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NU-ROOF. MAYEN 24M GENERAL ASSEMBLY January 16th-17th 2012. Agenda. Current status of the project. WP1: concept. WP2: research. WP3: application guidelines and thermal modeling. WP4: knowledge management system. WP5: demo. WP6: business models. WP7: training. WP8: management.

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slide1

NU-ROOF

MAYEN 24M GENERAL ASSEMBLY

January 16th-17th 2012

slide3

Current status of the project

WP1: concept

WP2: research

WP3: application guidelines and thermal modeling

WP4: knowledge management system

WP5: demo

WP6: business models

WP7: training

WP8: management

Duration: 36 Months

Start: January 2010 End: December 2012

slide4

Advancement on Product Development

STILL SOME MINOR TECHNICAL ISSUES TO SOLVE (shrinkage, stiffness)

LAB TESTS

START: TO BE DISCUSSED

START: TODAY!

NATURAL AGEING TESTS 6 MONTHS

APPLICATION TESTS AND TRAINING

ARTIFICIAL AGEING TESTS 6 MONTHS

UNYA

ALMOST DONE, MAYBE ANOTHER ROUND IS NEEDED

START: SPRING 2012

ONE OR TWO FINAL PRODUCTS: DEMO

slide5

Advancement on the Knowledge Base

Module 1:

DOCUMENTS SEARCH

Module2:

COLLABORATIVE TOOLS

Module 3:

CUSTOMIZATION SUPPORT SYSTEM

Module 4:

E LEARNING AND APPLICATION GUIDELINES

OK, TO BE TESTED WITH ASSOCIATIONS

OK, TO BE TESTED WITH ASSOCIATIONS

80% READY, TO BE TESTED WITH ASSOCIATIONS

NOTHING YET!

slide6

Objectives of this meeting

  • Sara willremind the Financial Issues
  • Wehaveto start the applicationtrials and learnasmuchaspossible
  • ActionPlantofix the remainingproblems on the membrane (shrinkage, stiffness)
  • Wehaveto decide aboutnextageingtests
  • Wehavetoplan the nextapplicationtrials (March 2012?) and the DEMO start up (June 2012)
  • Redhada and DAPP need a feedback for the KM platform
  • Wehavetomake the first decisions on Exploitation
slide7

24 Month Meeting

Productionof Top Layers

Romy

slide8

Top layer: situation in summer 2011

  • At the meeting in Delft first prototype compounds for top layer were presented.
  • Occurring problems:
  • Delamination of layers
  • Oil staining  oil resistance of the coated nonwoven layer was too low
  • Main activities in WP2 after the meeting in Delft
  • were to improve the top layer and find technical solutions to prevent delamination and oil staining
  • close cooperation with Börner, NOTT, TNO and NANOPHOS
slide9

Top layer: variant 1

  • Variant 1: Application of PVB
  • First Attempt: Back coating with Polyvinylbutyral (PVB) granulate
  • PVB has good properties concerning oil resistance and adhesion
  • NRVII nonwoven (PA; 35 g/m²) was coated in September 2011 with PVB granulate using a flatbed lamination unit. Coating was possible, but to achieve an even surface, a relatively thick PVB layer had to be applied
  • onto the nonwoven.
  • Results:
  • This led to a stiff and rigid material  great disadvantage for the subsequent top coating with SURFA paint. Nonwoven material could not be fixed onto the needle belt for coating since it was immediately destroyed when fixed.
  •  first attempt failed

TwolayersofNanophosSurfapaint

NRVII nonwoven

PVB granulate

(or film)

slide10

Top layer : variant 1

  • Variant 1: Application of PVB
  • Second Attempt: Back coating with Polyvinylbutyral (PVB) film
  • Solution against stiffness and uneveness was to use a PVB film
  • Tests with different thicknesses  thin films with about 70 µm are suitable
  • Film was delivered to STFI by Börner
  • Results:
  • Easy to apply onto the nonwoven layer by lamination
  • Coating at the lab unit possible without problems
  • Coating paint was SURFA paint with 3% Arginotec
  • Water permeability behaviour: very good
  • Material was sent to Börner for further assembling
  • Manufacturing cost estimation: 6,40 €/m² (STFI machinery and personnel cost + raw materials, high costs due to the material price for PVB film)
  • Testing results on the overall membrane will be given by Börner and TNO in their presentations
slide11

Top layer – machineryfor variant 1

Flatbedlamination

unitat STFI

Coatingunit

at STFI

slide12

Top layer: variant 2

  • Variant 2:
  • Back coating with Ethylenvinylacetat (EVA) incl. 10% ARGINOTEC and compound with a second nonwoven layer (spunbondnonwoven)
  • EVA granulate with 10% ARGINOTEC was delivered by NOTT
  • First processing step: application of EVA with 10% ARGINOTEC onto the NRVII nonwoven (PA; 35 g/m²) was done at the hotmelt unit
  • Application of EVA to the NRVII nonwoven without problems

TwolayersofNanophosSurfapaint

NRVII nonwoven

EVA incl. 10% Arginotec

slide13

Top layer: variant 2

  • Variant 2:
  • Back coating with EVA incl. 10% ARGINOTEC and compound with a second nonwoven layer (spunbond nonwoven)
  • Second processing step: a spunbond nonwoven was laminated onto the EVA layer by a flatbed lamination unit.
  • Processing at the flatbed unit and therefore an additional heating of EVA led to better adhesion of the EVA at the nonwoven layer.
  • Manufacturing cost estimation: 6,50 €/m² (STFI machinery and personnel cost + raw materials)  high costs due to the second nonwoven layer and an additional processing step

NRVII nonwoven

TwolayersofNanophosSurfapaint

EVA incl. 10% Arginotec

Second layerofspunboundnonwoven

slide14

Top layer : variant 2

  • Variant 2:
  • Back coating with EVA incl. 10% ARGINOTEC and compound with a second nonwoven layer (spunbond nonwoven)
  • Material was sent to Börner for assembling and further testing
  • Results: Staining could not be prevented completely
  • Solution: application of EVA granulate with 20% ARGINOTEC  already delivered to STFI by NOTT
  • Next trials with hotmelt unit not possible before mid of January due to machine failure and needed maintenance
  • Coated hand samples were sent to TNO for NIR testing
  • Testing results on the overall membrane will be given by Börner and TNO
slide16

Conclusions

  • Variant 1:
  • easy to manufacture
  • resists to delamination and oil penetration  following first testing results from Börner
  • has good water permeability properties
  • the raw material is expensive (especially the PVB layer)
  • Variant 2:
  • is a more complex composite
  • Version with 20% Arginotec has probably better performances concerning delamination and oil staining but has still to be produced at STFI
  • high costs due to second nonwoven layer and an additional processing step (lamination)
slide17

NU-ROOF

Optimisation of the Top Membrane by using Arginotec as an additive for functionalization (Variant 2)

Mathias

slide18

System:

The back sideofthe top membraneisapplicatedwith an EVA- hotmelttojointogetherthe top membrane (carryingthe top coat) withthebasemembrane.

The EVA-hotmeltchoosenby STFI is a commercialproductnamed KLEIBER 713.0

(advantagesare: approvedcommercialproduct, lowcost)

slide19

Task caused of problems in detail:

  • Preventionof
  • diffusionofoilfromthebitumenbasemembraneintothe top membrane
  • becauseofthat, partial delaminationofthe top membranefromthebasemembrane
  • andcolouringofthe top coat
slide20

Approach to solution:

  • Arginotecbrings
  • barrierproperties
  • andhas a sorptioncapacity
  • Wehaveverygoodexperiences in realizationofsuccessfuldevelopments in EVA.
  • Weareabletoproduce an Arginotecmodifiedcompound in EVA.
slide21

Trials:

Due toourexperiences in barrierproperties an amountof 10 % is a minimum.

In contrasttothisfillers will reduceadhesion.

So westartedcarefullyproducing a 10 % compound (based on Kleiber EVA) withourextruderlinespeciallyconfiguratedforthisproduct.

slide22

First experiences:

Save Applicationispossible (Kleiber enablestorisetemperature in application, STFI improvesapplication in detail).

A goodapproachforblockingoildiffusionisshown.

slide23

Further adaption:

RiseuptheamountofArginotecto 20 % (toimprovebarrierproperties).

Riseuptemperature in application (toimproveadhesion).

Modifiedcompoundisalreadyproducedanddeliveredto STFI forapplication.

Configurationofeqipmentforproductionisfinished so weareabletocalculate a prizeof 0,33 €/m² (based on theamountusedby STFI).

slide25

Productfornewroofs (selfadhesive/ welded)

NUROOF concept: prefabricatedreflective top layer

Press section

Top surfacecoater

Release foilsupply

Impregnationvat

Bottomsurfacecoater

PartiallyRecycled Polymer Modified Bitumen

slide26

Productforrefurbishmentofoldroofs (selfadhesive/welded)

NUROOF concept: prefabricatedreflective top layer

Release foilsupply

Coatingvat

Bottomsurfacecoater

slide28

Projected Retail Prices

  • Cost of top layer = 6,4€ (Romy)
  • RetailPrices fortheoverallmembrane (excl. VAT): 
    • Product for new roofs, self adhesive, 4,5 mm       : € 13,60
    • Product for new roofs, to be welded, 4,5 mm       : € 12,40
    • Product for refurbishment, self adhesive, 3 mm    : € 12,50
    • Product for refurbishment to be welded 3,5 mm : € 11,80
slide29

Conclusions:

  • SOLUTION N.5 seems to have chances to succeed on market
  • Shrinkage and flexibility problems should be solved,
  • Solution n.2 (EVA - arginotec)is, anyway,good plan B
  • Top layer cost must be reduced
  • The following material will be tested today for application:
  • two rolls, 0,5x2 m with a very flexible traditional polymer bitumen sheet including woven glass reinforcement (WELDING)
  • one roll, 0,5x2 m with the basic self adhesive waterproofing compound including PES/glass reinforcement. (SELF ADHESIVE BUT STILL QUITE STIFF)

Tasks andtargets

slide30

Key learningsfromyesterdaydiscussions:

Self adhesive is more indicated than welding for NUROOF

Abutments: a white liquid applied membrane is needed

We have to find a white commercial liquid applied or, alternatively, develop something specific

Increasing flexibility can also avoid the need of liquid applied membranes (-> refurbishment version is already flexible)

Curing time on the overlaps is excessive

New or different applications could be possible (corrugated sheets, ...)

slide32

Day 2:

FIRST STEPS TOWARD AN

AGREEMENT ON

EXPLOITATION RULES

Antonio

slide33

The basic rules of our Consortium Agreement

The RTDs are not allowed to own the results of the NUROOF project, but they can ask to access some of those results at “fair and reasonable conditions”;

2. The industrial intellectual property should go to the SMEs (Borner, Nott, Nanophos) having risked more on the project but also the other SMEs must, on the other hand , have rightful access to the results;

3. If we do dissemination without protection it will be impossible to patent afterward;

4. As Coordinator D’Appolonia will facilitate the arbitration until a general

agreement is reached. In case of contrast, the General Assembly will use the voting procedure.

slide34

The RESULTS

1)the top reflective layer

2)the “concept 1” base layer (bitumen and recyclable materials)

3) the “concept 2” base layer (Phase Change material)

4) the Knowledge Base (including the source code and installation into server)

slide35

A possible Exploitation Strategy (D’Appolonia proposal)

  • CO-OWNERSHIP OF THE NUROOF PATENTS, WITH DIFFERENT WEIGHTS AND USE CONDITIONS
  • OWNERSHIP OF THE KNOWLEDGE BASE SOFTWARE AND INSTALLATION IN SERVER
  • SPECIAL PRIVILEGE FOR SALE / PRODUCTION OF NUROOF FUTURE PRODUCTS
  • (EXCLUSIVENESS, DISCOUNTS,…)
  • RIGHT TO USE THE NUROOF KNOW HOW FOR NON COMPETITIVE FUTURE RESEARCH
slide36

Objectives of parallel session 1

  • Wehavetoplan the newapplicationtrials (March 2012? Where?)
  • ActionPlantofix the remainingproblems on the membrane (shrinkage, stiffness)
  • Wehaveto decide aboutnext round ofageingtests (natural, artificial?)
  • Wehaveto take a decision on whiteliquidappliedbitumenmembranes
  • Wehaveto validate the conceptof the e-training system (especiallyfor self adhesive)
  • Redhada and DAPP need a feedback formodule 1,2 3

Objectives of parallel session 2

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