Laminated structure of flat, dimensionally stable building panels and self-supporting air

Abstract

The invention relates to a laminated structure of flat, dimensionally stable building panels (2), comprising at least: a first layer (3) of dimensionally stable mineral wool; a second layer (4) of aluminum foil arranged in such a way that the first large surface (5) of the second layer (4) is on the first large surface (6) of the first layer (3), characterized in that a third layer in the form of a woven reinforcement layer (9) consisting essentially of mineral fibres is arranged between the first large surface (5) of the first layer (4) and the first large surface (7) of the second layer (4), the second large surface (8) of the second layer (4) is exposed to the environment and thus the second layer (4) is the outermost layer. The invention also relates to a self-supporting air duct (12) made of the laminated structure (1).

Description

TECHNICAL FIELD

[0001] The present invention relates to a laminated structure of a flat, dimensionally stable building panel and a self-supporting air duct made of the laminated structure. BACKGROUND

[0002] US 6,311,456 B1 discloses a practical, improved rigid panel of high-density glass wool for the construction of air distribution ducts in air conditioning and heating installations made of a box-shaped body of high-density glass wool with an optional reinforcing mesh of glass fibers between the glass wool body and the outermost aluminum layer. With regard to the geometric characteristics, the rigid panel is formed with a stepped portion on the opposite side, covered with aluminum strips on the larger surface, with an overlap of the aluminum strips on the stepped portion, extending around the smaller side thereof.

[0003] This is a well-known and accepted solution for building and establishing self-supporting air ducts for air conditioning and heating installations, providing adequate air tightness and adequate mechanical stability to the commonly used air ducts, and making the core duct of metal unnecessary.

[0004] In shipbuilding, ventilation ducts are usually made of steel. This is to comply with the SOLAS regulations (Safety of Life at Sea, IMO Resolution), which require ducts made of steel of equivalent fire-resistant material. Mineral wool insulation is usually installed around the steel ducts to guarantee thermal and acoustic insulation.

[0005] However, there is a need to improve the mechanical stability and fire resistance of such panels in order to meet the specific requirements of the shipbuilding technology, such as enhanced fire resistance requirements and enhanced mechanical stability, which is necessary because the ship body is always moving during the lifetime of the ship, thus increasing the mechanical force impact on the duct system compared to land-based duct systems. Furthermore, there is a tendency that such duct systems made of rigid glass wool panels must meet higher fire resistance requirements when used in a ship environment. SUMMARY

[0006] These objects of the present invention are achieved by a laminated structure of a flat, dimensionally stable building panel, comprising at least:

[0007] - a first layer of dimensionally stable mineral wool;

[0008] - a second layer of aluminum foil, whereas between the first large surface of the first layer and the first surface of the second layer a third layer in the form of a woven reinforcing layer consisting mainly of mineral fibers is arranged. The second large surface of the second layer is exposed to the environment. Thus, the second layer is the outermost layer of the laminated structure.

[0009] It has been found that the addition of a reinforcing woven layer made mainly of mineral fibres, configured between the first and second layers, significantly improves the mechanical stability as well as the fire resistance and meets the corresponding requirements within the shipbuilding industry. Surprisingly, the addition of only one woven reinforcing layer to the known rigid panel significantly improves the performance of an air duct made of such rigid panel in terms of mechanical stability and in particular fire resistance.

[0010] According to one embodiment of the present application, a fourth layer of glass fabric can be configured on the second major surface of the first layer opposite the first major surface of the first layer.

[0011] Such fourth layer forms the inner layer of the air duct made of such rigid building panel of the present application, thereby significantly reducing the airflow resistance and also improving the sound damping properties.

[0012] Such fourth layer of glass fabric configured on the second major surface of the first layer forms the second outermost layer of the sandwich structure, contributing to minimize the airflow resistance of the air duct, wherein this second outermost layer of the sandwich structure forms the innermost layer of the air duct.

[0013] In another embodiment, the woven reinforcing layer

[0014] - is a woven fabric made of glass fibres;

[0015] - is a woven fabric made of basalt fibre-based glass fibres.

[0016] Such woven reinforcing layer contributes to meet the strengthened requirements in terms of mechanical stability as well as fire resistance required in the shipbuilding industry.

[0017] According to another embodiment, the woven reinforcing layer is a woven fabric made of single filaments of basalt filaments.

[0018] According to another embodiment, the reinforcing woven layer is attached to the first layer by means of a bonding agent used for bonding the first layer or by means of a PE-based adhesive / hot melt. The use of the bonding agent of the first layer advantageously allows the application of the reinforcing woven layer as a facing layer before the solidification of the first layer and the reinforcing woven layer using standard techniques known to the professionals.

[0019] According to another embodiment, the aluminium foil is attached to the reinforcing woven layer by means of a polyurethane adhesive and / or by means of a polyacrylate adhesive.

[0020] The use of such adhesives contributes to improve the mechanical connection between the woven reinforcing layer and the aluminium foil, thereby improving the transfer of the shear forces into the reinforcing woven layer.

[0021] The first layer is preferably adhesive-bonded glass wool, providing a low-weight product with improved mechanical properties and high fire resistance to reinforce the weave layer, allowing for the construction of dimensionally stable, self-supporting air ducts in marine applications. As an alternative, products manufactured by the applicant under the trade name... Mineral wool sold according to WO2005033032A1. Asbestos also meets the requirements for enhanced refractoriness. However, due to its high slag content, it is heavier and less preferred.

[0022] In a preferred embodiment, the aluminum foil is fabric-reinforced.

[0023] Regarding air duct systems, the object of the present invention is achieved by a self-supporting air duct made of a laminated structure as defined above.

[0024] The method for producing the air duct of the present invention made of a dimensionally stable panel is disclosed in US 6,311,456 B1 above, and the method is also applicable to the present invention. Attached Figure Description

[0025] The invention will be described in more detail with the aid of the accompanying drawings. The drawings show:

[0026] Figure 1 This is a schematic cross-sectional view of the stacked structure of the present invention;

[0027] Figures 2A to 2C This is a schematic diagram of an air duct formed by a dimensionally stable building panel with a layered structure according to the present invention.

[0028] Figure 3 This is a schematic isometric view of an air channel made of multiple air ducts, which are constructed using the stacked structure of the present invention. Detailed Implementation

[0029] Figure 1 An embodiment of the laminated structure 1 of the present invention is shown, which is a flat, dimensionally stable building panel 2, which is rigid enough to produce a self-supporting hollow structure, such as an air duct 11 (see Figure 3 ).

[0030] The laminated structure 1 has a first layer 3 made of dimensionally stable mineral wool. The first layer 3 also has a first large surface 5, and opposite to the first large surface 5, the first layer 3 has a second large surface 6.

[0031] The first layer 3 has a capacity of 18kg / m 3 and 100kg / m 3The density varies between 20 mm and 100 mm, and the thickness can vary between 20 mm and 100 mm. The first layer 3 (i.e., dimensionally stable mineral wool, which can usually be glass wool or asbestos) can be made into a fibrous structure with layered, crimped, or sheet-like types.

[0032] Between the first layer 3 and the second layer 4 made of aluminum foil, more specifically, between the first large surface 5 of the first layer 3 and the first large surface 7 of the second layer 4, a third layer in the form of a woven reinforcement layer 9 is provided. The woven reinforcement layer 9 is primarily composed of mineral fibers, preferably basalt fibers. A suitable density basis weight of the woven reinforcement layer 9 made of basalt fibers is 250 g / m³. 2 Up to 500g / m 2 Within the range, especially 300 to 400 g / m 2 Especially 350g per square meter. The woven reinforcement layer 9 forms an interlayer of the laminated structure 1 between the first layer 3 and the second layer 4. The second large surface 8 of the second layer 4 forms the outer surface of the air ducts 11 and the air channels 17 made of multiple air ducts 11, and is exposed to the environment ( Figure 2B , Figure 2C , Figure 3 ).

[0033] The design of the woven overlay 9, based on the aforementioned details, meets the so-called steel equivalent requirements for ventilation ducts in the shipbuilding industry. This requires that it be non-combustible and must meet the standard 30-minute fire resistance test as a non-load-bearing structure. This test follows the test "B" category classification (B-0 classification), which focuses on the "integrity" test standard.

[0034] The embodiment of the present invention uses a density of 80 kg / m³ 3The glass wool, wherein the first layer 3 has a LOI (Loss on Ignition, determined according to EN 13820:2003 for thermal insulation materials used in building applications; determination of organic content) of 6% by weight, and the basalt fiber textile used to weave the reinforcing layer 9 has passed and meets the integrity criteria required for B-0 classification. The test was conducted under the standard ISO 834 fire curve. In addition to measuring the gap specifications, no flames, especially at the gaps, must be present during the 30-minute test run. It was found that no integrity degradation was observed in the samples after 30 minutes of testing. The tested embodiment did not include the aluminum foil layer 4 and the adhesive used to attach the aluminum foil to the basalt fiber textile. In the test, the exposed surfaces were exposed to fire. Under the test conditions (temperatures exposed to the ISO 834 fire curve), the aluminum layer caused rapid melting of the aluminum foil, while the additional fire load of the adhesive was negligible compared to the fire curve. Therefore, the product has aluminum foil on top of the basalt textile, which is made of Basaltex BAS 350A in particular, to achieve the required airtightness and also meet this fire resistance test.

[0035] In the comparative test, it had 80 kg / m 3 Glass wool products with the same density and LOI but without basalt fiber textile reinforcement failed the integrity test.

[0036] The primary purpose of the aluminum foil is to provide airtightness of the product of the present invention in the thickness direction of the laminated structure 1, thereby providing an air duct 11 made of the product according to the present invention. Compared to the woven reinforcement layer 9, it makes only a negligible contribution to improved mechanical properties.

[0037] The proper connection between the woven reinforcement layer 9 and the second layer 4 can be achieved by polyurethane adhesive or by polyacrylate adhesive.

[0038] The woven reinforcement layer 9 (i.e., basalt textile) is in direct contact with the first layer 3 (its first large surface 5) and is preferably bonded to the first layer 3 by the same adhesive used to bond the first layer 3.

[0039] Additionally, there is a possibility of enhancing the adhesion of the second layer 4 by inserting a glass fiber fabric mesh (not shown) between the first large surface 7 and the woven reinforcement layer 9.

[0040] To minimize airflow resistance in the air duct 11 made of the laminated structure 1 of the present invention, a glass fiber fabric for establishing the fourth layer 10 is disposed on the second large surface 8 of the first layer 3. The glass fiber fabric preferably forms the second outermost layer of the building panel 2. When the air duct 11 is made of the laminated structure 1 of the present invention, the glass fiber fabric of the fourth and third layers forms the innermost layer facing the hollow space surrounded by the air duct 11 and is in direct contact with the air flowing through the air duct 11.

[0041] The advantages of the present invention, and especially the advantages of air ducts made from the laminated structure of the present invention, provide the following advantages:

[0042] Compared to steel channels commonly used in the shipbuilding industry, this invention offers a specific channel size with lower weight per meter and faster installation time because it eliminates the need for a metal core channel that must first be manufactured and then packaged into the facility. Although the steel channel is no longer present, the same fire resistance can be achieved with air ducts made from the laminated structure of this invention, thereby meeting the fire resistance requirements of the shipbuilding industry.

[0043] The formation of air duct 11 is due to Figures 2A to 2C It is shown and will be described below.

[0044] Starting with the dimensionally stable building panel 2, multiple L-shaped grooves 12 are cut at intervals between each other. The grooves 12 partially remove the fourth layer / glass fiber fabric mesh 10 and the first layer 3 of the dimensionally stable mineral wool, while the third layer / woven reinforcement layer 9 and the second layer / aluminum foil 4 remain unaffected (see [link]). Figure 2A The remaining small areas of the third layer 9 and the second layer 4 are dimensionally flexible, thus providing hinged joints for adjacent remaining portions of the first and fourth layers. Adjacent portions of the first and fourth layers can be bent relative to each other, as shown by arrow 13.

[0045] An elongated tongue 14 is formed in the area of ​​the side portion of the building panel 2, consisting only of the flexible composite laminate portion of the third layer 9 and the second layer 4.

[0046] By bending adjacent portions of the first and fourth layers along arrow 13, an air duct 11 with, for example, a rectangular cross-section is formed (see...). Figure 2B And finally, the elongated tongue 14 is bent to overlap with the adjacent portion along one of the edges of the air duct 11. After the overlap is established, the overlapping portion 16 is preferably pre-fixed by nails and / or sealed and finally tightened with adhesive tape (not shown) having at least one aluminum support layer.

[0047] The contact area between the elongated tongue 14 and the overlapping portion 16 can also be bonded with refractory adhesive.

[0048] To form an air passage 17 from multiple such air ducts 11, it is further preferred to enhance the mechanical stability of the entire air passage by fastening two adjacent air ducts 11 together at their leading edges 15 using fire-resistant adhesive. Finally, the joint is secured with adhesive tape (not shown) with at least one aluminum support layer.

[0049] The aforementioned refractory adhesive can be a self-curing water glass adhesive with mineral fillers.

[0050] Explanation of reference numerals in the attached figures

[0051] 1. Layered structure

[0052] 2 Building Panels

[0053] 3 First layer / mineral wool

[0054] 4 Second layer / aluminum foil

[0055] 5 First layer / First large surface of mineral wool

[0056] 6 First layer / Second largest surface of mineral wool

[0057] 7. Second layer / first large surface of aluminum foil

[0058] 8. Second layer / second largest surface of aluminum foil

[0059] 9 Third layer / Weaving reinforcement layer

[0060] 10. Fourth layer / glass fiber fabric mesh

[0061] 11. Air ducts

[0062] 12 slots

[0063] 13 arrows

[0064] 14. Long tongue

[0065] 15. Prelude

[0066] 16. Overlapping parts

[0067] 17. Air passage

Claims

1. A laminated structure of a flat, dimensionally stable building panel (2) comprising at least: - a first layer (3) of dimensionally stable mineral wool; - a second layer (4) of aluminium foil, which is arranged in such a way that a first large surface (7) of the second layer (4) is on a first large surface (5) of the first layer (3), characterized in that between the first large surface (5) of the first layer (3) and the first large surface (7) of the second layer (4) a third layer in the form of a woven reinforcing layer (9) consisting mainly of mineral fibres is arranged, a second large surface (8) of the second layer (4) being exposed to the environment and the second layer (4) thus being the outermost layer.

2. The laminate structure according to claim 1, characterized in that, A fourth layer (10) of a glass fibre fabric web is arranged on a second large surface (6) of the first layer (3) opposite the first large surface (5) and forms an outermost layer, in particular on the side of the first layer (3) on which the second large surface (6) of the first layer (3) is located.

3. The laminate structure according to claim 1 or 2, characterized in that, The woven reinforcing layer (9) - is a woven fabric made of glass fibres; - is a woven fabric made of basalt fibre-based glass fibres.

4. The laminate structure according to any one of the preceding claims, characterized in that The woven reinforcing layer (9) is a woven fabric made of monofilaments of basalt filaments.

5. The laminate structure according to any one of the preceding claims, characterized in that, The second layer (4), i.e. the aluminium foil, is attached to the reinforcing woven layer (9) by means of a polyurethane adhesive and / or by means of a polyacrylate adhesive.

6. The laminate structure according to any one of the preceding claims, characterized in that The first layer (3) is made of binder-bonded glass wool or binder-bonded mineral wool formation.

7. The laminate structure according to any one of the preceding claims, characterized in that, The aluminium foil (4) is fabric-reinforced.

8. A self-supporting air duct made of the laminated structure (1) according to any one of claims 1 to 7.

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