ES1241509U - Prefabricated lightened plaster with polyurethane foam residues (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

Prefabricated plaster lightened with polyurethane foam from industrial waste, in the form of a suspended ceiling plate, with the following composition: - commercial plaster or plaster; - crushed polyurethane foam residues of industrial origin, with a particle size of less than 2 mm; - reinforcing fibers, which improve the mechanical properties of the prefabricated, in a proportion of 1% by weight; - additives to improve the physical characteristics/performance of the product, in a proportion of 0.5% by weight and - Water, the proportion being plaster: polyurethane foam residues of 1: 1.5 by volume. (Machine-translation by Google Translate, not legally binding)

Description

DESCRIPTION

PREFABRICATED LIGHTENED PLASTER WITH FOAM WASTE

POLYURETHANE

TECHNICAL FIELD OF THE INVENTION

The present invention is encompassed in the field of preparation of prefabricated plaster for use in the construction industry.

More specifically, the invention provides a prefabricated plaster lightened with polyurethane foam from industrial waste, in the form of a suspended ceiling plate, including precast plaster a mixture of plaster, water and polyurethane foam residues of industrial origin, as well as reinforcing fibers and additives.

BACKGROUND OF THE INVENTION

Currently polymeric materials (plastics) are present in any area of our life (food, sanitary, refrigeration, construction, industrial, sports, etc.) and their use has brought great advantages, such as the improvement in the energy efficiency of buildings and refrigeration systems, versatility and weight reduction in car design or improvements in the field of food preservation.

However, like almost all materials, it has a certain useful life, after which one of these paths follows: recycling, recovery with incineration techniques or landfill. Although the volume of recycled plastics is increasing year after year, the figures of landfill of these materials are much higher, not forgetting the problems of emissions of CO ² and other pollutants derived from incineration techniques.

Thus, the importance of recycling and revaluing polymeric or plastic waste generated in industrialized societies is essential. Foams of Polyurethane is widely used in numerous fields and in a wide variety of products, mainly due to its excellent qualities and properties, among which its high capacity for protection (impact absorption) and thermal and acoustic insulation, as well as its lightness and ease of forming, which allow it to adapt to the needs of each situation.

The polyurethane foam itself is used as an insulator in the construction sector. Therefore, it is logical to think that the use and recycling of this material (with a prior crushing) and mixed with plaster could compete with other more traditional products, including efficient and effective thermal and acoustic insulating properties in manufacturing. These properties, together with the fact that plaster is a bad conductor of heat and electricity, make this material a suitable compound for use as a building material.

The lightened construction plaster according to the definition UNE-EN-13279-1: 2009 is composed of a mixture of calcium sulfate in its different phases of dehydration (anhydrite, hemihydrate or dihydrate) and purity (traditionally known as rough plaster, plaster fine or plaster) with a certain content of lime (calcium hydroxide), which incorporates inorganic light aggregates (such as expanded perlite or vermiculite, for example) or organic light aggregates, to which kneading water must be added for putting in work.

The use of raw and inert materials of different densities for the manufacture of light plasters is widely known and exploited since ancient times. However, the benefits that polyurethane foams bring to the properties of these products with respect to agglomerates made of traditional materials, gives these products clear advantages.

The present invention, in view of the aforementioned needs to revalue the polyurethane foam residues, intends to extend the useful life of one of these polymers, the polyurethane foams, reusing them and re-including them in the industrial cycle, foundation on the that the concept of circular economy is based.

The effective cost of using this polymer waste in a new prefabricated Plaster improves significantly compared to a market material with similar technical characteristics.

The application of various materials in a plaster or plaster matrix is known, these materials being of both natural and industrial origin, in binders and prefabricated materials, for example, materials based on plaster or plaster lightened with natural cork (pruning waste in granular form) or artificial (expanded polystyrene beads (ES2170612B1)). Plaster mortars with expanded vermiculite (WO2009 / 121984A1), with pyrolized fruit bones (ES2385620A1), with polyamide powder residues (ES2396096A1) or with crushed polyurethane residues (ES2381726B1), as well as mixtures of plaster with residues are also known of extruded polystyrene (ES2515640B2), plaster as the main matrix with binary additions of expanded polystyrene (ES2292309A1), polyurethane foamed plaster (GB1498614A) and with rice husk (ES233139A1).

Prefabricated materials are also known in the form of a plate and panel based on gypsum or lightened plaster with expanded plastic granules (ES2277776B1), prefabricated plaster with expanded polystyrene wastes (MX2011008622A), parts for gypsum partitions with natural cork (ES153733A1) and with pieces of rigid polyurethane foam (ES284858U), construction plates made of plaster and paper pulp (ES2242536B1), large format prefabricated plates and panels for use in construction, consisting of plaster or plasterboard with expanded polystyrene (ES2292309B2 ), prefabricated panels for interior lining phase change materials (ES2346282B8), panels designed for use in interior partitions and exterior partitions with coconut shell additions in its gypsum matrix or lightened plasterboard with granulated cork (ES1137231U) .

In spite of the numerous known antecedents, none of the obtained products allows to obtain a prefabricated of lightened plaster with polyurethane foam from industrial waste, in the form of a suspended ceiling plate (according to the UNE-EN 14246: 2007 standard), using for its production gypsum or commercial plaster (according to UNE-EN 13279-1: 2009), water and industrial polyurethane foam residues, and optionally reinforcing fibers and additives.

In particular, the use of polyurethane foam from industrial waste in the gypsum matrix or plasterboard of a prefabricated plasterboard in the form of a suspended ceiling plate allows to increase the recycling rates of this waste. In addition, it provides improvements in the physical characteristics of the prefabricated, with weight reductions of up to 25% with respect to the standard plates and an increase in the insulating capacity of the elaborated material, the final cost of the material being 12% lower compared to a material of similar benefits already known.

DESCRIPTION OF THE INVENTION

The present invention is established and characterized in the independent claim, while the dependent claim describes other features thereof.

The invention provides a prefabricated plaster lightened with polyurethane foam from industrial waste, in the form of a suspended ceiling plate, including the prefabricated plaster mixture of plaster, water and polyurethane foam residues of industrial origin, as well as fibers of reinforcement and additives.

The prefabricated plaster lightened with polyurethane foam from industrial waste in the form of a suspended ceiling plate according to the invention has the following composition:

• plaster or commercial plaster;

• crushed polyurethane foam residues of industrial origin, with a particle size of less than 2 mm;

• reinforcing fibers, which improve the mechanical properties of the prefabricated, in a proportion of 1% by weight;

• additives to improve the physical characteristics / performance of the product, in a proportion of 0.5% by weight and

• Water,

the proportion being plaster: polyurethane foam residues of 1: 1.5 by volume.

In one embodiment, the plaster or plaster is of type A (E35) according to EN 13279-1: 2009, indicating a purity index> 92%, with setting principle> 10 minutes and with a mechanical resistance to flexotraction> 3.4 N / mm2.

The polyurethane foam residues to be used in the present invention can come from many different sources, for example, from the refrigeration or automobile industry.

Examples of polyurethane foam residues that can be used in this invention and their physical properties are shown in Table 1 below.

Table 1

Reinforcing fibers for the prefabricated lightened plaster according to the invention, can be selected from glass or polypropylene fibers, with lengths between 2 and 7 cm and a diameter of 30 and 60 pm.

Likewise, the additives for improving the physical characteristics / performance of the product are based on melanins or polycarboxylates.

As indicated above, the prefabricated plaster lightened with polyurethane foam from industrial waste according to the invention, containing the proportions of its indicated components, provides improvements in the physical characteristics of the prefabricated, with weight reductions of up to 25% with respect to the standard plates and an increase in the insulating capacity of the elaborated material, all with a final cost 12% lower compared to a material of similar benefits in the market.

By way of illustration, a procedure for obtaining prefabricated lightened plaster with polyurethane foam from industrial waste in the form of a plate for suspended ceilings is presented.

Thus, the process includes the following stages:

i) milling the polyurethane waste to transform it into a powdery material and sieved to a particle size of less than 2 mm,

ii) dry mixing the plaster with the polyurethane residue powder,

iii) addition of fibers, additives and water in sufficient quantity to achieve adequate workability of the mixture,

iv) homogenization of the mixture, molded into standard molds, mechanical vibration and subsequent setting at factory ambient conditions 21 ° C and relative humidity of 50 ± 1%,

v) drying, in a mechanical dryer at 40 ± 2 ° C.

In the iv) homogenization step, the obtained conglomerate is kneaded and tested according to the UNE-EN 13279-2: 2006 construction plasters and plaster-based conglomerates for construction, Test methods. The suspended ceiling plate obtained with this procedure complies with current regulations (UNE-EN 14246: 2007, Plasterboard for suspended ceilings).

By way of illustration, the use of prefabricated lightened plaster with polyurethane foam from industrial waste in the form of a suspended ceiling plate for the construction of both new construction and rehabilitation under existing slabs is cited, in order to achieve an improvement aesthetic, acoustic or fire protection.

The following non-limiting examples are intended to illustrate the invention.

Example 1

Type A plaster, crushed type 1 polyurethane foam with particle sizes smaller than 2 mm in 1 / 1.5 ratio (one part of plaster per 1.5 parts of foam) is mixed. 1% fibers and 0.50% additive are added, and mixed with water. The properties in the fresh and hardened state are reflected in Tables 2, 3 and 4.

Example 2

Type A plaster, crushed type 2 polyurethane foam with particle sizes smaller than 2 mm in 1 / 1.5 ratio (one part of plaster per 1.5 parts of foam) is mixed. 1% fibers and 0.50% additive are added, and mixed with water. The properties in the fresh and hardened state are reflected in Tables 2, 3 and 4.

Example 3

Type A plaster, crushed type 3 polyurethane foam with particle sizes smaller than 2 mm in 1 / 1.5 ratio (one part of plaster per 1.5 parts of foam) is mixed. 1% fibers and 0.50% additive are added, and mixed with water. The properties in the fresh and hardened state are reflected in Tables 2, 3 and 4.

Example 4

Type A plaster, crushed type 4 polyurethane foam with particle sizes smaller than 2 mm in 1 / 1.5 ratio (one part of plaster per 1.5 parts of foam) is mixed. 1% fibers and 0.50% additive are added, and mixed with water. The properties in the fresh and hardened state are reflected in Tables 2, 3 and 4.

Example 5

Type A plaster, crushed type 5 polyurethane foam with particle sizes smaller than 2 mm in 1 / 1.5 ratio (one part of plaster per 1.5 parts of foam) is mixed. 1% fibers and 0.50% additive are added, and mixed with water. The properties in the fresh and hardened state are reflected in Tables 2, 3 and 4.

Table 2

Table 3

Table 4

The tests were carried out in accordance with standard UNE-EN 13279-2: 2006 Construction plasters and plaster-based binders for construction, Test methods, complying in all cases with the requirements required by said standard.

Applying the exposed process, plasterboard was manufactured with industrial polyurethane residues of various origins, with the dosages indicated in the following table 5. The suspended ceiling plates obtained with this procedure comply with current regulations (UNE-EN 14246 : 2007, Plasterboard for suspended ceilings).

Table 5

The weight reduction was then calculated in the case of the plates obtained according to the invention and in comparison with a standard plasterboard, as shown in the following table 6.

Table 6

The thermal conductivity of the plates manufactured according to the invention has been established, according to the UNE-EN 12667: 2002 standard, Determination of the thermal resistance by the hot plate method and the heat flow meter method.

The results of decrease in the thermal conductivity of the plates manufactured against a standard plate (without residues) are reflected in Table 7.

Table 7

Various tests have been carried out in the mixtures to know their classification to fire. The tests carried out are established in the UNE EN-ISO 1182 standard "Reaction to fire tests of products. Non-combustibility test", the data obtained are reflected in Table 8.

Table 8

With the UNE EN-ISO 1716 standard "Reaction to fire tests of products. Determination of the gross heat of combustion" the data obtained are reflected in Table 9.

Table 9

In accordance with the procedures established in the UNE-EN 13501 1: 2007 + A1: 2010 standard “Classification according to the fire behavior of construction products and building elements. Part 1: Classification based on data obtained in Fire Reaction tests ”the data obtained allow us to classify these plates as A1.

Claims (2)

1.-Prefabricated lightened plaster with polyurethane foam from industrial waste, in the form of a suspended ceiling plate, with the following composition: • plaster or commercial plaster; • crushed polyurethane foam residues of industrial origin, with a particle size of less than 2 mm; • reinforcing fibers, which improve the mechanical properties of the prefabricated, in a proportion of 1% by weight; • additives to improve the physical characteristics / performance of the product, in a proportion of 0.5% by weight and • Water, the proportion being plaster: polyurethane foam residues of 1: 1.5 by volume. 2. Prefabricated plaster lightened with polyurethane foam according to claim 1, characterized in that the plaster is type A (E35) according to EN 13279-1: 2009, with a purity index> 92%, setting principle> 10 minutes and mechanical resistance to flexotraction> 3.4 N / mm2.