Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/12—Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives
  • C08J5/124—Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives using adhesives based on a macromolecular component
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/22—After-treatment of expandable particles; Forming foamed products
  • C08J9/224—Surface treatment
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
  • C08J9/22—After-treatment of expandable particles; Forming foamed products
  • C08J9/228—Forming foamed products
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
  • C08J2325/02—Homopolymers or copolymers of hydrocarbons
  • C08J2325/04—Homopolymers or copolymers of styrene
  • C08J2325/06—Polystyrene

Definitions

• This invention means a production method of integral panels with build-in functional and/or decorative elements from expanded polystyrene. Its use is mainly in construction industry.
• Additional insulation is rather labor-intensive form. For example, to insulate 1 square meter of concrete panel house, it is needed about 1.05 hour of labor, which is close to the time needed to build such a building from concrete panels. Quantity of material needed is great as well. To insulate 1 m 2 only 1.4 to 2.8 kg is used in form of plates, according to different thickness and density, but other materials used are 3 kg of plaster and 1.1 m 2 of fiberglass mesh or fabric. Material described above is calculated for simple application of polystyrene plates directly to the wall being insulated. For a better quality insulation, a grid from wooden or Al profiles fastened to the wall is attached first and it is more labor-intensive.
• Main walls blocks are build, made of bricks, wood, steel and then supporting wooden or steel or aluminum grids with U or C profiles.
• Main blocks or grids are made the way that water or electricity components can be readily installed.
• plates forming the outer walls are installed, insulation material based on fibers or expanded materials fixed and inner wall plates fixed.
• the final steps are filling with putty the joints or painting the walls.
• the lifespan of such building can be 80-100 years, thermal resistance over 5 m 2 K / W, and sound resistance index around 50 DB.
• Labor requirement of such building is 2-2.5 times higher than that of concrete panels building. Another advantage is that no heavy machinery is used.
• NCO groups are favorably masked by compounds based on compounds with phenolic core, caprolactam, secondary amines or other compounds containing NCO groups.
• Surface of integral part can be partially or completely covered by polymer foil, wallpaper, veneer or other functional and/or decorative elements.
• Integral part is favorably polystyrene construction block and functional elements are surface plates or strengthening elements such as mesh, wires, tubes and water or electricity distribution components.
• Invention fundamentals of integral panels is in treating the contact surface of elements being joined with the expanded polystyrene core are treated with liquid co-polymer contains NCO group compound, favorably masked by compound contains phenolic caprolactam group or other compounds which by use of with water from saturated water steam, reacting with NCO group.
• NCO group is by reacting with water forming a solid polymer according this equation:
• Method of integral parts production according to the invention is allowing to produce a light panel based on extruded polystyrene with build-in functional and/or decorative elements from expanded polystyrene prior to its use on construction site, whereas labor requirement for such component production is only slightly bigger than that of extruded core.
• Panel can contain surface plates, connecting elements, strengthening elements such as mesh, wires, tubes and water or electricity distribution components, improving the panel functional and decorative elements function. All parts are with the integral panel light section firmly fixed. Strength of formed joint is bigger than the structural strength of extruded polystyrene and it is resistant to heath up to 140 °C. Thermal insulating properties and sound proofing qualities of buildings using this system are comparable with classical panel construction buildings and there is no need tor heavy equipment.
• Advantage of this invention is the fact that joining the surface elements of light core with other elements and possible firm installation of utility elements or others is done during the light core production, using one only form, during single technological step.
• Core surface can be strengthened by a glass fiber mesh for example.
• Inner surface can be covered by wallpaper etc.
• Chipboard 12.5 mm is treated with liquid butadiene-styrene rubber, NCO group based, was inserted into mold bottom where sticky surface is directed into the mold space. NCO group content with this liquid rubber is 1.8%, quantity used was 150 g/m 2 .
• 250 mm deep mold was equipped with nozzles for hot steam insertion. Insulated electricity tube was inserted there as well, With the same pre-polymer.
• a mold was than filled with pre-expanded polystyrene pearls with the 30 kg/m 3 pouring density. To this polystyrene filling a plaster board 12 mm thick was applied, with the glue of 100 g/m 2 weight, the film facing the mold space. After the mold was closed, a steam was opened.
• Fibrecement plate 15 mm thick containing glass fiber was coated with liquid polyurethane co-polymer (NCO group content of 2%) with the weight of 1 0 g/m 2 . NCO group was masked by caprolactam. Plate was inserted into mold 300 mm deep, with the nozzles for steam in its sides. Mold was, than filled with pre-expanded polystyrene pearls with the 35 kg/m J . On this filling surface was mesh laid made of polystyrene fibers weight 0.15 kg/m 2 and polyester foil with the surface as the realistic outer wall grain and on the other side a film of earlier mentioned pre- polymer with the 200 g/m 2 density. After the mold was closed, a hot steam was applied. This way an integral panel, construction block was produced, including the finished surface. There was measured thermal resistance 6.2 m 2 K/W and air soundproofing index around 75 DB.
• Method according to the invention can be applied in any field where a solid joining of expanded polystyrene core with other parts in its surface or inside the expanded polystyrene structure core.
• Primary use is in construction industry.

Landscapes

• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Manufacturing & Machinery (AREA)
• Laminated Bodies (AREA)
• Building Environments (AREA)
• Panels For Use In Building Construction (AREA)
• Finishing Walls (AREA)

Applications Claiming Priority (2)

Publications (1)

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Citations (4)

Family Cites Families (5)

• 2012
  • 2012-02-20 CZ CZ2012-120A patent/CZ306893B6/cs not_active IP Right Cessation
• 2013
  • 2013-02-19 WO PCT/CZ2013/000017 patent/WO2013123919A1/en active Application Filing

Patent Citations (4)

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