• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A product a product for insulation of buildings. The boards of composite is attached to the walls. The composite comprises as example a foam layer and an aircrete layer. A method for its preparation is also disclosed.
    公开号:DK201870315A1
    申请号:DKP201870315
    申请日:2018-05-28
    公开日:2019-05-08
    发明作者:Gorm Hilding Rasmussen Elith
    申请人:H+H Danmark A/S；
    IPC主号:
    专利说明:

    Title: Insulating composite for insulation of buildings
    Abbreviations
    AAC - Autoclaved Aerated Concrete
    Description
    The present invention relates to an insulation component for buildings, a method for preparation of the insulation component, and uses of said insulation component.
    More specifically it relates to an insulation component comprising an insulation material and a hydrothermal hardened calcium silicate hydrate material, and a method for preparation of the insulation component.
    The governments around the civilized world face the consumers of energy for heating both in private housings and in industrial buildings with still higher requirements to lower heat loss to the environment in order to save energy and thus decrease CO2 emission. The purpose is to mitigate the increasing average temperatures and consequences of the climate change caused by e.g. increased concentration of CO2 in the air.
    The buildings today are insulated to avoid loss of heat through the walls.
    One typical method is to plaster the walls, if on the outside, with mineral wool and, put on top of that a wind barrier and finally cladding.
    First the wall is covered with laths of wood, then mineral wool is inserted between the laths. After that the wind barrier has to be created. On the wind barrier a ventilated cladding has to be mounted. Finally, the cladding is protected against algae and rod by painting the cladding with a chemical fungizide.
    DK 2018 70315 A1
    The disadvantages of the method of prior art are that the insulation process requires several steps and is very work intensive and costly.
    Maintaining the construction is work intensive and has to be done in short intervals.
    Thus, the objective problem of the invention is to provide a material for insulation of buildings whereby the heat loss and installation costs are lowered, while the fabrication process of the materials is not more expensive than materials of prior art.
    Summary of the invention.
    The above problem has surprisingly been solved by providing a material for insulation of buildings according to claim 1 wherein said material is a composite of a diffusive open rigid insulting layer and a diffusive open loadable hydrothermal hardened calcium silicate hydrate layer.
    The layers are attached to each other by an adhesive diffusive open layer or by the adhesive character of the first layer.
    The fire protecting by using the invention is highly improved compared with traditional methods due to the second layer which cannot bum.
    An anticipated embodiment of the invention as in claim 2 is where the diffusive open insulation material is a rigid phenol foam, which is attached to the diffusive open loadable hydrothermal hardened calcium silicate hydrate layer which may be an aircrete layer where the attachment is facilitated by an adhesive layer or, preferably, as anticipated by the adhesive character of the rigid phenolic foam layer when extruded on a support layer of glass fibre or a layer of aircrete.
    The layers are diffusive open and rigid, and the foam layer has a closed cell structure i.e. about 90% of the cells are closed.
    DK 2018 70315 A1
    A phenolic foam layer as the insulation layer provides a fire protection, which is highly improved compared to traditional methods for insulation as the second layer cannot bum and the first layer according to fire tests is much more resistant than other insulation materials to fire.
    An anticipated embodiment of the invention as in claim 3 is where the phenolic foam is formed from a liquid resol resin, calcium carbonate, using a catalyst and a blowing agent.
    Another embodiment is where the adhesive layer is a layer of a glue as anticipated in claim 4The adhesive layer may be a glue e.g. a thin layer mortar as claimed.
    The layer of glue is anticipated to be a Kunststofharzdispersion (synthetic aqueous copolymer dispersion) which as claimed in claim 5 is an air-hardening moistens fast synthetic aqueous copolymer dispersion which in the present case is based on styrene and an acrylic acid ester with a solid content of 20-80%, preferably 50% +/-1%.
    Other anticipated embodiments are as claimed in claim 5 to 9.
    Further product claims are, a wall made from two or more of the boards of insulting composites of the invention as claimed in claim 9.
    The invention further provides in claim 10 a board comprising at least a composite insulation material according to claim 11 wherein the board further comprises fixing means for attaching the board to a wall.
    A wall made from the boards of claim 10 or 11 is claimed in claim 12.
    An anticipated embodiment of such a wall is where the boards of insulating composites are of different thickness, claim 13.
    DK 2018 70315 A1
    An embodiment of a wall where the board are mechanically fixed are anticipated in claim 14, as in claim 15 combined with glue.
    Methods for preparing a composite of the invention are claimed in claim 16 to 19.
    A method of preparing the composite of the invention comprises the steps:
    - providing or preparing a diffusive open loadable hydrothermal hardened calcium silicate hydrate layer e.g. an aircrete layer by using standard methods as e.g. published in European Product Documentation on Nonreinforced aircrete, see the table below.
    - wait until the aircrete layer has cooled down,
    - prepare the a diffusive open rigid insulation material as a foam layer on the support layer using standard method for preparing foam boards, e.g. as published in Enviroment Product Declaration Koolterm K5,
    - and optionally cover the free side of the foam layer with a protective layer.
    Another anticipated method is wherein the diffusive open insulation material is a phenolic foam resin as claimed in claim 18 or 19.
    Another anticipated method comprises to prepare the composite by
    - preparing the foam layer on a support layer which also serves as a first protective layer,
    - provide an aircrete layer pre-prepared using standard methods,
    - applying an adhesive layer to the foam layer’s free side or to the aircrete layer using an adhesive allowing the final composite to be diffusive open,
    - attaching the foam layer to the adhesive layer whereby the foam layer is attached to the aircrete layer.
    DK 2018 70315 A1
    The aircrete may deviate in its composition for the example as follows.
    Base materials / Auxiliaries DescriptionValueUnitSand40-72%Cement9-45%Caustic lime10-20%Anhydrite / Gypsum2-5%Aluminium0.01-0.4%
    A third method is also claimed in claim 18.
    Further, claims 19 to 21 are claims on uses of a composite or a wall comprising the composite of the invention.
    In order that the invention may be well understood, some non-limiting examples will now be described in which:
    Fig. 1 shows a composite insulation board according to the invention for plastering a wall.
    The foam layer, 1, is attached to an aircrete layer, 2. Either, the foam layer is sticking to the aircrete layer, or an adhesive layer (not shown) joins the foam and aircrete layer together.
    Fig. 2 shows a composite insulation board according to the invention for rendering a wall for paint. The foam layer, 1, is attached to an aircrete layer, 2. Either, the foam layer is sticking to the aircrete layer, or an adhesive layer (not shown) joins the foam and aircrete layer together. The edges are chamfered.
    Fig. 3 shows a cross section of the board in Fig. 1 which has a plaster layer, 3, on the outside.
    Fig. 4 shows a cross section of the board in Fig. 2. The outmost layer is a layer of paint, 4. As seen, the edges are chamfered and the joint sealed, 5. The paint covers both the boards and the joint.
    DK 2018 70315 A1
    Fig. 5 shows an example of how composite insulations boards for plastering are installed.
    Fig. 6 shows an example of how composite insulations boards for paint are installed.
    Fig. 7 shows an example of a composite comprising in addition to an insulation layer, B, and an aircrete layer, D, also the support layers of e.g. diffusive open glass fibre layers, A. B is the phenolic foam insulation layer, C the adhesive layer and D the aircrete layer.
    One way of manufacturing of the phenolic foam needs a surface covering to prevent the foam from sticking to the production equipment but also a firm support layer or surface to form the foam. So, on the market such phenolic foam layers are sold sticking to a special glass surface with a releasable protective foil on the other surface. The composite layer of the invention may or may not comprise this support layer. Other manufacturing methods for preparing a phenolic foam layer may not need a surface covering or a firm support layer. Such another method may be the parallel vertical placement of two surfaces of any two of an aircrete wall or a firm support layer e.g. a glass plate and forming the foam layer in between this set of layers.
    The invention is now described in further detail and where possible by referring to the figures above.
    Fig. 1 to 7 show each at least one composite insulation board according to the invention for insulating a wall. It is anticipated that the foam layer may be made from a phenolic resin such as a resol resin.
    The insulating phenolic resin is commercially available and may be converted into a thermoset modified resin according to the known method published in
    DK 2018 70315 A1
    Kooltherm K5 from Kingspan. The thermoset modified resin may also be performed according to the example below. It has a composition, if it includes a facing material, of:
    About 70% resol resin, about 15% additives, 9% facing material e.g. a glass plate onto which the resin is foamed, and a propellant with no ozone depletion potential 5%. Due to the closed cells propellant remains in the closed cells.
    The thermoset modified resin is made from a liquid resol resin, calcium carbonate, additives and a blowing agent. The foam is rigid and has 90 % closed cells. The cell structure is formed in the resin under the influence of heat generated by the chemical reaction.
    A method for insulation of a building by insulation its walls comprises applying a layer of a glue to the first layer of said insulation composite and attaching said composite to the wall or vice versa.
    Another method for insulation of a building by insulating its walls is where an insulation composite has a protective layer on top a layer of glue. The method comprises removing said protective layer and attaching the composite to the wall.
    The boards are fixed to a wall either mechanically or with glue.
    An advantage of the composite of the invention is the combination of properties to improve the thermal insulation properties while maintaining a low thermal conductivity.
    Further advantages are:
    The second layer, 2, reduces noise as the mineral layer has a high density compared to conventional insulation composites for walls of buildings.
    The product is much more stable compared to traditional external thermal insulation composite systems (ETICS) against mechanical impacts.
    DK 2018 70315 A1
    The thickness of the second layer, 2, may also vary from board to board in order to obtain a variated design structured fagade surface.
    The composite of claim 2 is also very fire resistant and the composite cannot be modified by constructors making it very attractive for tall buildings from which it is difficult to escape in case of fire.
    Further, the insulation composite material of the invention provides a high heat capacity at the outside wall. The thermal buffer keeps up the temperature during night whereby less condensed water is generated, making it easier to keep the surface clean.
    Example
    A phenol layer may be prepared as follows:
    A phenol resole resin composition comprising 240 g of the commercially available liquid phenol formaldehyde resin supplied by Sumikomo Bakelite, R330, having a viscosity of 8000-10000 cP at 25°C, weight average molecular weight 600-1200 and pH 5,3 to 6,3, containing from 2 to 4% free phenol and 3 to 4% free formaldehyde, with a phenol/formaldehyde molar ratio of 1:2 and a water content of 11 to 13%, is mixed at 15oC with 12,0 g powdered urea and 6,0 g of a castor oil-ethylene oxide adduct as plasticiser and allowed to stand 14 hours. Then 12 g calcium carbonate is added and mixed into the resin until uniformly dispersed. Finally, 20 g of blended isopropyl chloride/isopentane 85/15 parts by weight as blowing agent is mixed at 1°C into the resin. Once a uniform suspension is formed the resin mixture is cooled to 8°C. Then 40,0 g liquid paratoluene sulfonic acid/xylene sulfonic acid blend 65/35 parts by weight at 92% concentration at 8°C is quickly mixed in. 200 g of the resin mix is quickly poured onto a glass plate, and then cured at elevated temperature 70°C. 50kPa is applied to a lid over the casing with the glass plate and foamed layer. The foam is cured for 10 minutes and cured in an oven afterwards for another 2 hours.
    DK 2018 70315 A1
    See also EP1922356B1 or EP1922357B1 for a description of a similar applicable process.
    权利要求:
    Claims (22)
    [1] 1. A composite insulation material for insulation of a building characterised in that it comprises at least two layers, where a first layer, 1, is a diffusive open rigid insulation material and a second layer, 2, is a diffusive open loadable hydrothermal hardened calcium silicate hydrate layer, the layers being attached to each other by an adhesive diffusive open third layer or, preferably, by the adhesive character of the first layer.
    [2] 2. A composite insulation material according to claim 1 wherein the first layer, 1, is a rigid phenolic foam with closed cells though still diffusive open and wherein the second layer, 2, is a diffusive open autoclaved aerated concrete layer.
    [3] 3. A composite insulation material according to claim 1 or 2 wherein the rigid phenol foam is prepared from a liquid resol resin and calcium carbonate using a catalyst and a blowing agent.
    [4] 4. A composite insulation material according to any of the claims 1 to 3 wherein said adhesive diffusive open third layer is a layer of glue such as a thin layer mortar.
    [5] 5. A composite insulation material according to claim 4 wherein said glue is an air-hardening moistens fast synthetic aqueous copolymer dispersion based on styrene and an acrylic acid ester with a solid content of 2080%, preferably 50% +/-1%.
    DK 2018 70315 A1
    [6] 6. A composite insulation material according to claim 5 wherein said synthetic aqueous copolymer dispersion is a styrol acrylic acid esters.
    [7] 7. A composite insulation material according to any of the claims 1 to 5 wherein the foam layer on the top of its free surface further comprises a layer of a glue.
    [8] 8. A composite insulation material according to claim 7 wherein said layer of glue is covered by a protective layer.
    [9] 9. A composite insulation material according to any of the claims 1 to 8 wherein the mineral layer of the second layer has a high thickness so as to provide a high mass density up to around 2200 kg/m3 compared to conventional rigid external thermal insulation composite systems (ETICS).
    [10] 10. A board comprising at least a composite insulation material according to any of the claims 1 to 9.
    [11] 11. A board comprising at least a composite insulation material according to claim 10 wherein the board further comprises fixing means for attaching the board to a wall.
    [12] 12. A wall with boards according to claims 10 or 11
    [13] 13. A wall of boards according to claim 10 or 11 wherein the boards have different thickness of the second layer, 2.
    [14] 14. A wall of claim 12 or 13 wherein the boards are mechanical fixed to the wall.
    [15] 15. A wall of claim 12 or 13 wherein the boards are mechanical fixed to the
    DK 2018 70315 A1 wall combined with glue.
    [16] 16. A method for preparing a composite for insulating a wall characterised in providing a second layer of a diffusive open loadable hydrothermal hardened calcium silicate hydrate layer, 2, and attaching a first layer, 1, which is a board made from a diffusive open rigid insulation material.
    [17] 17. A method for preparing a composite for insulating a wall characterised in applying a layer of a glue to a first layer, 1, which is a board made from a diffusive open rigid insulation material, and attaching the layer of glue to a second layer of a diffusive open loadable hydrothermal hardened calcium silicate hydrate layer, preferably, at a minimum forming temperature of 3-5°C for a film to dry and form a crack-free layer, the film hereby becoming soft and flexible film having a high resistance to water and alkali and low-water uptake.
    [18] 18. A method for preparing a composite for insulating a wall according to claim 16 or 17 wherein the diffusive open rigid insulation material is a diffusive open rigid phenol resin foam with a major part such as 90% closed cells, optionally prepared on a diffusive open glass fibre support layer, and wherein the diffusive open loadable hydrothermal hardened calcium silicate hydrate layer is a diffusive open autoclaved aerated concrete layer.
    [19] 19. A method for preparing a composite for insulating a wall according to claim 18 wherein the foam layer is prepared by mixing a phenol resole resin composition comprising 240 g of the commercially available liquid phenol formaldehyde resin, having a viscosity of 8000-10000 cP at 25°C, weight average molecular weight 600-1200 and pH 5,3 to 6,3, containing from 2 to 4% free phenol and 3 to 4% free formaldehyde, with a phenol/formaldehyde molar ratio of 1:2 and a water content of 11 to 13%, at 15oC with 12,0 g powdered urea and 6,0 g of a castor oil-ethylene
    DK 2018 70315 A1 oxide adduct as plasticiser and allow the mixture to stand 14 hours, adding 12 g calcium carbonate and mixing it into the resin until uniformly dispersed, and finally, mixing 20 g of blended isopropyl chloride/isopentane 85/15 parts by weight as blowing agent at 1°C into the resin, once a uniform suspension is formed the resin mixture is cooled to 8°C, 40,0 g liquid para-toluene sulfonic acid/xylene sulfonic acid blend 65/35 parts by weight at 92% concentration at 8°C is quickly mixed in, 200 g of the resin mix is quickly poured onto a glass plate, and then curing it at elevated temperature 70°C, applying 50kPa to a lid over a casing with the glass plate and foamed layer, the foam is cured for 10 minutes and cured in an oven afterwards for another 2 hours.
    [20] 20. Use of a composite insulation material according to any of the claims 1 to 9 for insulation of and plastering a wall or for insulation of and painting a wall.
    [21] 21. Use of a composite insulation material according to claim 9 for noise reduction of walls.
    [22] 22. Use of composite insulation materials according to any of the claims 1 to 9 for building a wall with complete fire protection.
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    同族专利:
    公开号 | 公开日
    EP3701100A4|2021-08-11|
    EP3701100A1|2020-09-02|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    CN205077710U|2015-08-25|2016-03-09|吉林市恒业科技有限公司|Wall body self preservation temperature building brick|
    法律状态:
    2019-05-08| PAT| Application published|Effective date: 20190428 |
    2021-01-11| PHB| Application deemed withdrawn due to non-payment or other reasons|Effective date: 20200729 |
    优先权:
    申请号 | 申请日 | 专利标题
    DKPA201770810|2017-10-27|
    DKPA201770810|2017-10-27|EP18870940.6A| EP3701100A4|2017-10-27|2018-10-22|Insulating composite for insulation of buildings|
    PCT/DK2018/050264| WO2019080978A1|2017-10-27|2018-10-22|Insulating composite for insulation of buildings|
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