DK180181B1

DK180181B1 - Thermal composite wall element

Info

Publication number: DK180181B1
Application number: DKPA201800307A
Authority: DK
Inventors: Gorm Hilding Rasmussen Elith
Original assignee: H H Danmark As
Priority date: 2017-11-24
Filing date: 2018-06-29
Publication date: 2020-07-16
Also published as: DK201800307A1; EP3714111A4; EP3714111A1

Abstract

A composite thermal wall element for new buildings and extentions are disclosed. The composite thermal wall element comprises as an example a foam layer and two CSH-component layers, one CSH-component layer on each side of the foam layer, one layer being reinforced. Methods for its preparation are also disclosed.

Description

DK 180181 B1 Composite thermal wall element Description The present invention relates to a wall element for new buildings and extensions, methods for preparation of the wall element, and a use of said wall element.

More specifically it relates to a wall element comprising an insulation material and a calcium silicate hydrate (CSH)-component material on both sides of the insulation material, and methods for preparation of the wall element.

The governments around the civilized world face the consumers of energy for heating both in private housings and in industrial buildings with still higher requirements to lower heat loss to the environment in order to save energy and thus decrease CO» emission. The purpose is to mitigate the increasing average temperatures and consequences of the climate change caused by e.g. increased concentration of CO, in the air.

New buildings and extensions have today and for many years been built the same way. First the foundation is made, then the walls are set up. Subsequently, the walls are insulated in order to avoid loss of heat through the walls.

One traditional construction method for external walls comprises the following steps each m?: Firstly, the inner wall of e.g. either 63 clay bricks and 40-50 kg masonry mortar or light weight concrete blocks laid in masonry mortar, layer by layer, is built.

Secondly, mineral insulation is mounted on the outside on the inner wall.

Thirdly, the wall ties are mounted evenly distributed into the inner wall, through the insulation layer.

Fourthly, the outer wall is built of 63 clay bricks and 40-50 kg masonry mortar, layer by layer.

All external joints are manually scratched clean on the face side for preparing

> DK 180181 B1 final filling, Thereafter the surface is brushed clean manually with a stiff brush for cleaning off loose mortar remains. Then all joints in the brickwork are manual sealed with compacted weather resistant mortar. Finally, all surfaces are cleaned in a 1,5 % solution of HCI. The disadvantages of the method of prior art are that the total building process requires several steps and the insulation of the walls are not very effective, and because it is a construction with so many parts and processes, there always is many risks of failures e.g. air tightness, waterproofness, frost damages and failures in mortar cohesion in between the bricks/blocks and the mortar, which can result in failure.

Thus, it is highly desirable to provide a wall material for new buildings and extensions whereby the heat loss and construction costs are lowered by significant less parts lowering the risks for failure e.g. airtightness, waterproofness, frost damages and failures in mortar cohesion, while the fabrication process of the wall materials is not more expensive than the total costs of the wall and insulation materials of prior art.

Prior art describes in EP2395171A1 a board of a composite material with a sandwiched structure, an insulation material of porous concrete in the middle and two outer layers, one on each side of the insulation material. The outer layers and the insolation layer are made from porous concrete i.e. calcium silicate hydrate, and, the middle layer has pores of a smaller diameter. It is a monolithic structure.

However, the composite is suited as a building material only for a minor block wall. If it is a large element it would break during transport and handling to the building site. It is not strong enough against mechanical load from e.g. wind load,

2 DK 180181 B1 roof load and transport impacts, because the CSH-layers are not strong enough. Summary of the invention.

The present invention solves the problem above by providing according to claim 1 a wall material for construction and insulation of new buildings and extensions wherein said wall material is a composite comprising an insulating layer and two diffusion open calcium silicate hydrate (CSH) layers, e.g. hydrothermal hardened, on each side of the insulating layer, wherein at least one of the calcium silicate hydrate layers are reinforced with rods or fibres, and wherein the layers are by the adhesive character of the insulating layer or, optionally, by an adhesive diffusion open third layer, attached to each other. An anticipated embodiment is where the insulation layer and the CSH- component layers are further specified as in claim 2 and 3. Yet other anticipated embodiments are wherein the regid phenol foam is further specified as in claim 4 or 5. Claims 6 to 8 claim embodiments wherein the glue for adhesion is further specified. Claim 9 claims an embodiment wherein the rigid phenol foam is specified by its preparation from its starting materials. Anticipated embodiments wherein the diffusion open gid instdation materist Is further specified, are claimed in claim 10, anticipated embodiments wherein the rods or fibres are further specified, are claimed in claim 11. A method for preparation of the composite thermal wall element is claimed in claims 12 to 16.

In order that the invention may be well understood, some non-limiting examples will now be described in which: Fig.1 shows a cross-section of a building and where a composite wall element of the invention is intended for use. The reinforcement is not shown. Fig. 2 shows a composite wall element of the invention comprising three layers. Fig. 3 shows a composite wall element of the invention comprising five layers.

1 DK 180181 B1 Fig. 4 shows a composite wall element of the invention comprising seven layers. Fig. 5 shows a cross-section of a composite wall of the invention intended for plastering. Fig. 6 shows a cross-section of a composite wall of the invention intended for a raw appearance or for paint.

Fig. 7 shows an example of wall made from composite thermal wall elements of the invention. The reinforcement is not shown. Fig. 8 shows an example of a wall made from composite thermal wall elements of the invention for a window opening. The reinforcement is not shown.

The advantages of the present invention are now described and where possible by referring to the figures above. Fig. 1 shows a cross-section of a building. The arrows point to where the composite thermal wall element of the invention may be applied, i.e. for the external structural walls, in the basement, at first or higher floors, or in the middle of the house in-between rooms that needs thermal or acoustic insulation. The wall has a low thermal conductivity and is noise reducing as well. It is very effective for thermal insulation. The reinforcement is not shown.

Referring to Fig. 2 the composite thermal wall element according to the invention comprises at least three layers. The foam layer, 1, is attached on each face side, 11, visible on the figure and 12, not visible, to a CSH-component layer, 2. Either, the foam layer is sticking to the CSH-component layer, 2, or an adhesive layer (not shown) joins the foam, 1, and CSH-component layer, 2, see Fig. 3. An advantage of the composite wall element of the invention is improved construction speed, fire protection and thermal insulation. The thermal insulation properties are improved by lowering the thermal conductivity while maintaining good fire resistance properties. Both the insulation material and the mineral CSH-component have high resistance to fire, and improvement of thepå DK 180181 B1 reinforcement can raise the load bearing capacity even further. The construction speed and the working environment regarding healthy and safety is improved, because the walls are installed by using special lifting tools and less manual handling.

Fig. 3 shows another composite thermal wall element according to the invention. It has five layers. The foam layer, 1, is attached to an adhesive layer, 3, on both face sides, 11 and 12, and the adhesive layers, 3, are each attached to a CSH- component layer, 2.

Fig. 4 shows a composite thermal wall element according to the invention. It has seven layers. The foam layer, 1, is in the middle and by the adhesive characteristic of the foam layer, 1, attached on each face side to a protective glass-fibre fabric layer, 4. The protective layers, 4, are each on their other face sides, one is not visible, attached to an adhesive layer, 3, and the adhesive layers, 3, are each attached to a CSH-component layer, 2.

The above composite is prepared directly from products available on the market.

Fig. 5 shows a reinforced cross section of joined composite thermal wall elements as in Fig. 2. The wall elements are covered with a layer of plaster that can be reinforced by a mesh of glass fibre fabric on the whole surface. 5. The outmost layer is typically a voluntary optical layer of paint, 6.

Fig. 6 shows a reinforced cross section of a joined composite thermal wall elements as in Fig. 2. The edges are chamfered. The outmost layer is a layer of paint, 6. As seen, the edges are chamfered, 7, and the joint sealed, 8. The paint covers both the CSH-component and the joint. The ends of the rods, 10, of the reinforcement are shown.

Fig. 7 shows an example of how composite thermal wall elements are installed. In between the complete thermal wall elements in the vertical joints, there ispå DK 180181 B1 used an adhesive layer of thin layer mortar, synthetic glue or other practical functioning adhesive.

The rods of the reinforcement are not shown.

Fig. 8 shows an example of how composite thermal wall elements can be installed around windows.

In between the complete thermal wall elements in the vertical joints, there is an adhesive layer of thin layer mortar, synthetic glue or other practical functioning adhesive.

The rods of the reinforcement are not shown.

Fig. 2 to 7 show all an embodiment of a thermal wall element according to the invention.

The insulating phenolic foam is commercially available.

It is anticipated that the foam layer may be made from a resole.

This has a composition, if it includes a facing material, of: About 70% resole resin, about 15% additives, 9% facing material and a propellant with no depletion potential 5%. It is made from a liquid resole resin, calcium carbonate as filler, additives and a blowing agent.

The foam is rigid and has 90% or more closed cells.

Examples are published in EP1922356 B1 and EP1922357 B1. The CSH-component of the claimed embodiments of the composite thermal wall element may deviate in its composition as follows:

Corpse seen |19E [Wea It is anticipated that e.g. a light weight aircrete for the CSH-component may have the following composition: Base materials / Value Unit JE |

, DK 180181 B1 The traditional manufacturing of the phenolic foam needs a surface covering to prevent the foam from sticking to the production equipment but also a firm support layer or surface to form the foam. So, on the market the foam layer is sold sticking on both sides to a glass fibre fabric. A thermal wall element of the invention may or may not comprise the support layer.

Example1. Preliminary experiment. Two CSH-component boards are provided from H+H Deutschland GmbH. They have been prepared according to a well-known method, see Environmental Product Declaration of Non-reinforced autoclaved aerated concrete, 2014. A similar adhesive foam, which has the adhesive property of phenol foam, polyurethane foam, is used in investigating tests to confirm that a proper adhesion of the formed foam to the CSH-components can be achieved. The CSH-components are placed aligned and plan parallelly, vertically, at a distance of 10 cm and the polyurethane foam is raised and filled up the cavity. No glue layer is used as the freshly formed foam itself between the CSH- components established the necessary cohesion to the CSH-components. A composite with good insulation properties was obtained.

Example 2. Vertical preparation. Two autoclaved aerated concrete CSH-component boards are provided from H+H Deutschland GmbH. They have been prepared according to a well-known method published in Environmental Product Declaration of Non-reinforced

8 DK 180181 B1 autoclaved aerated concrete, 2014. The following test is performed with non-reinforced boards as these were available, and the test should show whether a composite could be prepared applying the adhesive character of a foam prepared from a liquid resole resin.

Two concrete CSH-component boards are aligned plan parallelly, vertically, at a distance of 5 to 20 cm, tempering the CSH-component layers to 50°C to 80°C, and filling in between a liquid phenol resin with calcium carbonate as filler, an acid catalyst and a blowing agent, forming an insulation material layer, 1, in between the preheated CSH- component layers, by applying the liquid phenol resin with calcium carbonate as filler, an acid catalyst and a blowing agent and wait until the curing step has finished. As a preferred example the tempering step is performed to 60°C to 70°C. Example 3. Horizontal preparation.

An anticipated method of preparing the composite wall element of the invention comprises, to prepare the composite wall element by preparing a foam layer with the preferred characteristics of claim 2, according to standard methods on a support layer which also serves as a first protective layer, placing a second protective layer on the other side of the foam layer, provide at least two CSH-component layers pre-prepared using standard methods, applying a suitable adhesive layer to each protective layer's face side or to one side of each CSH-component layer, which have been cooled down fromo DK 180181 B1 production, and combining the layers, thereby attaching the protective layers to the CSH- component layers and allowing the resulting composite to be diffusive open. A suitable adhesive is an air-hardening moistens fast synthetic aqueous copolymer dispersion, in German called a "Kunststofharzdispersion”, based on styrene and an acrylic acid ester with a solid content of 20-80%, preferably 50% +- 1%.

Example 4. Horizontal preparation.

Yet another anticipated method comprises, providing two CSH-component layers, each layer may be prepared by using standard methods as e.g. published in Environmental Product Declaration of Non-reinforced CSH-component, and wait until the CSH-component layers have cooled down, fill onto one of the CSH-component layers a composition comprising a phenol resin, using a standard method for preparing foam boards, e.g. as published in Environmental Product Declaration Kingspan Kooltherm K5, or EP1922356B1 or EP1922357B1, except for that the curing process is postponed as the next step is placing on the other side a second CSH-component layer as a second foam support layer or carrier and then performing a curing step for the foam forming process above, applying the adhesive property of the formed foam for attaching the layers of CSH-component, one on each side of the foam layer.

DK 180181 B1 10 The phenolic foam may, preferably, be formed from a liquid resole resin comprising calcium carbonate as filler, an acid catalyst and a blowing agent.

An additive may also be present.

For walls of buildings if the wall is made from a CSH-component the amount of glue for the attachment of a CSH-component to the foam layer is 5 kg/m? CSH- component.

Claims

DK 180181 B1 1 Patent claim

A thermal wall element for a building, the thermal wall element being a composite comprising at least three layers, a first layer, 1, being a diffusion-open rigid insulating material, and a second layer, 2, attached thereto , and a third layer, 2, are diffusion-open calcium silicate hydrate layers, the first, 1, and second layer, 2, being attached to each other, and the first, 1, and third layer, 2, being attached to each other, characterized in that at least one of the diffusion-open calcium silicate hydrate layers, 2, is a layer reinforced with rods or fibers, and wherein any of these layers, 2, is attached to an adhesive diffusion-open layer, 3, or which by the adhesive property of the first layer, 1.

The thermal wall element according to claim 1, wherein the rigid, open insulating layer, 1, is a rigid phenolic resin foam with more than 70%, preferably more than 90%, closed cells.

A thermal wall element according to claim 1 or 2, wherein the at least two diffusion-open calcium silicate hydrate layers or the second layer, 2, and the third layer, 2, have a density of 250-2500 kg / m 2? and a compressive strength of 1.5-40 MPa.

A thermal wall element according to any one of claims 2 to 3, wherein the rigid phenolic foam is made from a composition comprising a liquid resole resin and calcium carbonate as filler using an acid catalyst and a foaming agent.

The thermal wall element of claim 4, wherein the composition further comprises a plasticizer.

A thermal wall element according to any one of claims 1 to 5, wherein the adhesive diffusion-open layer, 3, is an adhesive layer such as a non-softened aqueous copolymer dispersion based on styrene and an acrylic acid ester.

DK 180181 B1 2

The thermal wall element according to claim 6, wherein the adhesive is an air-curing moisture-resistant synthetic aqueous copolymer dispersion based on styrene and an acrylic acid ester with a solids content of 20-80%, preferably 50% +/- 1%.

The thermal wall element of claim 7, wherein the synthetic aqueous copolymer dispersion is a styrene acrylic acid ester.

A thermal wall element according to any one of claims 2 to 8, wherein the rigid phenolic foam is made of a phenolic resin composition comprising a phenolic resin, a foaming agent comprising at least one of butane, hexane and isomers thereof, an acid catalyst and a metal hydroxide or metal carbonate with an equilibrium solubility (Ksp) less than 10% when measured at 25 ° C and present in an amount from 1 to 10 parts by weight per 100 parts by weight of phenolic resin, and wherein the phenolic foam comprises a plasticizer for the phenolic resin, wherein the plasticizer has a molecular structure containing both an ester backbone and a hydroxyl group, an organic modifier for co-reaction with the phenolic resin, wherein the phenolic foam has a pH of 5 or more.

A thermal wall element according to any one of claims 1 to 9, wherein the diffusion-open, rigid insulating material, 1, is a polyurethane layer.

A thermal wall element according to any one of claims 1 to 10, wherein the rods or fibers are steel rods, synthetic, organic, inorganic fibers, mineral fibers or metallic fibers.

A method of manufacturing a thermal composite wall element, characterized in that it comprises the steps of providing a first and a second diffusion-open CSH component layer, 2, from 50 to 80 ° C, preferably 60 to 70 ° C, where at least one is reinforced with rods or fibers,

DK 180181 B1 3 formation of an insulating material layer, 1, preferably horizontally, on top of one side of the first diffusion-open CSH component layer, 2, by applying a liquid phenolic resin with calcium carbonate as filler, an acid catalyst and a foaming agent, foaming and curing the phenolic resin to provide a diffusion-open, rigid insulating material, 1, having over 70%, preferably over 90% closed cells, and, before curing is complete, attaching the second diffusion-open CSH component layer, 2, from 50 to 80 ° C, preferably 60 to 70 ° C, by applying the adhesive property of the foam to the attachment, to a composite.

A method of manufacturing a thermal composite wall element, characterized in that it comprises the steps of providing a first and a second diffusion-open CSH component layer, 2, at least one of which is reinforced with rods or fibers, placement of the second diffusion-open CSH component layer, 2, plane parallel, preferably vertically at a distance from the first diffusion-open CSH component layer, providing the CSH component layers pre-tempered to 50 to 80 ° C, and a composition comprising a liquid phenolic resin, calcium carbonate as filler, an acid catalyst and a foaming agent, forming an insulating material layer, 1, between the preheated CSH component layers, by applying the composition comprising a liquid phenolic resin, calcium carbonate as filler , an acid catalyst and a foaming agent,

DK 180181 B1 4 and curing the foam, thereby providing a diffusion-open, rigid insulating material, 1, with over 70%, preferably over 90% closed cells, whereby a composite is obtained by using the adhesive property of the foam for the attachment.

The method of claim 13, wherein the preheating is performed at a temperature of from 60 ° C to 70 ° C.

The method of claim 12, 13 or 14, wherein the liquid phenolic resin composition comprises a plasticizer.

A method according to any one of claims 12 to 15, wherein the liquid phenolic resin is a resole resin.