WO2007146919A2 - Matériaux granulés légers - Google Patents

Matériaux granulés légers Download PDF

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Publication number
WO2007146919A2
WO2007146919A2 PCT/US2007/070968 US2007070968W WO2007146919A2 WO 2007146919 A2 WO2007146919 A2 WO 2007146919A2 US 2007070968 W US2007070968 W US 2007070968W WO 2007146919 A2 WO2007146919 A2 WO 2007146919A2
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WO
WIPO (PCT)
Prior art keywords
pellets
expanded
coating
polymer
mineral
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2007/070968
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English (en)
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WO2007146919A3 (fr
Inventor
Norman G. Schabel, Jr.
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Schabel Polymer Technology LLC
Original Assignee
Schabel Polymer Technology LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Schabel Polymer Technology LLC filed Critical Schabel Polymer Technology LLC
Priority to CA002655312A priority Critical patent/CA2655312A1/fr
Publication of WO2007146919A2 publication Critical patent/WO2007146919A2/fr
Publication of WO2007146919A3 publication Critical patent/WO2007146919A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7604—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only fillings for cavity walls
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22—After-treatment of expandable particles; Forming foamed products
    • C08J9/224—Surface treatment
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/746—Recycled materials, e.g. made of used tires, bumpers or newspapers

Definitions

  • the present invention relates to an engineered lightweight peiletized or beaded material
  • insulation materials have been proposed for abating sound and thermal transmission from a source thereof to some protected area or enclosure.
  • insulation materials can be used to abate sound or thermal transmission through the walls and ceilings of houses, buildings and the like; from appliances, such as washing machines, refrigerators, and dishwashers; from the exterior of vehicles, such as automobiles, airplanes, trains, and ships; from machinery, such as presses, compressors, blowers, and IiVAC systems; and from tanks, storage vessels, pipes and duct work.
  • loose- Il 11 insulation in an unconstrained space such as an attic
  • loose-fill insulation curre ⁇ tl> used in the industry does not prevent the conduction of heat as well as blanket insulation
  • the higher conductivity of loose-Oil it is applied in greater depth than blanket insulation to achieve an equivalent R- value.
  • the compressed loose-fill is added to the hopper of a blower where the loose-Oil is mechanical K recovered and broken into smaller portions. After being blown into position, numerous small gaps or voids remain between the blown portions of insulation. These voids raise the thermal conductivity of the insulation requiring more glass to be employed to achieve a specified insulating value, or result in a shortfall in insulating -value.
  • the blown insulation includes relatively ineffective insulating flakes or wads of the insulation incorporated into the blown insulation. These flakes or wads add significantly to the densit ⁇ of the insulation, in essence increasing the amount of glass used relative to its insulating value.
  • the present invention relates to an engineered materia! that comprises a plurality of pellets.
  • Hie pellets can include at least one of a polymer, mineral synthetic, or biomass based material.
  • the pellets can have a substantially homogenous structure, a specific gravity of at least about 0,01 g/cm' lo about OJ g/era* and be substantially free-flowing, substantial!) dust-free, dtmensionaJly stable, substantial!)- non-hygroscopic, and resistant to settling and compression -3-
  • the pellets ears comprise an expanded material.
  • the expanded materia! can include at least one of expanded polymers, expanded glasses, expanded mineral materials, or expanded biomass material.
  • the material can have an R-vaiue of about 2,0 to about 4.0 and be either untreated or be substantially encapsulated with a coating, ⁇ he coating can be substantially free of voids and comprise less than about 20% by volume of the pellets.
  • the coaling can be selected from the group consisting of a coupling agent, a urethanc, an epoxy, an acrylic, a silicone, a latex, an alkyd, an ole ⁇ resinous vehicle, a water reducible resin, and blends thereof.
  • the pellets can also include at least one of a hiocjde, fungicide, insecticide, r ⁇ dcnticide, mildewcide, bactericide, colorant, flame retardant, smoke suppressant, radiation absorber or anti-blocking agent.
  • the pellets can comprise at least one of expanded polyethylene, expanded polypropylene, copolymers thereof or biends thereof as well as expanded glass beads, expanded mineral based materials, such as expanded c ⁇ ay, expanded bcntonhe, expanded montmoriHonite, expanded calcium carbonate, or expanded calcium sulfate.
  • pellets when used as an insulation material can have a bulk density of about 1 to about 18 pounds per cubic foot.
  • the pellets when used as a bulk insulation can be free-flowing and have an average ⁇ /e of about 1 mm to about 25 mm.
  • the pellets can be provided in a coating composition or fluid carrier S) stem.
  • the coating composition or fluid carrier system can be capable of adhering to the surface of a structural assembly or merely act as a method of installation.
  • the pellets cars also be provided in at least one of a mastic, paste, adhesive, spackle, or stucco.
  • the pellets can further be adhered in a paste form or in an adhesive mass to a flexible sheet that is capable of being wrapped about or adhered to a structural assembly, or provided in a bag or pouch that can be installed in a cavity of a structural assembly.
  • the pellets can be used as a filler, extender, or spacer material in formulating and compounding applications.
  • the pellets can ha ⁇ e an average diameter of about 0.1 -4-
  • the pellets can have an average diameter of about 12 mm to about 25 rom.
  • Fig. I illustrates a schematic cross-sectional view of a pelletized material in accordance with an aspect of the invention.
  • Fig, 2 illustrates the pelletized material provided between the walls of a construction assembly
  • [llfJlSJ Fig. 3 illustrates the pelletized material provided in a compounded tape or roll composition in accordance with an aspect of the invention.
  • Fig. 4 illustrates the compounded tape of Fig. 3 with a plurality of spacers.
  • the present invention relates to an engineered pelletized material that can be used in insulation applications as well as industrial formulating and compounding applications.
  • pelletized ⁇ t is meant that the engineered materia! is in the form of distinct pellets, such as particles, granules, chips, nodules, or prills and is not m the form of fibers, filaments, whiskers or other high aspect ratio forms where, for example, the length to diameter is greater than about 20.
  • the pelletized materia! is in the form of distinct pellets, such as particles, granules, chips, nodules, or prills and is not m the form of fibers, filaments, whiskers or other high aspect ratio forms where, for example, the length to diameter is greater than about 20.
  • the pelietized material in accordance with the present invention -5-
  • the peiletized material can be used in both new and retrofit applications.
  • the peiletized material can also be used as a filler or extender in industrial formulating and compounding applications.
  • the pelletized material in accordance with the present invention comprises a substantially homogenous peiletized polymer based material mineral based material, synthetic based material, and/or biomass based material that is free- flowing, dimensionaliy stable, substantially dust-free, substantially resistant to settling and compression once installed for insulation applications, and substantially non-hygroscopic.
  • Iy resistant to settling and compression it is meant that the peiletized material once applied retains its shape and/or integrity as well as exhibits an increase of bulk density over time of less than about 10%, for example less than about 5%.
  • substantially non- hygroscopic it is meant that the peiletized material is resistant to moisture absorption from its surroundings during handling, storage, or after application.
  • the pelletized material has a specific gravity of about 0.01 g/cm 3 to about 03 g/cm ⁇
  • the specific gravity of the pelletized materia! can be varied from about 0.01 g.'cm 3 to about 0.15 g/cm i .
  • the specific gravity as well as the composition of the peiletized material can be tailored to provide a peiletized material that is capable of damping, attenuating, and/or isolating various energies, such as vibrational energy, acoustic energy, thermal energy, electromagnetic energy, or radio waves.
  • the pelietized material in accordance with the present invention can have a thermal resistance value (i.e., R -value) of at least about 2.0 per inch (e.g., about 2 to about 4 ⁇ and a sound attenuation factor (i.e.,, STC factor) of at least about 30.
  • the peiletized material in accordance with the present invention can also be clean handling and have a minimal toxicity', high heat resistance, low rate of moisture absorption, and high dimensional stability.
  • the peiletized material can comprise expanded, foamed, and/or multicellular polymer pellets (e.g., expanded polymer spheres or pellets) that have an average pellet size of about 0.1 mm to about 25 mm.
  • the expanded polymer pellets cart include thermoplastic or thermoset synthetic polymers that when expanded, blown, or gasified have a specific gravity of about 0.01 g/cnr' to about 0.3 g/crn".
  • thermoplastic and thermoset polymers cars include nylon, PVC. PVDC, poiv ethylene, polystyrene, polypropylene, poljphenylene oxide (PPO), ethylene propylenc-dicne monomer (EPDM), polyacrylonitrile (PAN), f ⁇ uorocarbons. pol ⁇ urethanes, acrylic resins, aery late, silicone based resins, polymer alloys thereof, copolymers thereof, and blends thereof.
  • the expanded thermoplastic or thermoset polymer can be an e!a.st ⁇ mer.
  • thermoplastic po ⁇ vmer can also be modified b> cross-linking or vulcanization to form a rubber.
  • thermoplastic or thermuset polvmer can be expanded by combining the polymer with a bi ⁇ wing agent to foam the pol>mer and produce expanded or foamed pellets eomprsing a plurality of closed cells.
  • An example of one type of blowing agent that can be used in accordance with the present invention is a chemical foaming agent
  • a chemical foaming agent is a foaming agent that upon exposure to an elevated temperature undergoes a chemical reaction and produces, a gas.
  • the chemical foaming agent can be an endothermlc chemical foaming agent, an exothermic chemical foaming agent, or a mixtuie of an cndothcrraic chemical foaming agent and an exothermic chemical foaming agent.
  • Tt is meant a chemical foaming agent that reacts endothermicaUv to produce a gas.
  • exothermic chemical foaming agent it Ls meant a chemical foaming agent that reacts e ⁇ oth ⁇ rmicaiiv to produce a gas.
  • thermoplastic ⁇ r thermoset polymer can also be expanded using other blowing agents, such as compressed gases, which expand during formation of the pelletized material, and liquids, such aj> water, carbon dioxide, butane, pentane, hexane, and nitrogen, that develop closed cells in the pelleti/ed material when they change to gases.
  • blowing agents such as compressed gases, which expand during formation of the pelletized material
  • liquids such as water, carbon dioxide, butane, pentane, hexane, and nitrogen, that develop closed cells in the pelleti/ed material when they change to gases.
  • polymer blends, alloys and copolymers can be advantageous! ⁇ formulated to utilize the diff ⁇ enees in polymer structure. compatibility and rrselt properties to form a skin on the surface of the pellets or beads n ⁇ the heat processing stages. This skin can provide improved surface and performance properties to toe pellet ami reduce or eliminate the need for a subsequent coating layer, as described above.
  • a pellet of expanded polystyrene can be modified with about 0,5% to about 10% poJyolef ⁇ n (e.g., polypropylene), such as about l% to about 3% polyolelm. which will migrate or "bloom" to the surface during an extrusion or heat expansion process. This polyolefln modification enhances surface characteristics, increases chemical and heat resistance and mitigates static charge, a common problem with expanded polystyrene,
  • poJyolef ⁇ n e.g., polypropylene
  • the peiietfeed material can comprise expanded mineral or ceramic pellets (e.g., expanded clay pellets or expanded glass spheres) that have an average pellet size of about 0.1 to about 25 mm.
  • expanded miners e.g., expanded clay pellets or expanded glass spheres
  • the expanded mineral or ceramic pellets can include any mineral material or ceramic material that when expanded, blown, or gasified has a specific gravity of about 0.0 f g/cm 3 to about 0.3 g/crr ⁇
  • Examples of mineral materials or ceramic materials can include clay, periite, vermicuHte, hent ⁇ rtite, montmorillonite, alum mum silicates, slate, kaolin, diatom ite, keratin, mica, calcium carbonate, calcium sulfate, silica, silicate, calcium carbonate, calcium sulfate, and combinations thereof.
  • the expanded mineral or ceramic pellets can comprise expanded clay materials.
  • the expanded clay materials can be made, for example, by feeding clay agglomerates into a rotary kiln.
  • the clay agglomerates can be fired (e.g., sintered or calcined) and expanded at a temperature increasing up to about 900 0 C in the firing zone.
  • the expanded clay materials are ceramic products, which upon removal from the kiln, are approximately ball-shaped and normally have a diameter within the range of about 0.1 to about 25 mm.
  • the expanded clay materials have an internal structure with a large number of air bubbles in a matrix of fired clay.
  • the outer surface is relatively dense and forms a barrier against free flow of fluids from the s ⁇ rroundings into the expanded ball.
  • the expanded mineral based or ceramic pellets can comprise expanded or foamed glass or glass-like material.
  • the glass or glass-Hke materia! can be s virgin, reclaimed, or recycled materia!.
  • the expanded glass and/or giass-like pellets can be produced, for example, from glass and/or glass-like material and an activator.
  • the activator which brings about the formation of pores in the glass and/or glass-Hke material in the course of expansion in the expanding furnace or in an expanding pipe, can be composed of silicon, silica, silicate, silicon carbide and carbon as well as borax or at ieast one oieta! oxide.
  • the expanded glass and/or glass- ⁇ ike pellets can also be produced from a liquid slag or liquid glass that can be foamed directly by mixing a gas-form i ⁇ ig foaming agent into the liquid melt. The foaming agent releases gas immediately after contact with the hot slag and causes the latter to foam.
  • the palletized material can comprise a biomass base material, such an agricultural or textile waste material and/or by -prod act.
  • the biomass material can include, for example, any kind of waste or by-product from hemlceHulose-containing lignocell ⁇ losic materials. These materials can include waste or by-products from whole or coarse ground grains and pulse crops, such as durum wheal, bard red spring wheat, corn, barley, rice, sunflower and beans.
  • Such by-products or waste can include com fiber, oat hulls, rice hulls, wheat middling, cotton-mil!
  • hull generally denotes the outer covering, rind, shell, pod or husk of any fruit or seed, but the term as employed herein also embraces, for example, the outer covering of an ear of maize.
  • Hulls of cereals including those mentioned among the above hulls, and others are generally of interest in the context of the invention, ⁇ n this connection it may be mentioned by way of example that oat hulls are often available in large quantities at low cost as a byproduct of oat-processing procedures for the production of oatmeal, porridge oats, rolled oats and the like.
  • Otber types of hulls of relevance in relation to processes of the invention include, for example, rice hulls, palm shells, peanut shells, coconut shells, other types of nut shells, and coconut husk. -9-
  • lig ⁇ oeeilulosic materials may necessitate, or at least make it desirable, to carry out comminution of the material (e.g., by milling, abrading, grinding, crushing, chopping, chipping or the Hke) to some extent in order to obtain pellets, pieces, strands, wafers, flakes or the like of material of sufficiently small size and/or sufficiently high surface area to mass ratio.
  • comminution of the material e.g., by milling, abrading, grinding, crushing, chopping, chipping or the Hke
  • numerous types of hulls e.g.
  • cereal grain or seed hulls in general including oat hulls and rice hulls as employed in the working examples reported herein, have in their native form sufficiently small dimensions and a sufficiently high surface area to mass ratio to enable them to be used directly, without prior comminution, as iignoce ⁇ iulosic materials in a process according to the present invention.
  • the biomass base material can be sifted or separated to a particular size and include a coating and additives to prevent mold, kill bugs and generally treat and encapsulate the base material.
  • the pelletized material can comprise crumb rubber, rubber based, or polymer based material
  • the crumb rubber used in the pelletized material of the invention can include rubber pellets that have as average particulate size of about 0.1 mm to about 25 mm.
  • the crumb rubber pellets can include a natural, thermoplastic or synthetic rubber or mixtures of the rubbers. In most cases, the rubber can be comprised of repeat units, which are derived from one or more conjugated diolefin monomers, such as 1,3-butadiene or isoprene.
  • Examples of synthetic rubbers are poly sal fides, polychioroprene, butadiene-sty re ⁇ e copolymers (SBR), polyisoprene, butyl rubber (isobutylene- isoprene copolymers), pelyacrylonitrite, polyurethane, silicone and nitrite (acrylonitrile-butadiene copolymers) poiybutadiene polymers, styrene-isoprene, isoprene-butadiene rubber, styrene-isop ⁇ .ne-butadiene (SIBR), nitrite rubber (NBR) or carboxylated nitriie polymers (XNBR).
  • SIBR styrene-isoprene
  • SIBR styrene-isop ⁇ .ne-butadiene
  • NBR nitrite rubber
  • XNBR carboxylated nitriie polymers
  • Thermoplastic rubbers include block copolymers of styrene-butadiene or styrene isoprene.
  • (IO38] The rubber may be obtained from recycled or reclaimed scrap rubber material. Included among the types of scrap rubber materials contemplated for use in the present invention are those derived from natural rubber, ethylene propylene diene polymer (EPDM), EPM copolymer, styrene butadiene rubber, poiybutadiene -10-
  • Examples of types of post industrial scrap rubber sources include, (1) rubber scraps and rejected rubber parts generated from tire manufacturing processes, such scraps constituting mostly styrene butadiene rubber, potybutadiene rubber and natural rubber, (2) rubber scraps generated from automobile parts molding processes, such as molding Slashes and rejected rubber parts, such scraps constituting EPDM rubber, (3) rubber scraps generated from extrusion processes m the manufacture of automobile windshields and window seals, such as start up rejects, blemished portions and rejected lengths, such scraps constituting EPDM rubber, (4) robber scraps generated from calendaring processes in the manufacture of EPDM rooting membranes, such as torn sections, blemished and short run rejects, and (5) rubber scraps generated in the manufacturing processes of natural rubber latex gloves.
  • vehicle recovery programs such as Ford Motor Company's Vehicle Recycling Program
  • the crumb rubber can be produced from the scrap rubber by grinding or shredding the scrap rubber and removing fibrous arsd steel material from the ground rubber. The recovery and use of such crumb rubber pellets are more fully described in U.S. Patent No. 5,81 1.477, the description of which is incorporated herein by reference. It will be appreciated that the crumb rubber need not be from scrap rubber sources and any portion or all of the rubber may be prime grade material,
  • thermoplastic or therraoset polymers can include nylon, PVC, polyethylene, polystyrene, polypropylene, fluorocarbons, polyurethanes, acrylic resins (aerylates), and blends thereof.
  • Preferred thermoplastic polymers Include polyethylene, polypropylene, and blends thereof.
  • thermosetting polymers can include cross-linked polyethylene, phersolks, epoxies. polyurethanes. and polyester resins.
  • thermoplastic and thermosetting polymers can be obtained from scrap polymers, plasties, and/or elastomers as well as wide specification, virgin, or prime resin.
  • Hie scrap thermoplastic and/or thermosetting synthetic polymer can he regr ⁇ und or recycled to provide the pellets.
  • scrap plastic resin components contemplated for use in the present invention are polypropylene copolymers (PP), polyethylene, low density polyethylene (LDPE) and high density polyethylene (HDPE), TPE as well as recycled plastic resins of these materials, such as polypropylene, polyethylene, and polyethylene terephthalate, derived from recycling processes in the recovery of used battery cases, beverage bottles and plastic shopping bags.
  • scrap polymers, plastics, elastomers, and/or resins disclosed herein are meant to be illustrative only and that scrap polymers, plastics, elastomers, and/or resins derived from other sources may be used in the Instant invention.
  • the pel letted material can include combinations, blends, or mixtures of the expanded polymer, expanded mineral, expanded ceramic, biomass, crumb rubber or polymeric materials. The particular combination, blend, or mixture will depend on such factors as the specific application or use of the pdlefeed material, as well as the commercial availability.
  • ft will also be appreciated that the p ⁇ iletized material can be provided in a polydiverse pellet ⁇ ze distribution. By this It Ss meant that the peiletized material can comprise a blend of pellets with different sizes and that these pellet sizes (or diameters) can range from about 0.1 mm to about 25 mm. Additionally, the pellets can comprise different shapes, including rounded, spherical, cylindrical, Irregular ⁇ e.g., multi-faceted shapes) and regular shapes. -12-
  • each of the pellets of expanded polymer, expanded mineral, expanded ceramic, biomass, crumb rubber or polymeric materials used to form the pelieiized material can be untreated or can be provided with a void-free surface coating that encapsulates individual pellets.
  • void-free it is meant the coating encapsulating each pellet is substantially free of voids, cavities, and does not have an expanded or cellular structure.
  • Fig. I is a schematic cross-sectional view of an example of a pellet 10 provided with a surface coating 12.
  • the surface coating 12 can have a thickness less than about 0.10 mm.
  • the surface coating 12 has a thickness less than about 100 microns (e.g., about 50 microns),
  • the surface coating 12 in accordance with the present invention can comprise any coupling agent and/or polymeric material
  • the surface coating can enhance humidity resistance and/or minimise hygroscopic characteristics.
  • Expanded polymer, expanded mineral agglomerates, expanded ceramic, biornass, crumb rubber or polymeric materia! s can potentially include compounds, such as volatile organic compounds (e.g., organic plas ⁇ cizers and organic solvents) or residual chemicals that can be released (e.g., emitted and/or evaporated) from the materia!.
  • crumb rubber typically includes about 1 % to about 2% volatile organic compounds, which can evaporate from the rubber over time.
  • the released compound can be in the form of liquid or gas, which can be malodorous as well as potentially toxic when accumulated (e.g., ingested or inhaled) in a high enough percentage.
  • the coating of the present invention can substantially mitigate the release of such gas or liquid to allow the pelietized material to be substantially non-toxic and odorless.
  • Coupling agents that can be used as a surface coating 12 in accordance with invention include si lanes, such as organic stlanes (e.g., R n Si(OR) ⁇ n with "R" being an alkyi, aryl.
  • SILQUEST such as A-174, A-189 and A-I 100, which are commercially -13-
  • the coating agent include a urethane, an epoxy, an acrjUc. a silicone, a latex, a siloxane, an aikyd, oleor ⁇ smous vehicles, water based resin, and blends thereof.
  • the coating agent include a urethane, an epoxy, an acrjUc. a silicone, a latex, a siloxane, an aikyd, oleor ⁇ smous vehicles, water based resin, and blends thereof.
  • the pelici ⁇ zed material in accordance with the present invention can further include one or more agents that can act as a flame retaidant. smoke suppressant, biocide, fungicide. Insecticide, mildew cide, bactericide, rodentieide, colorant, tadiation absorber (eg , actinic or LV), or anti-blocking agent.
  • a number of various insecticides or mildewcides can be used Including organic based compounds, such as borax, boric acid, barium metaborale. or other orga ⁇ o-chemicai compounds
  • Organic based insecticides that can be used include, for example, ⁇ o&e sold under the names Dia/inon and Maiathion.
  • fiarn ⁇ retarda ⁇ tv examples include alumina hydrate, antimony oxide, bromines, and/ or bora ⁇ hydrate, which on combustion release water or other compounds to extinguish flames.
  • the colorant can be added to facilitate identification of particular blends
  • fhese agents can be compounded with the pellets of expanded polymer, expanded mineral expanded ceramic, bbmass, crumb rubber or polymeric materials or w Hb the surface coating material.
  • the peileti/ed material can include at least one filler.
  • the filler can comprise any relatively inert substance that can be used to modify (e g increase or decrease) the density of the pelietked material so that the peiletized mateuai has a specific gra ⁇ it> of about 0.01 g/cm* to about 0.3 g'cm ⁇ -14-
  • the filler will generally be in the form of small panicles (e.g., less than about 0.5 mm), although it will be appreciated that larger particles ⁇ e.g., greater that about 0.5 mm) can also be used.
  • the filler in addition to modifying the density of the p ⁇ liet ⁇ zed material can also be used to provide or modify other properties of the pelletized material.
  • the filler can be used to modify the thermal and/or acoustic insulation properties.
  • the filler cart act as a flame retardarst, smoke suppressant, biocide, insecticide, rodenticide, pigment, free-flow additive, and/or surface texture modifier.
  • fillers that can be used in accordance with the present invention can include clay, talc, dolomite, calcium carbonate, calcium sulfate, fly ash, perlite, vermiculite. aluminum hydrate, antimony oxide, barium sulfate, carbon black, kaolin, diatom ite, keratin, mica, and molybdenum disulfide, glass beads, silica, silicate, aluminum silicates, ground rubber, ground thermoplastic or thermoset plastic material as well as any of the previously described biomass materials. It will be appreciated that the fillers used in accordance with the present invention need not be limited to (he foregoing fillers and that other fillers can also be used.
  • the filler can be compounded with the pellets of expanded polymer, expanded mineral, expanded ceramic, bioraass, crumb rubber or polymeric materials or mixed with the surface coating.
  • a free-flow additive and/or a carrier fluid can be added to the surface of the pelletized materia! to facilitate transport and free-flow of the pelletized material.
  • the free-flow additive can include a powdered material such as talc, that can be applied to the surface coating material
  • the carrier fluid can include an oil, such as silicone oil or mineral oil, or other inert fluid that can be readily mixed with the pelletized material.
  • the pelletized insulation materia! can be used alone as a free flowing dry pelletized insulation material.
  • the pelletized insulation materia! can have an average pellet size of about 1.0 mm to about 25 ram. This average pellet size allows the free-flow pelletized materia) to be readily provided in cavities of construction assemblies, such as crawl spaces, walls, and between ceiling joists or floor joists, by conventional pumping or blowing methods. It will also be -15-
  • the free-flowing pelletized insulation materia! can be provided with a poiydiverse peHet ske distribution and different shapes to tailor the packing density and void density of the insulation material. Adjusting material composition, density, and size allows both the thermal and acoustic insulation properties of the peHetized insulation to be readily adjusted for specific applications.
  • Apparatuses for pumping or blowing pelletized insulation material in cavities of construction or structural assemblies are well known, e.g., Unisul YOLUMAT ⁇ C Commercial Blowing Machine. These apparatuses can typically include a feed pipe that is connected to a blower or pump. The blower or pump cart provide an air stream or create pressure, which will move the peJtetteeti insulation material through the feed pipe to the cavity.
  • the pelletized insulation material can be brought to the point of installation of a construction assembly, such as a wall or ceiling cavity, in the form of a continuous roving or strand that can be wrapped or wound about a spool.
  • a construction assembly such as a wall or ceiling cavity
  • the continuous roving or strand can be unwound and continuously passed through a cutting device or "chopper gun".
  • the cutting device cuts or chops the roving or strand into a free-flowing dry pelletized material (e,g, average pellet size of about 1,0 mm to about 25 mm) that can he installed in the wall or ceiling cavity.
  • a free-flowing dry pelletized material e,g, average pellet size of about 1,0 mm to about 25 mm
  • FIG. 2 is a schematic illustration that shows the free flowing pelietized insulation material 20 provided between walls 22 of a construction assembly 24.
  • the free-flowing pelletized insulation materia! 20 can be arranged between the walls 22 such that Individual pellets 26 contact each other and form an insulation with a plurality of dead air-cells 30 substantially uniformly distributed between the pellets 26. These dead air-cells 30, along with the specific density and visco-elastic properties of the polymer, provide both thermal and acoustic isolation and damping effects.
  • the free-flowing peilettzed insulation material 20 provided -16-
  • the pelietized materia! can be mixed with a vehicle system or resin system to provide a coating composition that can be coated on to the surface of an assembly, such an a ceiling, partition, or wall, the interior surface of a vehicle, motor housing or appliance, or the exterior surface of a storage vessel, tank, pipe or duet.
  • the peltetteed material when used in a coating composition, preferably has an average pellet size of about 1 mm to about 12 mm and comprises about 20% to about 80% b> weight of the coating composition. It will be appreciated that the average pellet sue and weight percentage of the pellet szed material in the coating composition cart be greater or lower depending on the formulation and the specific use.
  • the resin system used in the coating composition can include polymers, such as resins, latexes, urethaRes, silicones, epoxies, and acrylics, a ⁇ kyd, oleoresino ⁇ s vehicles, as well as water reducible resins and other well-known polymers that are used in coaling compositions.
  • the polymers should preferably be in the form of a liquid in an uncured state and readily solidify once cured. Curing of the polymers can be performed by, for example, drying or chemical reaction.
  • the coating composition should have a viscosity that allows the coating composition to be readily applied to surfaces by established techniques of spray coating, dip coating, extrusion coating, flow coating, spread coating, brash coating, pouring, or gravity flow methods.
  • the viscosity of the coating composition can b ⁇ modified (e.g.. lowered) by Including one or more diluents (e.g., water or gi)co! and/or other liquids.
  • the diluent and/or other liquid should readily dilute the resi ⁇ i system but not dilute or solvate the peiletked material.
  • the coating composition can include other compounds, such as fillers and other ingredients described above, which can be added to the -17-
  • trie pellet ⁇ zed material can be mixed with s viscous resin or polymer to provide an adhesive, mastic, or paste that can be installed in a cavit) or on the surface of an assembly or structure.
  • the pelletized material when used in a mastic or paste composition, preferably has an average pellet size of about 1.0 mm to about 25.0 mm and comprises about 20% to about 95% by weight of the mastic or paste composition.
  • the average pellet size and weight percentage of the pellet ⁇ zed material in the adhesive, mastic, or paste composition can be greater or lower depending on the formulation and the specific use. It will also be appreciated that a pigment or colorant can be included in the adhesive, mastic, or paste composition to read!!) distinguish different formulations, end use applications, or different adr-eshe, mastic, or paste compositions,
  • the viscous rcs ⁇ n or polymer used to form the mastic or paste can include anv resin pol> mer than can act as a bonding agent to hold the pellets together and/or bind the mastic or paste to the surface or substrate.
  • polymers or resins that can be used include polyesters, pol ⁇ amides, pclyurethanes, epoxies. silicones, latexes. aSkyds ⁇ oil resinous vehicles, water reducible resins, pol> butadiene SBR polymers, ethylene vinyl acetate (HVA) or EVA copolymers, and acrylics 'acrylates. as well as other well-known polymers that are used in mastic or paste compositions.
  • HVA ethylene vinyl acetate
  • the polymers should preferably be a ⁇ isc ⁇ us liquid in an uncured state aad readilj solidified once cured. Curing of the resin or polymers can be performed, b> for example dr> ing or chemical reaction, [0063J
  • the mastic or paste should have a viscosity such that the mastic or paste can be applied to surfaces or cavities by, for example, troweling, brushing, pouring, spraying, pumping or gravity flow techniques. Depending on the particular formulation, the viscosity of the coating composition can be modified (e.g . lowered or increased) by including a viscosity modifier or by adjusting the formulation of the resin system. -18-
  • the mastic, adhesive, or paste composition can include other ingredients, such as fillers, colorants, and agents described above, which can be added to the pelletized material. It will be appreciated that other fillers, colorants, or agents besides the fillers., colorants, and agents described above can be used in accordance with the present invention.
  • the pelletlzed materia! can be provided in compounded tape or roll form, fig, 3 is a sectional view diagrammatical Iy illustrating one embodiment of the compounded tape 50.
  • the compounded tape 50 includes a first substrate film 52, a second substrate film 34 extending substantially parallel to the first film 52 and a plurality of pellets 56 of the material in accordance with the present invention adhered between the first substrate film 52 and the second substrate film 54,
  • the material used to form the first substrate film 52 and the second substrate film 54 is not subject to any particular limitation as long as it can support the peiletized material.
  • Materials that can be used to form the first substrate tilm 52 and the second substrate film 54 include, for example, plastic films, such as polypropylene films, ethylene/propylene copolymer films, polyester films or polyvinyl chloride) films; papers such as Japanese paper or kraft paper; fabrics such as cotton fabrics or staple-fiber fabrics; nonwove ⁇ fabrics, such as polyester jionwoven fabrics or vinyl nonwoven fabrics; and metal foils.
  • the plastic films may be either r ⁇ stretched films or stretched ⁇ uniaxial! ⁇ ' stretched or biaxially stretched) films.
  • the above-mentioned substrates can have an average thickness of about 1 mm to about 4 mm or more.
  • the first substrate 52 and the second substrate 54 can include a non-porous film or a porous film or mesh.
  • any material can be used as long as it can be processed into a porous film or mesh.
  • a porous film or mesh can be made from a polyolefin resin, for example, polyethylene, polypropylene, ethylene/vinyl acetate copolymer and the like.
  • the porous film or mesh allows condensed moisture to evaporate or drain from the material once installed, and allows the insulating value to be maintained. -19-
  • the peSleti/ed materia! can foe adhered between the first substrate and the second substrate using conventional adhesives (not shown).
  • adhesives can include, for example, a viscous resin or poljmer that can act as a bonding agent to bind the pellets to the surfaces of the substrates.
  • polymers or resins that can be used include polyesters, polya ⁇ iides.
  • polyurcthanes epoxie.s silicones, latexes, alk ⁇ ds, oleorcsinous vehicles, water reducible resins, polybutadicne SBR pohirters, and acr> Hcs/acrj iates, LVA copolymers, as well as other well-known polymers used in adhesive formulations,
  • the outer adhesive layer can be coated on at least one of the first substrate 52 and the second substrate 54 with, for example, an aqueous dispersion type pressure-sensitive adhesive composition to form the adhesive layers
  • the release liner 62 can then be hooded to the resulting outer adhesive layer 60, fOO7 ⁇ j
  • the release liner 62 can comprise a sheet substrate and be disposed on the outer adhesive layer.
  • the release liner 62 may be the conventional release liner.
  • the release liner 62 may comprise a release coating that is applied to an outer surface of the compounded tape 50 opposite the surface to which the outer adhesive k>er is applied. This allows the compounded tape 50 to be wound so that the outer adheshe layer 60 is in contact with the release layer when stored in a rolled stale.
  • the compounded tape so formed can have an average thickness of, for example, about 0.5 cm to about 5 cm.
  • the thickness as well as the width of the compounded tape can vary depending on the specific application.
  • the compounded tape can have a thickness greater than about 5 cm or less than aboui 0.5 cm. f ⁇ 6?2]
  • the p ⁇ lietked material can be provided in flexible bags or in a resin starved paste in a backing or bag.
  • the bags can be used as insulation to fill ca ⁇ ities in construction assemblies, such as the stud area of building construction.
  • the bag can be a perforated mesh or porous bag and be formed, for e ⁇ ample, from a polymer mesh, such as a polyethylene web.
  • the perforated mesh or porous bags allovt condensed moisture to evaporate or drain -20-
  • the bags can also be provided as perforated sheets that can be stored on rolls.
  • the perforations can allow the bags to be readily removed from the sheets and allow for installation of the bags at various lengths.
  • the peiletbed material when used in a coating, mastic, compounded iapc system, or other construction can be mixed with one or more spacer materials.
  • the spacer materials can be used to inhibit or mitigate compaction of the pelietized material.
  • Hie spacer materials can also assure desired insulation thickness b ⁇ defining a thickness ⁇ f the coating, mastic, or compounded tape system for the desired application,
  • the spacer material can, for example, comprise particles that have an a ⁇ erage dimension size thai is greater than the dimension size of the pelietized material,
  • Fig. 4 illustrates one example of the use of spacer materials in accordance with the present invention in a compounded tape system.
  • the compounded tape ?0 has a construction similar to the construction ofthe compounded tape as illustrated Sn Fig 3, except a plurality ot spacer materials 72 are provided between the first substrate 74 and the second substrate 76.
  • the spacer materials 12 can separate the first substrate 74 and the second substrate 76 to define a desired thickness to the compounded tape 70. This allows the compounded tape 70 to be advantageous!) em ⁇ .o>ed about structural assemblies where a predefined insulation thickness is required.
  • the particles can have an average size of about Q. I mm to about 12 ram ⁇ e.g., about 0. i mm to about 2.5 mm).
  • the particles can have an average particle size of about 12 mm to about 25 mm.
  • the pellcti/ed material can provided in pol> diverse particle shapes, sizes, and materials to optimize density, application characteristics, -21-
  • volume packing acoustic, thermal, attenuation, cost factors, or combinations thereof.
  • the pelletized material contained a colorant or dye as an identifier, a flame retardant, and a biocide, as well as about 2 % polypropylene as modifier to improve surface characteristics, heat and chemical resistance and mitigate static charge.
  • the remainder of the formulation was comprised of prime or recycled polystyrene and pe-ntane gas blowing agent.
  • the pellet was extruded, drawn, cooled and cut to size, it was expanded through a common steam-heated processing unit, which activated the pe ⁇ tane gas blowing agent, causing the expansion of the pellet into a bead of approximately 1 pound per cubic foot apparent bulk density and me ranges of about 2 mm to about 8 ram.
  • the pellets were then coated with a small amount of coating, which contained complimentary colorant and other additives, such as supplemental biocide and fire resistant agents.
  • This coating was applied at about 1% to about 5% weight concentration under low shear agitation and cured.
  • the coating improved the surface properties of the insulation pellets, reduced odor or volatile emissions from the base polymer > and provided color identification, j ⁇ Slj
  • the pellets so formed can be used as a loose fill biown-in insulation or be compounded into a coating, liquid or mastic for structural assembly -22-
  • the pellets so formed exhibited an R- Value of abuut 2.5-3.5 per Inch. Insulation pellets uf this type are uniquely clean and non-dust ⁇ to handle, non-compressrve and non-settling in. application, resistant to moisture as well as the formation of moid, mildew or fungus.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Architecture (AREA)
  • Materials Engineering (AREA)
  • Medicinal Chemistry (AREA)
  • Structural Engineering (AREA)
  • Electromagnetism (AREA)
  • Acoustics & Sound (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Civil Engineering (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Building Environments (AREA)
  • Thermal Insulation (AREA)
  • Silicon Compounds (AREA)

Abstract

L'invention porte sur une pluralité de granulés qui comprennent un matériau synthétique et/ou de biomasse et/ou minéral et/ou polymère. Les granulés précités peuvent posséder une gravité spécifique d'environ 0,01 à environ 0,3g/cm3 et sont de dimensions stables, sensiblement dépourvus de poussières, sensiblement non hygroscopiques et résistants à la sédimentation et à la compression.
PCT/US2007/070968 2006-06-12 2007-06-12 Matériaux granulés légers Ceased WO2007146919A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA002655312A CA2655312A1 (fr) 2006-06-12 2007-06-12 Materiaux granules legers

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US81289306P 2006-06-12 2006-06-12
US60/812,893 2006-06-12

Publications (2)

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WO2007146919A2 true WO2007146919A2 (fr) 2007-12-21
WO2007146919A3 WO2007146919A3 (fr) 2008-03-20

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104403398A (zh) * 2014-11-11 2015-03-11 安徽综艺包装科技有限公司 一种高强耐水腻子粉及其制备方法
DK201600012A1 (en) * 2016-01-08 2017-07-24 Jakob Würtzen A noise barrier for acoustic damping
CN111121079A (zh) * 2019-12-20 2020-05-08 张家港市长泰机械科技有限公司 一种用于生物质发电燃料储运及给料系统

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Publication number Priority date Publication date Assignee Title
US4500586A (en) * 1981-01-29 1985-02-19 Bussey Harry Jun Billowed filling elements for packaging
US5641584A (en) * 1992-08-11 1997-06-24 E. Khashoggi Industries Highly insulative cementitious matrices and methods for their manufacture
US5908501A (en) * 1998-01-27 1999-06-01 Pucillo; Patric M. Composition and a method for preventing dustfall from material
US6560948B1 (en) * 1999-04-08 2003-05-13 Free-Flow Packaging International, Inc. Tear-off cushions of loose fill packing material, and machine and method for making the same
US6508362B2 (en) * 2000-12-13 2003-01-21 Foamex L.P. Hinged flexible polyurethane foam protective packaging and shipping element
WO2003000752A1 (fr) * 2001-06-20 2003-01-03 Polypropylene Belgium (Naamloze Vennootschap) Composition a base de polymere propylene, procede d'obtention associe et utilisation pour la fabrication de granules expanses et d'articles cellulaires
US6761012B2 (en) * 2001-12-18 2004-07-13 Atlanta Nisseki Claf, Inc. Pre-prepared mesh-film web for use on form, fill and seal machines
US7993741B2 (en) * 2002-12-06 2011-08-09 Cardinal Cg Company Preventing damage with separators

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104403398A (zh) * 2014-11-11 2015-03-11 安徽综艺包装科技有限公司 一种高强耐水腻子粉及其制备方法
DK201600012A1 (en) * 2016-01-08 2017-07-24 Jakob Würtzen A noise barrier for acoustic damping
DK179008B1 (en) * 2016-01-08 2017-08-07 Jakob Würtzen A noise barrier for acoustic damping
EP3190231B1 (fr) 2016-01-08 2019-09-25 Würtzen, Jakob Sac amortissant pour isolation acoustique, barrière avec un tel sac et procédé d'installation d'une telle barrière
CN111121079A (zh) * 2019-12-20 2020-05-08 张家港市长泰机械科技有限公司 一种用于生物质发电燃料储运及给料系统

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CA2655312A1 (fr) 2007-12-21

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