U.S. patent application number 14/508532 was filed with the patent office on 2015-04-16 for exterior insulation and thermal insulation composite area, as well as wall structure, comprising the composite thermal insulation or thermal insulation composite and complex process for the production of wall structures.
The applicant listed for this patent is DAW SE. Invention is credited to Thomas LOHMANN.
Application Number | 20150101276 14/508532 |
Document ID | / |
Family ID | 49447315 |
Filed Date | 2015-04-16 |
United States Patent
Application |
20150101276 |
Kind Code |
A1 |
LOHMANN; Thomas |
April 16, 2015 |
EXTERIOR INSULATION AND THERMAL INSULATION COMPOSITE AREA, AS WELL
AS WALL STRUCTURE, COMPRISING THE COMPOSITE THERMAL INSULATION OR
THERMAL INSULATION COMPOSITE AND COMPLEX PROCESS FOR THE PRODUCTION
OF WALL STRUCTURES
Abstract
The present invention relates to a thermal insulation composite,
in particular a panel-shaped thermal insulation composite. The
invention further relates to a thermal insulation composite area,
in particular a thermal insulation panel area, comprising thermal
insulation composites or thermal insulation panels. The invention
also relates to a wall structure comprising at least one thermal
insulation composite or a thermal insulation composite area.
Finally, the invention relates to a method for manufacturing wall
structures.
Inventors: |
LOHMANN; Thomas; (Ladenburg,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DAW SE |
Ober-Ramstadt |
|
DE |
|
|
Family ID: |
49447315 |
Appl. No.: |
14/508532 |
Filed: |
October 7, 2014 |
Current U.S.
Class: |
52/404.1 ;
428/292.1; 428/317.9; 52/745.1 |
Current CPC
Class: |
Y10T 428/249986
20150401; E04B 1/7675 20130101; Y10T 428/249924 20150401; E04B
1/762 20130101; E04C 2/243 20130101; E04C 2/46 20130101 |
Class at
Publication: |
52/404.1 ;
428/292.1; 428/317.9; 52/745.1 |
International
Class: |
E04C 2/24 20060101
E04C002/24; E04B 1/76 20060101 E04B001/76; E04B 2/00 20060101
E04B002/00; E04B 2/72 20060101 E04B002/72 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 11, 2013 |
EP |
13004887.9 |
Claims
1. A thermal insulation composite, in particular a panel-shaped
thermal insulation composite, having a first side, in particular a
wet or condensation water side, and an opposing second side, in
particular a dry or interior space side, comprising at least one
insulating material unit and at least one capillary conductive
segment containing capillary conductive material, wherein the
capillary conductive segment extends continuously from the first
side to the second side, characterised in that at least in the
region of the at least one capillary conductive segment extending
from the first side to the second side the second side is provided
in sections or entirely, in particular entirely, with at least one
first diffusionally active coating of a or containing a first
hydrophobic or hydrophobised coating material, and wherein the at
least one capillary conductive segment and the first diffusionally
active coating are in contact with one another.
2. The thermal insulation composite according to claim 1,
comprising at least two, in particular cuboid-shaped or
cubical-shaped, insulating material units, each having a length,
height and width dimension and an edge line or edge surface
extending at least in sections along the length and width
dimension, wherein adjacent insulating material units are glued to
one another in sections or entirely, in particular entirely, along
the edge lines adjoining or facing one another with at least one
adhesive composition containing a binder and applied in particular
by means of brushing, rolling, doctoring, pouring and/or spraying,
forming the at least one capillary conductive segment, wherein the
adhesive layer formed by said adhesive composition is capillary
conductive in its cured state and extends at least in sections from
the first side to the second side, and wherein preferably at least
two adjacent adhesive layers, in particular all adhesive layers,
are essentially parallel to one another at least in sections.
3. The thermal insulation composite according to claim 2,
characterised in that at least one insulating material unit,
preferably at least two adjacent, and particularly preferably all,
insulating material units are formed of or comprise fibrous
materials and/or foam products, in particular foam products.
4. The thermal insulation composite according to claim 3,
characterised in that the foam products are selected from the group
consisting of foam glass, expanded styrene polymers, in particular
expanded polystyrene, expanded polypropylene, elastomeric foam,
polyisocyanurate foam, polyethylene foam, phenolic resin foam,
polyurethane rigid foam, urea formaldehyde resin foam,
hydrophobised silica, hydrophobised aerogels, extruded styrene
polymers, in particular extruded polystyrene foam, expanded cork or
any mixture of these components, preferably expanded styrene
polymers, particularly preferably expanded polystyrene, and/or that
the fibrous materials are selected from the group consisting of
mineral wool, synthetic fibres, hydrophobised wood fibres, in
particular soft wood fibres, wood wool, cotton and cellulose fibres
or parts thereof or any mixture thereof.
5. The thermal insulation composite according to claim 1,
characterised in that the capillary conductive material, which in
particular does not contain any fillers, of the capillary
conductive segment or the binder-containing adhesive compositions,
which in particular do not contain any fillers, contain as binders,
in particular exclusively, mineral binders, in particular hydrous
and/or hydraulic binders, in particular selected from the group
consisting of cement, lime, gypsum, aluminous cement, water glass
or any mixture thereof.
6. The thermal insulation composite according to claim 1,
characterised in that the first side at least in the region of the
at least one capillary conductive segment extending from the first
side to the second side, in particular in the region of the at
least one adhesive layer extending from the first side to the
second side, is provided, in sections or entirely, in particular
entirely, with at least one first capillary conductive coating of
or containing at least one first capillary conductive coating
material, or in segments or entirely, in particular entirely, with
at least one second diffusionally active coating of a second or
containing at least one second hydrophobic or hydrophobised coating
material, and wherein the at least one capillary conductive
segment, in particular the at least one adhesive layer, and the
first capillary conductive coating or the second diffusionally
active coating are in contact with one another.
7. The thermal insulation composite according to claim 1,
characterised by at least one adhesion promoting layer applied to
the first diffusionally active coating and/or by at least one
diffusionally active plaster coating, in particular a finishing
plaster coating, preferably on a silicate basis, on the adhesion
promoting layer or on the first diffusionally active coating,
and/or by at least one diffusionally active coating of paint, in
particular comprising a silicate paint or a silicate dispersion
paint, and/or by at least one reinforcement fabric, in particular
on the basis of glass fibres, present at or in the first
diffusionally active coating, preferably partially or entirely
embedded into said coating, and/or by at least a third
diffusionally active coating of a third or containing at least a
third hydrophobic or hydrophobised coating material on the at least
one first capillary conductive coating of the or containing the
first capillary conductive coating material present on the first
side and/or by at least one second capillary conductive coating, in
particular in the form of an adhesive layer, on the at least one
first capillary conductive coating of the or containing the first
capillary conductive coating material present on the first
side.
8. The thermal insulation composite according to claim 1,
characterised in that the hydrophobic or hydrophobised coating
material of the first, second and/or third diffusionally active
coating comprises at least one hydrophobing agent, in particular
fatty alcohols or fatty acids or fatty acid esters or fatty acid
salts or derivatives thereof or any mixture thereof, in particular
at an amount within the range of 0.05% by weight to 3.0% by weight
in relation to the dry mass of the coating material.
9. The thermal insulation composite according to claim 1,
characterised in that the first and/or second and/or third
diffusionally active coating is not or essentially not capillary
conductive and/or that the first, second and/or third diffusionally
active coating essentially correspond to one another in their
compositions and/or that the first and second capillary conductive
coating essentially correspond to one another in their
compositions.
10. A thermal insulation composite area, in particular a thermal
insulation panel area, comprising at least two, in particular a
plurality of, thermal insulation composites, in particular thermal
insulation panels, according to claim 1, each having a first and an
opposing second side and an edge line or edge surface
circumferencing at least in sections and connecting the first and
the second side and having a length and width dimension, wherein
adjacent thermal insulation composites, in particular thermal
insulation panels, are arranged adjacent to one another at least in
sections along their edge lines or edge surfaces, in particular in
a flush manner.
11. The thermal insulation composite area according to claim 10,
characterised in that adjacent thermal insulation composites or
panels are glued to one another at least in sections along their
edge lines or edge surfaces, in particular in a flush manner, using
a binder-containing adhesive composition, wherein the adhesive
layer formed by this composition is capillary conductive in its
cured state and extends from the first side to the second side at
least in sections.
12. A wall structure, comprising a building wall having an exterior
side and an opposing interiors side, in particular an outer
building wall, and having at least one thermal insulation composite
according to claim 1 or at least one thermal insulation composite
area on the interior side, wherein the thermal insulation composite
area, in particular a thermal insulation panel area, comprising at
least two, in particular a plurality of, thermal insulation
composites, in particular thermal insulation panels, according to
claim 1 each having a first and an opposing second side and an edge
line or edge surface circumferencing at least in sections and
connecting the first and the second side and having a length and
width dimension, wherein adjacent thermal insulation composites, in
particular thermal insulation panels, are arranged adjacent to one
another at least in sections along their edge lines or edge
surfaces, in particular in a flush manner, wherein the first side
of the thermal insulation composite or the thermal insulation
composite area is arranged to face the interior side.
13. The wall structure according to claim 12, characterised in that
the first side of the thermal insulation composite or the thermal
insulation composite area is provided in sections or entirely, in
particular entirely, with the at least one first capillary
conductive coating of one or containing at least one first
capillary conductive coating material or with the at least one
second diffusionally active coating of one second or containing at
least one second hydrophobic or hydrophobised coating material,
preferably so as to form a connection with the interior side of the
building wall.
14. The wall structure according to claim 12, further comprising,
in sections or entirely, in particular entirely, at least a third
diffusionally active coating of a third or containing at least a
third hydrophobic or hydrophobised coating material, said coating
connecting the building wall, in particular the interior side
thereof, to the at least one first capillary conductive coating of
one or containing at least one first capillary conductive coating
material.
15. The wall structure according to claim 12, characterised in that
the building wall represents a building wall based on a timber
frame type of construction, in particular a platform or balloon
frame type of construction.
16. A method for manufacturing at least one wall structure
according to claim 12, comprising the steps of: attaching a
precursor thermal insulation composite product, in particular a
panel-shaped precursor thermal insulation composite product, having
a first side, in particular a wet or condensation water side, and
an opposing second side, in particular a dry or interior space
side, comprising at least one insulating material unit and at least
one capillary conductive segment containing capillary conductive
material, wherein the capillary conductive segment extends
continuously from the first side to the second side, over the first
side thereof by means of at least one capillary conductive coating
material forming a capillary conductive coating at least in
sections or entirely, in particular entirely, to the building wall,
in particular the interior side of the outer building wall, or
attaching a precursor thermal insulation composite product, in
particular a panel-shaped precursor thermal insulation composite
product, having a first side, in particular a wet or condensation
water side, and an opposing second side, in particular a dry or
interior space side, comprising at least one insulating material
unit and at least one capillary conductive segment containing
capillary conductive material, wherein the capillary conductive
segment extends continuously from the first side to the second
side, having the at least one first capillary conductive coating of
a or containing at least the first capillary conductive coating
material on the first side, over the first side thereof by means of
at least one capillary conductive coating material forming a
capillary conductive coating at least in sections or entirely, in
particular entirely, or preferably by means of the second
hydrophobic or hydrophobised coating material forming the second
diffusionally active coating to the building wall, in particular
the interior side of the outer building wall, and applying the at
least one first diffusionally active coating of the or containing
the first hydrophobic or hydrophobised coating material to the
second side, such that the at least one capillary conductive
segment is in contact with the first diffusionally active
coating.
17. The method according to claim 16, characterised in that the
precursor thermal insulation composite product, in particular the
panel shaped precursor thermal insulation composite product
comprises at least two, particularly cuboid-shaped or
cubical-shaped, insulating material units, each having a length,
height and width dimension and an edge line or surface extending at
least in sections along the length and width dimension, wherein
adjacent insulating material units are glued to one another in
sections or entirely along the edge lines adjoining or facing one
another with at least one adhesive composition containing a binder
and applied particularly by means of brushing, rolling, doctoring,
pouring and/or spraying, forming the at least one capillary
conductive segment in the form of an adhesive layer, wherein the
adhesive layer formed by said adhesive composition is capillary
conductive in its cured state and extends at least in sections from
the first side to the second side, and wherein preferably at least
two adjacent adhesive layers, in particular all adhesive layers are
essentially parallel to one another at least in sections.
Description
[0001] The present invention relates to a thermal insulation
composite, in particular a panel-shaped thermal insulation
composite. The invention further relates to a thermal insulation
composite area, in particular a thermal insulation panel area,
comprising thermal insulation composites or thermal insulation
panels. The invention also relates to a wall structure comprising
at least one thermal insulation composite or a thermal insulation
composite area. Finally, the invention relates to a method for
manufacturing wall structures.
[0002] Increasingly, buildings are retrofitted with thermal
insulation. Also with new buildings there is a particular focus on
thermal insulation with a view to saving energy. Facade insulation,
i.e. the heat insulation attached to the exterior side of the outer
building wall, has been established for decades. Such an exterior
facade insulation is often not possible, however, due to provisions
in relation with the protection of monuments or ensembles or other
regulations or because the builder wishes otherwise. In such cases
it is possible, for example, to carry out an interior building
insulation, i.e. to attach the thermal insulation on the interior
side of the outer building wall.
[0003] When installing the interior insulation it is important for
various reasons that this be done in a professional manner.
Different systems are available for interior insulation, for
example systems with and without vapour seals or barriers,
insulants with capillary conduction and composite panels with an
integrated insulant. The disadvantage of vapour-tight interior
insulations is that they can be easily damaged even during minor
repair work or installations and consequently cannot fulfil their
task any longer. Furthermore, attention has to be paid to the fact
that the moisture balance of an outer building wall, in particular
a wall exposed to driving rain, can be noticeably affected in a
negative way. This is because a building facade absorbs water over
the course of a year, which does not cause any damage as long as
the moist masonry can dry towards the inside during the summer.
After attaching a vapour-tight interior insulation this will no
longer be possible. Moisture will accumulate behind the insulating
material, and the masonry will become wetter and wetter. This will
increase the hazard of mould formation and also the risk of frost
damage. Structural damage can then not be excluded any longer.
[0004] Capillary active or conductive interior insulations do not
use a vapour barrier. With such an insulation the disadvantages
described above as a rule do not occur or occur to a lesser degree,
depending on the quality of the interior insulation.
[0005] For a capillary active interior insulation homogeneous
open-cell mineral panels are used, for example. This includes
calcium silicate panels such as the commercially available product
Calsitherm, mineral insulants containing perlite as a filler, e.g.
the product lectern, and the porous concrete Multipor. Reference is
made in this context to DE 197 23 426 C1 and DE 10 2010 005 361 A1.
These insulating panels essentially have in common that the
homogeneous material has to fulfil the functions of both thermal
insulation and capillary conductivity at the same time; it is thus
inevitably only a compromise. These plates generally have a bulk
density of approximately 120 to 300 kg/m.sup.3 at a thermal
conductivity (dry) of approximately 0.045 to 0.065 W/mK.
[0006] Furthermore, panels of expanded cork, such as described in
DE 10 2007 025303 A1 are used for a capillary active interior
insulation, the cavities of which extend through the entire panel
and have been filled under vacuum with modified loam. While the
first material is responsible for thermal insulation (cork), the
further material (loam) provides the capillary conductivity. The
bulk density of the filled cork panel is 120 to 150 kg/m.sup.3 at a
thermal conductivity (dry) between 0.04 to 0.06 W/mK. It is
desirable to have better thermal insulation values.
[0007] In EP 2 447 431 A2 a panel of expanded polystyrene, the
individual prefoamed beads of which have remained largely circular
and assumed only to a small extent the polyhedral shape usually
present in polystyrene panels, serves as the component responsible
for thermal insulation. This panel has cavities which extend
through the entire panel and which are partly interconnected, said
cavities having been filled, in a similar manner to DE 10 2007 025
303 A1, under vacuum with a composition on a lime/cement basis
serving as the capillary conductive material. The essential feature
of the above-described realisation of insulation panels is that
basically two individual anisotropic matrices are placed into one
another, one being responsible for thermal insulation and the other
for capillary conductivity. Consequently there is neither a
preferred direction for thermal conductivity nor for capillary
conductivity.
[0008] According to a further realisation, insulation panels can
also have insulation panel sections arranged in a chequered manner,
such as can be gathered from EP 86 681 B1, which are connected to
one another via capillary active cuboid-shaped bridges. Insulation
panels having cuboid-shaped capillary active bridges are also
disclosed in DE 10 2010 044 791 A1 and DE 10 2010 044 789 A1. The
bridges are made of calcium silicate, the insulation panels are
vacuum insulation panels and foil-laminated polyurethane rigid
foam.
[0009] In WO 92/10624 an insulation panel is provided with
through-holes which are to be filled with capillary conductive
material after the panel has been attached to the wall. Insulation
panels having through-holes filled with a capillary active material
are also described in DE 10 2007 040 938 A1, EP 2 183 099 A1, DE 10
2007 040 938 and DE 10 2011 050 830 A1. Moreover, EP 2 183 099 A1
and DE 10 2007 040 938 both recommend to provide with a capillary
conductive coating both the visible side of the capillary active
insulation panel, i.e. the side which, after installation, faces
the interior space, and its condensation water side, i.e. the side
which, as a rule, faces the interior surface of a(n outer) building
wall, in order to ensure the transport of fluids. In particular
when larger amounts of fluid or moisture enter the described
capillary active insulation panel via the outer building wall, this
type of coating on both surfaces entails the hazard of the
formation of stains or the capillary conductive passages becoming
visible or the capillary conductive joints of this capillary
conductive insulation panel becoming visible on the visible side,
for example on a finishing coat of plaster applied to the capillary
conductive coating of the insulation panel or on a layer of paint
applied to said coating, e.g. due to fluid seeping through locally
and/or due to the accumulation of condensation water.
[0010] Many insulating materials made of fibres are often not or
not sufficiently capillary conductive, even though they exhibit a
high water vapour permeability. They, too, require the addition of
a capillary conductive material, which can also be ensured by
providing holes which are filled accordingly.
[0011] The capillary active insulation panels available so far have
various different shortcomings.
[0012] Insulants such as the ones disclosed in DE 197 23 426 C1 and
DE 10 2010 005 361 A1 are relatively heavy and have significantly
poorer insulating properties in their dry state than the insulants
commonly used for exterior insulation (such as EPS, PU or PF). Due
to their high bulk density and because of the larger panel
thickness which is required for comparable energy savings because
the thermal insulation they provide is only moderate, the
consumption of resources is also high when using said insulants. In
addition, these insulants usually exhibit hardly any resistance
against mechanical loads, resulting in the small panel dimensions
which often have to be used in practice. It is not uncommon for
parts to break out or off when an insulated interior wall is being
constructed, in particular at the panel edges, which then are often
filled with mortar which does not have any thermally insulating
properties and consequently represents a thermal bridge. Also the
formation of cracks and blisters over a large area cannot be
excluded due to the manufacturing methods applied. In such regions
the capillary conduction is interrupted.
[0013] Insulants such as those described in WO 92/10624 generally
use significant amounts of capillary conductive material. Thus,
valuable space for the thermally insulating component is wasted.
Moreover, the manufacturing process of such insulants is often
anything but trivial. In addition the machinery requirements are
rather complex. Due to the required vacuum the capillary active
material can only be filled into blocks having small
dimensions.
[0014] With the insulating panels according to DE 10 2007 040 938
A1 and DE 10 2011 050 830 A1, it has been found that cooler areas,
i.e. the regions of the through-holes containing capillary active
material, will become visible after a while as dark areas. An
unwanted pattern then forms on the interior side of the wall. To
avoid this effect, it is usually required to provide a final coat
of a material with good heat conducting properties, said coat
having a thickness of at least 5 to 10 mm. According to DE 10 2010
44 791 A1 and DE 10 2010 044 789 A1 cover panels with a thickness
of approximately 10 mm are used for this purpose.
[0015] It would be desirable to be able to use insulants or
insulation panels which do not any longer have the disadvantages of
the state of the art and which in particular ensure a consistently
good thermal insulation. The object of the present invention has
therefore been to provide insulants which overcome the
disadvantages of the state of the art and which in particular
enable an interior building insulation which is easy to construct
and which, at the same time, minimizes or entirely eliminates the
hazard of thermal bridges without having to rely on a vapour
barrier. A further object of the invention has been to make
available an interior insulation which is cost-effective and which
minimizes or eliminates the problem of the formation of
condensation water and/or the problem of mould formation.
Furthermore it has been the object of the invention to provide
insulating materials or insulants which have good flexural
strength. Moreover it has been an object of the invention to
provide insulants or insulation panels which do not become visible.
It has further been an object of the invention to enable large
panel dimensions which are suitable for construction sites and
which can be installed quickly and to provide a stability suitable
for construction sites. It has also been an object of the invention
to provide a surface which is easy to grind to be able to
conveniently remove uneven regions after gluing the insulation
panels to the interior side of the outer wall. In addition it has
been an object of the present invention to provide insulating
materials for interior insulation which do not have the tendency to
form moisture stains and/or so-called salt efflorescence on the
visible side. Finally, it has been an object of the invention to
create or maintain a comfortable indoor climate irrespective of the
season by using an interior insulation.
[0016] The object of the invention is achieved accordingly by a
thermal insulation composite, in particular a panel-shaped thermal
insulation composite, having a first side, in particular a wet or
condensation water side, and an opposing second side, in particular
a dry or interior space side, comprising at least one insulating
material unit and at least one capillary conductive segment
containing capillary conductive material, wherein the capillary
conductive segment extends continuously from the first side to the
second side, wherein at least in the region of the at least one
capillary conductive segment extending from the first side to the
second side the second side is provided in segments or entirely, in
particular entirely, with at least one first diffusionally active
coating of a or containing a first hydrophobic or hydrophobised
coating material, and wherein the at least one capillary conductive
segment and the first diffusionally active coating are in contact
with one another.
[0017] With the thermal insulation composites or insulation panels
of the invention, fluid, which first of all gets from the first to
the opposing second side through the at least one insulating
material unit by means of capillary conduction via the capillary
conductive segments or the capillary conductive adhesive layers, is
then transferred by means of diffusion towards the interior space
via the subsequent first diffusionally active coating.
[0018] As a thermal insulation composite in terms of the present
invention also a thermal insulation panel is to be regarded, for
example of foamed plastic material, such as EPS, which has or is
provided with at least one capillary conductive segment extending
continuously from the first side to the opposing second side.
Accordingly, the term of composite is to express that aside from
the at least one insulating material unit at least one capillary
conductive segment containing capillary conductive material is to
be present.
[0019] A diffusionally active coating in terms of the present
invention is to mean a coating wherein the moisture transport
occurs entirely or essentially entirely by means of diffusion
rather than by means of capillary conduction. Consequently moisture
transport by means of capillary conduction does not play a role or
only an insignificant, minor role with the diffusionally active
coatings of the present invention. Accordingly, the first (and/or
second and/or third) diffusionally active coating is not or
essentially not capillary conductive.
[0020] In terms of the present invention the first side of the
thermal insulation composite of the invention for the interior
insulation (i.e. on the interior side of the outer building wall)
is also referred to as the wet or condensation water side and the
second side as the dry side or the side facing the interior space.
In terms of the present invention the terms capillary conductive
and capillary active are always used synonymously.
[0021] In a particularly convenient realisation it is provided that
the thermal insulation composite of the invention comprises at
least two, in particular cuboid-shaped or cubical-shaped,
insulating material units, each having a length, height and width
dimension and an edge line or edge surface extending at least in
sections along the length and width dimension, wherein adjacent
insulating material units are glued to one another in sections or
entirely, in particular entirely, along the edge lines adjoining or
facing one another with at least one adhesive composition
containing a binder and applied in particular by means of brushing,
rolling, doctoring, pouring and/or spraying while forming the at
least one capillary conductive segment in the form of an adhesive
layer, wherein the adhesive layer formed by said adhesive
composition is capillary conductive in its cured state and extends
at least in sections from the first side to the second side, and
wherein preferably at least two adjacent adhesive layers, in
particular all adhesive layers are essentially parallel to one
another at least in sections.
[0022] The capillary active adhesive layers can preferably have a
thickness of e.g. 0.2 mm to 3 mm and particularly preferably 0.3 mm
to 1.2 mm. On the first and/or the second side of the thermal
insulation composites, in particular the thermal insulation panels,
of the invention the adhesive layers in a particularly preferred
realisation take up in total only approximately 0.1 to 5%,
preferably 0.5 to 3% and particularly preferably 1.0 to 1.5%, of
the total area of the respective lateral surface. In this manner it
can be ensured that the original insulant, i.e. the foam product
and/or the fibrous material, is reduced in its insulating
performance by only a few milliwatts per meter and Kelvin. Another
advantage of the thermal insulation composites according to the
invention is that in one realisation it is possible for the volume
of the capillary conductive adhesive layer, in relation to the
total volume of the thermal insulation composite, to be not more
than 1% by volume. Even with these small volume fractions and also
with volume fractions below 1% the effect of the invention is
achieved. The thermal conductivity of the material as such is not
or hardly noticeably affected by the adhesive layer. It is an
advantage that the narrow capillary active adhesive layers do not
serve as thermal bridges and that moreover these adhesive layers do
not become visible on the surface during the service life, e.g. in
the form of a darkened region, also when only a very thin coat of
plaster is used.
[0023] It can be provided that at least one insulating material
unit, preferably at least two adjacent and particularly preferably
all insulating material units are formed of or comprise fibrous
materials and/or foam products, in particular foam products.
Suitable fibrous materials can be selected from the group
consisting of mineral wool, synthetic fibres, hydrophobised wood
fibres, in particular soft wood fibres, wood wool, cotton and
cellulose fibres or parts thereof or any mixture thereof.
[0024] The use of foam products is preferred. Suitable foam
products can be selected from the group consisting of foam glass,
expanded styrene polymers, in particular expanded polystyrene,
expanded polypropylene, elastomeric foam, polyisocyanurate foam,
polyethylene foam, phenolic resin foam, polyurethane rigid foam,
urea formaldehyde resin foam, hydrophobised silica, hydrophobised
aerogels, extruded styrene polymers, in particular extruded
polystyrene foam, expanded cork or any mixture thereof.
[0025] Particularly preferably embodiment variants are used for the
thermal insulation composites according to the invention where at
least one insulating material unit, in particular the at least two,
preferably adjacent, insulating material units and particularly
preferably all insulating material units, comprise or consist of
expanded styrene polymers, in particular expanded polystyrene.
[0026] For example, natural, i.e. white expanded styrene
polymerisates, e.g. polystyrene, can be used, as can styrene
polymerisates which have been coloured black (such as the product
Neopor), known from EP 981 574. Moreover, for the thermal
insulation composites or thermal insulation units of the present
invention naturally also those expanded styrene polymerisate
products can be used which are formed of a mixture of white, i.e.
unpigmented, styrene polymerisate particles and styrene
polymerisate particles containing pigment, for example graphite or
carbon black. Such insulation panels having a spotted appearance
are disclosed, for example, in EP 1 731 552.
[0027] The insulating material units forming or contained in the
thermal insulation composite preferably have a cuboid-shaped, e.g.
panel-shaped, or a cubical-shaped basic shape.
[0028] Thermal insulation composites which are particularly well
suited are panel-shaped and accordingly represent a thermal
insulation panel, in particular comprising a first and an opposing
second side.
[0029] It has been found to be particularly convenient to use for
the capillary conductive segment those binder-containing adhesive
compositions which contain as binders, in particular exclusively,
mineral binders. Particularly good results are also achieved if the
capillary conductive material or the binder-containing adhesive
composition do not contain any fillers. In such an embodiment the
capillary conductive effect which the segment formed of the
capillary conductive material and/or the adhesive layer formed of
the adhesive composition has in its cured state is particularly
pronounced.
[0030] Suitable mineral binders in particular comprise or consist
of hydrous and/or hydraulic binders and are preferably selected
from the group consisting of cement, lime, gypsum, aluminous
cement, water glass or any mixture thereof.
[0031] The adhesive layers according to the invention or the
capillary conductive materials of the segment in their cured state
are characterised in that they are able to be wetted with water, in
particular that they are essentially entirely wettable with water.
Particularly well suited cured capillary active adhesive layers or
capillary conductive materials and/or the mineral binders used
therefore have preferably a contact angle (also referred to as
wetting angle or wetting angle of contact) with water within the
range of 0.degree. to less than 90.degree., particularly preferably
0.degree. or nearly 0.degree.. In one realisation these materials
accordingly exhibit a capillary activity as is known, for example,
from the calcium silicate panels of the prior art. Suitable
materials which can also be added to the adhesive composition or
the capillary conductive materials of the segment also comprise,
for example, activated alumina, clay minerals such as bentonites
and attapulgites, zeolites, superabsorber, rheology additives or
any mixture of such components. In a further embodiment it is
provided that hygroscopic salts are added to the binder-containing
adhesive composition and/or the capillary conductive materials of
the segment in order to increase the capillary conductive
effect.
[0032] Making the water transport capability more uniform is in
particular also achieved by combining two or more different
capillary conductive materials as components of the adhesive
composition or the materials for the capillary conductive segment.
In this context, an embodiment is particularly advantageous wherein
within the adhesive layer of the thermal insulation composite of
the invention the capillary active material having the larger pores
faces the outer wall and the capillary active material having the
finer pores faces the interior space. Of course the two embodiments
outlined above can also be combined.
[0033] A suitable capillary conductive binder-containing adhesive
material or capillary conductive material for the capillary
conductive segment which can be used preferably has a bulk density
within the region of 0.1 to 2.0 kg/l, and in particular of 0.5 to
1.5 kg/l. The binder-containing adhesive composition or the
capillary conductive material for the capillary conductive segment
contains the, preferably hydraulic and/or hydrous, binders and
water advantageously at a ratio such that the bulk densities
described above are obtained.
[0034] In the particularly preferred thermal insulation composites
of the invention the binder-containing adhesive composition or the
capillary conductive material for the capillary conductive segment
contains at least one fibrous material, in particular synthetic
fibres, natural fibres, mineral fibres, e.g. basalt, ceramic and/or
glass fibres, or any mixture thereof. In addition or alternatively
also hollow fibres and/or nanotubes can be taken into consideration
as fibres. The latter ones are advantageous in that they can also
participate in capillary transport. Moreover, also fibre mats or
fibre fabrics can be integrated or incorporated into or placed on
the adhesive layer of the thermal insulation composites of the
invention.
[0035] If various capillary conductive materials are to be used,
the application of adhesive compositions can also occur
successively, for example.
[0036] Moreover it can be provided that the fibres have a length
e.g. within the region of 2 to 40 mm, in particular within the
region of 4 to 20 mm, and particularly preferably within the region
of 8 to 15 mm. It is particularly preferred for the average length
of the fibres to be a maximum of 16 mm, in particular a maximum of
12 mm, and particularly preferably a maximum of 8 mm. Accordingly
in one realisation it can be provided that the capillary conductive
material of the capillary conductive segment and/or the
binder-containing adhesive composition contains at least one
fibrous material, in particular synthetic fibres, natural fibres,
mineral fibres, e.g. basalt, ceramic and/or glass fibres, or any
mixture thereof, preferably having an average fibre length of a
maximum of 16 mm, in particular a maximum of 12 mm, and
particularly preferably a maximum of 8 mm. With the fibrous
material a reinforcement, elastification and/or shrinkage reduction
of the adhesive layers or the capillary conductive segments can be
achieved. In addition or alternatively fibres can also be sprinkled
or blown onto the applied adhesive layer while it is still wet.
[0037] In a particularly suitable realisation of the thermal
insulation composites of the invention the capillary conductive
material for the capillary conductive segments or the adhesive
layer, i.e. the adhesive composition, comprises at least one
mineral component, e.g. silicates such as aluminium silicates, for
example sheet silicates, fibres, for example glass fibres,
preferably with an average length of a maximum of 12 mm or a
maximum of 8 mm, gypsum and cement. The cement is preferably used
as the main component.
[0038] Thermal insulation composites of the invention with an
average adhesive layer thickness of a maximum of 1.0 mm, in
particular a maximum of 0.7 mm, and particularly preferably a
maximum of 0.5 mm in the cured state have been found to be
particularly advantageous. Moreover also those thermal insulation
composites which have an adhesive layer thickness of a maximum of
2.0 mm, in particular 1.5 mm and particularly preferably 1.0 mm in
the cured state are particularly well suited. In a particularly
convenient embodiment variant it has been found advantageous to add
at least one support particle to the binder-containing adhesive
composition. The precise adherence to a desired layer thickness is
thus achieved in a particularly reliable manner. Large aggregates
such as pumice granulate are also an option.
[0039] The binder-containing adhesive composition on the one hand
provides a capillary conductive (adhesive) layer and on the other
hand ensures the adhesion of the insulating material units to one
another.
[0040] In a convenient realisation of the invention it is provided
that the average width of the insulating material units and/or the
edge lines is within the region of 10 mm to 200 mm, in particular
within the region of 20 mm to 160 mm, and preferably within the
region of 40 mm to 140 mm.
[0041] The objects of the invention are achieved in a particularly
satisfactory manner by realisations of the thermal insulation
composites wherein the first side at least in the region of the at
least one capillary conductive segment extending from the first
side to the second side, in particular in the region of the at
least one adhesive layer extending from the first side to the
second side is provided, in sections or entirely, in particular
entirely, with at least one first capillary conductive coating of
or containing at least one first capillary conductive coating
material, or in sections or entirely, in particular entirely, with
at least one second diffusionally active coating of a second or
containing at least one second hydrophobic or hydrophobised coating
material, and wherein the at least one capillary conductive
segment, in particular the at least one adhesive layer, and the
first capillary conductive coating or the second diffusionally
active coating are in contact with one another. It is particularly
preferred for the first side to be provided, in particular in the
region of the adhesive layer extending from the first side to the
second side, at least in sections, in particular entirely, with at
least one capillary active first coating material, forming a first
capillary active coating, which is connected at least in sections
to at least one adhesive layer or at least one capillary active
segment in a capillary active manner.
[0042] A realisation variant of a thermal insulation composite of
the invention is particularly advantageous wherein essentially the
entire surface of the first side is provided with the first
capillary conductive coating material forming the first capillary
conductive coating and/or essentially the entire surface of the
second side is provided with the first hydrophobic or hydrophobised
coating material forming the first diffusionally active
coating.
[0043] In one realisation it has been found to be particularly
convenient that the first and the second hydrophobic or
hydrophobised coating material essentially correspond to one
another, in particular regarding the composition and/or application
thickness of these coating materials, and/or that the first
capillary conductive coating material comprises the
binder-containing adhesive composition or the capillary conductive
material of the capillary conductive segment or is formed thereof
and/or that the capillary conductive material of the capillary
conductive segment and the binder-containing adhesive compositions
essentially correspond to one another.
[0044] Usually it is sufficient if the first and/or second
capillary conductive coating has a thickness of only a few tenths
of a millimetre. The supply and drainage of potentially
accumulating water to the capillary active adhesive strips can be
improved noticeably in this manner.
[0045] Particularly good results as to an increased capillary
activity also are achieved due to the fact that the first capillary
conductive coating spaced apart form the adhesive layer has a
smaller thickness than in the region, in particular in the
direction of the extension, of the adhesive layer.
[0046] A particularly convenient thermal insulation composite of
the invention is characterised in that at least two adjacent
adhesive layers, in particular all adhesive layers, are essentially
parallel to one another at least in sections.
[0047] With the thermal insulation composites of the invention the
adhesive layers can be oriented advantageously such that they
extend essentially horizontally after having been attached to the
building wall. One advantage of this essentially horizontal
arrangement is that if, for example, moisture accumulates at a
certain spot behind the insulation panel, the fluid flows off
downwardly due to gravity and in this manner encounters a capillary
conductive adhesive layer. Moisture cannot spread across the entire
surface in this manner.
[0048] To make the water transport capability more uniform,
preferably in each section, from the interior side of the outer
wall towards the interior space, it has been found to be
advantageous to apply a larger amount of binder-containing adhesive
composition within the thermal insulation composites towards the
interior space. Accordingly the adhesive layers can also be carried
out with a thickness which is not consistent. Rather, also those
thermal insulation composites of the invention are advantageous, in
particular regarding an increased capillary activity, wherein the
thickness of the adhesive layer from the first side towards the
seconds side, i.e. the interior space side, increases, in
particular continuously.
[0049] The thermal insulation composite of the invention preferably
represents a thermal insulation panel, in particular an interior
thermal insulation panel, preferably having a polygonal basic
shape, in particular selected from square, rectangular, triangular
basic shapes.
[0050] In a particularly convenient realisation it is further
provided that the at least one adhesive layer, in particular all
adhesive layers, of the thermal insulation composite of the
invention extend along the, in particular entire, length dimension
thereof.
[0051] In a realisation which is also particularly convenient it is
provided that the thermal insulation composite of the invention
further has at leas.sub.t one adhesion promoting layer applied to
the first diffusionally active coating.
[0052] In a further particularly convenient realisation it is
provided that the thermal insulation composite of the invention
further has at least one diffusionally active plaster coating, in
particular a finishing plaster coating, preferably on a silicate
basis, on the adhesion promoting layer on the first diffusionally
active layer.
[0053] In a realisation which is also particularly convenient it is
provided that the thermal insulation composite of the invention
further has at least one diffusionally active coating of paint, in
particular comprising a silicate paint or a silicate dispersion
paint.
[0054] In a further particularly convenient realisation it is
provided that the thermal insulation composite of the invention has
at least one reinforcement fabric, in particular on the basis of
glass fibres, present at or in the first diffusionally active
coating, preferably partially or entirely embedded into said
coating.
[0055] In a further particularly convenient realisation it is
provided that the thermal insulation composite of the invention
further has at least a third diffusionally active coating or at
least one second capillary conductive coating, in particular in the
form of an adhesive layer on the at least one first capillary
conductive coating present on the first side and made of or
containing the first capillary conductive coating material.
[0056] The first capillary conductive coating material or the first
capillary conductive coating layer intended for the first capillary
conductive coating of the first side, i.e. the wet or condensation
water side, of the thermal insulation composite may or may not
correspond to the second capillary conductive material or the
second capillary conductive coating layer for the second capillary
conductive coating. Both the first and the second coating material
or coating layer may also be formed of or comprise multiple
different components, each being capillary active. It is also
possible for the first and/or second capillary active coating
material or the first and/or second capillary active coating layer
to be executed in two or more layers, the respective layers being
formed of or comprising different capillary active materials.
[0057] For the first and the second capillary conductive coating
material grout containing mineral binders such as cement, gypsum or
aluminous cement may be used, for example.
[0058] In an exemplary realisation the curing of the capillary
conductive material for the capillary conductive segment and/or the
first and/or second capillary conductive coating material has
usually reached a point after, preferably a maximum of, three days
at 20.degree. C. and a relative humidity of 90%, or preferably
higher, where the capillary conductive properties have already
formed and preferably the mechanical stability is sufficient for
further processing. Such degree of curing is usually often obtained
already after 24 hours.
[0059] Furthermore, the first, second and/or third diffusionally
active coatings can essentially correspond to one another in their
compositions.
[0060] Preferably the hydrophobic or hydrophobised coating material
of the first, second and/or third diffusionally active coating
comprises at least one hydrophobing agent, in particular fatty
alcohols and/or fatty acids and/or fatty acid esters and/or fatty
acid salts or derivatives thereof or any mixture thereof, in
particular at an amount within the range of 0.05% by weight to 3.0%
by weight in relation to the dry mass of the coating material.
Suitable hydrophobing agents comprise e.g. stearates such as zinc
stearate. In one realisation the hydrophobised coating materials
for the first, second and third diffusionally active coatings can
be also obtained, for example, by adding the hydrophobing agent
mentioned above, for example the salt or ester of a fatty acid such
as stearic acid, to conventional grouts containing binders such as
cement, gypsum or aluminous cement, such grouts being known to a
person skilled in the art.
[0061] The object of the invention is further achieved by a thermal
insulation composite area, in particular as thermal insulation
panel area, comprising at least two, in particular a plurality of
thermal insulation composites of the invention, in particular
thermal insulation panels, each having a first and an opposing
second side and an edge line or surface circumferencing at least in
sections and connecting the first and the second side and having a
length and width dimension, wherein adjacent thermal insulation
composites, in particular thermal insulation panels, are arranged
adjacent to one another at least in sections along their edge lines
or surfaces, in particular in a flush manner.
[0062] For example embodiments are also suitable wherein the
adjacent thermal insulation composites or panels are glued to one
another at least in sections along their edge lines or edge
surfaces, in particular in a flush manner, using a
binder-containing adhesive composition and wherein the adhesive
layer formed by this composition is capillary conductive in its
cured state and extends from the first side to the second side at
least in sections.
[0063] The object of the invention is also achieved by a wall
structure comprising a building wall having an exterior side and an
opposing interior side, in particular an outer building wall, and
at least one thermal insulation composite of the invention or at
least one thermal insulation composite area of the invention on the
interior side, wherein the first side of the thermal insulation
composite or the thermal insulation composite area is arranged to
face the interior side.
[0064] In a convenient realisation it is provided that the first
side of the thermal insulation composite or the thermal insulation
composite area is provided in sections or entirely, in particular
entirely, with the at least one first capillary conductive coating
of one or containing at least one first capillary conductive
coating material or with the at least one second diffusionally
active coating of one second or containing at least one second
hydrophobic or hydrophobised coating material. Preferably the first
capillary conductive coating is used for this purpose. Said coating
can also be connected to the interior side of the building wall of
the wall structure of the invention, for example as an adhesive or
an adhesive layer.
[0065] Wall structures of the invention are particularly preferred
which further comprise in sections or entirely, in particular
entirely, at least a third diffusionally active coating of a third
or containing at least a third hydrophobic or hydrophobised coating
material, said coating connecting the building wall, in particular
the interior side thereof, to the at least one first capillary
conductive coating of one or containing at least one first
capillary conductive coating material. Said third diffusionally
active coating material in this case functions as an adhesive for
the thermal composite by means of which said composite is affixed
to the building wall. By using a hydrophobic or hydrophobised
adhesive the moisture balance of the wall structure of the
invention can be adjusted in an even better manner for the entire
year.
[0066] It can be further provided that the thermal insulation
panels or composites of the wall structure represent a foam
product, in particular containing or formed of foam glass, expanded
styrene polymers, in particular expanded polystyrene, expanded
polypropylene, elastomeric foam, polyisocyanurate foam,
polyethylene foam, phenolic resin foam, polyurethane rigid foam,
urea formaldehyde resin foam, hydrophobised silica, hydrophobised
aerogels, extruded styrene polymers, in particular extruded
polystyrene foam, expanded cork or any mixture thereof. Extruded
styrene polymers, in particular extruded polystyrene foam, are
particularly preferred.
[0067] The thermal insulation composites or thermal insulation
panels of the invention as well as the thermal insulation composite
areas of the invention are used in a suitable manner for the
thermal insulation of buildings, in particular on the interior side
of the outer walls of buildings.
[0068] The object of the invention is further achieved by a method
for manufacturing at least one wall structure of the invention,
comprising the steps of:
[0069] attaching a precursor thermal insulation composite product,
in particular a panel-shaped precursor thermal insulation composite
product, having a first side, in particular a wet or condensation
water side, and an opposing second side, in particular a dry or
interior space side, comprising at least one insulating material
unit and at least one capillary conductive segment containing
capillary conductive material, wherein the capillary conductive
segment extends continuously from the first side to the second
side, over the first side thereof
[0070] by means of at least one capillary conductive coating
material forming a capillary conductive coating at least in
sections or entirely, in particular entirely,
[0071] to the building wall, in particular the interior side of the
outer building wall, or
[0072] attaching a precursor thermal insulation composite product,
in particular a panel-shaped precursor thermal insulation composite
product, having a first side, in particular a wet or condensation
water side, and an opposing second side, in particular a dry or
interior space side, comprising at least one insulating material
unit and at least one capillary conductive segment containing
capillary conductive material, wherein the capillary conductive
segment extends continuously from the first side to the second
side, having the at least one first capillary conductive coating of
a or containing at least the first capillary conductive coating
material on the first side, over the first side thereof
[0073] by means of at least one capillary conductive coating
material forming a capillary conductive coating at least in
sections or entirely, in particular entirely, or preferably by
means of a second hydrophobic or hydrophobised coating material
forming the second diffusionally active coating
[0074] to the building wall, in particular the interior side of the
outer building wall, and
[0075] applying the at least one first diffusionally active coating
of the or containing the first hydrophobic or hydrophobised coating
material to the second side, such that the at least one capillary
conductive segment is in contact with the first diffusionally
active coating.
[0076] In a particularly convenient realisation the method of the
invention provides that the precursor thermal insulation composite
product, in particular the panel shaped precursor thermal
insulation composite product comprises at least two, in particular
cuboid-shaped or cubical-shaped, insulating material units, each
having a length, height and width dimension and an edge line or
edge surface extending at least in sections along the length and
width dimension, wherein adjacent insulating material units are
glued to one another in sections or entirely along the edge lines
adjoining or facing one another with at least one adhesive
composition containing a binder and applied in particular by means
of brushing, rolling, doctoring, pouring and/or spraying while
forming the at least one capillary conductive segment in the form
of an adhesive layer, wherein the adhesive layer formed by said
adhesive composition is capillary conductive in its cured state and
extends at least in sections from the first side to the second
side, and wherein preferably at least two adjacent adhesive layers,
in particular all adhesive layers are essentially parallel to one
another at least in sections.
[0077] The precursor thermal insulation composite product or the
panel-shaped precursor thermal insulation product differs from the
thermal insulation composite of the invention in that it has not
yet a first diffusionally active coating of a first hydrophobic or
hydrophobised coating material.
[0078] Finally, the invention also comprises the use of the thermal
insulation composites, in particular thermal insulation panels, of
the invention, the thermal insulation composite areas, in
particular the thermal insulation panel areas, of the invention for
the thermal insulation of buildings, in particular of outer walls,
particularly preferably on the interior side of said outer
walls.
[0079] A specific realisation of the thermal insulation composites
of the invention will now be explained in greater detail.
[0080] A polystyrene particle foam block is cut into strips using
oscillating hot wires, the strips having the dimensions of e.g.
(1000 mm).times.(20 to 150 mm).times.(insulation thickness).
Subsequently these strips are glued back together using the
capillary active binder-containing adhesive composition. The
capillary active adhesive layers can preferably have a thickness of
e.g. 0.2 mm to 3 mm and particularly preferably 0.3 mm to 1.2 mm.
The insulation panel size commonly used on construction sites, said
size being 500 mm.times.1000 mm.times. insulation thickness, can be
achieved, or nearly achieved, again in this manner, for example.
The strip width, i.e. the width of the edge line, is preferably 20
mm to 150 mm, and particularly preferably 50 mm to 100 mm,
according to the invention.
[0081] The insulation panel is coated on one side with a capillary
conductive material, for example with the material of the
binder-containing adhesive composition.
[0082] To make the water transport capability more uniform in each
section from the interior side of the outer wall towards the
interior space, it has been found to be advantageous to apply a
larger amount of binder-containing adhesive composition within the
thermal insulation composites towards the interior space.
Accordingly the adhesive layer can also be carried out with a
thickness which is not consistent. Rather, it is advantageous for
its thickness to increase towards the interior space side.
[0083] Making the water transport capability more uniform is in
particular also achieved by combining two or more different mineral
binders or capillary conductive materials as components of the
adhesive composition. For example, cement and gypsum can be
simultaneously present in the adhesive composition or the cured
adhesive layer, supplemented by lime and/or aluminous cement, if
required. In this context, an embodiment is particularly
advantageous wherein within at least one adhesive layer of the
thermal insulation composite of the invention the capillary active
material or the cured adhesive layer having the larger pores faces
the outer wall and the capillary active material or the cured
adhesive layer having the finer pores faces the interior space. Of
course the two embodiments outlined above can also be combined.
[0084] Moreover, by a tapering cross-section of the adhesive layer,
starting preferably at a distance, e.g. 5 mm, from the interior
space side of the panel surface, an adhesive strip can remain on
the panel surface which is sufficiently small such that the problem
of temperature differences becoming visible can be entirely
neglected. In this region close to the panel surface the
transported water can already partly evaporate through the
insulation panel.
[0085] To obtain more stable thermal insulation composites, in
particular thermal insulation panels, according to the invention,
the profile of the adhesive layers can be stabilised by special
shapes. In this manner the flexural strength can be increased by a
factor of 1.5 to 2 for example.
[0086] A method for manufacturing thermal insulation composites can
be as follows: An expanded polystyrene rigid foam block having a
volume of several cubic metres is cut into pieces applying the hot
wire method. As a next step the fluid binder-containing adhesive
composite is applied as a coat on one side by means of doctoring,
brushing, pouring, rolling, spraying, doctoring and/or injecting.
The adhesive composition preferably contains fibres. In addition or
alternatively fibres can also be sprinkled or blown onto the
applied adhesive layer while it is still wet. This procedure is
advantageous in that there are no process-related limitations
regarding the fibre length and/or fibre amount. Unusually high
concentrations of fibres are thus possible. The longer the fibres
are, the more the shrinkage can be prevented which can occur during
the curing of the adhesive composition. In this manner the
formation of defects interrupting the capillary conduction can be
effectively prevented. Moreover it is also possible to apply a
woven or a non-woven fabric instead of or in addition to the fibres
and to rejoin the freshly coated panels only afterwards. The woven
or non-woven fabric can exhibit a coarse capillarity, aside from
its stabilising function, thus completing the pore structure of the
capillary conductive adhesive layer towards the upper end. Hollow
fibres and/or nanotubes and/or natural fibres such as cellulose
fibres or cotton, or possibly also wood particles, can be taken
into consideration as fibres which can also participate in
capillary transport. If various capillary conductive materials are
to be used, the application can occur successively, for
example.
[0087] The panels coated on one side are then reassembled to form a
single block again. The size of this block can differ from the
original shape of the foamed block, thus enabling different panel
dimensions to be selected with low scrap production.
[0088] After curing, preferably at a high humidity, a trimming cut,
e.g. using hot wires or a band saw, can be performed. Subsequently
the block is cut to the desired panel thickness and, if required,
trimmed one last time and cut into individual panels. The panels
can then be coated on one or two sides, depending on the design, or
packaged without any coating.
[0089] The coating material for the first side, i.e. the
condensation water side, or the binder-containing adhesive
composition for the adhesive layers is preferably selected such
that it cures without the supply of heat or drying on e.g. a tray
trolley. The coated panels can thus be packaged immediately.
[0090] During the finishing or the attachment of the thermal
insulation composites as interior insulation a hydrophobised
coating mass is applied to the second side of the thermal
insulation units, said mass forming a diffusionally active coating.
Preferably a reinforcement fabric is incorporated into this coating
which, as a rule, forms the so-called undercoat. Adjacent fabric
strips are embedded into said undercoat preferably so as to overlap
one another. Subsequently a so-called finishing coat of plaster can
be applied. Preferably a diffusionally active coating material is
used also for this purpose. Subsequently paint can be applied
depending on the application. The paint can also be applied
immediately on the undercoat mentioned above.
[0091] A particular advantage of the thermal insulation composite
of the invention is that the thermal energy stored in the
insulating material units can be used to evaporate on the side
facing the interior space of a building the water penetrating
through the adhesive layer. That is, the water leaving the thermal
insulation units is transported through the hydrophobised layer
into the interior space by means of diffusion. Another advantage of
the thermal insulation composites of the invention is that on the
side with the first diffusionally active coating (second side or
visible side), moisture staining as a rule does not occur or occurs
to a far lesser degree (compared e.g. to an insulation panel with
capillary conduction which is provided with capillary conductive
coatings on both sides on its opposing surfaces) or the capillary
conductive adhesive layers or segments which penetrate through the
insulation material do not become visible on the visible side or
become visible to a far lesser degree even if lager amounts of
fluid or moisture enter via the outer building wall. Also, no salt
efflorescence occurs at these locations, or it occurs to a far
lesser degree. The application of a coating of a hydrophobised or
hydrophobic coating material, where the moisture transport
essentially occurs by means of diffusion rather than by means of
capillary conduction, on the second side, i.e. the side of the
thermal insulation unit which forms the visible side, contributes
decisively to the above-described advantages of the invention. It
has been found to be particularly advantageous if such a thermal
insulation unit, which has a capillary conductive coating on the
first side, i.e. on the side facing the building wall after having
been attached, is glued to the building wall in sections or over
the entire surface by means of a diffusionally active,
non-capillary conductive adhesive of or comprising a hydrophobic or
hydrophobised coating material.
[0092] Further features and advantages of the invention will become
apparent from the following description, where preferred
embodiments of the invention are explained by way of example and
with reference to a schematic drawing in which:
[0093] FIG. 1: shows a schematic sectional view of a wall structure
with interior insulation according to the invention.
[0094] FIG. 1 shows a schematic view of a wall structure 1 of the
invention having an outer building wall 2 which on its interior
side 4 has a thermal composite area 6 according to the invention.
The thermal insulation composite area 6 is formed by a plurality of
thermal insulation composites 8 attached in a flush manner via
their edge surfaces (in their length and width extension) in the
form of thermal insulation panels which are glued to the interior
side of the building outer wall 2 with an adhesive 9 in the form of
a capillary conductive coating applied on the entire surface. The
thermal insulation composites 8 each have been manufactured from a
plurality of essentially cuboid-shaped insulating material units
10, which are connected to one another via adjacent capillary
active cured adhesive layers 12 which in this case each extend
parallel to one another. As shown in FIG. 1, the thermal insulation
composite area 6 is covered entirely on the interior side, i.e. on
the second side, by the first diffusionally active coating 11 of
the first hydrophobic or hydrophobised coating material plaster
coating Optionally, also adjacent thermal insulation composites 8
can be glued with the binder-containing adhesive composite via
their horizontal edge surfaces. A reinforcement fabric is embedded
into the diffusionally active, non-capillary conductive coating 11.
Furthermore, an adhesion promoting layer 16, applied to the coating
11, a likewise diffusionally active finishing plaster coating 18
and a diffusionally open layer of paint 20, can be see from FIG. 1.
The insulating material units 10 can be attached to the building
wall 2 additionally via wall plugs 22.
[0095] The features of the invention disclosed in the above
description, in the claims and in the drawings can be essential,
both individually and in any combination, for the realisation of
the invention in its various embodiments.
* * * * *