GB2608391A

GB2608391A - Construction product, method of making, and method of use

Info

Publication number: GB2608391A
Application number: GB2109359.6A
Authority: GB
Inventors: Ward Jonathan
Original assignee: Corksol Uk Ltd
Current assignee: Corksol Uk Ltd
Priority date: 2021-06-29
Filing date: 2021-06-29
Publication date: 2023-01-04
Also published as: WO2023275515A1; GB202109359D0

Abstract

A thermal insulation material for application onto building surfaces comprises a tree-based component, aerogel, and vapour-permeable binder. Typically, the tree-based component comprises cork and the binder is an acrylic emulsion. Preferably, the thermal insulation material comprises ≥2 wt.% aerogel, ≥4 wt.% cork, and ≥50 wt.% binder. The cork may be in granular form and the aerogel may have a particle size of ≥100 microns. A method of mixing an insulating mixture composed of a tree-based component, aerogel, and vapour-permeable binder comprises dry mixing the aerogel and tree-based component. Typically, the binder is diluted with water and/or wetting agent before addition to the aerogel and tree-based component mixture. A method of insulating a building structure comprises applying a mixture composed of a tree-based component, aerogel, and diluted vapour permeable binder onto a wall, allowing it to dry, and skimming over with plaster. The material may be applied by spraying or trowelling.

Description

CONSTRUCTION PRODUCT, METHOD OF MAKING, AND METHOD OF USE The present invention relates to a construction product, a method of preparation, and a method of application of the product. In particular, the present invention is concerned with a tree-based construction product,such as cork, that acts as an insulating material, and associated methods.

Appropriate thermal insulation of buildings is important to retain heat and thereby reduce energy costs. The use of insulating materials can be helpful in reducing carbon emissions and their negative impact on the environment.

Typical thermal insulation materials for buildings include natural and synthetic fibres, and also foams which are often used in roofs, walls and floors.

Cork is a natural material that is harvested from the barks of trees, such as from the cork oak tree. Cork is known as a good insulator, which is largely due to its microscopic structure. The cork cells comprise air which can inhibit the transfer of heat through the cork.

Aerogels are also known in the art for being good insulators. Aerogels are a highly porous, ultra-light synthetic material made from gels by replacing the solvents on the gel with air. This material has very low density and low thermal conductivity due to its mesopores typically being 50 nm or less. This structure also resists heat transfer through conduction, convection and radiation. However, because the aerogels have low mechanical resistance and are brittle, they are difficult to work with and to apply to building surfaces including walls, floors and ceilings.

A poorly applied layer of aerogel, or any type of insulation, can lead to so-called cold bridges, or thermal bridges, which allow the transmission of heat and build-up of moisture leading to poor energy performance.

When applying insulation wet, water and surfactants can be added to an aerogel insulating mixture to make it more workable. However, if the water content in the insulation mixture is too great initially, cracking of the insulation can also occur as it dries, due to the hygroscopic nature of the aerogel.

Ideally, insulation is installed during the construction of the building, so that it can be easily applied and then hidden once installed.

However, older, poorly insulated buildings also require insulation to be retrofitted, for example by applying an insulating layer over the walls of a room. A common problem with this, when applying to the internal surfaces of the walls, is the ensuing reduction in room size that retrofitting insulation causes. Layers of insulating materials must be installed which are then typically covered in plaster board/drywall and then skimmed over with a thin layer of plaster before a decorative finish is applied. Not only does the extra wall thickness introduced reduce the volume of the room, but certain types of fixtures and fittings, such as radiators and electrical sockets for example, must be moved and refitted after the installation, increasing the total cost and time scale of the project. A further problem is that when applying insulation around windows, the amount of light that enters a room may be reduced.

In the case of many older buildings whose walls are constructed without a cavity and which are designed for water vapour to pass through, the retro-applied installation of vapour-closed insulation materials prevents walls functioning as designed, with the consequent risk over time of moisture build-up within the walls which can cause rot, mould, condensation and reduce the thermal performance of the wall.

Embodiments of the present invention aim to provide an insulating material, and a method of mixing and applying the material, in which at least some of the aforementioned problems are addressed.

The present invention is defined in the attached independent claims, to which reference should now be made. Further, preferred features may be found in the sub-claims appended thereto.

According to one aspect of the present invention, there is provided a thermal insulation material for application onto a building surface, wherein the material comprises a mixture of at least 2% by weight of aerogel, at least 4% by weight of a tree-based component and at least 50% by weight of binder.

Preferably the mixture may comprise at least 3% by weight of aerogel, more preferably at least 6%. Preferably the mixture may contain at least 6% by weight of tree-based component, more preferably at least 8% by weight of tree-based component. Preferably the mixture may comprise at least 60% by weight of binder, more preferably at least 75% by weight of binder.

The mixture may be vapour permeable when applied.

According to another aspect of the present invention, there is provided a thermal insulation material for application onto a building surface, wherein the material comprises a mixture of tree-based component, aerogel and a binder, wherein the mixture is vapour permeable when applied.

According to another aspect of the present invention there is provided a thermal insulation material for application onto a building surface, the material comprising a mixture of a tree-based component, aerogel, and binder, wherein the binder is vapour permeable.

The binder may comprise an acrylic emulsion. The tree-based component may comprise cork.

The mixture may comprise at least 2% by weight of aerogel, at least 4% by weight of cork and at least 50% by weight of binder. Preferably the mixture may comprise at least 3% by weight of aerogel, more preferably at least 6%. Preferably the mixture may contain at least 6% by weight of cork, more preferably at least 8% by weight of cork. Preferably the mixture may comprise at least 60% by weight of binder, more preferably at least 75% by weight of binder.

The cork may be in granular form. The binder may be diluted with water and/or wetting agents.

The aerogel in the mixture may have an average particle size within the range of 100-3500 um. Prefereably, the aerogel in the mixture may have an average particle size within the range of 500-3500 lam. Even more preferably, the aerogel in the mixture may have an average particle size within the range of 1000-3500 lam.

The mixture may comprise cork, aerogel, and diluted binder only.

The mixture may have anti-mould and/or anti-condensation properties.

According to a further aspect of the present invention, there is provided a method for preparing a thermal insulating material, the method comprising mixing together a tree-based component and aerogel in a substantially dry state and then adding a vapour permeable binder. The binder is preferably diluted with water and/or a wetting agent before adding to the cork and aerogel mixture.

The tree-based component may comprise cork. The vapour permeable binder may comprise an acrylic emulsion.

The mixing may take place on site and may take place immediately prior to use of the mixture.

In another aspect, the present invention provides a method of thermally insulating at least a portion of a building surface, the method comprising the steps of applying to the building surface an insulating material comprising a mixture of a tree-based component, aerogel and vapour permeable binder and thereafter applying a layer of plaster material onto the insulating material.

The thermal insulating material may comprise at least 2% by weight of aerogel, at least 4% by weight of cork and at least 50% by weight of binder. Preferably the mixture may comprise at least 3% by weight of aerogel, more preferably at least 6% by weight of aerogel. Preferably the mixture may contain at least 6% by weight of cork, more preferably at least 8% by weight of cork. Preferably the mixture may comprise at least 60% by weight of binder, more preferably at least 75% by weight of binder.

Preferably, the method comprises applying the plaster material directly to the insulating material. In a preferred arrangement, the method includes allowing the insulating material to dry substantially before applying the plaster material.

The method may comprise skimming the plaster material after, and/or during applying it to the insulating material.

The method may comprise applying the insulating material to an internal wall of a building.

Preferably the skimmed plaster has a thickness of 1-3 mm. Preferably the insulating material is applied to the wall by spraying. Alternatively or additionally, the material is applied to the wall by trowelling.

The thickness of the insulating material may be of a range of 2-25mm. More preferably the thickness of the insulating material may be of a range of 4-8 mm.

The invention may include any combination of the features or limitations referred to herein, except such a combination of features as are mutually exclusive, or mutually inconsistent.

A preferred embodiment of the present invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which: Figure 1 shows a schematic section of part of a wall with retrofitted insulation according to prior art; and Figure 2 shows a schematic section of part of a wall with retrofitted insulation according to an embodiment of the present invention.

Turning to Figure 1, in accordance with a previously considered retro-fit insulation process, a wall to be insulated is shown generally at 100. A layer of insulating material 110 lies on the wall surface. On top of the insulating material is a portion of plaster board 120, onto which has been skimmed a thin layer of plaster 130. The cumulative thickness of these layers is represented by T. Turning to Figure 2, the wall to be insulated is shown generally at 200. Applied to the wall 200 is a layer of insulating material 210, in accordance with an embodiment of the present invention. On top of the insulating mixture is a layer of skimmed plaster 230. The thickness of the cumulative layers of insulator and skimmed plaster is represented by I'. T' is of a shorter length than T of Figure 1. Insulating material 210 has a thickness of less than 25 mm, more preferably a thickness of less than 4-8mm.

The insulating material layer 210 is a mixture of cork granules, aerogel and binder. The cork granules comprise natural cork with particle size of 0.5-2mm in diameter. The aerogel may have an average particle size of 100-3500 pm. Preferably, the aerogel may have an average particle size of 500-3500 pm. Even more preferably, the aerogel may have an average particle size of 1000-3500 um. The binder may be a vapour permeable acrylic emulsion.

The present invention allows for the application of an effective insulation layer onto surfaces of a room, which layer can be applied during the construction of a building or else can be retrofitted to an existing building. The insulating material comprises a relatively thin layer that does not significantly reduce the volume of a room when applied to its walls, nor does it require the movement or replacement of any fixtures and fittings.

The insulating layer thus formed is vapour permeable and relatively smooth, which allows plaster to be skimmed straight onto it when it has substantially dried. This eliminates the need for any levelling work to be carried out and/or plasterboard to be installed over the insulation prior to a final skim, thus saving time and cost. Because of the permeability of the insulating material, when the plaster is skimmed on top of the insulation, the plaster can dry out at an optimal rate to provide a good bond to the insulation, without cracking.

A further benefit of the insulation being vapour permeable is that it allows for moisture control within a building. This is especially beneficial when the insulation is fitted to an already breathable wall, so as to preserve this feature and prevent condensation and/ or rotting of timbers within the wall.

Embodiments of the present invention obviate the need for surfactants to be used in the insulating mixture.

Embodiments of the present invention have demonstrated increased thermal performance over the prior art.

Insulating material according to embodiments of the present invention comprises aerogel which has been mixed in a way so that it can be applied by spraying, or trowelling.

The mixture also comprises the natural component cork, which is a carbon-negative product. The harvesting of cork does not require mature trees to be felled and instead encourages the trees to absorb more carbon by regrowing their cork bark after each harvest.

The low water content of the material further reduces the possibility of the insulating mixture cracking as it dries after application.

The composition of the mixture allows it to be flexible, strong, and to adhere to a range of different surfaces, such as plaster and stone.

Furthermore, the material is economical to manufacture, to store and to apply.

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance, it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and/or shown in the drawings, whether or not particular emphasis has been placed thereon.

Claims

CLAIMS1. A thermal insulation material for application onto a building surface, wherein the material comprises a mixture of a tree-based component, aerogel, and a binder, wherein the binder is vapour permeable.
2. A mixture according to Claim 1, wherein the binder comprises an acrylic emulsion.
3. A mixture according to previous claims, wherein the tree-based component comprises cork.
4. A mixture according to Claim 3, wherein the percentage of aerogel by weight is at least 2%, the percentage of cork by weight is at least 4% and the percentage of binder by weight is at least 50%.
5. A mixture according to Claim 4, wherein the percentage of aerogel by weight is at least 3%, more preferably at least 6%.
6. A mixture according to Claim 4, wherein the percentage of cork by weight is at least 6%, more preferably at least 6%.
7. A mixture according to Claim 4, wherein the percentage of binder by weight is at least 60%, more preferably at least 75%.
6. A mixture according to any of Claims 3-7, wherein the cork is in granular form.
9. A mixture according to any preceding claim, wherein the aerogel has an average particle size of at least 100 um.
10. A method of mixing an insulating mixture for application onto a surface wherein the mixture comprises a tree-based component, aerogel, and a vapour permeable binder whereby the tree-based component and aerogel are first mixed together dry.
U. A method according to Claim 10, wherein the tree-based component comprises cork.
12. A method according to Claim 11, wherein the insulating mixture comprises at least 2% by weight of aerogel, at least 4% be weight of cork, and at least 50% by weight of diluted vapour permeable binder.
13. A method according to Claim 12, wherein the insulating mixture comprises at least 3% by weight of aerogel, more preferably at least 6.,*, at least 6% by weight of cork, more preferably at least 8%, and at least 60% by weight of diluted binder, more preferably at least 75%, whereby the cork and aerogel are first mixed together dry.
14. A method according to any of Claims 10-13, wherein the vapour permeable binder is an acrylic emulsion.
15. A method according to any of Claims 10-14, wherein the binder is diluted with water prior to being added to the tree-based component and aerogel mixture.
16. A method according to any of Claims 10-14, wherein the binder is diluted with a wetting agent prior to being added to the tree-based component and aerogel mixture.
17. A method according to any of Claims 10-14, wherein the binder is diluted with water and a wetting agent prior to being added to the tree-based component and aerogel mixture.
18. A method of insulating part of a building structure, wherein a mixture comprising aerogel, a tree-based component and diluted vapour permeable binder is applied onto a wall, allowed to dry, and skimmed over with plaster.
19. A melhod according Lc Claim 18, wherein Lhe Lreebased component comprises cork.
20. A method according to Claim 19, wherein a mixture comprising at least 2', by weight of aerogel, at least 4?, by weight of cork, and at least 50'3 by weight of diluted binder is applied onto a wall, allowed to dry, and skimmed over with plaster.
21. A method according to Claim 20, wherein a mixture comprising at least 3% by weight of aerogel, more preferably at least 6, at least 6% by weight of cork, more preferably at least 8%, and at least 60', by weight of diluted binder, more preferably at least 75% is applied onto a wall, allowed to dry and skimmed over with plaster.
22. A method according to Claim 20 or 21, wherein a mixture is applied to a wall in the room by spraying.
23. A method according to Claim 20 or 21, wherein a mixture is applied to a wall in the room by trowelling.
24. A method according to any of Claims 18-23, wherein the thickness of the applied mixture is between 2-25
25. A method according to Claim 24, wherein the thickness of the applied mixture is between 4-8 mm.