SI26304A - Procedure for making building board by recycling styrofoam scraps - Google Patents

Abstract

The essence of the invention is a new process for recycling Styrofoam waste with the addition of a new liquid facade mortar to the bin (2) for pouring and filling the space in the bin (3) and enables the production of new auxiliary products (4) for insulation and reduces the consumption of input raw materials.

Description

PROCEDURE FOR MANUFACTURING BUILDING PANELS WITH RECYCLING

REMAINS OF STYROPORE

The present invention relates to a new process by which useless Styrofoam waste is recycled. Unusable Styrofoam residues are generated in construction or other similar activities. With it, we get a new building product, suitable for installation in industrial buildings, residential buildings or buildings that require thermal insulation. It is a field of chemical technology, namely Styrofoam residues, which are created as construction residues or waste.

Until now, the known solutions for obtaining insulating materials, regardless of the raw material base, have not yet provided this type of solution, as proposed. The technical problem of the invention is how to protect the environment with a uniform technical process, the protective problem of the generation of Styrofoam residues, which is generated as construction waste mainly in the construction industry. So far, it has been collected in tin barrels or bags in accordance with the Rules on Waste Management (Official Gazette of the RS, No. 13/03, 41/04, 34/08) and the Rules on Amendments to the Rules on the Management of Waste Generated in Construction parts (Official Gazette of the RS, no. 50/04, 62/04, 34/08).

In the search for a solution, we came up with a unique solution, we invented a process for obtaining a new construction product from the remains of the mentioned materials, which have utility in the form of panels, walls suitable for laying as thermal insulation. In this way, the new construction product, manufactured according to the presented process, gained versatile utility in the construction industry as a hard material.

At the same time, the process allows us to destroy Styrofoam residues in several ways. To the greatest extent, this type of waste is disposed of in the landfills of authorized organizations, where it takes up a lot of space.

In our case, we studied the possibilities of processing Styrofoam and insulating materials. Remnants of styrofoam during the construction of buildings are created in various phases of the construction of the building, as classic construction waste, which must be handled in accordance with the Rules for handling waste generated during construction work. Insulating materials and Styrofoam are treated in the same way. Styrofoam waste is produced as waste during thermal insulation of buildings, where it is necessary to adapt the seams to the individual dimensions of the building.

When devising a solution for the process for recycling waste, styrofoam remains, we start from known technical solutions of individual devices used in chemical technology for various technological processes such as: grinding, tearing, pressing, cutting, crushing, mixing, sorting, gluing, drying, adding additives and the experience of producers of insulation materials, styrofoam and construction companies and also in similar areas of waste processing such as plastic, paper, experience in the recycling of car scraps. With this aim, after preliminary research and invention, we found that the purpose of the invention is to provide a different process for recycling styrofoam scraps using already known devices and to place them in the correct sequence of our process, which will eventually give the desired result, which is evident after the application for the grant of a patent. It is essential to conclude that we have come up with a new construction product that meets the prescribed standards in terms of quality and enables versatility of use and at the same time solves environmental problems. The presented invention solves the cost and environmental burden in construction and other similar activities and enables authorized organizations, where this type of waste is disposed of in one place, to carry out additional processing activities.

We have found that there are patent applications that deal with the recycling of individual types of waste and scraps of various materials, which are mainly related to the recycling of unnecessary paper and other scraps of cellulose, plastic, waste rubber, as well as the recycling of useless polyurethane foam and textile scraps that are produced in textile industry, but no application solved the problem of recycling Styrofoam residues, and more precisely defined some products from this recycled mixture.

When examining the reported inventions, the applicants are only aware of the process for granular recycling of polyurethane, polystyrene residues, glass wool residues, this type of recycling solution. There are various technical solutions for lines for the recycling of the above-mentioned scraps, but for our object of protection or for the recycling of Styrofoam scraps according to our process, we have not found a similarly reported solution apart from the ones mentioned above. We will list some already reported solutions that demonstrate the innovativeness of the solution and serve as a defensive element in proving the innovation:

IT BL92A000019, which provides a solution for the process of manufacturing hard boards from scrap paper, pulp and similar materials.

SI 20267 A also provides a solution for using cellulose waste materials in conjunction with cement.

AT 1318/85 and AT 2896/85 deal with formwork walls that are filled with glass wool, which otherwise has similarities with the use in one of the useful forms of my insulating material,

EP 08429667 A2 deals with composite material in the production of glass and mineral fibers from glass wool and as such has no point of contact with my patent,

According to the data known to us, no manufacturer of this type of equipment, which is proposed according to the patent, has so far combined this or a similar device into a single comprehensive system and in such a way that the processing of Styrofoam residues is enabled.

The novelty is mainly in the use of combinations of styrofoam residues, it is about making a new product from styrofoam residues. The new product created in this way is a commercial product for wide use due to its insulating, water-repellent and anti-noise properties.

The described invention innovatively solves the problem of binding Styrofoam residues.

The basic idea of the invention stems from the possibility of re-mechanical and chemical processing or recycling of the listed waste. In the experimental work, we came to the following conclusions: a) styrofoam can be processed by mechanical crushing and the use of fresh adhesive again in the insulating material,

On the basis of the established state of the art and the experiments carried out in production, we have confirmed certain advantages of the process according to the invention, which is manifested in the simplicity of the process.

We will show the invention with sketches as follows, because we believe that it is so simple and that the necessary devices for its realization can be found in an unlimited number of versions in terms of quality and capacity, so that everyone can adapt it to their technological needs.

The invention is described in the following steps and figures showing:

Procedure steps:

a) crushing styrofoam construction remnants from 1 dm ³ to 5 dm ³ ,

b) pouring crushed styrofoam into the basket in a ratio of up to 50% by volume,

c) pouring the remains with fresh facade mortar of the manufacturer's existing recipe into the basket and applying the new mixture to the panel and the reinforced mesh

d) drying and hardening of the new product in accordance with the instructions of the manufacturer of the facade mortar used,

e) cutting into desired dimensions of standard dimensions.

The optimal recommended ratio is up to 50% by volume of crushed Styrofoam residues and 50% by volume of the addition of new facade mortar according to the manufacturers' instructions. The recycling process takes place by mechanically crushing Styrofoam residues into crumbs/granules (1), the size of e.g. from 1 dm ³ to 5 dm ³ , and fill the basket with it to a maximum of 50% of the volume of the mold (2). Figure 1 shows a bin filled with shredded Styrofoam waste. The crushed stone/granules are poured over with fresh liquid facade mortar raw material according to the manufacturer's recipe, regardless of the type of mortar recipe, as only this serves as a binder for the crushed stone. The binder pours over the residue or a mixture of residues and fills the space in the mold (3), 100% pouring and binding of the residue in a closed mold (2) e.g. size of 3 m ³ is possible by slightly shaking the mold to fill the space between the crushed stone. Pouring the crumb and drying the mass in a closed mold enables a hard bond. The mixture of residues and new mass applied to the panels is left to dry on racks for 24 hours to harden according to the facade mortar manufacturer's instructions, and after drying and hardening, it is cut into boards (4) of the desired standard dimensions as a new insulating material. The resulting product is cut into plates (4) of the desired standard dimensions as shown in Figure 2. It is about the production of plates intended for insulation, e.g. screeds in the house, insulation of houses, production of eaves, fences, partitions in very humid rooms, saunas,... The resulting product is suitable as an insulator in the construction industry.

The invention solves:

The problem of accumulation of construction waste in municipal landfills

The problem is reducing the cost of disposal of construction waste

The problem solves the consumption of the basic raw material and returns it recycled for further use in the construction industry

Claims (1)

1. The process for recycling styrofoam scraps and scraps for the production of new insulation material, various solid boards for a wide variety of uses and manufactured products, especially for thermal insulation of various spaces, as well as for use in the construction industry, is designed to use raw materials such as remains of Styrofoam (1) and their mixtures, which are first roughly crushed into small particles, and filled with them in the mold (2), characterized by the fact that the remains of Styrofoam (1) are crushed and poured into the mold up to 50% of the volume of the mold ( 2), and liquid facade mortar according to the manufacturer's recipe is used as a binder, which pours residues or a mixture of residues up to 100% of the volume of the mold and fills the space in the mold (3), and the new material is allowed to dry and harden according to the instructions of the manufacturer of the facade mortar and after drying and hardening, we cut it into panels (4) of the desired standard dimensions as a new insulating material.