SE510848C2 - Fiber reinforced and heat insulating as well as supporting construction - 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.

Description

Ü> 510 848 List of figures Fig. 1 shows a construction part (1) consisting of expanded plastic particles (2) and binders such as cement (4) and filling material (5) such as sand.

Fig. 2 shows a construction part (1) consisting of fibers (3) and binder (4) as well as filling material (5).

Fig. 3 shows a construction part (1) according to the invention as described in the claim, consisting of expanded plastic particles (2) eg expanded polystyrene, natural fibers (3) eg jute and binder eg cement (4) and filler material (5) eg sawdust.

The float protection means and aids are not separately marked in the figure.

The mixing ratios may vary in different parts of the load-bearing structural part for optimization of the desired overall properties. Fig. 4 shows, for the sake of clarity, on an exaggerated scale, an example of an inventive construction part (1) in which the various components (2,3,4,5) mixing ratios vary in different parts of the construction part.

Fig. 5 shows a corresponding example of a construction part according to the invention where the mixing conditions vary in different parts of the product in order to obtain optimal properties.

Fig. 6 shows an example of joining construction details according to the invention to, for example, a house or a container. Possible other property-improving agents, such as fire protection and anti-rot agents, are not excellent in the figures. , 10 »848 Description, special part its service life.

The mixing ratios of the components can vary stepwise as needed in different innovations and the invention consists in numerous, earlier per se but only separately and in completely different mixtures deviating from this and giving completely superior and also surprising properties to the product according to the invention. Especially the surprising ecological benefits are undeniable.

Mixing the coffee industry's large problem waste of emptied and broken natural fiber bags, the electronics and food industry's problematic waste of 510 848 å This innovation requires in-depth cross-scientific knowledge and special knowledge of several completely different industries. It is not possible for a person skilled in the art in only one, or even two different industries to make this innovation, let alone develop the product according to the invention.

The invention cannot be considered obvious to a construction professional, whether he is a carpenter, mason or concrete mixer (especially as it is a well-known fact for builders that cellulose in contact with concrete molds and rots and must therefore be carefully avoided), a professional in The food industry, for example a coffee roastery, does not know anything about the construction industry or the plastic industry and for him the empty bags are a big waste problem, a specialist in the sawmill industry spreads the sawdust in nature to jogging tracks or burns up the sawdust waste, a specialist in the plastics industry does not know the construction industry can certainly not, on the basis of the completely different production methods of the plastics industry, which always require extremely pure raw materials without any contaminants, understand to mix the expanded waste plastic and possibly contaminated recycled plastic with sawdust and natural fibers in a completely different process, which is insensitive ig for contaminants such as sand, pieces of paper, sticks, rust, etc.

However, a person skilled in the construction industry can subsequently, with the aid of the patent documents, understand both the great commercial, technical and ecological advantages that the invention brings.

A typical base material combination is obtained by a mixing ratio consisting of sawdust, expanded plastic particles, fibers and cement in the volume ratio 1: 1: 1: 1. The mixing ratio can be adjusted in different parts of the construction so that the properties desired for different uses are obtained giving optimal total properties with material savings and lower costs.

Water is added as needed to obtain a mass of the desired consistency, which mainly depends on the manufacturing process.

The sawdust usually has a grain size of less than 3 mm and the type of wood is the most advantageous coniferous tree. The filler sawdust gives compressive strength to the mixture. The amount of sawdust and I or sand is typically 1 ... 2 volume units. A heavier product with better sound-insulating properties and better compressive strength is obtained by, for example, increasing the amount of sawdust or replacing some of the sawdust with, for example, sand, slag or other finely divided minerals. In the recipe preparation, the sand is counted as part of the sawdust.

The volume weight of the expanded plastic particles is typically in the range 10 40 kg / m3- The grain size is a mixture of different sizes, usually below 10 mm, the main amount typically in the range 5 ... 7 mm. The foamed plastic particles are mainly responsible for the product's thermal insulation properties. The amount of plastic particles typically varies from 1 to 4 volume units. The fibers, sawdust and other components insulate heat worse than the expanded or foamed plastic granules and cannot be considered part of the thermal insulation.

Lighter constructions with better insulating properties are obtained by, for example, increasing the proportion of the plastic granules foamed in Ö, i 51 e, -a -ft in certain parts, while the amounts of the other components remain unchanged.

The moisture-absorbing natural fibers with an uneven surface adhere to the usually water-based pulp considerably better than the smooth water-repellent synthetic fibers, which gives better mechanical, among other things, tensile and bending properties to the product according to the invention. The natural fibers should be as long as possible for the best mechanical properties, but still allow for efficient and even mixing. A frequently used suitable fiber length is 35 times the largest particle diameter of the mixture. The amount of fiber is usually 2 ... 10% by weight of the dry mass, but other conditions are also made as needed.

The fibers make the product according to the invention very tough, which is very important for buildings, for example in earthquake areas, which prevents the tough buildings from completely collapsing, such as brittle card houses of eg masonry "light" concrete blocks, lecastones or traditional bricks. which saves lives in case someone falls under it after all.

The binder is suitably ordinary Portland cement. Typical amount is 1 ... 2 volume units. Additives can be water glass and polymer dispersion, such as alkali-resistant acrylic dispersion, which improves the adhesion between the various components.

The amount of water depends on the desired consistency of the pulp. Water volume typically 1-2 volume units. The water is partially bound to the chemical binder (cement) and the rest evaporates so the product is dry during use.

The amounts of different components are adjusted step by step or continuously in different parts of the construction depending on the desired properties, eg more fibers, sawdust, sand at the end of a board and more foamed plastic, eg in the middle. This results in a harder protective surface and a heat-insulating softer inner part. Surface treatment and fastenings are easy to perform and digging out for eg electrical wiring is easy to do inside.

Possible other aids are added to the pulp as desired, such as water-repellent surface treatment, fire protection and flame retardants, mold and rot protection, etc.

The amount of additives is usually small compared to the main products.

Some of the advantages of the invention in the different manufacturing and use stages of the new combination: The invention does not apply to the manufacturing process or the mixing order, which can be carried out in different ways, but some comments below. The production of a material combination according to the invention of the waste products crushed (ground) foam plastic possibly with the addition of newly expanded polystyrene, sacks of natural fiber treated so that the fibers have been released and sawdust together with binders such as cement is simple and can be done without major energy supply. at room temperature (does not need to be burned or steamed at high temperature) with simple tools and without major pressure (the mass can in some cases be vibrated to obtain a smoother and denser packed product) either as continuous production or batch in molds its 848 W ß The products can all desired shapes are easily given and the properties can be optimized according to the desired area of use by designing and varying the proportions of the various components.

The material combination breathes naturally and provides simple but effective wall constructions, which do not need to be provided with, for example, a separate plastic foil such as a moisture barrier on the inner side. Suitable for use in both exterior and interior walls.

Thickness is made according to needs and wishes. The surface is easy to treat and coat in the desired way. Plaster, wallpaper, boards, paint, etc. are easy to attach to the finished surface of, for example, a wall element. Water-soluble adhesives adhere well, nails and screws hold well due to the fibers and sawdust in contrast to leca, siporex / ytong where the nails easily come off on their own.

Building elements according to the invention can easily be joined together in the traditional way with nails and battens, glued with eg PU foam, cast together with cement, etc.

The products are easy to combine with other products.

The construction-friendly material is very easy to handle even in terms of weight, which saves expensive machine costs. The products can be easily machined with standard hand tools such as hand or chainsaws for openings and shaped to size. The sawdust does not wear the tools as well as sand-based products.

The new material does not crack in heat (eg in a fire) like ordinary concrete, because evaporating gases such as water vapor can be freely removed through the construction's fibers and natural materials and pores. The material is non-combustible through the inorganic binders and possible fire protection agents that completely surround all organic components, whereby a sufficient amount of air is not obtained for combustion.

The combination emits no toxic gases other than those emitted by wood when heated above 200 °. The plastic EPS only decomposes at 600 degrees and gives only carbon dioxide and water. However, polyurethane foam (PU / PUR) and polyvinyl chloride (PVC) emit hydrocyanic acid or hydrochloric acid, so EPS is preferred. Plastic fibers melt and lose their mechanical properties already at 150-200 degrees, the organic natural fibers char and keep their mechanical strength longer. The thermal insulation protects the underlying layers, which provides greater security.

The wall also does not crack in the cold, possible moisture can freely expand in the air pores formed in the construction. Construction can therefore also be easily performed in cold and rain.

The construction does not absorb water like glass wool and ordinary building timber, which then rots and molds inside the walls. The wall breathes naturally, which is why the traditional moisture and mold problems do not occur.

The thermal insulation is good and adjusted as needed, a house with an inventive construction does not need to be additionally insulated and the house can be left out even over the winter.

The acoustics are without echo, the sound insulation is good and gets even better when sand is added.

The integrated patentable construction has all the necessary features ready-built.

Products with new material combinations according to the invention provide greater 7 'ï s1o ° iífs4s living comfort without additional costs. The price will be lower than for previously known materials, all good properties integrated in the same finished material mixture that does not need finishing.

Claims (1)

1. 510 s4s I i? A fiber-reinforced heat-insulating and load-bearing structure (1), consisting of per se known plastic granules (2), fibers (3), binders (4) and filling materials (5) and possible property-improving aids, k. components form a combination of heat-insulating plastic particles such as expanded or foamed polystyrene and / or foamed polyurethane, polyethylene, polypropylene, polyvinyl chloride and load-bearing fillers such as sawdust and / or sand and reinforcing natural fibers such as jute and / or sisal, hemp, manilla, linen, cotton, reeds and binders such as cement and / or water glass, polymer dispersion and possible other property-improving agents which, for example, inhibit fire and / or prevent mold or rot and that the mutual ratio of the components may vary in different sections of the construction part