Note: Descriptions are shown in the official language in which they were submitted.
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1
ROOF AND WALL CLADDING
This invention relates to bonded man-made vitreous
fibre (MMVF) batts which are constructed for use as
external roof or wall cladding or as pipe sections, i.e.,
insulation for fitting around pipes which may be internal
or external.
Batts for external use are much more exposed to
adverse conditions such as moisture, sun, temperature and
wind than batts for internal use. The combination of
moisture and heat can create an aggressive environment for
the fibres, but conventional MMVF fibres, in conventional
batt constructions, resist this. The exposure to wind can
promote delamination, but sufficient structural strength
can be provided by known techniques such as bonding with a
bonding agent and by constructing the batt with the fibre
direction predominantly perpendicular, as lamellar boards,
instead of the conventional orientation of being
substantially parallel to the face of the batt.
Similarly batts for internal or external pipe sections
insulation are more exposed to humid conditions than batts
for regular internal uses, especially when enclosed in an
aluminium membrane or plastics membrane or~ other
impermeable sheath.
More recently, there has been a trend to develop MMV
fibres which have some degree of solubility in
physiological fluids. Most of the publications on this
topic of solubility emphasise the desirability of the
fibres having some degree of solubility in physiological
saline at pH around 7.5.
Fibres which, instead, have improved solubility at
around pH 4.5 are described in W096/14454 and W096/14274.
A problem which arises with the use of MMVF baits made
from fibres having appreciable solubility at near neutral
pH (approximately pH 7.5) in roof or wall cladding is that
the fibres are liable to degrade when exposed to
atmospheric humidity for prolonged periods or when exposed
CONFIRMATION COPY
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to condensation or direct contact with water. Accordingly
it can be unsatisfactory to use such fibres for external
roof or wall cladding, unless special precautions are taken
to minimise this problem.
It would be desirable to be able to provide pipe
sections external roof or wall cladding formed from MMVF
fibres which are regarded as having good physiological
solubility under relevant test conditions but which have
less tendency to degrade when exposed to ambient humidity.
According to the present invention, we provide pipe
sections or external roof or wall cladding which is a
bonded MMVF batt wherein the fibres are formed of a
composition which includes, by weight of oxides,
Si02 32 to 48%
A1203 10 t o 18 %
Ca0 10 to 30%
Mg0 2 to 20%
Fe0 2 to 15%
Na20 + K20 0 to 6
TiOZ 0 to 6%
Other Elements 0 to 15%
and the composition has a viscosity at 1400°C of 10 to
70 poise, and the fibres have a dissolution rate of at
least 20nm per day when measured at a pH of 4.5 (by the
methods described in W096/14274). Preferably they are
relatively insoluble at pH 7.5
The invention includes the MMVF cladding batts
themselves, their use as external wall or roof cladding in
buildings and building components which are to be on the
exterior of a building, and the buildings or building
components themselves which include the defined MMVF batts .
the invention includes the use of pipe sections for
insulating pipes.
The building or building component generally comprises
a metal, wood or other frame work on to which the MWF
batts are secured in a position such that they will be on
the exterior of the building in use. The building may be
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an entire building, but the invention also includes
building components, for instance a roof structure or wall
structure. For instance the roof ~or wall structure may
constitute an entire roof or wall for a building or several
such structures, each containing a plurality of batts, may
be assembled on site to provide a roof or wall.
The cladding batt as initially manufactured (ie before
leaving the plant where it is manufactured) or before
installation in or on the building component or building is
often provided with a substantially overall or impermeable
coating on its external surface. This protective coating
may be of water-repellant materials such as roofing felt or
it may be of a foil or a decorative material such as paint.
Even if such a coating is not applied before assembly, the
external surface of the bait or batts in the building
component or building are usually provided with a coating.
For instance roof boards may be coated with roof felt,
asphalt, wood plate, vlies, foil or solar heating units.
The roof boards are preferably sufficiently stiff that one
can walk on them. Wall cladding may be coated with plaster
(either inorganic or organic), cement, paint, polyurethane,
roof felt, foil (for instance aluminium), glass or solar
heating units.
One type of cladding batt according to the invention
is a very high density MMVF batt, typically having a
density 500 to 2,000 Kg/m3, often 700 to 1,200 Kg/m3. This
high density product usually carries a coating of paint or
other substantially impermeable or overall surface
covering. Other batts according to the invention may have
lower density than this and can be roof boards or wall
boards of more conventional construction.
The cladding batts of the invention usually have a
density of at least 50 Kg/m3 and often at least 70 Kg/m3,
typically up to 500 Kg/m3. Batts of differing densities
can be laid one upon the other in use, with the higher
density batt usually on the outside.
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Preferred cladding products of the invention have a
multi-density construction, usually a dual density
construction, with the MMVF layer which is on the outside
of the building in use having a higher density than, and
formed substantially integral with, the remainder of the
MMVF batt. For instance the outer layer usual has a
density of at least 60 Kg/m3 and preferably at least 70 or
80 Kg/m3, and often it has a density of at least 20 Kg/m3,
and frequently at least 50 Kg/m3, above the density of the
layer beneath it. The high density outer layer is usually
at least 5 mm thick, often 10 to 40 mm thick and typically
constitutes 2 to 30%, often 3 to 15 or 20%, of the total
thickness of the MMVF batt.
The cladding batts are usually square or rectangular
slabs but can have other, more complex, shapes, especially
when they form parts of roofs. The batts generally have a
thickness of 10 to 500 mm. The thicker batts are stiff and
are provided as slabs but some of the thinner batts, for
instance as facade or wall boards, may sometimes be
supplied as a roll of sheet material.
The cladding batts and pipe sections are usually
bonded by incorporation of conventional phenolic or other
binder, typically in amounts of 1 to 5%, often 2 to 4%, by
weight of the batt.
Water-repellent material may additionally be included
in the cladding batts and pipe sections during manufacture
in conventional manner, for instance an oil may be included
to improve water-repellency. The total ignition loss of
the batts is generally in the range 2 or 3% up to 5 or 6%.
The batts can be made by any of the conventional
techniques known for making batts of the desired
construction for description of suitable methods of making
and using external MMVF wall and roof cladding and pipe
sections, reference should be made to any or all of EP
133,083, 277,500, 420,837, 435,942, 518,964, 521,058,
560,878, 590,098 and 654,100, GB 1,027,799 and 2,223,248,
DK 155,163 and DK-U3-9200033, DE-U1-29616962, DE.4,143,387,
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WO 99/09270 PCT/EP98/03980
4,319,340 and 4,432,866, and W094/16162, 94/16163, 94/16164
and 95/20708, and W089/07731, W089/07733, W096/37728 and
W097/01060. All these are herein incorporated by
reference.
5 The fibres may be substantially parallel to the
external face of the batt or the fibres may be
substantially perpendicular to the face of the batt, the
product then being of the type conventionally known as a
lamellar batt or slab.
External roof cladding can have any of the normal
configurations of roof boards or other roof cladding and
generally has a density in the range 100 to 400, preferably
100 to 200, Kg/m3 and a thickness of 10 to 500, usually 10
to 300 mm.
Single layer roof boards often have a density of 100-
300kg/m3 and a thickness of 10-300mm. Instead of using a
single layer, several layers may be applied one on top of
the other, for instance as a combination of lamellar and
normal batts, but preferably with the outer layer having
the highest density and/or being a lamellar batt.
Preferred roof cladding is formed of dual density
batts. The density of the bottom may be 60-200kg/m3 and
the density of the top is usually at least 50kg/m3 more and
is usually 200-400 kg/m3. The thickness of the bottom may
be at least l5mm and the thickness of the top may be 100-
300mm. The maximum total thickness is usually 350mm.
Wall cladding can be of two types. The first type is
what is commonly known as a facade board. The other type
of wall cladding is often known as a lamella board. The
wall cladding generally has a density in the range 50 to
400, often 50 to 200 Kg/m3, often around 50 to 150 Kg/m3.
For instance facade boards may have a density of around 70
to 150 Kg/m3 whilst lamellar boards may have a density of
50 to 100 or 150 Kg/m3. They may have a thickness
typically of 10 to 300, often 10 to 200 mm.
Lamella boards can be made with lower densities
compared to the normal single layer boards. Furthermore,
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lamella boards can resist the influence of the wind
(delamination strength) , which can be a problem with normal
single layer boards having the same density. Lamella
boards normally have an impermeable surface coating, for
instance of wood, foil, roofing felt or other substantially
impermeable sheet material.
Typical facade boards have a width of 20cm or more,
e.g., 60cm, and can typically have a length of 1-2 metres
( a . g . , 1. 2m) but can be a rol l ( a . g . , 1 Om) . Roof boards
usually have a width of above 50cm (e.g., 60cm or 120cm up
to 150cm) and a length which is more (e.g., 90cm up to
300cm, e.g., 180 or 140cm).
Pipe sections are used for heating insulation, cooling
insulation or condensing insulation around internal or
external pipes and pipe fittings. Condensing insulation
has a thickness or shape designed so that vapour condenses
on the outer surface of the pipe section and/or so that
condensed vapour is drained out of the pipe section in
order to prevent corrosion of the pipes (see EP 739,470,
W094/05947; EP 528,936, W097/16676).
The sections can be covered with impermeable aluminium
foil or plates; paper coated with aluminium; metal plates,
i.e., steel plates, preferably galvanised metal plates,
with a corrosion-preventing plastic film or coating;
roofing felt; or woven or non-woven glass fibre fleece or
cloth. Also the pipe sections may be coated with: canvas,
paint, plastic foil, i.e., PVC, cardboard or paper. The
covering material can be impregnated with bitumen in order
to be weather resistant.
The covering material can be fire resistant.
Usually pipe sections have a density from 40-400Kg/m3,
preferably 60-300Kg/m3. The pipe sections may include
support rings which are part of the insulation. Pipe
sections may consist of two types of wool, one type for the
pipes and another more dense type for the support rings.
These support rings have the purpose for cold pipes to
avoid condensation and for hot pipes to avoid thermal loss .
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Pipe section support rings usually have densities from 150-
400Kg/m3 preferably 250-350Kg/m3 and preferred around
300Kg/m3. Wool for the remainder of the pipe section
typically has density of 4o-200Kg/m3, preferably 60
180Kg/m3.
Tn the invention, the preferred amount of Si02, MgO,
CaO, FeO, alkali, TiOZ and other elements, and the
preferred viscosities and dissolution rates (at pH 4.5 and
at pH 7.5) are all preferably as described in W096/14454
and W096/14274 and reference should be made to those. The
preferred amount of A1z03 is 14 to 18%. Preferably it is
not more than 17.5%.
The following are examples of suitable compositions.
CA 02301261 2000-02-16
WO 99/09270 PCT/EP98/03980
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