GB2464369A - Thermally insulating sandwich wall liner panel with aerogel and fibre core - Google Patents

Thermally insulating sandwich wall liner panel with aerogel and fibre core Download PDF

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Publication number
GB2464369A
GB2464369A GB0914185A GB0914185A GB2464369A GB 2464369 A GB2464369 A GB 2464369A GB 0914185 A GB0914185 A GB 0914185A GB 0914185 A GB0914185 A GB 0914185A GB 2464369 A GB2464369 A GB 2464369A
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GB
United Kingdom
Prior art keywords
wall
fibre
wall liner
layer
fibre reinforced
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.)
Withdrawn
Application number
GB0914185A
Other versions
GB0914185D0 (en
Inventor
Sam Proctor
Iain Fairnington
Graeme Berry
Michael James Mapston
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
A Proctor Group Ltd
Original Assignee
A Proctor Group Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by A Proctor Group Ltd filed Critical A Proctor Group Ltd
Publication of GB0914185D0 publication Critical patent/GB0914185D0/en
Publication of GB2464369A publication Critical patent/GB2464369A/en
Withdrawn legal-status Critical Current

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Classifications

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    • B32LAYERED PRODUCTS
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    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
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    • EFIXED CONSTRUCTIONS
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    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76Heat, 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
    • E04B1/7675Insulating linings for the interior face of exterior walls
    • EFIXED CONSTRUCTIONS
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    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76Heat, 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
    • E04B1/78Heat insulating elements
    • E04B1/80Heat insulating elements slab-shaped
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    • B32B2305/00Condition, form or state of the layers or laminate
    • B32B2305/10Fibres of continuous length
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    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

The panel comprises an aerogel fibre composite 16 between fibre reinforced layers 12, 14. The composite is preferably hydrophobic. The fibre reinforced layers 12, 14 may be bonded to the core 16 with fire resistant glue. The reinforced layers 12, 14 preferably comprise woven or knitted glass or mineral fibre tissue, paper, or fibre reinforced polymer (FRP). The panels can be bonded to a building's wall or ceiling, preferably by means of an acrylic adhesive. Disclosed polyester fibre reinforced aerogels 16 include silica, alumina, similar metal oxides, carbon, resocinol formaldehyde resin, melamine formaldehyde resin, polyimide, polyurethane and polyisocyanurate.

Description

WALL LINER
The present invention relates to a wall liner and to a wall lining system for the internal thermal insulation of S buildings and other structures. The invention also relates to a wall lining having fireproof qualities and characteristics. As used herein the term wall includes also reference to ceilings.
With ever increasing fuel and energy costs there is a desire to reduce the impact caused by energy use in buildings and there is a continuous drive to improve the thermal efficiency of both old and new build buildings.
Older building constructions generally have poor thermal S...
efficiency and it is becoming increasingly difficult when **** refurbishing older properties to be compliant with building standards relating to thermal insulation and fire * .** protection.
One conventional method of improving the thermal efficiency of an older building is to increase the thickness of the thermal insulation. A significant drawback of this approach when using traditional thermal laminates is that room sizes are reduced for a given footprint area of building. In some cases retrofitting such insulation can reduce the size of a room to an unacceptable level. There is therefore a move towards "thin wall solutions". Such thin wall solutions have included a layer of polystyrene applied horizontally to a wall or other thin thermally insulating material. Existing thin wall solutions have had various drawbacks including their inability to provide adequate insulation; their inability to be fireproof; poor knock resistance i.e. easily damagable; and not being particularly suitable for receiving decorative layers such as wallpaper, and in particular for subsequent redecoration without affecting the integrity of the insulation layer.
It is an object of the present invention to provide a wall lining and wall lining system that avoids or at least
S
** : minimises one or more of the disadvantages of known methods * *** * S 0.5 and constructions. *0** * S S S. 0
According to a first aspect the present invention provides *.SS : a wall liner panel comprising a first outwardly facing fibre reinforced layer and a second inwardly, wall facing, fibre reinforced layer, said first and second fibre reinforced layers being bonded to, and sandwiching, a layer of an aerogel fibre composite.
Monolithic aerogels are extremely low density materials (typically 0.1mg/cm3) which are a sponge like structure composed of a network of interconnected nano-particles.
They can be composed of a variety of materials including silica, alumina, metal oxides, organic and inorganic polymers and carbon. Monolithic aerogels are particularly good thermal insulating materials as they resist heat transfer, whether by convection, conduction or radiation, though a typical monolithic aerogel, such as a silica aerogel, is susceptible to damage in use as they are extremely brittle.
Recently aerogel fibre composite materials have been developed which substantially retain the thermal insulation properties of the aerogel whilst providing improved : mechanical properties due to the presence of the fibres in * *** * * ***.
the matrix. Aerogel fibre composites can be provided with * * * a selected degree of flexibility to provide an insulation layer that is more durable than a solid (monolithic) *.** aerogel layer, but still returns sufficient strength to resist compression (knock) damage.
Suitable aerogel fibre composites for a wall liner of the present invention are available from Aspen Aerogels Inc of Northborough MA, USA and their use in general for insulating purposes is described in WO 2006/091812. The preferred aerogel fibre composites for use in the wall liner of the present invention comprise a silica aerogel in a polyester fibre matrix. Various thicknesses of aerogel fibre composite are available and for use with the present invention the aerogel fibre composite layer will generally have a thickness in the range 2mm to 10mm, typically 3mm, 6mm or 9mm. Aerogel fibre composite layers of these thicknesses, or of other available thicknesses (for example 5mm or 10mm), may conveniently be employed for many applications but even thicker layers can be provided if required.
The aerogel fibre layer may comprise silica, alumina, or other metal oxides that have been modified by the incorporation of organic polymers. Highly crossed linked organic polymer systems can also be used to produce an *.** * S S...
appropriate aerogel component for use as the aerogel layer. *5S
. : For example, resorcinol-formaldehyde, melamine-formaldehyde, polyimides, polyurethanes, polyisocyanurates, S...
and polymers of various unsaturated hydrocarbons.
Preferably the aerogel fibre composite is hydrophobic. A hydrophobic composite resists the ingress of moisture and thus makes the wall liner according to the present invention particularly suitable for use with buildings which suffer from condensation or dampness problems.
The fibre reinforced layers (first arid second) may comprise a glass or mineral fibre tissue or sheet which is bonded using, preferably, a fire resistant glue, to the front and back of the layer of aerogel fibre composite.
Such tissues or sheets have the form of a thin mat' of glass fibres or mineral fibres. Typically the fibres of the mat are held together with the assistance of a suitable polymer, which acts as bonding agent between the fibres.
Alternatively woven or knitted fibre sheets may be employed in one or both of the fibre reinforced layers.
Alternatively the fibre-reinforced layers may take the form of a fibre reinforced composite layer wherein fibres, for i.. . * S example glass or mineral fibres, reinforce a sheet of for example a polymer material. The fibres may be embedded in the sheet material. The fibre reinforced layers may further comprise additional materials acting as fillers or other layers of sheet material.
Other fibre reinforcing may be employed. For example the fibre reinforced layer may take the form of a paper sheet which may, for example, be of cellulose fibres.
The fibre reinforced layers serve to protect the aerogel fibre composite from impact damage and give resistance to tearing. They provide suitable surfaces for use of the wall liner. The first outwardly facing fibre reinforced layer can accept a lining paper, a wallpaper or in some cases may be capable of being painted directly. The second, inwardly, wall facing, fibre reinforced layer be bonded to a wall or ceiling surface. Thus the wall liner of the invention allows normal decorative finishes to be applied to a lined wall or ceiling surface. The fibre reinforced layer can also protect the aerogel fibre composite layer from damage during removal of a wallpaper layer when redecoration is being carried out.
The fibre reinforced layers may have weights in the range : of from 2Ogsm to lOOgsm, typically 42gsm.
SIS
Conveniently the type and weight of fibre reinforced layer employed is the same on both sides of the wall liner panel. * S I
This can allow the liner to be reversible, either side of the liner can be used as the layer which is bonded to a wall or ceiling in use.
Alternatively, if desired, different weights or types of fibre reinforced layer may be employed as the first and second fibre reinforced layers. For example, the first, outwardly facing, layer is a glass fibre tissue having a weight in the range of from 2ogsm to 3Ogsm, typically 25gsm and the second, inwardly facing layer is also a glass fibre tissue having a weight in the range of 4Ogsm to 6ogsm, typically Sogsm.
Preferably the fibre reinforced layers are bonded to the layer of aerogel fibre composite using a fire resistant glue or adhesive.
Preferably the wall liner according to the present invention is supplied in the form of a rectangular panel which can be secured to the face of a wall in use of the wall liner. Typically the wall liner panel has dimensions of 1,200mm by 600mm and when installed on a wall in use * S * thereof are arranged in a "brick bond" pattern with the S... * S * .1.
longest dimension length wise. S.., * .. *5 S
Advantageously one long side and one short side (typically * . . * the top and right hand side) of a wall liner panel has the first outwardly facing fibre reinforced layer extending beyond the edge of the layer of aerogel fibre composite such that, in use, on a wall, there is an overlap with adjacent edges of adjacent wall liner panels. These overlaps are bonded, by gluing, directly to the face of the abutting adjacent wall liner panel to form a continuous surface without visible joints and this arrangement further improves the insulation and fire resistant characteristics and qualities of the wall liner.
Thus and according to a second aspect the present invention provides a wall lining system, which system comprises a plurality of wall liners, said wall liners comprising a first outwardly wall facing fibre reinforced layer and a second inwardly facing fibre reinforced layer, said first and second fibre reinforced layers being bonded to and sandwiching a layer of aerogel fibre composite, said wall liner panels being bonded to a wall or ceiling in use of *:::: the wall lining system. * S.. * * S...
Thus with a wall liner and wall liner system according to the present invention it is possible to insulate a wall with a high degree of insulation without impacting upon the space within the room in use of the system.
Preferably there is provided a lining sheet, typically a lining paper which can be applied, by bonding, to the surface of the outwardly facing fibre reinforced layer, said lining paper being formed and arranged for receiving a decorative coating, e.g. a paint, or a wallpaper.
Preferably the wall liner panels are bonded to a wall, typically a plaster or plasterboard wall using an acrylic resin based adhesive formed and arranged for bonding fibre -9.-laminated polymeric sheets thereto. An adhesive suitable for use is Apollo Chemical Limited' s product number A6805 -roof deck adhesive (acrylic resin). The bonding adhesive for use in bonding the fibre reinforced layers to the aerogel fibre layer is a sprayable laminating adhesive of the type manufactured by Apollo Chemicals Limited under their product number A7625.
According to a third aspect, the present invention provides a method f or insulating a building structure comprising the step of mounting, by bonding, a plurality of wall liner panels according to a first aspect of the present invention and applying a lining paper to the outwardly wall facing layer.
Further preferred features and advantages of the present invention will appear from the following detailed
description given by way of example of a preferred
embodiment illustrated with reference to the accompanying drawings in which: -Figure 1 is a section through a wall liner according to the invention; and Figure 2 is a perspective view of a wall liner panel according to the invention.
A wall liner according to the present invention is shown in section in Figure 1 and is generally indicated by reference number 10. The wall liner has a first surface 12 which faces away from a wall in use of the wall liner, the first surface being a fibre reinforced layer, in this case a glass fibre tissue. A second fibre reinforced layer 14, again a glass tissue, is provided which is wall facing and both the layers 12, 14 are bonded to and sandwich a layer of an aerogel fibre composite 16 to provide a laminated panel.
In this example the wall facing side 14 of the wall liner panel 10 is a 5ogsm layer of glass tissue and the room S...
*:::: facing side 12 is a 2sgsm glass tissue. Both layers are bonded to the aerogel layer 16 which, in this embodiment, has a thickness of 6mm, by a layer of fire resistant adhesive glue. Alternatively both sides 12,14 of the wall liner panel 10 may be of the same weight of glass tissue.
Turning now to figure 2 and the wall liner panel 10 shown therein, the top 18 and right 20 hand sides of the panel are provided with a 50mm overhang 22 to the room facing side 12 of the fibre reinforced layer so that, in use, when a plurality of wall liner panels are mounted to a wall in a brick bond pattern, the overlap can be glued to an adjacent abutting panel to form a continuous surface without visible joints.
Test Results Tests undertaken by the applicant have shown that the wall liner according to the present invention has significantly improved insulation characteristics over alternative wall lining materials and systems as follows.
1. The applicant' s SPACETHERMTM WP6 wall lining product comprises a 6mm layer of aerogel fibre bonded between two glass fibre tissue layers having 5ogsm and 25gsm weights respectively. When bonded to a 13mm layer of plaster applied to a 220mm thick brick wall (total thickness 233mm) the wall had a (rounded) U-value of l.17W/m2K.
2. A similar wall construction comprising a 10mm layer of SEMPATAPTM thermal wall covering, applied to a wall having a 13mm layer of plaster applied to a 220mm thick brick wall (total thickness 233mm) had a (rounded) U-value of l.57W/m2K.
Various modifications may be made to the above described embodiment without departing from the scope of the present invention, thus for example there may be utilised a double (or indeed triple) layer of aerogel fibre composite, wherein each of the aerogel fibres has different insulation and fire resistant qualities. * S * *5 S S... * . S... S... * . . * S.. * SI *

Claims (17)

  1. CLAIMS1. A wall liner panel comprising a first outwardly facing fibre reinforced layer and a second inwardly, wall facing, fibre reinforced layer, said first and second fibre reinforced layers being bonded to, and sandwiching, a layer of an aerogel fibre composite.
  2. 2. A wall liner panel according to claim 1 wherein the layer of an aerogel fibre composite has a thickness of from 2mm to 10mm. * *** * S S S. S
  3. 3. A wall liner panel according to claim 1 or claim 2 wherein the aerogel fibre composite is hydrophobic.
  4. 4. A wall liner panel according to any one of claims 1 to 3 wherein the first and second fibre reinforced layers are bonded to the layer of an aerogel fibre composite by means of a fire resistant glue.
  5. 5. A wall liner panel according to any preceding claim wherein the first and second fibre reinforced layers each have weights in the range of 2ogsm to lOOgsm.
  6. 6. A wall liner panel according to any preceding claim wherein at least one of the first and second fibre reinforced layers comprises a glass or mineral fibre tissue or sheet.7. A wall liner panel according to any one of claims 1 to 5 wherein at least one of the first and second fibre reinforced layers comprises a fibre reinforced composite layer.
  7. 7. A wall liner panel according to any one of claims 1 to 5 wherein at least one of the first and second fibre reinforced layers comprises a paper sheet. S... * . . *. S
  8. 8. A wall liner panel according to any one of claims 1 to *5S* wherein at least one of the first and second fibre * * * *. S reinforced layers is woven or knitted. * .** * S * * *
  9. 9. A wall liner panel according to any preceding claim wherein at least one of the first and second fibre reinforced layers is bonded to the layer of an aerogel fibre composite by means of a fire resistant adhesive.
  10. 10. A wall liner panel according to any preceding claim having the form of a rectangular panel wherein one long side and one short side of the panel has the first outwardly facing fibre reinforced layer extending beyond the edge of the layer of aerogel fibre composite such that, in use, on a wall, there is an overlap with adjacent edges of adjacent wall liner panels.
  11. 11. A wall lining system comprising a plurality of wall liner panels according to any one of claims 1 to 10, said plurality of wall liner panels being bonded to a wall or ceiling in use of the wall lining system.
  12. 12. A wall lining system according to claim 11 further comprising a lining sheet which can be applied, by bonding, to the surface of the outwardly facing fibre reinforced layer, said lining paper being formed and arranged for receiving a decorative coating. * * . ** *
  13. 13. A wall lining system according to claim 11 or claim 12 wherein the plurality of wall liner panels are bonded to a wall or ceiling by means of an acrylic resin based adhesive.
  14. 14. A method for insulating a building structure comprising the step of mounting, by bonding, a plurality of wall liner panels according to any one of claims 1 to 10 to a wall or ceiling of said building.
  15. 15. A method according to claim 14 further comprising applying a lining paper to the outwardly facing fibre reinforced layer of the wall liner panels.
  16. 16. A wall liner panel substantially as hereinbefore described and with reference to Figure 1 of the drawings.
  17. 17. A wall liner panel substantially as hereinbefore described and with reference to Figure 2 of the drawings. S... * . . *5 * *I.. * S S.'.. **eb * . S S* * * a.. * . a * .
GB0914185A 2008-08-13 2009-08-13 Thermally insulating sandwich wall liner panel with aerogel and fibre core Withdrawn GB2464369A (en)

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WO2013014683A1 (en) * 2011-07-25 2013-01-31 Giemme S.N.C. Di Corradini Marco & C. Method of making an insulation panel and insulation panel obtainable with said method
ES2398119A1 (en) * 2012-12-27 2013-03-13 Universidad Politécnica de Madrid Freeform panelling system with high energy efficiency
ITMO20110298A1 (en) * 2011-11-21 2013-05-22 Giemme S N C Di Corradini Marco & C PROCEDURE FOR CONSTRUCTION OF AN INSULATING PANEL AND RELATIVE INSULATING PANEL OBTAINED.
ITPD20120039A1 (en) * 2012-02-17 2013-08-18 Everlux S R L INSULATING PANEL FOR BUILDING AND PROCEDURE FOR ITS REALIZATION
US8539986B2 (en) * 2010-10-20 2013-09-24 Isolite Gmbh Hot gas conducting component
DK201400604A1 (en) * 2014-10-23 2016-05-02 Create Dk Vacuum Insulated wallpaper
US20170210108A1 (en) * 2016-01-27 2017-07-27 Aspen Aerogels,Inc. Laminates comprising reinforced aerogel composites
GB2579867A (en) * 2018-12-19 2020-07-08 Jun Rong Chun Insulation material
IT202000020293A1 (en) * 2020-08-20 2022-02-20 Giuseppe Librizzi PANEL OF A DUCT FOR THE CONVEYANCE OF AIR INTO AN AMBIENT CONDITIONING SYSTEM, AND RELATED EQUIPMENT AND METHOD FOR THE CONSTRUCTION OF SUCH PANEL
US11547977B2 (en) 2018-05-31 2023-01-10 Aspen Aerogels, Inc. Fire-class reinforced aerogel compositions

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CN114440014B (en) * 2020-11-04 2024-03-29 中国石油化工股份有限公司 Thermal-insulated heat preservation nonmetallic composite pipe

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WO2006002440A2 (en) * 2004-06-29 2006-01-05 Aspen Aerogels, Inc. Energy efficient and insulated building envelopes
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GB1350661A (en) * 1970-06-10 1974-04-18 Micropore International Ltd Thermal insulating materials
US6103036A (en) * 1997-10-12 2000-08-15 Porextherm-Dammstoffe Gmbh Microporous pressed molded thermal insulator body and method for its production
WO2006002440A2 (en) * 2004-06-29 2006-01-05 Aspen Aerogels, Inc. Energy efficient and insulated building envelopes
WO2008110818A1 (en) * 2007-03-14 2008-09-18 A. Proctor Group Ltd Wall insulation system

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Publication number Priority date Publication date Assignee Title
US8539986B2 (en) * 2010-10-20 2013-09-24 Isolite Gmbh Hot gas conducting component
WO2013014683A1 (en) * 2011-07-25 2013-01-31 Giemme S.N.C. Di Corradini Marco & C. Method of making an insulation panel and insulation panel obtainable with said method
ITMO20110298A1 (en) * 2011-11-21 2013-05-22 Giemme S N C Di Corradini Marco & C PROCEDURE FOR CONSTRUCTION OF AN INSULATING PANEL AND RELATIVE INSULATING PANEL OBTAINED.
ITPD20120039A1 (en) * 2012-02-17 2013-08-18 Everlux S R L INSULATING PANEL FOR BUILDING AND PROCEDURE FOR ITS REALIZATION
WO2013120845A1 (en) * 2012-02-17 2013-08-22 Everlux S.R.L. Insulating panel for the building sector and method for manufacturing it
WO2014102424A1 (en) * 2012-12-27 2014-07-03 Universidad Politécnica de Madrid Freeform panelling system with high energy efficiency
ES2398119A1 (en) * 2012-12-27 2013-03-13 Universidad Politécnica de Madrid Freeform panelling system with high energy efficiency
DK201400604A1 (en) * 2014-10-23 2016-05-02 Create Dk Vacuum Insulated wallpaper
US20170210108A1 (en) * 2016-01-27 2017-07-27 Aspen Aerogels,Inc. Laminates comprising reinforced aerogel composites
US11072145B2 (en) 2016-01-27 2021-07-27 Aspen Aerogels, Inc. Laminates comprising reinforced aerogel composites
US11547977B2 (en) 2018-05-31 2023-01-10 Aspen Aerogels, Inc. Fire-class reinforced aerogel compositions
GB2579867A (en) * 2018-12-19 2020-07-08 Jun Rong Chun Insulation material
IT202000020293A1 (en) * 2020-08-20 2022-02-20 Giuseppe Librizzi PANEL OF A DUCT FOR THE CONVEYANCE OF AIR INTO AN AMBIENT CONDITIONING SYSTEM, AND RELATED EQUIPMENT AND METHOD FOR THE CONSTRUCTION OF SUCH PANEL

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GB0814789D0 (en) 2008-09-17

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