WO2012087259A2

WO2012087259A2 - Alternative isolation / building materials and production method

Info

Publication number: WO2012087259A2
Application number: PCT/TR2011/000280
Authority: WO
Inventors: Yavuz Tuncay DERELI; Çerezci ATTILLA; Muhammet ALICI
Original assignee: Peryum Araştirma Geliştirme İnşaat Makine Elektronik Danişmanlik Hizmetleri Sanayi Ticaret Limited Şirketi
Priority date: 2010-12-25
Filing date: 2011-12-23
Publication date: 2012-06-28
Also published as: WO2012087259A3; EP2655294A2

Abstract

The present invention is related to the isolation and building materials, applied on surfaces of the structures, floors, interior and exterior facades of the buildings and installations, that prevent temperature variations, that are inflammable and have sound insulation features and save time and labour due to their easy installation, and to a process/method for manufacturing these materials. The present invention is including the isolation and building materials which consist of expanded perlite aggregates (1), pumice and/or expanded vermiculate aggregates (2), chopped glass fiber (3), water (4), bentonite (5), gel formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄O₇ 5H₂O (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9).

Description

DESCRIPTION

ALTERNATIVE ISOLATION/BUILDING MATERIALS AND PRODUCTION

METHOD

The present invention is related to the isolation and building materials, applied on such surfaces as concrete, brick, pumice, gas concrete, wood, metal etc. at the structures, floors, interior and exterior facades of the buildings and installations, that prevent temperature variations, that are inflammable and have sound insulation features and save time and labour due to their easy installation, and to a process/method for manufacturing these materials.

STATE OF THE ART

The process used to reduce the heat transfer between two media with different temperatures is called thermal insulation. The materials that provide this process are referred to as thermal insulation materials. The basic feature of the thermal insulation materials is the coefficient of heat transfer (λ).

Coefficient of heat transfer (λ): When the difference between the temperatures of two parallel surfaces of a material is 1 °C, it is the amount of heat passing in 1 hour, through a unit area of the surface (1 m²) and through the unit thickness (lm) in a perpendicular direction. This feature determines the heat insulation property of the material. As the coefficient of heat transfer increases, the heat insulation property of the material decreases (worsens). According to ISO and CEN Standards, those materials with a coefficient of heat transfer below 0,065 W/mK are defined as the thermal insulation materials. Other materials are considered as building materials. Some of the thermal insulation materials and building materials that are being used for the purpose of isolation in the buildings and plants, and the coefficient of heat transfer values of these materials are as follows:

- Extruded Polystyrene (XPS) Thermal Conductivity (lambda) Value λ = 0,030 - 0,040 W/mK

- Expanded Polystyrene (EPS) Thermal Conductivity (lambda) Value λ = 0,033 - 0,040

W/mK

- Polyurethane (PUR) Thermal Conductivity (lambda) Value λ = 0,019 - 0,040 W/mK

- Glass Wool Thermal Conductivity (lambda) Value λ = 0,035 - 0,040 W/mK - Rock Wool Thermal Conductivity (lambda) Value λ = 0,035 - 0,040 W/mK

- Rubber Foam Thermal Conductivity (lambda) Value λ = 0,038 W/mK

- Polyethylene Foam Thermal Conductivity (lambda) Value λ = 0,040 W/mK

- Expanded Perlite Thermal Conductivity (lambda) Value λ = 0,040 - 0,060 W/mK - Cellulose Insulation Thermal Conductivity (lambda) Value λ = 0,036 - 0,038 W/mK

- Insulation Plasters Thermal Conductivity (lambda) Value λ = 0,054 - 0,064 W/mK

- Brick Thermal Conductivity (lambda) Value λ = 0, 180 - 0,500 W/mK

- Pumice Thermal Conductivity (lambda) Value λ = 0, 120 - 0,470 W/mK

- Gas Concrete Thermal Conductivity (lambda) Value λ = 0,1 10 - 0,310 W/mK

Among these insulation materials, those other than perlite, rock wool, glass wool, plasters and cellulosic insulation, i.e. polstyrene, polyurethan, polymer foam, XPS, EPS, PVC- based insulaton materials are petroleum (carbon) based and as these products are flammable and aging over time due to the loss of the insulating gases that they contain, they have such disadvantages as insulation and dimension instability. Whereas the rock and glass wool which are usually used for roof insulation in spite of their non flammable nature, they have size instability. The plasters having fire proof properties are not preferred, because the application of a certain thickness is required (e.g. at least 9 cm of thickness is required in order to obtain the insulation provided by 5 cm of XPS or EPS, therefore at least 4 (four) layers of plaster has to be applied to obtain this thickness), and they have a high material and labor cost. In practice, l-3cm of insulation plasters is applied in order to reduce the labor costs. Moreover, it is not physically possible to apply more than 5cm of plaster. For this reason, the quality of the insulation does not meet the requirements of the standards (Region 1 U (W/m²K) Value = 0.70, Region 2 U (W/m²K) Value = 0.60, Region 3 U (W/m²K) Value = 0.50 and Region 4 U (W/m²K) Value = 0.40) particularly set for cold regions (3rd and 4th regions). This situation leads to the exploitaion of those who want to get thermal insulation and to the inefficient use of energy as insulations as required according to the regions cannot be performed.

In spite of their low thermal conductivity values (λ = 0,019 - 0,040 W/mK) i.e. high insulation values, the weaknesses of the polstyrene, polyurethan, polymer foam, XPS, EPS, PVC-based insulaton materials are as follows:

As they are carbon-based, they are flammable. The maximum temperature of use of these materials is 75 - 1 10 °C degrees and only in case of srecial production they can resist temperatures up to 170 °C temperatures. As required by the regulation for the fire-protection of the buildings, it not possible to use flammable insulation materials for the isolation of buildings having more than 1 (one) storeys. These insulation materials are used when covered with plaster. However, this process can delay the burning of the flammable materials only for a short time. Although there are special production cements with aluminate that resist a temperature of 1300 - 1400 °C, in case the maximum operating temperature of the portland cement used in the plasters is exceeded, it burns and looses its binding feature. During a fire, when the temperature reaches 500 °C, the irons used in the building lose their resistance by 1/3. Researches show that the temperature raises above 1000 °C'during a fire. In case the temperature exceeds 500 °C during a fire the resistance of the building and the installations are weakened which in turn leads to the occurence of structural defects, as the result of exploding and falling down of the plasters, these carbon-based insulation materials start to burn, contributing the fire and causing the expansion of the fire.

The problem of tissue incompatibility occurs between the materials used in the construction of a building and the carbon-based materials depending on their nature. The 8 (eight) operations to be performed during installation in order to overcome this mismatch are listed respectively below:

1. Binding the foam (polstyrene, polymer foam, XPS, EPS, PVC- based plates onto the wall,

2. Drilling the wall,

3. Attaching fasteners and suppression/compression process,

4. Re-applying adhesives on the foam (polstyrene, polymer foam, XPS, EPS, PVC- based) plates,

5. Drawing mesh over the adhesive applied surface and thus over the foam plates, 6. Coating the mesh with a filler,

7. Coating the filler with mineral plaster,

8. Painting.

This chain of precesses extends the labour time and increases the labour cost. The materials used during these processes, such as mesh, fasteners (dowel, washer, screw, etc.) and the drilling tools and devices (drill and drill bit) as well as the adhesives and the fillers also increase the cost of materials.

Flexion occurs as the result of the expansion/contraction caused by variations in temperature over time plus the mismatch originating from the the ability to change size of the insulating material and tissue incompatibility, lead to the separation of the foam-type 0 insulating material from the facade. Thus meeting the technical requirements during the installation of the products requires a large amount of labor and time. In practice, by ignoring the application instructions of the insulating foam manufacturing companies, fasteners are not used efficiently for the installation of the insulating materials to the facades, particularly due to the difficulty of the drilling process, in order to reduce the costs of labour. In case these materials are mounted according to the manufacturers' instructions, the average m² cost is 50 - 60 TL whereas the insulation cost can be reduced to 30 - 40 TL by ignoring the instructions and this discrepancy between the costs is evaluated as the necessary sensitivity is not shown during installation in order to reduce the costs of labour and material. This leads to the exploitation of the insulation requests as well as to an inefficient use of energy due to the fact that the required insulation cannot be obtained although it is requested. Certain damages occur on the insulated facade due to the expansion and contraction occuring over time. The entire facade has to be repaired and painted in order to eliminate the reduction of insulation and visual pollution that ocur over time on the facades due to the damages. These weaknesses lead to negative effects on construction costs.

It is well-known that the foam (polstyrene, polyurethan, polymer foam, XPS, EPS, PVC- based) plates are not natural materials and that CFC (chlorofluorocarbon) and HCFC (hydro chloro fluoro carbon) obtained through chemical ways and used for the production of these products damage the ozone layer, so they are not environment-friendly materials. Although the said insulating materials are determined to be harmful for human health by the scientists who have specified that they have to be used on the exterior of the buildings and serious measures should be taken to avoid them from penetrating to the interiors of the buildings, these products are used for the insulation procedures on the interios also by the unconscious practitioners in the practice in our country and this practice is an issue that threatens human health.

As these materials are petroleum-based, i.e. carbon-based products, they are products dependent on overseas. Their costs increase according to the increases in the oil prices. This puts the foam-type insulating materials among the factors affecting the dependence of our country to other countries.

The strength and resistance required for the building materials, particularly for the wall blocks used for building walls, differ according to the location of usage. Walls are classified as load-bearing walls and non-load bearing walls. The load-bearing walls are the building elements that transmit the load of the building itself which continuously bears the compressive stres of the building and the its mobile loads as well as the wind load to the other load bearing elements and to the floor and their compression resistance/strength should not be less than 50 kg/cm². The compression strength of the building element of the load-bearing wall to be used at the basements should be 50 kg/cm² (TS EN 771 and TS 2510). Whereas the non-load bearing walls are the building elements that do not bear any loads other than their own weights, however they can safely transmit the possible horizontal loads such as wind, seismic effects, etc. to the adjacent carrier elements in contact with the walls, such as a load- bearing wall, flor plates, columns, etc. Exterior non-load bearing walls are usually implemented in carcass structures. The weight of the interior non-load bearing walls should not be more than 700 kgf/m, including plaster and coating. In case these walls are supported by carrier beams, they can weigh more than 700 kgf/m (TS 2510). One of the important criteria for the evaluation of wall blocks is the determination of the coefficient of quality in terms of resistance. In determining this criterion, the value found as the ratio of the compression strength of the wall block to the unit mass weight of the block, is defined as the resistance quality factor (fa) of the wall block. The standard resistance quality factors are identified by using the resistance quality factors, minimum compression resistance value and the average compression resistance values of the wall blocks as well as the values defined as the geratest unit mass weights, and its lower limit is 2.00. The products with a value below this cannot be used as wall blocks (TS EN 771-3, TS EN 772-1, 2005). Examples of resistance quality factors are given below:

Quality Factors of Resistance

20 (min.) 2.50 Low Quality Standard Interior

800

25 (av.) 3.12 Medium Standard Interior

Quality

20 (min.) 2.00 Low Quality Standard Interior

1000

25 (av.) 2.50 Medium Standard Interior

Quality

For instance; the resistance values of the gas concrete products that are among the building materials vary according to the place they are used (Class GI: 10 kgf/cm², Class G2: 20 kgf/cm², Class G3: 30 kgf/cm², Class G4: 40 kgf/cm², Class G5: 50 kgf/cm²). The gas concrete products manufactured in Classes Gl, G2, G3 ve G4 are adequate for the production of partition-purposed (non-bearing) walls, whereas they are not sufficient for load-bearing usages of walls.

DESCRIPTION OF THE INVENTION Various patent and utility model applications are also available to eliminate the deficiencies seen in the related insulating materials. Among these applications, the utility model no. TR 2003/01848 is related to a facade coating element, the patent application no. TR 2004/00799 is related to a plaster, the patent application no. TR 2006/06858 is related to a plaster, the patent no. TR 2007/02734 is related to an insulating mortar, the patent no. 2008/00392 is related to polyurethan rigid foam, the patent application no. EP 1339653 is related to an insulating material manufacturing process. Considering the weaknesses, alternative economical and natural insulating materials that can be used as plaster or sheet plates with the features that could provide an alternative insulation for the foam (polystyrene, polyurethan, polymer foam, XPS, EPS, PVC based) plates, could not be obtained.

Among the currently used insulating materials, expanded perlite being a natural material with a content that is compatible with the building materials is used with the binding elements such as cement and gypsum, for the production of plaster, alum and isolation concrete. In addition to its tissue compatibility with other building materials and being economical, due to its fire- resistance, acid resistance, infinite resistance to bacterial decomposition properties, it is a product with indispensable advantages as compared to other insulating materials. Because of its sound-insulating feature, plastering the walls of large halls with perlite containing plaster provides an accoustic property that increases the sound quality by eliminating resonation and echoing. Perlite having an inorganic nature has superior fire-resistance properties as compared to the carbon-based artificial materials that can compete with it, particularly in terms of lightness and insulation. Fire-resistant perlite plates are used for the protection of important structural elements from unwanted damages, as they have a long term resistance without being affected at high temperatures and heat insulation features as well as fire resistance. Protective perlite plate layers arranged in appropriate details can protect the load bearing steel elements at the fire temperatures between 700 °C - 900 °C, for up to 4 hours. These plates which are used to prevent fire cannot be utilized as heat insulation plates due to their high heat transfer coefficients. Despite all these features, expanded perlite could not be brought to a form of ready-to-use building materials that can be used for facade coatings with a quality to be used instead of foam, alum, plate, and such building materials as brick, pumice, gas concrete, etc.

The perlite, vermiculite and pumice reserves in the world are sufficient to meet the need for insulation in the world. 40% of the world perlite reserves (4.5 billion tons) and 15% of the world's pumice reserves (3 billion tons) are in our country and so our reserves are at a level - . that can meet the needs of our country entirely for hundreds of years.

As mentioned above, in our country expanded perlite is used as alum and plaster and pumice is used as pumice, with insulation purposes for the construction of walls. However, such additives as cement, plaster, gypsum, etc. used in the process to form plaster and pumice effect the coefficient of heat transfer of the pumice and expanded perlite and lead to a reduction in the insulation function. For this reason, expanded perlite is packed in the form of a mattress or a small amount of a cement-typed binding is added to it, in order to avoid the reduction in the insulation value in the building and installations, and is also used as insulating materials at the roof and attic. Similarly, brick, roof tile and concretes containing perlite are also used. However, the excessive amount of the binding materials used for the production of these products causes a reduction in the insulation value and an increase in the thermal conductivity (λ = W/mK) values. In fact, although the coefficient of thermal conductivity of vermiculite is (λ = 0,065 W/mK) and of pumice is (λ = 0,080 - 0,20 W/mK), the coefficient of thermal conductivity increases (λ = 0,120 - 0,470 W/mK) because of the method and bindings that are utilized. These values impede the achievement of the desired insulation value in the buildins and installations. As a result, since the plated and blocked insulating materials that eliminate the drawbacks of the state of art are not available and the insufficiency of the existing solutions, an improvement, a development and innovation in the related area have become compulsory. 0

With the present invention, the insulation plate, plaster, alum and building element to be used for insulation purposes in the buildings and installations instead of foam, with the features of the contained expanded perlite aggregates that are superior to their equivalents,( Class Al fire-resistant, stabile in terms of size, easy and cost-friendly to install, of a structure that does not contain environmentally harmful gases and that can be produced by using completely natural resources) that can be utilized instead of the existing building elements (brick, pumice, gas concrete, briquette, etc) are brought ready to be used as less costly, lighter than the equivalents with a higher insulation value and thus leaving no need for an extra insulation, and the area of usage of these entirely natural products in the construction sector has been expanded. Economy in insulation has been provided by saving time and labour.

Furthermore, since the products according to the invention do not have inflammability properties, a greater amount of damage to be caused by the loss of life and property has been prevented by impeding the spreading of the fire in the building and installations. Its lightness increases the resistance of the structures against earthquake, by mitigating their burdens. The costs of investment and operating have also been reduced. Potential damages given by the state of art products (polystyrene, polyurethan, polymer foam, XPS, EPS, PVC based plates) and the production technology, to the environment and to the living creatures have been eliminated.

EXPLANATION OF THE PRESENT INVENTION

The present invention will be better understood with the attached figures and the following explanation section. These figures are;

Figure 1 - A schematic presentation of the method for the production of heat insulating and building materials

Figure 2 - A schematic presentation of the materials and devices used in the production of heat insulating and building materials

To facilitate a better understanding of the invention the reference numbers of the materials used are listed listed as follows:

1) Expanded perlite aggregates

2) Pumice and/or expanded vermiculite aggregates 3) Chopped glass fiber

4) Water

5) Bentonite

6) Intumescent substances in gel form

7) Hydrated lime and/or cement and/or gypsum

8) Borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite)

9) Paraffin-based water repellents and/or agents preventing water and moisture impregnation

10) Molds required by the product

1 1) Vibrator

12) Compressor

13) Drying oven running with the principle of heating from the outside to the inside

14) Drying oven running with the principle of heating from the inside to the outside or everywhere simultaneously

15) Cooking oven functioning with the principle of heating from the outside to the inside

16) Dosing process

17) Mixing process

18) Molding process

19) Vibration process

20) Suppression/compression process

21) Drying process

22) Cooking process

23) Tempering process

The structure and production of the insulating panel, plaster, alum and building elements according to the invention are as follows: The present invention consists of expanded perlite aggregates (1), pumice and/or expanded vermiculate aggregates (2), chopped glass fiber (3), water (4), bentonite (5), gel formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin- based water repellents and/or agents preventing water and moisture impregnation (9), moulds required by the product (10), vibrator (11), compressor (12), drying oven running with the principle of heating from the outside to the inside (13), drying oven running with the principle of heating from the inside to the outside or everywhere simultaneously (14), cooking oven functioning with the principle of heating from the outside to the inside (15) and its production method consists of the following items; dosing process (16), mixing process (17), molding process (18), vibration process (19), suppression/compression process (20), drying process (21), cooking process (22) and tempering process (23). The materials and production methods used for the production of the insulating material which is the subject of the present invention and which contains expanded perlite aggregates (1) are as follows: In the current method used for the mixing process, the binding agents used in powder form are added to the expanded perlite and/or pumice and/or expanded vermiculate aggregates (1 and 2) and stirred, then water (4) is sprayed or mixed with it. During this process, the binding agents melt in water (4), they enter and fill the cells present in the aggregates (1 and/or 2) together with water (4). In case water (4) in the cells withdraws, the occupation of the binders becomes permanent which decreases the insulation values of the aggregates (1 and/or 2). Although the heat transfer coefficient of the pumice (2) used in the production by this mixing method is (λ = 0,080 - 0,20 W/mK), heat transfer coefficient of the end product pumice almost doubles (λ = 0,120 - 0,470 W/mK) . Whereas in our mixing method, the aggregates (1 and/or 2) are first mixed with water (4) or gel formed and intumescent substances (6) then other binding agents (5 and/or 7) in powder form, are added by sieving or spraying while mixing and stirring continues. The differences and advantages of the mixing process (17) compared to the state of art mixing process of the used method are described below. In this mixing process, first water (4) enters the cells in the gel formed and intumescent substances (6) and in the aggregates (1 and/or 2) and thus increases the resistance of the aggregates (1 and/or 2) and prevent their breaking during the mixing process. While adding bentonite (5) and slaked lime and/or cement and/or gypsum (7) particles in powder form to the mixture by sieving them or by spraying, the particles adhere to the water (4) or to the gel formed and intumescent substances (6) encircling the aggregates (1) so that they cannot enter the cells of the aggregates (1 and/or 2). The adhesion force, in other words the attraction force against the molecules of other substances in the water (4) encircling the aggregates (1 and/or 2) and the capturing feature of the binding agents (5 and 6) in gel form, act as filters and prevent the impregnation of the other binding agents (5 and 7) into the cells of the aggregates (1 and/or 2), thus avoiding any negative impacts on thermal insulation. Furthermore, the high surface tension created by the high cohesion force between the molecules of water (4) is another factor which is effective in preventing the binding agents (5 and 7) from entering the cells. The prevention of the binding agents (5 and 7) from entering the cells of the aggregates (1 and/or 2), reduces the cost of product by decreasing the amount, of the binding agents (5 and 7) and increases the binding within the aggregate (1 and/or 2), thus augmenting the pressure resistance of the product. Moreover, continuing to stirring while adding bentonite (5) and slaked lime and/or cement and/or gypsum (7) particles in powder form to the mixture by sieving them or by spraying, provide the homogeneous distribution of the binding agents (5 and 7) among the aggregates (1 and/or 2)..In the studies conducted, the best results are obtained by using potato starch in gel form and rice flour (6) and filtering can also be provided by using all materials (6) in gel form- that are intumescent. With this method, materials in gel form (5 and/or 6) even in trace amounts penetrate into the cells of the aggregate (1 and/or 2). When water (4) contained in the materials in gel form (5 and/or 6) leaves the product, these materials shrink 5 - 20 fold by volume. In the cell, a small amount of materials remains due to contraction, but this is at an acceptable level and due to the evaporation of water the air space in the cell is maintained and thus the heat insulating feature is protected.

The product in the form of an insulating panel, is passed through the dosing process of the expanded perlite aggregates (1), chopped glass fiber (3), water (4), bentonite (5) and/or gel formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9), and is exposed to the mixing process (17) in required proportions after dosing process (16), and finally obtained mixture is poured into the moulds (10) to put it in a plate form. The mixing process (17) and the moulding process (18) show differences depending on the content of the product. As the best results are obtained by using potato starch in gel form and rice flour (6) among all intumescent materials in gel form (6), first potato starch and rice flour (6) are measured and put into a gel form by mixing it with hot water (4), then they are passed through a dosing process (16) and poured into the expanded perlite aggregates (1) to realize the mixing process (17) and the moulding process (18) is reached. In case bentonite (5) is used as the binding agent, a pre-determined amount of water (4) is added to the expanded perlite aggregates (1) and the mixing process (17) is performed. Following the entrance of water (4) into the aggregates (1) and wetting these aggregates (1), while the stirring process (17) is still continuing bentonite (5) in powder form is passed through the dosing process (16) and added to the mixture by sieving or 0 spraying, so that a homogeneous distribution between the aggregates (1) is obtained. After bringing the bentonite (5) in the mixture to a gel form, moulding process (18) is started. In this mixing method, water (4) enters the cells of the aggregate (1) and increases its resistance. Although it is possible to perform the mixing process (17) by adding bentonite (5) to the aggregates (1) in dry form after being passed through the dosing process (16) and then adding water (4), since bentonite (5) absorbs water (4) immediately after it comes into contact with water, it is difficult to obtain a homogeneous mixture. It has been seen that the expanded perlite aggregates (1) are broken during this mixing process (17) and that an increase in the weight of the product and in the amount of the aggregate (1) used, in line with this beaking, had a negative effect on the cost of product and the capacity to insulate. By exposing the bentonite (5)-containing insulation plate to a drying process (21) the evaporation of the water and moisture to leave the plate, is provided. Bentonite (5) gains and maintains its binding feature at a temperature of 320 - 1000 °C during the cooking process. Tempering (23) is realized by sending cold air current on the cooked plate or by putting in in a cold environment or in cold water.

In case borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) is used as the binding agent in the product, borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) melted in a predetermined amount of hot water (4) is added to the expanded perlite aggregates (1) and the mixing process (17) is performed while it is still warm. Following the entrance of water (4) containing borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) in the aggregates (1) to wet them, while the stirring process (17) is still continuing, bentonite (5) in powder form that is passed through the dosing process (16) is added to the mixture by sieving or spraying, so that a homogeneous distribution between the aggregates (1) is obtained. After bringing the bentonite (5) in the mixture to a gel form, moulding process (18) is started. In this mixing method, water (4) enters the cells of the aggregates (1) and increases their resistance and prevents the breaking of the aggregates (1) durimg the mixing process (17). Although it is possible to perform the mixing process (17) by adding bentonite (5) to the aggregates (1) in dry form after being passed through the dosing process (16) and then adding water (4), since bentonite (5) absorbs water (4) immediately after it comes into contact with water, it is difficult to obtain a homogeneous mixture. It has been seen that the expanded perlite aggregates (1) are broken during this mixing process (17) and that an increase in the weight of the product and in the amount of the aggregate (1) used, in line with this beaking, had a negative effect on the cost of product and the capacity to insulate. By exposing the borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) and bentonite (5) -containing insulation plate to a drying process (21 ) the evaporation of the water and moisture to leave the plate, is provided. Borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), like bentonite (5), gains and maintains its binding feature at a temperature of 700 - 1000 °C during the cooking process. Tempering (23) is realized by sending cold air current on the cooked plate or by putting in in a cold environment or in cold water. Borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), increases the resistance provided by bentonite (5) and contributes the appearance of the insulating plate. The appearance of the borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) containing insulation plate shows that the product can be used for facade coating.

The raw material mixing ratio of the product; each and every material added into the expanded perlite aggregates (1) have a negative impact on the (λ) value i.e. its thermal conductivity as well as the cost of the product. For this reason, the contents and their ratios vary according to the environment in which they shall be used. In case they are used in the form of a sandwich, it is sufficient to use the binding agents (5, 6, 7 and 8) just in an amount to hold the perlite aggregates (1) together. In case they are used for interior insulation, paraffin-based water repellents and/or agents preventing water and moisture impregnation (9) have to be used with a ratio that is lower than that is used exterior insulation. In this product, pumice and/or expanded vermiculate aggregates (2) are not used, as their heat conductivity coefficient is not at the desired level of values (λ < 0,065 W/mK). This mixture (1 , 3, 4, 5, 6, 7, 8 and 9) which can also be prepared by adding pigments or another colorant, is poured into a mould (10). Following the screeding, a vibration process (19) performed by a vibrator (1 1) provides the settlement in the mould (10) thoroughly. Flexible materials that will not crush the aggregates between the expanded perlite aggregates (1) by the compressor (12) during the suppression/compression process (20) can be used. The vibration process (19) can be performed during the pouring of the mixture into the mould (10), as well as during the suppression/compression process (20). For the drying process (21), drying ovens running with the principle of heating from the outside to the inside (13) and drying ovens running with the principle of heating from the inside to the outside or everywhere simultaneously (14) can be used. Although they are classified as convection and infrared systems and considered as different heating systems, the drying ovens running with the principle of heating from the outside to the inside (13) realize the heating process with the same logic with small differences. As can be understood from its name, the drying ovens running with the principle of heating from the outside to the inside (13) heat the product in it, and the flow of heat is towards the inside of the product. In this type of heating systems (13) first the outer surface of the product is dried and creates the outer form of the product. The existing building materials are also produced, dried and cooked in this type of ovens. For this reason, the composite mixture brought. out from the mould (10) is first put in this type of ovens (13) in order to dehydrate it. Now, the dehydrated and partially dried composite mixture has become a plate. In this case, bentonite (5) potato starch and/or rice flour (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin- based water repellents and/or agents preventing water and moisture impregnation (9), as binding agents wrap around the perlite aggregates (1) to bind the aggregates (1) to each other. The binding at the plate in this position is at a level just sufficient to hold the aggregate particules (1) together but the existing binding level is not advanced enough to use the plate. Furthermore, the excessive amount of the contained water and moisture increases the thermal conductivity coefficient of the plate, and this is at a level to prevent the product from being an insulaing plate. In the drying ovens (14) running with the principle of heating from the inside to the outside or everywhere simultaneously, also referred to as the micro- wave ovens, heating starts at every location at the same time although it is perceived that heating starts from the inside outwards. The ovens (14) running with this type of heating principle dry all surfaces of the product at the same time. In the next process, the plate is sent to the drying oven (14) running with the principle of heating from the inside to the outside or everywhere simultaneously so that the water and moist contained in it is evaporated and leaves the product. In case the drying ovens (14) running with the principle of heating from the inside to the outside or everywhere simultaneously are not used for the drying process (21), this process continues in the drying ovens (13) running with the principle of heating from the outside to the inside or in a natural environment until it does not contain water and moist, depending on the thickness of the plate. However, this has a negative impact on the duration of the process for obtaining the product. In case cement (7) is contained as the binder, it is a technical obligation that the drying process (21) is realized after gaining the mechanical strength. In case only bentonite (5) and/or borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) is contained as the binder, the plate is cooked in the drying ovens(13) running with the principle of heating from the outside to the inside at a high temperature (300 - 1000 °C).

After the cooking process (22), the tempering process (23) is realized by sending cold air flow on the plate taken out of the cooking oven (15) functioning with the principle of heating from the outside to the inside or by placing it in a cold environment or in cold water. Although the tempering process (23) is not obligatory, it is one of the items that increase the resistance of the insulating plate. As the tempering temperature rises, the resistance of the insulating material also increases. Another item that increases the strength of the heat insulating plate is the chopped glass fibers (3) contained in the mixture and they serve as the resistance/strength providers similar to the steel wires in concrete or like the straws used in making adobe. As in the other existing glass fiber (3) reinforced composite applications, it increases the strength of the materials. In case the required resistance is provided or the composite is negatively affected, the tempering process (23) will not be performed and chopped glass fiber (3) will not be used in the mixture. In the drying process (21) only the drying ovens (14) running with the principle of heating from the inside to the outside or everywhere simultaneously are sufficient, this shortens the production process and reduces the cost of energy. The difference of the drying ovens (14) running with the principle of heating from the inside to the outside or everywhere simultaneously from the other drying ovens (13) running with the principle of heating from the outside to the inside is that they heat the water particles in the composite mixture at the same time and by evaporating them with less energy, enables it to leave the product in a short time. Although the drying ovens (13) running with the principle of heating from the outside to the inside are also sufficient for the drying process (21), this type of a drying process (21 ) extends the production time and increases the cost of energy. The product in the form of an insulating plate, shall be prepared as described above, packed and be made ready for use.

Products in the form of building materials (wall block, brick, block wall, block floor/ceiling, panel board, ceramic tiles, artificial marble, etc.) and their production method are as follows:

The fact that the building materials require high resistance values in line with the purpose of their usage, necessitated the use of pumice and/or expanded vermiculate aggregates (2) with low insulation values but with high resistance values, in addition to expanded perlite (1), for the production of the building materials (wall block (brick, pumice, gas concrete), block wall, block floor/ceiling, panel board, ceramic tiles, artificial marble etc.).

The resistances required by the building materials vary according to the location of their use. In order to obtain building materials with a high insulation value and required resistance, priorly expanded perlite (1) will be used and in case expanded perlite (1) is not efficient to provide the required resistance, pumice and/or expanded vermiculate aggregates (2) will be used as additives or as main ingredients. In the production of building materials (wall block

(brick, pumice, gas concrete), block wall, block floor/ceiling, panel board, ceramic tiles, artificial marble etc.) comprising expanded perlite aggregates (1), pumice and/or expanded vermiculate aggregates (2), chopped glass fiber (3), water (4), bentonite (5), and/or gel formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), and/or borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9), the production methods and stages that are used for the production of the insulating plate.

The way of producing such materials as artificial marble and ceramics is the dressing method.

Artificial marble is obtained by glazing and coating the surfaces of the products produced in suitable forms for this method, with such products as ceramics, polyesther, etc.

The heat insulation panel and building materials that are produced can be fixed to each other and/or to their places at the building or insyallation and can be installed to the desired surface.

As mentioned above, Turkey is divided in 4 (four) regions with regard to the rules of thermal insulation, and since the insulation value required for each region is different, the thickness of the materials should also be different and variable. This requirement is valid for different regions of the world too. For this reason, it is obvious that the thickness of the products will vary according to the needs of the regions they are used in.

The product in the form of insulating plaster and alum is a mixture obtained by passing expanded perlite aggregates (1), chopped glass fiber (3), water (4), bentonite (5) and/or gel formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9) through a dosing process (16) and by being subjected to a mixing process (17) in suitable proportions, and will be used for plastering the floors, facades and insulating panels. For the production of the insulating panel and alum, the production methods and stages applied for the insulating panel will be used in addition to the items enabling the formation of the product.

It is obvious that the thickness of the plaster and alum to be used and each substance added to the plaster will affect the insulating value and other features of the plaster and alum. In fact the thicknes of plaster that can be implemented is around 1 - 3 cm due to technical issues. This thickness is far from being satisfactory in terms of the specified insulation values of the existing insulation plasters particularly for cold regions (3 and 4). However, it has been evaluated that in case the insulating plaster according to the invention is used in warm regions (1 and 2) or is applied on the insulating panel, it can meet the insulation values specifiedfor the cold regions (3 and 4). The product in the form of an insulating plaster and alum will be prepared as described above, packed and be made ready for use.

The fact that the location and purpose of using the insulating and building elements are variable necessitates the use of different materials and implementation of different methods in the production of these products. The content ratios of the substances used in the products that will provide a beter understanding the products produced as the thermal insulation panel, thermal insulation plaster and building materials, are given below:

For the thermal insulation panel, plaster and alum, expanded perlite aggregates (1) are added in a ratio of 50 - 99%, for the building materials expanded perlite and/or vermiculate and/or pumice aggregates (1 and/or 2) are added in a ratio of 50 - 98%, and if required chopped glass fiber (3) is added in a ratio of 1 - 5%. The following materials are added on this content in the shown ratios and mixed using the above described methods: Bentonit (5) 1 - 5%, gel formed and intumescent substances (6) 1 - 5%, hydrated lime and/or cement and/or gypsum (7) 1 - 5%, borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) 1 - 5%, paraffin- based water repellents and/or agents preventing water and moisture impregnation (9) 1 - 5%.

Claims

An alternative isolation/building materials and production method, characterized in that the present invention consists of expanded perlite aggregates (1), pumice and/or expanded vermiculate aggregates (2), chopped glass fiber (3), water (4), bentonite (5), gel-formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9), moulds required by the product (10), vibrator (11), compressor (12), drying oven (13) running with the principle of heating from the outside to the inside, drying oven (14) running with the principle of heating from the inside to the outside or everywhere simultaneously, cooking oven (15) functioning with the principle of heating from the outside to the inside; and its production method consists of the following items: dosing process (16), mixing process (17), molding process (18), vibration process (19), suppression/compression process (20), drying process (21), cooking process (22) and tempering process (23).

The building materials (wall block, block wall, block floor/ceiling, panel board, ceramic tiles, artificial marble, etc.) according to the Claim 1, characterized in that it consists of expanded perlite aggregates (1), and/or pumice and/or expanded vermiculate aggregates (2), chopped glass fiber (3), water (4), bentonite (5), gel-formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9).

Thermal isolation material (panel, plaster, alum, etc.) according to the Claim 1, characterized in that it consists of expanded perlite aggregates (1), pumice and/or expanded vermiculate aggregates (2), chopped glass fiber (3), water (4), bentonite (5), gel-formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9). The production method for the building materials according to Claims 1 and 2, characterized in that expanded perlite aggregates (1), pumice and/or expanded vermiculate aggregates (2), chopped glass fiber (3), water (4), bentonite (5), gel- formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9) are included in proportions required by the building material and mixed after being exposed to the mixing process (17), and the mixture obtained after these processes is poured into the moulds (10) that put it in a form required by the product, following the screeding, vibration process (19) provides the settlement into the mould (10) thoroughly and the form is obtained as a result of suppression/compression process (20) by the compressor (12).

Production method for the isolation material according to Claims 1 and 3, characterized in that expanded perlite aggregates (1), chopped glass fiber (3), water (4), bentonite (5), gel-formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9) are included in proportions required by the building material and mixed after being exposed to the mixing process (17) and the mixture obtained after these processes is poured into the moulds (10) that put it in a form required by the product, following the screeding, vibration process (19) provides the settlement into the mould (10) thoroughly and the form is obtained as a result of suppression/compression process (20) by the compressor (12).

Production method for the thermal isolation plaster and alum according to Claims 1 and 3, characterized in that expanded perlite aggregates (1), pumice and/or expanded vermiculate aggregates (2), chopped glass fiber (3), water (4), bentonite (5), gel-formed and intumescent substances (6), hydrated lime and/or cement and/or gypsum (7), borax pentahydrate Na₂B 0₇ 5H₂0 (Tincal konite) (8), paraffin-based water repellents and/or agents preventing water and moisture impregnation (9) are included in proportions required by the product and obtained by the mixing process (17).

Method for mixing process (17) according to Claims 1, 2, 3, 4, 5, and 6, characterized in that high surface tension in the water (4) encircling the aggregates (1 and/or 2) and the attraction (adhesion) force of other substances against the molecules and/or the capturing features of binding agents (5 and 6) gel- formed are used as filter.

8) Method for mixing process (17) according to Claims 1, 2, 3, 4, 5, 6, and 7, characterized in that the aggregates (1 and/or 2) are mixed by blending after adding water (4) firstly and then gel-formed and intumescent agents (6); and while the mixing is proceeding, the other binders (5 and/or 7) are added into by sieving them into powder or spraying.

9) Method for mixing process (17) according to Claims 1, 2, 3, 4, 5, 6, 7, and 8, characterized in that the resistance of the aggregates (1 and/or 2) is increased with entrance of water (4) and gel-formed and intumescent agents (6) into the cellules in the aggregates (1 and/or 2) after adding water (4) firstly and then gel- formed and intumescent agents (6) and during the mixing process (17) the break of the aggregates (1 and/or 2) is prevented.

10) Method for mixing process (17) according to Claims 1, 2, 3, 4, 5, 6, 7, 8, and 9, characterized in that during adding process of bentonite (5) and/or slaked lime and/or cement and/or gypsum (7) particles into the mixture by sieving in powders and spraying, the particles are prevented from clinging to the water (4) encircling the aggregates (1) and/or gel-formed and intumescent agents (6) and they are prevented from penetrating into the cellules in the aggregates (1 and/or 2) thanks to the filter role of surface tension in water (4) and gel-formed binding agents (5 and

6) ·

11) Method for mixing process (17) according to Claims 1, 2, 3, 4, 5, 6, 7, 8, 9, and

10, characterized in that mixing proceeds during the addition of the binding agents (5 and 7) by sieving in powder and spraying to the mixture in order to provide the homogeneous dispersion of binding agents (5 and 7) between the aggregates (1 and/or 2).

12) Method for mixing process (17) according to Claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10,

11, and 12, characterized in that the water (4) encircling the aggregates (1) and/or gel-formed and intumescent agents (6) prevent the binding agents (5 and/or 7) from entering the aggregate (1 and/or 2) cellules and enable the binding agents (5 and/or

7) remain between the aggregates (1 and/or 2), thus the production cost decreases by lowering the amount of the binding agents (5 and 7) and the binding between the aggregates (1 and/or 2) increases thus augmenting the pressure resistance.

13) Method for the production of building and thermal isolation materials according to Claims 1, 2, 3, 4, and 5, characterized in that the structure and the thermal isolation material that are formed, are exposed to the drying process (21) consisting of drying and draining them firstly in natural environment or in drying ovens (13) running with the principle of heating from the outside to the inside, and then the water and the moist present in the materials are evaporated and leave the product thanks to the drying oven (14) running with the principle of heating from the inside to the outside or everywhere simultaneously.

14) Method for the production of building and thermal isolation materials according to Claims 1, 2, 3, 4, 5, and 12, characterized in that after the drying process (21), the products comprising bentonite (5) and/or borax pentahydrate Na₂B₄0₇ 5¾0 (Tincal konite) (8) as binding agents are exposed to the cooking process (22) in the cooking oven (15) running with the principle of heating from the outside to the inside.

15) Method for the production of building and thermal isolation materials according to Claims 1, 2, 3, 4, 5, 12, and 13, characterized in that the products that are taken out of the cooking oven (15) functioning with the principle of heating from the outside to the inside after the cooking process (22) are exposed to the tempering process (23) by being sent cold air flow or remained in the cold environment or water.

16) Method for the production of building and thermal isolation materials according to Claims 1, 2, and 3, characterized in that only the bentonite (5) is used as binding agent and the dried products containing bentonite (5) are cooked.

17) Method for the production of building and thermal isolation materials according to Claims 1, 2, and 3, characterized in that bentonite (5) and borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) are used together as binding agents

. and the dried products are cooked.

18) Method for the production of building and thermal isolation materials according to Claims 1, 2, and 3, characterized in that borax pentahydrate Na₂B₄0₇ 5H 0 (Tincal konite) (8) is melt in the hot water (4) and added into the perlite aggregates (1) and while the mixing is proceeding, the bentonite (5) is added by sieving in powder or spraying.

19) Method for the production of building and thermal isolation materials according to Claims 1, 2, and 3, characterized in that the binding property of borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) is used by cooking the products containing borax pentahydrate Na₂B₄0₇ 5H₂0 (Tincal konite) (8) at high temperature.

20) Method for the production of building and thermal isolation materials according to Claims 1, 2, and 3, characterized in that only gel-formed and intumescent agents (6) are used as binding agents.

21) Method for the production of building and thermal isolation materials according to Claims 1, 2, and 3, characterized in that only potato starch and/or rice flour are used among gel-formed and intumescent agents (6) as binding agents.

Yavuz Tuncay DERELl 25.12.2010