METHOD FOR PRODUCING A HYDROPHOBIC ELEMENT AND USE THEREOF

Abstract

A method for producing a hydrophobic element is disclosed and includes the following steps: a) preparing a mixture of water and an organic material from sustainably renewable resources, b) moulding the mixture prepared in step a) to obtain a moulded element, c) drying and densifying the moulded element obtained in step b) to obtain a dried and densified element-, and d) impregnating to the core the dried and densified element obtained in step c) with a binder composed of organic materials from sustainably renewable resources. A covering hydrophobic element containing more than 90%, and preferably more than 99%, of an organic material from sustainably renewable resources is also disclosed.

Claims

1. Method for manufacturing a hydrophobic covering element, characterised in that it comprises the following steps: a) preparation of a mixture of water and of organic material coming from sustainably renewable resources; b) moulding of the mixture prepared in step a) in order to obtain a moulded element, c) drying and densification of the moulded element obtained in step b) in order to obtain a dried and densified element, d) full impregnation of the dried and densified element obtained in step c), in a binder composed of organic materials coming from the resources that are sustainably renewable in order to obtain a hydrophobic covering element.

2. Method according to claim 1, characterised in that the step c) of drying and densification is carried out by a pressing system comprising at least a pressing mould and counter-mould pair.

3. Method according to claim 2, characterised in that the mould and counter-mould pair is placed under a depression, while being heated, and the mould and counter-mould are pressed against one another.

4. Method according to claim 2, characterised in that the pressing system comprises a plurality of pressing mould and counter-mould pairs, the pairs being disposed in a circle and capable of moving by rotation of said circle.

5. Method according to claim 1, characterised in that step c) comprises an additional drying in a hot air or infrared or microwave or high-frequency oven.

6. Method according to claim 1, characterised in that the binder comprises an organic material, coming from the resources that are sustainably renewable, in liquid form between 20 and 150 C. or of a mixture of organic materials coming from the resources that are sustainably renewable, the mixture being in liquid form between 20 and 150 C.

7. Method according to claim 1, characterised in that the binder is a plant binder composed of derivatives of Tall-oil, such as Tall-oil pitch.

8. Method according to claim 1, characterised in that it comprises an additional step e), involving coating the hydrophobic element obtained in step d) with a coating.

9. Method according to claim 8, characterised in that the coating is one or more layers of a finishing material, like a paint, chosen from the group comprising materials containing mineral pigments and mineral fillers, biosourced organic pigments coming from the resources that are sustainably renewable, materials containing plant resins coming from biomass, materials containing synthetic resins.

10. Method according to claim 8, characterised in that a fireproofing and/or hydrophobic treatment is carried out in step a) and/or during step e).

11. Hydrophobic element for covering at least a portion of a surface, such as a wall and/or a ceiling and/or a surface in contact with the outside, said element having a developable or non-developable shape and comprising a back in contact with said surface and a visible front, characterised in that it comprises more than 90%, and preferably more than 99%, organic material coming from sustainably renewable resources.

12. Hydrophobic element according to claim 11, the visible front of which is capable of having a relief with a decorative appearance.

13. Use of the hydrophobic covering element according to claim 11, for the covering of at least a portion of a surface in contact with the outside, such as roofing or cladding.

14. Use of a hydrophobic covering element according to claim 11, as a decorative object chosen in particular from the group comprising friezes, complaints, mouldings, decorative panels.

15. Use of the hydrophobic covering element prepared according to claim 1 for the covering of at least a portion of a surface in contact with the outside, such as roofing or cladding.

16. Use of a hydrophobic covering element prepared according to claim 1 as a decorative object chosen in particular from the group comprising friezes, complaints, mouldings, decorative panels.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0157] Other objects, features and advantages of the present invention will appear in the following description via examples that are only for informational purposes and in no way limiting to the scope of the invention, and on the basis of the appended illustrations in which:

[0158] FIG. 1 is a schematic front view illustrating the steps a) and b) of the method of the invention,

[0159] FIG. 2 is a schematic front view of a forming mould used during step b) of the method of the invention,

[0160] FIGS. 3 and 4 are diagrams illustrating alternatives of step b) of the method of the invention,

[0161] FIG. 5 is a diagram illustrating step c) of the method of the invention,

[0162] FIG. 6a is a schematic front view of a pressing mould used during step c) of the method of the invention,

[0163] FIG. 6b is a schematic top view of the mould of FIG. 6a.

[0164] FIG. 7 is a schematic perspective top view of an example of a hydrophobic element for covering roofing,

[0165] FIG. 8 is a schematic front view of an alternative of FIG. 7.

[0166] FIG. 9 shows an example of a hydrophobic element for covering a wall viewed from above.

[0167] FIG. 10 shows a wall being covered by hydrophobic elements of FIG. 9.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0168] In the rest of the description, the terms horizontal, vertical, transverse and longitudinal, should be understood as qualifying elements resting in a fixed manner in parallel to the ground.

[0169] The method of the invention comprises the following steps: [0170] a) Preparation of a mixture of water and of organic material coming from the resources that are sustainably renewable, [0171] b) Moulding of the mixture prepared in step a) in order to obtain a moulded element, [0172] c) Drying and densification of the moulded element obtained in step b) in order to obtain a dried and densified element, [0173] d) Full impregnation of the dried and densified element obtained in step c) in a binder composed of organic materials coming from the resources that are sustainably renewable.

[0174] The method of the invention allows to obtain a hydrophobic element.

[0175] The steps a) and b) of preparing a mixture M of water and of cellulose fibres, and of moulding said mixture are illustrated in FIG. 1.

[0176] A mixture M of water and of 1 to 20% cellulose fibres is prepared in a tank 1 at a temperature between 10 and 75 C. and preferably between 35 and 45 C.

[0177] A mould, called forming mould 2 (shown in more detail in FIG. 2) is then immersed, under vacuum, in the tank 1 containing the mixture M, in such a way that a portion P of the mixture M is transferred onto said mould.

[0178] The forming mould 2 is disposed on a drum or shaft 3 having four faces 3A, 3B, 3C, 3D, each comprising a mould 2.

[0179] The drum 3 thus successively carries out rotations of 90 about a central axis X in such a way that each mould of each face 3A, 3B, 3C, 3D is immersed in the tank 1 containing the mixture M.

[0180] The speed of rotation of the drum 3 is approximately 1.5 to 30 rpm.

[0181] The portion P of the mixture M transferred onto the surface of each mould 2 is thus moulded under vacuum, in such a way as to obtain a moulded element E.

[0182] The moulded element E is then transferred onto the surface of a transfer counter-mould 4, under vacuum, disposed on a plate 40 above the drum 3.

[0183] This step of transfer of the moulded element E is possible via the creation of an overpressure (stoppage of the vacuum) in the mould 2 comprising the moulded element E, and of a depression (vacuum) in the transfer counter-mould 4.

[0184] More precisely, the moulding step involves: [0185] Immersing the face 3A of the drum 3, comprising a mould 2, in the tank 1 comprising the mixture M, in such a way as to transfer a portion P of the mixture M onto the surface of the mould 2, via a first rotation of the drum 3 by 90 in the clockwise direction, according to the arrow F1, [0186] After a time of between 0.5 and 10 seconds, carrying out a second rotation of the drum 3 by 90 in the clockwise direction, according to the arrow F1, in such a way that the face 3A is located perpendicularly to the tank 1, outside of said tank, [0187] Applying a cloth, called moulding cloth 5, onto the portion P of the mixture M, for a time of between 0.5 and 10 seconds, in order to increase the effect of suction in the mould 2 and obtain the moulded element E, said cloth carrying out a movement of horizontal translation in the direction of the mould 2 in the direction of the arrow f, [0188] Carrying out a third rotation of the drum 3 by 90 in the clockwise direction, according to the arrow F1, in such a way that the face 3A, and the moulded element E, are located in parallel to the transfer counter-mould 4, [0189] Lowering the transfer counter-mould 4 onto the moulded element E, according to the arrow F2, [0190] Creating a depression in the mould 2 and raising the transfer counter-mould 4 in such a way that the moulded element E is disposed on the surface of said counter-mould.

[0191] Thus, the mould 2 of the face 3A is empty.

[0192] A fourth rotation of the drum 3 by 90 in the clockwise direction allows to position the face 3A perpendicularly to the tank 1, then the steps described above are repeated in such a way as to mould a plurality of elements E.

[0193] The vacuum created inside the mould 2 allows to maintain the portion P of the mixture M on the surface of the mould 2.

[0194] When the transfer counter-mould 4 is lowered against the mould 2, the moulded element E is smoothed and densified.

[0195] FIG. 2 shows that each mould 2 comprises orifices 20 and is lined with a wire mesh, called bottom mesh 21.

[0196] The orifices 20 have a thickness of between 3 and 10 mm.

[0197] The bottom mesh 21 comprises a mesh having a size smaller than the orifices 20.

[0198] In a second embodiment, illustrated in FIG. 3, a mould 2 is immersed, under vacuum, in the tank 1 comprising the mixture M, then the mould 2, comprising a portion P of the mixture M, carries out a movement of vertical translation according to the arrow F1 in order to remove the mould 2 from the tank 1.

[0199] Then, the mould 2 carries out a movement of horizontal translation in the direction of a belt conveyor (not shown), according to the arrow F2, until a moulded element E is obtained.

[0200] The moulded element E is then deposited on the belt conveyor (not shown), after creation of an overpressure (stoppage of the vacuum) in the mould 2.

[0201] The mould 2 is suspended from a plate 40, by elements allowing its vertical and horizontal movement.

[0202] The belt conveyor allows to move the moulded element E in the direction of a pressing system 6 (FIG. 5).

[0203] In a third embodiment illustrated in FIG. 4, a mould 2 is immersed, under vacuum, in the tank 1 comprising the mixture M, then the mould 2 carries out a movement of vertical translation according to the arrow F1 and a movement of rotation of 180 according to the arrow F2, in such a way as to present the moulded element E opposite a transfer counter-mould 4 as described with regard to FIG. 1.

[0204] The transfer of the moulded element E from the forming mould 2 to the transfer counter-mould 4 takes place in the same way as above, in the first embodiment.

[0205] FIG. 5 shows that the moulded element E is transferred to a carrousel pressing system 6.

[0206] The carrousel pressing system 6 comprises four pressing mould 70 (FIGS. 6a, 6b) and counter-mould (not shown) pairs 7A, 7B, 7C, 7D.

[0207] More precisely, the moulded element E is transferred into a first pressing mould and counter-mould pair 7A in which the mould and counter-mould are pressed against one another, under vacuum, the mould and counter-mould being heated to a temperature of between 160 and 280 C.

[0208] The carrousel pressing system 6 then carries out a succession of rotation by 90 in the anti-clockwise direction, arrows R1, R2, R3, R4, in such a way that each pair 7A, 7B, 7C, 7D can receive a moulded element E.

[0209] When the pair 7A has carried out three rotations of 90, a dried and densified element S is obtained.

[0210] The mould and counter-mould of the pair 7A move apart from one another and the dried and densified element S is transferred to the step of impregnation (not shown).

[0211] As shown in FIGS. 6a and 6b, each pressing mould 70 comprises orifices 72 having a size preferably between 3 and 10 mm.

[0212] These orifices 72 are closed by nozzles 73 with slots or holes.

[0213] Each counter-mould also has orifices and nozzles.

[0214] In the context of construction, the invention will be more particularly described with regard to a hydrophobic covering element for roofing, or a hydrophobic element for covering roofing, without being limited to such a use.

[0215] Covering element for roofing means an element capable of covering at least a portion of the surface of a roof.

[0216] In the rest of the description, the term element for covering roofing designates both the main covering elements for roofing, such as the plates or tiles, and the accessories, such as ridge tile, flashing or bargeboard.

[0217] FIG. 7 shows an example of a hydrophobic element H obtained after the step of impregnation (not shown).

[0218] The hydrophobic element H is intended for a use in roofing.

[0219] It is in the form of a corrugated plate, with a visible front 11 and an opposite back. The plate is substantially parallelepipedic, with a length L equal to 1020 mm, a width W equal to 665 mm, a thickness T equal to 2.5 mm and a non-developable shape.

[0220] In its length L, it comprises six rows of five tiles 8. The tiles 8 being parallel to each other, and the longitudinal direction of a tile 8 being identical to the longitudinal direction of the hydrophobic element H.

[0221] Each row of tile 8 is separated by an offset 9 and the tiles 8 of the same row are connected to each other by a groove 10.

[0222] Each tile 8 has a length L of 160 mm.

[0223] FIG. 8 shows an alternative H of the hydrophobic element H of FIG. 7.

[0224] In this alternative, the hydrophobic element H is intended to be used as a ridge tile or ridge accessory.

[0225] Its longitudinal direction consists of four tiles 8 longitudinally fitter together.

[0226] FIG. 9 shows another example of a hydrophobic covering element H, with a width W length L and thickness T, viewed from above. The hydrophobic element H comprises a visible front 11 comprising a relief 12 consisting of a spindle shape repeated six times.

[0227] FIG. 10 shows the placement of hydrophobic elements H on a surface 13 formed by a wall. The hydrophobic elements H are those shown in FIG. 9. A plurality of hydrophobic elements H are already placed on the wall 13 for example using glue. The arrows p1 and p2 in FIG. 10 indicate the direction of placement in order to finish completely covering the wall 13.