COMPOSITE, GREENING SYSTEM AND DEVICE FOR THERMAL INSULATION

Abstract

A composite including a first fabric layer having a water permeability W.sub.1 and adjacent to a second fabric layer having a water permeability W.sub.2, wherein W.sub.2 and W.sub.1 fulfill the relation W.sub.2<W.sub.1, and wherein the composite is folded to exhibit a folded structure, wherein the folded structure includes a plurality of folds. Furthermore, a greening system, a device for thermal insulation, a device for acoustic noise insulation and a multifunctional device for greening and/or thermal insulation and/or acoustic insulation including the composite described before.

Claims

1. A composite comprising a first fabric layer having a water permeability W.sub.1 and adjacent to a second fabric layer having a water permeability W.sub.2, wherein W.sub.2 and W.sub.1 fulfill the relation W.sub.2<W.sub.1, and wherein the composite is folded to exhibit a folded structure, wherein the folded structure comprises a plurality of folds.

2. The composite according to claim 1, wherein the composite comprises a third fabric layer adjacent to the first fabric layer, wherein the third fabric layer has a water permeability W.sub.3, wherein in any case W.sub.3 fulfills the relation W.sub.3<W.sub.1, and wherein W.sub.3 either fulfills the relation W.sub.3=W.sub.2 or the relation W.sub.3W.sub.2.

3. The composite according to claim 1, wherein the first fabric layer is a nonwoven, water-permeable fabric, and the second fabric layer is a fabric of woven tapes or a knitted fabric or a warp-knitted fabric.

4. The composite according to claim 2, wherein the third fabric layer is a fabric of woven tapes or a membrane or foil having a water permeability W.sub.3, wherein W.sub.3 either is 0 or ranges from 1.Math.10.sup.4 to 1.Math.10.sup.7 l/(s.Math.m.sup.2).

5. The composite according to claim 1, wherein the folds exhibit a meandering fold shape, and wherein the meandering fold shape of a single fold is defined by a hinge which defines a point at which a radius of curvature of the fold reaches its minimum value r.sub.min, wherein the hinge is flanked by a first limb which exhibits radii of curvature r.sub.first limb>r.sub.min, wherein the first limb extends from the hinge to a first inflection point which exhibits zero curvature, and wherein the first inflection point is followed by a first line having radii of curvature r.sub.first line>r.sub.first limb, and a second limb which exhibits radii of curvature r.sub.second limn>r.sub.min, wherein the second limb extends from the hinge to a second inflection point which exhibits zero curvature, and wherein the second inflection point is followed by a second line having radii of curvature r.sub.second line>f.sub.second limb.

6. The composite according to claim 5, wherein the first inflection point is followed by a first line of approximately zero curvature, and the second inflection point is followed by a second line of approximately zero curvature.

7. The composite according to claim 6, wherein the first line of approximately zero curvature runs nearly parallel to the second line of approximately zero curvature.

8. The composite according to claim 1, wherein the first line exhibits a length L.sub.4 and the second line exhibits a length L.sub.4, and L.sub.4 differs from L.sub.4 at most by 20% .

9. The composite according to claim 1, wherein the water permeability W.sub.1 of the first fabric layer is at least 2-fold higher than the water permeability W.sub.2 of the second fabric layer.

10. The composite according to claim 3, wherein the nonwoven, water-permeable fabric is made of 70 wt. % fibers of synthetic polymers and 30 wt. % of cotton fibers.

11. The composite according to claim 3, wherein the nonwoven, water-permeable fabric has an areal density in the range of 100 to 2000 g/m.sup.2.

12. The composite according to claim 3, wherein the fabric of woven tapes comprises tapes made of polypropylene (PP), polyethylene (PE), polyester (PES), polyamide (PA), or mixtures of at least two of the polymers.

13. The composite according to claim 3, wherein the fabric of woven tapes has an areal density in the range of 50 to 300 g/m.sup.2.

14. The composite according to claim 3, wherein the nonwoven water-permeable fabric is adhered to the fabric of woven tapes.

15. A greening system comprising a composite according to claim 1.

16. A device for thermal insulation comprising a composite according to claim 1.

17. A device for acoustic noise insulation comprising a composite according to claim 1.

18. A multifunctional device for greening and/or thermal insulation and/or acoustic noise insulation comprising a composite according to claim 1.

Description

[0028] FIG. 1 schematically shows a single fold as described immediately above: Said single fold exhibits a hinge 1 which defines a point at which a radius of curvature of the fold reaches its minimum value r.sub.min. The hinge 1 is flanked by a first limb 2 which extends from the hinge 1 to a first inflection point 3 which exhibits zero curvature. The first infection point 3 is followed by a first line 4 of zero curvature. Furthermore, the hinge 1 is flanked by a second limb 2 which extends from the hinge 1 to a second inflection point 3 which exhibits zero curvature. The second infection point 3 is followed by a second line 4 of zero curvature, and the first line 4 of zero curvature runs parallel to the second line 4 of zero curvature.

[0029] In a further preferred embodiment of the composite according to the present invention the first line 4 exhibits a length L.sub.4 and the second line 4 exhibits a length L.sub.4, and L.sub.4 differs from L.sub.4 at most by 20%, more preferred at most by 5% or, most preferable, L.sub.4 equals L.sub.4.

[0030] In the meandering fold shape of the composite according to the present invention neighbored folds are preferably not connected with one another. In this preferred embodiment of the composite the preferably meandering fold shape allows a direct planting between the folds. However, it is preferred that adjacent folds contact one another. This contact between adjacent folds can be reached, if during the folding operation which is described in the examples in more detail, a folding pressure is applied which is sufficiently high to result in adjacent folds which contact one another. If adjacent folds contact one another, water which is present in a lower fold is capillary pumped into the contacting upper fold with the aid of the capillary effect generated by capillaries in the first fabric layer and/or in the second fabric layer. Said capillary pumping of water from a lower fold into the contacting upper fold effects that the time during which water is available for the plants which may be implanted between the folds is further extended. And said capillary pumping of water from a lower fold into the contacting upper fold is also advantageous for applications of the composite according to the present invention wherein no plants are present between the folds, like in the later described application of thermal insulation, because the extended presence of water in the composite extends the time during which the composite can thermally insulate a wall or an inclined roof at which the composite is installed from the thermal conditions on the outer side of the wall or roof, respectively.

[0031] In any embodiment of the composite according to the present invention the first and second fabric layers exist as individual layers, wherein the first fabric layer has a water permeability W.sub.1 which is higher than the water permeability W.sub.2 of the second fabric layer.

[0032] Within the scope of the present invention the term nonwoven fabric is defined in accordance with DIN EN ISO 9092:2011. Therein, nonwoven fabrics are defined to represent structures of textile materials, like fiber structures, endless filaments or staple fiber yarns, independent from their properties or origin, which have been formed into a fabric by whatever process, and, thereafter, have been bonded by any method, except by braiding of yarns, like in a woven fabric, knotted fabric, knitted fabric, lace or tufted fabric.

[0033] In the composite according to the present invention the water permeability W.sub.1 of the first fabric layer, which preferably is a nonwoven, water-permeable fabric is preferably at least 2-fold higher, more preferred at least 10-fold higher and most preferred at least 100-fold higher than the water permeability W.sub.2 of the second fabric layer, which preferably is a fabric of woven tapes.

[0034] Preferably, the nonwoven, water-permeable fabric comprised by the composite according to the present invention is made of fibers of synthetic polymers, like polypropylene (PP), polyethylene (PE), polyester (PES), polyamide (PA), polylactic acid (PLA), or mixtures of at least two of said polymers. Preferably, the fibers of synthetic polymers have a titer in the range from 15 to 1 dtex, more preferred from 10 to 3 dtex, and most preferred around 5 dtex.

[0035] Furthermore, the nonwoven, water-permeable fabric comprised by the composite according to the present invention can be made [0036] of fibers of natural inorganic origin, like mineral fibers, for example mineral wool, also known as rock wool, and manufactured from heated dolomite, i.e., from heated CaMg(CO.sub.3).sub.2, or [0037] of fibers of natural organic origin derived from hemp, sheep wool, coconut, and cotton, or of mixtures of mineral fibers and one or more of said organic fibers.

[0038] Preferably, the nonwoven, water-permeable fabric comprised by the composite according to the present invention is made of less than 95 to more than 70 wt. % of optionally mixed fibers of synthetic origin and more than 5 to more than 30 wt. % of cotton fibers, more preferred of approximately 70 wt. % of optionally mixed fibers of synthetic polymers listed above and approximately 30 wt. % of cotton fibers.

[0039] Especially preferred, the nonwoven, water-permeable fabric comprised by the composite according to the present invention is made of 70 wt. % of optionally mixed fibers of synthetic polymers listed above and 30 wt. % of cotton fibers.

[0040] It is even possible that in the nonwoven, water-permeable fabric comprised by the composite according to the present invention substrates of organic and/or mineral origin are embedded between the above mentioned fibers of synthetic polymers, or between the above mentioned fibers of natural origin. Said substrates serve to hold plant nutrients and water in the system for an extended time, as required. And said substrates serve as a filler (root zone) for higher plant varieties.

[0041] Preferred substrates of organic origin are a mixture of peat and clay (in German Einheitserden), pure peat and other peat-mixtures. Other combinations of organic wastes, like for example waste wood, banks, mulch, and straw, are also possible. Preferred substrates of mineral origin are volcanic rock (lava) in different shape, and recycled ceramic wastes, like crushed engineering bricks.

[0042] Especially, if the composite according to the present invention shall be installed in semi-arid and arid zones, it is recommended to combine the substrates listed above with industrially produced earths, like for example expanded clay (lecaton) or perlite (vermiculite), as well as with a super absorber, like for example a hydrogel, or with a polyurethane foam.

[0043] Preferably, the first fabric layer, e.g. the nonwoven, water-permeable fabric comprised by the composite according to the present invention has an areal density in the range of 100 to 2000 g/m.sup.2, especially preferred in the range of 500 to 1200 g/m.sup.2, and especially preferred from 600 to 800 g/m.sup.2.

[0044] Preferably, the second fabric layer, e.g. the fabric of woven tapes and/or of the third fabric layer optionally comprised by the composite according to the present invention comprises tapes made of polypropylene (PP), polyethylene (PE), polyester (PES), polyamide (PA) or mixtures of at least two of said polymers.

[0045] Preferably, the second fabric layer, e.g. the fabric of woven tapes and/or the third fabric layer optionally comprised by the composite according to the present invention has an areal density in the range of 50 to 300 g/m.sup.2, especially preferred in the range of 100 to 200 g/m.sup.2.

[0046] Preferably, the first fabric layer, e.g. the nonwoven water-permeable fabric, is adhered to the second fabric layer, e.g. to the fabric of woven tapes, preferably by gluing in stripes. If the third layer is present in the composite, the first fabric layer, e.g., the nonwoven water-permeable fabric, may also be glued in stripes with the third layer.

[0047] As already mentioned, the second fabric layer, e.g. the fabric of woven tapes, retains a water surplus in the those parts of the folds which extend more or less parallel to the ground, and, therefore, extend more or less perpendicular to the field lines of the gravity so that the retained water remains available for a planting of the composite. Simultaneously, the second fabric layer, e.g. the fabric of woven tapes ensures a certain permeability for air and water (drainage). Therefore, a greening system comprising such a composite is also part of the present invention. For said purpose, the composite according to the present invention is provided with a soil suitable for growing the desired plants. Said soil may be applied between the folds of the folded structure. The greening system according to the present invention can advantageously be used for indoor and outdoor applications, e.g. for greening a wall of a building, or for roof greening on steep roofs and on flat roofs.

[0048] The composite according to the present invention can also be applied outside the field of greening systems. This is, because the water contained in the composite according to the present invention evaporates, and thereby consumes thermal energy so that a cooling effect occurs which cools and thereby thermally insolates the wall of a building or the inclined roof at which it is installed from the thermal conditions on the outer side of the wall or roof, respectively. Independent from the just described cooling effect, the water contained in the composite according to the present invention constitutes a barrier for thermal radiation and thereby hinders or at least retards the transport of heat, especially in combination with additional thermally insolating materials, like mineral wool or polystyrene (Styropor). Therefore, a device for thermal insulation comprising a composite according to the present invention is also part of this invention.

[0049] Furthermore, the fold shape of the composite according to the present invention constitutes a diffusor for acoustic waves. The diffusor hinders or at least attenuates the transport of acoustic waves through the composite, especially in combination with additional sound-absorbing materials, like foam or mineral wool. This effect can advantageously be used both for indoor and outdoor applications, like indoor and outdoor partitions, and in noise protection walls. Therefore, a device for acoustic noise insulation comprising a composite according to the present invention is part of this invention, as well.

[0050] A skilled person who knows the present invention can easily provide a device that combines the effects of greening, thermal insulation, and acoustic noise insulation. Therefore, a multifunctional device for greening and/or thermal insulation and/or acoustic noise insulation comprising a composite according to the present invention is also part of the present invention.

[0051] The composite according to the present invention can be realized in a modular setup: The composite is preferably fixed permanently in the already mentioned corpus or box or on a pre-manufactured mounting frame, for example on a three-dimensional mounting frame, preferably with the aid of special catching clips. The mounting frame bearing the permanently-fixed composite can be installed in a simple manner for example [0052] on a front of a building, and/or [0053] on a roof of a building, e.g. on a roof having a slope of 35 or more

[0054] without additional water storage materials, like water-storing felts or an additional layer of substrate, which are needed in conventional greening systems to ensure that the greening system exhibits a sufficient tare weight, and, therefore, is neither blown away nor flushed away during extreme weather situations. A further advantage of permanently fixing the composite according to the present invention on a pre-manufactured mounting frame is that shrinkage of the composite during complete drying-out is limited.

[0055] Generalized, the composite according to the present invention comprises a first material layer having a water permeability W.sub.1, wherein said first material layer is adjacent, preferably adhered [0056] to a second material layer having a water permeability W.sub.2, and optionally [0057] to a third material layer W.sub.3 having a water permeability W.sub.3,

[0058] wherein

[0059] W.sub.2 and W.sub.1 fulfill the relation W.sub.2<W.sub.1,

[0060] W.sub.3 fulfills the relations W.sub.3<W.sub.1, and W.sub.3=W.sub.2 or W.sub.3W.sub.2,

[0061] and wherein the composite is folded to exhibit a folded structure, wherein the folded structure comprises a plurality of folds, wherein the folds exhibit a meandering fold shape.

[0062] In a preferred embodiment the first material layer of said generalized composite is a first fabric layer.

[0063] In a further preferred embodiment the second material layer of said generalized composite is a second fabric layer.

[0064] In a further preferred embodiment the third material layer of said generalized composite is a third fabric layer.

[0065] In further preferred embodiments of said generalized composite the same applies for the first, second, and third material layer as already explained for the non-generalized composite of the present invention.

[0066] Furthermore, materials other than fabric layers may serve for the first, second, and, if present, for the third material layer, provided that their water permeabilities W.sub.1, W.sub.2, and W.sub.3 fulfill the relations required in the generalized composite. For example, a film or a perforated film may serve as the second material layer, if the water permeability W.sub.2 of said film or perforated film is lower than the water permeability W.sub.1 of the first material layer. Furthermore, a film or a perforated film may serve as the third material layer, if the water permeability W.sub.3 of said film or perforated film is [0067] lower than the water permeability W.sub.1 of the first material layer, and [0068] either equal to or different from the water permeability W.sub.2 of the second material layer.

[0069] In the following examples the composite according to the present is described in more detail.

EXAMPLE 1

[0070] A reinforced nonwoven, water-permeable fabric (XF 154 Wasserspeicher Recycling-Vlies obtainable from Bonar Xeroflor GmbH, Gro Ippener, DE, consisting of approx. 70 wt. % mixed recycled synthetic fibers made of synthetic polymers and approx. 30 wt. % cotton) having an areal density of 800 g/m.sup.2 was adhered to a fabric of woven tapes (PPX obtainable from Bonar Xeroflor GmbH, Gro Ippener, DE, consisting of woven tapes of polypropylene) having an areal density of 130 g/m.sup.2 by gluing in stripes.

[0071] The resulting composite was folded into a folded structure by the following method: Two rods of zinc-coated steel were fixed in a wood arbor. The composite was perforated at uniform distances. Said rods of zinc-coated steel were inserted in said uniform perforations of the composite, and the composite was pushed together with a folding pressure which is sufficiently high to obtain a folded structure which exhibits a plurality of folds wherein adjacent folds contact one another. The folded structure had a height of 1400 mm, a width of 800 mm and a thickness of 50 mm. Each folded structure exhibits a hinge 1 which defines a point at which a radius of curvature of the fold reaches its minimum value r.sub.min. The hinge 1 is flanked by a first limb 2 which extends from the hinge 1 to a first inflection point 3 which exhibits zero curvature. The first inflection point 3 is followed by a first line 4 of zero curvature. Furthermore, the hinge 1 is flanked by a second limb 2 which extends from the hinge 1 to a second inflection point 3 which exhibits zero curvature. The second inflection point 3 is followed by a second line 4 of zero curvature, and the first line 4 of zero curvature runs parallel to the second line 4 of zero curvature. Both the length of the first line 4 and the length the second line 4 is about 5 cm. The weight ratio of nonwoven, water-permeable fabric to fabric of woven tapes in the folded composite amounts to about 6:1.

[0072] The folded composite was installed vertically by placing the composite on the wood arbor, and was watered with the watering system MICRO DRIP from GARDENA on its front surface. The watering system contained 6 watering nozzles having a distance of 15 cm. The nozzles contacted the most upper fold of the composite. A water flow through the nozzles of maximally 1.5 liter per hour was provided at a working pressure of 2 bar. The folded composite was soaked with water along its whole front surface area, i.e., along its surface facing the watering system after about 7 hours. This result was obtained after the first time when the composite was brought into service. On the rear side of the folded composite no water was noticeable. The water was distributed exclusively along the meandering folds.

[0073] After about 65 hours at an air temperature of 14 C. and at a relative humidity of about 35 to 40% without any watering of the folded composite water was still noticeable by hand between the folds in the upper region of the composite at the front side of the folded composite. The amount of said water was sufficient to allow the growth of plants. In the lower region of the composite about 10 cm above the wood arbor humidity was clearly noticeable, i.e. in said lower region the composite was wet all over.

EXAMPLE 2

[0074] A reinforced nonwoven, water-permeable fabric (XF 154 R Wasserspeicher Recycling-Vlies obtainable from Bonar Xeroflor GmbH, Gro Ippener, DE, consisting of approx. 70 wt. % mixed recycled synthetic fibers made of synthetic polymers and approx. 30 wt. % cotton) having an areal density of 800 g/m.sup.2 was adhered to a fabric of woven tapes (Type SG 20/20 obtainable from Bonar Xeroflor GmbH, Gro Ippener, DE, consisting of woven tapes of polypropylene) having an areal density of 84 g/m.sup.2 by gluing in stripes.

[0075] The resulting composite was folded into a folded structure by the following method: Two rods of zinc-coated steel were fixed in a wood arbor. The composite was perforated at uniform distances. Said rods of zinc-coated steel were inserted in said uniform perforations of the composite, and the composite was pushed together with a folding pressure which is sufficiently high to obtain a folded structure which exhibits a plurality of folds wherein adjacent folds contact one another. The unfolded structure had a length of 4000 mm. The folded structure had a height of 500 mm, a width of 500 mm and a thickness of 50 mm. Each folded structure exhibits a hinge 1 which defines a point at which a radius of curvature of the fold reaches its minimum value r.sub.min. The hinge 1 is flanked by a first limb 2 which extends from the hinge 1 to a first inflection point 3 which exhibits zero curvature. The first inflection point 3 is followed by a first line 4 of zero curvature. Furthermore, the hinge 1 is flanked by a second limb 2 which extends from the hinge 1 to a second inflection point 3 which exhibits zero curvature. The second inflection point 3 is followed by a second line 4 of zero curvature, and the first line 4 of zero curvature runs parallel to the second line 4 of zero curvature. Both the length of the first line 4 and the length the second line 4 is about 5 cm. The weight ratio of nonwoven, water-permeable fabric to fabric of woven tapes in the folded composite amounts to about 10:1.

[0076] The geometrical area of the surface of the folded structure was 2 m.sup.2 (4000 mm length.Math.500 mm width).

Determination of the Residual Water Content

[0077] The determination was performed indoor at a temperature of about 20 C. and at a relative humidity of about 35%.

[0078] The folded structure was dipped for 24 h in a water bath so that the water level of the bath was above the highest felt of the structure. Thereafter, the water-soaked folded structure was taken out of the water bath and placed vertically for dripping. After 2 h the initial weight w.sub.i of the water in the folded structure was determined in [kg]. After certain time intervals the weight w.sub.t in the folded structure was determined in [kg] till w.sub.t dropped below 0.1 kg and till w.sub.r dropped below 2%. The residual water content w.sub.r after a time t was calculated in % by equation (1)

w.sub.r=(w.sub.t/w.sub.i).Math.100 [%](1).

[0079] The results are shown in table 1.

EXAMPLE 3

[0080] Example 3 was performed as example 2 with the only difference that the folded structure consisted of a nonwoven, water-permeable fabric (Type XF 159 obtainable from Neaustima and consisting of approx. 70 wt. % mixed recycled synthetic fibers made of synthetic fibers and approx. 30 wt. % cotton) having an areal density of 1200 g/m.sup.2. The results are shown in table 1.

EXAMPLE 4

[0081] Example 4 was performed as example 2 with the only difference that the folded structure consisted of a nonwoven, water-permeable fabric (Type XF 163 obtainable from Neaustima and consisting of approx. 70 wt. % mixed recycled synthetic fibers made of synthetic fibers and approx. 30 wt. % cotton) having an areal density of 600 g/m.sup.2. The results are shown in table 1.

[0082] Table 1 shows that after 1 day the residual water content w.sub.r of the folded structures of in the composites of examples 2, 3, and 4 are above 80%. After 7 days w.sub.r is 31% in the composite of example 2, 53% in the composite of example 3 and 40% in the composite of example 4. After 14 days w.sub.r is 5% in the composite of example 2, 27% in the composite of example 3 and 15% in the composite of example 4. It takes more than 16 days in the composite of example 2, more than 24 days in the composite of example 3, and more than 22 days in the composite of example 4 till w.sub.r drops below 2%.

TABLE-US-00001 TABLE 1 time Example 2 Example 3 Example 4 2 h W.sub.i [kg] = 4.55; W.sub.i [kg] = 5.65; W.sub.i [kg] = 5.1; w.sub.r [%] w.sub.r [%] w.sub.r [%] 1 day 86 84 83 2 days 70 79 71 3 days 58 69 63 4 days 49 65 58 5 days 43 61 52 6 days 36 57 46 7 day 31 53 40 8 days 26 49 35 9 days 23 45 31 10 days 20 43 27 11 days 16 37 25 12 days 12 34 21 13 days 9 30 18 14 days 5 27 15 15 days 4 23 12 16 days 2 20 9 17 days 18 8 18 days 15 6 19 days 12 5 20 days 10 4 21 days 7 3 22 days 4 2 23 days 3 24 days 2