EP4675056A1

EP4675056A1 - Insulating panel for construction industry

Info

Publication number: EP4675056A1
Application number: EP25186394.0A
Authority: EP
Inventors: Nicola Busatta; Emilio MAZZER; Federico Cais
Original assignee: Tema Tech and Materials Srl; Tema Technologies and Materials SRL
Current assignee: Tema Tech and Materials Srl; Tema Technologies and Materials SRL
Priority date: 2024-07-01
Filing date: 2025-06-30
Publication date: 2026-01-07

Abstract

The present finding refers to an insulating panel (1) for construction industry, comprising:
- a first studded membrane (2), impermeable to water and vapour, comprising a first flat plate (3) from a first face (3a) of which a plurality of first studs (4), hollow, protrudes, the interior of which is accessible through respective first openings (5) present on a second face (3b) of the first flat plate (3), opposite to the first face (3a);
- a second studded membrane (6), impermeable to water and vapour, comprising a second flat plate (7) from a third face (7a) of which a plurality of second studs (8), hollow, protrudes, the interior of which is accessible through respective second openings (9) present on a fourth face (7b) of the second flat plate (7), opposite to the third face (7a);
wherein first free ends (4a) of the first studs (4) and of the first studded membrane (2) face second free ends (8a) of the second studs (8) of the second studded membrane (6), and the first openings (5) of the studded membrane (2) and the second openings (9) of the second studded membrane (6) are in fluid communication with the outside of the panel (1).

Description

The present finding refers to an insulating panel for construction industry.
In particular, the finding refers to a panel with thermal, acoustic, and moisture insulation properties, typically used for making floors and partitions of building structures, such as for example for making floors or partitions of bathrooms, showers, saunas, and decorative elements (e.g., niches) inside such environments.
Insulating panels for construction industry are known, which are typically positioned on top of the screed of a floor or fixed by screws or nails to aluminium or wood battens, and then covered with a walkable and/or finishing surface, such as for example a layer of tiles, with the interposition, between the panel and the walkable and/or finishing surface, and, in the case of positioning on screed, also between the screed and the panel, of a cement glue or cement, in order to firmly constrain such components to each other.
For example, insulating panels for construction industry are known, which comprise an internal insulating layer, made of extruded polystyrene (XPS), typically having a thickness of a few centimetres, to whose two larger faces are respectively fixed two covering layers, each comprising a first layer of high-density polyethylene (HDPE), fixed to the internal insulating layer, and a non-woven fabric layer, facing the side opposite to the internal insulating layer.
The high-density polyethylene layers reinforce the internal insulating layer, which, being made of extruded polystyrene, has a relatively low flexural strength; the non-woven fabric layers promote the fixing of the panel to the cement or cement glue. Other known solutions provide the presence of further layers between the internal insulating layer and the non-woven fabric layers.
Although such known solutions have various advantages, they however have room for improvement.
Indeed, the cost of such known-type panels is typically relatively high, in particular due to the high cost of extruded polystyrene (XPS).
Furthermore, such known-type panels are relatively heavy, which makes their transport and installation relatively difficult.
The main task of the present finding is therefore to overcome the above-mentioned drawbacks, and in particular to obtain an insulating panel for construction industry which has, at least once operated, mechanical and insulation features comparable to the known panels described above, while having lower production costs.
In the scope of such task, an object of the present finding is to obtain an insulating panel for construction industry which has, at least once operated, mechanical and insulation features comparable to the known panels described above, while having a lower specific weight.
The task and object according to the present finding are achieved by an insulating panel for construction industry, as in claim 1.
The task and object according to the present finding are also achieved by a method for making floors or partitions of building structures by using a panel according to the finding, comprising the following steps:

a) in order to fix such panel to a screed or a wall of a building, penetrating cement glue or cement into the first openings or the second openings, orienting them towards such screed or wall, until respectively filling the first studs or the second studs with such cement glue or cement;
b) solidifying the cement glue or cement inside the first studs or the second studs until fixing the panel, respectively, to the screed or the wall;
c) penetrating cement glue or cement into those among the first openings and second openings which do not face the screed or the wall;
d) fixing a walkable and/or decorative surface to the panel, by the cement glue or cement penetrated into the second openings which do not face the screed or the wall.

The task and object according to the present finding are also achieved by a floor or partition of a building comprising a screed or a wall to which a panel according to the finding is fixed,

wherein the fixing of the panel to the screed or wall is obtained by the action of cement glue or cement penetrated and solidified respectively in those among the first openings or second openings facing the screed or wall,
wherein the panel is fixed to a walkable and/or decorative surface, on the side opposite to the screed or wall, by cement glue or cement penetrated and solidified respectively in those among the first openings or second openings facing the side opposite to the screed or wall.

The task and object according to the present finding are also achieved by a method for making partitions of building structures by using a panel according to the finding, comprising the following steps:

a1) mechanically fixing (e.g., by nails) the panel to a plurality of metal and/or wood battens, previously fixed to a wall of a building, orienting the first openings towards the battens;
b1) penetrating cement glue or cement into the second openings, which are facing the side opposite to the battens, until filling the second studs with the cement glue or cement;
d1) fixing a walkable and/or decorative surface to the panel, by the cement glue or cement penetrated into the second openings.

The task and object according to the present finding are also achieved by a partition of a building comprising a wall to which a panel according to the finding is fixed,

wherein the fixing of such panel to the wall is obtained by mechanically fixing (e.g., by nails) the panel to a plurality of metal and/or wood battens, previously fixed to the wall, orienting the first openings towards the battens,
wherein the panel is fixed to a decorative surface, on the side opposite to the battens, by cement glue or cement penetrated and solidified into the second openings facing the side opposite to the battens.

Other advantageous features of the finding are indicated in the dependent claims.
The features and advantages of the present finding will become more apparent from the following exemplary and non-limiting description, referred to the attached schematic drawings in which:

Figure 1 is a schematic side view of a first advantageous embodiment of a panel according to the finding;
Figure 2 is a schematic top view of the panel of Figure 1;
Figure 3 is a schematic bottom view of the panel of Figure 1;
Figure 4 is an exploded schematic side view of the panel of Figure 1;
Figure 5 is a schematic side view of a second advantageous embodiment of a panel according to the finding;
Figure 6 is a schematic side view of a third advantageous embodiment of a panel according to the finding;
Figure 7 is a schematic side view of a fourth advantageous embodiment of a panel according to the finding;
Figure 8 is a schematic plan view of the panel of Figure 7.

With reference to the attached figures, number 1 overall indicates an insulating panel for construction industry according to the finding.
According to the finding, the panel 1 comprises a first studded membrane 2, impermeable to water and vapour, comprising in turn a first flat plate 3, from a first face 3a of which a plurality of first studs 4, hollow, protrudes, the interior of which is accessible through respective first openings 5 present on a second face 3b of the first flat plate 3, opposite to the first face 3a.
Advantageously, the first studded membrane 2 is made of polyethylene, polypropylene, or mixtures of such materials.
Advantageously, the first studs 4 have a truncated-conical shape; other shapes, for example truncated-pyramidal or cylindrical, are however contemplated in the finding.
Advantageously, the height of such first studs 4 is between 2 mm and 25 mm.
Advantageously, the thickness of the first flat plate 3 is between 0.3 mm and 1.5 mm.
Advantageously, the overall thickness (first studs 4 plus first flat plate 3) of the first studded membrane 2 is between 2.3 mm and 26.5 mm.
Preferably, the first openings 5 overall affect between 25% and 65% of the area of the first flat plate 3, more preferably between 40% and 50% of the area of the first flat plate 3.
Advantageously, the first studs 4 are present in a number between 400 and 25,000 studs per m² of membrane. According to the finding, the panel 1 comprises a second studded membrane 6, impermeable to water and vapour, comprising a second flat plate 7, from a third face 7a of which a plurality of second studs 8, hollow, protrudes, the interior of which is accessible through respective second openings 9 present on a fourth face 7b of the second flat plate 7, opposite to the third face 7a.
Advantageously, the second studded membrane 6 is made of polyethylene, polypropylene, or mixtures of such materials.
Advantageously, the second studs 8 have a truncated-conical shape; other shapes, for example truncated-pyramidal or cylindrical, are however contemplated in the finding.
Advantageously, the height of such second studs 8 is between 2 mm and 25 mm
Advantageously, the thickness of the second flat plate 7 is between 0.3 mm and 1.5 mm.
Advantageously, the overall thickness (second studs 8 plus second flat plate 6) of the second studded membrane 6 is between 2.3 mm and 26.5 mm.
Preferably, the second openings 9 overall affect between 25% and 65% of the area of the second flat plate 6, more preferably between 40% and 50% of the first flat plate 6.
Advantageously, the second studs 8 are present in a number between 400 and 25,000 studs per m² of membrane. According to the finding, first free ends 4a of the first studs 4 of the first studded membrane 2 face second free ends 8a of the second studs 8 of the second studded membrane 6.
It is emphasized that the expression "facing" does not imply that such first free ends 4a and second free ends 8a directly face each other, without any further element of the panel 1 being therebetween; indeed, as will be better explained below, the finding contemplates both versions of the panel 1 in which the first free ends 4a are fixed directly to the second free ends 8a, possibly with the interposition of an adhesive layer, and versions in which one or more further layers of the panel 1, distinct from both the first studded membrane 2 and the second studded membrane 6, are interposed between the first free ends 4a and the second free ends 8a.
In other words, stating that the first free ends 4a and the second free ends 8a face each other means that they face the inside of the panel 1.
It is emphasized that the air layer between the first studs 4 and between the second studs 8, inside the panel 1, forms a barrier against the passage of heat, contributing to enhance of the thermal insulation properties of the panel 1.
Furthermore, according to the finding, the first openings 5 of the first studded membrane 4 and the second openings 9 of the second studded membrane 6 are in fluid communication with the outside of the panel 1 or, in other words, they are not completely closed by other layers of the panel 1; in this way, when placing the panel 1, the cement glue or cement used to fix the panel 1, for example, between the screed of a building, not illustrated, and a walkable surface (e.g., a layer of tiles, also not illustrated), or to fix the panel 1, for example, to a finishing surface (e.g., a layer of tiles) in the case of using the panel 1 to make a partition or a decorative element (e.g., a niche) of a building, not illustrated, penetrates the first openings 5 and/or the second openings 9 (depending on whether the cement glue or cement is applied to one or both faces of the panel 1) and respectively fills the first studs 4 and/or the second studs 8, depending on whether the cement glue or cement is applied to one or both faces of the panel 1).
Once solidified inside the respective first studs 4 and/or second studs 8, the cement glue or cement makes the structure of the panel 1 particularly resistant to flexure, thereby reducing, for example, the risk that the panel 1 deforms under the weight of the walkable and/or decorative surface and of the bodies that can be positioned thereon.
In first advantageous embodiments, such as for example that illustrated in Figure 1, the first free ends 4a of the first studs 4 are fixed directly to the second free ends 8a of the second studs 8; it is emphasized that the expression "fixed directly" does not exclude the presence of a glue or adhesive layer between such first free ends 4a and second free ends 8a.
Advantageously, the first free ends 4a of the first studs 4 are fixed directly to the second free ends 8a, for example by gluing or welding.
In other advantageous embodiments, such as for example that illustrated in Figure 5, the panel 1 comprises one or more laminar layers 10 interposed between the first free ends 4a of the first studs 4 and the second free ends 8a of the second studs 8.
In advantageous embodiments, the one or more laminar layers can comprise, for example, a non-woven polypropylene fabric and/or a glass fiber mesh.
It is emphasized that the expression "laminar layers" means layers shaped as a sheet or thin membrane, or in which the thickness is lower than 1 mm.
In other advantageous embodiments, such as for example those illustrated in Figures 6 to 8, the panel 1 comprises one or more layers of expanded or extruded polymeric material 11 interposed between the first free ends 4a of the first studs 4 and the second free ends 8a of the second studs 8.
Preferably, the layer of expanded or extruded polymeric material 11 is made of expanded polystyrene (EPS), or extruded polystyrene (XPS), or foamed expanded polyethylene (EPE).
Advantageously, the thickness of the layer of expanded or extruded polymeric material 11 is between 6 mm and 50 mm.
In other advantageous embodiments, not illustrated, the panel 1 comprises, between the first free ends 4a of the first studs 4 and the second free ends 8a of the second studs 8, both one or more layers of expanded or extruded polymeric material 11 and one or more laminar layers 10.
In further advantageous embodiments, such as for example that illustrated in Figures 7 and 8, the panel 1 comprises a first layer of mesh 12 fixed to the second face 3b of the first studded membrane 2 in such a way to leave the first openings 5 in fluid communication with the outside of the panel 1. Advantageously, such first mesh 12 is made of polyethylene, polypropylene, or glass fiber. Advantageously, the first mesh 12 has a thickness lower than 1.5 mm.
Advantageously, the first mesh 12 is fixed to the second face 3b by gluing or welding.
Such first mesh 12 increases the flexural strength of the panel 1 without reducing the fixing toughness of the panel 1 to the cement glue or cement used to fix the panel 1 to a walkable and/or finishing surface and, in the case of positioning on screed, also to the screed.
In further advantageous embodiments, such as for example that illustrated in Figures 7 and 8, the panel 1 comprises a second layer of mesh 13 fixed to the fourth face 7b of the second studded membrane 6, in such a way to leave the second openings 9 in fluid communication with the outside of the panel 1. Advantageously, the second mesh 13 has a thickness lower than 1.5 mm.
Advantageously, the second mesh 13 is fixed to the fourth face 7b by gluing or welding.
Such second mesh 13 increases the flexural strength of the panel 1 without reducing the fixing toughness of the panel 1 to the cement glue or cement used to fix the panel 1 to a walkable and/or finishing surface and, in the case of positioning on screed, also to the screed.
It has thus been found that the finding solves the above-stated task and objects, since, due to the presence of the first and second studs (respectively of the first and second studded membranes, made of a material impermeable to water and vapour), whose respective first and second free ends face each other, and then facing the inside of the panel, air layers which obstruct the passage of heat are created inside the panel; in this way, it is possible to obtain a panel with a high degree of thermal insulation even without necessarily using a layer of expanded polymeric material, or at least using a layer of expanded polymeric material with lower thickness and therefore lower cost, compared to the known solutions described above.
The overall cost of the panel according to the finding, for the same thermal and moisture insulation, is therefore lower than the known solutions described above.
In this respect, the Applicant has carried out comparative tests between an advantageous exemplary embodiment of a panel according to the finding and panels in the prior art.
In particular, the following samples were compared.

Sample 1 (prior art)

A panel consisting solely of extruded polystyrene (XPS) with a density equal to 30 kg/m³ and an overall thickness equal to 12.7 mm

Sample 2 (prior art)

A panel with an overall thickness equal to 12.7 mm, having the following layer structure:

external non-woven fabric layer with a thickness equal to 0.4 mm;
300 g/m² polyethylene layer with a thickness equal to 0.35 mm;
extruded polystyrene (XPS) layer with a density equal to 30 kg/m³ and a thickness equal to 11.2 mm;
polyethylene layer with a density equal to 300 g/m² and a thickness equal to 0.35 mm;
external non-woven fabric layer with a thickness equal to 0.4 mm.

Sample 3 (prior art)

external non-woven fabric layer with a thickness equal to 0.35 mm;
polyethylene layer with a thickness equal to 0.1 mm;
paper layer with a thickness equal to 0.25 mm;
extruded polystyrene (XPS) layer with a density equal to 30 kg/m³ and a thickness equal to 11.4 mm;
paper layer with a thickness equal to 0.25 mm;
polyethylene layer, with a thickness equal to 0.1 mm;
external non-woven fabric layer with a thickness equal to 0.35 mm.

Sample 4 (example of a panel according to the finding)

studded membrane made of high-density polyethylene, with a number of studs equal to 2500 per square meter and a thickness equal to 3 mm;
extruded polystyrene (XPS) layer, with a thickness equal to 6.7 mm;
studded membrane made of high-density polyethylene, with a number of studs equal to 2500 per square meter and a thickness equal to 3 mm.

Such samples were subjected to a measure, performed according to the UNI EN ISO 12667 reference standard, of thermal conductivity at 20°C and thermal resistance "R", using a heat flow meter of the LaserComp 300 type. Such measures have detected the following:

Sample 1 (prior art):
- Thermal conductivity at 20°C: 0.030 W/mK
- Thermal resistance R: 0.42 m²K/W
Sample 2 (prior art):
- Thermal conductivity at 20°C: 0.034 W/mK
- Thermal resistance R: 0.37 m²K/W
Sample 3 (prior art):
- Thermal conductivity at 20°C: 0.035 W/mK
- Thermal resistance R: 0.36 m²K/W
Sample 4 (example of panel according to the finding):
- Thermal conductivity at 20°C: 0.034 W/mK
- Thermal resistance R: 0.37 m²K/W

Such comparative tests have shown that the example panel made according to the finding has thermal insulation features (represented by its thermal conductivity at 20°C and its thermal resistance, measured according to the UNI EN ISO 12667 standard) comparable to those of the known panels, despite using a significantly lower thickness of extruded polystyrene, and thus having a lower cost.
Furthermore, due to the fact that the first and second access openings are in fluid communication with the outside of the panel, when placing the same, the cement glue or cement used to fix the panel penetrates such first and/or second openings and respectively fills the first and/or second studs (depending on whether the cement glue or cement is applied to one or both faces of the panel); once solidified inside the respective first and/or second studs, the cement glue or cement makes the structure of the panel, once operated, particularly resistant to flexure. Due to the presence of solidified cement glue or cement inside the first and/or second studs, the mechanical features, in particular the flexural strength, of the panel, once operated, are therefore comparable to, or even higher than, the known panels described above (in which flexural resistance is not affected by the presence of cement glue or cement, but solely related to the type of materials used), while the panel itself, due to the presence of the hollow studs, has a lower specific weight (and therefore is easier to transport and place) compared to such known panels.
Finally, it is clear that the panel according to the finding is susceptible to numerous modifications and variants, all falling within the finding; furthermore, all details are replaceable by technically equivalent elements. In practice, the materials used, as well as the dimensions, can be any depending on the technical requirements.

Claims

Insulating panel (1) for construction industry, comprising:
- a first studded membrane (2), impermeable to water and vapour, comprising a first flat plate (3) from a first face (3a) of which a plurality of first studs (4), hollow, protrudes, the interior of which is accessible through respective first openings (5) present on a second face (3b) of said first flat plate (3), opposite to said first face (3a);

- a second studded membrane (6), impermeable to water and vapour, comprising a second flat plate (7) from a third face of which (7a) a plurality of second studs (8), hollow, protrudes, the interior of which is accessible through respective second openings (9) present on a fourth face (7b) of said second flat plate (7), opposite to said third face (7a);
characterized by the fact that
first free ends (4a) of said first studs (4) of said first studded membrane (2) are facing towards second free ends (8a) of said second studs (8) of said second studded membrane (6)
and that

said first openings (5) of said first studded membrane (4) and said second openings (9) of said second studded membrane (6) are in fluid communication with the outside of said panel (1).
Panel (1), as in claim 1, wherein said first studded membrane (2) is made of polyethylene, polypropylene, or a mixture of such materials.
Panel (1), as in a previous claim, wherein said second studded membrane (6) is made of polyethylene, polypropylene, or a mixture of such materials.
Panel (1), as in a previous claim, wherein said first free ends (4a) of said first studs (4) are fixed directly to said second free ends (8a) of said second studs (8).
Panel (1), as in claims 1 to 3, comprising one or more laminar layers (10) interposed between said first free ends (4a) of said first studs (4) and said second free ends (8a) of said second studs (8).
Panel (1), as in claim 5, wherein said one or more laminar layers (10) comprise a non-woven polypropylene fabric and/or a glass fiber mesh.
Panel (1), as in claim 1 or 3, or in claim 5 or 6, comprising one or more layers of expanded or extruded polymeric material (11) interposed between said first free ends (4a) of said first studs (4) and said second free ends (8a) of said second studs (8).
Panel (1), as in claim 7, wherein said layer of expanded or extruded polymeric material (11) is made of expanded polystyrene (EPS) or extruded polystyrene (XPS).
Panel (1), as in a previous claim, comprising a first layer of mesh (12) fixed to said second face (3b) of said first studded membrane (2) in such a way to leave said first openings (5) in fluid communication with the outside of said panel (1).
Panel (1), as in a previous claim, comprising a second layer of mesh (13) fixed to said fourth face (7b) of said second studded membrane (6) in such a way to leave said second openings (9) in fluid communication with the outside of said panel (1).
Method for making floors or partitions of building structures by using a panel (1) as in one or more of the preceding claims, characterized by comprising the following steps:
a) in order to fix said panel (1) to a screed or a wall of a building, penetrating cement glue or cement into said first openings (5) or into said second openings (9), orienting them towards said screed or wall, until respectively filling said first studs (4) or second studs (8) with said cement glue or cement;

b) solidifying said cement glue or cement inside said first studs (4) or second studs (8) until fixing said panel (1), respectively, to said screed or wall;

c) penetrating cement glue or cement into those among said first openings (5) and said second openings (9) which do not face said screed or wall;

d) fixing a walkable and/or decorative surface to said panel (1) by said cement glue or cement penetrated into said second openings (9) which do not face said screed or wall.
Floor or partition of a building characterized in that it comprises a screed or a wall to which a panel (1) as in one or more of the preceding claims is fixed, wherein the fixing of said panel (1) to said screed or to said wall is obtained by the action of cement glue or cement penetrated and solidified respectively in those among said first openings (5) or second openings (9) facing said screed or said wall,
wherein said panel (1) is fixed to a walkable and/or decorative surface, on the side opposite to said screed or wall, by cement glue or cement penetrated and solidified respectively in those among said first openings (5) or second openings (9) facing the side opposite to said screed or said wall.
Method for making partitions of building structures by using a panel (1) as in one or more of the preceding claims, characterized by comprising the following steps:
a1) mechanically fixing said panel (1) to a plurality of metal and/or wood battens, previously fixed to a wall of a building, orienting said first openings (5) towards said battens;

b1) penetrating cement glue or cement into said second openings (9), which are facing the side opposite to said battens, until filling said second studs (8) with said cement glue or cement;

d1) fixing a walkable and/or decorative surface to said panel (1) by said cement glue or cement penetrated into said second openings (9).
Partition of a building characterized in that it comprises a wall to which a panel (1) as in one or more of the preceding claims is fixed,
wherein the fixing of said panel (1) to said wall is obtained by mechanically fixing said panel (1) to a plurality of metal and/or wood battens, previously fixed to said wall, orienting said first openings (5) towards said battens,

wherein said panel (1) is fixed to a decorative surface, on the side opposite to said battens, by cement glue or cement penetrated and solidified in said second openings (9) facing the side opposite to said battens.