GB2525100A - Insulation panel for a cavity wall - Google Patents

Insulation panel for a cavity wall Download PDF

Info

Publication number
GB2525100A
GB2525100A GB1509502.9A GB201509502A GB2525100A GB 2525100 A GB2525100 A GB 2525100A GB 201509502 A GB201509502 A GB 201509502A GB 2525100 A GB2525100 A GB 2525100A
Authority
GB
United Kingdom
Prior art keywords
breathable membrane
insulation panel
facer
insulation
panels
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.)
Granted
Application number
GB1509502.9A
Other versions
GB201509502D0 (en
GB2525100B (en
Inventor
Eoghan Hynes
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Priority to GB1509502.9A priority Critical patent/GB2525100B/en
Priority to IE20150210A priority patent/IE87073B1/en
Publication of GB201509502D0 publication Critical patent/GB201509502D0/en
Publication of GB2525100A publication Critical patent/GB2525100A/en
Application granted granted Critical
Publication of GB2525100B publication Critical patent/GB2525100B/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered 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
    • B32B5/22—Layered 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
    • B32B5/32—Layered 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 at least two layers being foamed and next to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/06—Interconnection of layers permitting easy separation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Landscapes

  • Building Environments (AREA)
  • Laminated Bodies (AREA)

Abstract

An insulation panel 1 comprising a substantially rectangular polymer foam core 3 having a facer bonded to one side thereof, a breathable membrane 9 having a vapour resistance less than or equal to 0.60 MN.s/g bonded to the facer 5, the breathable membrane being dimensioned to extend beyond a pair of adjacent edges of the foam core thereby forming a breathable membrane tab 15. Also claimed is a method of manufacturing the insulation panel 1 comprising the steps of forming a polymeric foam core from foam reactants between a first and second facer 5, 7; allowing the polymeric foam core to harden and cutting into panels. The web of breathable membrane 9 is then cut into sheets having length and width dimensions greater than the dimensions of the facer; and is bonded to one of the facers such that a breathable membrane tab 15 is formed extending beyond a pair of adjacent edges of the foam core. In some embodiments the breathable membrane tab has an adhesive strip 43 thereon and the edge of the foam polymer core has one of a tongue 25, 29 and a groove cut therein or a rebate edge 63, 65, 67, 69 cut therein.

Description

"Insulation Panel for a Cavity Wall"
Introduction
This invention relates to an insulation panel for a cavity wall.
It is known to insulate cavity walls with insulation panels to improve the thermal performance of a building. When the cavity is filled with insulation it is desirable to waterproof the insulation panels to prevent ingress of moisture that has passed through the external brickwork passing into and through the insulation panels where it can cause damage. One very effective way of achieving this has been to provide insulation panels with a high impact polystyrene (HIPS) facer. The HIPS facer with profiled ribs directs water away from the insulation panel and back towards the outer brickwork. However, although highly effective, these HIPS facers add to the manufacturing cost and complexity.
It is also necessary to waterproof the joints between adjacent insulation panels to prevent water seeping into the foam core of the insulation panel and into the inner brickwork of the building. This waterproofing is usually accomplished rather crudely by taping over the joints after installation of the insulation panels. This requires the installer to carry a roll of tape on their person, which is cumbersome and can be unsafe when working at height. Furthermore, taping adjacent insulation panels together is time-consuming.
It is an object of the present invention to provide a solution to one or more of the above-mentioned problems and also to provide a useful choice to the consumer.
Statements of Invention
According to the invention there is provided an insulation panel comprising a substantially rectangular polymer foam core having a facer bonded to one side thereof, a breathable membrane having a vapour resistance less than or equal to 0.60 MN.s/g bonded to the facer, the breathable membrane being dimensioned to extend beyond a pair of adjacent edges of the foam core thereby forming a breathable membrane tab.
Such an insulation panel will be more cost-effective and easier to manufacture. The breathable membrane will waterproof the insulation panels and will be a more cost-effective alternative to a HIPS facer. Furthermore, the substitution of the HIPS facer with the breathable membrane will simplify the manufacturing process of the insulation panel.
The breathable membrane tab is designed to overlap with adjacent insulation panels once assembled and consequently waterproof the joints between the panels, thereby facilitating installation of the insulation. Advantageously, by using a breathable membrane to waterproof the insulation panels and the joints between adjacent insulation panels, this obviates the formation of condensation on the inner face of the insulation.
In one embodiment of the invention there is provided an insulation panel in which the breathable membrane has a vapour resistance less than or equal to 0.25 MN.s/g.
In one embodiment of the invention there is provided an insulation panel in which the breathable membrane has a vapour resistance less than or equal to 0.17 MN.s/g.
In one embodiment of the invention there is provided an insulation panel in which the breathable membrane extends beyond the bottom edge and one side edge of the polymer foam core to form an L-shaped breathable membrane tab. This is a preferred embodiment of the invention as it promotes better water run-off over the insulation panels.
In one embodiment of the invention there is provided an insulation panel in which the breathable membrane tab has a width of no less than O.05m.
In one embodiment of the invention there is provided an insulation in which the breathable membrane tab has a width of the order of 0.0Gm.
In one embodiment of the invention there is provided an insulation panel in which the breathable membrane tab has an adhesive strip thereon. The provision of such an adhesive strip eliminates the need for duct tape and thereby greatly simplifies the installation of the panels.
In one embodiment of the invention there is provided an insulation panel in which the adhesive strip extends along the length of the tab.
In one embodiment of the invention there is provided an insulation panel in which the adhesive strip is L-shaped.
In one embodiment of the invention there is provided an insulation panel in which the adhesive strip is between 0.03m and 0.05m wide.
In one embodiment of the invention there is provided an insulation panel in which the adhesive strip is protected by a peel-away sacrificial strip.
In one embodiment of the invention there is provided an insulation panel in which the adhesive strip is spaced apart from the edge of the breathable membrane tab by 0.01 m.
In one embodiment of the invention there is provided an insulation panel in which each edge of the foam polymer core has one of a tongue and a groove cut therein, a tongue being on the top edge and on one side edge and a groove being on the bottom edge and on the other side edge. It is advantageous to have the tongue on the top edge of the panel to prevent the accumulation of water in the joint.
In one embodiment of the invention there is provided an insulation panel in which each edge of the foam polymer core has a rebate edge cut therein.
In one embodiment of the invention there is provided an insulation panel in which there is a facer on the rear side of the panel.
In one embodiment of the invention there is provided an insulation panel in which the facer is a metal foil.
In one embodiment of the invention there is provided an insulation panel in which the metal foil has been perforated.
In one embodiment of the invention there is provided an insulation panel which has an aged thermal conductivity, A, of «= 0.026 WmK'.
In one embodiment of the invention there is provided an insulation panel which has an aged thermal conductivity, A, of «= 0.021 WHK* In one embodiment of the invention there is provided an insulation panel which has an aged thermal conductivity. A, of «= 0.018 Wm1K1.
In one embodiment of the invention there is provided an insulation panel in which the breathable membrane is bonded to the facer with an adhesive.
In one embodiment of the invention there is provided an insulation panel in which the adhesive for bonding the breathable membrane to the facer is applied in a dotted pattern. This is a preferred embodiment as both vapour-permeable and vapour-impermeable adhesives can then be used without compromising the breathability of the breathable membrane.
In one embodiment of the invention there is provided an insulation panel in which the adhesive for bonding the breathable membrane to the facer is applied in rows.
In one embodiment of the invention there is provided an insulation panel in which the foam polymer core is a polyisocyanurate foam.
In one embodiment of the invention there is provided an insulation panel in which the foam polymer core is phenolic foam.
In one embodiment of the invention there is provided an insulation panel in which the loam polymer core is polyurethane foam.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel comprising the steps of: providing a first facer; laying foam reactants onto the first facer; providing a second facer on top of the foam reactants and the first facer; forming a polymeric foam core and allowing the polymeric foam core to harden; cutting the hardened polymeric foam core and facers into panels; providing a web of breathable membrane having a vapour resistance less than or equal to 0.60 MN.s/g; cutting the web of breathable membrane into sheets in which the length and width dimensions of each sheet are greater than the length and width dimensions of the facer of the insulation panel; and bonding the breathable membrane sheet to one of the facers, the breathable membrane extending beyond a pair of adjacent edges of the foam core thereby forming a breathable membrane tab.
This is a very efficient and inexpensive method of producing a waterproof insulation panel.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel comprising the step of applying an adhesive strip to the breathable membrane in a position corresponding to the breathable membrane tab.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the adhesive strip is applied at least 0.01 m from the edge of the breathable membrane.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the adhesive strip is applied to the breathable membrane in a band between 0.03m and 0.05m wide.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the breathable membrane is bonded to one of the facers with an adhesive, and in which the method comprises the intermediate step of applying an adhesive to one of the facer and the breathable membrane.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the adhesive is applied in a dotted pattern.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the adhesive is applied in a plurality of rows.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the step of cutting the hardened polymeric foam core and facers into panels further comprises cutting a tongue and a groove into opposing edges of the panels.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the step of cutting the hardened polymeric foam core and facers into panels further comprises cutting rebated edges into the panel.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the foam core is polyisocyanurate foam.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the foam core is phenolic foam.
In one embodiment of the invention there is provided a method for the manufacture of an insulation panel in which the foam core is polyurethane foam.
Detailed Description of the Invention
The invention will now be more clearly understood from the following description of some embodiments thereof given by way of example only with reference to the accompanying drawings, in which: Figure 1 is perspective view of an insulation panel according to the invention; Figure 2 is an exploded view of the insulation panel of Figure 1; Figure 3 is a rear view of the insulation panel of Figure 1; Figure 4 is a perspective view of an alternative embodiment of insulation panel according to the invention; Figure 5 is an exploded front view of the insulation panel shown in Figure 4; Figure 6 is a rear view of the breathable membrane for use with the insulation panel of Figures 4 and 5; Figure 7 is a rear perspective view of another alternative embodiment of insulation panel according to the invention; Figure 8 is a rear perspective view of a further still alternative embodiment of the insulation panel according to the invention; Figure 9 is a view of a portion of a breathable membrane tab; Figure 10 is a front perspective view of a plurality of assembled insulation panels; and Figure 11 is a flow diagram of a method of manufacturing an insulation panel according to the invention.
Referring to Figures 1 to 3 inclusive, there is shown an insulation panel, indicated generally by the reference numeral 1 comprising a polymer foam core 3 having a front facer 5 and a rear facer 7 bonded thereto. The insulation panel further comprises a breathable membrane 9 bonded to the front facer 5. The breathable membrane 9 is dimensioned to cover the front facer and protrude beyond the front facer and polymer foam core along the bottom edge 11 and one of the side edges 13 of the polymer foam core, thereby forming an L-shaped breathable membrane tab 15 (indicated by dashed line 17).
BS 5250: 2002 (Code of practice for control of condensation in buildings) defines a breathable membrane as a membrane with a vapour resistance that must not exceed 0.60 MN.s/g. It further sub-defines breathable membranes into two types: HR breathable membranes having a vapour resistance > 0.25 MN.s/g; and LR breathable membranes having a vapour resistance that must not exceed 0.25 MN.s/g. Ventilation and Condensation Risk Condensation can be controlled, in timber frame walls, by ensuring there is a layer of high vapour resistance on the warm side of the insulation. The breathable membrane simply has to be more breathable than the facer on the insulation foam, either the foil or perforated foil. In the present embodiment, the breathable membrane has a vapour resistance of less than or equal to 0.60 MN.s/g. In the embodiment shown, the breathable membrane has a vapour resistance of the order of 0.17 MN.s/g.
Referring specifically to Figures 1 and 2, the [-shaped breathable membrane tab is delineated from the remainder of the breathable membrane by dashed line 7.
In use, a plurality of insulation panels 1 will be placed in rows and columns in the normal manner however the breathable membrane will prevent water that has entered through the external brickwork from coming into contact with the foam core. In addition to this, the breathable membrane tab will extend across the gap between adjacent insulation panels thereby preventing ingress of moisture between the panels into the insulation layer towards the inner layer of blockwork but allowing egress of vapour outwardly towards the outer layer of brickwork.
Referring specifically to Figure 3, it can be seen that the breathable membrane tab 15 extends beyond the bottom edge 11 and side edge 13 of the insulation panel 1. The breathable membrane tab extends outwardly from the edge by a distance of approximately O.06m. This will provide sufficient overlap between the breathable membrane tab and the adjacent panel to prevent ingress of water through the gaps between the insulation panels. By having the breathable membrane tab extending beyond the bottom edge of the foam core, this will facilitate water run-off as it passes down the insulation panels.
Referring now to Figures 4 and 5, there is shown an alternative embodiment of insulation panel, indicated generally by the reference numeral 21, where like parts have been given the same reference numeral as before. The insulation panel 21 differs from the insulation panel illustrated in Figure 1 to 3 in that the polymer foam core 23 comprises a complementary tongue and groove arrangement along the edges of the polymer foam core. The polymer foam core 23 comprises a tongue 25 on the top edge 27 of the polymer foan core and a tongue 29 on the side edge 31 of the polymer foam core. A groove (not shown) is cut into the bottom edge 11 of the polymer foam core 23 and another groove is cut into the side edge 13 of the polymer foam core 23. In use, as a plurality of panels are brought into engagement with each other, the tongue 29 is inserted into a groove on the side edge 13 of an adjacent panel. Similarly, the tongue 25 is inserted into the groove on the bottom edge 11 of an adjacent panel. Tongue and groove joints provide additional structural integrity to the insulation layer. It is favourable to have a tongue on the top edge as a groove on the top edge could conceivably collect water. A breathable membrane 41, described in more detail below with reference to Figure 6, is bonded to one of the facers.
Referring now to Figure 6, there is shown a rear view of an alternative embodiment of breathable membrane for use with the insulation panel of Figures 4 and 5. The breathable membrane, indicated generally by the reference numeral 41, comprises an adhesive strip 43 extending along the length of the breathable membrane tab 15. During transit and prior to use, the adhesive strip will typically be covered with a sacrificial peel-away strip (not shown) of silicon paper or other suitable material. It will be understood that this adhesive strip 43 will be used to seal the breathable membrane tab against the breathable membrane of an adjacent insulation panel (not shown). An adhesive (not -10-shown) may be applied to the remainder of that side of the breathable membrane (excluding the breathable membrane tab) to bond the breathable membrane to a facer of an insulation panel (not shown).
In the embodiment shown, the adhesive strip is formed in two sections however a single section or indeed more than two distinct sections of adhesive strip may be provided. The adhesive strip 43 is preferably of the order of between 0.03 and 0.05m wide and is preferably spaced approximately 0.Olm from the edge of the breathable membrane tab 15. The adhesive strip is a particularly useful feature of the invention as it provides a convenient means for securing the tabs to the adjacent panels. It removes the need to use duct tape or similar, as is the common practice.
Referring to Figure 7, there is shown a rear view of an alternative embodiment of an insulation panel indicated generally by the reference number 51 in which like parts have been given the same reference numbers as before. The insulation panel 51 differs from the insulation panel 21 shown in figures 4 and 5, in that there is no rear facer on the insulation panel 51. In the embodiment shown in figure 7 it is possible to see a groove 53 in the side edge, 13, of polymer foam core 3.
Referring to Figure 8, there is shown an alternative embodiment of insulation panel indicated generally by the reference numeral 61. The insulation panel 61 differs from the insulation panel 51 shown in Figure 7, in that the insulation panel 61 has rebated edges, 63, 65, 67 and 69, instead of a tongue and groove arrangement. Generally speaking, rebated edges provide a less secure fit than tongue and groove edges but are sturdier and better suited when the polymer foam core material is prone to cracking, such as phenolic foam, or when the polymer foam core is particularly thin.
Referring to Figure 9, there is shown a view of a portion of a breathable membrane tab 15, comprising the adhesive strip 43 and peel-away sacrificial strip 91.
Referring now to Figure 10, there is shown a front perspective view of a plurality of assembled insulation panels 21(a), 21(b), 21(c), 21(d), 21(e) and 21(f), where like parts have been given the same reference numerals as before. In this embodiment, the -11 -breathable membrane tabs 15 are provided with adhesive strips 43. The panels are connected together in two rows of three panels.
In order to join the plurality of panels together, panels 21(d) and 21(e) are joined together by inserting the tongue 29 on the edge 31 of the panel 21(d) into the groove in the edge 13 of the insulation panel 21(e). Once the tongue is inserted into the groove, the peel-away sacrificial strip is removed and the breathable membrane tab of 21(e) is secured to the breathable membrane 41 of the panel 21(d). Then, panels 21(e) and 21(f) are joined together by inserting the tongue 29 on the edge 31 of the panel 21(e) into the groove in the edge 13 of the insulation panel 21(f). Once the tongue is inserted into the groove, the peel-away sacrificial strip is renoved and the breathable membrane tab of 21(f) is secured to the breathable membrane 9 of the panel 21(e). The bottom row of insulation panels is now constructed.
Thereafter, the panel 21(a) is connected to the panel 21(d) by inserting the tongue 25 of panel 21(d) into the groove in the bottom edge 13 of panel 21(a). The peel-away sacrificial strip is removed and the breathable membrane tab of 21(a) is secured to the breathable membrane 41 of the panel 21(d) and the breathable membrane tab 15 of panel 21(d). Then, the panel 21(b) is connected to panels 21(a) and 21(e) by inserting the tongue 25 of panel 21(e) into the groove in the bottom edge 13 of panel 21(b) and inserting the tongue 29 of panel 21(a) into the groove in the side edge 11 of panel 21(b).
The peel-away sacrificial strip is removed and the breathable membrane tab of 21(b) is secured to the breathable membrane 41 of the panels 21(e) and 21(a). Finally, the panel 21(c) is connected to panels 21(b) and 21(f) by inserting the tongue 25 of panel 21(f) into the groove in the bottom edge 13 of panel 21(c) and inserting the tongue 29 of panel 21(b) into the groove in the side edge 11 of panel 21(c). The peel-away sacrificial strip is removed and the breathable membrane tab of 21(c) is secured to the breathable membrane 41 of the panels 21(f) and 21(b). The top row of insulation panels is now constructed and attached to the bottom row.
The edges of the foam polymer cores 3 of the panels are shown in dotted lines. The edges of the breather membranes are shown in solid line and it can be seen that they overlap the joints between adjacent panels, side edges and bottom edges. It can be seen that the breathable membrane tabs 15 of the top row of panels 21(a), 21(b) and -12- 21(c) overlap the breathable membranes 41 of the bottom row of panels 21(d), 21(e) and 21(f) thereby facilitating water run-off. In the embodiment shown there are six panels arranged in two rows and three columns. However, it will be understood that a plurality of panels could be arranged in more or fewer rows and more or fewer columns. In the embodiment shown in Figure 10, the portion of the breathable membrane tab extending below the core of the panels 21(d), 21(e) and 21(f) and the portion of the breathable membrane tab to the side of panels 21(a) and 21(d) may be trimmed if desired.
Referring to Figure 11, there is shown a flow diagram of a method of manufacturing an insulation panel according to the invention, indicated generally by the reference numeral 101. The method comprises the initial step of providing a first facer and laying foam reactants onto the first facer in step 103. In step 105. a second lacer is drawn over the top of the foam reactants and the first facer and in step 107 the polymeric foam core is formed and allowed to harden. In step 109, the hardened polymeric foam core and facers are cut into panels. In step 111, a web of breathable membrane having a vapour resistance less than or equal to 0.60 MN.s/g is provided and the web of breathable membrane is cut into sheets in which the length and width dimensions of each sheet are greater than the length and width dimensions of the facer of the insulation panel. Finally, in step 113, adhesive is applied to the breathable membrane in strips on the breathable membrane tab and in a dotted pattern on the remainder of the breathable membrane and the breathable membrane sheet is bonded to one of the facers. The breathable membrane extends beyond a pair of adjacent edges of the foam core thereby forming a breathable membrane tab.
In addition to the foregoing, the side edges of the polymeric foam core may be cut into complementary tongue and groove configurations or alternatively may be rebated to provide a firm engagement between adjacent insulation panels. As an alternative to a dotted pattern, the adhesive may be laid in a plurality of rows. Preferably, the adhesive strip is of the order of 0.03 metres (m) to 0.05 metres wide and the breathable membrane web is cut to provide a breathable membrane tab that protrudes beyond the edge of the foam core by no less than O.O6rn. Depending on the type of foam used in the process, a laminator and/or an oven and/or a cooling station may be used to form and harden the polymer foam core. A trimming station may also be used to remove rough -13-edges from the edges of the foam core and a stacking and a packaging station may be provided to package a stack of boards for transit.
It will be understood that the breathable membrane 41 with adhesive strip and variants thereof may be used to good effect with other configurations of insulation panels such as those shown in Figures 1 to 3 inclusive.
In this specification the terms comprise, comprises, comprised and comprising" and the terms include, includes, included and including" are all deemed totally interchangeable and should be afforded the widest possible interpretation.
The invention is in no way limited to the embodiments hereinbefore described but may be varied in both construction and detail within the scope of the claims. -14-
GB1509502.9A 2015-06-02 2015-06-02 Insulation panel for a cavity wall Active GB2525100B (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB1509502.9A GB2525100B (en) 2015-06-02 2015-06-02 Insulation panel for a cavity wall
IE20150210A IE87073B1 (en) 2015-06-02 2015-06-24 Insulation panel for a cavity wall

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1509502.9A GB2525100B (en) 2015-06-02 2015-06-02 Insulation panel for a cavity wall

Publications (3)

Publication Number Publication Date
GB201509502D0 GB201509502D0 (en) 2015-07-15
GB2525100A true GB2525100A (en) 2015-10-14
GB2525100B GB2525100B (en) 2016-05-04

Family

ID=53677616

Family Applications (1)

Application Number Title Priority Date Filing Date
GB1509502.9A Active GB2525100B (en) 2015-06-02 2015-06-02 Insulation panel for a cavity wall

Country Status (2)

Country Link
GB (1) GB2525100B (en)
IE (1) IE87073B1 (en)

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3111787A (en) * 1960-12-16 1963-11-26 Koppers Co Inc Sandwich roofing element
GB1549943A (en) * 1976-01-22 1979-08-08 Pirelli Wall or ceiling coverings
US20030021979A1 (en) * 2001-03-19 2003-01-30 Ramesh Natarajan S. Composite materials containing a metallic layer and methods for producing same
US20050144850A1 (en) * 2003-12-11 2005-07-07 Hageman John P. Roof having improved base sheet using metal/fabric layers with overhangs
EP1655421A2 (en) * 2004-11-09 2006-05-10 Johns Manville International, Inc. Prefabricated multi-layer roofing panel and system
WO2011088184A2 (en) * 2010-01-13 2011-07-21 Pacific Insulated Panel, Llc Composite insulating building panel and system and method for attaching building panels

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3111787A (en) * 1960-12-16 1963-11-26 Koppers Co Inc Sandwich roofing element
GB1549943A (en) * 1976-01-22 1979-08-08 Pirelli Wall or ceiling coverings
US20030021979A1 (en) * 2001-03-19 2003-01-30 Ramesh Natarajan S. Composite materials containing a metallic layer and methods for producing same
US20050144850A1 (en) * 2003-12-11 2005-07-07 Hageman John P. Roof having improved base sheet using metal/fabric layers with overhangs
EP1655421A2 (en) * 2004-11-09 2006-05-10 Johns Manville International, Inc. Prefabricated multi-layer roofing panel and system
WO2011088184A2 (en) * 2010-01-13 2011-07-21 Pacific Insulated Panel, Llc Composite insulating building panel and system and method for attaching building panels

Also Published As

Publication number Publication date
GB201509502D0 (en) 2015-07-15
IE87073B1 (en) 2019-12-11
IE20150210A1 (en) 2017-01-11
GB2525100B (en) 2016-05-04

Similar Documents

Publication Publication Date Title
US9828776B2 (en) Integrated fiber cement and foam as insulated cladding with enhancements
EP0568587B1 (en) Structure comprising two or more elongated tongue-and-groove building elements
CA2777166C (en) Insulation and ventilation systems for building structures
EP1987208B1 (en) Thermal insulation plate comprising an insulating core and an elevated surface portion, thermally insulated structure of such plates and method for constructing such structure
US20150135623A1 (en) Systems, devices, and methods of an insulated panel structure
WO2008149090A1 (en) Thermal insulation structure
US20170138041A1 (en) Single Leaf Separating Wall
EP1956155A1 (en) A compressible insulation element with reduced friction
EP3239423A1 (en) Fire resistant construction panel element system
EP2657426B1 (en) Sandwich panel and panel system
US20190316352A1 (en) Wall/Roof Construction System and Related Method
US20140345219A1 (en) Roof panel
KR20100078522A (en) Lining paper for joint of plaster board and method thereof
US20140234565A1 (en) Sealing membrane
GB2525100A (en) Insulation panel for a cavity wall
US20200217063A1 (en) Wall/Roof Construction System and Related Method
US11028578B2 (en) Insulation panels with perforated facers
EP2400072B1 (en) Profile system for fitting insulation panels
US9217246B2 (en) Surface covering foundation
US2867007A (en) Building structures
JPH0332161Y2 (en)
EP1611298A1 (en) Aerated insulating panel and process for manufacturing thereof
IE87074B1 (en) A full-fill wall cavity insulation panel
JP5756963B2 (en) Roof panel
EP3385464B1 (en) Insulating panel and method for fixing thereof

Legal Events

Date Code Title Description
732E Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977)

Free format text: REGISTERED BETWEEN 20170622 AND 20170628