Extruded Polystyrene Insulation Panels Using Recycled Scrap
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Solution Overview
Problem
The high cost of raw materials for heat insulation slabs or panels made from extruded polystyrene limits their widespread adoption in construction due to the expensive first-quality polystyrene granules, necessitating a cost-effective solution that maintains high insulation efficiency.
Innovation Solution
A closed-cell expanded article and production plant using re-granulated polystyrene from industrial scrap, with a specialized extrusion unit capable of processing polystyrene with high Melt Flow Index (M.F.I.) values, allowing up to 100% reuse of scrap material, combined with additives for enhanced insulation and soundproofing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If first-quality polystyrene granules are used to manufacture heat insulation slabs or panels, then the insulation efficiency and quality are maintained high, but the raw material cost becomes very high
Solution Approach 1:
The invention changes the physical and chemical parameters of recycled polystyrene by controlling the extrusion process, temperature, and pressure to achieve proper melting and expansion of high M.F.I. material, transforming it into a usable insulating product with appropriate density and cell structure
Solution Approach 2:
The invention recovers and reuses polystyrene scrap material from industrial production processes, converting waste products back into valuable heat insulation panels, thereby reducing raw material costs while maintaining production continuity
2Quantity of substance
If re-granulated polystyrene with high M.F.I. values is used, then the material cost is reduced, but the viscosity becomes low causing problems with gas amalgamation
Solution Approach 1:
The invention modifies processing parameters including extrusion temperature, pressure, and residence time to compensate for the low viscosity of high M.F.I. material, enabling proper gas bubble formation and distribution during the expansion process
Solution Approach 2:
The invention uses the extrusion process as an intermediary mechanism to control and regulate the behavior of high M.F.I. polystyrene, managing its low viscosity characteristics through controlled melting and expansion to achieve proper gas amalgamation
3Quantity of substance
If re-granulated material from scrap is used, then the production cost is limited, but the material becomes unusable with current plants and working processes due to high M.F.I. values
Solution Approach 1:
The invention implements specific parameter changes in the extrusion process including temperature profiles, pressure conditions, and processing time to make current plants compatible with high M.F.I. recycled polystyrene material
Solution Approach 2:
The invention makes existing extrusion plants capable of processing both traditional low M.F.I. polystyrene and high M.F.I. recycled material, thereby universalizing the equipment's functionality without requiring complete plant replacement
Data Source
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AI summary
Method and device (114) for producing an article based on extruded polystyrene, in the form of a slab, panel or flexible sheet to make heat insulations by using re - granulated polystyrene from industrial working or production scrap, or from primary production plants.