Note: Descriptions are shown in the official language in which they were submitted.
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INSULATION SYSTEM COMPRISING INTERCONNECTED INSULATION
PANELS DISPOSED AGAINST A WALL
The invention concerns a wall system comprising a building wall with an
insulating layer, said building wall being the facade wall of a building or an
inner wall and a method for installing such a wall system.
This type of wall systems is known from DE 101 47 831 Al, describing a
wall with C-profiles as the load-bearing construction and insulation panels
arranged between the C-profiles. Covering layers such as plasterboards are
mounted on both sides of the wall. The insulation layer is thicker than the
distance between the two flanges of the C-profile. Therefore, the covering
layer on one side of the wall is fixed directly to one flange of the C-
profile,
while the cover layer on the other side is placed against the insulation layer
and fixed to the other flange of the C-profile by screws extending through
the insulation. This type of construction reduces the heat loss through
thermal bridges and improves the sound reduction slightly compared to a
traditional construction where the C-profile extends from one cover layer to
the other-
Such a wall system, however, still has the significant disadvantage of a
considerable number of screws. These screws togeth"er with the C-profile to
which they are attached will still transport a significant amount of heat
energy from one side of the wall system to the other and thereby reduce the
heat insulating capacity of the wall. Also the sound insulating capacity is
reduced-
This problem has been solved by arranging the wall system according to
the present invention. Thereby the wall system comprises two individual
walls placed next to each other and secured individually to the rest of the
building construction. The two individual walls may be placed closely together
and may be fitted together by use of an adhesive, or there may be a small air
gap
ensuring ventilation. This will often be necessary when the wall is an outer
wall
where the
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temperature difference may be relatively high, increasing the risk of
condensation of vapour.
The wall system according to the invention comprises a building wall with an
insulation layer, said building wall being the facade wall of a building or an
inner wall and the insulation layer comprises insulation panels. The
insulation panels have two substantially parallel major surfaces and minor
surfaces connecting the major surfaces. The insulation panel is positioned
between at least two profiles where each profile has a base portion
substantially parallel with and in contact with a part of one minor edge
surface of the insulation panel. Means for engaging the insulation panels
and holding them in position are arranged in connection with the base
portion of the profile. The insulation panel has a thickness larger than the
width of the base portion of the profiles.
At least one profile is arranged and fastened to parts of the building
different
from the building wall in such way that no single element or combination of
elements except the insulation panels themselves extends from a plane
formed by the major surfaces facing the inside of the building to a plane
formed by the major surfaces of the insulation panels facing the outer wall.
Preferably, a slit is made in a minor surface and extending substantially
parallel with the major surfaces of the insulation panels. Preferably, the
profile is provided with a flange portion substantially parallel with the
major
surfaces of the insulation panel.
The profiles are arranged and fastened so that practically no parts will span
from one major surface to the opposite major surface of the insulation
panels and the building wall is not directly connected with the major surface
of the insulation panels opposite the building walls, by mechanical means
other than possibly part of the heat insulating layer.
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One further advantage of this new wall system is that the two parts of the
wall system can be installed independently from each other, which means
that the system is suitable for renovation projects and improvements of the
insulation performance of a building. E.g. an existing non-insulated facade
wall can be used as the first outer wall part, i.e. the building wall, in the
new
wall system, and the second part comprising the insulation can be installed
independently.
To achieve this new wall system with two independent wall parts, the inner
part of the wall system comprising the insulation could be secured to the
ceiling, roof and/or wall construction and not to the outer building wall
other
than by the insulation material, possibly with some adhesive.
The advantages of this wall system is that there is no thermal bridging nor
elements suitable for transporting sound from one side of the wall to the
other. This means that both improved heat and sound insulation can be
achieved. Also, the fire properties will be improved with the wall system
according to the invention, as the heat from a fire starting at the building
wall
side of the insulation will be insulated from the profiles, and therefore
these
will be affected and e.g. starting bending at a later stage of the fire. This
will
delay the fire break through of the second wall part comprising the insulation
layer.
The profiles will extend a distance of maximum 85 % of the thickness of the
insulation layer, preferably a maximum of 75 %, and even more preferably a
maximum of 60 %. Obviously, this distance will depend on the thickness of
the insulation layer. If the profiles extend 75 % of a 100 mm thick insulation
layer, the same profile will only extend 37.5 % of a 200 mm thick insulation
layer. The profiles are preferably made of metal, preferably steel or
aluminium. Perforations in the profiles in order to reduce the heat
conductivity could be advantageous. The profiles could also be made from a
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material having lower heat conductivity than metal e.g. plastic or wood. Also
a combination of different materials is a possibility.
The insulation material used in the new wall system may be any known
insulation material such as fibrous or foam or plastic based materials.
Mineral fibre insulation such as glass wool or stone wool is particularly
useful due to the better fire properties. Especially stone wool provides very
good fire properties and has also good acoustic properties. Mineral wool will
also offer an easier installation as these products are more flexible than
e.g.
foam insulation.
This new wall system can be used for refurbishments of existing buildings,
for new buildings and also for prefabricated facade elements.
In a first embodiment the wall system is made as an outer wall where the
first part of the wall without insulation is the outer building wall part,
typically
made of bricks and/or concrete, also being the facade of the building. Often
there will be an air gap between the two parts of the wall. The second part,
often being the inner wall part, comprises the insulation placed in a
framework of profiles. Each insulation panel has four minor surfaces where
a slit extending substantially parallel with the major surfaces is made in at
least one minor surface. The insulation panels are each placed between at
least two profiles. Each profile has a base portion being substantially
parallel with and in contact with one minor surface of the insulation panel
and one flange portion being substantially parallel with the major surfaces of
the insulation panel and extending into said slit in a minor surface of the
insulation panel. The insulation panels have thicknesses larger than the
width of the base portion of the profiles.
In a preferred embodiment the wall system according to the invention has
substantially all profiles arranged and fastened to parts of the building
different from the building wall, so that no elements connected to said
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profiles except the insulation panels them selves span from the first major
surfaces of the insulation panels to the second major surfaces of the
insulation panels. Preferably, also the base portions of the profiles are
placed parallel to a minor surface of the insulation panels and between the
5 first major surface of the insulation panels and the slit in a minor surface
of
the insulation panels.
This means that the two wall parts are not directly connected by mechanical
means. If there is an air gap between the two wall parts they will not be
connected at all. If there is no air gap they will only be connected through
the heat insulating material, possibly with some adhesive between the
second major surface of the insulation panel and the building wall.
Preferably, C- or U- profiles are applied for the framework holding the
insulation panels. These profiles will comprise one base portion and two
flange portions extending from the base portion. One of these flange
portions are arranged to penetrate into the slit in the insulation panels in
order to hold the insulation panel in position. Other means for achieving this
purpose could also be applied, e.g. punched out pieces from the base
portion or screws or clips, and then an L-profile could be sufficient. The
other flange portion is arranged to be flush with a major surface of the
insulation panel. This major surface of the insulation will often be the outer
surface opposite the first part of the wall. These types of profiles have the
advantage of fixing the insulation panels better into the correct position.
Furthermore, a flange placed opposite the other first part of the wall and
flush with the outer major surface of the insulation panel, may be used for
attaching a cover layer to this side of the wall. This cover layer could be
gypsum boards, wood panels, fibre boards or any other material suitable for
cladding of inner walls.
In a further preferred embodiment the wall system according to the invention
has two substantially vertical profiles holding the insulation panel, and a
first
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profile has a flange portion extending into the slit in the insulation panel
and
a second profile has a flange portion pointing away from said insulation
panel. The flange portion pointing away from the insulation panel is
arranged for holding a neighbouring insulation panel. Furthermore, the
second profile may be provided with fixation means for holding the said first
mentioned insulation panel in place. These fixation means may e.g. be
arranged after placement of first mentioned insulation panel but before
placing the second neighbouring insulation panel in position.
The framework of profiles, which usually form one or more frames in which
the insulation panels are installed, will often be attached to the floor and
the
ceiling with one horizontal profile attached to the floor and one attached to
the ceiling. Vertical profiles are placed between the horizontal profiles. In
building or parts of buildings where the distance between floor and ceiling is
particularly large one or more vertical supporting profile could be added in a
position between the floor and the ceiling.
The framework of profiles could also be attached to the walls perpendicular
to and adjoining the new inventive wall system. This would be especially
relevant when the new wall system is applied for an external wall being part
of the building facade.
In a further preferred embodiment of the invention the majority of the
insulation panels, preferably of mineral wool, comprise at least two different
layers having different densities. Often, this will be made as so-called dual
density boards, meaning that the panels comprise layers, extending parallel
to the major surfaces, of different densities. Usually, this will be in the
form
of one relatively thin layer (up to 25 % of the total thickness of the
insulation panel) with a high density, e.g. higher than 60 kg/m3. The
remaining part of the insulation will be of a lower density, e.g. below 45
kg/m3. One advantage of such an insulation panel is that a high degree of
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mechanical stability may be achieved from the high density layer without
getting a very heavy product.
In a further embodiment of the invention a high density layer of the
insulation could substitute a cover layer. If the surface of the insulation
facing the occupied room is sufficiently hard and stable, it may not always
be necessary with a separate cladding layer. In these cases the. high density
layer of the insulation could be covered by a fleece and/or paint in order to
improve the aesthetic appearance of the surface and/or to improve the wear
resistance of the surface. If the mineral wool is covered by a fleece or a
paint layer having an open or porous surface it will have the advantageous
effect of higher acoustic absorption than a traditional covering layer of e.g.
gypsum boards. In such an embodiment the layer in the insulation with the
highest density will be placed opposite the building wall of the system.
The layer in the insulation with the highest density may also be placed
facing the building wall, depending on the purpose. This placement would
be relevant if the purpose is to reduce the risk of blocking an air gap for
ventilation between the two wall parts. Such blocking could be a result of
soft insulation material buckling out.
The high density layer will have a mechanical stabilising effect on the part
of
the wall comprising the insulation. This means that the risk for the
insulation
panels buckling out will be reduced. Such buckling out could result in open
air gaps between the insulation panels, reducing the heat and acoustical
insulating effect significantly.
Preferably a ventilation air gap is provided between the building wall, i.e.
the
first wall part, and the second wall part comprising the insulation panels.
This has the advantage of removing humidity condensed on the building
wall. If no air gap is provided, the building wall and the second major
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surface of the insulation panels may be interconnected by use of an
adhesive. This would give the wall system improved mechanical stability.
In a further embodiment of the invention one or more minor surfaces of the
insulation panel has been made more flexible than the rest of the insulation
panel. This could be by a method similar to the method described in
European patent application 04388066.5. This would serve two purposes:
first to ensure a close fit between the insulation panels and the profiles,
and
second to allow some minor variations in the distance between the profiles.
The invention also covers a method of installing a wall system according to
any of the above described embodiments. This method comprise the step of
installing a framework of profiles for a second wall part, parallel to a
building
wall, i.e. a first wall part, usually an outer wall, without connecting at
least
one profile to the building wall. The method further comprises the step of
arranging the insulation panels between the base portions of the profiles so
that the means, which are arranged in connection with the base portion of
the profile, for engaging the insulation panels will hold them in position.
The
insulation panel has a thickness larger than the width of the base portion of
the profiles. The arrangement of the insulation panels also means that it is
pushed into position between at least two profiles.
In a preferred embodiment of the method one of the two profiles have a
flange portion penetrating into the insulation material and the insulation
panel is placed in the framework by aligning a slit in the insulation panel to
fit over this flange portion. Preferably, the other profile will have a flange
portion pointing away from the insulation material, and preferably the
insulation panel is secured to this second profile by fixation means. These
fixation means could be a screw, a nail or any kind of clips.
In the following the invention will be described in more details with
reference
to the figures.
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Figure 1 illustrates an example of the new wall system.
Figure 2 illustrates an insulation panel to be used in the new wall system.
Figure 3 illustrates a method for installing the insulation panels between the
profiles.
Figure 4 illustrates an embodiment of the profile.
In figure 1 an embodiment of the wall system (1) according to the invention
is illustrated. The building wall (5) is often an outer wall made of bricks,
concrete etc. It may be an existing wall or a newly erected wall. The second
wall part is made up of insulation panels (3), profiles (4) and preferably an
outer cladding layer (2) which could be gypsum boards or wood boards.
There will usually be a ventilation air gap (6) between the first and the
second part of the wall system.
Figure 1 further illustrates an embodiment of the profile (4) to be used in
the
wall system (1) having a base portion (13), at least one flange portion (11)
and preferably also a second flange portion (12). In the shown embodiment
the outer cladding layer (2) is secured to the second flange portion (12) of
the profiles by e.g. screws (not shown). Preferably it is possible to apply
fixation means (14) holding the insulation panel (3) on the side of the
profile
opposite the one or two flange portions (11, 12) in place. This fixation
means (14) could have the form of nails e.g. barbed in order to prevent the
insulation panel (3) from detaching from the profile (4) once installed.
Figure 2 illustrates an embodiment of the insulation panel (3) to be used in
the wall system. The insulation panel have two major surfaces (7,8); the first
major surface (7) facing the outer cover layer (2), and the second major
surface (8) facing the building wall (5). The insulation panel also comprises
four minor edge surfaces (9, 9'). In at least one of these (9') a slit (10) is
made. This slit (10) is made to fit together with one flange (11) of the
profile.
There may be slits in more than one minor edge surface of the insulation
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panel. This is of relevance if the insulation panel is held in place by flange
portions of profiles on more than one minor edge surface. This would be the
case if horizontal profiles also are provided, e.g. attached to the ceiling
and/or to the floor and/or in a position in between. For this purpose two
slits
5 should be applied. The slits may be pre-cut from factory or they may easily
be cut on site at the time of installation.
Figure 3 illustrates a method for installing the insulation panels (3) in the
new wall system. This method comprises the steps of installing a framework
10 of profiles (4) fastened to parts of the building construction other than
the
building wall of the new wall system. Insulation panels are placed in this
framework of profiles by aligning a slit (10) in a minor edge (9') to fit over
a
flange portion (11) of a first profile (4'). Then the insulation panel (3) is
pushed into position between at least two profiles (4). Optionally, the
insulation panel is secured in position by fixation means (14) securing the
panel to a second profile (4"). As illustrated in figure 3 the insulation
panel
may be of the dual density type comprising a layer (20) of relatively high
density and a layer (21) of relatively low density. The high density layer
(20)
will give the necessary mechanical stability while the other layer will ensure
the insulating capacity.
Figure 4 illustrates an embodiment of the profile where an L-shaped profile
(4) is used. Instead of the flange portion entering a slit in the insulation
panel a small area of the base portion (13) of the profile is punched partly,
e.g. in a V-shape so that a triangular shaped piece (31) can be bended out.
A number of such pieces (31) along the length of the profile will be able to
hold the insulation in position. These bend out pieces (31) will be able to
penetrate the insulation material without a pre-cut slit. They may be bend
beforehand or during installation, preferably by hand. The angle could be
from 0 degrees and up to 90 degrees. If an angle in the range 10 - 40
degrees are applied, the bend out pieces (31) may act as a kind of barbs. If
the angle is closer to 90 degrees the function will be more like the flange of
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a C-profile, except that it may not be necessary having a pre-cut slit in the
insulation panel. The fixation means (14) for holding the insulation panel on
the other side of the profile may also be cared for by bending out such
punched pieces to the other side of the base portion (13). Obvious, also
other means for holding the insulation in place may be applied. This could
be screws, or special clips of any type. These could be applied for holding
the insulation to both sides of the base portion (13).
In an example of the invention the insulation panels (3) has a thickness of
150 mm (may be in the range 100 to 200 mm). Insulation materials will be
mineral wool or foam or plastic based. Often a mono density insulation
material is applied with a density in the range 15 to 150 kg/m3, preferably
around 70 kg/m3. If dual density insulation is applied, the thickness of the
high density layer is preferably around 25 mm and the density is about 60
kg/m3, while the density of the low density layer is preferably about 35
kg/m3. The slit (10) provided in the insulation panel (3) is cut-out by a saw,
and with a minimum width of 3 mm and a depth of around 50 mm. The
cladding layer (2) may e.g. be gypsum plaster board or gypsum fibre board
with a width of 60 - 90 cm or 120 cm. The thickness of these boards is in
the range 10 - 20 mm, often 12 mm. The cladding layer may be arranged in
one or two layers. The profiles (4) are metal-stud C-profiles with a width of
the base portion (13) from 50 to 150 mm preferably around 75mm, and a
width of the flange portions (11, 12) of 25 - 75 mm preferably around 50
mm. The profiles (4) have a distance from each other of 60, 45 or 30 cm
center-to-center. This distance is preferably arranged so that the
plasterboards can be fastened to a profile along at least the two longer
edges of the plasterboard. The insulation panels may have a lining at the
side facing the cladding layer (2). This lining is a vapour barrier in the
form
of a PE or aluminium foil. This lining may be secured to the insulation
panels (3). At the side of the insulation facing the building wall (5) an open
foil (such as perforated PE foil, aluminium, glass fibre or plastic tissues
like
non-woven) can be arranged e.g. secured to the insulation panels (13). The
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cladding layer (2) e.g. gypsum plasterboard may be arranged with a lining in
the form of a barrier foil (e.g. PE or aluminium foil) at the side facing the
insulation panels (3). The building wall (5), usually being the outer wall, is
preferably made of bricks, concrete bricks, limestone, genuine natural stone
bricks or wood. The system may secure a ventilation air gap (6), preferably
with a minimum width of 20 mm, and has no cold-bridge when installing
insulation to existing outer walls (5). The system is also suitable for
horizontal and pitched ceilings.
The metal-stud system of preferably C-profiles is supporting itself but not
meant to be applied as a constructive wall. The system should preferably be
constructed between an existing floor and ceiling, either of which may be
made of e.g. concrete, wood or steel. U- or C-profiles are attached to the
floor and ceiling by e.g. plugs and screws. The vertical C-profiles are
arranged and preferably secured to the horizontal U- or C-profiles, e.g. by
screws, rivets or by simply stamping them together. The insulation panels
are arranged between the C-profiles, whereas the slit (10) should be
positioned over one flange portion (11) of the C-profile.
The vapour barrier is arranged between the cladding layer (2) and the
insulation (3). It may be pre-attached to either the cladding layer e.g.
gypsum boards or to the insulation. The vapour barrier may also be secured
to the C-profiles e.g. by the use of two-sided adhesive tape.
The new wall system has many applications in both new buildings and in
refurbishment. It can also be used in prefabricated building elements. Other
applications are for pitched ceilings mounted against the pitched roof
construction being the building wall (5), and even for horizontal ceiling
constructions. The wall system may also be applied for inner walls and for
separation walls between two adjacent houses.
