Compositions: coating or plastic – Coating or plastic compositions – Inorganic settable ingredient containing
Patent
1997-09-19
1999-05-18
Marcantoni, Paul
Compositions: coating or plastic
Coating or plastic compositions
Inorganic settable ingredient containing
106724, 106727, 106745, 106808, C04B18/18
Patent
active
059047631
DESCRIPTION:
BRIEF SUMMARY
The present invention applies to an insulating mortar, which is employable for floor- and roof fillings with high insulating thermal and acoustic qualities.
The invention has its most important use in the building industry, it is suitable for the covering of concrete layers and as a filling material in different types of buildings.
A composition known from document WO-91 04 291 is supposed to provide the covering layer; it consists of a mixture of phenol resin and cement. An ester catalyst speeds up the reaction between the two components. The mixture can be employed as a filling material, as solid material and as a reinforcement piece.
Furthermore, an insulating material based on cement and vermiculite is known from document EP-A-0 219 579. This product has a heightened resistance to pressure and to forces of pressure. It can be utilized for the production of pre-manufactured panels.
Both documents concern an insulating material with high insulating qualities, thermal as well as acoustic, yet this material does not allow the recycling of waste products.
The present invention has made it its task to convert a waste product, which is found in high quantities, into a valuable product.
The insulating mortar according to the invention has considerably higher insulating values than the already existing mortars, typical values being:
On increasing the cement portion of the mixture, one can increase the resistance to pressure and change the insulating values.
Recycled polyurethane from various industrial branches serves as a basic component. Some examples for this would be car bumpers, insulating roof panels, refrigerators, freezers, boilers and other waste products containing solid polyurethane.
This solid polyurethane foam is ground up into a mixture of pieces and refined granulates with a grain size <8 mm and mixed up to achieve a constant volume, because the provided materials possess a different density in the area from 35 kg/m.sup.3 to more than 200 kg/m.sup.3.
After very diligent blending, additional substances such as cement, hydraulic lime and dye are added to achieve a dry mortar mixture, which hardens under the addition of water. This dry mixture is packed in paper or plastic bags. One only has to add water, which makes it also possible to produce the mixture at the place at which it will be used.
The mortar according to the application consists of at least 70%, preferably 80% ground up and thus recycled foamed solid polyurethane, the rest is cement; if needed, aggregates, especially a dye, is added. The amount of cement is chosen in such a way that at least a satisfying or even a strengthened setting can be reached. Thus the addition of cement cannot fall below a certain value, which is largely defined by the surface area of the ground up polyurethane. A preferred percentage is 94%; however, 90% to 94% vol percentage is acceptable.
The size of the polyurethane pieces is not very important, yet it has been shown that pieces sized less than 20 mm, preferably even less than 8 mm, can be handled easily. During the grinding, dust emerges. This dust portion fills the otherwise empty space between particles and increases the total surface area. Thus, if there is a large portion of dust, more cement needs to be added.
It has been shown to be of great advantage to add an antifoaming agent to the basic mixture. For this purpose, light acids or acidic salts are used; they have the task of destroying the bubbles which appear during the mixing. An addition of below 3%, preferably below 1% of the weight of the whole mixture is usually sufficient.
It has also shown to be of advantage to utilize an interlacing or surface-active agent; for this task, one usually utilizes phosphates. An addition of less than 1% has shown itself to be adequate.
It is also of advantage to add a liquefier such as melamine resin, naphthalene, sulfite liquor (e.g. dried sulfite liquor). The amount of added liquefier can also remain below 1% of the weight of the whole mixture.
Finally, retarders and accelerators for the setting of the cem
REFERENCES:
patent: 4229225 (1980-10-01), Kraszewski et al.
patent: 4407676 (1983-10-01), Restrepo
patent: 5387282 (1995-02-01), Jakel
patent: 5641815 (1997-06-01), Fehlmann
"Utilization of Polyurethane Foame Wastes" Dreval et al. Kholod. Tekh. (1991), (7), 31.
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