Thermal insulation material and its manufacturing method

Abstract

A heat insulating material, particularly a permeable fire-resistant heat insulating material comprising water glass and polystyrene, comprising a hardening mixture containing 1 to 32.4% by weight of expanded polystyrene, 57.5 to 96.0% by weight of an aqueous sodium silicate solution, 2 to 6% by weight of aluminum hydroxide, 0.8 to 2.6% by weight of a water glass hardener, and 0.1 to 0.5% by weight of a water glass stabilizer, and carbon black constituting 0.1 to 1% by weight of the total weight is provided on the surface of the expanded polystyrene. A method for producing a heat insulating material, particularly a permeable fire-resistant heat insulating material comprising water glass and polystyrene, comprising: first, mixing polystyrene beads with an aqueous carbon black solution to coat the entire surface; then, adding aluminum hydroxide to the aqueous sodium silicate solution and mixing the whole to form a heat insulating mixture; then, adding a water glass stabilizer to the aqueous sodium silicate solution; then, mixing a water glass hardener into this solution; and stirring this solution for another 1 to 10 minutes to form a binder solution; adding the heat insulating mixture to the binder solution while constantly stirring; mixing the whole; and then pouring the resulting mixture onto the application site.

Description

[Technical field]

[0001] The present invention relates to an insulating material, in particular a permeable fire-resistant insulating material containing water glass and polystyrene, and a method for producing the same. [Background technology]

[0002] From the current technology, it is known to use expanded polystyrene as a thermal insulation material in various types of buildings. Its disadvantage is its low fire resistance.

[0003] For the insulation of horizontal surfaces, modern sprayed insulation made of PUR foam, as well as polystyrene panels, are used. The disadvantages of this foam are its low fire resistance and rapid aging.

[0004] Another known method of insulating horizontal and vertical surfaces is mineral wool insulation. Mineral wool has higher fire resistance but is absorbent, so it loses its insulating properties and mold grows in it.

[0005] From patent application CZ PV2017-127, a soundproofing and thermal insulation material for use in structures is known. 3 It consists of a slurry of an air-hardening mixture containing 5-76% by weight of bulk insulation material with a specific volumetric mass of less than 0.001-1 mm, 9-36% by weight of 0.001-1 mm brick dust fraction, 6-30% by weight of water glass, 7-30% by weight of water and up to 5% by weight of detergent. The disadvantages of this material are poor insulation properties, high flammability and poor cohesion.

[0006] From utility model CZ 31095 a mixture for permeable fire-resistant lightweight polystyrene insulation systems is known. The mixture contains 10% by weight of expanded polystyrene beads with a diameter of 3-6 mm, 88% by weight of sodium silicate water glass, 1% by weight of carbon black and 1% by weight of water glass stabilizer - hydrophilic alkoxyalkyl-ammonium salt. The disadvantage of this mixture is that the carbon black is not a protective material on the surface of the balls, but is freely distributed in the insulation material, which causes a higher thermal conductivity and a lower thermal stability of the insulation material, thus limiting the fire-resistant properties and making it less resistant to UV radiation and therefore deteriorating very quickly. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Czech Republic Patent Application No. CZ PV2017-127 [Patent Document 2] Czech Republic Utility Model No. CZ 31095 Summary of the Invention [Problem to be solved by the invention]

[0008] From the above current technology, it is clear that the main drawback of the current technology is the low thermal insulation properties of the known materials and their high degradation rate.

[0009] The object of the present invention is a lightweight insulating material construction that is highly fire resistant while at the same time being flexible, pliable, and resistant to degradation. [Means for solving the problem]

[0010] The above-mentioned disadvantages are largely eliminated and the object of the present invention is achieved by an insulating material, in particular a permeable fire-resistant insulating material containing water glass and polystyrene. According to the present invention, the material comprises a hardening mixture containing 1-32.4% by weight of expanded polystyrene, 57.5-96.0% by weight of an aqueous solution of sodium silicate, 2-6% by weight of aluminum hydroxide, 0.8-2.6% by weight of a water glass hardener and 0.1-0.5% by weight of a water glass stabilizer, while the expanded polystyrene Complete The surface is coated with carbon black, which accounts for 0.1 to 1% of the total weight. direct The insulating material is characterized in that it is provided with a carbon black coating. The advantage of this insulating material is that it has significantly improved fire resistance properties, as well as significantly higher thermal stability, higher resistance to UV radiation and a significantly lower degree of degradation. The advantage is also a very good permeability. To improve the flame retardancy, the mixture contains aluminum hydroxide. The advantage of providing the surface of the expanded polystyrene with carbon black is that the carbon black thus provided has the advantage of reducing the thermal conductivity and that the carbon black is absorbed to a certain extent by the polystyrene beads, thereby stabilizing their bond with the polystyrene beads in the resulting mixture. A further advantage is that the carbon black acts as a flame retardant co-retardant. The insulating material further advantageously comprises a hardener, which may be glycerol monoacetate-triacetate or a mixture thereof.

[0011] Advantageously, expanded polystyrene beads have a diameter of 3-6 mm. Its advantage is the possibility of optimizing the structure of the material in terms of optimal placement.

[0012] It is also advantageous that the water glass stabilizer is a hydrophilic alkoxyalkyl-ammonium salt.

[0013] In this case, the sodium silicate solution is 1370 to 1400 kg / m 3It is highly advantageous for the silica to sodium oxide molar mass ratio to be in the range of 3.2-3.4. The molar mass ratio of silica to sodium oxide and the associated solution density and solution concentration have a significant effect on the rheological properties of the water glass as a polymer mixture, its electrical properties in electrolytes, compressibility and adhesive strength, as well as hardness, strength, etc. The advantage of the above mentioned parameters is that the resulting insulating material is partially flexible and pliable after curing.

[0014] The above disadvantages are largely eliminated and the object of the present invention is achieved by a method for producing a heat insulating material, in particular a method for producing a permeable fire-resistant heat insulating material containing water glass and polystyrene. According to the present invention, the method is characterized in that polystyrene beads are first mixed with an aqueous carbon black solution so that their entire surface is covered, then aluminum hydroxide is added, the whole is mixed to form a heat insulating mixture, then a water glass stabilizer is added to an aqueous sodium silicate solution, then a water glass hardener is mixed into the solution, the solution is stirred for 1-10 minutes to form a binder solution, then the heat insulating mixture is poured into the binder solution with constant stirring, the whole is further mixed, and then the resulting mixture is poured onto the application site. Its advantage is that it is possible to produce both solid products such as heat insulating panels and fittings, and the heat insulating material can be applied in its liquid state. Effect of the Invention

[0015] It is convenient to pour the resulting mixture into a mould, which is the application site, and then extrude a quantity of binder solution from the resulting mixture by means of a press, so as to produce a desired ratio of insulating mixture and binder solution. The advantage of this is that it is possible to easily produce products with precise parameters.

[0016] It is also advantageous to finally leave the mixture obtained until it hardens, the advantage of which is that the insulation obtained can be made precisely with respect to the geometric parameters of the insulating space: due to the fact that the hardening length can be regulated, the insulation material can be precisely molded to the desired shape.

[0017] The main advantage of the insulating material according to the invention and the method for its manufacture is that it has insulating properties comparable to the polystyrene products used so far, while unlike existing materials it is non-combustible, vapor permeable, resistant to rainwater and moisture, antifungal, strong, flexible and resistant to external influences such as UV radiation. Another advantage is the simple method of application. Both covering plates and fittings can be made from the insulating material, which can be easily applied as a liquid mixture by stretching, casting or spraying. The insulating material is therefore suitable for floors and ceilings, horizontal and slightly sloping roofs, replacing mineral wool, polystyrene concrete or polyurethane foam. Unlike insulation with mineral wool or polystyrene boards, it is successfully applied in hard-to-reach places and on edges with uneven surfaces. It has good adhesion to various substrates, including trapezoidal and folded sheets, eternit or asphalt, which are usually found on roofs. At the same time, the insulating material is strong enough and can also be walkable. A major advantage of the insulating material according to the invention over existing materials is also the possibility of combining the board with a liquid mixture. One of the problems associated with the fastening of conventional polystyrene boards is the filling of the joints between the boards and the holes around the dowels. Thanks to the possibility of filling these gaps and openings with insulating material in liquid form, a uniform surface with no heat escape routes is created very easily and quickly. A great advantage is also that the semi-finished insulating material in the form of a liquid mixture can be applied as an insulating lining in industry, for example in household appliances, electrical technology, automobiles, etc. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] Example 1

[0019] The permeable fire-resistant insulating material is made of an air-hardening mixture containing 10% by weight of expanded polystyrene in the form of spheres with a diameter of 3 to 6 mm, 83.0% by weight of an aqueous solution of sodium silicate, 4% by weight of aluminum hydroxide, 0.3% by weight of a water glass stabilizer, and 2.3% by weight of a hardener.

[0020] The surface of the expanded polystyrene is provided with carbon black, which constitutes 0.4% by weight of the total weight.

[0021] The waterglass stabilizer is a hydrophilic alkoxyalkyl-ammonium salt of N,N,N',N'-tetrakis(2-hydroxypropyl)ethylenediamine in the form of a 98% aqueous solution.

[0022] The density of sodium silicate solution is 1390kg / m 3 and the molar ratio of SiO2 to Na2O is 3.3.

[0023] The waterglass hardener is a mixture of pure glycerol diacetate / triacetate in a ratio of 7:3 parts by volume, with a concentration of 2.8% by weight relative to pure waterglass.

[0024] According to the manufacturing method of this heat insulating material, first, polystyrene beads are mixed with an aqueous solution of carbon black with a concentration of 25% by weight, and the entire surface is coated with carbon black, then aluminum hydroxide is added, and the whole is mixed to form a heat insulating mixture, then a water glass stabilizer is added to an aqueous solution of sodium silicate, a water glass hardener is added to this solution, and the whole is mixed to form a binder solution, then this heat insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is poured into the application site, which is a silicone mold, and further, from the resulting mixture, such an amount of binder solution is extruded by means of a press so as to obtain a desired ratio of the heat insulating mixture to the binder solution.

[0025] Finally, the mixture is left to harden. The resulting product is an insulation board, or more precisely, an insulation layer placed on an OSB board, or between two OSB boards.

[0026] Example 2

[0027] The permeable fire-resistant insulating material is made of an air-hardening mixture containing 1% by weight of expanded polystyrene in the form of spheres with a diameter of 3 to 6 mm, 96.0% by weight of an aqueous solution of sodium silicate, 2% by weight of aluminum hydroxide, 0.1% by weight of a water glass stabilizer, and 0.8% by weight of a hardener.

[0028] The surface of the expanded polystyrene is provided with carbon black, the carbon black constituting 0.1% by weight of the total weight.

[0029] The waterglass stabilizer is a hydrophilic alkoxyalkyl-ammonium salt of N,N,N',N'-tetrakis(2-hydroxypropyl)ethylenediamine in the form of a 98% aqueous solution.

[0030] Density is 1370kg / m 3 and the molar ratio of SiO2 to Na2O is in the range of 3.2.

[0031] The waterglass hardener is a mixture of pure glycerol diacetate / triacetate in a ratio of 7:3 parts by volume, with a concentration of 0.8% by weight relative to pure waterglass.

[0032] According to the manufacturing method of this insulating material, first, polystyrene beads are mixed with an aqueous solution of carbon black with a concentration of 25% by weight, and the entire surface is coated with carbon black, and then aluminum hydroxide is added and the whole is mixed to form an insulating mixture, then a water glass stabilizer is added to an aqueous solution of sodium silicate, a water glass hardener is added to this solution, and the solution is mixed for 1 minute to form a binder solution, and then the insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, and the resulting mixture is poured into a flat divided attic space, spread, surface-treated, and left to harden.

[0033] Example 3

[0034] The permeable fire-resistant insulating material is made of an air-hardening mixture containing 32.4% by weight of expanded polystyrene in the form of spheres with a diameter of 3 to 6 mm, 57.5% by weight of an aqueous solution of sodium silicate, 6% by weight of aluminum hydroxide, 0.5% by weight of a water glass stabilizer, and 2.6% by weight of a hardener.

[0035] The surface of the expanded polystyrene is provided with carbon black, which constitutes 1% by weight of the total weight.

[0036] The waterglass stabilizer is a hydrophilic alkoxyalkyl-ammonium salt of N,N,N',N'-tetrakis(2-hydroxypropyl)ethylenediamine in the form of a 98% aqueous solution.

[0037] Density is 1400kg / m 3 and the molar ratio of SiO2 to Na2O is in the range of 3.4.

[0038] The waterglass hardener is a mixture of pure glycerol diacetate / triacetate in a ratio of 7:3 parts by volume, with a concentration of 4.5% by weight relative to pure waterglass.

[0039] According to the manufacturing method of this heat insulating material, firstly, polystyrene beads are mixed with an aqueous solution of carbon black with a concentration of 25% by weight, and the entire surface is coated with carbon black, then aluminum hydroxide is added, and the whole is mixed to form a heat insulating mixture, then a water glass stabilizer is added to an aqueous solution of sodium silicate, then a water glass hardener is added to this solution, and the whole is mixed to form a binder solution, then the heat insulating mixture is added to the binder solution with constant stirring, and the whole is mixed, then the resulting mixture is poured onto the outer wall of a building equipped with a formwork having a silicone surface, and finally the resulting mixture is left to harden, and then the formwork is removed. [Industrial Applicability]

[0040] The insulating material according to the invention can in particular be used in the building industry to make permeable fire-resistant insulation systems.

Claims

1. A heat insulating material, particularly a permeable fireproof heat insulating material, comprising water glass and polystyrene, characterized in that the heat insulating material comprises a hardening mixture containing 1-32.4% by weight of expanded polystyrene, 57.5-96.0% by weight of an aqueous sodium silicate solution, 2-6% by weight of aluminum hydroxide, 0.8-2.6% by weight of a water glass hardener, and 0.1-0.5% by weight of a water glass stabilizer, and that carbon black, which constitutes 0.1-1% by weight of the total weight, is directly provided on the entire surface of the expanded polystyrene.

2. The heat insulating material according to claim 1, characterized in that the expanded polystyrene is in the form of spheres having a diameter of 3 to 6 mm.

3. 3. The thermal insulation material according to claim 1, wherein the water glass stabilizer is a hydrophilic alkoxyalkyl-ammonium salt.

4. The density of the sodium silicate aqueous solution is 1370 to 1400 kg / m ３ The heat insulating material according to any one of claims 1 to 3, characterized in that the range of

5. The sodium silicate aqueous solution is Na ２ SiO to O ２ The heat insulating material according to any one of claims 1 to 4, characterized in that the molar ratio of is in the range of 3.2 to 3.

4.

6. The method for producing the heat insulating material according to any one of claims 1 to 5, particularly the method for producing the permeable fireproof heat insulating material comprising water glass and polystyrene, is characterized in that firstly, polystyrene beads are mixed with an aqueous solution of carbon black to cover the whole surface thereof, then aluminum hydroxide is added and the whole is mixed to form a heat insulating mixture, then water glass stabilizer is added to said aqueous solution of sodium silicate, then water glass hardener is mixed into this solution, and this solution is stirred for another 1 to 10 minutes to form a binder solution, said heat insulating mixture is added to said binder solution under constant stirring, the whole is mixed, and then the resulting mixture is poured onto the application site.

7. 7. The method for producing an insulating material according to claim 6, characterized in that the mixture obtained is poured into an application site, which is a mould, and then from the mixture obtained, such an amount of binder solution is extruded by a pressing means so as to obtain a desired ratio of insulating mixture to binder solution.

8. A method for producing an insulating material according to claims 6 or 7, characterized in that finally the mixture obtained is left undisturbed to harden.