THERMAL AND/OR ACOUSTIC INSULATION SYSTEM AS WATERPROOFING FOR A FLAT OR A FLAT INCLINED ROOF OF A BUILDING AND METHOD FOR PRODUCING A THERMAL AND/OR ACOUSTIC INSULATION SYSTEM AS WATERPROOFING

Abstract

The disclosure relates to a thermal and/or acoustic insulation system as waterproofing for a flat or flat inclined outside surface of a building, especially for a flat roof or a flat inclined roof, consisting of at least one insulation element made of mineral wool, preferably made of stone wool, and having a major surface, and a lining element consisting of at least a first layer made of lining material and a second layer made of a glue activatable by heat and oriented to the major surface of the insulation element, whereby the major surface of the insulation element is free of protrusions, especially flights, and cavities thereby being planar and whereby the area connection between the insulation element and the lining element is at least 70%, preferably at least 80% of the major surface area of the insulation element.

Claims

1. A thermal and/or acoustic insulation system as waterproofing for a flat or flat inclined outside surface of a building, especially for a flat or flat inclined roof, comprising at least one insulation element made of mineral wool, preferably made of stone wool, and having a major surface, and a lining element comprising at least a first layer made of lining material and a second layer made of a glue activatable by heat and oriented to the major surface of the insulation element, whereby the major surface of the insulation element is free of protrusions, flights, and cavities thereby being planar and whereby the area connection between the insulation element and the lining element is at least 70% of the major surface area of the insulation element.

2. The thermal and/or acoustic insulation system according to claim 1, wherein the insulation element has at least two layers of different bulk density whereby the layer with the higher bulk density is in contact with the lining element.

3. The thermal and/or acoustic insulation system according to claim 1, wherein the area connection between the insulation element and the lining element covers 90% up to 99% of the major surface area of the insulation element.

4. The thermal and/or acoustic insulation system according to claim 1, further comprising a peel off strength perpendicular to the major surface of the insulation element of at least 15 [N/50 mm], preferably of at least 18 [N/50 mm].

5. The thermal and/or acoustic insulation system according to claim 1, further comprising a wind uplift resistance of at least 3.500 N/m.sup.2, preferably of at least 4.000 N/m.sup.2.

6. The thermal and/or acoustic insulation system according to claim 2, wherein the bulk density of the insulation element layer being in contact with the lining element is 40% up to 100%, preferably 50% up to 75% higher than the bulk density of the layer being oriented opposite the lining element.

7. The thermal and/or acoustic insulation system according to claim 1, wherein a second major surface of the insulation element being oriented parallel to the major surface of the insulation element is free of protrusions, especially flights, and cavities thereby being planar.

8. A method for producing a thermal and/or acoustic insulation system as waterproofing for a flat or flat inclined outside surface of a building, especially for a flat or flat inclined roof, comprising at least one insulation element made of mineral wool, preferably made of stone wool and having a major surface, and a lining element comprising at least a first layer made of lining material and a second layer made of a glue activatable by heat and oriented to the major surface of the insulation element, whereby protrusions, flights, and cavities are removed from the major surface of the insulation element so that the major surface is planar, whereby the insulation element is placed on the outside surface of the building with the planar surface being oriented distant from the outer surface of the building, whereby the lining element is placed on the planar surface of the insulation element with its layer of glue being at least partly in contact with the major surface area of the insulation element and whereby the glue is heated up to its melting temperature.

9. The method according to claim 8, wherein the lining element is placed at a roll on top of the planar surface of the insulation element whereby an upper area of the roll is heated up to the melting temperature and whereby the roll is then scrolled until the heated upper area gets into contact with the planar surface of the insulation element.

10. The method according to claim 8, wherein any protrusions of the major surface of the insulation element are removed by sawing and/or grinding followed by removing the fibers not being bound to the insulation element.

11. The method according to claim 8, wherein the lining element is connected to the insulation element on at least 70%, preferably on at least 80% of the planar surface area of the insulation element.

12. The method according to claim 8, wherein the lining element is connected to an insulation element having at least two layers of different bulk densities whereby the layer with the higher bulk density is in contact with the lining element.

13. The method according to claim 8, wherein the lining element is connected to a planar surface of the insulation element in which the fibers are mostly oriented perpendicular or at least inclined to the planar surface of the insulation elements.

14. The method according to claim 8, wherein protrusions, flights, and cavities are removed from a second major surface of the insulation element being oriented parallel to the major surface of the insulation element so that the second major surface is planar.

Description

DRAWINGS

[0042] 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.

[0043] The disclosure is illustrated in the accompanying drawings showing preferred embodiments of the disclosure. The drawings show in

[0044] FIG. 1 a flat roof according to the prior art in a schematic side view;

[0045] FIG. 2 a flat roof according to the disclosure in a schematic side view;

[0046] FIG. 3 the installation of a lining element on top of an insulation element according to the prior art;

[0047] FIG. 4 the insulation of a lining element on top of an insulation element according to the disclosure;

[0048] FIG. 5 a lining element in a schematic side view and

[0049] FIG. 6 the preparing of an insulation element before a lining element is applied to the major surface of the insulation element.

[0050] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0051] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0052] FIG. 1 shows a commonly known prior art thermal and/or acoustic insulation system as waterproofing for a flat roof 1 which consists of a structural support 2, e.g. a continuous steel deck, a vapor control layer 3, a mineral wool insulation element and a lining element 5 being arranged on top of the insulation element 4.

[0053] The insulation element 4 consists of mineral fibers, in particular stone wool fibers and an organic binder, for example a phenolic binder with added silane. The binder is hardened in a not shown hardening device thereby producing protrusions 6 on top of a major surface 7 being oriented to the lining element 5.

[0054] The lining element 5 is glued to the protrusions 6, thereby not being in contact with the major surface 7.1 between the protrusions 6.

[0055] The lining element 5 is made of a bituminous layer which can be heated to a temperature melting the bitumen and thereby connecting the bituminous layer to the protrusions 6. To connect the lining element 5 to the major surface 7.1 a high amount of bitumen has to be inserted into the areas between the protrusions 6 to improve the connection between the insulation element 4 and the lining element 5.

[0056] FIG. 2 shows the flat roof 1 in a schematic side view according to the disclosure. Once again the flat roof 1 consists of a structural support 2 and a vapor control layer 3. The mineral wool insulation element 4 is arranged on top of the vapor control layer 3 which covers the support 2.

[0057] The insulation element 4 has a major surface 6 being free of protrusions and/or cavities so that the major surface 7.2 is planar and prepared for fixing the lining element 5 on top of the major surface 7.2.

[0058] The lining element 5 which is shown in more detail in FIG. 5 consists of a first layer 8 made of lining material and a second layer 9 made of a glue or an adhesive which is activatable by heat. The second layer 9 therefore comprises a thermal setting adhesive or is made of a thermal setting adhesive. The second layer 9 compared to the first layer 8 is very thin and has a thickness of approximately 0.5 up to 2 mm which makes it possible to activate the thermal setting adhesive in short time with less heating energy, compared and contrary to the prior art bitumen membranes comprising relatively thick second layer of more than 3 mm of bitumen which require a substantial amount of heat to make the bitumen reactive and sticky.

[0059] The insulation element 4 used for the thermal and/or acoustic insulation system according to the disclosure is shown in FIG. 6 in more detail. According to FIG. 6 the insulation element 4 has two layers 10 and 11 of different density and thickness. It can be seen from FIG. 6 that the layer 11 has a lower density and a higher thickness compared to the layer 10.

[0060] Furthermore, FIG. 6 shows a blade 12 which is used to remove a thin layer 13 of the layer 11. By removing the layer 13 a part of the major surface 7.1 being equipped with protrusions 6, namely flights is removed as well as a part of the layer 11 in which the fibers are oriented parallel to the major surface 7.1. In consequence, the major fiber orientation in layer 11 is perpendicular to the major surface 7.1 avoiding fibers being oriented parallel to the major surface 7.2.

[0061] Finally, FIGS. 3 and 4 show a method of applying the lining element 5 to the major surface 7.1 or 7.2 of the insulation element 4.

[0062] FIG. 3 represents the prior art and shows that a flame 14 provided by a burner 15, e.g. a gas torch, is directed into a crotch 16 being arranged between a roll 17 of a traditional bituminous lining element 5 and the major surface 7.1 of the insulation element 4. Using this flame 14 in the crotch 16 means to heat up the major surface 7.1 of the insulation element 4 and thereby burn the binder between the fibers at least in the area of the major surface 7.1. The organic binder between the fibers can already be destroyed by temperatures of approximately 200° C. Destroying the binder means that a part of the fibers of the insulation element 4 are not bound any longer and therefore reduce the peel off strength of the insulation element 4. In consequence, a lot of adhesive of the lining element 5 is to be used to connect the lining element 5 to the insulation element 4 thereby connecting the unbound fibers into the surface area of the major surface 7.1 of the insulation element 4 in that the fibers are captured in the adhesive. I.e., this way of heating the prior art lining element 5 however is necessary to liquefy a sufficient amount of adhesive or bitumen to ensure a proper connection.

[0063] In contrast to that, according to the disclosure the flame 14 of a burner 15 is used to only heat up an area 18 of the surface of the lining element 5 being arranged as a roll 17 on top of the planar surface 7.2 of the insulation element 4. The area 18 which is useful to be heated up is shown in FIG. 4 as an arrow 19. It can be seen that the flame 14 does not get into contact with the major surface 7.2 of the insulation element 4 thereby preventing the destruction of binder between the fibers.

[0064] After the area 18 of the roll 17 is heated up to the melting temperature of the adhesive the roll 17 is scrolled partly for example in the length of arrow 19 to connect the sticky adhesive to the major surface 7.2 of the insulation element 4.

[0065] Of course, on top of a roof several insulation elements 4 are used side by side and it will be necessary to use lining elements 5 being arranged side by side and overlapping partly. Therefore, the adhesive used for connecting the lining element 5 to the insulation element 4 is also useable for connecting two lining elements 5 being arranged side by side and overlapping each other partly.

[0066] 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.