Field of the Invention

This invention relates to a thermal insulation coating for Roofs and Buildings. Thermal Insulation is a material or combination of materials that under ordinary conditions, efficiently retards heat transfer. Thermal Insulation has been used commercially for well over a decade. The present invention describes a combination of light weight waterproofed material covered with a coating that provides thermal insulation to buildings.

Background

Thermal insulation of buildings has been known for a long time and is one of the seriously needed requirements in India because of the prevailing climatic conditions. Moreover we in India need any new system that can contribute to energy saving.

In countries like India, because of economic conditions, it became necessary to use flat roofs over most buildings. Waterproofing of flat roofs (terraces) has been a challenge for scientists working in this field. It is a complex subject and often the wrong products are used, resulting in a variety of problems caused by seepage and leakage, loss of slope due to structural problems, collapse in the underlying insulation, or a host of other reasons.
In view of the shortage of energy generation and the rising cost of crude oil, energy saving has assumed great significance. Due to Global Warming, weather patterns are changing and it is expected to see a rise in temperatures, especially in urban clusters. Green Concrete is the need of the hour. It is, therefore, very important that operating costs as well capital costs for environmental control are minimized. Thermal insulation of buildings is a very essential step in this direction. The argument to control environmental temperature is valid for both summers and winters. Only the direction of heat flow changes. The term thermal insulation is used for materials, which reduce the rate of heat transfer, or the methods and processes used to reduce heat transfer. Heat energy can be transferred by conduction, convection, or radiation. Flow of heat can be delayed by addressing one or more of these mechanisms and is dependent on the physical properties of the material employed to do this.

Advantages of Thermal Insulation

1. Due to thermal insulation, the room remains cooler in summer and warmer in winter than outside. Hence, a room provided with thermal insulation gives comfort both in summer and winter.

2. Energy Saving: Due to thermal insulation transfer of heat between inside and outside of the room is restricted. This results in less energy being required for maintaining the desired temperature in the room.

3. Prevention of thermal stress on roofs. Due to thermal stresses, roof decks tend to crack. These would be reduced to a great extent.

4. Generally over-the-deck insulation materials are much lighter than the currently used brickbat coba or concrete, resulting in reduced deadweight on the roof slab

5. Non-toxic, environmentally friendly solutions

6. Energy saving resulting in reduced costs of

a. Running cost of Air-conditioning

b. Capital equipment cost reduction

7. No heat absorption and subsequent dissipation.

8. 5°C to 1O°C drop in temperature, depending on outside temperature

9. Composite approach to:

• Thermal Insulation
• Waterproofing
• Slope Creation

Sources of Heat Transfer

1. Roof Decks: In a building, the upper roof surface is exposed for the longest duration directly to almost intense perpendicular solar heat radiation. The heat accumulated in the roofing material is transmitted gradually through the roof into the rooms below during the day and even after the sunsets. If the rooftop is insulated, the accumulation of heat on roof and subsequent transmission to the rooms below is stopped, thus bringing the room temperatures down significantly. The use of cooling devices such as coolers and air conditioners is reduced, effecting a saving in energy costs.

2. Walls: Walls, especially west facing walls, cause transfer of heat in summers from outside.

3. Glass Windows/Doors/Panels:
These are also a major source of heat transfer from outside into building.

PRIOR ART

US 4332618 relates to a thermal barrier coating adapted to provide a thermally insulating protective barrier on a component, the coating being capable of being applied to the components by spraying methods and being ductile when exposed to high temperatures. The coating comprises a mixture containing constituents of finely divided hollow glass microspheres; a ceramic frit of finely divided particles of alkali silicate titanate glass; and a refractory filler material of finely divided partiles such as micronized mica; aluminum oxide of mullite. All of the constituents of the mixture are suspended in a high temperature resistant binder material such as potassium silicate, sodium silicate or aluminum orthophosphate.

US 20040232893 teaches a thermal switching element that has a quite different configuration from that of a conventional technique and can control heat transfer by the application of energy, and a method for manufacturing the thermal switching element. The thermal switching element includes a first electrode, a second electrode, and a transition body arranged between the first electrode and the second electrode. The transition body includes a material that causes an electronic phase transition by application of energy. The thermal conductivity between the first electrode and the second electrode is changed by the application of energy to the transition body.

US 4977711 teaches a thermal insulation material as insulating and sealing layer for roof areas which can be used as sole roofing element for the roof areas,which can be applied on larger areas at a time and in which the disadvantages of the known solution such as the formation of buckling wrinkles and blistering are avoidable, a thermal insulation material is provided as insulating and sealing layer for roof areas which makes it possible to cover larger areas of several square meters at a time, comprising strips of insulation material bonded onto a substrate web, in which case the strips of insulation material (120) are bonded onto a suitable sheet web as a sealing layer (130) in such a way that the thermal insulation material is constructed as insulating and sealing layer so that, when it is laid, it will not be necessary to lay an additional sealing layer.

HOLISTIC APPROACH TO CREATING AN ENERGY EFFICIENT BUILDING

1. Salient Features of Treatment:

• Environmentally Friendly
• Energy Saving
• Reduction in Dead Weight
• Long Lasting
• No Heat Transmitted to Surroundings

2. Why Insulate:

• Heating and Cooling (Space Conditioning) account for 50% to 70% of the total energy used in a typical commercial establishment.

• On the other hand, lighting and appliances and everything else account for 10% to 30% of the energy used in most buildings.

• inadequate insulation and air leakages are leading causes of energy waste.

• Insulation saves money and energy resources

3. Thermal Insulation of Roofs:
a) Conventional Method of Thermal Insulation:

Under Deck Thermal Insulation

Disadvantages;

Scheme allows heat energy to be absorbed by top deck. This hot mass of concrete radices heat in the environment. Waterproofing not available

b) Method according to the present invention:
Over Deck Thermal Insulation

Advantages:

Thermal Insulation ensures negligible heat absorption by top deck. Materials have good bonding and excellent water resistance. Light weight materials

Solution must incorporate:

• EFFECTIVE & LONGLASTING WATERPROOFING.
• GRADIENT FOR BAILING OUT RAIN WATER.
• THERMAL INSULATION

THERMAL INSULATION MATERIALS

Normally we use surkhi as insulating material which has not produced any results and in some buildings Thermocol has been used for the same purpose but once the concrete or the mortar surface develops cracks water enters and gets absorbed by Thermocol, which becomes detrimental to the life of the building.

Recently ceramic microspheres and some natural clay along with redispersable spray dried polymers have played a key role towards thermal insulation by radiation / reflection. These materials are coated as self contained materials or as paint additives.

It is well known that lightweight materials like light weight natural clays, furnace slag, fly ash, kaolin etc., are the ideal base for built-up and single-ply roofing systems and have superior wind and fire resistance over other roof insulation materials. For the last few years, lightweight micaceous minerals like Vermiculite / Perlite have been used. Thermal Conductivity of Vermiculite Insulation product is around 0.053-0.056 at 70OCentigrade. The problem with these products is that they are very porous in nature and absorb copious amounts of water and therefore their usage is limited unless they are waterproofed, which is an extra expense. Moreover they are soft, and laying of tiles over them is often required.

After considerable research, the present invention changes the water absorption as well as strength of these materials to make them suitable for over-the-deck insulation. It offers:
The thermal insulation coating hereinafter called Protekta TIP has been developed such that the formulation provides thermal insulation, strength and a lightweight product which is totally water resistant. To achieve results, natural clays are used, which are waterproofed by means of aqueous acrylic emulsion and spray dried polymers which also increase the compressive strength and flexural strength of the concrete.

In addition to these materials organic chemicals can be used which gives cohesiveness, no tackiness and enhance thermal conductivity. One of the water-redispersible spray dried polymers used is very suitable and is recommended for insulation. This product not only improves the thermal conductivity but also helps to enhance the adhesion, flexural strength, plasticity, abrasion resistance and workability of the modified compounds without appreciably affecting flow, thixotropy or water retention. It is therefore compatible with mortar additives used to achieve special processing characteristics, namely,

Properties
Thickness 20-50 mm
Density 780 kg/m3
Thermal conductivity 0.038 Kcal/hrs/m2/C
Temperature range 20° C to 90° C
Water absorption 0.2%
Water vapour permeability : Nil

Another Thermal Insulation product hereinafter called Protekta KP, a flexible weatherproof coating enhanced with ceramic spheres providing properties to reflect heat and perform as a shield against heat transfer into protected surfaces, particularly roof substrates. Once cured, this coating provides a seamless waterproof coat that not only resists varying climates but also demonstrates excellent heat rejecting properties by functioning as a barrier against thermal conduction, reducing heat absorption into building substrates. This lightweight insulative protection has the potential to offer substantial energy savings in build environments where volume usage of cooling systems are a significant expense.

Protekta KP (white in colour) which is coated on top of Protekta TIP or plastering, it is primarily based on chemispheres and ceramic microspheres. These special chemispheres are made for thermal insulation and are quite useful in providing insulation for a variety of industrial purposes, including satellites. But to ensure it is a ready made thermal insulation product, several other organic additives are added to provide strength, water repetiency and resistance to heat and U.V. Light. The base of this product is anionic acrylic polymer which adds to further properties of this product in providing low thermal conductivity, reduction of water absorption.

Properties
Thickness upto 2mm
Density ; negligible weight
Thermal conductivity 0.032 Kcal/hrs/m2/C
Temperature range - 20° C to 90° C
Water absorption < 0.1%
Water vapour permeability : Nil
Test Results:

Sl.No, TIP KP
01 Thickness (cm) 8.6 9.0
02. Area (cm2) 26,0x13.5 26.0x13.5
03. Hot Face deg C 200 200
04 Cold Face deg C 47 49
05. Time (Sec) 2700 2700
06. Thermal Conductivity 0.038 0.032
Kcal/hrs/m2/C

CONDUCTIVITY COMPARISON OF VARIOUS MATERIALS:

Sl. I Material Density in Thermal Conductivity
No. Kg//M 3 (k)
1. Artificial stone 1760 114
2. Asbestos cement 1520 0.25
sheet
3. Asphalt 2240 105
4. Cement concrete 2240 to 2480 1.24 (1:2:4)
5. Compressed straw 368 0.074 slab
6. Fiberboard 240 to 400 0.046 to 0.056
7. Glass 2510 0.905
8. Glass cellular 168 0.061
9. Glass fiber 48 0.029
10. Granite 2640 2.52
11. Hair felt 80 0.034
"12. Limestone 2180 132

13. Ordinary bricks 1760 0.70 to 1.44
14. Plastering 1280 to 1600 0.50
15. Sand-lime bricks 1840 0.93
16. Sandstone 2000 1.12
17. Samdstone 192 0.051
18 Terrazo 2430 1363
19. Timber 480 to 270 0.124 .
20.. Wood-wool slab 400 0.071
21. Vermiculite 777 to 1412 0.056
22. Brick Bat Coba 1900 0.84
23. Protekta TIP (LW) ----- K037
24. "Protekta TIP(S) ------ 0.05
25. Protekta KP --- 0.032
Uses of Protekta KP:
Insulation and weather barrier for Roofs: Application of Protekta KP to a
standard "built-up" roof will add years of life to the roof plus reduce heating and air conditioning costs by as much as 40%.
Metal Buildings: Protekta KP on metal buildings provides the same durable weather resistant insulation benefits as on built-up roofs plus protection from corrosion due to salt, fog and chemicals
Steam Pipes, Tanks, and Boilers: It can be applied to hot surfaces up to 450 degrees. Protekta KP conserves energy by containing heat while reducing surface temperatures, while adding safety by reducing risk of burns. It provides a protective coating against corrosion and eliminates problems from arising saturation and sagging, which are typical with fiberglass.
HVAC Ductwork: Application of the present coating to air ducts eliminates radiant heat on hot ducts and impedes condensation on cold ducts. Fibreglass, foam, and other insulation materials can be eliminated, reducing the amount of space required for insulation.

It also works as an excellent insulation and vapour barrier for walls, floors and ceilings. The other embodiment can also serve as the finishing coat, thus eliminating the need for paint.

THERMAL INSULATION OF WALLS, COLUMNS & BEAMS

There are 2 options to prevent heat transfer into buildings through walls.

Option: I

Thermal Insulation plastering instead of standard wall plastering. This will not only reduce the heat transfer, but will also act as a sound barrier.

Option: II
Protekta Paint Insulate additive to wall paint.Protekta KP when added, will convert an ordinary paint into a heat-eflecting,insulating, and thermal barrier coating. This additive is completely inert and can be mixed into any paint,
composite or coating,

How the additive works:

When solar radiation strikes an uncoated roof, it is converted into Infra Red radiation. This radiated energy passes down through the roof, and is absorbed by everything inside the building. The internal temperature then continually rises throughout the day, which is why air-conditioning runs continuously in the summertime. An average uncoated roof reflects about 20% of the available solar radiation and absorbs about 80%. This energy is then radiated into the building below. Circulating air absorbs this heat from the underside of the roof and increases the overall inside temperature.
A coated roof reflects and emits about 90% of the Infra Red radiation striking it.

HEAT TRANSFER INTO BUILDING THROUGH WINDOWS

Generally double glazed glasses with an air gap or film between them act as good thermal and sound insulation. This has been found to be very effective and will definitely reduce heat entry through glass windows / panels.

HOW USE OF THESE MATERIALS HELP IN DESIGN OF GREEN BUILDINGS

Environmental friendly green materials are being used. Some of them are:

By-products: Unused or waste material from one manufacturing or energy producing process that can be used in another manufacturing or energy-producing process. E.g. furnace slag.

Diversion: Avoidance of landfill disposal of a material or product through reuse or recycling
Life Cycle: All stages of production, including raw materials extraction, manufacturing, distribution, use, maintenance, reuse or recycling, disposal, and all transportation
Rapidly renewable: Material that is replenished relatively quickly, usually in less than ten years

Recyclable: Having the potential for being recycled by possessing such traits as highly recoverable, easily separated from other materials, not contaminated by toxic coating etc.,

Solid waste product: Material or product, typically long lasting and not biodegradable, disposed of in landfills or incinerators

Statement of the invention:

According to the invention a process for preparing thermal insulation coating for roofs and buildings comprises:

a) Taking 10 to 18% w/v of marble powder and 10 to 18% w/v of china clay powder in a mixer/blender,

b) Adding 10 to 25% w/v lime powder to the mixture and 5 to 10% of zirconium silicate and mixing it thoroughly to obtain a homogeneous mixture 'A',

c) Taking 5 to 25% w/v of copolymer powder/terpolymer in an another vessel,

d) Adding 1 to 10% of retarding agent, 5 to 40% of quartz sand and 10 to 50% of calcium carbonate, stirring it to get a homogeneous mixture 'B',

e) Stirring both the mixtures for 20 minutes to get a homogeneous mixture 'C'

f) Taking 2 to 10% of titanium di oxide, 1 to 8% of methylcellulose ether, 5 to 20% of natural cellulose fibres and 20 to 50% of microspheres in another vessel, mixing and stirring to obtain a mixture 'D'.

g) Mixing the mixture C and D, stirring the mixer/blender vigorously for 15 minutes to obtain a thermal insulation coating composition for roofs and buildings.

The invention is described with reference to the examples, which are provided by way of illustration only, and these examples should not be construed to limit the scope of the present invention:

EXAMPLE 1:

PROCESS: (KP)
Take a 100 Itr open vessel fitted with powder blender. Take 10 to 15 % of marble powder and 10 to 15 % of china clay powder in a mixer. In the same vessel 10 to 20 % lime powder, 5 to 10 % of zirconium silicate are added. While china clay increases the percentage of aluminum silicate the other materials produce a mix of different metal silicates and lime powder not only gives calcium to the mixture but is also required to maintain the specific pH. To this mixture is added a combination of 5 to 20 % of vinyl acetate-ethylene copolymer powder/ terpolymer of vinyl versatile-vinyiactate acrylic ester/ terpolymer of ethylene, vinyl-laurate and vinyl chloride, 1 to 2 % of common salt, 2 to 3 % of sodium nitrite. Sodium nitrite and common salt act as retarding agent. Add 5 to 30 % of quartz sand (300 mesh) and 10 to 40 % of calcium carbonate, stir for 20 minutes. Add 2 to 3 % of titanium dioxide and 1 to 2 % of methylcellulose ether, add 5 to 10 % of natural cellulose fibres and add 20 to 40 % of micro ceramic powder, add 20 to 50 % of microspheres which is a unique product of thermoplastic blowing agent and stir for 15 minutes. The final product is Known as Protekta KP.

EXAMPLE -2

PROCESS: (KP)
A100 Itr open vessel fitted with powder blender was taken. 15% of marble powder and 14% of china clay powder were taken in a mixer. In the same vessel 20% lime powder was added. To this mixture a combination of 17% of vinyl acetate-ethylene copolymer powder/terpolymer of ethylene, viny-laurate and vinyl chloride, 5 % of common salt, 7 % of sodium nitrite were added. Sodium nitrite and common salt act as retarding agent, 25% of quartz sand (300 mesh) and 35% of calcium carbonate were added, and the mixture was stirred for 20 minutes. 7% of titanium dioxide and 6 % of methyl cellulose ether were added, 15% of natural cellulose fibres and 35% of microspheres were added which is a unique product of thermoplastic blowing agent and the mixture was stirred for 15 minutes. The final product obtained was Protekta KP.

When mixed with fresh cement are uniformly dispersed as particles in the cement paste phase. In the second step, with drainage due to the development of the cement gel structure, the polymer particles are gradually confined in the capillary pores. Once this reaction has taken place cellulose ether is added which exhibits excellent water retention.

EXAMPLE - 1

PROCESS: (TIP)
A 50 Itr open vessel fitted with a mixer was taken. 25% of vermiculite / perlite,
add 20% of cement were added, 5% of gypsum, 6% of china clay powder, 10% of zeolite were added and the mixture was stirred for 15 minutes, 17% of vinyl acetate-ethylene copolymer powder / terpolymer of ethylene, vinyl-laurate and vinyl chloride, 5% of methyl cellulose ether, 7% of microcermic, 7% of microspheres of thermoplastic blowing agent were added and the mixture was stirred for 2Q minutes, The final product obtained was Protekta Tip.

EXAMPLE - 2

PROCESS: (TIP)
A 50 Itr open vessel fitted with a mixer was taken. 35% of mineral slag, 30% of cement, 7% of china clay powder, 10% of dolomite were added and the mixture was stirred for 15 minutes. 22% of vinyl acetate-ethylene copolymer powder / terpolymer of ethylene, vinyl-laurate and vinyl chloride, 7% of methyl cellulose ether, add 8% of microspheres of thermoplastic blowing agent were added and the mixture was stirred for 20 minutes, The final product obtained was Protekta Tip.

Properties of Protekta TIP

• It provides Thermal Insulation.
• Barrier against early water penetration
• Increases cohesive strength thus giving durable coatings
• Provides flexibility
• Improves compressive strength & flexural strength
• Increases the durability and impact resistance.
• Protects concrete and reinforcing steel.
• This is a ready mix to use on the roof for Thermal Insulation of the buildings specially roofs.
Properties of Protekta KP
• Waterproofing
• Thermal Insulation
• Seals hairline cracks

We Claim:

1. A process for preparing thermal insulation coating for roofs and buildings
comprising the following steps:

a) Taking 10 to 18% w/v of marble powder and 10 to 18% w/v of china clay powder in a mixer/blender,

b) Adding 10 to 25% w/v lime powder to the mixture and 5 to 10% of zirconium silicate and mixing it thoroughly to obtain a homogeneous mixture 'A',

c) Taking 5 to 25% w/v of copolymer powder/terpolymer in an another vessel,

d) Adding 1 to 10% of retarding agent, 5 to 40% of quartz sand and 10 to 50% of calcium carbonate, stirring it to get a homogeneous mixture 'B',

e) Stirring both the mixtures for 20 minutes to get a homogeneous mixture 'C'

f) Taking 2 to 10% of titanium di oxide, 1 to 8% of methylcellulose ether, 5 to 20% of natural cellulose fibres and 20 to 50% of microspheres in another vessel, mixing and stirring to obtain a mixture 'D'.

g) Mixing the mixture C and D, stirring the mixer/blender vigourously for 15 minutes to obtain a thermal insulation coating composition for roofs and buildings.

2. A process for preparing thermal insulation coating as claimed in claim 1, wherein the retarding agent is sodium nitrite and common salt.

3. A process for preparing thermal insulation coating as claimed in claim 1, wherein the copolymer is vinyl acetate-ethylene.

4. A process for preparing thermal insulation coating as claimed in claim 1, wherein the terpolymer is selected from vinyl versatile-vinylacetate acrylic ester, ethylene vinyl laurate and vinyl chloride.

5. A process for preparing thermal insulation coating for roofs and buildings
comprising the following steps:

a) Taking 10 to 55% of mineral slag in a vessel,

b) Adding 10 to 40% cement,

c) Adding 2 to 10% china clay powder,

d) Adding 5 to 15% zeolite of dolomite,

e) Mixing them and stirring for 15 minutes to obtain the homogeneous composition 'A'.

f) Taking 10 to 30% of copolymer powder/terpolymer in a vessel,

g) Adding 2 to 8% of methyl cellulose ether,

h) Adding 5 to 10% of microceramics,

i) Adding 5 to 10% of microspheres,

j) Mixing and stirring to obtain a mixture 'B'

k) Mixing 'A' and 'B' to obtain a thermal insulation coating for roofs and buildings.

6. A process for preparing thermal insulation coating as claimed in claim 5, wherein the copolymer is vinyl acetate-ethylene.

7. A process for preparing thermal insulation coating as claimed in claim 5,wherein the terpolymer is selected from ethylene vinyl laurate and vinyl chloride.

8. A thermal insulation coating for roofs and buildings comprising 10 to 18% w/v of marble powder, 10 to 18% w/v of china clay powder, 10 to 25% w/v lime powder, 5 to 10% of zirconium silicate, 5 to 25% w/v of copolymer powder/terpoiymer, 1 to 10% of retarding agent, 5 to 40% of quartz sand and 10 to 50% of calcium carbonate, 2 to 10% of titanium di oxide, 1 to 8% of methylcellulose ether, 5 to 20% of natural cellulose fibres and 20 to 50% of microspheres.

9. A thermal insulation coating for roofs and buildings comprising 10 to 55% of mineral slag, 10 to 40% cement, 2 to 10% china clay powder, 5 to 15% zeolite of dolomite, 10 to 30% of copolymer powder/terpolymer in a vessel, 2 to 8% of methyl cellulose ether, 5 to 10% of microcerarnics, 5 to 10% of microspheres.

10. A thermal insulation coating for roofs and buildings as claimed in any of the preceding claims, wherein the retarding agent is sodium nitrite and common salt.

11. A thermal insulation coating for roofs and buildings as claimed in any of the preceding claims, wherein the copolymer is vinyl acetate-ethylene.

12. A thermal insulation coating for roofs and buildings as claimed in any of the preceding claims, wherein the terpolymer is selected from vinyl versatile-vinylacetate acrylic ester, ethylene vinyl laurate and vinyl chloride.

13. A process for preparing thermal insulation coating for roofs and buildings substantially as hereinbefore described with reference to the accompanying examples.

14. A thermal insulation coating for roofs and buildings substantially as hereinbefore described with reference to the accompanying examples.