Construction material of the future 

 

 

Our partners have many years of experience in materials research in the field of nano-compounds. There are now revolutionary findings for this.

New applications for nano-composite materials are in the forefront as technical applications for the following sectors:

 

 

  • Insulation panels

  • Facade claddings

  • Flooring

  • Coverings

  • Construction areas, structural panels

  • Furniture production (garden furniture, car ports, fences, garage doors, doors, roof beams, etc.)

  • Interior fittings

  • The automotive industry

 

The inorganic nano composite materials can be used as insulation for use in numerous industrial areas, for example in automotive manufacturing, the construction industry, and in refrigerating and heating plant construction. All of the materials presented hereafter are fireproof, non-flammable and non-toxic. The environmental compatibility is exceptional.

 

Applications can be realised in the following ranges according to customer wishes:

 

 

- Gross densities of these composites between 300 and 1,000 kg/m³

- Pressure strengths between 4 and 10 MPa

- Corresponding bending tensile strengths between 0.2 and 3.5 MPa

- Thermal conductivity between 0.04 and 0.047 W/(mK)

 

Comparison

Nano-wood-stone

Sand-lime brick

Pressure resistance

4-10 MPa

35 MPa

Bending tensile strength

0.2-3.5 MPa

6-20 MPa

Thermal conductance

0.04-0.047 W

1.4 W

Price per m³

€ 150 to € 450

€ 250

 

 

The insulation values exceed those of existing materials many times over.

Furthermore, the price development of these materials is no more expensive than that of materials used today.

It is also possible to dispense with additional insulation.

The rooms remain breathable.

It is possible to effectively prevent mould and mildew.

As a foamed material this nano composite material is also a good insulating material for use in existing rooms for example.

 

We would like to demonstrate this in the following example with styrofoam panels:

Example calculation using rigid foam panels which are in standard use as house insulation:

 

Styrofoam rigid foam

EPS 040 WI/DI

Nano rigid foam

EPS 120 WI/DI

Application

Wall interior insulation,
roof interior insulation,
no compressive loads

Wall interior insulation,
roof interior insulation,
no compressive loads

Rated value of the
thermal conductance
W/m·K

0.04

0.02

Fire behaviour

Difficult to ignite per DIN 4102

Construction material class B1

Non-combustible
Fireproof to 500 degrees Celsius

Price

€ 120 per m³ sale

€ 100 per m³ sale

 

Here it can be seen that more than just the fire behaviour is significantly better than conventional styrofoam. The insulation value is also significantly better. The price for this is also cheaper. Now when we take the high level of environmental compatibility into account, we can see a clear market advantage both for the manufacturer and for the customers.

 

In order to replace 1 cm nano rigid foam we would require 6.8 cm of wood wool panels or 9.0 cm porous concrete blocks or 52.5 cm sand-lime brick. PUR panels have a comparable insulation value, but are at least 3x as expensive.

 

Of course, we can carry out this example calculation for any desired application and can thus document where the advantages for these materials lie. Zero-energy houses no longer need to be expensive to the point of being unprofitable.

 

In fact, in the near future it will be possible to build ecological houses that need not be more expensive than houses built using conventional techniques and materials. The customer will then be able to save the majority of their conventional heating costs. A clear advantage for the customer and an unbeatable sales argument for the builder. Fire protection requirements per fire protection class A1 can be demonstrated with ease.

 

 

Inorganic, nano-structured
insulation materials

Manufacturing process

Manufactured from inorganic alumino-siliceous minerals as well as reactive mineral powder, inorganic nano-binding agents, water and propellant. As a result, one can also add water-repellent agents and reinforcing fibres where required.

Physical characteristic values

Thermal conductance λ(R):                        0.040-0.047 W/(mK)

Spec. thermal storage capacity c:             1,000 J/(kgK)

Water vapour diffusion resistance μ:                2-6

Construction material class:                        A 1, A 2

                                                              Non-combustible

Gross density ρ:                                       80-300 kg/m³

Primary energy content:                        Unknown (kWh/m³)

Application

Wall:                                         Exterior and interior insulation

Ceiling:                                                 Underside insulation

Remarks

Nano-structured insulation is a new insulation material.

The raw materials required for the manufacturing of these composites are available without restrictions and are good value.

Environmental aspects

+ Nano-structured insulation is inorganic in nature and thus easily recycled or disposed of in landfill

+ Insulation does not contain any hazardous substances

The bonding agent systems are purely inorganic in nature and are thus resistant to fire, moisture and chemical attack.

Dust may be developed during the manufacturing of the raw material.

Standards

+ Formaldehyde-free inorganic materials, as non-combustible construction materials class A1

Further info

  • Almost unlimited raw materials available

  • Due to their low thermal conductance, the new nano-hybrid materials offer advantages compared to conventional insulation. As a result, the energy saving potential compared to conventional insulation is ca. 25%.

 

 

Evaluation of findings and thermal behaviour of the nano-composite

 

 

 

Investigation of various samples for resistance to thermal shock and thermal insulation performance of highly thermally insulated mouldings (Isonanokit).

 

 

Thermal investigation

 

 

Influence of temperature on the developed materials by means of flames and storage in the high temperature oven

 

 

Thermal behaviour of mouldings

 

 

 

 

Investigation of various different sample bodies for resistance to thermal shock

 

 

 

 

 

Appearance of the sample before and after the thermal treatment

 

Project presentation

 

This report documents the practice-oriented development activities of a project. The development objective is therefore to provide a process for the manufacturing of a binding agent system with low energy requirements, attractive economics and technical simplicity. The bonding agent systems manufactured via a poly-condensation process are purely inorganic in nature and are thus resistant to fire, moisture and chemical attack.

Furthermore, they are distinguished by high temperature and oxidisation stability as well as being resistant to temperature change. In addition, the raw materials required for the manufacturing of these composites are available without restrictions and are good value. Furthermore, the mechanical characteristics such as resistance and stiffness of the materials manufactured can be improved with organic or inorganic fibres. With the project conception, various different binding agent systems based on nano-structured inorganic materials were developed as formaldehyde-free binding agents and the use of new binding agent systems tested with the manufacturing of new nano-composite materials.

 

 

use of new binding agent systems with the manufacturing of wood composite materials (see also nano-composite materials made from wood)

 

 

The new binding system represents both a substitute product and a complementary product, e.g. for the manufacturing of panel materials. Alongside panel materials, three-dimensionally shaped mouldings can be manufactured from the new binding agent.

 

 

For the manufacturing of new composite materials, in particular wood composite materials e.g. chipboard, wood particles such as wood fibres or wood chippings are processed with a nano-hybrid binding agent under pressure and with increased temperature. The application examples for the new binding agent system are almost boundless.

 

 

For this purpose, new nano-composites were tested for their suitability as nano-binders and modifications to established binding systems were undertaken. The binding systems developed should exhibit improved characteristics and also a cost advantage with the production of wood composite materials.

 

 

Various different wood particles, different grades of wood chippings, beech shavings, wood chips, conifer shavings and even scrap wood are used as filler. In principle, all waste wood in the form of sawdust and saw chippings can be used with nano-binders to manufacture various different composite materials and mouldings or even insulation panels.

 

 

The properties of these binding agents systems (nano-hybrid composite) can be adjusted through the degree of compacting and the size of the chippings used. The gross density of this composite can also be arbitrarily adjusted through their composition. The gross density of these composites can vary between 300 and 1000 kg/m³, the pressure resistance between 4 and 10 MPa and the corresponding bending strengths between 0.2 and 3.5 MPa.

 

 

As a result of the ecological evaluation of the nano-hybrid composite it was determined that the use of natural materials such as wood chippings as natural organic additives yielded a positive contribution towards environmental protection. The findings of the investigation revealed that the effects on the environment with the manufacturing of inorganic composites was lower than that of other non-mineral additives.

 

 

It is particularly significant that the new binding agent combinations can be used for the manufacturing of wood composites without pre-treatment of the wood being required. It doing so it is apparent that wood composites could also be manufactured using wood chippings and other wood residues. From a technical and economical perspective, it is also possible that further optimisation could be achieved through material composition.

 

 

In principle, the nano-hybrid composite can be used both as a replacement for mineral raw material and for the increased use of the renewable raw material wood. This opens up new areas of application.

 

 

This wood composite was developed for various different areas of application - e.g. as panels for wall elements and for interior and exterior spaces as covering panels (e.g. as suspended ceilings etc.).

 

 

 

Open-celled damping and insulation systems made from inorganic nano-materials

 

Conventional damping and insulation units are generally comprised of known natural or synthetic thermally insulating and open-celled plastic foams or fibrous materials as well as additives or other plastic filler materials for example.

 

The manufacturing of such insulation systems, i.e. damping materials based on mineral oil or other fossil-based raw materials, whereby the cellulose damping material is used for fire protection, is also very widespread. The starting products here are very expensive, the raw materials are available for a limited time and require significant costs to create them.

 

Damping and insulating materials based on new materials and renewable raw materials are very much in demand for alternative insulation, which is used in various different areas of industry.

 

So, we have developed a new damping and insulation system based on nano-structured materials whereby old or new wood made from natural wood waste, sawdust and wood chippings and even dust from the wood processing industry can be used as the base materials for the manufacturing of this.

 

Due to their low thermal conductance, the new nano-hybrid materials offer advantages compared to conventional insulation. As a result, the energy saving potential compared to conventional insulation is ca. 25%.

 

The development of new nano-hybrid materials using open-pored or closed-pored materials as insulation systems is very much in demand. They exhibit low thermal conductivity and are easy to produce.

 

Characteristics:

 

Development of a new technology for creating micro or nano structured mouldings.

 

The objective of this project was the development of a new technology to manufacture micro or nano structured mouldings from inorganic, nano-modified binding agents, nano-composite and/or nano-hybrid materials with improved thermal and fire resistance for industrial use.

 

The structured mouldings created by this are of significant importance, for example for the development of dimensionally stable and thermally conductive materials. This involves new methods of developing and producing new materials with the desired characteristics. One of these applications is in the manufacturing of non-combustible mouldings based on new material concepts such as new hybrid materials and inorganic nano binders, for example.

 

The new inorganic nano composites and the adhesive cement exhibit a higher breaking strength, higher elasticity and better resistance to chemicals and heat, in comparison to existing non-aqueous and organic mouldings, which were developed accepting problems with fire load, the development of smoke and disposal. In contrast to conventional mouldings, the nano technology based composite materials were developed as thermally resistant materials that contain no hazardous materials and which do not release toxic decomposition products when exposed to fire and which enable environmentally friendly disposal. Because the physical and chemical resistance of the binding agent can be optimally influenced, the new types of ceramic mouldings not only have good fire protection characteristics but can therefore also be employed in a multitude of other industrial applications on a large scale. In doing so, the fire resistance of the nano composite materials or nano composites is likewise increased compared to other materials. The effectiveness of the heat conductance of such mouldings can also be influenced by the structured material composition.

 

The new composite materials that this project is based upon are formulations composed of powdered, reactive and passive filler components that have been embedded in a cross-linked inorganic matrix. The thermal conductivity is therefore brought about by the thermal conductivity of the inorganic matrix and the amorphous or crystalline ceramic powder. An additional parameter arises through the interface of the inorganic matrix and the filler particles. The thermal resistance and the strength are caused by the cross-linking, dependent on hollow spaces with gas inclusions and impurities, so that optimal chemical binding of the matrix to the particle surface is prevented. Thus the interfaces are of corresponding importance with ideal cross-linking and binding.

 

The requirements of a new solution were therefore initially sketched out as follows: With the requirements of the new solution, it is necessary to modify the thermal transport between nano composite materials or nano composites and metal thermal conductors in order to optimise the binding matrix by means of filler composition and grain size distribution, so that on the one hand the thermal conductivity, i.e. the transport of heat between mouldings and metal thermal conductors, is optimised by modifying geopolymer formulations and on the other hand the best possible thermal insulation properties are assured so that no unnecessary heat losses occur. Finally, it is a matter of transferring heat between two different bodies in a closed system without losses.

 

In conclusion, there is now only the question of the technical feasibility of such technologies. Schematics for the various different manufacturing options can be seen below. This relies on existing technology. Thus the expenditure when constructing a production plant is minimised.

 

Here is an example for the manufacturing of mouldings.

 schematic 1

 

Construction panels can be manufactured in this way.

 

schematic 2

 

 

Here is an example of an existing production plant which could be used for production.

 

schematic 3

 

In conclusion, existing technologies can thus be relied upon for production. The actual innovation lies in the material and not in the manufacturing process. It is thus possible to implement an industrial production in a short period of time.

 

We would be delighted to assist if you have any questions.

 

Licence holders sought for production.