WO2020226596A1 - Procédé de production d'un panneau thermo-isolant et panneau thermo-isolant produit à l'aide de ce procédé - Google Patents

Procédé de production d'un panneau thermo-isolant et panneau thermo-isolant produit à l'aide de ce procédé Download PDF

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Publication number
WO2020226596A1
WO2020226596A1 PCT/TR2020/050389 TR2020050389W WO2020226596A1 WO 2020226596 A1 WO2020226596 A1 WO 2020226596A1 TR 2020050389 W TR2020050389 W TR 2020050389W WO 2020226596 A1 WO2020226596 A1 WO 2020226596A1
Authority
WO
WIPO (PCT)
Prior art keywords
thermal insulation
wet blend
insulation board
belt
blender
Prior art date
Application number
PCT/TR2020/050389
Other languages
English (en)
Inventor
Mehmet Bahattin Daloglu
Timucin Daloglu
Original Assignee
Dalsan Yatirim Ve Enerji Anonim Sirketi
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 Dalsan Yatirim Ve Enerji Anonim Sirketi filed Critical Dalsan Yatirim Ve Enerji Anonim Sirketi
Publication of WO2020226596A1 publication Critical patent/WO2020226596A1/fr

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Classifications

    • 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
    • E04C2/10—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00—Roofs; Roof construction with regard to insulation
    • E04B7/20—Roofs consisting of self-supporting slabs, e.g. able to be loaded
    • E04B7/22—Roofs consisting of self-supporting slabs, e.g. able to be loaded the slabs having insulating properties, e.g. laminated with layers of insulating material
    • 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
    • E04C2/10—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/205—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 wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced

Definitions

  • the present invention relates to production method of a low-density thermal insulation board which has a mineral-based core, and thermal insulation boards which are produced by this method.
  • Thermal insulation materials are one of the most commonly used construction elements being frequently used today.
  • Thermal insulation boards are materials which have thermal conductivity coefficients less than 0,065 W/m.K and thereby, they are materials used for reducing heat losses and gains in buildings. These boards used for the purpose of thermal insulation can be classified as open and closed porous. Glass wool, rock wool (mineral wools), wood wool, ceramic wool, slag wool can be cited as an example for open porous or fibrous materials whereas expanded polystyrene, extruded polystyrene, elastomeric rubber, polyethylene shell obtained from petroleum-derived materials or glass foam obtained by expanding silica sand under high temperature n be cited as an example for closed porous materials.
  • Thermal insulation boards usually have low density.
  • a great majority of petroleum- derived materials and glass wool have a density lower than 30 kg/m 3 in general and they are produced in a thermal conductivity value between 0,03-0,04 W/m.K.
  • ceramic and rock wool are produced in a thermal conductivity value between 40-200 kg/m 3 and rock wool, which is often used in exterior insulation of buildings, is produced in a thermal conductivity value between 100-150 kg/m 3 due to its incombustibility feature.
  • the said ceramic and rock wool preferably have a thermal conductivity coefficient lower than 0,045 W/m.K.
  • thermal insulation boards which are open porous or fibrous such as glass wool and rock wool are obtained by melting silica sand or basalt in furnaces preferably at high temperatures at first and then turning them into fiber form by cooling and laying them onto a continuous belt following these. Due to both high installation costs and high operating costs of melting furnaces operated at high temperatures, the glass and rock wools having the said incombustibility feature are more expensive than petroleum-derived thermal insulation materials.
  • Non-combustibility of insulation boards is determined by methods described in EN ISO 1716 and materials are classified according to their gross calorific potential (PCS Potentiel Calorifique Superieur) values. All kinds of mineral wool, rock wool, ceramic wool and glass foams are A1 class insulation materials known. All of these materials are obtained by very high energy consumption and they are high cost materials. In addition, all mineral wools, rock wools and ceramic wools are affected by moisture and water. All rock-based wools based on stone or ceramic, particularly mineral wools, significantly lose their thermal insulation features after getting humid or contacting water or they are fold or piled up by not being able to maintain their integrity at the application sites.
  • PCS Potentiel Calorifique Superieur PCS Potentiel Calorifique Superieur
  • US4297311 discloses a series of recipes with a density higher than kg/m 3 by breaking the grains upon crushing the expanded perlite under press while the expanded perlite is being hardened by urea formaldehyde (UF).
  • UF formaldehyde
  • the said products are bare products to the degree that they will be partially open to dusting or crumbling. Also, non-combustible material is not targeted in the invention disclosed in this document as well.
  • US4313997 discloses a perlite-based board obtained by binding polyacrylic (Styrene Butadiene (SB)) or latex. Latex is used for giving flexibility to the board.
  • SB Styrene Butadiene
  • US4451294 discloses a perlite-based non combustible board which is obtained by hardening sodium silicate and perlite, and gets support from use of borax for non-combustibility.
  • US5256222 discloses a production method comprising transactions of turning expanded perlite and sodium silicate into a mortar form; laying this mortar between two cardboards on a moving belt as in the methods being used in the production of plasterboard and setting on the belt; and then firing it upon cutting.
  • the product obtained by this method comprises combustible paper and a lightweight drywall board which can substitute plasterboard is received as target product.
  • An objective of the present invention is to realize a method for producing a lightweight and economical thermal insulation board on a belt continuously without using a moulding technique, and thermal insulation boards produced by this method such as insulated roof board.
  • Another objective of the present invention is to realize a method for producing a mineral-based thermal insulation board which is A1 class, non-combustible and less affected by moisture and water, and thermal insulation boards produced by this method.
  • Another objective of the present invention is to realize a method for producing a thermal insulation board which is A1 class, non-combustible and preferably has a thermal conductivity coefficient less than 0,065 W/m.K by using intense perlite instead of insulation boards having intense energy consumption obtained by melting rocks such as glass or stone or ceramic wool at high temperatures, and thermal insulation boards produced by this method.
  • Another objective of the present invention is to realize a method for producing a thermal insulation board on which it is possible to walk and which is A1 class, non combustible and preferably has a thermal conductivity coefficient less than 0,065 W/m.K, and thermal insulation boards produced by this method.
  • Figure 1 is a schematic view of the production line wherein the inventive thermal insulation board is produced.
  • the inventive method for enabling to produce a low-density thermal insulation board (1) which has a mineral-based core comprises steps of:
  • the inventive method also comprises step of obtaining thermal insulation boards (1) which are taken into a desired size by cutting the dry blend slab (5) exiting the heat treatment station (F) by means of suitable cutters in a cutting station (G).
  • the dry blend slab (5) is cut in the cutting station (G) both from its edges and lengthwise. Thereby, it is enabled to increase the production speed.
  • the thermal insulation board (1) exiting the heat treatment station (F) becomes ready for shipment.
  • the inventive method also comprises step of feeding at least one strengthening material having incombustible feature from at least one coil (not shown in the figures) positioned between the blender (C) and the front press belt (D), to the wet blend (2) fed from the blender (C) onto the moving belt conveyor (B).
  • the strengthening material remains inside the wet blend (2) layer hardened. Thereby, it is enabled to increase the strength of the final thermal insulation board (1) obtained.
  • a certain degree of compressed wet blend (3) is obtained by compressing the wet blend (2) on the moving belt conveyor (B) by means of the front press belt (D) which an opening reducing in the direction of progress of the conveyor belt (B).
  • the belt used in the conveyor belt (B) is made of a belt material of PVC-based endless type.
  • the belt used in the front press belt (D) is made of a belt material of PVC-based endless type.
  • the press (E) used for obtaining the wet blend slab (4) is a reciprocating press.
  • the press (E) used for obtaining the wet blend slab (4) is a sheet belt press.
  • the press (E) used for obtaining the wet blend slab (4) can be a hot press. Thereby, it is ensured to shorten the hardening time of the binder.
  • the wet blend (2) fed from the blender (C) onto the moving conveyor belt (B) comprises at least organic binders in perlite and liquid and/or solid state.
  • perlite is included within the wet blend (2) between 50% to 95%, preferably 60% to 80%.
  • the organic binders are selected from the group comprising polyvinyl alcohol, polyvinyl acetate, urea formaldehyde, phenol formaldehyde, melamine formaldehyde, styrene butadiene in such a way that the PCS value of the final thermal insulation board is 2 MJ/kg maximum.
  • Type of binder, maximum binder amount and PCS values of these binders are provided as an example in the following Table 1.
  • Organic binders of various types like vegetable-based organic binders such as latices, methyl celluloses, carboxy methyl celluloses, starches; organic binders of synthetic monomer type such as acrylonitriles, cyanoacrilites, all acrylic monomers and resorcinol; organic binders of synthetic polymer type such as epoxy resins, ethylene, vinyl acetate, polyamides, polyester-based resins, polyethylene binders, polypropylenes, polysulfides, polyurethanes, polyvinylpyrrolidone, silicone resins, modified silyl polymers and styrene acrylic copolymers -including but not limited to the organic binder types shown in the Table 1 entirely by way of example- can be used in the invention by way of illustration without being limiting to realize the invention.
  • synthetic monomer type such as acrylonitriles, cyanoacrilites, all acrylic monomers and resorcinol
  • organic binders of synthetic polymer type such
  • the wet blend (2) can also comprise silicon and its derivatives for changing water repellency or water absorption feature and even other additional materials in line with the requirement of colouring.
  • a gauze or net made of glass fiber that is taken into a fabric form by means of a woven or non-woven, spunbond or spunlace technique is used as the strengthening element.
  • the thermal insulation board (1) obtained by the above-mentioned method is an A1 class non-combustible insulation board.
  • the said A1 class non-combustible insulation board is obtained from a wet blend (2) comprising 200 units of expanded perlite, 45 units of 30% active polyvinyl alcohol binder, 0,2 units of silicon and 65 units of water by weight.
  • the A1 class non-combustible insulation board having 5 cm thickness obtained after a 50-minutes of drying which does not preferably exceed 190°C in the heat treatment station (F) following a pressing transaction of 4 kg/cm 2 in the press (E) has a density of 118 kg/m 3 and a PCS value of 1,88 MJ/kg.
  • Thermal conductivity coefficient of the A1 class non-combustible insulation board obtained in this way has a 0,042 W/m.K value.
  • the thermal insulation board (1) obtained by the above-mentioned method is an A1 class non-combustible insulated roof board.
  • the said A1 class insulated roof board is obtained from a wet blend (2) comprising 200 units of expanded perlite, 45 units of 30% active polyvinyl alcohol binder, 0,65 units of silicone and 65 units of water by weight.
  • the A1 class insulated roof board having 6 cm thickness obtained after a 60-minutes of drying which does not preferably exceed 175°C in the heat treatment station (F) following a pressing transaction of 9,5 kg/cm 2 in the press (E) has a density of 235 kg/m 3 and a PCS value of 1,9 MJ/kg.
  • Thermal conductivity coefficient of the A1 class insulation board obtained in this way has a 0,065 W/m.K value.
  • thermal insulation boards (1) such as an A1 class non-combustible insulation board or an A1 class non combustible insulated roof board without the need for using high-cost coating technique which is frequently used in the prior art, by shaping the expanded perlite by means of a front press belt (D) and particularly at least one press (E) on a moving belt conveyor (B) via organic binders continuously in an economic way.

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

Abstract

La présente invention concerne un procédé de production d'un panneau thermo-isolant de faible densité (1) qui possède une partie centrale à base de minéral, et des panneaux thermo-isolants (1) qui sont produits à l'aide de ce procédé. Il est possible, grâce au procédé selon l'invention, de produire des panneaux thermo-isolants (1) tels qu'un panneau isolant non combustible de classe A1 ou un panneau pour toiture isolé non combustible de classe A1 sans avoir besoin d'utiliser une technique d'application de revêtement de coût élevé qui est fréquemment utilisée dans l'état de la technique, par la mise en forme de la perlite expansée au moyen d'une courroie de pression avant (D) et en particulier d'au moins une presse (E) sur un transporteur à bande mobile (B) par l'intermédiaire de liants organiques en continu d'une manière économique.
PCT/TR2020/050389 2019-05-09 2020-05-06 Procédé de production d'un panneau thermo-isolant et panneau thermo-isolant produit à l'aide de ce procédé WO2020226596A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2019/06987A TR201906987A2 (tr) 2019-05-09 2019-05-09 Bi̇r isi yalitim levhasi üreti̇m yöntemi̇ ve bu yöntemle üreti̇len isi yalitim levhasi
TR2019/06987 2019-05-09

Publications (1)

Publication Number Publication Date
WO2020226596A1 true WO2020226596A1 (fr) 2020-11-12

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PCT/TR2020/050389 WO2020226596A1 (fr) 2019-05-09 2020-05-06 Procédé de production d'un panneau thermo-isolant et panneau thermo-isolant produit à l'aide de ce procédé

Country Status (2)

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TR (1) TR201906987A2 (fr)
WO (1) WO2020226596A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117429133A (zh) * 2023-10-23 2024-01-23 尤特森新材料集团有限公司 一种耐高低温的弹性隔热板及其制备工艺

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1300511A2 (fr) * 2001-09-20 2003-04-09 Armstrong World Industries, Inc. Panneau acoustique thermoformable
US20070009688A1 (en) * 2005-07-11 2007-01-11 Enamul Haque Glass/polymer reinforcement backing for siding and compression packaging of siding backed with glass/polymer
US20090252941A1 (en) * 2008-04-03 2009-10-08 Usg Interiors, Inc. Non-woven material and method of making such material
US20110079746A1 (en) * 2009-10-02 2011-04-07 Fernando Joseph A Ultra Low Weight Insulation Board

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1300511A2 (fr) * 2001-09-20 2003-04-09 Armstrong World Industries, Inc. Panneau acoustique thermoformable
US20070009688A1 (en) * 2005-07-11 2007-01-11 Enamul Haque Glass/polymer reinforcement backing for siding and compression packaging of siding backed with glass/polymer
US20090252941A1 (en) * 2008-04-03 2009-10-08 Usg Interiors, Inc. Non-woven material and method of making such material
US20110079746A1 (en) * 2009-10-02 2011-04-07 Fernando Joseph A Ultra Low Weight Insulation Board

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117429133A (zh) * 2023-10-23 2024-01-23 尤特森新材料集团有限公司 一种耐高低温的弹性隔热板及其制备工艺
CN117429133B (zh) * 2023-10-23 2024-04-16 尤特森新材料集团有限公司 一种耐高低温的弹性隔热板及其制备工艺

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Publication number Publication date
TR201906987A2 (tr) 2020-11-23

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