An insulating plate formulation and a production method of an insulating plate comprising the same

Abstract

The insulating plate formulation according to the present invention comprises 30-70% by weight of vermiculite raw material, 20-60% by weight of at least one inorganic binder, 1-5% by weight of at least one organic binder, and 3-15% by weight of at least one montmorillonite group compound. In addition, a production method of an insulating plate according to the present invention comprises the steps of: mixing at least a first amount of vermiculite raw material, at least a second amount of inorganic binder, at least a third amount of organic binder and at least a fourth amount of montmorillonite group compound by means of at least one mixer for at least a first period; pressing the mixture obtained from the mixing process by applying a pressure in at least a first pressure range by means of a uniaxial press, thereby shaping the mixture into a plate; introducing carbon dioxide gas to the plate-shaped mixture for at least a second period to perform a curing process, and baking the cured plate-shaped mixture in a furnace at at least a first temperature range for at least a third period of time, thereby obtaining at least one insulating plate.

Description

[0001] AN INSULATING PLATE FORMULATION AND A PRODUCTION METHOD OF AN INSULATING PLATE COMPRISING THE SAME

[0002] Technical Field

[0003] The present invention relates to an insulating plate formulation containing vermiculite raw material, and a production method of an insulation plate comprising this formulation.

[0004] Background of the Invention

[0005] An insulating plate is an important component preventing heat escape from a combustion chamber of a natural gas combi boiler, thereby affecting both efficiency and safety. The known-state of the art uses methods such as hot isostatic pressing and vacuum shaping to form the insulating plates. However, currently, production processes of insulating plates negatively affect human health, as they may be made of variable materials. In addition, the insulating plates obtained by these methods are not easy to treat, and do not have high thermal insulation properties.

[0006] Patent document JPH072559A discloses a fire-resistant composition for thermal insulation. Said composition comprises 10-50% light aggregate by weight, 50-90% plastic refractory clay by weight, and 0.1-10% inorganic or organic binder by weight. Vermiculite is preferred as the lightweight aggregate, bentonite as plastic refractory clay, sodium silicate as inorganic binder and phenol resin as organic binder. Since the composition provided in the aforementioned patent document contains low amounts of inorganic or organic binders (between 0.1-10%), optimum strength cannot be achieved for insulating plates, with a low insulation efficiency.

[0007] Patent document CN103449793A discloses a composite plate comprising vermiculite for ammunition boxes. Said composite plate comprises 60-80% vermiculite by weight, 15- 25% sodium silicate by weight, 2-3% zinc fluorosilicate by weight, 10-15% aluminum by weight and 3-8% bentonite by weight. Said raw materials are mixed homogeneously and 5-7 MPa pressure is applied to the prepared mixture at 120-160°C for 1.5-2.5 hours. However, due to the low temperature applied to the composite plates provided in the patent document and due to the short period of heat application, said plates cannot be resistant to impacts.

[0008] Therefore, introduction of new materials that are eco-friendly and harmless to human health is crucial, especially for use in stoves, fireplaces, insulating combustion chambers, condensing and non-condensing boilers, fire doors, or any application requiring insulation.

[0009] Brief Description of the Invention

[0010] The insulating plate formulation according to the present invention comprises 30-70% by weight of vermiculite raw material, 20-60% by weight of at least one inorganic binder, 1- 5% by weight of at least one organic binder, and 3-15% by weight of at least one montmorillonite group compound.

[0011] A production method of an insulating plate according to the present invention comprises the steps of: mixing at least a first amount of vermiculite raw material, at least a second amount of inorganic binder, at least a third amount of organic binder and at least a fourth amount of montmorillonite group compound by means of at least one mixer for at least a first period; pressing the mixture obtained from the mixing process by applying a pressure in at least a first pressure range by means of a uniaxial press, thereby shaping the mixture into a plate; introducing carbon dioxide gas to the plate-shaped mixture for at least a second period to perform a curing process, and baking the cured plate-shaped mixture in a furnace at at least a first temperature range for at least a third period of time, thereby obtaining at least one insulating plate.

[0012] The present invention provides an insulating plate formulation with high thermal insulation properties that can be used in stoves, fireplaces, insulation combustion chambers, condensing and non-condensing boilers, fire door, or any application requiring insulation, and a production method of an insulating plate comprising this formulation.

[0013] Object of the Invention An object of the present invention is to provide an insulating plate formulation which is light-weight, easy to process and produce without causing negative effects on human health during production, and a production method of an insulating plate comprising this formulation.

[0014] Another object of the present invention is to provide an insulating plate formulation resistant to breakage and impacts during production, and a production method of an insulating plate comprising this formulation.

[0015] A further object of the present invention is to provide an insulating plate formulation with high thermal insulation properties that can be used in stoves, fireplaces, insulation combustion chambers, condensing and non-condensing boilers, fire doors, or any application requiring insulation, and a production method of an insulating plate comprising this formulation.

[0016] Description of the Invention

[0017] Insulating plates increase both efficiency and safety by preventing heat escape from the combustion chamber of natural gas combi boilers. Said insulating plates should be easy to process and resistant to breakage, have high thermal insulation properties, and produced without causing harm to human health. Therefore, the present invention provides an insulating plate formulation that meets said criteria, and a production method of an insulating plate comprising this formulation.

[0018] The insulating plate formulation according to the present invention comprises 30-70% by weight of vermiculite raw material, 20-60% by weight of at least one inorganic binder, 1- 5% by weight of at least one organic binder, and 3-15% by weight of at least one montmorillonite group compound.

[0019] The production method of an insulating plate according to the present invention comprises the steps of: mixing at least a first amount of vermiculite raw material, at least a second amount of inorganic binder, at least a third amount of organic binder and at least a fourth amount of montmorillonite group compound by means of at least one mixer for at least a first period; pressing the mixture obtained from the mixing process by applying a pressure in at least a first pressure range by means of a uniaxial press, thereby shaping the mixture into a plate; introducing carbon dioxide gas to the plate-shaped mixture for at least a second period to perform a curing process, and baking the cured plate-shaped mixture in a furnace at at least a first temperature range for at least a third period of time, thereby obtaining at least one insulating plate.

[0020] The insulating plate formulation according to the present invention comprises 30-70% by weight of vermiculite as the main refractory raw material, 20-60% by weight of at least one inorganic binder (specifically, preferably sodium silicate and / or potassium silicate), 1-5% by weight of at least one organic binder (specifically, preferably, novolac and / or resol) and 3-15% by weight of at least one montmorillonite group compound for providing filling and flexibility (specifically, the montmorillonite group compound is preferably clay, kaolin and / or bentonite). When the vermiculite raw material is used below 30% by weight in the formulation, plates with low insulation properties are obtained. Additionally, if the inorganic binder is used below 20% by weight, sufficient strength cannot be achieved. In addition, when the inorganic binder is used above 60% by weight in the formulation, extra hard insulating plates are produced, which causes the plates to break during processing.

[0021] The production method of an insulating plate according to the present invention comprises mixing 30-70% by weight of vermiculite, 20-60% by weight of at least one inorganic binder (specifically, preferably sodium silicate and / or potassium silicate), 1-5% by weight of at least one organic binder (specifically, preferably novolac and / or resol), and 3-15% by weight of at least one montmorillonite group compound (specifically, preferably, clay, kaolin and / or bentonite) by means of at least one mixer (specifically, preferably an S mixer or a flat blade mixer) for at least a first period (specifically, preferably between 1 and 30 minutes). The resulting mixture from the mixing process is pressed and shaped into a plate by applying pressure in at least a first pressure range (specifically, preferably in the range of 8-100 tons or 20-240 bars) by means of a uniaxial press. The curing process is carried out by introducing carbon dioxide gas to the plate-shaped mixture for at least a second period (between 5 seconds and 3 minutes). The cured plate-shaped mixture is baked in the furnace (specifically, preferably, roller furnace, tunnel furnace, guinea tunnel or trolley tunnel) at at least a first temperature range (specifically, preferably between 150- 200°C) for at least a third period (specifically, preferably between 1-6 hours), so that at least one insulating plate is obtained. Said curing process can be carried out during the step of shaping the mixture into a plate, or it can be carried out immediately after the step of shaping the mixture into a plate.

[0022] The present invention provides an insulating plate formulation with high thermal insulation properties that can be used in stoves, fireplaces, insulation combustion chambers, condensing and non-condensing boilers, fire door, or any application requiring insulation, and a production method of an insulating plate comprising this formulation.

Claims

CLAIMS1. An insulating plate formulation comprising 30-70% by weight of vermiculite raw material, 20-60% by weight of at least one inorganic binder, 1-5% by weight of at least one organic binder, and 3-15% by weight of at least one montmorillonite group compound.

2. An insulating plate formulation according to claim 1 , characterized in that said inorganic binder comprises sodium silicate and / or potassium silicate.

3. An insulating plate formulation according to any of the preceding claims, characterized in that said organic binder comprises novolac and / or resol, which belong to the phenolic resin group.

4. A production method of an insulating plate comprising the steps of: mixing at least a first amount of vermiculite raw material, at least a second amount of inorganic binder, at least a third amount of organic binder and at least a fourth amount of montmorillonite group compound by means of at least one mixer for at least a first period; pressing the mixture obtained from the mixing process by applying a pressure in at least a first pressure range by means of a uniaxial press, thereby shaping the mixture into a plate; introducing carbon dioxide gas to the plate-shaped mixture for at least a second period to perform a curing process, and baking the cured plate-shaped mixture in a furnace at at least a first temperature range for at least a third period of time, thereby obtaining at least one insulating plate.

5. A production method of an insulating plate according to claim 4, characterized in that said at least a first amount is in the range of 30-70%.

6. A production method of an insulating plate according to claim 4, characterized in that said at least a second amount is in the range of 20-60%.

7. A production method of an insulating plate according to claim 4, characterized in that said at least a third amount is in the range of 1-5%.

8. A production method of an insulating plate according to claim 4, characterized in that said at least a fourth amount is in the range of 3-15%.

9. A production method of an insulating plate according to claim 4, characterized in that said mixer is an S mixer or a flat blade mixer.

10. A production method of an insulating plate according to claim 4, characterized in that said at least a first period is in the range of 1-30 minutes.

11. A production method of an insulating plate according to claim 4, characterized in that said at least a first pressure is in the range of 8-100 tons or 20-240 bar.

12. A production method of an insulating plate according to claim 4, characterized in that said at least a second period is in the range of 5 seconds to 3 minutes.

13. A production method of an insulating plate according to claim 4, characterized in that said at least a third period is in the range of 1-6 hours.

14. A production method of an insulating plate according to claim 4, characterized in that said at least a first temperature is in the range of 150-200°C.

15. A production method of an insulating plate according to claim 4, characterized in that said furnace is a roller furnace, a tunnel furnace, a guinea furnace or a trolley furnace.

16. An insulating plate formulation according to claim 1 , characterized in that said montmorillonite group compound is clay.

17. An insulating plate formulation according to claim 1 , characterized in that said montmorillonite group compound is kaolin.An insulating plate formulation according to claim 1 , characterized in that said montmorillonite group compound is bentonite.