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Title:
CONSTRUCTION MATERIALS WITH HIGH THERMAL INSULATION PROPERTY AND PRODUCTION METHOD
Document Type and Number:
WIPO Patent Application WO/2016/186593
Kind Code:
A1
Abstract:
The invention is about insulation and construction materials, which are used in floors, interior and exterior facades of buildings and facilities, prevent temperature differences, incombustible, have noise insulation property, save time and labor due to their easy installation property and about production process/method of these materials. With this invention, prefabricated building elements that can be used instead of existing building elements (brick, pumice, gas concrete, briquette, plaster, screed, etc.) as a building element that doesn't require additional insulation (cheaper, lighter and having higher insulation value than its equivalents), has been produced.

Inventors:
ÇEREZCI, Alperen (Haci Yusuf Mescit Mh. Ravsa Sk. No:19, Karatay/Konya, TR)
SUBAŞI, Rumeysa (Haci Yusuf Mescit Mh. Ravsa Sk. No:19, Karatay/Konya, TR)
Application Number:
TR2016/000069
Publication Date:
November 24, 2016
Filing Date:
May 13, 2016
Export Citation:
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Assignee:
ÇEREZCI, Alperen (Haci Yusuf Mescit Mh. Ravsa Sk. No:19, Karatay/Konya, TR)
SUBAŞI, Rumeysa (Haci Yusuf Mescit Mh. Ravsa Sk. No:19, Karatay/Konya, TR)
International Classes:
C04B28/04; B28B3/08; B28B23/00; B30B11/04; C04B38/08; C04B40/00
Domestic Patent References:
2012-06-28
2013-02-21
2006-09-28
Foreign References:
US1770767A1930-07-15
US20060201392A12006-09-14
US6083318A2000-07-04
US5852077A1998-12-22
CN1493544A2004-05-05
EP1900705A12008-03-19
TR200503979U2005-12-21
TR200606533A2
TR200707398A22009-05-21
TR200901739A22010-07-21
TR200905753A22011-02-21
TR201104274A22012-11-21
TR201010904A2010-12-25
TR201204354A2
US20070112098A12007-05-17
AU2913177A1979-04-05
FR2814740A12002-04-05
Attorney, Agent or Firm:
DERELİ, Yavuz Tuncay (Nişantaş Mah. Zehmeri Sokak No:1/B, Selçuklu/Konya, TR)
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Claims:
CLAIMS

The invention is construction materials with high thermal insulation property and production method and its property is as follows; It consists of following materials and processes; very lightweight aggregates (1), solution preventing floccules (flocculations) (2), mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), bentonite (4), Portland cement (5), other inorganic and/or organic binders (6), other gelling and swelling agents (7), "Wood, OSB, Plasterboard, Calcium Silicate, Magnesium Oxide, Fibrocement and Metal, etc." boards (8), mixer (9), moulds (10), double-sided compressor (11), dosing process (12), mixing process (13), moulding process (14), double-10 sided pressure/compression process from opposite directions (15), one-sided pressure/compression process (16), setting process (17), Faraday air barrier (18).

These are construction materials stated in Claim 1 (wall block, wall board, sandwich panel wall, etc.) and their properties are as follows; They consist of very lightweight aggregates (1), solution preventing floccules (flocculations) (2), bentonite (4), Portland cement (5), other inorganic and/or organic binders (6), other gelling and swelling agents (7), "Wood, OSB, Plasterboard, Calcium Silicate, Magnesium Oxide, Fibrocement and Metal, etc." boards (8). These are construction materials stated in Claim 1 (plaster, screed, etc.) and their properties are as follows; They consist of very lightweight aggregates (1), solution preventing floccules (flocculations) (2), bentonite (4), Portland cement (5), other inorganic and/or organic binders (6), other gelling and swelling agents (7).

This is main cluster or production method of construction materials stated in Claim 1, 2 or 3 (wall block, wall board, sandwich panel wall, plaster, screed, etc.) and its property is as follows; Main cluster consists of very lightweight aggregates (1), solution preventing floccules (flocculations) (2), bentonite (4) as a main filler, Portland cement (5) as a main binder.

This is substitution cluster or production method of construction materials stated in Claim 1, 2 or 3 and its property is as follows; In order to improve quality of the product, it consists of other inorganic and/or organic binders (6) and/or other gelling and swelling agents (7), in place of or in addition to the materials in the main cluster (4 and/or 5) and additives that can be used together with cement (5) can be added.

6) These are construction materials or production method stated in Claim 1, 2, 3, 4 or 5 and their properties are as follows; All dust particles in the Portland cement (5) which is the binder in the main cluster, can enter into hydration and adhesion > cohesion = getting wet condition can be provided by reducing or eliminating cohesive force between water molecules and/or cement (5) molecules in order to prevent floccules (flocculations).

7) These are construction materials or production method stated in Claim 1, 2, 3, A, 5 or 6 and their properties are as follows; Provision of adhesion > cohesion = getting wet condition can also be achieved before or after addition of cement (5) and it can be achieved together with bentonite (4) and/or other gelling and swelling agents(7).

8) This is order of addition of materials used in production of construction

materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; This can be made with one of the 1st, 2nd, 3rd, 4th, 5th or 6th ordering methods stated in instruction book under the title of "In order to obtain the product which is the subject of invention, necessary orders needed during additions are as follows;".

9) This is order of addition of materials used in production of construction

materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; Very lightweight aggregates (1) are firstly mixed with solution preventing floccules (flocculations) (2) in the mixer (9) and then,the mixture which is obtained by adding bentonite (4) which is used as a filler and/or other gelling and swelling agents (7), is mixed again with Portland cement (5).

10) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; Bentonite (4) which is used as a filler and/or other gelling and swelling agents (7) are poured into mixer (9) firstly and then, during mixing them by adding very lightweight aggregates (1), they are mixed by spraying mist/pulverized solution preventing floccules (flocculations) (2) on them and this mixture is mixed again with Portland cement (5). 11) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; Portland cement (5) is poured into mixer (9) firstly and then, during mixing the mixture by adding very lightweight aggregates (1), they are mixed with solution preventing floccules (flocculations) (2) by spraying on them and this mixture is mixed again with bentonite (4) which is used as a filler and/or other gelling and swelling agents (7).

12) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; In case of pouring fillers (4 and 7) and/or binder (5) into the mixer (9) at first, because bentonite (4) and/or Portland cement (5) and/or other gelling and swelling agents (7) stay at the bottom of the mixer (9) because of the density difference and absence of liquid which may adhere to them during mixing process, very lightweight aggregates (1) meet sprayed mist/pulverized solution preventing floccules (flocculations) (2) by staying at the top and absorb it and during mixing process, aggregates (1) that become heavier with solution (2) that they absorb, move downwards and they meet bentonite (4) and/or Portland cement (5) and/or other gelling and swelling agents (7) presenting at the bottom of the mixer (9) and they are mixed.

13) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; Solution preventing floccules (flocculations) (2) is mixed with bentonite (4) and/or other gelling and swelling agents (7) and following this, it is mixed with lightweight aggregates (1) and this mixture is mixed with Portland cement (5) again.

14) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; Very lightweight aggregates (1) are mixed with solution preventing floccules (flocculations) (2) in a mixer (9) first, right after this, this mixture is mixed by adding Portland cement (5).

15) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; Very lightweight aggregates (1) and solution preventing floccules (flocculations) (2) are mixed in a mixer (9) first, following this, after Portland cement (5) is added, bentonite (4) and/or other gelling and swelling agents (7) are added as fillers and this mixture is mixed.

16) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; Solution preventing floccules (flocculations) (2), bentonite (4) containing solution (2) and/or other gelling and swelling agents (7) present in the mixtures before Portland cement (5) which is a binder, is added. «

17) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; First of all, very lightweight aggregates (1) are mixed with water in a mixer (9) and then, it is mixed with bentonite (4) and/or other gelling and swelling agents (7) as a filler, following this, solution preventing floccules (flocculations) (2) is added to this mixture right after Portland cement (5) is added as a main binder, it is mixed.

18) This is order of addition of materials used in production of construction

materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; It is enabled that solution preventing floccules (flocculations) (2) is absorbed by aggregates (1) and/or bentonite (4) and/or other gelling and swelling agents (7) and it is trapped in them, and these are used as storage, then, cement (5) which is added later, uses solution (2) in the amount needed for hidration by taking it from bentonite (4) and/or other gelling and swelling agents (7) and/or aggregates (1).

19) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; Use of aggregates (1), bentonite (4) and/or other gelling and swelling agents (7) as storage and, then contact of cement (5) with solution (2) which is more than needed for hydration, are prevented. 20) This is order of addition of materials used in production of construction materials stated in Claim 1, 2 or 3, mixing process (13) or its method and its property is as follows; Remaining solution (2) stays within bentonite (4) and/or other gelling and swelling agents (7) and/or aggregates (1), and it functions by cooling the product by means of evaporating after taking hydration heat on it.

21) This is moulding process (14) used in production of construction materials stated in Claim 1 or 2 or its method and its property is as follows; Mortar which is prepared with very lightweight aggregates (1), is poured into a mould (10) which can carry out double-sided pressure/compression process from opposite directions (15), and moulding process (14) is performed.

22) This is moulding process (14) used in production of construction materials stated in Claim 1 or 2 or its method and its property is as follows; Pressure/compression process (15) is applied to mortar which is prepared with very lightweight aggregates (1) and poured into a mould (10) from opposite directions and it is formed.

23) This is moulding process (14) used in production of construction materials stated in Claim 1 or 2 or its method and its property is as follows; Mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), is laid on mould (10) as a thin layer and (normal) mortar which is prepared with very lightweight aggregates (1) by mixing process (13), is poured into mould (10) on it and mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), is laid on it as a thin layer again, then, products are covered by harder and more resistant surface after double-sided pressure/compression process applied from opposite directions (15).

24) This is double-sided pressure/compression process from opposite directions (15) used in production of construction materials stated in Claim 1 or 2 or its method and its property is as follows; Desired shape/form is given to mortar which is prepared with very lightweight aggregates (1) by applying pressure following moulding process (14).

25) This is double-sided pressure/compression process from opposite directions (15) used in production of construction materials stated in Claim 1 or 2 or its method and its property is as follows; Desired shape/form is given to mortar which is prepared with very lightweight aggregates (1) by applying pressure in the mould (10) which works in a double-sided compressor (11).

26) This is double-sided press/compressor (11) used in production of construction materials stated in Claim 1 or 2 and its property is as follows; Desired shape/form is given to mortar which is prepared with very lightweight aggregates (1) by applying double-sided pressure/compression process from opposite directions (15).

27) This is production method of construction materials stated in Claim 1 or 2 and its property is as follows; Mortar which is prepared with very lightweight aggregates (1) and/or solution preventing floccules (flocculations) (2) and/or bentonite (4) and/or Portland cement (5) and/or other inorganic and/or organic binders (6) and/or other gelling and swelling agents (7) and mixing process (13), is poured into moulds (10), subjected to moulding process (14) in double-sided compressor (11) with double-sided pressure/compression process (15), and desired shape/form is given with setting process (17).

28) This is construction materials or production method stated in Claim 1 or 2 and its property is as follow; Desired shape/form is created with double-sided compressor (11) which can apply double-sided pressure/compression from opposite directions (15) in the mould (10).

29) This is construction materials or production method stated in Claim 1 or 2 and its property is as follow; Mortar which is prepared with very lightweight aggregates (1), solution preventing floccules (flocculations) (2), bentonite (4) and/or Portland cement (5) and/or other inorganic and/or organic binders(6) and or other gelling and swelling agents (7) and mixing process (13), is poured between panels made from "Wood, OSB, Plasterboard, Calcium Silicate, Magnesium Oxide, Fibrocement and Metal, etc." boards (8) or on these boards (8), then, pressed/compressed from one side (16) and it is formed with setting process (17) occur between panels(8).

30) This is construction materials or production method stated in Claim 1 or 2 and its property is as follow; Mortar which is prepared with very lightweight aggregates (1), solution preventing floccules (flocculations) (2), bentonite (4) and/or other inorganic and/or organic binders (6) and or other gelling and swelling agents (7) and mixing process (13), is poured between panels made from "Wood, OSB, Plasterboard, Calcium Silicate, Magnesium Oxide, Fibrocement and Metal, etc." boards (8) or on these boards (8), then, it is form with one-sided pressure/compression process (16).

31) This is solution (2) used in both construction materials stated in Claim 1, 2 or 3 and production method stated in Claim 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 27, 29, 30 or 31 and its property is as follow; It has a structure containing different types (powder or liquid) of plasticizers and/or air entrainer and/or synthetic lime resins which have different properties

(normal and/or high rates of (normal, medium, high, super, hyper) water reducer) and which exist in the market.

32) 31) This is solution (2) used in both construction materials stated in Claim 1, 2 or 3 and production method stated in Claim 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 27, 29, 30 or 31 and its property is as follow; It is a structure consisting of dispersions/solutions of all kinds of concentrated (condensed) liquid plasticizers and/or air entrainer and/or synthetic lime resins which are diluted with water and are used in the market.

33) This is solution (2) used in both construction materials stated in Claim 1, 2 or 3 and production method stated in Claim 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 27, 29, 30 or 31 and its property is as follow; As it may be made from materials stated in claim 31 and may have the structure stated in claim 32, it is also a structure that contains other liquids needed.

34) This is solution (2) used in both construction materials stated in Claim 1, 2 or 3 and production method stated in Claim 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 27, 29, 30 or 31 and its property is as follow; As the solution (2) can be obtained by dissolving powder formed plasticizers and/or air entrainers and/or synthetic limes which are used in the market, they can also be used by being added to cement (5) and/or bentonite (4) and/or other gelling and swelling agents (7) as a powder.

35) This is solution (2) used in both construction materials stated in Claim 1, 2 or 3 and production method stated in Claim 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15,

16, 17, 18, 19, 20, 27, 29, 30 or 31 and its property is as follow; It ensures elimination and reduction of high attraction (cohesive) force between molecules in water and other materials (4, 5, 6 and 7) that are used in order to make mortar.

36) By being not in connection with any abovementioned claim, this is production method of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follow; Desired shape/form is given to mortar which is prepared with very lightweight aggregates (1) by applying double-sided pressure/compression from opposite directions (15) in the mould (10).

37) By being not in connection with any abovementioned claim, this is production method of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follow; Double-sided pressure/compression from opposite directions (15) can be applied to mortar containing very lightweight aggregates (1) in it.

38) By being not in connection with any abovementioned claim, this is a method for covering outer surfaces of products in the production of construction

materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follow; Mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), is laid on mould (10) as a thin layer and (normal) mortar which is prepared with very lightweight aggregates (1), is poured on it and mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), is laid on it as a thin layer again and it is filled, then, double-sided pressure/compression process from opposite directions (15) is applied to the mortar which is in the form of sandwich in the mould (10).

39) By being not in connection with any abovementioned claim, these are construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or production method and their

properties are as follow; All dust particles in the Portland cement (5) which is used as a binder in mortars prepared with very lightweight aggregates (1), can enter into hydration and adhesion > cohesion = getting wet condition can be provided by reducing or eliminating cohesive force between water molecules and/or cement molecules in order to prevent floccules (flocculations). 40) By being not in connection with any abovementioned claim, these are construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or production method and their properties are as follow; Provision of adhesion > cohesion = getting wet condition can be achieved before or after addition of cement (5) and it can also be achieved together with bentonite (4) and/or other gelling and swelling agents(7).

41) By being not in connection with any abovementioned claim, this is order of addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; This can be made with one of the 1st, 2nd, 3rd, 4th, 5th or 6th ordering methods stated in instruction book under the title of "In order to obtain the product which is the subject of invention, necessary orders needed during additions are as follows;".

42) By being not in connection with any abovementioned claim, this is order of

addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; Very lightweight aggregates (1) are firstly mixed with solution preventing floccules (flocculations) (2) in the mixer (9) and then, the mixture which is obtained by adding bentonite (4) which is used as a filler and/or other gelling and swelling agents (7), is mixed again with Portland cement (5).

43) By being not in connection with any abovementioned claim, this is order of addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; Bentonite (4) which is used as a filler and/or other gelling and swelling agents (7) are poured into mixer (9) firstly and then, during mixing them by adding very lightweight aggregates (1), they are mixed by spraying mist/pulverized solution preventing floccules (flocculations) (2) on them and this mixture is mixed again with Portland cement (5).

44) By being not in connection with any abovementioned claim, this is order of addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; Portland cement (5) is poured into mixer (9) firstly and then, during mixing the mixture by adding very lightweight aggregates (1), they are mixed with solution preventing floccules (flocculations) (2) by spraying mist/pulverized solution preventing floccules (flocculations) (2) on them and this mixture is mixed again with bento ite (4) which is used as a filler and/or other gelling and swelling agents (7).

45) By being not in connection with any abovementioned claim, this is order of

addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; In case of pouring fillers (4 and 7) and/or binders (5 and 6) into the mixer (9) at first, because these materials (4, 5, 6 and 7) stay at the bottom of the mixer (9) because of the density difference and absence of liquid which may adhere to them, very lightweight aggregates (1) meet sprayed mist/pulverized solution preventing floccules (flocculations) (2) by staying at the top and absorb it and during mixing process, aggregates (1) that become heavier with solution (2) that they absorb, move downwards and they meet other materials (4, 5, 6 and 7) presenting at the bottom of the mixer (9) and they are mixed.

46) By being not in connection with any abovementioned claim, this is order of

addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows;

Solution preventing floccules (flocculations) (2) is mixed with bentonite (4) and/or other gelling and swelling agents (7) and following this, it is mixed with lightweight aggregates (1) and this mixture is mixed with Portland cement (5) again.

47) By being not in connection with any abovementioned claim, this is order of

addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows;

Very lightweight aggregates (1) are mixed with solution preventing floccules (flocculations) (2) in a mixer (9) first, right after this, this mixture is mixed by adding Portland cement (5).

48) By being not in connection with any abovementioned claim, this is order of addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; Very lightweight aggregates (1) and solution preventing floccules (flocculations) (2) are mixed in a mixer (9) first, following this, after Portland cement (5) is added, bentonite (4) and/or other gelling and swelling agents (7) are added as fillers and this mixture is mixed.

49) By being not in connection with any abovementioned claim, this is order of addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; Solution preventing floccules (flocculations) (2), bentonite (4) containing solution (2) and/or other gelling and swelling agents (7) present in the mixtures before Portland cement (5) which is a binder, is added.

50) By being not in connection with any abovementioned claim, this is order of addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; First of all, very lightweight aggregates (1) are mixed with water in a mixer (9) and then, it is mixed with bentonite (4) and/or other gelling and swelling agents (7) as a filler, following this, solution preventing floccules (flocculations) (2) is added to this mixture right after Portland cement (5) is added as a main binder, it is mixed.

51) By being not in connection with any abovementioned claim, this is order of addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; It is enabled that solution preventing floccules (flocculations) (2) is absorbed by aggregates (1) and/or bentonite (4) and/or other gelling and swelling agents (7) and it is trapped in them, and these are used as storage, then, cement (5) which is added later, uses solution (2) in the amount needed for hidration by taking it from bentonite (4) and/or other gelling and swelling agents (7) and/or

aggregates (1).

52) By being not in connection with any abovementioned claim, this is order of

addition of materials used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or it is mixing process (13) or its method and its property is as follows; Use of aggregates (1), bentonite (4) and/or other gelling and swelling agents (7) as storage and, then contact of cement (5) with solution (2) which is more than needed for hydration, are prevented.

53) By being not in connection with any abovementioned claim, this is moulding process (14) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or its method and its property is as follows; Mortar which is prepared with very lightweight aggregates (1), is poured into a mould (10) which can carry out double-sided pressure/compression process from opposite directions (15), and moulding process (14) is performed.

54) By being not in connection with any abovementioned claim, this is moulding process (14) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or its method and its property is as follows;. Pressure/compression process (15) is applied in the mould (10) to mortar which is prepared with very lightweight aggregates (1) and poured into a mould (10) from opposite directions and it is formed.

55) By being not in connection with any abovementioned claim, this is moulding process (14) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or its method and its property is as follows; Mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), is laid on mould (10) as a thin layer and (normal) mortar which is prepared with very lightweight aggregates (1) by mixing process (13), is poured into mould (10) on it and mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), is laid on it as a thin layer again, then, products are covered by harder and more resistant surface after double-sided pressure/compression process applied from opposite directions (15).

56) By being not in connection with any abovementioned claim, this is double-sided pressure/compression process from opposite directions (15) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or its method and its property is as follows; Desired shape/form is given to mortar which is prepared in the mould (10) with very lightweight aggregates (1) by applying pressure.

57) By being not in connection with any abovementioned claim, this is double-sided pressure/compression process from opposite directions (15) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or its method and its property is as follows; Desired shape/form is given to mortar which is prepared with very lightweight aggregates (1) by applying pressure in the mould (10) which works in a double-sided compressor (11).

58) By being not in connection with any abovementioned claim, this is double-sided compressor (11) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or its method and its property is as follows; Desired shape/form is given to mortar which is prepared with very lightweight aggregates (1) by applying double- sided pressure/compression process from opposite directions (15).

59) By being not in connection with any abovementioned claim, these are construction materials which contain very lightweight aggregates (1), no matter what other materials they contain or their production method and their properties are as follows; Desired shape/form is created with double-sided compressor (11) which can apply double-sided pressure/compression from opposite directions (15) in the mould (10).

60) By being not in connection with any abovementioned claim, this is solution (2) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follows; It has a structure containing different types (powder or liquid) of plasticizers and/or air entrainer and/or synthetic lime resins which have different properties (normal and/or high rates of (normal, medium, high, super, hyper) water reducer) and which exist in the market.

61) By being not in connection with any abovementioned claim, this is solution (2) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follows; It is a structure consisting of dispersions/solutions of all kinds of concentrated (condensed) liquid plasticizers and/or air entrainer and/or synthetic lime resins which are diluted with water and are used in the market.

62) By being not in connection with any abovementioned claim, this is solution (2) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follows; It is a structure containing other liquids.

63) By being not in connection with any abovementioned claim, this is solution (2) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follows; It ensures elimination and reduction of high attraction (cohesive) force between molecules of water or cement (5).

64) By being not in connection with any abovementioned claim, this is solution (2) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follows; As the solution (2) can be obtained by dissolving powder formed plasticizers and/or air entrainers and/or synthetic limes which are used in the market, they can also be used by being added to cement (5) and/or bentonite (4) and/or other gelling and swelling agents (7) as a powder.

65) By being not in connection with any abovementioned claim, this is mould (10) used in production of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follows; Double-sided pressure/compression from opposite directions (15) can be applied to mortar containing very lightweight aggregates (1) in it.

66) By being not in connection with any abovementioned claim, this is production method of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follows; Desired shape/form is created with double-sided compressor (11) which can apply double-sided pressure/compression from opposite directions (15) in the mould (10).

67) By being not in connection with any abovementioned claim, this is production method of construction materials which contain very lightweight aggregates (1), no matter what other materials they contain and its property is as follows;

There is Faraday air barrier (18) on the product.

Description:
CONSTRUCTION MATERIALS WITH HIGH THERMAL INSULATION

PROPERTY AND PRODUCTION METHOD

The invention is about insulation and construction materials, which are used in floors, interior and exterior facades of buildings and facilities, prevent temperature differences, incombustible, have noise insulation property, save time and labor due to their easy installation property and about production process/method of these materials.

PRIOR ART

The process which is performed in order to reduce heat transmitted between two environments, is called thermal insulation. Materials that enable this, are called thermal insulation materials. Each material has more or less thermal insulation property. Insulating value of a material depends on its heat transmission coefficient (λ). As long as heat transmission coefficient increases, thermal insulation property of the material (gets worse) decreases. According to ISO and EN Standards, materials whose heat transmission coefficient is less than 0,065 W/mK, are defined as thermal insulation materials. Other materials are considered as construction materials. Some construction materials that are currently used for insulation in buildings and facilities and heat transmission coefficients of these materials are as follows.

- Brick (Hollow-solid) Thermal Conductivity Resistance Value λ = 0,180 - 0,500 W/mK

- Pumice Thermal Conductivity Resistance Value λ = 0,120 - 0,470 W / mK

- Gas Concrete Thermal Conductivity Resistance Value λ = 0,110 - 0,310 W/mK - Adobe Brick Thermal Conductivity Resistance Value λ = 0,400 - 0,700 W/mK

- Briquette Thermal Conductivity Resistance Value λ = 0,920 - 0,990 W/mK

- Natural Stone Thermal Conductivity Resistance Value λ = 1,160 - 3,500 W/mK Thermal insulation in the walls of buildings/facilities (Brick, Pumice, Gas Concrete, etc.) also depends on Heat Transmission Coefficient (λ) Values of wall blocks and thicknesses of the wall block used. However, increase in thickness of the block also increases dead load on the structure while increasing cost of the wall, and this increase in load affects static calculations used in the structure and increases amount of material (iron and cement) to be used, thus increases cost of the construction, and it also reduces the structure's resistance to earthquakes in addition to reduction in structure's area of usage (E.g.: Adobe brick is a kind of wall block whose Heat Transmission Coefficient (λ) Value is 0,40 W/m-K and which has been used for dividing for thousands of years. It is not preferred in high-rise buildings because of its weight and reduction in its area of use). Therefore, walls of buildings and facilities are generally made with wall blocks(Brick, Pumice, Gas Concrete, etc.). In order to ensure insulation (U) value that varies according to temperature zones, additional insulation is required to be performed with Foam Type (Polystyrene, polyurethane, polymer foam, XPS, EPS-based) or Mineral (Glass, Stone, etc.) Wool boards which have low heat transmission coefficient. Additional insulation is another factor that increases wall cost. Moreover, these (Foam Type) boards have some weaknesses such as; they don't breathe and they are combustible, they have limited lifetime and their insulation value decreases in time as a result of replacement of gases contained in them with air. Mineral wool (glass, stone) boards also lose their form in time and their insulation value decreases. In each case, users are faced with various problems and costs, and they prefer additional insulation because of their effect on area of use and low weight. In the present case, wall block having high thermal insulation value or similar materials are needed.

Bulk weights of sand and gravel, known as conventional aggregate, are higher than 1.500 Kg/m 3 . Bulk weights of lightweight aggregates vary between 300 and 1.500 kg/m 3 according to kind and type of aggregate. Aggregates such as diatomite, pumice, scoria, expanded clay and schist, expanded blast furnace slag, calcined fly ash etc. are called lightweight aggregates because their densities are lower than 1.500 Kg/m 3 . Aggregates such as expanded perlite, expanded vermiculite, diatomite, expanded glass are also called very lightweight aggregates because their densities are lower than 300 kg/m 3 . For the purpose of thermal insulation in buildings and facilities, prefabricated building elements such as lightweight and very lightweight aggregate based insulation board and wall block are produced and used.

In order to produce products having better thermal insulation properties than others from expanded perlite which is one of the very lightweight aggregates, blocks and building materials have been produced from it by using it alone or together with other materials and various binders. Expanded perlite and various binders and additives have been used in the utility model with registration number TR 2005 03979, patent with registration number TR 2006/06533, patent with registration number TR 2007/07398, patent application with number TR 2009/01739, patent with registration number 2009/05753 with the purpose of providing thermal insulation.

Patent application with number TR 2011/04274 contains expanded perlite, boron (colemanite), clay, coal dust. In the patent application with no TR 2010/10904, there are expanded perlite aggregates, pumice and/or expanded vermiculite aggregates, chopped fiberglass, water, bentonite, gelling and swelling agents, slacked lime and/or cement and/or plaster, borax pentahydrate Na2B 07 5H20 (Tincalconit), paraffin-based water repellents and/or agents preventing water and moisture absorption. In the content of patent applications with no TR 2012/04354; there are expanded perlite aggregates, pumice and/or expanded vermiculite aggregates, chopped fiberglass, water, gelling and swelling agents, clay, boron mineral and/or boron products and/or particularly waste product after production of boron products. It has been also stated in the patent named "Perlite composition and method of making the same" number US 2007/0112098 Al that "It has been found that the order of addition of the starting materials is important, i.e., simultaneous mixing of perlite, binder and cement does not produce the desired products. Rather, it is preferred to first treat the expanded perlite with binder followed by mixing thereof with cement to form the formable mixture." and it is intended to cover expanded perlite with adhesive/binder material which is an aqueous dispersion. The product to be used in order to achieve this purpose is defined as follows; "Commercially available product which is named QUIKRETE® bonding adhesive, which is a milky white liquid having a melting point of 32° F., a specific gravity from about 1.0-1.2, a boiling point of 212° F., and a vapor pressure of 17 mm Hg at 68° F. Depending upon the desired characteristics in the final mixture, the binder may be applied as received, or can be diluted with water. Current practice is to dilute the binder at a ratio of 1 gallon binder/10 gallons water for use in the station. The binder is normally applied to the expanded perlite at a level of from about ¾ to 1½ parts binder per 34 parts of expanded perlite, and more preferably from about 1 part binder per 34 parts." then, related binder material (aqueous dispersion/solution containing a concentrated or diluted synthetic resin such as a vinyl acetate/ethylene copolymer and a vinyl alcohol polymer) is added to expanded perlite moving on a belt firstly, then, Portland cement is added and these are mixed in a mixer, following mixing process by adding water if needed, it is poured into flexible moulds and waited for them to take shape. It is seen that expanded perlite aggregates, fiberglass (glass wool), water and bentonite are used in the patent dated NOVEMBER 3, 1964 and number USA-44764/64 (1.052.996). In the patent dated 22.11.1976 and number AU-A 29131/77, it has been seen that there are expanded perlite, fly ash deposit, diatomaceous earth or mixture of these), fiberglass (glass wool), bentonite and water, these materials are mixed especially in dry state and then, water is added and it is continued to be mixed until it is mixed

5 completely, this mixture is poured into mould and dried and fired at up to 800°C and this product is formed like this. Also, in the patent number 2814740, registered by France; expanded perlite, expanded vermiculite, expanded clay, silicone elastomer, adhesive binder, gellant benton, organic bentonite, precipitated silica, polymerizable resin, hydraulic binder (cement), grade 42 aluminum silicate refractory compound, common

LO corundum, magnesium oxide, magnesium oxide, retarding agents, aluminum

oxide are used.

It can be seen that in some of these patents that were registered in different times from each other, materials that are very lightweight aggregates such as expanded perlite, ί 5 water, bentonite, fiberglass (glass wool), boron and derivatives and Portland cement, are common ingredients, however, they have different additional (aqueous dispersion/solution containing a concentrated or diluted synthetic resin such as a vinyl acetate/ethylene copolymer and a vinyl alcohol polymer) ingredients and same materials are used in various combinations with different methods. Generally in these

!O patents, during conventional mixing process, aggregates used and Portland cement and other binders/adhesives are added first and mixed then, water is added and mixed. In this mixture method, water and Portland cement and other binders/adhesives penetrate into cellules in the aggregates and reduce the thermal insulation value, and also, cause increase in amounts of binders/adhesives used and costs. Unlike other patents, in patent

!5 applications with numbers TR 2010/10904 and TR 2012/04354, very lightweight aggregates are mixed with water first and then, binders such as bentonite, lime, Portland cement etc. are added and weaknesses resulting from cellules filled by binders are tried to be prevented. In this method, it is aimed to prevent binders from penetrating into cellules of aggregates and filling them by letting force of attraction, i.e., adhesive force so work as a filter against molecules of other substances in the water surrounding the aggregates and prevent them from affecting thermal insulation negatively. However, some of the studies has showed that binders that are used react differently according to their types, for example; bentonite and clay interact with water physically like salt, but hydraulic binders such as lime, plaster, Portland cement, etc. chemically react with water. In case of using Portland cement as a binder, when Portland cement reacts with water chemically (hydration), floccules (flocculations) occur and cement particles in the floccule can't react. Only binder granules other than floccules (flocculation) are possible 5 to react chemically. In this case, Portland cement that can't react with water in the floccules (flocculations), stays dry in mortar and can't bind aggregates to each other sufficiently. Lightness of aggregates increase flocculation just the opposite rather than preventing flocculation. When high speed mixing is performed in order to disaggregate floccules (flocculations), aggregates are damaged. As it is known, adhesion is an 0 attractive force between two different matters. Cohesion is the attraction of molecules among its own kind. For example, if we think about a thin glass tube containing water, we can talk about "cohesion" force between water molecules and "adhesion" force between glass and water. Rising and lowering movements of liquids in thin tubes are completely associated with surface tension forces related to the interaction between

15 these two forces and a concave or a convex curve is observed at the top level of liquid due to surface tension in the thin tubes. As a rule; if liquid's "cohesive force" is higher than "adhesive force" between walls of capillary structure in which it is present, liquid level tends to decrease and convex curve is seen on the liquid surface. However, if the situation is the exact opposite, i.e., attraction force between walls of capillary structure

»0 and liquid is higher, liquid level tends to rise at this time and concave curve is seen on the top surface. "Wetness" or "getting wet" which is seen in materials, is naturally associated with the interaction between these two forces. "Wetness" or "getting wet" is named according to the relationship between these forces in chemistry and physics: If adhesive force is higher than cohesive force, the condition is (adhesion > cohesion) =

!5 "getting wet", if there is its opposite, i.e., cohesive force is higher than adhesive force, the condition is (cohesion > adhesion) = "not getting wet". Expanded perlite has glassy structure as it is seen in the example and capillary/micron size cellules, an event occurs which is similar to one in a thin tube and there are "cohesion" force between water molecules in cellules of expanded perlite and "adhesion" force between cell surfaces.

0 These principles, "adhesion" force in the cellules and high surface tension (cohesion) between water molecules and surface tension created by "cohesion" force between cement molecules collectively prevent water molecules from penetrating into floccules (flocculations) and from getting into reaction (hydration). Namely; because Portland cement is calcined at 1.400 °C - 1.500 °C during production, it is a binder which is affected by even humidity and is hungry for water. However, this hunger is not enough for overcoming cohesive forces between water molecules and cement molecules and preventing floccules (flocculations). Even in large mortars prepared by using sand and gravel aggregates whose bulk weights are higher than 1.500 Kg/m 3 , adhesive forces between water molecules and cement molecules and surface tension in these materials can't be overcome and floccules (flocculations) can't be prevented. Lightness of aggregates whose bulk weights (densities) are lower than 300 Kg/m 3 , is a factor increasing flocculation floccules (flocculations). It is not enough to increase water amount in order to eliminate floccules (flocculations) and this causes light aggregates to be damaged. As it is seen, surface tension created by cohesive force prevent water from penetrating into cement molecules. For these reasons, it is possible to use cohesion and adhesive forces in the water as a filter with existing ingredients in patent applications with numbers TR 2010/10904 and TR 2012/04354, because Portland cement prevents hydration, it should be made ineffective with an opposite process and if it is possible, it should be eliminated.

Another issue which is applicable practically but unsuitable for production, is pressure/compression process which is stated in TR 2010/10904, TR 2012/04354 and similar patents containing wall block. The pressure/compression process which is applied in here, is also used in production of pumice wall block and solid brick block. In production of pumice wall block, pressure/compression process is applied as follows; the mortar prepared is poured into mold, pressure is applied with or without vibrator in such a manner that there will be no gaps between pumice aggregates and/or other aggregates and the pressure is applied from top enough to enable aggregates to be brought together in such a matter that there will be no fracture and it will have been compressed at the rate of 10-20%. In the production of brick wall block, because fracture doesn't occur in clay, pressure/compression process is applied as follows; the mortar prepared is poured into mould, pressure is applied from top and bottom with or without vibrator in such a manner that there will be no gaps and it will have been compressed at the rate of 10-30%. This method is tried to be used in the wall blocks for which aggregates whose bulk weights (densities) are lower than 300 Kg/m 3 are used. However, deformation occurs in the products and uniform strength can't be obtained. Increasing amount of the binder which is used in order to increase deformation and to prevent strength, reduces the insulation value of the product and increases the cost. In order to prevent this weakness in the patent with registration number 2012 00682, mortar is needed to be made ready (to a runny consistency like plaster) for pressure after 30 minutes of mixing process, to be compressed at 120 °C and fired for 1 hour in 5 order to make wall block. But, this causes binders used to penetrate into cellules and reduces insulation value while increasing the cost. Because products existing in all valid patents in Turkey and abroad and existing in the market, are not economical besides functionality, their usages are limited.

LO DESCRIPTION OF THE INVENTION

With this invention, prefabricated building elements that can be used instead of existing building elements (brick, pumice, gas concrete, briquette, plaster, screed, etc.) as a building element that doesn't require additional insulation (cheaper, lighter and having higher insulation value than its equivalents), has been produced and usage area of these

L5 completely natural products in the construction sector has been expanded. Time and labor are saved and economy in the insulation has been provided. Due to incombustibility feature of the products related to the invention, loss of life and property damages in the larger proportion have been prevented by preventing fire from spreading to buildings and facilities. Its lightness has lightened the buildings' loads and

10 increased their resistance to earthquake. Investment costs and operating costs have been reduced. Damages that are given to environment and living creatures by existing foam-type insulation products (Polystyrene, polyurethane, polymer foam, XPS, EPS, PVC- based boards) and their production method, have been eliminated. Deformations occurring in the wall blocks that are made by using aggregates whose bulk weights

>5 (densities) are lower than 300 Kg/m 3 , have been prevented and it has been ensured not to use additional binder.

DISCLOSURE OF THE INVENTION

The invention will be understood better with figures in this attachment and further iO expression section. These figures are as follows;

Figure 1 - Schematic representation of the production method of materials having high thermal insulation property

Figure 2 - Schematic representation of a section of the wall block production with double-sided pressure/compression process (15) from the opposite directions Figure 3 - Schematic representation of a section of the board production with double- sided pressure/compression process (15) from the opposite directions

Figure 4 - Schematic and sectional representation of sandwich panel wall production with one-sided pressure/compression process (16)

Figure 5 - Representation of wall blocks from top/bottom

Figure 6 - Perspective representation of wall blocks from top

Materials that are used for production of construction materials with high thermal insulation property (wall block, wall board, sandwich panel wall, plaster, screed, etc.) and their production methods are as follows: The numbering of the used materials, which will help better understanding of the invention, is as follows:

1) Aggregates which are in the very lightweight class

2) Solution preventing floccules (flocculations)

3) Mortar which is prepared with lightweight aggregates (1) with high binding ratio

4) Bentonite

5) Portland Cement

6) Other inorganic and/or organic binders

7) Other gelling and swelling agents

8) ""Wood, OSB, Plasterboard, Calcium Silicate, Magnesium Oxide, Fibrocement and Metal, etc." boards

9) Mixer

10) Moulds

11) Double-sided compressor

12) Dosing process

13) Mixing process

14) Moulding process

15) Double-sided pressure/compression process from opposite directions

16) One-sided pressure/compression process

17) Setting process

18) Faraday air barrier

Materials forming the structure of building elements with high thermal insulation property which is the subject of the invention and production processes are as follows: It consists of following materials and processes; very lightweight aggregates (1), solution preventing floccules (flocculations) (2), mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), bentonite (4), Portland cement (5), other inorganic and/or organic binders (6), other gelling and swelling agents (7), "Wood, OSB, Plasterboard, Calcium Silicate, Magnesium Oxide, Fibrocement and Metal, etc." boards (8), mixer (9), moulds (10), double-sided compressor (11), dosing process (12), mixing process (13), moulding process (14), double-sided pressure/compression process from opposite directions (15), one-sided pressure/compression process (16), setting process (17), Faraday air barrier (18). The binder which is called Portland cement (5) in here, consists of all kinds of Portland cements used in the market (Portland Cement, White Portland Cement, Blended Cement, Trass Cement, Slag Cement, Fly Ash Cement , Sulphate-Resisting Cement, Mortar Cement, Portland Slag Cement, Portland Limestone Cement, Portland Composite Cement, Pozzolanic Cement, Composite Cement, etc.). Related solution preventing floccules (flocculations) (2), is also consists of synthetic lime, air entraining agents, plasticizing agents and all kinds of liquid containing these kinds of materials. In other words, as the solution (2) may consist of only these materials, it also

may comprise solution (2) containing other liquids. While developing this product, it has been inspired by methods that are used for growing plants in agricultural sector and protection systems used in the human body. As it is stated in the patent number US 2007/0112098 Al, the order of addition of the materials used is important. If materials to be used in the mixture (1, 2, 3, 4, 5, 6 and 7) are mixed at the same time and

simultaneously or if they mixed not simultaneously but with a wrong order, this situation prevents obtaining desired products. Therefore, in order to obtain invention product, dosing process (12) is performed and necessary materials (1, 2, 3, 4, 5, 6 and/or 7) are prepared. Order of addition to be used in the product will be described below.

It will be used when it is needed to use mortar (3) prepared with aggregates (1) which are in the ligtweight class and whose binding ratio are high, and it will be prepared in another mixer (9) and it will be used in the stage of double-sided pressure/compression process (15) from the opposite directions. The main group consists of very lightweight aggregates (1), solution preventing floccules (flocculations) (2), bentonite (4) and Portland cement (5), and if it is needed to improve the quality of the desired product, additive agents for different purposes, which can be used together with other inorganic and/or organic binders (6) and/or other gelling and swelling agents (7) and/or cement (5), may be added.

Difference of method which is applied in the mixing process (13) from existing mixing processes, its reason, purpose and benefits are as follows; As it is stated, adhesion > cohesion = getting wet condition and cohesion > adhesion = not getting wet condition which occur on the materials treated with water. Again in plants, these principles apply to transmission of water taken from roots to other organs of plants and its movement in opposite direction of gravity. These principles are much more effective in very lightweight aggregates (1) and if high surface tension generated by the cohesive forces between water molecules, and surface tension generated by cohesive force between cement (5) molecules are higher than adhesive force, this situation prevent water molecules from penetrating into cement (5) and getting into reaction (hydration). If and only if high attraction (cohesive) force between water molecules and/or cement (5) particles is eliminated or reduced and adhesion > cohesion = getting wet condition is provided, these will be possible; all dust particles in Portland cement (5) will get into reaction (hydration); i.e., floccules (flocculations) will be prevented by these principles. The way of provision of this condition and order of addition do not constitute a problem for applications made by using sand and gravel aggregates, because these aggregates don't contain cellules, however, they constitute a problem for lightweight aggregates (1) having porous structure and they are very important. Namely; as it has been stated before, even in mortars prepared by using sand and gravel aggregates whose bulk weights are higher than 1.500 Kg/m 3 , adhesive force between water molecules can't be overcome and floccules (flocculations) can't be prevented. It is clear that prevention of floccules (flocculations) in mortars prepared by using aggregates (1) whose densities are lower than 300 Kg/m 3 , is not possible. One of two methods which are used in order to overcome this problem existing in mortars prepared by using sand and gravel whose densities are more than 1.500 Kg/m 3 , is increasing water amount and the other is using various additives. Weight ratio of water required for the hydration of Portland cement (5) is 14-32%. Water/cement ratio in existing applications is 45 - 65%. It is aimed to disaggregate floccules (flocculations) and to enable fluidity in these mixtures. However, large amount of water affects strengths of concrete, plaster, etc. products negatively in available applications. Therefore, because large amount of water causes damage in lightweight aggregates (1) and reduces insulation value of the products, this method is not appropriate for disaggregating floccules (flocculations). The other method for disaggregating floccules (flocculations) occurring in existing mortars, is the use of various types of plasticizers as additives. In order to gain higher strength with plasticizers in concretes, it is aimed to prevent increase of cement amount or to reduce heat of hydration or to ensure ease of placeability that can be enabled with mixtures with high rate of water. When these additives are added into concrete by being used in the appropriate conditions, 11 - 19% of reduction in the water amount of the mixture can be obtained on condition that providing same placeability. While some of the related additives/plasticizers have effect on Portland cement (5), some of them has effect on water. While some types of plasticizers increase placeability, dispersion of cement particles with electrostatic repulsion and/or sterical effect, some of them are substances, reducing surface tension of water with their chemical configurations having spaces, dissolving in the water and/or they prevent flocculation by entraining air into cement (5). For these processes, air entraining additives improving placeability of the concrete, synthetic lime and plasticizer additives that are available in the market with different brands (normal, medium, high, super, hyper, etc.), are used. When these materials are used without reducing the amount of water in the mixture, they improve pumpability by improving placeability of mortar significantly. As it is known, strength of concretes is important, not thermal insulation. Regardless of their types, all synthetic lime and/or plasticizers and/or air entrainers are used in order to increase strength and reduce water by thickening mortar to be used to make concrete mortar runny and easily placeabile. As it is seen, same materials can be used for different purposes and different results are obtained according to usage. Being different from these applications existing in production process of product which is the subject of the invention, mortar containing Portland cement (5) and lightweight aggregate (1) need to have a feature of plastic by being runny and easily placeable. It is prevention of amount of binder (5) which will bind aggregates (1) from affecting insulation value on the product negatively due to prevention of floccules (flocculations) in the target mortar.

In case of preparing mortar by adding solution (2), cement (5) and aggregate (1) into the mixer (9) and mixing it as in existing mixing methods, cellules of aggregates (1) having porous structure are filled with cement (5) particles together with solution (2). Existing mixing methods increase amount and cost of cement (5) used as binder and reduce thermal insulation. It is seen that a method which is different from existing applications made with sand and gravel in order to prevent reduction in thermal insulation and increase in cement (5) cost, is needed. As a result of research made, it was seen that similar problem was present in agricultural sector. When fertilizers that are sprinkled on the ground, come into contact with surface irrigation water or rain water, they dissolve in the water and go underground. In this method, desired efficiency can't be obtained from fertilizer and need for fertilizer increases. In addition to increasing fertilizer amount and cost, they contaminate groundwater and also affect the environment negatively. This problem in the agricultural sector was solved by using liquid-absorbing materials as follows: Solution containing fertilizer is stored in these liquid-absorbing materials and it is ensured that plant takes fertilizer and water needed through its roots. In the hydroponic agriculture conducted in greenhouses or outdoor areas today, aqueous culture fluid which is needed by plants, are stored in superabsorbent materials obtained chemically and cellules of very lightweight aggregates (1) such as mineral structured expanded perlite, vermiculite, etc. Plant nutrition is ensured by enabling plant roots to take the solution containing fertilizer and/or medicine in the amount needed by plant from these cellules in these aggregates (1). By being inspired by nutrition method used in plants, it was enabled cellules in the expanded perlite aggregates (1) to take solution preventing floccules (flocculations) (2) in the amount needed by Portland cement (5) for hydration without being filled by cement (5) particles together with solution (2) with the help of mixing process (13) which is also used in production related to the invention. Solution preventing floccules (flocculations) (2) is a structure containing diluted dispersion/solution of all kinds of (normal and/or high rates of (normal-medium-super-hyper) water reducer ) plasticizers and/or air entrainer and/or synthetic lime resins which are used in the market in the powder or liquid forms. Depending on the properties desired, as the solution preventing floccules (flocculations) (2) can be taken directly as a concentrate, it can also be prepared by being diluted. As this solution (2) can be obtained by dissolving powder formed plasticizers and/or air entrainers and/or synthetic limes, they can also be used by being added to cement (5) and/or bentonite (4) and/or other gelling and swelling agents (7) as a powder. As it is stated before, the order of addition of the materials used is important and different order prevents obtaining desired products. In order to obtain the product which is the subject of invention, necessary orders needed during additions are as follows; 1st Ordering Method; very lightweight aggregates (1) and solution preventing floccules (flocculations) (2) are mixed in a mixer (9) by being blended and then, bentonite (4) and/or other gelling and swelling agents (7) are added as a filler, right after this, Portland cement (2) is added as a main binder, then, this mixture is mixed again and mixing process (13) is completed.

2nd Ordering Method; Mixing process (13) can be performed by firstly adding bentonite (4) and/or other gelling and swelling agents (7) and then, very lightweight aggregates (1) to a mixer (9) and mixing them and by spraying mist/pulverized solution preventing floccules (flocculations) (2) on them during this process. Because very lightweight aggregates (1) can't be mixed with bentonite (4) and/or other gelling and swelling agents (7) because of the density difference and absence of liquid which may adhere to them during mixing process, very lightweight aggregates (1) are mixed with sprayed solution preventing floccules (flocculations) (2) by staying at the top and absorb it.

During mixing process, aggregates (1) whose density is increased by the solution preventing floccules (flocculations) (2), change place with lighter aggregates (1). Lightweight aggregates (1) reaching sufficient density move downwards because of gravity and they are mixed with bentonite (4) and/or other gelling and swelling agents (7) presenting at the bottom of the mixer (9). This mixture which is prepared by adding Portland cement as a main binder after these, is mixed again and mixing process (13) is completed.

3rd Ordering Method; In the mixing process (13), it is possible to mix it with lightweight aggregates (1) following mixing solution preventing floccules (flocculations) (2) with bentonite (4) and/or other gelling and swelling agents (7). This mixture which is prepared by adding Portland cement (2) after these, is mixed again and mixing process

(13) is completed.

4th Ordering Method; In the mixing process (13), very lightweight aggregates (1) are mixed with solution preventing floccules (flocculations) (2) in a mixer (9) by being blended first, after this, mixture prepared by adding Portland cement (2) as a main binder, is mixed.

5th Ordering Method; In the mixing process (13), very lightweight aggregates (1) and solution preventing floccules (flocculations) (2) are mixed in a mixer (9) by being blended and then, Portland cement (2) is added as a main binder, right after this, bentonite (4) and/or other gelling and swelling agents (7) are added as a filler, this mixture is mixed.

As it is seen here, the important factor is adding solution preventing floccules (flocculations) (2) and bentonite and/or other gelling and swelling agents (7) before Portland cement (5) added as a main binder in here. However, this is not an essential factor, it is possible to add solution preventing floccules (flocculations) (2) to the mixture of very lightweight aggregates (1) and Portland cement (5) later. By making a change in the order, it can be enabled to be in the mixture after Portland cement (5). I.e.;

6th Ordering Method; First of all, very lightweight aggregates (1) are mixed with water in a mixer (9) and then, it is mixed with bentonite (4) and/or other gelling and swelling agents (7) as a filler, following this, solution preventing floccules (flocculations) (2) is added to this mixture right after Portland cement (5) is added as a main binder, it is mixed again and mixing process (13) is completed.

As it is seen here, solution preventing floccules (flocculations) (2) is added after Portland cement (5) which is a main binder in this order however, entrance of Portland cement (5) into fillers (4 and 7) and very lightweight aggregates (1) is prevented even if partially. If it is needed in order to increase the quality of desired product, other inorganic and/or organic binders (6) and/or additive materials for different purposes that can be used together with cement (5), can also be added to this mixture. The most efficient method is enabled by adding solution preventing floccules (flocculations) (2) to very lightweight aggregate (1) mixture initially. Because solution preventing floccules (flocculations) (2) which is stored in cellules of lightweight aggregates (1), is absorbed by bentonite (4) and/or other gelling and swelling agents (7) during mixing process (13) and it is trapped ir hem, then, cement (5) which is added, uses solution (2) in the amount needed for hidration by taking it from bentonite (4) and/or other gelling and swelling agents (7). Bentonite (4) is a type of clay that is also known as montmorillonite and swells to 2 - 10 times of its normal volume when it contacts with water and shrinks when it gets dry. Other gelling and swelling agents (7) are also organic or inorganic materials that swell by absorbing 10 - 200 times their own weights when they contact with water and shrink when water dries up. This feature enables bentonite (4) and/or other gelling and swelling materials (7) to be used as both filling and storage. Cement (5) primarily supplies water which is needed for hidration from solution (2) contained by bentonite (4) and/or other gelling and swelling agents (7) and/or aggregates (1), and cement (5) doesn't contact with solution which is more than needed. Because additives in the solution (2) reduce cohesive force between molecules of materials in the mixture, flocculation doesn't occur and all cement (5) molecules in the mixture can get into reaction. Remaining solution (2) stays within bentonite (4) and/or other gelling and swelling agents (7) and/or aggregates (1), and it leaves the product by evaporating after taking hydration heat on it. As it is known, sweat is a liquid which is used in cooling system of the body. We sweat to adjust our body temperature when we have fever or do exercise. When the water in the form of sweat appears on the skin, cools the body by evaporating. Similarly, the water that is stored in bentonite (4) and/or other gelling and swelling agents (7) and aggregates (1) and doesn't get into reaction with cement (5), serves a function in cooling by taking heat generated during hydration on it.

Difference of method which is applied in the moulding process (14), its reason, purpose and benefits are as follows;

In the existing moulding processes, mortars prepared are poured into moulds appropriate for one-sided pressure and by pressing mortar which is in the mould on one side (16), pumice and (some) brick type wall blocks are formed. Unlike these methods, in our process, moulding process (14) is completed by filling the mould (10) which is appropriate for double-sided pressure/compression process from opposite directions (15) with lightweight aggregates (1) which are prepared by mixing process (13). Wall block form is created with double-sided pressure/compression process performed from opposite directions (15) in the mould (10). Our partition wall block which is the subject of the invention, has a sufficient strength that will meet the needs, and properties desired in wall blocks may vary and it may be necessary to increase strength of the outer surfaces of the wall blocks in order to provide properties desired. In order to improve the quality of desired wall blocks, mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), will be used and outer surfaces of wall blocks will be covered with this mortar (3) during moulding process (14). Mortar which is prepared with lightweight aggregates (1) with high binding ratio (3), is laid on mould (10) as a thin layer and normal mortar which is prepared by mixing process(13), is poured into mould (10) on it and moulding process (14) is completed by laying mortar which is prepared with lightweight aggregates (1) with high binding ratio (3) as a thin layer again. With double-sided pressure/compression process applied from opposite directions (15) to mortar which have become a sandwich in a mould (10), outer surfaces of wall block become harder and more resistant than the middle portion. Likewise, it has the surface structure needed by plaster to be applied on our partition wall block and it may be needed to enlarge area of the outer surface of the wall blocks in order to ensure better adhesion of plaster. Adhesion area of plaster on the surfaces of products that can be formed during moulding process (14), can be enlarged optionally.

Double-sided pressure/compression process from opposite directions (15) for the purpose of creating form for products which are formed in wall block, wall board, etc., its difference from existing pressure/compression processes, its reason, purpose and benefits are as follows; Desired shape/form can be given to mortar which is prepared by mixing process (13) with compressor by being poured into moulds as in pumice and solid brick production. As a result of examination made, it has been seen that in case of applying existing methods to wall blocks for which aggregates (1) whose densities are lower than 300 Kg/m 3 , are used, aggregates (1) in the mortar situated in a mould (10) are crushed by being damaged because of one-sided pressure/compression which is applied on the top or bottom (As it is seen Figure 2), i.e., mortar consisting of lightweight aggregates (1) acts like a shock absorber or a bellow, it absorbs the pressure applied on the mortar and can't transmit the pressure to the other side of the mould, i.e., other aggregates (1) that are in the closed side of the mould and that will form the wall block at the desired level and uniform compression can't be provided. Unlike existing practices, double-sided pressure/compression method (15) has been developed by double-sided pressure/compression process applied from opposite directions (15) in the mould (10) situated in double-sided compressor (11) (As it is seen Figure 2) in order to provide a uniform compression. Double-sided pressure/compression process from opposite directions (15) occurs inside of the mould (10).

Products which are formed by mixing process (13), moulding process (14), double- sided pressure/compression process from opposite directions (15), are brought into use after they have desired strength as a result of setting process (17). As the wall blocks that we have developed can be produced as solid like gas concrete, they can also be produced as hollowed like pumice wall blocks. As hollows reduce the density of the product, they serve as an air barrier that prevent heat transmission. Still Air's Thermal Conductivity Resistance Value (λ) is = 0,023 - 0,025 W/mK and it has superior thermal and sound insulating properties. As a result of studies made, it has been seen that air gaps should vary between 50 mm - 18 mm, air barrier created by gaps having different sizes than these don't contribute to the insulation. In "Faraday Cage", as it is known, in case of presence of more conductive material in the environment, electricity proceeds on conductive material. Likewise, heat also moves through the materials which have less resistance to heat transmission because of the resistance of the air barrier formed by the gaps. Therefore, staggered designs were made for some pumices and bricks with air spaces and the path of heat was tried to be extended and products with lower Thermal Conductivity Resistance Value (λ) = 0,05 W/mK could be produced. When reaction of heat to the extension of its path, existing applications and data of results obtained were analyzed, it was concluded that heat acts like electricity. Instead of creating a large number of staggered air barriers as in existing pumice, etc. all blocks, integral air barrier (18) has been formed by getting inspired by action of heat in Faraday Cage". The calculatons has shown that the path through which heat flows is approximately 12,2% longer than staggered design.

In the 190 mm of wall block, the average distance which will be covered by heat is as follows;

In the wall block with 6 rows of hollow, which is not staggered, the average is 190 mm In the staggered wall block with 6 rows of hollow, the average is 573 mm

In the staggered wall block with 3 rows of faraday hollow, the average is 653 mm heat transmission path is as follows;

It was extended 463 mm, i.e., 243% ((653-190)xlOO/653) in comparison with wall block with hollow, which is not staggered

It was extended 80 mm, i.e., 12,2% ((653-573)xl00/653) in comparison with staggered wall block with hollow. In other words, insulation ability of the wall block was increased.

The products which are in the shape of sandwich panel are produced as follows; mortar which is produced by using only bentonite (4) and/or other inorganic and/or organic binders(6) with cement (5) or without cement (5), is poured between "Wood, OSB, Plasterboard, Calcium Silicate, Magnesium Oxide, Fibrocement and Metal, etc." boards (8) or on these boards (8), then, pressed from one side (16) and boards are mounted on them. Setting process (17) and/or drying process occur in panels. It can also be formed by putting wall blocks whose setting process has happened outside, into panels.

In the products which are in the form of plaster and screed, the mortar which is prepared by mixing process (13) and method is adhered to the application surface or poured on the floor and setting process (17) occurs on the surface or floor. Raw material mixing ratio of the product; every binder material which is added to mortar consisting of all very lightweight aggregates (1) has a negative effect on insulation value of the product, i.e., heat transmission coefficient and the cost. Therefore, products' ingredients and rates vary according to environment in which they will be used. Depending on using cement (5), amounts of solution (2) and/or bentonite (4) and/or cement (5) and/or other inorganic and/or organic binders (6), and/or other gelling and swelling agents (7) vary. In the sandwich panels that are produced by using board (8), use of cement (5) as a stabilizer is not compulsory. It is sufficient to use other materials (4, 6 and 7) in the amount which is enough to hold perlite aggregates together. However, during block production, amounts of additive materials for different purposes increase together with these materials (2, 4, 5, 6 and 7).

Variability of usage area and purpose of building elements and the thermal insulation which is the subject of the invention, necessitates using different materials and using different methods in the production of products. At the same time, materials which help products produced as thermal, fire and noise insulation materials to be understood more clearly, and which are used in it, ingredient ratios are presented below:

For construction materials which can be used in walls, floors and ceilings, 75 - 93% of very lightweight aggregates (1) containing expanded perlite and/or vermiculite are added. 1 - 10% of Portland cement (5) which is the main binder, 1 - 10% of bentonite (4) which is used as a filler and 0,5 - 1% of solution preventing floccules (flocculations) (2) are added to this content according to abovementioned methods. In case of using other inorganic and/or organic binders (6) and/or other gelling and swelling agents (7), their amounts are same as amounts of materials which are substituted by them.