GB2620231A - Method for filling a cavity in a building component and a building component - Google Patents
Method for filling a cavity in a building component and a building component Download PDFInfo
- Publication number
- GB2620231A GB2620231A GB2305421.6A GB202305421A GB2620231A GB 2620231 A GB2620231 A GB 2620231A GB 202305421 A GB202305421 A GB 202305421A GB 2620231 A GB2620231 A GB 2620231A
- Authority
- GB
- United Kingdom
- Prior art keywords
- cavity
- building component
- insulation
- filler
- flowable
- 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.)
- Pending
Links
- 238000000034 method Methods 0.000 title claims abstract description 130
- 238000009413 insulation Methods 0.000 claims abstract description 164
- 239000000945 filler Substances 0.000 claims abstract description 114
- 239000000853 adhesive Substances 0.000 claims abstract description 96
- 230000001070 adhesive effect Effects 0.000 claims abstract description 95
- 230000009969 flowable effect Effects 0.000 claims abstract description 91
- 239000004793 Polystyrene Substances 0.000 claims description 13
- 229920002223 polystyrene Polymers 0.000 claims description 13
- 239000011324 bead Substances 0.000 claims description 6
- 239000007788 liquid Substances 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 5
- 239000004794 expanded polystyrene Substances 0.000 claims description 5
- 229910001220 stainless steel Inorganic materials 0.000 claims description 5
- 239000010935 stainless steel Substances 0.000 claims description 5
- 239000010959 steel Substances 0.000 claims description 5
- 238000007789 sealing Methods 0.000 claims description 4
- 239000000126 substance Substances 0.000 claims description 4
- 230000001419 dependent effect Effects 0.000 claims description 3
- 239000012774 insulation material Substances 0.000 abstract description 25
- 239000000463 material Substances 0.000 abstract description 18
- 238000011065 in-situ storage Methods 0.000 abstract description 3
- 239000002184 metal Substances 0.000 description 11
- 229910052751 metal Inorganic materials 0.000 description 11
- 230000008878 coupling Effects 0.000 description 10
- 238000010168 coupling process Methods 0.000 description 10
- 238000005859 coupling reaction Methods 0.000 description 10
- 239000007787 solid Substances 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 4
- 210000002105 tongue Anatomy 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 230000001788 irregular Effects 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 230000004888 barrier function Effects 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/29—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/04—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal
- E04C3/06—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web
- E04C3/07—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of metal with substantially solid, i.e. unapertured, web at least partly of bent or otherwise deformed strip- or sheet-like material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C2003/023—Lintels
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Building Environments (AREA)
- Joining Of Building Structures In Genera (AREA)
- Adhesives Or Adhesive Processes (AREA)
Abstract
A method (100 figure 1) for at least partially filling a cavity in a building component 1 e.g. a lintel. The method comprises providing a building component having a cavity (step 101 figure 1) and forming an insulation member within the cavity of the building component (step 102 figure 1). The insulation member comprises filler material and an adhesive. The building component 1 has a plurality of walls (4 figure 2) and two open ends 8. The building component 1 comprises a central protruding portion (9 figure 2) and two lateral portions (10 figure 2). Each lateral portion (10 figure 2) is generally planar and is configured for supporting the building component 1 in situ on a pair of spaced apart support walls. The cavity 2 is defined in the central protruding portion (9 figure 2) between the walls (4 figure 2) and is configured for receiving the insulation member. Forming the insulation member within the cavity 2 comprises forming a flowable insulation material; providing the flowable insulation material within the cavity 2, and allowing the flowable insulation material to set, cure or harden.
Description
METHOD FOR FILLING A CAVITY IN A BUILDING COMPONENT AND A BUILDING
COMPONENT
The present invention relates to a method for filling a cavity in a building component such 5 as a lintel, and a building component such as a lintel.
Building components such as lintels are commonly used to support brickwork and other structures above apertures for windows and doors, etc. It is common for lintels to extend horizontally between supporting members such as the walls on either side of an aperture, and to span between the interior and exterior of the building envelope. Metal lintels, such as box lintels and top-hat lintels, are typically formed from a metal sheet which is folded into a predetermined shape having an internal cavity between the open ends. Since metals are good conductors of heat, the use of metal lintels runs the risk of creating 'cold bridges' between the interior and exterior of a building. Cold bridging can allow heat to escape from a building, and can lead to Is condensation on the internal walls.
In the past the problem of cold bridging in building components such as lintels has been addressed by filling a cavity in the building component with an insulation member such as a preformed polystyrene block. While these pre-formed insulation members can help to reduce the overall thermal conductivity of the building component, it can be difficult to accurately machine insulation members to fit perfectly within the cavity. Loose-fitting insulation members can leave uninsulated gaps within the cavity and are liable to fall out of the open ends thereof, for example during transport. Furthermore, while a preformed polystyrene block can easily be slid into a cavity formed of exclusively straight walls, it can be impractical or impossible to slide a pre-formed polystyrene block into a cavity formed of curved walls, for example as found in arched or parabolic lintels. As a result, curved building components such as arched and parabolic lintels often go without any insulation in their cavities.
It is an object of the present invention to obviate or mitigate the problems outlined above. In particular, it is an object of the invention to insulate a building component in such a way 30 that obviates or mitigates the disadvantages of the methods described above.
It is a further object of the invention to provide a method of filling the cavity of a building component.
It is a further object of the invention to provide a method for insulating a wide variety of building components having a wide variety of shapes.
It is a further object of the invention to provide an insulated building component.
It is a further object of the invention to provide a building component comprising secure insulation.
According to a first aspect of the invention there is provided a method for at least partially filling a cavity in a building component, the method comprising: forming an insulation means within the cavity of a building component, wherein the insulation means comprises filler means and an adhesive means. Advantageously the filler means is held within the cavity by the adhesive means.
Preferably the method is for filling a cavity in a lintel.
Preferably the method is for providing insulation in a lintel.
Preferably the method is for providing insulation in the cavity of a lintel, such as a straight, arched, curved or parabolic lintel.
Preferably the method comprises providing a building component.
Preferably the method comprises providing a building component, wherein the building component comprises a cavity.
Preferably the method comprises providing a lintel, such as an open-profile lintel. Preferably the method comprises forming a flowable insulation means. By "flowable" it is meant that the insulation means is able to flow, for example into a cavity. Advantageously, the 15 flowable insulation means is able to flow into the cavity where it will conform to the shape of the cavity.
Preferably the method comprises mixing filler means with an adhesive means.
Preferably the method comprises mixing solid-state filler means with a liquid-state adhesive means. Advantageously, the solid-state filler means can be suspended in the liquid-20 state adhesive means to form a material which is able to flow i.e. a flowable insulation means. Preferably the method comprises mixing filler means having a low thermal conductivity with an adhesive means. Advantageously, the low thermal conductivity of the filler means can provide suitable insulation for the cavity of a building component.
Preferably the method comprises mixing a plurality of filler elements with an adhesive means.
Preferably the method comprises mixing a plurality of filler elements with an adhesive means, wherein each of the filler elements are substantially identical or similar.
Preferably the method comprises mixing a plurality of filler elements with an adhesive means, wherein each of the filler elements are substantially identical or similar in size, shape 30 and/or material composition.
Preferably the method comprises mixing a plurality of filler elements with an adhesive means, wherein each filler element, or at least one filler element, comprises or is formed from a polymeric substance.
Preferably the method comprises mixing a plurality of filler elements with an adhesive 35 means, wherein each filler element, or at least one filler element, comprises or is formed from polystyrene, such as expanded polystyrene.
Preferably the method comprises forming a flowable insulation means by mixing filler means with an adhesive means, wherein the filler means comprises polystyrene balls or beads.
Preferably the method comprises forming a flowable insulation means by mixing a plurality of filler elements with an adhesive means, wherein the plurality of filler elements comprises a plurality of polystyrene balls or beads.
Preferably the method comprises forming a flowable insulation means by mixing a plurality 5 of filler elements with an adhesive means, wherein each filler element is spherical or substantially spherical.
Preferably the method comprises forming a flowable insulation means by mixing a plurality of filler elements with an adhesive means, wherein the volume of each filler element is substantially less than the volume of the cavity. Advantageously, such filler elements can easily 10 fit into the cavity, even if the cavity has an irregular shape.
Preferably the method comprises forming a flowable insulation means by mixing a plurality of filler elements with an adhesive means, wherein each filler element has a volume less than 10 cm3, ideally less than 1 cm3.
Preferably the method comprises forming an insulation means by mixing filler means with IS a water-based adhesive means. Advantageously, use of a water-based adhesive means does not degrade or dissolve the filler means and/or the plurality of filler elements during mixing of the filler means and the adhesive means.
Preferably the method comprises forming the flowable insulation means before providing the flowable insulation means within the cavity.
Optionally the method comprises forming the flowable insulation means within the cavity.
Preferably the method comprises closing or sealing one or more openings or apertures in the building component.
Preferably the method comprises closing or sealing an open end of the building component.
Preferably the method comprises closing or sealing at least one opening or aperture in the building component with a retaining means.
Preferably the method comprises providing a retaining means over an opening or aperture in the building component. Advantageously, the retaining means is able to retain the flowable insulation means within the cavity while the adhesive means sets, cures or hardens.
Preferably the method comprises at least partially filling the cavity.
Preferably the method comprises at least partially filling the cavity with flowable insulation means. Advantageously, the flowable insulation means is adapted to fill the cavity and closely conform to the internal shape of the cavity, providing an insulation means which accurately fits within the cavity.
Preferably the method comprises filling substantially the entire cavity with flowable insulation means.
Preferably the method comprises filling substantially the entire cavity with flowable insulation means, wherein the flowable insulation means comprises an adhesive in a liquid state.
Preferably the method comprises pouring flowable insulation means into the cavity.
Preferably the method comprises providing flowable insulation means into the cavity while the insulation means is in a flowable state. By "flowable state" it is meant that the flowable insulation means is able to flow, as opposed to its solidified, set, cured or hardened state in which it cannot flow.
Preferably the method comprises providing flowable insulation means into the cavity while the adhesive means is in a flowable or liquid state Preferably the method comprises providing flowable insulation means into the cavity using a dispensing means.
Preferably the method comprises providing flowable insulation means into the cavity using a dispensing means, wherein the dispensing means comprises a dispensing nozzle connected to a hopper. Advantageously, the flowable insulation means may be blown into the building component, for example in a high pressure spray from a pressurised hopper containing a supply of flowable insulation means.
Optionally the method comprises locating filler means in the cavity.
Optionally the method comprises pouring the adhesive means into a cavity which has been pre-filled with filler means.
Preferably the method comprises allowing air to exit the cavity.
Preferably the method comprises allowing air to exit the cavity while the cavity is being 20 filled with flowable insulation means, filler means and/or adhesive means.
Preferably the method comprises allowing air to exit the cavity via one or more apertures or openings.
Preferably the method comprises allowing air to exit the cavity via one or more apertures or openings in the retaining means.
Preferably the method comprises tilting the building component.
Preferably the method comprises tilting the building component during filling of the cavity. Advantageously, tilting the building component during filling can encourage the flowable insulation means, filler means and/or adhesive means to flow into parts of the cavity under the force of gravity.
Preferably the method comprises forming an insulation means within the cavity.
Preferably the method comprises forming a solid insulation means within the cavity.
Preferably the method comprises forming a solid insulation means within the cavity by allowing the flowable insulation means and/or adhesive means to set, cure or harden within the cavity.
Preferably the method comprises solidifying the flowable insulation means and/or adhesive means.
Preferably the method comprises allowing the flowable insulation means and/or adhesive means to set, cure or harden within the cavity.
Preferably the method comprises allowing the flowable insulation means and/or adhesive means to set, cure or harden while the insulation means and/or adhesive means is/are located inside the cavity.
Preferably the method comprises allowing the flowable insulation means and/or adhesive 5 means to become solid.
Preferably the method comprises retaining the flowable insulation means within the cavity. Preferably the method comprises retaining the flowable insulation means within the cavity while the flowable insulation means and/or adhesive means solidifies.
Preferably the method comprises retaining the flowable insulation means within the cavity 10 while the flowable insulation means and/or adhesive means sets, cures or hardens.
Preferably the method comprises removing the retaining means from the building component.
Preferably the method comprises removing the retaining means from an open end of building component.
IS Preferably the method comprises removing the retaining means after the flowable insulation means and/or adhesive means has solidified.
Preferably the method comprises removing the retaining means after the flowable insulation means and/or adhesive means has set, cured or hardened.
Preferably the method comprises forming an insulation means comprising at least 50% by 20 volume of filler means.
Preferably the method comprises forming an insulation means comprising at least 75% by volume of filler means.
Preferably the method comprises forming an insulation means comprising up to or less than 50% by volume of adhesive means.
Preferably the method comprises forming an insulation means comprising up to or less than 25% by volume of adhesive means.
According to a second aspect of the invention there is provided a method for forming an insulation means for the cavity of a building component, the method comprising: mixing filler means and an adhesive means; and allowing the adhesive means to solidify, set, cure and/or harden. Advantageously, the insulation means can be provided in a wide variety of cavities having many different shapes.
According to a third aspect of the invention there is provided a building component comprising a cavity and an insulation means, the insulation means comprising filler means and an adhesive means, wherein the insulation means is locatable within the cavity. Advantageously the adhesive means is operable, in use, to prevent the filler means from becoming dislodged from the cavity of the building component.
Preferably the insulation means comprises an insulation member. Advantageously, the insulation means provides insulation and thereby reduces and/or prevents cold bridging through the building component.
Preferably the insulation means fills at least a part of the cavity.
Preferably the insulation means fills substantially the entire cavity.
Preferably the insulation means is a solid insulation means Preferably the insulation means is formed from a flowable insulation means. Advantageously, the shape of the insulation means substantially conforms to the internal shape of at least part of the cavity.
Preferably the insulation means is in a set, cured or hardened state.
Preferably the insulation means has solidified.
Preferably the adhesive means is in a solid state.
Preferably the adhesive means is in its set, cured or hardened state. Preferably the filler means is configured for filling at least part of the cavity.
Ideally, the filler means comprises polystyrene, such as expanded polystyrene.
Preferably the filler means comprises a plurality of filler elements.
Preferably the filler means comprises a plurality of substantially identical or similar filler elements, such as balls or beads.
Preferably the filler means comprises a plurality of filler elements that are substantially 20 identical or similar in size, shape and/or material composition.
Preferably each filler element, or at least one filler element, comprises or is formed from a polymeric substance.
Ideally each filler element, or at least one filler element, comprises or is formed from polystyrene, such as expanded polystyrene.
Preferably the plurality of filler elements comprises a plurality of polystyrene balls or beads.
Preferably each filler element is spherical or substantially spherical.
Preferably the volume of each filler element is substantially less than the volume of the cavity. Advantageously, such filler elements can easily fit into the cavity, even if the cavity has an 30 irregular shape.
Preferably each filler element has a volume less than 10 cm', ideally less than 1 cm'. Preferably the filler means is at least partially held within the cavity by the adhesive means. Preferably the adhesive means is configured for retaining the filler means within the cavity. Preferably the adhesive means is configured for adhesively fixing the filler means within the cavity.
Preferably the adhesive means is configured for retaining the plurality of filler elements within the cavity.
Preferably the adhesive means is configured for adhesively fixing the plurality of filler elements within the cavity.
Preferably the adhesive means is a water-based adhesive means. Advantageously, use of a water-based adhesive means does not degrade or dissolve the filler means and/or the 5 plurality of filler elements.
Preferably, in use, the adhesive means holds the filler means and/or filler elements inside the cavity.
Preferably the adhesive means, in its set cured or hardened state, holds the filler means and/or filler elements inside the cavity.
Preferably the adhesive means prevents the filler means and/or filler elements from moving within the cavity and/or exiting the cavity.
Preferably the adhesive means is configured for adhesively bonding the filler means. Preferably the adhesive means is configured for adhesively bonding the insulation means to the building component.
Preferably the adhesive means configured for adhesively bonding the insulation means to the walls defining the cavity. Advantageously, adhesive bonding between the insulation means and the walls of the cavity prevents the insulation means from becoming dislodged from the cavity. Preferably the adhesive means is configured for adhesively bonding the filler means to the building component.
Preferably the insulation means comprises at least 50% by volume of filler means.
Preferably the insulation means comprises at least 75% by volume of filler means. Preferably the insulation means comprises up to or less than 50% by volume of adhesive means.
Preferably the insulation means comprises up to or less than 25% by volume of adhesive means.
Preferably the building component is locatable above an opening in a building.
Preferably the building component is configured for supporting brickwork in a building or structure.
Preferably the building component is configured for supporting brickwork above an 30 aperture or opening, such as a window or door aperture in a wall.
Preferably the building component is an elongate building component.
Preferably the building component is a lintel.
Optionally the building component is a curved building component, such as an arched, curved or parabolic lintel.
Preferably the building component is an open-profile lintel.
Preferably the building component has at least one open end, for example two open ends. Preferably the building component has a top-hat cross section.
Optionally the building component has a box-shaped cross section.
Preferably the building component is formed from a folded metal sheet.
Preferably, the building component is roll formed or pressed from a single sheet of material.
Preferably the building component is formed from a plurality of metal sheets.
Preferably the building component is formed from a plurality of welded metal sheets.
Preferably the building component is formed from steel or stainless steel.
Preferably the building component comprises one or more walls.
Preferably the cavity is defined between one or more walls of the building component. Preferably the cavity is located between the one or more walls.
Preferably the cavity is configured for receiving insulation means. Advantageously, insulation means within the cavity reduces the overall thermal conductivity of the building component.
Preferably one or more of the walls are flat.
Optionally one or more of the walls are curved.
Preferably the cavity is open on at least one side.
Preferably the cavity is open on at least two sides.
Preferably the cavity is open on two or three sides.
Preferably the building component comprises one or more lateral portions.
Preferably the building component comprises two lateral portions.
Preferably the or each lateral portion is configured for supporting the lintel in situ on a pair of spaced apart support means.
Ideally, the or each lateral portion is generally planar.
Preferably the building component comprises a central protruding portion.
Preferably the central protruding portion spans between two lateral portions.
Preferably a gap exists between the two lateral portions.
Preferably the cavity is defined in the central protruding portion.
Preferably the building component comprises a thermal break plate. Advantageously the thermal break plate is adapted to minimise the thermal bridge effect across the thermal break plate.
Preferably the thermal break plate is adapted to span the gap between the two lateral portions.
Preferably the thermal break plate is adapted to span the gap along at least part of the length of the building component.
Ideally the thermal break plate is adapted to couple the two lateral portions together along at least part of the length of the building component. Advantageously, the thermal break plate improves the structural performance of the building component. Additionally, the thermal break plate and insulation means function synergistically to improve the insulation characteristics of the building component.
Preferably the thermal break plate is manufactured from a single sheet of material and most preferably punched or cut from a sheet of material.
Preferably the thermal break plate is manufactured from a single sheet of metal.
Preferably the thermal break plate is manufactured from steel or stainless steel.
Ideally the thermal break plate is adapted to couple the lateral portions together.
Preferably the thermal break plate comprises coupling means.
Ideally the thermal break plate comprises coupling means for mechanically coupling the thermal break plate to the building component, for example the lateral portions of the building component.
Preferably the coupling means overlap the underside surface of the lateral portions of the building component.
Ideally the coupling means protrude from one or more longitudinal edges of the thermal break plate.
Ideally the coupling means comprise one or more tabs.
Preferably the tabs are co-planar with the main plane of the thermal break plate.
Ideally the tabs are spaced apart on each longitudinal side of the thermal break plate. Preferably the thermal break plate comprises a plurality of rebated portions.
Preferably the thermal break plate comprises a plurality of rebated portions located between the coupling means.
Preferably the rebated portions provide air gaps between the thermal break plate and the lateral portions of the building component. Advantageously, the air gaps provide insulation to the lintel reducing the effect of thermal bridging when the building component is installed.
Ideally the thermal break plate comprises movement restriction means.
Ideally the thermal break plate comprises movement restriction means for preventing 25 movement of the insulation means relative to the building component.
Preferably the movement restriction means extends into the cavity.
Ideally the movement restriction means comprises one or more tongues.
Preferably the tongues are perpendicular to the main plane of the thermal break plate.
Preferably the thermal break plate comprises one or more discontinuities.
Advantageously, having a plurality of discontinuities creates a thermal barrier by forming a tortuous path for heat transfer between the two longitudinal sides of the thermal break plate.
Preferably the one or more discontinuities comprise a plurality of apertures in the thermal break plate. Advantageously, the plurality of apertures which also act as air gaps increase the insulation properties of the thermal break plate.
Preferably the one or more discontinuities comprises at least one elongate slot.
Preferably the one or more discontinuities comprises rows of elongate slots.
According to a fourth aspect of the invention there is provided a retaining means for retaining a flowable insulation means within the cavity of a building component. Advantageously, the retaining means acts to keep the flowable insulation means within the cavity and prevents escape of the flowable insulation means therefrom.
Preferably the retaining means is a planar member.
Preferably the retaining means comprises a body.
Preferably the retaining means comprises one or more apertures or openings. Advantageously the one or more apertures or openings allow air to pass through the body of the retaining means.
Preferably in use, the retaining means acts to retain the flowable insulation means within the cavity and prevents escape of the flowable insulation means therefrom.
Preferably in use, the retaining means acts to retain the flowable insulation means while the flowable insulation means solidifies, sets, cures or hardens.
According to a fifth aspect there is provided a method for manufacturing a building component, the method comprising forming an insulation means within the cavity of the building component, wherein the insulation means comprises filler means and an adhesive means. Advantageously, the insulation means is adapted to provide thermal insulation within the cavity of the building component.
Preferably the method comprises forming a building component.
Preferably the method comprises forming a building component, wherein the building component is a lintel having a cavity.
Preferably the method comprises forming a building component comprising one or more walls Preferably the method comprises forming a building component comprising two lateral portions.
Preferably the method comprises arranging a thermal break plate between the two lateral portions.
Preferably the method comprises arranging a thermal break plate to span the gap between 30 the two lateral portions.
Preferably the method comprises defining a cavity between the one or more walls and the thermal break plate.
Preferably the method comprises attaching the thermal break plate to the building component.
Preferably the method comprises attaching the thermal break plate to the lateral portions.
Preferably the method comprises attaching the thermal break plate to the building component either before or after forming the insulation means in the cavity.
Preferably the method comprises attaching the thermal break plate either before or after forming the insulation means between the one or more walls of the building component. Preferably the method comprises arranging the insulation means such that the insulation means contacts the one or more walls and the thermal break plate. Advantageously, the adhesive 5 means of the insulation means functions to improve the fix between the thermal break plate and the two lateral portions, thereby improving the structural integrity of the building component.
According to a sixth aspect of the invention there is provided a building component comprising a cavity, wherein a plurality of filler elements are locatable within the cavity. 10 Advantageously the plurality of filler elements are adapted to substantially fill at least a portion of the cavity.
It will be appreciated that optional features applicable to one aspect of the invention can be used in any combination, and in any number. Moreover, they can also be used with any of the IS other aspects of the invention in any combination and in any number. This includes, but is not limited to, the dependent claims from any claim being used as dependent claims for any other claim in the claims of this application.
The invention will now be described with reference to the accompanying drawings which 20 show by way of example only an embodiment of a method in accordance with an aspect of the invention, and an embodiment of an apparatus in accordance with an aspect of the invention.
Figure 1 is a schematic view of a method according to an aspect of the invention. Figure 2 is a perspective view of a building component.
Figure 3 is a perspective view of a building component according to an aspect of the invention.
In figure 1 there is shown a method 100 for at least partially filling a cavity in a building component according to an aspect of the invention. The method 100 comprises providing a building component having a cavity (step 101) and forming an insulation member within the cavity of the building component (step 102). The insulation member comprises filler material and an adhesive. In preferred embodiments the insulation member is formed by mixing the filler material and the adhesive while the adhesive is in a flowable or liquid state, and subsequently allowing the adhesive to set, cure or harden into a solid state (i.e. to solidify). In use, the filler material is held within the cavity by the adhesive.
In step 101 a building component having a cavity is provided, such as the building component 1 shown in figure 2. The building component 1 is an elongate building component in the form of an open-profile lintel 1. In particular, the building component 1 is a top-hat lintel having a top-hat cross section. The building component 1 has a plurality of walls 4 and two open ends 8. The building component 1 comprises a central protruding portion 9 and two lateral portions 10. Each lateral portion 10 is generally planar and is configured for supporting the building component 1 in situ on a pair of spaced apart support walls. The cavity 2 is defined in the central protruding portion 9 between the walls 4 and is configured for receiving an insulation member. The example building component 1 is formed, particularly roll formed or pressed, from a folded metal sheet such as a steel or stainless steel sheet.
As can be seen in figure 2, a gap 12 exists between the two lateral portions 10 of the building component 1. A thermal break plate 11 spans the gap 12 between the two lateral portions 10 and couples the two lateral portions 10 of the building component 1 together. The thermal break plate 11 is manufactured from a single sheet of material and most preferably punched or cut from a sheet of material. In preferred embodiments the thermal break plate 11 is formed from steel or stainless steel and is welded to the lateral portions 10. The thermal break plate 11 is adapted to minimise the thermal bridge effect across the thermal break plate 11.
The thermal break plate 11 comprises coupling members in the form of a plurality of tabs 13 protruding from one longitudinal edge of the thermal break plate 11. The tabs 13 are adapted for mechanically coupling the thermal break plate 11 to a lateral portion 10 of the building component 1. The tabs 13 are co-planar with the main plane of the thermal break plate 11 and overlap the underside surface of a lateral portion 10 of the building component 1. A plurality of rebated portions 14 are located between the tabs 13. The rebated portions 14 provide insulating air gaps between the thermal break plate 11 and a lateral portion 10 of the building component 1.
The thermal break plate 11 further comprises movement restriction arrangements 15 for holding an insulation member in position within the cavity 2, and for preventing lateral movement of an insulation member within the cavity 2. The movement restriction arrangements 15 comprise tongues 15 which extend from a peripheral edge of the thermal break plate 11 into the cavity 2. The tongues 15 are perpendicular to the main plane of the thermal break plate 11.
The thermal break plate 11 further comprises a plurality of discontinuities in the form of elongate slots 16. The slots 16 create a thermal barrier by forming a tortuous path for heat transfer between the opposing edges of the thermal break plate 11. The rows of elongate slots 16 are :30 staggered such that the gap between slots on one row coincides with a slot 16 on an adjacent row and vice versa. The discontinuities may also be circular, zig-zag or any shape capable of providing a discontinuity in order to retard heat transfer from one side of the thermal break plate 11 to the other.
Returning to figure 1, in step 102 an insulation member is formed within the cavity of the building component 1. Forming an insulation member within the cavity 2 comprises: forming a flowable insulation material; providing the flowable insulation material within the cavity 2; and allowing the flowable insulation material to set, cure or harden. By "flowable" it is meant that the insulation material is able to flow into the cavity 2 where it will conform to the shape of the cavity.
The flowable insulation material is formed by mixing filler material 5 with an adhesive 6. Particularly, the method 100 comprises mixing solid-state filler material 5 having a low thermal conductivity with a liquid-state adhesive 6. In preferred embodiments the filler material 5 comprises a plurality of filler elements 7 that are substantially identical in size, shape and/or 5 material composition. Ideally the plurality of filler elements 7 comprises a plurality of polystyrene balls or beads 7. In contemplated embodiments the filler material 5 can comprise any suitable filler elements 7 comprising or being formed from polystyrene, such as expanded polystyrene, or any other suitable polymeric substance. In preferred embodiments each filler element 7 is spherical or substantially spherical and has a volume less than 10 cms, ideally less than 1 cms. 10 As will be appreciated, such filler elements 7 will be substantially smaller than the cavity 2 and therefore can easily fit into and fill the cavity 2, even if the cavity 2 has an irregular shape.
In preferred embodiments the adhesive 6 is a water-based adhesive which has a flowable or liquid state and can set, cure or harden to a solid state. Use of a water-based adhesive 6 does not degrade or dissolve the plurality of filler elements 7 during mixing with the adhesive 6.
IS Example adhesives that are suitable for use in the present invention include water based-adhesives. Any other suitable adhesives, such as two-part epoxies, may be used.
The adhesive 6 is mixed with the filler material 5 while the adhesive is in its flowable or liquid state. This forms the flowable insulation material. The flowable insulation material is then provided within the cavity 2 by e.g. pouring or dispensing through a nozzle from a hopper. In an example, the flowable insulation material may be blown into the cavity 2 of the building component 1, for example in a high-pressure spray. A pressurised hopper containing a supply of flowable insulation material may be used to dispense flowable insulation material into the cavity 2. The flowable insulation material may be poured and/or dispensed into the cavity until the cavity 2 is partially filled, or substantially full. The flowable insulation material is adapted to flow into and closely conform to the internal shape of the cavity 2. During filling, the building component may be tilted to encourage flowable insulation material to flow into certain parts of the cavity 2 under the force of gravity.
When the flowable insulation material enters the cavity 2 via e.g. a first open end 8 thereof, air is displaced from the cavity 2 and can escape via e.g. the open end 8, the other open end and/or the discontinuities in the thermal break plate 11 and the rebated portions 14. The other open end (and optionally the first open end 8) can be closed or sealed by a retaining member (not shown), such as a sheet of plastic film, which substantially covers the other open end. The retaining member may have one or more holes or apertures to allow air to escape from the cavity through the retaining member while preventing the flowable insulation material from escaping from the cavity 2 while it sets, cures or hardens. The retaining member is used to retain the flowable insulation material within the cavity 2 while the adhesive 6 sets, cures or hardens.
Once the cavity 2 has been sufficiently filled with flowable insulation material, the flowable insulation material is allowed to set, cure or harden into a solid state. The result of this procedure is shown in Figure 3 in which the building component 1 is shown comprising an insulation member 3 that has been formed within the cavity 2. The insulation member 3 is solid and fills substantially the entire cavity 2. Once the insulation member 3 is in its solid state, the retaining members may be removed from the open end(s) 8 of the building component 1. In preferred embodiments the formed insulation member 3 comprises at least 50% by volume of filler means and up to or less than 50% by volume of adhesive means. In the most preferred embodiments, the formed insulation member 3 comprises at least 75% by volume of filler means and up to or less than 25% by volume of adhesive means.
In use, the building component 1 is locatable above an opening in a building and is configured for supporting brickwork above an aperture or opening, such as a window or door aperture in a wall. The insulation member 3 is configured for reducing the amount of cold bridging between the interior and exterior of the building in which the building component 1 is incorporated. Advantageously, the insulation member 3 has a low thermal conductivity and therefore will reduce the overall thermal conductivity of the building component 1, thereby reducing and/or preventing IS cold bridging through the building component 1.
In use, the insulation member 3 is prevented from moving within the cavity 2 by the adhesive 6 which adhesively bonds to the interior of the walls of the cavity 2 and the thermal break plate 11. It will be appreciated that the adhesive 6 is configured for adhesively fixing the filler 5, in particular the plurality of filler elements 7, within the cavity 2. The insulation member 3 is also prevented from moving within the cavity 2 by its tight fit within the cavity 2, and by the movement restriction arrangements 15 which extend into the formed insulation member 3, locking it in place within the cavity 2. In this way, the movement restriction arrangements 15 act to prevent movement of the insulation member 3 relative to the building component 1, and prevent lateral movement of the insulation member 3 towards or out of the open ends 8 of the building component 1.
The method 100 can be used as part of a method for manufacturing a building component, wherein the building component is a lintel having a cavity. The method for manufacturing a building component may comprise the following steps: forming a building component 1 comprising one or more walls 4 and two lateral portions 10; arranging a thermal break plate 11 between the two lateral portions 10 to span the gap 12 between the two lateral portions 10 to define a cavity 2 between the walls 4 and the thermal break plate 11; attaching the thermal break plate 11 to the lateral portions 10 of the building component 1; and forming, in accordance with step 102 outlined above, an insulation member 3 within the cavity 2 such that the insulation member 3 contacts the one or more walls 4 and the thermal break plate 11. As will be appreciated, the thermal break plate 11 may be attached either before or after the insulation member 3 has been formed between the walls 4 of the building component 1. In this example method for manufacturing a building component 1, the insulation member 3 is formed from the flowable insulation material as described above (see step 102). Advantageously, the adhesive 3 functions to improve the fix between the thermal break plate 11 and the two lateral portions 10, thereby improving the structural integrity of the building component 1.
As will be understood by the skilled person, the example embodiments presented above can be modified in a number of ways without departing from the scope of the invention. For example, the method 100 may be used for providing insulation in the cavity of any suitable lintel, such as a straight, arched, curved or parabolic lintel. The method 100 may comprise forming the flowable insulation material before providing the flowable insulation material within the cavity, or optionally the flowable insulation material may be formed within the cavity. For example, the adhesive 6 may be inserted into the cavity 2 after the cavity 2 has been pre-filled with filler lo elements 7. The building component 1 may have any suitable cross-sectional shape, such as a top-hat cross section or a box cross section. The building component 1 may be formed from a plurality of metal sheets, for example a plurality of welded metal sheets. The cavity 2 may be open on one, two or three sides. The building component 1 have one or more curved walls. Coupling members 13, rebated portions 14 and/or movement restriction arrangements 15 can be provided IS on one or both sides of the thermal break plate 11.
In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of the values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of the parameter, lying between the more preferred and the less preferred of the alternatives, is itself preferred to the less preferred value and also to each value lying between the less preferred value and the intermediate value.
The features disclosed in the foregoing description or the following drawings, expressed in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of attaining the disclosed result, as appropriate, may separately, or in any combination 25 of such features be utilised for realising the invention in diverse forms thereof.
Claims (25)
- CLAIMS1 A method for at least partially filling a cavity in a building component, the method comprising: forming an insulation means within the cavity of a building component, wherein the insulation means comprises filler means and an adhesive means.
- 2 A method as claimed in claim 1, wherein the method comprises providing the building component having the cavity.
- 3 A method as claimed in claim 1, wherein the method comprises mixing a plurality of filler elements with the adhesive means, wherein the or each filler element, or at least one filler element, comprises or is formed from polystyrene, such as expanded polystyrene.
- 4 A method as claimed in claim 1, wherein the method comprises forming the insulation means by mixing the plurality of filler elements with the adhesive means; wherein the plurality of filler elements comprises a plurality of polystyrene balls or beads; and wherein the insulation means is a flowable insulation means.
- A method as claimed in claim 1, wherein the flowable insulation means is able to flow into the cavity where it will conform to the shape of the cavity.
- 6 A method as claimed in claim 3, wherein the or each filler element is spherical or substantially spherical.
- 7 A method as claimed in claim 1, wherein the method comprises forming the flowable insulation means before providing the flowable insulation means within the cavity.
- 8 A method as claimed in claim 1, wherein the method comprises closing or sealing one or more openings or apertures in the building component with a retaining means.
- 9 A method as claimed in claim 1, wherein the method comprises providing the flowable insulation means into the cavity while the adhesive means is in a flowable or liquid state.
- 10. A method as claimed in claim 1, wherein the method comprises providing flowable insulation means into the cavity using a dispensing means, wherein the dispensing means comprises a dispensing nozzle connected to a hopper.
- 11. A method as claimed in claim 1, wherein the method comprises allowing air to exit the cavity while the cavity is being filled with flowable insulation means, filler means and/or adhesive means.
- 12. A method as claimed in claim 1 while dependent on 8, wherein the method comprises allowing air to exit the cavity via one or more apertures or openings in the retaining means.
- 13. A method as claimed in claim 1, wherein the method comprises tilting the building component during filling of the cavity.
- 14. A method as claimed in claim 1, wherein the method comprises retaining the flowable insulation means within the cavity while the flowable insulation means and/or adhesive means sets, cures or hardens.
- 15. A method as claimed in claim 1, wherein the method comprises removing the retaining means after the flowable insulation means and/or adhesive means has set, cured or hardened.
- 16 A building component comprising a cavity and an insulation means, wherein the insulation means comprises filler means and an adhesive means, wherein the insulation means is locatable within the cavity.
- 17 A building component as claimed in claim 16, wherein the insulation means comprises an insulation member for providing insulation and thereby reduces and/or prevents cold bridging through the building component.
- 18 A building component as claimed in claim 16, wherein the insulation means is formed from a flowable insulation means; and the shape of the insulation means substantially conforms to the internal shape of at least part of the cavity.
- 19 A building component as claimed in claim 16, wherein the insulation means is in a set, cured or hardened state.
- 20. A building component as claimed in claim 16, wherein the adhesive means is in its set, cured or hardened state.
- 21 A building component as claimed in claim 16, wherein the filler means is configured for filling at least part of the cavity.
- 22 A building component as claimed in claim 16, wherein the filler means comprises a plurality of filler elements; and wherein the or each filler element, or at least one filler element, comprises or is formed from a polymeric substance.
- 23 A building component as claimed in claim 16, wherein the adhesive means is configured for retaining the plurality of filler elements within the cavity.
- 24 A building component as claimed in claim 16, wherein the building component is a lintel.
- 25. A building component as claimed in claim 16, wherein the building component is formed from steel or stainless steel.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GBGB2205481.1A GB202205481D0 (en) | 2022-04-13 | 2022-04-13 | Method for filling a cavity in a building component and a building component |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB202305421D0 GB202305421D0 (en) | 2023-05-31 |
| GB2620231A true GB2620231A (en) | 2024-01-03 |
Family
ID=81653145
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GBGB2205481.1A Ceased GB202205481D0 (en) | 2022-04-13 | 2022-04-13 | Method for filling a cavity in a building component and a building component |
| GB2305421.6A Pending GB2620231A (en) | 2022-04-13 | 2023-04-13 | Method for filling a cavity in a building component and a building component |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GBGB2205481.1A Ceased GB202205481D0 (en) | 2022-04-13 | 2022-04-13 | Method for filling a cavity in a building component and a building component |
Country Status (1)
| Country | Link |
|---|---|
| GB (2) | GB202205481D0 (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2274293A (en) * | 1992-06-02 | 1994-07-20 | Catnic Ltd | Lintel with insulation and keying means |
| GB2285818A (en) * | 1993-12-17 | 1995-07-26 | Keystone Lintels Ltd | Providing expanded insulation in lintel |
| GB2287262A (en) * | 1994-03-11 | 1995-09-13 | Keystone Lintels Ltd | Inserting insulation into lintel |
| GB2325258A (en) * | 1997-05-15 | 1998-11-18 | Keystone Lintels Ltd | Lintel with bracing member |
-
2022
- 2022-04-13 GB GBGB2205481.1A patent/GB202205481D0/en not_active Ceased
-
2023
- 2023-04-13 GB GB2305421.6A patent/GB2620231A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2274293A (en) * | 1992-06-02 | 1994-07-20 | Catnic Ltd | Lintel with insulation and keying means |
| GB2285818A (en) * | 1993-12-17 | 1995-07-26 | Keystone Lintels Ltd | Providing expanded insulation in lintel |
| GB2287262A (en) * | 1994-03-11 | 1995-09-13 | Keystone Lintels Ltd | Inserting insulation into lintel |
| GB2325258A (en) * | 1997-05-15 | 1998-11-18 | Keystone Lintels Ltd | Lintel with bracing member |
Also Published As
| Publication number | Publication date |
|---|---|
| GB202205481D0 (en) | 2022-05-25 |
| GB202305421D0 (en) | 2023-05-31 |
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