Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
  • B28B19/0015—Machines or methods for applying the material to surfaces to form a permanent layer thereon on multilayered articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
  • B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
  • B28B19/0046—Machines or methods for applying the material to surfaces to form a permanent layer thereon to plastics
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
  • B29C44/06—Making multilayered articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams

Definitions

• the present invention relates to a process for preparing a precast polyurethane-based concrete insulation element, specifically by applying a first polyurethane reaction system on the uncured concrete to prepare the precast polyurethane-based concrete insulation composite.
• the present invention also relates to a precast polyurethane-based concrete insulation element comprising a base layer, a core layer and optional surface layer, particularly to a precast polyurethane-based concrete insulation element comprising a base layer, a barrier layer, a core layer and optional surface layer.
• Precast concrete insulation element is commonly used in the industrialized fabricated concrete construction for insulation. It generally has two concrete slabs connected by insulation tie, and a lightweight polyurethane insulation slab is disposed between the two slabs.
• the element may have functions of load-bearing, containment, insulation, sound insulation and decoration.
• the element has an inner concrete layer serving as the structure layer, and an outer layer as the decorative layer, and it can be configured as different styles according to architectural styles, such as fair-faced concrete, colored concrete, brick facing and stone facing.
• EP1010828B1 discloses a process for preparing a precast polyurethane-based concrete insulation element, wherein a base layer /or surface layer is formed by pouring uncured concrete, and followed by curing, and then an insulation layer is formed on the base layer /or surface layer by pouring a polyurethane reaction system onto the surface layer /or the base layer. After curing the polyurethane reaction system, the components are flipped onto a second uncured concrete layer, and further curing to provide the desired insulation element.
• Another process for preparing a precast polyurethane-based concrete insulation element comprises steps of: applying uncured concrete into the mould, and then paving polyurethane boards onto the cured base layer, finally applying uncured concrete onto the polyurethane insulation board, thus after curing the precast polyurethane-based insulation board is produced.
• the polyurethane boards need to be cut into the desired shape manually, which is time-consuming and labor-intensive. And some slab joints will be formed after being paved onto the base layer, which may be detrimental to the insulation effect.
• a process for preparing a precast polyurethane-based concrete insulation element comprising a base layer, a core layer and optional surface layer, comprising the steps of:
• forming the core layer on the base layer by applying a first polyurethane reaction system onto the base layer, wherein the first polyurethane reaction system cures to form a polyurethane rigid foam serving as the core layer;
• the core layer has a thickness of 20- 100mm.
• the process further comprises a step of: V) forming a barrier layer on the uncured base layer before forming the core layer on the barrier layer, wherein the barrier layer is formed by applying a second polyurethane reaction system onto the uncured base layer and curing the second polyurethane reaction system.
• the pot life of the second polyurethane reaction system is less than 20 seconds.
• the second polyurethane reaction system cures to form a polyurethane rigid foam, flexible polyurethane foam or polyurethane elastomer.
• the barrier layer has a thickness of l-20mm.
• the barrier layer has a density of 15- 1000 kg/m 3 .
• a precast polyurethane-based concrete insulation element comprising:
• the core layer has a thickness of 20- 100mm.
• the precast polyurethane-based concrete insulation composite further comprises: c) a barrier layer, wherein the barrier layer is disposed between the base layer and the core layer and contacting with the base layer, and is prepared from a second polyurethane reaction system.
• the pot life of the second polyurethane reaction system is less than 20 seconds.
• the pot life of the second polyurethane reaction system is less than 20 seconds.
• the second polyurethane reaction system cures to form a polyurethane rigid foam, flexible polyurethane foam or polyurethane elastomer.
• the barrier layer has a thickness of l-20mm.
• the barrier layer has a density of 15-1000 kg/m 3 .
• the present invention provides to a high-efficiency and low-cost process for preparing a precast polyurethane-based concrete insulation element which comprises a base layer, a core layer and optional surface layer, comprising the steps of:
• the present invention involves steps of applying (by spraying or injecting) a first polyurethane reaction system onto the uncured base layer; and after the first polyurethane reaction system cures to form a core layer, the uncured or cured concrete is optionally applied onto the core layer to serve as a surface layer; and finally cures the obtained composite to produce the precast polyurethane-based concrete insulation element.
• the term 'concrete' has the common meaning in the art, which refers to a composition comprising inorganic binders (eg. cement), fillers (eg. gravel, sand), water and optional additives and/or auxiliaries, wherein the term 'cement' has the common meaning in the art which refers to a dry powder prepared from calcined limestone, silica, aluminium oxide, lime, iron oxide, magnesium oxide and clay etc.
• the meaning of the term 'concrete' also covers the commonly used term 'mortar' in the art.
• the 'concrete' and 'mortar' in the present invention only differ in the maximum particle size of the fillers.
• 'mortar' refers to the compositions made of fillers having a particle size of up to 4 mm.
• 'concrete' refers to the compositions made of coarser fillers, however the terms 'concrete' and 'mortar' are not distinguished in the present invention.
• the term 'the uncured concrete' refers to the concrete which has not fully cured to have the basic strength, that is to say , before the final setting, wherein the final setting time can be determined according to GB/T 50080-2002("Standard for testing the performance of conventional concrete mixture” , chapter 4, "determination of setting time”).
• the uncured base layer is formed by applying the uncured concrete onto a mould, and the cured base layer is formed by curing the uncured base layer.
• the core layer is formed on the uncured base layer by applying a first polyurethane reaction system onto the uncured base layer and the curing the first polyurethane reaction system to form a polyurethane rigid foam which serves as the core layer.
• the first polyurethane reaction system can be the conventional polyurethane system for preparing the polyurethane rigid foam in the art.
• the first polyurethane reaction system includes:
• the polyisocyanates are selected from MDI and TDI prepolymer, or monomer mixtures, more preferably MDI prepolymer, or monomer mixtures;
• the polyols are one or more selected from the group consisting of: polyether polyols initiated by sucrose, glycerol, sorbitol or diethanolamine, polyester polyol based on phthalic anhydride;
• one or more catalysts having an amount of 0-2 wt.% based on 100 % by weight of lb) and lc).
• the first polyurethane reaction system may also comprise the common additives in the art, for example, fire retardants, cross-linker, chain extenders and the like.
• the first polyurethane reaction system may be applied onto the uncured base layer by a known method in the art, such as spraying or injection.
• the first polyurethane reaction system can be applied in multiple layers, and the produced core layer may have a thickness of 20- 100mm.
• a barrier layer is formed by applying the second polyurethane reaction system onto the uncured base layer to form monolayer or multilayer polyurethane rigid foam, flexible polyurethane foam or polyurethane elastomer. Then the core layer is formed by applying the first polyurethane reaction system onto the barrier layer.
• the second polyurethane reaction system can be the conventional systems for preparing polyurethane rigid foam, flexible polyurethane foam or polyurethane elastomer.
• the uncured concrete comprises some water and alkali materials which may react with the first polyurethane reaction system, thus may be detrimental to the properties of the polyurethane rigid foam.
• the second polyurethane reaction system comprises:
• the polyisocyanates are selected from MDI and TDI prepolymer, or monomer mixtures, more preferably MDI prepolymer, or monomer mixtures;
• polyol and/or amine-terminated polyether having a molecular weight of more than 100-8000 and a functionality of 2-6 wherein the polyol is the one or more selected from the group consisting of: polyether polyol, polyester polyol, polycarbonate polyol, polycaprolactone polyol, polytetrahydrofuran polyol;
• the first polyurethane reaction system may also comprise the common additives in the art, for example, fire retardants, cross-linker, chain extenders and the like.
• the second polyurethane reaction system has a pot life of less than 40 seconds, more preferably less than 20 seconds, and most preferably less than 10 seconds.
• the polyurethane reaction system with shorter pot life shows higher activity, thus are less affected by the water and the alkali materials in the uncured concrete.
• the second polyurethane reaction system may cure to form polyurethane rigid foam, flexible polyurethane foam or polyurethane elastomer, and thus forms the barrier layer.
• the thickness of the barrier layer can be l-20mm.
• the polyurethane rigid foam, flexible polyurethane foam or polyurethane elastomer for forming the barrier layer have a density of 15-1000 kg/m 3 , preferably 20-200 kg/m 3 , and most preferably 25-100 kg/m 3 .
• the second polyurethane reaction system can be applied onto the uncured base layer by a known way in the art, for example, by spraying or injecting.
• uncured or cured concrete can be optionally applied onto the core layer wherein the uncured concrete cures to form the surface layer.
• the uncured concrete for forming the surface layer may be same or different to those for forming the base layer.
• the uncured concrete can be cured by the conventional methods in the art, for example, the conventional methods for curing concrete in the art.
• the conventional curing methods in the art include natural curing, steam curing, dry/wet steam theraml curing, autoclave curing, electric curing, infrared ray curing and solar curing etc.
• the above components are cured under a temperature of 20 + 3 ° C and a humidity of no lower than 90 % until a desired concrete strength is obtained, whereby obtaining the precast polyurethane-based concrete insulation element.
• the present invention further relates to a precast polyurethane-based concrete insulation element comprising:
• the precast polyurethane-based concrete insulation composite further comprises: c) a barrier layer, wherein the barrier layer is disposed between the base layer and the core layer and contacting with the base layer, and is prepared from a second polyurethane reaction system as illustrated above.
• the barrier layer can broaden the latitude of the core layer and improve the insulation performance of the polyurethane rigid foam core layer.
• This precast polyurethane-based concrete insulation element of the present invention can be used in precast concrete - polyurethane insulation wall slabs for external wall insulation, and also can be polyurethane insulation concrete floor slabs etc.
• the precast concrete-polyurethane insulation wall slabs comprises the base layer, the core layer, the surface layer, and optional floated coat, architectural surface etc. Furthermore, according to the installation methods, the insulation slabs may further have embedded parts, hoisting parts, connectors and the like disposed therein.
• Desmodur 44V20L poly MDI Isocyanate with a NCO content of 31.5% and a viscosity of 160 mPa-s
• BAYMER® BJ3-5601I polyurethane rigid foam spraying system with a viscosity of 125 mPa-s 25 °C purchased from BAYER MATERIAL SCIENCE AG;
• BAYMER® BJ3-5603I polyurethane rigid foam spraying system with a viscosity of 285 mPa-s 25 °C purchased from BAYER MATERIAL SCIENCE AG;
• BAYMER® SPRAY AL 810 polyurethane rigid foam spraying system with a viscosity of 270 mPa-s
• BAYMER® SPRAY H03 polyurethane rigid foam spraying system with a viscosity of 1250 mPa-s 25 °C purchased from BAYER MATERIALSCIENCE AG;
• Desmodur 44V20L and BAYMER® SPRAY H03 (1 : 1 of v/v) of the second polyurethane reaction system are heated to 45-50 ° C, and sprayed onto a fresh poured wet concrete base layer by Graco Reactor A-20.
• the polyurethane system reacts, foams, and cures to form a 1-5 mm barrier layer.
• the properties of the spraying polyurethane barrier layer are showed in table 1-1.
• the component of the first polyurethane reaction system, Desmodur 44V20L and BAYMER ® BJ3-5601I (1 : 1 of v/v) of the first polyurethane reaction system are heated to 45-50 ° C , and sprayed onto the barrier layer.
• the polyurethane system reacts, foams, and cures to form a 20-30mm core layer. Repeat the spraying process until a desired thickness is obtained.
• the properties of the spraying polyurethane core layer are showed in table 1- 1.
• the ambient temperature is about 25 ° C .
• the surface temperature of the polyurethane foam obtained from the first polyurethane reaction system is about 20-25 ° C .
• the polyurethane rigid foam core layer prepared from the first polyurethane reaction system has favorable physical properties and heat-insulating properties.
• Example 2
• Desmodur 44V20L and BAYMER® BJ3-5603I (1 : 1 of v/v) of the second polyurethane reaction system are heated to 45-50 ° C, and sprayed onto a fresh poured wet concrete base layer by Graco Reactor A-20.
• the polyurethane system reacts, foams, and cures to form a 1-5 mm barrier layer.
• the properties of the spraying polyurethane barrier layer are showed in table 1-1.
• the ambient temperature is about 25°C.
• the surface temperature of the polyurethane foam obtained from the first polyurethane reaction system is about 20-25°C.
• the component of the first polyurethane reaction system, Desmodur 44V20L and BAYMER ® BJ3-5601I (1 : 1 of v/v) of the first polyurethane reaction system are heated to 45-50 ° C , and sprayed onto the barrier layer.
• the polyurethane system reacts, foams, and cures to form a 20-30mm core layer. Repeat the spraying process until a desired thickness is obtained.
• the properties of the spraying polyurethane core layer are showed in table 2-2.
• the ambient temperature is about 25 ° C .
• the surface temperature of the polyurethane foam obtained from the first polyurethane reaction system is about 20-25 ° C .
• the formed rigid foam layer has a thickness of 2-10mm, a lower density, and a higher open cell rate.
• This rigid foam layer exhibits a higher thermal conductivity of 23-24 mW/mK. The surface which doesn't contact the concrete shows defects and has a wave-like shape.
• the precast polyurethane-based concrete insulation composite has favorable physical properties and heat-insulating properties
• the polyurethane rigid foam core layer has favorable mechanical properties and external structures

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Citations (4)

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• 2013
  • 2013-12-31 CN CN201310756919.9A patent/CN104746794B/zh not_active Expired - Fee Related
• 2014
  • 2014-12-23 WO PCT/EP2014/079107 patent/WO2015101549A1/en active Application Filing

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