Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4209—Inorganic fibres
  • D04H1/4218—Glass fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4266—Natural fibres not provided for in group D04H1/425

Definitions

• the invention relates to an insulating product, more particularly to a fibrous insulating product.
• Insulating products based on mineral wool are well known. They are very good thermal insulators, thanks to their oriented fibrous structure which limits the thermal conductivity through the product.
• mineral wools are made mainly from mineral materials, including natural or recycled products (recycled glass), and thus have an interesting environmental balance.
• insulating products based on plant fibers
• They are less efficient thermal insulators than insulating products based on mineral fibers, mainly because the shape of the fibers and the production techniques make it possible to obtain products where the orientation and organization of the fibers is not sufficient. controlled.
• These products nevertheless meet a growing demand for building materials derived from biobased materials, particularly if they are of local geographical origin close to the place of production.
• the fibers of vegetable origin are wood fibers or hemp fibers.
• the binder resin is based on starch, or a formophenolic resin and starch, or an acrylic resin.
• the nodules or flakes of mineral wool are made of glass wool with a micronaire less than 15 L / min, in particular less than 12 L / min, preferably less than 10 L / min, especially between 3 and 7 L / min, especially 5 to 6 L / min or rockwool with a fasonaire of at least 250.
• the nodules or flakes of mineral wool have a length of between 0.3 and 3 cm, in particular between 0.5 and 2 cm.
• the mass ratio of the nodules or flakes of mineral wool on the fibers of plant origin is between 85/15 and 20/80, and the percentage of binder resin is between 3 and 20% of the total mass. preferably between 4 and 15% of the total mass.
• the fibers of plant origin have a diameter of between 0.8 and 55 decitex, preferably between 0.8 and 25 decitex, more preferably between 0.8 and 17 decitex, and a length between 0.2 and 20 mm, preferably between 0.3 and 4 mm.
• the coating of plant fibers and nodules or flakes of mineral wool by the liquid binder resin is achieved by passing the plant fibers and nodules or flakes of mineral wool, conveyed at a speed between 20 and 40 m / s, in a tunnel in which the liquid binder resin is in suspension.
• the formation of the mattress is carried out by passing through a curtain of spiked rollers and then through an inclined belt of spike feed rollers.
• the nodules or flakes of mineral wool provided are of mineral wool of the type to blow, preferably free of binder, and may contain anti-dust and / or anti-static additives.
• the fibers of plant origin provided are wood fibers or hemp fibers.
• the liquid binder resin is based on starch, or a formophenolic resin and starch, or an acrylic resin.
• the nodules or flakes of mineral wool provided are glass wool with a micronaire less than 15 L / min, especially less than 12 L / min, preferably less than 10 L / min, in particular between 3 and 7 L / min, especially 5 to 6 L / min or rockwool with a fasonaire of at least 250.
• the nodules or flakes of mineral wool provided have a length of between 0.3 and 3 cm, in particular between 0.5 and 2 cm.
• the mass ratio of the nodules or flakes of mineral wool provided on the fibers of plant origin provided is between 85/15 and 20/80 and the percentage of binder resin is between 3 and 20% of the mass. total, preferably between 4 and 15% of the total mass.
• the fibers of plant origin provided have a diameter of between 0.8 and 55 decitex, preferably between 0.8 and 25 decitex or between 25 and 55 decitex, more preferably between 0.8 and 17. decitex, and a length of between 0.2 and 20 mm, preferably between 0.3 and 4 mm.
• the invention relates to an insulating product comprising fibers of plant origin, nodules or flakes of mineral wool comprising mineral fibers, and binder resin encapsulating the fibers of plant origin and the nodules or flakes of mineral wool.
• the fibers of vegetable origin and the nodules or flakes of mineral wool are bonded together by the binder resin.
• the invention manages to offer a combination of mineral wool and plant fibers, which has a better insulating power than that of a plant fiber product.
• the binder resin coats all the fibers and nodules or flakes of the insulating product homogeneously, which allows a very good cohesion between the fibers. This also makes it possible to assemble fibers of distant dimensional characteristics.
• the insulating product of the invention is an insulating blanket which may be in the form of panels or rolls. It comprises fibers of plant origin, such as wood fibers or any vegetable fibers, and nodules or flakes of mineral wool. Binder resin makes it possible to assemble and bind together the fibers of plant origin and the mineral fibers. The binder resin gives the product good mechanical strength, which allows its handling in the form of a panel, but also a good resilience, which allows its roll-up in the form of roll of mattresses, with the insurance for the mattress to recover its thickness after being unrolled.
• wood fibers as a preferred form of fibers of plant origin, but it is understood that this term generally means fibers of vegetable origin which are useful according to the invention. .
• the fibers of plant origin are mainly networked reinforcing fibers, with a dispersion of nodules or flakes of mineral wool in the interstices of the network.
• the binder resin will contribute all the more to the frame that it will be in large quantities.
• Mineral wool nodules or flakes are packaged fibers, and not individualized fibers such as wood fibers, which allows them to appropriately fill the interstices of the reinforcing fiber network, thereby reducing thermal conductivity. of the assembly by preventing the air from being able to circulate through the insulating product.
• the nodules or flakes of mineral wool are preferably made of glass wool, with a micronaire preferably less than 15 L / min, especially less than 12 L / min, preferably less than 10 L / min, especially between 3 and 7 L / min, especially 5 to 6 L / min.
• the average diameter of the fibers is then preferably less than 2 microns, or even 1 micron.
• the micronaire is measured according to the method described in the document WO-A-03/098209 .
• the nodules or flakes of mineral wool are made of rockwool with a fasonaire of at least 250.
• the fasonaire is determined in the following manner: a test piece (5g) consisting of a tuft of mineral wool is weighed oil and binder but may have non-fibrous components (slug). This test piece is compressed in a given volume and is traversed by a stream of gas (dry air or nitrogen) maintained at a rate constant. The measurement of fasonaire is then the pressure drop across the test piece, evaluated by a water column graduated in conventional unit. Conventionally, a result of fasonaire is the average of the pressure losses observed for ten specimens.
• the nodules or flakes of mineral wool have a length of between 0.05 and 3 cm, in particular between 0.1 and 1 cm. These flakes or nodules are made up of fibers that get entangled in the form of small packets, small wicks or "pilling". By length of the flakes or nodules is meant in this description the length of these packets in their largest dimension.
• the nodules or flakes of mineral wool are, for example, glass wool flakes of the type used for blown wool insulation, for example of the type of wool marketed by Saint-Gobain Isover under the brands Comblissimo® or Kretsull® or by Certainteed under the brand name Insulsafe®. These flakes are generally free of binder and may contain anti-dust and / or anti-static additives such as oils. Alternatively, nodules or flakes containing a small amount of binder, less than 6% by dry weight relative to the mass of the nodules, can be used, for example in the case of mineral wool (glass or rock) nodulated obtained from a mattress.
• the nodules or flakes of mineral wool provided are for example derived from a mineral wool having a resistance to the passage of air greater than or equal to 10 kPa.s / m 2 for a density greater than or equal to 10 kg / m 3 .
• the fibers of plant origin typically wood or hemp, have a diameter of between 0.8 and 55 decitex, preferably between 0.8 and 25 decitex, more preferably between 0.8 and 17 decitex, and length between 0.2 and 20 mm, preferably between 0.3 and 4 mm.
• the binder resin is for example a starch-based resin (for example 100% starch after drying), or a formophenolic resin and starch, or an acrylic resin. It is applied liquid on the fibers before the formation of the mattress. The mattress is then placed in an oven to dry the resin.
• a starch-based resin for example 100% starch after drying
• a formophenolic resin and starch or an acrylic resin.
• the mass ratio of the nodules or flakes of mineral wool on the fibers of plant origin is generally between 85/15 and 20/80, the terminals being included. Thus this mass ratio is for example equal to 85/15, 80/20, 65/35, 70/30, 60/40, 50/50, 40/60, 35/65, 30/70 or 20/80.
• the thermal conductivity and the resistance to the passage of air vary according to this mass ratio.
• the color of the insulating product varies according to this mass ratio. Indeed, the wood fiber is brown while the mineral wool is generally of different color.
• the insulating product according to the invention thus makes it possible to propose a range of products of different grades, each shade corresponding to a mass ratio of the fibers of the nodules or flakes of mineral wool to the fibers of plant origin, and which can be associated with a conductivity. thermal or other property representative of the insulating power.
• the level of binder resin in the finished product is between 3 and 20%, preferably between 4 and 15%, of the total mass. It must be sufficient to ensure good cohesion of the insulation blanket, especially when it is handled, and as little as possible to limit costs and limit the input of polymer products with mechanical function.
• the mineral wool content is between 5 and 95% of the total mass.
• the fiber content of plant origin is between 5 and 95% of the total mass.
• the insulating product of the invention is produced by a mechanical method, which is also the subject of the invention.
• fibers of vegetable origin and nodules or flakes of mineral wool, as described above, are provided, packaged in bales of compressed material.
• the nodules or flakes made of glass wool are for example produced by fiberizing, by means of an internal centrifugation device comprising a centrifuge, or centrifugation plate, able to rotate about a vertical axis and whose peripheral band is pierced with a plurality of orifices.
• a basket with a solid bottom is associated with the bottomless centrifuge.
• the cylindrical wall of the basket is pierced with a small number of relatively large orifices, for example with a diameter of about 3 mm.
• a stream of molten glass feeds the centrifuge and flows into the basket.
• the molten glass, passing through the orifices of the basket, is then distributed in the form of primary nets and directed towards the inside of the peripheral strip from which they are expelled through the orifices of the plate under the effect of the centrifugal force in the form of filaments.
• the flow rate of the molten material arriving in the centrifuge is less than 18 tonnes / day for a centrifuge having a number of orifices of at least 32,000, and preferably at most 14 tonnes / day and a number of orifices. for a centrifuge having a number of orifices of at least 36,000.
• the centrifugation plate has a diameter of between 200 and 800 mm, preferably equal to 600 mm.
• the height of the piercing band of the plate, the height over which the orifices spread, does not exceed 35 mm.
• the plate contains two or more annular zones superimposed on each other, the centrifuge orifices having from one zone to another of the rows of orifices of different diameter and the diameter per annular row being decreasing from the top to the bottom of the peripheral band of the plate in the centrifugation position.
• the diameter of the orifices is between 0.5 and 1.1 mm.
• the distance between the centers of the neighboring orifices of the same annular zone is essentially constant over a whole annular zone, this distance varying from one zone to the other by at least 3% or even by at least 10% and decreasing by top down the circumferential band of the plate in the centrifugation position, with in particular a distance of between 0.8 mm and 2 mm.
• the internal centrifugation device also comprises a gas stretching device consisting of an annular burner which delivers a gaseous stream at high temperature and speed along the wall of the centrifuge.
• This burner serves to maintain the high temperature of the wall of the centrifuge and contributes to the thinning of the filaments to turn them into fibers.
• the stretching gas stream is generally channeled by means of an enveloping cold gas layer. This gaseous layer is produced by a blowing ring surrounding the annular burner. Cold, it also helps to cool the fibers whose mechanical strength is thus improved by a thermal quenching effect.
• the temperature of the gas jet at the outlet of the burner is between 1350 and 1500 ° C, preferably around 1400 ° C.
• a burner pressure of 500 mm CE makes it possible to generate micronaire fibers of 5.5 L / min.
• the mineral wool fibers are made into nodules as explained in the document FR-A-2,661,687 .
• Fibers of vegetable origin in particular wood fibers, can be prepared as indicated below.
• the wood fibers come from softwood logs.
• the logs are cut into rectangular shaped plates having a length of between 2 and 5 cm and a thickness of between about 10 mm and about 40 mm.
• the platelets then undergo a temperature increase of between 70 ° C. and 90 ° C. and are softened by steam injection.
• the moisture content of the platelets is then regulated between 80% and 140%, preferably about 140%, so as to obtain the best conditions for the defibration.
• the excess water is discharged through a tube pierced with a plurality of orifices.
• the flexible and expanded plates are then defibrated by means of a defibration device.
• the defibration device comprises a static disk and a rotating disk comprising segments 42 mm high and rotating at a speed of 1500 rpm.
• the two discs are arranged vertically, parallel to each other, and the pads pass between the two discs. The smaller the spacing between the segments, the smaller the diameter of the fibers extracted from the platelets.
• the fibers extracted from the platelets may undergo a treatment, for example flame retardant and / or anti-moisture and / or anti-static and / or anti-fungal and / or hydrophobic and / or resin coating.
• a treatment for example flame retardant and / or anti-moisture and / or anti-static and / or anti-fungal and / or hydrophobic and / or resin coating.
• the wood fibers are then dried to reduce their moisture content. At the end of drying, the moisture content of the wood fibers is between 4 and 25%.
• the fibers of vegetable origin and the nodules or flakes of mineral wool are firstly mixed.
• the balls of materials tablets are open.
• Wood fibers or nodules or flakes of mineral wool are aerated to facilitate mixing.
• the wood fibers and nodules or flakes of mineral wool are loaded by different loading devices on a collector conveyor to achieve a premix. This makes it easy to adjust the quantities of each material.
• the premix penetrates into a pre-ouvreuse, machine comprising a cylinder of diameter 750 mm provided with radial points of diameter 0.8 mm and rotating at a speed of 700 rpm.
• the pre-worker can mix wood fibers and nodules or flakes of mineral wool in an intimate way.
• an opener for example an opener named "EXEL” marketed by Laroche.
• the opener can comb and refine wood fibers and nodules or flakes of mineral wool.
• the opener comprises a 500 mm diameter cylinder with 75,000 inclined tips of 0.8 mm diameter.
• the opener has for example a width of between 1 and 2 m.
• the mixture of wood fibers and nodules or flakes of mineral wool is introduced between a roller and a trough, which keeps the wood fibers and the nodules or flakes of mineral wool tight against each other during the work of the opener.
• the fibers of plant origin and the nodules or flakes of mineral wool once mixed are then coated with liquid binder resin.
• the fibers of plant origin and the nodules or flakes of mineral wool are launched at a speed of between 20 and 40 m / s in a tunnel about 100 m long.
• the liquid binder resin suspended in the tunnel encapsulates the fibers of plant origin and the nodules or flakes of mineral wool.
• This method of coating the fibers with a liquid binder resin which will be subsequently dried in an oven, makes it possible to produce a mattress with fibers (wood and mineral) of very different dimensional characteristics: coarse wood fibers, which serve frame and mineral fibers, very fine, which fit into the interstices of the reinforcement network and which improve the thermie.
• This process also makes it possible to coat all of the wood fibers and mineral wool nodules or flakes in a homogeneous manner, which will subsequently make it possible to obtain a mattress that holds well and is resilient.
• the fibers of plant origin and the nodules or flakes of mineral wool mixed and coated with liquid binding resin are then formed into a mattress by an aeromechanical process.
• the aeromechanical shaping process is for example carried out by the "formstation” machine marketed by Dieffenbacher or Siquelkampf.
• the fibers and flakes or nodules pass through a substantially vertical curtain of spiked rollers arranged horizontally and parallel to each other.
• the roll of the rollers has a height similar to that of the thickness of the fibers and flakes or nodules, about 1.5 m.
• the distribution rollers are spiked rollers arranged horizontally and parallel to one another. This spreader roll mat is at an angle of 45 ° or more with the horizontal. He climbs away from the curtain of spiked rollers. The larger the angle, the larger the mattress will be.
• the fibers and flakes or nodules fall on a conveyor belt.
• a clipping roller closes the top of the mattress to give it a uniform thickness.
• the mat thus obtained is then passed through an oven to dry the binder and consolidate the mattress for handling.
• the thermo-fixing furnace comprises in enfilade four to six heating chambers and two cooling chambers.
• the temperature in the heating chambers gradually increases, for example from 120 ° C to 250 ° C, from one chamber to the next. This makes it possible to obtain homogeneity of crosslinking of the binder resin. Adjustable speed ventilation is provided in the different rooms.
• the dried binder resin creates a junction between the fibers of plant origin and the nodules or flakes of mineral wool, which makes it possible to obtain cohesion between all the fibers, of vegetable and mineral origin.
• a thermal shock for example passing from a temperature of 250 ° C. to a temperature of 40 ° C.
• the binder resin is then cured.
• the insulating product as described above is then fixed, while being resilient.
• the described method makes it possible to produce an insulating product as described above, very good thermal insulator.
• the inventors have found that the thermal conductivity of the insulating product increases when the mass of wood relative to the mass of mineral wool decreases. This makes it possible to propose a varied range of insulating products according to the invention. This also proves that the conductivity of insulating products based on plant fibers is improved thanks to the invention.
• the inventors have also found that the resistivity to the passage of air increases and the thermal conductivity decreases when the amount of glass wool increases.
• the combination of plant fiber + glass flake + binder resin coating the wood fibers and glass flake fibers with aeromechanical process makes it possible to form a surprisingly resistive mattress with regard to its porosity.
• the insulating product according to the invention makes it possible to improve the thermal conductivity and the air resistance of an insulating product derived from biosourced materials.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Inorganic Chemistry (AREA)
• Nonwoven Fabrics (AREA)

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Citations (4)

• 2012
  • 2012-10-16 FR FR1259853A patent/FR2996904B1/fr active Active
• 2013
  • 2013-10-16 EP EP13188890.1A patent/EP2722429B8/de active Active
  • 2013-10-16 HU HUE13188890A patent/HUE036156T2/hu unknown
  • 2013-10-16 PT PT131888901T patent/PT2722429T/pt unknown
  • 2013-10-16 SI SI201330786T patent/SI2722429T1/sl unknown
  • 2013-10-16 DK DK13188890.1T patent/DK2722429T3/en active
  • 2013-10-16 ES ES13188890.1T patent/ES2640015T3/es active Active
  • 2013-10-16 PL PL13188890T patent/PL2722429T3/pl unknown
  • 2013-10-16 LT LTEP13188890.1T patent/LT2722429T/lt unknown

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