High-strength, water-resistant heat and sound insulation board

Abstract

The invention relates to an insulation board (1) comprising waste plastic (14), waste sponge (13), industrial hemp (12) (Cannabis stavia L.), plastic (14) and air cavities (11) for use as heat and sound insulation to increase human comfort in living spaces such as residences, offices, schools and workplaces. The heat and sound insulation board in question is produced by mixing waste plastic (14) obtained from all types of usage, waste sponge (13) obtained from all types of usage, and industrial hemp (Cannabis stavia L.) tow and fibre combination and compressing the mixture at the melting temperature of the plastic, turning them into boards. The invention can be used as an insulation board to provide heat and sound insulation, minimising the damage to human health and the environment thanks to its organic origin. It is durable, has high strength thanks to the plastic in its content, eliminates the need for an additional structural element, and can also be applied as a structural separator in flooring and wall partitions.

Description

[0001] HIGH-STRENGTH, WATER-RESISTANT HEAT AND SOUND INSULATION BOARD

[0002] Technical Field

[0003] The invention relates to a high-strength, water-resistant heat and sound insulation board. The heat and sound insulation board in question is produced by mixing waste plastic, waste sponge, and industrial hemp (Cannabis stavia L.) tow and fibre combination and compressing the mixture at the melting temperature of the plastic, turning them into boards. The insulation board subject to the invention is suitable for use in living spaces such as homes, offices, schools, and workplaces. It is healthconscious, organic-based, and durable.

[0004] State of the Art

[0005] Insulation is the process of reducing energy flow from the existing environment to the outside as much as possible. The main types of insulation are heat, sound, and water insulation. Insulation materials are used to protect building components from all kinds of undesirable effects. Building elements can be endowed with properties such as heat, sound, and water insulation through these materials. Heat insulation boards are effective insulation materials that enhance the energy efficiency of buildings and protect interior spaces from external factors. Although the initial investment cost of thermal insulation materials is high, they help reduce the use of fossil fuels over the lifespan of the building and prevent issues such as frost and moisture damage that may occur in the building's structure. For an effective heat insulation application, in addition to good craftsmanship, the material's properties are crucial. Nowadays, in building heat insulation, foam materials such as expanded polystyrene rigid foam (EPS), extruded polystyrene foam (XPS), polyurethane foam, as well as fibrous materials such as mineral wool materials like stone wool and glass wool, and wood wool are commonly preferred in the construction of insulation blocks

[0001] . Sound insulation boards are materials produced to provide acoustic sound treatment and sound isolation. Sound insulation materials can be produced in various sizes and with different types of coatings, such as mats, boards, pipes, and casts, depending on their place and purpose of use. Insulation materials frequently used for sound insulation are acoustic fabric-covered panels, sponges with sound-cutting properties, and floor insulation materials. Stone wool is considered a good sound absorber. It also provides heat and sound insulation behind facade claddings as it has non-flammable properties [2],

[0006] In the current technique, commonly used thermal and sound insulation materials often do not contain any organic components. They pose risks to human health and harm the environment due to factors such as the suspension of particles in the air caused by dusting at the installation point and the inhalation of gases formed by oxidative combustion (oxidation) over time. Thus, the lack of organic origin in insulation materials makes it impossible to prevent the harm caused to human health and the environment by the particles released during installation.

[0007] In another known state of the art, modern insulation boards are manufactured from raw materials such as plastics, waste textiles and waste compressed foam containing a hollow structure for lightweight. However, the physical resistance of these insulation boards to compressive forces is quite low. Therefore, if they are used on floor and wall facades, they need to be supported with an additional structural element (screed plaster for the floor, plaster or a cladding board such as plasterboard for walls and ceilings). Hence, the problem of low strength, frequently encountered in insulation boards, and the need for an additional structural element to enhance their strength cannot be avoided.

[0008] In another known state of the art, Zukowski (2010) explains the heat insulation properties of modern bricks filled with perlite. Modern hollow bricks filled with perlite provide high thermal resistance and can be applied without the need for any additional insulation layer. However, during application, mortar can enter the cavities of the bricks, which negatively affects thermal insulation [3]. As a result, in modern hollow bricks filled with perlite, the risk of compromised thermal insulation due to mortar infiltration into the cavities cannot be prevented. The limitations and inadequacies of current solutions, such as the harm caused to human health and the environment due to the non-organic origin of commonly used thermal and sound insulation materials, the frequent issue of low strength in thermal and sound insulation boards requiring additional structural elements for reinforcement, and the risk of compromised thermal insulation in modern hollow bricks due to mortar infiltrating the cavities, have necessitated advancements in this field.

[0009] Brief Description and Objectives of the Invention

[0010] The invention relates to a high-strength, water-resistant heat and sound insulation board. The heat and sound insulation board in question is produced by mixing waste plastic, waste sponge, and industrial hemp (Cannabis stavia L.) tow (hemp hurd) and fibre combination and compressing the mixture at the melting temperature of the plastic, turning them into boards.

[0011] One objective of the invention is to develop a heat and sound insulation material that does not adversely affect human health due to particles arising during the installation of building materials and is not harmful to the environment compared to existing building materials. Due to the organic content of industrial hemp in the heat and sound insulation board produced in the invention, damage to human health and the environment is minimised.

[0012] Another objective of the invention is to prevent the need for an additional structural element due to the low physical resistance of building materials to compressive forces. The waste plastic used in the heat and sound insulation board produced in the invention not only serves as a binder but also enhances the structural strength properties of the board, thereby eliminating the need for an additional structural element during manufacturing.

[0013] A further objective of the invention is to develop a partition structural element for floors and wall divisions. In cases where the floor in residential buildings is to be covered with laminate flooring, the insulation board subject to the invention can be placed on the concrete slab, with the laminate flooring applied directly on top. The heat and sound insulation board subject to the invention can also be used by decorating its surfaces with various laminated coatings.

[0014] Another objective of the invention is to develop a heat and sound insulation board with long-lasting durability. The waste plastic component in the insulation board not only helps eliminate the short- and long-term adverse effects of free water and moisture on the product but also contributes to making the material long-lasting and resistant to environmental impacts.

[0015] Another objective of the invention is to develop a board material that can serve as an alternative to chipboard or medium-density fiberboard (MDF) in the furniture industry. The heat and sound insulation board subject to the invention can be used instead of chipboard or MDF due to its lightweight and high strength.

[0016] Another objective of the invention is to prevent the use of intense chemical adhesives in furniture boards. By using waste plastic as a binder and incorporating dense organic material in the heat and sound insulation board, it enables the avoidance of heavy chemical adhesives commonly used in furniture boards.

[0017] The goal is for this insulation board to be used in living spaces such as residential buildings, offices, schools, and workplaces to provide thermal and sound insulation. Thanks to its organic-based content, it minimises harm to human health and the environment. It is durable due to the waste plastic it contains and eliminates the need for an additional structural element. Furthermore, it can also be applied as a partition structural element in floors and wall divisions.

[0018] Description of the Figures

[0019] Figure 1. General perspective view of the insulation board subject to the invention Figure 2. A-A section view of the insulation board subject to the invention Definitions of the Elements / Parts of the Invention

[0020] I . Insulation board

[0021] I I . Air cavity

[0022] 12. Hemp (Cannabis stavia L.)

[0023] 13. Sponge

[0024] 14. Waste plastic

[0025] Detailed Description of the Invention

[0026] The invention relates to a high-strength, water-resistant heat and sound insulation board.

[0027] The heat and sound insulation board subject to the invention is an organic-based and long-lasting insulation board sensitive to human health and can be used in living spaces such as residences, offices, schools and workplaces (1 ). Figure 1 shows a general perspective view of the insulation board subject to the invention. Figure 2 shows the A-A cross-sectional view of the heat and sound insulation board subject to the invention. The heat and sound insulation board (1 ) subject to the invention comprises air cavities (1 1 ), hemp (12), sponge (13) and waste plastic (14). The invention provides heat and sound insulation through air cavities (11 ) of different sizes in the combination of tow and fibre hemp (12) and waste chopped sponge (13) contained in the heat and sound insulation board. Thanks to the organic origin content provided by the combination of industrial hemp (12) (Cannabis stavia L.) tow and fibre in the heat and sound insulation board, the damage to human health and the environment caused by the particles generated during the installation of building materials is minimised.

[0028] The waste plastic (14) in the heat and sound insulation board acts as a binder to hold this mixture together and as a carrier matrix in the structure with its physical strength. Thus, it does not require an additional structural element during manufacturing. In addition, the waste plastic additive contributes to eliminating the short / long-term adverse effects of free water and moisture and is a long-lasting material that can withstand environmental effects. The heat and sound insulation board subject to the invention is used as a partition structural element in floors and wall divisions. In cases where the floor will be covered with laminate flooring, the insulation board can be placed on the concrete slab, and laminate flooring can be applied directly on top. Additionally, its surface can be decorated by using various laminated coverings. Waste plastic (14), collected and separated according to its material origin, can be used in the mixture by grinding to a fine size in a mechanical grinder after being purified from pollutants that adversely affect the environment and human health. The mixture prepared in the production of the heat and sound insulation board can be transformed into heat and sound insulation boards with different production methods, layer combinations, and layer thicknesses ranging from 1 to 10 cm, depending on the insulation level required from the board subject to the invention. The heat and sound insulation board subject to the invention is produced by mixing waste plastic (14) obtained from various uses, waste sponge (13) from various uses, and the tow and fibre combination of industrial hemp (12) (Cannabis sativa L.), and then compressing the mixture at the melting temperature of the plastic to form the board. The use of the invention in the furniture industry enables the production of lighter and more durable furniture and contributes to economic solutions by making use of the convenience of being light in furniture used in mobile living spaces such as caravans.

[0029] Two approaches are proposed as the production method of the heat and sound insulation board subject to the invention.

[0030] In one implementation of the invention, the production method of the heat and sound insulation board comprises the following process steps: i. ionising the pulverised waste plastic (14) with a quantity of liquid, ii. homogenising the hemp (12) with a combination of tow and fibre by mixing in a kneading mixer, iii. adding waste sponge (13) to the mixture, iv. compression and cooling of the plastic (14) by pouring it into a mould.

[0031] In another implementation of the invention, the production method of the heat and sound insulation board comprises the following process steps: i. making a homogenised mixture of a combination of pulverised waste plastic (14) and hemp (12) tow and fibre in a heated extruder, ii. adding ground waste sponge (13) to the mixture, iii. placing the mixture into a mould while it is still hot and cooling it.

[0032] Different layer combinations can be designed using the production method of the board (1 ), subject to the invention. The first combination is a homogeneous mixture of all additives (a combination of tow and fibre hemp (12), sponge (13) and waste plastic (14)). The second combination involves placing a mixture of waste plastic (14) and tow and fibre hemp (12) on the top and bottom surfaces of the board (1 ), while the middle layer is composed of shredded waste sponge (13) in a thickness that can maintain the rigidity of the panel. Depending on the thickness of the produced board (1 ), the sponge (13) layer can be applied as multiple layers, and a thin impermeable plastic (14) board (1 ) can be manufactured from powder / shredded plastic (14) as a sound barrier inside the board (1 ) during the same processes. Boards of various layer thicknesses (1 ) can be manufactured in equivalent thicknesses to those used in practice and in shapes and designs deemed suitable for special productions.

[0033] Table 1 describes the components and weight ranges required for 1 m3 of board in the production of the heat and sound insulation board (1 ) subject to the invention.

[0034] Table 1. Components, ratio ranges and ratios required for 1 m3 board production. The heat and sound insulation board subject to the invention comprises waste sponge (13), industrial hemp (12) (Cannabis stavia L.) tow, plastic (14), air cavities (1 1 ) and pure water.

[0035] In one implementation of the invention, said heat and sound insulation board comprises 120-135 kg of hemp tow, 13-19 kg of hemp fibre (wool), 190-210 kg of pure water, 175-195 kg of waste plastic and 50-60 kg of waste sponge in a volume of 1 m3.

[0036] In one implementation of the invention, said heat and sound insulation board comprises 127.78 kg of hemp tow, 16.67 kg of hemp fibre (wool), 194.44 kg of pure water, 183.33 kg of waste plastic and 55.56 kg of waste sponge in a volume of 1 m3.

[0037] In one implementation of the invention, said heat and sound insulation board comprises 120-135 kg of hemp in a volume of 1 m3.

[0038] In one implementation of the invention, 13-19 kg of hemp fibre is used for the production of 1 m3 of board.

[0039] In one implementation of the invention, said heat and sound insulation board comprises 190-210 kg of pure water in a volume of 1 m3.

[0040] In one implementation of the invention, said heat and sound insulation board comprises 194,44 kg of pure water in a volume of 1 m3.

[0041] In one implementation of the invention, said heat and sound insulation board comprises 175-195 kg of waste plastic in a volume of 1 m3 10.

[0042] In one implementation of the invention, said heat and sound insulation board comprises 183.33 kg of waste plastic in a volume of 1 m3.

[0043] In one implementation of the invention, said heat and sound insulation board comprises 50-60 kg of waste sponge in a volume of 1 m3. In one implementation of the invention, said heat and sound insulation board comprises 55.56 kg of waste sponge in a volume of 1 m3.

[0044] REFERENCES

[0045] [1] izoder, (Isi, su ve Ses izolasyonculari Dernegi), T.C. Baymdirlik ve iskan Bakanligi Yapi Denetim Kuruluglan Yalitim Semineri, (2003).

[0046] [2] Kirbiyik E., “Ses ve Isi Yalitimli Ekolojik Yapi Malzemelerinin incelenmesi ve Trakya Bolgesinde Yetigtirilen Aygigegi Bitkisinin Yalitim Malzemesi Olarak Aragtinlmasi”, Yuksek Lisans Tezi, Trakya Universitesi Fen Bilimleri Enstitusu, (2012).

[0047] [3] Zukowski M., Haese G., "Experimental and numerical investigation of a hollow brick filled with perlite insulation", Energy Build, 42:1402-8, (2010).

Claims

CLAIMS1. It is an insulation board (1 ) production method to be used for heat and sound insulation in living spaces such as residences, offices, schools and workplaces, and its feature is that it includes the following process steps: i. toz hale getirilmi§ atik plastigin (14) bir miktar SIVI ile iyonize hale getirilmesi, ionising the pulverised waste plastic (14) with a quantity of liquid, ii. homogenising the hemp (12) with a combination of tow and fibre by mixing in a kneading mixer, iii. adding waste sponge (13) to the mixture, iv. compression and cooling of the plastic (14) by pouring it into a mould.

2. It is an insulation board (1 ) production method to be used for heat and sound insulation in living spaces such as residences, offices, schools and workplaces, and its feature is that it includes the following process steps: v. making a homogenised mixture of a combination of pulverised waste plastic (14) and hemp (12) tow and fibre in a heated extruder, vi. adding ground waste sponge (13) to the mixture, vii. placing the mixture into a mould while it is still hot and cooling it.

3. A method according to claims 1 or 2, characterised in that it uses 120-135 kg of hemp tow for the production of 1 m3 of board.

4. A method according to claims 1 or 2, characterised in that it uses 127.78 kg of hemp tow for the production of 1 m3 of board.

5. A method according to claims 1 or 2, characterised in that it uses 13-19 kg of hemp fibre (wool) for the production of 1 m3 of board.

6. A method according to claims 1 or 2, characterised in that it uses 16.67 kg of hemp fibre (wool) for the production of 1 m3 of board.

7. A method according to claims 1 or 2, characterised in that it uses 190-210 kg of pure water for the production of 1 m3 of board.

8. A method according to claims 1 or 2, characterised in that it uses 194.44 kg of pure water for the production of 1 m3 of board.

9. A method according to claims 1 or 2, characterised in that it uses 175-195 kg of waste plastic for the production of 1 m3 of board.

10. A method according to claims 1 or 2, characterised in that it uses 183.33 kg of waste plastic for the production of 1 m3 of board.

11. A method according to claims 1 or 2, characterised in that it uses 50-60 kg of waste sponge for the production of 1 m3 of board.

12. A method according to claims 1 or 2, characterised in that it uses 55.56 kg of waste sponge for the production of 1 m3 of board.

13. Heat and sound insulation boards produced by a method according to any one of the preceding claims.

14. A heat and sound insulation board according to claim 13, characterised in that it comprises waste plastic (14), waste sponge (13), industrial hemp (12) (Cannabis stavia L.) tow, plastic (14), air cavities (11 ) and pure water.

15. A heat and sound insulation board according to claim 13, characterised in that it uses 120-135 kg of hemp tow for the production of 1 m3 of board.

16. A heat and sound insulation board according to claim 13, characterised in that it uses 127.78 kg of hemp tow for the production of 1 m3 of board.

17. A heat and sound insulation board according to claim 13, characterised in that it uses 13-19 kg of hemp fibre (wool) for the production of 1 m3 of board.

18. A heat and sound insulation board according to claim 13, characterised in that it uses 16.67 kg of hemp fibre (wool) for the production of 1 m3 of board.

19. A heat and sound insulation board according to claim 13, characterised in that it uses 190-210 kg of pure water for the production of 1 m3 of board.

20. A heat and sound insulation board according to claim 13, characterised in that it uses 194.44 kg of pure water for the production of 1 m3 of board.

21. A heat and sound insulation board according to claim 13, characterised in that it uses 175-195 kg of waste plastic for the production of 1 m3 of board.

22. A heat and sound insulation board according to claim 13, characterised in that it uses 183.33 kg of waste plastic for the production of 1 m3 of board.

23. A heat and sound insulation board according to claim 13, characterised in that it uses 50-60 kg of waste sponge for the production of 1 m3 of board.

24. A heat and sound insulation board according to claim 13, characterised in that it uses 55.56 kg of waste sponge for the production of 1 m3 of board.

25. A heat and sound insulation board according to claim 13, characterised in that the industrial hemp (12) (Cannabis stavia L.) in its content is in the form of tow.

26. A heat and sound insulation board according to claim 13, characterised in that the industrial hemp (12) (Cannabis stavia L.) in its content is in the form of fibre.

27. A heat and sound insulation board according to claim 13, characterised in that it has different layer thicknesses of 1 -10 cm.

28. A heat and sound insulation board according to claim 13, characterised in that, depending on the thickness of the manufactured board (1 ), the sponge (13) layer comprises multiple layers.

29. A heat and sound insulation board (1 ) for use in living spaces such as residences, offices, schools and workplaces, characterised in that it contains waste plastic (14), waste sponge (13), industrial hemp (12) (Cannabis stavia L.) tow, plastic (14), air cavities (1 1 ) and pure water.

30. A heat and sound insulation board (1 ) for use in living spaces such as residences, offices, schools and workplaces, characterised in that it contains 120-135 kg hemp tow, 13-19 kg hemp fibre (wool), 190-210 kg pure water, 175- 195 kg waste plastic, and 50-60 kg waste sponge in 1 m3 volume.

31. A heat and sound insulation board (1 ) for use in living spaces such as residences, offices, schools and workplaces, characterised in that it contains 127.78 kg hemp tow, 16.67 kg hemp fibre (wool), 194.44 kg pure water, 183.33 kg waste plastic, and 55.56 kg waste sponge in 1 m3 volume.

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