WO2012035515A1 - A method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained - Google Patents

A method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained Download PDF

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Publication number
WO2012035515A1
WO2012035515A1 PCT/IB2011/054051 IB2011054051W WO2012035515A1 WO 2012035515 A1 WO2012035515 A1 WO 2012035515A1 IB 2011054051 W IB2011054051 W IB 2011054051W WO 2012035515 A1 WO2012035515 A1 WO 2012035515A1
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WIPO (PCT)
Prior art keywords
mixture
belt
obtaining
particles
station
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PCT/IB2011/054051
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French (fr)
Inventor
Max Canti
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Max Canti
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Publication of WO2012035515A1 publication Critical patent/WO2012035515A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • B09B3/20—Agglomeration, binding or encapsulation of solid waste
    • B09B3/25—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/525—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement containing organic fibres, e.g. wood fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B5/00—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping
    • B28B5/02—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type
    • B28B5/026—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of indefinite length
    • B28B5/027—Producing shaped articles from the material in moulds or on moulding surfaces, carried or formed by, in or on conveyors irrespective of the manner of shaping on conveyors of the endless-belt or chain type the shaped articles being of indefinite length the moulding surfaces being of the indefinite length type, e.g. belts, and being continuously fed
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/12—Multiple coating or impregnating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the invention regards a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained, using hemp hurds, i.e. the residue of the hackling of the hemp, or chips (i.e. small pieces) deriving from the fragmentation of the whole hemp plant, which comprise fibrous bark, or plant biomass chips of any nature, e.g. kenaf, ramie, rice hull, bamboo, flax shives, wheat chaff, sunflower and maize stalks, jute, lake reed, common reed, broom, agave and coconut.
  • hemp hurds i.e. the residue of the hackling of the hemp
  • chips i.e. small pieces
  • the current state of the art comprises two separate processes, carried out in different corresponding plants.
  • the first process employs a mixture of wood chips from trees - generally spruce - mixed with Portland cement, by using conventional mixers.
  • the obtained mixture is deposited in layers in planar formworks that are superimposed on each other and subjected to pressing with a static press between two surfaces. After the application of the pressure, such two surfaces are bound together with clamps.
  • the pressure is eliminated and the surfaces are collected for a new use, while the formworks that contain the panels are placed to mature in the setting, until the maturation period is completed on average after several days. At this point, the panels are extracted from the planar formworks so that they can be employed for a new use.
  • the second known process provides for mixing the wood cut into voluminous curls, normally poplar wood, with a binder composed of a liquid mixture of magnesite and magnesium sulfate.
  • the obtained mixture is deposited in layers in the formworks, which are subjected to the action of hot press surfaces, generally heated to 180°C, in order to trigger the binder reaction.
  • This second process has the advantage of having a quicker execution.
  • a first drawback is that both processes create functioning difficulties for the plants used to carry them out, due to the extensive dirtying of the machinery from the use of inorganic hydraulic binders with very quick setting.
  • a second drawback is that due to the dirtying, the plants must be periodically stopped, cleaned and inspected.
  • a third drawback is that two specific plants are necessary for the actuation of the two known processes, and each of such plants can only be used for actuating the process for which it was designed.
  • a fourth drawback is that the production of the insulating sheets mainly requires the use of wood, and for this reason a long cultivation is necessary followed by the felling of a high number of trees, of which only the trunk is used, discarding the branches, foliage and bark.
  • One object of the invention is to improve the prior art.
  • Another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained which allows using a single plant for actuating the two known production processes.
  • a further object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that does not dirty the machinery used in the plant for obtaining the insulating sheets, and therefore does not require frequent, long stoppage times to execute cleaning and maintenance operations on the machinery.
  • Another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that allows considerably limiting the use of wood in the manufacturing of insulating sheets, and mainly in the form of discards deriving from other processing.
  • Still another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that allows obtaining insulating sheets that are fireproof and have at least one surface arranged with decorations already in the obtainment step.
  • a further object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that allows obtaining, in addition to the insulating sheets, also insulating mattresses for use in the external insulation facing of buildings.
  • Another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that allows, for the obtainment of the sheets, using natural plant fibers that have very brief cultivation and maturation times.
  • Still another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that, for obtaining the insulating sheets, also allows using so-called Roman cement, i.e. natural cement.
  • thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained, in accordance with the characteristics of claim 1 .
  • thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained, in accordance with the characteristics of claim 16.
  • thermoacoustic insulation it is a raw material that, in chip form, has a mass density that is considerably lower (at least three times lower) than the chipped mass of chips derived from trees, and that it therefore contains a greater number of dry microtubules full of static air that provide a higher degree of thermoacoustic insulation ;
  • thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained, illustrated as indicative and non-limiting in the drawing set, in which :
  • Figure 1 schematically shows a side view of a first embodiment of a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings according to the invention ;
  • Figure 2 schematically shows a variant of the plant of Figure 1 , for obtaining insulating sheets in sandwich form ;
  • Figure 3 is a schematic, enlarged view of a portion of a sheet-sandwich obtainable according to the variant of Figure 2.
  • a coating apparatus is indicated overall with "P”, i.e. an apparatus in which particles in chip form are introduced together with a humidifier liquid in order to make the binder initially adhere to the particles, as well as a binder, normally in powder form, in order to cover the particles with an external film.
  • the coating apparatus comprises a drum rotating around a longitudinal and tilted rotation axis "A", inside of which longitudinal sectors are mounted which, during rotation, lift and remix the particles that fall on themselves until they become dry once again and covered with a binder film.
  • the tilt of the rotation axis "A" causes the continuous advancement of the particles towards a discharge opening of the drum.
  • a meter is indicated for the particles already coated with binder powder; such meter consists of a meter tray 101 that at the base has a slit with adjustable opening that leads to an underlying conveyor belt 2, which carries out the level extraction of a thin, substantially uniform particle layer "S1 ".
  • the particles When the particles fall from an upper conveyor belt to a lower one, they are sprayed in the fall section with a nebulized hydrating liquid, in order to hydrate the inorganic binder film that covers them.
  • the spraying occurs by means of pistols (or equivalent devices), schematically indicated with 6 in the Figure.
  • the nebulization of the hydrating liquid allows, as said, hydrating the particles covered with binder, without however washing away the binder.
  • the hemp particles are preferably coated with a film of natural cement powder, known as Roman cement, known and used since the beginning of the 19 th century (before the advent of Portland cement).
  • This natural Roman cement is obtained from marl, i.e. a mineral containing calcium carbonate and clay, and is fired at temperatures around 800-1000 °C, whereas Portland cement is fired at 1200-1300 °C.
  • a retardant agent generally citric acid in powder form, is added to the Roman cement.
  • the cement's high reaction and setting speed is slowed, by means of a lowering of the cement pH.
  • binders Even if Roman cement is the preferred binder, according to the invention it is also possible to use other quick-setting cements as binders. These include for example aluminate cement, to which calcium hydrate is added, or sulfoaluminate cement, to which hydrated line or calcium oxide is added in a quantity comprised between 1 % and 13%.
  • a hydrating liquid comprising a concentrated (32°Be) and nebulized solution of magnesium sulfate or magnesium chloride, or a combination of the two.
  • the final belt 7 passes under a continuous press "PC” which comprises a series of pressure rollers "R” abutting against the same final belt 7.
  • the continuous press "PC” comprises a further belt 9 made of rubberized fabric, which is closed as a loop on motor rollers and/or tightener rollers 11 and which is placed on top of the upper section of the final belt 7, abutting against a series of pressure rollers "R"' activated to maintain the fine size of the mixture layer up to the completion of the binder setting.
  • the lower activated section of the belt 9 slides, in the initial inlet part 9a, on a series of rollers "R"" which have rotation axes parallel to each other and which are arranged along an ideal line, tilted and converging towards the upper activated section of the final belt 7, in the advancement direction indicated with the arrow "A".
  • the tilted initial section 9a determines, in this first part, the size of the mixture "M" belt.
  • Blades "C" Coupled to the rollers 10 and collaborating with the latter are blades "C", which keep the rollers 10 perfectly clean.
  • the chipped particles employed according to the invention can be of many types, e.g. they can derive from the waste of fiber extraction processing for yarn production, as in the case of hemp, flax, ramie, jute and kenaf particles, or the whole plant can be employed, or the following can be used: pine bark, sawmill waste, cork tree processing waste, rice hulls or grain chaffs, malt from dried sludge deriving from beer fermentation, natural or synthetic fibers obtained from recycled fabric from discarded clothes, sheep wool and mineral wools.
  • Other particles employable in the method according to the invention can be obtained from light, even expanded plastic material, coming from recycling or new; from inorganic expanded materials, such as expanded clay, cellular glass, expanded porous glass, vermiculite, perlite and pumice.
  • inorganic expanded materials such as expanded clay, cellular glass, expanded porous glass, vermiculite, perlite and pumice.
  • the final conveyor belt 7 can be equipped, if required, with bilateral vertical edges (not visible in the drawings), which preferably but not necessarily are independent of the final belt 7. Such edges are closed as a loop like the belt and are slidable in sync therewith, maintained abutted against the final belt 7 even when crossing the continuous press "PC".
  • the abutment rollers "FT are alternated with several bars “B” that emit microwaves or radiofrequency waves for heating the mixture "M", in a manner so as to speed up the setting of the binder.
  • a layer “M1” can be distributed with a distribution machine " ⁇ ; such layer “M1 " is a two-component mixture constituted by hydrated aluminous cement and by calcium hydrate which, being plastic, is self-leveling.
  • this layer can be in turn processed in a manner so as to obtain decorations, e.g. by means of a decorator roller "RS" that can be mounted downstream of the distributor machine " ⁇ .
  • a decorator roller "RS” that can be mounted downstream of the distributor machine " ⁇ .
  • the decorator roller “RS” will be of the type known to the man skilled in the art. It is normally constituted by a roller made of silicone material which has its peripheral surface provided with incisions, which form the decorations to be applied on the layer "M1 ".
  • the decorator roller "RS” can be supported by a movable trolley 13 that can in turn be slidably mounted on bilateral rails 14, in a manner such that it is possible to position it each time at the ideal point of the final conveyor belt 7, where the mixture "M1 " reaches the plastic state; the position where this plastic state is reached is variable and influenced by the external setting temperature, hence the need to reposition the roller "RS" each time.
  • microwave or radiofrequency emissions of the emitter bars "B" can optionally occur in order to accelerate the setting of the binders, especially when the external temperature is low, like during the winter.
  • the binders require different setting temperatures; for example, the Roman cement, or the hydrated aluminous-lime mixture or the sulfoaluminate cement require that the bars "B” raise the temperature to 30-40 °C or a little higher, whereas the binder constituted by magnesite and magnesium sulfate or magnesium chloride require that the bars "B" increase the temperature to close to 100°C.
  • the method according to the invention allows obtaining, downstream of the continuous press "PC", a continuous thermoacoustic insulating sheet “LC” which is abutted against the final belt 7 and which is subsequently transversely divided with cuts into sheets “L”, which have predetermined size, by means of the process known as "cut on-line” executed in a cutting station "T".
  • final finishing operations are carried out, e.g. those of calibration and squaring.
  • a particular embodiment of a rigid and light sheet can be obtained by spraying the defibrated particles, i.e. those made of flocks, of hemp and other plants or sheep wool or plumage, bird meat processing waste, natural or synthetic recycled fabrics, with a binder constituted by a suspension of magnesic cement paste diluted in water to make it sprayable.
  • This cement paste is obtained by mixing, in the ratio indicated below, magnesium oxide and magnesium sulfate or chloride in solution of about 32°Be (or a combination of the latter two): the ratio between oxide and solution is comprised between 1 :0.7 and 1 :1 .
  • the particles sprayed with the cement paste are subjected to the heat and to the sizing of the continuous press "PC".
  • These sheets can substitute conventional rigid polystyrene or polyurethane panels, or those made of another expanded plastic material, or high-density rock wool.
  • a first pre-pasted skin “SP” is first applied on the lower layer, upstream of the plant; such skin is made with the same hydrated binder used to obtain the stratification, as described above.
  • the upper external layer "SE” is prepared by applying a second skin “SP” thereto, this also obtained with the same hydraulic binder; such upper layer with second skin applied thereto is deposited on the internal layer, or mixture “M”, before introducing the formed sandwich "L1 " into the continuous press "PC".
  • the sheets “L” and “L1 " or the mattresses obtained with the method according to the invention, as already stated above, can be used in the thermoacoustic functional and decorative coating of buildings, or even as disposable formwork for concrete castings, in a manner so as to obtain the coating, the insulation as well as a wall in a single, simultaneous step.
  • the sheets or the mattresses can also be employed in the foundations of lightened floors, and in this case it is possible to obtain with automatic machinery, e.g. numerical control machinery, concave impressions for the positioning of floor heating tubes.
  • automatic machinery e.g. numerical control machinery, concave impressions for the positioning of floor heating tubes.
  • the sheets “L” and “L1 " can be used for obtaining external curtain walls and partitions for conventional buildings, and can be coupled together in order to obtain walls with required thickness, in which concave impressions can be obtained for the passage of service network ducts (electricity, water, gas).
  • service network ducts electricality, water, gas

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Abstract

The method for continuously obtaining compact sheets (L; L1) with materials arranged in a particulate state mixed with a binder constituted by hydraulic powder of a quick-setting cement comprises the steps of: moistening the particles with a humidifying liquid in a quantity according to a pre-established ratio by weight; coating said particulate materials with a film of said quick- setting powder binder; stratifying, with meter means (1), the dried and coated particles onto a movable belt (2) in a substantially uniform layer (S1); transferring the particles from said meter means (1) onto a further belt (3), nebulizing said humidifying liquid on the same particles during the transfer, without washing away said film; repeating said transfer onto further belts (4, 5) until a pre-established quantity of humidifying hydration liquid is supplied, obtaining a hydrated mixture; transferring the hydrated mixture onto a final conveyor belt (7), forming a mixture layer (M) of said particulate materials; adjusting the speed of such final belt (7) with respect to said further belts (4, 5) as a function of the thickness of said mixture layer (M) to be obtained; introducing said final belt (7) and mixture layer (M) into continuous press means (PC) equipped with a size adjustable inlet at least with regard to height, obtaining a continuous, height-calibrated sheet (LC); and cutting the hardened, continuous sheet (LC) to size, obtaining cut sheets (L), and collecting said cut sheets (L) from said movable belt (7) with collection means.

Description

A METHOD AND A PLANT FOR CONTINUOUSLY OBTAINING THERMOACOUSTIC INSULATING SHEETS FOR THE CONSTRUCTION OF ECO-COMPATIBLE AND BIOCOMPATIBLE BUILDINGS AND INSULATING SHEETS THUS OBTAINED
Technical field of the invention
The invention regards a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained, using hemp hurds, i.e. the residue of the hackling of the hemp, or chips (i.e. small pieces) deriving from the fragmentation of the whole hemp plant, which comprise fibrous bark, or plant biomass chips of any nature, e.g. kenaf, ramie, rice hull, bamboo, flax shives, wheat chaff, sunflower and maize stalks, jute, lake reed, common reed, broom, agave and coconut.
State of the art
The current state of the art comprises two separate processes, carried out in different corresponding plants.
In detail, the first process employs a mixture of wood chips from trees - generally spruce - mixed with Portland cement, by using conventional mixers.
The obtained mixture is deposited in layers in planar formworks that are superimposed on each other and subjected to pressing with a static press between two surfaces. After the application of the pressure, such two surfaces are bound together with clamps.
In this manner, the action of the pressure is maintained, even after the extraction from the formwork press, for a relatively long time period.
Subsequently, the pressure is eliminated and the surfaces are collected for a new use, while the formworks that contain the panels are placed to mature in the setting, until the maturation period is completed on average after several days. At this point, the panels are extracted from the planar formworks so that they can be employed for a new use.
The second known process provides for mixing the wood cut into voluminous curls, normally poplar wood, with a binder composed of a liquid mixture of magnesite and magnesium sulfate.
The obtained mixture is deposited in layers in the formworks, which are subjected to the action of hot press surfaces, generally heated to 180°C, in order to trigger the binder reaction.
This second process, with respect to the preceding, has the advantage of having a quicker execution.
Nevertheless, both known processes have several drawbacks.
A first drawback is that both processes create functioning difficulties for the plants used to carry them out, due to the extensive dirtying of the machinery from the use of inorganic hydraulic binders with very quick setting.
This dirtying considerably slows the productive capacity.
A second drawback is that due to the dirtying, the plants must be periodically stopped, cleaned and inspected.
This causes an increase of the production costs, which negatively affects the cost of the final product, i.e. of the insulating sheets to be used in building construction.
A third drawback is that two specific plants are necessary for the actuation of the two known processes, and each of such plants can only be used for actuating the process for which it was designed.
Therefore, if one wishes to obtain insulating sheets according to both known processes, it is necessary to purchase and manage two separate production plants.
A fourth drawback is that the production of the insulating sheets mainly requires the use of wood, and for this reason a long cultivation is necessary followed by the felling of a high number of trees, of which only the trunk is used, discarding the branches, foliage and bark.
Objects of the invention
One object of the invention is to improve the prior art.
Another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained which allows using a single plant for actuating the two known production processes.
A further object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that does not dirty the machinery used in the plant for obtaining the insulating sheets, and therefore does not require frequent, long stoppage times to execute cleaning and maintenance operations on the machinery. Another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that allows considerably limiting the use of wood in the manufacturing of insulating sheets, and mainly in the form of discards deriving from other processing.
Still another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that allows obtaining insulating sheets that are fireproof and have at least one surface arranged with decorations already in the obtainment step. A further object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that allows obtaining, in addition to the insulating sheets, also insulating mattresses for use in the external insulation facing of buildings. Another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that allows, for the obtainment of the sheets, using natural plant fibers that have very brief cultivation and maturation times.
Still another object of the invention is to obtain a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained that, for obtaining the insulating sheets, also allows using so-called Roman cement, i.e. natural cement.
According to one aspect of the invention, a method is provided for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained, in accordance with the characteristics of claim 1 .
According to another aspect of the invention, a plant is provided for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained, in accordance with the characteristics of claim 16.
The invention therefore allows obtaining the following advantages:
maintaining the production plants without any dirtying, limiting the need for stoppage for periodic cleaning and maintenance;
increasing the production capacity of the production plants, so that very reactive hydraulic binders can be used;
obtaining insulating, fireproof sheets and mattresses that have a structure with layers coupled together, also obtained with materials of different nature and density;
limiting the use of natural wood as preferred base material, and thus preserving vegetation;
obtaining insulating sheets that are provided, from the time of their production, with at least one face with decorations, even bas-relief decorations;
obtaining sheets, also in the form of rigid or substantially rigid mattresses, to be used for making building facing, known as external insulation facing;
cutting the sheets or mattresses into requested formats, during the same method step;
with a single plant, obtaining insulating sheets or mattresses by following both of the known state of the art processes;
using mainly hemp for the obtainment of the insulating sheets or mattresses, which has the following advantages:
it is a natural and renewable raw material that comes from non-alimentary cultivation ; from sowing to harvest, only 3.5 months are required;
it is a raw material that has a 1 -year productive capacity at least four times greater than the 1 -year productive capacity of a biomass obtained from a tree forest, given the same extension ;
it is a raw material that, in chip form, has a mass density that is considerably lower (at least three times lower) than the chipped mass of chips derived from trees, and that it therefore contains a greater number of dry microtubules full of static air that provide a higher degree of thermoacoustic insulation ;
it is a raw material that can be dried without costs, simply via exposure to the summer sun ;
it is a raw material that does not require being stripped of branches and bark, as do trees before drying.
Embodiments of the invention
Further characteristics and advantages of the invention will be clearer from the detailed description of a method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained, illustrated as indicative and non-limiting in the drawing set, in which :
Figure 1 schematically shows a side view of a first embodiment of a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings according to the invention ;
Figure 2 schematically shows a variant of the plant of Figure 1 , for obtaining insulating sheets in sandwich form ;
Figure 3 is a schematic, enlarged view of a portion of a sheet-sandwich obtainable according to the variant of Figure 2.
In detail, a coating apparatus is indicated overall with "P", i.e. an apparatus in which particles in chip form are introduced together with a humidifier liquid in order to make the binder initially adhere to the particles, as well as a binder, normally in powder form, in order to cover the particles with an external film. The coating apparatus comprises a drum rotating around a longitudinal and tilted rotation axis "A", inside of which longitudinal sectors are mounted which, during rotation, lift and remix the particles that fall on themselves until they become dry once again and covered with a binder film.
The tilt of the rotation axis "A" causes the continuous advancement of the particles towards a discharge opening of the drum.
With 1 , a meter is indicated for the particles already coated with binder powder; such meter consists of a meter tray 101 that at the base has a slit with adjustable opening that leads to an underlying conveyor belt 2, which carries out the level extraction of a thin, substantially uniform particle layer "S1 ".
With 3, 4, 5, further conveyor belts are indicated that are arranged in cascade form and downstream of the belt 2.
When the particles fall from an upper conveyor belt to a lower one, they are sprayed in the fall section with a nebulized hydrating liquid, in order to hydrate the inorganic binder film that covers them.
The spraying occurs by means of pistols (or equivalent devices), schematically indicated with 6 in the Figure.
The nebulization of the hydrating liquid allows, as said, hydrating the particles covered with binder, without however washing away the binder.
Indicated with 7 is a final conveyor belt, whose function will be described further on in the description.
The hemp particles (or those of another raw material) are preferably coated with a film of natural cement powder, known as Roman cement, known and used since the beginning of the 19th century (before the advent of Portland cement).
This natural Roman cement is obtained from marl, i.e. a mineral containing calcium carbonate and clay, and is fired at temperatures around 800-1000 °C, whereas Portland cement is fired at 1200-1300 °C.
A retardant agent, generally citric acid in powder form, is added to the Roman cement. In such a manner, the cement's high reaction and setting speed is slowed, by means of a lowering of the cement pH.
Even if Roman cement is the preferred binder, according to the invention it is also possible to use other quick-setting cements as binders. These include for example aluminate cement, to which calcium hydrate is added, or sulfoaluminate cement, to which hydrated line or calcium oxide is added in a quantity comprised between 1 % and 13%.
It is also possible, according to the invention, to coat moist hemp particles, or particles of another material, with magnesium oxide, and in this case hydrate the particles as they fall from one belt to the next, by means of a hydrating liquid comprising a concentrated (32°Be) and nebulized solution of magnesium sulfate or magnesium chloride, or a combination of the two.
On the final conveyor belt 7, the final stratification of the predetermined thickness is received together with the mixture "M".
The final belt 7 passes under a continuous press "PC" which comprises a series of pressure rollers "R" abutting against the same final belt 7.
The continuous press "PC" comprises a further belt 9 made of rubberized fabric, which is closed as a loop on motor rollers and/or tightener rollers 11 and which is placed on top of the upper section of the final belt 7, abutting against a series of pressure rollers "R"' activated to maintain the fine size of the mixture layer up to the completion of the binder setting.
The lower activated section of the belt 9 slides, in the initial inlet part 9a, on a series of rollers "R"" which have rotation axes parallel to each other and which are arranged along an ideal line, tilted and converging towards the upper activated section of the final belt 7, in the advancement direction indicated with the arrow "A".
The tilted initial section 9a determines, in this first part, the size of the mixture "M" belt.
This size is preserved for a long section of the final belt 7, up until the setting of the binder; such setting is manifested with the absence of swelling of the attained size in the formed sheets, hence with the stabilization of the size. Upstream of the continuous press "PC", the mixture "M" crosses a series of chromate rollers 10 which are situated above the mixture "M" belt in a manner so as to execute repeated and successive flattening of the mixture "M" itself; immediately after the passage under one of the rollers 10, being free from the pressure of the latter, the mixture swells up again, causing a consequent regularization of the binder distribution around the particles.
Coupled to the rollers 10 and collaborating with the latter are blades "C", which keep the rollers 10 perfectly clean.
The chipped particles employed according to the invention can be of many types, e.g. they can derive from the waste of fiber extraction processing for yarn production, as in the case of hemp, flax, ramie, jute and kenaf particles, or the whole plant can be employed, or the following can be used: pine bark, sawmill waste, cork tree processing waste, rice hulls or grain chaffs, malt from dried sludge deriving from beer fermentation, natural or synthetic fibers obtained from recycled fabric from discarded clothes, sheep wool and mineral wools.
Other particles employable in the method according to the invention can be obtained from light, even expanded plastic material, coming from recycling or new; from inorganic expanded materials, such as expanded clay, cellular glass, expanded porous glass, vermiculite, perlite and pumice.
The final conveyor belt 7 can be equipped, if required, with bilateral vertical edges (not visible in the drawings), which preferably but not necessarily are independent of the final belt 7. Such edges are closed as a loop like the belt and are slidable in sync therewith, maintained abutted against the final belt 7 even when crossing the continuous press "PC".
These vertical edges have the specific function of bilaterally containing the loose particles.
The flexible surfaces of the final belt 7 and the belt 9 accompany the mixture "M" up until the completion of the binder setting and hardening step.
In addition, downstream of the section 9a, the abutment rollers "FT are alternated with several bars "B" that emit microwaves or radiofrequency waves for heating the mixture "M", in a manner so as to speed up the setting of the binder.
If required, on the upper faces of the formed sheets, indicated with "L" downstream of the continuous press "PC", a layer "M1 " can be distributed with a distribution machine "Β ; such layer "M1 " is a two-component mixture constituted by hydrated aluminous cement and by calcium hydrate which, being plastic, is self-leveling.
In this case, this layer can be in turn processed in a manner so as to obtain decorations, e.g. by means of a decorator roller "RS" that can be mounted downstream of the distributor machine "Β .
The decorator roller "RS" will be of the type known to the man skilled in the art. It is normally constituted by a roller made of silicone material which has its peripheral surface provided with incisions, which form the decorations to be applied on the layer "M1 ".
The decorator roller "RS" can be supported by a movable trolley 13 that can in turn be slidably mounted on bilateral rails 14, in a manner such that it is possible to position it each time at the ideal point of the final conveyor belt 7, where the mixture "M1 " reaches the plastic state; the position where this plastic state is reached is variable and influenced by the external setting temperature, hence the need to reposition the roller "RS" each time.
The use of the microwave or radiofrequency emissions of the emitter bars "B" can optionally occur in order to accelerate the setting of the binders, especially when the external temperature is low, like during the winter.
The binders require different setting temperatures; for example, the Roman cement, or the hydrated aluminous-lime mixture or the sulfoaluminate cement require that the bars "B" raise the temperature to 30-40 °C or a little higher, whereas the binder constituted by magnesite and magnesium sulfate or magnesium chloride require that the bars "B" increase the temperature to close to 100°C.
The method according to the invention allows obtaining, downstream of the continuous press "PC", a continuous thermoacoustic insulating sheet "LC" which is abutted against the final belt 7 and which is subsequently transversely divided with cuts into sheets "L", which have predetermined size, by means of the process known as "cut on-line" executed in a cutting station "T".
With the expression "cut on-line", it is intended a cutting of the continuous sheet "LC" executed transverse to the advancement direction "A" with a cutting apparatus that is moved with alternating motion, outgoing motion in sync with the final belt 7 during the cutting step and deactivated return motion in the direction opposite that of direction "A".
When the sheets "L" are obtained, they are transferred into dryers Έ" for maturation.
When the maturation is completed, final finishing operations are carried out, e.g. those of calibration and squaring.
Still with reference to Figure 1 , it is observed that a particular embodiment of a rigid and light sheet can be obtained by spraying the defibrated particles, i.e. those made of flocks, of hemp and other plants or sheep wool or plumage, bird meat processing waste, natural or synthetic recycled fabrics, with a binder constituted by a suspension of magnesic cement paste diluted in water to make it sprayable.
This cement paste is obtained by mixing, in the ratio indicated below, magnesium oxide and magnesium sulfate or chloride in solution of about 32°Be (or a combination of the latter two): the ratio between oxide and solution is comprised between 1 :0.7 and 1 :1 .
After the spraying, the particles sprayed with the cement paste are subjected to the heat and to the sizing of the continuous press "PC".
These sheets obtained with magnesic cement fibers, being rigid, can be employed in the external insulation of building faces, since it is possible to stratify above the sheets a finish layer with conventional plaster or with the finishing normally used above expanded plastic material insulations.
These sheets can substitute conventional rigid polystyrene or polyurethane panels, or those made of another expanded plastic material, or high-density rock wool.
With reference to Figures 2 and 3, it is observed that with the method according to the invention, it is also possible to obtain a sheet-sandwich "L1 " that is composed of two high-density external layers "SE", an upper and a lower layer, previously obtained with another processing, as well as an internal layer "M" with lower density than that of the external layers "SE".
In order to apply the two external layers "SE" to the internal layer "M", a first pre-pasted skin "SP" is first applied on the lower layer, upstream of the plant; such skin is made with the same hydrated binder used to obtain the stratification, as described above.
Subsequently, the upper external layer "SE" is prepared by applying a second skin "SP" thereto, this also obtained with the same hydraulic binder; such upper layer with second skin applied thereto is deposited on the internal layer, or mixture "M", before introducing the formed sandwich "L1 " into the continuous press "PC".
The sheets "L" and "L1 " or the mattresses obtained with the method according to the invention, as already stated above, can be used in the thermoacoustic functional and decorative coating of buildings, or even as disposable formwork for concrete castings, in a manner so as to obtain the coating, the insulation as well as a wall in a single, simultaneous step.
The sheets or the mattresses can also be employed in the foundations of lightened floors, and in this case it is possible to obtain with automatic machinery, e.g. numerical control machinery, concave impressions for the positioning of floor heating tubes.
Analogously, the sheets "L" and "L1 " can be used for obtaining external curtain walls and partitions for conventional buildings, and can be coupled together in order to obtain walls with required thickness, in which concave impressions can be obtained for the passage of service network ducts (electricity, water, gas).
It has been observed that that the invention attains the pre-established objects.
The invention is susceptible to modifications and variations, all falling within the inventive concept.
In addition, all details can be substituted with other technically equivalent elements, without departing from the protective scope of the following claims.

Claims

1 ) Method for continuously obtaining compact sheets (L; L1 ) with materials arranged in a particulate state mixed with a binder constituted by hydraulic powder of a quick-setting cement, characterized in that it comprises the steps of:
- moistening the particles with a humidifying hydration liquid in a quantity according to a pre-established ratio by weight;
- coating said particulate materials with a film of said quick-setting powder binder;
- stratifying, with meter means (1 ), the dry and coated particles on a movable belt (2), in a substantially uniform layer (S1 );
- transferring the particles from said meter means (1 ) onto a further belt (3), nebulizing said humidifying hydration liquid on the same particles during the transfer without washing away said film;
- repeating said transfer onto further belts (4, 5) until a pre-established quantity of humidifying hydration liquid is supplied, obtaining a hydrated mixture;
- transferring the hydrated mixture onto a final conveyor belt (7), forming a mixture layer (M) of said particulate materials;
- regulating the speed of such final belt (7) with respect to said further belts
(4, 5) as a function of the thickness of said mixture layer (M) to be obtained;
- introducing said final belt (7) and mixture layer (M) into continuous press means (PC) equipped with a size adjustable inlet at least with regard to height, obtaining a continuous, height-calibrated sheet (LC); and
- cutting to size the continuous, hardened sheet (LC), obtaining cut sheets (L) and collecting said cut sheets (L) from said final movable belt (7) with collection means.
2) Method according to claim 1 , wherein said powder binder is selected from the following: Roman cement, a mixture of aluminous cement and hydrated lime; a sulfoaluminate cement, magnesite powder.
3) Method according to claim 1 , wherein said powder binder is used in a quantity by weight comprised between one-third and six times the overall weight of said materials arranged in a particulate state.
4) Method according to claim 1 , wherein said materials in a particulate state (M) are selected from: hemp, waste wood from food product extraction processing, pine bark; cork tree waste; broken-up wood, flax shives or kenaf shives; ramie, sunflowers, maize, organic and/or inorganic expanded light materials, plastic materials, foam rubber, expanded clay, cellular glass, expanded porous glass, perlite, vermiculite, animal wools, natural or artificial fibers that are new or from recycled discarded clothing, paper, residue from pressing alfalfa, sugar cane processing residue, tequila processing residue, anhydrous beer fermentation sludge, paper mill sludge, skiving residues of the tanning of anhydrous hides, olive pit residue of olive-pomace oil extraction.
5) Method according to claim 1 , wherein said humidifying liquid is selected from water, a concentrated solution of magnesium sulfate or magnesium chloride, a combination of magnesium sulfate and magnesium chloride.
6) Method according to claim 1 , wherein between said introducing and cutting to size, said mixture layer (M) is heated with heating means (B).
7) Method according to claim 1 , wherein downstream of said cutting to size, a further two-component and self-leveling liquid mixture (Bl) is distributed on said mixture layer (M), such mixture (Bl) comprising hydrated aluminous cement and hydrated lime, both in combination with inert calcium carbonate.
8) Method according to claim 7, wherein downstream of said distribution, decorations are applied with roller applicator means (RS). 9) Method according to claim 8, wherein said roller means are supported at a trolley (13) movable on movement and guide rails (14), in a manner so as to apply said decorations in a pre-established time period. 10) Method according to any one of the preceding claims, characterized in that said powder binder comprises colorant pigments.
11 ) Method according to claim 1 , wherein said continuous press means (PC) comprise heating means, said heating means comprising bars (B) supplying microwaves or radiofrequency waves.
12) Method according to claims 1 and 11 , wherein said heating bars (B) are situated at said final belt (7) and said continuous press means (PC). 13) Method according to claim 1 , wherein before said introduction, preheating is provided for said mixture with further heating means.
14) Method according to claim 1 , wherein after said collection of said cut sheets (L), it is provided to transfer them into drying / maturation means (E).
15) Method according to any one of the preceding claims, wherein said particulate materials have grain size comprised between 0.1 millimeters and 20 millimeters, preferably between 5 millimeters and 20 millimeters. 16) Plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings, characterized in that it comprises:
- a first station (P) for pre-mixing a material in a particulate state with a binder powder and with a humidifying liquid, obtaining a mixture (M) of particles coated with said binder powder;
- a second station (1 ) for metering said mixture and depositing it on at least a first movable conveyor surface (2), obtaining a mixture layer (M); - a station (6) for spraying said mixture with a hydrating liquid, during said depositing;
- a station for the continuous pressing of said hydrated mixture (M) with a continuous press (PC), obtaining a continuous and substantially rigid sheet (LC) of said mixture;
- a station (T) for cutting said continuing sheet (LC) into cut sheets (L) which have pre-established size; and
- a station (E) for the storage, drying and maturation of said cut sheets (L).
17) Plant according to claim 16, wherein said continuous pressing station (PC) comprises heating means (B) for heating said mixture layer (M).
18) Plant according to claim 16, wherein between said cutting station (T) and said storage station (E), a station (RS) is interposed for decorating surfaces of said cut sheets (L).
PCT/IB2011/054051 2010-09-17 2011-09-16 A method and a plant for continuously obtaining thermoacoustic insulating sheets for the construction of eco-compatible and biocompatible buildings and insulating sheets thus obtained WO2012035515A1 (en)

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ITPS2010A000024 2010-09-17
IT000024A ITPS20100024A1 (en) 2010-09-17 2010-09-17 MACHINE AND METHOD FOR REALIZING THERMO ACOUSTIC INSULATING SLABS FOR ECO-BIO PASSIVE HOUSES COMPATIBLE. SLABS WITH IT OBTAINED

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3708873A1 (en) * 1987-03-18 1988-09-29 Baehre & Greten Process and device for producing a free-flowing mixture, intended in particular for the production of boards, of fibrous and/or chip-shaped wood material and gypsum
DE3818117A1 (en) * 1988-05-27 1989-11-30 Baehre & Greten Method and apparatus for producing shaped articles, in particular boards, from hydration water-containing, cellulose- and/or lignocellulose-containing particles and a mineral binder
US5102596A (en) * 1989-12-01 1992-04-07 G. Siempelkamp Gmbh & Co. Method of producing shaped articles of fiber/binder mixtures

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3708873A1 (en) * 1987-03-18 1988-09-29 Baehre & Greten Process and device for producing a free-flowing mixture, intended in particular for the production of boards, of fibrous and/or chip-shaped wood material and gypsum
DE3818117A1 (en) * 1988-05-27 1989-11-30 Baehre & Greten Method and apparatus for producing shaped articles, in particular boards, from hydration water-containing, cellulose- and/or lignocellulose-containing particles and a mineral binder
US5102596A (en) * 1989-12-01 1992-04-07 G. Siempelkamp Gmbh & Co. Method of producing shaped articles of fiber/binder mixtures

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