Glass wool panel for sound absorption, associated manufacturing method and use

Abstract

The invention relates to a glass wool panel intended to be used as an acoustic panel and having: - a density greater than or equal to 60 kg / m3 and less than or equal to 80 kg / m3, a thickness of between 10 mm and 70 mm, and an average micronaire value of between 2.4 / 5 g and 8.5 / 5 g, or - a density strictly greater than 80 kg / m3 and strictly less than 90 kg / m3, a thickness of between 30 mm and 70 mm, and an average micronaire value of between 5 / 5 g and 8.5 / 5 g, preferably between 5.7 / 5 g and 8.5 / 5 g, or - a density equal to 90 kg / m3, a thickness of between 10 mm and 40 mm, preferably between 10 mm and 38 mm, and an average micronaire value of between 3 / 5 g and 8.5 / 5 g, or - a density equal to 100 kg / m3, a thickness of between 10 mm and 30 mm, and an average micronaire value of between 3.3 / 5 g and 8.5 / 5 g.

Description

Description Title of the invention: Glass wool panel for sound absorption, manufacturing process and associated use Previous technique

[0001] The present invention relates to the general field of manufacturing products for improving sound absorption in interior spaces. More particularly, it relates to a glass wool panel intended for use as an acoustic panel. It also relates to a method for manufacturing such a panel and to its use in interior spaces.

[0002] Throughout this description, the term "acoustic panel" refers to a panel which, due to its glass wool composition, may provide thermal insulation properties, but is primarily designed to improve sound absorption within an interior space, such as a room in a dwelling (e.g., a bedroom in a house, an office in a workplace, etc.).

[0003] As a reminder, sound absorption determines the amount of sound absorbed within a single interior space, specifically by all the elements that make up that space (walls, floors, curtains, etc.). For example, in a large, empty space with hard walls and floors and no furniture, sound absorption is low and reverberation is high. This space will therefore sound hollow and produce a resonant effect. Conversely, the more soft, absorbent surfaces a space contains, the better the absorption will be and the less resonance there will be.

[0004] To ensure good mechanical strength of an acoustic panel, more particularly good resistance of its edges, the parameter considered to be of paramount importance during the manufacture of the panel is the density of the glass wool composing it, it being understood that the greater this density, the better the mechanical strength.

[0005] To date, and for the reasons mentioned above, the production of glass wool panels is largely driven by the density parameter. This method of However, this approach proves disadvantageous when the sound absorption capacities of these panels must be taken into account.

[0006] Indeed, it has been observed that playing on the single parameter of density, by aiming to increase it, has the effect of increasing the airflow resistance of a panel, thus leading to a degradation of the acoustic absorption performance. Description of the invention

[0007] The present invention aims to remedy all or part of the disadvantages of the prior art, in particular those set out above, by proposing a solution which makes it possible to provide a glass wool panel which, for a given density, has better sound absorption performance than prior art panels of the same density.

[0008] To this end, and according to a first aspect, the invention relates to a glass wool panel intended for use as an acoustic panel and having: - a density greater than or equal to 60 kg / m³ 3 and less than or equal to 80 kg / m 3 , a thickness between 10 mm and 70 mm, and an average micron index between 2.4 / 5g and 8.5 / 5g, or - a density strictly greater than 80 kg / m³ 3 and strictly less than 90 kg / m 3, a thickness between 30 mm and 70 mm, and an average micron index between 5 / 5g and 8.5 / 5g, preferably between 5.7 / 5g and 8.5 / 5g, or - a density equal to 90 kg / m³ 3 , a thickness between 10 mm and 40 mm, preferably between 10 mm and 38 mm, and an average micron index between 3 / 5 g and 8.5 / 5 g, or - density equal to 100 kg / m³ 3 , a thickness between 10 mm and 30 mm, and an average micron index between 3.3 / 5g and 8.5 / 5g.

[0009] In the following description, "a parameter P is between a value VI and a value V2" means that this parameter P is greater than or equal to VI and less than or equal to V2.

[0010] As is well known, the micron index (also called "the micronaire") represents the fineness of the glass fibers used to form the panel. Measuring this micron index specifically reflects their surface area. This is specifically achieved by measuring the aerodynamic pressure drop when a given quantity, i.e., a sample (typically 5 grams), of fibers extracted from an uncoated panel is subjected to a given pressure from a gas, typically air or nitrogen. Such a measurement is common in mineral fiber production units and is performed according to DIN 53941 or ASTM D 1448 using a device known as a "micronaire apparatus."

[0011] For more details concerning the measurement of the micron index of a sample, as well as the design and operation of said micron apparatus, it is possible, for example, to consult document W02003098209.

[0012] It follows from the above that the term "average micron index," when referring to an acoustic panel, refers to an average value of micron indices determined from several samples taken from said acoustic panel. In other words, the micron index measurable by taking a sample from an acoustic panel can vary considerably around this average micron index, depending on where the sample is taken from the panel.

[0013] By way of non-limiting example, the relative variation of the micron index within an acoustic panel according to the invention is less than 15%. "Relative variation" conventionally refers to the ratio between, on the one hand, the difference between the extreme micron index values ​​within the panel, and, on the other hand, the minimum micron index value within the panel. Having a relative variation of less than 15% ensures good homogeneity (in terms of micron index) of the acoustic panel.

[0014] In general, the important information on which the present invention is based is that the higher the average micron index, the lower the airflow resistivity (the measurement of this resistivity being classically carried out according to ISO 9053).

[0015] Thus, the invention proposes, for a given density and thickness of glass wool panel, to increase another parameter to improve sound absorption, namely the average micron index. In this sense, the invention contradicts the prior art assumption that it would not be possible to improve the sound absorption performance of a glass wool panel of constant density and thickness without using suitable scrim(s) (the prior art of the technique considering that improving these performances necessarily implies aiming for at least a reduction in the panel density).

[0016] In other words, the invention is particularly advantageous in that it allows for the optimization of sound absorption performance for a given density and thickness of glass wool panel, so as to also guarantee good thermal insulation performance.

[0017] In practice, thanks to numerical simulation tools as well as manufacturing and testing campaigns, the inventors were able to determine the micron ranges characterizing the glass wool panels according to the invention, such that these panels exhibit excellent sound absorption performance (typically an airflow resistivity of approximately 20 kPa.s / m²). 2 and 100 kPa.s / m 2 ).

[0018] Correspondingly, it was found that these ranges of values ​​improve sound absorption across the entire frequency range from 100 Hz to 4000 Hz compared to prior art panels. Furthermore, it was observed that the panels according to the invention stand out particularly, to their advantage, from prior art panels in a frequency range around 500 Hz.

[0019] It should be noted that the upper limit considered for the panels of the invention, in terms of average micron index, is 8.5 / 5g. The inventors have indeed observed, through the various tests carried out, that the manufacture of glass wool panels with an average micron index exceeding this upper limit is not realistically feasible with the production methods known to date.

[0020] In specific embodiments, the panel has a density greater than or equal to 60 kg / m³ 3 and less than or equal to 80 kg / m 3 , a thickness between 20 mm and 70 mm, and an average micron index between 3 / 5g and 8.5 / 5g, preferably between 3 / 5g and 7.5 / 5g.

[0021] In specific embodiments, the panel has a density greater than or equal to 60 kg / m³ 3 and less than or equal to 80 kg / m 3, a thickness between 10 mm and 60 mm, and an average micron index between 2.4 / 5g and 8.5 / 5g, preferably between 2.4 / 5g and 7.5 / 5g.

[0022] In specific embodiments, the panel has a density greater than or equal to 60 kg / m³ 3 and less than or equal to 80 kg / m 3 , a thickness between 20 mm and 60 mm, and an average micron index between 3 / 5g and 8.5 / 5g, preferably between 3 / 5g and 7.5 / 5g.

[0023] In specific embodiments, the panel has a density greater than or equal to 60 kg / m³ 3 and less than or equal to 80 kg / m 3 , a thickness between 10 mm and 50 mm, and an average micron index between 2.4 / 5g and 8.5 / 5g, preferably between 2.4 / 5g and 7.5 / 5g.

[0024] In specific embodiments, the panel has a density greater than or equal to 60 kg / m³ 3and less than or equal to 80 kg / m 3 , a thickness between 20 mm and 50 mm, and an average micron index between 3 / 5g and 8.5 / 5g, preferably between 3 / 5g and 7.5 / 5g.

[0025] In certain embodiments, the panel has a density strictly greater than 80 kg / m³ 3 and strictly less than 90 kg / m 3 , a thickness between 30 mm and 70 mm, and an average micron index between 5.7 / 5g and 7.5 / 5g.

[0026] In certain embodiments, the panel has a density strictly greater than 80 kg / m³ 3 and strictly less than 90 kg / m 3 , a thickness between 30 mm and 60 mm and an average micron index between 5 / 5g and 8.5 / 5g, preferably between 5.7 / 5g and 8.5 / 5g, even more preferably between 5.7 / 5g and 7.5 / 5g.

[0027] In certain embodiments, the panel has a density strictly greater than 80 kg / m³ 3 and strictly less than 90 kg / m 3 , a thickness between 30 mm and 50 mm and an average micron index between 5 / 5g and 8.5 / 5g, preferably between 5.7 / 5g and 8.5 / 5g, even more preferably between 5.7 / 5g and 7.5 / 5g.

[0028] In particular embodiments, the glass wool panel may also include one or more of the following characteristics, taken individually or in all technically possible combinations.

[0029] In specific embodiments, the panel has a density of 60 kg / m³ 3 , a thickness between 10 mm and 50 mm and an average micron index between 2.4 / 5g and 7.1 / 5g.

[0030] In specific embodiments, the panel has a density of 70 kg / m³3 , a thickness between 10 mm and 50 mm and an average micron index between 2.5 / 5g and 7.5 / 5g.

[0031] In specific embodiments, the panel has a density of 80 kg / m³ 3 , a thickness between 10 mm and 50 mm and an average micron index between 2.7 / 5g and 7.5 / 5g.

[0032] The invention covers further, more specific examples of embodiment, as described in detail later.

[0033] According to a second aspect, the invention relates to a method for manufacturing a glass wool panel according to the first aspect.

[0034] Such a manufacturing process typically includes an internal centrifugation step implemented using an installation comprising: - at least one centrifuge capable of rotating around a given axis, in particular a vertical one, and whose peripheral band is pierced with a plurality of orifices to deliver filaments of a molten material, - a high-temperature gaseous drawing method in the form of an annular burner which ensures the drawing of filaments into fibers, and - a receiving mat combined with suction means to receive the fibers.

[0035] The centrifuge(s), also called fiber-forming plates, are used to create mineral fibers or other thermoplastic materials through an internal centrifugation process combined with drawing using a high-temperature gas stream. Internal centrifugation is particularly useful in the industrial production of glass wool, intended for use in thermal and / or acoustic insulation products. A stream of molten glass is introduced into each centrifuge, which rotates at high speed and is perforated around its periphery by a large number of orifices. Through these orifices, the glass is projected as filaments by centrifugal force. These filaments are then subjected to an annular drawing current at high temperature and speed, flowing along the centrifuge wall. This current thins the filaments and transforms them into fibers.The fibers formed are carried by this gaseous drawing current towards a receiving device generally consisting of a gas-permeable belt, called a receiving mat.

[0036] The implementation of the manufacturing process depends on several parameters, the values ​​chosen for these parameters having an influence, in particular, on the density and the average micron index of the panel manufactured.

[0037] Examples of parameters to adjust to implement the manufacturing process include: the viscosity of the molten glass, the burner pressure, the total glass output per day and per centrifuge, the number of holes per centrifuge, the rotation speed of each centrifuge, etc.

[0038] In general, a person skilled in the art knows how to choose suitable values ​​for the parameters of the manufacturing process, so as to obtain a glass wool panel with density, thickness and average micron index characteristics within the ranges according to the invention.

[0039] Preferably, the manufacturing process is carried out by applying a binder in the form of powder or sprayed (atomized) droplets of binder solution to the glass fibers before collection on the receiving conveyor (preferably, the binder does not contain thermoplastic bonding fibers). The panel is then consolidated by hardening the binder.

[0040] As an example, the binder content is between 2% and 30%, preferably between 3% and 15%, more preferably between 4% and 10%.

[0041] According to a third aspect, the invention relates to the use of a glass wool panel according to the first aspect to improve sound absorption within an interior space, said panel being fixed to a wall surface of said interior space.

[0042] In particular modes of implementation of said insulation process, the wall surface is a ceiling.

[0043] Of course, nothing prevents us from considering other wall surfaces, such as a vertical wall or even a floor.

[0044] According to a fourth aspect, the invention relates to a glass wool panel intended for use as an acoustic panel and having: - a density between 40 kg / m³ 3 and 55 kg / m 3 , a thickness between 10 mm and 50 mm, and an average micron index between 2 / 5g and 5.5 / 5g, or - a density between 60 kg / m³ 3 and 85 kg / m 3, a thickness between 10 mm and 50 mm, and an average micron index between 2.4 / 5g and 8.5 / 5g, or - a density equal to 90 kg / m³ 3 , a thickness between 10 mm and 40 mm, preferably between 10 mm and 38 mm, and an average micron index between 3 / 5 g and 8.5 / 5 g, or - density equal to 100 kg / m³ 3 , a thickness between 10 mm and 30 mm, and an average micron index between 3.3 / 5g and 8.5 / 5g.

[0045] In particular embodiments, the glass wool panel may also include one or more of the following characteristics, taken individually or in all technically possible combinations.

[0046] In specific embodiments, the panel has a density of 40 kg / m³ 3 , a thickness between 10 mm and 50 mm and an average micron index between 2.1 / 5g and 4.4 / 5g.

[0047] In specific embodiments, the panel has a density of 50 kg / m³ 3 , a thickness between 10 mm and 50 mm and an average micron index between 2.2 / 5g and 5.5 / 5g.

[0048] In specific embodiments, the panel has a density of 60 kg / m³ 3 , a thickness between 10 mm and 50 mm and an average micron index between 2.4 / 5g and 7.1 / 5g.

[0049] In specific embodiments, the panel has a density of 70 kg / m³ 3 , a thickness between 10 mm and 50 mm and an average micron index between 2.5 / 5g and 7.5 / 5g.

[0050] In specific embodiments, the panel has a density of 80 kg / m³ 3 , a thickness between 10 mm and 50 mm and an average micron index between 2.7 / 5g and 7.5 / 5g.

[0051] In particular embodiments, the relative variation of the micron index is less than 15%.

[0052] The invention covers further, more specific examples of embodiment, as described in detail later.

[0053] According to a fifth aspect, the invention relates to a method for manufacturing a glass wool panel according to the fourth aspect.

[0054] Such a manufacturing process typically includes an internal centrifugation step implemented using an installation comprising: - at least one centrifuge capable of rotating around a given axis, in particular a vertical one, and whose peripheral band is pierced with a plurality of orifices to deliver filaments of a molten material, - a high-temperature gaseous drawing method in the form of an annular burner which ensures the drawing of filaments into fibers, and - a receiving mat combined with suction means to receive the fibers.

[0055] The centrifuge(s), also called fiber-forming plates, are used to create mineral fibers or other thermoplastic materials through an internal centrifugation process combined with drawing using a high-temperature gas stream. Internal centrifugation is particularly useful in the industrial production of glass wool, intended for use in thermal and / or acoustic insulation products. A stream of molten glass is introduced into each centrifuge, which rotates at high speed and is perforated around its periphery by a large number of orifices. Through these orifices, the glass is projected as filaments by centrifugal force. These filaments are then subjected to an annular drawing current at high temperature and speed, flowing along the centrifuge wall. This current thins the filaments and transforms them into fibers.The fibers formed are carried by this gaseous drawing current towards a receiving device generally consisting of a gas-permeable belt, called a receiving mat.

[0056] The implementation of the manufacturing process depends on several parameters, the values ​​chosen for these parameters having an influence, in particular, on the density and the average micron index of the panel manufactured.

[0057] Examples of parameters to adjust to implement the manufacturing process include: the viscosity of the molten glass, the burner pressure, the total glass output per day and per centrifuge, the number of holes per centrifuge, the rotation speed of each centrifuge, etc.

[0058] In general, a person skilled in the art knows how to choose suitable values ​​for the parameters of the manufacturing process, so as to obtain a glass wool panel with density, thickness and average micron index characteristics within the ranges according to the invention.

[0059] Preferably, the manufacturing process is implemented by adding a binder in the form of powder or droplets of binder solution. The bonding agent is sprayed (atomized) onto the glass fibers before collection on the receiving conveyor (preferably, the binder does not contain thermoplastic bonding fibers). The panel is then consolidated by hardening the binder.

[0060] As an example, the binder content is between 2% and 30%, preferably between 3% and 15%, more preferably between 4% and 10%.

[0061] According to a sixth aspect, the invention relates to the use of a glass wool panel according to the fourth aspect to improve sound absorption within an interior space, said panel being fixed to a wall surface of said interior space.

[0062] In particular modes of implementation of said insulation process, the wall surface is a ceiling.

[0063] Of course, nothing prevents us from considering other wall surfaces, such as a vertical wall or even a floor. Description of examples of achievements

[0064] As mentioned above, more specific examples of the production of glass wool panels according to the invention will now be described.

[0065] More specifically, the glass wool panels described in these examples are those for which the inventors were able to determine, in terms of average micron index, optimal acoustic performance at given density and thickness.

[0066] Thus, for each of these examples, when the panel thickness is 20 mm (or 40 mm respectively), the resulting airflow resistivity is approximately 60 kPa.s / m 2 (respectively approximately equal to 30 kPa.s / m 2 ).

[0067] Examples no. 1 and no. 1 bis of a panel with a density of 40 kq / m³ 3

[0068] According to example no. 1, a panel with a density of 40 kg / m³ is considered 3 as well as a thickness of 20 mm and an average micron index of 2.4 / 5g.

[0069] According to example no. 1 bis, a panel with a density of 40 kg / m³ is considered 3as well as a thickness of 40 mm and an average micron index of 3.3 / 5g.

[0070] Examples #2 and #2 bis of a panel with a density of 50 kq / m³ 3

[0071] According to example #2, a panel with a density of 50 kg / m³ is considered 3 as well as a thickness of 20 mm and an average micron index of 2.6 / 5g.

[0072] According to example no. 2 bis, a panel with a density of 50 kg / m³ is considered 3 as well as a thickness of 40 mm and an average micron index of 4 / 5g.

[0073] Examples #3 and #3 bis of a panel with a density of 60 kg / m³ 3

[0074] According to example #3, a panel with a density of 60 kg / m³ is considered 3 as well as a thickness of 20 mm and an average micron index of 3 / 5g.

[0075] According to example no. 3 bis, a panel with a density of 60 kg / m³ is considered 3 as well as a thickness of 40 mm and an average micron index of 5 / 5g.

[0076] Examples #4 and #4 bis of a panel with a density of 70 kq / m³ 3

[0077] According to example #4, a panel with a density of 70 kg / m³ is considered 3 as well as a thickness of 20 mm and an average micron index of 3.4 / 5g.

[0078] According to example no. 4 bis, a panel with a density of 70 kg / m³ is considered 3 as well as a thickness of 40 mm and an average micron index of 6.3 / 5g.

[0079] Examples #5 and #5 bis of a panel with a density of 80 kq / m³ 3

[0080] According to example no. 5, a panel with a density of 80 kg / m³ is considered 3as well as a thickness of 20 mm and an average micron index of 3.9 / 5g.

[0081] According to example no. 5 bis, a panel with a density of 80 kg / m³ is considered 3 as well as a thickness of 40 mm and an average micron index of 7.5 / 5g.

[0082] Examples #6 and #6 bis of a panel with a density of 90 kq / m³ 3

[0083] According to example no. 6, a panel with a density of 90 kg / m³ is considered 3 as well as a thickness of 20 mm and an average micron index of 4.5 / 5g.

[0084] According to example no. 6 bis, a panel with a density of 90 kg / m³ is considered 3 as well as a thickness of 40 mm and an average micron index of 7.5 / 5g.

[0085] Example #7 of a panel with a density of 100 kg / m³ 3

[0086] According to example no. 7, a panel with a density of 100 kg / m³ is considered 3 as well as a thickness of 20 mm and an average micron index of 5.2 / 5g.

[0087] Example #8 of a panel with a density of 85 kB / m³ 3

[0088] According to example no. 8, a panel with a density of 85 kg / m³ is considered 3 as well as a thickness of 40 mm and an average micron index of 7.5 / 5g.

Claims

Claims

1. Glass wool panel intended to be used as an acoustic panel and having: - a density greater than or equal to 60 kg / m 3 and less than or equal to 80 kg / m 3 , a thickness between 10 mm and 70 mm, and an average micronaire index between 2.4 / 5g and 8.5 / 5g, or - a density strictly greater than 80 kg / m 3 and strictly less than 90 kg / m 3 , a thickness of between 30 mm and 70 mm, and an average micronaire index of between 5 / 5g and 8.5 / 5g, preferably between 5.7 / 5g and 8.5 / 5g, or - a density equal to 90 kg / m 3 , a thickness between 10 mm and 40 mm, preferably between 10 mm and 38 mm, and an average micronaire index between 3 / 5g and 8.5 / 5g, or - density equal to 100 kg / m 3 , a thickness between 10 mm and 30 mm, and an average micronaire index between 3.3 / 5g and 8.5 / 5g.

2. Panel according to claim 1, said panel having a density equal to 60 kg / m 3 , a thickness between 10 mm and 50 mm and an average micronaire index between 2.4 / 5g and 7.1 / 5g.

3. Panel according to claim 2, said panel having: - a thickness equal to 20 mm and an average micronaire index equal to 3 / 5g, or - a thickness equal to 40 mm and an average micronaire index equal to 5 / 5g.

4. Panel according to claim 1, said panel having a density equal to 70 kg / m 3 , a thickness between 10 mm and 50 mm and an average micronaire index between 2.5 / 5g and 7.5 / 5g.

5. Panel according to claim 4, said panel having: - a thickness equal to 20 mm and an average micronaire index equal to 3.4 / 5g, or - a thickness equal to 40 mm and an average micronaire index equal to 6.3 / 5g.

6. Panel according to claim 1, said panel having a density equal to 80 kg / m 3 , a thickness between 10 mm and 50 mm and an average micronaire index between 2.7 / 5g and 7.5 / 5g.

7. Panel according to claim 6, said panel having: - a thickness equal to 20 mm and an average micronaire index equal to 3.9 / 5g, or - a thickness equal to 40 mm and an average micronaire index equal to 7.5 / 5g.

8. Panel according to claim 1, said panel having a density equal to 90 kg / m 3 as well as : - a thickness equal to 20 mm and an average micronaire index equal to 4.5 / 5g, or - a thickness equal to 40 mm and an average micronaire index equal to 7.5 / 5g.

9. Panel according to claim 1, said panel having a density equal to 100 kg / m 3 , a thickness equal to 20 mm and an average micronaire index equal to 5.2 / 5g.

10. A panel according to any one of claims 1 to 9, wherein the relative variation in the micronaire index is less than 15%.

11. A method of manufacturing a glass wool panel according to any one of claims 1 to 10.

12. Use of a glass wool panel according to any one of claims 1 to 11 for improving sound absorption within an interior space, said panel being fixed to a wall surface of said interior space, said wall surface being for example a ceiling.