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GB2448467A - Insulating panel - Google Patents

Insulating panel Download PDF

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Publication number
GB2448467A
GB2448467A GB0707676A GB0707676A GB2448467A GB 2448467 A GB2448467 A GB 2448467A GB 0707676 A GB0707676 A GB 0707676A GB 0707676 A GB0707676 A GB 0707676A GB 2448467 A GB2448467 A GB 2448467A
Authority
GB
United Kingdom
Prior art keywords
adhesive
layer
insulating panel
layers
laminated insulating
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.)
Withdrawn
Application number
GB0707676A
Other versions
GB0707676D0 (en
Inventor
Colin William Taylor
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.)
PARASOL PANEL SYSTEMS LLP
Original Assignee
PARASOL PANEL SYSTEMS LLP
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 PARASOL PANEL SYSTEMS LLP filed Critical PARASOL PANEL SYSTEMS LLP
Priority to GB0707676A priority Critical patent/GB2448467A/en
Publication of GB0707676D0 publication Critical patent/GB0707676D0/en
Priority to PCT/GB2008/001388 priority patent/WO2008129281A2/en
Publication of GB2448467A publication Critical patent/GB2448467A/en
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/007—Outer coverings for walls with ventilating means
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0885—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements specially adapted for being adhesively fixed to the wall; Fastening means therefor; Fixing by means of plastics materials hardening after application
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/18—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00—Other details of constructional parts for finishing work on buildings
    • E04F19/02—Borders; Finishing strips, e.g. beadings; Light coves
    • E04F19/06—Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements
    • E04F19/062—Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements used between similar elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00—Other details of constructional parts for finishing work on buildings
    • E04F19/02—Borders; Finishing strips, e.g. beadings; Light coves
    • E04F19/06—Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements
    • E04F19/065—Finishing profiles with a T-shaped cross-section or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/026—Porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/70—Scrap or recycled material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2327/00—Polyvinylhalogenides
    • B32B2327/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • 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
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/24—Structural elements or technologies for improving thermal insulation
    • 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

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)

Abstract

A planar laminated insulating panel (1), particularly suitable for use externally in the insulation of a building structure such as static caravans, park homes or mobile homes, includes a layer of aerogel fibre composite material (2), sandwiched between first and second layers (4,6) of a relatively flexible, in isolation, protective 10 plastic sheet material, by bonding with an adhesive(8,9). The laminated insulating panel (1) has sufficient rigidity in use so as to be self supporting. The panels may be bonded to a wall (10) by means of adhesive portions 12 leaving an air gap 14. T section edging strips may provide edging seals between panels.

Description

Insulating Panel The present invention relates to the provision of an
improved insulation panel suitable for use in the external thermal insulation of buildings and other structures.
There are a large number (about 200,000) low cost static caravan' or Park homes' in the United Kingdom and many more exist throughout the world. Such homes have relatively poor thermal insulation and acoustic insulation as a consequence of the lightweight and inexpensive construction of their walls and roofs. The walls of a typical static home consist of a timber frame with a loose polystyrene insulation. The frame is fitted with an internal plasterboard finish and an external cladding of 1.2mm coated steel, or a 6mm plywood layer with a cementatious rendered surface. Accordingly such buildings tend to be too cold in winter and too hot in summer conditions. This is a particular problem in winter conditions where expensive heating is required to maintain a reasonable temperature level.
The insulation of such low-cost buildings can be improved by applying secondary insulation. The secondary insulation may be applied as an internal layer. This has the disadvantage of reducing the space within the structure requiring the provision of new wall and ceiling finishes (e.g. a plasterboard layer) on top of the insulating material layer. Alternatively, different forms of insulated rendering may be applied to the external walls and/or roof of the structure. These are of varying effectiveness and can be difficult to apply. Conventional external insulated rendering panels are required to be at least 60mm thick to provide reasonable levels of insulation and require additional decoration after fitting. Existing methods of internal or external insulation also have the disadvantage that they require modifications to be carried out to the structure of the existing building, increasing the cost and inconvenience to the occupant. *... * *
It is an object of the present invention to provide thermal insulation that avoids or at least rninimises one or more of *:*. the disadvantages of known methods and constructions.
*****. * *
Thus according to a first aspect the present invention provides a planar laminated insulating panel, particularly suitable for use externally in the insulation of a building structure, comprising a layer of aerogel fibre composite material, sandwiched between first and second layers of a relatively flexible, in isolation, protective plastic sheet material, by bonding with an adhesive, said laminated insulating panel having sufficient rigidity in use so as to be self supporting.
It will be understood that the term self supporting in this context means that the insulating panels have sufficient rigidity to support their own weight without buckling or sagging, in use. For example, when insulating (cladding) a wall, the panels have sufficient rigidity, resistance to bending, so as to present a smooth, generally nonundulating or sagging appearance even if the wall to which they are attached is somewhat uneven. Insulating panels of the invention can be made in sizes up to 5m x l.35m, or greater, and still be self supporting. * *
The insulating panel of the invention is particularly suited for the external cladding insulation of an existing *:*. structure, for example a mobile home' or a caravan.
However, the panels can find other uses, for example in internal insulation of a building.
The insulating panel of the invention comprises a sheet of an aerogel fibre composite. Suitable aerogel fibre composite materials are available from Aspen Aerogels Inc of Northborough MA United States of America and sold under the trade name SpaceloftTM. These products combine a silica aerogel with reinforcing fibres to produce a flexible water repellent sheet material with exceptional insulating properties. The use of aerogel fibre composites as insulation generally is described in W02006/091812 (Aspen Aerogels Inc.) Aerogel fibre composite materials tend to be soft, deformable and somewhat friable and so susceptible to damage in handling and in use. The layers of protective plastic sheet material provide weather resistant, waterproof, protective outer layers to the insulating panel. Thus the aerogel fibre composite sheet is protected from damage and wear which would reduce its effectiveness as insulator. Furthermore, in use, when an adhesive is used to fix the panels of the invention to a wall or other surface, the plastic layer adjacent the wall provides a firm smooth substrate for the adhesive bonding between the wall and the panel. This makes fixing the panels to a structure, in on-site conditions, much easier than if the aerogel fibre composite sheet was to be itself directly bonded to the wall.
The sheet of aerogel fibre composite may be used in any thickness to produce the desired insulation level for the panel of the invention. The insulating panel may include more than one sheet of aerogel fibre composite bonded together to provide an increased thickness. Preferably a single 9mm thick sheet of aerogel fibre composite is employed. Sheets of this thickness have been found to produce the desired levels of thermal and sound insulation when panels of the invention are used to insulate a typical static park' or mobile home as described hereafter with reference to specific embodiments.
Preferably the first and second layers of plastic protective sheet material are thin, to minimise the overall thickness of the insulating panels. Preferably each layer have a thickness of 4mm or less. More preferably they are 3mm thick or less. Desirably they are of 2mm thickness.
Thinner layers may be employed provided the panels that result retain the required rigidity characteristics and S...
provide appropriate insulation levels and durability for the intended use. For some applications the first and *:*. second layers of protective plastic sheet may each have a different thickness. For example a thicker layer may be provided on the side of the panel that faces outwards, in use, to provide enhanced weather protection.
Preferably the protective plastic sheet material is of a PVC plastic material, desirably of a recycled and recyclable vc plastic material. Suitable 2mm thick PVC material is available from Novafloor of Coquelles, Calais, France and sold under the trade name NovacladTM. This material has the advantage that it can be painted or coated with decorative rendering, to increase its durability and present an attractive appearance. Particularly preferred insulating panels of the invention comprise a 9mm sheet of aerogej. fibre composite with a 2mm layer of a PVC flexible plastic laminated to each face. This provides a 13mm thick fully water repellent insulating panel with excellent thermal insulation and sound attenuation properties.
The first and second plastic layers and the aerogel fibre composite sheet are bonded together by an adhesive to form the planar laminated insulating panel. Preferably the adhesive employed is a polyurethane adhesive. More preferably the adhesive is a one component, water curable, * S..
polyurethane adhesive. Surprisingly, when a suitable adhesive is used to bond the relatively flexible plastic layers to the, highly flexible, aerogel sheet a rigid panel is obtained. Thus panels particularly suited to cladding the exterior of a structure are obtained. Suitable polyurethane adhesives include SikaforceTM -7120 L40, a one-component, polyurethane based adhesive available from Sika Limited, United Kingdom. Preferably a layer of adhesive of from 0.5mm to 1.0mm thickness is used. The layers of adhesive provide a strong bond between each layer of plastic sheet material and the aerogel fibre composite, to give a suitably rigid panel. The rigidity or stiffness of the panel means that simple overciadding of horizontal or vertical surfaces (walls or roofs) can be achieved without needing to remove or modify existing features such as window and door frames, fascias, soffits or vents. The S panels present a smooth planar finish to a structure, overlying any minor irregularities. They can readily be cut to fit round features such as window frames. When fitted the appearance of a smooth continuous wall or roof is obtained. I0
The panels of the invention, especially the particularly preferred 13mm thick panels described above, are lightweight and easily attached by a suitable adhesive to the walls of a structure such as a mobile home, without adding substantially to the overall dimensions of the structure. Furthermore, a panel of the preferred materials has been shown to have good fire resistance (one hour prevention of frame spreading) and complies with the relevant building regulations. Use of other possible materials for the protective layers has been found to be less satisfactory for various reasons. Surprisingly, even when using the preferred type of adhesive, both 2mm plywood layers and 1.8mm glass reinforced plastic (GRP) layers produced panels that tended to buckle or give an undulating appearance when used to clad a wall. Furthermore, a panel with a plywood surface would require weatherproofing (e.g. by painting) . GRP layers present the additional problem that they cannot readily be painted to produce a desired decorative finish.
According to a second aspect the present invention provides a method of manufacturing a planar laminated insulating panel, particularly suitable for use externally in the insulation of a building structure, and having sufficient rigidity in use so as to be self supporting, comprising the steps of: providing a layer of an aerogel fibre composite material and bonding first and second layers of a relatively flexible, in isolation, protective plastic sheet material to each face of the said layer of aerogel fibre composite material.
Preferably the adhesive is a water curable, one component polyurethane adhesive, which is applied to one side of the first layer of protective plastic sheet material and wetted with water to activate it. The layer of aerogel fibre composite is then applied to the activated adhesive layer and the second layer of protective plastic sheet material applied with the adhesive in similar fashion. Preferably the method further includes the step of vacuum pressing the insulating panel assembly during the curing of the adhesive. Preferably the vacuum pressing is carried out at a pressure of about 5 bar. The vacuum pressing has the advantage of applying a consistent even pressure to the insulating panel during curing of the adhesive and has been found to result in a strongly bonded, rigid panel with even external surfaces. Typically, with a water cureable, one-component, polyurethane adhesive a curing time of about two hours is required to fully set' the bonds between the layers of the panel.
According to a third aspect the present invention provides an insulating system for a structure comprising: planar laminated insulating panels, particularly suitable for external use in the insulation of a building structure, comprising a layer of aerogel fibre composite material, sandwiched between first and second layers of a relatively *S9.
flexible, in isolation, protective plastic sheet material, by bonding with an adhesive, said laminated insulating panel having sufficient rigidity in use so as to be self supporting; and edging sections, said edging sections being formed and arranged to frame the edge of a said panel in use of the insulating system.
The edging sections frame the edge of a panel, in use on a structure, enclosing the edge to prevent or reduce the ingress of air or moisture, thus maintaining the high thermal insulation properties of the aerogel fibre composite sheet. The edging sections may be formed from any suitable weather resistant material. Extruded PVC section is preferred. The edging sections may be snap-fit, channel or T' section in form to suit the framing required at any particular panel edge. For example, where a large expanse of wall is being clad with a number of insulating panels of the invention, they are laid substantially adjacent to each other on the wall to present a substantially Continuous cladding surface. The edging sections between panels may then be of a T' section shape with the cross bar of the T' forming a bridge between the edges of adjacent insulating panels as shown hereafter with reference to specific embodiments. * *.*
The insulating system of the invention may further comprise * SSU an adhesive for bonding the insulating panels to a structure in use of the system. Preferably the adhesive * employed is a single component, elastic, MS-polymer * S. :; universal bonding adhesive such as SABATM Seal-tack 750 MC-Polymer universal bonding adhesive available from SABA Dinxperlo By, Netherlands.
According to a fourth aspect the present invention provides a method for insulating a building structure comprising the steps of: providing planar laminated insulating panels, said panels comprising a layer of aerogel fibre composite material, sandwiched between first and second layers of a relatively flexible, in isolation, protective plastic sheet material, by bonding with an adhesive, said laminated insulating panel having sufficient rigidity in use so as to be self Supporting; and attaching said insulating panels to external surfaces of a said building structure.
Preferably said insulating panels are framed by edging sections and are laid on the external surface adjacent to each other so as to present a substantially continuous insulating layer. Preferably said panels are attached to an external surface of the building structure by adhesive bonding. Other means of fixing, for example, screws or bolts passing through the panels may be employed, but these will tend to lead to some loss of insulation performance due to "thermal bridging" across the fixings employed. a * S
* *:. Preferably a discontinuous layer of an adhesive is used to *:*. bond the insulating panels to the structure. For example an adhesive may be applied in lines or discrete portions (blobs') to either the panel or a wall or roof being insulated. The panel is then pressed to the wall/roof to attach it. By applying the adhesive in a discontinuous layer an air gap is formed, where the adhesive is not present, between the surface of the wall or roof and the insulating panels. This has the effect of providing enhanced thermal and acoustic insulation to the structure.
Further preferred features and advantages of the present invention will appear from the following detailed
description of some embodiments and test results
illustrated with reference to the accompanying drawings in which: Figure 1 shows schematically an insulating panel of the invention; and Figure 2 illustrates the attachment of insulating panels and edging strips to a wall.
Figure 1 shows on insulating panel 1 of the invention in cross section. The panel 1 comprises a 9mm thick sheet of :. an aerogel fibre composite sheet 2 sandwiched between two 2mm thick sheets of a recycled vc plastic sheet material :. 4,6. The PVC sheets 4,6 are bonded to the aerogel fibre * : composite sheet 2 by layers of a polyurethane adhesive 8,9 **.
I
*:*. which has the effect of making the panel 1 sufficiently rigid so as to be self supporting. The panel 1 has a total *I**.* * S thickness of only about 13mm but provides the highly effective thermal and acoustic insulation properties indicated in the test results given hereafter.
Figure 2 shows schematically the use of two insulating panels 1, of the same form as that shown in Figure 1, in the insulation of a wall 10. The panels 1 are bonded to the wall 10 by means of adhesive portions 12, leaving an air gap 14 between the wall 10 and the insulating panels 1 to give enhanced insulation. A PVC T' section edging strip 16 provides a bridging seal between the two panels 1 and is attached to the panels 1 by means of a suitable adhesive (not shown for clarity) . The insulating panels 1 and edging strips such as the T section example 16 constitute an insulating system of the invention.
Test results Insulating panels of the invention of the form shown in Figure 1 and described above were fitted to the exterior walls of a typical static "mobile home" by the means shown in Figure 2 and described above. A layer of conventional internal loft insulation was also installed. Before fitting * S* of the panels the external walls of the home were 60mm * thick, comprising 10mm internal plasterboard, 20mm loose polystyrene in the timber frame void and an external facing board with cementatjous render.
**S*.. * S
External and internal thermal imaging of the walls of the insulated mobile home, were compared to those of an adjacent, identical mobile home. The insulated and non-insulated mobile homes showed substantial differences.
Images taken of the non-insulated structure showed a large number of thermal anomalies i.e. the images indicated that there was substantial energy loss/warm air leakage from the structure. Images taken of the home fitted with panels of the invention showed relatively few anomalies, indicating a relatively uniform level of thermal insulation was being achieved. The thermal insulation performance (measured as the "U" value) of the two structures was obtained to quantify the improvement. The unmodified mobile home was found to have a very poor U value of 0.930 W/m2K. In contrast the mobile home fitted with the insulating panels of the invention was found to have a U value of 0.410 W/m2K, close to the currently accepted requirement for a conventionally constructed building of 0.35 W/m2K. Thus the panels and insulating system of the invention can provide :. exceptional thermal insulation to a structure, even those with such poor original insulation as found in a typical * *e.
mobile home. *S * * * **.
S S.. * . S *
S
S
SSSS** S 5

Claims (25)

  1. Claims 1. A planar laminated insulating panel for use externally in the
    insulation of a building structure, comprising a layer of aerogel fibre composite material, sandwiched between first and second layers of a relatively flexible, in isolation, protective plastic sheet material, by bonding with an adhesive, said laminated insulating panel having sufficient rigidity in use so as to be self Supporting.
  2. 2. A planar laminated insulating panel according to claim 1 wherein the layer of aerogel fibre composite comprises more than one sheet of aerogel fibre composite bonded together.
  3. 3. A planar laminated insulating panel according to claim 1 wherein a single 9mm thick sheet of aerogel fibre composite is employed.
  4. 4. A planar laminated insulating panel according to any one of claims 1 to 3 wherein each of the first and second layers of plastic protective sheet material have a thickness of 4mm or less.
  5. 5. A planar laminated insulating panel according to claim 4 wherein each of the first and second layers of plastic sheet material are of 2mm thickness.
  6. 6. A planar laminated insulating panel according to any preceding claim wherein the first and second layers of protective plastic sheet each have a different thickness.
  7. 7. A planar laminated insulating panel according to any preceding claim wherein the first and second layers of protective plastic sheet material are of a PVC plastic material.
  8. 8. A planar laminated insulating panel according to claim 7 wherein the first and second layers of protective plastic sheet material are of a recycled and recyclable PVC plastic material.
  9. 9. A planar laminated insulating panel according to claim 1 or claim 3 comprising a 9mm sheet of aerogel fibre composite with a 2mm layer of a PVC flexible plastic laminated to each face.
  10. 10. A planar laminated insulating panel according to any preceding claim wherein the adhesive employed is a polyurethane adhesive.
  11. 11. A planar laminated insulating panel according to claim 10 wherein the adhesive is a one component, water curable, polyurethane adhesive.
  12. 12. A planar laminated insulating panel according to any preceding claim wherein the adhesive is in a layer from 0.5mm to 1.0mm in thickness.
  13. 13. A method of manufacturing a planar laminated insulating panel, suitable for use externally in the insulation of a building structure, and having sufficient rigidity in use so as to be self Supporting, comprising the steps of: providing a layer of an aerogel fibre composite material and bonding first and second layers of a relatively flexible, in isolation, protective plastic sheet material to each face of the said layer of aerogel fibre composite material.
  14. 14. A method according to claim 13 wherein a water curable, one component polyurethane adhesive is employed for bonding and the method further comprises the steps of applying the adhesive to one side of the first layer of protective plastic sheet material and wetting it with water to activate it; applying the layer of aeroge]. fibre to the activated adhesive layer; and then bonding the second layer of protective plastic sheet material to the layer of aerogel fibre with the adhesive.
  15. 15. A method according to claim 13 or claim 14 wherein the insulating panel assembly is subjected to vacuum pressing during the bonding of at least one of the first and second layers of protective plastic sheet material to the layer of aerogel fibre composite material.
  16. 16. An insulating system for a structure comprising: planar laminated insulating panels, suitable for external use in the insulation of a building structure, comprising a layer of aerogel fibre composite material, sandwiched between first and second layers of a relatively flexible, in isolation, protective plastic sheet material, by bonding with an adhesive, said laminated insulating panel having sufficient rigidity in use so as to be self supporting; and edging sections, said edging sections being formed and arranged to frame the edge of a said panel in use of the insulating system.
  17. 17. An insulating system according to claim 16 wherein the edging sections are formed from extruded PVC section.
  18. 18. An insulating system according to claim 16 or claim 17 wherein the edging sections are snap-fit, channel or T' section in form to suit the framing required at any particular panel edge.
  19. 19. An insulating system according to any one of claims 16 to 18 further comprising an adhesive for bonding the insulating panels to a structure in use of the system.
  20. 20. An insulating system according to claim 19 wherein the adhesive employed is a single component, elastic, MS-polymer universal bonding adhesive.
  21. 21. A method for insulating a building structure comprising the steps of: providing planar laminated insulating panels, said panels comprising a layer of aerogel fibre composite material, sandwiched between first and second layers of a relatively flexible, in isolation, protective plastic sheet material, by bonding with an adhesive, said laminated insulating panel having sufficient rigidity in use so as to be self Supporting; and attaching said insulating panels to external surfaces of a said building structure.
  22. 22. A method according to claim 21 wherein said insulating panels are framed by edging sections and are laid on the external surface adjacent to each other so as to present a substantially continuous insulating layer.
  23. 23. A method according to claim 21 or claim 22 wherein said insulating panels are attached to an external surface of the building structure by adhesive bonding.
  24. 24. A method according to claim 23 wherein a discontinuous layer of an adhesive is used to bond the insulating panels to the structure.
  25. 25. A planar laminated insulating panel substantially as described hereinbefore and with reference to Figure 1 of the accompanying drawings.
GB0707676A 2007-04-20 2007-04-20 Insulating panel Withdrawn GB2448467A (en)

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PCT/GB2008/001388 WO2008129281A2 (en) 2007-04-20 2008-04-21 Insulating panel

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EP2277691A1 (en) * 2009-06-25 2011-01-26 Knauf Insulation Technology GmbH Aerogel comprising laminates
DE102010035165A1 (en) * 2010-08-23 2012-02-23 Roman Zahner Insulating element i.e. insulation board, for insulating ceiling of building, has adhesive agent surfaces made of planar layer from deformable adhesive with layer thickness of greater than or equal to specific mm and provided on rear side
ITPD20120065A1 (en) * 2012-03-05 2013-09-06 Everlux S R L PROCEDURE FOR THE REALIZATION OF A MATTER CONTAINING AEROGEL AND PLANT TO REALIZE THIS PROCEDURE
CN105735494A (en) * 2016-01-29 2016-07-06 卓达新材料科技集团有限公司 Novel aerogel vacuum insulation board and preparation method thereof
CN106121157A (en) * 2016-06-30 2016-11-16 上海澍澎新材料科技有限公司 A kind of aeroge integrated board collecting insulated fire sound insulation and decoration functions
CN103510654B (en) * 2012-06-20 2016-12-21 辽宁辽杰科技有限公司 A kind of high-strength anti-flaming sound-insulating and heat-insulating battenboard and preparation method thereof
GB2529269B (en) * 2014-08-15 2019-07-17 Clews Susan Insulation module assembly
EP3587699A1 (en) * 2018-06-22 2020-01-01 Fliesenmarkt Herberhold GmbH External wall

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WO2010126792A1 (en) 2009-04-27 2010-11-04 Ulrich Bauer Aerogel compositions and methods of making and using them
JP5620487B2 (en) 2009-07-29 2014-11-05 ダウ グローバル テクノロジーズ エルエルシー Thermal insulation polymer foam / airgel composite article
ITMO20110298A1 (en) * 2011-11-21 2013-05-22 Giemme S N C Di Corradini Marco & C PROCEDURE FOR CONSTRUCTION OF AN INSULATING PANEL AND RELATIVE INSULATING PANEL OBTAINED.
PT106781A (en) 2013-02-15 2014-08-18 Inst Superior Tecnico FLEXIBLE HYBRID AERIALS PREPARED IN SUBCRYTIC CONDITIONS AND PREPARATION PROCESS FOR THE SAME
JP6862651B2 (en) * 2015-08-28 2021-04-21 株式会社安藤・間 Adhesion method of heat insulating panel and sound insulation structure in directly attached heat insulating panel
TW201806911A (en) * 2016-04-27 2018-03-01 維蘇威克魯什伯公司 Lightweight ceramic thermal insulation materials
CN106592855A (en) * 2016-12-27 2017-04-26 上海城建物资有限公司 Precast aerogel reinforced concrete sandwich thermal insulation wallboard
CN107984820A (en) * 2017-12-22 2018-05-04 横琴国际知识产权交易中心有限公司 A kind of inner wall of building thermal insulation board

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EP2277691A1 (en) * 2009-06-25 2011-01-26 Knauf Insulation Technology GmbH Aerogel comprising laminates
DE102010035165A1 (en) * 2010-08-23 2012-02-23 Roman Zahner Insulating element i.e. insulation board, for insulating ceiling of building, has adhesive agent surfaces made of planar layer from deformable adhesive with layer thickness of greater than or equal to specific mm and provided on rear side
ITPD20120065A1 (en) * 2012-03-05 2013-09-06 Everlux S R L PROCEDURE FOR THE REALIZATION OF A MATTER CONTAINING AEROGEL AND PLANT TO REALIZE THIS PROCEDURE
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CN103510654B (en) * 2012-06-20 2016-12-21 辽宁辽杰科技有限公司 A kind of high-strength anti-flaming sound-insulating and heat-insulating battenboard and preparation method thereof
GB2529269B (en) * 2014-08-15 2019-07-17 Clews Susan Insulation module assembly
CN105735494A (en) * 2016-01-29 2016-07-06 卓达新材料科技集团有限公司 Novel aerogel vacuum insulation board and preparation method thereof
CN106121157A (en) * 2016-06-30 2016-11-16 上海澍澎新材料科技有限公司 A kind of aeroge integrated board collecting insulated fire sound insulation and decoration functions
EP3587699A1 (en) * 2018-06-22 2020-01-01 Fliesenmarkt Herberhold GmbH External wall

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WO2008129281A3 (en) 2009-01-15
WO2008129281A2 (en) 2008-10-30

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