EP2139655B1 - Production of non-woven elements made of natural fibres - Google Patents

Description

The invention relates to a method according to claim 1 for the production of insulating mats from a raw material of grass plants, wherein the grass plants are first processed with a conditioner, which strikes the Strängelstrukturen the grass plants.

It also relates to an insulating mat according to claim 13 produced by this method and an apparatus according to claim 15 therefor.

STATE OF THE ART

The production of fibrous webs of synthetic fibers with admixture of supporting fibers has been industrially unset for decades. Also known is the production of insulation boards from wood, flax or hemp fibers using support fibers. Such a way of producing insulating elements made of natural fibers, for example DE 200 23 167 U1 Known: wood fibers or flax fibers are mixed with plastic supporting fibers and crosslinked by heating.

US 2007/0044891 describes the production of a nonwoven fabric for the production of paper tissues, wipes, etc. from a mixture of pulp with binder fibers and possibly other additives, a nonwoven fabric is formed in a dry process. The fleece can be further dried, steamed, treated with other materials and crosslinked by heating and fusing the binder fibers.

Before being laid, the pulp can be processed in a wet process to separate the fibers ("debonding"). Subsequently, the pulp is dried again before, for example, the binding fibers are added.

The processing of grass is content of several patent applications: FR-A-2294648 teaches the mechanical dehydration of alfalfa and grass for subsequent drying of the press cake to feed cubes. WO 2005/017251 shows the defibration of grass for the production of fiber material. None of these publications relates to non-woven fabrics made from grass fibers and three-dimensionally bonded using supporting fibers.

DASTELLUNG OF THE INVENTION

It is an object of the invention to provide a method and an apparatus of the type mentioned for the production of insulating mats which have improved properties over previously known insulating mats.

• Vertrocknen der Graspflanzenfasern,
• Zumischen von thermoaktivierbaren Bindefasern,
• Aufsprühen von Additiven.

This object is achieved according to the invention by the above method, characterized in that the grass plants are dried in the field to a dry matter content of 25-40%, then taken up and pressed in a silo under air, further torn by hammer mills and torn open and 10 -30 mm in length and 1-3 mm in thickness, and finally prepared for defibration to produce a first intermediate product of moist grass weed fibers having a dry matter content of 30 to 50%, preferably approximately 40%, and a second intermediate of the first intermediate is produced, wherein the following process steps are carried out:

• Drying up the grass plant fibers,
• Admixing of thermally activated binding fibers,
• Spraying additives.

The first intermediate product therefore consists of pre-processed grass fibers, also referred to below as natural fibers or as plant fibers. The second intermediate product is a mixture of these natural fibers with binder fibers and additives, which mixture can be used for a subsequent nonwoven production.

The term "grass" covers all sorts of grasses (Gramineae family), including cereals such as wheat, barley, oats, rye and millet, as well as sugar cane and corn. These raw materials are harvested in the green state and stored in the form of silage for year-round, weather-independent processing. Also covered by the term "grass" are residues from the processing of sugar millet and sugar cane, which are known in professional circles as bagasse.

The term "binder fiber" includes fibers that are thermally activated and in mixture with the natural fibers give them a three-dimensionally fixed structure. These may be melt fibers made of polypropylene or polyethylene, plastic recyclate or bico (bi-component) fibers with a shedding component and a temperature-resistant core component. Binder fibers also include fibers made, for example, from starch or lactic acid which are biodegradable. These fibers are also referred to in the art as support fibers. In a preferred embodiment of the invention, the weight fraction of the binder fibers is 4% to 20%, preferably 5% to 15% or 10%. The inventive method, the proportion of binder fibers and thus the costs can be reduced.

• Als Dämmstoff zum Schutz vor Kälte, Hitze und Schall.
• In der Automobilindustrie zur Herstellung von Innenverkleidungen.
• Als Matratzen.
• Als Bodenabdeckung und/oder Nährsubstrat in der Landwirtschaft.
• Ähnliches.(Schuheinlagen, ...)

The term "nonwoven elements" refers to three-dimensional, flexible or rigid mats of a nonwoven fabric, that is to say of a structure of cross-linked fibers. The nonwoven elements can be flexible or rigid, have different thicknesses and densities and can be used for numerous applications. These include applications

• As an insulating material to protect against cold, heat and sound.
• In the automotive industry for the production of interior trim.
• As mattresses.
• As a soil cover and / or nutrient substrate in agriculture.
• Similar things (shoe inserts, ...)

• Dämmmatten mit einer Dichte von 30-50 kg/m³ und einer Dicke von 50-250 mm: Flächengewicht 1,5-12,5 kg/m², vorzugsweise 3-10 kg/m²
• Trittschallelemente und Fassadenplatten mit einer Dichte von 90-120 kg/m³ und einer Dicke von 10-100 mm: Flächengewicht 0,9-12 kg/m², vorzugsweise 2-10 kg/m².

The insulating elements preferably have the following dimensions and basis weights:

• Insulating mats with a density of 30-50 kg / m ³ and a thickness of 50-250 mm: basis weight 1.5-12.5 kg / m ² , preferably 3-10 kg / m ²
• Impact sound elements and façade panels with a density of 90-120 kg / m ³ and a thickness of 10-100 mm: basis weight 0.9-12 kg / m ² , preferably 2-10 kg / m ² .

The admixing of the binding fibers preferably takes place before the introduction of the additives (such as flame retardants and biocides), so that the binding fibers are also provided by the additives.

The blending of the binder fibers can be done at different degrees of moisture of the natural fibers of the first intermediate product. In a preferred embodiment of the invention, the admixing occurs at a dry matter content of natural fibers of about about 85%. This requires that the pre-drying of natural fibers already happens before mixing.

In another preferred embodiment of the invention, admixing occurs at a dry matter content of the natural fibers of about 40% to about 85%. Depending on how large the dry matter content of the first intermediate product, there is no pre-drying before mixing, but only after or during mixing.

An apparatus for carrying out a core function of this invention, i. Pre-drying, blending of binder fibers and spraying of additives, preferably consists of a standing container which is fed from above with moist natural fibers and binder fibers and in which rising from below hot air is blown. The two types of fiber are confused and mixed in the container and withdrawn from the container with the flow of hot air through a dispensing nozzle and tubing. The natural fibers are pre-dried. In the pipeline, a spray device is installed, which allows a uniform application of the additives and at the same time does not hinder the material passage. To support the turbulence and / or the hot air promotion, the container may have a propeller which rotates about a vertical axis.

In a further preferred embodiment of the invention, admixing takes place in an aqueous suspension, ie at a dry matter content of the natural fibers of less than about 10%. Thus, the requirements for dewatering by preprocessing for the production of the first intermediate product are relatively low. The pre-drying of the suspension after admixing is preferably done mechanically, optionally coupled with air drying.

When pre-drying by hot air during or after admixing the binding fibers, the temperature of the drying air is kept below the temperature required to activate the binding fibers. Preferably, the Temperature of the hot air in the range between about 80 ° C and about 200 ° C. Preferably, this pre-drying is done in a transport section in which the fibers are conveyed by hot air.

The second intermediate is thus a mixture of natural fibers and binder fibers, with a binder fiber content of 4% to 20%, preferably 5% to 15% or 10%, equipped with additives, and having a dry matter content of preferably about 40% to 75%. Of course, the amount of dry matter depends very much on how much liquid is added by the spraying of the additives, and whether pre-drying takes place even after spraying.

The preparation of the first intermediate product, ie the preprocessed plant fibers, is preferably done by the raw material is fiberized and digestible components of the raw material are separated. Digestible components are in particular e.g. Lactic acid, acetic acid, amino acids, proteins and minerals.

The raw material according to the invention grass silage (silated grass), preferably with a dry matter content of 20% to 40%, in particular 25% to 35%. In another preferred variant of the invention, the raw material is gold oat (Trisetum flavescens).

The defibering, in turn, takes place in an aqueous suspension with a macerator and / or a deflaker, which is also preceded by a hammer mill for tearing the raw material. When using a macerator in conjunction with a Entstipper the macerator is preferably upstream of the Entstipper.

The separation of the digestible components is preferably done by separating the fibers from the aqueous suspension after defibering, leaving the digestible components in the suspension.

The digestible ingredients are preferably processed into feed or food additives in a separate branch of processing. This is done by concentrating these ingredients in the suspension into nutrients, with the water portion preferably being recycled.

The digestible components preferably comprise organic acids, proteins and minerals, and preferably also enzymes, vitamins and / or hormone-like substances, in particular vitamin D3 hormone. The presence of these substances depends on the choice of the raw material, ie on the plants used and on optional silage additives.

To produce the nonwoven element from the second intermediate product, ie from the finished and conditioned fiber mixture, a nonwoven fabric is preferably formed and the binding fibers are activated by heating, so that they bond with the natural fibers and form a matrix. The web formation can be done by the second intermediate product has a dry matter content of about 60% to 85% or higher and is thus used directly for the formation of the web, wherein optionally a residual drying takes place during heating of the web to activate the binder fibers. Alternatively, the web formation can be done by the second intermediate product has a dry matter content of 40% to about 60%, placed on a conveyor belt, after-dried by hot air, for example, and optionally loosened again, and then heated to activate the binding fibers.

The fleece laying, eventual drying and activation is preferably carried out in a continuous process for producing a nonwoven tape. From the finished Fleece band, the nonwoven elements can be cut off. Alternatively, the nonwoven laying, etc., but also done in batch mode, with individual nonwoven elements are formed in predetermined shapes ..

1. (a) Der Rohstoff Gras wird in feuchtem Zustand verdichtet und luftdicht verpackt. Dieses Verfahren ist in der Landwirtschaft seit langem unter dem Begriff "silieren" bekannt.
2. (b) Das silierte Gras wird für die weitere Verarbeitung konditioniert, das heisst, so vorbereitet, dass die Herstellung einer rühr- und pumpfähigen Suspension möglich ist.
3. (c) Der konditionierte Rohstoff wird zerfasert und von verdaulichen Begleitstoffen weitgehend befreit.
4. (d) Die Grasfasern werden entwässert, mit Bindefasern gemischt, mit Additiven ausgerüstet und für die Vlieslegung vorbereitet.
5. (e) Aus dem vorbereiteten Fasergemisch wird ein dreidimensionales Vlies hergestellt und thermisch fixiert.

In summary, in a preferred embodiment of the invention, the method according to the invention comprises the following steps:

1. (a) The raw material grass is compacted in a moist state and packed airtight. This process has long been known in agriculture as "ensiling".
2. (b) The ensiled grass is conditioned for further processing, that is prepared so as to allow the production of a stirrable and pumpable suspension.
3. (c) The conditioned raw material is defibered and largely freed of digestible accompanying substances.
4. (d) The grass fibers are dewatered, mixed with binder fibers, provided with additives and prepared for lay-up.
5. (e) From the prepared fiber mixture, a three-dimensional nonwoven fabric is produced and thermally fixed.

• Die Bereitstellung des Rohstoffs für die ganzjährige Nutzung in gleich bleibender Qualität.
• Die Herstellung von Grasfasern aus diesem Rohstoff.
• Die Verarbeitung der Grasfasern zu einem dreidimensionalen, stabilen Vlies- bzw. Dämmstoff.

The invention thus enables

• The provision of raw material for year-round use in consistent quality.
• The production of grass fibers from this raw material.
• The processing of grass fibers into a three-dimensional, stable fleece or insulating material.

Further preferred embodiments emerge from the dependent claims. Characteristics of the method claims are analogously combined with the device claims and vice versa.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following, the subject invention will be explained in more detail with reference to preferred embodiments, which are illustrated in the accompanying drawings. FIG. 1 schematically shows a procedure and FIG. 2 a structure of a plant for fleece production from grass plants.

WAYS FOR CARRYING OUT THE INVENTION

The following is a nonwoven production, starting with the production of raw materials, based on FIG. 1 described: First, the raw grass is mowed on the field. In this case, it is preferably processed with a conditioner which strikes the stem structures in such a way that they soften and lose moisture more quickly. The mown grass is wilted on the field, that is, dried to a dry matter content of 25-40%. It is then picked up and pressed in a silo with the exclusion of air or ensiled. In this form, the raw material can be stored without loss over a very long period of time and is available for processing at any time and weather-independent. Silage is preferably carried out in large, horizontal silos, but can also be done in silo bales or silos standing. Furthermore, also Silierhilfsmittel can be added.

For processing, the raw material is tapped from the silo, loosened 1 and fed to a metering device 2. This leads the raw material into one or more hammer mills, where it is torn 3 or torn open and crushed to about 10-30 mm in length and about 1-3 mm in thickness. This will prepare the plant parts for subsequent defibering.

With the crushed plant material with the addition of water, the production of a 4 stirrable and pumpable raw material suspension is possible. The raw material suspension is fed to a mechanical defibration 5. This is accomplished by fiberizing aggregates which have been successfully used in the pulp industry for decades, e.g. Deflaker, macerators or refiner. To optimize the fiberization with regard to the fiber length and the fiber thickness, these aggregates can also be connected in series. It has been shown that the sequence of macerator and deflaker is particularly well suited for the present task. In this sequence, the macerator, which can suck in the raw material suspension itself, takes over the further homogenization of the raw material suspension as well as the feed of the directly downstream degasser. This results in fibers with predominantly about 3-30 mm in length and about 0.05-0.5 mm thickness. In the course of defibration, a mass transfer of the soluble and digestible raw material components into the liquid phase takes place. The defibration can be carried out temperature-independently. However, it has been shown that a temperature of over 40 ° C in the suspension brings advantages in terms of processability, the quality of the fibers obtained and the fiber cleaning.

After defibration, the fibers are mechanically dewatered. 7. This is preferably done by removing the fibers from the suspension and then pressing the fibers in a screw press. The removal from the suspension is preferably carried out with a screening device, e.g. with a bow sieve or a drum sieve. With a screw press, for example, the fiber mixture can be dewatered to a dry matter content of approx. 36-46%.

The soluble and digestible raw material components of the suspension consist mainly of organic acids (lactic acid, acetic acid, amino acids), non-fermented sugars, proteins and minerals. By adding suitable silage aids, eg bacterial cultures, the conversion of the raw material into the raw material can controlled fermentable sugars are controlled. For example, such a ratio of lactic acid to acetic acid can be achieved.

The soluble and digestible raw material components can be concentrated after separation from the fibers and used as a special feed. Of particular note is the value of this special feed as an acidifier, as a flavor carrier and as an actual feed. In addition, depending on the type of grass used, valuable enzymes, vitamins or hormone-like substances may also be present in this material stream. An example of this is the grass species Goldgrass (Trisetum flavescens), which contains a vitamin D3 derivative, which is partially water-soluble and supports the bone formation of mammals and humans.

All listed ingredients and properties can be used not only in animal nutrition, but also as an additive for human nutrition. The required concentration of the ingredients can be done by filtration and / or evaporation. It should be noted that the minerals may partially precipitate out of the solution during the concentration.

The further processing of the dewatered fibers is described below: In the subsequent steps, the drying or pre-drying 8 of the fibers, the admixture 9 of the binding fibers and the equipment 10 of the fibers with additives take place.

For the admixture 9 of binder fibers, the textile industry offers both continuous and batch processes which are well suited. When processing grass fibers, the binder fibers are added at a weight fraction of 4-25%, preferably 5-15% of the product weight.

The equipment 10 of the fibers with additives is made by spraying the loose fibers. In order to ensure the most uniform application of the additives to the fibers, the spraying is preferably carried out in an air stream in which the fibers move freely. The spraying can be carried out with flame retardants customary in the insulating industry, e.g. with borates or ammonium compounds and with a water repellent and / or a fungicide. These additives can be mixed in a solution or sprayed individually onto the fibers.

With the drying or predrying 8, the fibers are adjusted to a dry matter content which is advantageous for the subsequent nonwoven laying and thermal bonding. This dry matter content is preferably 60-85% of the total weight of the fibers. In this state, the fibers are still elastic and can withstand mechanical processing well. In addition, the fibers are less prone to sticking in cards or similar, possibly used for web forming equipment. Furthermore, the fibers have limited self-weight at this moisture content and can therefore be laid to a non-woven with the largest possible volume or the lowest possible density.

The drying or pre-drying 8 can be achieved with various drying techniques, e.g. Air-layer dryer, drum dryer or belt dryer.

In principle, different sequences of the processing steps mixture 9 with binder fibers, metered addition of the additives 10 and drying or pre-drying 8 are possible. It should be noted that the transport of the fibers in the air stream can lead to a not insignificant drying effect and can also be used selectively.

As an alternative to pre-drying 8, it is also possible to use the fibers provided with bonding fibers and additives without actual pre-drying 8, i. with a dry matter content of 36-50% of the web formation.

As a further alternative to pre-drying 8, it is also possible to completely remove the fibers prior to web formation, i. to dry to a dry matter content of over 85%.

For nonwoven laying, the industry offers various methods, e.g. Air lay, direct web formation 11, scattering, carding, or the like, which are suitable for the present task.

In the case of thermobonding 12 of the nonwoven fabric (or activation of the binder fibers), the heating of the nonwoven fabric takes place at the melting temperature of the sheath component of the support fibers and the setting of the desired plate thickness or density. The plate density or thickness is adjusted with an overflowing band, which compresses the nonwoven fabric to a thickness of about 3 mm to 250 mm, thereby giving it a uniform surface. The heating of the web takes place with a supply air temperature of 120-180 ° C, preferably 140-170 ° C. The Thermobondierofen is also suitable for removing the residual moisture in the nonwoven fabric.

After heating, the nonwoven fabric is cooled, cut to the desired mass of fiber mats 13, palletized and packaged.

FIG. 2 shows an overview of the structure of a plant for nonwoven production: a pre-processing unit 21 has the devices for tearing, fraying and dewatering, so to provide the plant fibers 101. A core unit 22 has the means for mixing 9, spraying 9 of additives and drying 8 and thus to Forming the fiber mixture 102 on. A web-forming device 23 comprises the devices for fleece laying, Thermobondierung and for cutting to form nonwoven elements 103. An optional concentrator 24 has means for concentrating the digestible constituents 104 separated from the suspension into feeds 105.

Nonwovens having a density of 25-90 kg / m 3 were produced from grass using the method according to the invention. The low density panels are slightly flexible, somewhat compressible and comfortable to handle. A thermal conductivity of 0.034-0.040 W / (m, K) was measured.

For the higher density panels, the binder fibers can be selected so that the product has increased mechanical compressive strength and is thus also suitable for impact sound insulation as well as directly plastered exterior facades.

The use of the fleece for the production of mattresses special binding fibers can be used, which influence the recovery behavior of the fleece.

Other properties, e.g. Odorlessness and water repellency can be achieved by targeted influencing of the fibers, for example by being treated with an oxidizing agent or with a hydrophobing agent.

The process allows the use of a hitherto barely used raw material for the production of a high quality product. Associated with this are significant ecological advantages in the provision of raw materials (renewable raw material), the processing (low energy consumption), product use (optimal combination of cold protection, thermal insulation and sound insulation) and product disposal (recyclability).

Claims (17)

1. A method of manufacturing an insulation mat from a raw material comprising grass plants, characterized in that:

   i. the raw material grass is mowed in the field,

   ii. the mowed grass is withered in the field meaning to pre-dry the grass to a dry substance content of 25-40%,

   iii. the raw material is being collected (1)and pressed in a silo under the exclusion of air,

   iv. the raw material is removed from the silo, being loosened (1) and moved to a metering device (2),

   v. the device moves the raw material into one or more hammer mills, where it is ripped apart 3 and reduced into parts of an approx. 10-30 mm in length and 1-3 mm in thickness,

   vi. by adding water to the de-fibered plant matter, a raw material suspension, which can be stirred or pumped, is manufactured (4),

   vii. the raw material suspension is moved to a mechanical de-fibering (5),

   viii. the fibers are withdrawn (6) from the suspension,

   ix. then, the fibers are being mechanically drained (7), to obtain a first intermediate product (101) made of moist, natural grass fibers which have a dry substance component of 30% to 50%, preferably nearly 40%,

   x. and a second intermediate product (102) is obtained from a first intermediate product (101) by implementing the following steps:

   • pre-drying (8) of the grass fibers to a dry substance content of 60-85% of the total weight of the fibers or drying up to a dry substance content greater than 85 %, of the total weight of the fibers,

   • adding (9) of binding fibers up to a content by weight of 4-25%, preferably 5-15% of the product's weight,

   • spraying (10) of the additives.
2. The method according to claim 1, characterized in that the binding fibers added to the natural fibers (9) are in a watery suspension which dry substance content is under 10%.
3. The method according to one of the above claims, characterized in that the step of the pre-drying (8) is at least partially occurring in at least one conveying section in which the fibers are exposed a hot air flow.
4. The method according to claim 1, characterized in that, to manufacture the first intermediate product, the digestible parts of the raw material (100) are being separated from the raw material (100).
5. The method according to claim 1, characterized in that, the vegetable raw material (100) is being de-fibered (5), in a watery suspension (4) by means of a mechanical de-fibering system, preferably a macerator and/or deflaker.
6. The method according to claim 5, characterized in that, a macerator as well as a deflaker are used, with the macerator positioned in front of the deflaker.
7. The method according to one of the claims 4 to 6, characterized in that, the separation of the digestible parts is done by separating the vegetable grass fibers from the suspension (4), after the de-fibering (5), with the digestible parts remaining in the suspension.
8. The method according to claim 7, characterized in that, the digestible parts (104) contain mainly acids, proteins and minerals and are concentrated into a special feeding stuff or to a nutrient additive (105).
9. The method according to claim 7, characterized in that, the digestive parts (104) further comprise at least one of enzymes, vitamins, similar hormone matter and vitamin D3 hormone.
10. The method according to one of the above claims, , characterized in that an insulation mat is manufactured from the second intermediate product (102), by the additional steps of:

    • forming (11) a fleece from the second intermediate product (102),

    • activating (12) of the binding fibers through the heating of the fleece, whereby the binding fibers and natural fibers are bonding together.
11. The method according to claim 10, characterized in that, the second intermediate product (102) has a dry substance content of approximately 60% to 85% for manufacture of the fleece, wherein a residual drying is provided by heating the fleece in order to activate (12) the binding fibers.
12. The method according to claim 10, characterized in that, the second intermediate product (102) has a dry substance content of approximately 40% to 60%, is positioned on a conveyor belt, is post-dried, and is loosened up, the activation (12) of the binding fibers then occurring.
13. An insulation mat produced according to the method according at least one the claims 1 to 12.
14. An insulation mat according to claim 13 with a density of 25-90 kg/m3.
15. A device for the manufacturing of an insulation mat from grass plants by the method according at least one the claims 1 to 12 comprising a core unit (22) for producing a second intermediate product (102) from a first intermediate product (101), whereby the core unit (22) comprises: a hot air based drying unit, a mixer unit for mixing natural fibers with binding fibers, which may be thermally activated, and a provider unit for providing additives to the fibers.
16. A device according to claim 15 comprising a pre-processing system (21), having equipment for de-fibering the grass plants and separating the digestible parts from the fiber for manufacturing the first intermediate product (101).
17. A device according to claim 15 or 16 comprising a fleece production system (23), further comprising units for fleece laying of the second intermediate product (102), and having units for heating the fleece, above a binding fiber activation temperature, for activating the binding fibers.

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