Non-combustible water-resistant vapour permeable material and method of its production

Abstract

A non-combustible water-resistant vapour permeable material made from crushed material from mixed waste for the production of boards, panels, bricks and parts of various shapes consists in the fact that it is formed by a mixture that contains 50 to 73 wt% of the crushed material from mixed waste, 22.9 to 47 wt% of an aqueous solution of sodium silicate, 2 to 4 wt% of an aqueous solution of potassium silicate and 0.1 to 1 wt% of a water glass stabilizer. The solution also consists in a method of production of a non-combustible water-resistant vapour permeable material made from mixed waste for the production of structural boards, panels, bricks and parts of various shapes, which consists in that the dried crushed material from mixed waste is mixed with a soot solution so that its entire surface is covered with soot; then an aqueous solution of sodium silicate and potassium silicate is mixed, and a water glass stabilizer is added to the resulting solution, and then a water glass hardener is mixed into this solution, wherein further this solution is stirred for 5 minutes so that a binder solution is formed; then the mixture of the crushed material from mixed waste is inserted into the binder solution with constant stirring and everything is mixed; then the resulting mixture is divided into two parts, the first half of the mixture is poured into a form, a glass reinforcing fabric is laid on top of the mixture and the second half of the mixture is then poured in and everything is compressed with a press under a pressure of 10 MPa when cold; and the resulting mixture is finally left undisturbed until it hardens.

Description

[0001] Non-combustible water-resistant vapour permeable material and method of its production

[0002] Technical Field

[0003] The invention relates to a construction material, in particular a non-combustible water- resistant vapour permeable material made from crushed material from sorted or unsorted municipal mixed waste, in particular from crushed material of paper, plastics, metals, glass, ash, textiles and biological waste, for the production of boards, panels, bricks and parts of various shapes, and the method of its production.

[0004] Background Art

[0005] From the background art, a number of designs of boards made of chipboard, glass, basalt and other fibres, granulates made of glass, ceramics, basalt, fly ash, cement, etc. are known.

[0006] Polyurethane binders or phenol-formaldehyde, urea-formaldehyde and other resins are used as binders.

[0007] There are also known boards made of shredded sorted waste from paper, plastics, textiles and metals, which are produced by pressing at high temperatures, at which the plastic crushed material melts, which then serves as a binder.

[0008] Patent document GZ PV 1990-2151 A3 discloses a mixture for surface treatment, which contains cork and rubber waste crushed material, volcanic glass and limestone as the filler, the binder is an acrylate dispersion. The disadvantage of the material is its high density and. due to the organic origin of the binder, especially its low heat resistance.

[0009] Another patent document RU 2634451 C1 discloses a board made of cellulosic and lignocellulosic materials including rice husks, straw, corn cobs, wool and cotton, where the binder is organic polymers such as polyacrylamide. The disadvantage of this board is its high combustibility. Patent document CZ PV 1998-1690 A3 discloses a mixture based on sodium water glass, halogen, sulfate and carbonate salts and ethylene glycol with crushed paper, hemp fibre or wood sawdust supplemented with polyvinyl alcohol, which is complicatedly pressed and dried. Wood sawdust with organic glue and water are also used. The material with wood is thermally stable at 800 °C, but it is not fireproof.

[0010] It is clear from the above-mentioned background art that the main disadvantage of the known background art is that the known boards are combustible or highly combustible. Another problem is their low resistance to water and possibly the release of dangerous organic substances in the case of boards that contain phenol-formaldehyde, ureaformaldehyde, melamin-formaldehyde or tannin-formaldehyde resins and their mutual combinations.

[0011] Another disadvantage is low vapour permeability.

[0012] The objective of the invention is the construction of a water-resistant material that will have high fire resistance and will be vapour permeable, ecological and harmless to health, recyclable, resistance external influences and biological attack.

[0013] Summary of the Invention

[0014] The stated disadvantages are largely eliminated and the objectives of the invention are met by a non-combustible water-resistant vapour permeable material from shredded mixed waste, in particular from crushed material of paper, plastics, metals, glass, ash, textiles and biological waste, for the production of boards, panels, bricks and parts of various shapes, the essence of which is that it consists of a mixture that contains 50 to 73 wt% of the crushed material from mixed waste, 22.9 to 47 wt% of an aqueous solution of sodium silicate, 2 to 4 wt% of an aqueous solution of potassium silicate and 0.1 to 1 wt% of a water glass stabilizer. The advantage of the material is its lightness, strength, vapour permeability, high fire resistance and high water resistance. At the same time, the material has anti-fungal effects, resistance to biological attack and external influences, is ecological and harmless to health. It is very advantageous when the surface of the crushed material from mixed waste, is provided with soot, wherein pure soot constitutes 0.025 to 0.25 wt% of the total weight. The advantage is that soot arranged in this way reduces combustibility, with the fact that the soot is preferably absorbed to a certain extent into the crushed material, which stabilizes Its bond with the soot. The advantage is that the soot acts as a flame coretardant. it is also advantageous when the aqueous solution of silicate is an aqueous solution of sodium silicate and an aqueous solution of potassium silicate. it is also advantageous that the crushed material from mixed municipal waste is dried crushed material of paper, plastics, metals, glass, ash, textiles and biological waste.

[0015] It is also preferred when the water glass stabilizer is a hydrophilic hydroxyalkyiethylenediamine.

[0016] It is also advantageous when the aqueous solution of sodium silicate has a density in the range of 1370 to 1400 kg / m3and when the molar ratio of SiO2to Na2O is in the range of 3.2 to 3.4. The advantage is that such water glass is partially flexible after solidification. it. is also advantageous when the aqueous solution of potassium silicate has a density in the range of 1650 to 1670 kg / m3and when the molar ratio of SiO2to K2O is in the range of 1.67 to 1.73. The advantage is that such a mixture has greater resistance to flame.

[0017] Furthermore, it is advantageous when the material from the crushed material from mixed waste further contains a water glass hardener.

[0018] It is also advantageous that a glass reinforcing fabric is inserted in the half of the thickness of the board, it increases the strength and flexibility of the boards.

[0019] Furthermore, the stated disadvantages are largely eliminated and the objectives of the invention are met by a method of production of a non-combustibie water-resistant vapour permeable material from crushed material from mixed waste for the production of structural boards, panels, bricks and parts of various shapes, the essence of which Is that the dried crushed material is mixed with a soot solution so that its entire surface is covered with soot, then an aqueous solution of sodium silicate and potassium silicate is mixed, and a water glass stabilizer is added to the resulting solution, and then a water glass hardener is mixed into this solution, wherein further this solution is stirred for 5 minutes so that a binder solution is formed, and then the mixture of the crushed material from municipal waste is inserted into the binder solution with constant stirring and everything is mixed, and then the resulting mixture is divided into two parts, the first half of the mixture is poured into a form, a glass reinforcing fabric is laid on top of the mixture and the second half of the mixture is then poured in and everything is compressed with a press under a pressure of 10 MPa when cold. The resulting mixture is finally left undisturbed until it hardens.

[0020] The main advantage of the insulating material and the method of its production according to ths invention is that it is highly non-combustible. The entire surface of the crushed material from waste is covered with soot, which acts as a flame co-retardant. It is very advantageous that sodium water glass is used as a binder, which, after drying, resembles classic glass in its composition and properties. It is very hard, abrasionresistant, heat-resistant up to temperatures of 1000 °C, water-resistant and vapour permeable. At the same time, it is ecological and harmless to health. It reflects UV radiation well, ft does not release any organic toxic substances. This binder has excellent adhesive and sealing effects and good adhesion to common base materials. This binder can be used to bond crushed material very well and effectively. At the same time, the crushed material from mixed waste is coated with this binder over Its entire surface and is thus protected against the effects of water, flame and UV radiation. At the same time, the non-combustlbility of the mixture is increased by the addition of potassium water glass to the binder; the potassium water glass increases the flame resistance. Insulation boards with this binder are hard, strong, abrasion-resistant, non- combustible and heat-resistant, water-resistant, vapour permeable, resistant to biological attack, ecological and harmless to health without the emission of organic substances. Examples of Embodiments of the Invention

[0021] Example 1

[0022] The non-combustible water-resistant vapour permeable material made from crushed material from municipal waste is made of a mixture that contains 73 wt% of the crushed material 22.9 wt% of an aqueous solution of sodium silicate, 4 wt% of an aqueous solution of potassium silicate and 0.1 wt% of a water glass stabilizer.

[0023] The water glass stabilizer is hydrophilic hydroxyalkylethylenediamine, in the form of a 98% aqueous solution of N,N,N' ,N ~ Tetrakis(2-hydroxypropyl)ethylenediamine.

[0024] The aqueous solution of sodium silicate has a density of 1370 kg / m3and its molar ratio of SiO2to Na2O is 3.2.

[0025] The aqueous solution of potassium silicate has a density of 1650 kg / m3and its molar ratio of SiO2to K2O is 1 .67.

[0026] The material from the crushed material from municipal waste further contains a water glass hardener, which is a mixture of pure glycerol diacetate / triaoetate in a ratio of 7:3 parts by volume, with a concentration of 0.5 to 5 wt% to pure water glass.

[0027] According to the production method of the non-combustible water-resistant material the dried crushed material is mixed with a soot solution so that its entire surface is covered with soot, then an aqueous solution of sodium silicate and potassium silicate is mixed, and a water glass stabilizer is added to the resulting solution, and then a water glass hardener is mixed into this solution, wherein further this solution is stirred for 5 minutes so that a binder solution is formed, and then the mixture of the crushed material from municipal waste is inserted into the binder solution with constant stirring and everything is mixed, and then the resulting mixture is divided into two parts, ths first half of the mixture is poured into a form, a glass reinforcing fabric is laid on top of the mixture and the second half of the mixture is then poured in and everything is compressed with a press under a pressure of 10 MPa when cold. The resulting mixture is finally left undisturbed until it hardens. Example 2

[0028] The con-combustible water-resistant material made of straw is made of a mixture that contains 50 wt% of the crushed material from mixed waste, 47 wt% of an aqueous solution of sodium silicate, 2 wt% of an aqueous solution of potassium silicate and 1 wt

[0029] % of a water glass stabilizer.

[0030] The water glass stabilizer is hydrophilic hydroxyalkyiethylenedlamine. in the form of a

[0031] 98% aqueous solution of N,N,N' ,N ~Tetrakis(2-hydroxypropyl)ethylenediamine.

[0032] The aqueous solution of sodium silicate has a density of 1400 kg / m3and its molar ratio of SiO2to Na2O is 3.4.

[0033] The aqueous solution of potassium silicate has a density of 1670 kg / m3and its molar ratio of SiO2to K2O is 1.73.

[0034] The material from the crushed material further contains a water glass hardener, which is a mixture of pure glycerol diaoetate / triacetate in a ratio of 7:3 parts by volume, with a concentration of 0.5 to 5 wt% to pure water glass.

[0035] According to the production method of the non-combustible water-resistant material the dried crushed material is mixed with a soot solution so that its entire surface is covered with soot, then an aqueous solution of sodium silicate and potassium silicate is mixed, and a water glass stabilizer is added to the resulting solution, and then a water glass hardener is mixed into this solution, wherein further this solution is stirred for 5 minutes so that a binder solution is formed, and then the mixture of the crushed material from municipal waste is inserted into the binder solution with constant stirring and everything Is mixed, and then the resulting mixture is divided into two parts, the first half of the mixture is poured into a form, a glass reinforcing fabric is laid on top of the mixture and the second half of the mixture is then poured in and everything is compressed with a press under a pressure of 10 MPa when cold. The resulting mixture is finally left undisturbed until it hardens. Example 3

[0036] The non-combustible water-resistant vapour permeable material made from crushed material from municipal waste is made of a mixture that contains 57.6 wt% of the crushed material from municipal waste, 39.3 wt% of an aqueous solution of sodium silicate, 2.8 wt% of an aqueous solution of potassium silicate and 0.3 wt% of a water glass stabilizer.

[0037] The water glass stabilizer is hydrophilic hydroxyalkylethylenediamine, in the form of a 98% aqueous solution of N,N,N' ,N ~Tetrakis(2-hydroxypropyl)ethylenediamine.

[0038] The aqueous solution of sodium silicate has a density of 1390 kg / m3and its malar ratio of SiO2to Na2O is 3.3.

[0039] The aqueous solution of potassium silicate has a density of 1660 kg / m3and its molar ratio of SiO2to K2O is 1 .70.

[0040] The material from the crushed material further contains a water glass hardener, which is a mixture of pure glycerol diacetate / triacetate in a ratio of 7:3 parts by volume, with a concentration of 0.5 to 5 wt% to pure water glass.

[0041] According to the production method of the non-combustible water-resistant material the dried crushed materia! is mixed with a soot solution so that its entire surface is covered with soot, then an aqueous solution of sodium silicate and potassium silicate is mixed, and a water glass stabilizer is added to the resulting solution, and then a water glass hardener is mixed into this solution, wherein further this solution is stirred for 5 minutes so that a binder solution is formed, and then the mixture of the crushed material from municipal waste is inserted into the binder solution with constant stirring and everything is mixed, and then the resulting mixture is divided into two parts, the first half of the mixture is poured into a form, a glass reinforcing fabric is laid on top of the mixture and the second half of the mixture is then poured in and everything is compressed with a press under a pressure of 10 MPa when cold. The resulting mixture is finally left undisturbed until it hardens. Industrial Applicability

[0042] The non-combustibte. water-resistant, vapour permeable material made from crushed material from mixed waste according to the invention can be used for the production of shaped products or flat boards, which are useful especially in the construction industry.

Claims

Claims1. A non-combustible water-resistant vapour permeable material made from crushed material from mixed waste for the production of non-combustible boards, panels, bricks and parts of various shapes, characterized in that it consists of a mixture that contains50 to 73 wt% of the crushed material from mixed waste, 22.9 to 47 wt% of an aqueous solution of sodium silicate, 2 to 4 wt% of an aqueous solution of potassium silicate and0, 1 to 1 wt% of a water glass stabilizer.

2. The non-combustible water-resistant vapour permeable material made from crushed material from mixed waste, according to claim 1 , characterized in that the crushed material from mixed waste is a crushed material of paper, plastics, metals, glass, ash, textiles and biological waste.

3. The non-combustible water-resistant vapour permeable material made from crushed material from mixed waste, according to one of the preceding claims, characterized in that the surface of the crushed material is provided with soot, wherein the soot constitutes 0.025 to 0.25 wt% of the total weight.

4. The non-combustible water-resistant vapour permeable material made from crushed material from mixed waste, according to one of the preceding claims,, characterized in that the water glass stabilizer is hydrophilic hydroxyalkyiethylenediamine.

5. The non-combustible water-resistant vapour permeable material made from crushed material from mixed waste, according to one of the preceding claims, characterized In that the aqueous solution of sodium silicate has a density in the range of 1370 to 1400 kg / m3.

6. The non-combustible water-resistant vapour permeable material made from crushed material from mixed waste, according to one of the preceding claims, characterized in that the aqueous solution of sodium silicate has a molar ratio of SIO2to Na2O in the range of 3.2 to 3.4.7, Ths non-combustible water-resistant vapour permeable material made from crushed material from mixed waste, according to one of the preceding claims, characterized in that the aqueous solution of potassium silicate has a density in the range of 1650 to 1670 kg / m3.

8. The non-combustible water-resistant vapour permeable material made from crushed material from mixed waste, according to one of the preceding claims, characterized in that the aqueous solution of potassium silicate has a molar ratio of SiO2to K2O in the range of 1 ,67 to 1 .73,9, The non-combustible water-resistant vapour permeable material made from crushed material from mixed waste, according to one of the preceding claims, characterized in that it further contains a water glass hardener.

10. A method of producing a non-combustible water-resistant vapour permeable material made from crushed material from mixed waste for the production of non- combustible boards, panels, brinks and parts of various shapes according to one of claims 1 to 9, characterized In that the dried crushed material from mixed waste is mixed with a soot solution so that its entire surface is covered with soot: then an aqueous solution of sodium silicate and potassium silicate is mixed, and a water glass stabilizer is added to the resulting solution, and then a water glass hardener is mixed into this solution, wherein further this solution is stirred for 5 minutes so that a binder solution is formed; and then the mixture of the crushed material from mixed waste is inserted into the binder solution with constant stirring and everything is mixed; and then the resulting mixture is divided into two parts, the first half of the mixture is poured into a form, a glass reinforcing fabric is laid on top of the mixture and the second half of the mixture is then poured in and everything is compressed with a press under a pressure of 10 MPa when cold; the resulting mixture is finally left undisturbed until it hardens.

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