WO2023161663A2 - Procédé arid de matériau - Google Patents

Procédé arid de matériau Download PDF

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Publication number
WO2023161663A2
WO2023161663A2 PCT/GB2023/050453 GB2023050453W WO2023161663A2 WO 2023161663 A2 WO2023161663 A2 WO 2023161663A2 GB 2023050453 W GB2023050453 W GB 2023050453W WO 2023161663 A2 WO2023161663 A2 WO 2023161663A2
Authority
WO
WIPO (PCT)
Prior art keywords
fibres
insulation
base material
composite material
wood fibres
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/GB2023/050453
Other languages
English (en)
Other versions
WO2023161663A3 (fr
Inventor
Mike JACOB
Simon CURLING
Graham ORMONDROYD
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kiss House Ltd
Original Assignee
Kiss House Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kiss House Ltd filed Critical Kiss House Ltd
Priority to EP23721439.0A priority Critical patent/EP4493372A2/fr
Publication of WO2023161663A2 publication Critical patent/WO2023161663A2/fr
Publication of WO2023161663A3 publication Critical patent/WO2023161663A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/007—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and at least partly composed of recycled material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/06—Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/10—Moulding of mats
    • B27N3/12—Moulding of mats from fibres
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00—Silicon; Compounds thereof
    • C01B33/113—Silicon oxides; Hydrates thereof
    • C01B33/12—Silica; Hydrates thereof, e.g. lepidoic silicic acid
    • C01B33/14—Colloidal silica, e.g. dispersions, gels, sols
    • C01B33/157—After-treatment of gels
    • C01B33/158—Purification; Drying; Dehydrating
    • C01B33/1585—Dehydration into aerogels
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
    • C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
    • C08L61/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
    • D21H11/16—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only modified by a particular after-treatment
    • D21H11/18—Highly hydrated, swollen or fibrillatable fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H15/00—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
    • D21H15/02—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution characterised by configuration
    • D21H15/10—Composite fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H15/00—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
    • D21H15/02—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution characterised by configuration
    • D21H15/10—Composite fibres
    • D21H15/12—Composite fibres partly organic, partly inorganic
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/59—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/16—Special fibreboard
    • D21J1/20—Insulating board
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N1/00—Pretreatment of moulding material
    • B27N1/02—Mixing the material with binding agent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/10—Moulding of mats
    • B27N3/14—Distributing or orienting the particles or fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B80/00—Architectural or constructional elements improving the thermal performance of buildings
    • Y02B80/10—Insulation, e.g. vacuum or aerogel insulation

Definitions

  • SIP structural insulated panel
  • OSBs wood-based oriented strand boards
  • Some of these insulating materials are potentially harmful to the environment.
  • EP2924058 discloses a composite material comprising natural wood fibres, a polyisocyanate binder and silica-based nano porous particles (aerogel). This material is however weak and prone to disintegrate, making handling difficult.
  • the refined wood fibres may be pre-processed to select wood fibres that provide optimum performance within the insulating material.
  • the refined wood fibres may be pre-processed wood fibres having at least one of the following properties: a specified range of lengths and/or dimensions, recycled and/or reclaimed fibres; a specified type of wood fibre; and/or separated wood fibres.
  • the refined wood fibres may have a size (length) of about 0.5 mm to about 5.0 mm.
  • the refined wood fibres may have a size (length) of between around 1 mm to about 5 mm.
  • the refined wood fibres may have a size (length) of between around 3 mm to about 5 mm.
  • the refined wood fibres may be soft wood fibres.
  • the refined wood fibres may comprise virgin pine fibres or pine chips.
  • the refined wood fibres may comprise recycled medium density fibreboard (MDF) fibres.
  • MDF medium density fibreboard
  • the use of recycled MDF fibres provides a further sustainability benefit which is a key incentive for implementation and use of the insulation in the construction industry.
  • the refined wood fibres may be pre-processed to separate individual fibres. Separation of individual wood fibres is advantageous since it prevents ‘clumping’ and aggregation of the wood fibres to enhance even mixing of the constituent parts of the insulating material.
  • the refined wood fibres may be pre-processed to reduce the moisture content of the fibres.
  • the refined wood fibre content may be at least 20 wt%.
  • the refined wood fibre content may be less than 70 wt%.
  • the refined wood fibre content may be around between 50 and 65 wt%.
  • the refined wood fibre content may be around between 55 and 60 wt%.
  • the resin binder may comprise a setting polymeric material.
  • the polymeric material may comprise urea-formaldehyde.
  • the polymeric material may comprise resorcinol formaldehyde adhesive.
  • the polymeric material may comprise polyisocyanate. Other known resin binders may be used.
  • the aerogel content may be in the range between 5 to 40 wt%.
  • the aerogel may comprise at least 6 % of the weight of the insulating composite material.
  • the aerogel content may be in the range of 8 to 30 wt%.
  • the aerogel content may be at least 10wt%. Preferably, the aerogel content may be in the range of 10 to 25 wt%.
  • the aerogel may comprise particles having a largest diameter of less than 5500 microns.
  • the aerogel may comprise comprises particles having a largest diameter of less than 1500 microns.
  • the silica-based aerogel particles may be hydrophilic.
  • the aerogel may comprise hydrophilic aerogel.
  • the aerogel may comprise Quartzene Z1.
  • the insulating composite may comprise micro- crystalline cellulose.
  • the insulating composite may comprise nano- crystalline cellulose.
  • the microfibrillated cellulose (MFC) content may be between around 1 and 10 wt%.
  • the MFC content may be at least 3 wt%.
  • the MFC content may be between around 2 and 6 wt%.
  • the MFC content may be around 5 wt%.
  • Use of MFC in the composite of the invention is advantageous, since the MFC have been found to be capable of stabilising the natural fibre composites of the present invention, providing structural resilience.
  • Microfibrillated cellulose has a high surface area entanglement of fibre strands. It is derived from natural wood, such as spruce. As such it is an ecologically sustainable material.
  • the fibres promote H-bonding and thus, chemical integration into a range of compositions and binders is possible.
  • the insulating composite material may be configured in a preselected form to provide thermal insulation.
  • the insulating composite material may be configured in a preselected form to provide thermal insulation for large scale structures, such as buildings.
  • the insulating composite material may be configured to form thermal insulation having a thickness of at least 2 mm.
  • the insulating composite material may be configured to form thermal insulation having a thickness of 5 mm or more.
  • the insulating composite material may be configured to form thermal insulation having a thickness of 10 mm or more.
  • the insulating composite material may be a building insulating composite material.
  • the building insulating composite material may be formulated for use as large-scale insulation.
  • the insulating composite material may be configured as insulation boarding.
  • the material may be formed into a block or panel for use in construction of buildings.
  • the insulating composite material may be configured to form insulation boarding having a thickness of at least 15 mm.
  • the insulating composite material may be configured to form insulation boarding having a thickness of 20 mm or more.
  • the insulating composite material within the insulation boarding may have a density of at least 100 kg/m 3 .
  • the insulating composite material within the insulation boarding may have a density in the range between around 115 and 230 kg/m 3 .
  • the insulating composite material within the insulation boarding may have a density of at least 135 kg/m 3 .
  • the insulating composite material may be configured as semi- flexible or sheet insulation.
  • the insulating composite material may further comprise a bi-component fibres.
  • the bi-component fibre may comprise an inner core and an outer sheath, the outer sheath having a lower melting point compared with the outer sheath.
  • the inner core and the outer sheath may comprise two different materials.
  • the bi-component fibres may be formed from naturally derived materials.
  • the bi-component fibres may be formed from a bio-degradable material.
  • the bi- component fibres may be formed from bio-derived PBS (polybutylene succinate) and/or PLA (polylactic acid).
  • the bi-component fibre content may be between around 10 and 35 wt%.
  • the bi-component fibre content may be between around 15 wt% and 25 wt%.
  • the bi-component fibre content may be between around 15 wt%.
  • the balance may comprise refined wood fibres coated with MFC and aerogel using a resin binder.
  • the insulating composite material may be configured to form semi-flexible or sheet insulation having a thickness of at least 2 mm.
  • the insulating composite material may be configured to form semi-flexible or sheet insulation having a thickness of between around 5 mm and 15 mm.
  • the material may be moulded into any desired shape before setting, and further processed by cutting or incorporating into other structures, such as structural insulated panels (SIPs).
  • SIPs structural insulated panels
  • an insulation board comprising the insulating composite material according to the first aspect of the invention.
  • the insulation board may have a thickness of at least 15 mm.
  • the insulation board may have a thickness of 20 mm or more.
  • the insulation board may have a density of between 115 and 230 kg/m 3 .
  • the insulation board may have a density of at least 135 kg/m 3 .
  • semi-flexible or sheet insulation comprising the insulating composite material according to the first aspect of the invention.
  • the sheet insulation may have a thickness of at least 5 mm.
  • the insulating composite material may be configured to form semi-flexible or sheet insulation having a thickness of 10 mm or more.
  • the semi-flexible or sheet insulation may have a density of between 35 kg/m 3 and 75 kg/m 3 .
  • the semi-flexible or sheet insulation may have a density of between 40 kg/m 3 and 70 kg/m 3 .
  • the semi-flexible or sheet insulation may have a density of between 45 kg/m 3 and 65 kg/m 3 .
  • the semi-flexible or sheet insulation may have a density of around 65 kg/m 3 .
  • a method of forming a composite material as hereinbefore described comprising: applying a resin binder to refined wood fibres with a liquid mixture of silica-based hydrophilic aerogel particles and microfibrillated cellulose, in a turbulent flow of fluid to form a base material; reducing the moisture content of the base material; and forming and setting the base material into a composite.
  • the refined wood fibres within the composite are coated with aerogel particles and microfibrillated cellulose.
  • the method may comprise the step of applying the resin binder and liquid mixture to the wood fibres in a blowline.
  • Advantageously use of the blowline generates a turbulent fluid flow to comprehensively mix the components forming the base material.
  • Use of hydrophilic aerogel particles is advantageous during the manufacture of the insulating material, as the wet mixture is less prone to clumping and clogging flowlines during manufacture.
  • the step of reducing the moisture content of the base material may comprise flash drying the material.
  • the step of reducing the moisture content of the base material may comprise reducing moisture content to less than 15 %.
  • the step of reducing the moisture content of the base material may comprise reducing moisture content to between around 4 and 10 %.
  • the step of forming the base material may comprise pressing the base material.
  • the step of setting the base material into a composite may comprise heating the material.
  • the step of forming and setting the base material into a composite may comprise simultaneously pressing and heating the material.
  • the method may further include the step of altering physical properties of the composite material by altering at least one of the following: depth of press; temperature; and/or speed of the pressing step.
  • the method may further comprise the step of mixing bi- component fibres into the base material.
  • Mixing bi-component fibres into the base material may include turbulent mixing and/or mechanical mixing.
  • the bi- component fibre content may be added in a quantity between around 10 and 35 wt% of the overall material.
  • the bi-component fibre content may be around 15 wt%.
  • the step of forming and setting the base material into a composite may comprise laying the required quantity of mixed fibres onto a surface and heating the material to a predetermined temperature to form a sheet of insulation.
  • the required quantity of mixed fibres may be attained by weighing the mixed fibres laid on a surface.
  • the mixed fibres may be laid in a uniform sheet in the required quantity.
  • the bi-component fibre within the fibre mixture may comprise an inner core and an outer sheath having a lower melting point than the inner core.
  • the step of setting the base material into an insulating composite may comprise heating the material to a predetermined temperature between the melting point of the inner core and outer sheath of the bi-component fibres such that the outer sheath of the bi-component fibres melts to bind the composite material into a sheet of insulation.
  • the melted outer sheath binds the material, while the solid inner core holds the fibres in spaced relation giving the material loft and thereby improving the insulation properties.
  • the method may comprise recycling wood fibres.
  • the recycled wood fibres may be obtained from recycled MDF.
  • the method may comprise providing virgin wood fibres.
  • the method may comprise providing wood fibres of a preselected size.
  • the method may comprise refining wood fibres.
  • the method may comprise preselecting wood fibres having a length between around 0.5 to 5.0 mm.
  • the method may comprise preselecting wood fibres having a length between around 0.5 to 3 mm.
  • the method may comprise preselecting wood fibres having a length between around 3 to 5 mm.
  • the method may comprise processing wood fibres to separate the fibres. It may be advantageous to process the fibres to minimise ‘clumping’ and reduce the presence of ‘shives’ (or bunches of fibres).
  • the method may comprise forming an insulating composite material according to the first aspect of the invention.
  • the method may comprise forming insulation board from the insulating composite material according to the second aspect of the invention.
  • the method may comprise forming sheet insulation from the insulating composite material according to the third aspect of the invention.
  • a method of forming an insulating composite material comprising the steps of: mixing wood fibres, particles, microfibrillated cellulose and a bonding agent in a stream of air to form a web of base material; and bonding the base material to form an insulating composite material.
  • the method may comprise air laying or air forming.
  • the bonding step may comprise one or more of the following methods: latex bonding, thermal bonding, and/or high-pressure bonding. High pressure bonding may include hydroentanglement.
  • composite insulation made by method steps according to any of the fourth or fifth aspects of the invention.
  • An additive liquid mixture is created using the aerogel, MFC and water. Hydrophilic aerogel particles in the form of Quartzene Z1 and microfibrillated cellulose (MFC) are well mixed and dissolved in the water with a total combined concentration of 130 g/L for both additives.
  • a blowline is used to spray and mix the refined wood fibres with urea- formaldehyde (UF) resin and the liquid aerogel/MFC solution. The turbulent flow of resin, wood fibres and additives in solution cause a thorough wet mix of the base material that provides a uniform dispersion in the final product.
  • the size of the spray nozzles for the blowline and the required pump power are preselected and adjusted according to the required quantities of the base materials and/or speed of manufacture.
  • the resulting base material is pre-pressed. This is followed by a consolidation step to form the base material into the required shape and depth in a rectilinear panel mould using a computer controlled hot-press.
  • the forming, pressing and heating steps result in creation of a wood fibre composite in the form of a board, which is partially structural and can support its own weight.
  • Figure 2 shows a photograph of stacked wood fibre composite boards 20 made using the process described. Physical properties of the insulation boards 20 can be altered during the pressing step by adjusting characteristics such as press depth, press speed and temperature.
  • a one-step manufacturing process employing a ContiRoll® press may be used as part of a press production line to continually form and shape the base material. At the end of this process the wood fibre composite is cut to the required size.
  • the wood fibre composite resulting from the above described method of manufacture provides an insulating composite that is suitable for use in the construction industry.
  • the schematic figure 1 shows a basic view of how an individual wood fibre 10 might be seen in the finished composite.
  • the wood fibre 10 is coated with a plurality of silica-based aerogel particles 14 which improve thermal properties of the finished composite and bonded with MFC particles 12, which improve structural integrity. Experiments were conducted investigating different variables associated with manufacture of the wood fibre composite insulation board.
  • the base material is weighed and mixed in the required quantity with naturally derived (or ‘bio’) bi-component fibres.
  • Bi- component fibres are added as a resin to bind the material as well as provide structural integrity.
  • bio bi-component fibres constitute around 15 wt% of the composite material composition with the remaining 85 wt% being the base material comprising refined wood fibres coated with MFC and aerogel.
  • An example of an individual bi-component fibre with a generally round cross- section is shown schematically at 30 in figures 7a and 7b.
  • the bi-component fibre is a naturally derived polymer that is bio-degradable, which advantageously reduces the environmental impact of the formed insulation.
  • the fibre 30 has a density of 1.25 g/cm3.
  • the bi-component fibre 30 comprises an inner core 31 of polylactic acid (PLA Ingeo TM) with a melting point of 160 °C.
  • the bi-component fibre 30 comprises an outer polymer sheath 33 of polybutylene succinate (PBS) and has a melting point of 116 °C.
  • the outer sheath 33 has a melting point that is less than the melting out of the inner core 31 to ensure that the outer sheath 33 melts before the inner core 31 to bind the bi-component fibre 30 within the base material during processing, while the inner core 31 remains stiff to retain the shape of the fibre 30 within the resulting composite.
  • the base material comprising refined wood fibres coated with MFC and aerogel
  • a thorough mixing process is required to ensure an even distribution of the bi-component fibres 30 amongst the fibres of the base material.
  • One example of such a process includes two stages of blending. A first stage involves entraining the fibres (base material and bi-component) within an air flow to cause turbulent mixing with several acute changes in direction and vertical portions where the fibres travel up and down portions of tubing within the air flow. A second stage involves mixing with mechanical aids.
  • the air-flow with entrained fibres is sucked under negative pressure through a vertically oriented tubing and a mechanical mixing device in the form of rotating discs with interlocking teeth.
  • the mixed material contains a thorough blend of base material and bi- component fibres evenly distributed within the material.
  • the mixed fibres are laid onto a conveyer, which controls and weighs the required amount of material laid onto the surface of the conveyor to ensure the final insulation sheets are formed with the required density.
  • the material passes at a controlled rate through a thermosetting oven set at a temperature of between 80 – 200 °C (depending on the properties of the bi-component fibres 30) to ensure melting of the outer sheath 33.
  • the insulation sheet transits through the oven at a linear speed of no more than 15 m/min (depending on weight of the material). Melting of the outer sheath 33 occurs in the oven which binds the mixture of fibres into a sheet. Once the material exits the oven on the conveyor, the material is cooled and the outer sheath 33 sets into a solid to form a cohesive stable semi-flexible sheet of insulation.
  • the resulting composite material is a sheet of relatively stiff self-supporting insulation that is semi-flexible and can be cut and bent into the required shape and form for the anticipated end use.
  • the insulating sheet material can be formed with a thickness of up to around 150 mm. The optimal density range appears to be between around 30 kg/m 3 and 80 kg/m 3 .
  • various method steps may be combined to enhance efficiency of the insulation manufacturing process.
  • the method of coating the refined wood fibres with MFC and aerogel may be achieved on the same production line as the thorough mixing of bi-component fibres and subsequent heating and formation into a sheet of semi-flexible insulation.
  • different types of bi-component fibres may be mixed with the base material prior to the air-lay process.
  • the bi-component fibre may be formed from polylactic acid (PLA) and modified co-PLA or any other material having the required properties.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Dispersion Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

L'invention concerne un matériau composite isolant approprié pour une formation en produits d'isolation conçus pour réduire la perte thermique dans des structures à grande échelle. Le matériau composite isolant comprend : des fibres de bois affinées, des particules d'aérogel à base de silice, un liant de résine et de la cellulose microfibrillée, les fibres de bois affinées étant revêtues de particules d'aérogel à base de silice et de cellulose microfibrillée. De manière avantageuse, le composite ainsi obtenu fournit une isolation thermique et une intégrité structurale requises pour une utilisation en tant qu'isolant dans l'industrie de la construction, et avec un impact environnemental réduit par comparaison avec des produits d'isolation classiques. L'invention concerne en outre un procédé de formation du matériau composite par : application d'un liant de résine à des fibres de bois affinées avec un mélange liquide de particules d'aérogel hydrophile à base de silice et de cellulose microfibrillée dans un écoulement turbulent de fluide pour former un matériau de base ; réduction de la teneur en humidité du matériau de base ; et formation et durcissement du matériau de base en un composite.
PCT/GB2023/050453 2022-02-28 2023-02-28 Procédé arid de matériau Ceased WO2023161663A2 (fr)

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GBGB2202736.1A GB202202736D0 (en) 2022-02-28 2022-02-28 Material and method

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2924058A1 (fr) 2014-03-28 2015-09-30 Huntsman International Llc Composites de fibres naturelles organiques renforcées

Family Cites Families (9)

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Publication number Priority date Publication date Assignee Title
DE19533564A1 (de) * 1995-09-11 1997-03-13 Hoechst Ag Faserhaltiges Aerogel-Verbundmaterial
TW201817783A (zh) * 2016-08-09 2018-05-16 日商太陽控股股份有限公司 印刷配線板用硬化性樹脂組成物、乾薄膜、硬化物及印刷配線板
KR102278958B1 (ko) * 2017-03-24 2021-07-19 엘지전자 주식회사 나노셀룰로오스 제조방법 및 나노셀룰로오스 함유 실리카 에어로겔 복합소재
CN108658623A (zh) * 2017-03-30 2018-10-16 中国矿业大学(北京) 一种含二氧化硅气凝胶常温养护发泡保温板及其制备方法
JP7121595B2 (ja) * 2017-09-28 2022-08-18 住友理工株式会社 断熱材用塗料および断熱材
EP3653579B1 (fr) * 2018-11-16 2023-07-19 Fundación Tecnalia Research & Innovation Aérogel de silice renforcé avec une éponge de cellulose et son procédé de préparation
JP7429508B2 (ja) * 2019-09-17 2024-02-08 明星工業株式会社 断熱パネルの製造方法
WO2021067355A1 (fr) * 2019-10-01 2021-04-08 Outlier Solutions Llc Appareil, systèmes et procédés de fabrication de produits en papier isolés retriturables
CN115231898A (zh) * 2022-09-21 2022-10-25 北京石墨烯技术研究院有限公司 气凝胶复合材料及其制备方法和应用

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2924058A1 (fr) 2014-03-28 2015-09-30 Huntsman International Llc Composites de fibres naturelles organiques renforcées

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GB2616126B (en) 2026-03-25
WO2023161663A3 (fr) 2024-01-11
GB2616126A (en) 2023-08-30
GB202202736D0 (en) 2022-04-13
EP4493372A2 (fr) 2025-01-22
GB202302943D0 (en) 2023-04-12

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