WO2022167931A1 - Procédé optimisé de production d'une isolation thermique composite - Google Patents

Procédé optimisé de production d'une isolation thermique composite Download PDF

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Publication number
WO2022167931A1
WO2022167931A1 PCT/IB2022/050859 IB2022050859W WO2022167931A1 WO 2022167931 A1 WO2022167931 A1 WO 2022167931A1 IB 2022050859 W IB2022050859 W IB 2022050859W WO 2022167931 A1 WO2022167931 A1 WO 2022167931A1
Authority
WO
WIPO (PCT)
Prior art keywords
resin
woven fabric
thermal insulation
production
optimized method
Prior art date
Application number
PCT/IB2022/050859
Other languages
English (en)
Inventor
Nicolò MOSCA
Original Assignee
Agotex S.R.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Agotex S.R.L. filed Critical Agotex S.R.L.
Publication of WO2022167931A1 publication Critical patent/WO2022167931A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only

Definitions

  • the invention relates to the field of heat-insulating materials, in particular in the automotive sector. More specifically, the present invention proposes a new and innovative method for making a material suitable for isolating the heat generated by the engine block during combustion or during any operating step.
  • Prior art In the automotive sector research on new materials and, in particular, on new polymers, is always at the forefront due to the growing needs of the market. For years both customers and international regulations have been pushing car manufacturers to constantly innovate materials to provide maximum technical performance while maintaining low costs and respect for the environment.
  • Some international patents relate to this type of vehicle components, such as, for example, the Korean patent extended worldwide WO/2017/190596.
  • This patent relates to a poly ketone fiber material obtained by centrifuging the copolymer, washing, drying and stretching.
  • Polyketone fiber has excellent properties of resistance to mechanical stress, elongation, water resistance, heat resistance and thermal conductivity and allows the production of highly resistant objects not only at high temperatures but even bulletproof.
  • the object of the patent is therefore to provide an innovative production method for the production of heat-insulating material that is easily available on the market and therefore accessible to all customers, without neglecting the insulating capabilities of the material.
  • an optimized method for the production of a composite thermal insulation is implemented which effectively solves the aforementioned problems.
  • the method object of the present invention provides for making a non-woven fabric which, in collaboration with the aluminum foil applied on the upper part of the non-woven fabric, is capable of increasing the thermal insulation generated by the engine apparatus of the most common vehicles.
  • the aluminum applied to the non-woven fabric has the feature of extending and making the amount of heat emitted by the engine more uniform, so as not to always stress the same point of the carbon panel.
  • the heat-insulating material obtained assumes a composition called “sandwich” which further amplifies the insulating properties of the material by virtue of the plurality of layers that make up said heat-insulating material.
  • the optimized method for the production of a composite thermal insulation involves multiple steps and related variants, everything starts with the production of non-woven fabric rolls which are subsequently unrolled by means of an unwinding roller.
  • the fibers used are based on polyacrylonitrile and polyethylene.
  • thermosetting resin and its catalyst is prepared by a special automatic mixer.
  • Said automatic mixer is adapted to dose the right quantity of catalyst by means of a sensor which detects the exact weight of the resin extracted from its container to proceed with the rolling.
  • the spreading of the resin occurs initially on one face of said non-woven fabric by means of a dispenser.
  • Rolling takes place via a plurality of lamination rollers which spread the resin uniformly over the entire non-woven fabric.
  • the rolling is carried out using the vacuum technology, which requires the use of a suitable vacuum bag, a vacuum pump and suitable conduits provided with valves to manage the flow of resin.
  • Vacuum rolling ensures a uniform distribution of resin and prevents the formation of air bubbles, which would weaken the structure.
  • Hardening said resin takes place by means of an oven adapted to dry and generate said composite material by means of an irreversible adhesion between said non-woven fabric and said resin.
  • Hardening in one of its embodiments may take place inside a female mold where the non-woven fabric has been previously rolled in order to give it the shape that best suits the customer's request.
  • the thermal insulation panels are cut by means of an automatic robot provided with special blades. The dimensions of the panels are then checked by means of a laser scanner.
  • the material compliant with the customer's requests and the standards set by the company may proceed to storage and stowage by means of special conveyor belts.
  • FIGURE 1 shows the thermal insulation panel object of this innovative embodiment. It may be noted that the non-woven fabric 10, together with the aluminum foil 11, constitutes a “sandwich” adapted to insulate the heat emanating from the engine apparatus more effectively.
  • the aluminum foil 11 is glued to the non-woven fabric 10 by means of a quick-setting glue.
  • FIGURE 2 shows the production line of the optimized method for making a composite thermal insulation.
  • the non-woven fabric of pre-oxidized polyacrylonitrile fiber and fire- retardant polyethylene glycol terephthalate fiber starts from the unwinding roller 12 and, after being subjected to tensioning by special rollers 13, is wetted with resin 17 already joined to the catalyst 16.
  • Rolling continues by means of two lamination rollers 18 which spread the resin 17 uniformly on the carbon fibers.
  • An oven 19 is adapted to dry the non-woven fabric 10 obtained.
  • a cutting robot 21 takes care of cutting the heat-insulating material into panels, according to the dimensions requested by the customer.
  • a laser scanner 22 analyzes dimensions and validates parts that meet company standards and requirements.
  • the heat-insulating material manufactured by the optimized manufacturing method, object of the present invention is shown.
  • the non-woven fabric 10, combined with the aluminum foil 11 creates a sandwich membrane which tends to drastically reduce thermal transmittance. This allows this heat-insulating material to be often used as a lining of the engine compartment in the most common vehicles.
  • the aluminum foil 11 is capable of reflecting heat and transmitting it over the entire surface, thus avoiding to always stress the same areas of the non-woven fabric 10.
  • the aluminum foil 1 1 has a thickness of a few tenths of a millimeter while the non-woven fabric 10 may even reach 5 millimeters.
  • Said optimized method for the production of a composite thermal insulation comprises the steps of:
  • thermosetting resin 17 together with the relative cataly st 16 by means of a suitable mixer 15 with automatic control;
  • the whole system is driven by an electric motor that moves the rollers.
  • the operators are dedicated to the maintenance of the system but especially to the replacement of the unwinding roller 12 when the roll of non-woven fabric runs out.
  • the resin 17 used in the production line may be of the vinyl ester type or of the epoxy type, depending on the quality required by the customer.
  • Rolling may take place inside a female mold to better model the final shape that the heatinsulating material should acquire.
  • rolling preferably takes place with vacuum technology, that is through the use of special bags and vacuum pumps adapted to allow a more homogeneous distribution of resin 17 inside the non-woven fabric 10.

Abstract

La présente invention concerne un procédé optimisé pour la production d'une isolation thermique composite, comprenant un tissu non tissé composé d'un mélange de fibre de polyacrylonitrile pré-oxydé et de fibre de polytéréphtalate d'éthylène glycol ignifuge, sur lequel une feuille d'aluminium est superposée, qui comprend les étapes consistant à : - produire un tissu non tissé non inflammable et isolant thermique lié à des aiguilles ; - tendre et aligner les rouleaux ainsi obtenus au moyen d'une pluralité de rouleaux ; - mélanger une quantité prédéfinie de résine thermodurcissable (17) avec le catalyseur relatif ; - étaler ladite résine sur une face dudit tissu non tissé au moyen d'un distributeur ; - laminer ladite résine ; - durcir ladite résine au moyen d'un four ; - appliquer une colle à prise rapide sur la surface opposée à celle revêtue de résine ; - appliquer une feuille d'aluminium sur la surface opposée à celle revêtue de résine ; - découper l'isolation thermique obtenue ; - vérifier les dimensions des panneaux ; - stocker le matériau isolant thermique obtenu.
PCT/IB2022/050859 2021-02-08 2022-02-01 Procédé optimisé de production d'une isolation thermique composite WO2022167931A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT102021000002696A IT202100002696A1 (it) 2021-02-08 2021-02-08 Metodo ottimizzato per la produzione di un termoisolante composito
IT102021000002696 2021-02-08

Publications (1)

Publication Number Publication Date
WO2022167931A1 true WO2022167931A1 (fr) 2022-08-11

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PCT/IB2022/050859 WO2022167931A1 (fr) 2021-02-08 2022-02-01 Procédé optimisé de production d'une isolation thermique composite

Country Status (2)

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IT (1) IT202100002696A1 (fr)
WO (1) WO2022167931A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116353154A (zh) * 2023-04-26 2023-06-30 浙江中超新材料股份有限公司 一种基于铝膜覆盖无纺布的生产工艺

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110045724A1 (en) * 2009-08-19 2011-02-24 Pradip Bahukudumbi Multi-layer composite material
US20150266265A1 (en) * 2013-03-14 2015-09-24 Cta Acoustics, Inc. Thermal Insulation
WO2016190596A2 (fr) 2015-05-27 2016-12-01 (주)효성 Produit de polycétone industriel comprenant des fibres de polycétone et son procédé de fabrication
US20170165943A1 (en) * 2015-12-11 2017-06-15 Hyundai Motor Company Noise absorbent fabric having improved heat and sound insulation property and method for manufacturing the same

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110045724A1 (en) * 2009-08-19 2011-02-24 Pradip Bahukudumbi Multi-layer composite material
US20150266265A1 (en) * 2013-03-14 2015-09-24 Cta Acoustics, Inc. Thermal Insulation
WO2016190596A2 (fr) 2015-05-27 2016-12-01 (주)효성 Produit de polycétone industriel comprenant des fibres de polycétone et son procédé de fabrication
US20170165943A1 (en) * 2015-12-11 2017-06-15 Hyundai Motor Company Noise absorbent fabric having improved heat and sound insulation property and method for manufacturing the same

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116353154A (zh) * 2023-04-26 2023-06-30 浙江中超新材料股份有限公司 一种基于铝膜覆盖无纺布的生产工艺
CN116353154B (zh) * 2023-04-26 2023-12-01 浙江中超新材料股份有限公司 一种基于铝膜覆盖无纺布的生产工艺

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