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

Insulating product for a construction element comprising a cavity Field of invention

[0001] 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. State of the art

[0002] 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).

[0003] These different solutions are not without drawbacks. The filling of cavities with the insulating material is not always homogeneous, leading to the creation of thermal bridges and therefore to a deterioration in thermal insulation performance. These homogeneity defects can occur over time or during the transport of construction elements to the construction site, in the case of prefabricated elements. For example, mineral wool-based materials can tend 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.

[0004] 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.

[0005] This aim is achieved within the framework of the present invention by means of 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 a blown glass wool forming flakes, - the product comprising a hydrophobic additive, the hydrophobic additive being a branched and crosslinked organosilicon polymer compound, and - a median size of the flakes being less than 20 mm.

[0006] The present invention is advantageously supplemented by the following characteristics, taken individually or in any of their technically possible combinations:

[0007] – 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:- a mass percentage of flakes remaining at the 25 mm sieve is less than 5% by mass, preferably less than 3% by mass and- a mass percentage of flakes remaining at the 19 mm sieve is less than 10% by mass, preferably less than 3% by mass,

[0008] - the median size of the flakes is 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,

[0009] – 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,

[0010] – 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,

[0011] – the product comprises an anti-dust additive, the anti-dust additive comprising a hydrocarbon oil,

[0012] - a mass rate of an antistatic additive is less than 0.2%, the product preferably being free of an antistatic additive,

[0013] – the product has a density of less than 15 kg / m 3 , preferably less than 13 kg / m 3 ,

[0014] – the product has a resistance to the passage of air greater than 2500 Pa.s / m 2 , and preferably greater than 3000 Pa.s / m 2 .

[0015] 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.

[0016] Another aspect of the invention is a wall comprising a construction element according to one embodiment of the invention.

[0017] 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 with a product according to an embodiment of the invention, the method comprising a step during which a non-blown product is blown into the cavity by means of a nozzle so as to manufacture the thermal insulation product according to an embodiment of the invention.

[0018] Advantageously, one of the two walls comprises a through orifice, the nozzle being arranged in the orifice.

[0019] Advantageously, the nozzle has an internal diameter of less than 20 mm, in particular less than 15 mm. Description of figures

[0020] 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:

[0021] – schematically illustrates a construction element according to an embodiment of the invention,

[0022] - illustrates a cumulative distribution of the mass proportion of different sizes of product flakes according to embodiments of the invention,

[0023] - is a photograph taken by a scanning electron microscope of a product other than the invention,

[0024] - is a photograph taken by a scanning electron microscope of a product according to an embodiment of the invention,

[0025] – 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,

[0026] – illustrates the variation in the resistance to the passage of air of a product according to an embodiment of the invention with the density of the product.

[0027] Throughout the figures, similar elements have identical references. Definitions

[0028] Air resistance is measured according to international standard EN29053.

[0029] The term "blowing" of mineral wool means blowing as defined by standard EN 14064-1:2007.

[0030] 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 (DIN 53941 and ASTM D 1448 standards) and it uses a device called a "micronaire device". The method for measuring the micronaire is also described in document WO 2003098209. Detailed description of the invention

[0031] General description of the insulation product

[0032] With reference to the, 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 when injecting known products through a nozzle.

[0033] One of the walls of the construction element may comprise an orifice 6. Thus, it is possible to insert a nozzle 5 into the cavity 4 to blow a non-blown product so as to manufacture the product 1. An internal diameter of the orifice 6 may be less than 20 mm and in particular less than 15 mm.

[0034] Measuring the size of the flakes

[0035] The median size of glass wool flakes can be measured using the method described below. The principle of 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 required for this measurement includes a sample of blown wool, 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 "RetschSieveShaker" 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 measuring 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 are weighed into the plastic beaker. The sieves are stacked from the smallest mesh (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. It is important that as much of the surface as possible is covered to prevent large flakes from preventing smaller ones from falling. A lid is placed and tightened over the stack of sieves. The sieve shaker is started for a measurement time of 5 minutes. The resulting material on each of the sieves is weighed after vibration has ended. The mass percentage is calculated by dividing the mass of material on the sieve in question 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 sieve machine power is adjusted. For example, the sieve machine power is set to 65% when using four sieves and between 45% and 65% when using seven sieves to achieve the same vibration level.

[0036] 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 the, 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.

[0037] The table [Table 1] below describes, for example, the result of the mass percentage measurements for five samples of the same product according to one embodiment of the invention, according to the method previously described.

[0038] Sieve size < 6 mm [6 mm ; 13 mm [[13 mm ; 19 mm [[19 mm ; 25 mm [25 mmPercentage by mass - sample n°112%54%32%2%0%Percentage by mass - sample n°213%36%51%0%0%Percentage by mass - sample n°314%47%34%5%1%Percentage by mass - sample n°414%44%43%0%0%Percentage by mass - sample n°50%55%32%0%0%Average of the percentages by mass10%47%38%2%0%

[0039] 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: - a mass percentage of flakes remaining at the 25 mm sieve is strictly less than 5% by mass, preferably strictly less than 3% by mass and - a mass percentage of flakes remaining at the 19 mm sieve less than 10% by mass, preferably less than 3% by mass.

[0040] Micronaire of the insulation product

[0041] The product may have a micronaire of between 4 L / min and 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 the, a relative size of the flakes decreases with a reduction in the micronaire of the product.

[0042] Resistance to air passage & density of the product 1 blown

[0043] With reference to the, the product may have a resistance to the passage of air 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 .

[0044] Hydrophobic additive

[0045] 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 altering its homogeneity. However, known hydrophobic additives are not necessarily compatible with the desired flake size and do not prevent clogging in the nozzle during installation of the product.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.

[0046] 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 µm. 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.

[0047] The product may be free of a hardener suitable for polymerization of 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.

[0048] Anti-dust additive

[0049] The product 1 may comprise a dust-proof additive. A dust-proof additive makes it possible, in a known manner, to limit dust emissions from the product 1 when it is blown, and thus to increase the installation comfort of the installer. A product 1 may comprise a dust-proof additive comprising a hydrocarbon oil. Thus, it is possible to limit or prevent cyclosiloxane emissions, which are possible when using known dust-proof additives comprising Si-O type chains. The inventors discovered that a dust-proof 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).

[0050] Antistatic additive

[0051] A mass rate of antistatic additive in product 1 may be less than 0.2%. Product 1 may be devoid of an antistatic additive, in particular 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, 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.

[0052] Loss on ignition

[0053] 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 disadvantages 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.

[0054] Manufacturing of the insulation product

[0055] Glass fiberization can be carried out by the TEL process, as described in patent EP 0 091 866. 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 near 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.

[0056] The fiber draw per plate orifice per day is equal to the flow rate of molten raw material passing through each orifice per day. The fiber draw per plate orifice per day can be between 0.30 kg / day and 0.8 kg / day, particularly between 0.4 kg / day and 0.7 kg / day.

[0057] The spinner of the centrifugation device may comprise at least 30,000 orifices, for example when the diameter of the spinner is equal to 600 mm. Preferably, the spinner of the centrifugation device may comprise at least 36,000 orifices, for example when the diameter of the spinner is equal to 400 mm.

[0058] The plate of the centrifugation device has a diameter 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.

[0059] The holes are formed and distributed over the drilling strip of the plate. The height of the drilling strip, in the direction of the X axis of rotation of the centrifugation device, is preferably less than 35 mm. The diameter of the holes is between 0.5 and 1.1 mm.

[0060] The distance between the centers of neighboring holes 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 holes may decrease in a direction oriented towards the lower part of the plate.

[0061] 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 fiber grinding step. The fiber grinding step allows the flake size to be controlled. The fiber grinding step involves passing the fibers through a knife mill and then a grid selector. The grid size can be chosen to obtain a flake size within the product range, all other parameters being constant.

[0062] The method for manufacturing the product then comprises a step of blowing the previously obtained product, implemented by blowing the previously obtained product into the cavity 4 by means of a nozzle 5 so as to manufacture the thermal insulation product 1. One of the two walls 3 may comprise an orifice 6 passing through the wall. 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. The nozzle may have an internal diameter of less than 20 mm, in particular 15 mm. Thus, it is not necessary to open the wall over too large a surface area to inject the non-blown product.

Claims

Thermal and / or acoustic insulation product (1) 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 - a median size of the flakes is less than 20 mm. 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. Product (1) according to one of claims 1 to 2, having a micronaire of between 4 L / min and 7 L / min. Product (1) according to one of claims 1 to 3, having a loss on ignition of between 0.1% and 1.5% by mass. Product (1) according to one of claims 1 to 4, comprising an anti-dust additive, the anti-dust additive comprising a hydrocarbon oil. 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 devoid of an antistatic additive. Product (1) according to one of claims 1 to 6, having a density of less than 15 kg / m 3 , preferably less than 13 kg / m 3 . Product (1) according to one of claims 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 . 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. Wall comprising a construction element according to claim 9. 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 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. Method according to the preceding claim, in which one of the two walls comprises a through orifice (6), the nozzle (5) being arranged in the orifice (6). Method according to the preceding claim, in which the nozzle (6) has an internal diameter of less than 20 mm, in particular less than 15 mm.

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