FR2884589A1 - Supple roof insulating material has under-surface reflective layer connected to inner mattress by joining zones with holes filled with permeable fibers - Google Patents

Abstract

The insulating material (I), comprising an upper breathing reflective layer (I1), an intermediate fibre mattress (I2) that is permeable to water vapour and a reflective and breathing under-layer (I3), has the latter connected to the mattress by joining zones (6) with holes (7, 8) that have groups of mattress fibers (9) passing through them. The fibers, which can be of hydrophobic, hydrophilic or metallized polymer, prevent air from passing through the holes but do not prevent the passage of water vapours. They are inserted through the holes by barbed felting needles.

Description

thermal performance improvement provided that it remains

  relatively immobile, is set in motion because of the multitude of holes made in the inner facing, including a needling operation.

  The purpose of the invention is, above all, to significantly improve the contribution of the air knife included in the interlayer fiber mat in the insulation performance of this thin insulation, while simplifying the assembly of the inner facing and the mattress. The invention also aims to facilitate the placement of the insulation on an inclined support, under-roofing.

  According to the invention, the flexible thermal insulation, thin and reflective, in the form of sheet or sheet, comprising at least three elements constituted by a reflective outer coating breathable, an interlayer of fibers open to the passage of steam water, and a non-watertight breathable reflective interior facing, is characterized in that the reflective inner facing is secured to the interlayer by connecting areas which comprise, in the facing, holes traversed by groups of fibers of the interleaved mattress protruding outside, and which form a kind of down. In doing so, the fibers entrained through the perforation constitute a source of pressure drop when the air moves from one of the faces of the inner facing towards the other, while not preventing the diffusion of the water vapour.

  The bonding areas occupy between 10% and 80% of the surface of the thin reflective insulation. The inner facing is mechanically attached to the mattress by the fibers passing through the holes and tightened in the latter. The penetrations of air from an air space under the thin insulation in the mattress are slowed down, especially because of the proportion of fibers passing through the holes.

  The inner facing is pierced with holes distributed over most of its surface. The bonding areas comprise all the holes. The connecting zones can be divided into densely densified zones into exceeding fibers and into weakly densified zones into such fibers.

  The inner face may be pierced by needling holes creating connection areas obtained using pin needles adapted to cause fibers interlayer mattress.

  The fibers of the interlayer mat may be hydrophobic, or hydrophilic to promote the passage of water vapor.

  On the outer face of the inner facing a multitude of fibers appear which form a superficial down. This superficial down is useful because the protruding fibers can cling to the lumber on which this thin insulation is unwound, thus avoiding slippage, especially if the slope is important.

  However, the superficial down of fibers protruding from the reflective interior facing can alter the emissivity properties. To reduce this undesirable effect, the fibers of the interlayer are advantageously metallized, for example composed of compounds (compounds) of metallized polymer or of a polymer chosen from materials having a very high gloss (extremely flat surface condition) or a polymer formulated so as to be very reflective in essence.

  The fibers of the interlayer mat can be hollow to improve the thermal insulation properties.

  Preferably, the thermal insulation is in the form of a web with interlayer whose longitudinal edges are set back from the longitudinal edges of the outer and inner faces, which are joined by gluing or welding, and a longitudinal strip without holes is provided along the longitudinal edges, the width of this band being at least equal to the width of overlapping successive les, to avoid capillary rise by holes.

  The invention also relates to a method of manufacturing a thermal insulation, as defined above, according to which the assembly of the inner facing is carried out firstly with the interlayer of fibers, and then it is put in place, in particular by gluing, the outer face on the mattress, this method being characterized in that the assembly of the inner facing to the interlayer mat is made by needling with needles comprising in the lower part hooks shaped pins which, when they pass through the mattress interlayer, drive the fibers beyond the face of the inner facing opposite to the direction of piercing.

  The assembly method may be provided such that highly densified bonding areas having a high number of protruding fibers are formed, and weakly densified bonding regions having very few exceeding fibers.

  The highly densified bonding zones are obtained by choosing needles comprising a large number of pins, the weakly densified zones are obtained by choosing needles, with a smaller number of pins.

  Highly densified bonding areas can be linearly, or centrally concentrated, circular or square, or the like, the appearance of which is similar to that achieved by spot welding. These highly densified bonding areas can be obtained by a localized concentration of needles comprising a large number of pins, fixed on a needle board which serves as a support. These needles having a large number of pins can form parallel continuous lines distributed according to an agreed spacing or highly concentrated localized areas of circular, square or any other shape, or o a combination of both. The highly densified bonding zones locally create a reduction in the thickness of the mattress forming localized depressions inducing a fleece effect. This localized thickness reduction can reach up to 70% of the total thickness.

  The densely bonded bonding areas serve to secure the lower facing to the intermediate batt to impart the mechanical tensile strength perpendicular to the facings of the thin insulation; the weakly densified zones of connection are mainly intended to distribute the points of passage of the water vapor and, because of the small number of fibers exceeding, to limit the density of the down exceeding and to increase the reduction of the value of emissivity Insulating Lower Siding The reinforced plastic films used in the manufacture of the inner cladding of the insulation are generally composed of common plastics such as polyester, polyethylene, polypropylene, or any other polymer having similar properties.

  The inner reflective facing of the insulation may consist of a reflective metal sheet associated by bonding to a plastic film, in particular a multilayer, as defined above, but not comprising a metallized film. Before piercing holes, this inner facing is a waterproof barrier to water vapor and water.

  The interleaved fiber mat may consist of: synthetic fibers having a hydrophobic treatment, in particular bound together by any appropriate means to form a three-dimensional network, or hydrophilic fibers, facilitating the passage of water vapor, - or metallized synthetic fibers or having a very high gloss, or natural fibers such as glass wool or rock or fibers of vegetable or animal origins.

  The interlayer mat may have a thickness of between 5 mm and 20 mm, the weight per unit area being between 100 and 1000 g / m2. The flexible, thin and reflective thermal insulation has a coefficient of thermal conductivity equal to or less than 0.04. W / mK (watt per meter.degree Kelvin).

  The holes created by the passage of the needles, distributed over the entire surface of the sheet of waterproof material used to make the facing inside, have a diameter of between 0.01 mm and 1 mm, depending on the type of needle used; the needles having a small number of lugs having the smallest diameter, the number of holes thus varying between 20,000 to 150,000 holes per square meter depending on the distribution chosen for the densification of the bonding areas. The inner facing has, due to these openings, a permeance value at least equal to or greater than that of the outer facing.

  Whatever the method of manufacture, the thin insulation may comprise an adhesive tape incorporated at the surface, positioned in the overlap area of the strips, on one of the longitudinal edges, and protected by a film, in particular paper or film, peelable that will be removed when installing insulation strips.

  The invention consists, apart from the arrangements set out above, in a certain number of other arrangements which will be more explicitly discussed hereinafter with regard to particular embodiments described with reference to the accompanying drawings, but which do not are in no way limiting. In these drawings: FIG. 1 is a diagrammatic view in partial vertical section of a roof with a sheet of thin reflective insulation according to the invention.

  2 is a vertical section on a larger scale of a portion 30 of reflective thermal insulation according to the invention, FIG. 3 is a vertical section on a larger scale of a portion of interlayer mat assembled on the inner facing of the insulator according to the invention.

  Fig. 4 is a partial elevational view, on a large scale, of two needle pins of a different type.

  Fig.5 is a schematic bottom view of an inner facing pierced in a linear arrangement of the holes.

  Fig.6 is a schematic bottom view of an inner facing pierced in an arrangement of holes grouped into squares or circles.

  Fig. 7 is a vertical elevation diagram illustrating an overlap of insulating strips.

  FIG. 8 is a partial vertical section, on a larger scale, of the longitudinal edges of an insulation strip.

  Fig.9 is a schematic view from below with respect to Fig.8, and Fig.10 is a cross section of pin needle.

  Referring to Fig.1 there can be seen a roof T with sloping rafters C on which are stretched strips 1 of a thin thermal insulation and reflective and breathable, in the form of sheet. The strips overlap for example on their edges parallel to the direction of implementation, orthogonal to the line of greatest slope of the roof. Alternatively, the strips can be oriented with their large dimension parallel to the line of greater slope and the overlapping edges are then parallel to this line.

  Counter battens d, placed above the insulator I along the rafters C, are used for nailing the insulator I to the rafters. Strips j, orthogonal to the line of greater slope, are fixed parallel to each other on the counter-slats d and allow the attachment of the roof elements 2, for example tiles or slates.

  A blade A ventilation air is thus formed between the upper face of the insulator I and the roof. The height h (FIG. 1) of this air gap A corresponds to the height of the counter-batt d. The air gap A opens in the lower part above the gutter G and in the upper part communicates with the outside atmosphere.

  A layer of thermal insulation 3, for example a layer of glass wool, is fixed below the insulator I, at a distance, so that another non-ventilated air space B is provided below the underside. of the screen I. Regardless of the method of manufacture, the thin insulation may comprise an adhesive strip 4 (FIG. 2) incorporated on the surface, positioned in the overlapping zone of the strips, on one of the longitudinal edges, and protected by a film 5, in particular paper or film, peelable which will be removed during the installation of insulation strips.

  The insulator I (FIG. 2) comprises three elements consisting of an outer skin 11 and a breathable reflective inner lining, separated by an interlayer of fibers 12, open to the passage of water vapor.

  Thin insulation I is continuous ridge and, at its lateral ends, is folded vertically against the layer 3 of insulation, without space capable of forming a blade between the two vertical parts. The air knife B is inert, since it is closed at the top and at the bottom. It contributes to thermal insulation.

  Water vapor from the interior of the building can pass through the vapor permeable insulator I, so that there is no harmful condensation in the form of droplets of water falling on the insulation 3.

  The outer face 11 of the thermal insulation may consist of at least one waterproof sheet L with a high water vapor permeability characterized by a permeance value of between 1.10-8 and 1.10-9. kg / m2.s.Pa is an equivalent air height defined by the value Sd expressed in meters between 1.10 "2 m and 20. 10" 2 m.

  The sheet L, the thickness of which is between 100 μm and 300 μm, and the basis weight between 50 g / m 2 and 120 g / m 2, can be obtained from polyethylene-based synthetic fibers, or any other synthetic material. having similar properties.

  According to the invention, the reflective interior facing 13 is secured to the interlayer 12 by densely densified bonding areas 6 (Fig.2, 3), 6a (Fig.6) 6b (Fig.6) and weakly densified areas 7 The bonding zones comprise, in the facing, holes 8 traversed by more or less dense groups of fibers 9 of the mattress 12 projecting outwards. The fibers 9 protruding are clamped by the edge of the through hole. This results in a mechanical connection between the facing 13 and the mattress 12 and a brake on the penetration of the air inside the mattress. The weakly densified zones 7 are distributed over most of the surface of the facing 13. highly densified bonding lines 6, 6a, 6b occupy between 10% and 20% of the surface of the thin reflective insulation, The assembly of the interlayer is advantageously made by needling with needles 10 or 10a (FIG. lower part a plurality of hooks in the form of lugs 11, facing downwards. The needles 10a have a number of lugs 11 greater than that of the needles 10, distributed along the length, to cause more fibers. The needles 10a are used for densely densified areas, the needles 10 for weakly densified areas The mattress 12 is placed on the inner facing 13 and the needles 10 or 10a, fixed on a board not shown, are pressed from top to bottom to through the mattress 12 and the facing 13 to create the holes 8. During their passage through the interlayer 12, the needles 10, 10a cause the fibers 9 beyond the face of the inner facing 12 opposite to the direction of drilling. During their vertical ascent, the needles do not carry the fibers 9 because of the orientation of the lugs 11.

  The mechanism of a needling machine (not shown) causes the needle board to reciprocate from top to bottom and from bottom to top; when the board is in the up position a lateral movement advances the reflective facing and the mattress for a new operation.

  Other needling machines are equipped with separate needling and advancement mechanisms which do not require synchronization. In this way and according to the speed of advance chosen the number of needle strokes and therefore the number of holes vary.

  The dimensions of the needle board are such that its length corresponds to the width of the reflective facing 13 and the interlayer 12; the width of the board may correspond to the pitch of the lateral movement when it is synchronized with the advancement of the band to needling.

  In a first operational mode, the selected needles having a small number of hooks are distributed uniformly over the entire surface of the needle board without creating densified areas.

  According to a second operational mode, the needles used are such that highly densified connecting zones 6 are created comprising a large number of fibers 9 protruding and 7 more weakly densified connecting zones obtained with needles having a smaller number of hooks.

  According to a third operational mode the needles used are chosen so that highly densified or weakly densified bonding zones are created and non-bonded zones obtained with smooth needles without pins. This case reduces the inertia of the air gap of the mattress.

  The highly densified bonding zones can be obtained by a localized concentration of needles comprising a large number of hooks which, according to their arrangement on the needle board, can form, for example, parallel continuous lines (see FIG. localized highly concentrated circular shape 6a (Fig.6), square 6b (Fig.6) or any other shape whose appearance is similar to that obtained by a spot weld.

  These localized bonding areas may have a diameter of about 10 to 20 mm and be distributed staggered or evenly over the entire surface.

  The highly densified bonding zones may also be a combination of the two modes described above, that is to say comprise linear zones interspersed with localized zones; this combination makes it possible to better distribute the connections in order to respond to the mechanical stresses of the insulation when it is used on the framework.

  The assembly process shows on the outer face of the inner facing a multitude of fibers 9 protruding which form a surface down covering the facing 13. This superficial down, whose thickness can be between 1 mm and 2 mm is useful because the protruding fibers 9 can cling to the lumber on which the thin insulation is unwound, thus avoiding sliding, especially if the slope of the cover is important, and facilitating the establishment.

  The fibers 9 of the interlayer mat may be hydrophobic, or hydrophilic to promote the passage of water vapor.

  The fibers of the interlayer are advantageously metallized, for example consisting of compounds (compounds) of metallized polymer, to avoid altering the emissivity properties of the inner facing.

  Advantageously, the fibers used for the mattress 12 are synthetic and made from a polymer containing fine reflective metal particles, such as for example aluminum, so that during the extrusion of this specially formulated compound the walls of these fibers are reflective. Their reflectivity is at least 90% preferably 98% of the incident energy, for temperatures between 20 C and 80 C, lying essentially in the field of infrared wavelengths; the average hemispherical emissivity C of such fibers is generally 0.1, but preferably less than 0.02, measured in the wavelength band between 3 μm and 25 μm for a temperature of between 20 ° C. and 60 ° C.

  The fibers of the interlayer mat can be hollow to improve the thermal insulation properties.

  Preferably, in a web 1 of thermal insulation (see FIGS. 8 and 9), the longitudinal edges 12a, 12b of the interlayer mat 12 are set back, in particular about 10 to 20mm, from the longitudinal edges of the outer faces and inside, which are joined by gluing or welding along lines 13a, 13b. A longitudinal strip 14a, 14b devoid of holes is provided along the longitudinal edges. The width W of this strip is at least equal to the width Q (FIG. 7) of overlapping successive strips to prevent capillary rise through holes 8.

  The reflective facing 13 may be constituted by a reflective metal sheet which, once pierced with a multitude of holes, allows the passage of water vapor.

  The highly densified bonding zones 6, 6a, 6b locally create a reduction in the thickness of the mattress forming localized depressions (FIGS. 2 and 3) inducing a fleece effect. This reduction in localized thickness o may reach up to 70% of the total thickness of the mattress 12. After placing, in particular by bonding, the outer facing 11 on the mattress 12, the depressions 15 form essentially closed chambers, contributing to thermal insulation.

  During the manufacture of the thin reflective breathable insulation the upper facing of the insulation covers the entire surface of the intermediate layer. This facing is subject to the intermediate layer by gluing or welding or any other equivalent means in a continuous line that closes the longitudinal edges of the insulation.

  The laterally fixed facing is therefore stretched over the surface of the intermediate layer leaving, in the zones of connection to the right of the localized depressions 15, inert air volumes located opposite the inner face of very low emissivity of the outer facing contributing to to improve in these places the thermal insulation of these blades of air.

  According to the preferred method of manufacture, the needling of the inner facing of the insulation on the intermediate insulating layer is interrupted over a width corresponding to the width of the longitudinal overlap of the strips of this thin reflective breathable insulator; practically this leads to a width of 100 mm. This arrangement avoids the capillary rise in the overlapping area les.

  Insulation I can be used in addition to a thermal insulation in place preserved, being installed from the outside, without creating harmful condensation. In this configuration, the insulation also performs the functions of a flexible underlays screen with high water vapor permeability (HPV screen). The reinforced plastic films used for the manufacture of the interior facing of the insulation are generally compounds of common plastics such as polyester, polyethylene, polypropylene, or any other polymer having similar properties.

  The inner reflective facing 13 may consist of a reflective metal sheet associated by bonding to a plastic film, in particular multilayer as defined above, but not comprising a metallized film. This film, waterproof by itself, becomes permeable after drilling holes 8.

  The interlayer fiber mat 12 may consist of: synthetic fibers having a hydrophobic treatment bonded together by any appropriate means to form a three-dimensional network, or hydrophilic fibers facilitating the passage of water vapor, - or metallized synthetic fibers or having a very high gloss, - or natural fibers such as glass wool or rock or fibers of vegetable or animal origins.

  With hydrophobic fibers, during the eventual superficial condensation of water vapor from the interior volume of the building, the fine droplets of water are trapped by the fibers of this superficial mattress preventing them from falling back inside.

  With hydrophilic fibers, during superficial transient condensation, the fine water droplets are trapped by the protruding fibers which carry them inside the intermediate layer and then are evacuated by the breathable outer skin With metallized fibers, it is avoided alter the emissivity properties of the inner facing.

  The synthetic fibers used for the intermediate insulating layer may be hollowed so as to increase their thermal insulating properties.

  Advantageously, this intermediate mat has a thickness of between 5 mm and 20 mm, the density per unit being between 100 and 1000 g / m 2, the flexible thermal insulation, thin and reflective, has a coefficient of thermal conductivity equal to or less than 0.04 W / mK (watt per meter.degree Kelvin).

  The holes 8 created by the passage of the needles, distributed over the entire surface of the sheet of waterproof material used to make the inner facing, have a diameter of between 0.1 mm and 1 mm; their number is between 20,000 to 150,000 holes per square meter. The inner facing has, due to these openings, a permeance value at least equal to or greater than that of the outer facing.

  Advantageously, the outer cladding I1, 13 have a spectral average hemispheric emissivity generally of 0.4 but preferably less than 0.25, measured in the wavelength band between 3pm and 14pm for a temperature between 20 C and C. The average reflectivity is at least 60% but preferably greater than 75% of the total energy received.

  The facing 13 has a spectral mean hemispheric emissivity e generally of 0.02 measured in the wavelength band between 3pm and 14pm for a temperature of between 20 ° C. and 60 ° C. The average reflectivity is at least 98%. the total energy received.

Claims (1)

13 Claims   1. Flexible, thin and reflective thermal insulation, in the form of a sheet or sheet, mainly for use as a sub-roof, comprising at least three elements consisting of a breathable reflecting outer facing (I1), an interlayer (12) of fibers open to the passage of steam, and a non-watertight breathable reflective inner facing (13) directed towards the interior of the building, characterized in that the reflective interior facing (13) is secured to the interlayer mat (12) by connecting zones (6, 6a, 6b, 7) which comprise in the facing holes (8) traversed by groups of fibers (9) of the interlayer mat projecting to the outside, preventing the air to move in the perforations, but without hindering the diffusion of water vapor, and which form a kind of down.   2. Insulation according to claim 1, characterized in that the inner facing is pierced with holes (8) distributed over its surface, and that the bonding zones comprise densified areas (6,6a, 6b) and weakly densified areas (7). ) in fibers (9) protruding.   3. Insulation according to claim 1 or 2, characterized in that the holes (7) have a diameter of between 0.01 mm and 1 mm, and their number is between 20 000 to 150 000 holes per square meter.   4. Insulation according to one of claims 1 to 3, characterized in that the inner face is pierced with holes (8) by needling, and that the bonding areas were obtained using needles (10,10a ) with pins (11) adapted to cause fibers (9) of the interlayer mat (12).   5. Insulation according to one of claims 1 to 4, characterized in that the fibers (9) of the interlayer mat (12) are hydrophobic.   6. Insulation according to one of claims 1 to 4, characterized in that the fibers (9) of the interlayer mat (12) are hydrophilic.   7. Insulation according to one of the preceding claims, characterized in that the fibers of the interlayer mat (12) are metallized.   8. Insulation according to one of claims 1 to 6, characterized in that the fibers of the interlayer mat (12) are made of polymer selected from very high-gloss materials 9. Insulation according to one of claims 1 to 6, characterized in that the fibers of the interlayer mat (12) are essentially reflective polymer.   10. Insulation according to any one of the preceding claims characterized in that the fibers of the interlayer mat (12) are hollow. to   11. Insulation according to any one of the preceding claims in the form of strips (1) which overlap over a width (Q) during placement on a roof, characterized in that a longitudinal strip (14a, 14b) devoid of holes is provided along the longitudinal edges of the lé, the width (W) of this band being at least equal to the width (Q) of overlapping successive les.   12. A method of manufacturing a thermal insulation according to any one of the preceding claims, wherein is first carried out the assembly of the inner facing (13) to the interlayer mat (12) of fibers, and then is implemented, in particular by bonding, the outer facing (II) on the mattress, characterized in that the assembly of the inner facing (13) to the interlayer mat (12) is made by needling with needles (10, 10a) having in the lower part hooks in the form of lugs (11) which, during their passage in the interlayer, cause the fibers (9) beyond the face of the inner facing opposite the drilling direction.   13. Manufacturing process according to claim 12, characterized in that it is provided in such a way that highly densified bonding zones (6, 6a, 6b) are formed having holes with a high number of fibers (9) exceeding and weakly densified bonding regions (7) having holes with fewer fibers protruding.   14. The manufacturing method as claimed in claim 13, characterized in that the highly densified bonding zones (6, 6a, 6b) are obtained with needles (10a) having a greater number of lugs (11) than the needles ( 10) used for weakly densified bonding areas (7).