durability combined with very high thermal insulation.

The products ( 1 ) according to the invention, the shapes of which can be chosen as desired, are made entirely from problem waste, e.g. B. foam and cellular plastic ( 2 ), and unusable bags ( 3 ), which are unusable for conventional manufacturing processes. Other components are readily available binders ( 4 ) such as. B. cement, filling material ( 5 ) such. B. sand and sawdust and auxiliaries ( 5 ) such as dispersion glue, sodium silicate solutions, etc.

The production costs of the products according to the invention are calculated negatively with regard to the main components, since problem waste, which was previously unused and unusable, is used as the raw material. The consumer pays for the disposal of this problem waste, ie reinforcing fiber ( 3 ) and heat-insulating plastic ( 2 ), which forms a usable raw material for the production of the products according to the invention. The price advantage compared to conventional products is therefore considerable.

If not sufficient quantities of suitable Waste can be available, of course also clean and unused plastic, as the sole raw material or mixed with waste, be used.

In comparison to the products of insulating plastics known to date, the products ( 1 ) according to the invention have good echo-free acoustics and good noise insulation due to their structure. The properties of the overall work according to the invention are better than the individual components added together.

If you as a binder for the raw materials ( 1 and 2 ) z. B. uses an inexpensive cement mix ( 4 and 5 ), the product gets a certain mass. This improves the acoustic properties if the noise is absorbed by the porous construction. The mechanical properties of the products according to the invention are also better than in products which are made exclusively from plastic.

Because the products of the invention are the largest Part are made of very light plastic  the product according to the invention very easily process which the forces and the Protects your back. As for the processing of the light products according to the invention z. B. No crane is required here either Saved costs.

The products according to the invention are also included simple tool, e.g. B. by sawing to the desired Easy to shape. Man can also put normal nails in the products beat. The nails are stuck and the surface does not split, as in the past known heavy s. G. Lightweight concrete blocks.

The surfaces can be treated as desired be, e.g. B, the inside of the load-bearing Walls can be papered or painted, and the outsides z. B. be cleaned. All known methods and materials, e.g. B. Sheet metal, wood, brick, can be used for this become.

By choosing an appropriate strength one obtains for the wall according to the invention a breathable wall, so there is none Moisture barrier required.

Thermal insulation can either be continuous run without continuous cold bridges, or other parts can be built into the products or put together with them.

The official insulation regulations are without Easy to keep additional costs.

A product according to the invention with cement mixture as a binder forms a safe, non-combustible stone construction, the Fire insurance costs are less than e.g. B. for wooden houses.

The thickness of the outer walls does not affect the production speed since the Hardening of the used as a binder Fabric, e.g. B. cement, of the strength of the Product is almost unaffected, however, that a thicker product generates more heat and thus hardens faster. The  So the situation is exactly the opposite of that that for previously known EPS plastic constructions Was valid.

The curing speed and the Porosity of the outer layer can vary Desired to be regulated with additives. The products are mainly at room temperature made with no energy in the heating and evaporation of the water lost, or cold water for that Cooling of the hot EPS products is required which is compared to the conventional one Plastic manufacturing the environment less burdened and economic savings brings with it.

All production residues and waste from the Plate edges can be ground and used in the manufacturing process can be entered again. So there is no waste.

Any waste generated at the construction site, e.g. B. when sawing out a window, on be disposed of in an environmentally friendly manner by reusing everything, or as Frost barrier digs into the ground. The invention Product does not separate dangerous ones or harmful components.

The plastic material used can be dirty be and impurities such. B. wood chips, Paper labels, plastic film parts, Containing sand and stones, without this the good properties of the Products affected by the invention. This deviates entirely from the conventional manufacturing method at which, as already stated, completely clean plastic raw material without any of the impurities listed, is needed. In the products according to the invention the impurities combine with the binder, e.g. B. cement, suitable Glue or other materials that improve adhesion, without causing problems. The products can be used despite possible contamination be shaped arbitrarily. The mentioned example cement as a binder does not limit the choice of binders this only material.  

The possibility of using unclean plastic ( 2 ) and natural fiber ( 3 ) according to the invention represents a significant advantage and a decisive improvement over previously known manufacturing processes.

In conventional plastics processing Even clogging small amounts of contaminants the nozzles of an extruder, or break the hot wires when cutting from the EPS sheets. When cutting fresh EPS containing pentane lead to the impurities to an apparent fire hazard.

In old and ventilated EPS is not a fire hazard Pentane present, the processing of products according to the invention therefore safe and constructions from such are fire safe. Old PUR foam included not freon and therefore the products harmless to consumers and residents. The products are burdened by any secretions not the environment.

Any residual freon is bound in the product and can be difficult in the room or in the Solve nature, which is the case when using of fresh PUR foam.

The particles in the granulate ( 2 ) made from plastic waste are angular and have a rough surface. That is why they also adhere mechanically better to the binder as a new raw material with a smooth surface that can also be used.

Large quantities of products packed in sacks are imported annually, e.g. B. coffee, potatoes, etc. The natural fiber bags used ( 3 ) are part of the problem waste and bring major disposal problems and additional costs for the industry. There is no use for the used and torn sacks, which have to be disposed of by unnecessary extra sorting work and against payment. The problems are the same as in other countries.

The sacks used are a waste product, now according to the invention for new valuable Products can be recycled.  

The natural fibers of the waste bags ( 3 ) in the heat-insulating and strong product according to the invention ( Fig. 1.) completely replace the inside of the outer layers in the previously known sandwich construction, or the earlier known fibers in the outer and inner layers, and at the same time lead to a number of technical advantages and economic profit.

The manufacture of previously known edge reinforced Products and the double manufacturing process for sandwich constructions (separate processes for outer and inner layers) are expensive.

The conventional plastic manufacturing required high temperature consumed disproportionate energy and pollutes the environment, cooling the thermal insulation Products wasted and contaminated Cooling water, the procedures are time consuming, sticking between the inner and outer layers is unsafe, it becomes unusable Waste on etc. The formability and the regulation of product properties are limited here.

Acoustics and noise insulation in products, which are made only of cellular and foam plastic are bad.

Manufactured using conventional processes Products have a high price, too a number of serious disadvantages.

A fibrous outer layer according to the invention, as well as the whole construction part through and through, is extremely tough and splits not when bumping, pulling or bending like conventional concrete pieces or products like only made of insulating plastic were. A product according to the invention changed not change over time either the plaster does not burst like the conventional one Plaster.

A porous fibrous outer layer ( 3 ) does not split if the weather, e.g. B. Frost, is exposed. The product also does not split at high temperatures, like normal concrete, because the gases, e.g. B. steam, can evaporate freely and the heat, due to the good thermal insulation, spreads more slowly.

The fiber used in the invention Products are used to their Structure porous and can be distinguished thereby with the binders, e.g. B. cement, Combine glue, sodium silicate solution.

So that the natural fiber ( 3 ) does not rot when it comes into contact with cement or other materials ( 4 ) or with moisture in the construction, it can be treated with the above-mentioned or other aids ( 5 ). The additives used can have several functions at the same time.

By treating the fibers, the Properties changed, less sensitive to burning and made rot-proof, after which the construction does not burn or rot.

Between dense non-combustible outer layers existing, or under construction self contained, from non-organic Binder surrounded and protected Components have no oxygen supply and cannot do without air burn.

Also the amount of new fiber and / or old waste fiber regulates the properties of the products.

According to the invention, the fibers ( 3 ) are mostly distributed evenly into the plastic granulate or crumb mixture ( 2 ) over the entire product. But it is also possible to distribute the various components unevenly over the product, or to concentrate in certain parts of the product, e.g. B. so that a sandwich-like construction is obtained.

In general, the best results are achieved if the fiber reinforcement ( 3 ) protrudes in the outer layer. The components are held together by the binders.

The properties can also be added of aids and filling material as desired be regulated.

All substances used can be water-soluble and be water compatible, whereby one, in order to protect the environment, the addition from Z. B. can avoid solvents without however only that organic and other solvents are used can.

Claims (1)

A fiber-reinforced and heat-insulating structural part ( 1 ), mainly consisting of granules ( 2 ), fibers ( 3 ) and binder ( 4 ), and also with or without the addition of fillers and auxiliary materials ( 5 ), characterized in that the granules ( 2 ) made of plastic, such as. B. expanded polystyrene, polyurethane foam or the like, the fiber ( 3 ) made of natural fibers such. B. sacks, sisal, jute, hemp, manilla, cotton, linen, reeds, grass, straw or the like ( 4 ), the binder made of cement, water glass, glue, polyurethane or equivalent, the filler ( 5 ) made of sand, sawdust or Corresponding, and the auxiliary materials ( 5 ) consist of, among other things, fire protection agents, anti-rot agents, silicate solutions and adhesion-improving or other property-regulating materials.