EP4324998A2 - Method for producing a wall structure with internal insulation - Google Patents

Abstract

The invention relates to a method for producing a wall structure (10) with a wall (12) and internal insulation (20). In this case, a substantially cuboid strip of insulation material (22) made of a water-impermeable material is provided, an adhesive bed (30) is provided for each strip of insulation material (22) with at least one adhesive layer (34) on the wall side and an adhesive layer (32) on the support surface, the wall-side adhesive layer ( 34) is attached directly to the wall (12) and the adhesive layer (32) on the support surface is applied directly to the floor adjacent to the wall (12) or to the top of another strip of insulation material (22), and at least one of the adhesive layers (32, 34), preferably both adhesive layers (32, 34) are each designed to be capillary conductive. The cuboid strip of insulation material (22) is inserted into the adhesive bed (30). The steps are repeated until the wall (12) is covered to form a capillary-conductive insulation layer (36) formed from the insulation strips (22) and the adhesive layers (32, 34). Finally, the capillary-conductive insulation layer (36) is plastered or filled with a capillary-conductive plaster or filler (40) to complete the interior insulation (20) of the wall (12).

Description

The invention relates to a method for producing a wall structure with a wall and internal insulation. Furthermore, a process for energy-efficient renovation of a building wall from the inside is described.

STATE OF THE ART

Typically, buildings are insulated on the outside of the masonry or equipped with an insulating material. As a result, the temperature of the wall is relatively high even at low outside temperatures because the drop in temperature takes place particularly in the external insulation material. If the wall is insulated on the inside, the temperature drop essentially takes place in the inside insulation material. This means that the temperature of the masonry is much lower than with external insulation. The vapor pressure gradient is then higher and more moisture gets into the wall. The condensation level is located near the insulation layer on the inside of the wall. The condensate can cause structural damage.

To avoid structural damage, especially moisture and mold problems in the wall area EP 2 183 099 B2 a wall structure with an inside insulation layer is known, which is designed to be open to diffusion. The insulating layer has capillary conductive areas which run from one side of the insulating layer to the other side of the insulating layer. Through the capillary conductive areas, the condensate can be removed from the outside of the insulation layer, i.e. from the wall side of the insulation layer, and led back into the interior. Moisture that has penetrated the facade from outside can also be released inside. This ensures that the structure dries sufficiently.

To create the wall structure EP 2 183 099 B2 A thermal insulation board is factory-fitted with openings that extend perpendicular to the plane of the board and completely penetrate the board. A capillary conductive mortar is placed in the openings. According to the teachings of EP 2 183 099 B2 The mortar can be introduced into the openings either at the factory or when the insulation board is installed on the wall to be insulated. In the latter case, the wall to be insulated is covered with a capillary-conductive layer on the wall of such a thickness that when the insulation board is pressed with openings, the openings are filled by the still-moist capillary-conductive material.

In practice it has been shown that suitable capillary conductive mortars are so tough that the latter method does not work reliably. The openings therefore have to be filled industrially in advance. This leads to not inconsiderable manufacturing costs for the capillary-conductive insulation board. When the capillary openings are prefabricated at the factory, the insulation panels cannot be designed in different thicknesses without the system for punching and filling the panels always having to be retooled.

There is therefore a need to simplify the process for producing a wall structure with a wall and internal insulation.

Out of EP 2 765 251 A1 a thermal insulation composite and a method for producing thermal insulation composites for the thermal insulation of buildings are known, in which at least two cuboid insulation material units are provided to produce the thermal insulation composites and are glued together along their edges to form a capillary-active adhesive layer. At least two, preferably a plurality, of thermal insulation composites are glued together using a binder-containing adhesive composition to form a thermal insulation composite area, the adhesive layer being capillary active in the hardened state and extending in sections from the first side to the second side of the thermal insulation composite area. Here too, the thermal insulation composite is prefabricated in the factory. The disadvantage of the factory-prefabricated insulation material units that are interconnected in layers is that the capillary-active areas are exposed to considerable stress during transport and handling on the construction site, which can lead to fractures in the hardened capillary-active adhesive. The thermal insulation composites must be handled with corresponding care during transport and on the construction site. When the thermal insulation composites are cut to size on site, they can break apart because cutting or sawing causes high mechanical stress, increased by the change in material between the insulation and the adhesive, which also prevents cutting with a hot wire.

In DE 10 2017 010 713 A1 describes a method for producing an insulated wall, particularly for internal insulation of a building. A plate-shaped insulation layer is attached to an on-site substrate using an adhesive compound, with an adhesive layer first being applied to the substrate or to the insulation board using either the "floating" or "buttering" process, and the connection being made by attaching the insulation board to the substrate the insulation board is made with the substrate. To avoid air pockets and voids, it is suggested to vibrate the insulation board using a suitable device. The typical butt and bearing joints remain between the insulation panels.

OBJECT OF THE INVENTION

The invention aims to propose a simple method for producing a wall structure with internal insulation, which uses robust starting materials and enables safe production of capillary conductive areas.

DISCLOSURE OF INVENTION

The object is achieved by a method for producing a wall structure with a wall and interior insulation with the features of claim 1. Further aspects of the invention relate to a method for energy-efficient renovation of a building wall from the inside.

In the method according to the invention, a substantially cuboid strip of insulation material made of a substantially water-impermeable material is provided. Suitable materials include PS, PUR and/or foam glass.

In particular, for example, a silicate-based airgel or a PU airgel is suitable, with an airgel in the context of the present disclosure being a highly porous solid whose volume consists of over 99.8% pores.

Furthermore, an EPS material containing pyrolysis oil is suitable, the pyrolysis oil being obtained, for example, by pyrolysis of organic substances, such as biomass or plastic waste, at temperatures of approximately 500 ° C. BASF products sold under the trade name NEOPOR can still be used.

The insulation strip can advantageously contain, for example, up to 10% or up to 20% recyclate from mechanically recycled EPS waste, for example from the packaging sector. In addition, the insulation strip can be made entirely or partially from raw materials from chemical recycling of plastic waste.

The insulation strip can also advantageously be a biomass-certified product, for example insulation materials made from more than 90% renewable raw materials.

Suitable cuboid insulation strips, for example, have a length of up to 1.5 m. The insulation material strips are preferably from 15 cm to 1.5 m long, more preferably from 30 cm to 1.5 m, particularly more preferably from 50 cm to 1.5 m.

The thickness of the insulation strips depends directly on the insulation value of the board and can vary greatly. Suitable cuboid strips of insulation material typically have a thickness of up to 30 cm in the direction perpendicular to the wall, preferably from 1 cm to 30 cm, more preferably from 5 cm to 30 cm and particularly more preferably from 8 cm to 20 cm.

Suitable cuboid insulation strips have a height of up to 50 cm, preferably from 5 cm to 30 cm, more preferably from 10 cm to 20 cm.

In one step of the method, an adhesive bed is provided for each such strip of insulation material with at least one wall-side adhesive layer and one support surface-side adhesive layer, the wall-side adhesive layer being attached directly to the wall and the support surface-side adhesive layer directly on the floor adjacent to the wall or on the top of a further insulation strip is applied, and at least one of the adhesive layers, preferably both adhesive layers, are each designed to be capillary conductive.

In the context of the present disclosure, “capillary-conductive” means that condensate can be removed from the outside of the insulation layer, i.e. here the wall-side side of the insulation layer, and led into the interior. For example, a porous material that can form capillary flows is referred to as capillary-conductive. The porous material has connected pores, the capillary radii of which are preferably up to 1 mm, more preferably up to 0.1 mm, even more preferably up to 10 μm and even more preferably up to 1 μm.

The adhesive layer on the wall side and the support surface side can consist of different materials. To simplify things, it is preferably provided that the adhesive layers consist of the same material.

Suitable materials for the adhesive layers preferably consist of a mortar, the mortar consisting of clay and/or mineral binder such as cement, gypsum, alumina cement, silicate or phosphate. Alternatively, the mortar can be based on resins such as natural resins, two-component resins, in particular epoxy resins, PMMA or PU or dispersion resins such as acrylate or styrene-butadiene.

Clay is particularly suitable due to its low cost, practically unlimited availability, sufficient tolerability and sufficient testing. Clay adhesive layers can also be easily dismantled.

The adhesive layers on the support surface side are preferably applied with a thickness of 0.2 mm to 3 mm, more preferably 0.5 mm to 2 mm, and particularly preferably up to 1 mm. The layer thicknesses ensure, on the one hand, sufficient thermal insulation of the insulation, as large cold and heat bridges are avoided, and, on the other hand, sufficient removal of the condensate.

The wall-side adhesive layers are preferably applied with a thickness of 1 mm to 7 mm, more preferably 2 mm to 5 mm and particularly preferably up to 3 mm. The layer thicknesses ensure, on the one hand, that the cuboid strips of insulation material adhere adequately to the wall and, on the other hand, that the condensate is sufficiently removed.

In a further step of the process, the cuboid strip of insulation material is inserted into the adhesive bed.

The steps described are repeated insulating strip by insulating strip until the wall is covered. Here, a capillary-conductive insulation layer is formed on the wall from the insulation strips and the adhesive layers.

Between 5 and 15 strips of insulation material are preferably arranged one above the other at a wall height of 1000 mm.

In a final step, the capillary-conductive insulation layer is plastered over or filled with a capillary-conductive and/or diffusible plaster or filler to complete the interior insulation of the wall.

Suitable capillary conductive plasters or fillers preferably consist of clay and/or mineral binders such as cement, gypsum, alumina cement, silicate or phosphate. Alternatively, the capillary-conductive plaster or filler can consist of or be based on resins such as natural resins, two-component resins, in particular epoxy resins, PMMA or PU or dispersion resins such as acrylate or styrene-butadiene or similar capillary-conductive materials. Suitable materials such as glycols, water-storing polymers or the like can also be included for buffering. Both porous and non-porous forms can be used as fillers for the mortar.

In the method according to the invention, the adhesive layers on the support surface preferably make up from 0.1% to 5%, more preferably from 0.5% to 3%, of the area of the insulating layer. These ranges represent a compromise between the water conductivity with the effects described and the thermal insulation effect of the insulation layer. Since the capillary-conductive adhesive layers form thermal or cold bridges between the insulation strips, the preferred area ratios ensure that there is sufficient thermal insulation of the insulation.

The cuboid insulation strips preferably have a µ-value (µ is the water vapor diffusion resistance number) of at least 20 in the direction perpendicular to the wall, whereby the determination of the µ-value is based on DIN ISO 12572 | 2017-05 is pointed out. The smallest µ value determined using the determination methods described there is the relevant one. With regard to usual design values, reference is also made to DIN 4108-4 | 2020-11 referred.

At low relative humidity, moisture transport occurs predominantly through water vapor diffusion. This diffusion can be measured using the so-called “dry cup method”. At higher humidity levels of up to around 95%, vapor and liquid moisture flows occur simultaneously. This increasing liquid transport causes an exponential increase in diffusion and can be measured under isothermal conditions using the “wet cup method” (as well as other intermediate stages).

With a minimum µ value of the cuboid insulation strips and a minimum thickness of 0.01 m in the direction perpendicular to the wall, the cuboid insulation strips have an Sd value of at least 0.2 m, the Sd value preferably being at least 1 m, more preferably is at least 1.6 m. The S _d value is defined by the µ value and the layer thickness used: $${\mathrm{S}}_{\mathrm{d}}-\mathrm{Value}\left[\mathrm{m}\right]=\mathrm{Water\; vapor\; diffusion\; resistance\; number}\mathrm{\mu }\times \mathrm{Layer\; thickness}\left[\mathrm{m}\right]$$

It is further preferred that the insulation has a thermal conductivity level WLS of up to 040, preferably up to 035, more preferably up to 032 and particularly more preferably from 016 to 032. For the definition of WLS, reference is made to DIN 4108-10:2015 and DIN 4108-4:2017 as well as DIN EN 13162 to 13171, each in the 2015-04 edition.

In a method for energy-efficient renovation of a building wall from the inside, in a first step the building wall is freed from wallpaper, old paint and the like and in a second step a wall structure with the building wall and the inside insulation is produced according to one of the previously described methods.

Finally, the invention also relates to a kit for carrying out the method, the kit comprising a quantity of cuboid strips of insulation material and an adhesive for forming capillary-conductive adhesive layers.

ADVANTAGES OF THE INVENTION

Interior insulation with capillary conductive layers avoids moisture and mold problems in the wall area. Moisture that has penetrated from outside can also be released inside and the construction is dried.

The capillary-conductive layers are advantageously only produced on the construction site, so that the prefabrication of the capillary-conductive insulation panels at the factory is no longer necessary. The cuboid insulation strips made of the essentially water-impermeable material can be cut to size in a simple manner. Further processing steps are not absolutely necessary at the factory. The process is therefore easy to implement and flexible. In comparison to attaching large-area panels with capillary-conductive openings or capillary-conductive layers prefabricated at the factory, no so-called buttering and floating is necessary during bonding, as the insulation strips can be easily adjusted to any unevenness in the wall surface by pressing, which means that void-free bonding is possible even when the adhesive is applied on one side is.

Advantageously, with the invention, the energy-related renovation of a building wall can be largely carried out by the end user, who can take over the preparation of the surface in the form of removing wallpaper and old paint and can also attach the insulation strips to the building wall. The craftsman or professional finally completes the work, for example in the form of plastering and filling over the system, attaching and gluing reveal panels and attaching and gluing insulation strips to detailed connections and openings such as pipe openings. Of course, all of the work steps can be carried out by a professional.

BRIEF DESCRIPTION OF THE FIGURES

The invention is described in more detail below with reference to the figures, whereby the description of the preferred embodiments is not to be interpreted as restricting the invention. Rather, a person skilled in the art will recognize a large number of modifications that are possible within the scope of the claims.

Fig. 1a bis 1j

Herstellungsschritte eines Wandaufbaus mit einer Wand und einer innenseitigen Dämmung nach einer Ausführungsform der Erfindung und

Fig. 2

einen quaderförmigen Dämmstoffstreifen in perspektivischer Darstellung.

Show it:

Fig. 1a to 1j

Manufacturing steps of a wall structure with a wall and interior insulation according to an embodiment of the invention and

Fig. 2

a cuboid strip of insulation material in a perspective view.

EMBODIMENTS OF THE INVENTION

Fig. 1a shows an inside corner of a building, which is formed from two walls 12 and a floor 14. For example, the left of the walls 12 is subsequently provided with internal insulation 20 (cf. Fig. 1j ).

Fig. 1b shows an adhesive layer 32 on the support surface, which was applied to the floor 14 by the end user or by a professional. The adhesive layer 32 on the support surface is, for example, 1 to 2 mm thick.

In Fig. 1c the support surface-side adhesive layer 32 was supplemented by a wall-side adhesive layer 34, which was attached directly to the wall 12. The wall-side adhesive layer 34 was also applied in a layer thickness of 1 to 2 mm. The adhesive layer 32 on the support surface and the adhesive layer 34 on the wall form an adhesive bed 30.

Fig. 1d shows a cuboid strip of insulation material 22, which was inserted into the adhesive bed 30.

In Fig. 1e In addition to the cuboid insulation strip 22, a further adhesive layer 32 on the support surface was formed on the floor.

In Fig. 1f was, analogous to Fig. 1b and c , the support surface-side adhesive layer 32 is expanded by a further support surface-side adhesive layer 32 and two further wall-side adhesive layers 34.

In Fig. 1g were, analogous to Fig. 1d , two further cuboid strips of insulation material 22 are inserted into the adhesive bed 30.

Fig. 1h shows a second layer of cuboid insulation strips 22, which were applied to the first layer with the first three cuboid insulation strips 22. As before, an adhesive bed 30 was prepared, with the adhesive layer 32 on the support surface being applied directly to the top sides of the cuboid insulation strips 22 lying below. The second layer of the cuboid insulation strips 22 was horizontally offset by half the length of the insulation strips 22 compared to the first layer.

Fig. 1i shows a third layer of cuboid insulation strips 22, which were arranged on the second layer. The insulation strips 22 and adhesive layers 32, 34 form a capillary-conductive insulation layer 36.

Fig. 1j shows the final step of plastering over the capillary-conductive insulation layer 36 with a capillary-conductive plaster or spatula 40 to complete the interior insulation 20 of the wall 12.

Fig. 2 shows a cuboid strip of insulation material 22, which is suitable for use in the method according to the invention. The cuboid insulation material 22 has a main axis with a length L, for example of 1 m, and two thickness (D) and height dimensions H, for example of 20 cm each, which are significantly smaller than the length L.

REFERENCE MARKS

10 wall structure; 12 wall; 14 floor; 20 insulation; 22 strips of insulation material; 30 glue bed; 32 adhesive layer on the support surface; 34 wall-side adhesive layer; 36 capillary conductive insulation layer; 40 plaster or putty

Claims (14)

Method for producing a wall structure (10) with a wall (12) and internal insulation (20), with the following steps: a. Providing a substantially cuboid strip of insulation material (22) made of a water-impermeable material; b. Providing an adhesive bed (30) for each strip of insulation material (22) with at least one wall-side adhesive layer (34) and an adhesive layer (32) on the support surface, the wall-side adhesive layer (34) being attached directly to the wall (12) and the support surface-side adhesive layer ( 32) is applied directly on the floor adjacent to the wall (12) or on the top of a further strip of insulation material (22), and at least one of the adhesive layers (32, 34), preferably both adhesive layers (32, 34), are each designed to be capillary conductive; c. Inserting the cuboid insulation strip (22) into the adhesive bed (30); d. Repeat steps a. to c. until the wall (12) is covered to form a capillary-conductive insulation layer (36) formed from the insulation strips (22) and the adhesive layers (32, 34); and e. Plastering or filling over the capillary-conductive insulation layer (36) with a capillary-conductive plaster or filler (40) to complete the inside insulation (20) of the wall (12). Method according to claim 1, characterized in that the adhesive layers (32) on the support surface make up from 0.1% to 5%, preferably from 0.5% to 3%, of an area of the insulating layer (36). Method according to claim 1 or 2, characterized in that 5 to 15 strips of insulation material (22) are arranged one above the other at a wall height of 1000 mm. Method according to one of the preceding claims, characterized in that the adhesive layers (32) on the support surface side are applied with a thickness of 0.2 mm to 3 mm, preferably 0.5 mm to 2 mm, more preferably up to 1 mm thick. Method according to one of the preceding claims, characterized in that the wall-side adhesive layers (34) are applied with a thickness of 1 mm to 7 mm, preferably 2 mm to 5 mm, more preferably up to 3 mm thick. Method according to one of the preceding claims, characterized in that the cuboid insulation strips (22) have a length (L) of up to 1.5 m, preferably from 15 cm to 1.5 m, more preferably from 30 cm to 1.5 m , particularly more preferably from 50 cm to 1.5 m. Method according to one of the preceding claims, characterized in that the cuboid insulation strips (22) have a thickness (D) of up to 30 cm in the direction perpendicular to the wall (12), preferably from 1 cm to 30 cm, more preferably from 5 cm to 30 cm, particularly more preferably from 8 cm to 20 cm. Method according to one of the preceding claims, characterized in that the cuboid insulation strips (22) are made from a material containing PS and/or PUR and/or foam glass, for example from a PU airgel or from an EPS material, in particular an EPS containing pyrolysis oil. material or made of NEOPOR. Method according to one of the preceding claims, characterized in that the cuboid insulation strips (22) have a µ value of at least 20 in the direction perpendicular to the wall (12). Method according to one of the preceding claims, characterized in that the cuboid insulation strips (22) have an S _D value of at least 0.2 m, preferably at least 1 m, more preferably at least 1.6 m in the direction perpendicular to the wall (12). . Method according to one of the preceding claims, characterized in that the adhesive layers (32, 34) consist of the same material or different materials. Method according to one of the preceding claims, characterized in that the adhesive layers (32, 34) each consist of a mortar, the mortar being based on clay and/or mineral binders such as cement, gypsum, alumina cement, silicate or phosphate and/or resins such as natural resins , 2-component resins, especially epoxy resins, PMMA or PU or dispersion resins such as acrylate or styrene-butadiene based. Method according to one of the preceding claims, characterized in that the insulation (20) has a thermal conductivity level WLS of up to 040, preferably up to 035, more preferably up to 032, particularly more preferably from 016 to 032. Method for the energetic renovation of a building wall from the inside, wherein in a first step the building wall is freed from wallpaper, old paint and the like and in a second step a wall structure (10) with the building wall and the inside insulation (20) according to the method according to one of the preceding claims is produced.

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