Paint with thermal insulation characteristic

The Related Art

The invention relates to paints produced in paint industry. The invention particularly relates to paints used as building and car paints and comprising Aerogel. The Prior Art

Aerogel is a material used as a kind of transparent insulation material in the field of architecture. Its most significant characteristics are being ultra-light and being an ultra-insulator. It is used in various fields due to these and other characteristics. The surface of Aerogel, formed of millions of tiny holes, resembles a sponge. It is formed of 99.8 % air and it is an ultra-insulator. Aerogel has much more superior characteristics than known foams and other insulation substances.

Aerogels are materials that are quite expensive to produce, but have a high contribution to architecture. It is a material with a frozen smoke appearance and looks like glass. Due to its similarity to glass, its use on facades and even on roofs is possible for buildings. At the same time, Aerogels have quite good insulation against fire.

Until today, Aerogels have been produced and used in the form pallets, blankets, micro-sized granules etc. However, its use as particle coating is not present. In the prior art, Aerogels increase the thickness of the structures they are used on. In addition, the application prices of Aerogels are also high.

The bonds found in the Aerogel structure are generally physical bonds, and therefore generally pure Aerogel is used in industry, regardless of the chemical and mechanical bonds between the additives. Brief Description of the Invention

The invention relates to a paint with thermal insulation characteristic, which meets the above said requirements, eliminates all of the drawbacks, and brings some additional advantages.

The primary purpose of the invention is to ensure use of a single product for insulation and painting purposes in the construction sector.

The invention aims to reduce costs by 50 % by using a single product for insulation and painting purposes in the construction sector.

A purpose of the invention is to ensure 95 % energy saving in buildings.

The invention also aims to ensure sound and thermal insulation in buildings.

Another purpose of the invention is to ensure protection of walls from the impact of vapour in areas with heavy rain.

Another purpose of the invention is to reduce energy consumption for heating purposes.

Another purpose of the invention is to ensure obtaining long-lasting paint that is durable against scratches and fire. Another purpose of the invention is to reduce paint consumption from 650 grams to 150 grams per square meter.

Another purpose of the invention is to provide decorative coating in a single step application, in addition to insulation.

Another purpose of the invention is to ensure UV insulation on glasses/windows of museums and libraries. Another purpose of the invention is to eliminate the need for using thick sealant for facades.

Another purpose of the invention is to develop a paint comprising Aerogel to be used as building and car paint.

Another purpose of the invention is to ensure obtaining a cheaper and more effective construction and automotive paint compared to similar products. In order to achieve the above said purposes, the paint comprises pigment and resin as well as Aerogel.

In order to achieve the purposes of the invention, said paint comprises extender and/or additive. Said Aerogel is SiO2-based.

In an alternative embodiment of the invention, said Aerogel is in the form of nanosize ground powder.

In an alternative embodiment of the invention, said paint comprises Aerogel obtained by sol-gel method, and into which pigment is added during the step of obtaining with sol-gel method. The size of said pigment can be larger or smaller than the size of Aerogel gaps.

In an alternative embodiment of the invention, said paint comprises resin-pigment mixture impregnated Aerogel.

In order to achieve the purposes of the invention, the production method of said paint comprises the operation steps of:

• obtaining Aerogel, and

· mixing the obtained Aerogel with resin and pigment.

In an alternative embodiment of the invention, an extender and/or additive is also added. In an alternative embodiment of the invention, the production method of said paint comprises the operation steps of:

• obtaining said Aerogel in block form,

• pulverizing the block-form Aerogel into nanosize powder,

· mixing the powder-form Aerogel with resin and pigment.

In an alternative embodiment of the invention, the production method of said paint comprises the operation steps of:

• obtaining Aerogel by sol-gel method,

· during the step of obtaining Aerogel, adding pigment into the sol-gel phase and mixing therein,

• drying,

• grinding, and

• adding and mixing resin. Pigment, which is smaller or larger than the size of the Aerogel gaps, is added into the sol-gel phase.

In an alternative embodiment of the invention, the production method of said paint comprises the operation steps of:

• grinding the obtained Aerogel,

· heating the resin up to the melting point and adding the pigment powder and mixing therein,

• adding the Aerogel granules into the resin-pigment mixture, and mellowing therein, and

• cooling and re-grinding the Aerogel granules. Paint obtained according to this method is heated up to the resin melting temperature before use, and sprayed onto the painting surface after heating operation.

The structural and characteristic features of the invention and all of its advantages shall be understood better with the below given detailed description. Therefore, the assessment should be made by taking into account the detailed descriptions.

Detailed Description of the Invention In this detailed description, the preferred embodiments of the paint with thermal insulation characteristic are only disclosed for better understanding of the subject without forming any limiting effect. The invention consists of paint comprising Aerogel in its structure. The invention particularly relates to building and car paints. Aerogel is used in place of extender in the paint or combined with the pigment structure.

In case of using Aerogel material instead of extender in paint production, the following operation steps are applied:

• obtaining an SiO2-based Aerogel block that is suitable in terms of polarity (hydrophilic or hydrophobic in terms of polarity),

• pulverizing the resulting Aerogel block into nanosize particles in accordance with the structure of the paint via blasting or grinding methods (grinding in chemical and dimensional harmony with the pigment, resin, extender and other additives found in the paint structure),

• mixing the obtained powder form Aerogel with the resin and pigment in a reactor at a certain temperature and time (according to paint standards). Extenders are one of the important phases of paint used during paint production, which gives volume to the paint and increases the covering capacity. These materials increase the overlapping power of the paint without affecting the colour tone of the pigment. Extenders often have a larger percentage in the paint than the pigments, and the adhesion capacity of the resin is equally divided between the pigment and the extender.

According to the resin structure, the Aerogel block is obtained in hydrophobic or hydrophilic form. This application increases the adhesion capacity of the resin. The Aerogel block obtained in hydrophobic or hydrophilic form is ground by grinding machines to the desired size for the paint structure. The powder form Aerogel is used instead of Extender in the production of paint without using Extender or by decreasing the amount of Extender. The use of Aerogel material in place of extender in paint production takes place in 3 stages. In the first stage where SiO2-based Aerogel block is obtained, the pH value of Aerogel material is adjusted according to pigment and resin chemistry, and Aerogel is produced at appropriate pressure according to the structure of the paint. Depending on the pressure, the gap dimensions of the Aerogel structure are adjusted to ensure compatibility with the pigments and resin. Various pressures, suitable for the structure of the paints, are applied. The pressure control changes the size of the pores in Aerogel structure and makes them compatible with the structure. As the gap sizes increase, the paint weight decreases, and said gap sizes are adjusted depending on the paint quality. In the second stage, depending on the size of the Aerogel gaps, the Aerogel block is milled with ultrasonic or mechanical milling method to a size suitable for the paint structure. The resulting powder Aerogel is mixed with resin, pigment, and required additives (antifoam, matting agents etc.) in the third stage in a reactor at a certain time interval and temperature, until they become homogeneous, and thus the paint is obtained.

Extender materials are diverse and are specific to each paint according to standards. They are much heavier compared Aerogel, and do not provide insulation. Since they make the structure incompatible with the production of paints, they restrict the use of resin and pigment varieties. Aerogel obtained in Extender form suitable for pigment and resin structure has thermal insulation characteristic and is ultralight. In this way, the alternatives of pigment and resin types that can be used in paint production can be increased. The advantages of this method are:

a) increasing the covering capacity of the paint by reducing the extender weight, b) obtaining more durable paint against scratching,

c) ensuring the production of the structure which prevents passage of vapour, d) increasing the resin overlap capacity and decreasing the cost,

e) being the easiest and most inexpensive technology method.

Approximately 70 % of insulating characteristic is provided in the paint obtained with this method. It needs to be used in a suitable environment depending on the weather conditions. // Aerogel material is coated on pigment, the following operation steps are applied; · adding pigment into the sol-gel phase, which is larger than the size of the Aerogel gaps, in the stage of obtaining Aerogel by sol-gel method and obtaining Aerogel,

• forming a homogenous suspension by mixing at a certain temperature and time,

· drying the Aerogel structure in suspension and obtaining Aerogel in solid form,

• grinding the obtained Aerogel,

• mixing the obtained Aerogel-coated pigments with resin and additives.

In the second method, the paint production procedure is included in the production of Aerogel. In this technique, first of all, the dimensions of the gaps found in the Aerogel structure are determined according to the parameters applied in the production process of Aerogel. The pigments to be used in the production of the paint are brought into a more suitable form than said spaces. In this method, the Aerogel pore sizes should be much smaller than the pigment. While Aerogel is being prepared, pigments are added to the system and the Aerogel making process continues normally. After the process is completed, the solid Aerogel is ground to the desired size. With this method, powdered pigments coated with Aerogel are obtained.

In the stage of Aerogel production, the sol-gel phase of the Aerogel structure is prepared. This phase has the power to make chemical compound depending on pH value. For this reason, appropriate pigment powder is added depending on the polar and chemical interaction. Sol-gel is prepared from S1O2, ethyl alcohol, and similar materials (group of alcohols), and appropriate pigment powder is added in accordance with the pH value (in accordance with paint standard). The resulting mixture is mixed at a certain time interval and temperature depending on the particle size (pigment size) to form a homogeneous suspension. Then the suspension of Aerogel structure is dried with SCD (Super critical drying) method, and becomes a painted block. This step is a method of making Aerogels by common methods, but at this stage, the production pressure of Aerogel is applied depending on the pigment size. Pigment sizes need to be larger than the aerogel gaps. Therefore, low pressure ratios are chosen. At this stage, solid Aerogel is obtained. The obtained Aerogel structure is milled by ultrasound or grinding method to the appropriate size (suitable for other materials found in the paint). This is a computer aided process. The obtained Aerogel-coated pigments, resin, and additives are mixed to form the paint structure.

The advantages of this method are:

a) Pigments become completely thermally insulating.

b) Aerogel that covers the pigments takes the place of the Extender and there is no need to add an Extender. Therefore, 2 phases of the paint are completely insulative. c) The resin bonds with Aerogel instead of pigment, and the amount of resin is lower because the two structures are produced compatibly. Reducing the amount of resin increases fire durability and increases thermal insulation and reduces production costs.

d) Agglomeration of pigments is unlikely during production.

e) The paint provides thermal insulation of about 80 %. Pigments are covered with Aerogel and act as Extender. At this stage, the pigment size must be larger than the Aerogel pores (gaps).

// the pigments are homogeneously dispersed in the aerogel material, the following operation steps are applied:

· adding pigment into the sol-gel phase, which is smaller than the size of the Aerogel gaps, in the stage of obtaining Aerogel by sol-gel method and obtaining Aerogel,

• forming a homogenous suspension by mixing at a certain temperature and time,

· drying the Aerogel structure in suspension and obtaining Aerogel in solid form,

• grinding the obtained Aerogel,

• mixing the obtained pigments that are homogeneously dispersed in the Aerogel with resin and additives. This method uses the same technique as the second method, but there are some differences. According to the pressure settings, the size of the Aerogel gaps is larger than the pigments, and the resulting structure has a more homogeneous shape after grinding. Pigments are trapped within the gaps. Painted Aerogel particles are obtained.

In this method, the sol-gel phase of the Aerogel structure is prepared in the first step. This phase has the capacity to make chemical compounds depending on the pH value, and accordingly, the appropriate pigment powder is added depending on the polar and chemical interaction. Sol-gel is prepared from S1O2, ethyl alcohol, and similar materials (group of alcohols), and appropriate pigment powder is added in accordance with the pH value (in accordance with paint standard). The resulting mixture is mixed at a certain time interval and temperature depending on the particle size (pigment size) to form a homogeneous suspension. Then the suspension of Aerogel structure is dried with SCD method, and becomes a painted block. This step is a method of making Aerogels by common methods, but at this stage, the production pressure of Aerogel is applied depending on the pigment size. Pigment sizes need to be smaller than the gaps. For this reason, high pressure ratios are chosen. At this stage, solid bulk Aerogel is obtained. The obtained bulk Aerogel structure is milled by ultrasound or grinding method to the appropriate size (suitable for other materials found in the paint). This is a computer aided process. Homogenously dispersed pigments are obtained in Aerogel. These granules are mixed with resins and additives to form the paint structure.

The advantages of this method are:

a) As the pigments are smaller, the total surface area increases, and the diffraction of the light increases, resulting in a stronger paint. b) The size of the pigments get smaller and Aerogel becomes more active and the insulation increases. c) Grinding can be done at the desired size. This shows that the paint is better quality and homogeneous. d) In this method, the resin only interacts with Aerogel. The fact that the granules are in a smaller size increases the adhesion force of the resin. Therefore, again the amount of resin is decreased. e) By acting as the Extender, Aerogel makes the Extender to be homogeneously compatible with the Pigments.

The thermal and sound insulation rate of the Aerogel obtained with this method is increased by 90 %.

// resin pigment mixture is impregnated into the Aerogel material, the following operation steps are applied;

• obtaining and grinding Aerogel,

• heating the thermoplastic resin up to the melting point and adding the pigment powder and mixing therein,

· adding the Aerogel granules into the resin-pigment mixture, and mellowing therein, and

• cooling and re-grinding the Aerogel granules.

With this method, it is aimed to bring the amount of resin to a lower level. Decrease of the resin increases fire resistance and increases the insulation rate of the structure. In addition, the pigment cost is much lower in this method, and the superior phase in the structure is the Extender phase which is produced completely from Aerogel. In this method, 90 % and more of the paint structure is covered by Aerogel. First of all, Aerogel is obtained in pure form and as comprising air gaps in desired size, with the prior art methods. The obtained Aerogel material is granulated by grinding. A thermoplastic resin is chosen for paint production. Aerogel granules are immersed into the molten resin containing pigment particles for a certain period of time. Aerogel granules are kept at the same temperature until the liquid mixture is absorbed and then cooled. The particle size of the pigments used in this method need to be much smaller than the Aerogel gap dimensions. It is possible that the pigment grain sizes are in the nano size. Aerogel granules immersed into the pigment-resin mixture superficially absorb the liquid resin-pigment mixture, and are thus superficially painted. Afterwards, the Aerogel granules are cooled (the solidification temperature of the thermoplastic resin applied), and, after cooling, purified and re-milled and packed in powder form. In this way, ready-made granule paints are obtained.

The paint consisting of resin- and pigment-impregnated Aerogel granules is heated to the resin melting temperature during application, and sprayed onto the desired surface. By heating, the Resin-Pigment thermoplastic mixture, which is trapped in the surface structure of the Aerogel granules, becomes liquid and come out, and the present powder mixture turns into a fluid form. The resin-pigment thermoplastic mixture leaks out of the Aerogel granules and thus covers the Aerogel granule surface. When said granules are sprayed on the wall surface in this state, they immediately cool down and solidify on the wall surface. In other words, Aerogel granules adhere to each other superficially and form the paint layer. The advantages of this method are:

a) Up to 95 % of thermal insulation can be provided.

b) If the amount of resin is too low, then the fire resistance of the paint is high. Also the cost of resin is low.

c) No solvents are required. Temperature acts as the solvent. This is quite important in terms of cost and not causing malodour.

d) Painting speed is high, and drying is possible within a few minutes.

Aerogel is generally produced and used in the form of pallets, blankets, micro-sized granules, etc., but it is not used in particle coated form. As a result of the applications made in the scope of the invention, Aerogel coated paint pigments are obtained. With the obtained Aerogel coated paint pigments, it is possible to reduce the structure thickness up 8-12 folds (when compared to old and new products such as glass wool and EPS, respectively) and reduce the application price.

The bonds found in the Aerogel structure are generally physical. Therefore generally pure Aerogel is used in industry, regardless of the chemical and mechanical bonds between the additives. The Aerogel production conditions for the product according to the invention vary according to the additive materials, and by forming chemical, polar, and mechanical bonds within the structure, the hardness, insulation, and adhesion of the lattice structure increases and appears as a coating.

In the scope of the invention, a new product is obtained by adding Aerogel to the paint structure. This new paint product is much cheaper, lighter in weight, and more efficient than similar products. Similar products are available on the market, but are made with other methods and base materials and are also more expensive in price. In addition, since the base material of this product is made of silicon up to 90 %, it has an environmentally friendly structure. Aerogel material has been used in various insulation industry fields so far, but it is still not used in paint industry.

Within the scope of the invention; paint is obtained in a cheaper and more effective way than similar products. As a method, it allows application of Aerogel into paint structure.

The product of the invention is an Aerogel based nano-technological insulating paint produced by Aerogel modification. While other thermally insulative paints and pastes are effective less than 60 %, the paint according to the invention is effective up to 95 %. It is possible to obtain the paint of the present invention in hydrophobic, hydrophilic, or air permeable form.