INSULATION ELEMENT FOR THERMAL AND/OR ACOUSTIC INSULATION OF A FLAT OR FLAT INCLINED ROOF AND METHOD FOR PRODUCING AN INSULATION ELEMENT

Abstract

Insulation element for thermal and/or acoustic insulation of a flat roof, comprising a first layer made of mineral wool and a second layer made of at least one fabric, whereby the second layer is fixed to a major surface of the first layer by an adhesive, whereby the first layer is made of at least one lamella having a fiber orientation predominantly perpendicular to major surfaces of the second layer, whereby the first layer contains a cured binder whereby the adhesive is arranged partly in an area between fibers close to the major surface of the first layer directed to the second layer and in an area close to the major surface of the second layer directed to the first layer so that the adhesive connects the first layer and the second layer in such a way that forces directed perpendicular to the second layer can be compensated by the tensile strength of the second layer in combination with the adhesive and/or the deflection of the fibers of the first layer causing a maximum deformation of ≤5% of the thickness of the first and second layer.

Claims

1. An insulation element for thermal and/or acoustic insulation of a flat or flat inclined roof, comprising a first layer made of mineral wool, especially stone wool and a second layer made of at least one fabric, especially a fleece, whereby the second layer is fixed to a major surface of the first layer by an adhesive, whereby the first layer is made of at least one lamella having a fiber orientation predominantly perpendicular to major surfaces of the second layer, and whereby the first layer contains a cured binder, wherein the adhesive is arranged partly in an area between fibers close to the major surface of the first layer directed to the second layer and in an area close to the major surface of the second layer directed to the first layer so that the adhesive connects the first layer and the second layer in such a way that forces directed perpendicular to the second layer can be compensated by the tensile strength of the second layer in combination with the adhesive and/or the deflection of the fibers of the first layer causing a maximum deformation of ≤5% of the thickness of the first and the second layer and whereby the adhesive is provided in an amount between 60 g/m.sup.2 and 400 g/m.sup.2, preferably between 100 g/m.sup.2 and 250 g/m.sup.2, more preferably in an amount of 150 g/m.sup.2, between the first layer and the second layer.

2. The insulation element according to claim 1, wherein the second layer is made of a glass fleece, preferably having an E-modulus of 450 to 900 MPa, preferably of 500 to 800 MPa and/or a tensile strength between 50 and 110 N, preferably between 70 and 90 N.

3. The insulation element according to claim 1, wherein the second layer is connectable to a bituminous membrane by torching or to membranes by cold gluing.

4. The insulation element according to claim 1, wherein the adhesive is chosen from melamine urea formaldehyde, preferably as two component glue, water borne acrylic glue, phenol formaldehyde powder binder, water borne neoprene foam glue, polyamide based powder glue, polyurethane glue, preferably as two component glue, polyurethane moisture curing glue or silane modified binder, preferably as one component moisture curing glue.

5. The insulation element according to claim 1, wherein a dry applied adhesive, preferably a phenol formaldehyde powder binder or a polyamide based powder glue, is arranged in an amount between 60 g/m.sup.2 and 250 g/m.sup.2, preferably between 80 g/m.sup.2 and 150 g/m.sup.2, between the first layer and the second layer.

6. The insulation element according to claim 1, wherein the adhesive is provided full faced between the first layer and the second layer.

7. The insulation element according to claim 1, wherein the first layer made of mineral fibers and binder, the binder being present in an amount of preferably between 3 and 7 wt.-%, has a bulk density of 80 to 120 kg/m.sup.3 and a compression strength between 50 and 130 kPa.

8. A method for producing an insulation element according to claim 1, wherein a first layer made of at least one lamella having a fiber orientation predominantly perpendicular to its major surfaces and consisting of mineral fibers and a cured binder is connected to a second layer by an adhesive being arranged partly in an area between fibers close to the major surface of the first layer directed to the second layer and in an area close to the major surface of the second layer directed to the first layer so that the adhesive connects the first layer and the second layer in such a way that forces directed perpendicular to the second layer can be compensated by the tensile strength of the second layer in combination with the adhesive and/or the deflection of the fibers of the first layer causing a maximum deformation of ≤5% of the thickness of the first and second layer whereby the adhesive is applied to the first and/or the second layer before connecting the two layers and cure the adhesive and whereby the adhesive is provided in an amount between 60 g/m.sup.2 and 400 g/m.sup.2, preferably between 100 g/m.sup.2 and 250 g/m.sup.2, more preferably in an amount of 150 g/m.sup.2 between the first layer and the second layer.

9. The method according to claim 8, wherein the adhesive is arranged on the major surface of the first and/or second layer before the second layer is arranged on the first layer thereby pressing the adhesive into pores of the first and/or second layer and whereby the adhesive is cured after connecting the layers.

Description

DRAWINGS

[0034] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0035] The disclosure is illustrated in the accompanying drawing in which

[0036] FIG. 1 shows a part of a flat roof in cross-section;

[0037] FIG. 2 shows a diagram of the point load of a first embodiment of the insulation element;

[0038] FIG. 3 shows a point load work of the first embodiment of the disclosure according to FIG. 2;

[0039] FIG. 4 shows a diagram of the point load of a second embodiment of the insulation element and

[0040] FIG. 5 shows a point load work of the second embodiment of the disclosure according to FIG. 4.

[0041] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0042] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0043] FIG. 1 shows a part of a flat roof 1 comprising a structural support 2, a vapour control layer 3 and an insulation element 4. The insulation element 4 comprises a first layer 5 comprising stone wool fibers and a binder and a second layer 6 made of a fabric of a glass fleece, having an E-modulus of 573 MPa. The tensile strength of the glass fleece is 71 N.

[0044] The first layer 5 is represented by one or more lamella having a fiber orientation predominantly perpendicular to a major surface 7 of the second layer 6. The lamella and therefore the first layer 5 have a density of 110 kg/m.sup.3 and a typical thickness of 150 mm. The mineral fibers are bonded together via the binder being cured in a hardening oven before the second layer 6 is fixed to a surface 8 of the first layer 5 via an adhesive 9.

[0045] The adhesive 9 is arranged partly in an area 10 close to the major surface 8 of the first layer 5 directed to the second layer 6 and in an area 11 close to the major surface 7 of the second layer 6 directed to the first layer 5 so that the adhesive 9 connects the first layer 5 and the second layer 6 in such a way that forces directed perpendicular to the second layer 6 can be compensated by the tensile strength of the second layer 6 in combination with the adhesive 9 and/or the deflection of the fibers of the first layer 5. Such a force of e. g. 80 kPa directed perpendicular to the second layer 6 causes a limited deformation of smaller 5% of the insulation element 4 (first and second layer 5, 6) and therefore of not more than 7.5 mm related to the thickness of 150 mm of the first layer 5. The thickness of the second layer 6 is approximately not more than 1 mm and can therefore be disregarded in this calculation. A sufficient amount of adhesive 9 is arranged between the fibers of the first layer 5 thereby surrounding the fibers and building up a layer of adhesive 9 being anchored in the first layer 5.

[0046] The adhesive 9 is arranged with an amount of 80 g/m.sup.2 between the two layers 5 and 6 as an acrylic glue. A sufficient amount of the adhesive 9 diffuses in the first layer 5 and the second layer 6. The adhesive 9 constitutes therefore a layer connecting the first layer 5 and the second layer 6 and is anchored in both layers 5, 6.

[0047] FIG. 2 shows a diagram with two graphs whereby the lower graph (dotted line) is the relation of load to deformation in a lamella as already known from the prior art. The upper graph shows the load in relation to the deformation of an insulation element 4 according to the disclosure.

[0048] The density of the mineral wool lamella in the insulation element 4 according to the disclosure is 110 kg/m.sup.3. The second layer 6 has a tensile strength of 71 N and an E-modulus of 573 MPa. Both layers 5, 6 are connected via an acrylic glue in an amount of 80 g/m.sup.2.

[0049] As it can be seen from the upper graph, the point load strength of the insulation element 4 is improved significantly by the second layer 6 in connection with the layer of adhesive 9. In the area of small deformations between 0 and 1.5 mm both elements (lamella and insulation element according to the disclosure) show elastic properties but the insulation element according to the disclosure takes a higher load meaning this insulation element has a higher E-Modulus compared to a lamella as known from the prior art.

[0050] In the area from 1.5 to 12 mm, the insulation element 4 according to the disclosure is much stronger compared to a lamella known from the prior art. These improvements of the point load strength, especially at small deformations, can also be perceived as improved walkability.

[0051] FIG. 3 shows a second diagram for the before described insulation element 4 showing the point load work [j] in relation to the deformation. Once again, the upper graph belongs to the insulation element 4 according to the disclosure and the lower graph (dotted line) belongs to a lamella according to the prior art.

[0052] The current disclosure proves that the walkability of an insulation element 4 is related to the product of the load and the deformation that occurs when a person walks on the insulation element 4. A respective load can also be described as the force and the deformation as the displacement.

[0053] The product of point load and deformation is the work based on the general equation

work=force×displacement

[0054] Higher work means better walkability. Especially for deformation in the range of 0 to 10 mm or point load up to 800 N, this is important. In the graph (dotted line) according to FIG. 3, the work for the same lamella as in the previous graph in FIG. 2 is shown.

[0055] As it can be seen from the graph for the insulation element 4 according to the disclosure, the work is around 25% higher than after 5 mm deformation and around 80% higher after 10 mm deformation. This improves the walkability significantly.

[0056] Such results can even be achieved by using a lamella with a density of 85 kg/m.sup.3 as it is shown in FIGS. 4 and 5. All other parameters are equal to the parameters of FIGS. 2 and 3.

[0057] The point load measurements are carried out according to European Standard EN12430:2013, “Thermal insulating products for building applications—determination of behavior under point load”.

[0058] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are inter-changeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.