WO2021154187A2

WO2021154187A2 - Lightweight foam concrete heat insulation plate and block wall material with filling material therein

Info

Publication number: WO2021154187A2
Application number: PCT/TR2021/050082
Authority: WO
Inventors: Mustafa OZBEY; Ugur KARAKURT
Original assignee: Ondokuz Mayis Universitesi
Priority date: 2020-01-31
Filing date: 2021-01-28
Publication date: 2021-08-05
Also published as: DE112021000806T5; TR202001524A2; WO2021154187A3

Abstract

The present invention relates to a lightweight foam concrete construction material that comprises filling materials, volcanic rocks, hemp and/or polypropylene polyethylene fibers, silica aerogel and that is used as a block wall material and/or as a heat insulation plate, and a production method for said construction material.

Description

LIGHTWEIGHT FOAM CONCRETE HEAT INSULATION PLATE AND BLOCK WALL

MATERIAL WITH FILLING MATERIAL THEREIN

Technical Field

State of the Art

Energy is an essential need for human life. Population increase, industrialization, and urbanization cause energy demand to increase rapidly. Ever-increasing energy need also increases the energy consumption in parallel therewith. Today, fossil fuels like petroleum and natural gas, which respond to the majority of the world's energy need and have limited reserves, deplete at an unprecedented pace. In a world where energy demand increases continuously, but energy resources deplete rapidly, a great variety of programs are being implemented to promote the efficient use of energy sources. In this regard, heat insulation has begun to rise to prominence as one of the most successful means of saving energy. Heat insulation applications can prevent waste of energy by avoiding heat loss in buildings. To that end, several different types of heat insulation plates and block wall materials of various characteristics are utilized in the construction sector.

Heat insulation materials, which are obtained by expanding the raw material of Polystyrene and cutting it from the block form thereof into a plate shape, are called heat insulation plates. Expanded Polystyrene (EPS), i.e., the heat insulation plate, which may be manufactured to feature various densities by converting petroleum-derived materials into a foam through expanding these materials via various inflating gasses, is a closed-cell, organic exterior thermal insulation material. Furthermore, these may also be produced in a decorative heat insulation plate by expanding the material inside a mold. Expanded Polystyrene, i.e., the Styrofoam material, is a term used to define expanded polystyrene (EPS) foams. However, Styrofoam is a closed-cell polystyrene foam developed for heat insulation and handicraft applications. EPS foam heat insulation plate is a term used for any form of expanded Polystyrene. Expanded polystyrene insulation is a lightweight, rigid, closed cell insulation. EPS features a number of compressive strengths to resist load and backfill forces. The closed-cell structure provides minimal water absorption and low vapor retention, and it is generally used as an insulation material for walls, foundations, and roofs. During the manufacturing process of EPS heat insulation plates, Polystyrene raw materials are subjected to a vapor heat treatment process with pentane or butane gasses. Pentane or butane gasses relocate with air in a very brief period during and after the manufacturing process after they ensure that a significant number of tiny pores are created with raw material particles. 98% of the expanded polystyrene heat insulation plate products gain heat insulation features by means of the inert and dry air trapped within closed pores. Although it is a cost-efficient, easy-to-use, and lightweight material, it bears a high flammability risk since insulation plates are made of petroleum-derived raw materials. On the other hand, externally administered polystyrene-based materials like EPS and XPS may expand after being applied to the surface of a building, thereby creating fluctuations on the surface. Nowadays, wall blocks with insulation characteristics are used to achieve energy efficiency in new constructions. Wall blocks that are made of autoclaved aerated concrete and bricks are among the commonly preferred construction materials. Autoclaved aerated concrete, which makes versatile contributions to buildings, and therefore the use thereof is often preferred, is a lightweight construction material. Autoclaved aerated concrete, being widely used worldwide since it is a high- performing material, increases the fire and earthquake safety of buildings as it features high heat insulation characteristics. However, autoclaved aerated concrete wall blocks are insufficient for ensuring heat insulation, particularly in cold regions. In such cases, insulation plates made of EPS or XPS materials are applied both internally and externally to the building. However, these insulation plates counteract and therefore neutralize the noncombustible feature of autoclaved aerated concrete. Although autoclaved aerated concrete offers a practical and cost-efficient solution for heat insulation on external walls where the majority of the heat losses occur, external insulation applications eliminate the noncombustible feature of the autoclaved aerated concrete. Moreover, ensuring heat insulation in walls built with materials like bricks, stones, or briquettes requires the use of additional materials, thereby creating additional costs.

Another material commonly used in heat insulation applications in buildings nowadays is the product called rock wool or fiberglass. This product features a limited physical life due to its nature. The fact that it requires periodic renewal after being applied to the building creates additional costs. Furthermore, the fact that this material cannot be applied to buildings via profile-shaped structures further increases the intensity of loads imposed on the building. Just like EPS and XPS, rock wool and fiberglass also feature a flammable structure. Several different studies have been conducted to achieve heat insulation and increase fire resistance in buildings, leading to the development of novel products. One of these studies is the invention disclosed in the patent application numbered EP688261A4. Said invention relates to insulation barriers having a hydraulically settable component. Such insulation barriers comprise laminated insulation barriers having a highly insulative layer and a structural layer comprising a hydraulically settable matrix. Despite the fact that the highly insulative layer may include any known insulation material, it is generally an inorganic material such as aerogel, xonotlite, foamed hydraulically settable product, fiberglass, or rock wool. The structural matrix comprises a rheology modifying agent to increase the strength of the end product, inorganic aggregate material, and fiber materials, along with a hydraulically settable binding agent and reaction products of water. The hydraulically settable matrix may further include uniformly distributed voids in order the reduce the density and thermal conductivity of the insulation barrier.A dispersant may be added in order to improve the workability of the hydraulically settable mixture. However, the fact that said invention comprises fiberglass and rock wool, which have limited physical life and impose additional load on the building, as a binding agent constitutes a disadvantage.

Another study conducted in this regard is the invention disclosed in the patent document numbered WOl995021063A1. Said invention relates to an embodiment comprising a hydraulically setting sheath and a core. Hydraulically setting sheath includes a hydraulically setting matrix that comprises a hydraulic cement and reaction products of water. Hydraulic components, aggregate materials, fibers, and rheology-modifying agents may be used in the hydraulically setting matrix. The product disclosed in said application poses particular hazards to human health as it comprises materials like PVC and melamine, which release gasses containing halogen on exposure to flames.

Yet another study conducted in this regard is the invention disclosed in the patent application numbered CN109020378A. Said invention belongs to the technical field of inorganic materials and particularly relates to an expanded perlite aerogel composite thermal insulation board prepared by using iron tailings as raw material and a preparation method thereof. The fact that said thermal insulation board is made of perlite, and hydrophobic silicon dioxide causes cracks to occur during the drying process.

Consequently, the need for a construction material that is capable of overcoming the disadvantages present in the state of the art, as well as the inadequacy of available solutions, necessitated making an improvement in the relevant technical field.

Brief Description of the Invention

The present invention relates to a lightweight foam concrete construction material, which meets the requirements disclosed above, overcomes all disadvantages, brings in further advantages, and that is used as a block wall material and as a heat insulation plate, and a method for producing said construction material.

The object of the present invention, based on the state of the art, is to provide the construction material with a noncombustible characteristic by increasing the strength thereof by means of the filling materials incorporated therein and the foam concrete from which it is manufactured. The object of the present invention is to prevent any potential cracks that may occur during the drying period by means of the filling material and binding fibers included therein.

The object of the present invention is to ensure that the insulation material bears similar features with other cement- based construction materials used in the construction sector by producing the inventive insulation material cement-based, thereby ensuring that the inventive insulation material adheres to these products easily.

Yet another object of the present invention is to maintain the vaporization balance of water by using non-expanded volcanic rocks in the inventive insulation material, thereby preventing any cracks from occurring inside the product during the drying stage.

Yet another object of the present invention is to eliminate the water absorption property, which occurs due to perlite use and is disadvantageous, by using crushed 0-150 and/or 150-600 micron volcanic rocks as filling material.

Yet another object of the present invention is to ensure that filling materials and foam concrete bind each other better and that the strength thereof is further increased by using polyethylene, polypropylene, and/or hemp fiber as binding agents.

Yet another object of the present invention is to eliminate any potential need for using chemicals and to prevent the release of chemical gasses as a result of a potential reaction by making sure that the foaming agents used in the construction material create a solution without inducing any chemical reactions with water and by foaming the solution through mixing it with air by means of a hydrophore. Structural and characteristic features along with all advantages of the present invention will be understood more clearly by means of the detailed description provided below; therefore, the necessary evaluation should be conducted by taking the detailed description into consideration.

Detailed Description of the Invention

In the detailed description provided herein, the inventive lightweight foam concrete construction material that comprises filling materials, volcanic rocks, hemp and/or polypropylene polyethylene fibers, silica aerogel, and that is used as a block wall material and/or as a heat insulation plate, and a production method for said construction material will be described to provide a better understanding of the present invention by way of example only and without constituting any limiting effects thereon.

The inventive construction material, which is used in insulation applications for buildings and in the construction of walls, is basically obtained by filling and binding materials mixed into the lightweight foam concrete. The inventive construction material includes cement as the primary raw material. Fundamentally, cement is defined as a hydraulic binding material obtained by heating a mixture of natural limestone and clay to high temperatures and grinding them thereafter. The fact that the inventive construction material is made of cement allows the material to easily bind to all construction elements used in the construction sector and made of cement-based materials. Non- expanded perlite, which is a volcanic rock, is added to the aforementioned cement as a filling material. The water absorption feature of the inventive construction material is eliminated, and the product performance is further improved by using crushed 0-150 and/or 150-600 micron perlite as the filling material. While perlite removes water during the drying stage, it also prevents any potential cracks from occurring. The mixture is then turned into a mortar by adding water to the mixture after the cement and perlite mixture is obtained. Subsequently, the mixture, which has become a mortar, and which contains alkali sulphonate, is foamed, thereby obtaining the foam concrete. Hemp fibers and/or polypropylene, polyethylene fibers are added to the mixture in order to improve the binding features of the foam concrete and to increase the strength thereof. Silica aerogel is added to the product in order to improve further the heat insulation of the foam concrete doped with binding agents and poured into molds featuring hydrophobic surfaces. The molded mixture is then placed inside a kiln containing 70-80% vapor and heated to 80-90 degrees for the drying process. After the mixture inside the mold has dried, the construction material is obtained by cutting the product into desired shapes and sizes. The product obtained in desired measurements while cutting the construction material may be used as a block wall or as a heat insulation plate.

The inventive construction material may be used both in external thermal insulation applications for available buildings and in the wall construction of buildings to be erected. The noncombustible feature of the construction material ensures that it may be used safely in insulation applications of internal walls. The inventive insulation material further features sound insulation property in addition to the heat insulation property thereof. The inventive construction material does not necessitate performing a rough-casting step on the external walls of buildings in applications in which the inventive construction material is used as a heat insulation plate and can form a straight surface. The inventive construction material further renders rough casting on the outside of the walls unnecessary in applications in which it is used as a block wall. Another characteristic of the inventive construction material is that it is capable of reducing the total amount of iron to be used for the building since it features low density.

Claims

1. A construction material used in building insulation applications and in wall construction in the construction sector, characterized in that, it comprises;

- non-expanded perlite as filling material,

- hemp fiber and/or polypropylene, polyethylene fiber as a binding agent, and

- cement as the primary raw material.

2. A construction material according to Claim 1, characterized in that, it comprises crushed perlite with the size of 0- 150 and/or 150-600 microns.

3. A construction material according to Claim 1, characterized in that, it comprises silica aerogels added to foam concrete as filling material in order to improve heat insulation properties.

4. A construction material according to Claim 1, characterized in that, it comprises foam concrete obtained by foaming the water and perlite mixture.

5. A construction material according to Claim 1, characterized in that, foamed cement, water, and perlite mixture comprises alkali sulphonate.

6. A method for producing the construction material used in heat insulation applications in the construction sector, characterized in that, it comprises the process steps of;

- preparing the mortar by mixing cement, filling material, and water,

- preparing the foam concrete by foaming the mortar,

- adding the binding agent and filling material into the foam concrete and drying it inside hydrophobic molds.

7. A construction material according to Claim 6, characterized in that, it comprises the process step of creating a mortar by mixing cement, perlite, and water.

8. A construction material according to Claim 6, characterized in that, it comprises the process step of obtaining the foam concrete by foaming the mortar that consists of cement containing alkali sulphonate, perlite, and water.

9. A construction material according to Claim 6, characterized in that, it comprises the process step of adding hemp fiber and/or polypropylene, polyethylene fiber as a binding agent into the foam concrete.

10. A construction material according to Claim 6, characterized in that, it comprises the process step of adding silica aerogel as a filling material into the foam concrete.

11. A construction material according to Claim 6, characterized in that, it comprises the process step of pouring the foam concrete doped with silica aerogels into molds featuring hydrophobic surfaces, and drying them in a kiln containing 70-80% vapor by heating it to a temperature between 80-90 degrees.