Insulating product for a construction element comprising a cavity

Abstract

The present invention relates to a thermal and / or acoustic insulation product for filling a construction element comprising two walls facing each other so as to form a cavity, wherein the product comprises blown glass wool forming flakes, wherein the product comprises a hydrophobic additive, wherein the hydrophobic additive is a branched and crosslinked organosilicon polymer compound, the median size of the flakes being less than 20 mm.

Description

[0001] Description

[0002] Title of the invention: Insulating product for a construction element comprising a cavity

[0003] Field of invention

[0004] [1] The present invention relates to the field of construction. More specifically, it relates to a thermal and / or acoustic insulation product for filling a construction element. It also relates to the method for obtaining the construction element.

[0005] State of the art

[0006] [2] It is known to fill cavities in building elements, such as walls or parts of walls, with insulating materials, such as mineral wool or foams, whether inorganic (e.g. cement foams) or organic (e.g. polyurethane foams).

[0007] [3] These different solutions are not without drawbacks. The filling of the cavities with the insulating material is not always homogeneous, leading to the creation of thermal bridges and therefore to a degradation of the thermal insulation performance. These homogeneity defects can occur over time or during the transport of the construction elements to the site, when they are prefabricated elements. For example, mineral wool-based materials can have a tendency to settle. Finally, the injection of the product into a cavity is carried out using a nozzle. During injection, a phenomenon of "clogging", i.e. non-linear blockage, frequently occurs in the nozzle during the injection of the product. Presentation of the invention

[0008] [4] One aim of the invention is to propose a solution to overcome these drawbacks and to manufacture a construction element having an overall thermal conductivity lower than that of known construction elements, thanks to better homogeneity of the filling of the cavity.

[0009] [5] This aim is achieved within the framework of the present invention thanks to a thermal and / or acoustic insulation product for filling a construction element comprising two walls facing each other so as to form a cavity, the product comprising blown glass wool forming flakes,

[0010] - the product comprising a hydrophobic additive, the hydrophobic additive being a branched and crosslinked organosilicon polymer compound, and

[0011] - an average size of the flakes being less than 20 mm.

[0012] [6] The present invention is advantageously supplemented by the following characteristics, taken individually or in any of their technically possible combinations:

[0013] [7] - the product has a mass distribution of flakes obtained by sieving 2 g to 5 g of the insulation product using a vibrating sieve comprising a stack of sieves and a maximum oscillation amplitude of 3 mm set between 1.5 mm and 3 mm, preferably between 2 mm and 3 mm and better still at 2.85 mm, for 5 minutes, in which:

[0014] - a mass percentage of flakes remaining at the 25 mm sieve is less than 20% by mass, preferably less than 10% by mass, more preferably less than 5% by mass, preferably less than 3% by mass and

[0015] - a mass percentage of flakes remaining in the 19 mm sieve is less than 10% by mass, preferably less than 3% by mass,

[0016] [8] - the median size of the flakes is less than 20 mm, preferably less than 18 mm, in particular less than 15 mm, preferably between 5 mm and 20 mm and in particular between 7 mm and 18 mm, [9] - the median size of the flakes is less than 6 mm, in particular between 1 mm and 6 mm and preferably between 2 mm and 6 mm,

[0017]

[0010] - the product has a micronaire of between 4 L / min and 7 L / min, in particular between 5.5 L / min and 6.5 L / min,

[0018]

[0011] - the product has a loss on ignition of between 0.1% and 1.5% by mass, in particular between 0.1% and 1% by mass,

[0019]

[0012] - the product comprises an anti-dust additive, the anti-dust additive comprising a hydrocarbon oil,

[0020]

[0013] - a mass rate of an antistatic additive is less than 0.2%, the product preferably being devoid of an antistatic additive,

[0021]

[0014] - the product has a blown density of less than 15 kg / m 3 , preferably less than 13 kg / m 3 , for example between 5 and 15 kg / m 3 , especially between 7 and 13 kg / m 3 ,

[0022]

[0015] - the product has a resistance to the passage of air greater than 1500 Pa.s / m 2 , preferably greater than 2500 Pa.s / m 2 , and preferably greater than 3000 Pa.s / m 2 .

[0023]

[0016] Another aspect of the invention relates to a bag of loose blown wool, in particular for filling a construction element, comprising:

[0024] - compacted glass wool,

[0025] - a hydrophobic additive, the hydrophobic additive being a branched and crosslinked organosilicon polymer compound, the compacted glass wool having a density of 100 kg / m 3 at 200 kg / m 3 , preferably 120 kg / m3 at 180 kg / m 3 , the compacted glass wool forming, after blowing, glass wool flakes with an average size of less than 20 mm.

[0026] The blowing can be carried out, for example, according to standard EN 14064-1:2007. The loose blown wool can be blown so as to obtain an insulation product according to the invention, possibly supplemented by the characteristics mentioned above, taken individually or in any of their technically possible combinations.

[0027]

[0017] Another aspect of the invention is a construction element comprising two walls facing each other so as to form a cavity, the cavity being filled with a product according to an embodiment of the invention.

[0028]

[0018] Advantageously, the cavity is formed by the two walls, each of the two walls being a main wall, and formed by a plurality of side walls, for example by at least three side walls, preferably by at least four side walls. For example, the cavity of the building element may be formed by 2 main walls and by 3 or 4 side walls. The cavity of the building element may also be segmented into several spaces. For example, the cavity of the building element may be formed by 2 main walls and by 3 to 20, for example 4 to 20, for example 5 to 16, side walls.

[0029]

[0019] Advantageously, at least one of the walls, preferably at least one of the two main walls, preferably only one of the two main walls, is formed by a membrane. Said membrane may be permeable to air, for example perforated and / or formed of an air-permeable material.

[0030]

[0020] Advantageously, the membrane may comprise a polymer material and / or glass, for example glass fibers.

[0031]

[0021] Advantageously, the membrane is formed by a material permeable to air, in particular impermeable to flakes, and preferably by a material having a canvas or fabric structure.

[0032]

[0022] Advantageously, the membrane comprises polyethylene.

[0033]

[0023] Advantageously, at least one of the walls, preferably at least one of the two main walls, preferably only one of the two main walls, is a blowing wall. In other words, one of the walls is used for blowing the insulation product into the cavity. For example, the blowing wall may comprise at least one blowing orifice, in particular through which a nozzle may be arranged. Such an orifice has, for example, a diameter greater than 20 mm. Thus, the insulation product can be blown and retained in the cavity via the blowing wall. After the blowing step, the orifice of the blowing wall may be covered, for example by an adhesive film or by a closing wall. The blowing wall may be a rigid wall or a membrane. The blowing wall may be air-permeable, for example perforated and / or formed of an air-permeable material.

[0034]

[0024] Alternatively, at least one of the walls, preferably at least one of the two main walls, preferably only one of the two main walls, is a closing wall. In other words, one of the walls is used to close the open or partially open cavity of the building element, once the insulation product has been blown into the cavity. Thus, the closing wall is distinguished from a blowing wall. In particular, it is free of an orifice with a diameter greater than 20 mm. In other words, it is free of a blowing orifice (i.e., free of an orifice allowing the passage of a nozzle). The closing wall may be a rigid wall or a membrane. The closing wall is preferably non-permeable to air, for example, moisture-proof. Preferably, the closing wall comprises a vapor barrier film, for example, a polyethylene film.The closing wall may have an Sd coefficient (or equivalent air thickness) greater than 100 m, preferably greater than 150 m. The Sd coefficient is a measure of the resistance to diffusion of water vapor through a material (in meters). It can be measured, for example, according to the EN ISO 12572 standard.

[0035]

[0025] Advantageously, the cavity is formed by the two walls, each of the two walls being a side wall, and formed by at least one main wall.

[0036]

[0026] Another aspect of the invention is a wall comprising a construction element according to one embodiment of the invention.

[0037]

[0027] Another aspect of the invention is a frame element comprising a construction element according to an embodiment of the invention.

[0028] Another aspect of the invention is a method for obtaining a construction element comprising two walls facing each other so as to provide at least one cavity filled by a product according to an embodiment of the invention, the method comprising a step a) during which a non-blown product is blown into the cavity by means of a nozzle so as to manufacture the insulation product according to an embodiment of the invention.

[0038]

[0029] Advantageously, one of the two walls comprises a through orifice, the nozzle being arranged in the orifice.

[0039]

[0030] Advantageously, during step a), the nozzle is arranged through a blowing wall closing at least part of the cavity. In this case, the nozzle can be arranged, preferably fixed, in an orifice passing through the temporary blowing wall. Said blowing wall is preferably permeable to air, for example perforated and / or formed of an air-permeable material. This allows the cavity to be properly filled with the insulation product according to the invention during the blowing step a) without substantially increasing the pressure inside the cavity and while controlling the density of the insulation product in the cavity.

[0040]

[0031] According to one embodiment, said blowing wall is one of the walls of the construction element, preferably one of the main walls of the construction element.

[0041]

[0032] According to another embodiment, said blowing wall may be a temporary wall. In other words, the temporary blowing wall is temporarily placed on the construction element, before the blowing step a), so as to close at least part of the cavity of the construction element. The temporary blowing wall is then removed from the construction element, once the insulation product has been blown into the cavity. Preferably, the temporary blowing wall is crossed by a plurality of nozzles. In other words, the temporary blowing wall comprises a plurality of blowing orifices. Preferably, during step a), the temporary blowing wall is placed horizontally above the opening of the cavity.Once the temporary blowing wall is removed from the building element after blowing step a), the cavity of the building element can be closed by an additional wall, preferably an additional main wall.

[0042]

[0033] Advantageously, during step a), the cavity is formed by the two walls, each of the two walls being a main wall, and by a plurality of side walls.

[0043]

[0034] Advantageously, the nozzle has an internal diameter of less than 20 mm, in particular less than 15 mm.

[0044]

[0035] Advantageously, during step a), the construction element comprises two walls, each of the two walls being formed by a side wall, and also comprises two main walls distinct from the two walls, and, during step a) of the method, the cavity is formed by the two side walls and by at least one main wall.

[0045]

[0036] Advantageously, in step a), the construction element comprises two walls, each of the two walls being formed by a side wall, and also comprises two main walls distinct from the two walls, and, in step a) of the method, the cavity is formed by the two side walls, and by a single first main wall so that the cavity is open, the nozzle being arranged on the side opposite the side of the first main wall with respect to the cavity. More particularly, in step a), a temporary blowing wall may be placed on the open end of the cavity, the nozzle being fixed through said temporary wall. In this way, the insulation product can be retained in the cavity during blowing.

[0046]

[0037] Advantageously, the method comprises a step b), subsequent to step a), during which a closing wall, preferably a main wall, is installed so as to close the cavity of the construction element. Indeed, after the blowing step a), the cavity of the construction element can be open (for example if the cavity is filled using a temporary blowing wall) or partially open (for example if the blowing wall has an orifice allowing the passage of a nozzle). Step b) makes it possible to close any openings in the cavity of the construction element so that it is sealed against flakes of the insulation product according to the invention, or even to protect the insulation product from moisture.

[0038] Advantageously, during step a), the construction element comprises two walls, each of the two walls being formed by a side wall, and also comprises two main walls distinct from the two walls, and, during step a) of the method, the cavity is formed by the two walls and by at least one main wall, the method further comprising a step b) subsequent to step a), during which a second main wall is installed opposite the first main wall so as to close the cavity.

[0047] Description of figures

[0048]

[0039] Other characteristics, aims and advantages of the invention will emerge from the following description, which is purely illustrative and non-limiting, and which must be read in conjunction with the appended drawings in which:

[0049]

[0040] [ Fig.1 ] - Figure 1 schematically illustrates a construction element according to an embodiment of the invention,

[0050]

[0041] [Fig. 2] - Figure 2 illustrates a cumulative distribution of the mass proportion of different sizes of product flakes according to embodiments of the invention,

[0051]

[0042] [Fig. 3] - Figure 3 is a photograph taken by a scanning electron microscope of a different product of the invention,

[0052]

[0043] [Fig. 4] - Figure 4 is a photograph taken by a scanning electron microscope of a product according to one embodiment of the invention,

[0053]

[0044] [Fig. 5] - Figure 5 illustrates the variation of a relative size of the flakes of a product according to an embodiment of the invention with the micronaire of the product,

[0054]

[0045] [Fig. 6] - Figure 6 illustrates an example of resistance to the passage of air obtained for two products c) and d) according to the invention,

[0046] [Fig.7] - Figure 7 schematically illustrates a construction element according to an embodiment of the invention for a prefabricated element,

[0055]

[0047] [Fig. 8] - Figure 8 illustrates a construction element according to an embodiment of the invention for a “blow-in-blanket” type application.

[0056]

[0048] Throughout the figures, similar elements bear identical references.

[0057] Definitions

[0058]

[0049] Air resistance is measured according to international standard EN29053.

[0059]

[0050] “Blowing” of mineral wool means blowing as defined by standard EN 14064-1:2007.

[0060]

[0051] In the present application, the fineness of the mineral wool fibers is determined by the value of their micronaire, under 5g. The micronaire, also called "fineness index", is representative of the specific surface area of ​​the fibers. The measurement of the micronaire includes a measurement of the aerodynamic pressure drop when a given quantity of fibers extracted from the product is subjected to a given pressure of a gas, generally air or nitrogen. This measurement is common in mineral fiber production units, it is standardized (standards DI N 53941 and ASTM D 1448) and it uses a device called a "micronaire device". The method for measuring the micronaire is also described in document WO 2003098209.

[0061]

[0052] The walls designate surfaces which delimit or separate spaces. They are in particular impermeable to flakes of the insulation product according to the invention.

[0062] The walls may or may not be air-permeable. When they are air-permeable, they may be perforated or formed from an air-permeable material. By "perforated" wall is meant here a wall comprising one or more openings with a diameter smaller than the median size of the flakes of the insulation product according to the invention, for example with a diameter of less than 10 mm, preferably less than 5 mm, more preferably less than 1 mm. An air-permeable wall may, for example, have an air permeability value greater than 2 m 3 / hm 2 at 50 Pa. Wall air permeability is measured by pressurization tests, for example according to ISO 9052.

[0063] The walls may be rigid (i.e., they retain their general shape when placed vertically) or flexible (i.e., they deform when placed vertically). As non-limiting examples, a rigid wall may be made of a material chosen from wood, plaster, concrete, or a metallic material, preferably steel or aluminum. As non-limiting examples, a flexible wall, also referred to herein as a “membrane,” may be made of a woven or non-woven material, for example, a polymer material, preferably thermoplastic, or fiberglass.

[0064] A wall can possibly be made up of several layers or several membranes.

[0065] For the purposes of the present invention, the term "main wall" of a construction element means a wall which constitutes the dominant surface and extends parallel to the overall direction of the construction element (in other words which extends in the longitudinal direction of the construction element).

[0066] The "side wall" designates a wall perpendicular to the overall direction of the construction element (i.e. which extends in the direction of the thickness of the construction element).

[0067]

[0053] The term “membrane” means a flexible wall within the meaning of the present invention, in particular a wall whose thickness is sufficiently reduced so that it deforms under the effect of its own weight. The membrane may or may not be air-permeable. Preferably, the membrane is air-permeable, for example it may be perforated, preferably micro-perforated, or formed of an air-permeable material. Alternatively, the membrane may be impermeable to air, in particular moisture-proof. The membrane may, for example, be in the form of a canvas (or woven material), a fabric (textile material, i.e. made of fibers, woven or not), or a polymer film (for example polyethylene). The membrane may be multi-layered. The membrane may optionally be made of several membranes. Preferably, the membrane is chosen from a film made of polymer material, for example polyethylene, and / or a glass fiber fabric.

[0068]

[0054] By “blowing” wall (or membrane) is meant a wall (or membrane) through which the blown insulation product is introduced into the cavity of the construction element. The blowing wall is in particular provided with a blowing orifice, that is to say an orifice allowing the passage of a nozzle. Such an orifice may have a diameter greater than 20 mm. It is understood that, when a blowing orifice is present on a wall, several other blowing orifices may also be present. The blowing wall may advantageously be permeable to air, for example it may have an air permeability value greater than 2 m 3 / hm 2 at 50 Pa.

[0069] The blowing wall may be a wall of the building element, preferably a main wall.

[0070] Alternatively, the blowing wall may be a temporary wall, i.e. a wall temporarily placed on an open part of the cavity of the construction element, during the implementation of step a) of blowing. In particular, the temporary blowing wall may be placed before step a) of blowing the insulation product, then removed from the construction element after step a). The temporary wall allows the filling of an open or partially open cavity, in particular by retaining in the cavity the insulation product blown during step a). Such a temporary blowing wall may for example be an element of a blowing device, for example a “flat iron” type device.

[0071]

[0055] By "nozzle" is meant the end of an injection element for blowing the loose glass wool into the cavity. The nozzle may be of any diameter or shape allowing the injection of the product according to the invention, including in particular a pipe, for example with an internal diameter of 50 mm to 100 mm, a narrow nozzle, for example with an internal diameter of less than 50 mm, an adjustable or orientable nozzle, an anti-dust nozzle, etc. Detailed description of the invention

[0072]

[0056] General description of the insulation product

[0073]

[0057] With reference to Figure 1, Figure 7 and Figure 8, one aspect of the invention is a thermal and / or acoustic insulation product 1 for filling a construction element 2. The construction element 2 comprises two walls 3 facing each other so as to form a cavity 4. The product 1 comprises a blown glass wool forming flakes. The product comprises a hydrophobic additive. The hydrophobic additive is a branched and crosslinked organosilicon polymer compound. A median size of the flakes is less than 20 mm, in particular less than 18 mm and preferably less than 15 mm. Preferably, a median size of the flakes may be between 5 mm and 20 mm and preferably between 7 mm and 18 mm.The inventors have discovered that a flake size within the aforementioned ranges in combination with the aforementioned hydrophobic additive makes it possible, surprisingly, both to fill a cavity by injection in a more homogeneous manner than with known insulation products, so that it is possible to avoid forming thermal bridges in the cavity, and at the same time to avoid the "clogging" problems encountered during the injection of known products.

[0074]

[0058] Another aspect of the invention is a construction element 2 comprising a product according to an embodiment of the invention.

[0075]

[0059] With reference to Figure 1, the cavity 4 of the construction element 2 may be formed by the two walls 3, each of the two walls 3 being a main wall 7, and formed by a plurality of side walls 8.

[0076]

[0060] One of the walls of the construction element may comprise an orifice 6. Preferably, one of the main walls 7 may comprise an orifice 6. The diameter of the orifice 6 may be greater than 20 mm. Thus, it is possible to insert the outgoing end of a nozzle 5 into the cavity 4 to blow a non-blown product so as to manufacture the product 1, which makes it possible to manufacture the construction element 2. An internal diameter of the nozzle 5 may be less than 20 mm and in particular less than 15 mm. In this embodiment of the invention, a median size of the flakes may be between 5 mm and 20 mm. This median flake size range makes it possible to both fill a cavity by injection more homogeneously than with known insulation products, so that it is possible to avoid forming thermal bridges in the cavity, and to avoid the "clogging" problems encountered when injecting known products through a nozzle.

[0077]

[0061] After blowing the insulation product into the cavity, the opening 6 in the wall of the construction element 2 can be closed, for example using an adhesive film or an additional closing wall (not shown).

[0078]

[0062] With reference to Figure 7, the cavity 4 of the construction element 2 may be formed by the two walls 3, each of the two walls 3 being a side wall 8, and formed by at least one main wall 7. Thus, it is possible to manufacture a prefabricated construction element 2, intended for example for the subsequent assembly of a wall. In this embodiment of the invention, the median size of the flakes may be less than 20 mm, in particular between 5 mm and 20 mm, more particularly between 7 mm and 18 mm. According to another embodiment, the median size of the flakes may be less than 6 mm, in particular between 1 mm and 6 mm and preferably between 2 mm and 6 mm.This median size range of the flakes makes it possible both to fill a cavity by injection in a more homogeneous manner than with known insulation products, so that it is possible to avoid forming thermal bridges in the cavity, and at the same time to increase the injection speed of the flakes into the cavity 4 by a nozzle. Once the cavity 4 of the construction element 2 is filled with insulation product 1 according to the invention, it can be closed using a closing wall (not shown), preferably a main wall installed opposite the first main wall 7. The closing wall can be a rigid wall or a membrane.

[0079]

[0063] With reference to Figure 8, the product 1 may be used for a “blow-in-blanket” application. At least one of the two walls 3, and preferably only one of the two walls 3, may be a blowing wall, in particular formed by a membrane. The wall 3 formed by a membrane may be a main wall 7. After the product 1 has been blown into the cavity 4, the wall 3 formed by a membrane may be covered with another wall (or closing wall), preferably rigid. The membrane may comprise a polymer material and / or glass fibers. The membrane may be permeable to air, and preferably impermeable to flakes of product 1. Thus, it is possible to fill the cavity with product 1 without exerting excessive stress on the membrane, which would risk damaging the membrane, due to the pressure imposed in the cavity during blowing. For this purpose, the membrane may be formed by a material having a canvas or fabric structure.The membrane may also comprise polyethylene. The side or main walls of the cavity may be formed by at least one material chosen from wood, plaster, concrete and a metallic material, preferably steel or aluminum. The side walls 8 may be formed from steel or wood. The main walls 7 may be formed from wood and / or aluminum. Generally, at least one wall 3, preferably a side wall 8 or a main wall 7, has perforations and / or air passages. Thus, the wall 3 allows air to exit the cavity 4 selectively with respect to the blown product while lightening the construction element 2.

[0080]

[0064] Measuring the size of the flakes

[0081]

[0065] It is possible to measure the median size of glass wool flakes according to the method described below. The principle of the measurement consists of vibrating a stack of sieves of different diameters and sorting the flakes resulting from the vibration step according to their size. A sieve corresponds to a grid of more or less fine mesh, used to sort flakes, fixed on a frame. The sieves are vibrated using a sieve shaker corresponding to a vibrating device on which the sieves are installed. The equipment necessary for this measurement includes a sample of blown wool (in particular according to the aforementioned standard EN 14064-1:2007), a precision balance ± 0.05 g, a plastic beaker of approximately 500 mL, sieves and a lower container (without hole), an automatic sieve shaker, for example of the “Retsch Sieve Shaker” type model RX-24.Sieves of 20 cm (8") diameter with hole sizes defined below were used: 6 mm (0.25"), 13 mm (0.5"), 19 mm (0.75"), 25 mm (1"). A representative sample of the product is placed in a box of approximately 40x40x40 cm or larger. The product must not be compressed during handling or transport. Between 3.0 and 3.5 + / - 0.1 g of product is weighed into the plastic beaker. The sieves are stacked from the smallest mesh size (6 mm) to the largest on the sieve shaker. The sample is placed on the top sieve, i.e. the sieve with the largest mesh size. It is important that as much of the surface as possible is covered to prevent large flakes from preventing the smaller ones from falling. A lid is placed and tightened on the stack of sieves. The sieve shaker is started for a measurement time equal to 5 min. The resulting material on each of the sieves is weighed after the vibration is complete.The mass percentage is calculated by dividing the mass of material on the relevant sieve by the sum of the masses of all the sieves. The vibrating sieve machine includes a stack of sieves and a maximum oscillation amplitude of 3 mm. The oscillation amplitude is set between 1.5 mm and 3 mm, preferably between 2 mm and 3 mm, and best at 2.85 mm. The vibration process lasts five minutes. To achieve the desired oscillation amplitude, the power of the sieve machine is adjusted. For example, the power of the sieve machine is set to 65% when four sieves are used and between 45% and 65% when seven sieves are used to achieve the same vibration level.

[0082]

[0066] The results are expressed as a mass percentage per sieve. Five measurements are carried out with new samples for the same product. With reference to Figure 2, cumulative mass distributions are illustrated for two different products, each product being according to an embodiment of the invention. A median flake size for a product can be calculated from the cumulative mass distribution of the product. Curve (a) illustrates for example a product according to an embodiment of the invention comprising flakes having a median size equal to 9.25 mm, and curve (b) shows for example a different product according to an embodiment of the invention comprising flakes having a median size equal to 11.70 mm.

[0083]

[0067] The table [Table 1] below describes for example the result of the mass percentage measurements for five samples of the same product according to an embodiment of the invention, according to the method previously described

[0068] [Table 1]

[0084]

[0069] Product 1 may have a mass distribution of flakes, obtained by sieving 2 g to 5 g of the insulation product, using a vibrating sieve comprising a stack of sieves and a maximum oscillation amplitude of 3 mm set between 1.5 mm and 3 mm, preferably between 2 mm and 3 mm and better still at 2.85 mm, for five minutes, in which:

[0085] - a mass percentage of flakes remaining in the 25 mm sieve is strictly less than 5% by mass, preferably strictly less than 3% by mass and

[0086] - a mass percentage of flakes remaining in the 19 mm sieve less than

[0087] 10% by mass, preferably less than 3% by mass.

[0088]

[0070] Micronaire of the insulation product

[0071] The product may have a micronaire of between 4 L / min and

[0089] 7 L / min, in particular between 5.5 L / min and 6.5 L / min. It has been measured that a reduction in the micronaire of the product 1 in the aforementioned range makes it possible to obtain a flake size in the aforementioned range while increasing the homogeneity of the product 1 installed in the cavity 4 compared to a known product installed in the same cavity. With reference to Figure 5, a relative size of the flakes decreases with a reduction in the micronaire of the product.

[0090]

[0072] Resistance to air passage & density of the blown product 1

[0091]

[0073] With reference to Figure 6, the product may have a resistance to the passage of air greater than 1500 Pa.s / m 2 , preferably greater than 2500 Pa.s / m 2, especially greater than 3000 Pa.s / m 2 and preferably greater than 3500 Pa.s / m 2 . Product 1 may have a density of less than 15 kg / m 3 and preferably less than 13 kg / m 3 .

[0092]

[0074] Hydrophobic additive

[0093]

[0075] The hydrophobic additive is a branched and crosslinked organosilicon polymer compound. It is known to use a hydrophobic additive comprising an organosilicon polymer compound. Such an additive makes it possible to impart hydrophobicity to an installed product so as to prevent water infiltration into the product from modifying its homogeneity. However, known hydrophobic additives are not necessarily compatible with the desired flake size and do not prevent, during installation of the product, clogging in the nozzle.The inventors discovered that a flake size within the aforementioned range in combination with the hydrophobic additive comprising a branched and crosslinked organosilicon polymer compound made it possible, surprisingly, both to fill a cavity by injection in a more homogeneous manner than with known insulation products, so that it is possible to avoid forming thermal bridges in the cavity, and at the same time to avoid the "clogging" problems encountered when injecting the product through a nozzle.

[0094]

[0076] Figure 3 illustrates a photograph taken by a scanning electron microscope of a product different from a product according to one embodiment of the invention, comprising a hydrophobic additive, the hydrophobic additive comprising a reactive linear silicone. The scale bar corresponds to a length of 1 m. Figure 4 illustrates a photograph taken by a scanning electron microscope of a product according to one embodiment of the invention, comprising a hydrophobic additive, the hydrophobic additive comprising a branched and crosslinked organosilicon polymer. The scale bar corresponds to a length of 4 μm.

[0095]

[0077] The product may be devoid of a hardener suitable for polymerizing the polymer compound. Thus, it is possible to simplify the manufacture of the product by using the heat emitted by the glass wool following its manufacture to crosslink the hydrophobic additive. Commercial products such as SILRES (registered trademark) BS5160 produced by Wacker (registered trademark) or BRB BW5 produced by Siloen (registered trademark) comprise branched and crosslinkable organosilicon polymer compounds suitable for manufacturing a product 1.

[0096]

[0078] Anti-dust additive

[0097]

[0079] The product 1 may comprise an anti-dust additive. An anti-dust additive makes it possible, in a known manner, to limit dust emissions from the product 1 during its blowing, and thus to increase the installation comfort of the installer. A product 1 may comprise an anti-dust additive comprising a hydrocarbon oil. Thus, it is possible to limit or prevent cyclosiloxane emissions, which are possible when using known anti-dust additives comprising Si-O type chains. The inventors discovered that an anti-dust additive comprising a hydrocarbon oil was compatible with the injection of the product through a nozzle into a cavity 4 without causing clogging of the nozzle. The hydrocarbon oil may be a commercially available oil such as Finavestan A 100B oil marketed by the company Total (registered trademark).

[0098]

[0080] Antistatic additive

[0081] A mass content of antistatic additive in the product 1 may be less than 0.2%. The product 1 may be devoid of an antistatic additive, in particular of an antistatic additive different from the organosilicon compound, the organosilicon compound not being an antistatic additive. Thus, the resistance to the passage of air may be increased with respect to the same product comprising an antistatic additive. With reference to Figure 6, point (c) illustrates a product 1 devoid of an antistatic additive different from the organosilicon compound and point (d) illustrates the same product provided with an antistatic compound different from the organosilicon compound, of the “Momar” type.

[0099]

[0082] Loss on ignition

[0100]

[0083] The loss on ignition of the product may be between 0.1% and 1.5%, in particular between 0.1% and 1% by mass. Loss on ignition is understood to mean the difference in mass between the mass of the product 1 before calcination and after calcination, expressed as a percentage of the mass of the product before calcination. Thus, it is possible to maximize the thermal insulation of the blown product while avoiding the aforementioned drawbacks of the prior art. For this purpose, the mass content of the organosilicon compound may be adjusted so that the loss on ignition of the product is between 0.1% and 1.5% and in particular between 0.1% and 1% by mass.

[0101]

[0084] Manufacture of the insulation product

[0102]

[0085] Glass fiberization can be carried out by the TEL process, as described in patent EP 0091 866. A fiberization device for fiberizing glass comprises a centrifugation plate and a basket. A stream of molten glass is poured into an axis of a hollow shaft. The molten glass is received at the bottom of a basket. The rotation of the basket drives the molten glass onto the peripheral part of the basket which is pierced by a plurality of orifices. Under the effect of centrifugation, the material is projected onto an internal face of a peripheral wall of the centrifuge, which also has a plurality of orifices. The material passes through these latter orifices and is projected in the form of filaments outside the centrifuge. An annular burner, arranged close to the orifices, emits a gas jet making it possible to stretch the filaments and thus to form the glass fibers.The burner is configured so that the temperature of the gas jet at the burner outlet is between 1300°C and 1500°C, preferably around 1400°C. The variation in burner pressure, driving the gas jet, makes it possible to control the fineness of the fibers.

[0103]

[0086] The fiber draw per orifice of a plate per day is equal to the flow rate of molten raw material passing through each orifice per day. The fiber draw per orifice of a plate per day may be between 0.30 kg / day and 0.8 kg / day, in particular between 0.4 kg / day and 0.7 kg / day.

[0104]

[0087] The plate of the centrifugation device may comprise at least 30,000 orifices, for example when the diameter of the plate is equal to 600 mm. Preferably, the plate of the centrifugation device may comprise at least 36,000 orifices, for example when the diameter of the plate is equal to 400 mm.

[0105]

[0088] The plate of the centrifugation device has a diameter of between 50 mm and 800 mm, and preferably between 400 mm and 600 mm. The pull of the centrifugation device 2 varies with the diameter of the plate.

[0106]

[0089] The orifices are formed and distributed over the drilling strip of the plate. The height of the drilling strip, in the direction of the axis of rotation X of the centrifugation device, is preferably less than 35 mm. The diameter of the orifices is between 0.5 and 1.1 mm.

[0107]

[0090] The distance between the centers of neighboring orifices may be between 0.8 mm and 2 mm. This distance may vary by less than 10%, and preferably by less than 3%. The distance between the centers of neighboring orifices may decrease in a direction oriented towards the lower part of the plate.

[0108]

[0091] The manufacturing process may then include a step of recovering the mineral fibers from a carpet. Following the recovery step, the manufacturing process may include a step of grinding the fibers. The fiber grinding step makes it possible to control the size of the flakes. The fiber grinding step includes passing the fibers through a knife mill and then preferably through a grid selector. It is possible to choose the size of the grids so as to obtain a flake size within the product range, all other parameters being constant.

[0109]

[0092] The method of manufacturing the product then comprises a step of blowing the product obtained previously, implemented by blowing the product obtained previously into the cavity 4 by means of a nozzle 5 so as to manufacture the thermal insulation product 1.

[0110]

[0093] Another aspect of the invention is a method for obtaining a construction element 2 according to an embodiment of the invention. The method comprises a step a) in which a non-blown product is blown into the cavity 4 by means of a nozzle 5 so as to manufacture the thermal insulation product 1.

[0111]

[0094] With reference to Figure 1 and Figure 8, one of the two walls 3 may be a blowing wall and comprise an orifice 6 passing through the wall. The orifice 6 may have a diameter greater than 20 mm. The nozzle 5 is then arranged in the orifice 6 during blowing. It may be arranged partially in the orifice or entirely so as to reach the cavity. When one of the walls 3 is formed by a membrane, the orifice 6 may be formed by piercing the membrane by the nozzle 5. Following the blowing of the product 1 into the cavity 4, it is possible to close the orifice 6 by depositing an adhesive film on the orifice 6 and on the membrane or by installing a closing wall. The nozzle 5 may have an internal diameter less than 20 mm, in particular 15 mm. This means that it is not necessary to open the wall over too large an area to inject the non-blown product.In step a) of the method, the cavity 4 is formed by the two walls 3, each of the two walls 3 being a main wall 7, and by a plurality of side walls 8. More particularly, with reference to FIG. 8, one of the two walls 3, 7 may comprise a blowing wall, in particular in the form of a membrane, for example permeable to air (for example a glass fiber fabric) and a closing wall, in particular in the form of a membrane, for example impermeable to air (for example a polyethylene film). In step a) of the method, the cavity 4 is formed by the two walls 3, each of the two walls 3 being a main wall 7, and by a plurality of side walls 8, preferably at least 3 side walls, for example 3 to 20 side walls.

[0112]

[0095] With reference to Figure 7, the construction element 2 obtained by the method may comprise two walls 3, each of the two walls 3 being formed by a side wall 8, and also comprise two main walls 7 distinct from the two walls 3. During step a), the cavity 4 is formed by the two walls 3 and by at least one main wall 7 and preferably formed by the two walls 3 and by a single main wall 7. The cavity 4 is then at least partially open (on top). The nozzle 5 may be arranged on the side opposite the side of the first main wall 7 with respect to the cavity 4. Preferably, a plurality of nozzles 5, for example between 3 and 6 nozzles, are arranged on the side opposite the side of the first main wall 7 with respect to the cavity 4. Thus, it is possible to fill the cavity 4 to obtain a prefabricated construction element 2.The product 1 can be transported (in particular blown) into the cavity 4 by means of a device comprising a resting wall, or temporary blowing wall (not shown), in which orifices are formed, each end of a nozzle being fixedly mounted to an orifice. Such a device is known as a "flat iron". The resting wall is installed on the cavity 4 so as to close it. The resting wall may comprise a semi-permeable wall, preferably a membrane, adapted to be crossed by air and to retain the blown wool flakes. Thus, it is possible to inject the product 1 while controlling its density into the cavity 4. The resting wall, as a temporary blowing wall, can be placed on the construction element 2 temporarily for the entire duration of the blowing step a). It can then be removed from the construction element 2, leaving the upper end of the cavity 4 open.

[0113]

[0096] The method may comprise a step b), subsequent to step a), during which a second main wall 7 is installed opposite the first main wall 7 so as to close the cavity 4. Thus, it is possible to obtain a prefabricated construction element 2. The second main wall (or closing wall) may be a rigid wall or a membrane

[0097] According to other embodiments, the invention may relate to one or more of the following objects:

[0114] 1. Product (1) for thermal and / or acoustic insulation for filling a construction element (2) comprising two walls (3) facing each other so as to form a cavity (4), the product (1) comprising blown glass wool forming flakes, the product (1) being characterized in that:

[0115] - the product (1) comprises a hydrophobic additive, the hydrophobic additive being a branched and crosslinked organosilicon polymer compound, and

[0116] - an average size of flakes is less than 20 mm.

[0117] 2. Product (1) according to object 1 in which the median size of the flakes is between 5 mm and 20 mm and in particular between 7 mm and 18 mm;

[0118] 3. Product (1) according to one of objects 1 to 2, having a micronaire between 4 L / min and 7 L / min.

[0119] 4. Product (1) according to one of the objects 1 to 3, having a loss on ignition of between 0.1% and 1.5% by mass.

[0120] 5. Product (1) according to one of the objects 1 to 4, comprising an anti-dust additive, the anti-dust additive comprising a hydrocarbon oil.

[0121] 6. Product (1) according to one of objects 1 to 5, in which a mass rate of an antistatic additive is less than 0.2%, the product preferably being free of an antistatic additive.

[0122] 7. Product (1) according to one of the objects 1 to 6, having a density less than 15 kg / m 3 , preferably less than 13 kg / m 3 .

[0123] 8. Product (1) according to one of the objects 1 to 7, having a resistance to the passage of air greater than 2500 Pa.s / m 2 , and preferably greater than 3000 Pa.s / m 2 .

[0124] 9. Construction element (2) comprising two walls (3) facing each other so as to form a cavity (4), the cavity (4) being filled with a product (1) according to one of claims 1 to 8.

[0125] 10. Construction element (2) according to object 9, in which the cavity (4) is formed by the two walls (3), each of the two walls (3) being a main wall (7), and formed by a plurality of side walls (8).

[0126] 11. Construction element (2) according to objects 9 or 10, in which only one of the two walls (3) is formed by a membrane.

[0127] 12. Construction element (2) of the object 9, in which the cavity (4) is formed by the two walls (3), each of the two walls (3) being a side wall (8), and formed by at least one main wall (7). 13. Wall comprising a construction element according to one of the objects 9 to 12.

[0128] 14. Method for obtaining a construction element (2) comprising two walls (3) facing each other so as to provide at least one cavity (4) filled with a product (1) according to one of claims 1 to 8, the method comprising a step a) during which a non-blown product is blown into the cavity (4) by means of a nozzle (5) so as to manufacture the thermal insulation product 1.

[0129] 15. Method according to the preceding object, in which one of the two walls (3) comprises a through orifice (6), the nozzle (5) being arranged in the orifice (6).

[0130] 16. Method according to object 14 or 15, in which, during step a), the cavity (4) is formed by the two walls (3), each of the two walls (3) being a main wall (7), and by a plurality of side walls (8).

[0131] 17. Method according to one of the objects 14 to 16, in which the nozzle (6) has an internal diameter less than 20 mm, in particular less than 15 mm.

[0132] 18. Method according to object 14, the construction element (2) comprising two walls (3), each of the two walls (3) being formed by a side wall (8), and also comprises two main walls (7) distinct from the two walls (3), in which, during step a), the cavity (4) is formed by the two side walls (3) and by at least one main wall (7).

[0133] 19. Method according to the preceding subject, in which, during step a), the cavity (4) is formed by the two walls (3), and by a single first main wall (7) so that the cavity (4) is open, and the nozzle (5) is arranged on the side opposite to the side of the first main wall (7) with respect to the cavity (4).

[0134] 20. Method according to the preceding subject, further comprising a step b) subsequent to step a), during which a second main wall (7) is installed opposite the first main wall (7) so as to close the cavity (4).

Claims

Claims 1. Product (1) for thermal and / or acoustic insulation for filling a construction element (2) comprising two walls (3) facing each other so as to form a cavity (4), the product (1) comprising blown glass wool forming flakes, the product (1) being characterized in that: - the product (1) comprises a hydrophobic additive, the hydrophobic additive being a branched and crosslinked organosilicon polymer compound, and - an average size of flakes is less than 20 mm.

2. Product (1) according to claim 1 in which the median size of the flakes is between 5 mm and 20 mm and in particular between 7 mm and 18 mm.

3. Product (1) according to one of claims 1 to 2, having a micronaire of between 4 L / min and 7 L / min.

4. Product (1) according to one of claims 1 to 3, having a loss on ignition of between 0.1% and 1.5% by mass.

5. Product (1) according to one of claims 1 to 4, comprising an anti-dust additive, the anti-dust additive comprising a hydrocarbon oil.

6. Product (1) according to one of claims 1 to 5, in which a mass rate of an antistatic additive is less than 0.2%, the product preferably being free of an antistatic additive.

7. Product (1) according to one of claims 1 to 6, having a blown density of less than 15 kg / m 3 , preferably less than 13 kg / m 3 .

8. Product (1) according to one of claims 1 to 7, having a resistance to the passage of air greater than 1500 Pa.s / m 2 , preferably greater than 2500 Pa.s / m 2 , and preferably greater than 3000 Pa.s / m 2 .

9. Bag of loose glass wool for blowing, in particular for filling a construction element, comprising: - compacted glass wool, - a hydrophobic additive, the hydrophobic additive being a branched organosilicon polymer compound and crosslinked, compacted glass wool with a density of 100 kg / m 3 at 200 kg / m 3 , preferably 120 kg / m 3 at 180 kg / m 3 , the compacted glass wool forming, after blowing, glass wool flakes with an average size of less than 20 mm.

10. Construction element (2) comprising two walls (3) facing each other so as to form a cavity (4), the cavity (4) being filled with a product (1) according to one of claims 1 to 8.

11. Construction element (2) according to claim 10, in which the cavity (4) is formed by two main walls (3, 7), and formed by a plurality of side walls (3, 8), preferably at least 3 side walls (3, 8).

12. Construction element (2) according to claim 10 or 11, in which at least one of the walls, preferably only one of the two walls (3), is formed by a membrane.

13. Construction element (2) according to any one of claims 10 to 12, in which at least one of the walls, preferably only one of the two walls (3), is a blowing wall.

14. Construction element (2) according to any one of claims 10 to 13, in which at least one of the walls, preferably only one of the two walls (3), is a closing wall.

15. Wall comprising a construction element according to one of claims 10 to 14.

16. Method for obtaining a construction element (2) comprising two walls (3) facing each other so as to provide at least one cavity (4) filled with a product (1) according to one of claims 1 to 8, the method comprising a step a) during which a non-blown product is blown into the cavity (4) by means of a nozzle (5) so as to manufacture the thermal insulation product (1).

17. Method according to the preceding claim, in which one of the two walls (3) comprises a through orifice (6), the nozzle (5) being arranged in the orifice (6).

18. Method according to any one of the preceding claims, wherein, in step a), the nozzle (5) is arranged through a blowing wall, closing at least part of the cavity (4).

19. Method according to claim 18, wherein the blowing wall is one of the walls (3) of the construction element, preferably one of the main walls (3, 7) of the construction element (2).

20. The method of claim 18, wherein the blowing wall is a temporary wall placed on the building element during step a).

21. Method according to any one of claims 16 to 20, comprising a step b), subsequent to step a), during which a closing wall, preferably a main wall, is installed so as to close the cavity (4) of the construction element (2).

22. Method according to claim 16, the construction element (2) comprising two walls (3), each of the two walls (3) being formed by a side wall (8), and also comprises two main walls (7) distinct from the two walls (3), in which, during step a), the cavity (4) is formed by the two side walls (3) and by at least one main wall (7).

23. Method according to the preceding claim, in which, during step a), the cavity (4) is formed by the two walls (3), and by a single first main wall (7) so that the cavity (4) is open, and the nozzle (5) is arranged on the side opposite to the side of the first main wall (7) relative to the cavity (4).

24. Method according to the preceding claim, further comprising a step b) subsequent to step a), during which a second main wall (7) is installed opposite the first main wall (7) so as to close the cavity (4).