GB1592862A - Foam-filled structures - Google Patents
Foam-filled structures Download PDFInfo
- Publication number
- GB1592862A GB1592862A GB2932577A GB2932577A GB1592862A GB 1592862 A GB1592862 A GB 1592862A GB 2932577 A GB2932577 A GB 2932577A GB 2932577 A GB2932577 A GB 2932577A GB 1592862 A GB1592862 A GB 1592862A
- Authority
- GB
- United Kingdom
- Prior art keywords
- sheet
- foam
- leaf
- sheets
- cavity
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 239000006260 foam Substances 0.000 title claims description 43
- 238000005253 cladding Methods 0.000 claims description 22
- 229910000831 Steel Inorganic materials 0.000 claims description 15
- 239000010959 steel Substances 0.000 claims description 15
- 229920003023 plastic Polymers 0.000 claims description 14
- 239000004033 plastic Substances 0.000 claims description 14
- 238000011065 in-situ storage Methods 0.000 claims description 13
- 238000000034 method Methods 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 12
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 claims description 12
- 239000004639 urea-formaldehyde foam Substances 0.000 claims description 11
- 238000009423 ventilation Methods 0.000 claims description 11
- 230000001413 cellular effect Effects 0.000 claims description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- 239000002184 metal Substances 0.000 claims description 8
- 229910052751 metal Inorganic materials 0.000 claims description 8
- 239000004800 polyvinyl chloride Substances 0.000 claims description 8
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 7
- 238000009413 insulation Methods 0.000 claims description 6
- 230000029058 respiratory gaseous exchange Effects 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 4
- 239000004698 Polyethylene Substances 0.000 claims description 3
- 229910003460 diamond Inorganic materials 0.000 claims description 3
- 239000010432 diamond Substances 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 3
- -1 polyethylene Polymers 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 2
- 229920001807 Urea-formaldehyde Polymers 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 229920000298 Cellophane Polymers 0.000 description 1
- 229920001944 Plastisol Polymers 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000004999 plastisol Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H5/00—Buildings or groups of buildings for industrial or agricultural purposes
- E04H5/10—Buildings forming part of cooling plants
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Building Environments (AREA)
Description
(54) IMPROVEMENTS IN AND RELATING TO
FOAM-FILLED STRUCTURES
(71) We, HERTFORDSHIRE COUNTY COUNCIL, a Local Authority of
County Hall, Hertford, Hertfordshire, SG13 8DD, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- The present invention relates to cavity wall construction and has particular, but not exclusive application to double skinned sheet material clad building structure (i.e.
building structures having a spaced pair of sheet material leaves rigidly supported on a frame to define a cavity between them).
It is well known to construct commercial buildings by erecting a frame, usually of steel, with vertically spaced and horizontally extending cladding rails, especially of channel section, and attaching, to the respective sides of said rails, impervious cladding sheets, also usually of steel, to enclose the areas between adjacent said rails and upright frame members. The cladding sheets can be profiled with horizontally spaced and vertically extending channels and a range of such profiled sheets are available commercially as "BSC
Profiles" from The British Steel
Corporation. BSC Profiles are formed of galvanised steel of 0.6, 0.725 or 0.9 mm thickness (including 0.04 mm zinc) usually coated on the external face with 0.2 mm embossed polyvinylchloride (PVC) plastisol and on the internal face with 0.05 mm smooth PVC organosol.The cladded structure is frequently sound and/or thermally insulated by the provision of a mineral insulating mat applied to the internal face of one or both opposed cladding sheets or, less usually, sandwiched between said sheets. However, said mats constitute a relatively expensive form of insulation. Further, because of the amount of cutting and fitting required, there are numerous cold bridges and the actual thermal insulation obtained is substantially reduced thereby. It is therefore an object of this invention to provide an alternative and potentially cheaper manner of insulating the cladded structure.
It is known to fill cavities of cavity walls having brick or other air and moisture permeable leaves with rigid cellular foam, especially polyurethanes or ureaformaldehydes, in order to increase the insulation provided by said walls by forming the foam in situ from a fluent composition.
An alternative manner of insulating the cladded structure referred to above would appear to be to fill the cavities between the cladding sheets with such an in situ formed foam. However, it would be necessary to use a non-breathing form (i.e. a foam which does not require ventilation) for this purpose unless special provision is made to allow adequate ventilation of the foam.
Non-breathing foams are relatively expensive and hence their cost would militate against their use for said purpose.
Similarly, additional costs in providing adequate ventilation to enable cheaper breathing foams to be employed could also militate against the said use of foam. It is therefore a further object of this invention to provide a relatively inexpensive means of ventilating foam formed in situ in the cavity between cladding sheets.
The Inventor has now found that the cavity between the cladding sheets can be insulated with in situ formed breathing rigid cellular foam (i.e. foam requiring ventilation) such as urea-formaldehyde foam available under the Trade Mark "Ufoam Plus" from Cape Insulation
Services Limited if the foam is separated from the internal face of at least one of the sheets by an air-permeable waterproof sheet covering said face and defining therewith vented air passages. However, such use of in situ formed foam is not restricted to double skinned sheet material clad buildings but is of more general application to cavity building structures, especially walls, having a spaced pair of rigid leaves defining a cavity between them and in which at least one of said leaves defining the cavity is impervious to air. Said structures are referred to hereinafter as "impervious cavity building structures".
According to a first aspect of the present invention therefore, there is provided an "impervious cavity building structure" (as hereinbefore defined) having an air and water vapour-permeable waterproof sheet covering the internal face of the said at least one impervious leaf and defining therewith one or more unfilled vented air passages, and an in situ formed rigid cellular foam in the remainder of the cavity bounded on the respective side by said sheet.
According to a second aspect of the present invention, there is provided a method of insulating an "impervious cavity building structure" (as hereinbefore defined) wherein an air and water vapourpermeable waterproof sheet is arranged to cover the internal face of the said at least one impervious leaf and to define therewith one or more unfilled vented air passages and forming in situ in the remainder of the cavity a rigid cellular foam bounded by said sheet whilst retaining one of more vented air passages between the sheet and said leaf.
As mentioned previously, the invention has particular application to double skinned sheet material clad building structures in which a structure, especially a wall, has a pair of spaced sheet material leaves rigidly supported on a frame to define a cavity between them. However, it has general application to other impervious cavity building structures (as hereinbefore defined), especially walls but also roofs. The structure can be an internal or, more usually, external structure and can be loadbearing or, more usually, non-load bearing.
At least one leaf of the structure is impervious to air and when the structure is an external structure, said leaf will almost invariably be the external leaf. Both leaves can be impervious, in which case one or both leaves can be covered in the specified manner with a respective air-permeable waterproof sheet.
The impervious leaf or leaves of the structure can be formed of any structurally acceptable material, such as asbestos, metal or plastics, and usually will be in sheet form.
Preferably in the case of a sheet cladding structure, the leaves are both consituted by metal, especially steel, sheets optionally but advantageously coated on at least one face with plastics, especially PVC. Particularly suitable steel sheets are galvanised steel sheets of 0.5 to 1.0 mm thickness coated on both faces with PVC.
The impervious leaf or leaves to be covered with an air-permeable waterproof sheet can be planar but it is much preferred that they are profiled so that air passages are formed by merely locating a planar waterproof sheet against the internal face of the leaf. Advantageously, the sheets are profiled with spaced parallel channels which extend substantially vertically in the installed attitude of the sheets.
The sheet covering the internal face of the structure leaf to define therewith air passages is pervious to air and water vapour but not to water in its liquid state.
Advantageously, the sheet is flexible but it must have sufficient strength to withstand the load imposed during in situ foam formation in the structure cavity. Suitably, the sheet is a microperforated plastics sheet of, for example, the kind used as a roof tile underlay instead of conventional sarking felt. A satisfactory microperforated sheet is that available under the Trade Mark "Tilene 200 P" from British Cellophane
Limited, which sheet is a polythene sheet of 0.20 mm nominal thickness, 0.185 kg/m2 nominal weight formed with 6400 microperforations/m2 in a diamond pattern and have a tensile strength of 105 kg/cm2 and an elongation of 150%.
The air-permeable waterproof sheet covers the internal face of the respective structure leaf and defines therewith one or more, preferably a plurality of air passages which permit the in situ formed foam cavity filling to breathe. Preferably, the said air passages are horizontally spaced and substantially vertically extending (when viewed in the erected structure). Suitably, the passages are constituted by channels in a profiled leaf over the internal face of which the waterproof sheet is located. However, the waterproof sheet can itself be profiled by, for example, mounting on a frame in the case of a flexible sheet to constitute channels to form or form part of said passages. The air passages are vented to the ambient atmosphere of the wall to permit moisture equilibrium between the foam in the cavity and the ambient atmosphere.
The cavity in the wall bounded by the face of the sheet remote from the respective wall leaf covered by the sheet is at least partially filled with foam which is formed in situ. The foam is a rigid cellular foam and will be selected having regard inter alia to the rigidity, stability, insulating and cost requirements for each particular wall.
Suitable foams are polyurethanes and ureaaldehydes, especially urea-formaldehyde which foams are well known for insulating buildings. The majority of such foams presently used in the building industry are breathing foams, i.e. require adequate ventilation to set and to subsequently breathe. The presence of the air-permeable waterproof sheet in the structure and the method of the invention provides such ventilation which would not otherwise exist in impermeable leaf cavity structures.
An example of a suitable foam is a ureaformaldehyde foam of8 to 10 kg/cm3 density available from Cape Insulation Services
Limited under the Trade Mark "Ufoam
Plus".
The following is a description by way of example only and with reference to the drawings accompanying the Provisional
Specification of a wall in accordance with a preferred embodiment of the present invention and of the method of manufacturing the wall. The single Figure of the drawing is a perspective cut-away view of said wall.
Referring to the drawing accompanying the Provisional Specification, a commercial or industrial building has a steel framework comprising upright columns 1 between which extend a plurality of vertically spaced and horizontally extending steel cladding rails 2 of channel section. Profiled galvanised steel sheets 3, 4 are attached to the said rails 2 to constitute respectively internal and external cladding. The sheets 3, 4 are coated with PVC on both their internal and external faces (relative to the cavity formed between the sheets) and, if desired, one or both of said sheets can be faced with additional materials for decorative or aesthetic reasons. The profile of the sheets 3, 4 provides a plurality of horizontally spaced and vertically extending channels in the internal face of the respective sheet.A flexible air-permeable waterproof sheet 5 of microperforated plastics covers the internal face of the external sheet 4 and is sandwiched between said sheet 4 and the cladding rails 2. Said flexible sheet 5 closes the open side of channels 5 in sheet 4 to define upwardly extending air passages. The cavity between flexible sheet 5 and internal sheet 3 is filled with a urea-formaldehyde foam 6 of 8 to 10 kg/m3 density which is ventilated to the outside of the building via flexible sheet 5 and the air passages of channels in sheet 4.
The wall illustrated in the drawing can be constructed by erecting in conventional
manner the framework and securing the
cladding 3, 4 thereto after, in the case
of external sheets 4, locating the flexible sheet 5 in position. A ureaformaldehyde foam composition is then pumped into the cavity between flexible sheet 5 and internal cladding 3 through appropriately located access holes and allowed to gel to the rigid cellular foam 6.
The provision of the air passages between sheets 4 and 5 facilitate gelling by providing ventilation.
It will be appreciated that the invention is not restricted to the particular details described above with reference to the drawings. Those details may be modified or varied without departing from the scope of the invention. In particular, an identical flexible sheet to sheet 5 could be provided to cover the internal cladding 3 in the same manner as external cladding 4 is covered.
Thus, ventilation could be provided on both sides of the foam cavity filling. Further, the foam can be introduced into the cavity through the channels formed by the profile sheets at cills, ceilings and roof levels instead of through the holes described above with reference to the drawings.
WHAT WE CLAIM IS:
1. An impervious cavity building structure (as hereinbefore defined) having an air and water vapour-permeable waterproof sheet covering the internal face of the said at least one impervious leaf and defining therewith one or more unfilled vented air passages, and an in situ formed rigid cellular foam in the remainder of the cavity bounded on the respective side by said sheet.
2. A structure as claimed in Claim 1 wherein both leaves are impervious and respective air and water vapour-permeable waterproof sheets cover the internal face of each leaf in the manner specified in Claim 1.
3. A structure as claimed in Claim 1 or
Claim 2 wherein the leaves of the structure are sheet material leaves.
4. A structure as claimed in Claim 3 wherein the sheet material leaves are formed of metal.
5. A structure as claimed in Claim 4 wherein the metal leaves are coated on at least one face with plastics.
6. A structure as claimed in Claim 5 wherein the metal leaves are galvanised steel sheets of 0.5 to 1.0 mm thickness coated on both faces with plastics.
7. A structure as claimed in Claim 5 or
Claim 6 wherein the plastics is polyvinylchloride.
8. A structure as claimed in any one of
Claims 3 to 7 wherein the said at least one impervious leaf is profiled so that air passages are formed by locating a planar waterproof sheet against the internal face of the leaf.
9. A structure as claimed in Claim 8 wherein the profiled leaf has spaced parallel.
channels which extend substantially vertically in the installed attitude of the leaf.
10. A structure as claimed in any one of the preceding Claims wherein the waterproof sheet is flexible.
11. A structure as claimed in Claim 10 wherein the waterproof sheet is a microperforated plastics sheet.
12. A structure as claimed in Claim 11 wherein the waterproof sheet is a polyethylene sheet of 0.2 mm nominal thickness, 0.185 kg/m2 nominal weight
**WARNING** end of DESC field may overlap start of CLMS **.
Claims (29)
1. An impervious cavity building structure (as hereinbefore defined) having an air and water vapour-permeable waterproof sheet covering the internal face of the said at least one impervious leaf and defining therewith one or more unfilled vented air passages, and an in situ formed rigid cellular foam in the remainder of the cavity bounded on the respective side by said sheet.
2. A structure as claimed in Claim 1 wherein both leaves are impervious and respective air and water vapour-permeable waterproof sheets cover the internal face of each leaf in the manner specified in Claim 1.
3. A structure as claimed in Claim 1 or
Claim 2 wherein the leaves of the structure are sheet material leaves.
4. A structure as claimed in Claim 3 wherein the sheet material leaves are formed of metal.
5. A structure as claimed in Claim 4 wherein the metal leaves are coated on at least one face with plastics.
6. A structure as claimed in Claim 5 wherein the metal leaves are galvanised steel sheets of 0.5 to 1.0 mm thickness coated on both faces with plastics.
7. A structure as claimed in Claim 5 or
Claim 6 wherein the plastics is polyvinylchloride.
8. A structure as claimed in any one of
Claims 3 to 7 wherein the said at least one impervious leaf is profiled so that air passages are formed by locating a planar waterproof sheet against the internal face of the leaf.
9. A structure as claimed in Claim 8 wherein the profiled leaf has spaced parallel.
channels which extend substantially vertically in the installed attitude of the leaf.
10. A structure as claimed in any one of the preceding Claims wherein the waterproof sheet is flexible.
11. A structure as claimed in Claim 10 wherein the waterproof sheet is a microperforated plastics sheet.
12. A structure as claimed in Claim 11 wherein the waterproof sheet is a polyethylene sheet of 0.2 mm nominal thickness, 0.185 kg/m2 nominal weight
formed with 6400 microperforations in a diamond pattern and having a tensile strength of 105 Kg/cm2 and an elongation of 150%.
13. A structure as claimed in any one of the preceding Claims wherein there are a plurality of horizontally spaced and substantially vertically extending (when viewed in the erected configuration) air passage between the waterproof sheet and the immediately adjacent impervious leaf.
14. A structure as claimed in any one of the preceding Claims wherein the foam is a breathing foam (as hereinbefore defined).
15. A structure as claimed in Claim 14 wherein the foam is a urea-formaldehyde foam.
16. A structure as claimed in Claim 15 wherein the urea-formaldehyde foam has a density of 8 to 10 kg/m3.
17. A structure as claimed in any one of the preceding Claims which is a wall.
18. A structure as claimed in Claim 1 and substantially as described herein with reference to and as shown in the drawings accompanying the Provision Specification.
19. A method of insulating an impervious cavity buildings structure (as hereinbefore defined) wherein an air and water vapourpermeable waterproof sheet is arranged to cover the internal face of the said at least one impervious leaf and to define therewith one or more unfilled vented air passages and forming in situ in the remainder of the cavity a rigid cellular foam bounded by said sheet whilst retaining one or more vented air passages between the sheet and said leaf.
20. A method as claimed in Claim 19 wherein both leaves are impervious and respective air and water vapour-permeable waterproof sheets cover the internal face of each leaf in the manner specified in Claim 19.
21. A method as claimed in Claim 19 and
Claim 20 wherein the waterproof sheet is flexible.
22. A method as claimed in Claim 21 wherein the waterproof sheet is a microperforated plastics sheet.
23. A method as claimed in Claim 22 wherein the waterproof sheet is a polyethylene sheet of 0.2 mm nominal thickness, 0.185 kg/m2 nominal weight.
formed with 6400 microperforations in a diamond pattern and having a tensile strength of 105 kg/cm2 and an elongation of 150%.
24. A method as claimed in any one of
Claims 19 to 23 wherein there are a plurality of horizontally spaced and substantially vertically extending (when viewed in the erected configuration) air passages between the waterproof sheet and the immediately adjacent impervious leaf.
25. A method as claimed in any one of
Claims 19 to 24 wherein the foam is a breathing foam (as hereinbefore defined).
26. A method as claimed in Claim 25 wherein the foam is a urea-formaldehyde foam.
27. A method as claimed in Claim 26 wherein the urea-formaldehyde foam has a density of 8 to 10 kg/m3.
28. A method as claimed in Claim 19 and substantially as hereinbefore described with reference to the drawings accompanying the
Provinsional Specification.
29. A building incorporating one or more structures as claimed in any one of Claims 1 to 18.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2932577A GB1592862A (en) | 1978-05-12 | 1978-05-12 | Foam-filled structures |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2932577A GB1592862A (en) | 1978-05-12 | 1978-05-12 | Foam-filled structures |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB1592862A true GB1592862A (en) | 1981-07-08 |
Family
ID=10289774
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB2932577A Expired GB1592862A (en) | 1978-05-12 | 1978-05-12 | Foam-filled structures |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB1592862A (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2702542A1 (en) * | 1993-03-09 | 1994-09-16 | Couvracier Sa | Insulating and acoustic jacket of the double-skin type |
| EP0887605A2 (en) * | 1997-06-24 | 1998-12-30 | Flavio Selan | Element of contenance of expanded materials used for wall insulation, especially of refrigerators |
| GB2372760A (en) * | 2000-12-22 | 2002-09-04 | Biomedy Ltd | Structural panel |
| ES2323209A1 (en) * | 2006-09-25 | 2009-07-08 | Carlos Maria Luquin Melero | System for simple ventilated facade (Machine-translation by Google Translate, not legally binding) |
-
1978
- 1978-05-12 GB GB2932577A patent/GB1592862A/en not_active Expired
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2702542A1 (en) * | 1993-03-09 | 1994-09-16 | Couvracier Sa | Insulating and acoustic jacket of the double-skin type |
| EP0887605A2 (en) * | 1997-06-24 | 1998-12-30 | Flavio Selan | Element of contenance of expanded materials used for wall insulation, especially of refrigerators |
| EP0887605A3 (en) * | 1997-06-24 | 1999-10-13 | Flavio Selan | Element of contenance of expanded materials used for wall insulation, especially of refrigerators |
| GB2372760A (en) * | 2000-12-22 | 2002-09-04 | Biomedy Ltd | Structural panel |
| US6739105B2 (en) | 2000-12-22 | 2004-05-25 | Biomedy Limited | Constructional elements |
| GB2372760B (en) * | 2000-12-22 | 2004-08-04 | Biomedy Ltd | Constructional elements |
| ES2323209A1 (en) * | 2006-09-25 | 2009-07-08 | Carlos Maria Luquin Melero | System for simple ventilated facade (Machine-translation by Google Translate, not legally binding) |
| ES2323209B1 (en) * | 2006-09-25 | 2010-04-19 | Carlos Maria Luquin Melero | SIMPLE VENTILATED FAÇADE SYSTEM. |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PS | Patent sealed | ||
| PCNP | Patent ceased through non-payment of renewal fee |