Non-combustible edges for insulating concrete sandwich wall panels

Abstract

To provide a thermal insulation system for sandwich wall panels. The insulation system of the present invention reduces the risk of flame spread into sandwich wall panels and provides a balance of good insulation and reduced flammability without the undesirable consequence of increasing the cost of the sandwich wall panels.

Description

[Technical Field]

[0001] The present invention relates to a thermal insulation system for buildings and residential structures, and more particularly to a system that solves various problems associated with conventional concrete sandwich wall panels.

[0002] REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 008,493, filed April 10, 2020, which is incorporated by reference in its entirety. [Background technology]

[0003] Conventional exterior architectural cladding (surfacing) is often constructed using prefabricated concrete wall panels. In many climates, the concrete panels require additional insulation. In one configuration of such exterior cladding, a panel or board of insulation (e.g., foam) is "sandwiched" between two segments of concrete wall paneling. To maximize insulation, it is desirable for the insulation to reach the edges of the concrete wall panel. However, this configuration often leaves potentially flammable foam insulation exposed, which can pose a fire hazard in certain circumstances. Summary of the Invention [Problem to be solved by the invention]

[0004] Therefore, there is a need for an insulation system that can provide adequate insulation for concrete sandwich wall panels while avoiding the potential combustibility of the insulation material. [Means for solving the problem]

[0005] The general concept of the present invention is based, in part, on the realization that conventional concrete sandwich wall panels present a risk of combustion of the inner insulation material. One way to address this problem is to replace the entire inner insulation with a non-combustible insulation material. However, such a modification is often cost-prohibitive and, in the case of cellular glass, can add significant weight. Therefore, the general concept of the present invention seeks to balance the thermal insulation properties and low cost of foam insulation with the non-combustible properties of cellular glass insulation. This is achieved by positioning the non-combustible cellular glass insulation as an edge around an otherwise combustible foam insulation panel.

[0006] In one particular exemplary embodiment, the general inventive concept contemplates a sandwich wall panel assembly including a first architectural wall panel and a second architectural wall panel positioned opposite each other, with a first insulating material and a second insulating material positioned between the first and second wall panels, the first insulating material being sized to occupy a majority of the area between the first and second wall panels, and the second insulating material being a ribbon-shaped material positioned on at least one edge of the periphery of the first insulating material.

[0007] In one particular exemplary embodiment, the general inventive concept contemplates a sandwich wall panel assembly including a first architectural wall panel having a first major surface facing a first outer surface of the sandwich wall panel assembly and a second major surface facing a first inner surface of the sandwich wall panel assembly, and a second architectural wall panel having a first major surface facing a second outer surface of the sandwich wall panel assembly and a second major surface facing a second inner surface of the sandwich wall panel assembly, the sandwich wall panel assembly further including a first insulation material having first and second major surfaces and a plurality of edges forming a periphery of the first insulation material, the first insulation material being positioned between the first and second architectural wall panels, and the sandwich wall panel assembly further including a second insulation material in the form of at least one segment positioned around at least one of the edges.

[0008] In one particular exemplary embodiment, the general inventive concept contemplates a method of manufacturing a sandwich wall panel assembly, the method comprising the steps of: providing a first architectural wall panel having a first major surface facing a first outer surface of the sandwich wall panel assembly and a second major surface facing a first inner surface of the sandwich wall panel assembly; providing a second architectural wall panel having a first major surface facing a second outer surface of the sandwich wall panel assembly and a second major surface facing a second inner surface of the sandwich wall panel assembly; positioning a first insulation material between the first and second architectural wall panels, the first insulation material having first and second major surfaces and a plurality of peripheral edges; and positioning a second insulation material in the form of at least one segment around at least one of the edges.

[0009] Other aspects and features of the general inventive concept will become readily apparent to those skilled in the art upon review of the following description of various exemplary embodiments in conjunction with the accompanying figures.

[0010] The general concepts of the present invention, as well as embodiments and advantages of these concepts, are described in detail below by way of example with reference to the drawings. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic diagram of a conventional concrete sandwich wall panel. [Figure 2] 1 shows an example of one embodiment of a sandwich wall panel according to the general inventive concept; FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] Certain exemplary embodiments will be described in detail with the understanding that the present invention is merely illustrative of the general inventive concept. Embodiments embodying the general inventive concept may take a variety of forms, and the general inventive concept is not intended to be limited to the specific embodiments described herein.

[0013] Although exemplary embodiments are described or suggested herein, other exemplary embodiments utilizing various methods and materials substantially the same or equivalent to the embodiments described or suggested herein are within the general inventive spirit.

[0014] Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention pertains. In this regard, unless otherwise specified, concentrations of components given herein refer to the concentration of those components in a masterbatch or concentrate, as is customary.

[0015] The general inventive concept relates to a system and method for insulating sandwich wall panels. In particular, the general inventive concept contemplates a system for insulating sandwich wall panels that reduces or avoids the flammability risks associated with conventional insulation materials (i.e., polymer foams).

[0016] In sandwich wall panel assemblies, the exterior surfaces of the wall panel assemblies are often made of concrete or other non-combustible or fire-resistant materials, which are poor insulators in many climates. Thus, additional insulation is often "sandwiched" between the exterior materials of the wall panel assemblies. However, while conventional insulation materials, such as polymer foams, have the advantages of being both inexpensive and efficient insulators, they also carry the risk of being flammable. The general technical idea of ​​the present invention is to address this flammability issue while maintaining the good insulation properties and low cost of conventional insulation materials.

[0017] Cellular glass is a structurally rigid, nonporous, closed-cell foam material with zero water vapor permeability and is non-flammable. Cellular glass has relatively high thermal insulating properties, making it a preferred insulating material for certain applications, particularly those that can take advantage of other unique properties of cellular glass, such as high mechanical strength, rigidity, dimensional stability, chemical inertness, waterproofness and / or water vapor impermeability, water / vapor resistance, insect / rodent resistance, and / or other barrier properties or resistance.

[0018] Although the general inventive concept can be applied to a variety of insulating materials, the cellular glass that can be used in accordance with the general inventive concept is characterized by its high dimensional stability and non-combustibility, which makes it an excellent choice for protecting the inner / first insulating material.

[0019] FIG. 1 illustrates an exemplary sandwich wall panel assembly 100. The panel includes opposing architectural wall panels 110, 130 of a building material (e.g., concrete). Positioned between the opposing architectural wall panels (110, 130) is a layer or board 120 of insulation material (e.g., polymer foam). As can be seen, the peripheral edges of the insulation material 120 are sized to extend substantially to the peripheral edges of the exterior wall panels 110, 130. In other words, the insulation material has a shape that is substantially identical to the shape of the wall panels. This configuration avoids heat / energy transfer through gaps between the insulation material.

[0020] FIG. 2 illustrates one embodiment of a sandwich wall panel assembly 200 according to the general inventive concept. The assembly is comprised of a first building wall panel 210 and a second building wall panel 230, forming a sandwich cavity between the wall panels. Each of the first and second building wall panels 210, 230 has a first major surface facing the exterior of the assembly 200 and a second major surface facing the interior of the assembly 200. A first insulation material 220 in the form of a layer or panel is positioned between the interior-facing major surfaces of the first building panel 210 and the second building panel 230. The building panels (e.g., concrete panels) are designed to be substantially the same size and have substantially the same major surface area. As can be seen in this illustration, the shape (i.e., perimeter) of the first insulation material 220 is smaller than the shapes (perimeters) of the first building panel 210 and the second building panel 230. A second insulation 240 in the form of a ribbon of insulating material is positioned around the first insulation applied to at least one peripheral edge. As can be seen, the area of ​​the second insulation is smaller than the area of ​​the first insulation. This view shows the second insulation 240 positioned to surround the first insulation 220 applied to the top edge, side edges 241, bottom edge 243, and interior edge 242. Interior edges or openings can be provided in the panel assembly to accommodate openings for windows or other access points. In certain exemplary embodiments, the second insulation is positioned around at least one edge of the first insulation, including up to each edge of the first insulation. In certain exemplary embodiments, the second insulation 240 is in the form of individual segments that abut each other around the perimeter of the first insulation 220. In certain exemplary embodiments, the secondary insulation is in the form of individual ribbon-shaped segments, including segments ranging in length from 18 inches (45.72 cm) to 36 inches (91.44 cm). In certain exemplary embodiments, the individual segments may be attached to one another with a conventional non-combustible cementitious material, such as gypsum cement, to form the long ribbon segments.

[0021] The general inventive idea envisages a sandwich wall panel assembly comprising a first architectural wall panel having a first major surface facing an exterior surface of the sandwich wall panel assembly and a second major surface facing an interior surface of the sandwich wall panel, and a second architectural wall panel having a first major surface facing the exterior surface of the sandwich wall panel and a second major surface facing the interior surface of the sandwich wall panel, the sandwich wall panel assembly further comprising a first insulation in the form of a panel having first and second major surfaces and a plurality of edges defining a perimeter, the first insulation being positioned between the first and second architectural wall panels, and the sandwich wall panel assembly further comprising a second insulation in the form of at least one ribbon-shaped segment positioned around at least one of the edges of the first insulation.

[0022] In certain exemplary embodiments, at least one of the first and second architectural wall panels is a concrete panel. In certain exemplary embodiments, both the first and second architectural wall panels are concrete panels.

[0023] In certain exemplary embodiments, the first insulating material is comprised of a foam selected from extruded polystyrene (XPS), expanded polystyrene (EPS), polyisocyanurate, and phenolic foam insulating materials. In certain exemplary embodiments, the first insulating material is combustible. In certain exemplary embodiments, the first insulating material is combustible when subjected to a fire and smoke rating according to ASTM E84 of greater than 0 flame and 0 smoke. In certain exemplary embodiments, the second insulating material is non-combustible. In certain exemplary embodiments, the flammability of the second insulating material is less than the flammability of the first insulating material.

[0024] In certain exemplary embodiments, the second insulation is cellular glass. In certain exemplary embodiments, the second insulation comprises a plurality of ribbon-shaped segments positioned along the peripheral edge of the first insulation. In certain exemplary embodiments, the area of ​​one surface of the second insulation is between 2% and 20% of the area of ​​one major surface of the first architectural wall panel. In certain exemplary embodiments, the area of ​​one surface of the second insulation is between 5% and 10% of the area of ​​one major surface of the first architectural wall panel. In certain exemplary embodiments, the area of ​​one surface of the second insulation is between 3% and 7% of the area of ​​one major surface of the first architectural wall panel. In certain exemplary embodiments, the second insulation has a width of between 2 inches (5.08 cm) and 12 inches (30.48 cm). In certain exemplary embodiments, the second insulation has a width of between 2 inches (5.08 cm) and 6 inches (15.24 cm). In certain exemplary embodiments, the second insulation has a width of 3 inches (7.62 cm) to 4 inches (10.16 cm). In certain exemplary embodiments, the second insulation has a thickness that is the same as or approximately the same as the thickness of the first insulation. In certain exemplary embodiments, the cellular glass segments are of unequal widths.

[0025] As one skilled in the art will recognize, various sizes of ribbons of secondary insulation (e.g., cellular glass) may be required based on the particular needs and specifications of the building to which the wall panel assembly is applied. For example, a particular building may require cellular glass in the form of wide or narrow ribbons. Similarly, a particular assembly may include segments of cellular glass of different widths within the same assembly. Each of these assemblies is within the scope of the general inventive concept.

[0026] In one particular exemplary embodiment, the general inventive concept contemplates a method of manufacturing a sandwich wall panel assembly, the method comprising the steps of: providing a first architectural wall panel having a first major surface facing an exterior surface of a concrete sandwich panel assembly and a second major surface facing an interior surface of the sandwich wall panel assembly; providing a second architectural wall panel having a first major surface facing the exterior surface of the sandwich wall panel assembly and a second major surface facing the interior surface of the sandwich wall panel assembly; positioning a first insulation material between the first and second architectural wall panels, the first insulation material having first and second major surfaces and a plurality of peripheral edges; and positioning a second insulation material in the form of a ribbon-shaped segment around at least one of the edges.

[0027] All references to a singular feature or limitation in this disclosure shall include the corresponding plural features or limitations, and vice versa, unless otherwise specified or expressly implied to the contrary by the context in which the reference is made.

[0028] All combinations of method or process steps used herein can be performed in any order, unless otherwise specified or expressly suggested to the contrary by the context in which the referenced combination is performed.

[0029] All ranges and parameters, including but not limited to percentages, parts, and ratios, are understood to include any and all subranges assumed and subsumed herein, as well as every number between the endpoints. For example, a range stated as "1 to 10" should be understood to include any and all subranges between the minimum value of 1 and the maximum value of 10, inclusive; that is, all subranges beginning at a minimum of 1 or more (e.g., 1 to 6.1) and ending at a maximum of 10 or less (e.g., 2.3 to 9.4, 3 to 8, 4 to 7), and ultimately to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, subsumed within the range.

[0030] The sandwich wall panel assemblies of the present invention can include, consist of, or consist essentially of the essential elements and novel features (limitations) of the present invention as described herein, and can include, consist of, or consist essentially of any additional or optional elements, components, or novel features (limitations) described herein or useful in foam glass composition applications.

[0031] Also, the sandwich wall panel assemblies of the present invention may be substantially free of any optional or selected components or features described herein, provided that the remaining composition still includes all of the required components or features as described herein. In this context, and unless otherwise specified, the term "substantially free" means that the selected composition includes no more than a functional amount of the optional component, typically 0.1% by weight or less (including zero weight percent) of such optional or selected required component.

[0032] When the terms "include," "includes," or "including" are used in the original specification or claims, they are intended to be inclusive in much the same way as "comprising," since this term is understood to be used as a transitional phrase in the claims. Furthermore, when the term "also" is used (e.g., A or B), it is intended to mean "A or B or both A and B." If the applicant intends to indicate "only A or B, but not both A and B," the phrase "only A or B, but not both A and B" would be used. Thus, the term "or" as used herein is inclusive, not exclusive. The terms "a" or "an" in the original specification should be construed to include both the singular and the plural. Conversely, any reference to a plurality of items should, where appropriate, include the singular.

[0033] It should be noted that in some embodiments, various inventive concepts can be utilized in combination with one another. In addition, any particular element described as relating to a particular disclosed embodiment should be construed as usable with all disclosed embodiments, provided that the description of a particular element does not necessarily correlate with the express requirements of that embodiment. Additional advantages and modifications will be readily apparent to those skilled in the art. Therefore, the present invention, in its broader aspects, is not limited to the specific details, representative apparatus, or illustrative examples shown and described herein. Accordingly, departures from such details may be made without departing from the spirit or scope of the general inventive concept.

[0034] Although the present invention has been illustrated and described in detail in the drawings and the foregoing text, the same should be considered as exemplary in nature and not as limiting the present invention. It should be understood that only exemplary embodiments have been shown and described, and all changes and modifications that fall within the spirit of the present invention are included in the protection scope of the present invention.

Claims

1. 1. A sandwich wall panel assembly comprising: a first architectural wall panel having a first major surface facing a first outer surface of the sandwich wall panel assembly and a second major surface facing a first inner surface of the sandwich wall panel assembly; a second architectural wall panel having a first major surface facing a second outer surface of the sandwich wall panel assembly and a second major surface facing a second inner surface of the sandwich wall panel assembly; a first insulating material having first and second major surfaces and a plurality of edges defining a perimeter of the first insulating material, the first insulating material being positioned between the first and second architectural wall panels; A sandwich wall panel assembly including a second insulation in the form of at least one segment positioned around at least one of said edges.

2. 10. The sandwich wall panel assembly of claim 1, wherein the first insulation material is comprised of XPS, EPS, polyisocyanurate, and / or phenolic foam insulation, faced glass fiber, or mineral fiber board.

3. The sandwich wall panel assembly of claim 1 , wherein said second insulating material is non-combustible.

4. 4. The sandwich wall panel assembly of claim 3, wherein said second insulating material is cellular glass.

5. The sandwich wall panel assembly of claim 1 , wherein said second insulation comprises a plurality of ribbon-shaped segments positioned along said edges.

6. 6. The sandwich wall panel assembly of claim 5, wherein said segments are of unequal widths.

7. 2. The sandwich wall panel assembly of claim 1, wherein the surface area of ​​the second insulation is between 2% and 25% of the area of ​​the second major surface of the first architectural wall panel.

8. The sandwich wall panel assembly of claim 1, wherein the width of said second insulation is between 2 inches (5.08 cm) and 12 inches (30.48 cm).

9. 1. A method of manufacturing a sandwich wall panel assembly, said method comprising: providing a first architectural wall panel having a first major surface facing a first outer surface of the sandwich wall panel assembly and a second major surface facing a first inner surface of the sandwich wall panel assembly; providing a second architectural wall panel having a first major surface facing a second outer surface of the sandwich wall panel assembly and a second major surface facing a second inner surface of the sandwich wall panel assembly; positioning a first insulation material between the first and second building wall panels, the first insulation material having first and second major surfaces and a plurality of peripheral edges; and positioning a second insulating material in the form of at least one segment around at least one of said edges.

10. The method of claim 9 , wherein the first insulation material comprises foam insulation.

11. The method of claim 9 , wherein the second insulating material is non-combustible.

12. The method of claim 11 , wherein the second insulating material is cellular glass.

13. The method of claim 9 , wherein the second insulating material includes a plurality of segments correspondingly positioned along a plurality of edges.

14. 10. The method of claim 9, wherein the surface area of ​​the second insulation is between 2% and 20% of the area of ​​the second major surface of the first architectural wall panel.

15. The method of claim 9, wherein the second insulation has a width between 2 inches (5.08 cm) and 12 inches (30.48 cm).

16. The method of claim 13 , wherein at least two of the segments have different widths.

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