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
  • 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
  • C08J9/236—Forming foamed products using binding agents
• • 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
  • C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
• • 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
  • C08J9/33—Agglomerating foam fragments, e.g. waste foam
• • 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
  • C08J2300/00—Characterised by the use of unspecified polymers
  • C08J2300/30—Polymeric waste or recycled polymer
• • 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
  • C08J2309/00—Characterised by the use of homopolymers or copolymers of conjugated diene hydrocarbons
  • C08J2309/06—Copolymers with styrene
  • C08J2309/08—Latex
• • 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
• • 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
  • C08J2409/00—Characterised by the use of homopolymers or copolymers of conjugated diene hydrocarbons
  • C08J2409/06—Copolymers with styrene
  • C08J2409/08—Latex
• • 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
  • C08J2425/00—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
  • C08J2425/02—Homopolymers or copolymers of hydrocarbons
  • C08J2425/04—Homopolymers or copolymers of styrene
  • C08J2425/06—Polystyrene
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors

Definitions

• the invention relates to insulating and lightweight floor elements. More specifically, the invention relates to a kit suitable for simply applying a thermal floor insulation, a method for applying a light floor insulation and said light floor insulation.
• Cellular concrete or aerated concrete is a type of concrete that is characterized by its low density and strong insulating capacity. By adding a gas-forming additive, a porous and insulating material is created. The air bubbles formed are not in communication with each other. After the mass is taken out of the mold, it is cut into the desired product type: blocks, lintels, reinforced plates.
• EPS Expanded polystyrene
• US 5,916,681 teaches the use of EPS as loose insulation, in a sandwich panel, as a preformed board and in combination with cement.
• US 4,1234,242 describes a loose insulation consisting of fibers and a granular material.
• the present invention aims at an improvement within the insulating layers for floors; in particular in the field of:
• BE 1 026 242 describes an insulating floor layer, kit and method for its manufacture.
• An unforeseen disadvantage of the combination of water-based polymer emulsion and a multitude of EPS granules is that this water has to escape from the kit in order to obtain good curing of the floor layer. This is particularly a problem with thicker floor layers with only one free surface. Poor curing is pernicious for the insulating effect of the floor layer. While this can be remedied with layer-by-layer application and curing of the floor layer, this method takes significantly more time and labor. using EPS granules in combination with a water-based polymer emulsion
• the invention relates to a kit suitable for forming an insulating floor layer according to claim 1.
• the inventors have surprisingly discovered that a moisture absorption by immersion of the EPS granules of up to 5% is essential for producing a thermally good insulating floor layer.
• the exclusion of moisture absorption by the EPS granules is advantageous for obtaining a better thermal insulation.
• the thermal insulation can always be improved by providing a thicker insulating layer. Thicker insulation layers, however, are more difficult to dry and harden. For example, water from a polymer- in-water binding emulsion can remain in the insulating layer. This absorbed water significantly reduces the thermal insulation, which can partly negate the advantage of a thicker insulating layer.
• water can also enter the insulating layer via other routes, such as rising groundwater in the event of a faulty water barrier.
• kits give rise to increased thermal insulation and compressive strength compared to kits with a lower weight percentage of EPS granules.
• the invention relates to a method for applying an insulating floor layer to a substrate, comprising (a) mixing a plurality of expanded polystyrene granules with a binding agent resulting in a substantially liquid insulating material according to a kit according to the first aspect, (b) distributing the liquid insulating material on the substrate, and (c) curing the liquid insulating material to form an insulating floor layer.
• the kit can be used in any form of any size.
• the substrate does not have to be flat, since the kit is form-free.
• the kit is also easy to transport and store in various forms, regardless of the shape of the intended insulating floor layer.
• This method is advantageous over known insulating foams as it is simpler and cleaner. Due to a limited reaction, fewer harmful gases are released, less heat is formed as a result of exothermic reactions and the volume of the insulation material remains more or less constant. Further, the steps in the second aspect can be performed in the simplest order. For example, large quantities of granules and binding agent can be easily mixed in industrial concrete mixing plants. Small amounts of binding agent can be easily applied to the EPS on the substrate. This way no further material is befouled. Finally, it is possible to simultaneously provide the EPS granules with binding agent and apply the resulting slurry to the substrate. This can be done, for example, using a blower or screw suitable for EPS granules, provided with binding agent at the end. Finally, this is beneficial for leveling a floor, and appropriate insulation around pipes and other facilities in the floor of a building.
• Kits with only EPS granules and binding agent, especially in this ratio, can be processed into a floor layer.
• This floor layer can later be cut into flakes; which flakes can be reprocessed into an insulating floor layer in combination with a binding agent.
• the invention relates to a kit consisting of recycled flakes, suitable for a re-recyclable floor layer according to claims 12-15. Excluding further components prevents undesired stacking or forced processing of these further components.
• the addition of cement-based products is strongly discouraged, as these crumble strongly during the recycling process and thus greatly reduce the quality of the recycled product.
• the invention relates to a method for recycling a floor layer.
• the invention relates to the insulating layer formed with a kit according to the first aspect or by means of the method according to the second aspect.
• This insulating layer has better thermal insulation and a lower specific gravity than aerated concrete and concrete with EPS granules. Furthermore, this insulating layer has a better compressive strength than polyurethane foams. Furthermore, this insulating layer is recyclable, unlike cement and foam-based products.
• the invention relates to a kit suitable for forming a light, insulating floor layer.
• the invention furthermore relates to a method for providing an insulating floor layer.
• the invention relates to a light insulating floor layer.
• 'a' and 'the' refer to both the singular and the plural, unless the context presupposes otherwise.
• 'a segment' means one or more segments.
• Dispersion polymerization is a type of precipitation polymerization, which means that the selected solvent is both the reaction medium and is a good solvent for the monomer and initiator but is not a good solvent for the polymer. As the polymerization reaction proceeds, particles of polymer form, forming a non- homogeneous solution. In dispersion polymerization, these particles are the site of polymerization. Quoting numerical ranges by endpoints includes all integers, fractions and/or real numbers between the endpoints, these endpoints included.
• the invention relates to a kit suitable for forming a recyclable insulating floor layer, the kit comprising:
• EPS expanded polystyrene
• binding agent comprises a polymer-in- water emulsion.
• a problem with water-based emulsions is that water can be absorbed by EPS granules.
• EPS granules that absorb water show a significantly lower thermal insulation. This is a problem especially with thicker insulation layers, where water escapes less easily.
• the inventors have discovered that coating the plurality of EPS granules allows to obtain EPS granules with a moisture absorption upon immersion of less than 5%. As a result, the EPS granules with low moisture absorption show an improved insulation value in the final product. The improvement also increases as the insulating layer increases in thickness.
• the moisture absorption upon immersion of the plurality of EPS granules is at most 4.5%, more preferably, the moisture absorption upon immersion of the plurality of EPS granules is at most 4.0%, more preferably, the moisture absorption upon immersion of the plurality EPS granules is at most 3.5%, more preferably, the moisture absorption upon immersion of the plurality of EPS granules is at most 3.0%, more preferably, the moisture absorption upon immersion of the plurality of EPS granules is at most 2.5%, more preferably, the moisture absorption upon immersion of the plurality of EPS granules is at most 2.0%, more preferably, the moisture absorption upon immersion of the plurality of EPS granules is at most 1.5%, more preferably, the moisture absorption upon immersion of the plurality of EPS granules is at most 1.0%, more preferably, the moisture absorption upon immersion of the plurality of EPS granules is 0.5% at most.
• the moisture absorption upon immersion is measured by immersion in water for 120 hours at a temperature of 23°C.
• the moisture absorption is then calculated as the difference in weight of the EPS granules before and after immersion, divided by the weight of the EPS granules before immersion, expressed in percent.
• the moisture absorption of the EPS granules is reduced by adding a base to the steam used to expand the polystyrene granules.
• 50 to 200 ml of aqueous base is added per m 3 of water; wherein the aqueous base has a pH between 10 and 14, preferably a pH between 12 and 13.
• the base is selected from the list of: sodium bisulfite, sodium hydroxide, sodium phosphonate or a mixture thereof.
• the inventors have discovered that adding an alkalizing agent to the steam boiler significantly reduces the moisture absorption by immersion of the obtained EPS granules.
• the plurality of expanded polystyrene (EPS) granules preferably have a density of
• the EPS granules have a density between 10-35 kg/m 3 .
• the EPS granules have a density between
• the EPS granules have a density between 16 and
• the EPS granules have a density between 17 and 33 kg/m 3 , more preferably the EPS granules have a density between 18 and 32 kg/m 3 , more preferably the EPS granules have a density between 18 and 31 kg/m 3 , more preferably the EPS granules have a density between 18 and 30 kg/m 3 , more preferably the EPS granules have a density between 18 and 29 kg/m 3 , more preferably the EPS granules have a density between 18 and 28 kg/m 3 , more preferably the EPS granules have a density between 18 and 27 kg/m 3 , more preferably the EPS granules have a density between 18 and 26 kg/m 3 , more preferably the EPS granules have a density between 18 and 25 kg/m 3 , more preferably the EPS granules have a density between 19 and 24 kg/m 3
• the plurality of expanded polystyrene (EPS) granules are fully preexpanded.
• the EPS granules have a diameter between 1 and 8 mm.
• Granules smaller than 1 mm gave rise to too much dust.
• Granules larger than 6 mm had a negative effect on the insulating effect of the final product.
• the diameter of the EPS granules is between 2 and 6 mm, even more preferably between 3 and 6 mm, most preferably between 4 and 6 mm.
• EPS granules with a diameter between 4 and 6 mm gave rise to the highest insulation value for the final material.
• Granules smaller than 4 mm lead to a long drying period and a reduced compressive strength of the final insulating layer.
• the EPS granules are "gray.”
• Gray EPS is known to those skilled in the art and consists of EPS granules containing graphite or carbon. These are produced by adding graphite or carbon when forming unexpanded EPS beads. Grey EPS granules have better insulating properties. These are passed on to the final insulation material.
• the mass fraction of the EPS granules in the kit is between 0.40 to 0.80, preferably between 0.61 to 0.75, even more preferably between 0.62 to 0.75, even more preferably between 0.63 to 0.75, even more preferably between 0.64 to 0.75, even more preferably between 0.65 to 0.75, even more preferably between 0.66 to 0.75, even more preferably between 0.67 to 0.74, even more preferably between 0.68 to 0.73.
• the kit consists of the following components:
• EPS expanded polystyrene
• the inventors discovered that the higher weight percentages of EPS granules give rise to an improved insulation (lower lambda value) in both the initial product but in particular in the recyclate that can be produced from this initial product. In this way a more favorable, higher quality recycled material is obtained.
• the binding agent is a polymer-in-water emulsion.
• the chain of this polymer consists mainly of carbon, oxygen, nitrogen, silicon such as polysiloxane.
• the binding agent is a latex. "Latex" in this text is defined as a stable dispersion or emulsion of polymer particles in a solvent. This solvent is water. Even more preferably, the binding agent is a polymer-based binder. A binding agent based on dispersion polymerization will usually give rise to a latex, being a dispersion of polymer particles in a solvent.
• the polymer is selected from the group consisting of: polystyrene (PS), polystyrene-butadiene copolymer, polybutadiene rubber (BR), isoprene rubber (IR), chloroprene rubber (CR), nitrile rubber (NBR), ethylene-propylene-diene-monomer (EPDM), isobutylene isoprene rubber (HR), polyisobutylene (PIB), silicone rubber (VMQ), fluorine rubber (FKM), ethyl vinyl acetate rubber (EVA), chlorosulfonated polyethylene rubber (CMS), acrylate rubber (ACM) or polyurethane rubber (AU or EU).
• PS polystyrene
• BR polystyrene-butadiene copolymer
• BR polybutadiene rubber
• IR isoprene rubber
• CR chloroprene rubber
• NBR nitrile rubber
• EPDM ethylene-propylene-d
• the polymer is selected from the group of: polystyrene (PS), polystyrene-butadiene copolymer, polybutadiene rubber (BR), isoprene rubber (IR), ethylene-propylene- diene-monomer (EPDM), isobutylene isoprene rubber (HR), polyisobutylene (PIB) or ethyl vinyl acetate rubber (EVA).
• PS polystyrene
• BR polystyrene-butadiene copolymer
• BR polybutadiene rubber
• IR isoprene rubber
• EPDM isobutylene isoprene rubber
• HR polyisobutylene
• EVA ethyl vinyl acetate rubber
• the polymer is selected from the group consisting of: polybutadiene rubber (BR), isoprene rubber (IR), ethylene- propylene-diene-monomer (EPDM) and polystyrene-but
• the polymer is polystyrene-butadiene copolymer.
• Polystyrene-butadiene copolymer gives good adhesion to polystyrene surfaces. This is particularly important to prevent micro-cracks and associated thermal bridges.
• the inventors have surprisingly discovered that the use of a polystyrene-butadiene-based binding agent allows to obtain lambda values lower than 0.030 W/mK.
• polystyrene- butadiene copolymer has very good mechanical properties, resulting in a floor layer with high compressive strength.
• the use of a largely polystyrene based insulating layer for both beads and binding agent allows better recycling.
• the absence of heteroatoms, in particular chlorine and fluorine, but to a lesser extent nitrogen, phosphorous and silicon also contributes to this.
• the binding agent is based on dispersion polymerization or copolymerization, preferably copolymerization.
• the solvent used for dispersion polymerization or copolymerization may be water. This is environmentally friendly.
• said binding agent being a latex or whether or not based on dispersion polymerization, has a dry substance content between 20 and 70%, preferably between 25 and 65%, even more preferably between 25 and 60%, even more preferably between 30 and 50%, even more preferably between 35 and 45%.
• a binding agent contained in a solvent allows the granules to be completely mixed with the binding agent, wherein the surface of the EPS granules is completely covered thanks to the solvent. This improves the bond between the EPS granules and the polymer matrix.
• the solvent does not remain in the final product in large quantities but leaves the insulation material almost completely during curing.
• the latex is formed by dispersion polymerization, which is stopped at a high degree of polymerization.
• a latex based on dispersion polymerization is capable of further polymerization after mixing with the EPS granules. This creates a strong, three-dimensional matrix.
• the polymerization during this last step can be very small; the vast majority of polymer chains are formed in the production of the latex based on dispersion polymerization.
• the properties of both the polymer and the latex can be controlled without being dependent on the user. This is advantageous for use as a kit, for example for do-it-yourselfers.
• a latex can be supplied ready for use in liquid form. This is advantageous over known polymer foams, such as polyurethane, wherein exothermic reactions are necessary to form the polymer.
• the polymerization reactions usually also lead to a significant volume increase in foaming. This makes it more difficult to apply said materials to form a floor. Due to this on-site reaction, the microscopic and macroscopic properties of these insulating foams are less consistent.
• the degree of polymerization, branching and end functionalities can be better controlled. This is because these properties change only very slightly, as the majority of the polymerization takes place during the production of the latex, and not when the latex is used as a binding agent. However, control over the degree of crosslinking is very important.
• the curing of insulating foams is accompanied by volatile, possibly toxic and environmentally harmful gases.
• the curing of a water-based latex polymer involves evaporation of water and little reaction. On the one hand, this is more environmentally friendly and, on the other hand, healthier for the skilled person who applies the insulation.
• the latex has a Brookfield viscosity of 1 to 10000 mPa.s, preferably 5 to 5000 mPa.s, even more preferably 1 to 1000 mPa.s, even more preferably 50 to 500 mPa.s, most preferably 50 to 300 mPa.s.
• This Brookfield viscosity is the viscosity measured with a Brookfield viscometer with spindle 1, at 50 revolutions per minute at a temperature of 20°C.
• the kit also has a better thermal insulation than aerated concrete based on similar EPS granules.
• the preferred polymers result in a good balance of compressive strength, weight and insulation.
• the mass fraction of the binding agent in the kit is between 0.10 and 0.60, preferably between 0.20 and 0.50, even more preferably 0.22 to 0.45, even more preferably 0.25 to 0.40, even more preferably 0.25 to 0.39, even more preferably 0.25 to 0.35, even more preferably 0.26 to 0.34, most preferably between 0.27 and 0.33.
• dlO is the particle size where 10 wt.% of the expanded polystyrene granules have a smaller particle size and 90 wt.% of the expanded polystyrene granules have a larger particle size.
• d90 is the particle size where 90 wt.% of the expanded polystyrene granules have a smaller particle size and 10 wt.% of the expanded polystyrene granules have a larger particle size.
• the particle size is preferably determined by laser diffraction; wherein the mass based particle size distribution is obtained by multiplying the volume of the particles by the average density of the EPS granules.
• the EPS granules have a narrow particle size distribution. More preferably, dgo - dio, i.e. particle size distribution of the 80 wt.% EPS granules with the intermediate particle sizes, is less than 3.0 mm, more preferably less than 2.5 mm, more preferably less than 2.0 mm, more preferably less than 1.5 mm, more preferably less than 1.2 mm, more preferably less than 1.0 mm, more preferably less than 0.9 mm, more preferably less than 0.8 mm, more preferably less than 0.7 mm, more preferably less than 0.6 mm, more preferably less than 0.5 mm, more preferably less than 0.4 mm, more preferably less than 0.3 mm, more preferably less than 0.2 mm, most preferably less than 0.1 mm.
• Such narrow particle size distributions are advantageous on the one hand for laying the floor layer, in particular for covering all granules with sufficient binding agent and for leveling the obtained floor layer, for obtaining an insulating layer with constant and predictable insulation values and pressure values, and for optimal recycling of the floor layer into flakes.
• the flake size can be better matched to the particle size of the EPS granules.
• the kit comprises further additives. These can be added to the kit as an additional component on the one hand, or they can be included in the latex or the EPS granules on the other. Additives that improve polymer properties are known to those skilled in the art, for example flame retardants to improve the flammability of the final material, additives to improve chemical resistance and the like. The addition of materials with a high specific gravity, for example sand or quartz sand, to increase the sound insulation of the material are also known. In a further, preferred embodiment, the kit contains lithium silicate as an additive. This additive is known as a densifier and hardening agent in concrete.
• lithium silicate was also found to have a very favorable effect on the compressive strength of a polymer matrix with EPS granules in between.
• the mass fraction of lithium silicate is preferably between 0.005 and 0.15, even more preferably between 0.02 and 0.10, most preferably between 0.03 and 0.07.
• the kit contains as few additives as possible, preferably no additives. In another preferred embodiment, the kit contains neither cement nor lithium silicate. In another preferred embodiment, the kit is free of foaming agents, in particular free of polysorbate, sodium lauryl ether sulfate, sodium coceth sulfate, sodium dodecyl sulfate, sodium bicarbonate and isocyanate, especially methylene diphenyl diisocyanate (MDI), hexamethylene diisocyanate (HDI) and isophorone diisocyanate (IPDI).
• MDI methylene diphenyl diisocyanate
• HDI hexamethylene diisocyanate
• IPDI isophorone diisocyanate
• the kit consists of the following components:
• EPS expanded polystyrene
• the kit further comprises reinforcement.
• This usually consists of metal, for example steel or a fiber material.
• This reinforcement serves to improve the structural properties of the matrix.
• polymer-based fibers are used. These adhere better in a polymer matrix and have a coefficient of expansion similar to the surrounding polymer matrix. This is advantageous to prevent delamination, the detachment of the reinforcement from the polymer matrix formed by the drying of the latex.
• the invention in the second aspect, relates to a method for applying an insulating floor layer to a substrate, comprising (a) applying a binding agent to at least a part of a surface of a plurality of expanded polystyrene (EPS) granules to form a slurry, (b) applying the slurry to the substrate, and (c) curing the slurry to form an insulating floor layer.
• EPS expanded polystyrene
• applying binding agent to the surface of the EPS granules comprises blending or mixing the granules well with the binding agent.
• Mixing can be done in a variety of methods. Traditional concrete mixers or other methods of mechanical stirring or mixing will suffice.
• liquid latex when applying the EPS granules to a floor, for example by means of a blower or feed screw.
• the mixing in can also be done by means of manual stirring, certainly for smaller quantities.
• Applying EPS and/or binding agent to the substructure includes any method that provides EPS granules and binding agent at the location where the structural element is formed.
• a slurry in this text is a mixture consisting of small, solid particles and a liquid. In bulk, the properties of a slurry resemble those of a viscous liquid. In this text, the small, solid particles are always EPS granules. A slurry is easy to apply as it is "formfree.” By this it is meant that a slurry, much like a fluid such as a viscous liquid, will take the shape of the container in which it is contained. This is advantageous for applying an insulating layer along, for example, pipes, foundations and structural elements. This is very beneficial for renovations to a home, such as insulating an existing home. There, space is often limited within an existing frame, which must be worked around.
• the form-free nature of the slurry ensures a close fit. This is advantageous for the insulating effect, since small gaps in the insulation give rise to thermal bridges. These thermal bridges are places where the insulation is interrupted and have a very detrimental effect on the complete insulation of a house.
• the slurry is not blown in under pressure.
• the mixing of known polymer foams usually takes place simultaneously with their application, under pressure. Due to the high pressure, this work is usually not clean.
• the house is usually covered with paper or plastics, or it has to be cleaned again.
• the slurry is preferably not applied under pressure. Combining and applying the elements of the kit can be done simultaneously, separately and sequentially.
• the EPS granules and latex can first be combined to fill a slurry, for example in known concrete mixers, after which this slurry is applied to a floor. This makes it easy to mix large amounts of EPS with binding agent. It is also possible to apply and mix in the EPS granules and the latex simultaneously on the floor.
• EPS and latex are mixed in evenly. Furthermore, material that comes into contact with the latex is reduced. Finally, simultaneous mixing and application is the fastest method for many floors. It is also possible to first apply the EPS granules and then add the latex. Conversely, the latex can also be applied first, which promotes careful application along existing elements, after which EPS granules are added. It is important here that part of the latex is still more or less liquid before adding the EPS granules. It is also possible to work in layers, wherein a layer of EPS and latex is used for laying different layers of insulation material at different intervals. This can speed up the curing of the insulation. A combination of the above is also possible. For example, it may be advantageous to first provide the irregular structural elements with a layer of latex, so that thermal bridges are further avoided.
• steps (b) mixing the EPS granules and the binding agent and (c) applying the expanded polystyrene to a floor and (d) applying the binding agent to a floor can be performed simultaneously, separately or sequentially.
• “Smoothing” or “leveling” is to make the floor layer flat, even or level.
• Leveling the slurry can be done in one or more steps. This can be done both before and after curing the slurry into an insulating layer.
• a first leveling takes place before the slurry hardens. This can be done very quickly by spreading out the slurry briefly, for example with a rake. If a completely flat surface is desired, the slurry can be completely smoothed out before or during curing. Furthermore, the surface can be polished or sanded smooth after curing. This is easier than with concrete as the material is considerably less hard.
• the EPS granules and the binding agent are mixed in for 30 seconds to 15 minutes, preferably for 30 seconds to 10 minutes, more preferably for 40 seconds to 5 minutes, more preferably for 50 seconds to 4 minutes.
• Curing of the slurry takes 2 to 96 hours. This mainly depends on the thickness of the insulating layer, and to a lesser extent on the temperature and humidity.
• the curing of the slurry can simply be done in the air.
• the curing of the slurry is stimulated. This can be done by forced or natural convection above the floor surface, for example by properly ventilating the house.
• the use of absorbents can also accelerate curing.
• the thickness of the insulating layer is between 1 and 60 cm, preferably between 2 and 50 cm, even more preferably between 3 and 50 cm, even more preferably between 4 and 50 cm.
• the upper limit of 50 cm is usually only used when building a floor, and of course not an intermediate floor, wherein both an insulating layer and a structurally supporting and leveling layer are desired. Above 60 cm lower lambda values are noted.
• the EPS granules and binding agent are applied under low pressure.
• it is often difficult to work cleanly. Masking and/or cleaning up leads to an extra cost.
• the substructure is the surface on which the floor is installed. This can be a concrete layer, another floor layer, the ground, the foundation or a combination of the above. Furthermore, the substructure can also comprise structural elements, pipes and the like. The slurry can easily be applied on top of these elements, regardless of their structure.
• the invention relates to a kit comprising recycled material, the kit suitable for forming a re-recyclable insulating floor layer, the kit comprising:
• EPS expanded polystyrene
• binding agent comprises a polymer-in-water emulsion.
• the average particle size of the recycled flakes dso,rec is at least 0.5 mm larger, preferably at least 1.0 mm larger, more preferably at least 1.5 mm larger, more preferably at least 2.0 mm larger, most preferably at least 2.5 mm larger, than the average particle size dso, EPS of the bonded expanded polystyrene (EPS) granules.
• EPS bonded expanded polystyrene
• the first and second binding agents are based on the same polymer or copolymer. Even more preferably, the first and second binding agents are based on the same polymer-in-water emulsion. In a preferred embodiment, the plurality of recycled flakes have a density comprised between 4 and 25 kg/m 3 , preferably between 15 and 25 kg/m 3 .
• an amount of (virgin) expanded polystyrene (EPS) granules can also be added to the recycled flakes. This addition will benefit the insulation value and compressive strength. Furthermore, a more manageable and predictable insulating layer is also obtained. However, the amount of recycled material is lower, and the amount of fresh material is higher, which means that this measure also has an ecological impact. It is therefore advantageous to produce the first floor layer and all recycled floor layers in such a way that the amount of new (virgin) material remains as low as possible; in order to keep the fraction of recycled material as high as possible and to optimize the ecological impact of the first product and the recyclates based on it.
• EPS expanded polystyrene
• the invention relates to a method for recycling a floor layer, this floor layer mainly consisting of bonded expanded polystyrene granules, comprising the steps of:
• the flakes are cut to an average particle size of the recycled flakes dso,rec at least 0.5 mm larger, preferably at least 1.0 mm larger, more preferably at least 1.5 mm larger, more preferably at least 2.0 mm larger, most preferably at least 2.5 mm larger than the average particle size dso, EPS of the bonded expanded polystyrene (EPS) granules being cut. This improves the compressive strength and insulation value of the recycled product.
• EPS bonded expanded polystyrene
• the method further comprises the step of: binding the recycled flakes by means of a binding agent, preferably a polymer-in-water emulsion, even more preferably the same polymer that binds said bonded expanded polystyrene granules.
• a binding agent preferably a polymer-in-water emulsion, even more preferably the same polymer that binds said bonded expanded polystyrene granules.
• the recycled flakes have a density between 4 and 25 kg/m 3 , more preferably between 15 and 25 kg/m 3 .
• the fifth aspect of the invention comprises an insulating floor layer formed with a kit according to the first or third aspect, or by the method according to the second aspect.
• This insulating floor layer is advantageous compared to aerated concrete thanks to a higher insulation value.
• the insulating floor layer is also lighter.
• the insulating floor layer according to the present invention has a better compressive strength and is easier to install.
• a floor layer according to this text can be located between the foundation and the ground floor, as well as between any two floors.
• the use of light insulation places less pressure on the structural elements of the building.
• a building according to this text can be any building, such as houses or office buildings, but also stables, warehouses and the like.
• the final, solid insulation layer has a lambda value of less than 0.040 W/mK, preferably less than 0.037 W/mK, even more preferably less than 0.035 W/mK, even more preferably less than 0.034 W/mK, even more preferably lower than 0.033 W/mK, most preferably lower than 0.032 W/mK.
• a low lambda value is advantageous for good insulation. It has been found that the use of a polymer based binding agent provides better thermal insulation than cement.
• the structurally stable insulating layer has a minimum compressive strength of 100 kPa, preferably the minimum compressive strength is greater than 110 kPa, even more preferably the minimum compressive strength is greater than 120 kPa, even more preferably the minimum compressive strength is greater than 130 kPa, even more preferably the minimum compressive strength is greater than 140 kPa, even more preferably the minimum compressive strength is greater than 150 kPa.
• the insulating layer has a specific gravity of 10 to 50 kg/m 3 , preferably 15 to 35 kg/m 3 , even more preferably 15 to 30 kg/m 3 , even more preferably a specific gravity of 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28 or 29 kg/m 3 .
• a light, insulating material can be used advantageously in apartments and the like. This saves a lot of weight. In renovations, the aim is often to add insulation without modifying the structural elements of the house. Aerated concrete is often too heavy for this.
• Expanded polystyrene granules were purchased as non-expanded beads. These nonexpanded beads are "white,” and therefore contain no graphite or carbon. These were expanded to a limited extent in a prefoamer under the influence of steam.
• the prefoamer is equipped with a mixer. Prefoaming was carried out for 45s, with steam at a pressure of 0.25 bar. This steam has a temperature between 104 and 120°C.
• the semi-expanded polystyrene granules are dried in a drying bed. Hot air is blown from under the semi-expanded granules into this drying bed. The hot air has a temperature of about 60° at the beginning of the bed. It drops to about 40°C at the end of the bed. The granules typically undergo two cycles through the drying bed. The EPS granules remain in the drying bed for approximately 2 minutes per cycle. The dry, semi-expanded PS granules are stored in a silo, where they cool further.
• the semi-expanded polystyrene granules are fully expanded in a block press measuring 4m x Im x 1.2m. Superheated steam is used for this, at a pressure of 900 bar and a temperature of 210°C, which acts on the prefoamed polystyrene granules for a short peak of 6 seconds.
• Example 1 was repeated with beads of the same commercial series but a higher specific gravity.
• hydrophilic polymer was added to the block press steam tank in a ratio of 0.0001 wt.% to water.
• Example 2 the example was repeated according to Example 1.
• 2 kg of lithium silicate hardening solution was further added.
• a solid insulating layer was again produced from this.
• the solid insulating layer had a lambda value of 0.0364 W/mK.
• the compressive strength of the final material was 157 kPa.
• Example 2 An insulating layer according to Example 2 was produced. Different diameters of EPS granules 1 were tested for their influence on the lambda value. The mass fraction of the EPS granules according to Examples 1-2 was thereby preserved. For EPS granules with diameters below 1 mm, dust problems were encountered. For EPS granules with diameters larger than 6 mm, the insulation value of the end result decreased sharply. For EPS granules with a diameter between 1 and 6 mm, the lambda value was always between 0.0350 W/mK and 0.0370 W/mK. For EPS granules with a diameter between 4 and 6 mm, the lambda value was always between 0.0350 W/mK and 0.0362 W/mK.
• Example 1 was repeated, but the EPS granules were now "grey" polystyrene granules. These gray granules contain graphite and are known to those skilled in the art. A solid insulating layer was again made from this. This insulation layer was also gray in color, resulting in a lower lambda value of 0.0329 W/mK.
• Example 5 Kit with gray EPS granules and lithium silicate
• Example 2 was repeated, with the gray polystyrene granules from Example 4.
• lithium silicate was found to greatly improve the compressive strength of the final material.
• the compressive strength was 159 kPa, and the lambda value for this product was 0.03344 W/mK.
• the acoustic insulation of the material was calculated to be 17 dB / 10 cm.
• the use of silicate significantly improved the compressive strength but had a negative impact on the insulating properties.
• Example 8 Intermediate floor
• An existing intermediate floor with wooden joists and OSB boards on top was further insulated and finished.
• a polypropylene film was applied on top of the OSB boards.
• a slurry of the same composition and procedure as Example 5 was produced. This was mixed in on top of the film to a thickness of 4 cm. It was completely leveled. Above this, wood laminate was applied.
• the floor was not only better thermally insulated, but also considerably quieter compared to stepping or walking on the intermediate floor.
• the applied insulation layer had an (acoustic) damping capacity.
• Example 1 was repeated, with the EPS granules 2 with lower moisture absorption.
• the lambda value of the solid insulation layer was measured as 0.0321 W/mK.
• the compressive strength was 41 kPa.
• the insulating layer according to Examples 1, 2 and 9 was cut into flakes with an average particle size of 7 mm. The flakes were rebonded with a latex binding agent. The insulation values were 0.044 W/mK, 0.048 W/mK and 0.039 W/mK respectively for the recyclate from Examples 1, 2 and 9.
• EPS granules 13—17 1 m 3 of EPS granules was mixed with 14 kg of polymer emulsion. These were mixed well into a slurry and poured into a 20 cm high mold and leveled along the top of the mold. The insulating slurry was allowed to cure for 1 week at a temperature of 20°C.
• the resulting insulating layers were tested and had the following properties:
• the compressive strength was measured at 10% compression in kPa.
• the lambda value was determined based on the steady-state thermal resistance.

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• 2021
  • 2021-11-05 BE BE20215864A patent/BE1029901B1/nl active IP Right Grant
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