ES2934836A1 - Construction material, panel and manufacturing process of said construction material (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

The invention relates to an insulating construction material comprising: a mixture of water and binder material, the water/binding material weight ratio being at least 0.6 and at most 1.0; and - rubber particles, the ratio by weight between the rubber particles and the binder material being at least 10% and at most 20%; the weight ratio between the rubber particles and the binder material being defined as: {IMAGE-01} where: r: is the weight ratio between the rubber particles and the binder material, m p : is the total mass of the rubber particles of construction material and m c: is the total mass of the binding material of the construction material. (Machine-translation by Google Translate, not legally binding)

Description

DESCRIPTION

Construction material, panel and manufacturing process of said construction material

TECHNIQUE SECTOR

The present invention belongs to the technical field of building materials. More in particular it belongs to the technical field of building materials comprising a binder material.

BACKGROUND OF THE INVENTION

Plaster is a traditional material that has been used in construction since ancient times. Gypsum has also been used in decoration, in medicine and even in food. To obtain construction plaster, a powdery product used in the manufacture of panels, prefabricated or directly on site, it is possible to start from the sedimentary rock called aljez, whose composition is dihydrated calcium sulphate, very abundant in nature.

The stucco differs from the plaster in that its granulometry is finer and its purity is above 80%. Among its advantages can be highlighted a great resistance to fire, good thermal and acoustic insulation. It is a durable, non-toxic material, with hygroscopic behavior, easy to apply and ideal for lining walls and ceilings with a high degree of comfort.

In Spain, around 25 million paddle tennis and tennis balls are consumed annually, generating approximately 2000 tons of waste per year. Recycling is very difficult due to the nature of its components (100% crosslinked rubber core combined with some chemical compounds and yellow felt covers) of low degradability, so it would take many years to decompose in landfills.

There are many investigations and patents found on plaster applications and compounds. Among which currently include:

Patent ES 1241509 U "Lightened plaster precast with polyurethane foam waste" tries to obtain a lightened precast with polyurethane foam (from industrial waste) and fibers that improve mechanical properties. Obtaining plasterboard for suspended ceilings achieving an aesthetic and acoustic improvement.

Patent ES 1227514 U entitled "Prefabricated plasterboard with high fire resistance" is based on the manufacture of prefabricated plates, with a core composed of aggregates from the steel industry, covered on both sides with a cellulosic coating. Obtaining a material for precast with greater fire resistance than traditional precast.

Patent ES 2176105 entitled "Multipurpose, insulating, anti-vibration, adhesive and fire-resistant product for different industrial sectors, especially for construction", investigates a material for linings and interior partitions composed of plaster and polyvinyl acetate, obtaining a product construction applicable as insulation and vibration damper.

The patent P201930955 "Plaster with rubber dust from end-of-life tires (nfu) and reinforced with carbon fibers, its production procedure and its use" describes the obtaining of lightened plaster with rubber dust (end-of-life tires) and carbon fibers, using it for the elaboration of lightened prefabricated plates and plaster panels.

The patent P202030595 "rapid-setting and lightweight plaster material with granulated polymers" results in a new lightweight plaster material for the production of false ceilings, with a reduction of between 15 and 20% in weight, a much faster setting faster and better thermal insulation, than the prefabricated ones for traditional roofs.

GENERAL DESCRIPTION OF THE INVENTION

The present invention tries to solve problems that have state-of-the-art solutions such as those mentioned above.

Prefabricated plaster plates and panels have been used in construction for several decades, having a wide field of application in building for the execution of linings, false ceilings and interior partitions, among others. These plates or panels must have a certain mechanical stability that allows them to withstand bending and buckling stresses, as well as possess certain thermal and acoustic insulation properties that improve comfort inside the rooms where they are executed. Today, research continues in this line with the intention of improving these physical and mechanical properties by designing new, more competitive plaster materials on the market.

For the purposes of this patent, a prefabricated plate or panel is understood to be any constructive element, or part thereof, previously manufactured in a place other than its final location. Preferably, said constructive element can consist of modules prefabricated, panels for interior divisions, ceilings and false ceilings, all of them of any surface and thickness.

The present invention makes it possible to reuse paddle ball waste in a binder material matrix, making it possible to reduce the consumption of raw material, that is, material extracted from nature, by substituting part of the binder material with said waste. In this way, the present invention contributes to the conservation of the environment, reducing the amount of CO2 produced when manufacturing the construction material and allowing the elimination of very slow decomposition residues, such as paddle tennis balls, including them in a construction material after having them. crushed.

A first aspect of the present invention refers to an insulating construction material comprising:

- a mixture of water and binder material, the ratio by weight of water/binding material being at least 0.6 and at most 1.0; and

- rubber particles, the ratio by weight between the rubber particles and the binder material being at least 10% and at most 20%; the weight ratio between the rubber particles and the binder material being defined as:

where:

r: is the ratio by weight between the rubber particles and the binder material,

mp: is the total mass of the rubber particles of the construction material and

mc: is the total mass of the binding material of the construction material.

The water/binding material weight ratio can be defined as:

s = ^a

mc

where:

s: is the water/binding material weight ratio,

ma: is the total mass of water in the construction material and

mc: is the total mass of the binding material of the construction material.

In the present disclosure, binding material is understood to be that which is capable of binding particles of one or more substances and giving cohesion to the whole. In some embodiments, the binder material is anhydrite, plaster, and/or plaster.

Any type of plaster or commercial plaster can be used as binder material, preferable to use plaster type E-35 or E-35-L (designated as Type A plaster-based binder according to standard 13279-1) due to its good properties. technical benefits. E-35 plaster is a material commonly used in construction, consisting mainly of semi-hydrated calcium sulphate (SO4Ca1/2H20), and which can incorporate setting regulating additives in its composition. It is a pulverulent material of high purity and fineness of grinding, with a minimum resistance of 3.5 N/mm2 to flexotraction and a thermal conductivity of approximately 0.34 W/mK. The setting of the E-35-L plaster is relatively slow.

In some embodiments, the construction material is a lightweight plaster.

According to the UNE-EN 13279-1:2009 standard, lightened plasters are understood to be those compounds formed by a mixture of calcium sulphate in its different phases of dehydration (anhydrite, hemihydrate or dihydrate), with a determined content of calcium hydroxide, that incorporates light inorganic or organic aggregates, to which mixing water must be added for its use. Therefore, the construction material object of the present invention, to which the rubber particles are incorporated, could be included within the definition included in the aforementioned standard.

For the production of this construction material, rubber particles are used, for example, from paddle tennis and/or tennis balls. The main intention when choosing these balls to crush them to a size preferably between 4 mm and 5 mm, is to give this rubber a second useful life and avoid the environmental impact generated by its slow natural degradation.

In this way, it is possible to obtain a construction material with excellent performance for the production of precast plates and panels, maintaining good technical performance and incorporating sustainability and circular economy criteria in the execution of the new construction materials that are more respectful with the environment. .

The developments of the state of the art have searched for a material that, mixed with different residues, improves the properties of the gypsum products, contributes to the recycling of the residue and helps to minimize the use of natural resources. But no state-of-the-art development has been found that includes mixtures of plaster with natural rubber. from paddle or tennis balls. Therefore, given the high use consumption of tennis and paddle tennis balls and the very short period of use, around three amateur matches and two professional matches, the purpose of the present invention is interesting.

The sum of the percentages by weight of the water, of the binder material and of the rubber particles of the construction material is less than or equal to 100% by weight of the construction material, the percentages being by weight with respect to the weight of the construction material .

In some embodiments, the water/binding material weight ratio is at least 0.6 and at most 0.8. These embodiments make it possible to improve the mechanical resistance of the construction material compared to embodiments with a higher water/binding material weight ratio.

In some embodiments, each rubber particle has a size such that the particle can be accommodated in a cube with a side of 5 mm and cannot be accommodated in a cube with a side less than 4 mm. The use of particles of this size is advantageous because they can be easily obtained, for example, by crushing tennis balls and/or paddle tennis balls.

In some embodiments, each rubber particle is adhered to a felt. The felt can comprise fibers such as polyamide, cotton and/or wool fibers. Although felting can reduce the mechanical strength of the building material compared to non-felted rubber particle building material, felted rubber particles can be easily obtained, for example, by grinding tennis balls and/or or paddle tennis balls and make it possible to obtain a construction material with suitable properties.

In some embodiments, the particles are fragments of tennis balls and/or paddle balls, such as used tennis balls and/or paddle balls. The main intention when choosing this type of raw material to crush it is to give the balls a second useful life and avoid the environmental impact generated by their slow natural degradation. Tennis balls and/or paddle tennis balls generally comprise a rubber sphere and a felt covering the sphere, the felt being adhered to the sphere. The rubber can be natural and/or synthetic.

In some embodiments, the rubber particles have a lower density than the mixture of water and building material binder material. Thus, this solid building material is lighter compared to a solid building material that comprised the mixture of water and binder material instead of the rubber particles.

A second aspect of the present invention relates to a panel, the panel comprising the construction material of the first aspect of the present invention. In some embodiments, the panel is a prefabricated panel.

A third aspect of the present invention refers to a manufacturing process for the construction material of the first aspect of the present invention, comprising the process

- grinding a rubber product to obtain particles of the rubber product;

- mixing the particles with binder material and with water, obtaining a mixture with a water/binding material weight ratio of at least 0.6 and at most 1.0; and the mixture having a weight ratio between the rubber particles and the binder material of at least 10% and a maximum of 20%, so that the construction material is obtained; the weight ratio between the rubber particles and the binder material being defined as:

where:

r : is the ratio by weight between the rubber particles and the binder material,

mp: is the total mass of the rubber particles of the construction material and

mc: is the total mass of the binding material of the construction material.

Therefore, the object of the present invention, unlike the materials and their methods of obtaining described in the state of the art, is to present a new construction material that allows the elaboration of precast elements with low density, with low thermal conductivity. and good mechanical properties. Said material is obtained by adding rubber particles, for example, from paddle tennis and/or tennis balls that are out of use. These rubber particles are incorporated into the manufacturing process of the plaster or plaster materials when they are still in a liquid state as the plaster or plaster powder has been combined with water and the resulting paste has been homogenized, in such a way that later a continuous setting and joint hardening of the resulting final mixture occurs.

In this way, it is possible to obtain a construction material with excellent performance for the production of precast plates and panels, maintaining good technical performance and incorporating sustainability and circular economy criteria in the execution of the new construction materials that are more respectful with the environment. .

In some embodiments, the rubber product is a tennis ball or paddle ball, for example, an end-of-life tennis ball or paddle ball. In this way, a building material is achieved with mechanical and insulating properties similar to those of a different building material in which the rubber particles are replaced by the water-binding material.

An example of an out-of-use padel or tennis ball is a padel or tennis ball with an internal pressure of less than 12 psi, 11 psi or 10 psi, that is, less than 82.7371 kPa, at 75, 8423 kPa or 68.9476 kPa. As the paddle or tennis balls are used or as the paddle or tennis balls spend time at atmospheric pressure, the pressure inside the balls decreases. By decreasing below the indicated pressures, the padel or tennis ball does not bounce enough to be used in padel or tennis matches, for which, in general, the ball is discarded.

In some embodiments, each particle is sized such that the particle can be accommodated in a cube 5mm on a side and cannot be accommodated in a cube with a side less than 4mm.

In some embodiments, the process comprises sieving the particles resulting from the crushing to separate from the rest of the particles the particles of such a size that each particle can be housed in a cube with a side of 5 mm and cannot be housed in a cube with a side of less than 4 mm. . This sieving makes it easy to separate particles of the right size.

In some embodiments, the process comprises mixing the particles with binder material and with water by gradually adding water to the particles and binder material so as to obtain intermediate mixtures with different water/particle weight ratios of the rubber product; and the process comprises stirring the intermediate mixtures. The combination of stirring with the gradual addition of water allows to improve the mechanical union between the rubber particles and the paste formed by the water and the binder material.

In some embodiments, the process comprises pouring the mixture into a mold. Of course, the mix is poured after adding the full amount of water to the mix. Molding allows the construction material to be given the desired shape. The mold has a shape complementary to a shape of the material of construction.

In some embodiments, the process comprises allowing the mixture to stand for at least forty-five seconds and at most seventy-five seconds from completion of agitation to pouring into the mold. The mixture is allowed to stand after the full amount of water has been added to the mixture. In general, this rest allows the mixture to settle, so as to improve the homogeneity of the mechanical properties of the solid matrix of water with binder material.

In some embodiments, the process comprises vibrating the mold with the mixture in the mold. The vibration of the mold allows, in those cases in which the mixture is settable, to accelerate the setting of the mixture.

The different aspects and embodiments of the invention defined above can be combined with each other, as long as they are mutually compatible.

Additional advantages and features of the invention will become apparent from the following detailed description and will be pointed out with particularity in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to help a better understanding of the characteristics of the invention according to examples of practical embodiments of the same, a set of drawings is attached as an integral part of the description, in which, for illustrative purposes, what has been represented has been following:

Figure 1 schematically shows a panel according to some embodiments of the invention.

Figure 2 schematically shows a panel according to some embodiments of the invention.

Figure 3 schematically shows a panel according to some embodiments of the invention.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

In view of this description and figures, the person skilled in the art will be able to understand that the invention has been described according to some preferred embodiments thereof, but that multiple variations can be introduced in said preferred embodiments, without departing from the object of the invention as such. and as it has been claimed.

In some embodiments, the construction material comprises type A plaster or type B construction plaster, water, and fragments of paddle tennis balls and/or tennis balls, the fragments of the balls having rubber. Gypsum is one of the most widely used binder materials and one with the strongest roots in construction traditions. Due to the different manufacturing systems and the different additives (chemical compounds) that improve and adjust the product to market demands, there is a wide variety of plasters. In some embodiments, an E-35 plaster generally used for precast, bonding paste, and refinishing work has been used. Table 1 shows characteristics of an E-35 plaster. At the filing date of this application this plaster is commercially available as E-35 plaster from IBERYOLA. IBERYOLA's E-35 plaster has the N mark for AENOR and is classified according to UNE-EN 13729-1:2009 as "gypsum-based binder for construction" type A:

Table 1

The rubber of the fragments of the tennis balls and/or the paddle balls can be a vulcanized natural rubber. The rubber may be covered with a felt of, for example, a blend of fibers, the blend of fibers having 37% polyamide, 13% cotton and 50% wool. The fragments/binding material weight ratio can be between 10.14% and a maximum of 20%.

The amount of water used in the mix can be adjusted so that the water/binding material ratio is at least 0.7 and at most 1.0.

Figures 1, 2 and 3 show examples of panels 21, 22, 23 made of the building material. The panels 21, 22, 23 have a length L, a width A and a total thickness E. The first panel 21 has a first section 11 in the shape of a rectangle. The second panel 22 has a second T-shaped section 12, the horizontal portion of the T having a thickness e2. The third panel 23 has a T-shaped section 13 superimposed with a L-shaped such that the vertical portion of the T coincides with the vertical portion of the L. The horizontal portion of the T of the third panel 23 has a thickness e3.

In one example, the construction material manufacturing process comprises grinding a rubber product, such as one or more tennis balls and/or paddle tennis balls. It can be shredded manually or automatically. The grinding action makes it possible to obtain rubber particles, that is, fragments of the rubber product, with a size suitable for the building material, for example, rubber particles with a size of at least 4 mm and at most 5 mm.

In order to select the rubber particles with a suitable size, the construction material manufacturing process may comprise sieving the rubber particles so as to separate the particles with a suitable size from the particles with a size not suitable for the construction material. . For example, the particles can be sieved in a first sieve that blocks the passage of particles with dimensions greater than a suitable maximum dimension of, for example, 5 mm. The particles that have passed through the first sieve can then be sieved on a second sieve. The second sieve blocks particles with dimensions greater than a suitable minimum dimension of, for example, 4 mm. In this way, the particles blocked by the second sieve have a suitable size for the building material.

In another stage of the manufacturing process of the construction material, the rubber particles are mixed with a binding material and with water, so as to obtain a mixture with a water/binding material weight ratio of at least 0.6 and as maximum of 1.0. The binder material can be plaster. A dry intermediate mix of rubber and gypsum particles can be carried out before adding the water to the intermediate mix.

In order to improve the uniformity of a subsequent set of the mixture, the construction material manufacturing process may comprise progressively adding water to the intermediate mixture and agitating the mixture with different amounts of added water. The mixture can be agitated, for example, by moving a paddle into the mixture so that the paddle describes a figure-eight motion. The mixture can be agitated for between forty-five seconds and seventy-five seconds to improve the uniformity of the mixture.

In order to improve the uniformity of a subsequent setting of the mixture, the construction material manufacturing process may comprise allowing the mixture to settle. The mixture can be allowed to settle, for example, for at least thirty seconds after a stage of agitation of the mixture. In general this standing allows the mix to settle, so that the formation of voids within the volume of the mix is minimized.

To give the mixture a concrete shape, the construction material manufacturing process may comprise pouring the mixture into a mould. For example, this pouring can be carried out after the stage of resting the mixture.

In another stage of the construction material manufacturing process, the mixture is set. Logically, this stage is present in construction material manufacturing processes in which the binder material is plaster, plaster or another binder material that can be set by mixing the binder material with water. It has been observed that a construction material with better mechanical properties is obtained if the mixture is set in an environment at a temperature of 22°C and with a relative humidity of 50%.

In another stage of the construction material manufacturing process, the set mixture can be dried, for example, in an environment at 40°C. This drying makes it possible to improve the thermal resistance of the construction material.

This construction material manufacturing process allows prefabricated products made from the construction material obtained by said process to comply with the UNE-EN 14246:2007 standard "Plaster sheets for suspended ceilings. Definitions, specifications and test methods."

Different types of plates can be made depending on the manufacturer, although a specific example of a specific manufacturing process for a product made from the construction material is given below. First, the amount of plaster necessary for the manufacture of plates is mixed dry with 14% by weight of paddle ball residue with respect to plaster. Subsequently, a quantity of water is added such that the water/gypsum weight ratio is equal to 0.7 in the dry mix. Next, a paste resulting from adding water to the dry mixture is kneaded for one minute as established in the UNE-EN 13279-2:2014 standard "Construction plasters and plaster-based binders for construction. Part 2: Methods of testing" .

Let the paste rest for thirty seconds and then pour it into the molds on the plate in three batches, tapping about five times between batches so that the thickness and distribution of the residue is as uniform as possible over the entire surface of the mold. The plate is then flushed so that the flushed surface is smooth.

During the setting of the plates, the metal mechanisms necessary for fixing the plates, for example square or rectangular, to the ceiling fastening elements can be installed.

Once dry, the plates admit any type of machining, painting or surface preparation. The whole system is simple, clean and easy to assemble.

The construction material obtained has been tested according to the UNE-EN 13279-2:2006 Standard "Construction plasters and plaster-based binders for construction. Part 2: Test methods", complying with the minimums established in said standard.

The invention can be applied as a plaster compound or as a material for the manufacture of prefabricated construction parts, as well as: panels for interior divisions, or plates for false ceilings.

The shape of the prefabricated component is adaptable, being generally square or rectangular for partitions, false ceilings; and being the most unique form for mouldings.

In this text, the term "comprises" and its variants (such as "comprising", etc.) should not be understood in an exclusive way, that is, they exclude the possibility that what is described includes other elements, steps, etc.

On the other hand, the invention is not limited to the concrete embodiments that have been described but also covers, for example, the variants that can be made by the average person skilled in the art (for example, regarding the choice of materials, dimensions , components, configuration, etc.), within what is apparent from the claims.

Claims (16)

1. Insulating construction material characterized by comprising: - a mixture of water and binder material, the ratio by weight of water/binding material being at least 0.6 and at most 1.0; and - rubber particles, the ratio by weight between the rubber particles and the binder material being at least 10% and at most 20%; the weight ratio between the rubber particles and the binder material being defined as:

where: r: is the ratio by weight between the rubber particles and the binder material, mp: is the total mass of the rubber particles of the construction material and mc: is the total mass of the binding material of the construction material. 2. The construction material of claim 1, the binder material being anhydrite, plaster and/or plaster. 3. The construction material of any one of the preceding claims, the ratio by weight of water/binding material being at least 0.6 and at most 0.8. 4. The construction material of any one of the preceding claims, each rubber particle having a size such that the particle can be housed in a cube with a side of 5 mm and cannot be housed in a cube with a side of less than 4 mm. The building material of any one of the preceding claims, each rubber particle being adhered to a felt. 6. The construction material of any one of the preceding claims, the particles being fragments of tennis balls and/or paddle balls. The building material of any one of the preceding claims, the rubber particles having a density less than a density of the mixture of water and binder material. Panel (21), the panel (21) comprising the building material of any one of the preceding claims. 9. Process for making the construction material according to any one of claims 1 to 7, characterized in that it comprises: - grinding a rubber product to obtain particles of the rubber product; - mixing the particles with binder material and with water, obtaining a mixture with a water/binding material weight ratio of at least 0.6 and at most 1.0; and the mixture having a weight ratio between the rubber particles and the binder material of at least 10% and a maximum of 20%, so that the construction material is obtained; the weight ratio between the rubber particles and the binder material being defined as:

where: r : is the ratio by weight between the rubber particles and the binder material, mp: is the total mass of the rubber particles of the construction material and mc: is the total mass of the binding material of the construction material. The process of claim 9, the rubber product being a tennis ball or a paddle ball. 11. The process of any one of claims 9 and 10, the particles having a size such that each particle can be housed in a cube with a side of 5 mm and cannot be housed in a cube with a side of less than 4 mm. 12. The process of claim 11, the process comprising sieving the particles resulting from the crushing to separate from the rest of the particles the particles of such a size that each particle can be housed in a cube of 5 mm on a side and cannot be housed in a cube of side less than 4 mm. The process of any one of claims 9 to 12, comprising mixing the particles with binder material and with water by gradually adding water to the particles and binder material so as to obtain mixtures intermediates with different ratios by weight of water/particles of the rubber product; and understanding the process agitate the intermediate mixtures. The process of any one of claims 9 to 13, comprising pouring the mixture into a mould. 15. The process of claims 13 and 14, comprising allowing the mixture to settle for at least forty-five seconds and at most seventy-five seconds from the completion of agitation until pouring into the mold. The process of claim 14 or 15, comprising vibrating the mold with the mixture in the mold.