Sustainable material obtained from wool for thermal insulation with bactericidal and fungicidal properties

Abstract

The present invention relates to a bactericidal or fungicidal material for thermal insulation comprising wool or hair / fur fibres. The material is characterised by a concentration of silica nano / microparticles between 0.04545 g / g (4.5% by mass) and 0.18181 g / g (18.2% by mass), or titania nano / microparticles at concentration between 0.0272 g / g and 0.0636 g / g (2.7 % and 6.4 % by mass of titania nano / microparticles, or silica and titania nano / microparticles. The present invention also refers to a process for obtaining the aforementioned material and its use in architecture or civil construction, in particular in optimising the energy efficiency of buildings, and also in technical textiles.

Description

[0001] DESCRIPTION

[0002] SUSTAINABLE MATERIAL OBTAINED FROM WOOL FOR THERMAL INSULATION WITH BACTERICIDAL AND FUNGICIDAL PROPERTIES

[0003] Field of Disclosure

[0004]

[0001] This disclosure falls within the fields of materials engineering, civil engineering, architecture and technical textiles.

[0005]

[0002] This disclosure refers to the development of a new eco-ef f icient thermal insulation product with improved firereaction and bactericidal properties based on the recycling of animal wool / fur fibres (sheep, goat, camel, alpaca, rabbit, vicuna, llama, among others) for use in civil construction of building envelope solutions (e. g. walls and roofs), contributing to improving their energy efficiency and promoting NZEBs (nearly-zero energy buildings), in architectural and technical textile solutions. This solution targets the energy efficiency of new and refurbished buildings and the design of new technical textile products (sleeping bags, duvets, thermal curtains and clothing), relying on recycled waste from the agriculture and livestock sectors. It thus contributes to sustainability and the circular economy, reducing waste and creating value, in line with the European Union' s goal of climate neutrality and decarbonisation.

[0006] Background to the Disclosure

[0007]

[0003] Buildings account for around 40% of energy consumption and 36% of greenhouse gas emissions [ 1, 2 ]. There is therefore a need to implement Nearly-Zero Energy Buildings (NZEBs), i. e. buildings with high energy performance, which is why the use of sustainable thermal insulation is extremelyimportant [3]

[0004] [5]

[0006] . As a result, several European directives and national regulations have been published aimed at improving the thermal resistance of building envelopes and the energy efficiency of buildings.

[0008]

[0004] New thermal insulation materials have been developed due to the key role played by the thermal insulation of the building envelope (walls, floors and roofs) in reducing buildings ' energy consumption for heating and cooling, and consequently their environmental impact

[0007] . Eco-ef f icient materials offer innovative solutions that have been designed and implemented not only in new construction, but also in the thermal rehabilitation of building envelopes, with a particular focus on bio-based materials that contribute to the decarbonisation of the construction life cycle.

[0009]

[0005] The market is currently mainly based on thermal insulation blankets and panels based on inorganic or non-biological organic raw materials which have a high carbon footprint despite their well-known thermal performance and fire resistance due to the reliance on the exploitation of non-renewable resources during the manufacturing process

[0008]

[0009]

[0010]

[0011]

[0012]

[0013]

[0014] .

[0010]

[0006] According to Villasmil et al.

[0015] , the European market for thermal insulation materials is essentially composed of two product groups:

[0011] Inorganic fibres: rock wool and glass wool, representing around 60% of the market.

[0012] Polymeric materials: expanded polystyrene (EPS), extruded polystyrene (XPS) and, to a lesser extent, polyurethane and polyisocyanurate (PUR-PIR), which account for around

[0007] Super-insulating materials also exist, such as vacuum insulation panels (VIP) and silica aerogel, which have a small market share.

[0013]

[0008] Despite the good thermal and acoustic insulation and fire resistance characteristics of mineral wool and rock wool insulation solutions - which result from the fusion of glass, sand and other mineral debris, and volcanic rocks such as limestone and basalt, in high-temperature furnaces, respectively - both are produced through the exploitation of non-renewable resources and require high energy consumption. For this reason, these products are not in line with current sustainability goals. In addition, they may cause some cutaneous and bronchial irritation when handled

[0016] .

[0014]

[0009] Despite their efficient thermal performance, XPS and EPS are heavily penalised by their fossil origin (GWP) and energy-intensive manufacturing process, which results in a large ecological footprint. Furthermore, they generally perform worse than mineral wool solutions with respect to acoustic performance and fire resistance.

[0015]

[0010] In an attempt to reduce the environmental impact caused by the production of the most commonly used insulation blankets, a range of new insulation solutions based on biobased, reusable materials and greener, more efficient production methods have emerged

[0017]

[0018]

[0019] .

[0016]

[0011] In this regard, there is a growing interest among the scientific community in testing a range of bio-based materials, both animal and plant origin, in order to expand the range of insulation solutions available on the market

[0020]

[0021]

[0022]

[0023]

[0024]

[0025] . A study by Cetiner et al.

[0017]

[0026] compares the thermal conductivity of some of these materials with their density, showing that the thermal conductivity values of some of these materials, such as sheep ' s wool and wood fibre, are very similar to those ofthe most commonly used materials. Although cork has excellent thermal properties, its high price, transport costs and low availability are an obstacle to its wider use as an insulating material in civil construction.

[0018]

[0012] Sheep ' s wool has been widely used throughout history, particularly in textile production and had great economic importance in the Mediterranean basin.

[0019]

[0013] The increase in the world population and the growing demand for clothing and insulation solutions have led to a drastic reduction in the importance of sheep ' s wool in global textile production and to a growth in demand for more competitive synthetic fibres (rapid production and low cost)

[0027]

[0028]

[0029] .

[0020]

[0014] In addition to competition from synthetic fibres, some breeds of sheep do not produce wool with characteristics that are valued in the clothing textile sector. Consequently, there is a pressing need to identify alternative applications for recycled sheep' s wool, owing to its relevant properties, particularly in terms of hygrothermal and acoustic performance

[0030]

[0031]

[0032] .

[0021]

[0015] This bio-based product has attracted growing interest in the sustainable construction sector, and there are now several sheep wool-based solutions on the market, including:

[0022] THERMAFLEECE - https: / / thermafleece. com / (with 75% sheep wool fibre and 25% polyester fibres);

[0023] HAVELOCKWOOL - https: / / havelockwool. com / (with 100% sheep wool fibre);

[0024] SHEEPWOOLINSULATION - https: / / sheepwoolinsulation. com / ( 100% sheep wool fibres which have undergone a plasma ion treatment).

[0016] In terms of technical textiles, the following commercial applications were found:

[0025] LAVALAN - https: / / www. lavalan. com /

[0026] GREENFIBRES - https: / / www. greenfibres. com /

[0027] NORSK ULLSÅLE - https: / / www. fredriksens fabrikk. no / WoolCool - https: / / www. woolcool. com /

[0028] FORCLAZ - https: / / www. decathlon. co. uk / sports / hi king / merino -wool - clothing / f-brand_forclaz

[0029] WOOLMARK - https: / / www. woolmark. com / industry /

[0030] Lanaco - https: / / lanaco. co. nz /

[0031]

[0017] The following are patented sheep wool solutions, identi fying the points of distinction in relation to the product developed:

[0032] use of sheep wool in construction solutions for buildings, but without any type of chemical treatment to enhance fire performance and bactericidal ef ficacy (RO133842A2, IES20130086A2, W02009136383A2, RO135991A0, DE4300815A1, EP0606844A1, DEI 9616304A1 );

[0033] - thermal insulation system for buildings made from a mixture of sheep wool and synthetic chemical fibres, a product distinct from the one now developed (RO133841A1, FR2861829A1 );

[0034] thermal insulation system for buildings based on chemically treated sheep wool (RO137299A1 ).

[0035]

[0018] The market is looking for new, more sustainable and low-cost thermal insulation materials that improve the hygrothermal and acoustic characteristics of building envelope, contributing to buildings ' energy ef ficiency and the comfort of occupants. Currently, there is greater concern about sustainabil ity, product li fe cycle, energy consumption and environmental impact, with sheep wool fibres representing a renewable and alternative raw material whichreduces waste and creates value, in line with the European Union' s climate neutrality, decarbonisation and circular economy goals.

[0036]

[0019] In fact, sheep ' s wool has unique characteristics that differentiate it from other materials, such as:

[0037] Reduced thermal conductivity;

[0038] Low density and high porosity, allowing for high sound absorption;

[0039] Sustainability, as it is a 100% bio-based material;

[0040] Hygroscopicity, which makes it a natural thermoregulator, absorbing moisture up to 33% of its weight without altering its properties;

[0041] Fire resistance;

[0042] Easy handling and transport, as it is a malleable and lightweight material.

[0043]

[0020] A study by Satyanarayana et al.

[0033] in Canada investigates sheep ' s wool as a sustainable alternative for insulation blankets. Sheep ' s wool has a higher sound absorption capacity and hygroscopicity than rock wool. Its high fire resistance is also a very important aspect to consider, given the material' s fire-retardant properties

[0034]

[0035]

[0036]

[0037]

[0038]

[0039] .

[0044]

[0021] A study by Altin et al.

[0040] compares the most relevant properties of sheep ' s wool with other thermal insulation materials commonly available on the market. Sheep ' s wool also has another significant advantage over mineral wool, which is that it does not cause cutaneous and / or bronchial irritation when handled.

[0045]

[0022] Considering all the above-mentioned factors, wool and other similar animal fibres are an excellent bio-basedraw material to be studied for use in thermal and acoustic insulation blankets.

[0046]

[0023] For a better understanding of the thermophysical properties of organic fibre materials, Table 1 includes the experimental results for different materials made from natural fibres

[0041] .

[0047] Table 1 Comparison of the measured thermophysical properties of different materials made from natural fibres - adapted

[0041]

[0048]

[0049]

[0024] The results indicate that there are some materials with high potential that could be used in sustainable building construction.

[0050]

[0025] Thermal conductivity is one of the main thermal properties of materials used in construction, which characterises the greater or lesser ease of heat transfer by conduction. The lower the thermal conductivity of the material, the greater its thermal resistance. Sheep ' s wool has a thermal conductivity very similar to rock wool

[0042] . Zach et al.

[0043] evaluated the thermal conductivity of sheep ' s wool for different thicknesses and service temperatures, observing values between 0.034 and 0.050 W / m. K, in the range of conductivity values of the materials most commonly used as insulation blankets.

[0026] Another important characteristic of building materials is their reaction to fire and their ability to prevent the spread of flames

[0044] .

[0051]

[0027] Sheep ' s wool has high fire-retardant properties and can act as a natural flame retardant, as its fibres are non-combustible and can even perform at the same level as mineral wools already on the market, depending on the type of treatment and impregnation

[0086] . Over the years, sheep ' s wool has been used industrially and militarily, with some chemicals incorporated to improve its performance in the presence of fire, such as zirconia and phosphates.

[0052]

[0028] As sheep ' s wool carbonises instead of igniting, it does not contribute to the spread of flames due to the release of nitrogen and is classified as class E. It, therefore, meets the minimum requirements for use as a thermal insulation material.

[0053]

[0029] The hygroscopicity of a material consists of its capacity to absorb and release moisture from the ambient air, depending on the surrounding environmental conditions

[0045] . Sheep ' s wool is extremely hygroscopic, with a high water absorption capacity, and can absorb up to 50% of its original mass. This characteristic makes wool an excellent regulator of the environment inside a building, absorbing excess moisture and releasing it to provide greater indoor environmental comfort

[0046]

[0047] .

[0054]

[0030] In buildings with wooden structure, it helps to maintain low moisture conditions, increasing their lifespan and reducing the risk of fungal colonisation.

[0055]

[0031] Untreated sheep ' s wool has a high moisture absorption capacity, which can be much higher than that of commercially available mineral wool, absorbing up to 23 kg / m3for relative humidity conditions close to 100%.

[0032] In addition to being an excellent thermal insulator, sheep ' s wool also has excellent sound absorption capacity due to its low density and porous structure

[0048]

[0049]

[0050]

[0051] .

[0056]

[0033] Zach et al.

[0043] analysed the sound absorption coefficient of sheep wool in accordance with ISO 10534-1

[0052] . In this study, samples of four different thicknesses measuring 300mm x 300mm were evaluated. Sound absorption tests were conducted in the 1 / 3 octave frequency band ranging from 100 to 3150 Hz.

[0057]

[0034] Sheep wool shows a great capacity to absorb sound waves at high frequencies, to which the human ear is most sensitive, even when not particularly thick. For lower frequencies, the thickness of the sample is more relevant, with a higher sound absorption coefficient for thicker s amp les.

[0058]

[0035] Another study on the acoustic and thermal properties of wool was conducted by Ghermezgoli et al.

[0053] , who characterised wool fibres and performed sound absorption tests, correlating fibre dimensions and porosity with the sound absorption coefficient. The study

[0053] concluded that the finer the fibres, the more porous they will be and, consequently, their porous network will be more complex, which will lead to greater sound absorption capacity.

[0059]

[0036] In the case of Portuguese wool fibres, the Merino and some Bordaleira breeds with the finest fibres are considered to be of 1st quality, while the Churras and some Bordaleira breeds are considered of 2nd quality, as they have thicker fibres and, therefore, a lower sound absorption capacity, although it does not affect the consistency of the compaction or impregnation capacities in blankets.

[0060]

[0037] Several studies

[0054]

[0055]

[0056]

[0057]

[0058]

[0059] compare the biological degradation of sheep ' s wool in adverseconditions, concluding that its hydrophobic surface, the possibility of establishing a high number of hydrogen and disulphide bonds, combined with the presence of other stabilisers such as salts, prevent the development of fungi and moulds.

[0061]

[0038] To assess the biological properties of sheep ' s wool and other natural materials, a study

[0040] conducted biological attack tests under real climatic conditions and in a laboratory environment prone to the development of fungi and moulds, with the introduction of nutrient agar at a temperature of 25°C and relative humidity above 50%. In the samples tested under real climatic conditions, no development of toxic fungi and moulds harmful to health was recorded.

[0062]

[0039] In the samples that were subjected to laboratory conditions prone to the development of fungi and moulds, the development of toxic moulds was observed, more specifically Alternaria, a pathogen that can cause irritation and asthma, among other effects. It is thus necessary to introduce some particles with bactericidal and fungicidal effects that increase the resistance of sheep ' s wool to these attacks.

[0063]

[0040] Table 2 includes some results of the resistance to biological attacks of different natural fibre materials.Table 2 - Results of laboratory tests to assess the resistance properties to biological attacks of various natural materials adapted from

[0040]

[0064] Material Fungal identification Possible risks

[0065] Alternaria Pathogenic, frequent, highly toxic, causes allergies and asthma, skin infections, Sheep' s wool Stachybotrys sinusitis, among others.

[0066] Possibly toxic, causes stachybotryotoxicosis.

[0067] Acremonium Rarely pathogenic, Hyalohyphomycosis, Flax fibre arthritis, osteomyelitis, peritonitis, pneumonia, skin infections, among others. Penicillium ( expansum, toxic, pathogenic, carcinogenic

[0068] Wood fibre

[0069] biverticillata )

[0070] Penicillium toxic, pathogenic

[0071] Hemp fibre

[0072] (biverticillata)

[0073] Alternaria Pathogenic, frequent, highly toxic, causes allergies and asthma, skin infections, Straw fibre

[0074] sinusitis, among others.

[0075] Fusarium Pathogenic, mycotoxicosis

[0076]

[0041] In Portugal, there are three major groups of wool fibres from native breeds - Merino, Bordaleira and Churra -which are subdivided into 16 native breeds, the last of which, " Churra Galega Bragangana Preta", was officially recognised in 2015.

[0077]

[0042] Merino wool is considered to be of excellent textile quality, with commercial value, extremely fine, homogeneous and elastic, with its commercial value increasing in recent years. In Portugal, there are three Merino breeds:

[0078] Merino da Beira Baixa;

[0079] Merina Branca;

[0080] Merina Preta.

[0081]

[0043] Sheep wool considered to be of second quality is essentially wool from the Bordaleira and Churra breeds, which has no significant commercial value and is usually buried and / or burned.

[0044] The National Association of Sheep Breeders of Serra da Estrela (ANCOSE) even states that shearing causes losses to producers (with the estimated cost of shearing around twice the sale value of the wool).

[0082]

[0045] This wool of second quality (i. e. fibres with a diameter generally greater than 27 pm

[0060] ) is of less industrial interest in the textile sector due to its difficulty in handling, rough feel, less uniform appearance, and a colour that is difficult to dye, making it a good candidate for use as thermal insulation in the thermal envelope of buildings or in technical textiles, combining its low cost with low thermal conductivity and high availability of the resource, which has not been properly researched and exploited to date

[0061] .

[0083]

[0046] Currently, there are some applications in Portugal, namely in the Serra da Estrela region, such as the production of ecological blankets and shoes, through the Portuguese burel art, as developed by Burel Factory in Manteigas, which produces various items made from 100% Bordaleira Serra da Estrela and Churra sheep wool. This promotes the sustainability and continued exploitation of these native breeds, keeping the species ' biodiversity alive and preserving ancient techniques such as manual shearing, which causes less suffering to the animal

[0032] . The Bordaleira comprises four breeds:

[0084] Bordaleira de Entre Douro e Minho;

[0085] Campaniça;

[0086] Saloia;

[0087] Serra da Estrela.

[0088]

[0047] The main interest in breeding Bordaleira sheep lies in the sale of meat in the Entre Douro e Minho region and in breeding them for milk and Serra da Estrela cheeseproduction, with the Bordaleira breed being the best dairy breed in the country.

[0089]

[0048] The Saloia breed is also mainly used for meat or milk, and only the Campaniça breed has been used for all three purposes - milk, meat and wool.

[0090]

[0049] The wool fibres of the Bordaleira breeds are slightly less fine and homogeneous than the Merino wool fibres, and slightly finer and more homogeneous than Churra wool fibres, which can sometimes make their commercialisation more complicated

[0061] .

[0091]

[0050] Because of this, shearing and wool are often an expense for producers. Despite this, there has been a change of mindset and an increasing number of companies are using wool for other purposes, such as Ecolā, which specialises in blankets made from 100% Bordaleira wool.

[0092]

[0051] The Churra breed is mainly raised for its meat, given that the wool produced has certain characteristics that make it less attractive for use in clothing, as its fibres are thicker and longer, and also less uniform. The Churra comprises the following nine breeds, out of the 16 that exist in Portugal

[0061] :

[0093] Churra Algarvia;

[0094] Churra Badana;

[0095] Churra da Terra Quente;

[0096] Churra do Campo;

[0097] Churra do Minho;

[0098] Churra Galega Mirandesa;

[0099] Churra Galega Bragançana Branca;

[0100] Churra Galega Bragançana Preta.There are some cases, such as the Churra Galega Mirandesa breed, where the wool from the sheep is used in clothing for people in the region and in handicrafts.

[0101]

[0052] The inventors of this disclosure, contrary to what is accepted in the state of the art, suggested that the wool fibres from these second-quality breeds would be good candidates for use as the main raw material in the production of thermal insulation blankets for buildings and technical textiles. Many of the breeds in this group are endangered due to the abandonment of rural life and the ageing population.

[0102]

[0053] These facts are disclosed in order to highlight the problem solved by the disclosure.

[0103] Summary of the Disclosure

[0104]

[0054] This disclosure refers to the development of a new eco-ef f icient thermal insulation product with improved fire-resistant and bactericidal / fungicidal properties, based on the recycling of animal wool / fur (sheep, goat, camel, alpaca, rabbit, vicuña, llama, among others) subj ect to mechanical and chemical treatments, for application in civil construction in NZEBs (nearly-zero energy buildings) and in architectural and technical textile solutions. This solution targets the energy efficiency of new and refurbished buildings and the design of new technical textile products such as sleeping bags, duvets or thermal curtains and is based on the recycling of waste from the agriculture and livestock sectors. In this way, it contributes to sustainability and the circular economy, reducing waste and creating value, in line with the European Union' s goal of climate neutrality and decarbonisation.

[0105]

[0055] A case study is presented on the use of native sheep' s wool in Portugal, some of which has no significantcommercial value and is not commonly used and is subsequently incinerated and / or buried.

[0106]

[0056] In a first stage, after shearing the sheep ' s wool, the usable parts are separated from those that are damaged (e. g. matted, dirty, damp, a combination of these characteristics or any others that make them unusable) and the wool fibres are washed with hot water and potassium carbonate or soap in a process that aims to remove animal and plant residues and dissolve the lanolin. The wool fibres are then subjected to a process of drying, opening and untangling so that the wool fibres can be carded and thus organised and oriented in parallel, resulting in a blanket.

[0107]

[0057] In one embodiment, in a subsequent stage, the wool fibre blankets are sprayed (at ambient temperature and pressure) with sol-gel precursors of metal oxides and / or sodium silicate solution (SSS ) which, after sol-gel reactions, give rise to the respective ceramic oxides. While the refractory elements (silica and / or titania) improve the fire reaction properties, the photoactive element (titania) plays a bactericidal / fungicidal role.

[0108]

[0058] In one embodiment, this innovative technological solution is based on spray impregnation with and / or titania precursors which, through sol-gel processes using hydrothermal water as a catalyst, produce silica and titania in a more sustainable way.

[0109]

[0059] This technology can be implemented in industry and scaled up, even in regions / countries with fewer resources, contributing to a circular economy.

[0110]

[0060] This solution meets United Nations goals 7, 11 and 13 and the market demand for more natural thermal insulation solutions, contributing to the development of the local economy, reducing the ecological footprint and improving buildings' energy efficiency and indoor comfort conditions.

[0061] This disclosure emphasizes the value and potential applications of wool of lower quality for textile manufacturing, thus increasing the possibility of extracting economic value from this type of wool, avoiding waste and promoting interest in the production and maintenance of native breeds

[0062] .

[0111]

[0062] In a preferred embodiment of the present invention relates to a bactericidal or fungicidal material for thermal insulation comprising wool or hair / fur fibres, the material characterised by its comprisal of silica nano / microparticles in a concentration between 0.04545 g / g (4.5% by mass) and 0.18181 g / g ( 18.2% by mass), preferably between 0.058 g / g and 0.1015 g / g (5.8 % and 10.2 % by mass), or titania nano / microparticles at concentration between 0.0272 g / g and 0.0636 g / g (2.7 % and 6.4 % by mass), preferably 0.0518 g / g (5.2 % by mass), or silica and titania nano / microparticles.

[0112]

[0063] An additional embodiment of the present invention relates to a material characterised by comprising silica and titania nano / microparticles, wherein the silica concentration is between 0.036 and 0.073 g / g, preferably 0.058 g / g (5.8 % by mass), and the concentration of titania is between 0.027 and 0.063 g / g, preferably 0.0518 g / g (5.2 % by mass).

[0113]

[0064] In an additional embodiment, the present invention relates to a material characterised in that the fibre matrices are obtained from sheep, goats, camels, alpacas, rabbits, vicunas or llamas.

[0114]

[0065] In a further embodiment, the present invention relates to a thermal insulation blanket characterised by comprising the material of any of the previous forms.

[0115]

[0066] In a further embodiment, the present invention relates to a material comprising the material of any of the previous forms.

[0067] In a further embodiment, the present invention relates to a textile material according to the previous form characterised by being a sleeping bag, a duvet, an insole, a thermal curtain or a garment, in particular personal protective equipment garments or technical and sports garments.

[0116]

[0068] In a further embodiment, the present invention relates to a building material characterised by the comprisal of the material of any of the previous forms, preferably for thermal insulation of buildings for walls, floors or roofs, or for interior architecture, in particular wall, ceiling or floor coverings for buildings.

[0117]

[0069] In a further embodiment, the present invention relates to a process for obtaining the material of the present invention, characterised by the following steps: i) obtaining a fleece of wool or hair / fur from sheep, goats, camels, alpacas, rabbits, vicuñas or llamas; ii) selecting the parts to be used and discarding the parts of the fleece with damaged or dirty fibres; iii) washing the animal fibres of the fleece with hot water and potassium carbonate and / or soap, with optional repetition of step iii; iv) drying; v) opening and carding the animal fibres, manually or mechanically, to untangle them and arrange them in parallel, resulting in a blanket; vi) spraying the blanket with sodium silicate solution (SSS) or sol-gel silica or titania precursors or both and hydrothermal water as an eco-catalyst.

[0118]

[0070] In an additional embodiment, the present invention relates to a process for obtaining the material of the present invention, characterised in that the spraying is carried out at ambient temperature and pressure.

[0119]

[0071] In an additional embodiment, the present invention relates to a process for obtaining the material of thepresent invention, characterised in that the metal alkoxides are sol-gel precursors of metal oxides.

[0120]

[0072] In a further form, the present invention relates to the use of the material of the present invention in architecture or civil construction, in particular in optimising the energy efficiency of buildings.

[0121]

[0073] In a further form, the present invention relates to the use of the material of the present invention in technical textiles.

[0122] Description of the Figures

[0123]

[0074] The following figures provide preferred forms of the disclosure and should not be understood as limiting its scope.

[0124]

[0075] Figure 1 shows the results of small flame reaction tests according to ISO-11925-2

[0064] on samples in natural state and impregnated wool fibres. Small flame reaction to fire test ( ISO-11925-2

[0064] ) of samples of wool fibres in their natural state and impregnated (M- Merino; C- Churra; S- Saloia; B- Bordaleira; R- Rock wool (reference); MSc2, p, MSc3, p - Merino impregnated by spraying with silica (concentration c2 of 0.1015 g / g and c3 of 0.058 g / g); MTc2, p - Merino impregnated by spraying with titania (concentration c2 of 0.0518 g / g); MSc3Tc2, p - Merino impregnated by spraying with silica (concentration c3 of 0.058 g / g) and titania (concentration c2 of 0.0518 g / g).

[0125]

[0076] Figure 2 illustrates the results of biological attack resistance tests on samples in natural state and impregnated wool fibres. Testing the resistance to biological attack in samples of wool fibres in their natural and impregnated states (M- Merino; MSc2, p, MSc3, p - Merino impregnated by spraying with silica (concentration c2 and c3); MTc2, p - Merino impregnated by spraying with titania(concentration c2 ); MSc3Tc2, p - Merino impregnated by spraying with silica (concentration c3) and titania (concentration c2 ).

[0126] Detailed Description of the Disclosure

[0127]

[0077] This disclosure presents a case study on the use of native sheep wool in Portugal.

[0128]

[0078] This disclosure refers to an innovative and ecoefficient thermal insulation product that incorporates silica and / or titania nano / microparticles with a diameter preferably less than 400 nm in wool / animal hair / fur fibre matrices (sheep, goat, camel, alpaca, rabbit, vicuña, llama, among others) with the purpose of improving reaction to fire and bactericidal / fungicidal properties.

[0129]

[0079] The wool / hair fibres result from the recycling of low commercial value agricultural waste such as animal fibres from sheep, goats, camels, rabbits, alpacas, vicuñas, llamas, among others, for the preparation of new thermal insulation materials to be used in civil construction and architecture: in the envelope of new and renovated buildings or in technical textiles such as sleeping bags, duvets, insoles, thermal curtains or clothing.

[0130]

[0080] The example presented in this disclosure is based on the use of wool from sheep native to Portugal (such as the Merino, Bordaleira and Churra breeds) for the production of thermal insulation batts.

[0131]

[0081] In one embodiment, a process for using and treating sheep ' s wool is disclosed, which begins with obtaining the wool in a single piece, the fleece. This is followed by the selection and elimination of parts of the fleece with damaged, dirty or matted fibres due to the animal ' s excrement.

[0082] The next step is to wash the wool, which is important for removing animal and plant residues, including lanolin, a natural fat released through the animal ' s pores. This should be done with hot water and potassium carbonate and / or soap, washing as many times as necessary.

[0132]

[0083] After washing, the wool is dried, optionally opened and then carded so that its fibres align without being cut or damaged

[0033] .

[0133]

[0084] The wool can be carded manually or mechanically, a step that promotes the separation of fibre clumps, turning them into a blanket of wool fibres with fibres orderly and parallel to each other.

[0134]

[0085] In a subsequent stage, the blankets of wool fibres are sprayed, preferably at ambient temperature and pressure, with metal alkoxides, preferably sol-gel precursors of metal oxides and / or sodium silicate solution (SSS) which, after hydrolysis and condensation, give rise to the respective ceramic oxides ( such as: SiCh, TiCh, ZnO, AI2O3). While the refractory elements improve the fire reaction properties, the photoactive elements play a bactericidal / fungicidal role (TiO2 and ZnO).

[0135]

[0086] This innovative technological solution is based on manual or automatic spray impregnation with sodium silicate solution (SSS) at a concentration between 0.04545 g / g (4.5% by mass) and 0.18181 g / g ( 18.2% by mass), preferably between 0.058 g / g and 0.1015 g / g (5.8 % and 10.2 % by mass) or titania nano / microparticles at concentration between 0.0272 g / g and 0.0636 g / g (2.7 % and 6.4 % by mass), preferably 0.0518 g / g (5.2 % by mass) of titania nano / microparticles or both, preferably with a concentration of 0.058 g / g (5.8 % by mass) of silica and 0.0518 g / g (5.2 % by mass) of titania, which, through sol-gel processes using hydrothermal water asa catalyst, produces silica and titania in a more sustainable way.

[0136]

[0087] Spray impregnation has the advantage of allowing the particles to be applied without altering the dimensions of the sample. The proposed technology is easy to implement and scale-up, even in regions / countries with fewer resources, contributing to a circular economy and address regional imbalances.

[0137]

[0088] The thermophysical properties of the product described in this disclosure were analysed using a stationary heat flow meter (HEM) method (in accordance with standards ISO 8301

[0063] , NP EN 12667

[0064] , ASTM C518

[0065] ) and a modified transient plane source (MTPS) method (according to standards ASTM D5334

[0066] and ASTM D5930

[0067] ) for sheep wool blankets in their natural state and impregnated with silica, titania and both. Additionally, a commercial rock wool blanket sample was also analysed and used as a reference for comparison purposes.

[0138]

[0089] Table 3 shows the thermophysical properties (density, p; thermal conductivity, X; volumetric specific heat, Cp; and thermal diffusivity, a) of natural and silica-and titania-impregnated wool fibres. A thermal conductivity (X) value of 0.043±0.001 (W.m-1K-1), specific volumetric heat (Cp) of 0.1523 ±0.017 (x106J.m-3K-1) and a thermal diffusivity (a) of 0.288 ±0.028 (xl0~6m2. s-1) for wool fibres from the Merino, Churra, Saloia and Bordaleira breeds in their natural state. Impregnation with silica, titania or silica and titania did not significantly alter the value of these properties (changes of between 0-1% in thermal conductivity, between 0-18% in volumetric specific heat and between 1.75-17% in thermal diffusivity). The thermophysical property values recorded for the wool fibres are close to those observed for a commercial rock wool blanket ( 0.042 W.nr1K-1thermal conductivity, 0.129 J.m-3K-1volumetric specific heat and 0.2810 m2.s-1thermal diffusivity), used as a reference.

[0139] Table 3 - Summary of thermophysical properties (density, p; thermal conductivity, X; volumetric specific heat, Cp; and thermal diffusivity, a) of samples of wool fibres in their natural state and impregnated

[0140] p Cp st dev A, st dev a st dev T Sample

[0141] [kg.m-3] [xl06J.m“3K-1] [%] [%] [xlO’WK-1] [%] [ °C] M 33.15 0.1395 2.65 0.0425 1.15 0.3131 2.39 33.89 (P rd C 19.51 0.1696 0.78 0.0440 0.69 0.2596 0.82 33.22 S 17.54 0.1347 1.47 0.0422 0.31 0.3166 1.35 33.21 rd 2 B 14.85 0.1655 1.66 0.0434 0.59 0.2627 1.64 35.08 rdZR 78.42 0.129 1.59 0.0418 0.33 0.281 1.37 31.67

[0142] 32.73 0.1395 1.51 0.0426 0.66 0.3076 0.22 31.97 MSc3,p36.47 0.1651 2.24 0.0425 0.25 0.2598 1.30 32.82 C

[0143] MTc2,p59.66 0.1279 2.01 0.0428 0.59 0.3058 0.91 32.00

[0144] 27.51 0.1533 1.65 0.0429 0.38 0.3092 2.03 31.67 Note: M- Merino; C- Churra; S- Saloia; B- Bordaleira; R- Rock wool ( control ); Msc2,p, MSC3,p - Merino impregnated by spraying with silica ( concentration c2 and c3); - Merino impregnated by spraying with titania ( concentration c2 );

[0145] - Merino spray- impregnated with silica ( concentration c3) and titania ( concentration c2 ); T - average test temperature ( °C); st dev - standard

[0146]

[0147] deviation.

[0148]

[0090] The fire reaction tests were carried out according to the small flame test specifications of ISO-11925-2

[0068] , at an average temperature of 22°C and relative humidity of 55.8% and air velocity in the exhaust chamber chimney of 0.72 m / s.

[0149]

[0091] Table 4 shows the fire reaction results for sheep wool in its natural state and when impregnated. The results obtained for the samples in their natural state fall into Euroclass E (with flame spread between 101 and 142 mm), except for the Saloia and Bordaleira breeds, which fall into a lower Euroclass (F, with flame spread greater than 150 mm), with flame initiation at 2 seconds for all samples. The reference sample of rock wool also obtained a fire reactionEuroclass E. Impregnation with silica, titania or silica / titania reduced flame spread by 70%, 60% and 65%, respectively, compared to the samples in their natural state, in accordance with the refractory nature of these ceramic oxides.

[0150] Table 4 - Fire reaction of natural and impregnated wool fibre samples Extinguishme, Instant when nt: Flame „, Ignition,,..,. the flame Sample, technician spread in, Category time ( s ) g exceeds 150

[0151] (T); test 20s (mm),, s amp 1 3 e ( P )1X1111Is) J[] M 2 P 142 - E C 2 P 101 - E H S 1 P >150 9 F d B 2 P >150 12 F R 0 - 0 - E o MSc2,p 2 P 42 - E £ Msc3,p 1 P 55 - E MTC2,P1 P 60 - E MSc3Tc2,p 1 P 30 - E Note: M- Merino; C- Churra; S- Saloia; B-Bordaleira; R- Rock wool ( control ); Msc2,p, MSC3,p - Merino impregnated by spraying with silica ( concentration c2 and c3); MTc2,p- Merino impregnated by spraying with titania ( concentration c2 ); MSC3TC2, P ~ Merino impregnated by spraying with silica ( concentration c3) and

[0152]

[0153] titania ( concentration c2 ).

[0154]

[0092] To analyse the bactericidal properties of the products developed, Aspergillus (as a model for the filamentous fungi group) and Candida (as a model for the yeast-like fungi group) were tested in agar culture medium. An efficacy of 83% was observed for wool blankets impregnated with silica, 89% for blankets impregnated with titania, and 94% for blankets impregnated with both silica and titania, as a result of the formation of reactive oxygen species (ROS) by the titania semiconductor.

[0155]

[0093] In one embodiment, the developed product, wool fibre blankets impregnated with silica, titania and silica / titania micro / nanoparticles, showed superior bactericidal / fungicidal and fire reaction performancecompared to non-impregnated blankets, without compromising their thermal and energy performance.

[0156]

[0094] The present disclosure, being produced at room temperature, without heat treatment, easy to implement and scale, meets the United Nations ' goals 7, 11 and 13 and the market demand for more bio-based thermal insulation solutions, contributing to the development of the local economy, reduction of regional imbalances and the ecological footprint, and improvement of buildings' energy efficiency and indoor comfort conditions.

[0157]

[0095] As will be apparent to an expert in the field, the present disclosure should not be limited to the forms of the invention described herein, as various modifications are possible that remain within the scope of the present disclosure.

[0158]

[0096] Of course, the preferred modes presented above can be combined in different ways, and we will not repeat all these combinations here.

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Claims

CLAIMS1. Bactericidal or fungicidal material for thermal insulation comprising wool or hair / fur fibres, the material characterised by comprising silica nano / microparticles at a concentration between 0. 04545 and 0. 18 181 g / g ( 4. 5 % and 18. 2 % by mas s ), preferably between 0.058 g / g and 0.1015 g / g ( 5. 8 % and 10. 2 % by mas s ) or titania nano / microparticles at a concentration between 0.0272 and 0.0636 g / g (2.7 % and 6.4 % by mass), preferably 0.0518 g / g (5.2 % by mass) or silica and titania nano / microparticles.

2. Material according to the previous claim characterised by comprising silica and titania nano / microparticles, wherein the silica concentration is between 0.036 and 0.073 g / g, preferably 0.058 g / g (5.8 % by mass) and the titania concentration is between 0.027 and 0.063 g / g, preferably 0.0518 g / g (5.2 % by mass).

3. Material according to any of the preceding claims characterised in that the fibre matrices are obtained from sheep, goat, camel, alpaca, rabbit, vicuña or llama.

4. Thermal insulation blanket characterised by comprising the material of any of the preceding claims.

5. Textile material characterised by comprising the material of any of the preceding claims.

6. Textile material according to the previous claim characterised in that it is a sleeping bag, a duvet, an insole,a thermal curtain or a clothing, in particular for personal protective clothing or technical and sports clothing.

7. Building material characterised by comprising the material of any of claims 1-3, preferably for the building thermal envelope for walls, floors or roofs, or for interior architecture, in particular building wall, ceiling or floor finishes.

8. Process for obtaining the material of any one of claims 1-3, characterised by comprising the following steps:( i ) obtaining a fleece made from the wool or hair / fur of sheep, goats, camels, alpacas, rabbits, vicuñas or llamas;ii ) selecting the parts for use and eliminating the parts of the fleece with damaged or dirty fibres;iii ) washing the animal fibres of the fleece with hot water and potassium carbonate and / or soap, with optional repetition of step iii;iv) drying;v) opening and carding the animal fibres, manually or mechanically, in order to untangle them and arrange them in parallel, giving rise to a blanket;vi ) pulverising the blanket with sol-gel precursors of silica, titania or both and hydrothermal water as an eco- catalyst or, optionally, with a sodium silicate solution ( SSS ).

9. Process according to the previous claim, characterised by the spraying being carried out at room temperature and pressure.

10. Process according to claim 8, characterised by the metal alkoxides being sol-gel precursors of metal oxides.

11. Use of the material according to claims 1-3 characterised by its application in building architecture or construction, in particular for optimising the energy efficiency of buildings.

12. Use of the material according to claims 1-3 characterised by its application in technical textiles.

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