FILLING

Technical Field

The invention relates to a composite panel with rice husk additive and polyurethane filling.

The invention specifically relates to, a panel with rice husk or rice husk powder or rice husk and rice husk mixture additive and polyurethane filling, that aesthetically solves the problem of outer shell of structures such as heat, water and sound insulation, and that is used on the roofs and facades of large-sized buildings the carrier system of which is steel or prefabricated, such as factories, industrial buildings, military buildings, social buildings, agricultural buildings, sports facilities, construction site buildings, silos, hypermarkets, shopping malls, cold stores, wholesale market buildings, in production of facades, roofs, cold storage, louver- shutter, refrigerators, in white goods industry, space and aviation industries.

Prior Art

Today, roof, facade and insulation materials with polyurethane filling are widely used. In almost all areas that we interact in daily life, it is possible to see roof, facade and insulation materials with polyurethane filling. The insulation materials are mainly used to be protected from heat, sound, water and external sourced variables or to prevent heat, sound and moisture from getting out of the insulation area. The roof, facade and insulation materials with polyurethane filling are produced to be used in the desired sizes in facades, roofs, cold air tanks and floors.

The bottom and top surface of the composite panels are formed by shaping two aluminum or galvanized sheets of the desired color and thickness, which enter the production line from one end of the sandwich or coating material, and then the composite facade and the roof panel with filling are formed by pouring polyurethane (PU) having different density and thickness, as insulation material between the boards. Polyol, Isocyanate (R-N = C = 0), catalyst, additive and pentane are used as raw materials in the production of the facade and roof panels with polyurethane filling. Panels are cut to the desired length and number and are made ready for shipment.

In the recent years, technological progress has had important effects in the fields of both industrial and agricultural production. Increasing production amounts as a result of the needs brought about the use of more chemicals and accumulation of waste materials. The increase in the products, in nature, used in the production phase and which come out as waste after production poses a threat to the environment and human health. Therefore, it is aimed to have lower carbon traces of the materials used in the production phase, to develop more environmentally friendly production methods and models, and to reduce environmental and human damage by using the wastes obtained after production as recycling materials and to provide cheaper production as a result of lower raw material input. Recycling activities are widely used in various industrial facilities in order to reduce the harmful effects of these wastes, to save energy and to use them as recycling material.

In the existing production methods, for example, in the production of polyurethane filled facade panels with a thickness of 40 mm, a total of 2015 gr Polyol, Isocyanate, Catalyst, Additive, Pentane raw materials are used.

As a result of the research on the subject in the literature, a utility model application numbered TR2016/11342 and titled "Insulated Polymer Sandwich Panel" was found in the Turkish Patent Institution. This application relates to; multi-layer trapezoidal, wavy or tile shaped polymer roof and facade cladding panel materials of different thicknesses formulated using 15 PVC-based raw materials as bottom and top layers of which are made by 100% new resin or recycled and, insulated polymer sandwich panel obtained by placing, there between, polyurethane (PUR) and polyisocyanate (PIR) of different densities and thicknesses as insulation material, that can be used in all kinds of houses and their terraces and porches, sports facilities, prefabricated buildings, factories and industrial buildings for storage purposes, public institution and establishment buildings, market places, car parks and all kinds of cattle and sheep farms, production facilities of meat and processed meat products, milk and processed dairy products, and all kinds of poultry feed, incubation and egg production facilities, slaughterhouses, cold stores, cultivated mushroom production facilities and buildings exposed to chemical effects creating corrosion effect, and roof and facade coatings of structures affected by high humidity environment such as sea and lake shores In this application, PVC -based recycling products are used. The use of PVC-based products do not provide a more environmentally friendly and a positive result for human health, but they only reduce the cost of production.

A further invention is a utility model application registered with the Turkish Patent Institution with the application number TR2011/05329 and titled "Novelty in Sandwich Panels". This application generally relates to; a sandwich panel with an insulation feature, on one side of which there is a sheet metal and on the other side, the insulation material is positioned at the inner part of the plate. This sandwich panel, comprises on one surface thereof, a galvanized sheet or painted sheet, painted galvanized sheet metal, and on the other surface, two sheets made of cement chipped or fiber cement or melamine coated chipboard or plywood, membrane or PVC based rolled sheet or other similar material, XPS (Extruded Polystyrene Hard Foam) or rock wool or rock wool-like wood wool vertebrate insulation material having an approximate 100 density located between these two layers; or an insulation material made of cellulose-based insulation material or similar material. By means of the invention, it is stated that there are different raw materials that can reduce production inputs and that can be used as fillers instead of environmentally friendly raw materials. However, as a result of the fact that all the raw materials mentioned are additional costs and that they will change the production pattern, usage problems occur.

As a result, due to the abovementioned disadvantages and the insufficiency of the current solutions for the subject, a development in the relevant technical field was deemed necessary.

Object of the Invention

The present invention relates to rice husk added polyurethane filling that meets the abovementioned requirements, eliminates all the disadvantages and brings some additional advantages.

The primary object of the invention is to add rice husk in order to reduce the production inputs of Polyol, Isocyanate (R-N = C = 0), Catalyst, Additive and Pentane as raw material, in the production of polyurethane filled facade, roof, cold storage, space and aviation industries, white goods industry, refrigerator production and louver- shutter panel production.

An object of the invention is to produce environmentally friendly and biodegradable new insulation panels with low carbon footprints as a result of reducing the amount of polyurethane used in the polyurethane filled facade, roof, cold storage, space and aviation industries, white goods industry, refrigerator production and roller louver- shutter panel production.

Another object of the invention is to develop and improve technical properties of composite panels such as thermal insulation, sound insulation, fire resistance, mechanical resistance, water absorption resistance, temperature resistance, air and water tightness and strength etc.

A further object of the invention is to ensure that the wastes obtained after the processing of agricultural products are used as alternative raw materials, and to create a new raw material input.

Still another object of the invention is to ensure that products that are considered as inert products or waste in agricultural production areas, are considered as alternative raw materials; and it aims to create different markets in said sectors, especially in the production of white goods, space and aviation, refrigerators and louver- shutters, including new production and raw material supply.

The structural and characteristic features and all of the advantages of the invention will be more clearly understood by the detailed description given below, and therefore the evaluation must be made by taking this detailed description into consideration.

Detailed Description of the Invention

In this detailed description, the composite panel with rice husk and polyurethane filling according to the invention is explained only to provide a better understanding of the subject matter without any limiting effect. In the production method of the invention, the composite panel or coating material with rice husk and polyurethane filling indicates forming the bottom and top surface of the composite panel by shaping two aluminum or galvanized sheets of the desired color and thickness, which enter the production line from one end of the sandwich or coating material, and then forming panels, in filled composite facade, the roof, cold storage, space and aviation sectors, white goods industry, refrigerator production and louver- shutter production by pouring polyurethane (PU) at different density and thickness as insulation material between the boards. Polyol, Isocyanate (R-N = C = 0), catalyst, additive and pentane are used as raw materials in the production of panels with polyurethane filling.

One of the problems encountered during the production stage of facade and insulation materials is that the cost of polyurethane required for production is high. Therefore, supporting the need for polyurethane raw materials with substituents or additional extra products during the production reduces the production costs and the amount of polyurethane usage. It is useful to choose the substituent material to be used along with the polyurethane, for similar tasks. For this purpose, using agricultural waste in addition to the use of polyurethane in the facade, roof, cold storage, aerospace and aviation industries, in the white goods industry, in the production of refrigerators, in the production of louver- shutter and insulation materials, reduces the production costs. As agricultural waste, during the addition of polyurethane, for example; the use of rice husk waste not only reduces production and input costs, but also produces new insulating materials with reduced environmental damage. By this way, as a result of reducing the ratio of raw materials in panel production, the amount of environmental pollutants used for panel production and the environmental effects of said substances are also reduced. In addition to these, as a result of the use of agricultural waste during the production phase, waste is recycled and production costs are reduced. Since composite panels are currently produced on the assembly line, the process of adding production waste to polyurethane during the panel production stage does not complicate panel production and does not cause time loss. Similarly, as a result of agricultural waste used at certain amounts during the stage of adding polyurethane raw material in the production stage of roof, cold storage, aerospace and aviation industries, in the white goods industry, in the production of refrigerators, louver- shutter panels and insulation materials, there is also a new sector emerging for those who manufacture or perform the manufacturing processes of said products. For example, when 25% of the amount of polyurethane used in the production stage of the panel with polyurethane with a thickness of 40 mm is added, approximately 503,75 g of polyurethane raw material is saved.

In order for said rice husk waste to be used in the polyurethane filled panel assembly line, the waste must first be reduced to the desired sizes with the help of a grinding machine. Then, the rice husk waste reduced to the desired sizes is mixed with polyurethane. There is no need for additional cost, personnel, time and heat treatment to add rice husk waste to the production of polyurethane filler panels.

Rice husks are one of the important agricultural by-products, also called paddy husk, and they are husks produced during the peeling process of the paddy. Rice husks constitute approximately 20% of the rice volume produced in the world, which is approximately 100 million tons per year. A total of 552.000 tons of rice production was made in Turkey in 2016. 71% of this production was in the Marmara region and 24% in the Black Sea region. The remaining 5% were from Central Anatolia (3%), Southeast Anatolia (2%) and other (1%) regions. Diizce, as a province located both in the western Black Sea and eastern Marmara, is producing paddy in an area of approximately 2.700 decares, and around 2 thousand tons of rice is produced. About 400 tons of rice husk waste is produced from the rice produced in Diizce. Also, since it is close to the regions where 95% of rice production is made in Turkey, it is easy to reach the rice husk wastes.

The rice husk waste is brought to the panel production facility from the area where the waste is created and stored. Rice husk waste is drawn by vacuuming method from the area where it is stored in the production facility, and after grinding with the help of a grinding machine, the polyurethane is added with the help of spraying during the polyurethane molding process. Panels are cut to the desired length and number and are made ready for shipment.

The composite panel or coating material with rice husk and polyurethane filling indicates forming the bottom and top surface of the composite panel by shaping two aluminum or galvanized sheets of desired color and thickness, which enter the production line from one end of the sandwich or coating material, and then forming panels, in filled composite facade, the roof, cold storage, space and aviation sectors, white goods industry, refrigerator production and in louver- shutter production by pouring polyurethane (PU) at different density and thickness as insulation material between the boards. In the production stage, Polyol, Isocyanate (R-N = C = 0), Catalyst, additive and Pentane raw materials are used. In Table 1, raw materials used in the production stage of composite facade panels in different thicknesses with rice husk and polyurethane filling, the amount in preferred weight (%) and the amounts in available weight (%) are given. In Table 2, raw materials used in the production stage of composite roof panels in different thicknesses with rice husk and polyurethane filling, the preferred amount by weight (%) and the available amounts by weight (%) are given.

Table 1. Composite facade panel with rice husk and/or rice husk powder additive and polyurethane filling having different thicknesses

Table 2. Composite roof panel with rice husk and/or rice husk powder additive and polyurethane filling having different thicknesses