NAME OF THE INVENTION: A construction compound with a natural binder

Author of the invention (inventor): Sergiy Kovalenkov (UA)

(1) The essence of the invention:

(2) The present invention relates to the field of eco-design, eco-construction. In particular, the object of the invention is a compound comprising a binder, for construction purposes with zero CO emission, the method of its obtaining is also claimed.

(3) The evolution of the cottages’ construction, in general, tends to use both natural resources (focusing on renewable resources) and energy conservation (both in production and especially during use), as well as health and comfort. Finally, the material should be disposed of (recycled) after a certain period for its use without creating new waste or without causing significant damage to the environment. In this context, it is important to establish that the construction materials obtained through the claimed invention are durable, biodegradable and environmentally friendly.

(4) In the construction field, cement is the most common binding agent or binder.

Cement is a powdery material that forms, with water and/or with salt, a viscous binder capable of agglomeration by varying the speed of curing of the constituent substances. It also may mean any material that is placed between two solids to connect them. In general, hardening occurs quickly and maximum cement strength is obtained in a few days. After drying, the cement composition retains its stability even underwater. Most often it is used to obtain concrete in the form of a compound comprising water, fine sand, and gravel. At present, cement is considered to be the best material in the construction industry.

(5) However, cement production requires large amounts of energy and generates significant carbon monoxide (C02) emissions. This creates environmental problems, in particular, related to the greenhouse effect and global warming Environment, Proceedings of the 4th International Conference on Greenhouse Gas Control Technologies, Interlaken, Austria. September 30, IEA GHG Research and Development Program, UK 1998).

(6) The amount of C02 emitted during cement production can be divided into two parts according to its source. Firstly, it is the combustion of fossil fuels needed to anneal raw materials, which is about 390 kg per ton of cement. Secondly, emissions are the result of carbon emission during decarbonization process, as carbon is contained in the raw material, that is approximately 425 kg per ton of cement. Thus, an average of 815 kg of C02 is released per ton of cement produced (Gartner E. Industrially Interesting Approaches to a Low C02 Environment, Cement and Concrete Research, Vol. 34, 2004, p. 1489- 1498).

(7) As the result of the development of materials with low environmental impact, previous solutions have proposed the use of lime hydraulic binder (comprising up to 10% pozzolans by volume) and lime. The mechanical strength of this type of binder ranges from 4 MPa for 14 days and up to 5 MPa for 15 months (Cerezo V., Thermal and Acoustic Mechanical Properties of Plant Particle Material: Experimental Approach and Theoretical Modeling, dissertation of the National School of Public and Socially Significant Works for the State, 2005). Moreover, the latest study highlights the long drying time and drawbacks of the rapid drying of the material.

(8) Brief description of the invention

(9) The present invention is intended to overcome the disadvantages of the prior art. For protection, the proposed compound for construction purposes does not harm the environment through the use of agro-resources.

(10) The insulation of existing buildings or construction with the claimed invention is achieved by composing all the necessary components in the mixer to obtain a material capable of being used in the construction and / or insulation of residential or other structures.

(1 1) Agro-resources means plant material (flax, straw, hemp, cane, with all agro resources, recommended to have them in fractions from 05 to 40 mm), for example, technical hemp, in particular, hemp hurds, which may be added as (including thermal) into the compound in order to impart specific properties pertaining to this plant.

(12) The proposed compound is an alternative to cement and has a less environmental impact since the calcination temperature of natural hydrated or hydraulic lime is lower than the cement needed (900 ° C in hydrated lime versus 1450 ⁰ C for cement). As for metakaolin, its production is based on the decarboxylation of kaolinite, a chemical process that provokes only water vapor emissions.

(13) Detailed description

(14) The applicant invented a compound named hereinafter as "Fifth element" (or 5 ^th E) in powder form on the basis of natural components without the use of cement, sand, hydraulic lime and toxic additives for the purpose of insulation of buildings or use as the insulating material of type "concrete" (hereinafter also named“hempcrete”).

(15) Hempcrete is a heat-insulating material (See Fig. 1) comprising hemp hurds, lime-based binder, and water. The 5 ^th E includes lime, bentonite and/or metakaolin.

(16) In this case, hydrated lime with an active amount of calcium oxides (CaO) of not less than 70% may be used in the compound the 5 ^th E. The higher the calcium oxide (CaO) content in lime, the better it is for use in the 5 ^lh E compound.

(17) It should be noted that hydraulic lime may not be used. Although hydraulic lime is an excellent fixer, in all its characteristics hydraulic lime is similar to cement, as it has the ability to harden underwater.

(18) The resulting 5 ^th E compound does allow not to use cement and/or hydraulic lime (the closest analog of Hempcrete uses hydraulic lime). Hydrated lime is often confused with hydraulic.

( 19) The essential element for use in the compound is bentonite, namely calcium- based bentonite as it may be confused with sodium-based bentonite. (20) Bentonite is used as a separate element in the field of drilling. The proportion of components by weight in the compound as follows:

a. Hydrated lime not less than 50% but not more than 85% by weight; and

b. Water (H20) not more than 1 % by weight; and

c. Bentonite (bentonite) from 15% but not more than 50% by weight, while using calcium-based bentonite (Calcium montmorillonite - Ca [(Al, MgFe3 +) 2 (OH) 2 [Si205]]. Ca (H20) 4) added soda (Na2C03); or

d. When using sodium bentonite (Sodium montmorillonite- Na [(Al, MgFe3 +) 2 (OH) 2 [Si205]] Na (H20) 4) soda is not added; or

e. Metakaolin is not more than 5% by weight as a bentonite substitute.

The simplified chemical formula for bentonite is as. follows: (Na, Ca) 0.3 (Al, Mg) 2 [Si4010] (OH) 2 · nH20.

Chemical components of bentonite as follows: the proportion of Si02 not less than 45%, but up to 55%, A1203 18-20%, MgO and Fe203 fractions, Na20 and CaO up to 1.5%, H20 up to 24-26%.

(21) The final hempcrete insulation material comprising the compound 5 ^th E has a fairly low density of 250 kg / m3 for the walls (See Fig. 1 and Fig. 2). The final density of the compound 5 ^th E depends on the size of the fractions of the material (hemp hurds) that were used in the preparation of the compound.

(22) Hempcrete with these components is a porous material that improves thermal performance better than any closest analog. Accordingly, it is necessary to apply less compound for the manufacture of l m3 of the construction or insulation compound (See Fig. 2).

(23) The advantages include: reducing C02 emissions, reducing the cost of the final product, reducing thermal conductivity and reducing heat losses. The uniqueness of the compound is the application of only natural components. The method of manufacture of hempcrete as follows: the compound 5 ^th E and water, hemp hurds 20 kg, then it should be added water 40 1, 5 ^th E compound - 25 kg, then again it should be added a water 5 1. The mechanism (mixer) link:

(24) https://sketchfab.com/models/dc769d0c75b5436e94889407c3578cd 5

(25) In the mixer, the auger is made in the form of a DNA molecule manufactured from metal rods. Due to the construction of the auger, hemperete compound will be ready within 90 seconds after mixing all of the components. In the mixer, a hole with a hatch that opens on both sides. The mixer can be moved by one person. The auger rotates in both directions. The mixing process may take place during a temperature above + 5C.

(26) Launch of a mixer (mixer) designed to produce a hemperete.

(27) The mixer shall be filled with hemp hurds with a fraction of not less than 05 mm (but not more than 40 mm).

(28) After 15 seconds, water is added in the proportion enough to moisten the entire area of hemp hurds fractions before adding the binder. The procedure of moistening improves the adhesion between hemp hurds and the 5 ^th E compound.

(29) After 30 seconds, the 5 ^th E compound is added.

(30) After 1 minute, the homogeneous insulation compound is ready for application.

(31) Temperature range for the production of the compound: 0 C .... +40 C

(32) The most favorable temperature range for the manufacturing of the compound: +10 C ... + 25 C

(33) Sodium bentonite or calcium bentonite is used in insulating materials, but hydrated with soda and thus artificially converted to sodium bentonite, hence it will be a calcium bentonite activated with soda (See Fig. 3).

(34) In the binder applied in the compound that is the subject matter of the application, bentonite acts as a thickener, a structure-forming agent and a resistance of the insulation compound.

(35) By reducing the environmental impact and its hygroscopic properties, this binder can be a part to renewable agricultural resources being an environmentally friendly insulation compound that meets new consumer requirements in terms of environmental protection, comfort and indoor air quality.

(36) The properties and advantages of the composition according to the present invention will become more apparent in the light of the following examples. They are purely illustrative and should not be construed as limiting the scope of the composition according to the invention, in particular to the means equivalent to those described in this application.