TR201906987A2 - A THERMAL INSULATION BOARD PRODUCTION METHOD AND THERMAL INSULATION BOARD PRODUCED BY THIS METHOD - Google Patents

A THERMAL INSULATION BOARD PRODUCTION METHOD AND THERMAL INSULATION BOARD PRODUCED BY THIS METHOD Download PDF

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TR201906987A2
TR201906987A2 TR2019/06987A TR201906987A TR201906987A2 TR 201906987 A2 TR201906987 A2 TR 201906987A2 TR 2019/06987 A TR2019/06987 A TR 2019/06987A TR 201906987 A TR201906987 A TR 201906987A TR 201906987 A2 TR201906987 A2 TR 201906987A2
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thermal insulation
insulation board
produced
press
class
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TR2019/06987A
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Turkish (tr)
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Daloğlu Ti̇muçi̇n
Bahatti̇n Daloğlu Mehmet
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Dalsan Yatirim Ve Enerji A S
Dalsan Yatirim Ve Enerji̇ Anoni̇m Şi̇rketi̇
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Priority to TR2019/06987A priority Critical patent/TR201906987A2/en
Priority to PCT/TR2020/050389 priority patent/WO2020226596A1/en
Publication of TR201906987A2 publication Critical patent/TR201906987A2/en

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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78Heat insulating elements
    • E04B1/80Heat insulating elements slab-shaped
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00Roofs; Roof construction with regard to insulation
    • E04B7/20Roofs consisting of self-supporting slabs, e.g. able to be loaded
    • E04B7/22Roofs consisting of self-supporting slabs, e.g. able to be loaded the slabs having insulating properties, e.g. laminated with layers of insulating material
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/205Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Acoustics & Sound (AREA)
  • Building Environments (AREA)

Abstract

Bu buluş; mineral esaslı çekirdeğe sahip olan, düşük yoğunluklu bir ısı yalıtım levhası (1) üretim yöntemi ve bu yöntemle üretilen ısı yalıtım levhalarıyla (1) ile ilgilidir. Buluş konusu yöntem vasıtasıyla genleşmiş perlitin organik bağlayıcılar ile hareketli bir bant konveyör (B) üzerinde bir ön pres bandı (D) ve özellikle de en az bir pres (E) vasıtasıyla şekillendirilmesi ile tekniğin bilinen durumunda sıklıkla kullanılan yüksek maliyetli kalıplama tekniğinin kullanılmasına gerek kalmadan A1 sınıf yanmaz yalıtım levhası ya da A1 sınıf yanmaz yalıtımlı çatı levhası gibi ısı yalıtım levhalarının (1) ekonomik bir şekilde kesintisiz olarak üretilmesi mümkün olmaktadır.This invention; It is related to the production method of a low density thermal insulation board (1) having a mineral-based core and the thermal insulation boards (1) produced by this method. By shaping the expanded perlite with organic binders on a moving belt conveyor (B) by means of a pre-press belt (D) and especially at least one press (E) by means of the method of the invention, A1 It is possible to economically and uninterruptedly produce thermal insulation boards (1) such as class fireproof insulation board or A1 class fireproof insulation roof plate.

Description

TARIFNAME BIR isi YALITIM L EV HASI ÜRETIM YÖNTEMI VE BU YÖNTEMLE ÜRETILEN isi YALITIM LEVHASI Teknik Alan Bu bulus; mineral esasli çekirdege sahip olan, düsük yogunluklu bir isi yalitim levhasi üretim yöntemi ve bu yöntemle üretilen isi yalitim levhalariyla Ile ilgilidir. Önceki Teknik Günümüzde siklikla kullanilan yapi elemanlarinin içinde en yogun olarak kullanilanlardan biri de isi yalitim malzemeleridir. ve bu sayede yapilarda isi kayip ve kazançlarinin azaltilmasinda kullanilan malzemelerdir. Isi yalitimi amaçli kullanilan bu levhalar açik gözenekli ve kapali gözenekli olarak sinitlandirilabilmektedir. Açik gözenekli ya da elyaIli malzemelere cam yünü; tas yünü (mineral yünler), ahsap yünü, seramik yünü, cüruf yünü; kapali gözenekli malzemelere ise petrol türevli malzemelerden elde edilen genlestirilmis polistiren, ekstürüde polistiren, elastomerik kauçuk, polietilen kabugu ve silis kumunun yüksek sicaklik altinda genlestirilmesi ile elde edilen cam köpügü örnek olarak gösterilebilmektedir. Mineral ve seramik yünler ile cam köpügü haricindeki yalitim malzemeleri yanici özellik göstermeleri sebebiyle bu malzemelerin kullanimlari yapi yönetmelikleri ile sinirlandirilmaktadir. malzemelerin büyük çogunlugu ile cam yünü genellikle 30 kg/m3 degerinden daha düsük yogunlukta ve 0,03-0,04 W/m.K arasinda olan isi iletkenlik degerinde üretilmektedirler. Seramik ve tas yünleri ise 40-200 kg/m3 arasinda olan bir yogunluk degerinde üretilmekle beraber yanmaz özelligi sebebiyle binalarin dis yalitiminda siklikla kullanilan tas yünü tercihen 100-150 kg/m3 arasinda bir yogunluk degerinde üretilmektedir. Bahsedilen seramik ve tas yünleri tercihen 07045 W/m.K degerinden düsük olan bir isi iletkenlik katsayisina sahiptirler. Cam yünü ve tas yünü gibi açik gözenekli ya da elyafli tüm isi yalitim malzemeleri SIlIS kumu ya da bazaltin ilk olarak tercihen firinlarda yüksek sicakliklarda eritilmesi ve bunun ardindan sogutularak elyaf haline getirilmesini takiben bunun kesintisiz bir bant üzerine serilmesi ile elde edilmektedir. Yüksek sicaklikta çalistirilan ergitme firinlarinin hem yüksek kurulum maliyeti hem de yüksek isletme maliyeti sebebiyle söz konusu yanmaz özellikli cam ve tas yünleri petrol türevli isi yalitim malzemelerine göre daha pahalidirlar. Binalarin yangindan korunmasina yönelik yönetmeliklerde malzemeler yanicilik siniflarina göre ayrilmis olup mahallerde kullanilacak malzemeler yapi tiplerine ve kullanim amaçlarina göre belirlenmektedir. Türkiyeide 9 Eylül 2009 tarihinde 27344 numarali Resmi Gazete"de yayinlanan "Binalarin Yangindan Korunmasi Gazetede yayinlanan degisikliklerde özellikle 28,5 metreden yüksek binalarin cephelerinde ve çatilarinda hiç yanmaz (A1) sinifinda olan malzemelerin kullanilmasi sart olarak kosulmustur. Yalitim malzemelerinin yanmazliklari EN ISO 17167da tarif edilen yöntemler ile belirlenmekte ve malzemeler brüt kalorifik potansiyel (PCSýpotentiel Calorifique Supérieur) degerlerine göre siniflanmaktadirlar. Bilinen A1 sinifi yalitim malzemeleri her türlü mineral yünler, kaya yünleri, seramik yünleri ve cam köpüklerdir. Bu malzemelerin tamami çok yüksek enerji tüketimi ile elde edilen malzemeler olup yüksek maliyetlidirler. Ayrica, tüm mineral yünler, kaya yünleri ve seramik yünler nemden ve sudan etkilenmektedirler. Özellikle mineral yünler basta olmak üzere kaya ya da seramik esasli tüm kayaç tabanli yünler nemlenmeleri ya da su ile temas etmeleri sonrasinda isi yalitim özelliklerini önemli ölçüde kaybetmektedirler ya da uygulama maha'l'lerindeki bütünlüklerini koruyamayarak bükülmekte ya da yigilmaktadirlar. Teknigin bilinen durumunda yalitim malzemesi üretiminde genlestirilmis perlit kullanimi yaygin olarak bilinmektedir. Bu ürünler arasindan Birlesik Devletler menseli Johns Manville firmasi tarafindan üretilen "Fesco" ticari markali ürün perlitin agirlikli olarak kullanildigi en basarili ticari ürün olarak gösterilebilir. Esas itibariyle bir çati yalitim levhasi olan Fesco 1960°li yillarin basindan beri üretilmektedir. Fesco özünde perlit ve hurda kagit elyafinin asfalt ile karistirilmasi ile Fourdrinier teknigi kullanilarak üretilmektedir. Teknigin bilinen durumunda yer alan US3042578 sayili Birlesik Devletler patent dokümaninda perlit ve hurda kagidin birlikte kullanilmasindan bahsedilmektedir. US4126512 sayili Birlesik Devletler patent dokümaninda da nisastanin kagit elyafi ve perlit karisimina eklenmesi ile bugüne kadar süre gelen Fesco ürününün esas reçetesi olusturulmaktadir. Teknigin bilinen durumunda yer alan US4011183 sayili Birlesik Devletler patent dokümaninda agirlik olarak %75 perlit ve %25 hurda kagidi lifine, metilen klorid ve difenilmetan diizosiyant sprey edilerek 200 kg/m3 yogunlukta levha elde edilmesinden bahsedilmektedir. Buna karsi bu patent dokümaninda elde edilen levha ve Fesco levha Al sinifi yanmaz bir yalitim malzemesi olmaktan çok uzaktadirlar. US4072533 sayili Birlesik Devletler patent dokümaninda ise, çimento esasli olmayan düsük yogunluklu bir yapi elemani yogun perlit ve poliester elyaf lif kullanilarak sodyum silikatin baglayiciligi ile elde edilmektedir. Söz konusu dokümanda açiklanan levha hem çok pahali bir reçeteye sahiptir hem de kaliplama teknigi ile yüksek maliyetle üretilmektedir. US4297311 sayili Birlesik Devletler patent dokümaninda genlestirilmis perlit üre formaldehit (UF) ile sertlestirilirken pres altinda genlesmis perlitin ezilmesi ile tanelerinin kirilarak 200 kg/m3 degerinden daha yüksek olan yogunlukta olan bir dizi reçete açiklanmaktadir. SÖZ konusu ürünler kismen tozlanma ya da ufalanmaya açik olacak derecede çiplak ürünlerdir. Bu dokümanda açiklanan bulusta ayrica yanmaz malzeme de hedeflenmemektedir. US4313997 sayili Birlesik Devletler patent dokümaninda poliakrilik (Stiren Butadien (SB)) ya da lateks ile baglanarak elde edilen bir perlit esasli levhadan bahsedilmektedir. Lateks, levhaya esneklik kazandirmak için kullanilmaktadir. US4451294 sayili Birlesik Devletler patent dokümaninda sodyum silikat ve perlitin sertlestirilmesi ile elde edilen ve yanmazlik için boraks kullanilmasindan destek alan bir perlit esasli yanmaz levhadan bahsedilmektedir. U55256222 sayili Birlesik Devletler patent dokümaninda genlesmis perlit ve sodyum silikatin harç haline getirilmesi ve alçi levha üretiminde kullanilan yöntemlerde oldugu gibi bu harcin hareketli bir bant üzerinde iki karton arasina serilerek bant üzerinde sertlesmesi ve ardindan kesilerek firinlanmasi islemlerini içeren bir üretim yönteminden bahsedilmektedir. Bu yöntemle elde edilen ürün yanici kagit içermekte olup hedef ürün olarak alçi levhayi ikame edebilen hafif bir kuru duvar levhasi alinmaktadir. U56355098 sayili Birlesik Devletler patent dokümaninda perlit, sodyum ya da potasyum silikat ile sertlestirilmekte olup yogun su ihtiva eden yas ürün konvansiyonel firinlarda kurutulmadan önce mikro dalga enerjisi kullanarak ürünün kurutulmasini hedefleyen bir üretim yönteminden bahsedilmektedir. Yukarida kisaca bahsedilen önceki teknige iliskin açiklamalarda ve atifta bulunulan patent dokümanlarinda her ne kadar yogun olarak genlestirilmis perlit kullanilarak organik ya da organik olmayan baglayicilar ile düsük yogunluga sahip olan levhalarin elde edilmesinden bahsedilse de bu açiklamalarin hiç birinde A1 sinifi yanmazlik saglayan bir isi yalitim levhasindan bahsedilmemektedir. Ayrica ayni basvuru sahibine ait olan TR2019/06279 sayili Türk patent dokümaninda mineral esasli çekirdege sahip ve yüzeyleri tül ya da file benzeri malzeme Ile kaplanan düsük yogunluklu isi yalitim levhasi üretim yönteminden ve bu yöntemle üretilen isi yalitim levhalarindan bahsedilmektedir. Bulusun Kisa Açiklamasi Bu bulusun amaci kaliplama teknigi kullanilmadan bant üzerinde kesintisiz olarak hem hafif hem de ekonomik bir isi yalitim levhasinin üretilmesi için olan bir yöntem ve bu yöntemle üretilen yalitimli çati levhasi gibi isi yalitimli levhalari gerçeklestirmektir. Bu bulusun baska bir amaci A] sinifi yanmaz, nemden ve sudan az etkilenen mineral esasli bir isi yalitim levhasinin üretilmesi için olan bir yöntem ve bu yöntemle üretilen isi yalitimli levhalari gerçeklestirmektir. Bu bulusun baska bir amaci cam ya da kaya ya da seramik yün gibi kayaçlarin yüksek sicakliklarda ergitilinesi ile elde edilen yogun enerji sarfiyatina sahip olan yalitim levhalarinin yerine yogun perlit kullanarak Al sinifi yanmaz ve tercihen 0,065 W/m.K degerinden düsük bir degerde isi iletkenlik katsayisina sahip olan bir isi yalitim levhasinin üretilmesi için olan bir yöntem ve bu yöntemle üretilen isi yalitimli levhalari gerçeklestirmektir. Bu bulusun baska bir amaci üzerinde yürünebilen, hafif ve Al sinifi yanmaz ve tercihen 0,065 W/m.K degerinden daha düsük bir degerde isi iletkenlik katsayisina sahip olan bir isi yalitim levhasinin üretilmesi için olan bir yöntem ve bu yöntemle üretilen isi yalitimli levhalari gerçeklestirmektir. Bulusun Ayrintili Açiklamasi Bu bulusun amacina ulasmak için gerçeklestirilen "B Ir Isi Yalitim Levhasi Üretim Yöntemi ve Bu Yöntemle Üretilen Isi Yalitim Levhalari" ekli sekilde gösterilmis olup, bu sekil; Sekil-1 Bulus konusu isi yalitim levhasinin üretildigi üretim hattinin sematik görünüsüdür. Sekillerde yer alan parçalar tek tek numaralandirilmis olup, bu numaralarin karsiliklari asagida verilmistir. Yas harman Sikistirilmis yas harman Yas harman kütük L.f'l-hLJ'tJI'\.J||-i Kuru harman kütük Üretim hatti Bant konveyör Harmanlayici Ön prens bandi Kesim istasyonu Mineral esasli çekirdege sahip düsük yogunluklu isi yalitim levhasinin (1) üretilmesini saglayan bulus konusu yöntem; bir harmanlayicida (Cl per lit ve en az bir türde olan baglayicinin karistirilmasiyla hazirlanan mineral esasli yas harmanin (2) yas harmani (2) tasimaya uygun yapida olan hareketli bir bant konveyör (B) üzerine beslenmesi, bant konveyör (B) üzerinde tasinan yas harmanin (2) bir ön pres bant (DJ vasitasiyla sikistirilarak bir sikistirilmis yas harrnanin (3) elde edilmesi, ön pres banttan (D) çikan sikistirilmis yas harrnanin (3) bir pres (E) vasitasiyla presleme islemine tabi tutularak istenilen kalinliga ve sertlige gelene kadar sikistirilmasiyla bir yas harman kütügün (4) elde edilmesi adimlarini içermektedir. Bulus konusu yöntem ayrica, presten (E) çikan yas harman kütügün (2) bir isil islem istasyonunda (F) isil isleme tabi tutulmasiyla bir kuru harman kütük (5) elde edilmesi adimini içermektedir. Bulusun tercih edilen uygulamasinda isil islem istasyonunda (F) bir kurutma firini vasitasiyla isil islem gerçeklestirilmektedir. Bulusun örnek bir uygulamasinda sözkonusu kurutmafirini ardisik sik rulolu ya da tel bant olabilmektedir. Bulus konusu yöntem ayrica, isil islem istasyonundan (F) çikan kuru harman kütügün (Sl bir kesim istasyonunda (G) uygun kesiciler vasitasiyla kesilerek istenilen boya getirilen isi yalitim levhalarinin (l) elde edilmesi adimini içermektedir. Bulusun tercih edilen uygulamasinda kuru harman kütük (H) kesim istasyonunda (G) ayni anda hem kenarlarindan hem de boydan kesilmektedir. Bu sayede üretim hizinin arttirilmasi saglanmaktadir. Isil islem istasyonundan (F) çikan isi yalitim levhasi (l) sevke hazir hale gelmektedir. Bulusun bir uygulamasinda bulus konusu yöntem ayrica, harrnanlayicidan (C) hareketli bant konveyör (B) üzerine beslenen yas harmana (2) harmanlayiei (C) ve ön pres bandi (D) arasinda konumlandirilan en az bir bobinden (sekillerde gösterilmemektedir) yanmaz özellige sahip olan en az bir güçlendirme malzemesi beslenmesi adimini içermektedir. Bu uygulama ile elde edilen nihai isi yalitim levhasinda (l) güçlendirme malzemesi sertlesen yas harman (2) tabakasinin içinde kalmaktadir. Bu sayede elde edilen nihai isi yalitim levhasinin (1) mukavemetinin arttirilmasi saglanmaktadir. Bulusun tercih edilen uygulamasinda hareketli bant konveyör (B) üzerindeki yas harman (2) konveyör bandin (B) ilerleme dogrultusunda azalan açikliga sahip ön pres bant (D) vasitasiyla sikistirilarak belirli derecede sikistirilmis yas harman (3) elde edilmektedir. Bulusun tercih edilen uygulamasinda bant konveyörde (B) kullanilan bant PVC esasli nihayetsiz türde olan bant malzemesinden mamuldür. Bulusun tercih edilen uygulamasinda ön prens bandinda (D) kullanilan bant PVC esasli nihayetsiz türde olan bant malzemesinden mamuldür. Bulusun bir uygulamasinda yas harman kütügün (4) elde edilmesi için kullanilan pres (E) hareketli bir prestir. Bulusun bir uygulamasinda yas harman kütügün (4) elde edilmesi için kullanilan pres (El sac bant prestir. Bulusun bir uygulamasinda yas harman kütügün (4) elde edilmesi için kullanilan pres (E) sicak pres olabilmektedir. Bu sayede baglayicinin sertlesme süresinin kisaltilmasi saglanmaktadir. Bulusun tercih edilen uygulamasinda harmanlayicidan (C) hareketli bant konveyör (B) üzerine beslenen yas harman (2) en azindan; perlit ve sivi ve/veya kati haldeki organik baglayicilar içermektedir. Bulusun tercih edilen uygulamasinda yas har man (2] içerisinde tercihen %60 ila %80 arasinda olmak üzere %50 ila %95 arasinda perlit bulunmaktadir. Bulusun tercih edilen uygulamasinda organik baglayicilar; polivinil alkol, polivinil asetat, üre formaldehit, fenol formaldehit, melamin formaldehit, Stiren `butadien içeren gruptan nihai isi yalitim levhasinin PCS degeri maksimum 2 MJ/kg olacak sekilde seçilmektedir. Asagida yer alan Tablo l"de A1 sinifi yanmaz isi yalitim levhasi (1) elde etmek için kullanilabilecek olan baglayici türü, azami baglayici miktari ve bu baglayicilarin PCS degerleri örnek olarak verilmektedir. Baglayici Tipi PCS (MJlkgl Maksimum % polivinil alkol 25 8 polivinil asetat 23,04 8,68 üre formaldehit 15,9 12,57 fenol formaldehit 27,9-3l,6 6,32 melamin formaldehit 19'33 10'34 stiren butadien 42 4,76 Tablo 1. Örnek baglayicilarin tam yanma sonrasi PCS degerleri Bulus yukarida yer alan Tablo l"de tamamen örnek yoluyla gösterilen organik baglayici türleriyle sinirlandirilmamakla beraber bulusu gerçeklestirmek için sinirlandirici olmamakla beraber örnegin lateksler, metil selülozlar, karboksi metil selülozlar, nisastalar gibi bitkisel esasli organik baglayicilar; akrilonitriller, Siyanoakrilitler, tüm akrilik monomerler ve rezorsinol gibi sentetik monomer türündeki organik baglayicilar; epoksi reçineler, etilen, vinil asetatlar, poliamitler, poliester tabanli reçineler, polietilen baglayicilar, polipropilenler, polisülfitler, poliüretanlar, polivinilpirolidon, silikon reçineler, modifiye silil polimerler ve Stiren akrilik kopolimerler gibi sentetik polimer türde olan organik baglayicilar gibi çok çesitli türlerde olan organik baglayicilar kullanilabilmektedir. Yukarida açikça belirtilen bilesenlerin disinda yas harinan (2] ayrica su itieilik ya da su emme özelliginin degistirilmesi için silikon ve türevlerini ve hatta renklendirme ihtiyacina göre baska ilave malzemeler de içerebilmektedir. Bulusun tercih edilen uygulamasinda güçlendirme elemani olarak dokuma ya da dokusuz non woven, spunbond ya da spunlace teknigi ile bir kumas formuna getirilen cam elyaftan mamul tül ya da file kullanilmaktadir. Bulusun bir uygulamasinda güçlendirme elemani olarak bir veya daha fazla kat cam elyaf file kullanilmaktadir. Özellikle nihai isi yalitim levhasinin (1) üzerinde yürünebilen çati yalitim levhasi oldugu bir örnekte güçlendimie malzemesi tercihen iki olmak üzere birden çok sayida kat cam elyaf file içerebilmekte ve böylece nihai isi yalitim levhasinin (ll egilmede kirilma direnci arttirilmaktadir. Bulusun alternatif bir uygulamasinda egilmede kirilma direnci arttirmak için cam elyaf file yerine karbon elyaf file ve benzeri özellik gösteren malzemeler de kullanilabilmektedi r. Bulusun bir uygulamasinda yukarida açiklanan yöntemle elde edilen isi yalitim levhasi (1] Al sinifi yanmaz bir yalitim levhasidir. Söz konusu Al sinifi yanmaz yalitiin levhasi bir örnekte agirlikça; 200 birim genlesmis perlit, 45 birim %30 aktif polivinil alkol baglayici, 0,2 birim silikon ve 65 birim su içeren bir yas harmandan (2] elde edilmektedir. Bu örnekte üretim esnasinda preste (E) 4 kg/cm2°lik presleme islemi sonrasinda isil islem istasyonunda (F) tercihen 190°C°yi geçmeyen 50 dakikalik bir kurutma sonrasi elde edilen 5 cm kalinligindaki Al sinifi yanmaz yalitim levhasi llS kg/m3 degerindeki yogunluga ve 1,88 MJ/kg degerinde PCS degerine sahiptir. Bu sekilde elde edilen Al sinifi yanmaz yalitim levhasinin isi iletim katsayisi 0,042 W/m.K degerine sahiptir. Bulusun baska bir uygulamasinda yukarida açiklanan yöntemle elde edilen isi yalitim levhasi (1) Al sinifi yanmaz yalitimli çati levhasidir. Söz konusu A] sinifi yalitimli çati levhasi bir örnekte agirlikça; 200 birim genlesmis perlit, 45 biri m %30 aktif polivinil alkol baglayici, 0,65 birim Silikon ve 65 birim su içeren bir yas harmandan (2] elde edilmektedir. Bu örnekte üretim esnasinda preste (E) 9,5 kg/cm2"`lik presleme islemi sonrasinda isil islem istasyonunda (F } tercihen 17 5°C°yi geçmeyen 60 dakikalik bir kurutma sonrasi elde edilen 6 cm kalinligindaki A1 sinifi yalitimli çati levhasi 235 kg/m3 degerindeki yogunluga ve 1,9 MJ/kg degerinde PCS degerine sahiptir. Bu sekilde elde edilen A1 sinifi yalitimli çati levhasinin isi Ileti rn katsayisi 0,065 W/m.K degerine sahiptir. Bulus konusu yöntem vasitasiyla genlesmis perlitin organik baglayicilar ile hareketli bir bant konveyör (B) üzerinde bir ön pres bandi (D) ve özellikle de en az bir pres (E) vasitasiyla sekillendirilmesi ile teknigin bilinen durumunda siklikla kullanilan yüksek maliyetli kaliplama tekniginin kullanilmasina gerek kalmadan A1 sinif yanmaz yalitim levhasi ya da A1 sinif yanmaz yalitimli çati levhasi gibi isi yalitim levhalarinin (1 i ekonomik bir sekilde kesintisiz olarak üretilmesi mümkün olmaktadir. Bulus konusu isi yalitim levhasi (1) üretim yönteminin ve bu yönteme uygun olarak üretilen isi yalitim levhalarinin (1) çok çesitli uygulamalarinin gelistirilmesi mümkün olup, bulus burada açiklanan örneklerle sinirlandirilamaz, esas olarak istemlerde belirtildigi gibidir. TR TR TR DESCRIPTION A HEAT INSULATION HOUSE COIL PRODUCTION METHOD AND THE HEAT INSULATION BOARD PRODUCED BY THIS METHOD Technical Field This invention; It is about a low-density thermal insulation board production method with a mineral-based core and the thermal insulation boards produced with this method. Prior Art Among the structural elements frequently used today, one of the most used ones is thermal insulation materials. They are materials used to reduce heat loss and gain in buildings. These sheets, which are used for thermal insulation purposes, can be classified as open porous and closed porous. Glass wool for open porous or fiber materials; rock wool (mineral wools), wood wool, ceramic wool, slag wool; Examples of closed-pored materials include expanded polystyrene obtained from petroleum-derived materials, extruded polystyrene, elastomeric rubber, polyethylene shell and glass foam obtained by expanding silica sand under high temperatures. Since insulation materials other than mineral and ceramic wool and glass foam are flammable, their use is limited by building regulations. Most of the materials and glass wool are produced with a density lower than 30 kg/m3 and a thermal conductivity value between 0.03-0.04 W/m.K. While ceramic and stone wool are produced at a density value between 40-200 kg/m3, stone wool, which is frequently used in the exterior insulation of buildings due to its fireproof feature, is preferably produced at a density value between 100-150 kg/m3. The mentioned ceramic and stone wool preferably have a thermal conductivity coefficient lower than 07045 W/m.K. All open-pored or fibrous thermal insulation materials such as glass wool and rock wool are obtained by first melting SILI sand or basalt at high temperatures, preferably in furnaces, and then cooling it into fibers and then laying it on a continuous band. Due to both the high installation cost and the high operating cost of melting furnaces operated at high temperatures, fireproof glass and rock wool are more expensive than petroleum-derived thermal insulation materials. In the regulations for fire protection of buildings, materials are separated according to flammability classes, and the materials to be used in spaces are determined according to their structure types and intended use. In the changes published in the "Fire Protection of Buildings Gazette" published in the Official Gazette numbered 27344 on September 9, 2009 in Turkey, it was stipulated that materials of the non-flammable (A1) class should be used, especially on the facades and roofs of buildings higher than 28.5 meters. The non-flammability of insulation materials is determined by the methods described in EN ISO 17167 and the materials are classified according to their gross calorific potential (PCSýpotentiel Calorifique Supérieur) values. Known A1 class insulation materials are all kinds of mineral wool, rock wool, ceramic wool and glass foam. All of these materials are produced with very high energy consumption and are costly. Additionally, all mineral wool, rock wool and ceramic wool are affected by moisture and water. All rock- or ceramic-based wools, especially mineral wools, lose their thermal insulation properties significantly after they become moist or come into contact with water, or they fail to maintain their integrity in the application areas and bend or pile up. In the state of the art, the use of expanded perlite in the production of insulation materials is widely known. Among these products, the "Fesco" trademarked product produced by the United States-based Johns Manville company can be shown as the most successful commercial product in which perlite is predominantly used. Essentially a roof insulation board, Fesco has been produced since the early 1960s. Fesco is essentially produced by mixing perlite and scrap paper fiber with asphalt using the Fourdrinier technique. In the United States patent document numbered US3042578, which is in the state of the art, the use of perlite and scrap paper together is mentioned. In the United States patent document numbered US4126512, the main recipe for the Fesco product, which continues to this day, is created by adding starch to the mixture of paper fiber and perlite. In the United States patent document numbered US4011183, which is in the state of the art, it is mentioned that 75% perlite and 25% scrap paper fiber by weight are sprayed with methylene chloride and diphenylmethane diisocyanate to obtain a plate with a density of 200 kg/m3. On the other hand, the plate obtained in this patent document and the Fesco plate are far from being an Al class fireproof insulation material. In the United States patent document numbered US4072533, a non-cement based, low density building element is obtained by using dense perlite and polyester fiber fiber and binding sodium silicate. The plate described in the document in question has a very expensive recipe and is produced at high cost using the molding technique. In the United States patent document numbered US4297311, a series of recipes are described in which the expanded perlite is hardened with urea formaldehyde (UF), while the expanded perlite is crushed under the press, its grains are broken, and the density is higher than 200 kg/m3. The products in question are partially bare and prone to dust or crumbling. The invention described in this document also does not target fireproof materials. In the United States patent document numbered US4313997, a perlite-based sheet obtained by bonding with polyacrylic (Styrene Butadiene (SB)) or latex is mentioned. Latex is used to give flexibility to the sheet. In the United States patent document numbered US4451294, a perlite-based fireproof board is mentioned, which is obtained by hardening sodium silicate and perlite and is supported by the use of borax for fireproofing. In the United States patent document numbered U55256222, a production method is mentioned that involves turning expanded perlite and sodium silicate into mortar and laying this mortar between two cardboards on a moving belt, hardening it on the belt, and then cutting and baking it, as in the methods used in the production of plasterboard. The product obtained by this method contains flammable paper, and a lightweight dry wall board that can replace gypsum board is taken as the target product. In the United States patent document numbered U56355098, perlite is hardened with sodium or potassium silicate, and a production method is mentioned that aims to dry the water-containing wet product using microwave energy before drying it in conventional ovens. Although it is mentioned in the explanations of the prior art briefly mentioned above and in the patent documents referred to that it is possible to obtain low density boards using organic or non-organic binders using expanded perlite, there is no mention of a thermal insulation board that provides class A1 fireproofing in any of these explanations. Additionally, the Turkish patent document numbered TR2019/06279, which belongs to the same applicant, mentions the low-density thermal insulation board production method, which has a mineral-based core and whose surfaces are covered with tulle or mesh-like material, and the thermal insulation boards produced with this method. Brief Description of the Invention The purpose of this invention is to produce a method for producing a lightweight and economical thermal insulation plate continuously on the tape without using the molding technique, and to realize thermal insulated sheets such as insulated roof sheets produced with this method. Another purpose of this invention is to produce a class A] fireproof, mineral-based thermal insulation board that is less affected by moisture and water, and to realize the thermal insulation boards produced by this method. Another purpose of this invention is to use dense perlite instead of insulation boards, which are obtained by melting rocks such as glass or rock or ceramic wool at high temperatures, which have high energy consumption. It is a method for producing a thermal insulation plate and to realize the thermal insulation plates produced by this method. Another purpose of this invention is to produce a walkable, lightweight, Al-class, non-flammable thermal insulation board that preferably has a thermal conductivity coefficient of less than 0.065 W/m.K and to realize the thermal insulation sheets produced by this method. Detailed Description of the Invention "A Thermal Insulation Board Production Method and Thermal Insulation Boards Produced by This Method", which was carried out to achieve the purpose of this invention, is shown in the attached figure; Figure-1 is the schematic view of the production line where the thermal insulation board that is the subject of the invention is produced. The parts in the figures are numbered one by one, and the equivalents of these numbers are given below. Fresh blend Compressed wet blend Fresh blend billet L.f'l-hLJ'tJI'\. J||-i Dry blend billet Production line Belt conveyor Blender Pre-pressure belt Cutting station The method of the invention, which enables the production of low-density thermal insulation board (1) with a mineral-based core; Feeding the mineral-based wet blend (2), prepared by mixing Cl per lit and at least one type of binder in a blender, onto a moving belt conveyor (B) that is suitable for carrying the wet blend (2), and the wet blend carried on the belt conveyor (B). (2) obtaining a compressed fresh mixture (3) by compressing it by means of a pre-press band (DJ), subjecting the compressed fresh mixture (3) coming out of the pre-press band (D) to a pressing process through a press (E) until it reaches the desired thickness and hardness. The method of the invention also includes the steps of obtaining a wet blend billet (4) by compressing the wet blend billet (2) coming out of the press (E) and obtaining a dry blend billet (5) by subjecting it to heat treatment in a heat treatment station (F). In the preferred embodiment of the invention, heat treatment is carried out by means of a drying oven in the heat treatment station (F). In an exemplary embodiment of the invention, the drying oven in question can be a consecutive roller or wire belt. The method of the invention also includes the step of obtaining thermal insulation boards (L) that are brought to the desired color by cutting the dry blend billet (S1) coming out of the heat treatment station (F) by means of suitable cutters in a cutting station (G). In the preferred application of the invention, the dry blend billet (H) ) is cut from both edges and lengths at the same time in the cutting station (G). In this way, the heat insulation plate (I) coming out of the heat treatment station (F) is ready for shipment. In an embodiment of the invention, the method of the invention is also cut from the blender ( C) This includes the step of feeding at least one non-flammable reinforcement material from at least one coil (not shown in the figures) positioned between the blender (C) and the pre-press band (D) to the wet blender (2) fed on the moving belt conveyor (B). In the final thermal insulation plate (1) obtained by the application, the reinforcement material remains inside the hardening wet mixture (2) layer. In this way, the strength of the final thermal insulation plate (1) obtained is increased. In the preferred application of the invention, the wet blend (2) on the moving belt conveyor (B) is compressed by the pre-press band (D) with a decreasing gap in the direction of the progress of the conveyor belt (B), and a wet blend (3) compressed to a certain degree is obtained. In the preferred application of the invention, the belt used in the belt conveyor (B) is made of PVC-based endless type belt material. In the preferred application of the invention, the tape used in the front principle tape (D) is made of PVC-based endless type tape material. In one embodiment of the invention, the press (E) used to obtain the wet blend billet (4) is a movable press. In one embodiment of the invention, the press (Hand) used to obtain the wet blend billet (4) is a sheet band press. In another embodiment of the invention, the press (E) used to obtain the wet blend billet (4) can be a hot press. In this way, the hardening time of the binder is shortened. The invention In the preferred embodiment of the invention, the wet blend (2) fed from the blender (C) onto the moving belt conveyor (B) contains at least 60% to 60% of the wet blend (2). Between 50% and 95% perlite is present. In the preferred application of the invention, the PCS value of the final thermal insulation board from the group containing organic binders: polyvinyl alcohol, polyvinyl acetate, urea formaldehyde, phenol formaldehyde, styrene and butadiene is maximum 2 MJ. It is selected as /kg. Table 1 below gives examples of the type of binder that can be used to obtain class A1 fireproof thermal insulation board (1), the maximum amount of binder and the PCS values of these binders. Binder Type PCS (MJlkgl Maximum % polyvinyl alcohol 25 8 polyvinyl acetate 23.04 8.68 urea formaldehyde 15.9 12.57 phenol formaldehyde 27.9-3l.6 6.32 melamine formaldehyde 19'33 10'34 styrene butadiene 42 4.76 Table 1. PCS values of sample binders after complete combustion. Although the invention is not limited to the organic binder types shown entirely by example in Table 1 above, in order to realize the invention, it is not limited to plant-based materials such as latexes, methyl celluloses, carboxy methyl celluloses, starches. organic binders; acrylonitriles, cyanoacrylates, all acrylic monomers and organic binders of the synthetic monomer type such as resorcinol; epoxy resins, ethylene, vinyl acetates, polyamides, polyester-based resins, polyethylene binders, polypropylenes, polysulphides, polyurethanes, polyvinylpyrrolidone, silicone resins, modified silyl polymers. Various types of organic binders can be used, such as organic binders that are synthetic polymers such as styrene acrylic copolymers. Apart from the components clearly stated above, the wet material (2) may also contain silicone and its derivatives to change the water repellency or water absorption properties and even other additional materials according to the need for coloring. In the preferred embodiment of the invention, woven or non-woven, spunbond or non-woven as reinforcement elements. In addition, tulle or mesh made of glass fiber formed into a fabric form with the spunlace technique is used. In one embodiment of the invention, one or more layers of glass fiber mesh are used as a reinforcement element, especially in an example where the final thermal insulation plate (1) is a walkable roof insulation plate. The material may contain multiple layers of glass fiber mesh, preferably two, thus increasing the fracture resistance of the final thermal insulation board in bending. In an alternative embodiment of the invention, carbon fiber mesh and materials with similar properties can be used instead of glass fiber mesh to increase the fracture resistance in bending. . In one embodiment of the invention, the thermal insulation board (1) obtained by the method explained above is an Al class fireproof insulation board. In one example, the weight of the Al class fireproof insulation board in question is; It is obtained from a wet blend (2) containing 200 units of expanded perlite, 45 units of 30% active polyvinyl alcohol binder, 0.2 units of silicone and 65 units of water. In this example, after a 4 kg/cm2 pressing process in the press (E) during production. The 5 cm thick Al class fireproof insulation board obtained after 50 minutes of drying in the heat treatment station (F), preferably not exceeding 190°C, has a density of 115 kg/m3 and a PCS value of 1.88 MJ/kg. The heat conduction coefficient of the Al class fireproof insulation board is 0.042 W/m.K. In another embodiment of the invention, the heat insulation board obtained by the above-described method is (1) Al class fireproof insulated roof board. In one example, the A] class insulated roof board weighs; It is obtained from a wet blend (2] containing 1 unit expanded perlite, 45 units 30% active polyvinyl alcohol binder, 0.65 units Silicone and 65 units water. In this example, 9.5 kg/cm2" is used in the press (E) during production. After the pressing process, the 6 cm thick A1 class insulated roof board obtained after a 60-minute drying in the heat treatment station (F} preferably not exceeding 17 5°C has a density of 235 kg/m3 and a PCS value of 1.9 MJ/kg. The heat conduction coefficient of the A1 class insulated roof plate obtained in this way has a value of 0.065 W/m.K. By means of the method of the invention, expanded perlite is shaped with organic binders by means of a pre-press band (D) and especially at least one press (E) on a moving belt conveyor (B), without the need to use the high-cost molding technique that is frequently used in the state of the art. It is possible to produce thermal insulation sheets (1) such as class A1 fireproof insulation board or A1 class fireproof insulated roof sheet (1) continuously in an economical way. The production method of the thermal insulation board (1) subject to the invention and the thermal insulation boards (1) produced in accordance with this method are It is possible to develop a wide variety of applications, and the invention cannot be limited to the examples explained here, it is essentially as stated in the claims.TR TR TR

TR2019/06987A 2019-05-09 2019-05-09 A THERMAL INSULATION BOARD PRODUCTION METHOD AND THERMAL INSULATION BOARD PRODUCED BY THIS METHOD TR201906987A2 (en)

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