WO2016038544A1 - Insulating layered device and method for insulating a wall - Google Patents

Insulating layered device and method for insulating a wall Download PDF

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Publication number
WO2016038544A1
WO2016038544A1 PCT/IB2015/056896 IB2015056896W WO2016038544A1 WO 2016038544 A1 WO2016038544 A1 WO 2016038544A1 IB 2015056896 W IB2015056896 W IB 2015056896W WO 2016038544 A1 WO2016038544 A1 WO 2016038544A1
Authority
WO
WIPO (PCT)
Prior art keywords
wall
insulating
layered device
insulating layered
gluing
Prior art date
Application number
PCT/IB2015/056896
Other languages
French (fr)
Inventor
Federico ZANNI
Original Assignee
Zanni Federico
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 Zanni Federico filed Critical Zanni Federico
Publication of WO2016038544A1 publication Critical patent/WO2016038544A1/en

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Classifications

    • 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
    • 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
    • E04B1/762—Exterior insulation of exterior walls
    • E04B1/7625—Details of the adhesive connection of the insulation to the wall
    • 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
    • E04B1/762—Exterior insulation of exterior walls
    • E04B1/7629—Details of the mechanical connection of the insulation to the wall
    • 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
    • E04B1/762—Exterior insulation of exterior walls
    • E04B1/7645—Exterior insulation of exterior walls with ventilation means for the insulation
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/3405—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by profiled spacer sheets
    • E04C2002/3411—Dimpled spacer sheets
    • E04C2002/3427—Dimpled spacer sheets with conical dimples

Definitions

  • the present invention relates to an insulating layered device for insulation of a wall, and to a method for insulating a wall by applying layers thereto.
  • the present invention relates to wall construction with regard to insulation of buildings, and to coverings or linings for walls comprising conduits for fluids.
  • thermal insulation of walls of a building can contribute to reducing heat loss (during the winter period) or heat build-up (during the summer period), thus increasing well-being of occupants and reducing energy consumption for heating or cooling of the inside of the building.
  • Document EP0159454A1 relates to an insulating facade coating with backside ventilation.
  • two foamed plastic insulating layers are applied to a wall and then covered with a plaster coat; the upper insulating layer is provided on its underside with an open hollow structure and forms together with the lower layer a ventilation and drainage channel system, which extends over the entire facade extent, thus providing rear- ventilation of the facade for removing moisture.
  • Document EP0204015A1 relates to a thermally insulated curtain- facade with rear ventilation, which consists of a board of insulating material with mutually spaced column-shaped spacers which are distributed over the entire board's side, and a covering board structure; the spacers provide unobstructed continuous air ducts for ventilation.
  • Document DE2938574A1 relates to a building heat insulation, comprising an external wall cladding with two layers of corrugated board, weatherproofed and impregnated to repel insects, cemented in a cruciform pattern; the air flowing in the corrugated board serves as a heat insulator.
  • the internal panel has larger perforations, while the external cover panel has fine perforations, and has a wire or plastics mesh for plaster adhesion.
  • foamed plastic insulating layers to a wall can result in a weak bond between layers, with the risk of the insulating layers detaching from the wall over the years. Even slight detachments of the insulating layers can be detrimental to the facade appearance, and moreover can cause possible danger of falling onto people or objects being in the vicinity of the wall.
  • some known construction techniques require to apply boards of insulating material which may be bulky and fragile, especially in case of foamed plastic materials.
  • the ventilated structure of some known insulating layers does not provide neither a satisfactory moisture evacuation performance, nor it is remarkably waterproof and steam-proof from the outside.
  • insulating plastic foam such as Polystyrene foam is somewhat a breathable material, so that moisture and humidity can pass through it, thus transferring water from the outside environment to the walls of the building.
  • the state of the art lacks a solution for an insulating layered device of improved performances.
  • an insulating layered device for insulation of a wall, a wall of a building comprising an insulated layered device and a method for insulating a wall by applying layers thereto, which comprise the features of the appended claims which are an integral part of the present description.
  • An idea at the basis of the present invention is to provide a insulating layered device which comprises a waterproof ventilation membrane having embossed a plurality of protrusions which define an internal air interspace for providing an airflow; the protrusions comprise respective abutment surfaces, for resting against a surface of a wall or of an internal or external cover of the wall, such as insulating panels or cover panels; as the edges of the ventilation membrane are at least partly open, air is allowed to outflow from the internal air interspace, thus evacuating moisture from the wall.
  • the protrusions have hollow bodies with respective openings facing towards a second side of the ventilation membrane which is opposite to the first side; these hollow bodies are configured as accumulation volume for gluing or cement paste which may be applied to the insulating layered device on the second side surface, for attachment to a wall or internal or external cover thereof.
  • the insulating layered device further comprises an adhesion membrane having a perforated fabric-like first sheet which is affixed to the second (waterproof) side of the insulating layered device; the fabric-like sheet comprises a plurality of holes for passage of gluing or cement paste and subsequent accumulation inside the hollow bodies.
  • the protrusions are made by plastic molding, and require no machining of the material; seen from the waterproof and non-ventilated second side of the insulating layered device, these protrusions resemble a bas-relief.
  • such structure of the insulating layered device is more sturdy, is easier to transport (as it can be rolled up) and provides an overall effectiveness during construction works.
  • these protrusions allow to create an air channel inside the internal air interspace; at the same time these protrusions provide for gaps inside the hollow bodies which can be filled by glue or cement in the liquid state; this glue or cement by solidifying inside the gaps ensures substantial mechanical coupling between the wall or cover thereof, and insulating layered device.
  • the insulating layered device constitutes a fundamental element of safety, reducing the risks of any detachment from the adhesive substrate, which may also occur as a result of structural movements within the building.
  • the adhesion can be improved as above for any side of the facade to which the insulating layered device is applied.
  • the second (holed) side of the insulating layered device can be applied either: to the wall of the building or cover thereof (such as an insulating cover); or to the facade covers towards the external surface of the wall (such as laminated stoneware and/or plaster). Therefore, after solidification of the adhesive penetrated into the gaps of the hollow bodies, an improved mechanical coupling between the substrate and the membrane is provided.
  • the ventilation effects and the characteristics of breathability of the insulating layered device will remain.
  • the insulating layered device provides for ventilation within the wall, to be further covered by a facade using laminated stoneware slabs or plaster, placed over the ventilated membrane.
  • the peculiar structure of the internal air interspace allows the movement of ascending air for stack effect.
  • the insulating layered device comprises a transpiration membrane comprising a permeable fabric-like second sheet, affixed to the abutment surfaces of the protrusions; the transpiration membrane can be attached by means of second gluing or cement paste to a wall or internal cover thereof (such as an insulating cover inside the wall), thus providing improved moisture transfer and evacuation.
  • the second fabric-like sheet further comprises a second plurality of holes configured for passage of moisture from the wall to the internal air interspace, and further configured for passage of the second gluing or cement paste applicable to the first side of the insulating layered device; at least a portion of said internal air interspace is configured to receive the second gluing or cement paste so as to act as second accumulation volume; the transpiration membrane can thus be applied to a wall or internal cover thereof (such as an insulating cover inside the wall).
  • the insulating layered device has a ventilated membrane and presents two layers on the opposite sides of the structure; the transpiration layer which is applied in direct contact with the building wall has its own peculiar permeability, while the adhesion layer in contact with the surface finish of the facade (such as laminated stoneware and/or plaster) is remarkably waterproof.
  • the insulating layered device provides for a sandwich structure having an internal air gap which creates a stack effect, which results in a ventilated ascending motion which allows a better insulation of the walls.
  • the microvortices of air ascending moving around the protrusions thanks to the peculiar breathable layer of the transpiration membrane, in addition to thermally and acoustically insulating the wall also inhale the steam and the humidity of the walls, allowing a drying effect even in presence of a continuous humidification process.
  • an impermeable layer protects the facade against the action of rain, wind and pollutants, providing great advantages in terms of thermal and acoustic insulation, since the thermal insulation provided by the air inside of the insulating layered device better exploits the thermal inertia of the materials and the reflection of sunlight contributing to the stack effect, so as to prevent accumulation of heat in the warm season and to limit the dispersion of heat in the cold season.
  • the wall ventilation is provided by stack effect, which is increased by heat; the insulating layered device becomes even more effective during summer seasons, as the more heat is absorbed by the wall, the more ventilation and insulation happens within the insulating layered device.
  • the present invention provides for a method for insulating a wall by applying layers thereto, by providing an insulating layered device according to the invention.
  • Figure 1 represents a first embodiment of an insulating layered device applied to a first wall.
  • Figure 2 represents a second embodiment of an insulating layered device applied to a second wall.
  • Figure 3 represents an enlarged detail of the insulating layered device of Fig. 1.
  • Figure 4 represents a third embodiment of an insulating layered device applied to a third wall.
  • Figure 5 represents a fourth embodiment of an insulating layered device applied to a fourth wall.
  • Figure 1 represents a preferred embodiment of an insulating layered device 1 applied to a first wall 100.
  • the insulating layered device 1 is applied over a plastic foam insulation layer 101 attached to the wall 100 by means of a glue or cement paste 102.
  • the insulating layered device 1 comprises a ventilation membrane 2 comprising a waterproof sheet having embossed thereon a plurality of protrusions 3.
  • the protrusions 3 define an internal air interspace in the insulating layered device 1 for providing an airflow along a first side surface (left side in Fig. 1) of the ventilation membrane 2.
  • the border edges of said ventilation membrane 2 are at least partly open to allow air outflow from said internal air interspace.
  • the insulating layered device 1 is preferably supported by a support 103, which comprise a perforated rigid structure; the support 103 increases mechanical stability of the insulating layered device 1 attached to the wall 100, and provides a regulated entry of airflow inside the air interspace, while at the same time avoiding dirt and insects to penetrate inside the ventilation membrane 2.
  • the insulating layered device 1 further comprises an adhesion membrane 4 comprising a perforated fabric-like first sheet.
  • the adhesion membrane 4 is affixed to a second side surface (right side in Fig. 1) of the ventilation membrane 2.
  • the insulating layered device 1 has, at the internal air interspace, a waterproof side of the ventilation membrane 2, which is waterproof towards the second side surface (outside of the wall 100).
  • the waterproof side is configured for application of wall covering material 104, such as laminated stone, tiles such as porcelain tiles, or plaster, which is attached to the insulating layered device 1 by means of gluing or cement paste 105.
  • the insulating layered device 1 further comprises a transpiration membrane 5 comprising a permeable fabric-like second sheet affixed to the first side (internal) surface of the ventilation membrane 2.
  • the transpiration membrane 5 is attached by means of second gluing or cement paste 106 to the internal cover 101, thus providing moisture transfer from the wall 100 to said internal air interspace of the ventilation membrane 2.
  • the ventilation layer could be reversed, attaching the second (waterproof) side to the wall 100 or cover 101 thereof, and the first (ventilated) side to the external cover 104, preferably without employing the adhesion membrane 4 and/or the transpiration membrane 5, for general insulating purposes; although this variant has decreased performances, it is easier and cheaper to manufacture.
  • the ventilation membrane 2 is preferably waterproof, and more preferably steam-proof as well.
  • the ventilation membrane 2 is preferably made of a layer of plastic, and is preferably made of a layer of Polyethylene.
  • the protrusions of the ventilation membrane are sized so as to be resistant to loads and mechanical stresses.
  • the transpiration membrane and/or the adhesion membrane are fabric-like sheets made of Polypropylene.
  • the first or second sheet is permeable to air, so as to allow evaporation at the internal side of the wall, and increase exsiccation of gluing or cement paste at the external side of the wall.
  • the first and second sheet are made of the same fabric and have the same features, for reducing costs.
  • the insulating layered device 1 is preferably associated by a further plurality of layers of insulating material and of gluing or cement paste, in order to increase insulation.
  • Such fixing means may include a wall plug / screw anchor 107, a screw 108 and a retaining element 109 applied to the external side of the insulating layered device 1, for increased mechanical stability.
  • the open-cell structure of insulating layered device 1, comprising alveoli allows for the creation of an internal air interspace, wherein air flows for stack effect. This causes an ascending ventilation flow, which allows for an improved thermal insulation of the building, plus it allows the evacuation of water steam which dampens the building, thus eliminating moisture from the walls.
  • the plurality of alveoli are in fluidic connection by means of a dense network of micropores, which provides for an excellent insulation of the building and, by suction effects, provides for moisture transfer to the alveoli system for subsequent evaporation.
  • the decompression effect due to the relevant airflow which takes place inside of the layer, is such that microvortices are created, which thermally insulate the walls and suction the water vapor, allowing for wall exsiccation even in conditions of continuous dampening of the building, such as in below-ground walls or wet foundations or for diffuse water infiltrations.
  • the usage in building and reconstructing of the structure of the insulating layered device comprising alveoli allows for better insulating the walls by means of a ventilated internal air interspace.
  • the alveolar structure of the ventilation membrane 2 having open interspace cells that are preferably applied under the wall surface finish (such as laminated stoneware 104) allows to realize within the structural sandwich a gap of air, which for stack effect results in a ventilated ascending motion of air.
  • This air better insulates the walls as well as allows to disperse the water vapor coming from the walls, thus eliminating moisture from the walls.
  • the alveoli are in fluidic connection with each other through a network of micropores, which in addition to ensuring perfect adhesion to the wall's surfaces, by osmosis allow moisture transport to the bigger receptacles closer to the protrusions in the internal air interspace, from which water is subsequently vaporized.
  • Figure 2 represents a second embodiment of an insulating layered device 1 applied to a second wall 200 made of cement.
  • the insulating layered device 1 of Figure 2 substantially corresponds to the device 1 above described with reference to Figure 1 ; it can thus be appreciated the flexibility of application to any kind of wall. Other components of the device 1 are analogous to what has been previously described.
  • Figure 3 represents an enlarged view of the insulating layered device 1, as derived from Fig. 1.
  • the protrusions 3 have hollow bodies each of which comprises a respective opening 301.
  • the openings 301 face towards the second side surface (waterproof side) of the ventilation membrane 2 which is opposite to said first side surface (transpiration side).
  • the hollow bodies of the protrusions 3 are configured as accumulation volume for gluing or cement paste 105, which is applicable to the insulating layered device 1 on said second side surface, for attachment to the external cover thereof.
  • the transpiration membrane and/or adhesion membrane can be omitted and the side surfaces comprising openings 30 lean be attached to the wall 100 or internal cover 101.
  • this variant has decreased performances, it is easier and cheaper to manufacture.
  • the first sheet of the adhesion membrane 4 comprises a plurality of holes 302 which are configured for passage of the gluing or cement paste 105 for accumulation inside the hollow bodies of the protrusions 3.
  • the protrusions 3 comprise respective abutment surfaces 300, for resting against a flat surface, such as the surface of the internal (insulating) cover 101 as depicted, or alternatively a flat surface of the wall 100 or external cover 104 thereof.
  • the transpiration membrane 5 is affixed to the abutment surfaces 300, over the first side (transpiration) surface of the ventilation membrane 2.
  • the second sheet of the transpiration membrane 5 further comprises a second plurality of holes 303 configured for passage of the moisture from the wall 100 (through the foam insulating layer 101) to the internal air interspace of the ventilation membrane 2.
  • the second plurality of holes 303 are further configured for passage of the second gluing or cement paste 106 applied to the first side of the insulating layered device 1, and a portion of the internal air interspace within the protrusions 3 is configured as second accumulation volume for the second gluing or cement paste 106.
  • the height of the protrusions 3 is at least 80%, preferably at least 90%, of the total thickness of said ventilation membrane 2.
  • the protrusions 3 comprise regularly spaced protrusions arranged according to a grid, for example as visible in Figure 3.
  • the protrusions 3 have truncated-conical shape, for example as visible in Figure 3.
  • the protrusions 3 could have a cylindrical shape. These round-section shapes have been found to better perform while interacting with the air ascending in the internal air interspace.
  • Figure 4 represents a third embodiment of an insulating layered device 1 applied to a third wall.
  • the transpiration membrane 5 is directly attached by means of second gluing or cement paste 106 to the wall 400, thus providing moisture transfer from the wall 400 to said internal air interspace of the ventilation membrane 2.
  • Other elements are analogous to what has been previously described.
  • Figure 5 represents a fourth embodiment of an insulating layered device applied to a fourth wall.
  • the transpiration membrane 5 is directly attached to a different wall 500 made of cement.
  • Other elements are analogous to what has been previously described.
  • the present invention relates to a method for insulating a wall by applying layers thereto.
  • the method provides for all the steps which are necessary for applying an insulating layered device 1 as herein described and claimed.
  • the insulating layered device according to the present invention can be associated to an external surface finish of the wall, such as laminated stoneware or plaster, or to a wide range of other surface finishes.
  • the thermal protection conferred to the building contributes to the definition of an aesthetic quality, allowing the development of multiple solutions tailored to the specific needs of each building project, to freely express the architectural idea while abandoning technical constraints for the support structures.
  • the ventilated wall comprising an insulating layered device according to the present invention, can be used without distinction for insulation of new concrete walls, for the recovery of an old facade and for the dehumidifying restoration and conservation of all types of masonry.
  • the insulating layered device according to the present invention improves performances of the insulation system, eliminates the moisture from the walls and is a remarkably waterproof product for the outside of the facade. Ease of installation, lightweight of the wall cover and easiness of application make the device according to the present invention a convenient solution to cover a wall facade.
  • the insulating devices secures all the advantages of wall ventilation combined with the strength of a bonded coating.
  • the insulating layered device has an overall thickness of approximately 12 mm, plus the thickness of any further insulation panel (i.e. foam) or facade cover (such as stoneware laminate); the combined weight for a total thickness of 35mm is less than 12 Kg for square meter of wall cover.
  • more than one insulating layered device according to the present invention can be superimposed one over the other, in further layers.
  • an insulating layered device according to the present invention can be applied to a wall in further combination with any other compatible insulating device.
  • the insulating layered device can be further supplemented with devices known in the art, for example could be supplemented by an external net structure for improving plaster adhesion.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Building Environments (AREA)
  • Polymers With Sulfur, Phosphorus Or Metals In The Main Chain (AREA)
  • Materials For Medical Uses (AREA)

Abstract

The present invention relates to an insulating layered device (1) for insulation of a wall (100, 200, 300, 400), comprising: a ventilation membrane (2) comprising a waterproof sheet having embossed thereon a plurality of protrusions (3) which define an internal air interspace in the insulating layered device (1); the internal air interspace is configured for providing an airflow along a first side surface of the ventilation membrane (2); the protrusions (3) comprise respective abutment surfaces (300) for resting against a surface of the wall (100, 200, 300, 400) or internal (101) or external cover thereof; the edges of the ventilation membrane (2) are at least partly open to allow air outflow from the internal air interspace; the protrusions (3) have hollow bodies each of which comprises a respective opening (301); the openings (301) face towards a second side surface of the ventilation membrane (2) which is opposite to the first side surface; the hollow bodies are configured as accumulation volume for gluing or cement paste (105) applicable to the insulating layered device (1) on the second side surface, for attachment of the insulating layered device (1) to the wall (100, 200, 300, 400) or internal (101) or external cover (104) thereof. The present invention also relates to a wall of a building comprising an insulated layered device, and to a method for insulating a wall.

Description

INSULATING LAYERED DEVICE AND METHOD FOR INSULATING A WALL
DESCRIPTION
Technical Field
The present invention relates to an insulating layered device for insulation of a wall, and to a method for insulating a wall by applying layers thereto.
In general, the present invention relates to wall construction with regard to insulation of buildings, and to coverings or linings for walls comprising conduits for fluids.
Background art
In order to improve thermal efficiency of buildings, thermal insulation has become increasingly important. Thermal insulation of walls of a building can contribute to reducing heat loss (during the winter period) or heat build-up (during the summer period), thus increasing well-being of occupants and reducing energy consumption for heating or cooling of the inside of the building.
It is widely known to perform thermal insulation of walls of buildings by laying different layers of insulating material, in direct contact with each other, on the facade of the building. A common way of insulating building walls is to apply over the walls a thick layer of insulating plastic foam, such as Polystyrene foam, and then to apply plaster onto the foam. In this way, a degree of thermal insulation of the building can be achieved; however, by applying a layer of insulating plastic foam the moisture balance of the walls may become impaired and excessive moisture build-up in the walls may happen, leading to damaged, moldy or rotten walls.
In order to avoid moisture build up in insulated walls, ventilated insulation has been proposed according to the prior art.
Document EP0159454A1 relates to an insulating facade coating with backside ventilation. According to document EP0159454A1, two foamed plastic insulating layers are applied to a wall and then covered with a plaster coat; the upper insulating layer is provided on its underside with an open hollow structure and forms together with the lower layer a ventilation and drainage channel system, which extends over the entire facade extent, thus providing rear- ventilation of the facade for removing moisture.
Document EP0204015A1 relates to a thermally insulated curtain- facade with rear ventilation, which consists of a board of insulating material with mutually spaced column-shaped spacers which are distributed over the entire board's side, and a covering board structure; the spacers provide unobstructed continuous air ducts for ventilation. Document DE2938574A1 relates to a building heat insulation, comprising an external wall cladding with two layers of corrugated board, weatherproofed and impregnated to repel insects, cemented in a cruciform pattern; the air flowing in the corrugated board serves as a heat insulator. According to DE2938574A1, the internal panel has larger perforations, while the external cover panel has fine perforations, and has a wire or plastics mesh for plaster adhesion.
Still, the known solution for ventilated insulations according to the prior art present some disadvantages.
For example, the application of foamed plastic insulating layers to a wall can result in a weak bond between layers, with the risk of the insulating layers detaching from the wall over the years. Even slight detachments of the insulating layers can be detrimental to the facade appearance, and moreover can cause possible danger of falling onto people or objects being in the vicinity of the wall.
Moreover, for example, some known construction techniques require to apply boards of insulating material which may be bulky and fragile, especially in case of foamed plastic materials.
Moreover, for example, the ventilated structure of some known insulating layers does not provide neither a satisfactory moisture evacuation performance, nor it is remarkably waterproof and steam-proof from the outside. In fact, insulating plastic foam such as Polystyrene foam is somewhat a breathable material, so that moisture and humidity can pass through it, thus transferring water from the outside environment to the walls of the building. In general, the state of the art lacks a solution for an insulating layered device of improved performances.
More in general, the state of the art lacks a solution for insulating a wall by applying layers thereto that is more practical, convenient and effective.
Summary of the invention
It is an object of the present invention to provide an insulating layered device for insulation of a wall, and a method for insulating a wall by applying layers thereto which are alternative to known solutions.
In particular, it is an object of the present invention to provide an insulating layered device whose adhesion to a wall is more secure and more stable, and whose application is easier, faster and more reliable.
It is also an object of the present invention to provide an insulating layered device which is sturdy and easier to transport.
It is also an object of the present invention to provide an insulating layered device which has better waterproof capability on the outside, and at the same time improved transpiration capability on the inside, in order to evacuate moisture from the wall.
It is also an object of the present invention to provide an insulating layered device which provides a more effective evacuation of moisture from the wall.
It is also an object of the present invention to provide an insulating layered device which provides a lasting and more stable construction of the layered wall.
It is also an object of the present invention to provide an insulating layered device which is improved with regard to safety of the insulated wall.
It is also an object of the present invention to provide an insulating layered device which is waterproof, soundproof and effective for energy savings.
In particular, it is a further object of the present invention to provide a method for insulating a wall which is also improved in the respects mentioned above.
These and further objects of the present invention are achieved by an insulating layered device for insulation of a wall, a wall of a building comprising an insulated layered device and a method for insulating a wall by applying layers thereto, which comprise the features of the appended claims which are an integral part of the present description.
An idea at the basis of the present invention is to provide a insulating layered device which comprises a waterproof ventilation membrane having embossed a plurality of protrusions which define an internal air interspace for providing an airflow; the protrusions comprise respective abutment surfaces, for resting against a surface of a wall or of an internal or external cover of the wall, such as insulating panels or cover panels; as the edges of the ventilation membrane are at least partly open, air is allowed to outflow from the internal air interspace, thus evacuating moisture from the wall.
According to an aspect, the protrusions have hollow bodies with respective openings facing towards a second side of the ventilation membrane which is opposite to the first side; these hollow bodies are configured as accumulation volume for gluing or cement paste which may be applied to the insulating layered device on the second side surface, for attachment to a wall or internal or external cover thereof.
Preferably, the insulating layered device further comprises an adhesion membrane having a perforated fabric-like first sheet which is affixed to the second (waterproof) side of the insulating layered device; the fabric-like sheet comprises a plurality of holes for passage of gluing or cement paste and subsequent accumulation inside the hollow bodies.
Advantageously, the protrusions are made by plastic molding, and require no machining of the material; seen from the waterproof and non-ventilated second side of the insulating layered device, these protrusions resemble a bas-relief. Advantageously, such structure of the insulating layered device is more sturdy, is easier to transport (as it can be rolled up) and provides an overall effectiveness during construction works.
Advantageously, these protrusions allow to create an air channel inside the internal air interspace; at the same time these protrusions provide for gaps inside the hollow bodies which can be filled by glue or cement in the liquid state; this glue or cement by solidifying inside the gaps ensures substantial mechanical coupling between the wall or cover thereof, and insulating layered device. The insulating layered device constitutes a fundamental element of safety, reducing the risks of any detachment from the adhesive substrate, which may also occur as a result of structural movements within the building.
Advantageously, the adhesion can be improved as above for any side of the facade to which the insulating layered device is applied. In fact the second (holed) side of the insulating layered device can be applied either: to the wall of the building or cover thereof (such as an insulating cover); or to the facade covers towards the external surface of the wall (such as laminated stoneware and/or plaster). Therefore, after solidification of the adhesive penetrated into the gaps of the hollow bodies, an improved mechanical coupling between the substrate and the membrane is provided.
Advantageously, in any case the ventilation effects and the characteristics of breathability of the insulating layered device will remain. In fact, the insulating layered device provides for ventilation within the wall, to be further covered by a facade using laminated stoneware slabs or plaster, placed over the ventilated membrane. The peculiar structure of the internal air interspace allows the movement of ascending air for stack effect.
According to a further aspect, the insulating layered device comprises a transpiration membrane comprising a permeable fabric-like second sheet, affixed to the abutment surfaces of the protrusions; the transpiration membrane can be attached by means of second gluing or cement paste to a wall or internal cover thereof (such as an insulating cover inside the wall), thus providing improved moisture transfer and evacuation.
Preferably, the second fabric-like sheet further comprises a second plurality of holes configured for passage of moisture from the wall to the internal air interspace, and further configured for passage of the second gluing or cement paste applicable to the first side of the insulating layered device; at least a portion of said internal air interspace is configured to receive the second gluing or cement paste so as to act as second accumulation volume; the transpiration membrane can thus be applied to a wall or internal cover thereof (such as an insulating cover inside the wall).
In a preferred embodiment, the insulating layered device has a ventilated membrane and presents two layers on the opposite sides of the structure; the transpiration layer which is applied in direct contact with the building wall has its own peculiar permeability, while the adhesion layer in contact with the surface finish of the facade (such as laminated stoneware and/or plaster) is remarkably waterproof.
Advantageously, the insulating layered device provides for a sandwich structure having an internal air gap which creates a stack effect, which results in a ventilated ascending motion which allows a better insulation of the walls. The microvortices of air ascending moving around the protrusions, thanks to the peculiar breathable layer of the transpiration membrane, in addition to thermally and acoustically insulating the wall also inhale the steam and the humidity of the walls, allowing a drying effect even in presence of a continuous humidification process.
In addition to the above, through the waterproof side of the adhesion membrane, an impermeable layer protects the facade against the action of rain, wind and pollutants, providing great advantages in terms of thermal and acoustic insulation, since the thermal insulation provided by the air inside of the insulating layered device better exploits the thermal inertia of the materials and the reflection of sunlight contributing to the stack effect, so as to prevent accumulation of heat in the warm season and to limit the dispersion of heat in the cold season.
Moreover, the wall ventilation is provided by stack effect, which is increased by heat; the insulating layered device becomes even more effective during summer seasons, as the more heat is absorbed by the wall, the more ventilation and insulation happens within the insulating layered device.
According to a further aspect, the present invention provides for a method for insulating a wall by applying layers thereto, by providing an insulating layered device according to the invention.
Further aspects and advantageous technical features of the present invention, are set out in the dependent claims.
Brief description of the drawings Further features and advantages of the present invention will become apparent in the detailed description of preferred non-exclusive embodiments, which are described as non-limiting examples with the help of the annexed drawings, wherein:
Figure 1 represents a first embodiment of an insulating layered device applied to a first wall.
Figure 2 represents a second embodiment of an insulating layered device applied to a second wall.
Figure 3 represents an enlarged detail of the insulating layered device of Fig. 1.
Figure 4 represents a third embodiment of an insulating layered device applied to a third wall.
Figure 5 represents a fourth embodiment of an insulating layered device applied to a fourth wall.
In general, the drawings may illustrate different aspects and embodiments of the present invention and, where appropriate, like elements or components or materials or actions in different figures are indicated by analogous reference numbers.
Detailed description of embodiments
Figure 1 represents a preferred embodiment of an insulating layered device 1 applied to a first wall 100.
The insulating layered device 1 is applied over a plastic foam insulation layer 101 attached to the wall 100 by means of a glue or cement paste 102.
The insulating layered device 1 comprises a ventilation membrane 2 comprising a waterproof sheet having embossed thereon a plurality of protrusions 3. The protrusions 3 define an internal air interspace in the insulating layered device 1 for providing an airflow along a first side surface (left side in Fig. 1) of the ventilation membrane 2. The border edges of said ventilation membrane 2 are at least partly open to allow air outflow from said internal air interspace.
The insulating layered device 1 is preferably supported by a support 103, which comprise a perforated rigid structure; the support 103 increases mechanical stability of the insulating layered device 1 attached to the wall 100, and provides a regulated entry of airflow inside the air interspace, while at the same time avoiding dirt and insects to penetrate inside the ventilation membrane 2.
The insulating layered device 1 further comprises an adhesion membrane 4 comprising a perforated fabric-like first sheet. The adhesion membrane 4 is affixed to a second side surface (right side in Fig. 1) of the ventilation membrane 2.
The insulating layered device 1 has, at the internal air interspace, a waterproof side of the ventilation membrane 2, which is waterproof towards the second side surface (outside of the wall 100). The waterproof side is configured for application of wall covering material 104, such as laminated stone, tiles such as porcelain tiles, or plaster, which is attached to the insulating layered device 1 by means of gluing or cement paste 105.
The insulating layered device 1 further comprises a transpiration membrane 5 comprising a permeable fabric-like second sheet affixed to the first side (internal) surface of the ventilation membrane 2.
The transpiration membrane 5 is attached by means of second gluing or cement paste 106 to the internal cover 101, thus providing moisture transfer from the wall 100 to said internal air interspace of the ventilation membrane 2.
In an alternative embodiment (not shown) the ventilation layer could be reversed, attaching the second (waterproof) side to the wall 100 or cover 101 thereof, and the first (ventilated) side to the external cover 104, preferably without employing the adhesion membrane 4 and/or the transpiration membrane 5, for general insulating purposes; although this variant has decreased performances, it is easier and cheaper to manufacture.
The ventilation membrane 2 is preferably waterproof, and more preferably steam-proof as well. The ventilation membrane 2 is preferably made of a layer of plastic, and is preferably made of a layer of Polyethylene. The protrusions of the ventilation membrane are sized so as to be resistant to loads and mechanical stresses.
Preferably, the transpiration membrane and/or the adhesion membrane are fabric-like sheets made of Polypropylene. Preferably, the first or second sheet is permeable to air, so as to allow evaporation at the internal side of the wall, and increase exsiccation of gluing or cement paste at the external side of the wall. Preferably, the first and second sheet are made of the same fabric and have the same features, for reducing costs.
The insulating layered device 1 is preferably associated by a further plurality of layers of insulating material and of gluing or cement paste, in order to increase insulation.
In order to increase adhesion to the wall, mechanical fixing means may be employed. Such fixing means may include a wall plug / screw anchor 107, a screw 108 and a retaining element 109 applied to the external side of the insulating layered device 1, for increased mechanical stability.
In general, the open-cell structure of insulating layered device 1, comprising alveoli, allows for the creation of an internal air interspace, wherein air flows for stack effect. This causes an ascending ventilation flow, which allows for an improved thermal insulation of the building, plus it allows the evacuation of water steam which dampens the building, thus eliminating moisture from the walls.
The plurality of alveoli are in fluidic connection by means of a dense network of micropores, which provides for an excellent insulation of the building and, by suction effects, provides for moisture transfer to the alveoli system for subsequent evaporation.
The decompression effect, due to the relevant airflow which takes place inside of the layer, is such that microvortices are created, which thermally insulate the walls and suction the water vapor, allowing for wall exsiccation even in conditions of continuous dampening of the building, such as in below-ground walls or wet foundations or for diffuse water infiltrations. The usage in building and reconstructing of the structure of the insulating layered device comprising alveoli, allows for better insulating the walls by means of a ventilated internal air interspace.
Moreover, the alveolar structure of the ventilation membrane 2, having open interspace cells that are preferably applied under the wall surface finish (such as laminated stoneware 104) allows to realize within the structural sandwich a gap of air, which for stack effect results in a ventilated ascending motion of air. This air better insulates the walls as well as allows to disperse the water vapor coming from the walls, thus eliminating moisture from the walls. The alveoli are in fluidic connection with each other through a network of micropores, which in addition to ensuring perfect adhesion to the wall's surfaces, by osmosis allow moisture transport to the bigger receptacles closer to the protrusions in the internal air interspace, from which water is subsequently vaporized.
Due to the temperature differences of the air contained in the interspace of the ventilation membrane, which may also be heated by solar radiation impacting on the wall, it occurs a suctioning effect due convective heating. The convective microvortices, in addition to thermally and acoustically insulating the walls, also suction steam and vaporize water, thus achieving drying of the wall
Figure 2 represents a second embodiment of an insulating layered device 1 applied to a second wall 200 made of cement.
The insulating layered device 1 of Figure 2 substantially corresponds to the device 1 above described with reference to Figure 1 ; it can thus be appreciated the flexibility of application to any kind of wall. Other components of the device 1 are analogous to what has been previously described.
Figure 3 represents an enlarged view of the insulating layered device 1, as derived from Fig. 1.
The protrusions 3 have hollow bodies each of which comprises a respective opening 301. The openings 301 face towards the second side surface (waterproof side) of the ventilation membrane 2 which is opposite to said first side surface (transpiration side).
The hollow bodies of the protrusions 3 are configured as accumulation volume for gluing or cement paste 105, which is applicable to the insulating layered device 1 on said second side surface, for attachment to the external cover thereof.
In an alternative embodiment, wherein the insulating layered device is reversed, the transpiration membrane and/or adhesion membrane can be omitted and the side surfaces comprising openings 30 lean be attached to the wall 100 or internal cover 101. As already mentioned, although this variant has decreased performances, it is easier and cheaper to manufacture.
According to the preferred embodiment, the first sheet of the adhesion membrane 4 comprises a plurality of holes 302 which are configured for passage of the gluing or cement paste 105 for accumulation inside the hollow bodies of the protrusions 3. As the first sheet is preferably permeable to water and steam, it allows a quick exsiccation of the gluing or cement paste 105. The protrusions 3 comprise respective abutment surfaces 300, for resting against a flat surface, such as the surface of the internal (insulating) cover 101 as depicted, or alternatively a flat surface of the wall 100 or external cover 104 thereof.
The transpiration membrane 5 is affixed to the abutment surfaces 300, over the first side (transpiration) surface of the ventilation membrane 2.
Preferably, also the second sheet of the transpiration membrane 5 further comprises a second plurality of holes 303 configured for passage of the moisture from the wall 100 (through the foam insulating layer 101) to the internal air interspace of the ventilation membrane 2.
The second plurality of holes 303 are further configured for passage of the second gluing or cement paste 106 applied to the first side of the insulating layered device 1, and a portion of the internal air interspace within the protrusions 3 is configured as second accumulation volume for the second gluing or cement paste 106. By that, application of the transpiration membrane 5 to the internal cover 101 (or alternatively, directly to the wall 100) is made more stable.
Preferably, the height of the protrusions 3 is at least 80%, preferably at least 90%, of the total thickness of said ventilation membrane 2.
Preferably, the protrusions 3 comprise regularly spaced protrusions arranged according to a grid, for example as visible in Figure 3.
Preferably the protrusions 3 have truncated-conical shape, for example as visible in Figure 3. Alternatively, the protrusions 3 could have a cylindrical shape. These round-section shapes have been found to better perform while interacting with the air ascending in the internal air interspace.
Figure 4 represents a third embodiment of an insulating layered device 1 applied to a third wall.
In this example, the transpiration membrane 5 is directly attached by means of second gluing or cement paste 106 to the wall 400, thus providing moisture transfer from the wall 400 to said internal air interspace of the ventilation membrane 2. Other elements are analogous to what has been previously described.
Figure 5 represents a fourth embodiment of an insulating layered device applied to a fourth wall.
To further exemplify the flexibility of application of the insulating layered device 1, in this example the transpiration membrane 5 is directly attached to a different wall 500 made of cement. Other elements are analogous to what has been previously described.
In general, it has to be noted that features of the insulating layered device according to the present invention could be singularly exploited in an insulating layered device, even independently from each other. In particular, the following features may be exploited individually in an insulating layered device comprising a ventilated membrane as described:
- Presence of hollow bodies for the protrusions 3, with described features thereof.
- Presence of an adhesion membrane 4, with described features thereof.
- Presence of a transpiration membrane 5, with described features thereof.
Moreover, the present invention relates to a method for insulating a wall by applying layers thereto. The method provides for all the steps which are necessary for applying an insulating layered device 1 as herein described and claimed.
Industrial applicability
The insulating layered device according to the present invention can be associated to an external surface finish of the wall, such as laminated stoneware or plaster, or to a wide range of other surface finishes.
As well as providing a technical solution in terms of weight reduction of the facade, the thermal protection conferred to the building contributes to the definition of an aesthetic quality, allowing the development of multiple solutions tailored to the specific needs of each building project, to freely express the architectural idea while abandoning technical constraints for the support structures.
The ventilated wall comprising an insulating layered device according to the present invention, can be used without distinction for insulation of new concrete walls, for the recovery of an old facade and for the dehumidifying restoration and conservation of all types of masonry.
The insulating layered device according to the present invention improves performances of the insulation system, eliminates the moisture from the walls and is a remarkably waterproof product for the outside of the facade. Ease of installation, lightweight of the wall cover and easiness of application make the device according to the present invention a convenient solution to cover a wall facade. The insulating devices secures all the advantages of wall ventilation combined with the strength of a bonded coating.
The insulating layered device has an overall thickness of approximately 12 mm, plus the thickness of any further insulation panel (i.e. foam) or facade cover (such as stoneware laminate); the combined weight for a total thickness of 35mm is less than 12 Kg for square meter of wall cover.
The system according to the invention, as merely exemplified in the present description with the implementing details herein given, is susceptible to a number of changes and variants which become apparent to the skilled in the art which considers the present description. Such variants do not depart from the scope of protection of the present invention, as defined by the appended claims.
For example, more than one insulating layered device according to the present invention can be superimposed one over the other, in further layers.
For example, an insulating layered device according to the present invention can be applied to a wall in further combination with any other compatible insulating device.
The insulating layered device can be further supplemented with devices known in the art, for example could be supplemented by an external net structure for improving plaster adhesion.

Claims

1. An insulating layered device (1) for insulation of a wall (100, 200, 300, 400), comprising:
- a ventilation membrane (2) comprising a waterproof sheet having embossed thereon a plurality of protrusions (3) which define an internal air interspace in said insulating layered device (1), said internal air interspace being configured for providing an airflow along a first side surface of said ventilation membrane (2), said protrusions (3) comprising respective abutment surfaces (300), for resting against a surface of said wall (100, 200, 300, 400) or internal (101) or external cover thereof, wherein the edges of said ventilation membrane (2) are at least partly open to allow air outflow from said internal air interspace;
characterized in that said protrusions (3) have hollow bodies each of which comprises a respective opening (301), said openings (301) facing towards a second side surface of said ventilation membrane (2) which is opposite to said first side surface, said hollow bodies being configured as accumulation volume for gluing or cement paste (105) applicable to said insulating layered device (1) on said second side surface, for attachment of said insulating layered device (1) to said wall (100, 200, 300, 400) or internal (101) or external cover (104) thereof.
2. The insulating layered device according to claim 1, further comprising:
- an adhesion membrane (4) comprising a perforated fabric-like first sheet, said adhesion membrane (3) being affixed to said second side surface, wherein said first sheet comprises a plurality of holes (302) configured for passage of said gluing or cement paste (105) for accumulation inside said hollow bodies.
3. The insulating layered device according to claim 2, wherein said internal air interspace comprises a waterproof side of said ventilation membrane (2) which is waterproof towards said second side surface, and wherein said waterproof side is further configured for application of wall covering material (104) attachable to said gluing or cement paste (105).
4. The insulating layered device according to any one of claims 1 to 3, further comprising:
- a transpiration membrane (5) comprising a permeable fabric-like second sheet, said transpiration membrane (5) being affixed to said abutment surfaces (300) over said first side surface of said ventilation membrane (2), said transpiration membrane (2) being configured for being attached by means of second gluing or cement paste (106) to said wall (100, 200, 300, 400) or internal cover (101) thereof, thus providing moisture transfer from said wall (100, 200, 300, 400) to said internal air interspace.
5. The insulating layered device according to claim 4, wherein said second sheet further comprises a second plurality of holes (303) configured for passage of said moisture from said wall (100, 200, 300, 400) to said internal air interspace, and further configured for passage of said second gluing or cement paste (106) applicable to said first side of said insulating layered device (1), a portion of said internal air interspace being configured as second accumulation volume for said second gluing or cement paste (106), for application of said transpiration membrane (5) to said wall (100, 200, 300, 400) or internal cover (101) thereof.
6. The insulating layered device according to any one of claims 1 to 5, wherein said waterproof sheet is made of a layer of plastic, and is preferably made of a layer of
Polyethylene.
7. The insulating layered device according to any one of claims 1 to 6, wherein the height of said protrusions (3) is at least 80%, preferably at least 90%, of the total thickness of said ventilation membrane (2).
8. The insulating layered device according to any one of claims 1 to 7, wherein said protrusions (3) comprise regularly spaced protrusions arranged according to a grid.
9. The insulating layered device according to any one of claims 1 to 8, wherein said protrusions (3) have truncated-conical shape or cylindrical shape.
10. Wall of a building comprising an insulating layered device (1) according to any one of claims 1 to 9.
11. A method for insulating a wall by applying layers thereto, the method comprising:
- providing an insulating layered device (1) comprising a waterproof sheet having embossed thereon a plurality of protrusions (3) which define an internal air interspace in said insulating layered device (1), said internal air interspace being configured for providing an airflow along a first side surface of said insulating layered device (1);
- applying said insulating layered device (1) by resting abutment surfaces (300) of said protrusions (3) against a surface of said wall (100, 200, 300, 400) or internal (101) or external cover thereof, wherein the edges of said ventilation membrane (2) remain at least partly open to allow air outflow from said internal air interspace;
- attaching said insulating layered device (1) to said wall (100, 200, 300, 400) or internal (101) or external cover thereof by applying gluing or cement paste (105) on openings (301) of said waterproof sheet, said openings (301) facing towards a second side surface which is opposite to said first side surface, to accumulate said gluing or cement paste (105) inside the hollow bodies of said protrusions (3).
12. The method for insulating a wall according to claim 11, further comprising:
- further providing said insulating layered device (1) with a perforated fabric-like first sheet (4) affixed to said second side surface;
- passing said gluing or cement paste (105) thorough a plurality of holes (302) of said first sheet (4).
13. The method for insulating a wall according to claim 12, further comprising:
- further providing external wall covering material (104) attached to said gluing or cement paste (105) on the waterproof side of said insulating layered device (1) which faces towards said second side surface.
14. The method for insulating a wall according to any one of claims 11 to 13, further comprising:
- further providing said insulating layered device (1) with a permeable fabric-like second sheet (5) affixed to said abutment surfaces (300) over said first side surface;
- attaching said insulating layered device (1) to said wall (100, 200, 300, 400) or internal cover (101) thereof, by means of second gluing or cement paste (106), thus providing moisture transfer from said wall (100, 200, 300, 400) to said internal air interspace.
15. The method for insulating a wall according to claim 14, further comprising:
- further providing said second sheet (5) with a second plurality of holes (303) for said moisture transfer;
- further passing said second gluing or cement paste (106) by means of said second plurality of holes (303) onto said first side of said insulating layered device (1), to accumulate said second gluing or cement paste (106) inside a portion of said internal air interspace;
- attaching said second sheet (5) to said wall (100, 200, 300, 400) or internal cover (101) thereof.
PCT/IB2015/056896 2014-09-09 2015-09-09 Insulating layered device and method for insulating a wall WO2016038544A1 (en)

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GB2599925A (en) * 2020-10-14 2022-04-20 Burren Precast Concrete Holdings Ltd A prefabricated modular building panel
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IE20210174A3 (en) * 2020-10-14 2023-03-15 Burren Precast Concrete Holdings Ltd A prefabricated modular building panel

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