An insulation material obtained from wastes

Abstract

The invention relates to an insulation material produced by recycled synthetic polymer-based wastes for use as an insulation material that contains no additional chemicals, causes low amounts of carbon emission, has a low weight by volume, is cost-effective, recyclable, and suitable for direct paint application.

Description

[0001] AN INSULATION MATERIAL OBTAINED FROM WASTES

[0002] Technical Field

[0003] The invention relates to an insulation material for use as an insulation material that contains no additional chemicals, causes low amounts of carbon emission, has a low weight by volume, is cost-effective, recyclable, and suitable for direct paint application.

[0004] State of the Art

[0005] Insulation materials are materials used to protect building elements from malefices. Thermal insulation, for example, refers to the applications that are designed to ensure that the desired ambient temperature in a volume is minimally affected by the ambient temperature around it. Therefore, insulation is used to limit the energy exchange between two volumes at different temperatures and thus reduce losses. In general, the materials used in water and moisture insulation are asphalt, tar and derivatives obtained by adding other materials into these. The materials used in thermal insulation are glass wool, rock wool and plastic foam-based materials. ISO24285 standards require these materials to have a thermal conductivity coefficient (X) of less than 0.065 W / mK. According to the ISO13788 standard, the material is water and moisture insulated if its water vapor resistance factor (p) and water vapor diffusionequivalent air layer thickness (Sa) are less than 1 and 0.2, respectively. For sound insulation, the ISO717-1 :2023 standard specifies that the sound intensity should be reduced by at least 32 dB. Since the vast majority of thermal insulation materials also meet sound insulation standards, a single material can be used for both purposes.

[0006] The abovementioned materials are not without their drawbacks. Tar, glass wool and rock wool contain chemicals that endanger human health. Asphalt is an extremely expensive insulation material. And XPS is a single-use material. These materials are not recyclable when used as insulation, and none are made from recycled materials. Furthermore, due to production techniques and raw material prices, their production is extremely costly. These materials are not eco-friendly due to their production techniques and disposal at the end of their useful life. These two processes (production and destruction) cause large amounts of carbon emissions into the environment. Finally, when these materials are used for insulation, an additional layer of external plastering material is required on top. The upper surfaces of these materials are not paintable in their raw state. This causes the cost and duration of insulation to increase.

[0007] As a result, all the abovementioned problems have made it compulsory to make an innovation in the relevant field.

[0008] Objects and Brief Description of the Invention

[0009] The primary object of the invention is to produce heat, sound, water, and moisture insulation material derived from recycled synthetic polymer-based waste that contains no chemicals when compared to existing products, has low carbon emissions, is light in volume, offers cost savings, can be recycled again, and is suitable for direct paint application.

[0010] The said invention differs from the state of the art in four main methods. One of the objects of the invention is to eliminate materials that are harmful to human health. The insulation material developed with the invention contains no chemicals as a product binder, it is composed of thermoplastic materials that melt when heated and solidify when cooled.

[0011] Another object of the invention is to make the product eco-friendlier by using synthetic fibers that can be recycled.

[0012] Another object of the invention is the production price of the product. In the state of the art, products are produced at high cost due to production methods and disposal methods. In the production technique of the invention, a low-temperature furnace is sufficient, whereas, in the known state of the art, extremely high temperatures are required. This also causes a negative effect in terms of carbon emissions. Furthermore, the raw material of the invention is synthetic polymers, which reduces the cost even further. Another object is to make the product easy to use. Thanks to its plastered surface, it can be painted without the need for plaster application because the paint can be applied directly on it, making application easier. Detailed Description of the Invention

[0013] The invention comprises a method to produce heat, sound, water, and moisture insulation material derived from recycled synthetic polymer-based waste that contains no chemicals when compared to existing products, has low carbon emissions, is light in volume, offers cost savings, can be recycled again, and is suitable for direct paint application.

[0014] Synthetic polymers are preferably obtained as raw materials or from regenerated (recycled) synthetic fiber waste. The synthetic polymer is mixed with an additive. It is preferably mixed with an additive whose melting temperature is equal to or lower than its own. The low melting point of the additive is due to the requirement that the main synthetic polymer's combustion temperature be 300°C and that it not bum when the additive is added.

[0015] The ratios of synthetic polymers and additives mentioned are given by weight.

[0016] The said additive can be added within the range of 30% to 70% and any other value in between.

[0017] The said fiber material can be added within the range of 30% to 70% and any other value in between.

[0018] The said additive may be a synthetic polymer, synthetic fiber, fiber comprising polyethylene polypropylene or thermoplastic fiber.

[0019] In the method of the invention, the said synthetic polymer is made homogeneous and bulky. This process is preferably performed by carding. Following the carding process, the synthetic polymer is laid on top of one another to increase its strength and physical properties.

[0020] The laying process is preferably done diagonally. Alternatively, linear laying, parallel laying, perpendicular laying, or aerial laying can be performed.

[0021] The homogeneous and bulky polymer, combined with the laying process, increases the strength and thickness of the product, reducing both thermal conduction and sound transmission. Following the laying process, heat treatment is applied to the synthetic polymer parts contained in layers.

[0022] The said production technique preferably uses the thermal bonding method used in nonwoven fabric technology. The reason for using these techniques is to reduce water permeability while improving tear and tensile strength. The said heat treatment is preferably performed in a furnace.

[0023] The parts are combined via melting during heat treatment and become a strong structure. The product is then solidified and hardened.

[0024] Preferably, a calendering application is performed to solidify and harden the product. With the calendar application, the product transforms into a plate with flat top and bottom surfaces. Calendering is a treatment that can keep thermal degradation at lower levels and consolidate homogeneous mixtures more effectively than other treatments. Alternatively, brushing, embossing, creping, drying, slab burning, shearing, flocking, polishing, and heat-setting shrinkage techniques can be used.

[0025] In an alternative configuration, the top surface, bottom surface or both surfaces can be patterned. In an alternative configuration, the plate that emerges from calendering with a flat surface is preferably patterned via embossing. The patterned surface allows the product to be painted without the need for an additional top layer of plaster, etc., while also providing a decorative appearance.

[0026] The final product is a ready-to-apply heat, sound, moisture, and water insulation material that can be produced in the desired thickness, has a dead air zone between the inner layers due to the geometry of the laying process, contains no chemical binders, is light in volume, has a structure that holds paint on the surface, has low production costs, and low carbon emissions.

Claims

CLAIMS1. Method of producing an insulation material, characterized in that it comprises the following steps; mixing a synthetic polymer-based recycled material with at least one additive, creating at least two layers of the said mixture, applying heat treatment to the said layers.

2. The method according to Claim 1, characterized in that said additive is a synthetic polymer different from recycled material.

3. The method according to Claim 1, characterized in that said additive is synthetic fiber.

4. The method according to Claim 1, characterized in that said additive is a polyethylene polypropylene containing fiber.

5. The method according to Claim 1, characterized in that said additive is thermoplastic fiber.

6. The method according to any one of the preceding claims, characterized in that the additive and the synthetic polymer are homogeneously mixed.

7. The method according to Claim 1 or 6, characterized in that the carding process is applied to the said mixture.

8. The method according to Claim 1, characterized in that said layers are laid on top of one another.

9. The method according to Claim 8, characterized in that said laying process is linear laying.

10. The method according to Claim 8, characterized in that said laying process is diagonal laying.

11. The method according to Claim 8, characterized in that said laying process is parallel laying.

12. The method according to Claim 8, characterized in that said laying process is perpendicular laying.

13. The method according to Claim 8, characterized in that said laying process is aerial laying.

14. The method according to Claim 1, characterized in that the heat treatment is carried out via a furnace.

15. The method according to Claim 1, characterized in that said layers are subjected to calendering to solidify and harden.

16. The method according to Claim 1, characterized in that the surface of the combined layers is patterned.

17. The method according to Claim 16, characterized in that said patterning is carried out via a calendering.

18. The method according to claim 1, characterized in that the melting point of the additive is lower than that of the recycled material.

19. The method according to claim 1, characterized in that the additive is between 30% and 70% by weight.

20. The method according to claim 1, characterized in that the recycled material is between 30% and 70% by weight.

21. The method according to claim 1, characterized in that said heat treatment is carried out between 8O-3OO°C.

22. An insulation material produced by a method according to any one of the preceding claims.

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