NO319754B1 - Insulating element for clamp installation between roof rafters or beams of other wooden structures - Google Patents

Abstract

The invention relates to an insulating element (1) for clamping installation between limiting surfaces, in particular between rafters (4) of roofs such as steep roofs, or between beams or the like, in particular of wooden frame constructions for outside or inside walls of buildings or wooden beam ceilings and the like, in particular made of mineral wool in the form of an insulating panel or insulating sheet wrappable into a roll or insulating panels obtained by cutting the insulating sheet, the panel/sheet having a plurality of insulating layers (2, 3) extending perpendicular to the thickness of the insulating element, at least one of which is designed as a clamping-type holding element (3) over the remaining insulating layers for clamping installation of the panel/sheet such that said holding element (3) exerts a greater pressure on the limiting surfaces in the installed state than the remaining insulating layers due to its higher elastic force, transmitted to said surfaces through its side surfaces.

Description

The present invention relates to an insulation element according to the preamble of claim 1,

Such insulation elements (or elements of insulation material) are known and used in particular for clamp installation of webs, or simple insulation boards cut from the web, between rafters, balconies or other limiting surfaces. This is a market with production figures that have been rising for several decades, as the insulation membrane is installed on site by experts from the building trade, but also very often by unskilled personnel, e.g. self builders. As it has become particularly common on the market to insulate steep roofs with mineral wool, such insulation webs, also known as clamp filters, have been able to continuously increase their market share.

In the production and storage of an insulation element, the manufacturer must generally take into account that the free width between the rafters in the ceiling or the beams of other wooden constructions and the height of these, e.g. the depth of the timbering can vary considerably. For these reasons, e.g. so-called shoulder mats for adaptation to different widths between the rafters or beams and are stocked in finely graded widths, e.g. with graduations of 100 mm. Furthermore, clamp felt thicknesses from about 80 mm to 220 mm or more are offered today. This naturally involves enormous stock-keeping in production, sales and distribution, and also on the construction site.

Another particular problem with such products is the necessary material consumption, which should always be reduced for cost reasons, but which is particularly important because large surfaces must be covered with insulating material in the preferred application cases such as insulation of steep roofs. Furthermore, the significant material costs are not least due to the fact that mineral wool is increasingly produced from biodegradable compositions and must be produced in accordance with special national regulations, which can lead to much higher prices.

From European patent application EP-Al-0 125 397 it is known a self-supporting plate of insulating material which has spring tongues on the edge sides. With the help of the spring tongues, the self-supporting plate can be placed between the rafters of a roof by pressing the plate into the space between the rafters.

German patent application DE-Al-44 37 457 also shows an insulating element which can be placed between the rafters of a roof by clamping the element between the rafters. For this purpose, the insulation element comprises several plates which are partially displaceable in relation to each other. In addition, one of the plates comprises spring elements which force this plate to protrude beyond the width of the insulation element, thereby squeezing the insulation element between the rafters.

The problem underlying the invention is to provide an insulation mat or insulation board for clamp installation between rafters, beams or other limiting surfaces which allows a reduction of material consumption without loss of necessary insulation properties, i.e. an optimization of the product so that only the material used is used. material that is necessary to fulfill the technical service value, especially the thermal insulation ability.

According to another aspect, the insulation elements for clamping installation between rafters or beams of wooden frame structures shall not only provide material savings compared to conventional insulation elements and yet optimal clamping effect, but shall also provide advantages with regard to storage, transport and packaging by reducing the package volume , taking into account that such insulation elements are marketed in a foil package.

A further aspect of the invention is to provide an insulation mat or insulation board in a thickness range which ensures full insulation as an insulation element with a certain thickness at different and varying beam thicknesses (trusswork depths) and which in particular allows continuous compensation for different thicknesses. The insulating mat should nevertheless be easy to produce, and the installation of the insulating mat or the insulating plates by clamping only must not be hindered in any way.

This problem is solved according to the invention by means of the features indicated in the characteristic of claim 1, as useful, particularly advantageous embodiments are characterized by features indicated in the subclaims.

The invention is mainly characterized by the fact that the insulation mat or plate has a special holding element of the clamping type, also referred to in the following as a clamping layer. This allows a very significant reduction of the material in the total insulation layer because only the clamping type part of the plate or mat which is necessary for the clamping installation, needs to be constructed with a view to its clamping function property to ensure perfect and lasting attachment of the material. The rest or the other layers of the plate or mat can be adapted in a suitable way without regard to the clamping and holding function, e.g. with a lower elasticity force than the clamping layer, especially with a lower room weight, and only needs to be constructed based on the requirements for thermal insulation. By e.g. grading the room weight in the board or mat thus achieves great material savings, especially from the fact that significant surfaces must be insulated if the material is to be used for insulation of steep roofs. In the present case, the clamping layer's properties are achieved by using a higher bulk density than the other layer. Higher room weight is used here to achieve the clamping function of the clamp-type holding element. The room weight in the other part of the insulation web or plate can be chosen according to the relevant requirement profile, especially with regard to thermal conductivity. The compression layer naturally also meets the requirement for thermal insulation.

In a particularly preferred embodiment, the plate or mat is divided into two layers, one which forms the clamping layer and which has a higher elastic force, especially due to a higher bulk density than the other layer, which only fulfills a filling or insulating function. The properties such as elastic force in the clamp-type holding element can be achieved not only by increased room weight, but also by suitable adjustment of the binder content and/or fiber quality and/or fiber orientation.

The multiple division, especially the two division, of the insulation element into at least two parts of different nature enables a material reduction according to the invention, while preserving or optimizing the clamping effect in relation to conventional insulation materials of mineral wool, as at least one part exerts a clamping effect. In this connection, a certain sag occurs in the installed state, e.g. between rafters due to the insulation element's own weight, so that the clamping layer, which is preferably located at the top, in this case exerts a clamping-inducing effect on the remaining insulation layer below. As the volume of the remaining insulation layer which serves as a filling layer can be minimized according to the invention, not only is material saving achieved, but also significant packaging advantages because the product can be compressed better. This is of particular advantage for insulation elements supplied in roll form because it enables a significant reduction of the package volume, resulting in reduced transport and storage volume.

In addition to the particularly preferred double-layer design of the insulation mat or insulation board, it is also possible to provide two filling layers, or two clamping layers in the case of only one filling layer, etc. The number and arrangement of the filling layers and clamping layers can thus be freely chosen by the person skilled in the art.

As mentioned above, the clamping layer's properties can also be adjusted in other ways than via the room weight, e.g. through the fiber geometry, fiber position, fiber formation, fiber orientation, binder content or other additives that strengthen the clamping layer. It is important that the clamping layer has sufficient spreading or elastic power to ensure the necessary frictional forces between the clamping layer and the limiting surfaces. It is usually enough that the clamping layer is stiff enough that the insulation element can be clamped between the rafters with sufficient pressure and here has a press fit, while the filling layer can be soft and sufficiently compressible to enable a thickness compensation function at different truss depths. When the elastic force is adjusted via the room weight, it is appropriate that the ratio between the room weight of the clamping layer and the room weight of the filling layer is > 1, preferably > 1.5.

In the following, preferred embodiments of the invention will be described with reference to the schematic drawing, where: fig. 1 shows a partial perspective view of an insulation element according to the invention,

fig. 2 shows a section illustrating the installation conditions for an insulation mat or insulation board within a field of a steep roof,

fig. 3 shows a section through an insulation mat or insulation board in the state at the beginning of the installation between beams or posts of a vertical wooden frame structure for a building wall or similar, if the thickness of the insulation element is to be adjusted to a truss depth that is less than the thickness of the insulation element,

fig. 4 shows a diagram similar to fig. 3, but with the insulation mat or insulation board in the installed condition,

fig. 5 shows an insulation mat wound into a roll, partially extended to show separation of insulation boards from this insulation mat for clamp installation between rafters, and

fig. 6 shows a diagram illustrating the saving potential when using the insulation element according to the invention.

The insulation element in the form of insulation mat or insulation plate 1 shown in perspective partial view in fig. 1 is constructed of two layers, namely the filling layer 2 denoted FS and the clamping layer 3 denoted KS. The two layers have different natures and thus also different properties. In a preferred case of the invention, namely for clamp installation of the insulation mat or insulation board 1 between the rafters of a roof construction or between the posts of a wooden frame construction, the layers are made of mineral wool with suitable binders constructed with different spatial weights. The clamping layer 3 is constructed with a bulk weight that aims at clamp installation of the mat or board and has a particularly larger bulk weight than the filling layer 2. The latter can be constructed independently of the clamping function and therefore has a reduced bulk weight, as its bulk weight is selected solely on the basis of the desired insulation properties.

Fig. 2 shows an insulation mat 1 cut from a mat

rolled into an insulation material roll according to fig. 5 in the installed position between two adjacent rafters 4 of a steep roof structure, the reference number 5 denoting a waterproof cover which is usually used in roofing work and is arranged on the upper side of the rafters 4. In the embodiment shown in fig. 2, the clamping layer 3 is arranged on the upper side, i.e. on the roof side, and thus next to the waterproof cover 5, while the filling layer 2 is arranged towards the room, i.e. below. The insulation mat 1 shown in fig. 2 is adjusted in terms of thickness to the thickness d3 of the rafters, but this is not necessarily the case. The layer thickness of the clamping layer 3 and the filling layer 2 is denoted by dl and d2. For installation, the insulation mat 1 is cut from a roll according to fig. 5 with an over-dimension in relation to the free width D between nearby barriers 4, the over-dimension being such that the insulation mat 1 is introduced in a pinching manner between nearby

blocks and is held using the clamping effect. A suitable oversize for conventional tiles is about 1 cm.

As mentioned above, both layers 2 and 3 are made of mineral wool, but they differ with regard to their mechanical properties. These different properties are achieved in the embodiment in fig. 2 by means of different bulk density in layers 2 and 3. The filling layer 2 has a bulk density that is lower than the bulk density of the clamping layer 3. With its greater bulk density, the clamping layer 3 has a higher elastic force between the limiting surfaces than the filling layer 2, the elastic force being such that the insulation board can be fixed with a press fit when it is placed between adjacent rafters so that no special fasteners are required. Suitable bulk weights for the clamping layer are £ 10 kg/m<3>, while a preferred range of application for clamp installation between rafters or posts of a timber frame structure is a bulk weight value in the range from 10 kg/m<3> to 30 kg/m<3> . A particularly preferred range for the room weight is from 15 kg/m<3> to 25 kg/m<3>, and particularly preferred room weights for the clamping layer are e.g. the range 17 to 19 kg/m<3>.

In order to adapt the space weight of the clamping layer 3 when used as roof insulation, especially for the insulation of horizontal wooden frame constructions, such as so-called frames between opposite rafters or panes at a roof angle of < 60°, it is important that the clamping layer 3 is sufficiently strong and rigid, but still flexible without breaking under the weight of the insulation element 1 consisting of layers 2 and 3. In the installed position in fig. 2, the insulation mat can sag somewhat under its own weight and this weight-induced slight sag or deflection results in a spread of the insulation mat clamped between the rafters 4, especially in the lower area of the filling layer 2, so that spreading forces are formed. The clamping attachment of the insulation mat between the rafters 4 is mainly caused by recovery and frictional forces which are formed due to the clamping layer 3 and which are further enhanced by the spreading forces in the filling layer 2 induced by the clamping layer 3, as the frictional forces of the filling layer 2 against the rafters 4 naturally also contribute to the clamping effect. In the embodiment in fig. 2, the clamping is therefore effected both by the actual clamping layer 3, whose strength is calculated based on the purpose of the clamping function, and by the filling layer 2 via the spreading forces created in it due to the suspension caused by the weight of the insulation mat.

An inverted arrangement of the insulation mat 1 between the limiting surfaces formed by rafters or beams of vertical wooden frame structures is of course also possible, whereby the filling layer 2 is placed against the waterproof cover 5 in the roof area and the clamping layer faces the room. In the case of vertical wooden frame constructions where the outer surface of the clamping layer 3 is flush with the outer surface of the beam 4, the filler layer 2 fills the remaining space up against the wall panel 5, e.g. a timber panel, and can therefore act as a compensation layer. Due to the good compressibility of the filling layer 2 produced with a low bulk density, different beam thicknesses d3 can be covered with one and the same insulation element. For example, it is conceivable to cover different thicknesses in the range from 140 mm to 220 mm continuously with an insulation board 1 with a thickness of 220 mm where the filling layer 2 is compressed to a greater or lesser extent and therefore performs a compensation function when the insulation board is mounted. The aforementioned value of 220 mm for the total thickness dl and d2 of the insulation mat 1 is of course an example of value as the thickness of the product can also be adapted to other truss depths. It is also possible to use two products of different thickness with the same grading, or if necessary three products of different thickness with even grading. This ultimately depends on the market conditions, especially the expected differences in rafter or beam thicknesses used in the individual constructions. This may vary from country to country, possibly with corresponding consideration of the building regulations.

Fig. 3 and 4 show the installation conditions for an insulation board or insulation mat between the posts or beams 4' of a vertical wooden frame construction, for example as used in building walls, especially industrially prefabricated room modules. The outer side is only illustrated here as an example with a wall panel of a timber-derived product or a paneled wall 5'. Fig. 3 shows the beginning of the installation process, where the fill layer designed as compensation layer 2' is placed in the space between the two beams 4'. The clamping layer 3 is then pressed between the beams 4' using a force P, so that the outer surface of the clamping layer 3 runs flush with the outer surface or the outer edge of the beams 4', as fig. 4 shows. When the clamping layer 3 is pressed in, the compensation layer 2' is correspondingly compressed and thus performs a compensation function in addition to the insulation function as different beam thicknesses can be covered with one and the same product, i.e. with an insulation element of the same thickness.

In this case of use, the clamping layer 3 is also constructed with higher strength than the compensation layer 2', especially with a higher bulk density, as the aforementioned areas are also applicable here. In both application cases, the bulk density of the filling layer is < 30 kg/cm<3>, or especially < 15 kg/cm3 and preferably < 10 kg/cm<3>, the two bulk weights being adapted to each other so that the ratio between the bulk density of the clamping layer and that of the filling layer space weight is > 1.

In particular, the thickness dl of the clamping layer 3 is minimized in all applications to the technically necessary thickness required to be able to fasten the insulation layer between the existing limiting surfaces of the rafters or beams in wooden truss constructions. The particular values for the thicknesses also depend on the structure of the wooden frame construction and especially on the width to be covered between nearby rafters or beams. As regards the filling layer 2, it is usually advantageous that this is more compressible than the clamping layer 2, which firstly allows the above-mentioned compensation function, but secondly also provides advantages in packing. One can thus achieve an insulation roll with a reduced diameter, but with the same length of the insulation mat, which reduces the package volume and thus entails significant transport and storage advantages. The insulation mat in the form of a roll is compressible in the areas 1 : 2.5 to 1 : 4.5. With such an insulation mat or insulation board cut off from the roll, a classification in thermal conductivity group 040 according to DIN 18165 can be achieved, where the filling layer is in thermal conductivity group 045 due to its bulk weight and the clamping layer is in thermal conductivity group 035 due to its bulk weight, while the average value of the insulation board or insulation mat fulfills the criteria in thermal conductivity group 040 according to DIN 18165. As it is well known that (lamda) X f(RD), by choosing the space weights (RD) in a suitable way, a total thermal conductivity of group 035.

Fig. 5 shows a particularly preferred embodiment, namely an insulation mat wound into a roll for clamping installation between the limiting surfaces of rafters or beams, especially the rafters in a steep roof. The insulation mat 6 is partially shown in an extended state. The reference number 2 here also denotes the filling layer with a compensation function and the reference number 3 the clamping layer, which is here arranged on the outside in the rolled-up state of the insulation roll. The clamping layer can also be placed on the inside in the rolled-up position, which depends on the application in the individual case according to the description in connection with fig. 2, i.e. the applicable installation conditions. On the surface 7 of the layer placed on the inside in the rolled-up position, i.e. the filling layer in the embodiment described here, there are marking lines 8 that extend perpendicular to the longitudinal edges 9 of the insulation mat 6. In the example, the marking lines 8 are placed at equal distances from each other, the distance d between two adjacent marking lines is preferably 100 mm. As fig. 5 shows, the marking lines 8 need not be made as continuous lines, but can also be broken lines. The marking lines 8 are advantageously not designed by cutting or the like, but are only optically effective without influencing the handling and efficiency of the material in the mineral wool mat 6. To fill a square with a given width of e.g. 700 mm, the longitudinal part L is measured with a length of 710 mm starting from the front edge 10 of the insulation mat 6 and along the marking lines 8, taking into account an over-dimension of e.g. 1 cm necessary for the press fit, and cut it off at 11. For this purpose, a knife 12 is placed at the measured cutting line in the manner indicated in fig. 5 and pulls it through the material in the direction of the arrow 13 parallel to the nearest marking line 8.

The insulation board 14 formed in this way is rotated for installation so that the former longitudinal edges 9 of the insulation mat 6 come to be above and below and the longitudinal part L thus determines the width of the mineral wool board 14. In this position, the mineral wool board 14 is inserted into the route between two adjacent rafters 4. The over-dimension 0 of the length portion L in relation to the width D of the route at the installation site which in the example is 10 mm or slightly more, results in the desired press fit of the mineral wool plate 14. After insertion between the rafters 4, the mineral wool plate 14 therefore has a press fit between the rafters due to the clamping effect. The insulation mat 6 shaped in this way can be used with the same width for laying in squares of different width D between nearby rafters if the plate 14 is cut from the insulation web in relation to the width D between the rafters. Due to the simultaneous possibility of compensation, one can therefore use the insulation mat shown in fig. 5 with uniform width dimension of the insulation mat and uniform thickness of the insulation mat for squares or fields with different width D and different rafter and beam thicknesses d3. This results in a significant saving when it comes to the selection because the insulation mat 6 no longer needs to be stocked in finely graded thicknesses as one insulation mat of uniform width and thickness can cover a variety of roof and timber frame constructions with different widths between the rafters or beams and with different truss depths.

Fig. 6 shows the savings potential for the insulation material in percent compared to conventional insulation mats available on the market. You thus achieve significant savings in the range of 10 - 23% for the thicknesses of insulating mats or sheets that are common for roof insulation, which leads to a significant material saving, taking into account the large quantities of insulating mats that are used per year for these purposes.

Table 1 shows, as an example, variants of layer combinations with different thickness, room weight and weight per unit area of the individual sub-layers.

This table indicates that all the variants according to the invention have a lower weight per area unit than the standard version and thus leads to significant material savings. You can also see that layer thickness, room weight and weight per surface unit of the sub-layers can thus be varied.

If e.g. the fill layer is adjusted so that its thickness can be compressed during installation depending on the height of the rafters or the depth of the truss, not only can material be saved, even if this is only to a lesser extent, but also the selection can be optimised. From Table 1 it can thus be seen that if e.g. a mat/plate of variant 3 with a thickness of 220 mm and a weight per unit area of 2.82 kg/m<2> is compressed to a beam thickness of 180 mm, a material saving of 0.06 kg/m<2> can still be achieved compared to a mat/plate of the standard version with a thickness of 180 mm and a weight per surface unit of 2.88 kg/m<2>. The advantage in this example lies mainly in the optimization of the selection. However, a significantly greater material saving results, e.g. with a beam thickness d3 of 200 mm because the weight per surface unit of the standard version of 3.00 kg/m<2>here is significantly higher compared to variant 3, again with 220 mm thickness a weight per surface unit of 2.82 kg/m<2>. The material saving is therefore 0.18 kg/m<2> in this example.

Claims (11)

1. Insulation element for clamping installation between limiting surfaces, especially between rafters (4) of roofs such as steep roofs, or between beams (4') or the like, especially in wooden frame constructions for external or internal walls of buildings or ceilings of wooden beams and the like, made of mineral wool in the form of an insulating sheet or insulating mat (6) which can be wound into a roll or insulating sheets (1) obtained by cutting the insulating mat, characterized in that the plate/mat (1,6) has several insulation layers that extend perpendicular to the thickness of the insulation element, at least one of which is designed as a clamp-type holding element over the other insulation layers for clamp installation of the plate/mat so that said holding element exerts a greater pressure against the limiting surfaces in the installed state than the other insulation layers due to its higher elastic force, which is transferred to said surfaces through its side surfaces. 2. Insulation element according to claim 1, characterized in that the elastic force of the holding element of the clamping type designed as a clamping layer (3) is obtained by appropriately determining the bulk density and/or the binder content and/or the fiber quality and/or the fiber orientation and/or other suitable reinforcements . 3. Insulation element according to claim 1 or 2, characterized in that the clamp-type holding element forms an outer surface of the plate/mat (1,6) or is arranged inside the plate/mat. 4. Insulation element according to one of the preceding claims, characterized in that the clamping layer (3) is mainly adapted in terms of thickness to the clamping function which is necessary for attachment between the limiting surfaces. 5. Insulation element according to one of the preceding claims, characterized in that the plate/mat (1,6) is designed with at least two layers and comprises the clamping layer (3) and another insulating layer such as a filling layer (2). 6. Insulation element according to one of the preceding claims, characterized in that the thickness of the clamping layer (3) is < 50% of the total thickness of the plate/mat (1,6) which includes the clamping and filling layers (2,3) before installation, it is preferably in the range 20 to 50%, especially 20 - 40% and particularly preferred 30 - 40%. 7. Insulation element for clamping installation between non-vertical limiting surfaces, especially between rafters (4) of a steep roof or between beams of other wooden constructions, such as wooden ceiling beams and the like, especially according to at least one of claims 1-6, characterized whereby the clamp-type holding element (clamp layer (3)) is placed so that it faces away from the room in the installed position of the plate/mat (1,6), e.g. between rafters (4). 8. Insulation element for clamping installation between vertical limiting surfaces, especially between rafters (4<1>) of wooden frame structures for external or internal walls of buildings or the like according to claims 5 and 6, characterized in that the filling layer consists of a compensation layer (2') for adaptation to different beam heights (travel depths). 9. Insulation element according to claim 8, characterized in that the compensation layer (2') is designed as a flexible compression zone. 10. Insulation element according to one of the preceding claims, characterized in that the clamping layer (3) has a bulk weight < 10 kg/m<3>, preferably in the range 10 to 30 kg/m<3>, especially in the range 15 to 25 kg/m <3>. 11. Insulation element according to one of the preceding claims, characterized in that the filling or compensation layer (2;2') has a bulk weight of < 30 kg/m<3>, preferably < 15 kg/m<3>.