NL8401498A - METHOD FOR PRODUCING INSULATING, PORO-FORMED OBJECTS, WALLS AND PARTS OF BUILDINGS CONTAINED WITH SUCH ARTICLES. - Google Patents

Description

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A method for manufacturing insulating, porous shaped articles, walls and parts of buildings formed with such articles.

The invention relates to a method for the production of insulating, porous shaped objects and buildings and / or parts of buildings that have been manufactured with such objects. More particularly, the invention relates to a method for the production of insulating, porous shaped objects such as flat plates, blocks or similar building elements, which can optionally be provided with channels or cavities.

| It is known from Dutch patent application no. 7113658 to manufacture porous shaped articles using expanded polystyrene spheres, more in particular polystyrene spheres, which are provided with a coating consisting of bituminous or tar-like products which adhere to the surface of the spherical they are applied and in which cement and / or sand particles are wholly or partly embedded, whereby the tackiness of the bituminous or tar-like product is nullified, after which these spheres are joined together by adding cement or cement / sand mixtures and water and wherein this mass hardens into molded articles in a mold.

An improvement of said method is described in European Patent No. 0031365, wherein the odor of the bitumen or tar is avoided and the strength of the molded article is increased by using a mixture of bituminous or tar-like products and water glass, wherein the water glass content can make up to 75% of the mixture. The molded articles thus obtained exhibit good insulating properties and are heat and moisture resistant.

However, the shaped objects have the drawback that due to mechanical forces, which are the result, for example

CV of transport and handling on the construction site as well as screwing and nailing the ff 35 both before and after finishing, releasing the Y-bound spheres from the molded object \ 840 1 4 38 «- 2 ~ which leads to undesired shape change and weak spots in the objects.

The present invention now has for its object to provide an improvement of this known method, whereby the product not only has the advantages of the already known products, but is also more easily nailable and screwable and can be processed with conventional hand tools without having to remove spherical balls from the binder.In addition, the weight per unit volume 10 as well as the compressive strength can be set optionally.

To this end, the invention provides a method for manufacturing insulating, porous molded objects, such as flat plates, blocks and other molded objects such as wall floors or preformed elements for structures, which can be provided with channels and / or cavities as desired, involving hollow or partially hollow objects such as styrene foam. spheres, hollow spheres of glass or plastics,! porous particles of ceramic material and other porous filling bodies are provided with an outer layer, which consists of a sticky substance which adheres to the surface of the filling bodies such as bituminous and tar-shaped products, resinous products such as paint binders based on natural or synthetic resins or polymers. in original form or in dilute or dissolved form or in the form of dispersions or emulsions in water or other non-solvents therefor.

The tacky layer may also be applied as a mixture of the tar or bituminous or resinous products or polymers, with a solution of soluble silicates, the silicate solution content of which may be up to 75%.

The sticky layer is powdered by adding powdery or fine-grained substances, for example cement, lime, chalk, sand, talc, gypsum and other substances that do not disturb the later hardening of the binder, until a mass consisting mainly of loose-coated spheres arises.

The coated spheres thus obtained are mixed with a binder which may consist of materials which have time-out 8401498. - 3 r · »hardening by chemical or physical processes such as mixtures of water with cement, plaster, lime, sand, clay or mixtures thereof, or by resins or plastics of natural or synthetic nature or mixtures thereof with 5 aforementioned binding substances such as mixtures of sand and emulsions of polyvinyl acetate, rubbers, or solutions or emulsions of resins or polymers, which form a form-retaining mass by drying or evaporating the solvent, whether or not in combination with chemical reactions.

Said binding substances can be used in both solid form and in foamed or whipped form, or yolum extender and weight-reducing additives can be added to it.

The mixture of filling bodies and binder thus obtained is formed into the desired objects by transferring the mass which has not yet hardened in a mold and allowing this mass to harden or partly harden so that the objects can be released from the mold. can then further harden in free space.

The mass can also be applied in an unpaved state and hardened at the final point of use.

When applying the unpaved mass in the mold or at the final point of use, vibrating or shaking operations can be applied or the mass can be transferred under pressing to achieve better homogeneity of the final molding.

The articles obtained in this way achieve a compressive strength of at least 10 kg / cm2 and preferably at least 4-0 kg / cm2, while the articles, depending on the choice of the binding substance, can be very fire resistant.

With suitable selection of the quantities and type of the raw materials, articles can be formed by this method. are obtained which have a compressive strength such that they are suitable as load-bearing elements or filling elements in buildings and for the manufacture of floors or floor elements.

With the right choice of raw materials, objects or bodies can be manufactured in this way, which can be excellently processed with conventional tools.

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If desired, the articles obtained after pressing and vibrating movements can be dried in the self-supporting state, without having to remain enclosed in molds during drying, as is the case with articles obtained according to the method described in European Patent No. 0031365 is.

In the method according to the invention, the pressing and / or vibrating operation can be carried out in a device of the type "Hydramat", as supplied by "Hess Machinenfabrik KG" for pressing ordinary non-porous concrete blocks, whereby the pressing pressure during the The method according to the invention is considerably lower than the pressing pressure required for pressing ordinary concrete blocks.

The tacky binder that is applied to the porous particles can be formed from a bituminous or tar-like product, but also from other tacky substances such as solutions dispersions or emulsions of polymers or resins of natural or synthetic origin. Some examples are solutions of shellac in alcohol polyvinyl acetate emulsions used in the manufacture of latex paints, solutions of natural and synthetic resins such as those used in the manufacture of paints and varnishes, as well as the paints and varnishes themselves insofar as they do not contain the porous objects or only very little * affect degree.

Also aqueous solutions of plastics or natural! products can in some cases act as a tacky binder.

The binder can be mixed with a solution of soluble silicates of metals from the first main group of the periodic table, preferably a solution of sodium or potassium silicate as known under the name of water glass, the content of water glass being up to 75% of the weight of the total human with the tacky binder.

The powdered substance is preferably added O at the end of the mixing operation with the powder particles adhering to the tacky binder forming a layer over the surface of the porous A 0401498 • 5- * particles. of a powdery substance which will later also be used in the hardening binder, but it is quite possible to use a different type of powdery substance in this way.

The hardening binder may be added in whole or in part during the first mixing or may be added in whole or in part after the first mixing. If necessary, the hardening binder 10 may first be premixed with water and optionally other additives such as foaming agents, stabilizers, dyes, accelerators, retarders and other components such as are known from the processing of concrete and are necessary to achieve the desired properties of the hardening binder.

As a foaming agent, a protein concentrate can be used as available from the company SKW in Trostberg, wherein the concentrate can be added in concentrated or diluted form, but other conventional foaming agents and surfactants can also be used, in addition to foaming or whipped resins.

The addition can be done with known dosing equipment.

The invention will now be further elucidated, starting from one of the possible formulations in this case on the basis of coated spheres of expanded polystyrene foam, wherein the coating consists of a bituminous product, water glass and cement, while the hardening binder consists of a mixture of 30 foamed concrete.

However, it is quite possible to manufacture other systems according to the principle of the invention in which the aforementioned components do not occur at all.

The invention is further elucidated in the example below with reference to the accompanying drawing.

Example

In a silo 1, expanded foam spheres manufactured in a known manner are stored.

I 4Q These can for instance consist of polystyrene. These balls 8401498 - 6 - spheres can have a diameter of 0.5 to 15 mm more in particular a diameter of 3 to 5 mm and a specific weight of 5 to 100 kg per cubic meter more in particular, a specific gravity of 10 to 15 kg j per cubic meter. At the bottom of the converging bottom end 2 of the silo there is a narrow rectangular discharge opening, including a conveyor screw in a cylindrical housing connecting directly to this discharge opening. is powered by a | 0 electric motor, which is either itself or of which a transmission gear in a wide speed range from

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standstill is gradually variable in speed, in order to drive the conveyor worm with an accurately adjustable speed. The conveyor worm unloads into a suction pipe 4 of an exhauster 5, the impeller of which has rounded blades so that the spheres can pass; without being damaged. The exhauster 5 blows the spheres through line 6 to a silo 7, which is provided with a suitable air discharge, for example a fine-mesh screen plate mounted in the top, so that the air coming from the exhauster can easily escape.

The spheres fall out of silo 7 into a first mixing mill 8, preferably consisting of a trough with two horizontal axes running parallel to one another, which are occupied with pins vertically mounted on the axis and which have been moved slightly in the circumferential direction relative to each other so that their free ends have a helical shape around the shaft. Mixer 8, for example, is 4 meters long and the distance between the pins on each shaft is 30, for example, 10 cm. The pins on the two shafts overlap, so that when the shafts are turned in opposite direction the pins pass each other a short distance and the pins in the area between the axes are moved downwards. The ends of the 33 pins move close to the trough wall of the mixer 8.

The pins span about three turns around the axis. Such mixing mills are essentially known. The shafts rotate i-1 at a speed of up to 200 revolutions per hour. Approximately 90 cm from the discharge opening of silo 7, / if desired, a feed device for the sticky * 8401498 ♦ or a mixture of the tacky substance and the soluble silicate solution, which accurately dosed adds an amount of the tacky substance to the porous particles in mixer 8. Mixing takes place in part of the road into mixer 8, after which at 12 a quantity of powdered substance is introduced into the mixing mill from bunker 13 by means of a cell wheel. Shortly before adding the powdery substance, the porous particles strongly adhere to each other by the sticky substance, or a mixture of the sticky substance and the soluble silicate, which is on the surface of the particles. The addition of the sticky substance or the mixture of tacky substance and the solution of the silicate can be effected at elevated temperature.

After addition of the powdered substance to the adhered particles, a mass of loose spheres is again obtained at a short distance in the mixer after the addition of the powdery substance. The total residence time of the spheres in the mixer 8 is 2 to 6 minutes, whereby In the first 3 meters only porous particles and the viscous liquid or a mixture thereof are mixed with the soluble silicate in the mixer and in the last meter of the mixer 8 the powdered substances are also present.

The pins 10 on shafts 9 themselves do not or hardly transport in the axial direction of the mixer 8. The transport therefore takes place mainly by displacing the material present in the mixer by adding new material. Because the spheres clump together, the powdery the material does not or hardly reach the spheres, which are not yet sufficiently mixed with the sticky substance.

At H the hardening binder, in this example cement, is added to the beginning of the conveyor belt 16 at the outlet of the mixer 8 from a bunker 15. Cell wheels can be used at 12 and 11. Belt 16 transports the porous particles, in this example polystyrene foam spheres, to a second mixer 17 which has the same construction as mixer 8, 'vX 10 but can be shorter than the last, for example 3 meters:] 84 0 1 4 s ε i -' w - Η - and with 2 1/2 screw thread on pins, in which water and, in this example, a protein foaming agent are added a short distance from the inlet from belt 16, preferably distributed over a number of points along the length of 5 reels 17, e.g. one meter in length. The water and, as in this example, the foaming agent can be supplied both collectively and separately via a dosing device, preferably a pump.

The mixture leaves the mill 17 at 19 where it is poured or pumped into molds 10, after which it is hardened in the mold or formwork. With sufficient hardening or stiffening, the mold for full hardening can already be removed, after which the molding hardens further.

A mixture as referred to in the example described above may consist of 20 kg of polystyrene foam spheres of the described dimensions, about 6 kg of tacky substance, or, for example, 5 kg of tacky substance and 10 kg of water glass, 50 kg of powdery substance such as cement or a mixture of sand and cement, 50 kg hardening binder, for example cement, 20 45 kg water and in this example about 3 kg protein concentrate as foaming agent.

The powdered substance and the hardening binder can consist of different substances, but can also consist of the same substance.

Additives can also be added to the hardening binder, such as, for example, sand, stones and other volume-increasing particles.

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Claims (9)

1. Method for manufacturing insulating porous objects, such as flat and channeled insulating plates, blocks and the like shaped articles, characterized in that the porous particles are pre-coated with a sticky liquid, or a mixture thereof with a solution of a silicate , which is subsequently rendered tack-free by adding a powdery or granular substance, whereby the mass again consists of individual particles wholly or partly, with the aforementioned sticky substance, or a mixture thereof with a solution of a soluble silicate, and to the the outside of which is covered with a powdery substance, the porous particle of which is connected by the sticky substance to the powdery substance, after which these particles are mixed with a hardening binder, the mass of which is transferred into a mold or formwork so that after curing a molding of the desired shape is obtained in a mold or formwork. 2. Process according to claim 1, characterized in that the sticky substance consists of a liquid polymer or solid polymer or resin of natural or synthetic origin or a solution, emulsion or dispersion thereof or of a tar-like or bituminous product in undiluted form or in the form of a solution, emulsion or dispersion thereof. 3. Method according to claims 1 and 2, characterized in that the powdered substance consists of cement, plaster, clay, talc, chalk, stone powder and the like, not in water-soluble powders or granular substances with a particle size of less than 9.5 mm. 4. Method according to claims 1-5, characterized in that the hardening binder consists of inorganic substances mixed with water such as cement, plaster, lime, chalk or mixtures thereof. Method according to claims 1-4, characterized in that one or more additives such as foaming agents, hardeners, accelerators, retardants, dyes and inert additives such as sand, pebbles, glass and other volume-increasing fillers are added to the hardening binder. - 10 - 6. A method according to claims 1-5, characterized in that in addition to the tacky substance as mentioned in claim 2, an amount of water-soluble silicate is added, wherein the amount of solution of silicate is a maximum of 75% by weight of the mixture. Method according to claims 1-6, characterized in that 10 as porous particles of polystyrene foam spheres are used with a diameter of 0.5 to 15 mm, preferably 3 to 5 mm with a specific weight of 5 to 100 kg per cubic meter, preferably 10 to 12 kg per cubic meter. S. A method according to claims 1-6, characterized in that during the filling of the molds a shaking or vibrating operation is used for better filling of the molds. 9. Method according to claims 1-7, characterized in that as a foaming agent as mentioned in claim 5 a protein concentrate. is used in an amount of 0.1 to 5% by weight based on the weight of the total solids of the final mixture. Method according to claim 8, characterized in that per 20 Kg foam balls approximately 6 kg of viscous material or 5 kg of viscous material and 10 kg of water glass, further 50 kg of sand, 50 kg of cement, 45 kg of water and 3 kg of protein concentrate are added * 'O 8401498 1 / É ..... .. ...