EP1412593A1

EP1412593A1 - Insulating material based on mineral wool, insulation system, insulation method

Info

Publication number: EP1412593A1
Application number: EP02770056A
Authority: EP
Inventors: Christine Le Bihan; Stéphane Cousin
Original assignee: Saint Gobain Isover SA France
Current assignee: Saint Gobain Isover SA France
Priority date: 2001-07-27
Filing date: 2002-07-24
Publication date: 2004-04-28
Also published as: EA200400232A1; EA005434B1; PL367984A1; FR2829162A1; FR2829162B1; WO2003012220A1

Abstract

The invention concerns an insulating material comprising at least two insulating layers based on mineral wool, one so-called lower layer designed to be in contact with a support surface, in particular a cover or steel wall or roof section, and a so-called upper layer further away from the support surface, wherein the lower layer consists essentially of glass wool with a density, mv1, ranging between 50 and 120 kg/m<3> and thickness, e1, ranging between 50 and 200 mm, wherein the upper layer consists essentially of mineral wool, in particular glass wool and/or rock wool, with a density, mv2, ranging between 100 and 250 kg/m<3> and thickness, e2, ranging between 10 and 50 mm, and wherein the mass density ratio of the upper and lower layers verifies the relationship: mv2/mv1 >/= 2.5.

Description

INSULATION MATERIAL BASED ON MINERAL WOOL, SYSTEM

INSULATION, INSULATION METHOD

The present invention relates to a thermal and / or acoustic insulation material to be fixed on a support surface such as a concrete screed or a steel tank constituting for example an element of a wall or of a roof of a building. More particularly, the material according to the invention is fixed to the external surface of the wall or of the roof and is usually covered with a layer of material constituting a seal, in particular a sheet of suitable material, plastic or other material, or else for example a layer molten bitumen.

The assembly, material according to the invention covered with the material forming a seal, is exposed to the outside atmosphere, weathering and humidity.

Such an assembly of material is called to undergo compressive forces and to have to resist them without significant damage or degradation of the desired insulation properties.

In particular when an assembly of this type is placed on a support surface to form a roof, the installer is led to walk on elements placed beforehand to arrange and assemble the following elements.

In addition it is also useful to be able to walk on the roof after the installation of the assembly to carry out maintenance operations and possible repairs.

It is known to use thermal wool and / or acoustic rock wool insulation panels on the roof, the thickness of which is for example of the order of 100 mm and the density of the order of 130 to 200 kg / m ³ , for example known under the trade reference PANOTOIT from Saint-Gobain Isover.

A material known under the trade name of Rockup NU 392 is sold by the company Rockwool. The panels made of this material have a thickness of the order of 100 mm and include a face (upper face to the assembly) which has been overdensified. Rock wool panels are thus obtained, the upper face of which has a density of the order of 200 kg / m ³ and a thickness of approximately 15 mm and the rest of the panel has a density of approximately 120 kg / m ³ .

Other materials have also been used as roofing elements, in particular assemblies of rock wool panels, the thickness of which is of the order of 100 mm, arranged against the support surface and covered with a second layer of other panels either of rock wool or of glass wool, panels whose thickness is of the order of 15 to 50 mm .

It should be noted that in all of the known solutions, the panel disposed against the support surface is made of rock wool.

This configuration is linked to the fact that a person skilled in the art combines characteristics of robustness and compressive strength with rock wool panels, while glass wool panels are considered to be too compressible and unsuitable as such. roof insulation from the outside. Indeed there is a fear of seeing the foot of the manipulator sink into a glass wool panel when he walks on it, even after this panel has been covered with a sealing layer.

However, solutions using thick rock wool panels as a layer placed against the support surface have drawbacks. A first drawback relates to the weight of the rock wool insulation which must be placed on the support surface to obtain thermal insulation equivalent to that obtained with a glass wool insulation. This overweight can be estimated at 25 to 50%.

A second drawback relates to the punching which is frequently observed on rock wool panels, in particular for panels of low density, for example for densities of the order of 120 to 140 kg / m ³ .

In fact, it has been observed that rock wool panels can be irreversibly damaged when you step on them. Punching or stamping then occurs which is detrimental to the quality and durability of the roof. It is noted in the stamped areas that the sealing layer tends to peel off or puncture, jeopardizing the protection of the assembly to the weather. The same applies when an object, in particular a tool, falls on a roof comprising such rock wool panels.

In addition, the sensation of walking on a roof comprising such rock wool panels is considered to be “hard”, that is to say without damping, and is unpleasant for the installer or the person responsible for maintenance. It is an object of the invention to provide an insulating material, in particular suitable for fixing to a support surface such as a screed or a steel tank, which allows a step or an impact without damaging consequences on the qualities of the material. insulation made using the material according to the invention. Another object of the invention is to provide insulating materials, suitable for roof insulation from the outside, of lower density than the materials known for this application.

These aims are achieved by the use of the material according to the invention which comprises at least two layers of insulation based on mineral wool, a so-called lower layer intended to be in contact with a support surface, in particular a screed or a steel tank. , and a so-called upper layer further from the support surface, where the lower layer consists essentially of glass wool of density, mvl, between 50 and 120 kg / m ³ and of thickness, e1, between 50 and 200 mm, where the upper layer consists essentially of mineral wool, in particular glass wool and / or rock wool, and of density, mv2, of between 100 and 250 kg / m ³ and of thickness, e2, of between 10 and 50 mm, and where the density ratio of the upper and lower layers respects the ratio: mv2 / mv1> 1, 5.

It should be noted that each of the lower and / or upper layers may even include a plurality of elementary layers of substantially neighboring density and that it is then necessary to consider the characteristics of the whole of the lower and / or upper layer. , for the density as resulting from the average of the densities of the elementary layers and for the thickness as the sum of the thicknesses of elementary layers.

The term “glass wool” is conventionally understood to mean wool consisting of mineral fibers and most often of a binder, in particular of the formophenolic type, said mineral fibers being obtained by an internal centrifugation process which makes it possible to obtain long fibers with a very low rate of infibers.

The usual term “rock wool” is a wool made up of mineral fibers and most often of a binder, said mineral fibers being obtained by an external centrifugation process which produces fibers shorter than glass fibers and a fairly high rate of infibers, called grains. Usually the glass fibers are obtained from molten silico-boro-soda-lime compositions and the rock fibers from molten silico-calcium compositions rich in iron.

Preferably, the average density of the material according to the invention is less than or equal to 120 kg / m ³ .

Preferably, the density, mvl, of the lower layer is greater than or equal to 60 kg / m ³ and / or in particular less than or equal to 100 kg / m ³ or even 80 kg / m ³ .

Preferably, the thickness, e1, of the lower layer is greater than or equal to 60 mm, or even greater than or equal to 80 mm and / or less than or equal to 150 mm, or even less than or equal to 120 mm.

Preferably, the density, mv2, of the upper layer is greater than or equal to 120 kg / m ³ and / or less than or equal to 200 kg / m ³ , or even less than or equal to 150 kg / m ³ . Preferably, the thickness, e2, of the lower layer is greater than or equal to 15 mm and / or less than or equal to 30 mm, or even 20 mm.

According to a variant of the invention, the ratio of the thicknesses of the lower and upper layers respect the ratio e1 / e2> 3, even e1 / e2> 5.

Preferably, the lower layer consists of glass wool comprising a crosslinked formophenolic binder whose content by weight relative to the entire layer is between 5 and 12%.

Preferably, the upper layer consists of glass wool comprising a crosslinked formophenolic binder whose weight content relative to the entire layer is between 5 and 12%. Advantageously, the lower and upper layers are arranged so that the edge of the plates of one layer is located opposite with a solid surface of the other layer in order to avoid thermal bridges which may appear if the edges of the plates different layers are next to each other. A light material is thus obtained which exhibits remarkable properties and is perfectly suitable for roof insulation applications from the outside.

It has the remarkable property of being much less sensitive to stamping and / or impact than known materials. In addition, comparative tests have made it possible to show that the walking comfort is considerably improved with the material according to the invention, in comparison with the other known solutions.

Without wishing to be bound by any scientific theory, one can think of attributing this remarkable effect to the damping system which the selection of fibrous insulators that the invention operates allows. Indeed, with the material according to the invention, a flexible, substantially compressible insulator is obtained which, after compression, is capable of recovering at least 70 to 80% of its initial thickness without damage. Such a property cannot be obtained with a material whose lower layer consists of rock wool. We can think that this remarkable effect is linked to the very advantageous length of the glass fibers of the lower layer. The upper layer advantageously makes it possible to distribute the force in the lower layer and the choice of the ratio between density of the upper and lower layers makes it possible to take advantage of the elasticity qualities of the lower layer, while preserving rigidity and surface resistance satisfactory of the upper layer which allows walking.

The choice of properties and parameters made to obtain the material according to the invention makes it possible to obtain an original material with remarkable properties.

The invention also relates to a fixing insulation system comprising the material according to the invention and covered with a sealing layer disposed on the upper layer of said material.

According to a preferred embodiment, the insulation system comprises: - at least the insulating material according to the invention defined above, on a support surface,

- at least one means of fixing the insulation to the support surface, comprising a first end to be fixed to the support surface, and a second end intended to cover and maintain the surface of the insulation opposite the support surface,

- At least one layer, in particular a sheet, for sealing covering the surface of the insulation opposite the support surface and the second end of the fixing means, and the fixing means being able to deform so as to absorb any deformation insulation. A particularly advantageous insulation system is then obtained since it makes it possible to avoid puncturing by the means of fixing the sealing layer when a deformation, resulting for example from walking or an impact, occurs in the thickness of the insulating material according to the invention. According to one embodiment of the insulation system according to the invention, the means for fixing the insulation to the support surface comprises:

- a fixing screw to the support surface, screw whose head, in the fixing position, is located below the insulating surface opposite the support surface, - and at least one capsule, the head of which covers and maintains the insulation surface opposite the support surface, the capsule being slidably mounted on the screw.

A particularly practical embodiment of this embodiment consists in that the head of the capsule is extended by a part to be introduced, in the fixing position of the insulator, in the thickness of the latter, the head and said part of the capsule having a first cylindrical hollow opening into the head of the capsule and of a diameter allowing the screw head to slide, the first cylindrical hollow being extended, on the side of the capsule opposite its head, by a second cylindrical hollow through axis coincides with that of the first but of smaller diameter, allowing the rod, but not the screw head to slide.

Preferably, the insulation system of the invention comprises an additional sealing sheet covering the surface of the insulation opposite the support surface, but covered and held by the second end of the fixing means. This additional sealing sheet advantageously constitutes a lower strip fixed by an appropriate number of said fixing means arranged at regular intervals along an edge line of the additional sealing sheet, an area of this edge encompassing the second emerging end. fixing means then having to be covered by said sealing sheet constituting an upper strip, since otherwise the required sealing could not be obtained at the place where the fixing means enters the additional sealing sheet.

When such an additional sealing sheet is used, it is suitably bonded with said sealing sheet by any suitable process: heat sealing of bituminous sheets, bonding or welding of sheets. of plastics. This bonding, in the case mentioned above of the lower and upper strips, concerns at most the overlap width of the edges; excellent fixing of said sealing sheet and additional sealing sheet can be obtained in this way. According to other characteristics of the invention:

- The support surface is metallic, such as consisting of a steel tank or equivalent (the invention is in fact particularly suitable for the external insulation of walls of technical buildings); it is possible to place the insulating material directly in contact with the steel tank, or also to put on the latter an intermediate support layer, in particular a metal sheet, in particular aluminum;

- The fixing means consists entirely or in part of a thermal insulating material which, in the above-mentioned particular embodiment, is achieved by the fact that said capsule is essentially made of a thermal insulating material, in particular a plastic material such as polyamide or equivalent; thermal conductor fastening means, for example entirely metallic, would on the contrary constitute thermal bridges detrimental to the insulation capacity of the assembly;

- Said support surface is flat, for example substantially horizontal, and constitutes the roof of a building;

- Said sealing sheet and additional sealing sheet are made of plastic such as poly (vinyl chloride) or equivalent, or bituminous;

- The waterproofing layer consists of bitumen poured on the upper layer of the insulating material.

The invention also relates to the use of the insulating material according to the invention as a material resistant to stamping and / or impact.

The invention also relates to the use of said material for the production of an insulation system exposed to walking and / or to impact. The invention also relates to a method of insulating a support surface, in particular a screed or a steel tank which comprises at least the following steps:

- supply of at least two sets of mineral wool panels, a first set of panels consisting essentially of glass wool of density between 50 and 120 kg / m ³ and thickness, between 50 and

200 mm and a second set of panels consisting essentially of mineral wool with a density between 100 and 250 kg / m ³ and a thickness between 10 and 50 mm, where the ratio of the density of the panels of the second set to that of panels of the first set is at least equal to 1, 5;

- provision of at least part of the panels of the first set against the support surface;

- arrangement of at least part of the panels of the second set opposite the panels of the first set. The insulation method according to the invention can also include the following optional steps:

- independent fixing of each set of panels, in particular by gluing;

covering the second set of panels with a sealing layer, in particular a layer of bitumen or a sealing sheet;

- Fixing of all the elements, consisting in particular of the support surface, of the two sets of panels, of a sealing layer by a fixing means, in particular by the fixing means described above;

- Covering, in particular by bonding the sealing layer, fixed to the support layer by a fixing means, by a second sealing layer which covers said fixing means.

Comparative examples make it possible to illustrate, without however limiting, the advantages of the insulating material selected by the invention.

Panels were placed on steel tanks of the HAIRONVILLE 34 SR type placed on two purlins spaced 2.5 m apart.

Ten installers accustomed to installing insulation for roofs of industrial buildings were asked to share their impression when walking on panels assembled with steel trays. The impressions were scored from 0 to 10 with a low score when the walking impression corresponds to an unpleasant feeling of hardness and a high score when the installer feels a feeling of comfort during the walk. An average value was established following the appreciation of the different installers.

Table I summarizes the tests. We report the type of insulating material, defined by the type of fiber used

(LV = glass wool, LR = rock wool), the thickness (in mm) and the density (in kg / m ³ ).

Examples 1 to 3 are examples according to the invention, examples 4 to 6 are comparative examples.

It is clear from these examples that walking comfort is considerably improved with the examples according to the invention compared to known solutions.

The installation system to be fixed according to the invention is now illustrated with reference to the accompanying drawings in which:

FIG. 1 is a perspective representation of the insulation system of the invention, and

- Figure 2 is a detailed representation in section of a fixing means according to the preferred embodiment of the invention. The support surface to be insulated is a steel tank 11 constituting the roof of a technical building. This is directly covered with an insulator 10 comprising a first layer of 90 mm thick glass wool of 80 kg / m ³ density and a second 25 mm thick and 120 kg / m ³ of density. The assembly of the two layers is carried out in such a way that the panels of the second layer cover the junction lines of the panels adjacent to the first, and vice versa.

The surface 12 of the insulator opposite the support surface 11 is covered with lower strips 14 and upper sealing 13 made of a sheet of poly (vinyl chloride). The edge line of the lower strip 14 is fixed to the steel tank through the insulator 10 - thus also fixed - and held by the second end 4 of the fixing means, of suitable shape, enlarged and flat.

The fixing means shown in Figure 2 comprises a fixing screw 1 to the steel tank 11 and a capsule 2 of polyamide. The head 4 of the capsule 2 is extended by a part 6 to be inserted, in the fixed position of the insulator 10, into the thickness of the latter. The head 4 and the part 6 of the capsule 2 have a first cylindrical recess 7 opening into the head 4 of the capsule 2 and of diameter allowing the head 5 of the screw 1 to slide. The first cylindrical hollow 7 is extended, on the side 6 of the capsule 2 opposite its head 4, by a second cylindrical hollow 8 crossing with an axis coincident with that of the first 7 but of smaller diameter, allowing the rod 9, but not the head 5 of the screw 1 to slide. ^~

If pressure is applied to the surface of the insulation system, the capsule 2 slides on the screw 1, in the direction of the end 3. The amplitude of this sliding should simply be expected to be greater than that of the compression of the insulator, so that the head 5 of the screw 1 cannot reach the height of the sealing strips 13, 14; This eliminates any risk of punching them.

Table 1

Claims

1. Insulating material comprising at least two layers of mineral wool-based insulation, a so-called lower layer intended to be in contact with a support surface, in particular a screed or a steel tank, and a so-called upper layer more distant from the surface support, characterized in that the lower layer consists essentially of glass wool of density, mvl, between 50 and 120 kg / m ³ and of thickness, e1, between 50 and 200 mm, in that the upper layer consists essentially of mineral wool, in particular glass wool and / or rock wool, and of density, mv2, between 100 and 250 kg / m ³ and of thickness, e2, between 10 and 50 mm, and in this that the density ratio of the upper and lower layers respects the ratio: mv2 / mv1> 1, 5.

2. Insulating material according to claim 1, characterized in that the density, mvl, of the lower layer is greater than or equal to 60 kg / m ³ and / or in particular less than or equal to 100 kg / m ³ or even 80 kg / m ³ and / or in that the thickness, e1, of the lower layer is greater than or equal to 60 mm, or even greater than or equal to 80 mm and / or less than or equal to 150 mm, or even less than or equal to 120 mm.

3. Insulating material according to claim 1 or claim 2, characterized in that the density, mv2, of the upper layer, is greater than or equal to 120 kg / m ³ and / or less than or equal to 200 kg / m ³ , or even less than or equal to 150 kg / m ³ and / or in that the thickness, e2, of the lower layer is greater than or equal to 15 mm and / or less than or equal to 30 mm, or even 20 mm.

4. Insulating material according to one of the preceding claims, characterized in that the thickness ratio of the lower and upper layers respect the ratio e1 / e2> 3, even e1 / e2> 5.

5. Insulating material according to one of the preceding claims, characterized in that the lower layer consists of glass wool comprising a crosslinked formophenolic binder whose content by weight relative to the entire layer is between 5 and 12% and / or in that the upper layer consists of glass wool comprising a crosslinked formophenolic binder whose content by weight relative to the entire layer is between 5 and 12%.

6. Insulation system comprising: - at least one layer of thermal and / or acoustic insulator (10) according to one of claims 1 to 5 on a support surface, in particular a screed or a steel tank (11),

- at least one fixing means (1, 2), in particular consisting at least in part of a thermal insulating material, of the insulator (10) on the support surface (11), comprising a first end (3) to be fixed to the support surface (11), and a second end (4) intended to cover and hold the surface (12) of the insulator (10) opposite the support surface (11),

- at least one sealing layer (13), in particular a bituminous layer or a plastic sealing sheet, covering the surface

(12) of the insulator (10) opposite the support surface (11) and the second end (4) of the fixing means (1,2), the fixing means (1, 2) being able to deform so as to absorb any deformation of the insulation (10).

7. Insulation system according to claim 6, characterized in that the means for fixing (1, 2) of the insulator (10) to the support surface (11) comprises:

- a fixing screw (1) to the support surface (11), a screw whose head (5), in the fixing position, is located below the surface (12) of insulation (10) opposite the surface support (11), - and at least one capsule (2) the head (4) of which covers and maintains the surface (12) of insulation (10) opposite the support surface (11), the capsule (2) being mounted sliding on the screw (1).

8. Isolation system according to claim 7, characterized in that the head (4) of the capsule (2) is extended by a part (6) to be introduced, in the position for fixing the insulator (10), in the thickness thereof, the head (4) and said part (6) of the capsule (2) having a first cylindrical hollow (7) opening into the head (4) of the capsule (2) and of diameter allowing the head (5) of screws (1) to slide, the first cylindrical recess (7) being extended, on the side (6) of the capsule (2) opposite its head (4), by a second cylindrical recess ( 8) crossing axis coincident with that of the first (7) but of smaller diameter, allowing the rod (9), but not the head (5) of screws (1) to slide.

9. Insulation system according to one of claims 6 to 8, characterized in that it comprises an additional sealing sheet (14) covering the surface (12) of the insulator (10) opposite the support surface (11), but covered and held by the second end (4) of the fixing means (1, 2).

10. Insulation system according to one of claims 6 to 9, characterized in that the support surface (11) is substantially horizontal, or inclined, and constitutes the roof of a building.

11. Use of the insulating material according to one of claims 1 to 5 as a material resistant to stamping and / or impact.

12. Use of the material according to claim 11 for the production of an insulation system exposed to walking and / or to impact.

13. Method of insulating a support surface, in particular a screed or a steel tank which comprises at least the following steps:

- supply of at least two sets of mineral wool panels, a first set of panels consisting essentially of glass wool with a density between 50 and 120 kg / m ³ and a thickness between 50 and 200 mm and a second set of panels consisting essentially of mineral wool with a density of between 100 and 250 kg / m ³ and a thickness of between 10 and 50 mm, where the ratio of the density of the panels of the second set to that of the panels of the first set is at less than 1.5;

- provision of at least part of the panels of the second set opposite the panels of the first set.

14. The insulation method according to claim 13 which comprises at least one of the following optional steps: - independent fixing of each of the sets of panels, in particular by gluing;