Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4209—Inorganic fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
  • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/593—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H13/00—Other non-woven fabrics
• • E—FIXED CONSTRUCTIONS
  • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
  • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
  • E02D31/00—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution
  • E02D31/06—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution against corrosion by soil or water
• • 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
  • E04B1/88—Insulating elements for both heat and sound
  • E04B1/90—Insulating elements for both heat and sound 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
  • E04D13/1687—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 the insulating material having provisions for roof drainage
• • 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
  • E04B1/82—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 sound only
  • E04B1/84—Sound-absorbing elements
  • E04B2001/8457—Solid slabs or blocks
  • E04B2001/8461—Solid slabs or blocks layered
• • 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
  • E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
  • E04D13/0404—Drainage on the roof surface
  • E04D13/0477—Underroof drainage layers
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
  • Y02A30/00—Adapting or protecting infrastructure or their operation
  • Y02A30/24—Structural elements or technologies for improving thermal insulation
  • Y02A30/254—Roof garden systems; Roof coverings with high solar reflectance
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
  • Y02B80/00—Architectural or constructional elements improving the thermal performance of buildings
  • Y02B80/32—Roof garden systems

Definitions

• a panel comprising mineral fibres and a th ⁇ rmosetting resin, use of the panel and method of preparing the panel .
• the present invention relates to a panel comprising mineral fibres and a thermosetting resin which panel is constituted by a hydrophobic layer and a hydrophilic layer.
• the invention also relates to the use of the panel and methods for preparing such panels.
• Panels comprising mineral fibres and a thermosetting resin are widely used.
• the panels are especially used for thermal and acoustic insulation purposes. For these uses it is normally preferred that the panels are hydrophobic, but for some specific uses and purposes it may sometimes be preferred that the panels or at least a part of the panels are hydrophilic.
• Such panels can be used as growth media for plants and for special insulation purposes e.g. for drainage and insulation of basement walls.
• Panels are normally considered to consist of four edges and two sides. Preferably, the panel has a rectangular shape.
• EP 0 889 175 A2 discloses a mineral-fibre board with a hydrophobic and a hydrophilic part.
• the board may be manufactured either from one panel which is impregnated with a hydrophobic agent in one part and a hydrophilic agent in another part, or from one hydrophobic board and one hydrophilic board, which are glued together.
• the hydrophilic part of the board is made hydrophilic by impregnating it with wetting agents, water-glass or silicic-acid esthers.
• the board may be used for covering fagades where the hydrophilic part is in contact with the fa ⁇ ade wall to remove salts and other unwanted species from the wall.
• the board may also be used as growth media for plants.
• GB 2 154 257 A discloses an insulating slab for basement walls.
• the slab consists of mineral fibres bonded with a hydrophobic bonding agent.
• the slab may also be impregnated with a hydrophobic impregnating agent.
• this side is subjected to a heat treatment so as to remove the hydrophobic bonding agent and the hydrophobic impregnating agent from those areas. Those treated areas then become hydrophilic and when the slabs are used for insulation of basement walls the hydrophilic areas serve as drain conduits.
• DK 173106 B discloses a method of applying binding agent onto mineral wool .
• the document describes a method in which different kinds of binding agents or mixtures of binding agents may be applied to the mineral wool.
• the document also describes that the amount of binding agent may vary in the mineral wool.
• the method is suitable for obtaining different properties in the wool.
• the document discloses nothing about mineral fibre panels having a hydrophobic layer and a hydrophilic layer.
• SE 464705 B discloses a method of applying binding agent or impregnating agent to a primary web of mineral wool.
• the document describes a method in which extra binding agent or impregnating agent is applied to one or both edges of the web which later when the web has been folded become the upper and lower side of the web.
• the method is suitable for improving the strength in the resulting mineral wool product.
• the document does not disclose anything about panels having a hydrophobic layer and a hydrophilic layer.
• the known panels comprising mineral fibres and a hydrophobic part and a hydrophilic part are usually manufactured from a relatively complicated process with after-treatment of the panels, which increases the cost of the panels. Furthermore, the known panels have the disadvantage that there is a tendency of water to enter into the hydrophobic part from the hydrophilic part when this contains large amounts of water and consequently the hydrophobic part becomes more and more wet. This problem particularly occurs when the panels are used for growth media or basement wall insulation. Furthermore, use of wetting agents to make a part of the panel hydrophilic has the disadvantage that the wetting agents have a strong tendency to migrate into the hydrophobic part, and thereby convert the hydrophobic part into a hydrophilic part, this being an undesired effect.
• the present invention provides a panel comprising mineral fibres and having a hydrophobic and a hydrophilic part, in which panel water can freely pass into the hydrophilic part and wherein substantially no water will pass into the hydrophobic part. Furthermore the panel is stable and has long-lasting properties due to the manufacturing method.
• the methods of preparing panels according to the invention are uncomplicated and cost-effective and no after-treatment of the panels is required.
• the methods according to the invention result in panels with improved qualities, which are stable and have excellent features and properties for many uses.
• the invention provides a very useful mineral fibre panel comprising a hydrophobic layer and a hydrophilic layer. Due to the relatively low production costs of the panel, the possible uses can be expanded to areas, where such type of panels has not been used so far because of the costs of such panels.
• the panel is excellent for covering and insulation of building fa ⁇ ades and also serves very well as insulation and for drainage purposes for basement" walls. Furthermore, the panel is extremely useful as growth media for plants, especially in connection with * green roofs" .
• hydrophilic part of the panel according to the invention may preferably be made hydrophilic without any use of wetting agents to eliminate the risk of having the hydrophobic part of the panel destroyed by migrating wetting agents.
• the mineral fibres used in the panel according to the invention may in general be any type of mineral fibres, preferably man-made vitreous fibres (MMVF) such as rock wool fibres, slag wool fibres, glass wool fibres and stone wool fibres.
• MMVF man-made vitreous fibres
• the panel according to the invention may also contain other additives such as fungicides and particles to improve the properties e.g. hygroscopic particles, carbon particles, etc.
• the panel may also contain dyestuff to modify the colour of the panel.
• the methods for production of the panel make the panel relatively cheap to produce, due to the fact that the panels are produced online without requirements for after treatment. Furthermore the panel has improved properties because of the production methods according to the invention.
• mineral fibre panels for use as growth media have been produced from a separate hydrophobic panel and a separate hydrophilic panel being glued together.
• These known panels have the disadvantage that the glue may be toxic to some plants. This disadvantage is avoided when using panels prepared by the methods according to the invention. If the hydrophobic layer is not fully impregnated with hydrophobic binding agent and optionally hydrophobic oil, this may cause a wetting of the hydrophobic layer. In such case the hydrophilic layer is able to remove the water or moisture from the hydrophobic layer due to the capillary effect of the hydrophilic layer induced by the density of the hydrophilic layer.
• the hydrophilic layer is able to prevent soil from entering the panel e.g. when the panel is used for insulation and drainage of a basement wall. Further, it has appeared that there is no need for sand to lead water to the drain-pipe which is normally used in traditional drainage systems.
• the strength of the panel is moreover increased as the density of the layers is increased.
• the panel according to the invention comprises mineral fibres and a thermosetting resin and comprises a hydrophobic layer and a hydrophilic layer, wherein the hydrophilic layer is in contact with the hydrophobic layer, said hydrophilic layer has a density which is equal to or higher than the density of said hydrophobic layer.
• the average density of the hydrophilic layer may preferably be at least 5% more, preferably at least 10% higher than the density of the hydrophobic layer.
• the panel comprises mineral fibres and a thermosetting resin and furthermore at least one hydrophobic layer and at least one hydrophilic layer, wherein the at least one hydrophilic layer has an average density of at least 60 kg/m 3 , preferably a density of 75 to 2200 kg/m 3 , more preferably a density of 150 to 2000 kg/m 3 .
• the average density of the hydrophilic layer is especially useful when the hydrophilic layer is divided into sub-layers of different densities. The densities of the single hydrophilic sub-layers are then used to calculate the average density of the hydrophilic layer.
• the hydrophobic layer has a density of 20-300 kg/m 3 , preferably 60-250 kg/m 3 , more preferably 80-200 kg/m J .
• This embodiment is particularly preferred for panels for use as thermal insulation and drainage purpose for basements walls and for use as growth media.
• the hydrophobic layer has an average density of 150-2000 kg/m 3 .
• This embodiment is particularly preferred for panels for use as covering and insulation of fa ⁇ ade walls.
• the hydrophilic layer or the sum of hydrophilic layers if more has a thickness of up to about it is preferred that the hydrophilic layer has a thickness up to about 100 mm.
• the hydrophilic layer has a thickness up to 10 mm which makes the panel very useful for covering and insulating of building fa ⁇ ades.
• the hydrophilic layer has a thickness of 1-45 mm which makes the panel very useful for insulation and drainage purposes in respect of e.g. basement walls.
• the hydrophilic layer has a thickness of 20-80 mm which makes the panel very useful as growth media for plants.
• the hydrophilic layer in a preferred embodiment comprises two or more sub-layers, and one of the hydrophilic sub-layers may preferably constitute an upper hydrophilic sub-layer defined as a layer constituting one side of the panel.
• the upper hydrophilic sub-layer has a density of 150-2000 kg/m 3 , and more preferably the upper hydrophilic sub-layer has a thickness up to 30 mm.
• the embodiment may be useful for covering and insulation of fa ⁇ ade walls.
• the hydrophobic layer may preferably comprise two or more sub-layers.
• a first hydrophobic sub-layer has a density of from 20 to 130 kg/m 3 , more preferably from 50 to 110 kg/m 3 .
• a second hydrophobic sub-layer has a density of from 130 to 280 kg/m 3 , more preferably of from 150 to 250 kg/m 3 .
• a second hydrophobic sublayer has a density of from 150 to 2000 kg/m 3 which may contribute to the strength of the panel.
• the panel has a hydrophobic layer consisting of two sub-layers, wherein the first hydrophobic sub-layer has a density from 50 to 130 kg/m 3 and the second hydrophobic sub-layer has a density from 150 to 250 kg/m 3 and the hydrophilic layer has a density from 300 to 2000 kg/m 3 .
• a hydrophobic layer consisting of two sub-layers, wherein the first hydrophobic sub-layer has a density from 50 to 130 kg/m 3 and the second hydrophobic sub-layer has a density from 150 to 250 kg/m 3 and the hydrophilic layer has a density from 300 to 2000 kg/m 3 .
• Such a panel is very useful for covering and insulation of fa ⁇ ade walls.
• the panel has both good strength and insulation properties .
• the panel has a hydrophobic layer consisting of three sub-layers, wherein the first hydrophobic sub-layer has a density of from 50 to 130 kg/m 3 , the second hydrophobic sub-layer has a density of from 150 to 250 kg/m 3 , the third hydrophobic sub-layer has a density of from 300 to 2000 kg/m 3 and the hydrophilic layer has a density of from 300 to 2000 kg/m 3
• the hydrophobic layer has a thickness of up to 500 mm and the hydrophilic layer has a thickness of up to 100 mm.
• Such panels are especially useful as growth media for plants.
• the drainage capacity of the panel may be varied by e.g. varying density and/or thickness. In a number of particularly preferred e°mbodiments as described below the drainage capacity may be even further improved.
• the panel comprises at least one internal cavity, the at least one internal cavity has a size sufficient to allow fluids, gasses or particles to flow freely in the panel.
• the internal cavity referred to is significantly larger than the voids which are naturally formed in the mineral fibre web during the production process, preferably the at least one internal cavity has a cross section area of at least 10 mm 2 .
• the internal cavities are substantially parallel with one edge of the panel and have a cross section area up to 50000 mm 2 , preferably 100-2500 mm 2 , and if more cavities present they preferably have a regular mutual spacing up to 1000 mm.
• the at least one internal cavity is preferably used in connection with a panel according to the invention for drainage purposes or as growth media for plants.
• one or more grooves are formed on one or both sides of the panel .
• the groove or grooves preferably have a depth of 3-150 mm and preferably a width of 3-50 mm, and they are preferably substantially parallel to one edge of the panel and if more grooves present they preferably have a regular mutual spacing of up to 1000 mm.
• one or both sides of the panel are covered with a non-woven and/or a woven material and/or a metal- foil.
• the panel according to the invention comprises two hydrophilic layers, a first and a second hydrophilic layer, separated by a hydrophobic layer.
• This embodiment may e.g. be used for covering and insulation of fagade walls, where the first hydrophilic layer is facing away from the fagade wall and coated with a rendering.
• the second hydrophilic layer is facing the wall and serves as a buffer for moisture.
• the first hydrophilic layer has a density of at least 100 kg/m 3 and the second hydrophilic layer has a density of at least 40 kg/m 3 , and the average density of the hydrophilic layer is at least 60 kg/m 3 .
• the first hydrophilic layer has a thickness of up to 100 mm and the second hydrophilic layer has a thickness of up to 50 mm.
• the invention also comprises use of a panel according to the invention for covering and/or insulation of fagade walls, and preferably the panel is mounted with the hydrophobic layer in contact with the fagade wall.
• the hydrophilic layer is coated with a rendering, as the hydrophilic layer is a good basis for applying water- based rendering or adhesive mortar.
• the panel comprising at least two hydrophilic layers, where the hydrophilic layers constitute the sides of the panel, the first hydrophilic layer is facing away from the fagade wall being coated with rendering and a second hydrophilic layer is facing and is preferably in contact with the fagade wall.
• the second hydrophilic layer will serve for removing moisture and unwanted salts from the fagade wall.
• the invention also comprises use of a panel according to the invention for thermal insulation and drainage of basement walls.
• the panel used has a hydrophilic and a hydrophobic layer, where the hydrophilic and hydrophobic layers constitute the sides of the panel, and the panel is mounted with the hydrophobic layer in contact with the basement wall.
• the use of a panel according to the invention also comprises general use for drainage purposes.
• the invention comprises the use of a panel according to the invention, in which the panel has a hydrophilic and a hydrophobic layer, where the hydrophilic and hydrophobic layers constitute the two sides of the panel for covering roof on buildings, and where the hydrophobic layer is in ' contact with the roof structure.
• the hydrophilic layer may preferably serve as a growth media for plants, and hereby making the panel very useful for green roofs".
• the panel When the panel is used to serve as "green roof” on pitched roofs it may preferably be provided with one or more cuts to prevent undesired flow of water.
• the one or more cuts are made through the whole hydrophilic layer and partly into the hydrophobic layer.
• the one or more cuts are substantially made in the direction perpendicular to the direction of the inclination of the roof.
• the one or more cuts may preferably be filled with waterproof material such as bitumen to improve the properties as water flow barriers.
• the two neighbouring edges of the panel may preferably be coated with waterproof material e.g. bitumen.
• a panel according to the invention may be used as a growth media for plants.
• the hydrophilic layer may be pre-treated before delivery to the user, e.g. the hydrophilic layer may be pre-treated by applying a gel or mat containing seeds of the plants wanted to grow in the panel.
• the hydrophilic layer may also be pre-treated by sowing seeds onto the layer and covering the layer with a woven or non-woven material to prevent birds or other animals to remove the seeds.
• fertilisers, pesticides and fungicides may be added.
• the invention comprises a fagade wall covered with a panel according to the invention.
• the invention furthermore comprises a roof covered with a panel according to the invention.
• the invention also comprises methods of preparing a panel according to the invention.
• a first method for preparation of panels according to the invention comprising a hydrophobic layer and a hydrophilic layer comprises the steps of providing a primary mineral fibre web comprising a hydrophobic binding agent and optionally a hydrophobic oil, impregnating the primary web with a hydrophilic binding agent in one longitudinally extending zone, leaving a longitudinally extending zone un-impregnated with hydrophilic binding agent, bringing the primary web to overlap itself by laying it out substantially transversally to the longitudinal direction of the primary web to form a secondary web comprising a hydrophobic layer and a hydrophilic layer, compressing the secondary web to obtain a tertiary web, curing or hardening the binding agents in said tertiary web and cutting the panels from the cured or hardened tertiary web.
• the secondary web is divided into a substantially hydrophobic sub-web and a substantially hydrophilic sub-web and the hydrophilic sub-web is compressed to a desired density and preferably the hydrophobic sub-web is compressed to a desired density, whereafter the compressed hydrophilic sub-web is contacted with the hydrophobic sub-web to obtain a tertiary web.
• the hydrophilic sub-web is compressed to obtain a density as described above for the preferred embodiments of the panel, preferably a density of at least 60 kg/m 3 , preferably 75 to 2200 kg/m 3 , more preferably 150 to 2000 kg/m 3 .
• the hydrophilic layer of the secondary web is divided into sub-layers, whereafter at least one of these sub-layers is further compressed and the sub-layers are united to obtain a hydrophilic layer with sub-layers of different densities.
• the hydrophobic layer of the secondary web is divided into sub-layers where after at least one of these sub-layers is compressed and the sublayers are united to obtain a hydrophobic layer with sublayers of different densities.
• the hydrophilic binding agent is added to the longitudinally extending zone in an amount sufficient to dominate the hydrophobic binding agent and the hydrophobic oil in said zone.
• the secondary web is provided with a bulk surface layer on one or both sides and preferably at least a part of said bulk surface layer is hydrophilic and preferably at least a part of said bulk surface layer is hydrophobic.
• a second method for preparation of panels according to the invention comprising a hydrophobic layer and a hydrophilic layer comprises the steps of providing a hydrophobic mineral fibre web constituting a hydrophobic layer, providing a bulk surface layer, distributing the bulk surface layer material onto one surface of the web to form a hydrophilic layer thereon to obtain a tertiary web constituted of the hydrophobic layer and the hydrophilic layer, curing or hardening the tertiary web while the hydrophilic layer is impregnated with a hydrophilic binding agent before or after the curing or hardening oven and cutting the panels from the cured or hardened tertiary web, said hydrophobic mineral fibre web comprising a hydrophobic binding agent and a hydrophobic oil and said bulk surface layer material having an average bulk density of at least 150 kg/m 3 and comprising a substantially homogenous mixture of at least one mineral material.
• the bulk surface material may be mineral fibres, milled mineral fibres, sand, quarts, Si0 2 / MgO, Ti0 2 , CaO, K 2 0, Na 2 0, A1 2 0 3 and similar material.
• the bulk surface material may further comprise additives such as hygroscopic particles, dyestuff, fungicides, etc.
• the average grain size of the bulk surface material is less than 10 mm.
• the hydrophilic layer is impregnated with a hydrophilic binding agent before the curing or hardening oven, and the hydrophilic binding agent is cured or hardened by the curing or hardening oven, or the hydrophilic layer is impregnated with a hydrophilic binding agent after the curing or hardening oven, and the hydrophilic binding agent is cured or hardened by the remaining heat in the tertiary web.
• the hydrophilic layer is compressed to obtain a density of from 300 to 2000 kg/m 3 , and preferably the hydrophobic layer is being compressed to obtain a density of from 50 to 250 kg/m 3 .
• the hydrophobic layer is divided to obtain a least two hydrophobic sub-layers.
• the hydrophobic layer is divided into two hydrophobic sub-layers, and the first hydrophobic sub-layer is compressed to obtain a density of from 50 to 130 kg/m 3 and the second hydrophobic sublayer is compressed to obtain a density of from 150 to 250 kg/m 3 .
• the hydrophobic layer is formed with a thickness of 10 to 100 mm and the hydrophilic layer is formed with a thickness of 0,5 to 5 mm.
• the hydrophobic layer is provided with a bulk surface layer on one or both sides and preferably at least a part of said bulk surface layer is hydrophilic, and preferably at least a part of said bulk surface layer is hydrophobic.
• a third method for preparation of panels according to the invention comprising a hydrophobic layer and a hydrophilic layer comprises the steps of providing a primary mineral fibre web, applying hydrophilic binder to one area extending in the longitudinal direction of the web and applying hydrophobic binder and optionally a hydrophobic oil to the remaining area of the web, bringing the primary web to overlap itself by laying it out substantially transversally to the longitudinal direction of the primary web to form a secondary web comprising a hydrophobic layer and a hydrophilic layer, compressing the secondary web to obtain a tertiary web, curing or hardening the binding agents in said tertiary web and cutting the panels from the cured or hardened tertiary web.
• the secondary web is divided into a substantially hydrophobic sub-web and a substantially hydrophilic sub-web and the hydrophilic sub-web is compressed to a desired density and preferably the hydrophobic sub-web is compressed to a desired density, whereafter the compressed hydrophilic sub-web is contacted with the hydrophobic sub-web to obtain a tertiary web.
• the density of the hydrophilic sub-web is at least 60 kg/m 3 , preferably 75 to 2200 kg/m 3 , and more preferably 150 to 2000 kg/m 3 .
• the hydrophilic layer of the secondary web is divided into sub-layers, whereafter at least one of these sub-layers is compressed and the sublayers is united to obtain a hydrophilic layer with sublayers of different densities.
• the hydrophobic layer of the secondary web is divided into sub-layers, whereafter at least one of these sub-layers is compressed and the sub- layers are united to obtain a hydrophobic layer with sublayers of different densities.
• the secondary web is provided with a bulk surface layer on one or both sides and preferably at least a part of said bulk surface layer is hydrophilic, and preferably at least a part of said bulk surface layer is hydrophobic.
• Figure 1 Shows a panel according to the invention for thermal insulation of a flat roof with a ⁇ X green roof” Figure 2. Shows a panel according to the invention used for covering and thermal insulation of fagade walls .
• Figure 3 Shows a panel according to the invention for use as thermal insulation and drainage aid for basement walls.
• Figure 4 Shows a panel according to the invention for thermal insulation of pitched roofs, serving as a N green roof” as well.
• a panel according to the invention for use as ⁇ X green roof" was produced using the third method according to the invention.
• To provide the hydrophobic layer a hydrophobic phenol resin was used and to provide the hydrophilic layer a hydrophilic furan resin was used.
• the resins are described in detail in the published international patent application WO 99/38372.
• the dimensions of the panel were: length: 2000 mm, width: 600 mm and thickness: 120 mm.
• the panel had a hydrophobic layer 1 to provide the thermal insulation of the roof and a hydrophilic layer 2 to provide a water reservoir for the green roof.
• the hydrophobic layer 1 had a density of 120 kg/m 3 and a thickness of 80 mm.
• the hydrophilic layer 2 had a density of 210 kg/m 3 and a thickness of 40 mm.
• the panel was installed on a flat roof. It was observed that no transport of water occurred from the hydrophilic layer 2 to the hydrophobic layer 1.
• a panel according to the invention was provided for covering and thermal insulation of a fagade wall.
• the panel was produced according to the second method of the invention.
• the resins were a hydrophobic phenol resin and a hydrophilic furan resin as in example 1.
• the panel consisted of a hydrophobic layer which was divided into two hydrophobic sub-layers 1 and 2.
• the panel further consisted of a layer divided into two sub-layers, a hydrophobic sub-layer 3 and a hydrophilic sub-layer 4.
• the dimensions of the panel were: length: 1000 mm, width: 600 mm and thickness: 205 mm.
• the hydrophobic sub-layer 1 had a density of 80 kg/m 3 and a thickness of 180 mm.
• the hydrophobic sub-layer 2 had a density of 180 kg/m 3 and a thickness of 20 mm.
• the hydrophobic sub-layer 3 had a density of 1000 kg/m 3 and a thickness of 4 mm.
• the hydrophilic sub-layer 4 had a density of 1000 kg/m 3 and a thickness of 1 mm.
• the surface of the panel constituted by the hydrophilic layer 4 was covered with a glass scrim 5.
• the glass scrim had overlap 6 on two sides, each having a width of 50 mm.
• the purpose of the glass scrim was to serve as reinforcement for a render system.
• the panel was mounted on a fagade wall and the joint where the panel was connected to other panels was covered by the overlap of the glass scrim. The rendering was then applied on the panel.
• the hydrophilic surface layer 4 provides the immediate tack of the render on the surface.
• the surface tension of the hydrophilic layer 4 was measured to approximately 72 mN/m compared to approximately 29 mN/m on standard insulation products for covering and thermal insulation of fagade walls. This explains the good properties of the panel with regard to application of rendering.
• Example 3
• a panel according to the invention similar to the panel in example 2 was produced.
• the panel was equal to the panel in example 2 apart from a hydrophilic surface layer 7 opposite to the hydrophilic surface layer 4 in fig. 2.
• the panel was installed on a fagade wall with the hydrophilic layer 7 facing the wall by means of render glue. It was observed that the gluing time of the panel to the wall was reduced because the hydrophilic surface layer 7 provided an immediate tack of the panel to the wall .
• a panel according to the invention used for thermal insulation and drainage of basement walls according to the invention was provided.
• the panel consisted of a hydrophobic layer 1 and a hydrophilic layer 3.
• the dimensions of the panel were: length: 2400 mm, width: 600 mm and thickness: 120 mm.
• the edges of the panel in the length direction were prepared with a bevel cut 4.
• the hydrophobic layer 1 had a density of 100 kg/m 3 and a thickness of 100 mm.
• the hydrophilic layer 3 had a density of 180 kg/m 3 and a thickness of 20 mm.
• cavities 2 were established in the interface between the hydrophobic layer 1 and the hydrophilic layer 3 .
• the cavities had a tubular shape and ran in the whole longitudinal direction of the panel.
• the cavities 2 had a diameter of 15 mm and were established with a mutual distance of 100 mm.
• the panel was installed to a basement wall 5 made of concrete.
• the hydrophobic layer 1 was fastened to the wall 5 by use of mechanical means.
• On top of the panel a moisture or vapour barrier 6 was attached. As more panels according to the invention were installed, they formed a closed envelope around the basement of the building.
• a drain-pipe 7 to lead away water was installed at the bottom of the structure.
• the basement wall Before installation of the panel according to the invention to the basement wall, the basement wall had been provided with a traditional drainage system consisting of gravel and a drain-pipe. The traditional system was not able to prevent water and moisture from entering the basement through the basement wall.
• the panel according to the invention was able to drain water from the ground into the hydrophilic layer 3 and vertically down through the hydrophilic layer 3 and the cavities 2 to the drain 7.
• the panel was also able to filter the water and prevent backfilled soil from entering the panel. Furthermore, the panel provided thermal insulation on the outside of the basement wall and allowed moisture from the construction to evaporate through the system.
• the basement was free of intruding water and moisture, and it was observed that the moisture content in the basement construction was significantly reduced.
• the panel according to the invention When the panel according to the invention is used for drainage of basement walls, the water needs to be drained vertically down to the drain at the bottom of the basement wall.
• the vertical drain capacity needs to correspond to the amount of water that can be expected.
• the vertical drain capacity through the hydrophilic part of a panel was found to vary with the density.
• the vertical flow through 10 cavities with a cross section area each of 70 mm 2 and a mutual spacing of 100 mm was found to be around 6,8 kg/meter/minute.
• the test showed that the drain capacity of the panels according to the invention was within the desired range according to DIN 1986.
• a panel according to the invention was produced for use as green roof" on buildings with pitched roof .
• the panel 1 consisted of a hydrophilic layer 3 and a hydrophobic layer 4.
• the dimensions of the panel were: length: 2400 mm, width: 600 mm and thickness: 150 mm.
• the edges on two sides of the panel perpendicular to the direction of the inclination of the roof were prepared with an overlap 5.
• the hydrophilic layer 3 had a density of 170 kg/m 3 and a thickness of 50 mm.
• the hydrophobic layer 4 had a density of 85 kg/m 3 and a thickness of 100 mm.
• the panel was provided with four cuts 6 with a regular mutual spacing of 600 mm perpendicular to the direction of the inclination of the roof.
• the cut went all through the hydrophilic layer 3 and partly into the hydrophobic layer 4.
• the purpose of the cuts was to stop an undesired flow of water when the panel was installed on the pitched roof.
• the edges of the panel were coated with a layer of bitumen.
• cavities 7 were established in the interface between the hydrophilic layer 3 and the hydrophobic layer 4 .
• the cavities had a tubular shape and ran in the whole longitudinal direction of the panel.
• the cavities 7 had a diameter of 15 mm and were established with a mutual distance of 100 mm.
• the purpose of the cavities 7 was to serve as reservoir for water and also to lead air to the roots of the plants in the hydrophilic layer 3.
• the panel was installed on a pitched roof to serve as an extensive green roof.
• the inclination of the roof was 25 degrees.
• a waterproof barrier layer 8 was installed between the roof and the panel. The installation time was much shorter than the traditional installation with a separate insulation panel and separate growth media panel .
• the panel was sowed with grass which grew extremely well in the hydrophilic layer.
• the hydrophobic layer remained dry and kept its insulation properties.

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• 2001
  • 2001-05-02 HU HU0301940A patent/HUP0301940A3/hu unknown
  • 2001-05-02 WO PCT/DK2001/000300 patent/WO2001085440A1/en not_active Application Discontinuation
  • 2001-05-02 AU AU2001256146A patent/AU2001256146A1/en not_active Abandoned
  • 2001-05-02 EP EP01929334A patent/EP1280660A1/de not_active Withdrawn
• 2002
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