ASH INSULATION PANELS

[0001] The invention generally relates to ash insulation panels used as thermal insulation in residential, public, and commercial buildings.

[0002] The ash insulation panels of the present invention are made of a novel composition prepared from ash and plastic and/or chemicals materials locally available in commercial quantities. It provides a solution for ash and plastic waste materials by the recycling thereof, which also increases their added value.

[0003] Scientific experiments have shown that the application of thermal insulation in residential, public, and commercial buildings: reduces the consumption of electric power by about 04%, maintains proper temperature inside buildings for longer time, reduces the long time use of air conditioners, allows the use of small capacity air conditioners which are low in cost and have less energy consumption, provides comfort to the building residents, and eliminates the need for air conditioners which are a source of noise pollution that has a negative impact on people health and psychology.

[0004] Thermal insulation provides protection for buildings from weather changes and fluctuations by reducing the variation of temperature from day to night. Variation in the degree of temperature between day and night causes stress cracks in walls of buildings and their parts such windows leading them to lose their natural and mechanical properties. In addition, temperature variation reduced the thickness of walls and ceilings which results in increasing thermal transmission into buildings and consuming more electricity.

[0005] At the present time, there are several types of thermal insulation materials for buildings available in the market. The following table shows some of these types accompanied by their thermal conductivity and density:

		Thermal
		Conductivity	Density
	Material	(W/m K)	(kg/m3)
	Wool	0.04	20-25
	Polystyrene EPS	0.035-0.04	15-30
	Polystyrene XPS	0.035-0.04	25-40
	Polyethylene foam	0.025-0.035	30
	Glass foam	0.04-0.055	10-160
	metal fiber	0.035-0.05	15-80
	Vacuum	0.002	1

[0006] The invention described herein further includes the process of producing ash insulation panels made of basic materials of different ratios and weights.

[0007] The ash insulation panels are produced by mixing ash with some types of plastics and solvents in sequential order, casting the mixture into molds of variable size and shape depending on the need, and then pressing it thermally.

[0008] One of the main features of the ash insulation panels is providing a solution that sustains environment by recycling waste and helps to rationalize the consumption of electricity.

[0009] Ash insulation panels are made of the following basic materials: ash (55-70%) and polystyrene (30-45%).

[0010] After preparing the desired ratios, they are mixed in an electric or mechanical mixer. During the mixing process, (10-20%) chloroform is gradually added to the mixture. The mixing process continues until the mixture becomes almost dry (wet). Then, the mixture is casted in an iron, plastic, or metal mold coated with thermal insulation to prevent the components from sticking to the mold. The mold is then pressed by a hydraulic piston under pressure of 3-30 tons depending on the thickness of the desired product. After the pressing process, the mold is placed in a thermal furnace for treating it at a temperature of 160-180° C. and it is left for about 4 to 2 hours. Then, when the temperature decreases into room temperature, the product is taken out from the thermal furnace.

[0011] The insulation panels are characterized by the following physical and mechanical properties:

Water			Compressive
Absorption	Density	Hardness	Strength	Temperature
%	(g/cm3)	(HRG)	(MPA)	C. °
2.83	1.43	63	26	180