WO2007117225A1 - Inorganic filling for panel core and method for its manufacturing - Google Patents

Inorganic filling for panel core and method for its manufacturing Download PDF

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Publication number
WO2007117225A1
WO2007117225A1 PCT/SI2007/000019 SI2007000019W WO2007117225A1 WO 2007117225 A1 WO2007117225 A1 WO 2007117225A1 SI 2007000019 W SI2007000019 W SI 2007000019W WO 2007117225 A1 WO2007117225 A1 WO 2007117225A1
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WO
WIPO (PCT)
Prior art keywords
panels
expanded perlite
water glass
additives
panel
Prior art date
Application number
PCT/SI2007/000019
Other languages
French (fr)
Inventor
Igor Plazl
Miha Kavcic
Urska Franko Dipalo
Darija Bohor
Original Assignee
Trimo D.D.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Trimo D.D. filed Critical Trimo D.D.
Priority to EA200870427A priority Critical patent/EA200870427A1/en
Priority to RSP-2008/0537A priority patent/RS20080537A/en
Publication of WO2007117225A1 publication Critical patent/WO2007117225A1/en
Priority to HR20080566A priority patent/HRPK20080566B3/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/049—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres completely or partially of insulating material, e.g. cellular concrete or foamed plaster
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/40—Porous or lightweight materials

Definitions

  • the insulation panels should fulfill the requirements of specific material properties: low density of the filling, good mechanical properties, low thermal conductivity, water resistance, water adsorption resistance, and flame resistance.
  • the biological and ecological friendliness, ecological manufacturing, and economic acceptability of the production are important. None of so far known solutions do not provide for all listed requirements therefore the manufacturers in general conclude compromises related to suitability of their products. In this invention the technology and the product meet all listed requirements.
  • Literature survey and patent survey shows wide usability of expanded perlite as basis for civil construction and heat insulation materials. In most cases as inorganic bonding component water solution of alkali methyl silicates with addition of various fibers is shown, these foreseen for strengthening of material structure or improve their mechanical properties.
  • the basic industrial properties of the material properties of the core panel are low volumetric mass of the filling ( ⁇ 130 kg/m 3 ), suitable mechanical properties (compressive strength ⁇ 100 kPa and compressive elasticity module ⁇ 7 MPa, tensile strength ⁇ 120 IdPa and tensile elasticity module ⁇ 20 MPa, shear strength ⁇ 75 kPa and shear module ⁇ 3.7 MPa), low thermal conductivity (below 0.06 W/mK), low water absorption ( ⁇ 1 kg/m 2 in 24 hours or ⁇ 3 kg/m 2 in 28 days - according to EN 1609).
  • the material for core panel should be in class Al according to standard DIN 4102.
  • Inorganic filling for panel core and method of its manufacturing solves the above shown technical problem and describes process for manufacturing of construction insulation panels fulfilling all criteria for construction as well as provide for desired technical characteristics, these panels being compact in their nature.
  • the invention fulfills requirements for specific material properties: low density, good mechanical properties, low thermal conductivity, water resistance, hydrophobic properties (low water adsorption), flame resistance.
  • the subject of this invention is therefore development of inorganic filling for construction insulation panel based on expanded perlite and method for continous manufacturing of construction insulation panels based on expanded perlite with new filling.
  • the developed product will fulfill the requirements of specific material properties such as: low density (from 100 to 160 kg/m 3 ), good mechanical properties, low thermal conductivity ( ⁇ 0.06 W/mK), water resistance, hydrophobic properties and flame resistance, and in addition, the product is biologically friendly and environmentally friendly products, the technology of manufacturing is economically sound and environmentally friendly.
  • the basic technological methods of development of new product are mixing of basic raw materials, compacting of material, microwave heating, thermal pressure treatment, hydrophobic treatment of manufactured inorganic filling panels and their bonding (using adhesives) into panels.
  • the basic raw material of suggested panel is expanded perlite.
  • This bulk material with bulk density between 30 and 150 kg/m 3 is highly porous and brittle, chemically inert, biologically stable, heat resistant and non-toxic. It is not water soluble, it is mould repelling and shows very good thermal and filtering properties. Its structure is amorphous. The experiments so far did not show any ill effects of expanded perlite on people health.
  • Expanded perlite is manufactured by process of expanding of vitrous inorganic volcanic stone or so called primary perlite which chemical composition can be found in the literature and comprises (the fraction of particular components is shown in weight percentage) 72.6- 74.84 % SiO 2 , 13.7-13.64 % Al 2 O 3 , 0.54-0.97 % Fe 2 O 3 , 0.45-0.97 % CaO, 0.2-0.26 % MgO, 3.77-3.95 % Na 2 O, 3.95-4.19 % K 2 O and 0.02-0.05 % TiO 2 .
  • the loss of material during heating is between 2 to 5 %.
  • soluble sodium silicate or silicate water glass As adhesive for forming of compact panels from expanded perlite one uses either soluble sodium silicate or silicate water glass, or soluble potassium-sodium silicate or as potassium-sodium water glass.
  • Sodium water glass is inorganic silicate compound in which the anion part is represented by silicate tetrahedron and sodium cation tetrahedron, its structure is amorphous.
  • potassium - sodium water glass is inorganic silicate compound in which the anion part is represented by silicate tetrahedron and potassium - sodium cation tetrahedron, its structure is amorphous.
  • the density of the commercially available potassium - sodium water glass which is in range from 1.36 to 1.38 g/cm 3 depends on weight share SiO 2 (26-27 %), K 2 O (5-6%) and Na 2 O (8-16 %).
  • Entry components of the process of industrial manufacturing of inorganic insulation panels are expanded perlite, additives and soluble sodium silicate or potassium - sodium water glass as adhesive (bonding agent).
  • the process of expanding of perlite from primary perlite is known and as such does not represent new matter.
  • the technological process of manufacturing of inorganic insulation panels is undertaken according to below described process.
  • Bulk expanded perlite with appropriate bulk density with appropriate particle size distribution is lead into a mixing reactor along with appropriate share of additives depending on intended use of a panel, and necessary amount of liquid adhesive (sodium or potassium - sodium water glass). All components are intensively (vigorously) mixed in the reactor so the homogenous mixture or uniform wettability of expanded perlite and additives with water glass is achieved. Time of mixing depends on type of mixer, quantity and required final properties of the filling.
  • Homogeneously mixed mixture of expanded perlite, additives and water glass is poured into the mold (cast) of desired form.
  • the mold filled with mixture is shaken on the vibration table to achieve uniform local distribution of bulk density of the mixture. Uniform distribution of bulk mass over whole volume of the mold provides for effective compacting of wetted bulk material and therefore better mechanical properties of the panel.
  • the density of the compacted panel is determined with total mass and composition of the mixture, and force of compression depending on particular thickness of the panel.
  • the compacted panels are exposed to microwave field with purpose of extensive acceleration of process of meshing of water glass.
  • the expanded perlite is transparent for microwave heating and does not absorb microwaves, however, the presence of rather large share of non-binded water in water glass causes absorption of the microwaves in depth of the panel and therefore change of mechanical energy into heat. In such a fashion the microwaves clearly accelerate evaporation of non-binded water from the system and simultaneous meshing of water glass with presence of CO 2 .
  • Technological time of exposure to microwave heating depends both on structure and dimension of the panel as well as on power and frequency of microwave heating.
  • Dried and compacted panels after microwave heating have particular mechanical properties, however, due to amorphous nature of the component are still not water resistant meaning that in presence of e.g. humidity (moisture) from the air the dissolution of water glass occurs again and therefore the failure of the panel occurs.
  • humidity moisture
  • Using hydrophobic process in this stage of the manufacturing the panel can be protected from entering the water into the porous material, however, in the long run this does not represent long term protection of material or water resistance of the material.
  • thermal treatment Based on studies it was established that in particular high temperature regime the reaction between expanded perlite and water glass occurs or in other words the transformation from amorphous into crystalline structure.
  • So produced meshed panels are then thermally treated for example in continuous tunnel furnace.
  • the first phase the panels are preheated, the second phase comprises heating into determined temperature range with partial crystallization of the material, and in the third and final phase the panels are cooled down to prevent temperature shocks.
  • the process temperatures are up 700°C, in the range of partial crystallization the panels are compressed (put under pressure load), the process temperatures are between 700 and 1000°C.
  • the final phase the panels are cooled down to desired temperature.
  • the holding times of the panels in particular phase depends on size and desired mechanical and thermodynamic properties.
  • So manufactured partially crystallized panels with defined mechanical properties are water resistant, however, the water absorption limit according to the standard EN 1609 is not appropriate.
  • the water repellant properties of the material can be increased by use of methyl silicon resins in such a way that they are heated up to high temperatures without oxygen presence. In such heating up the methyl silicon resins are not decomposed, they are partially oxidized. In case of final oxidation the SiO 2 (silica - flint stone or silicon acid), carbon dioxide and water are formed, however, they are unwanted so the process of thermal oxidation should be stopped in appropriate moment.
  • the panels manufactured according to described process show the following properties:
  • Figure 1 shows the reservoir of the primary perlite (1), inlet of expanded perlite (2), mixing reactor (3), container of water glass (4), container of additives (5), the first transporter (6), vibration table (7), the second transporter (8), microwave furnace (9), continuous tunnel furnace (10), depositing device (11), furnace for heating (12), device for application of adhesive (13).
  • a reservoir of primary perlite (1) is source of bulk expanded perlite of desired bulk density with corresponding particle distribution, said bulk expanded perlite delivered through an inlet of expanded perlite (2) into a mixing reactor (3).
  • Into said mixing reactor (3) is also delivered necessary quantity of water glass (liquid adhesive) from a container of water glass (4) and appropriate share of additives from a container of additives (5).
  • the components are mixed in said mixing reactor (3) in order to ensure homogeneous mixture or in other words uniform wettability of expanded perlite and additives with water glass.
  • Said homogeneously mixed mixture of expanded perlite, additives and water glass is poured into a mold (cast) of desired form.
  • Said mold is with the first transporter (6) transported onto a vibration table (7) where said mold is shaken in order to achieve uniform local distribution of bulk density of said mixture.
  • meshed panels are then thermally treated in a continuous tunnel furnace (10). Said panels are then treated with methyl silicon resin using a depositing device (11). Said panels are then heated in a furnace for heating (12) without presence of oxygen whereby said methyl silicon resins are not decomposed but partially oxidized. Said panels are then glued using a device for application of adhesive (13).
  • a computer program for regulation, control, and optimization of said process a computer program can be used, said computer program comprising programming means for executing any of previously described steps in accordance with any patent claim should such computer program be executed in general purpose computer.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Architecture (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

The subject of this invention is inorganic filling for panel core and method of its manufacturing and therefore development of inorganic Filling for construction insulation panel based on expanded perlite and method for continuous manufacturing of construction insulation panels based on expanded perlite with new filling. The developed product will fulfill the requirements of specific material properties such as: low density (from 100 to 160 kg/m3), good mechanical properties, low thermal conductivity (<0.06 W/mK), water resistance, hydrophobic properties and flame resistance, and in addition, the product is biologically friendly and environmentally friendly products, the technology of manufacturing is economically sound and environmentally friendly. The basic technological methods of development of new product are mixing of basic raw materials, compacting of material, microwave heating, thermal pressure treatment, hydrophobic treatment of manufactured inorganic filling panels and their bonding (using adhesives) into panels.

Description

Inorganic filling for panel core and method for its manufacturing
DESCRIPTION OF INVENTION
Technical Field
Building insulation panels, inorganic filling, expanded perlite, methyl of silicate resin, heat treatment, technological process of inorganic filling for panel core manufacturing.
Technical problem
Manufacturing of building insulation panels with inorganic filling is generally known. The insulation panels should fulfill the requirements of specific material properties: low density of the filling, good mechanical properties, low thermal conductivity, water resistance, water adsorption resistance, and flame resistance. In addition, the biological and ecological friendliness, ecological manufacturing, and economic acceptability of the production are important. None of so far known solutions do not provide for all listed requirements therefore the manufacturers in general conclude compromises related to suitability of their products. In this invention the technology and the product meet all listed requirements.
State of the art
Literature survey and patent survey shows wide usability of expanded perlite as basis for civil construction and heat insulation materials. In most cases as inorganic bonding component water solution of alkali methyl silicates with addition of various fibers is shown, these foreseen for strengthening of material structure or improve their mechanical properties.
The basic industrial properties of the material properties of the core panel are low volumetric mass of the filling (~130 kg/m3), suitable mechanical properties (compressive strength ~100 kPa and compressive elasticity module ~7 MPa, tensile strength ~120 IdPa and tensile elasticity module ~20 MPa, shear strength ~75 kPa and shear module ~3.7 MPa), low thermal conductivity (below 0.06 W/mK), low water absorption (<1 kg/m2 in 24 hours or <3 kg/m2 in 28 days - according to EN 1609). As far as flammability is concerned the material for core panel should be in class Al according to standard DIN 4102.
None of known solutions so far fulfills all the criteria needed for core panel filling.
Description of new invention
Inorganic filling for panel core and method of its manufacturing solves the above shown technical problem and describes process for manufacturing of construction insulation panels fulfilling all criteria for construction as well as provide for desired technical characteristics, these panels being compact in their nature. The invention fulfills requirements for specific material properties: low density, good mechanical properties, low thermal conductivity, water resistance, hydrophobic properties (low water adsorption), flame resistance.
The subject of this invention is therefore development of inorganic filling for construction insulation panel based on expanded perlite and method for continous manufacturing of construction insulation panels based on expanded perlite with new filling. The developed product will fulfill the requirements of specific material properties such as: low density (from 100 to 160 kg/m3), good mechanical properties, low thermal conductivity (<0.06 W/mK), water resistance, hydrophobic properties and flame resistance, and in addition, the product is biologically friendly and environmentally friendly products, the technology of manufacturing is economically sound and environmentally friendly. The basic technological methods of development of new product are mixing of basic raw materials, compacting of material, microwave heating, thermal pressure treatment, hydrophobic treatment of manufactured inorganic filling panels and their bonding (using adhesives) into panels.
The basic raw material of suggested panel is expanded perlite. This bulk material with bulk density between 30 and 150 kg/m3 is highly porous and brittle, chemically inert, biologically stable, heat resistant and non-toxic. It is not water soluble, it is mould repelling and shows very good thermal and filtering properties. Its structure is amorphous. The experiments so far did not show any ill effects of expanded perlite on people health. Expanded perlite is manufactured by process of expanding of vitrous inorganic volcanic stone or so called primary perlite which chemical composition can be found in the literature and comprises (the fraction of particular components is shown in weight percentage) 72.6- 74.84 % SiO2, 13.7-13.64 % Al2O3, 0.54-0.97 % Fe2O3, 0.45-0.97 % CaO, 0.2-0.26 % MgO, 3.77-3.95 % Na2O, 3.95-4.19 % K2O and 0.02-0.05 % TiO2. The loss of material during heating is between 2 to 5 %.
As adhesive for forming of compact panels from expanded perlite one uses either soluble sodium silicate or silicate water glass, or soluble potassium-sodium silicate or as potassium-sodium water glass. Sodium water glass is inorganic silicate compound in which the anion part is represented by silicate tetrahedron and sodium cation tetrahedron, its structure is amorphous. The density of the commercially available sodium water glass which is in range from 1.33 to 1.58 g/cm3 depends on weight share of SiO2 (25-34 %) and Na2O (8-16 %) or their molar ratio M = nSi02/nNa20 (1.9 - 3.4). Similarly, potassium - sodium water glass is inorganic silicate compound in which the anion part is represented by silicate tetrahedron and potassium - sodium cation tetrahedron, its structure is amorphous. The density of the commercially available potassium - sodium water glass which is in range from 1.36 to 1.38 g/cm3 depends on weight share SiO2 (26-27 %), K2O (5-6%) and Na2O (8-16 %). Entry components of the process of industrial manufacturing of inorganic insulation panels are expanded perlite, additives and soluble sodium silicate or potassium - sodium water glass as adhesive (bonding agent). The process of expanding of perlite from primary perlite is known and as such does not represent new matter. The technological process of manufacturing of inorganic insulation panels is undertaken according to below described process.
Bulk expanded perlite with appropriate bulk density with appropriate particle size distribution is lead into a mixing reactor along with appropriate share of additives depending on intended use of a panel, and necessary amount of liquid adhesive (sodium or potassium - sodium water glass). All components are intensively (vigorously) mixed in the reactor so the homogenous mixture or uniform wettability of expanded perlite and additives with water glass is achieved. Time of mixing depends on type of mixer, quantity and required final properties of the filling.
Homogeneously mixed mixture of expanded perlite, additives and water glass is poured into the mold (cast) of desired form. The mold filled with mixture is shaken on the vibration table to achieve uniform local distribution of bulk density of the mixture. Uniform distribution of bulk mass over whole volume of the mold provides for effective compacting of wetted bulk material and therefore better mechanical properties of the panel. The density of the compacted panel is determined with total mass and composition of the mixture, and force of compression depending on particular thickness of the panel.
The compacted panels are exposed to microwave field with purpose of extensive acceleration of process of meshing of water glass. The expanded perlite is transparent for microwave heating and does not absorb microwaves, however, the presence of rather large share of non-binded water in water glass causes absorption of the microwaves in depth of the panel and therefore change of mechanical energy into heat. In such a fashion the microwaves clearly accelerate evaporation of non-binded water from the system and simultaneous meshing of water glass with presence of CO2. Technological time of exposure to microwave heating depends both on structure and dimension of the panel as well as on power and frequency of microwave heating.
Dried and compacted panels after microwave heating have particular mechanical properties, however, due to amorphous nature of the component are still not water resistant meaning that in presence of e.g. humidity (moisture) from the air the dissolution of water glass occurs again and therefore the failure of the panel occurs. Using hydrophobic process in this stage of the manufacturing the panel can be protected from entering the water into the porous material, however, in the long run this does not represent long term protection of material or water resistance of the material. These can be achieved by thermal treatment. Based on studies it was established that in particular high temperature regime the reaction between expanded perlite and water glass occurs or in other words the transformation from amorphous into crystalline structure.
So produced meshed panels are then thermally treated for example in continuous tunnel furnace. In the first phase the panels are preheated, the second phase comprises heating into determined temperature range with partial crystallization of the material, and in the third and final phase the panels are cooled down to prevent temperature shocks. In the first phase the process temperatures are up 700°C, in the range of partial crystallization the panels are compressed (put under pressure load), the process temperatures are between 700 and 1000°C. In the final phase the panels are cooled down to desired temperature. The holding times of the panels in particular phase depends on size and desired mechanical and thermodynamic properties.
So manufactured partially crystallized panels with defined mechanical properties are water resistant, however, the water absorption limit according to the standard EN 1609 is not appropriate. The water repellant properties of the material can be increased by use of methyl silicon resins in such a way that they are heated up to high temperatures without oxygen presence. In such heating up the methyl silicon resins are not decomposed, they are partially oxidized. In case of final oxidation the SiO2 (silica - flint stone or silicon acid), carbon dioxide and water are formed, however, they are unwanted so the process of thermal oxidation should be stopped in appropriate moment.
Should the panels be built into construction panels, these panels are mechanically treated. The shown invention during manufacturing provides for minimum quantity of waste so in addition to ecological friendliness of the product and its ecologically friendly manufacturing, the panel manufacturing itself is environment friendly.
The panels manufactured according to described process show the following properties:
Mechanical properties: o Density: 120 to 160kg/m3 o Compressive strength: up to and around 300 kPa; Compressive elasticity module: around 28 MPa o Tensile strength: up to and around 15O kPa; Tensile elasticity module: around 20 MPa
Thermal conductivity: around 0.06 W/mK
They are water resistance (not soluble in water) which cannot be said for panels which are not thermally treated
If treated against water absorption as described previously the water absorption measured according to standard EN 1609 is as follows: o After 24 hours water absorption < 1 kg/m2 o After 28 days water absorption < 3 kg/m2.
More detailed essence of the invention is explained below with description of preferred embodiment and figures whereas the figure forms integral part of this patent application and shows as follows:
Figure 1 shows the reservoir of the primary perlite (1), inlet of expanded perlite (2), mixing reactor (3), container of water glass (4), container of additives (5), the first transporter (6), vibration table (7), the second transporter (8), microwave furnace (9), continuous tunnel furnace (10), depositing device (11), furnace for heating (12), device for application of adhesive (13).
In shown preferred embodiment a reservoir of primary perlite (1) is source of bulk expanded perlite of desired bulk density with corresponding particle distribution, said bulk expanded perlite delivered through an inlet of expanded perlite (2) into a mixing reactor (3). Into said mixing reactor (3) is also delivered necessary quantity of water glass (liquid adhesive) from a container of water glass (4) and appropriate share of additives from a container of additives (5). The components are mixed in said mixing reactor (3) in order to ensure homogeneous mixture or in other words uniform wettability of expanded perlite and additives with water glass.
Said homogeneously mixed mixture of expanded perlite, additives and water glass is poured into a mold (cast) of desired form. Said mold is with the first transporter (6) transported onto a vibration table (7) where said mold is shaken in order to achieve uniform local distribution of bulk density of said mixture.
In such fashion compact panels are obtained, said panels transported with the second transporter (8) to a microwave furnace (9) where they are exposed to a microwave field in order to clearly accelerate a process of meshing of said water glass.
In such fashion obtained meshed panels are then thermally treated in a continuous tunnel furnace (10). Said panels are then treated with methyl silicon resin using a depositing device (11). Said panels are then heated in a furnace for heating (12) without presence of oxygen whereby said methyl silicon resins are not decomposed but partially oxidized. Said panels are then glued using a device for application of adhesive (13).
For regulation, control, and optimization of said process a computer program can be used, said computer program comprising programming means for executing any of previously described steps in accordance with any patent claim should such computer program be executed in general purpose computer.
It is self evident that this solution can be executed in other form of embodiment, said embodiment not changing the essence of this invention.

Claims

PATENT CLAIMS
1. Inorganic filling for panel core, characterized in that the raw material of the core of said panel is expanded perlite with adhesive soluble sodium silicate or water glass, or soluble potassium-sodium silicate or potassium-sodium water glass.
2. Invention according to claim 1 characterized in that additives are added to expanded perlite and adhesive in order to improve core properties depending on purpose of said panel.
3. Invention according to claim 1 or claim 2 characterized in that the invention fulfills requirements related to material properties, including and not limited to low density of the filling, good mechanical properties, low heat conductivity, water resistance, water adsorption resistance and flame resistance.
4. Invention according to any of the claims 1 to 3 characterized in that the panels have density of 120 to 160kg/m3, compressive strength up to and around 300 IdPa, compressive elasticity module around 28 MPa, tensile strength up to and around 150 kPa, tensile elasticity module around 20 MPa and heat conductivity around 0.06 W/mK.
5. Method for manufacturing of inorganic filling for panel core characterized in that the appropriate share of additives and sodium or potassium-sodium water glass as adhesive is added to expanded perlite.
6. Method according to claim 5 characterized in that the components are vigorously mixed in order to achieve homogeneous mixture or uniform wettability of expanded perlite and additives with water glass.
7. Method according to claim 6 characterized in that.time of mixing depends on type of mixer, amount of filling, additives and adhesive, and required properties of the filling.
8. Method according to any of the claims 5 or 6 characterized in that the mixture of expanded perlite, additives, and water glass is poured into mold (cast) of desired form.
9. Method according to claim 8 characterized in that the mold with filled in mixture is shaken on a vibration table to achieve uniform local distribution of bulk density of the mixture.
10. Method according to any of the claims 5 or 9 characterized in that the density of the compact panel is determined with total mass and composition of the mixture, and force of compression depending on particular thickness of the panel.
11. Method according to any of the claims 5 or 10 characterized in that the compacted panels are exposed to microwave field in order to clearly accelerate process of meshing of said water glass.
12. Method according to the claims 11 characterized in that the technology time of exposure to microwave heating depends on structure and size of said panel as well as on power and frequency of microwave radiation.
13. Method according to any of the claims 5 or 12 characterized in that the water resistance of the material is achieved in particular high temperature region where the reaction between expanded perlite and water glass is taking place or where transformation from amorphous into crystal structure is takin place.
14. Method according to any of the claims 5 or 13 characterized in that the heat treatment is separated into preheating of said panels, heating of said panels in particular temperature range where the material partially crystallizes, and cooling down of panels to prevent temperature shocks.
15. Method according to any of the claims 5 or 14 characterized in that the water resistance of the material is increased by use of methyl silicon resins in such a way to heat them up in controlled manner to high temperatures, without presence of oxygen..
16. Method according to any of the claims 5 or 15 characterized in that the panels in case of building them into construction panels are additionally mechanically treated.
17. Method according to any of the claims 5 or 16 characterized in that it comprises inlet of expanded perlite, mixing reactor, inlet of water glass, inlet of additives, vibration table, microwave furnace, continuous furnace, depositing device, furnace for heating and device for application of adhesive.
18. Method for manufacturing of inorganic filling for panel core characterized in that reservoir of primary perlite (1) is source of bulk expanded perlite of desired bulk density with corresponding particle distribution, said bulk expanded perlite delivered through an inlet of expanded perlite (2) into a mixing reactor (3); further into said mixing reactor (3) is also delivered necessary quantity of water glass (liquid adhesive) from a container of water glass (4) and appropriate share of additives from a container of additives (5); further the components are mixed in said mixing reactor (3) in order to ensure homogeneous mixture or in other words uniform wettability of expanded perlite and additives with water glass; further said homogeneously mixed mixture of expanded perlite, additives and water glass is poured into a mold (cast) of desired form; further said mold is with the first transporter (6) transported onto a vibration table (7) where said mold is shaken in order to achieve uniform local distribution of bulk density of said mixture; further in such fashion compact panels are obtained, said panels transported with the second transporter (8) to a microwave furnace (9) where they are exposed to a microwave field in order to clearly accelerate a process of meshing of said water glass; further in such fashion obtained meshed panels are then thermally treated in a continuous tunnel furnace (10); further said panels are then treated with methyl silicon resin using a depositing device (11); further said panels are then heated in a furnace for heating (12) without presence of oxygen whereby said methyl silicon resins are not decomposed but partially oxidized; further said panels are then glued using a device for application of adhesive (13).
19. Method according to any of the claims 5 or 16 characterized in that for regulation, control, and optimization of said process a computer program can be used, said computer program comprising programming means for executing any of previously described steps in accordance with any patent claim should such computer program be executed in general purpose computer.
PCT/SI2007/000019 2006-04-11 2007-04-10 Inorganic filling for panel core and method for its manufacturing WO2007117225A1 (en)

Priority Applications (3)

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EA200870427A EA200870427A1 (en) 2006-04-11 2007-04-10 INORGANIC FILLER FOR THE PANEL HEART AND THE METHOD OF ITS MANUFACTURE
RSP-2008/0537A RS20080537A (en) 2006-04-11 2007-04-10 Inorganic filling for panel core and method for its manufacturing
HR20080566A HRPK20080566B3 (en) 2006-04-11 2008-11-08 Inorganic filling for panel core and method for its manufacturing

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SI200600087A SI22247A (en) 2006-04-11 2006-04-11 Inorganic filler for panel core and procedure for its manufacture
SIP-200600087 2006-04-11

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AT510508A1 (en) * 2010-09-30 2012-04-15 Horst Wustinger MATERIAL WHICH CONTAINS BLOWN VOLCANO GLASS
CN107827391A (en) * 2017-12-06 2018-03-23 佛山早稻田环保节能科技有限公司 A kind of energy-conserving and environment-protective material
WO2023230676A1 (en) * 2022-06-01 2023-12-07 Decibel Ad Method and composition for production of granular composite panels

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Publication number Priority date Publication date Assignee Title
AT510508A1 (en) * 2010-09-30 2012-04-15 Horst Wustinger MATERIAL WHICH CONTAINS BLOWN VOLCANO GLASS
AT510508B1 (en) * 2010-09-30 2013-06-15 Horst Wustinger MATERIAL WHICH CONTAINS BLOWN VOLCANO GLASS
CN107827391A (en) * 2017-12-06 2018-03-23 佛山早稻田环保节能科技有限公司 A kind of energy-conserving and environment-protective material
WO2023230676A1 (en) * 2022-06-01 2023-12-07 Decibel Ad Method and composition for production of granular composite panels

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HRP20080566A2 (en) 2009-02-28
EA200870427A1 (en) 2009-04-28
SI22247A (en) 2007-10-31
RS20080537A (en) 2009-05-06

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