A GEOPOLYMER ROOF TILES PRODUCED FROM RECYCLED GLASS AND PREPARATION METHOD THEREOF

Abstract

The present invention relates to a geopolymer roof tiles incorporating recycled glass to enhance strength, thermal insulation, and aesthetic appeal. The geopolymer tiles comprises of industrial by-products such as fly ash or slag, activated by alkaline solutions to form a sustainable binding matrix, 15-25 wt. % recycled glass particles to optimally enhances tile strength and insulation while providing a decorative finish, fine aggregates to create a smooth finish and improve workability, and superplasticizers to ensure proper mixing and distribution of the glass particles within the geopolymer matrix. Geopolymer technology uses aluminosilicate-based binders instead of traditional cement, resulting in lower carbon emissions and the ability to incorporate industrial by-products like recycled glass. Recycled glass particles in the tiles improve mechanical properties, reduce heat transfer, and create an appealing finish. The method involves mixing aluminosilicate precursors, recycled glass, and other aggregates, moulding, and curing at ambient temperatures, resulting in a durable, energy-efficient roof tile. Initial tests demonstrate a 15% increase in flexural strength and a 12% reduction in U-value with a 20% recycled glass composition. These tiles are intended as a low-carbon alternative for environmentally conscious construction.

Specification

Description:Field of the Invention
The present invention relates to a geocomposite composition using the geopolymer, more particular to a geopolymer roof tiles incorporating recycled glass to enhance strength, thermal insulation, and aesthetic appeal.
Background of the Invention
As the global construction industry evolves toward sustainable practices, researchers and developers are focusing on reducing the environmental impact of building materials. Traditional roofing materials, such as clay or cement tiles, are resource-intensive, high-energy products with a significant carbon footprint. Geopolymers, a class of inorganic polymers formed through the activation of aluminosilicate materials, offer a promising alternative. When produced at lower temperatures than conventional cement, geopolymers emit significantly less CO2 and can incorporate recycled or waste materials like fly ash, slag, or recycled glass.
In conventional roof tile production, clay tiles are kiln-fired, and cement-based tiles involve high-energy clinker production, both of which contribute to CO2 emissions. In contrast, geopolymers use alkali activation of aluminosilicate materials such as fly ash or slag to form a durable binder. Geopolymer binders are not only more sustainable but also chemically resilient, offering durability comparable to that of traditional roofing materials.
Recycled glass offers several benefits in construction. It reduces reliance on virgin materials, cuts down landfill waste, and improves the physical properties of building materials. This invention combines geopolymer and recycled glass technologies to produce roof tiles with superior strength, thermal performance, and aesthetic appeal, providing a durable, eco-friendly roofing solution.
The addition of recycled glass particles to geopolymer tiles offers further advantages. Recycled glass improves the mechanical properties of the tiles and enhances insulation, reducing heat transfer and contributing to energy-efficient building envelopes. By utilizing waste materials, this invention aligns with circular economy principles and reduces the ecological footprint of roofing materials.
In Patent no. KR101078336B1, disclosed a method for producing a geopolymer using waste glass and a geocomposite composition using the geopolymer. More particularly, the present invention relates to a method for producing a geopolymer using waste glass, and recycling waste glass to produce a geopolymer and a geocompression composition using the geopolymer.
None of the prior art indicated above either alone or in combination with one another disclose what the present invention has disclosed.
Object of the Invention
• The primary objective of the present invention is to develop durable, decorative roof tiles using a geopolymer binder incorporating recycled glass.
• Another objective of the present invention is to improve the structural and thermal performance of roof tiles by using recycled glass as a reinforcing and insulating component.
• The further objective of the present invention is to provide a low-carbon alternative to traditional roofing materials that can reduce reliance on virgin resources.
Detailed Description of the Invention
The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
In any embodiment described herein, the open-ended terms "comprising," "comprises," and the like (which are synonymous with "including," "having" and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like. As used herein, the singular forms "a", "an", and "the" designate both the singular and the plural, unless expressly stated to designate the singular only.
The present invention developed a geopolymer roof tiles by incorporating recycled glass to enhance strength, thermal insulation, and aesthetic appeal. The geopolymer roof tiles comprises of:
• Geopolymer Binder: The binder is formed by activating aluminosilicate sources, such as fly ash or blast furnace slag, with an alkaline solution (typically sodium or potassium hydroxide). This chemical process forms a robust, low-carbon matrix that can encapsulate various aggregates.
• Recycled Glass: Recycled glass particles are finely ground to a particle size of 100-500 microns, making up 15-25% of the tile's total weight. Preliminary tests suggest that a 20% recycled glass composition optimally enhances tile strength and insulation while providing a decorative finish.
• Additional Aggregates and Admixtures: Fine aggregates are added to create a smooth finish and improve workability. Superplasticizers may be used to ensure proper mixing and distribution of the glass particles within the geopolymer matrix.
The process of manufacturing these geopolymer roof tiles involves several key stages to ensure optimal material integration, durability, and aesthetic appeal.
• Mixing: The geopolymer binder, recycled glass, fine aggregates, and necessary admixtures are mixed in specified proportions to form a homogeneous mixture. Consistency in mixing is crucial for the even distribution of glass particles and for achieving the desired mechanical properties.
• Moulding: The mixture is poured into moulds designed to shape the material into roof tiles. During moulding, the material is subjected to vibrations and compaction to remove air pockets, ensuring a dense and uniform structure.
• Curing: The tiles are then cured under ambient conditions or slightly elevated temperatures. Curing over a period of 28 days allows the geopolymer reaction to progress fully, strengthening the matrix and improving thermal properties.
In the preferred embodiment of the present invention, the incorporation of approximately 20% recycled glass by weight into the geopolymer matrix increases flexural strength by around 15%. The improvement in strength is primarily due to the reinforcing properties of glass particles, which distribute stress more evenly across the tile surface. As a result, the tiles exhibit higher resistance to cracking and deformation, making them ideal for both residential and commercial roofing applications.
In preferred embodiment, the addition of recycled glass enhances the tile's insulation properties, reducing its U-value by about 12%. This reduction in heat transfer improves the building's overall energy efficiency, reducing the need for cooling in warm climates and heating in cold climates. The glass particles act as thermal barriers, trapping air within the matrix and thus lowering heat conductivity.
Advantages of the Invention
1. Enhanced Structural Properties
The addition of recycled glass increases flexural strength, making the tiles more resistant to external stresses. This improved durability helps extend the tile's lifespan and reduces maintenance costs.
2. Improved Thermal Efficiency
With a reduction in U-value by approximately 12%, these tiles provide superior thermal insulation, promoting energy savings and indoor temperature regulation.
3. Visual Appeal and Customization
The inclusion of glass particles creates a reflective surface that enhances aesthetic appeal. Customizable colors and textures make the tiles suitable for decorative applications, meeting modern architectural and design needs.
4. Sustainability and Reduced Environmental Impact
By integrating recycled glass and a geopolymer binder, the invention minimizes waste and reduces the environmental footprint associated with roofing tiles. Lower production temperatures and reduced use of virgin materials contribute to sustainable construction goals.
Applications
The sustainable nature of these geopolymer roof tiles makes them suitable for a wide range of applications:
1. Residential Roofing: Ideal for residential buildings aiming to meet green building standards, offering improved energy efficiency and decorative appeal.
2. Commercial Buildings: Suitable for large commercial projects that prioritize sustainability and aesthetic customization.
3. Architectural Projects: These tiles allow architects and designers to create unique roof finishes with customized glass patterns and textures.
Comparative Analysis with Traditional Roof Tiles
Feature Traditional Roof Tiles Geopolymer Roof Tiles with Recycled Glass
Material Clay or cement Geopolymer binder with recycled glass
Production Temperature High (kiln-fired) Low to ambient
CO2 Emissions High Low
Flexural Strength Moderate Increased by 15% with 20% glass
Thermal Insulation (U-Value) Standard Reduced by approximately 12%
Aesthetic Appeal Limited Customizable, reflective surface
Environmental Impact High Reduced through recycled materials
This invention presents an innovative approach to sustainable roofing materials by developing geopolymer roof tiles with recycled glass. The combination of geopolymer and recycled glass technology results in a roofing tile that is strong, thermally efficient, and visually appealing. This sustainable roofing solution aligns with green building standards, making it ideal for environmentally conscious projects.
In a global context that increasingly values sustainable construction, these geopolymer tiles provide a low-carbon alternative to traditional roofing. With enhanced structural integrity, improved thermal insulation, and the aesthetic flexibility offered by recycled glass, the tiles meet the requirements of modern architecture and environmental standards. By reducing reliance on virgin materials and decreasing CO2 emissions, this invention contributes to the shift towards greener, more sustainable building materials.

, Claims:1. A geopolymer roof tile, comprises of:
a) a geopolymer binder is formed by activating aluminosilicate materials, such as fly ash or slag, with an alkaline solution, typically sodium or potassium hydroxide;
b) 15-25 wt. % recycled glass particles to optimally enhances tile strength and insulation while providing a decorative finish;
c) fine aggregates to create a smooth finish and improve workability; and
d) superplasticizers to ensure proper mixing and distribution of the glass particles within the geopolymer matrix.
2. The geopolymer roof tile as claimed in the claim 1, wherein the recycled glass is ground to particle sizes of 100-500 microns to optimize strength and thermal properties.
3. The geopolymer roof tile as claimed in the claim 1, wherein the the process of manufacturing comprises the following steps:
• Step 1: The geopolymer binder, recycled glass, fine aggregates, and necessary admixtures are mixed in specified proportions to form a homogeneous mixture;
• Step 2: The mixtrure is poured into moulds that shape the bricks. Compaction techniques are used during moulding to remove air pockets and create a dense, uniform structure; and
• Step 3: curing the mixture at ambient or slightly elevated temperatures over a period of 28 days, allowing the geopolymer reaction to strengthen the matrix and optimize thermal properties.
4. The geopolymer roof tile as claimed in the claim 1, wherein the addition of 20% recycled glass in the matrix result in a 15% increase in flexural strength.
5. The geopolymer roof tile as claimed in the claim 1, wherein the geopolymer roof tile exhibits a reduction in U-value of approximately 12%, thereby enhancing thermal insulation.
6. The geopolymer roof tile as claimed in the claim 1, wherein the geopolymer roof tile minimizes waste and reduces the environmental footprint associated with roofing tiles.

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