EP2369084A2

EP2369084A2 - Panel for building construction

Info

Publication number: EP2369084A2
Application number: EP11159114A
Authority: EP
Inventors: Per Billengren
Original assignee: Zenergy AB
Current assignee: ZENERGY AB
Priority date: 2010-03-22
Filing date: 2011-03-22
Publication date: 2011-09-28
Anticipated expiration: 2031-03-22
Also published as: EP2369084B1; EP2369084A3; PL2369084T3; DK2369084T3; SE1050264A1; SE536690C2

Abstract

The present invention relates to an insulating construction panel 1 for the construction of a building, comprising a first face sheet 10 and a second face sheet 11, adapted to lend stability to the construction panel 1. The construction panel 1 further comprises an insulating core layer 12 arranged between the first 10 and the second 11 face sheet. The construction panel 1 also has a frame structure 13 fitted to the first face sheet 10, so that the first face sheet 10 is placed between the frame structure 13 and the core layer 12. At least one of the first and the second face sheet consists of a fireproof material.

Description

Technical field

The present invention relates to an insulating construction panel for the construction of a building.

Background

Traditional building methods for walls in buildings generally consist of a timber frame structure filled with insulation such as mineral wool. This timber frame structure extends through the entire wall, from its inner side to its outer side. With such a method, the wall is assembled on the building site, which means that damp enters easily into the wall construction, something which strongly impairs the insulating capacity of the wall and increases the risk of damp and mould damage in the wall. Furthermore, the method is not suitable for the construction of passive houses, where a higher insulating capacity in the wall is required in order to meet the criteria for passive houses. With a traditional building method of this kind, a very thick wall construction is required in order to meet these criteria, with thicker timber frame structure and more mineral wool. In very thick wall constructions, there is a greater risk of damp damage, since the dew point often ends up in the wall. Moreover, damp in the wall means that the insulating capacity of the wall is impaired, since water transports heat better than air. There is also a problem with fire safety in such wall constructions. Thick timber frame structures and a large amount of mineral wool compromise the fire safety of the wall construction.
So-called sandwich panels for walls, for example, have previously been used in the construction of buildings. A sandwich panel consists of two face sheets and a core layer arranged between the two face sheets. The face sheets are made of a stable material in order to support the construction. The function of the core layer is mainly to contribute insulating properties and to have a load-transmitting function between the two face sheets. These sandwich panels are prefabricated in a protected environment in order to avoid the entry of damp into the panel. Sandwich panels do not however solve the problem with fire safety in the wall construction.
The use of sandwich panels in wall construction does however change the building method for both the inner side and the outer side of a wall in a building. This can be difficult to get the building trade to accept, since contractors such as electricians, carpenters, masons, etc. are not used to working with such types of material. Furthermore, sandwich panels having wooden face sheets are generally used. Wooden face sheets can give rise, for example, to mould damage in the panel.
There is a requirement for a construction panel which solves the abovementioned problems in the construction of buildings.

Summary of the invention

At least one of the problems above is solved with the aid of a construction panel according to claim 1.
Embodiments of the invention emerge from the dependent claims and from the following description and the drawings.
According to a first aspect of the invention, an insulating construction panel for the construction of a building is provided, comprising a first face sheet and a second face sheet, adapted to lend stability to the construction panel. The construction panel further comprises an insulating core layer arranged between the first and the second face sheet. The construction panel also has a frame structure fitted to the first face sheet, so that the first face sheet is placed between the frame structure and the core layer. At least one of the first and the second face sheet consists of a fireproof material.
When the construction panel is fitted as a wall in the construction of a building, the frame structure may be directed towards the inner side of the wall, i.e. the side of the wall which is directed towards the inner side of the building. A wall structure which resembles traditional building methods for the inner sides of walls may thus be realized. The frame structure may be filled with further insulation, in the same way as in a traditional building method. Persons constructing the building may thus feel familiar with the building method and construct the inner side of the wall as previously. In the finishing of the inner side of the wall, the frame structure may be covered by plasterboards. By virtue of the insulating core layer, a construction panel according to the invention does not let through any damp and thus damp damage in the wall may be avoided. The core layer may have both an insulating function and a load-transmitting function to the face sheets. The load-transmitting function may contribute to the stability of the construction panel. Furthermore, such a construction panel may provide adequate insulating capacity with a thinner wall thickness than with a traditional building method. A building may thus gain larger internal dimensions, with maintained external dimensions, in relation to a traditional building method. A construction panel according to the invention further has the advantage that it may be prefabricated, which means that little time may be required at the building site for assembly and installation. This also may make the construction of the building cost-effective. Furthermore, the fact that the construction panel is prefabricated and that no organic materials are used against the outer side of the wall may mean that the wall construction effectively acts both as a climate shield and as a moisture barrier. Since cold bridges out towards the outer side of the wall may be avoided, it may make the wall construction more energy-efficient. By having a face sheet which is made of a fireproof material, a face sheet which not only stabilizes the construction panel but also has a fire safety function may be realized. There may be a considerable safety benefit from a wall construction in a building which also has advantages in terms of fire safety. Furthermore, a highly alkaline, yet inorganic material, such as magnesium oxide, may be used as the fireproof material in a face sheet and can thus prevent the possible incipient growth of mould, for example, in the construction in the event of damp formation. This may be in contrast to a situation in which, for example, wood is used in the face sheets.
In a further embodiment, the frame structure may be a timber frame structure. The inner side of a wall may thus be constructed with the timber frame structure, which then resembles a timber-framed wall constructed with a traditional building method.
In one embodiment of the invention, at least one of the first and the second face sheet may consist of a fireproof material. In a further embodiment, the fireproof material may be magnesium oxide.
In another embodiment of the invention, the core layer may consist of a plastics material, preferably a foamed plastics material. The principal object of the core layer to have an insulating function may thus be met. Furthermore, a plastics material of this kind may have the advantage that it is not organic, and thus further prevents mould growth, for example, in the panel. Moreover, such a material may not be water-permeable, which may give less risk of damp damage and greater insulating capacity.
In one embodiment, the first face sheet, the second face sheet and the core layer may together form a sandwich-type construction panel. A construction panel which is stable and thin, yet has very good insulating capacity may thus be realized. The same insulating capacity with a wall made from traditional building methods may require a much thicker wall, while, at the same time, such a wall may be less proof against damp damage.
In a further embodiment, on the second face sheet may be arranged a base for plaster against an outer facade of a building. There may thus be no need for further layers of the construction panel against the outer facade of the building when the construction panel may be fitted during construction of the building, but rather plaster may be applied directly to the construction panel. The need for an air gap against the outer side of the wall may thus be avoided. Since the plaster base may be pre-mounted on the construction panel, the risk of damp damage against the outer side of the wall may also be eliminated, as the construction panel may be produced in a protected environment.
In a further embodiment, on at least one of the first and the second face sheet may be arranged an aluminium foil. With an aluminium foil arranged on a face sheet, radiation heat may be reflected by the construction panel. With an aluminium foil arranged on the first face sheet, preferably on the side which is directed away from the core layer, radiation heat from within a building, when the construction panel is fitted as a wall in a building, may be reflected back into the building. In the same way, with an aluminium foil arranged on that side of the second face sheet which is directed away from the core layer, radiation heat from outside, against a building in which the construction panel is fitted as a wall, may be reflected back out, away from the building. The construction panel thus gains further insulating capacity.
In one embodiment, the construction panel may be prefabricated in a plant, prior to use of the construction panel in the construction of a building. The construction panel may thus be produced in a protected environment, without risk of the construction panel being exposed to high moisture contents.
In a further embodiment, the frame structure may be arranged to define a space intended for filling with an insulating material. The insulating material may be mineral wool, for example. When the frame structure defines such a space, the structure can resemble a frame structure for a wall according to a traditional building method. The inner side of a wall may thus be formed with traditional methods, despite the fact that the wall may be constructed of a construction panel containing a sandwich-type panel.

Brief description of the drawings

Fig. 1 shows a perspective view of a construction panel according to an embodiment of the invention.
Fig. 2 shows a schematic view in cross section of a construction panel according to an embodiment of the invention.
Fig. 3 shows a schematic view in cross section of a house construction comprising construction panels according to an embodiment of the invention.

Description of preferred embodiments

The present invention will be described in greater detail below with references to the appended drawings, in which preferred embodiments of the invention are shown. The invention can however be realized in many different forms and should not be deemed to be limited to the embodiments presented herein; rather, these embodiments are provided so that this description is thorough and comprehensive and will fully convey the scope of the invention to the person skilled in the art. In the drawings, the same number refers to the same element.
Fig. 1 shows a construction panel 1 according to one embodiment of the invention. A first face sheet 10 and a second face sheet 11 are arranged on one side each of a core layer 12. These three parts 10, 11, 12 together form a so-called sandwich panel. The face sheets 10, 11 are made of magnesium oxide. This gives the face sheets 10, 11 stable and fireproofing properties. The face sheets 10, 11 can also be made of other materials, such as polymer concrete, alkaline polymer or polyester mixed with a filler material such as sand, lime, potash or some ceramic material. The core layer 12 is made of a foamed plastics material, for example polyurethane foam or an EPS plastic (Expanded Polystyrene). The function of the core layer 12 is to contribute to the strength and insulating capacity of the construction panel 1. The core layer 12 has a function of transmitting load to the face sheets 10, 11.
On one side 15 of the first face sheet 10, the side which is intended to be directed inwards into a building, there is arranged a frame structure 13. The frame structure is preferably a timber frame structure 13. The frame structure can in other embodiments be made of other materials such as steel or aluminium. The first face sheet 10 is thus placed between the core layer 12 and the timber frame structure 13. The timber frame structure 13 is designed to resemble a timber frame construction according to a traditional building construction of a wall in a building. Contractors and others working on a building site on the construction of a building may thus feel at home with how it is used to look when, for example, the inner side of the wall of the building is to be finished. There is also less risk of handling errors on the building site, since the construction panel 1 is easy to fit. The difference compared with a wall erected according to a traditional building method is then, instead, that a wall erected with construction panels 1 according to the embodiment has a more effective insulating capacity and can be erected in shorter time.
When a construction panel 1 is fitted during erection of a wall in a building, the timber frame construction 13 is a part of the inner side of the wall in the building. On the opposite side of the construction panel 1, against the outer side of the wall in the building, a plaster base 14 is arranged in the construction panel 1. The plaster base is fixed to that side of the second face sheet 11 which is directed away from the core layer 12. The plaster base 14 can consist of a sheet of an EPS plastic or the like. The object of the plaster base 14 is, following the fitting of construction panels 1 in the construction of a building, to act as a base for plaster constituting the outer facade of the building. A construction panel 1 having such a plaster base 14 eliminates the need for air gaps against the outer side of the wall construction of the building.
In order to further improve the insulating capacity of the construction panel 1, one or both face sheets 10, 11 can have one side covered by an aluminium foil. One side 15 of the first face sheet 10, directed towards the timber frame structure, is then covered by an aluminium foil. Radiation heat from within the building can thus be reflected back into the building. Heat radiating inside the building for heating purposes can thus avoid heating up the sandwich part 10, 11, 12 of the construction panel 1. In the same way, one side of the second face sheet, the side directed towards the plaster base 14, is then covered by an aluminium foil. Heat radiation from outside is thus reflected back out, away from the building, and heating of the sandwich part 10, 11, 12 of the construction panel 1 is avoided. This increases the insulating capacity in the wall construction, since heat radiation from outside is reflected away and heat radiation from inside is kept inside the building.
Fig. 2 shows schematically an erected construction panel 1 for a wall in a building. The construction panel 1 is placed on a building foundation 40 so that the whole of the construction panel 1, apart from the plaster base 14, is located on the building foundation 40. Outside of the plaster base 14 there is arranged a plaster cladding 20 for constituting the outer facade of the building. On the timber frame structure 13 there is arranged a plasterboard 30 for constituting a part of the inner side of the wall of the building. For further insulation, a space is defined by the timber frame structure filled with mineral wool 31. In this way, the inner side of the wall of the building can be finished with just the supply of mineral wool 31 and plasterboard 30 following the erection of the construction panel 1. A considerable time saving is thereby achieved compared with the erection of a wall in a building according to a traditional building method. A section wall for a building according to a traditional frame construction with mineral wool is estimated to take about 2.5 - 3 hours per square metre to erect. A section wall having construction panels 1 according to the invention is estimated to take about 0.2 hours per square metre to erect.
Possible dimensions for one embodiment of the invention are described below. The sandwich part 10, 11, 12 of the construction panel 1 is around 14 cm thick. With a construction panel 1 according to the invention, a U-value of 0.1 can be attained with a sandwich part thickness of around 14 cm. A U-value indicates the thermal conductivity of a material layer. The value is quoted in Watts per square metre and Kelvin. The better the insulating capacity, the lower the U-value. Furthermore, the timber frame structure 13 is around 10 cm thick, and the plaster base 14 around 5 cm thick. This makes the thickness of the construction panel 1 around 29 cm. In the construction of a building, a wall can be constructed with a total thickness of around 30-31 cm, of which the construction panel 1 constitutes around 29 cm, and plaster 20 applied to the plaster base 14 and a plasterboard 30 arranged on the timber frame structure 13 account for the remaining thickness. Such a construction meets the criteria for passive houses and acts effectively as a climate shield and moisture barrier.
Fig. 3 shows a construction panel 2 erected in a multistorey building. The floor joists 50 for the upper storey are in this case suspended from timber frame structure 13 in the construction panel 2. Outside of this suspension, the face sheets 10, 11, the core layer 12 and the plaster base 14 protect against the formation of any cold bridges. A construction panel 2 which acts as a climate shield and moisture barrier even in a multistorey construction is thus attained.

Claims

Insulating construction panel (1) for the construction of a building, comprising,
a first face sheet (10) and a second face sheet (11), adapted to lend stability to the construction panel,
an insulating core layer (12) arranged between the first (10) and the second (11) face sheet,
a frame structure (13) fitted to the first face sheet (10), so that the first face sheet (10) is placed between the frame structure (13) and the core layer (12),
characterized in that
at least one of the first (10) and the second (11 ) face sheet consists of a fireproof material.
Insulating construction panel (1) according to Claim 1, wherein the frame structure (13) is a timber frame structure.
Insulating construction panel (1) according to any one of the above claims, wherein at least one of the first (10) and the second (11) face sheet consists of magnesium oxide.
Insulating construction panel (1) according to any one of the above claims, wherein the core layer (12) consists of a plastics material, preferably a foamed plastics material.
Insulating construction panel (1) according to any one of the above claims, wherein the first face sheet (10), the second face sheet (11) and the core layer (12) together form a sandwich-type construction panel.
Insulating construction panel (1) according to any one of the above claims, wherein on the second face sheet (11) there is arranged a base (14) for plaster intended to constitute an outer facade of a wall of a building.
Insulating construction panel (1) according to any one of the above claims, wherein on at least one of the first (10) and the second (11) face sheet there is arranged an aluminium foil.
Insulating construction panel (1) according to any one of the above claims, wherein the first face sheet (10), the second face sheet (11) and the core layer (12) together have a thickness of between 100-200 mm, preferably between 120-160 mm, more preferably between 135-150 mm.
Insulating construction panel (1) according to any one of the above claims, wherein the core layer (12) has a thickness of between 80-190 mm, preferably between 100-140 mm, more preferably between 110-130 mm.
Insulating construction panel (1) according to any one of the above claims, wherein the frame structure (13) has a thickness of between 70-120 mm, preferably between 90-100 mm.
Insulating construction panel (1) according to any one of the above claims, wherein the construction panel (1) is prefabricated in a plant, prior to use of the construction panel in the construction of a building.
Insulating construction panel (1) according to any one of the above claims, wherein the frame structure (13) is arranged to define a space intended for filling with an insulating material (31).