EP3298206A1

EP3298206A1 - Wall insulation system and method of assembling a wall insulation system

Info

Publication number: EP3298206A1
Application number: EP16725356.6A
Authority: EP
Inventors: Erling Jessen
Original assignee: Saint Gobain Isover AS
Current assignee: Saint Gobain Isover SA France
Priority date: 2015-05-21
Filing date: 2016-05-20
Publication date: 2018-03-28
Anticipated expiration: 2036-05-20
Also published as: RU2728139C2; PL3298206T3; EP3298206B1; RU2017144792A; DK3298206T3; WO2016184476A1; RU2017144792A3; ES2866042T3

Abstract

The invention relates to a system and a method for insulating a double shell exterior wall. The system comprises an inner shell (1; 101)and an outer shell (2; 102), and mounting anchors (8; 108)being fastened to the inner shell (1; 01) with lateral offsets, and in rows with uniform elevation offsets from one another. The mounting anchors (8; 108) comprise securing means (6; 106). The system further comprises at least one first insulation layer (4; 104) having insulation elements(41, 51; 141, 151), which are supported by the mounting anchors (8; 108) between the inner shell (1; 101) and the outer shell (2; 102).

Description

Wall insulation system and method of assembling a wall insulation system

The present invention relates to a wall insulation system for a double shell exterior wall, and a method for assembling such a wall insulation system.

A well-known construction system for exterior walls when constructing new buildings is a two-shell exterior wall comprising at least three layers: an inner shell, an outer shell and insulation means between the inner and the outer shell.

Buildings with this type of exterior walls are typically constructed so that the inner shell wall is built first, and then the insulation layer and the outer shell layer are provided subsequently. When the insulation layer is in place, heat can be applied to the interior of the building to dry out the construction if needed, and thereafter the interior construction can begin. Insulation is typically provided as an intermediary layer between the inner and the outer shell. In the construction process, the insulation layer is usually provided simultaneously with the outer shell, such that a first section of insulation is provided, e.g. a section extending one meter from the ground in parallel with the inner shell. This section of insulation is then covered by a corresponding first section of the outer shell, e.g. a masonry or brick facing wall. These steps are then repeated section by section, until the insulation layer and the outer shell have reached the full height of the building and thus cover the inner shell. The outer shell is typically used for keeping the insulation in place. This method requires the construction workers to perform several different steps for completing both the insulation layer and the outer shell simultaneously. In addition, more different building materials have to be available at hand at the same time which can be both costly and space-consuming. Furthermore, known wall systems are usually constructed by using insulation elements, such as webs, which are arranged against the inner shell so as to provide for an insulation layer. Such insulation elements are typically made from a material, making them prone to misplacement during the mounting thereof, thereby creating a risk of unintentionally forming air spaces within the insulation layer of the construction. Thus, thermal bridges may be formed, which are highly undesirable in the finished construction. The construction worker is therefore faced with extra work during the process, since the thermal bridges need to eliminated by filling the formed air spaces with extra insulation, e.g. in the form of compressible insulation strips or the like. This step thus further adds to the cost and the time needed to achieve a completed insulation layer with minimal thermal bridging.

On this background, it is an object of the invention to provide a wall insulation system for a double shell exterior wall of the kind mentioned in the introduction which enables an easier and simpler assembly than previously known systems. For some embodiments, it is a further object of the invention to provide a method of assembling a wall insulation system for a double shell exterior wall.

In a first aspect of the invention, a wall insulation system for a double shell exterior wall is provided, which comprises an inner shell extending in a first plane and an outer shell defining an intermediary space between them, and mounting anchors defining a second plane and extending substantially perpendicularly to the first plane, and being fastened to the inner shell with lateral offsets, and in rows with uniform elevation offsets from one another, wherein the mounting anchors comprise securing means and in an assembled state bridge the intermediary space, and further comprising at least one first insulation layer having insulation elements, which are supported by the mounting anchors in the intermediary space between the inner shell and the outer shell, wherein said insulation elements have a width in the direction between two adjacent rows of the mounting anchors and a length extending perpendicularly to the width, wherein each insulation element a main portion having a comprises a back surface, top and a bottom flange protruding from the main portion and extending along the length of the insulation element, wherein said top flange is configured to abut a complementary bottom flange of a second insulation element, such that a plurality of insulation elements in said assembled state define said at least one first insulation layer of said wall insulation system, said insulation elements being fastened to the inner shell by at least one securing means, wherein in the assembled state the back surface faces the inner shell and the at least one mounting anchor penetrates at least the bottom flange.

By means of the object of the invention, it is possible to complete the at least one first insulation layer independently of the construction of the outer shell. This provides for an easier and more simple task for the construction worker compared to known methods, and he/she only need the materials for the assembly of the at least one first insulation layer at hand. At the same time, the insulation layer can be completed even without the immediately subsequent completion of the outer shell, as the assembly of the insulation layer is a stable construction that does not require to be immediately supported nor protected by the completion of the outer shell. This is because the mounting anchor penetrates the bottom flange and a locking effect is provided, such that a lower insulation element, is kept in place as well by the attached insulation element above it. This is possible because the back surface of a lower insulation element faces the inner shell and the bottom flange of an upper insulation element covers this flange. Thus, for example in colder climates, the interior construction can begin, even if the construction of the outer shell is halted, e.g. to outdoor temperatures or material shortage. This means that, according to at least one embodiment of the invention, both time and cost can be minimized when constructing double shell exterior walls of the type mentioned above. The mounting anchors may be fastened during the initial production of the material which constitutes the inner shell, or the mounting anchors may be fastened post production. By penetration is meant that the insulation element is pushed over the mounting anchor.

The insulation element may be understood as one insulation element, not two or more elements being parallel displaced, forming a stepped profile.

The dimensions of the insulation element in the width direction is chosen according to the distance between adjacent rows of mounting anchors which is typically standardized measurements according to established building standards.

In one embodiment, the top flange and the bottom flange are configured to protrude from said main portion on each side of a longitudinal centerline in the width direction of said insulation element, so as to form a stepped portion or beveled face comprising a flange surface and a main portion surface at a top and bottom region of said insulation element.

In this way, suitable abutment surfaces are provided which is advantageous for a simple assembly of the insulation layer performed by the construction worker. In addition, a stable completed insulation layer is achieved.

In a preferred embodiment of the invention, the flange surface at the top region and the main portion surface at the bottom region of said insulation element, during assembly, together provide for guiding means for the insulation element in that the distance between two adjacent rows of mounting anchors corresponds to the distance from the flange surface at the top region to the main part surface of the bottom region of the insulation element.

This way a guiding and locking feature is provided, which is to be described further in the detailed description of the embodiments of the invention. This has the advantage of further simplifying the assembly of the insulation layer performed by the construction worker and also the stability of the completed insulation layer.

In a further preferred embodiment, the flange surface at the top region and the main portion surface at the bottom region of said insulation element are substantially horizontal. This way, the assembly work done by the construction worker is made easier in that the flange surface at the top region and the main portion surface at the bottom region are parallel with the mounting anchors. Thus, the flange surface at the top region and the main portion surface at the bottom region of the insulation element contact the mounting anchors. Thus, the insulation element is guided between the rows of the mounting anchors, while the construction worker pushes the insulation element towards the inner shell and into position. In an advantageous embodiment, at least one mounting anchor penetrates at least one of said top and/or bottom flanges in the assembled state.

In the assembled state, the mounting anchors help support the insulation elements as the insulation elements rest on the mounting anchors in addition to resting on the insulation element(s) below. Furthermore, the insulation layer is fastened by means of mounting anchors in that a mounting anchor penetrates a top and/or bottom flange. This way, a stable and coherent surface facing away from the inner shell is provided. The securing means is configured to abut this coherent surface. In this regard, coherent means that the surface is constituted by one insulation element, i.e. the securing means abuts a surface of a single insulation element.

In one embodiment, a ratio between the extension of the top flange in the second plane and the extension of the bottom flange in the second plane is approximately in the range from 2/98 to 98/2, preferably 25/75 to 75/25, more preferably 40/60 to 60/40, most preferably approximately 50/50.

The ratio between the extension of the top flange in the second plane and the extension of the bottom flange in the second plane is chosen while balancing two objects. Firstly, the stability of the insulation element in that the flange which is to be penetrated by a mounting anchor has to be sufficiently stable not to be deformed or even broken, when the insulation element is pressed against the mounting anchors in order for it to penetrate the flange. Secondly, the ease of assembly for the construction worker, as it is highly desirable that the assembly of the insulation layer and thus the penetration of the flange does not require too much force applied by the construction worker in order for the work not to be too strenuous. The ratios above balance these two objects and are stated in an order of preference.

In a preferred embodiment, the insulation elements of the at least one first insulation layer are made of a weather-resistant material.

For the purpose of describing the invention, weather resistance means that the material of the insulation elements of the at least one first insulation layer is suitable for being subjected to e.g. precipitation without being covered and thus protected by an outer shell functioning as a climate barrier over a longer period of time, e.g. 4-5 months, and still maintains its insulation capacity in the finished construction. Thus, the completed first insulation layer can be subjected to normal Scandinavian climate exposure conditions for longer periods of time, while the wall insulation system, including the outer shell, is under construction. In a preferred embodiment, the material is not deteriorated by normal precipitation, e.g. 300 mm over approximately 4-5 months.

Traditionally, construction of the outer shell is also used to keep the insulation layer in place. In cold climates, the inner shell has to be insulated before the interior construction can begin. At the same time, many materials used for the completion of the outer shell cannot be used below certain outdoor temperatures. Thus, when the completion of the insulation layer depends on the completion of the outer shell, as is the case with traditional products and methods, the overall construction process of a building of this type is somewhat halted at cold temperatures. This prolongs the construction process and makes it significantly less cost-effective. The wall insulation system of the invention enables the completion of the assembly of the at least one first insulation layer without the need for a simultaneous completion of the outer shell. Thus, the interior construction can begin, and the construction of the outer shell can take place independently, when e.g. the outdoor temperature according to the chosen materials of the outer shell so allows.

In a further preferred embodiment, the insulation elements of the first insulation layer are made of mineral wool, preferably at a density of 45 to 150 kg/m³ Glass wool and stone wool have proven to be suitable materials for the invention in that they are not damaged by precipitation. Furthermore, it is possible to make insulation elements of relatively high dimensional stability which means that a relatively tight fit can be achieved between the insulation elements so as to achieve an insulation layer without significant gaps which can cause thermal bridging. A certain dimensional stability is important for the insulation elements to be assembled to a insulation layer according to the invention. In one embodiment, the insulation elements of the first insulation layer are of a laminated structure comprising at least two components made of different materials and/or having different densities. This way, it is possible to have a wider array of materials to choose from for the insulation elements, as the two components do not necessarily have to have the same properties. For example, as one of the components is facing the inner shell, and another of the components are facing the outer shell, it is possible to choose materials which have appropriate characteristics which are desirable for that speciation location in the construction. For example, the outermost component can be made of a material which is better suited for exposure to weather, whereas the innermost component may be of a material which is for example more stable, strong or cheap compared to the material of the outermost component. It is also possible to provide an insulation element with two components of the same material but with different densities to achieve a cost-effective and functional product according to desired insulation element characteristics.

In a preferred embodiment, the at least two components are offset in the width direction so as to form an insulation element with a top flange and a bottom flange. This way, the cost of manufacturing profiled insulation elements is eliminated.

In one embodiment of the invention, the wall insulation system comprises at least one second insulation layer.

For some constructions, e.g. when a relatively thick insulation is required, it can be advantageous to provide a second insulation layer. As the second insulation layer is placed between the inner shell and the first insulation layer, the insulation elements of the second insulation layer do not necessarily have to have the same properties as the insulation elements of the first insulation layer. For example an insulation element of the second insulation layer does not have to be profiled so as to obtain a partial overlay over the insulation element below as is the case for the insulation elements of the first insulation layer. This means that the insulation elements of the second insulation layer can be manufactured in a simpler and thus less expensive way than the insulation elements of the first insulation layer.

In a preferred embodiment, insulation elements of the at least one second insulation layer are made of a different material than the insulation elements of said first insulation layer.

As the second insulation layer is placed between the inner shell and the first insulation layer, the insulation elements of the second insulation layer do not necessarily have to the same properties as the insulation elements of the first insulation layer. For example, the material of the insulation elements of the second insulation layer does not have to have the same characteristics as the material of the insulation elements of the first insulation layer. For cost reasons, it can e.g. be chosen to be a less expensive material than the material of the insulation elements of the first insulation layer. Alternatively, it can be chosen to have a different, e.g. higher, insulating capability than the material of the insulation elements of the first insulation layer. By providing a second insulation layer which comprises insulation elements of a different material than the insulation elements of said first insulation layer, it is thus possible to optimize both the functionality and cost of the insulation between the inner shell and the outer shell.

In one embodiment of the invention, the insulation elements of the at least one second insulation layer are made of mineral wool (e.g. glass wool or stone wool), PIR, PUR, vacuum insulation, fiber insulations, aerogel mats or the like. The density of the insulation elements of the at least one second insulation layer is dependent on the material used. Preferably, each material has a density according to the known standards within the industry when used for wall insulation.

For some of the embodiments of the invention, the assembly of the insulation elements of the first insulation layer provides for a labyrinth path hindering precipitation from travelling through the insulation elements in the direction of the extension of the mounting anchors.

As well as it is possible to use a standard mounting anchor, the mounting anchor may be provided in different configurations depending on the wall construction. The following mounting anchors and locking elements does not necessarily have to be used in connection with the invention, but may be used independent of the present invention. In a first embodiment the mounting anchor may comprise a first end and a second end, the first end configured to be positioned in the inner shell and a second end configured to face away from the inner shell, wherein the second end is provided with engagement means.

These engagement means may be provided in different forms as will be seen in the following embodiments. Furthermore the engagement means are adapted to engage with different locking elements such that reinforcement mesh, a similar mesh or a cross runner in metal, composite, wood similar items may be held in place In a first embodiment the engagement means is in the form of a transverse hole for receiving a locking element. The hole is transverse in relation to a length of the mounting anchor. This embodiment is particular suitable when the outside of the wall is to be plastered. By placing for example reinforcement mesh over the mounting anchor and subsequently placing a cane like locking element through the hole, the reinforcement mesh is held in place by engaging a crook of the cane like locking element with the reinforcement mesh. The reinforcement mesh is thereby attached to the wall structure and enable adhesion of the plaster.

No matter what kind of locking element is used any type of cladding may be provided on top of the insulation elements, but some locking elements or engagement means are more suitable to a particular cladding such as plaster, boarding or bricks.

Preferably the second end is disc shaped or in any other way flat, such that it is easier to press the insulation element over the second end of the mounting anchor. The flat disc shaped end may be shaped as a circle or a polygon. The disc of the second end may be provided by pressing the end of the mounting anchor flat. The first end of the mounting anchor in this embodiment may be stepped.

In a different embodiment the engagement means may comprise a thread. This enables the mounting anchor to be more adaptable and thereby a suitable locking element may be provided at a later stage in the construction. A suitable locking element for this mounting anchor may be a bushing provided with internal threads. A disc forming part of the bushing is positioned at the end of the bushing perpendicular to the extension of the internal threads. It functions as a locking element keeping mounting profile and/or cross runners and/or breather paper and/or fillets abutting the front surface of the insulation element in place. The mounting anchor may extend out through the bushing. Alternatively, a washer and a nut may simply be used as a locking element. This particular embodiment of the mounting anchor and the embodiments of the locking element are suitable for ventilated facades such as boarded and/or paneled timber frame walls.

In a further embodiment of the mounting anchor the engagement means may comprise a polygonal shaped end. The polygonal shaped end may be star shaped. The polygonal shaped end may be provided at the end of a number of threads on the mounting anchor as mentioned in the previous embodiment. In a particular advantageous embodiment the polygonal end is provided on a straight mounting anchor. The first end of the mounting anchor may comprise engagement means, such as a thread, including thread forming and self-tapping thread. This allows the mounting anchor to be used in particular for renovation of external walls. It may also be used for construction of new walls. The mounting anchor of this embodiment may be screwed into an existing wall, wherein the polygonal shaped end may be used to screw in the mounting anchor by means of a torque wrench.

As a locking element a bushing with a disc perpendicular to the extension of the internal threads or a washer and a nut may be used as mentioned above. The locking element is configured to keeping a fillet used as a basis for cladding on the outside of the wall, in place.

Furthermore a locking element in the form of a bushing with internal threads and a disc provided in extension of and in parallel to the internal threads may be provided. Thereby an end similar to the end described in the first embodiment of the mounting anchor is provided.

For any of the embodiments of the mounting anchor a securing means may used to fasten the insulation elements to the construction. In a second aspect of the invention, a method of assembling a wall insulation system for a double shell exterior wall is provided, comprising the steps of providing an inner shell extending in a first plane with mounting anchors extending substantially perpendicularly to the first plane and being fastened to the inner shell with lateral offsets, and in rows with uniform elevation offsets from one another, providing a plurality of insulation elements having a width in the direction between two adjacent rows of the mounting anchors and a length extending perpendicularly to the width, wherein an insulation element comprises a main portion having a back surface, top and a bottom flange protruding from the main portion and extending along the length of the insulation element, guiding a first insulation element in a direction towards the inner shell between two adjacent rows of mounting anchors, guiding a second insulation element in a direction towards the inner shell above the first insulation element, such that the top flange of the first insulation element abuts the bottom flange of the second insulation element, thereby locking the first and/or the second insulation element, and attaching securing means to the mounting anchor(s) to fasten the insulation elements to the inner shell, repeating the two guiding steps and the securing step, so that a plurality of insulation elements in an assembled state define at least one first insulation layer of said wall insulation system, wherein the first insulation element is guided in such a way that the back surface faces the inner shell and at least one mounting anchor penetrates at least the bottom flange of the first insulation element.

By applying the method of the invention, it is possible to complete the at least one first insulation layer independently of the construction of the outer shell. This provides for an easier and more simple task for the construction worker compared to known methods, and he/she only need the materials for the assembly of the at least one first insulation layer at hand. At the same time, the insulation layer can be completed even without the immediately subsequent completion of the outer shell, as the assembly of the insulation layer is a stable construction that does not require to be immediately supported nor protected by the completion of the outer shell. This is because the mounting anchor penetrates the bottom flange and a locking effect is provided, such that a lower insulation element, is kept in place as well by the attached insulation element above it. This is possible because the back surface of a lower insulation element faces the inner shell and the bottom flange of an upper insulation element covers this flange. Thus, for example in colder climates, the interior construction can begin, even if the construction of the outer shell is halted, e.g. to outdoor temperatures or material shortage.

In a further development of the second aspect of the invention, the method further comprises the step of providing an outer shell onto the first insulation layer. It is to be understood that corresponding considerations as stated under the first aspect of the invention apply.

In a preferred embodiment of the second aspect of the invention, the method further comprises the steps of providing a second insulation layer and mounting the second insulation layer onto the inner shell prior to assembly of the first insulation layer. It is to be understood that corresponding considerations as stated under the first aspect of the invention apply.

Both aspects of the invention including all embodiments can be applied to both ventilated and non-ventilated double shell exterior walls which will be readily understood by the skilled person.

In the following the invention will be described in further details with reference to the accompanying drawings, where

Fig. 1 is a cross-sectional view of a wall insulation system comprising insulation elements according to an embodiment of the invention,

Fig. 2 is a cross-sectional view of a wall insulation system comprising insulation elements according to a further embodiment of the invention,

Fig. 3 is a perspective sectional end view of a wall insulation system comprising insulation elements according to the embodiment of Fig. 2,

Fig. 4 is a perspective view of a first type insulation element,

Fig. 5 is a perspective view of a second type insulation element according to the invention,

Fig. 6 is a schematic representation of an assembly process of two insulation elements according to Fig. 5, Figs 7 to 10 show different embodiments of the insulation elements according to the invention,

Figs 1 1 to 13 illustrate further embodiments of the insulation elements of the first insulation layer according to the invention,

Fig. 14 is a cross-sectional view of a wall insulation system comprising insulation elements according to an embodiment of the invention and a particular embodiment of a mounting anchor used for a plastered facade,

Fig. 15 is a cross-sectional view of a wall insulation system comprising insulation elements according to an embodiment of the invention and two embodiments of the mounting anchors used for a ventilated facade,

Figs 16a-16c show three different embodiments of mounting anchors,

Figs 17a to 17d show four different embodiments of locking elements,

Fig. 18 is an embodiment of the securing means, and

Figs 19 and 20 show cross-sectional views corresponding to Fig. 15, on a larger scale, of different embodiments of locking elements.

Initially referring to Fig. 1 , a wall insulation system 10 is illustrated. In more detail, the wall insulation system comprises an inner shell 1 having a side facing an interior space of a room in a building and an outer side facing an outer most part of the building constituted by an outer shell 2. The inner shell 1 and outer shell 2 is in an assembled state arranged at a distance from each other so as to define an intermediary space 3 there between.

Furthermore, as illustrated in Fig. 1 , a plurality of mounting anchors 8 is fastened to the inner shell 1 . The mounting anchors are arranged with lateral offsets and in rows with uniform elevation off-sets from each other, so as to provide a uniform distribution of mounting anchors on the outer side surface of the inner shell 1. The mounting anchors 8 are in an assembled state in one end fastened to the inner shell 1 and in the other end fastened to the outer shell 2 so as to create a bridging of the intermediary space 3 between the inner shell 1 and the outer shell 2. In the embodiment of Fig. 1 , the wall insulation system 10 further comprises an insulation layer 4, which are made from a plurality of insulation elements 41 , 51 . The insulation elements 41 , 51 are provided within the intermediary space 3 between the inner shell 1 and outer shell 2. Here the insulation elements 41 , 51 are supported by the mounting anchors 8, the supporting mechanism to be explained in further detail throughout the description.

In the assembled state of Fig. 1 it is seen how the plurality of insulation elements 41 , 51 define a first insulation layer 4 of the wall insulation system 10, where the insulation elements 41 , 51 are fastened to the inner shell 1 by a plurality of securing means 6. The securing means 6 are arranged so that they provide a pressure to the insulation element 41 , 51 so as to provide a force acting by pressing the insulation element 41 , 51 in a direction towards the inner shell 1 , where the inner shell is defined by a first plane.

Furthermore as is seen from Figs 1 and 5, the insulation element 41 , 51 have a width W, which are given in the direction between two adjacent rows of the mounting anchors 8 and a length direction L extending perpendicularly to the width W. The width direction should be construed as the plane of the insulation element 41 , 51 , which in the assembled state of Fig. 1 is parallel with the first plane of the inner shell 1 .

The form and shape of an insulation element 41 used for the insulation layer 4 in the above described embodiment of Fig. 1 is illustrated in more detail in Fig. 5. As illustrated in Fig. 5 the insulation element 41 comprises a main portion 42 having a top flange 43 and a bottom flange 44 protruding from the main portion 42. The flanges 43, 44 each extend along the length L of the insulation element 41 .

In more detail, the insulation element 41 is configured such that the top flange 43 and the bottom flange 44 protrude from the main portion 42 on each side of a longitudinal centerline, c, in the width direction, W, of the insulation element. That is, the insulation element 41 is as seen in Fig. 5, in a top and bottom region thereof, provided with a stepped portion comprising a top flange surface 430, a bottom flange surface 440 and a top and bottom main portion surface 420, 421 .

Referring now to Fig. 6, the configuration of two insulation elements 41 , 51 in relation to each other is illustrated. Here it is seen how the stepped portions of the top and bottom region of the insulation elements 41 , 51 are configured in a shape so as to be complementary to each other. During assembly of the insulation elements 41 , 51 to form the insulation layer 4 of Fig. 1 , a plurality of insulation elements 41 , 51 are connected to each other. The stepped portions of the insulation elements 41 , 51 are as seen provided with a complementary shape such that when placing a second insulation element 51 onto a first insulation element 41 in the direction of arrow A in Fig. 6, the top flange surface 430 of the first insulation element 41 abuts a bottom main portion surface 521 of the second insulation element 51 . Furthermore, the top main portion surface 420 of the first insulation element 41 abuts the bottom flange surface 540 of the second insulation element 51. In this way, the two insulation elements 41 , 51 are in an assembled state illustrated in Fig. 1 combined to each other such that the bottom flange 54 of the second insulation element 51 provides a locking effect of the first insulation element 41 . As seen from the Figures, the stepped portions comprising the top and bottom flanges together with the main portion in a cross-section view of the insulation elements, in each of the top and bottom region substantially defines an L-shaped cross-section. The L-shaped cross-section of the top and bottom regions is configured up-side down in relation to each other.

As being apparent from Fig. 6 and the above description of the first insulation element 41 , the second insulation element 51 is in a similar manner provided with a main portion 52, having two protruding flanges 53, 54, which each gives rise to a top flange surface 530 and a bottom flange surface 540. Furthermore, the main portion 52 of the second insulation element 51 together with the flanges 53, 54 provides for a top main portion surface 520 and a bottom main portion surface 521 . The insulation elements 41 , 51 are thus configured to complement each other so as to provide a locking effect thereof, but also to provide the insulation elements 41 , 51 with guiding means used during assembly of the insulation layer, which mechanism will become apparent in the following. Especially with reference to Fig. 1 , the assembly of the insulation layer 4 is to be explained.

The wall insulation system 10 in Fig. 1 , as previously described, is assembled by first providing an inner shell 1 extending in a first plane and having mounting anchors 8 fastened thereto. The mounting anchors 8 extend substantially perpendicularly to the first plane and are fastened to the inner shell 1 with lateral offsets, and in rows with uniform elevation offsets from one another, as illustrated in Fig. 1 . This first step provides for the foundation of the wall insulation system, to which the first insulation layer 4 constituted by a plurality of insulation elements 41 , 51 is connected.

Thus, in a second step of assembling the wall system, a plurality of insulation elements 41 , 51 is provided. The insulation elements of this embodiment correspond to the form and shape of the insulation element described in Figs 5 and 6. During assembly of the first insulation layer 4, a first insulation element 41 is guided in a direction towards the inner shell 1 between two adjacent rows of mounting anchors 8. That is, a flange surface 430 at the top region of the insulation element 41 and a main part surface 421 at the bottom region of the insulation element 41 , during assembly, together provide for guiding means for the insulation element 41 . That is, the distance between two adjacent rows of mounting anchors 8, corresponds to the distance from the flange surface 430, at the top region, to the main part surface 421 of the bottom region of the insulation element 41 . With this configuration of the insulation element 41 , the top flange surface 430 of the top region provides a guiding surface for a first mounting anchor 8a, and the bottom main surface 421 of the insulation element 41 provides for a guiding surface of a second mounting anchor 8b as illustrated in Fig. 1. Due to this construction, the bottom flange 44 of the insulation element 41 is during assembly penetrated by a mounting anchor 8b, whereby the mounting anchor provides for a supporting and partly locking effect of the first insulation element 41 .

After the mounting of the first insulation element 41 to the inner shell 1 as just described, a second insulation element 51 is provided. The second insulation element 51 is guided in a direction towards the inner shell 1 above the first insulation element 41 , such that the top flange 43 of the first insulation element 41 abuts the bottom flange 54 of the second insulation element 51 , thereby locking the first and the second insulation elements 41 , 51 to each other. The first 41 and second insulation elements 51 are in more detail connected to each other as described above in relation to Fig. 6. In more detail, the complementary L-shaped form of each of the insulation elements 41 , 51 together provides for a locking effect of the lowermost insulation element, in the case illustrated in Fig. 1 , the lowermost insulation element being the first insulation element 41 . In other words, the bottom flange 54 of the second insulation element 51 covers the top flange 43 of the first insulation element 41 in the assembled state, wherein the mounting anchor 8a penetrates the bottom flange 54 of the second insulation element 51 .

This assembly of two complementary insulation elements 41 , 51 is repeated a plurality of times in order to assembly a plurality of insulation elements for providing an insulation layer 4 as illustrated in Fig. 1 . Further thereto, the insulation elements 41 , 51 are tightly fastened to the inner shell 1 by providing securing means 6 to the mounting anchors. The securing means 6 is guided on the free end of the mounting anchors 8 so as to be guided towards the insulation elements 41 , 51 at a front surface thereof, the front surface facing the outer shell in an assembled state. Here they are pushed tightly to the front surface 45 so as to fasten the insulation element 41 , 51 to the inner shell 1 . This procedure is repeated with regards to the plurality of insulation elements which constitutes the insulation layer 4. Additionally, as illustrated in Fig. 1 , the outer shell 2, in this case brickwork, is provided onto the front surface 45, 55 of the plurality of insulation elements. The insulation element 41 , 51 also has a back surface 46 facing the inner shell 1 .

Referring now to Figs 2 and 3, a second embodiment of a wall insulation system 100 according to the invention is illustrated. In the following description parts having the same or analogous function as previously described are denoted with the same reference numerals to which 100 has been added. In this embodiment an additional second insulation layer 9 is installed in the intermediary space 103 between the inner shell 101 and the outer shell 102. As is apparent from the Figs 2 and 3, the first insulation layer 104 corresponds to the first insulation layer 4 as previously described. That is, the insulation elements 141 , 151 should substantially be construed as having the properties and method of assembly as described in the embodiment according to Fig. 1 , and is therefore not explained in further detail in relation to Figs 2 and 3.

The second insulation layer 9 in the embodiment of Figs 2 and 3 comprises a second type insulation element 91 , which are substantially rectangular in shape, and to be seen in more detail in Fig. 4. Thus, the insulation elements 141 , 151 of the first insulation layer 104 differ in shape from the insulation elements 91 of the second insulation layer 9. As is clear to a skilled person, the second insulation layer 9 is in this embodiment fastened to the inner shell 1 prior to the assembly of the first insulation layer 104, which are therefore mounted onto the second insulation layer 9. In more detail, the insulation elements 91 of the second type are substantially guided towards the inner shell 101 within the distance between two adjacent rows of mounting anchors 108, such that the mounting anchors 108 also for the second insulation layer 9 provides guiding means for an upper surface 92 and lower surface 93 of the second insulation element 91 . After installation of the first insulation layer 104 onto the second insulation layer 9, the insulation layers 104, 9 are fastened to the inner shell 101 by securing means 106.

As is apparent from all the Figures and the above description, the insulation elements within an insulation layer have the same shape and/or with regards to the first insulation are configured so as to be complementary to each other, so as to be stacked in between the mounting anchors, where they are substantially kept in place.

The complementary feature as described above is also apparent from Figs 7 to 10 which illustrate different embodiments of insulation elements, especially insulation elements intended to be used in the outermost first insulation layer 4, 104. As is apparent from Figs 8 to 10, the insulation elements 241 , 251 ; 341 , 351 ; 441 , 451 ; 541 , 551 differ in shape in relation to each other but should be construed as having the same properties as described throughout the description in relation to the insulation elements 41 , 51 constituting the first insulation layer 4. Especially the flanges protruding from the main portion of the insulation elements differ in shape. Without being explained in further detail, the differences in shape of the insulation elements are apparent from the Figures.

If taking the embodiment of Fig. 8 as an example, especially the thickness of the bottom flange 343, 353 is varying in relation to the remaining embodiments. The variation in the thickness of the bottom flange influences the assembly process of the insulation layer, in that the thickness of the bottom flange 343, 353 defines the part of the bottom flange, which the mounting anchors 8 is to penetrate during assembly. That is, the more material to penetrate the more force needs to be applied from a construction worker assembling the insulation layer. Furthermore the extension of the flange portions 543, 553 as illustrated in Fig. 10 may also vary, so that more or less material provides for a locking of the first and second insulation element 541 , 551 .

In another embodiment of the invention, as illustrated in Figs 1 1 to

13, the insulation element may be made from at least two components, wherein one component is made from a different material and/or density than the other. That is, with reference to Fig. 1 1 , the insulation element 641 is constituted by a first component 650 and a second component 651 so as to be formed as a laminated insulation element. The first and second components are as illustrated in the Figs made from different materials, and are formed as described in the previous sections of the disclosure, so as to comprise a top flange 653 and a bottom flange 654.

Furthermore, as illustrated in Fig. 12, the two components 750, 751 of the insulation element 741 are, in one embodiment, made from a material having different densities. Also in this embodiment, the insulation element 741 comprises two flanges as previously described, and is therefore not dis- cussed in further detail.

In yet another embodiment, the insulation element may be made of at least three components, so as to form a laminated insulation element. In this embodiment, illustrated in Fig. 13, the insulation element 841 comprises a first 850, a second 851 and a third 852 component, each being made from different materials. In this case it could also be contemplated that at least one layer are made from a different material than the remaining two layers. In this embodiment, the shape of the insulation element differs slightly from the previously described embodiments. The insulation element 841 of the embodiment in Fig. 13 comprises two protruding flange portions, a top flange portion 853 and a bottom flange portion 854 similarly to the flange portions in the previously described embodiments. However, in this embodiment, the flange portions substantially form a stepped portion, such as a staircase structure, where an end of each component 850, 851 , 852 each defines a step surface 853a, 853b, 853c in the top region and a step surface 854a, 854b, 854c in the bottom region. In this embodiment, the main portion 842 from where the flanges protrude is thus defined along the borderline of step surface 853c in the top and step surface 854a in the bottom. That is, the step surfaces 853a and 854a together define the guiding means of the embodiment in Fig. 13, which further should be understood that in this embodiment, both the protruding flange portion of the second 851 and third 852 component of the insulation element 841 are penetrated by the at least one mounting anchor in an assembled state as already described with regards to the previously described embodiments.

As many of the features in Figs 14 and 15 are similar to Fig. 1 , only differences in relation to Figs 14 and 15 will be described. In Fig. 14 a solution for a plastered external wall, either renovation or newly constructed buildings, is described. In particular the focus on the mounting anchor and a locking element for keeping further cladding on the insulation elements in place. Fig. 14 shows three different solutions all suitable for a plastered facade. In upper most embodiment a mounting anchor 8 with engagement means 208a in the form of disc with an eye or hole is provided. The disc placed in parallel and in extension of the mounting anchor is easy to use for penetration of the insulation element 41 , 51 during mounting due to its flat configuration. After mounting of the insulation element 61 , a securing means 6 is placed over the mounting anchor, subsequently reinforcement mesh 7 is placed over the mounting anchor 8 and attached by means of a locking element 209a in the form of a cane. The crook of the cane is used for attaching the reinforcement mesh 7 to the construction by engaging the crook with the reinforcement mesh 7.

In the embodiment in the middle a mounting anchor with engagement means 208b in the form of threads has been used. Again the insulation element has been 51 pushed over the mounting anchor 8, securing means 6 has been placed over the mounting anchor 8 and a locking element 209c in the form of a bushing with internal threads and a disc with a hole has been attached to the mounting anchor 8. As the end of the mounting anchor 8 now is provided with an end similar to the upper most embodiment in this figure, a locking element 209a in the form of a cane is applied in a similar fashion as mentioned above.

In the lower most embodiment of this figure a mounting anchor with engagement means in the form of threads and a polygonal end 208c has been used. This mounting anchor does not need to be build into the inner shell during construction of the inner shell, but may be mounted subsequently by screwing it into the wall of the inner shell by using e.g. a torque wrench. Similar locking elements as shown in the middle embodiment of this figure has been mounted onto this mounting anchor 8.

In Fig. 15 only differences in relation to Fig. 1 will be described. Here two embodiments of mounting anchors have been used. These two embodiments are particular useful for ventilated facades, both renovation and newly build constructions, where the facade is provided with for example a boarded and/or panelled timber frame wall.

In the uppermost embodiment a stepped mounting anchor comprising treads at the second end, extends out from the inner shell 1 throughout the insulation element 61 . A vertical post or fillet 1 1 , provided with holes in suitable places, is placed over the mounting anchors 8 provided with threads 208b. In order to attach the vertical post or fillet to the construction, a bushing 209 with internal threads is placed over the mounting anchor 8.

In the lower most embodiment the mounting anchor of the previous embodiment has been replaced by a straight mounting anchor 209b with threads at both ends and a polygonal end for screwing the mounting anchor into the wall. Like the above embodiment of this figure a bushing 209b is used for attachment of the vertical post or fillet. A horizontal post or fillet 12 and boarding 13 are provided as a further layer on the vertical post or fillet 1 1. The horizontal post or fillet 12 and boarding 13 may be dispensed with. Instead the horizontal post or fillet may be directly attached to the insulation element and the vertical post or fillet on top of the

Figs 16a to 16c show different embodiments of mounting anchors. The different relations they may enter into have been shown in Figs 14 and 15.

Fig. 16a shows a first embodiment of a mounting anchor 8 with a stepped first end 14 and a second end provided with a disc 15 with a hole 16, constituting the engagement means 208a of the mounting anchor. The disc 15 extends in parallel to the length of the mounting anchor 8. The mounting anchor in fig. 16a is preferably used for plastered constructions both renovations and newly build constructions.

Fig. 16b shows a second embodiment of a mounting anchor 8 with a stepped first end 14 and a second end provided with threads constituting the engagement means 208b of the mounting anchor. The mounting anchor in fig. 16b is preferably used for ventilated facades both renovations and newly built constructions.

Fig. 16c shows a third embodiment of a mounting anchor 8 with a straight first end 18 and a second end provided with threads 17 and a polygonal end 19 both of which constitutes the engagement means 208c of the mounting anchor 8. The mounting anchor is seen from the side and from second end. The mounting anchor 8 in fig. 16c may be used for both plastered and ventilated facades and both for renovations and newly build constructions depending on what kind of locking means is mounted onto the second end.

Figs 17a to 17d show four embodiments of locking means that may be fitted onto the second end of one the mounting anchors provided with threads 17 at the second end.

Fig. 17a shows a first embodiment of a locking element with a cane like shape, also called a cane locking element 209a. The cane locking element is particular useful for engagement with the mounting anchor with the disc shaped engagement means 208a.

Fig. 17b shows a second embodiment of a bushing 209b with internal threads 221 and, constituting a part thereof, a disc 220 positioned at the end of the bushing perpendicular to the extension of the internal threads. The bushing is shown from the side and from above. This may function as a locking element keeping further cladding such as posts and fillets in place.

Fig.17c shows a third embodiment of a locking element. This is also a bushing 209c with internal threads 217, however, here a disc 210 is placed in parallel to the extension of the threads 217. The disc is provided with a hole for engagement with the cane locking element. The threads 217 of the bushing are adapted to engagement with the threads 17 of mounting anchor 208c or 208b.

Fig. 17d shows a nut 231 and a washer 230 that may be used as a locking element as well.

Fig. 18 shows a securing means 6 that is adapted to be placed on any of the mounting anchors, directly on the front face of the insulation element. This secures that the insulation element stays in place.

Figs 19 and 20 show close-up views of the mounted conditions of these embodiments.

As is apparent, the insulation elements may be shaped with different forms, why the invention should not be limited to the embodiments illustrated and described, but also includes similar embodiments, which would be apparent for a person skilled in the art.

Features from different embodiments may be combined freely in any usable way.

Even though some figures depict the wall insulation system of the invention with an outer shell, it is to be understood that the completed first insulation layer 4 is so stable that it needs not to be supported by the construction of the outer shell 2. The completed first insulation layer 4 can in this way stay not covered by an outer shell 2 even for months. Thus, the outer shell 2 can be constructed at a later stage in the building process.

Claims

P A T E N T C L A I M S

1. Wall insulation system (10; 100) for a double shell exterior wall, comprising an inner shell (1 ; 101) extending in a first plane and an outer shell (2; 102), said inner and outer shell (1, 2; 101, 102) defining an intermediary space (3; 103) between them, and mounting anchors (8; 108), the extension of which in an assembled state defines a second plane, extending substantially perpendicularly to the first plane, and being fastened to the inner shell (1; 101) with lateral offsets, and in rows with uniform elevation offsets from one another, wherein the mounting anchors (8; 108) comprise securing means (6; 106) and in said assembled state bridge the intermediary space (3; 103), and further comprising at least one first insulation layer (4; 104) having insulation elements (41, 51; 141, 151), which are supported by the mounting anchors (8; 108) in the intermediary space (3; 103) between the inner shell (1; 101) and the outer shell (2; 102), wherein said insulation elements (41, 51; 141, 151) have a width (W) in the direction between two adjacent rows of the mounting anchors (8; 108) and a length (L) extending perpendicularly to the width (W),

each insulation element (41, 51; 141, 151) comprises a main portion (42, 52) having a back surface (46), a top and a bottom flange (43, 44, 53, 54) protruding from the main portion (42, 52) and extending along the length (L) of the insulation element (41, 51; 141, 151), wherein said top flange (43) is configured to abut a complementary bottom flange (54) of a second insulation element (51; 151), such that a plurality of insulation elements (41, 51; 141, 151) in said assembled state define said at least one first insulation layer (4; 104) of said wall insulation system (10; 100), said insulation elements (41 , 51 ; 141, 151) being fastened to the inner shell (1; 101) by at least one securing means (6, 106) c h a r a c t e r i z e d in that in the assembled state the back surface (46) faces the inner shell (1; 101) and the at least one mounting anchor (8b) penetrates at least the bottom flange (44; 54).

2. Wall insulation system according to claim 1, wherein said top flange (43, 53) and said bottom flange (44, 54) are configured to protrude from said main portion (42, 52) on each side of a longitudinal centerline (C) in the width direction (W) of said insulation element (41 , 51 ; 141 , 151 ), so as to form a stepped portion comprising a flange surface (430, 530) and a main portion surface (420, 520) at a top and bottom region of said insulation element (41 , 51 ; 141 , 151 ).

3. Wall insulation element according to claim 2, wherein the flange surface (430, 530) at the top region and the main portion surface (420, 520) at the bottom region of said insulation element (41 , 51 ; 141 , 151 ), during assembly, together provide for guiding means for the insulation element (41 ,51 ; 141 , 151 ) in that the distance between two adjacent rows of mounting anchors (8, 108) corresponds to the distance from the flange surface (430, 530) at the top region to the main portion surface (420, 520) of the bottom region of the insulation element (41 , 51 ; 141 , 151 ).

4. Wall insulation system according to claim 2 or 3, wherein the flange surface (430, 530) at the top region and the main portion surface (420, 520) at the bottom region of said insulation element (41 ,51 ) are substantially horizontal.

5. Wall insulation system according to any of the preceding claims, wherein a ratio between the extension of the top flange (43, 53) in the second plane and the extension of the bottom flange (44, 54) in the second plane is approximately in the range from 2/98 to 98/2, preferably 25/75 to 75/25, more preferably 40/60 to 60/40, most preferably 50/50.

6. Wall insulation system according to any of the preceding claims, wherein the insulation elements (41 , 51 ; 141 , 151 ) of said at least one first insulation layer (4; 104) are made of a weather-resistant material.

7. Wall insulation system according to any of the preceding claims, wherein the insulation elements (41 , 51 ; 141 , 151 ) of the first insulation layer (4; 104) are made of mineral wool, preferably at a density of 45 to 150 kg/m³

8. Wall insulation system according to any of the preceding claims wherein the insulation elements of the first insulation layer are of a laminated structure comprising at least two components made of different materials and/or having different densities.

9. Wall insulation system according to any of the preceding claims, wherein the wall insulation system (10; 100) comprises at least one second insulation layer (9).

10. Wall insulation system according to claim 9, wherein insulation elements (91 ) of said at least one second insulation layer (9) are made of a different material than the insulation elements (41 , 51 ; 141 , 151 ) of said first insulation layer (4, 104).

1 1 . Wall insulation system according to claim 9 or 10, wherein the insulation elements (91 ) of the second insulation layer (9) are made of mineral wool (e.g. glass wool, stone wool), PIR, PUR, vacuum insulation, fiber insulations, aerogel mats or the like.

12. Mounting anchor (8) according to claim 1 , wherein the mounting anchor comprises a first end and a second end, the first end being configured to be positioned in the inner shell and a second end being configured to face away from the inner shell, wherein the second end is provided with an engagement means (208a; 208b;208c).

13. Mounting anchor (8) according to claim 12, wherein the engagement means (208a) is in the form of a transverse hole for receiving a locking element.

14. Mounting anchor (8) according to claim 13, wherein the second end is disc shaped.

15. Mounting anchor (8) according to claim 12, wherein the engagement means (208b; 208c) comprises a thread.

16. Mounting anchor (8) according to claim 12 or 15, wherein the engagement means (208c) comprises a polygonal shaped end.

17. Mounting anchor (8) according to any one of claims 13 to 17, wherein the first end comprises engagement means (210c), such as a thread, including thread forming and self-tapping thread.

18. Method of assembling a wall insulation system (10; 100) for a double shell exterior wall comprising the steps of

I) providing an inner shell (1 : 101 ) extending in a first plane with mounting anchors (8; 108) extending substantially perpendicularly to the first plane and being fastened to the inner shell (1 ; 101 ) with lateral offsets, and in rows with uniform elevation offsets from one another,

II) providing a plurality of insulation elements (41 , 51 ; 141 , 151 ) having a width (W) in the direction between two adjacent rows of the mounting anchors (8; 108) and a length (L) extending perpendicularly to the width (W), wherein an insulation element (41 , 51 ; 141 , 151 ) comprises a main portion (42, 52) having a back surface (46), a top and a bottom flange (43, 44, 53, 54) protruding from the main portion (42, 52) and extending along the length (L) of the insulation element (41 , 51 ; 141 , 151 ),

III) guiding a first insulation element (41 ; 141 ) in a direction towards the inner shell (1 ; 101 ) between two adjacent rows of mounting anchors (8;

108)

IV) guiding a second insulation element (51 ; 151 ) in a direction towards the inner shell (1 ; 101 ) above the first insulation element (41 ; 141 ), such that the top flange (43) of the first insulation element (41 ; 141 ) abuts the bottom flange (54) of the second insulation element (51 ; 151 ), thereby locking the first and/or the second insulation element (41 , 51 ; 141 , 151 ), and

V) attaching securing means (6; 106) to the mounting anchor(s) (8; 108) to fasten the insulation elements (41 , 51 ; 141 , 151 ) to the inner shell (1 ; 101 ),

repeating steps III) to V) so that a plurality of insulation elements (41 ,

51 ; 141 , 151 ) in an assembled state define at least one first insulation layer (4; 104) of said wall insulation system (10; 100) c h a r a c t e r i z e d in that the first insulation element (41 ; 141 ) is guided in such a way that the back surface (46) faces the inner shell (1 ; 101 ) and at least one mounting anchor (8; 108) penetrates at least the bottom flange (44, 54) of the first insulation element (41 ; 141 ).

19. Method of assembling a wall insulation system for a double shell exterior wall according to claim 19, further comprising the step of

VI) providing an outer shell (2; 102) onto the first insulation layer (4; 104).

20. Method of assembling a wall insulation system for a double shell exterior wall according to any of claims 19 to 20, further comprising the step of

la) providing a second insulation layer (9) mounted on the inner shell (1 , 101 ) prior to assembly of the first insulation layer (4, 104).