WO1993013277A1

WO1993013277A1 - Method of mounting an insulation layer on a support

Info

Publication number: WO1993013277A1
Application number: PCT/DK1992/000396
Authority: WO
Inventors: Peter Larsen
Original assignee: Rockwool International A/S
Priority date: 1991-12-27
Filing date: 1992-12-23
Publication date: 1993-07-08
Also published as: AU3345593A; DK207091D0; DK207091A

Abstract

Method of mounting an insulation layer (2) on a support (1) comprising using an insulation layer (2) having incorporated therein an elastically deformable reinforcing layer (5), said insulation layer (2) being pressed against fastening means (6) attached to and extending out from the support (1) and having such a shape that they can penetrate the reinforcing layer (5) and are capable of securing the insulation layer (2) to the support (1).

Description

METHOD OF MOUNTING AN INSULATION LAYER ON A SUPPORT

This invention relates to a method of mounting an insulation layer on a support, said method comprising pressing the insulation layer against fastening means attached to and extending out from said support, the fastening means being of such a shape that they are capable of being pressed into the insulation layer and securing it to said support.

CA patent specification No. 1,197,064 discloses a method of the above-mentioned type. The prior art method is based on the use of fastening means prepared from metal plates by punching and each consisting of a base plate which can be secured to the support, e.g. by means of a binder or screws, and an outwardly extending part having the shape of a harpoon, i.e. a tip with at least one barb. When the insulation layer is pressed against the fastening means the flat harpoon-like tips of said fastening means penetrate into the insulation layer and after the insulation layer has been correctly mounted the barbs will keep the insulation layer in the desired position.

Due to the relatively high brittleness of mineral fibres the fastening of insulation layers consisting of such fibres to a support by means of harpoon-like fastening means presents the drawback that incisions are cut in the insulation layers when they are pressed against these fastening means. Consequently, the barbs do not get hold in the insulation layer when the latter after being mounted on the support is subjected to the influence of forces which tend to disengage the insulation layer from the support.

According to the invention this drawback is eliminated or reduced by using an insulation layer having embedded therein a deformable reinforcing layer.

The deformable reinforcing layer is preferably a net and more preferably a plastic net and the following explanation of the invention is based on the use of an insulation layer having incorporated therein such a net. However, it should be understood that other types of net such as metal wire and glass fibre nets as well as other types of reinforcement layers such as plastic or metal films are also suitable.

When using an insulation layer having embedded therein a net of a ^•** plastic material the tips of the fastening means whether they are flat or rounded will cause the meshes of the net to expand and subsequently, if possible, to regain their original form. If the tips of the fastening means are provided with barbs or similar locking means the insulation layer will thus be prevented from being separated from the support.

The insulation layer used in the method of the invention is pre¬ ferably made from mineral fibres, such as rock wool fibres, glass fibres and slag fibres, and when using insulation layers of this type the reinforcement layer is preferably incorporated in the insulation layer in the manner described in US patent specification No. 4,950,355. This method comprises the steps of cutting a mineral fibre web in a plane which is parallel to the main surfaces thereof so as to form two separate fibrous layers. A reinforcement layer is introduced between said fibrous layers and subsequently the assembly of the two fibrous layers and the intervening reinforcement layer is introduced into a curing furnace so as to form a laminate which may then be cut Into units of a desired size. Such units can also be manufactured from pre-manufactured sheets by placing a reinforcement layer between two sheets and by combining the three layers to form a laminate by means of a binder.

The thickness of the insulation layer can vary within wide ranges, depending on the desired insulation effect. However, that part of the insulation layer which is located on the exterior side of the reinforcing layer should normally be sufficiently thick to prevent that the layer is penetrated by the fastening means during the mounting of the insulation layer. In practice, it is preferred to use mineral fibre batts having a density of from 10 to 400 kg/m and a thickness of from 20 to 500 mm, and wherein that part of the insulation layer which is located on the exterior side of the reinforcing layer in the final insulation has a thickness of at least 10 mm. The insulation layer may consist of other materials than mineral fibres. As an example, the layer may consist of foamed plastic having a reinforcing layer incorporated therein. Such reinforced foamed plastic layers may be prepared by cutting foamed plastic sheets in a plane parallel to the sheet surfaces and by placing a reinforcing layer between the foamed plastic sheets thus obtained and by bonding the layers together, optionally while they are pressed together by passage through the nib of a pair of rollers.

Furthermore, the part of the insulation layer which is located on the exterior side of the reinforcing layer in the final insulation may consist of another material than the material forming the part of the insulation layer which is located on the inner side of the reinforcing layer.

The fastening means can be of the type described in the above- mentioned CA patent specification, i.e. fastening means prepared from metal plates by punching and having a base which is to be attached to the support by means of a binder or screws.

However, it is preferred to use rod-shaped fastening means, e.g. in the form of dowels, pins, etc., having one end of such a shape that it can be moulded or hammered into or in another manner attached to the support and having a second end which has a cross-sectional area varying in its longitudinal direction. The fastening means may for example be of circular cross-sectional shape and have alternating large and small diameters. When such fastening means are pressed into a net, such as a plastic net, the net and consequently the insulation layer will be locked to the fastening means.

Also other forms of fastening means can be used, provided that they can be pressed into the reinforcing layer and effect an elastic deformation thereof, and provided that they have such a surface shape that the reinforcing layer is locked to the fastening means after the fastening means have penetrated the reinforcing layer and the reinforcing layer has regained - fully or partially - its original form. As mentioned above, the reinforcing layer is preferably a plastic net. Examples of such plastic nets are woven and non-woven nets, e.g. in the form of non-woven fabrics. The reinforcing layer may also be a metal wire net, optionally a net consisting of plastic coated metal wires. Similarly, a glass fibre net may comprise plastic-coated glass fibres.

An aluminum foil is an example of a suitable metal film and examples of suitable plastic films are polyester, polyethylene, and polypropylene films. Furthermore, glass fibre reinforced plastic films are suitable.

The reinforcing layer is preferably elastically deformable so that it will attempt to regain its original configuration after being penetrated by fastening means having varying cross-sectional dimensions in their longitudinal direction and to retain the insulation layer in the desired position.

However, instead of or in addition to using a plastically deformable reinforcing layer it may be desirable or use fastening means which are elastically or plastically deformable and of such a design that they engage the reinforcing net during the penetration into the insulation layer.

The method of the invention is suitable for mounting insulation layers on both indoor and outdoor supports, but is particularly suitable for mounting insulation layers on outer walls, partition walls and ceilings.

The invention will now be described in further detail with reference to the drawing in which

Fig. 1 shows a vertical sectional view of an insulation prepared by a preferred embodiment of the method of the invention, and

Fig. 2 shows a perspective view of the insulation according to Fig. 1 after removal of part of the outer insulation layer.

In the drawing 1 designates a support having mounted thereon an insulation layer 2 composed of two partial layers 3 and 4 and an intervening reinforcing net 5. The insulation layer 2 is attached to the support 1 by means of dowels 6 (only one is shown) having one end 7 anchored in the support and having a second end which is provided with annular grooves 8 inserted in the reinforcing net so as to maintain the insulation layer 2 in the position shown.

Claims

Patent Claims

1. Method of mounting an insulation layer (2) on a support (1) comprising pressing the insulation layer (2) against fastening means (6) attached to and extending out from the support, the fastening means being of such a shape that they are capable of being pressed into the insulation layer and securing it to said support, c h a r ¬ a c t e r i z e d in using an insulation layer (2) having incorporated therein a deformable reinforcing layer (5).

2. Method according to claim 1, c h a r a c t e r i z e d in that the deformable reinforcing layer is a net.

3. Method according to claim 2, c h a r a c t e r i z e d in that the deformable net is a plastic net, a glass fibre net, or a metal wire net.

4. Method according to claim 3, c h a r a c t e r i z e d in that the plastic net is a woven or non-woven net.

5. Method according to claim 1, c h a r a c t e r i z e d in that the reinforcing layer is a plastic film.

6. Method according to any of the preceding claims, c h a r a c - t e r i z e d in that the reinforcing layer is elastically deformable.

7. Method according to any of the preceding claims, c h a r a c ¬ t e r i z ed in that the fastening means (6) are elastically or plastically deformable and are of such a form that they engage with the reinforcing layer (5) during the penetration into the insulation layer.

8. Method according to any of the preceding claims, c h a r a c - t e r i z e d in that the insulation layer is a mineral fibre layer.

9. Method according to claim 8, c h a r a c t e r i z e d in that the insulation layer is made from rock wool fibres.

10. Method according to claim 1, c h a r a c t e r i z e d in that the insulation layer is a foamed plastic layer.

11. Method according to any of the preceding claims, c h a r a c ¬ t e r i z e d in using rod-shaped fastening means (6) having a free end of a cross-sectional area varying in the longitudinal direction of said fastening means.