GB2478331A

GB2478331A - Thermal and acoustic insulation tile

Info

Publication number: GB2478331A
Application number: GB1003577A
Authority: GB
Inventors: William David Prince; Steven Prince
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-03-04
Filing date: 2010-03-04
Publication date: 2011-09-07
Anticipated expiration: 2030-03-04
Also published as: GB2478331B; GB201003577D0

Abstract

An insulation tile comprising a layer of foam and at least one integral mechanical key C D that allows the tile to be plastered. The insulation tiles are adhesively bonded to the receiving surface, for example a wall or ceiling, each tile being butt jointed to the next. The adhesive bonding agent can be supplemented by mechanical fixings. The insulation the may consist of two or more layers of laminated foam A, B, the uppermost layer of laminated foam can have a pattern cut in it to create a primary mechanical key C for plastering. A second mechanical key may be in the form of a fibre glass mesh D bonded to the outer surface of the upper layer of foam. Fibre tape may be used on the butt joints to reduce the likelihood of cracking in subsequent plaster coatings. The insulation tiles can be used internally or externally. If used externally the insulated the may have a waterproof coating.

Description

Description Title

Thermal & acoustic plastered insulation for walls and ceilings.

Background

Modem construction techniques place strong emphasis on insulating external walls to prevent heat loss and save energy. Properties built since the 1930's typically have cavity wall construction, providing the opportunity to retrospectively insulate the wall structures. Properties built pre WWI however were of solid wall construction and therefore presented no opportunity for insulation within the wall structure.

In recent years there has been an increased focus on reducing sound transmission through party walls and through ceilings between lower and upper flats. The requirement to control noise transmission can be equally important within a single property.

Buildings with solid wall construction have presented a challenge in improving insulation values, resulting in the design of insulation systems that are applied to the wall surface either internally or externally.

Insulation systems intended for internal wall surfaces have taken several forms including sheets of rigid insulation, the construction of false walls to create a cavity that can be insulated, thermal board plaster (plasterboard with a polystyrene backing), wet applied thermal/acoustic plasters and foam-based thermallacoustic linings. A number of these approaches have been adapted for external use.

Foam based insulation linings are currently available that are applied (hung) in a similar fashion to wallpaper, adhesive being used to bond the material to the wall surface. One such type provides a finish suitable for decoration while another can also be plaster skim finished. In both cases, the bond between the insulation and wall surface relies entirely on the strength of the adhesive and quality of the wall surface to which it is bonded.

Foam based insulation systems that can be plaster finished have a material bonded to the foam that allows a plaster finish to grip the surface. The strength of the bond is limited and not suitable for anything more than a plaster skim of a few millimetres thickness. The plaster essentially sticks to the surface of the material and does not form a strong mechanical bond.

Statement of invention

The invention is a foam based insulation tile for use as part of a plastering system intended for improving insulation values in buildings with solid or cavity wall construction to reduce sound transmission, reduce heat loss and save energy. The foam based insulation tiles are individually bonded to the receiving surface (typically a wall or ceiling), each tile being butt jointed to the next. Where a stronger bond is required the adhesive bonding agent can be supplemented by a series of mechanical fixings. Once bonded, the insulation tiles are plastered utilising traditional skills and materials.

Although primarily intended for the improvement of thermal and acoustic insWation values of buildings with solid wall constructions, the insulation tile can be applied to any wall or ceiling surface where an improvement in thermal and acoustic values is required. The insulation tiles can be used internally or externally.

Advantages The foam based insulation tiles are individually bonded to the wall or ceiling surfaces with adhesive alone or with additional mechanical fixings where greater bond strength is required or there is a poor substrate.

The foam based insulation tiles reduce noise transmission and increase thermal value of the surface to which they are applied.

The foam based insulation tiles are manufactured from material with a recognised fire rating, making them suitable for use as part of a fire resistant plaster system.

The foam based insulation tiles include two mechanical keys that combine to create a bond suitable for plaster coatings of various types and thicknesses thereby allowing further improvement in thermal and acoustic insulation values with the appropriate choice of plaster.

The mechanical keys are integral to the foam based insulation tiles and accommodate the use of traditional plastering skills and materials. The keys also serve to strengthen the plaster, reducing the potential for cracking and providing resistance to impact damage.

The foam based insulation tiles can be manufactured in various thicknesses to suit different applications and differing acoustic and thermal insulation values.

The foam based insulation tiles are primarily intended to be applied internally but can also be applied externally with the use of an appropriate waterproof coating.

The foam based insulation tiles can be used at abutment walls to reduce cold bridging, the material being placed between the abutment wall and the potentially cold (outer) wall.

The foam based insulation tiles can be bonded on top of previously applied insulation tiles to achieve an improved insulation value.

introduction to drawings

Figure 1 shows a typical polyurethane foam based insulation tile constructed from two layers of foam laminated together with a meshed plaster key bonded to the upper-most layer.

Label A shows the backing foam layer. This layer of foam is typically constructed from thicker material than the upper-most layer of foam.

Label B shows the upper-most layer of foam. This layer of foam is typically around 3mm thickness and includes a series of holes cut into the material to form the primary mechanical key for plastering.

Label C shows a series of round holes cut out of the upper-most layer of foam. The holes form the primary mechanical key for plastering. The holes can be formed into various shapes and sizes.

Label D shows the mesh key bonded to the surface of the upper-most layer of foam.

The mesh forms the secondary mechanical key for plastering.

Detailed description

The invention is a fire resistant foam based insulation tile that can be plastered using traditional skills and materials. It is intended that the insulation tiles be produced in 8mm and 12mm thicknesses.

The insulation tiles are made up of two layers (A, B) of foam (for example polyurethane foam formed from waste material, otherwise referred to as chip foam').

The two layers of foam are laminated together to form a single sheet material.

The foam that forms the underside of the insulation tile (A) is typically of greater thickness than the foam that forms the upper side of the insulation tile (B). The upper layer of foam includes a pattern cut through it (C) that forms the first of two mechanical keys designed to hold the subsequent plaster coatings.

A meshed sheet (D) is bonded to the upper foam layer to form a second mechanical key to provide additional bond strength for the subsequent plaster coatings. The meshed sheet is typically plastic coated fibre glass formed into a series of squares (for example 4mm squares).

The combined mechanical keys create a surface on the insulation tile that accepts multiple plaster coatings. This can range from a simple skim coat plaster to a series of built-up layers of plaster. The mechanical keys combine to restrain plaster movement across the surface of the insulation tile and prevent plaster pulling off the surface of the material.

Before applying the insulation tiles, the receiving surface should be appropriately prepared. This would typically include removing any loose materials or material that could contaminate the bonding agent (adhesive). A primer may be required to seal a particularly porous surface.

The bonding agent (adhesive) can be applied to the receiving surface or be applied to the underside of the insulation tile.

The insulation tiles are individually applied to the receiving surface (typically a wall or ceiling). Each insulation tile is butt jointed to the next. The insulation tiles should ideally be cross-bonded in a similar way as a wall or ceiling would be plaster-boarded.

The insulation tiles can be cut or shaped around apertures and complex shapes using a sharp knife.

Once the bonding agent has cured, mechanical fixings can be used to supplement the strength of the bond if required. This may be desirable if multiple layers of plaster or heavier plasters are to be used. Mechanical fixings can also be used where the substrate does not allow an adequate bond using adhesive alone.

Prior to the application of plaster, fibre jointing tape should be applied over all joints between the insulation tiles.

Various types of plaster can be applied to the insulation tiles. As a minimum, a skim coat plaster should be used. Multiple layers of plaster can be used to level out an uneven surface or to achieve a specific purpose such as further improvement to acoustic or thermal insulation.

To achieve a greater insulation value the insulation tiles may be bonded on top of previously applied insulation tiles. In this case the joints should ideally be staggered.

Although the insulation tiles are intended to be produced in 8mm and 12mm thicknesses, it is envisaged the insulation tiles can also be manufactured in alternative thicknesses tailored for specific applications.

Additional layers of foam materials (or other suitable material) may also be laminated in to the insulation tile to achieve a particular performance. The size of the insulation tiles is envisaged to be approximately 1000mm x 500mm but other sizes would be equally viable. It is also envisaged that the insulation material could be producedin a roll form.

Claims

Claims 1. A foam based insulation tile for use on existing building surfaces such as walls and ceilings to improve thermal and acoustic values, that can be bonded to the receiving surface with adhesive alone or additionally be mechanically fixed where greater bond strength is required, having integral mechanical keys that allow the insulation tile to be plastered in a traditional fashion including the use of multiple built-up layers of plaster.
2. A foam based insulation tile according to claim 1, which includes two or more layers of foam laminated together to form a single foam sheet material.
3. A foam based insulation tile according to claims 1 and 2, where the foam layers can be manufactured in various thicknesses to achieve different acoustic and thermal insulation values suited to different applications.
4. A foam based insulation tile according to claims I and 2, where the upper-most layer of foam includes a pattern cut through the material to create a primary mechanical key that provides grip across the surface of the insulation tile suitable to allow one or more plaster coatings to be applied.
5. A foam based insulation tile according to claims 1 and 2, where the upper-most layer of foam has a fibre glass mesh bonded to its outer surface to form a secondary mechanical key providing increased grip to the surface of the insulation tile suitable to allow one or more plaster coatings to be applied.
6. A foam based insulation tile according to all the preceding claims, where the mesh secondary mechanical key bridges across the cut out sections of the upper-most foam layer (the primary mechanical key) allowing plaster to enter the body of the foam and grip the mesh from both sides.
7. A foam based insulation tile according to all preceding claims, where the primary and secondary mechanical keys combine to create a key for subsequent plaster coatings both across the face of the insulation tile and to the surface of the insulation tile.
8. A foam based insulation tile according to all the preceding claims, where the insulation tiles are individually bonded to the receiving wall or ceiling surface ideally but not necessarily in a cross-bonded pattern similar to that used in securing plasterboard.
9. A foam based insulation tile according to all the preceding claims, where the bonding adhesive can be applied to the receiving surface or directly to the insulation tile prior to fixing.
10. A foam based insulation tile according to all the preceding claims, where the insulation tile can be cut or shaped around apertures and complex shapes using a sharp knife.
11. A foam based insulation tile according to all the preceding claims, where the insulation tile can be secured in a supplementary fashion when required using mechanical fixings where the substrate is not suitable for an adhesive based bond alone.
12. A foam based insulation tile according to all the preceding claims, where the butt joints between the individual insulation tiles are bridged using fibre tape to reduce the likelihood of cracking in subsequent plaster coatings.
13. A foam based insulation tile according to all the preceding claims, where the increased plaster key strength generated by the primary and secondary mechanical keys allows the use of heavier plasters or render coats.
14. A foam based insulation tile according to all the preceding claims, where the insulation tiles may be bonded on top of previously applied insulation tiles to achieve an improved insulation value.
15. A foam based insulation tile according to all the preceding claims, where the insulation tile can also be applied externally with the use of an appropriate waterproof coating.
16. A foam based insulation tile according to all the preceding claims, where the increased plaster key strength generated by the primary and secondary mechanical keys allow the use of plasterboard based products and plasters that provide further improvement in thermal and acoustic insulation subject to the chosen material being suitable for the environment in which it is used.
17. A foam based insulation tile according to all the preceding claims, where a fire rating or other required value can be achieved by applying appropriate layers of plaster to the insulation tile.
18. A foam based insulation tile according to all the preceding claims, where the combination of mechanical keys strengthens the finished plaster coating to reduce the likelihood of cracking and increase the resistance to surface impact damage.