EP2601044A1 - Panneaux thermo-isolants composites en polystyrène expansé - Google Patents

Panneaux thermo-isolants composites en polystyrène expansé

Info

Publication number
EP2601044A1
EP2601044A1 EP11741194.2A EP11741194A EP2601044A1 EP 2601044 A1 EP2601044 A1 EP 2601044A1 EP 11741194 A EP11741194 A EP 11741194A EP 2601044 A1 EP2601044 A1 EP 2601044A1
Authority
EP
European Patent Office
Prior art keywords
xps
board
composite
boards
thermal insulation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP11741194.2A
Other languages
German (de)
English (en)
Inventor
Kurt MÜNDER
Mark Freeman
Felix Garcia
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ravago Sa
Original Assignee
Knauf Insulation SPRL
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Knauf Insulation SPRL filed Critical Knauf Insulation SPRL
Priority to EP11741194.2A priority Critical patent/EP2601044A1/fr
Publication of EP2601044A1 publication Critical patent/EP2601044A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • B29C65/2007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror
    • B29C65/2015—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror being a single welding mirror comprising several separate heating surfaces in different planes, e.g. said heating surfaces having different temperatures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • B29C65/2007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror
    • B29C65/203—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror" characterised by the type of welding mirror being several single mirrors, e.g. not mounted on the same tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/347—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients
    • B29C66/3472—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients in the plane of the joint, e.g. along the joint line in the plane of the joint or perpendicular to the joint line in the plane of the joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81433—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined being toothed, i.e. comprising several teeth or pins, or being patterned
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/843—Machines for making separate joints at the same time in different planes; Machines for making separate joints at the same time mounted in parallel or in series
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/843—Machines for making separate joints at the same time in different planes; Machines for making separate joints at the same time mounted in parallel or in series
    • B29C66/8432—Machines for making separate joints at the same time mounted in parallel or in series
    • 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
    • B32B5/32—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 at least two layers being foamed and next to each other
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
    • B29C65/26—Hot fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0015—Insulating
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/22—All layers being foamed
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating

Definitions

  • This invention relates to extruded polystyrene (XPS) insulation panels.
  • XPS insulation panels are manufactured by extruding polystyrene with a blowing agent through a die or nozzle.
  • the thermal conduction through an XPS insulating panel depends upon the panel's thickness and the panel's intrinsic properties (including, for example the cell structure created during extrusion and expansion and the insulating properties of the blowing agent used).
  • the intrinsic insulating properties tend to degrade as the thickness of the extruded XPS insulating material is increased. Consequently, it can be advantageous to laminate two XPS boards together to form a thicker board such that the intrinsic insulating properties of the laminated insulating board are better than would be obtained by extruding a monolithic XPS board of the same thickness. Furthermore, previously used blowing agents are being replaced by blowing agents which are more environmentally friendly but whose ability to enhance the intrinsic insulating properties of XPS boards is generally reduced.
  • European patent application EP1 213 1 18 A1 discloses laminating together two XPS boards whose extrusion skin has been removed using a water permeable adhesive. The removal of the extrusion skin and the use of water permeable adhesive is intended to ensure that no barrier is created between the two boards which could block water vapour transmission.
  • European patent application EP1 213 1 19 A1 discloses laminating together two XPS boards whose extrusion skin has been removed by solvent welding.
  • EP 1 231 1 18 A1 and EP 1 231 1 19 A1 are primarily concerned with composite XPS boards which consist of two individual boards joined together, they disclose that a 60mm thick board can be used to make composite boards of 120 mm, 180 mm and 240 mm by joining respectively two, three or four 60 mm boards together. Similarly, it is disclosed that a 50 mm thick board can be used to make boards of 100 mm, 150 mm, 200 mm or 250 mm by joining respectively two, three, four or five 50 mm boards together.
  • the composite XPS thermal insulation boards of the present invention provide a means for:
  • the present invention provides a composite XPS board as defined in claim 1 .
  • Other aspects of the invention are defined in other independent claims.
  • the dependent claims define preferred or alternative embodiments.
  • composite XPS board indicates a board comprising a plurality of individual XPS boards which are secured together.
  • EP1 213 1 18 A1 and EP1 213 1 19 A1 it was considered essential to remove the extrusion skins from each face of the individual XPS boards when manufacturing a laminated, composite XPS thermal insulation board. It is thus surprising that a composite XPS thermal insulation board having acceptable properties, including acceptable water vapour transmission, can be configured without removing each extrusion skin. Retaining the extrusion skin at each external face of the composite XPS board may improve the water vapour transmission characteristics of the composite XPS product.
  • Thermal performance of a composite XPS board is a function of, inter alia, its overall thickness. Removal of extrusion skins, which is generally achieved by planing (typically using a rotary plane) removes a layer of material from the individual XPS board, thus reducing thickness. Consequently, when each extrusion skin of the individual XPS boards is removed in the manufacture of the composite XPS board, individual XPS boards must be manufactured so that they have a greater thickness before removal of the extrusion skin than their desired thickness after removal of the extrusion skin.
  • the aspect of the present invention which provides for extrusion skin(s) to be retained not only reduces the number of steps in the manufacture of the composite XPS boards but also reduces the amount of raw material required to provide the individual XPS boards of the desired thickness. Retaining the extrusion skin on each contact face of a central XPS board has the additional advantage that this individual XPS board does not requires processing between its manufacture and its lamination to form the composite XPS board.
  • optimise the thickness tolerance of the composite XPS board When manufacturing an individual XPS board at a desired nominal thickness, the actual manufactured thickness will vary within a certain tolerance. In a composite XPS board, the variation in thickness will thus include the sum of the thickness tolerance of each individual XPS board.
  • Removing the extrusion skin from the contact face of a bottom and a top XPS board, especially where the composite XPS board consists of three individual XPS boards, provides an advantageous way of controlling the tolerance of the thickness of the composite XPS board to be less than the sum of the extrusion thickness tolerances; this is because the thickness tolerance associated with removal of the extrusion skin may be controlled more easily and to a tighter degree than the extrusion tolerance.
  • the tolerance of the thickness of the top and bottom XPS boards once their extrusion skins have been removed may be tighter than the tolerance of the thickness of the central XPS board.
  • the extrusion skin may be removed from each face of each XPS board.
  • variable intensity thermal weld designates a thermal weld in which the amount of melting or welding is more intense at some portions than at others.
  • the variable intensity weld may comprise:
  • the composite XPS board consists of or comprises top, central and bottom XPS boards
  • the individual XPS boards are preferably welded together simultaneously to produce the composite XPS board.
  • the thermal weld may be created using a weld bar or bars passing over and preferably contacting and pressing against a surface to be welded.
  • the weld bar(s) are stationary with relative movement with respect to the surface to be welding resulting from movement of the XPS board(s).
  • weld bar(s) move may also be envisaged.
  • the contact surface prior to welding may be substantially planar (for example in the state of a substantially flat XPS surface having its extrusion skin) or planar (for example an extruded surface having had its extrusion skin removed by rotary planing).
  • the contact surface prior to welding may be profiled, for example, it may comprise a plurality of crenulations or peaks and trough, preferably regularly spaced across its surface.
  • profiling may have (i) a pitch of greater than 10mm, or greater than 15 mm and/or less than
  • a profiled contact surface may be used (i) to create a variable intensity weld; and/or (ii) to optimise welding by melting primarily peaks of the profile to reduce the amount of material melted and/or increasing the area of the contact surface.
  • Such a profiled surface may be provided by (i) extruding the surface with the desired profile; (ii) planing an extruded surface to remove the extrusion skin and provide the desired profile; or (iii) planing an extruded surface to partially remove the extrusion skin and provide the desired profile.
  • the invention is particularly advantageous in respect of composite XPS boards having a thickness of at least 90 mm, especially where each individual XPS board has a thickness of at least 20mm.
  • its thickness may be less than 140 mm or less than 130 mm and/or greater than 210 mm or greater than 220 mm.
  • the thickness of individual XPS boards may be substantially the same; this facilitates the manufacturing process and manufacturing and stocking of the individual XPS boards as raw materials.
  • the thickness of the top and bottom XPS boards is substantially the same; the thickness of the bottom XPS board may be between ⁇ 10% of the thickness of the top XPS board.
  • the thickness of the central XPS board may be different from the thickness of each of the top and bottom XPS boards by at least 5mm, preferably by at least 10mm.
  • the composite XPS board is preferably free from adhesives. This facilitates recycling, both during manufacturing and at the end of the life of the product.
  • Fig 1 is a perspective view of a composite XPS thermal insulation board
  • Fig 2 is an enlarged schematic representation of a variable intensity thermal weld
  • Fig 3 is a schematic side view of apparatus suitable for manufacturing the XPS board of Fig 1 ;
  • Fig 4 is a side view of the welding bar shown in Fig 3;
  • Fig 5 is a schematic cross sectional view along line 5-5 of Fig 3;
  • Fig 6 is a schematic representation similar to Fig 5 of an alternative weld bar.
  • the composite XPS thermal insulation board 10 of Fig 1 comprises three individual XPS boards: bottom XPS board 1 1 , central XPS board 12 and top XPS board 13. It will be appreciated that the terms top, central and bottom are intended to indicate the relative positions of the individual XPS boards within the composite XPS board and not their orientation or the orientation of the composite XPS board.
  • Both the top external face 14 and the bottom external face 15 (hidden from view) of the composite XPS board comprise their XPS extrusion skins.
  • face indicates the major surfaces of the composite XPS board or of the individual XPS boards as opposed to their two side surfaces and two end surfaces.
  • contact face indicates a face at which an individual XPS board is in contact with another individual XPS board. In Fig 1 , only the edges of the contact faces are visible, the top 13 and central 12 XPS boards being secured together by thermal welding at their respective contact faces 13', 12' and the bottom 1 1 and central 12 XPS boards being secured together by thermal welding at their respective contact faces 1 1 ', 12".
  • the composite XPS board 10 has a thickness t, ie perpendicular to its external faces 14, 15 made up of the thicknesses of each individual XPS board 1 1 ,12, 13.
  • Fig 2 shows an enlarged representation of part of the connection between contact faces of individual XPS boards. This shows a variable intensity thermal weld 21 comprising welded beads 22 separated by less intensely welded portions 23.
  • Fig 3 illustrates a process of laminating bottom 1 1 , central 12 and top 13 XPS boards together to form composite XPS board 10.
  • the individual XPS boards 1 1 , 12, 13 are advanced in direction 31 such that their contact faces pass over and are pressed against (by un-shown pinch rollers) heating surfaces
  • each weld bar 36,37 may be monitored, preferably at spaced positions across its length, and adjusted automatically to a desired nominal temperature.
  • the weld bars 36, 37 are preferably electrically heated, though oil heating may be used.
  • each weld bar 36,37 Whilst a single heat source may be used for the entire length of each weld bar, it is preferred to configure independently controllable heat sources for at least the extremities of each weld bar 36,37; this may facilitate obtaining a constant temperature along the entire length of each weld bar 36,37 taking in to account edge effects which are liable to disrupt the temperature at the extremities.
  • each heating surface 34, 35 of the weld bar comprises crenulations 51 which, in this embodiment, have the form of V-shaped teeth forming V-shaped peaks 52 and troughs 53.
  • the crenulations may take the form of a series of square and/or rectangular shaped teeth.
  • the crenulations 51 may be used to:
  • a) facilitate contact between the contact face of an individual XPS board and the weld bar, especially when the contact face is pressed against the weld bar by a roller (not shown) ;
  • Figs 6 illustrates an alternative arrangement in which the position of the peaks 52 on one heating surface 35 correspond to the position of the peaks 52 on the other heating surface 34.
  • variable intensity thermal weld 21 comprises a weld of the entire (or substantially the entire) contact face of each XPS board having spaced weld portions 22 which are more intensely melted and/or welded. It has been found that this creates high mechanical strength at the join between individual XPS boards whilst also allowing acceptable levels of water vapour transmission for the composite XPS board.
  • XPS thermal insulation boards typically have a water vapour transmission of about 80-300.
  • Water vapour transmission properties are determined in accordance with EN 12086 and generally expressed as: - water vapour diffusion resistance factor, ⁇ , for homogeneous products; and

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Architecture (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

Cette invention concerne un panneau thermo-isolant composite en polystyrène expansé (XPS) peut comprendre un panneau XPS inférieur, un panneau XPS central et un panneau XPS supérieur. Chaque face externe du panneau composite XPS présente une peau d'extrusion. Les panneaux XPS individuels sont fixés les uns aux autres par soudure thermique au niveau de leurs faces de contact pour former le panneau composite XPS.
EP11741194.2A 2010-08-03 2011-08-02 Panneaux thermo-isolants composites en polystyrène expansé Withdrawn EP2601044A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP11741194.2A EP2601044A1 (fr) 2010-08-03 2011-08-02 Panneaux thermo-isolants composites en polystyrène expansé

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP10171751 2010-08-03
EP11741194.2A EP2601044A1 (fr) 2010-08-03 2011-08-02 Panneaux thermo-isolants composites en polystyrène expansé
PCT/EP2011/063319 WO2012016991A1 (fr) 2010-08-03 2011-08-02 Panneaux thermo-isolants composites en polystyrène expansé

Publications (1)

Publication Number Publication Date
EP2601044A1 true EP2601044A1 (fr) 2013-06-12

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EP (1) EP2601044A1 (fr)
CN (1) CN103052500B (fr)
DE (1) DE212011100129U1 (fr)
WO (1) WO2012016991A1 (fr)

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EP2669073A1 (fr) 2012-05-29 2013-12-04 Basf Se Procédé de fabrication de plaques de mousse à deux couches au moins par collage
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EP3434478A1 (fr) 2017-07-28 2019-01-30 Basf Se Procédé de fabrication de plaques, au moins bicouches, par collage à partir d'au moins une plaque de départ en matériau isolant inorganique

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DE212011100129U1 (de) 2013-03-20
CN103052500A (zh) 2013-04-17
CN103052500B (zh) 2015-09-30
WO2012016991A1 (fr) 2012-02-09

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