Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
  • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
  • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
  • E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
• • 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
  • E04B1/78—Heat insulating elements
  • E04B1/80—Heat insulating elements slab-shaped
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
  • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
  • E04D13/16—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
  • E04D13/1606—Insulation of the roof covering characterised by its integration in the roof structure
  • E04D13/1612—Insulation of the roof covering characterised by its integration in the roof structure the roof structure comprising a supporting framework of roof purlins or rafters
  • E04D13/1618—Insulation of the roof covering characterised by its integration in the roof structure the roof structure comprising a supporting framework of roof purlins or rafters with means for fixing the insulating material between the roof covering and the upper surface of the roof purlins or rafters
• • 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
  • E04B2001/7683—Fibrous blankets or panels characterised by the orientation of the fibres

Definitions

• Insulating material element made of mineral wool as well as a process for its production and use of the same
• the invention relates to an insulating material element made of mineral wool, a process for its production and use of the same.
• Insulating material elements made of mineral wool are produced by providing mineral fibres generated in a fibre-separating station with a binder and depositing them on a production belt, after which the fibre web produced in this way runs through a heating oven for curing the binder, with pressure being applied at the same time to produce the desired product thickness.
• a laminar alignment of the fibres that is substantially parallel to the surface of the production belt is obtained in the web.
• the compressive strength of the product, and consequently also its tensile strength in the opposite direction of loading can be set by choosing the thickness compression in the curing oven. If a high apparent density is produced in this way, a good compressive strength is obtained, but a relatively poor heat insulating capacity.
• the web is compressed only little in thickness in the curing oven, a soft product of low compressive strength but good heat insulating capacity is obtained. Moreover, such a product is distinguished by relatively low weight and relatively low production costs, since the use of material per unit volume is a major factor influencing the cost calculation.
• a heat insulating element made of mineral wool for insulating surfaces in particular for the over-rafter insulation of roofs, in particular steep roofs, or else other surfaces such as building facades, intermediate floors and the like, the body of which element exclusively consists of bonded mineral wool and which, in spite of an increased compressive strength in comparison with conventional heat insulating elements, has a good heat insulating capacity, can be easily manipulated by one person on account of its low weight and as far as possible can be produced inexpensively online.
• the mineral wool material of an insulating material element according to the invention has load-dissipating fillets of increased compressive strength made of mineral wool maintains the concept of a "monolithic" insulation with bonded mineral wool alone. Nevertheless, an increase in the overall strength is obtained in a way similar to the use of spacers of a different material, for example metal.
• the insulating material element still has a one-piece character and can be handled like a panel without such fillets as a single, compact part.
• the one- piece character, fully integrating the fillets, of an insulating panel formed in this way is enhanced by the mineral wool material of the fillets and of the insulating parts having open surfaces and penetrating into one another with these open surfaces when pressed together in the course of making the connection between the fillet and the insulating part, so that the mineral fibres on the respective surface of the insulating part and fillet reach over one another and possibly become hooked, and thus form a particularly intimate bond. Since the fillets can be restricted to a relatively small part of the surface area of the insulating material element, their heat insulating capacity, which is still high but comparatively lower with respect to the insulating part, is of no major significance overall.
• An insulating material element according to the invention may be produced for example by fabrication, with prefabricated portions of the material for the fillets and of the material for the insulating parts being pressed against one another and bonded, for example by means of an adhesive.
• a particularly advantageous process, especially suitable for the mass production of insulating material elements of this type, is specified in Claim 14.
• the insulating material elements may in this way also be provided particularly efficiently on one or both sides with outer layers, in particular with a hard skin, a lamination etc., so that combined insulating material elements for a large number of • applications can be produced continuously on the line, the said elements consisting exclusively of mineral fibres - except possibly for the laminating sheet - with the mineral fibres being bonded with the binder for the mineral wool, even from layer to layer, and thus representing integrally bonded and interlocked units, which however are of an inhomogeneous structure to the extent that the mineral fibres used have at the desired locations the respectively desired properties.
• An insulating element according to the invention made of mineral wool acquires particular significance in its use for the over-rafter insulation of a steep roof, since here the work of the roofer on the roof gives rise to quite particular requirements and conditions.
• Mineral wool has been extensively used for decades for roof insulation between rafters. Mineral wool is preferred over other insulating materials such as rigid foam because of its good flame retardant properties. It is to be endeavoured also to make use of these properties for the over-rafter insulation if, for visual reasons, the inner side of the roof is to remain visible and the insulation consequently has to be laid on the outer side of the roof in the region above the roof boarding. If in this case it is intended to dispense with the insulation of supports extending through, the insulating layer must absorb the forces acting as a result of the weight of the roof boarding and its load-bearing structure as well as any snow and wind loads, and consequently requires a not inconsiderable compressive strength. With the use of mineral wool, preferred for flame retardant reasons, it has so far only been possible to meet these requirements by making compromises with respect to reduced heat insulating properties, high costs and/or difficult laying procedures with which the roofer is not accustomed.
• DE 34 37 446 Al disclosed as much as 15 years ago a roof substructure which has rectangular mineral wool panels with a hard outer covering board, which is applied on one side, overlaps the layer of mineral wool on three sides and has on one of these sides a stiffening member fastened to the outer covering board.
• the stiffening member made of a compression-resistant material, may in the simplest case be made of wood, but according to the teaching of DE 34 37 446 Al is a composite profiled member comprising a rigid foam profile with a wooden board introduced between the rigid foam profile and the outer covering board for pressure distributing purposes.
• a uniform, homogeneous and "monolithic" insulating layer of a roof substructure was disclosed for the first time by DE 36 15 109 Al .
• insulating panels with an insulating layer of compressed rock wool which has a high compressive strength of over 40 kN/m ⁇ and is provided with a lamination overhanging the edges. These insulating panels can be laid in the accustomed, uncomplicated way, in rows from the eaves to the ridge, can be walked on and have proven very successful in practice.
• the compressive strength is achieved here by a relatively high apparent density and arrangement of the fibres with preference in the direction of the thickness of the insulating layer, which restricts the heat insulating capacity; as a result, only thermal conductivity group 040 can be attained.
• great insulating thicknesses would therefore have to be chosen, which together with the high apparent density leads to a quite considerable weight of the insulating panels, which in turn hinders their manipulation on a steep roof.
• the high use of material leads to a relatively high price.
• EP 682 161 Al has disclosed the inclusion between high-strength mineral wool strips, fastened on the outer side of the roof, of sheets of rolled felt, which have a low compressive strength and low apparent density of, for example, 15 kg/m.3.
• the lamination Since, in the roll, the lamination must always be on the outside, it comes to lie on the underside of the sheet when the rolled felt is rolled out on the roof, so that the long sheet has to be turned over before it is fitted. This may hinder work on a steep roof in a way which the roofer will accept only unwillingly.
• the roofer can step on the firm mineral wool strips, a neighbouring part of the soft mineral wool panel may easily be pressed in as a result, with the result that the laminating sheet is subjected to tensile stress and the adhesive bond on the overhanging edge is lost. In particular when there is wind, it is consequently repeatedly necessary for flapping-up laminating sheets to be provisionally fixed again.
• the roofer can step on the fillet regions of the panels, and any pressing in of the laminating sheet does not lead to detachment of an edge connection of the laminating sheet to neighbouring laminating sheets because of the adhesive bonding on the upper side of the insulating part, such detachment moreover possibly leading at most to a wind-induced lifting-off of the edge strip and not for instance of the entire laminating sheet.
• the insulating part is relatively compression-resistant, because of the laminar arrangement of fibres in the direction of its major surface, and is thus capable of additionally securing the fillet arranged above it against slipping, even when the roof has a great inclination.
• This provides for the first time a roof substructure with a homogeneous insulating layer made of mineral wool material which can compete in terms of price with roof substructures of other materials, for example with rigid foam, and nevertheless can be laid or fitted without any problem and in the accustomed way, so that it is accepted on the part of those owning and working on buildings, and therefore for the first time provides in practice the advantages of a homogeneous insulation on a mineral wool basis without painful eompromises in the area of costs or the area of laying difficulties.
• This provides for the first time an insulating element uniformly made of mineral wool for roof substructures which is classified in thermal conductivity group 035, increasing considerably the quality of the insulation.
• Figure 1 shows a schematic representation of a production line for the production of an insulating material element according to the invention
• Figure 2 shows a first embodiment of an insulating material element according to the invention
• Figure 3 shows a second embodiment of an insulating material element according to the invention
• Figure 4 shows a third embodiment of an insulating material element according to the invention.
• Figure 5 shows a fourth embodiment of an insulating material element according to the invention.
• Figure 6 shows a plan view of part of a roof substructure which has insulating material elements according to Figure 5, but without roof covering.
• An insulating material element 1 has a panel element 10 with at least one insulating part 11, with a high heat insulating capacity, and at least one load-dissipating fillet 12, with an increased compressive strength in comparison with the insulating part 11.
• the production line 2 includes a production belt 21, on which the mineral wool material is fed to the production line from a fibre-separating station in the form of a web, from which the insulating parts 11 of the insulating material elements 1 are then formed.
• This web which is provided with a still uncured binder, may in this case be slit over the entire thickness by means of a cutting device 22 at at least one predetermined position of its width and be spread by a following spreading device 23 in such a way that the mineral wool material which has been pretreated in another way and is intended for the forming of a load-dissipating fillet 12 of the panel elements 10 can be introduced between the separated portions of the web.
• the mineral wool material for a fillet 12 may be taken from the same fibre - separating station as the material for an insulating part 11.
• the mineral wool material for a fillet 12 is in this case pre-compacted by means of a customary compressing installation 24, with rollers of respectively reduced speed arranged one behind the other, and is turned through 90 before introduction between the portions of the slit web in such a way that a high proportion of the mineral fibres is arranged in the direction of the thickness of the panel element 10.
• the insulating parts 11, the fillets 12, the outer layer 13 and, if applicable, the laminations 14 are then pressed against one another and adhesively bonded to one another during the curing of the binder.
• the insulating part 11 and the fillet 12 are in this case also passed through the curing oven 27 as a unitary sheet, in a way not represented in Figure 1 and with pressing laterally applied.
• the insulating material sheet consequently formed as an endless product is finally cut to length into rectangular insulating material elements 1.
• the lamination 14 may also be applied and attached by means of an adhesive after the panel element 10 has left the curing oven 27, a so-called tunnel oven, which is the case in particular with laminations which are temperature-sensitive and not suitable for the hot air of the curing oven to pass through.
• the combined web may also be subjected to further compression before curing.
• a plurality of cutting devices 22 and spreading devices 23 may also be provided in order to arrange a plurality of fillets 12 in the insulating material element 1.
• Exemplary embodiments of insulating material elements 1 are shown in Figures 2 to 5.
• the fibres of the insulating parts 11 and of the fillets 12 of the insulating element 10 have an alignment with respect to one another that is substantially at right angles.
• the mineral wool of the insulating parts 11 is in this case aligned substantially parallel to the insulating surface and has an apparent density of between 20 and 70 kg/m3. so that it is possible to realize a low weight and a high heat insulating capacity.
• the mineral wool material of the fillets 12, on the other hand, is compacted and has a compressive strength of less than 40 kN/m.2. In this case, a high proportion of the mineral wool of this fillet 12 is aligned in the direction of the thickness of the insulating material element 1.
• the insulating material element 1 according to Figure 3 has insulating parts 11 which have been compressed before the insertion of the fillet material.
• the fillets 12 and each insulating part 11 are in each case of the same length. -Furthermore, the fillets 12 and the insulating parts 11 are arranged parallel to one another.
• the width of the insulating parts 11 of the insulating material element 1 is in this case a multiple of the width of the fillets 12, each fillet 12 having at least approximately a rectangular shape in plan view.
• the fillets 12 By forming the fillets 12 with a compressive strength of at least 40 kN/m2, a sufficient stability is provided at the insulating material element 1, also allowing for example the insulating material element 1 to be walked on in the regions of the fillets. Furthermore, the load-dissipating fillets 12 stiffen the insulating material element 1 , so that it does not sag, i.e. bow, as a floor panel. The load-dissipating fillets 12 also advantageously make it possible to use apparent densities of 20 to 70 kg/m3 for the insulating parts 11, in order nevertheless to obtain an adequate strength of the overall insulating material element.
• the essential basic idea of the present invention is "as much in terms of statics as necessary and as little in terms of insulating material as possible", i.e. optimum heat insulating capacity with lowest possible weight.
• the insulating material element 1 therefore has good compressive strength with at the same time good heat insulating properties, these measures also leading to a reduction in material consumption, and consequently costs.
• the insulating material element 1 according to Figure 4 has, as a further variant, an outer layer 13 comprising a so-called hard mineral wool skin, with an apparent density of over 200 kg/m.3.
• This outer layer makes it possible, for example, for this insulating material element 1 to be used for insulating flat roofs, since it can be walked on.
• an insulating material element of this type is also suitable as a facade insulating panel, in which case the outer layer 13 then serves as a plaster underlay.
• the latter may also be provided on at least one of its major surfaces with a surface-area-bonded lamination 14, which however is not represented in Figures 2 to 4.
• Figure 6 shows a perspective representation of an insulating layer 30 comprising a plurality of insulating material elements 1 according to the invention, as shown in Figure 5, arranged in series with one another and in a surface-covering manner.
• the insulating material element 1 according to Figure 5 or 6 has here a load-dissipating fillet 12, which is arranged at the edge and is adhesively attached laterally to a single insulating part 11, i.e. forms with the latter a one-piece panel element 10.
• the insulating material element 1 has, furthermore, on an upper side a laminating sheet 14, which overhangs the insulating part 11 or the fillet 12 on two sides.
• This laminating sheet 14 may in this case consist, for example, of a plastic-coated polyester spunbonded web and is open with respect to diffusion, but at the same time designed such that it is water-repellent (impervious to driving rain) and crush-resistant when stepped on. Since the laminating sheet 14 overhangs by a predetermined amount on one longitudinal side and one end side of each insulating material element 1, overlapping edges are produced with respect to the corners, respectively covering over the joints of abutting insulating material elements 1.
• the laminating sheet 14 is adhesively attached on the panel element 10 in spots or strips by means of a special adhesive.
• an insulating layer 30 of this type comprising insulating material elements 1, can be arranged on the roof 3, in particular a steep roof.
• the roof 3 contains rafters 31, onto which a closed roof boarding 32 is applied.
• an airtight and diffusion-resistant, film- like vapour barrier 33 which in the present example comprises a customary bituminous roofing sheet according to DIN 52143.
• Applied in a surface-covering manner on the vapour barrier 33 are a plurality of the insulating material elements 1 according to Figure 5, for forming the insulating layer 30.
• the overlapping edges of the longer side of the laminating sheets 14 of each insulating material element 1 respectively face in the direction of the eaves, so that rain water etc. can run down in the direction of the eaves.
• each rafter 31, above the insulating layer 30. are also counter-laths 34, by means of so-called screw-type nails, which reach through the insulating material elements 1 etc. into the respective rafters 31 and fix the counter-laths 34 on the rafter 31.
• roof laths 35 are also arranged over the counter-laths 34. on which roofing panels (not shown) can be arranged.
• the weight of the structure comprising the counter-laths 34 and the roof laths 35 in the fitted state is substantially absorbed by the fillets 12, whereas the entire load dissipation of the covered roof takes place through the screw-type nails.
• the load-dissipating fillets 12 of the panel elements 10 of the insulating material elements 1 are respectively arranged on the insulating material element 1 on the roof-ridge side and are parallel to the ridge.
• Each fillet 12 has in the present case an apparent density of at least 140 kg/m3 and a width of 1/8 to 1/5 of the width, measured in the direction of fall of the insulating material element 1.
• the mineral wool of the insulating part 11 on the other hand, has only an apparent density of 20 to 70 kg/m3 and in the present case 50 kg/m3, which advantageously makes possible a thermal conductivity classification in group 035.
• the compressive strength of the fillets 12 should be below 200 kN/m2, and in particular below 180 kN/m.2, to keep the total weight of the insulating material element 1 in a range which allows good handling.
• values of between 30 and 60 kg/m3 and preferably between 40 and 50 kg/m3 have proven to be most suitable.
• the overhanging edges of the lamination 14 in the region of the side facing the body of the insulating material element 1 may be coated with adhesive which can be activated in a known way during fitting.
• the insulating material element 1 may in this case consist entirely of rock wool or glass wool .
• the insulating material element 1 according to the invention can be used not only for the over-rafter insulation of roofs 3, and in particular steep roofs, but also - as already mentioned - for the insulation of other surfaces such as building facades, intermediate floors and the like. Moreover, they may also be used in the area of air-conditioned rooms as inlays for modules for cold stores, for example, and as an inlay for fire doors or for modular walls in the building of industrial sheds.
• the invention consequently provides a one-piece insulating material element 1 made of mineral wool as well as a process for its production which is designed on the basis of "as much in terms of statics as necessary and as little in terms of insulating material as possible".

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Physics & Mathematics (AREA)
• Acoustics & Sound (AREA)
• Electromagnetism (AREA)
• Building Environments (AREA)
• Roof Covering Using Slabs Or Stiff Sheets (AREA)
• Glass Compositions (AREA)

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• 1999
  • 1999-05-17 DE DE19922592A patent/DE19922592A1/de not_active Withdrawn
• 2000
  • 2000-05-17 DE DE60004462T patent/DE60004462T2/de not_active Revoked
  • 2000-05-17 EP EP00938648A patent/EP1099032B1/de not_active Revoked
  • 2000-05-17 AT AT00938648T patent/ATE247203T1/de not_active IP Right Cessation
  • 2000-05-17 DK DK00938648T patent/DK1099032T3/da active
  • 2000-05-17 WO PCT/EP2000/004479 patent/WO2000070161A1/en not_active Application Discontinuation
  • 2000-05-17 AU AU53948/00A patent/AU5394800A/en not_active Abandoned

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