Composite thermal insulation panel

Abstract

A composite thermal insulation panel (100) is described, comprising: an insulating sheet (105) of rigid closed-cell polyurethane foam, which has a first base face (110), a second base face (115), parallel and opposite to the first base face (110), and one or more side faces (120) and at least a first coating layer (125), preferably flexible, made of glass fibre added with mineral additives and having reaction-to-fire class B-s1-d0, which is placed to coat at least partially, preferably completely, the first base face (110) of the insulating sheet (105).

Description

Technical Field

[0001] The present invention relates to a composite thermal insulation panel adapted to be used in the building, industrial or any other construction sector, for example, but not exclusively, to coat structures and / or to make insulating prefabricated products, such as window-hole monoblocs to be installed in buildings.Background art

[0002] They are currently known many thermal insulation panels that are suitable to be used for coating building structures (e.g. walls or roofs) or industrial structures (e.g. sandwich panels in the refrigeration or furniture sector), in order to give the latter improved characteristics in terms of thermal and possibly acoustic insulation.

[0003] These thermal insulation panels often consist of XPS (extruded expanded polystyrene) or EPS (sintered expanded polystyrene).

[0004] However, composite thermal insulation panels are also known, i.e. formed by coupling several overlapping layers of different materials, in order to take advantage of the positive properties of each of them.

[0005] These composite thermal insulation panels include panels consisting of a sheet of polyiso (PIR) polyurethane foam interposed between two coating layers of glass fibre.

[0006] Thermal insulation panels and composite thermal insulation panels are also sometimes used to make prefabricated products, such as the aforementioned window-hole monoblocs, which are then installed as a single component.

[0007] The window-hole monobloc is in fact a sort of prefabricated thermal insulation frame which is installed on a building under construction (or renovation) in order to delimit the window hole and contain the window frame.

[0008] A drawback of today's XPS and EPS thermal insulation panels and composite thermal insulation panels, however, is that they have poor reaction-to-fire properties, making them substantially unsuitable for all applications where there is a risk of fire exposure.Disclosure of the invention

[0009] An object of the present invention is to solve the aforementioned drawback of the prior art, within the context of a simple, rational and cost-effective solution.

[0010] This and other objects are achieved by the characteristics of the invention reported in independent claim 1. The dependent claims outline preferred and / or particularly advantageous aspects of the invention which however are not strictly required for the implementation thereof.

[0011] In particular, an embodiment of the present invention makes available a thermal insulation panel, comprising: an insulating sheet of rigid, closed-cell polyurethane foam (e.g. Polyiso - PIR), which has a first base face, a second base face, parallel and opposite to the first base face, and one or more side faces, e.g. substantially orthogonal to the first and second base faces, and at least a first coating layer, preferably flexible, of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, which is placed to cover at least partially, preferably completely, the first base face of the insulating sheet.

[0012] Thanks to this solution, the coating layer of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, which during installation can be advantageously placed on the side most exposed to the risk of fire, is effectively able to protect the insulating sheet behind from fire, giving the composite thermal insulation panel, as a whole, a high fire resistance capacity, which makes it suitable also for applications wherein the current thermal insulation panels or composite thermal insulation panels would not be suitable.

[0013] In addition to this important advantage, the coating layer of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 provides the thermal insulation panel with mechanical strength and dimensional stability even at high temperatures.

[0014] According to an aspect of the present invention, the first coating layer (of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0) can be joined / fixed to the first base face of the insulating sheet during the formation of the insulating sheet itself. In practice, the expanded polyurethane foam that makes up the insulating sheet can be formed directly on the first coating layer, which remains joined / fixed to it thanks to the adhesiveness of the polyurethane being formed.

[0015] This ensures excellent adhesion of the glass fibre coating to the insulating sheet without deteriorating performance in terms of reaction to fire.

[0016] An embodiment of the present invention provides that the composite thermal insulation panel may further comprise a second coating layer of glass fibre, preferably of mineralised saturated glass-fibre, which is placed to at least partially, preferably entirely, coat the second base face of the insulating sheet.

[0017] This second coating layer of glass fibre has the effect of further improving the mechanical and dimensional strength of the thermal insulation panel, and also has good adhesion characteristics with any rigid and flexible support.

[0018] According to an aspect of the present invention, also the second coating layer of glass fibre can be joined / fixed to the second base face of the insulating sheet during the formation of the insulating sheet itself.

[0019] For example, the polyurethane foam that makes up the insulating sheet can be formed directly between the first and second coating layers, which remain joined / fixed to it thanks to the adhesiveness of the polyurethane being formed.

[0020] Another embodiment of the invention provides that the composite thermal insulation panel may further comprise at least one support layer, preferably rigid, made of a material having reaction-to-fire class A1 or A2, which is placed to at least partially, preferably entirely, cover the second coating layer.

[0021] This support layer gives the composite thermal insulation panel greater structural stability, while at the same time protecting the second coating layer of glass fibre and the insulating sheet interposed between it and the first coating layer from fire.

[0022] According to an aspect of this embodiment, the support layer can be joined / fixed to said second coating layer by the interposition of a polyurethane adhesive.

[0023] This ensures excellent adhesion of the rigid support layer to the glass fibre coating without deteriorating its performance in terms of reaction to fire.

[0024] Alternatively, the support layer can be replaced (or made up) by a layer of cement mortar having reaction-to-fire class A1 or A2.

[0025] According to a different alternative, the support layer could be replaced (or made up) by a layer of a paint, such as a water-based paint containing (or formulated with) synthetic resins and ceramic additives.

[0026] Another embodiment of the invention provides that the composite thermal insulation panel may directly comprise, instead of the second coating layer of glass fibre, a support layer, preferably rigid, of wood fibre and having reaction-to-fire class B-s1,d0, which is placed to at least partially, preferably entirely, cover the second base face of the insulating panel. Thus, in addition to increasing the structural stability of the composite thermal insulation sheet, the support layer allows to improve significantly the reaction to fire also at the second base face.

[0027] According to an aspect of this embodiment, the wood-fibre support layer can be joined / fixed to said second base face of the insulating sheet by the interposition of a polyurethane adhesive.

[0028] This ensures excellent adhesion of the support layer to the polyurethane of the insulating sheet without deteriorating performance in terms of reaction to fire.

[0029] An aspect of the invention, which is common to all the previously outlined embodiments, provides that each side face of the insulating sheet may be coated at least partially, preferably entirely, with an additional layer of coating of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0.

[0030] Thanks to this solution, it is advantageously possible to protect the insulating panel from fire, not only at the base face(s), but also at the side faces, where joints (grout lines) between two or more adjoining thermal insulation panels of a coating often occur during installation, and through which - however narrow - a fire could spread.

[0031] Unlike the first coating layer, this additional coating layer (of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0) can be joined / fixed to the respective side face of the insulation sheet by the interposition of an inorganic binder.

[0032] This ensures excellent adhesion of the glass fibre coating to the insulating sheet without deteriorating performance in terms of reaction to fire.

[0033] According to another aspect of the invention, the oft-mentioned coating of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 may be, in turn, a composite material comprising (or formed of) a glass fibre supporting layer, placed adjacent to the insulating panel, and a coating layer made of a material containing the mineral additives, for example an expanded graphite paste, placed to coat at least partially, preferably entirely, the glass fibre layer.

[0034] Thanks to this solution, while the glass fibre layer provides the mechanical strength and dimensional stability even at high temperatures, the coating layer containing the mineral additives has the property of expanding in contact with the flames and, therefore, of creating a barrier that draws the flames away from the insulating panel, slowing the development of the fire towards the core of the insulating panel itself.Brief description of the figures

[0035] Further features and advantages of the invention will be more apparent after reading the following description provided by way of a non-limiting example, with the aid of the figures shown in the accompanying tables. Figure 1 is an exploded axonometric view of a composite thermal insulation panel according to the present invention. Figure 2 is a cross-section of the composite thermal insulation panel in Figure 1. Figure 3 is an exploded axonometric view of a first preferred embodiment of the composite thermal insulation panel according to the present invention. Figure 4 is a cross-section of the composite thermal insulation panel in Figure 3. Figure 5 is an exploded axonometric view of a second preferred embodiment of the composite thermal insulation panel according to the present invention. Figure 6 is a cross-section of the composite thermal insulation panel in Figure 5. Figure 7 is an exploded axonometric view of a third preferred embodiment of the composite thermal insulation panel according to the present invention. Figure 8 is a cross-section of the composite thermal insulation panel in Figure 7. Detailed description

[0036] A composite thermal insulation panel 100, which can be advantageously used in the building, industrial or any other construction field, for example, but not exclusively, to coat structures (e.g. walls or roofs) and / or to make thermally insulating prefabricated products, such as hole-window monoblocs, is described with the aid of the Figures.

[0037] The composite thermal insulation panel 100 comprises first of all an insulating sheet 105 of rigid, closed-cell polyurethane foam (e.g. Polyiso - PIR), whose main function is thermal insulation.

[0038] Preferably, the rigid, closed-cell polyurethane foam of the insulating sheet 105 is an expanded foam without the use of either CFCs (chloro-fluorocarbons) or HCFCs (hydro-chloro-fluorocarbons).

[0039] The insulating sheet 105 is generally shaped as a slab, i.e. a thin body having a lower thickness than the other dimensions, preferably flat and / or of substantially constant thickness.

[0040] The insulating sheet 105 may therefore have a first base face 110, a second base face 115 parallel to and opposite to the first base face 110, and one or more side faces 120, generally orthogonal to the base faces 110 and 115, extending in the thickness direction and defining the perimeter of the insulating sheet 105.

[0041] In particular, the two base faces 110 and 115, which are the largest (or most extended) faces of the insulating sheet 105, may have the shape of a quadrilateral, e.g. a rectangle or a square, and may therefore be delimited by four side faces 120, e.g. parallel and opposite two by two.

[0042] By way of example and not limitation, the thickness of the insulating sheet 105 may be between 30 and 160 mm (ends included).

[0043] The width of the insulating sheet 105 can be between 600 and 1200 mm (ends included). The length of the insulating sheet 105 can be between 1200 and 4000 mm (ends included).

[0044] The rigid closed-cell polyurethane foam forming the insulating sheet 105 may have a density between 30 Kg / m 3< and 35 Kg / m 3< (ends included), e.g. equal to 33 Kg / m 3< .

[0045] The composite thermal insulation panel 100 may further comprise a first, preferably flexible, coating layer 125, which is joined / fixed so as to at least partially, more preferably completely, cover the first base face 110 of the insulating sheet 105.

[0046] This first coating layer 125 may comprise (or consist of) glass fibre (also known as "veil of glass" or "glass veil") added with mineral additives and having reaction-to-fire class B-s1,d0 according to EN 13501-1:2019.

[0047] By way of example and not limitation, the first coating layer 125 may have a thickness between 0.9 mm and 1.3 mm (ends included), e.g. equal to 1.1 mm.

[0048] The first coating layer 125 may also have a density between 580 Kg / m 3< and 600 Kg / m 3< (ends included), e.g. equal to 590 Kg / m 3< .

[0049] We would like to specify that "glass fibre" means a woven or non-woven fabric of glass fibres, for example having defined diameter and length, which are bonded together with polymer resin, e.g. dispersion resin.

[0050] A glass fibre added with mineral additives may thus be a composite material comprising (or consisting of) a glass fibre supporting layer 130 (as defined above) and a coating layer 135 of a material containing mineral additives, e.g. an expanded graphite paste, placed to at least partially, preferably entirely, coat the support layer of glass fibre 130, e.g. by a coating process.

[0051] In such a case, the glass fibre supporting layer 130 will be placed directly in contact with the insulating sheet 105, while the coating layer 135 containing the mineral additives will remain on the opposite side (towards the outside).

[0052] As mentioned, the glass fibre constituting the first coating layer 125 is chosen so as to fall within reaction-to-fire class B-s1,d0, i.e. it is a combustible but not flammable or hardly flammable material (letter B), which produces an amount of smoke in combustion that falls within the minimum parameter set by the standard (letter s1), and which, in the event of fire, does not generate dripping of flaming particles (letter d0).

[0053] In order to establish / declare that a material is in a given reaction-to-fire class, in this case class B-s1,d0, reference is always made to the aforementioned UNI EN 13501-1:2019 standard, which requires the material to be tested to undergo reaction to fire tests with SBI (Single Burning Item), as envisaged by UNI EN 13823:2022, and ignitability tests by direct flame attack, as envisaged by UNI EN ISO 11925-2:2020.

[0054] The first coating layer 125 can be joined (fixed) to the first base face 110 of the insulating panel 105 while forming the insulating panel 105.

[0055] For example, the expanded polyurethane foam (e.g. Polyiso - PIR) that makes up the insulating sheet can be formed directly on the first coating layer 125, which remains joined / fixed to it thanks to the adhesiveness of the polyurethane being formed, before it fully hardens.

[0056] In this regard, it should be noted that glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 can generally be found in sheets, tapes or strips, normally flexible, with a width between 30 and 1200 mm (ends included), which can be initially wound into reels.

[0057] During production, this material is spread out (e.g. unrolled from its reel) and all the raw materials required to form the polyurethane foam (Polyiso - PIR), e.g. polyol and isocyanate, are sprayed onto it, e.g. through nozzles, so that the chemical reaction leading to the formation of the insulating panel 105 takes place directly on the first coating layer 125. The adhesion between the insulating panel 105 and the first coating layer 125 can therefore take place because, during the chemical reaction (e.g. between polyol and isocyanate) that leads to the formation of polyurethane, the latter is generally adhesive like a glue.

[0058] The composite thermal insulation panel 100 may further comprise one or more additional coating layers 140, each of which may be joined / fixed so as to at least partially, more preferably completely, cover a respective side face 120 of the insulating sheet 105. Each of these additional coating layers 140 may also comprise (or consist of) said glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0.

[0059] These additional coating layers 140 can therefore have the same composition, thickness and density as the first coating layer 125.

[0060] Each of these additional coating layers 140 may be joined (fixed) to the respective side face 120 of the insulating sheet 105 by the interposition of a layer of an inorganic binder (or adhesive) 145.

[0061] This inorganic binder can have a density between 1550 kg / m 3< and 1650 kg / m 3< (ends included), e.g. equal to 1600 kg / m 3< .

[0062] In practice, it is possible to spread this inorganic binder over the base face 120 so as to form a layer 145 that covers it at least partially or, more preferably, completely.

[0063] This layer of inorganic binder 145 can have a thickness of between 0.9 mm and 1.1 mm, for example, of 1 mm.

[0064] After the layer of inorganic binder 145 has been applied, glass fibre added with mineral additives forming the coating layer 140 can be applied over it.

[0065] Thus, the insulating panel 105 can be completely coated with glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, except for the second face of base 115, which is, however, generally intended to be on the side that is less exposed to risk of fire.

[0066] Starting from this composition common to all embodiments of the invention, a first preferred embodiment, shown in Figures 3 and 4, provides that the second base face 115 of the insulating sheet 105 may be coated at least partially, preferably completely, with a second coating layer 150.

[0067] This second coating layer 150 may comprise (or consist of) glass fibre (or glass veil), preferably a mineralised saturated glass fibre.

[0068] By way of example and not limitation, the second coating layer 150 of (mineralised saturated) glass fibre can have a thickness between 0.8 mm and 1.2 mm (ends included), e.g. equal to 1 m.

[0069] The second coating layer 150 may also have a density between 270 Kg / m 3< and 290 Kg / m 3< (ends included), e.g. equal to 280 Kg / m 3<

[0070] The second coating layer 150 can also be joined / fixed to the second base face 115 of the insulating panel 105 during the formation of the insulating panel 105 itself.

[0071] For example, the expanded polyurethane foam that makes the insulating sheet 105 can be formed directly between the first and second coating layers 125 and 150, which remain joined / fixed to it thanks to the adhesiveness of the polyurethane being formed, before it fully hardens.

[0072] In particular, during production, the glass fibre veils forming the first and second coating layers 125 and 150 are stretched (e.g. unrolled from their respective reels) so that they are parallel to each other and spaced so that the mixture of raw materials, e.g. polyol and isocyanate, required to form the polyurethane foam (Polyiso PIR), which is firstly adhesive like a glue and thus tightly adheres to both the coating layers 125 and 150, can be dispensed (poured) between them.

[0073] In summary, the composite thermal insulation panel 100 of this first preferred embodiment can therefore comprise or consist of: an insulating sheet 105 made of rigid, closed-cell polyurethane foam (e.g. polyiso - PIR), a first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 applied and fixed on the first base face 110 of the insulating sheet 105, a second coating layer 150 of glass fibre, preferably mineralised saturated glass fibre, applied and fixed to the second base face 115 of the insulating sheet 105, and if necessary, one or more further coating layers 140 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, each of which is applied and fixed to a respective side face 120 of the insulating panel 105, e.g. by the interposition of a respective layer of inorganic binder 145.

[0074] The composite thermal insulation panel 100 thus formed can have a total density between 49 Kg / m 3< and 116 Kg / m 3< (ends included).

[0075] Composite thermal insulation panels 100 of this type may be applied to a substrate, with the second base face 115, i.e. the face coated with the second coating layer 150 of (saturated mineralised) glass fibre, facing the substrate itself, so as to leave the first base face 110, i.e. the face coated with the first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1-d0, exposed to the outside and, therefore, to the possible risk of fire.

[0076] The composite thermal insulation panel 100 can be fixed to the substrate by glueing or by mechanical means, such as screws, rivets and the like.

[0077] The substrate can be made of e.g. cement, plasterboard, calcium silicate, mineral wool, metal or wood fibres in class B-s1,d0.

[0078] According to another preferred embodiment of the invention, shown in Figures 5 and 6, at least one support layer 160, preferably rigid, can be added to the composite thermal insulation panel 100 described above, which is fixed to at least partially, more preferably completely, coat the second base face 115 of the insulating sheet 105, covering the second coating layer 150 of glass fibre, preferably mineralised saturated glass fibre, which therefore remains interposed and protected between the insulating sheet 105 and said support layer 160.

[0079] This support layer 160 may comprise (or consist of) a material having reaction-to-fire class A1 or A2 according to EN 13501-1:2019.

[0080] In particular, a class A1 or class A2 material is a non-combustible material, e.g. slabs of fibre cement, magnesium cement, magnesium oxide.

[0081] The support layer 160 may have a thickness between 3 mm and 20 mm (ends included) and / or a density between 900 Kg / m 3< and 1300 Kg / m 3< (ends included), e.g. equal to 950 or 1250 Kg / m 3< .

[0082] In any case, the support layer 160 can be joined (fixed) to the second coating layer 150 by the interposition of a layer of a polyurethane adhesive 165.

[0083] This polyurethane adhesive can have a density between 1450 kg / m 3< and 1550 kg / m 3< (ends included), e.g. equal to 1500 Kg / m 3< .

[0084] In practice, it is possible to spread this polyurethane adhesive over the second layer 150 of mineralised saturated glass fibre, obviously on the opposite side to the insulating sheet 105, so as to form a layer 165 that covers it at least partially or, more preferably, completely.

[0085] By way of example and not limitation, this layer of polyurethane adhesive 165 can have a thickness between 0.2 mm and 0.4 mm, e.g. equal to 0.3 mm.

[0086] After the layer of polyurethane adhesive 165 has been applied, it is possible to apply thereon the support layer 160 of material having reaction-to-fire class A1 or A2 in accordance with EN 13501-1:2019 .

[0087] In this regard, it should be noted that the support layer 160 of material having reaction-to-fire class A1 or A2 can generally already be found in sheets or panels, normally rigid, which can be effectively overlaid on the second coating layer 150, e.g. after the layer of polyurethane adhesive 165 has been applied.

[0088] In a variant of this composite thermal insulation panel 100, the support layer 160 can be replaced (or made up) by a layer of cement mortar having reaction-to-fire class A1 or A2. In another variant of this composite thermal insulation panel 100, the support layer 160 could be replaced (or formed) by a layer of a paint, for example a water-based paint containing (or formulated with) synthetic resins and ceramic additives.

[0089] To summarise, the composite thermal insulation panel 100 of this second preferred embodiment can therefore comprise or consist of: an insulating sheet 105 made of rigid, closed-cell polyurethane foam (e.g. polyiso - PIR), a first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 applied and fixed on the first base face 110 of the insulating sheet 105, a second coating layer 150 of glass fibre, preferably mineralised saturated glass fibre, applied and fixed on the second base face 115 of the insulation sheet 105, if necessary, one or more additional coating layers 140 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, each of which is applied and fixed to a respective side face 120 of the insulating sheet 105, e.g. by the interposition of a layer of inorganic binder 145, and at least one support layer 160, preferably rigid, made of a material having reaction-to fire class A1 or A2 (or of cement mortar with reaction-to-fire class A1 or A2, or of paint with synthetic resins and ceramic additives), applied and fixed on the second coating layer 150, e.g. by the interposition of a layer of polyurethane adhesive 165.

[0090] The composite thermal insulation panel 100 thus formed may have an overall density between 120 Kg / m 3< and 210 Kg / m 3< (ends included) and / or an overall thickness between 50 mm and 180 mm (ends included).

[0091] Composite thermal insulation panels 100 of this type can be applied to a substrate in any way whatsoever, since they have, thanks to the support layer 160 of a material having reaction-to-fire class A1 or A2 (or of cement mortar with reaction-to-fire class A1 or A2, or of paint with synthetic resins and ceramic additives), excellent reaction-to-fire-properties on all faces.

[0092] In particular, composite thermal insulation panels 100 of this type can be applied to a substrate, with the first base face 110, i.e., the one coated with the first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, facing the substrate itself, so as to leave the support layer 160 exposed to the outside and, therefore, to possible fire.

[0093] Alternatively, the same composite thermal insulation panels 100 may be applied to the substrate with the support layer 160 facing the substrate itself, so as to leave the first base face 110, i.e. the one coated with the first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, exposed to the outside and, therefore, to possible fire.

[0094] The composite thermal insulation panel 100 can be fixed to the substrate by glueing, or by mechanical means, such as screws, rivets and the like.

[0095] The substrate can be made of e.g. cement, plasterboard, calcium silicate, mineral wool in reaction-to-fire class A1 or A2, metal or wood fibres in reaction-to-fire class B-s1-d0, or paint with synthetic resins and ceramic additives in accordance with UNI EN 13501-5:2016.

[0096] According to a third preferred embodiment of the invention, shown in Figures 7 and 8, starting from composite thermal insulation panel 100 of the first preferred embodiment, the second coating layer 150 of glass fibre, preferably of mineralised saturated glass fibre, may be replaced with a support layer 170 of a wood fibre material and having reaction-to-fire class B-s1,d0 according to UNI EN 13501-1:2019.

[0097] In practice, the second base face 115 of the insulating panel 105 can be coated at least partially, preferably completely, with a support layer 170, preferably rigid, of said wood fibre material and reaction-to-fire class B-s1,d0.

[0098] This support layer 170 may have a thickness between 10 mm and 30 mm (ends included) and / or a density between 740 Kg / m 3< and 830 Kg / m 3< (ends included).

[0099] Please note that a wood fibre material is defined as a material comprising (non-woven) wood fibres, possibly compacted and bonded with a polymer resin or formaldehyde (e.g. OSB / 3).

[0100] An example of a wood fibre material suitable for making the support layer 170 is MDF (Medium-density fibreboard).

[0101] The support layer 170 can be joined (fixed) to the second base face 115 of the insulating sheet 105 by the interposition of a layer of a polyurethane adhesive 175.

[0102] This polyurethane adhesive can have a density between 1450 kg / m 3< and 1550 kg / m 3< (ends included), e.g. equal to 1500 Kg / m 3< .

[0103] In practice, it is possible to apply polyurethane adhesive to the second base face 115 of the insulating sheet 105 to form a layer 175 that covers it at least partially or, more preferably, completely.

[0104] By way of example and not limitation, this layer of polyurethane adhesive 175 can have a thickness between 0.2 mm and 0.4 mm, e.g. equal to 0.3 mm.

[0105] After the layer of polyurethane adhesive 175 has been applied, it is possible to apply thereon the support layer 170 made of wood fibre material and reaction-to-fire class B-s1,d0.

[0106] In this regard, it should be noted that wood fibre material can generally already be found in the form of foils, panels or sheets, normally rigid or almost rigid, which can be effectively overlaid on the second base face 115 of the insulating sheet 105, for example after the polyurethane adhesive layer 175 has been applied.

[0107] In summary, the composite thermal insulation panel 100 of this third preferred embodiment can therefore comprise or consist of: an insulating sheet 105 of rigid, closed-cell polyurethane foam (polyiso - PIR), a first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1-d0 applied and fixed on the first base face 110 of the insulation sheet 105, a second support layer 170 made of wood-fibre material and having reaction-to-fire class B-s1-d0 applied and fixed to the second base face 115 of the insulating panel 105, e.g. by the interposition of a layer of polyurethane adhesive 175, and if necessary, one or more additional layers of glass fibre 140 added with mineral additives and having reaction-to-fire class B-s1-d0, each of which is applied and fixed to a respective side face 120 of the insulating panel 105, for example by means of the interposition of a respective layer of inorganic binder 145.

[0108] The composite thermal insulation panel 100 thus formed may have an overall density between 171 Kg / m 3< and 262 Kg / m 3< (ends included) and / or an overall thickness between 60 mm and 190 mm (ends included).

[0109] Composite thermal insulation panels 100 of this type can also be applied to a substrate in any way, as they too have excellent reaction-to-fire properties on all their faces, thanks to the support layer 170 of wood-fibre material and having reaction-to-fire class B-s1,d0. In particular, composite thermal insulation panels 100 of this type can be applied to a substrate, with the first base face 110, i.e. the face coated with the first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, facing the substrate itself, so as to leave the support layer 170 of wood fibre material and having reaction-to-fire class B-s1,d0 exposed to the outside and, therefore, to possible fire.

[0110] Alternatively, composite thermal insulation panels 100 of this type can be applied to the substrate, with the support layer 170 of wood fibre material and reaction-to-fire class B-s1,d0, facing the substrate itself, so as to leave the first base face 110, i.e. the one coated with the first coating layer 125 of glass fibre added with mineral additives and reaction-to-fire class B-s1,d0, exposed to the outside and, therefore, to possible fire (even in this case the two faces can be exposed to fire).

[0111] The composite thermal insulation panel 100 can be fixed to the substrate by glueing or by mechanical means, such as screws, rivets and the like.

[0112] The substrate can be made of e.g. cement, plasterboard, calcium silicate, mineral wool having reaction-to-fire class A1 or A2, metal or wood fibre having reaction-to-fire class B-s1.0, or paint with synthetic resins and ceramic additives in accordance with UNI EN 13501-5:2016.

[0113] Obviously a person skilled in the art can make numerous modifications of a technical / application nature to the composite thermal insulation panels 100 described above, without departing from the scope of the invention as claimed below.

Examples

Embodiment Construction

[0036]A composite thermal insulation panel 100, which can be advantageously used in the building, industrial or any other construction field, for example, but not exclusively, to coat structures (e.g. walls or roofs) and / or to make thermally insulating prefabricated products, such as hole-window monoblocs, is described with the aid of the Figures.

[0037]The composite thermal insulation panel 100 comprises first of all an insulating sheet 105 of rigid, closed-cell polyurethane foam (e.g. Polyiso - PIR), whose main function is thermal insulation.

[0038]Preferably, the rigid, closed-cell polyurethane foam of the insulating sheet 105 is an expanded foam without the use of either CFCs (chloro-fluorocarbons) or HCFCs (hydro-chloro-fluorocarbons).

[0039]The insulating sheet 105 is generally shaped as a slab, i.e. a thin body having a lower thickness than the other dimensions, preferably flat and / or of substantially constant thickness.

[0040]The insulating sheet 105 may therefore have a first b...

Technical Field

[0001] The present invention relates to a composite thermal insulation panel adapted to be used in the building, industrial or any other construction sector, for example, but not exclusively, to coat structures and / or to make insulating prefabricated products, such as window-hole monoblocs to be installed in buildings.Background art

[0002] They are currently known many thermal insulation panels that are suitable to be used for coating building structures (e.g. walls or roofs) or industrial structures (e.g. sandwich panels in the refrigeration or furniture sector), in order to give the latter improved characteristics in terms of thermal and possibly acoustic insulation.

[0003] These thermal insulation panels often consist of XPS (extruded expanded polystyrene) or EPS (sintered expanded polystyrene).

[0004] However, composite thermal insulation panels are also known, i.e. formed by coupling several overlapping layers of different materials, in order to take advantage of the positive properties of each of them.

[0005] These composite thermal insulation panels include panels consisting of a sheet of polyiso (PIR) polyurethane foam interposed between two coating layers of glass fibre.

[0006] Thermal insulation panels and composite thermal insulation panels are also sometimes used to make prefabricated products, such as the aforementioned window-hole monoblocs, which are then installed as a single component.

[0007] The window-hole monobloc is in fact a sort of prefabricated thermal insulation frame which is installed on a building under construction (or renovation) in order to delimit the window hole and contain the window frame.

[0008] A drawback of today's XPS and EPS thermal insulation panels and composite thermal insulation panels, however, is that they have poor reaction-to-fire properties, making them substantially unsuitable for all applications where there is a risk of fire exposure.Disclosure of the invention

[0009] An object of the present invention is to solve the aforementioned drawback of the prior art, within the context of a simple, rational and cost-effective solution.

[0010] This and other objects are achieved by the characteristics of the invention reported in independent claim 1. The dependent claims outline preferred and / or particularly advantageous aspects of the invention which however are not strictly required for the implementation thereof.

[0011] In particular, an embodiment of the present invention makes available a thermal insulation panel, comprising: an insulating sheet of rigid, closed-cell polyurethane foam (e.g. Polyiso - PIR), which has a first base face, a second base face, parallel and opposite to the first base face, and one or more side faces, e.g. substantially orthogonal to the first and second base faces, and at least a first coating layer, preferably flexible, of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, which is placed to cover at least partially, preferably completely, the first base face of the insulating sheet.

[0012] Thanks to this solution, the coating layer of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, which during installation can be advantageously placed on the side most exposed to the risk of fire, is effectively able to protect the insulating sheet behind from fire, giving the composite thermal insulation panel, as a whole, a high fire resistance capacity, which makes it suitable also for applications wherein the current thermal insulation panels or composite thermal insulation panels would not be suitable.

[0013] In addition to this important advantage, the coating layer of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 provides the thermal insulation panel with mechanical strength and dimensional stability even at high temperatures.

[0014] According to an aspect of the present invention, the first coating layer (of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0) can be joined / fixed to the first base face of the insulating sheet during the formation of the insulating sheet itself. In practice, the expanded polyurethane foam that makes up the insulating sheet can be formed directly on the first coating layer, which remains joined / fixed to it thanks to the adhesiveness of the polyurethane being formed.

[0015] This ensures excellent adhesion of the glass fibre coating to the insulating sheet without deteriorating performance in terms of reaction to fire.

[0016] An embodiment of the present invention provides that the composite thermal insulation panel may further comprise a second coating layer of glass fibre, preferably of mineralised saturated glass-fibre, which is placed to at least partially, preferably entirely, coat the second base face of the insulating sheet.

[0017] This second coating layer of glass fibre has the effect of further improving the mechanical and dimensional strength of the thermal insulation panel, and also has good adhesion characteristics with any rigid and flexible support.

[0018] According to an aspect of the present invention, also the second coating layer of glass fibre can be joined / fixed to the second base face of the insulating sheet during the formation of the insulating sheet itself.

[0019] For example, the polyurethane foam that makes up the insulating sheet can be formed directly between the first and second coating layers, which remain joined / fixed to it thanks to the adhesiveness of the polyurethane being formed.

[0020] Another embodiment of the invention provides that the composite thermal insulation panel may further comprise at least one support layer, preferably rigid, made of a material having reaction-to-fire class A1 or A2, which is placed to at least partially, preferably entirely, cover the second coating layer.

[0021] This support layer gives the composite thermal insulation panel greater structural stability, while at the same time protecting the second coating layer of glass fibre and the insulating sheet interposed between it and the first coating layer from fire.

[0022] According to an aspect of this embodiment, the support layer can be joined / fixed to said second coating layer by the interposition of a polyurethane adhesive.

[0023] This ensures excellent adhesion of the rigid support layer to the glass fibre coating without deteriorating its performance in terms of reaction to fire.

[0024] Alternatively, the support layer can be replaced (or made up) by a layer of cement mortar having reaction-to-fire class A1 or A2.

[0025] According to a different alternative, the support layer could be replaced (or made up) by a layer of a paint, such as a water-based paint containing (or formulated with) synthetic resins and ceramic additives.

[0026] Another embodiment of the invention provides that the composite thermal insulation panel may directly comprise, instead of the second coating layer of glass fibre, a support layer, preferably rigid, of wood fibre and having reaction-to-fire class B-s1,d0, which is placed to at least partially, preferably entirely, cover the second base face of the insulating panel. Thus, in addition to increasing the structural stability of the composite thermal insulation sheet, the support layer allows to improve significantly the reaction to fire also at the second base face.

[0027] According to an aspect of this embodiment, the wood-fibre support layer can be joined / fixed to said second base face of the insulating sheet by the interposition of a polyurethane adhesive.

[0028] This ensures excellent adhesion of the support layer to the polyurethane of the insulating sheet without deteriorating performance in terms of reaction to fire.

[0029] An aspect of the invention, which is common to all the previously outlined embodiments, provides that each side face of the insulating sheet may be coated at least partially, preferably entirely, with an additional layer of coating of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0.

[0030] Thanks to this solution, it is advantageously possible to protect the insulating panel from fire, not only at the base face(s), but also at the side faces, where joints (grout lines) between two or more adjoining thermal insulation panels of a coating often occur during installation, and through which - however narrow - a fire could spread.

[0031] Unlike the first coating layer, this additional coating layer (of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0) can be joined / fixed to the respective side face of the insulation sheet by the interposition of an inorganic binder.

[0032] This ensures excellent adhesion of the glass fibre coating to the insulating sheet without deteriorating performance in terms of reaction to fire.

[0033] According to another aspect of the invention, the oft-mentioned coating of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 may be, in turn, a composite material comprising (or formed of) a glass fibre supporting layer, placed adjacent to the insulating panel, and a coating layer made of a material containing the mineral additives, for example an expanded graphite paste, placed to coat at least partially, preferably entirely, the glass fibre layer.

[0034] Thanks to this solution, while the glass fibre layer provides the mechanical strength and dimensional stability even at high temperatures, the coating layer containing the mineral additives has the property of expanding in contact with the flames and, therefore, of creating a barrier that draws the flames away from the insulating panel, slowing the development of the fire towards the core of the insulating panel itself.Brief description of the figures

[0035] Further features and advantages of the invention will be more apparent after reading the following description provided by way of a non-limiting example, with the aid of the figures shown in the accompanying tables. Figure 1 is an exploded axonometric view of a composite thermal insulation panel according to the present invention. Figure 2 is a cross-section of the composite thermal insulation panel in Figure 1. Figure 3 is an exploded axonometric view of a first preferred embodiment of the composite thermal insulation panel according to the present invention. Figure 4 is a cross-section of the composite thermal insulation panel in Figure 3. Figure 5 is an exploded axonometric view of a second preferred embodiment of the composite thermal insulation panel according to the present invention. Figure 6 is a cross-section of the composite thermal insulation panel in Figure 5. Figure 7 is an exploded axonometric view of a third preferred embodiment of the composite thermal insulation panel according to the present invention. Figure 8 is a cross-section of the composite thermal insulation panel in Figure 7. Detailed description

[0036] A composite thermal insulation panel 100, which can be advantageously used in the building, industrial or any other construction field, for example, but not exclusively, to coat structures (e.g. walls or roofs) and / or to make thermally insulating prefabricated products, such as hole-window monoblocs, is described with the aid of the Figures.

[0037] The composite thermal insulation panel 100 comprises first of all an insulating sheet 105 of rigid, closed-cell polyurethane foam (e.g. Polyiso - PIR), whose main function is thermal insulation.

[0038] Preferably, the rigid, closed-cell polyurethane foam of the insulating sheet 105 is an expanded foam without the use of either CFCs (chloro-fluorocarbons) or HCFCs (hydro-chloro-fluorocarbons).

[0039] The insulating sheet 105 is generally shaped as a slab, i.e. a thin body having a lower thickness than the other dimensions, preferably flat and / or of substantially constant thickness.

[0040] The insulating sheet 105 may therefore have a first base face 110, a second base face 115 parallel to and opposite to the first base face 110, and one or more side faces 120, generally orthogonal to the base faces 110 and 115, extending in the thickness direction and defining the perimeter of the insulating sheet 105.

[0041] In particular, the two base faces 110 and 115, which are the largest (or most extended) faces of the insulating sheet 105, may have the shape of a quadrilateral, e.g. a rectangle or a square, and may therefore be delimited by four side faces 120, e.g. parallel and opposite two by two.

[0042] By way of example and not limitation, the thickness of the insulating sheet 105 may be between 30 and 160 mm (ends included).

[0043] The width of the insulating sheet 105 can be between 600 and 1200 mm (ends included). The length of the insulating sheet 105 can be between 1200 and 4000 mm (ends included).

[0044] The rigid closed-cell polyurethane foam forming the insulating sheet 105 may have a density between 30 Kg / m 3< and 35 Kg / m 3< (ends included), e.g. equal to 33 Kg / m 3< .

[0045] The composite thermal insulation panel 100 may further comprise a first, preferably flexible, coating layer 125, which is joined / fixed so as to at least partially, more preferably completely, cover the first base face 110 of the insulating sheet 105.

[0046] This first coating layer 125 may comprise (or consist of) glass fibre (also known as "veil of glass" or "glass veil") added with mineral additives and having reaction-to-fire class B-s1,d0 according to EN 13501-1:2019.

[0047] By way of example and not limitation, the first coating layer 125 may have a thickness between 0.9 mm and 1.3 mm (ends included), e.g. equal to 1.1 mm.

[0048] The first coating layer 125 may also have a density between 580 Kg / m 3< and 600 Kg / m 3< (ends included), e.g. equal to 590 Kg / m 3< .

[0049] We would like to specify that "glass fibre" means a woven or non-woven fabric of glass fibres, for example having defined diameter and length, which are bonded together with polymer resin, e.g. dispersion resin.

[0050] A glass fibre added with mineral additives may thus be a composite material comprising (or consisting of) a glass fibre supporting layer 130 (as defined above) and a coating layer 135 of a material containing mineral additives, e.g. an expanded graphite paste, placed to at least partially, preferably entirely, coat the support layer of glass fibre 130, e.g. by a coating process.

[0051] In such a case, the glass fibre supporting layer 130 will be placed directly in contact with the insulating sheet 105, while the coating layer 135 containing the mineral additives will remain on the opposite side (towards the outside).

[0052] As mentioned, the glass fibre constituting the first coating layer 125 is chosen so as to fall within reaction-to-fire class B-s1,d0, i.e. it is a combustible but not flammable or hardly flammable material (letter B), which produces an amount of smoke in combustion that falls within the minimum parameter set by the standard (letter s1), and which, in the event of fire, does not generate dripping of flaming particles (letter d0).

[0053] In order to establish / declare that a material is in a given reaction-to-fire class, in this case class B-s1,d0, reference is always made to the aforementioned UNI EN 13501-1:2019 standard, which requires the material to be tested to undergo reaction to fire tests with SBI (Single Burning Item), as envisaged by UNI EN 13823:2022, and ignitability tests by direct flame attack, as envisaged by UNI EN ISO 11925-2:2020.

[0054] The first coating layer 125 can be joined (fixed) to the first base face 110 of the insulating panel 105 while forming the insulating panel 105.

[0055] For example, the expanded polyurethane foam (e.g. Polyiso - PIR) that makes up the insulating sheet can be formed directly on the first coating layer 125, which remains joined / fixed to it thanks to the adhesiveness of the polyurethane being formed, before it fully hardens.

[0056] In this regard, it should be noted that glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 can generally be found in sheets, tapes or strips, normally flexible, with a width between 30 and 1200 mm (ends included), which can be initially wound into reels.

[0057] During production, this material is spread out (e.g. unrolled from its reel) and all the raw materials required to form the polyurethane foam (Polyiso - PIR), e.g. polyol and isocyanate, are sprayed onto it, e.g. through nozzles, so that the chemical reaction leading to the formation of the insulating panel 105 takes place directly on the first coating layer 125. The adhesion between the insulating panel 105 and the first coating layer 125 can therefore take place because, during the chemical reaction (e.g. between polyol and isocyanate) that leads to the formation of polyurethane, the latter is generally adhesive like a glue.

[0058] The composite thermal insulation panel 100 may further comprise one or more additional coating layers 140, each of which may be joined / fixed so as to at least partially, more preferably completely, cover a respective side face 120 of the insulating sheet 105. Each of these additional coating layers 140 may also comprise (or consist of) said glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0.

[0059] These additional coating layers 140 can therefore have the same composition, thickness and density as the first coating layer 125.

[0060] Each of these additional coating layers 140 may be joined (fixed) to the respective side face 120 of the insulating sheet 105 by the interposition of a layer of an inorganic binder (or adhesive) 145.

[0061] This inorganic binder can have a density between 1550 kg / m 3< and 1650 kg / m 3< (ends included), e.g. equal to 1600 kg / m 3< .

[0062] In practice, it is possible to spread this inorganic binder over the base face 120 so as to form a layer 145 that covers it at least partially or, more preferably, completely.

[0063] This layer of inorganic binder 145 can have a thickness of between 0.9 mm and 1.1 mm, for example, of 1 mm.

[0064] After the layer of inorganic binder 145 has been applied, glass fibre added with mineral additives forming the coating layer 140 can be applied over it.

[0065] Thus, the insulating panel 105 can be completely coated with glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, except for the second face of base 115, which is, however, generally intended to be on the side that is less exposed to risk of fire.

[0066] Starting from this composition common to all embodiments of the invention, a first preferred embodiment, shown in Figures 3 and 4, provides that the second base face 115 of the insulating sheet 105 may be coated at least partially, preferably completely, with a second coating layer 150.

[0067] This second coating layer 150 may comprise (or consist of) glass fibre (or glass veil), preferably a mineralised saturated glass fibre.

[0068] By way of example and not limitation, the second coating layer 150 of (mineralised saturated) glass fibre can have a thickness between 0.8 mm and 1.2 mm (ends included), e.g. equal to 1 m.

[0069] The second coating layer 150 may also have a density between 270 Kg / m 3< and 290 Kg / m 3< (ends included), e.g. equal to 280 Kg / m 3<

[0070] The second coating layer 150 can also be joined / fixed to the second base face 115 of the insulating panel 105 during the formation of the insulating panel 105 itself.

[0071] For example, the expanded polyurethane foam that makes the insulating sheet 105 can be formed directly between the first and second coating layers 125 and 150, which remain joined / fixed to it thanks to the adhesiveness of the polyurethane being formed, before it fully hardens.

[0072] In particular, during production, the glass fibre veils forming the first and second coating layers 125 and 150 are stretched (e.g. unrolled from their respective reels) so that they are parallel to each other and spaced so that the mixture of raw materials, e.g. polyol and isocyanate, required to form the polyurethane foam (Polyiso PIR), which is firstly adhesive like a glue and thus tightly adheres to both the coating layers 125 and 150, can be dispensed (poured) between them.

[0073] In summary, the composite thermal insulation panel 100 of this first preferred embodiment can therefore comprise or consist of: an insulating sheet 105 made of rigid, closed-cell polyurethane foam (e.g. polyiso - PIR), a first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 applied and fixed on the first base face 110 of the insulating sheet 105, a second coating layer 150 of glass fibre, preferably mineralised saturated glass fibre, applied and fixed to the second base face 115 of the insulating sheet 105, and if necessary, one or more further coating layers 140 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, each of which is applied and fixed to a respective side face 120 of the insulating panel 105, e.g. by the interposition of a respective layer of inorganic binder 145.

[0074] The composite thermal insulation panel 100 thus formed can have a total density between 49 Kg / m 3< and 116 Kg / m 3< (ends included).

[0075] Composite thermal insulation panels 100 of this type may be applied to a substrate, with the second base face 115, i.e. the face coated with the second coating layer 150 of (saturated mineralised) glass fibre, facing the substrate itself, so as to leave the first base face 110, i.e. the face coated with the first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1-d0, exposed to the outside and, therefore, to the possible risk of fire.

[0076] The composite thermal insulation panel 100 can be fixed to the substrate by glueing or by mechanical means, such as screws, rivets and the like.

[0077] The substrate can be made of e.g. cement, plasterboard, calcium silicate, mineral wool, metal or wood fibres in class B-s1,d0.

[0078] According to another preferred embodiment of the invention, shown in Figures 5 and 6, at least one support layer 160, preferably rigid, can be added to the composite thermal insulation panel 100 described above, which is fixed to at least partially, more preferably completely, coat the second base face 115 of the insulating sheet 105, covering the second coating layer 150 of glass fibre, preferably mineralised saturated glass fibre, which therefore remains interposed and protected between the insulating sheet 105 and said support layer 160.

[0079] This support layer 160 may comprise (or consist of) a material having reaction-to-fire class A1 or A2 according to EN 13501-1:2019.

[0080] In particular, a class A1 or class A2 material is a non-combustible material, e.g. slabs of fibre cement, magnesium cement, magnesium oxide.

[0081] The support layer 160 may have a thickness between 3 mm and 20 mm (ends included) and / or a density between 900 Kg / m 3< and 1300 Kg / m 3< (ends included), e.g. equal to 950 or 1250 Kg / m 3< .

[0082] In any case, the support layer 160 can be joined (fixed) to the second coating layer 150 by the interposition of a layer of a polyurethane adhesive 165.

[0083] This polyurethane adhesive can have a density between 1450 kg / m 3< and 1550 kg / m 3< (ends included), e.g. equal to 1500 Kg / m 3< .

[0084] In practice, it is possible to spread this polyurethane adhesive over the second layer 150 of mineralised saturated glass fibre, obviously on the opposite side to the insulating sheet 105, so as to form a layer 165 that covers it at least partially or, more preferably, completely.

[0085] By way of example and not limitation, this layer of polyurethane adhesive 165 can have a thickness between 0.2 mm and 0.4 mm, e.g. equal to 0.3 mm.

[0086] After the layer of polyurethane adhesive 165 has been applied, it is possible to apply thereon the support layer 160 of material having reaction-to-fire class A1 or A2 in accordance with EN 13501-1:2019 .

[0087] In this regard, it should be noted that the support layer 160 of material having reaction-to-fire class A1 or A2 can generally already be found in sheets or panels, normally rigid, which can be effectively overlaid on the second coating layer 150, e.g. after the layer of polyurethane adhesive 165 has been applied.

[0088] In a variant of this composite thermal insulation panel 100, the support layer 160 can be replaced (or made up) by a layer of cement mortar having reaction-to-fire class A1 or A2. In another variant of this composite thermal insulation panel 100, the support layer 160 could be replaced (or formed) by a layer of a paint, for example a water-based paint containing (or formulated with) synthetic resins and ceramic additives.

[0089] To summarise, the composite thermal insulation panel 100 of this second preferred embodiment can therefore comprise or consist of: an insulating sheet 105 made of rigid, closed-cell polyurethane foam (e.g. polyiso - PIR), a first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0 applied and fixed on the first base face 110 of the insulating sheet 105, a second coating layer 150 of glass fibre, preferably mineralised saturated glass fibre, applied and fixed on the second base face 115 of the insulation sheet 105, if necessary, one or more additional coating layers 140 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, each of which is applied and fixed to a respective side face 120 of the insulating sheet 105, e.g. by the interposition of a layer of inorganic binder 145, and at least one support layer 160, preferably rigid, made of a material having reaction-to fire class A1 or A2 (or of cement mortar with reaction-to-fire class A1 or A2, or of paint with synthetic resins and ceramic additives), applied and fixed on the second coating layer 150, e.g. by the interposition of a layer of polyurethane adhesive 165.

[0090] The composite thermal insulation panel 100 thus formed may have an overall density between 120 Kg / m 3< and 210 Kg / m 3< (ends included) and / or an overall thickness between 50 mm and 180 mm (ends included).

[0091] Composite thermal insulation panels 100 of this type can be applied to a substrate in any way whatsoever, since they have, thanks to the support layer 160 of a material having reaction-to-fire class A1 or A2 (or of cement mortar with reaction-to-fire class A1 or A2, or of paint with synthetic resins and ceramic additives), excellent reaction-to-fire-properties on all faces.

[0092] In particular, composite thermal insulation panels 100 of this type can be applied to a substrate, with the first base face 110, i.e., the one coated with the first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, facing the substrate itself, so as to leave the support layer 160 exposed to the outside and, therefore, to possible fire.

[0093] Alternatively, the same composite thermal insulation panels 100 may be applied to the substrate with the support layer 160 facing the substrate itself, so as to leave the first base face 110, i.e. the one coated with the first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, exposed to the outside and, therefore, to possible fire.

[0094] The composite thermal insulation panel 100 can be fixed to the substrate by glueing, or by mechanical means, such as screws, rivets and the like.

[0095] The substrate can be made of e.g. cement, plasterboard, calcium silicate, mineral wool in reaction-to-fire class A1 or A2, metal or wood fibres in reaction-to-fire class B-s1-d0, or paint with synthetic resins and ceramic additives in accordance with UNI EN 13501-5:2016.

[0096] According to a third preferred embodiment of the invention, shown in Figures 7 and 8, starting from composite thermal insulation panel 100 of the first preferred embodiment, the second coating layer 150 of glass fibre, preferably of mineralised saturated glass fibre, may be replaced with a support layer 170 of a wood fibre material and having reaction-to-fire class B-s1,d0 according to UNI EN 13501-1:2019.

[0097] In practice, the second base face 115 of the insulating panel 105 can be coated at least partially, preferably completely, with a support layer 170, preferably rigid, of said wood fibre material and reaction-to-fire class B-s1,d0.

[0098] This support layer 170 may have a thickness between 10 mm and 30 mm (ends included) and / or a density between 740 Kg / m 3< and 830 Kg / m 3< (ends included).

[0099] Please note that a wood fibre material is defined as a material comprising (non-woven) wood fibres, possibly compacted and bonded with a polymer resin or formaldehyde (e.g. OSB / 3).

[0100] An example of a wood fibre material suitable for making the support layer 170 is MDF (Medium-density fibreboard).

[0101] The support layer 170 can be joined (fixed) to the second base face 115 of the insulating sheet 105 by the interposition of a layer of a polyurethane adhesive 175.

[0102] This polyurethane adhesive can have a density between 1450 kg / m 3< and 1550 kg / m 3< (ends included), e.g. equal to 1500 Kg / m 3< .

[0103] In practice, it is possible to apply polyurethane adhesive to the second base face 115 of the insulating sheet 105 to form a layer 175 that covers it at least partially or, more preferably, completely.

[0104] By way of example and not limitation, this layer of polyurethane adhesive 175 can have a thickness between 0.2 mm and 0.4 mm, e.g. equal to 0.3 mm.

[0105] After the layer of polyurethane adhesive 175 has been applied, it is possible to apply thereon the support layer 170 made of wood fibre material and reaction-to-fire class B-s1,d0.

[0106] In this regard, it should be noted that wood fibre material can generally already be found in the form of foils, panels or sheets, normally rigid or almost rigid, which can be effectively overlaid on the second base face 115 of the insulating sheet 105, for example after the polyurethane adhesive layer 175 has been applied.

[0107] In summary, the composite thermal insulation panel 100 of this third preferred embodiment can therefore comprise or consist of: an insulating sheet 105 of rigid, closed-cell polyurethane foam (polyiso - PIR), a first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1-d0 applied and fixed on the first base face 110 of the insulation sheet 105, a second support layer 170 made of wood-fibre material and having reaction-to-fire class B-s1-d0 applied and fixed to the second base face 115 of the insulating panel 105, e.g. by the interposition of a layer of polyurethane adhesive 175, and if necessary, one or more additional layers of glass fibre 140 added with mineral additives and having reaction-to-fire class B-s1-d0, each of which is applied and fixed to a respective side face 120 of the insulating panel 105, for example by means of the interposition of a respective layer of inorganic binder 145.

[0108] The composite thermal insulation panel 100 thus formed may have an overall density between 171 Kg / m 3< and 262 Kg / m 3< (ends included) and / or an overall thickness between 60 mm and 190 mm (ends included).

[0109] Composite thermal insulation panels 100 of this type can also be applied to a substrate in any way, as they too have excellent reaction-to-fire properties on all their faces, thanks to the support layer 170 of wood-fibre material and having reaction-to-fire class B-s1,d0. In particular, composite thermal insulation panels 100 of this type can be applied to a substrate, with the first base face 110, i.e. the face coated with the first coating layer 125 of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, facing the substrate itself, so as to leave the support layer 170 of wood fibre material and having reaction-to-fire class B-s1,d0 exposed to the outside and, therefore, to possible fire.

[0110] Alternatively, composite thermal insulation panels 100 of this type can be applied to the substrate, with the support layer 170 of wood fibre material and reaction-to-fire class B-s1,d0, facing the substrate itself, so as to leave the first base face 110, i.e. the one coated with the first coating layer 125 of glass fibre added with mineral additives and reaction-to-fire class B-s1,d0, exposed to the outside and, therefore, to possible fire (even in this case the two faces can be exposed to fire).

[0111] The composite thermal insulation panel 100 can be fixed to the substrate by glueing or by mechanical means, such as screws, rivets and the like.

[0112] The substrate can be made of e.g. cement, plasterboard, calcium silicate, mineral wool having reaction-to-fire class A1 or A2, metal or wood fibre having reaction-to-fire class B-s1.0, or paint with synthetic resins and ceramic additives in accordance with UNI EN 13501-5:2016.

[0113] Obviously a person skilled in the art can make numerous modifications of a technical / application nature to the composite thermal insulation panels 100 described above, without departing from the scope of the invention as claimed below.

Examples

Embodiment Construction

[0036]A composite thermal insulation panel 100, which can be advantageously used in the building, industrial or any other construction field, for example, but not exclusively, to coat structures (e.g. walls or roofs) and / or to make thermally insulating prefabricated products, such as hole-window monoblocs, is described with the aid of the Figures.

[0037]The composite thermal insulation panel 100 comprises first of all an insulating sheet 105 of rigid, closed-cell polyurethane foam (e.g. Polyiso - PIR), whose main function is thermal insulation.

[0038]Preferably, the rigid, closed-cell polyurethane foam of the insulating sheet 105 is an expanded foam without the use of either CFCs (chloro-fluorocarbons) or HCFCs (hydro-chloro-fluorocarbons).

[0039]The insulating sheet 105 is generally shaped as a slab, i.e. a thin body having a lower thickness than the other dimensions, preferably flat and / or of substantially constant thickness.

[0040]The insulating sheet 105 may therefore have a first b...

Claims

1. A composite thermal insulation panel (100), comprising: - an insulating sheet (105) made of rigid, closed-cell polyurethane foam, which has a first base face (110), a second base face (115), parallel and opposite to the first base face (110), and one or more side faces (120), and - at least a first coating layer (125), preferably flexible, made of glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0, which is placed to coat at least partially, preferably completely, the first base face (110) of the insulating sheet (105).

2. A composite thermal insulation panel (100) according to claim 1, wherein the first coating layer (125) is joined to said first base face (110) of the insulating sheet (105) while forming the insulating sheet (105) itself.

3. A composite thermal insulation panel (100) according to claim 1 or 2, comprising a second coating layer (150) of glass fibre, preferably of mineralised saturated glass fibre, which is placed to coat at least partially, preferably completely, the second base face (115) of the insulating sheet (105).

4. A composite thermal insulation panel (100) according to claim 3, comprising at least one support layer (160), preferably rigid, made of a material of reaction-to-fire class A1 or A2, which is placed to coat at least partially, preferably completely, the second coating layer (150).

5. A composite thermal insulation panel (100) according to claim 4, wherein said support layer (160) is joined to said second coating layer (150) by the interposition of a polyurethane adhesive (165).

6. A composite thermal insulation panel (100) according to claim 3, comprising a layer of cement mortar having reaction-to-fire class A1 or A2, which is placed to coat at least partially, preferably completely, the second coating layer (150) of the insulating panel (105)7. A composite thermal insulation panel (100) according to claim 1 or 2, comprising a support layer (170), preferably rigid, made of wood fibre and having reaction-to-fire class B-s1,d0, which is placed to coat at least partially, preferably completely, the second base face (115) of the insulating sheet (105).

8. A composite thermal insulation panel (100) according to claim 7, wherein the support layer (170) made of wood fibre is joined to said second base face (115) of the insulating sheet (105) by the interposition of a polyurethane adhesive (175).

9. A composite thermal insulation panel (100) according to any one of the preceding claims, wherein each side face (120) of the insulating sheet (105) is coated at least partially, preferably entirely, with an additional coating layer (140) of said glass fibre added with mineral additives and having reaction-to-fire class B-s1,d0.

10. A composite thermal insulation panel (100) according to claim 9, wherein said additional coating layer (140) is joined to the respective side face (120) of the insulating sheet (105) by the interposition of an inorganic binder (145).

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