EP3488038A1

EP3488038A1 - Unfired heat and/or sound insulation product and insulation blanket obtained therefrom

Info

Publication number: EP3488038A1
Application number: EP17748546.3A
Authority: EP
Inventors: Julien THIERRY
Original assignee: Saint Gobain Isover SA France
Current assignee: Saint Gobain Isover SA France
Priority date: 2016-07-22
Filing date: 2017-07-19
Publication date: 2019-05-29
Also published as: JP7071326B2; JP2019528382A; FR3054249A1; US11299418B2; KR20190031502A; FR3054249B1; WO2018015657A1; KR102405001B1; CA3031011A1; US20190185366A1; MA45746A

Abstract

The invention relates to an unfired heat and/or sound insulation product, made from mineral wool, advantageously glass wool, in the form of a mat comprising a layer of mineral wool sized with at least one binder, said sized layer having: - a basis weight, or grammage, less than or equal to 350g/m², preferably less than or equal to 300g/m², or even less than or equal to 250g/m², and, optionally, greater than or equal to 200g/m², - a micronaire of at most 3 under 5 grams, preferably at most 15 l/min, more preferably at most 12 l/min, and at least 9 l/min, and the mat having a thickness greater than or equal to 10mm, or even greater than or equal to 15mm, or even greater than or equal to 25mm. The aim of the invention is to offer a product for heat and/or sound insulation that is lighter while retaining satisfactory heat and/or sound insulation properties and good mechanical strength.

Description

NON-COOKED THERMAL AND / OR PHONIC INSULATION PRODUCT AND INSULATION LINER OBTAINED THEREFROM

The invention relates to a thermal and / or sound insulating product, based on mineral wool, such as glass wool, intended to be used in particular for the manufacture of insulating gaskets. These fittings allow acoustic and / or thermal insulation of the engine, or of the passenger compartment, of a vehicle. The invention also relates to the method of manufacturing such a product and the method of manufacturing such a liner.

Phonic insulators made from foam-type materials, such as polyurethane or melamine foams, which attenuate sound through viscous losses, are known. However, these foams, derived from petroleum products, are unecological and highly toxic in case of fire. They emit, in fact, volatile organic compounds commonly called VOCs. In addition, they have an auto-lift that is not satisfactory because of their low rigidity.

Currently, there is a range of products marketed by Saint-Gobain Isover® under the name "Glass Wool Automotive Green Mat" which is in the form of a layer or layer of glass wool impregnated with a thermosetting binder at about 200 Formophenolic resin, having a basis weight between 400 and 1800 g / m ² , in particular 425 g / m ² . This glass wool layer or batt is coated with polyester or polypropylene, and is fire-resistant or water and oil resistant. This type of product, uncooked, is used to manufacture insulating gaskets of vehicles, molded by thermo-compression.

It is also known from FR1429543 a motor vehicle roof lining comprising a molded element, made from a sheet of glass fibers, lying on a surface coating sheet.

The fiberglass web is produced in a forming line where the formed fibers are sprayed with phenol formaldehyde resin binder in a proportion of 10 to 26% by weight based on the weight of the final fiber product. The fibers thus treated then fall at random and gather in the form of a tablecloth. The dimensions of the glass fibers produced may vary within wide limits and have a diameter of less than 0.009 mm. A 50 mm thick blank with a density of 16 g / dm ³ (ie 800 g / m ² ) is cut from a sheet of glass fibers containing uncooked binder, and placed in a mold to be compressed to to reach a thickness of 6.4 mm after cooking. Blank densities are disclosed ranging from 8 to 32 g / dm ³ (ie between 400 and 1600 g / m ² ), or more.

However, these products are heavy, while the automotive industry requires reducing the weight of vehicles ever more in order to reduce fuel consumption.

There is therefore a need for a thermal insulation product and / or sound that is lighter while maintaining satisfactory thermal and / or sound insulation properties and good mechanical strength.

For this purpose, the invention proposes an uncured thermal and / or acoustic insulation product, based on mineral wool, advantageously glass wool, comprising a layer of mineral wool seamed with at least one binder, said layer having:

- a mass per unit area, or basis weight of less than or equal to 350 g / m ^2, preferably less than or equal to 300g / m ^2, or even less than or equal to 250g / m ^2, and, optionally greater than or equal to 200g / m ² , and

a micronaire of at most 3 at 5 grams, preferably at most 15 l / min, more preferably at most 12 l / min, and at least 9 l / min. The micronaire "under 5 grams" is measured according to DIN 53941 or ASTM D144. For very fine fibers, the micronaire in l / min is measured according to the process described in the patent application WO2003 / 098209, which amounts to adding a flowmeter to the apparatus of the standard DIN 53941.

Thus, the thermal insulation and / or sound insulation product according to the invention is lighter than the known products, with a grammage less than or equal to 350 g / m ² , which makes it possible to limit the quantity of material used, as well as to limit the weight of the vehicle on which the product, processed into a lining, will be installed. This product also has surprisingly high thermal and / or phonic properties, as we will see later.

According to another feature, the product comprises between 8% and 14% by weight of binder, preferably between 9% and 13% by weight of binder, relative to total weight of the mineral wool and binder mixture, and is selected from thermosetting binders.

According to another feature, the binder is chosen from thermosetting binders based on (i) formaldehyde resin, (ii) polyepoxides, or (iii) carbohydrates.

In another feature, the mineral wool fibers are coated on a web, woven or non-woven, hydrophobic and / or oleophobic.

According to another particularity, the veil has, in addition, fire-retardant and / or fungicidal properties thanks to a compound attached to said veil by impregnation, coating or heat-setting.

In another feature, the web is a polyester woven web or nonwoven web, needle punched, based on (i) polyester and / or viscose fibers, (ii) polypropylene fibers, or (iii) carbon fiber, or a polyester reinforced glass veil.

According to another feature, the product is a sheet having a thickness greater than or equal to 10 mm, even greater than or equal to 15 mm, or even greater than or equal to 25 mm and / or having a recovery in thickness greater than or equal to 10 mm , even greater than or equal to 15 mm, or even greater than or equal to 25 mm following roll conditioning of at least 6 weeks.

The invention also relates to a lining obtained from a thermal and / or sound insulating product according to the invention by molding in a form at a binder polymerization temperature, the liner, optionally non-flat conforming to the contours of the invention. the support surface on which it is intended to be mounted.

According to another feature, the liner has a thermal conductivity of less than or equal to 40 mW / (m · K), preferably less than or equal to 38 mW / (m · K), and / or has:

a resistivity to the passage of air greater than or equal to 28000 Ns / m ⁴ when said layer of mineral wool has a thickness greater than or equal to 10 mm, or

a resistivity to the passage of air greater than or equal to 13500 Ns / m ⁴ when said layer of mineral wool has a thickness greater than or equal to 15 mm, or a resistivity to the passage of air greater than or equal to 8000 Ns / m ⁴ when said layer of mineral wool has a thickness greater than or equal to 25 mm.

According to another particularity, the lining has an acoustic absorption greater than or equal to 0.8 between 1300 and 9000 Hz, advantageously between 1800 and 9000 Hz, measured according to the standard DA 49 1997.

The invention also relates to a process for producing an uncooked thermal and / or phonic insulation product, based on mineral wool, advantageously glass wool, as described above, with the aid of a installation comprising an internal centrifugation device which comprises at least one centrifuge capable of rotating about an axis X, in particular vertical, and the peripheral band of which is pierced with a plurality of orifices for delivering filaments of a molten material, a high temperature gas stretching means in the form of an annular burner which stretches the fiber filaments, and a receiving mat associated with suction means for receiving the fibers, comprising adjusting a combination of parameters who are at least:

the burner pressure, which is between 250 and 750 mm CE, preferably between 280 and 440 mm CE,

- the temperature of the burner, which is between 1350 ° C and 1450 ° C, - the fiber flow per day and per centrifuge orifice, which is not more than

1 kg, the total output being not more than 26 kg / day, and

- The product (P) of the speed of travel of the conveyor belt by the width of said carpet, which is between 38 and 90m ² / min.

According to another feature, the speed of rotation of the centrifuge is between 1500 to 3000 revolutions / minute, and / or the diameter of the centrifuge is between 200 and 800 mm, preferably 400 mm and / or in which the mineral wool fibers are received on the reception mat in the form of wicks having a length of between 10 and 50 cm.

According to another feature, the speed of travel of the receiving mat is between 30 m / min and 50 m / min and wherein the width of the receiving belt is between 700 mm and 1800 mm.

The invention also relates to a method of manufacturing a packing described above, comprising the method of manufacturing a thermal and / or sound insulation product, also described above, followed by a step of thermocompression, simultaneously implementing (i) a heating process of said product at a temperature sufficient to soften or polymerize the binder included in said product and (ii) a deformation process of said product which thus conforms to the desired shape of the filling .

The invention also relates to a use of a lining described above as a thermal and / or acoustic insulation in a vehicle, in particular for the thermal and / or sound insulation of an engine or passenger compartment. vehicle, on a ceiling, a wall or a wall, under a roof or in a piece of household appliances.

For the purposes of the invention, the term "packing" means any finished article ready to be used or marketed resulting from the processing of the insulating product according to the invention. It can be a panel, a partition, a door panel, a roof liner, a hood liner, a battery liner or an external dashboard , among others. It can also be a lining of household appliances such as a washing machine liner or dishwasher.

By "wick" is meant, in the sense of the invention, a grouping of several hundred mineral fibers.

By "ply" or "felt" is meant, in the sense of the invention, the arrangement of several wicks as defined above and optionally comprising a resistive veil to any flow of air on and / or under which rest said wicks. We can then speak of tablecloth, or felt, surfaced (e).

The "thermal conductivity" characterizes, in the sense of the invention, the behavior of the materials during the heat transfer by conduction and represents the energy (amount of heat) transferred per unit area and time under a temperature gradient of 1 Kelvin per meter. It is denoted λ (or k in English). It is measured according to ISO 8301 at 10 ° C.

For the purposes of the invention, "grammage" is intended to mean a quantity characterizing the surface mass, that is to say the mass per unit area of said mineral wool. The unit is typically the gram per square meter (g / m ² ). A layer of mineral wool is all the more flexible as its grammage is low and all the more robust that its weight is high. The basis weight is defined from EN 822 standards. The "resistivity to the passage of air", whose unit is Ns / m ⁴ , characterizes, in the sense of the invention, the resistance of a given product or medium to the passage of air. This resistance is intrinsic to said product or medium. As regards its measurement, those skilled in the art use a well-known procedure according to the ISO 9053 standard.

The "acoustic absorption" is measured, in the sense of the invention, by using the sound absorption coefficient alpha (a), whose value is between 0 and 1.00. Zero represents the absence of absorption (total reflection), and 1, 00 represents the total absorption of the sound.

Depending on the case, for the measurement of the sound absorption coefficient, an alpha-cabin or alpha sabine is used, according to the manufacturer's standard DA 49 1997 of the diffuse field meter. Diffuse field absorption in the alpha cabin is usually used by the automotive industry.

The term "average" means "arithmetic mean".

Other features, details, advantages of the invention will appear better on reading the following description, given by way of illustration and in no way limiting with reference to the appended drawings, in which:

FIG. 1 represents a graph of the absorption coefficient as a function of the frequency in Hz, measured according to the manufacturer's procedure D 49 1977, for a glass felt according to the invention of grammage 300 g / m ² , and a glass felt according to the prior art of grammage 425 g / m ² . Felt pens are all 30 mm thick.

The products based on mineral wool, in particular glass wool, are obtained by a known internal centrifugation process associated with drawing by a gas stream at high temperature. In their path, between the centrifugation device and the fiber collection belt, an aqueous sizing composition, also called binder, is vaporized on the still hot fibers, which then undergoes, during the processing of the product as a filling, a reaction. thermosetting at temperatures of about 200 ° C.

Thus, the manufacture of insulating products based on mineral wool generally comprises a step of manufacturing the glass fibers by a centrifugation process.

The method for forming mineral fibers consists in introducing a stream of molten glass, via a basket pierced at the periphery, in a centrifuge, rotating at high speed and having a fiber-forming plate pierced at its periphery. by a very large number of orifices through which the glass is released in the form of filaments under the effect of the centrifugal force.

These filaments are then subjected to the action of an annular drawing current at high temperature and speed, produced by a burner, and which runs along the wall of the centrifuge. Said stream thins the filaments and transforms them into fibers.

The fiber output orifice is adapted to the diameter of the fibering plate, the centrifuge may have a diameter of between 200 and 800 mm, preferably 400 mm.

The total output of the molten material arriving in the centrifuge (s) is less than 26 tons / day and greater than 15 tons / day. It is preferably between 18 and 24 tons / day.

As for the speed of rotation of the centrifuge, it is between 1500 to 3000 revolutions / min, advantageously greater than or equal to 2000 revolutions / minute.

This process of transforming glass into fibers requires the balancing of a number of variable parameters. In particular, the pressure and temperature of the burner, as well as the speed of the drawing gas, play an important role in the optimization of the fiber refining.

Thus, the burner pressure is between 250 and 750 mm CE, preferably between 280 and 440 mm CE, which reduces turbulence. When the pressure of the burner is between 280 and 440 mm CE, the space between the centrifuge (s) and the receiving carpet of the mineral fibers is less loaded with gas. This makes it possible to reduce the suction under the receiving mat, and thus to have a thicker layer of mineral fibers, in particular of at least 10 mm, even greater than or equal to 15 mm, or even greater than or equal to 25 mm. mm. Thus, the lining obtained by thermocompression of this layer of mineral fibers has a satisfactory thickness to allow good sound absorption.

The temperature of the burner, between 1350 ° C. and 1500 ° C., is advantageously 1450 ° C.

The fiber output per day and orifice of the centrifuge (s) is at most 1 kg, preferably at most 0.8 kg and at least 0.5 kg.

The fibers formed, naturally grouped together in the form of strands consisting of a set of fibers, are entrained by this stretching gas stream towards a reception device or receiving mat, which is moving and generally constituted by a gas permeable band associated with suction means.

At the same time, binder is sprayed onto the fibers as they fall to the receiving device. Thus, the fibers are chemically bonded by the application of at least one uncured binder of the thermosetting type, sprayed onto said fibers at the outlet of the fiberizing plate and which coats said fibers.

At this stage, the fibers, freshly sized or coated with binder, are deposited or projected on the receiving device or moving carpet, thus forming a web. The speed of travel of the fiber receiving carpet, associated in the form of locks, is between 30 and 50 m / min.

The accumulation of fibers on the receiving device under the effect of suction provides a sheet of fibers whose thickness may vary according to the final basis weight of the product to be manufactured.

In addition, during the manufacturing process, the mineral wool fibers can be received on the conveyor belt over a width of 700 mm to 1800 mm, preferably between 850 mm and 1500 mm.

Advantageously, the mineral wool fibers are received on the receiving carpet in the form of wicks having a length of between 10 and 50 cm, and more particularly of 15 to 20 cm. This size of locks is advantageous for obtaining a good distribution of said locks in terms of grammage both in the length and in the width of said product.

The method allows a good distribution of the fibers in the width of the insulation product, namely the width of the passing conveyor belt.

In addition, an essential parameter of the invention is the product P of the speed of the conveyor belt by the width of said belt. This product P is between 38 and 90 m ² / min, preferably between 40 and 60 m ² / min, or between 40 and 50 m ² / min. It represents the equivalent of a surface flow. This size is essential for defining the product's weight characteristics.

According to one embodiment, a web, woven or non-woven, can be implemented before the reception of the fibers: it is then disposed on the conveyor belt upstream of receiving the locks on said carpet. The fiber locks therefore come to the output of the fibering plate to lie on said veil. There is then a web, lying on the conveyor, having from the bottom upwards, a web and a layer of strands of mineral fibers. Finally, it is conceivable to have a second sail during conveying, this second sail "sandwiching" the mineral fibers with the first web described above. The sheet, lying on the conveyor, is then composed, starting from the bottom upward, of a first web, in the lower position, a layer of strands of mineral fibers and a second web in the upper position.

At the output of the receiving device, a sheet having a thickness greater than 10 mm, advantageously ranging from 15 to 50 mm, and more generally ranging from 20 to 30 mm, with a basis weight ranging from 200 to 350 g / m ² , is obtained. .

The sheet can then be cut in width or even in length, rolled up and stored. At the time of use, it can be unwound, cut, moved, manipulated, placed and / or deformed in the mold in the most satisfactory manner.

It is recalled that the fineness of the fibers is determined by the value of their micronaire. The measurement of the micronaire also called "fineness index" accounts for the specific surface area by measuring the aerodynamic pressure drop when a given amount of fiber extracted from a non-sized mattress is subjected to a given pressure of a gas, usually air or nitrogen. This measurement is usual in the mineral fiber production units, and is carried out according to DIN 53941 or ASTM D 1448 and uses a so-called "micronaire apparatus" device. This device gives a value in "under 5g". The micronaire is influenced by the average diameter of the fibers. A weak micronaire generally corresponds to fibers of small average diameter. At equivalent density, the reduction of the micronaire leads to an increase in the resistivity at the passage of the air.

However, such an apparatus has a limit of measurement as to a certain fineness of the fibers. For very fine fibers, a fineness ("micronaire") can be measured in l / min by a known technique and described in the patent application WO2003 / 098209. This patent application relates to a device for determining the fineness index of fibers comprising a device for measuring the fineness index, said device for measuring the fineness index being provided on the one hand with at least a first orifice connected to a measuring cell adapted to receive a sample consisting of a plurality of fibers and secondly, a second orifice connected to a device for measuring a differential pressure located on either side of said sample, said differential pressure measuring device being intended to be connected to a fluid flow generating device, characterized in that the fineness index measuring device comprises at least one volumetric flow meter of the fluid passing through said cell. This device gives correspondences between "micronaire" values under 5g and "micronaire" values in liters per minute (l / min).

By way of indication, it may be noted according to this document WO2003 / 098209, a correspondence relation between the micronaire values and the value of the average diameter of the fiber sample. Overall, a micron value of about 12 l / min corresponds to an average diameter of about 2.5 to 3 micrometers, a value of about 13.5 l / min corresponds substantially to an average diameter of 3 to 3.5 micrometers, and finally a value of about 18 l / min corresponds to about an average diameter of about 4 to 5 micrometers.

The insulation product according to the invention, which can be obtained by the process described above, can accumulate a certain number of characteristics, namely:

the weight per unit area of the mineral wool layer may preferably be less than or equal to 300 g / m ² , or even less than or equal to 250 g / m ² , and, optionally, greater than or equal to 200 g / m ² ; and or

the micronaire of the mineral wool layer may preferably be at most 15 l / min, more preferably at most 12 l / min, and at least 9 l / min.

The product according to the invention based on mineral wool, advantageously glass wool, and which forms the web described above, further comprises at least one binder, which may advantageously be chosen from thermosetting binders.

A thermosetting binder involves an irreversible polymerization which leads to a solid, generally rigid finished product. It is prepared by crosslinking a resin and a crosslinking agent, which react under the action of heat in the presence of reagents, namely catalyst and polymerization accelerator.

As thermosetting binders, mention may be made of binders based on (i) formaldehyde resin, (ii) polyepoxides or (iii) carbohydrates. Formo-phenolic resins are preferably chosen from resins with low levels of free formaldehyde, in particular those described in applications WO-2008/043960 and WO-2008/043961. For example, liquid resins consisting essentially of phenol-formaldehyde and phenol-formaldehyde-amine condensates with a free formaldehyde content of less than or equal to 0.1% can be mentioned for the application WO-2008/043960 and with a free formaldehyde content of less than or equal to 0.3% and a free phenol content of less than or equal to 0.5% for the application WO-2008/043961, the levels being expressed as total weight of liquid.

In the present application, "carbohydrates" refers to products derived from renewable sources. They include, in the present application not only carbohydrates in a strict sense, that is to say reducing sugars or carbohydrates of the formula C _n (H ₂ O) _p having at least one aldehyde or ketone group (group reducing agent), but also the hydrogenation products of these carbohydrates where the aldehyde or ketone group has been reduced. Mention may thus be made of reducing sugars, non-reducing sugars, sugar alcohols or hydrogenated sugars comprising all the products resulting from the reduction of a saccharide chosen from monosaccharides, disaccharides, oligosaccharides and polysaccharides and mixtures of these products.

Polyepoxides, also called epoxy or improperly "epoxy" polymers, are manufactured by polymerization of epoxy monomers with a hardener which is a crosslinking agent which may be based on acid anhydride, phenol or most often amine (polyamine, aminoamide). Epoxy (or epoxy) resins harden irreversibly in the presence of a hardener under the effect of heat.

The binder content in the product according to the invention can range from 8% to 14% by weight, preferably from 9% to 13% by weight, relative to the total weight of the mineral wool and binder mixture.

The mineral wool fibers are advantageously coated on a web, woven or non-woven, which may be hydrophobic and / or oleophobic. The veil may also have been treated beforehand in order to have, in addition, fireproof and / or fungicidal properties following a compound attached to said veil by impregnation, coating or heat-setting. For example, we can cite as a particular veil in accordance with the invention, a polyester woven web or nonwoven web, needle-punched, based on (i) polyester and / or viscose fibers, (ii) polypropylene fibers, or (iii) carbon fiber, or a polyester reinforced glass veil.

The product according to the invention can thus be in the form of a sheet having a thickness greater than or equal to 10 mm, even greater than or equal to 15 mm, or even greater than or equal to 25 mm and / or having a recovery in thickness greater than or equal to 10 mm, even greater than or equal to 15 mm, or even greater than or equal to 25 mm following a roll conditioning of at least 6 weeks.

The webs can then be used to make composite products by molding, such as toppings. The formation of the linings is effected by thermo-compression molding. The thermocompression molding makes it possible to obtain parts by deformation and distribution of the material between a die and a punch (mold and against-mold) mounted on a vertical press.

This process is based on the principle of the mold and against-mold. The molding materials are arranged on the lower part of the mold. The upper part of said movable mold compresses these materials to fill the cavity and form the part. The closing time is a function of the time required for the binder to act, in particular the time required for its polymerization.

The thermo-compression process therefore comprises successively in order:

a step of depositing the product or sheet to be molded on the mold,

a step of closing the press with the mold and the counter-mold facing each other, said product or said sheet being sandwiched between the latter,

a step of pressurizing and heating the mold and against a mold at a temperature, adapted to the selected binder and being able to extend over a space of 180 to 230 ° C., inclusive, in order to polymerize the binder,

a stage of opening of the mold and demolding of the product or of the molded sheet (e) thus obtained, a step of trimming to the exact dimensions or deburring in the case of use of preform in order to obtain a lining according to the invention. It is conceivable, prior to the thermo-compression process, either (i) to remove a veil from the sheet when the latter has at least one, or (ii) to add at least one veil to the sheet. The veil can be an aluminum film or any other woven or nonwoven veil chosen according to the target liner and the targeted application.

It is also conceivable to have at least two layers, according to the invention, identical or different. They are then placed one on the other in the mold in the removal step.

Advantageously, the step of depositing the product, which is advantageously a surfaced web, that is to say a web comprising at least one web, woven or non-woven, is accompanied by a positioning of said product vis-à-vis -vis walls of a mold, namely external walls of said mold in the case of a male mold or internal walls of said mold in the case of a female mold.

In addition, the method may comprise a step of evacuating the air located between said product, or web, and the mold, this step following said positioning step, said air evacuation taking place either (i) by spraying pressurized air on said product, displacing air between said product and the mold or (ii) sucking said air or (iii) applying a mechanical compressive force to said product, the process terminating by a demolding step with recovery of said liner.

The heat treatment during the heating step which consists in heating the mold and therefore the product or the sheet makes it possible to cause the polymerization of the thermosetting binder. Indeed, the binder is formed by crosslinking: two ingredients, one of which is typically a "resin", react under the action of heat in the presence of reagents such as catalyst and polymerization accelerator. The formed three-dimensional structure is stable, exhibits thermomechanical and chemical resistance. Finally, after cooling the product treated by the thermocompression molding process, solid bridging was created by the binder between the fibers. The lining resulting from the molded web thus has good cohesion and is made easy to handle. The lining according to the invention is manufactured from a thermal and / or sound insulation product as defined above. This lining is derived from a molding of said insulating product. A liner is thus molded into an optionally non-flat shape conforming to the contours of the support surface on which it is intended to be mounted.

Advantageously, the packing according to the invention may furthermore have (i) a thermal conductivity of less than or equal to 42 mW / (mK), preferably less than or equal to 40 mW / (mK), and / or (ii) can present:

a resistivity to the passage of air greater than or equal to 13500 Ns / m ⁴ when said mineral wool layer has a thickness greater than or equal to 15 mm; or

· A resistivity to the passage of air greater than or equal to 8000 Ns / m ⁴ when said layer of mineral wool has a thickness greater than or equal to 25 mm.

The liner may also have an acoustic absorption greater than or equal to 0.8 between 1300 and 9000Hz, advantageously between 1800 and 9000Hz, measured according to the standard DA 49 1997.

The linings according to the invention may be intended to be implemented in a vehicle, on a ceiling, under a roof or on a wall or a wall, or in household appliances such as a washing machine or a washing machine. dishwasher.

When they are implemented in a vehicle, they can thus thermally and / or acoustically isolate the engine of said vehicle and / or the driver's cab of this vehicle. The vehicle is selected from an automobile, a bus, a truck, an agricultural vehicle, a boat, an aircraft and a train. Advantageously, it is a car.

The invention has the advantage of not requiring the use of several combinations of materials such as foams, cotton webs Indeed, only a suitable sheet, resistive to the passage of air, is sufficient. The implementation time is reduced, which generates productivity gains. This sheet may, in addition, also have other functions, possibly cumulative such as a hydrophobic and / or oleophobic function, and may also have an aesthetic appearance.

In addition, by lowering the weight, the amount of resin to be cooked also decreases, and therefore, in turn, the molding / cooking cycle time is also reduced allowing, again, a significant productivity gain.

The following is an example of a product of the invention obtained according to the process of the invention. EXAMPLE 1 Manufacture of a Glasswool Sheet According to the Invention

A sheet of glass wool is obtained from two fiber plates, arranged in series, said plates having 300 mm in diameter and 13150 holes, each, and with a manufacturing method having the following characteristics:

o Fired glass is 10 tonnes / day and the centrifuge hole is 0.76 kg / day.

o The rotation speed of the centrifuge is 2500 rpm.

o The burner pressure is 290 mm wc.

o The burner temperature is 1450 ° C.

o The width of the reception mat is 1250 mm.

o The speed of the reception mat is 39 m / min.

o The product P is equal to 48.75 m ² / min.

The binder used is a phormophenolic resin at a content of 10% by weight relative to the total weight of fibers + binder.

The thickness of the sheet obtained is about 30 mm. The average length of the locks is about 200 mm.

The uncured product according to the invention obtained here has the following characteristics:

• The grammage is 300 g / m ² . To measure the grammage, take a test piece of 300mm x 1000 mm of the product according to EN822, cut in the direction of the length of the matted glass fiber mat. Calculating the surface area in m ² of said test piece, namely 0.3 m ^2. The weight in grams of this test piece is then measured. Then, we calculate the grammage in g / m ² by dividing the weight measured in gram by the surface calculated in m ² . • The micronaire or fiber fineness index is 2.9 / 5g, measured according to DIN 53941.

The web, thus obtained, then undergoes a cooking process of compressing said web between two plates heated at 210 ° C for 90 seconds.

The packing, according to the invention, obtained here, has the following characteristics:

• The thermal conductivity is 40 mW / m.K measured at 10 ° C according to ISO 8301.

· The resistivity at the passage of the air is 8000 Nsnr ⁴ , measured according to the standard EN29053 (ISO9053).

• The sound absorption coefficient is 0.94 to 3150Hz, measured according to standard DA 49 1997.

This product can be compared with a sheet of glass wool obtained in a standard manner and not in accordance with the invention.

COMPARATIVE 1: Manufacture of a sheet of glass wool not in accordance with the invention

o The glass fired is 1 1, 5 tons / day and the centrifuge hole drawn is 0.87 kg / day.

o The rotation speed of the centrifuge is 2500 rpm.

o The burner pressure is 330 mm wc.

o The burner temperature is 1430 ° C.

o The width of the reception mat is 1000 mm.

o The speed of the reception mat is 35 m / min.

o The product P is equal to 35 m ² / min.

The binder used is a formophenolic resin at a content of 10% by weight relative to the total weight of fibers + binder.

The thickness of the sheet obtained is about 30 mm. The average length of the locks is about 350 mm. The uncured product, not according to the invention, obtained here has the following characteristics:

• The grammage is 425 g / m ² . The measurement was made according to the method described in Example 1 above.

· The micronaire or fineness index of the fibers is 3.3 / 5g, measured according to DIN 53941.

The packing, not according to the invention, obtained here, has the following characteristics:

• The thermal conductivity is 38 mW / m.K measured at 10 ° C according to ISO 8301.

• The resistivity to the passage of air is 5000 Nsnr ⁴ measured according to EN29053 (ISO9053).

• The sound absorption coefficient is 0.96 to 3150Hz, measured according to standard DA 49 1997.

The fiber drawing process according to the invention has thus made it possible, in a non-obvious manner, to provide a thermal and acoustic insulation product which until now did not exist, thanks to several technical characteristics essentially related to the speed of rotation. the fiberizing plate, the temperature and pressure of the burner, the drawing of fibers, and the speed of the conveyor belt.

The product, according to the invention, has an acoustic impedance comparable to the products on the market as well as a low thermal conductivity despite a sharp decrease in grammage, allowing to achieve a high level of thermal resistance and an acoustic impedance almost identical with a thickness of web reduced significantly.

Finally, the product according to the invention by its relatively low basis weight is in the form of thin plates, flexible and light which can be stored in the form of rolls. These plates then make it possible to produce rigid gaskets, molded by thermo-compression, and of various shapes.

And, as can be seen from the comparative example, the Applicant has succeeded in reducing the grammage of an insulation product, the latter thus being less heavy, while degrading very little thermal insulation properties and maintaining the sound insulation properties of said product.

Claims

1. Thermal insulation product and / or uncooked sound, based on mineral wool, preferably glass wool, comprising a layer of mineral wool sized by at least one binder, said sized sheet having:

- a mass per unit area, or basis weight of less than or equal to 350 g / m ^2, preferably less than or equal to 300g / m ^2, or even less than or equal to 250g / m ^2, and, optionally greater than or equal to 200g / m ² , measured according to EN 822,

a micronaire of at most 3 under 5 grams, preferably at most 15 l / min, more preferably at most 12 l / min, and at least 9 l / min, and

a thickness greater than 10 mm, even greater than or equal to 15 mm, or even greater than or equal to 25 mm.

2. Product according to claim 1, comprising between 8% and 14% by weight of binder, preferably between 9% and 13% by weight of binder, relative to the total weight of the mixture of mineral wool and binder, and is chosen from binders. thermosets.

3. The product of claim 2, wherein the binder is selected from thermosetting binders based on (i) formophenolic resin, (ii) polyepoxides, or (iii) carbohydrates.

4. Product according to one of claims 1 to 3, wherein the mineral wool fibers are coated on a web, woven or non-woven, hydrophobic and / or oleophobic.

5. The product of claim 4, wherein the haze has, in addition, fireproof and / or fungicidal properties with a compound attached to said web by impregnation, coating or heat-fixing.

6. Product according to claim 4 or 5, wherein the web is a polyester woven web or a nonwoven web, needle punched, based on fibers (i) polyester and / or viscose, (ii) fibers polypropylene, or (iii) carbon fiber, or polyester reinforced glass fleece.

7. Gasket obtained from a thermal insulation product and / or sound according to one of claims 1 to 6 by molding in a form at a polymerization temperature of the binder, the gasket, optionally non-planar conforming to the contours the support surface on which it is intended to be mounted.

8. Gasket according to claim 7, having a thermal conductivity less than or equal to 42 mW / (mK), preferably less than or equal to 40 mW / (mK), measured according to ISO 8301 at 10 ° C, and / or presenting:

a resistivity to the passage of air greater than or equal to 28000 Ns / m ⁴ , measured according to ISO 9053, when said sheet of mineral wool has a thickness greater than or equal to 10 mm, or

an air flow resistivity greater than or equal to 13500 Ns / m ⁴ , measured according to ISO 9053, when said mineral wool mat has a thickness greater than or equal to 15 mm, or

· A resistivity to the passage of air greater than or equal to 8000 Ns / m ⁴ , measured according to the ISO 9053 standard, when said sheet of mineral wool has a thickness greater than or equal to 25 mm.

9. Gasket according to claim 7 or 8, having an acoustic absorption greater than or equal to 0.8 between 1300 and 9000 Hz, preferably between 1800 and 9000 Hz, measured according to standard DA 49 1997.

10. Process for the production of an uncooked thermal and / or acoustic insulation product, based on mineral wool, advantageously glass wool, according to one of claims 1 to 6, using an installation comprising an internal centrifugation device which comprises at least one centrifuge rotatable about an axis X, in particular vertical, and whose peripheral band is pierced with a plurality of orifices for delivering filaments of a molten material, a high temperature gas stretching means in the form of an annular burner which stretches the fiber filaments, and a receiving mat associated with suction means for receiving the fibers, of adjusting a combination of parameters which are at least:

the temperature of the burner, which is between 1350 ° C. and 1450 ° C., - fiber per day and per centrifuge orifice, which is not more than 1 kg, the total output being not more than 26 tonnes per day, and

1 1. Manufacturing method according to claim 10, wherein the speed of rotation of the centrifuge is between 1500 to 3000 revolutions / minute, and / or the diameter of the centrifuge is between 200 and 800 mm, preferably 400 mm and / or in which the mineral wool fibers are received on the landing mat in the form of wicks having a length of between 10 and 50 cm.

12. The manufacturing method according to claim 10 or 1 1, wherein the running speed of the receiving belt is between 30 m / min and 50 m / min and wherein the width of the receiving belt is between 700 mm and 1800 mm.

13. A method of manufacturing a gasket according to one of claims 7 to 9, comprising the method of manufacturing a thermal insulation product and / or sound, according to one of claims 10 to 12, followed by a thermocompression step, simultaneously implementing (i) a process for heating said product to a temperature sufficient to soften or polymerize the binder included in said product and (ii) a deformation process of said product which thus conforms to the desired shape of the filling.

14. Use of a gasket according to one of claims 7 to 9, as a thermal and / or acoustic insulation in a vehicle, in particular for the thermal and / or sound insulation of an engine or a vehicle. vehicle interior, on a ceiling, a wall or a wall, under a roof or in a piece of household equipment.