EP3323576B1 - Procédé de fabrication de panneaux d'isolation/nattes ignifugés base de matières premières renouvelables - Google Patents

Procédé de fabrication de panneaux d'isolation/nattes ignifugés base de matières premières renouvelables Download PDF

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Publication number
EP3323576B1
EP3323576B1 EP17201181.9A EP17201181A EP3323576B1 EP 3323576 B1 EP3323576 B1 EP 3323576B1 EP 17201181 A EP17201181 A EP 17201181A EP 3323576 B1 EP3323576 B1 EP 3323576B1
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EP
European Patent Office
Prior art keywords
flame retardant
mats
mixture
fibers
fire retardant
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EP17201181.9A
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German (de)
English (en)
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EP3323576A1 (fr
Inventor
Hossein Ehsaei
Warda Khamis
Ulrich Fehrenbach
Alexander Dr. Kirsch
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GUTEX Holzfaserplattenwerk H Henselmann GmbH and Co KG
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GUTEX Holzfaserplattenwerk H Henselmann GmbH and Co KG
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Priority to PL17201181T priority Critical patent/PL3323576T3/pl
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N9/00—Arrangements for fireproofing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/10—Moulding of mats
    • B27N3/12—Moulding of mats from fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7654—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
    • E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/745—Vegetal products, e.g. plant stems, barks

Definitions

  • the present invention relates to a method for producing a fire-retardant insulating panel or mat and a corresponding blow-in insulating material made from fibers based on renewable raw materials.
  • DIN 4102 with the designation "Fire behavior of building materials and components” represents a standard for the fire behavior of building materials and components.
  • the building materials and components are assigned to building material classes or fire resistance classes.
  • a national classification according to DIN 4102-1 of building materials and components is divided into classes A1 and A2, which are classified as “non-flammable", in class B1, which is classified as “hardly inflammable”, in class B2, which is classified as “normally flammable” and in class B3, which is classified as "easily flammable”.
  • Insulating materials based on renewable raw materials in general and insulating materials containing lignocellulose in particular are now classified in Class B2 according to DIN 4102 and in Class E for "normally flammable” according to DIN EN 13501-1, the standard for the classification of building products and building types in terms of their fire behavior " classified.
  • the afterglow which decisively prevents the classification in the "hardly flammable” area, is to be evaluated particularly critically. Fire loads in the magnitude of the fire test prescribed by the standard ensure such a high energy input into the product that afterglow and continued glowing cannot be prevented.
  • the aim is to expand the use of bio-based insulating materials to applications that are not possible or permitted due to their "normally flammable" properties. This applies in particular to the use of such insulating materials in higher building classes. This lays another cornerstone for the industrial and sustainable production of insulation materials from renewable raw materials. The consumption of fossil resources (minerals, hard coal, oil and natural gas) can thus be further reduced.
  • a generic method for producing a fire-retardant wood-based panel from a mixture of lignocellulose-containing chips and expandable graphite is from DE 10 2009 005 155 B4 or the EP 2 208 594 B1 known.
  • Wood-based panels are becoming more widespread due to their technical properties and are among the fastest growing wood-based products worldwide. Thicknesses of 2 mm to 60 mm with a density of 600 kg/m 3 to 1000 kg/m 3 are usually commercially available.
  • a method for the production of fire-retardant wood-based panels is also from U.S. 2004/258898 A1 known.
  • intumescent flame retardants are chemical fire retardants. Intumescent systems inflate into foams, which are used to protect combustible materials from the effects of heat and fire. Basically, the flame retardant effect is due to the use of synergistic mechanisms. With their help, the combustion process of the wood fibers is prevented both chemically and physically.
  • Phosphate compounds are the main components of the chemically active substances. Their water solubility is a prerequisite for the use of wood fibers. Phosphate compounds can also serve as a reactive flame retardant solution, chemically binding the flame retardant to the wood fiber.
  • the physical effect of acid intercalated types of graphite is used. In this case, the expandable graphite is present as a separate particle in the wood fiber matrix.
  • insulating boards or mats made from fibers based on renewable raw materials have significantly lower densities of up to 300 kg/m 3 . Due to the different densities, insulation fiber boards differ significantly from wood-based panels in terms of fire behavior. Insulation boards made of fibers based on renewable raw materials have significantly larger internal spaces and significantly lower thermal conductivity than wood-based panels. On the one hand, these circumstances produce the desired insulating effect, but on the other hand - particularly in the event of a fire - lead to the disadvantageous effect that heat present in the insulating board is dissipated extremely poorly. So can the residual heat stored in the insulation board can lead to the insulation material smoldering and smoldering even after a fire has supposedly been over.
  • the object of the present invention is to provide fire-retardant insulating materials based on renewable raw materials that achieve class B1 according to DIN EN 4102 and, in the case of flame exposure, reduce the critical heat input in order to effectively prevent afterglow.
  • the object of the invention is achieved by the subject matter of claim 1, relating to a method for producing fire-retardant insulation boards/mats from a mixture containing fibers based on renewable raw materials and a physical and/or chemical fire protection agent.
  • the insulation panels / mats are made from a mixture which fibers based on renewable raw materials such.
  • a chemically active fire retardant can be applied to the surface of the wood fiber in such a way that it partially penetrates into the molecular structure of the wood fiber and is fixed or chemically modified (thereby binding the flame retardant to the fibre).
  • the surface of the wood fibers can be modified using various chemical additives and the surface tension of the fire retardant can also be reduced.
  • the achievement of class B1 according to DIN EN 4102 is ensured by the equipment of the bio-based insulating materials according to the invention.
  • the physical flame retardant forms an insulating layer in the event of flaming and thus reduces the critical heat input so that afterglow - triggered by a pyrolysis effect - is prevented.
  • a chemically active fire retardant such as B. a chemical compound based on phosphorus can be used. Through various, e.g. B. physically and chemically acting fire retardant types synergistic effects can be achieved.
  • intumescence refers to expansion or swelling, ie an increase in volume of the fire protection agent, preferably when exposed to heat above the so-called activation temperature.
  • An intumescent fire retardant preferably forms an insulating layer with low thermal conductivity when it expands. This effect is used within the scope of the invention in order to prevent the fibers or other components of the insulating board from igniting.
  • Insulation boards or mats made from fibers based on renewable raw materials in particular insulation boards containing lignocellulose fibers or wood fiber insulation boards, sometimes also called soft wood fiber boards or softwood fiber boards, are a type of fiber boards, namely panel insulation materials made from fibers based on renewable raw materials, which are mostly used for thermal insulation of the outer shell surfaces of a building . They counteract the passage of heat. Sometimes they are also used in dry construction for the construction of internal building parts (wall, floor). They are among the oldest industrially produced ones Natural insulating materials and were already being produced in this way in the first half of the 20th century.
  • Wood fiber insulation boards usually consist of approx. 90 to 95% dry weight of wood fibers. Softwoods are preferred as the starting material because of their higher fiber quality.
  • Wood fiber insulation boards are particularly suitable for roof insulation and exterior wall insulation outdoors, indoors as floor insulation, insulation of ceilings and interior walls and in cavities (intermediate rafters, partition walls, beam layers).
  • wood fiber insulation boards are also suitable for soundproofing indoors and outdoors and for footfall soundproofing even of apartment dividing ceilings with increased requirements.
  • Round wood (trunks), wood chips, slabs, possibly waste wood, residual rolls from rotary cut veneer production, veneer residues and sawdust are preferably used as the fibrous, renewable raw material for the production of the insulating fiber boards according to the invention.
  • the raw material is preferably debarked and mechanically crushed, sorted or sieved and cleaned.
  • Foreign matter is preferably removed from the raw material by machine, preferably in a so-called “dry cleaning” or a so-called “wet cleaning".
  • dry cleaning the raw material is cleaned with the help of a gaseous medium, e.g. B. air, from heavy bodies freed.
  • wet cleaning stones, sand and metals are separated from the raw material in a liquid medium, e.g. e.g. water.
  • the raw material Before defibration, the raw material usually goes into a pre-steaming tank for hydrothermal pre-treatment, where it is pre-steamed at up to 100°C. This treatment softens the central lamella, favoring both the compressibility of the raw material and subsequent defibration.
  • the partially plasticized raw material reaches z. B. via a vibratory discharge floor or via a stuffing screw in a cooker.
  • the hydrothermal pre-treatment is not absolutely necessary, so that the raw material can also be fed directly into the digester.
  • the stuffing screw has an increasing gradient towards the downstream end and compresses the raw material into a relatively pressure-tight plug, whereby the so-called squeeze water is squeezed out.
  • the plug forms a seal with the digester.
  • the raw material is boiled at a steam pressure of preferably between 6 and 16 bar, with the steam pressure varying depending on the type of wood and the requirements placed on the fibers.
  • the raw material After a residence time in the digester of preferably one to eight minutes, the raw material preferably passes through a conveyor screw and via the feed screw into the refiner (defiberer).
  • the refiner the raw material is defibrated between grinding discs and blown out of the refiner via a controllable valve through a "blow line” (or blow line).
  • the steam pressure in the refiner is preferably in the range from 6 to 16 bar, with the steam forming the means of transport for the fibers on their way through the blow line into the dryer.
  • the fibers obtained are preferably dried in a stream dryer with simultaneous conveyance by hot air in the drying tunnel, so that the fibers with about 8 to 12% moisture (based on the dry mass of the fibers) are separated from the air stream in cyclones.
  • the fibers can optionally be dried down to approx. 2% (based on the dry mass of the lignocellulose fibres), provided the fibers are not further processed with the existing wood moisture.
  • the inherent binding forces of the fibers based on renewable raw materials are used by the fibrous raw material being defibrated and bonded in the form of a fiber cake under the action of heat.
  • lignin is released, which takes on the function of an otherwise necessary binding agent when the fiber cake sets.
  • the use of a separate binder can therefore be omitted.
  • the fire retardant is preferably only added in step B3.
  • the fibers based on renewable raw materials are preferably dried directly after defibration in step A to the residual moisture required for gluing (approx. 8% based on the dry mass of the fibers) and then preferably in one Glue channel or tower or mixer glued with the binder.
  • Steps C1 and/or C2 and/or C4 drying, gluing and spreading of the fibers
  • the fire retardant can be distributed very evenly over the fibers in order to achieve an advantageous fire protection effect over the entire cross section of the insulation board/mat.
  • a chemically active fire retardant can partially penetrate into the molecular structure of the wood fiber and be fixed or chemically modified thereon, as a result of which the fire retardant is bonded to the fiber.
  • the surface of the wood fibers can be modified by various chemical additives and the surface tension of the fire retardant can also be reduced.
  • Another aspect of the invention relates to an insulating board/mat made from a mixture containing fibers based on renewable raw materials and a physical and/or chemical fire protection agent, preferably using the method according to one of the preceding statements.
  • blow-in insulation material produced from a mixture containing fibers based on renewable raw materials and a physical and/or a chemical fire protection agent, preferably according to the method according to one of the preceding statements, the blow-in insulation material preferably having a density in the range of 20 to 60 kg/m 3 , particularly preferably a density in the range from 28 to 40 kg/m 3 .
  • fire-retardant insulating boards/mats are made from a mixture which contains fibers based on renewable raw materials, such as e.g. B. lignocellulose fibers, and a physical and / or chemical fire retardant, such as. B. contains an intumescent fire retardant.
  • renewable raw materials such as e.g. B. lignocellulose fibers
  • a physical and / or chemical fire retardant such as. B. contains an intumescent fire retardant.
  • the lignocellulose fibers are obtained according to the process steps described above from lignocellulose-containing raw material, in particular wood, mixed with the intumescent fire retardant and processed into the fire-retardant, lignocellulose-fiber-containing insulation boards/mats, for example in a wet process or dry process.
  • lignocellulose fibers fibers based on other renewable raw materials such. B. hemp and / or other fire retardants can be used instead of the intumescent fire retardant.
  • the exemplary embodiments disclosed within the scope of the invention differ primarily in the form in which the fire retardant is administered and the point in time or the method step in which the fire retardant is mixed with the fibers.
  • the preferred dosage forms can vary of the fire retardant and the selection of the preferred point in time for mixing the fire retardant with the fibers.
  • the flame retardant used in the process according to the invention is, for example, an effective and environmentally friendly intumescent flame retardant based on a modified and intercalated mineral made from pure carbon as a halogen-free intumescent agent.
  • modified graphites in question, which expand when heated to temperatures above 150 ° C.
  • Such graphites are known and commercially available. They can contain stored acids as blowing agents. Acid-intercalated expandable graphites are preferred.
  • Expandable graphite which is produced by chemical treatment of graphite, contains particularly effective intumescent components.
  • graphite is treated with substances, mostly strong acids and/or oxidizing agents such as hydrogen peroxide or potassium permanganate.
  • the acids and/or oxidizing agents are incorporated into the lattice structure of the graphite. This incorporation into the graphite structure widens the interlayer spacing of the graphite layers. Under the effect of heat, a graphite pretreated in this way will expand with a large increase in volume in the event of a fire.
  • Expandable graphite is suitable as a flame retardant additive because a protective intumescent layer forms on the surface when exposed to heat, slowing down the spread of fire and counteracting the spread of toxic gases and smoke.
  • the expandable graphite z. B. as a flaky or flaky powder, as granules or in the form of preformed particles. Mixtures of expandable graphites of different shapes and/or types are also possible.
  • the expandable graphite can also be partially expanded before it is used.
  • the intumescence preferably starts at the lowest possible temperatures in order to ensure faster response behavior of the equipped building components in the event of a fire.
  • the intumescent fireproofing agent preferably has an activation temperature between 100°C and 1000°C.
  • a mixing ratio between small and large inflation volumes has proven particularly advantageous.
  • the particle sizes of the graphite are to be selected according to the expansion volumes to be achieved and can range predominantly between 1 and 1000 ⁇ m, preferably between 150 and 700 ⁇ m.
  • the surface of the fire retardant is pH-neutral, with a pH value of up to 10 (alkaline/basic).
  • the effectiveness of the fire retardant can be significantly improved by admixing specially tailored additives, preferably inorganic fire retardants, preferably a chemical compound based on phosphorus, and/or starch-based organic substances with the function of enclosing the wood fibers (encapsulation effect), preferably based on plants.
  • specially tailored additives preferably inorganic fire retardants, preferably a chemical compound based on phosphorus, and/or starch-based organic substances with the function of enclosing the wood fibers (encapsulation effect), preferably based on plants.
  • the invention envisages special application methods or forms of administration in connection with application locations that make sense in terms of production technology. These are described in more detail below, including the necessary chemical adjustments to the fire retardant.
  • the fire retardant can be introduced into the process in pure form as a powder or as a mixture, incorporated in an emulsion, a foam, a gel or a binder.
  • Possible application locations for the fire retardant are in the refiner, in the preheater, in the stuffing screw between the preheater and grinding disks), in the blowline (between the refiner and flash dryer), in the glue tower (area of dry gluing of the fibers), during the spreading process, in the mixing chest (for the wet process production).
  • the first embodiment of the invention relates in the first variant to a process for the production of fire-retardant, lignocellulose fiber-containing insulation panels/mats in the wet process according to steps A and B from a mixture containing lignocellulose fibers and intumescent fire retardant, the intumescent fire retardant in the form of expandable graphite being dry and is added in pure form as a powder in step B1 and/or B2 and/or B3 (in the mixing chest), for example exclusively in step B3.
  • the second variant of the first exemplary embodiment of the invention relates to a method for producing fire-retardant insulating panels/mats containing lignocellulose fibers using a dry method after steps A and C of a mixture containing lignocellulose fibers and intumescent fire retardant, the intumescent fire retardant in the form of expandable graphite being dry and in pure form as a powder in step C2 (in the glue tower) or in step C4 (directly in the spreading process), for example exclusively in Step C2, is brought into the process.
  • the fire retardant which is usually in powder form, pumpable and sprayable, it can be bound in an emulsion as a carrier material.
  • An emulsifier (bifunctional or bifunctional silanes or ether-based synthetic oils) is added to the water to form the emulsion.
  • the second exemplary embodiment of the invention relates to a method for producing fire-retardant, lignocellulose-fiber-containing insulating boards/mats in the wet process according to steps A and B from a mixture containing lignocellulose fibers and intumescent fire retardant, the intumescent fire retardant in the form of expandable graphite being incorporated in an emulsion is added as carrier material in at least one of steps A1, A2, A3 or A4 (preheating until defibration) and/or in step B1 and/or B2 and/or B3 (in the mixing chest).
  • the second variant of the second exemplary embodiment of the invention relates to a method for producing fire-retardant insulation boards/mats containing lignocellulose fibers in a dry process according to steps A and C from a mixture containing lignocellulose fibers and intumescent fire retardant, the intumescent fire retardant in the form of expandable graphite being incorporated in a Emulsion is introduced into the process as a carrier material in at least one of steps A1, A2, A3 or A4 (preheating until defibration) and/or in step C2 (in the gluing tower) and/or in step C4 (directly in the spreading process).
  • the advantages of supplying the intumescent fire retardant integrated in an emulsion as a carrier material lie in the good distribution when mixed with lignocellulose fibers.
  • This dosage form works particularly well in the shredder or refiner because the flame retardant is very finely distributed by the mechanical work of the shredder or refiner and, when bound in the emulsion, can adhere very well to the lignocellulose fibers.
  • the fire retardant which is usually in powder form, is embedded in a stable foam and applied.
  • water and anionic/cationic additives are mixed in a special unit and a foam is formed.
  • the foam can also be formed using water with the addition of a foaming siliceous binder.
  • the foam structure must be additionally stabilized.
  • an ether-based surface-active additive or a carboxymethylcellulose-containing additive is used as a foam stabilizer.
  • a surface modifier is used that reduces the surface tension. This results in better binding power between the fire retardant and lignocellulose fibers.
  • the third exemplary embodiment of the invention accordingly relates to a method for producing fire-retardant, lignocellulose fiber-containing insulating panels/mats in a dry process according to steps A and C from a mixture containing lignocellulose fibers and intumescent fire retardant, the intumescent fire retardant in the form of expandable graphite incorporated in foam as the carrier material introduced into the process in step C2 (in the blow line or in the gluing tower) and/or in step C4 (directly in the forming process).
  • the advantages of supplying the intumescent fire retardant integrated in foam as a carrier material lie in the very small amount of water added, good distribution when mixed with lignocellulose fibers, and protection of the structure of the fire retardant.
  • the fire retardant which is usually in powder form, is bound in a gel and fed to the lignocellulose fibers embedded in this carrier material.
  • the gel water glass and a Silica dispersion (as a so-called nanosol) mixed in a special unit and the gel formed.
  • a starch-based cellulose ether is added to modify the rheology of the gel structure.
  • the gel serves as an adhesion promoter between the fire retardant and lignocellulose fibers.
  • the fourth exemplary embodiment of the invention accordingly relates to a method for producing fire-retardant insulating boards/mats containing lignocellulose fibers in a dry process according to steps A and C from a mixture containing lignocellulose fibers and intumescent fire retardant, the intumescent fire retardant in the form of expandable graphite incorporated in gel as the carrier material introduced into the process in step C2 (in the blow line or in the gluing tower) and/or in step C4 (directly in the forming process).
  • the advantages of supplying the intumescent fire retardant bound in gel as a carrier material are the very small amount of water added, the good distribution when mixed with lignocellulose fibers and the protection of the structure of the fire retardant.
  • the fire retardant is premixed or admixed directly into the binder system.
  • the binder system can be diluted in order to ensure better mixing and later distribution to the lignocellulose fibers.
  • Adhesive systems based on isocyanates, synthetic resins, PVAC, proteins (e.g. caseins, enzymatic proteins) and starch are preferably used as binder systems.
  • the combination with adhesive systems on an aqueous, nanostructured, silicate basis is conceivable.
  • the fifth exemplary embodiment of the invention consequently relates to a method for producing fire-retardant, lignocellulose-fiber-containing insulating boards/mats in a dry process according to steps A and C from a mixture containing lignocellulose fibers and intumescent fire retardant, the intumescent fire retardant in the form of expandable graphite incorporated in a binder as the carrier material introduced into the process in step C2 (in the blow line or in the gluing tower) and/or in step C4 (directly in the forming process).
  • the fire retardant to form a mixture such as an aerosol.
  • the (expandable) graphite is modified by means of an organic compound, e.g. based on phosphorus, which also fulfills the function of a flame retardant. This reduces the surface tension of the graphite particles. The lower surface tension of the particles increases their ability to flow or pour. This is the prerequisite for forming a heterogeneous mixture (dispersion) of solid suspended particles in a gas, with the result that the modified graphite is present as aerosol particles or aerosol particles.
  • the particle mixture is then applied to the fiber flow in the channel by means of negative or positive pressure.
  • the dry mixture can be applied to the fibers together with a liquid flame retardant.
  • the fire retardant to form a mixture of expandable graphite and a nanosol, consisting and premixed of water glass (sodium or potassium silicate) and preferably 10% silicic acid sols.
  • This mixture is preferably added in the refiner or in the blowline.

Claims (7)

  1. Procédé de fabrication de panneaux/tapis isolants ignifugés, dans lequel les panneaux/tapis isolants sont fabriqués à partir d'un mélange contenant des fibres à base de matières premières renouvelables et un agent de protection physique contre l'incendie et/ou un agent de protection chimique contre l'incendie,
    caractérisé en ce que
    pour faire office de panneau/tapis isolant, un panneau isolant en fibres de bois est produit à partir dudit mélange grâce à un procédé par voie humide avec une épaisseur située dans la plage comprise entre 4 et 250 mm et une densité située dans la plage comprise entre 80 et 250 kg/m3 ou un panneau isolant en fibres de bois est produit à partir dudit mélange grâce à un procédé par voie sèche avec une épaisseur située dans la plage comprise entre 10 et 300 mm et une densité située dans la plage comprise entre 80 et 300 kg/m3 ou un panneau isolant flexible en fibres de bois est produit à partir dudit mélange grâce à un procédé par voie sèche avec une épaisseur située dans la plage comprise entre 10 et 400 mm et une densité située dans la plage comprise entre 35 et 80 kg/m3, dans lequel le procédé par voie humide est mis en œuvre en dispersant les fibres avec de l'eau afin d'obtenir une bouillie, en ajoutant des additifs et l'agent de protection contre l'incendie à la bouillie, en transformant la bouillie en un tourteau de fibres, en déshydratant le tourteau de fibres, en découpant le tourteau de fibres et en séchant la découpe de tourteau de fibres,
    le procédé à sec est mis en œuvre en produisant une dispersion à partir des fibres, de l'agent de protection contre l'incendie et du liant et/ou d'autres additifs, en comprimant la dispersion afin d'obtenir des panneaux/tapis isolants et en durcissant les panneaux/tapis isolants, et
    l'agent de protection contre l'incendie est un agent de protection contre l'incendie intumescent ou comprend un composant intumescent d'agent de protection contre l'incendie.
  2. Procédé selon la revendication 1, caractérisé en ce que, dans une étape A du procédé, la fourniture de fibres à base de matières premières renouvelables intervient grâce à la mise en œuvre d'au moins une des sous-étapes ci-dessous :
    a. étape A1 : fournir une matière première fibreuse renouvelable,
    b. étape A2 : préchauffer la matière première fibreuse renouvelable,
    c. étape A3: transporter et/ou compresser et/ou cuire la matière première fibreuse renouvelable,
    d. étape A4 : défibrer la matière première fibreuse renouvelable afin d'obtenir les fibres.
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que, dans une étape B du procédé, la fabrication des panneaux/tapis isolants dans un procédé par voie humide intervient grâce à la mise en œuvre d'au moins une des sous-étapes ci-dessous :
    a. étape B1 : disperser les fibres avec de l'eau afin d'obtenir une suspension contenant une proportion d'eau allant jusqu'à 98%,
    b. étape B2 : ajouter des additifs contenant de la résine ou du bitume à la suspension,
    c. étape B3 : stocker temporairement la bouillie,
    d. étape B5 : déshydrater le tourteau de fibres en exprimant mécaniquement l'eau contenue dans le tourteau de fibres,
    e. étape B7 : sécher la découpe de tourteau de fibres à des températures comprises entre 110 et 220°C,
    f. étape B8 : coller plusieurs découpes de tourteau de fibres afin d'obtenir un panneau/tapis isolant multicouche,
    g. étape B9 : découper les panneaux/tapis isolants.
  4. Procédé selon la revendication 1 ou 2, caractérisé en ce que, dans une étape C du procédé, la fabrication des panneaux/tapis isolants intervient dans un procédé par voie sèche grâce à la mise en œuvre d'au moins une des sous-étapes ci-dessous :
    a. étape C1 : sécher les fibres,
    b. étape C2 : mélanger les fibres avec le liant grâce à un collage en mélangeur, un collage en ligne de soufflage et/ou un collage à sec,
    c. étape C3 : ajouter des fibres textiles synthétiques ou des fibres à base de matières premières renouvelables afin d'augmenter la flexibilité des fibres, et divers additifs afin d'améliorer encore les propriétés,
    d. étape C4 : préparer la dispersion dans une machine à dispersion,
    e. étape C5 : grâce à une unité de calibrage et de durcissement, compresser la dispersion afin d'obtenir des panneaux/tapis isolants,
    f. étape C6 : durcir les panneaux/tapis isolants grâce à un mélange de vapeur et d'air,
    g. étape C7 : découper les panneaux/tapis isolants.
  5. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce qu'un agent de protection contre l'incendie présentant au moins une des caractéristiques ci-dessous est utilisé afin de créer le mélange :
    a. l'agent de protection contre l'incendie est un agent de protection contre l'incendie chimique ou chimiquement actif ou comprend un composant chimique ou chimiquement actif d'agent de protection contre l'incendie.
    b. la température d'activation de l'agent de protection contre l'incendie est comprise entre 100°C et 1 000°C.
    c. l'agent de protection contre l'incendie comprend divers composants.
    d. l'agent de protection contre l'incendie comprend des particules dont la taille se situe dans la plage comprise entre 1 µ et 1 000 µm.
    e. l'agent de protection contre l'incendie présente une valeur de pH située dans la plage comprise entre 3 (acide) et 10 (alcalin/basique).
    f. l'agent de protection contre l'incendie contient un agent gonflant.
    g. l'agent de protection contre l'incendie comprend au moins un des additifs ci-dessous, dans un dosage allant jusqu'à 20 % :
    i. agents ignifuges minéraux,
    ii. substances organiques à base d'amidon présentant une fonction de piégeage des fibres,
    iii. additifs synergiques,
    h. l'agent de protection contre l'incendie est ou contient du graphite,
    i. l'agent de protection contre l'incendie est modifié et/ou intercalé et/ou contient du carbone,
    j. l'agent de protection contre l'incendie est préparé par traitement chimique avec des acides forts et/ou des agents oxydants tels que le peroxyde d'hydrogène ou le permanganate de potassium,
    k. l'agent de protection contre l'incendie est présent en un dosage compris entre 3 et 30 pour cent en poids par rapport à la masse sèche des fibres.
  6. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que l'agent de protection contre l'incendie est combiné avec les fibres dans au moins l'un des états ci-dessous afin d'obtenir un mélange :
    a. l'agent de protection contre l'incendie présente un état où l'intumescence n'a pas encore commencé ou s'est produite partiellement,
    b. l'agent de protection contre l'incendie se présente sous forme de poudre ou de billes,
    c. l'agent de protection contre l'incendie est un mélange,
    d. l'agent de protection contre l'incendie est incorporé dans une émulsion faisant office de matériau support, dans lequel l'émulsion est créée à partir d'eau et d'un émulsifiant,
    e. l'agent de protection contre l'incendie est incorporé dans une mousse faisant office de matériau support, grâce à la mise en œuvre d'au moins une des sous-étapes ci-dessous :
    i. création d'une mousse à partir d'eau et d'additifs anioniques/cationiques et/ou d'un liant silicate moussant en tant qu'agent moussant,
    ii. stabilisation de la structure de mousse à l'aide d'un additif tensioactif à base d'éther et/ou d'un additif contenant de la carboxyméthylcellulose en tant que stabilisant de mousse,
    iii. modification de surface de l'agent de protection contre l'incendie afin de réduire la tension superficielle et obtenir une meilleure force de liaison vis-à-vis des fibres,
    iv. incorporation de l'agent de protection contre l'incendie dans la mousse,
    f. l'agent de protection contre l'incendie est incorporé dans un gel faisant office de matériau support, grâce à la mise en œuvre d'au moins une des sous-étapes ci-dessous :
    i. création du gel par mélange de verre soluble et d'une dispersion de dioxyde de silice (également appelé nanosol) ;
    ii. modification de la rhéologie de la structure de gel grâce à l'ajout d'un éther de cellulose à base d'amidon,
    iii. incorporation de l'agent de protection contre l'incendie dans le gel,
    g. l'agent de protection contre l'incendie forme un mélange avec un liant contenant au moins l'un des composants ci-dessous :
    i. un adhésif à base d'isocyanates, de résines synthétiques, de PVAC, de protéines (par exemple caséines, protéines enzymatiques) et/ou d'amidon en combinaison avec des systèmes adhésifs à base de silicate aqueux nanostructuré,
    ii. une colle à base de caséine et/ou d'amidon,
    h. l'agent de protection contre l'incendie forme un aérosol, dans lequel l'agent de protection contre l'incendie se présente sous forme de particules et est modifié au moyen d'un composé organique, de sorte que la tension superficielle des particules est réduite et leur aptitude à l'écoulement ou à l'épandage est augmentée afin de former un mélange hétérogène de particules solides en suspension dans un gaz.
  7. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que l'agent de protection contre l'incendie est mélangé avec les fibres afin d'obtenir un mélange dans au moins l'une des étapes de procédé ci-dessous :
    a. à l'étape A, dans au moins une des sous-étapes A1, A2, A3, A4 et/ou entre deux desdites sous-étapes,
    b. à l'étape B, dans au moins une des sous-étapes B1, B2 ou B3, et/ou entre deux desdites sous-étapes,
    c. à l'étape C, dans au moins une des sous-étapes C1, C2 ou C4, et/ou entre deux desdites sous-étapes,
    d. entre les étapes A et B et/ou entre les étapes A et C.
EP17201181.9A 2016-11-10 2017-11-10 Procédé de fabrication de panneaux d'isolation/nattes ignifugés base de matières premières renouvelables Active EP3323576B1 (fr)

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DE102016121590A1 (de) 2016-11-10 2018-05-17 Gutex Holzfaserplattenwerk H. Henselmann Gmbh + Co. Kg Verfahren zur Herstellung von brandhemmenden Dämmplatten/-matten und brandhemmendem Einblasdämmstoff aus Fasern auf Basis nachwachsender Rohstoffe
DE102019204436A1 (de) 2019-03-29 2020-10-01 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Kompositplatte, Verfahren zu ihrer Herstellung sowie Verwendungen hiervon

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