Insulating product for a building element comprising a cavity

Abstract

The present invention relates to a thermal and / or acoustic insulation product for filling a building element comprising two facing walls forming a cavity, the product comprising blown glass wool forming flakes, the product comprising a hydrophobic additive, the hydrophobic additive being a branched and cross-linked organosilicon polymer compound, a median flake size being less than 20 mm.

Description

Title of the invention: Insulating product for a building element comprising a cavity Scope of the 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 building element. It also relates to the process for obtaining the building element. State of the art

[0002] It is known to fill cavities made in building elements, such as walls or parts of walls, with insulating materials, such as mineral wool or foams, inorganic (e.g. cement foams) or organic (e.g. polyurethane foams).

[0003] These various 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 degradation of thermal insulation performance. These homogeneity defects can occur over time or during the transport of building 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 "clogging" phenomenon, i.e., non-linear blockage, frequently occurs in the nozzle during the injection of the product. Description of the invention

[0004] An object of the invention is to propose a solution to overcome these disadvantages and to manufacture a building element exhibiting an overall thermal conductivity lower than that of known building elements, thanks to a better homogeneity of the cavity filling.

[0005] This objective is achieved within the framework of the present invention by means of a thermal and / or acoustic insulation product for filling a building element comprising two facing walls so as to form a cavity, the product comprising blown glass wool forming flakes, - the product comprising a hydrophobic additive, the hydrophobic additive being a branched and cross-linked organosilicon polymer compound, and - a median flake size being less than 20 mm.

[0006] The present invention is advantageously complemented by the following features, taken individually or in any of their technical combinations: only possible:

[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 shaker 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 at 2.85 mm, for 5 minutes, wherein: - a mass percentage of flakes remaining on the 25 mm sieve is less than 5% by mass, preferably less than 3% by mass and - a mass percentage of flakes remaining on 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 between 4 L / min and 7 L / min, in particular between 5.5 L / min and 6.5 L / min,

[0010] - the product exhibits 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 includes a dust-suppressing additive, the dust-suppressing additive comprising a hydrocarbon oil,

[0012] - a mass percentage of an antistatic additive is less than 0.2%, the product being pre preferentially devoid of an antistatic additive,

[0013] - the product has a density of less than 15 kg / m3, preferably less than 13 kg / m3,

[0014] - the product exhibits an air resistance greater than 2500 Pa.s / m2, and preferably greater than 3000 Pa.s / m2.

[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 building element according to an embodiment of the invention.

[0017] Another aspect of the invention is a method for obtaining a construction element comprising two facing walls so as to provide at least one cavity filled by a product according to an embodiment of the invention, the method comprising a step in 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 includes 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 the figures

[0020] Other features, objectives and advantages of the invention will become apparent from the following description, which is purely illustrative and not limiting, and which should be read in conjunction with the accompanying drawings on which:

[0021] [Fig-1] - [Fig.1] schematically illustrates a construction element according to a method of embodiment of the invention,

[0022] [Fig.2] - [Fig.2] illustrates a cumulative distribution of the mass proportion of different sizes of product flakes according to embodiments of the invention,

[0023] [Fig.3] - [Fig.3] is a photograph taken by a scanning electron microscope of a different product of the invention,

[0024] [Fig.4] - [Fig.4] is a photograph taken by a scanning electron microscope of a product according to an embodiment of the invention,

[0025] [Fig.5] - [Fig.5] illustrates the variation in the relative size of the flakes of a product according to an embodiment of the invention with the micron of the product,

[0026] [Fig.6] - [Fig.6] illustrates the variation of 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 bear identical references. Definitions

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

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

[0030] In this application, the fineness of mineral wool fibers is determined by their micronaire value, under 5g. The micronaire, also called the "fineness index," is representative of the specific surface area of ​​the fibers. The micronaire measurement 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, is standardized (DIN 53941 and ASTM D 1448 standards), and uses an apparatus known as a "micronaire apparatus." 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 [Fig. 1], one aspect of the invention is a thermal and / or acoustic insulation product 1 for filling a building element 2. The building element 2 comprises two facing walls 3 such that Forming a cavity 4. Product 1 comprises blown glass wool in the form of flakes. The product includes a hydrophobic additive. The hydrophobic additive is a branched and cross-linked organosilicon polymer compound. A median flake size is less than 20 mm, in particular less than 18 mm and preferably less than 15 mm. Preferably, a median flake size can be between 5 mm and 20 mm and preferably between 7 mm and 18 mm. The inventors discovered that a flake size within the aforementioned ranges, in combination with the aforementioned hydrophobic additive, surprisingly allows for both more homogeneous filling of a cavity by injection than with known insulation products, thus avoiding the formation of thermal bridges in the cavity, and avoiding the clogging problems encountered when injecting known products through a nozzle.

[0033] One of the walls of the construction element may include an orifice 6. Thus, it is possible to insert a nozzle 5 into the cavity 4 to blow a non-blown product in order 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] Measurement of flake size

[0035] The median size of glass wool flakes can be measured using the method described below. The principle of the measurement consists of vibrating a stack of sieves of different diameters and sorting the resulting flakes according to their size. A sieve is a grid of varying mesh size, used to sort flakes, fixed to a frame. The sieves are vibrated using a sieve shaker, which is a vibrating device on which the sieves are mounted. 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 holes), and an automatic sieve shaker, for example, a Retsch Sieve Shaker 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 container 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 the product are weighed into the plastic beaker. The sieves are stacked from smallest mesh (6 mm) to 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 area as possible is covered to prevent large flakes from blocking the smaller ones. A lid is placed and tightened on the stack of sieves. The sieve shaker is run for a measurement time of 5 minutes. The resulting material on each sieve is weighed once the vibration cycle is complete. The percentage... The mass fraction 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 shaker consists of 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 ideally at 2.85 mm. The vibration cycle lasts five minutes. To obtain the desired oscillation amplitude, the power of the sieve shaker is adjusted. For example, the power of the sieve shaker is set to 65% when four sieves are used and between 45% and 65% when seven sieves are used to obtain the same level of vibration.

[0036] The results are expressed as mass percentages per sieve. Five measurements are taken with new samples for the same product. With reference to [Fig. 2], cumulative mass distributions are shown 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 with a median size of 9.25 mm, and curve (b) shows, for example, a different product according to an embodiment of the invention comprising flakes with a median size of 11.70 mm.

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

[0038] [Tables] Sieve size < 6 mm [6 mm; 13 mm [ [13 mm; 19 mm [ [19 mm; 25 mm [ 25 mm Mass percentage - sample #1 12% 54% 32% 2% 0% Mass percentage - sample #2 13% 36% 51% 0% 0% Mass percentage - sample #3 14% 47% 34% 5% 1% Mass percentage - sample #4 14% 44% 43% 0% 0% Mass percentage - sample #5 0% 55% 32% 0% 0% Average mass percentages 10% 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 shaker 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 at 2.85 mm, for five minutes, wherein: - a mass percentage of flakes remaining on 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 on the 19 mm sieve of less than 10% by mass, preferably less than 3% by mass.

[0040] Micronaire of the insulation product

[0041] The product can have a micronaire 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 decrease in the micronaire of product 1 within the aforementioned range makes it possible to obtain a flake size within the aforementioned range while also increasing the homogeneity of product 1 installed in cavity 4 compared to a known product installed in the same cavity. With reference to [Fig. 5], the relative size of the flakes decreases with a decrease in the micronaire of the product.

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

[0043] With reference to [Fig. 6], the product may have an air resistance greater than 2500 Pa.s / m², in particular greater than 3000 Pa.s / m² and preferably greater than 3500 Pa.s / m². Product 1 may have a density less than 15 kg / m³ and preferably less than 13 kg / m³.

[0044] Hydrophobic additive

[0045] The hydrophobic additive is a branched and cross-linked 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 in such a way 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 product installation.The inventors discovered that a flake size within the aforementioned range, in combination with the hydrophobic additive comprising a branched and cross-linked organosilicon polymer compound, surprisingly allowed both a more homogeneous filling of a cavity by injection than with known insulation products, thus avoiding the formation of thermal bridges in the cavity, and also avoiding the "clogging" problems encountered when injecting the product through a nozzle.

[0046] Figure 3 illustrates a photograph taken by a scanning electron microscope of a product different from a product according to an 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 pm. Figure 4 illustrates a scanning electron microscope photograph of a product according to an embodiment of the invention, comprising a hydrophobic additive, the hydrophobic additive comprising a branched and cross-linked organosilicon polymer. The scale bar corresponds to a length of 4 pm.

[0047] The product may be free of a hardener suitable for polymerizing the polymer compound. Thus, it is possible to simplify the manufacturing process by using the heat emitted by the glass wool after its production 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] Dust suppressant additive

[0049] Product 1 may include a dust suppressant additive. A dust suppressant additive is known to limit dust emissions from product 1 during its application, thereby increasing the installer's comfort during installation. Product 1 may include a dust suppressant additive comprising a hydrocarbon oil. This makes it possible to limit or prevent cyclosiloxane emissions, which are possible when using known dust suppressant additives comprising Si-O chains. The inventors discovered that a dust suppressant additive comprising a hydrocarbon oil is compatible with the injection of the product through a nozzle into a cavity 4 without causing the nozzle to clog. The hydrocarbon oil may be a commercially available oil such as Finavestan A 100B, marketed by Total (registered trademark).

[0050] Antistatic additive

[0051] The mass percentage of antistatic additive in product 1 may be less than 0.2%. Product 1 may be free of an antistatic additive, in particular an antistatic additive other than the organosilicon compound, the organosilicon compound not being an antistatic additive. Thus, the resistance to airflow may be increased compared to the same product containing an antistatic additive. With reference to [Fig. 6], point (c) illustrates a product 1 free of an antistatic additive other than the organosilicon compound and point (d) illustrates the same product containing an antistatic compound other than the organosilicon compound, of the "Momar" type.

[0052] Loss in fire

[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 in percentage of the product's mass before calcination. Thus, it is possible to maximize the thermal insulation of the blown product while avoiding the aforementioned drawbacks of the prior art. To this end, the mass percentage of the organosilicon compound can be adjusted so that the product's loss on ignition is between 0.1% and 1.5%, and specifically 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 glass comprises a spinning plate and a basket. A stream of molten glass is poured into the shaft of a hollow shaft. The molten glass is received at the bottom of a basket. The rotation of the basket directs the molten glass onto the peripheral part of the basket, which is perforated by a plurality of orifices. Under the effect of centrifugation, the material is projected onto an inner face of a peripheral wall of the centrifuge, which also has a plurality of orifices. The material passes through these orifices and is projected in the form of filaments outside the centrifuge. An annular burner, arranged near the orifices, emits a gas jet that stretches the filaments and thus forms 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, allows control of the fiber fineness.

[0056] The fiber yield 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 yield per orifice of a plate per day can be between 0.30 kg / day and 0.8 kg / day, in particular between 0.4 kg / day and 0.7 kg / day.

[0057] 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.

[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 stroke of the centrifugation device 2 varies with the diameter of the plate.

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

[0060] The distance between the centers of adjacent orifices can be between 0.8 mm and 2 mm. This distance can vary by less than 10%, and preferably by less than 3%. The distance between the centers of adjacent orifices can decrease in one direction. oriented towards the lower part of the plate.

[0061] The manufacturing process may then include a step of recovering the mineral fibers on a conveyor belt. Following the recovery step, the manufacturing process may include a fiber grinding step. The fiber grinding step allows control of the flake size. The fiber grinding step includes passing the fibers through a knife mill and then through a screen selector. It is possible to select the screen size to obtain a flake size within the product range, all other parameters being constant.

[0062] The manufacturing process for the product then includes a step of blowing the previously obtained product, carried out 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 include an orifice 6 passing through the wall. The nozzle 5 is then positioned in the orifice 6 during the blowing process. It may be positioned partially in the orifice or fully 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 an area to inject the unblown product.

Claims

Demands

1. Product (1) for thermal and / or acoustic insulation for filling a building element (2) comprising two facing walls (3) forming a cavity (4), product (1) comprising blown glass wool in the form of flakes, product (1) being characterized in that: - product (1) comprises a hydrophobic additive, the hydrophobic additive being a branched and cross-linked organosilicon polymer compound, and - a median flake size of less than 20 mm.

2. Product (1) according to claim 1 wherein 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 any one of claims 1 to 2, having a mid-cycle between 4 L / min and 7 L / min.

4. Product (1) according to any 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 any one of claims 1 to 4, comprising a dust suppressant additive, the dust suppressant additive comprising a hydrocarbon oil.

6. Product (1) according to any one of claims 1 to 5, wherein a mass percentage of an antistatic additive is less than 0.2%, the product preferably being devoid of an antistatic additive.

7. Product (1) according to any one of claims 1 to 6, having a density of less than 15 kg / m3, preferably less than 13 kg / m3.

8. Product (1) according to any one of claims 1 to 7, having an air resistance greater than 2500 Pa.s / m2, and preferably greater than 3000 Pa.s / m2.

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

10.

11. A wall comprising a building element according to claim 9. A method for obtaining a building element (2) comprising two facing walls (3) so as to provide at least one cavity (4) filled with a product (1) according to any one of claims 1 to 8, the method comprising a step in which a non-blown product is blown into the cavity (4) by means of a nozzle (5) so as to

12. manufacture the thermal insulation product. Method according to the preceding claim, wherein one of the two walls comprises a through orifice (6), the nozzle (5) being arranged in the orifice (6).

13. Method according to the preceding claim, wherein the nozzle (6) has an internal diameter of less than 20 mm, in particular less than 15 mm.

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