Insulating panel for construction industry

Abstract

The present finding refers to an insulating panel (1) for construction industry, comprising: a central layer (2), made of expanded or extruded polymeric material, enclosed between a first polymeric film (3) and a second polymeric film (4); a first external layer (5), rigid, made of cement resin, superimposed on the first polymeric film (3) on the side opposite to the central layer (2).

Description

[0001] INSULATING PANEL FOR CONSTRUCTION INDUSTRY

[0002] The present finding refers to an insulating panel for construction industry .

[0003] In particular, the finding refers to a panel with thermal, acoustic, and moisture insulation properties , typically used for making floors and walls of building structures , such as for example for making bathroom, shower or sauna floors or walls and decorative elements (e . g . , niches ) inside such environments .

[0004] Insulating panels for construction industry are known, which are typically positioned over the screed of a floor, or fixed by screws or nails to aluminium or wood battens , and then covered with a walkable and / or finishing surface, such as for example a layer of tiles , with the interposition, between the panel and the walkable and / or finishing surface and, in the case of positioning on screed, also between the screed and the panel, of cement glue or cement , in order to firmly constrain such components to each other .

[0005] For example, insulating panels for construction industry are known, which comprise an internal insulating layer, made of extruded polystyrene (XPS ) , typically having a thickness of a few centimetres , at whose two larger faces two covering layers are respectively fixed, each comprising a first layer made of high-density polyethylene (HDPE ) , fixed to the internal insulating layer, and a non-woven fabric layer, typically of the so-called "spunbond" type, facing the side opposite to the internal insulating layer .

[0006] The high-density polyethylene layers reinforce the internal insulating layer which, being made of extruded polystyrene, has relatively low flexural strength; the non-woven fabric layers facilitate the fixing of the panel to the cement or cement glue .

[0007] Typically, the non-woven fabric layer is fixed to the high-density polyethylene layer by a hot-adhesion process ; the high-density polyethylene layer is fixed to the internal insulating layer by gluing .

[0008] In some known solutions , in addition to the abovedescribed layers , there are further layers positioned between the internal insulating layer and the non-woven fabric layers .

[0009] Although such known solutions have several advantages , they still have room for improvement .

[0010] In fact , it has been observed that in some known solutions the non-woven fabric layer, in particular that of the so-called " spunbond” type, fixed to the respective high-density polyethylene layer by hot adhesion, can detach from the high-density polyethylene layer or even split itself into the two layers of which it is typically composed ( such phenomenon is commonly known as "delamination" ) , particularly at the corners of the panel, thereby compromising the subsequent fixing of the panel to the cement mortar or glue .

[0011] Furthermore, in the case where the panel undergoes such a delamination process , the same cannot be sold, which is problematic for the producer of the panel, who is forced to discard the same and provide for a proper disposal thereof , with the resulting economic loss involved thereby .

[0012] The main task of the present finding is therefore to overcome the above-mentioned drawbacks , and in particular to obtain an insulating panel for construction industry which, once made, maintains its adhesion properties to cement glue and mortar unaltered for a relatively long time .

[0013] In the scope of such task, an object of the present finding is to obtain an insulating panel for construction industry having low production costs , preferably lower than the known panels described above . The task and the object according to the present finding are achieved by an insulating panel for construction industry, as in claim 1 .

[0014] The task and object according to the present finding are also achieved by a method for making a panel according to the finding, as in claim 20 .

[0015] Other advantageous features of the finding are indicated in the dependent claims .

[0016] The features and advantages of the present finding will become more apparent from the following exemplary and non-limiting description, referred to the attached schematic drawings in which :

[0017] - Figure 1 is a schematic side view of a first advantageous embodiment of a panel according to the finding;

[0018] - Figure 2 is a schematic side view of a second advantageous embodiment of a panel according to the finding;

[0019] - Figure 3 is a schematic perspective view of an advantageous embodiment of a panel according to the finding during a step of its making .

[0020] With reference to the attached figures , number 1 overall indicates an insulating panel for construction industry according to the finding . Such panel 1 can be installed, for example, above the screed (not illustrated) of a floor of a building (not illustrated) and then covered with a walkable surface, not illustrated, such as for example a layer of tiles , with the interposition of a cement glue , not illustrated, or cement , not illustrated, in order to firmly constrain such panel 1 to the walkable surface . Once installed, the panel 1 acts as a barrier against the passage of moisture, noise, and heat between the walkable surface and the screed .

[0021] The panel 1 can also be advantageously used, for example, for making walls of building structures ( such as for example bathroom walls , showers , saunas ) and of decorative elements (e . g . , niches ) inside such structures ; in this case, the panel 1 can be fixed, for example by screws or nails , to aluminium or wood battens , not illustrated, and covered with a finishing surface, such as for example a layer of tiles , with the interposition, between the panel and the finishing surface, of cement glue or cement , in order to firmly constrain such components to each other .

[0022] The panel 1 comprises a central layer 2 , made of expanded or extruded polymeric material, such as preferably expanded (EPS ) or extruded (XPS ) polystyrene .

[0023] Advantageously, the central layer 2 has a thickness comprised between 6 mm and 50 mm .

[0024] The central layer 2 is enclosed between a first polymeric film 3 and a second polymeric film 4 , which are advantageously relatively low-stretchable .

[0025] Such first polymeric film 3 and second polymeric film 4 , being relatively low-stretchable, increase the flexural strength of the panel 1 .

[0026] It is emphasized that the expression " relatively low- stretchable" means that , when subjected to tensile force with a load lower than their transverse breaking load, their dimensions increase by less than 60% of their original dimension .

[0027] The first polymeric film 3 and the second polymeric film 4 can be equal to or different from each other .

[0028] Advantageously, the first polymeric film 3 is made of polyester (PES ) or bioriented polypropylene (BOPP ) or general-purpose polystyrene (GPPS ) or high impact polystyrene (HIPS ) .

[0029] Advantageously, the second polymeric film 4 is made of polyester (PES ) or bioriented polypropylene (BOPP ) or general-purpose polystyrene (GPPS ) or high impact polystyrene (HIPS )

[0030] Advantageously, the first polymeric film 3 has a thickness comprised between 25 and 150 microns , preferably between 50 and 100 microns , more preferably equal to 80 microns .

[0031] Advantageously, the second polymeric film 4 has a thickness comprised between 25 and 150 microns , preferably between 50 and 100 microns , more preferably equal to 80 microns .

[0032] Advantageously, the first polymeric film 3 and the second polymeric film 4 are fixed to the internal layer by gluing, for example by a mono- or bi-component polyurethane-type glue .

[0033] In an advantageous embodiment , such as for example that illustrated in the attached figures , the first polymeric film 3 is fixed directly (or without the interposition of further layers , except possibly a glue layer, not illustrated) to the central layer 2 .

[0034] In other advantageous embodiments , not illustrated, the first polymeric film 3 is fixed to the central layer 2 with the interposition of one or more further layers , not illustrated, adapted to confer desired properties ( for example, resistance to the passage of gases such as radon or methane ) to the panel 1 .

[0035] In an advantageous embodiment , such as for example that illustrated in the attached figures , the second polymeric film 4 is fixed directly (or without the interposition of further layers , except possibly a glue layer, not illustrated) to the central layer 2 .

[0036] In other advantageous embodiments , not illustrated, the second polymeric film 4 is fixed to the central layer 2 with the interposition of one or more further layers , not illustrated, adapted to confer desired properties ( for example, resistance to the passage of gases such as radon or methane ) to the panel 1 .

[0037] According to the finding, the panel 1 further comprises a first external layer 5 , rigid, made of cement mortar or cement resin, superimposed on the first polymeric film 3 , on the side opposite to the central layer 2 .

[0038] It is emphasized that , in the present text , the expression " rigid" , referred to an external layer made of cement mortar or cement resin, identifies a layer that , when subjected to a flexural test according to the ASTM C947 standard, breaks under a deformation of less than 1 mm .

[0039] Advantageously, the first external layer 5 completely covers the first polymeric film 3 .

[0040] Advantageously, the first external surface 5a of the first external layer 5 , facing the side opposite to the first polymeric film 3 , forms a first external face la of the panel 1 .

[0041] The first external layer 5 , made of cement mortar or cement resin, has excellent adhesion properties to cement glue and cement , and can therefore face, with its external surface 5a ( corresponding to the first external face la of the panel 1 ) , the side opposite to the screed ( in the case of using the panel 1 for constructing a floor) or the battens forming the frame of a wall or construction accessory ( in the case of using the panel to make a wall or building accessory, such as for example a niche ) , so that it can then be covered with a layer of cement glue or mortar (not illustrated) , onto which a walkable and / or finishing surface, not illustrated, such as for example a layer of tiles , can finally be applied; the high adhesion between the first external layer 5 and the cement glue or mortar ensures a high adhesion between the panel 1 and the walkable and / or finishing surface .

[0042] Preferably, the first external layer 5 has a thickness comprised between 0 . 1 mm and 3 mm, more preferably between 0 . 4 mm and 2 mm .

[0043] Advantageously, the first external layer 5 is applied to cover the first polymeric film 3 in a liquid or semi-liquid state, for example by a dedicated spreading roller 7 or another spreading or spraying system; by solidifying, such first external layer 5 becomes rigid and adheres firmly and stably to the first polymeric film 3 .

[0044] In an advantageous embodiment , such as for example that illustrated in the attached figures , the first external layer 5 is fixed directly (or without the interposition of further layers ) to the first polymeric film 3 .

[0045] The Applicant has found that such advantageous embodiment is particularly preferred in the case where the first polymeric film 3 is made of polyester; indeed, it is known that polyester is chemically unstable when being in a basic environment , and that the cement mortars and cement resins , before solidification, have a typically basic pH which then causes partial chemical degradation of the first polymeric film 3 . This degradation, which at first glance can appear as a disadvantage, has actually proven to be an advantage for the panel 1 according to the finding, since a partial degradation of the first polymeric film 3 leads to the formation of indented, or however non-smooth, areas thereon, which are filled by the cement mortar or cement resin of the first external layer 5 before its solidification, thus promoting gripping between the first polymeric film 3 and such first external layer 5 .

[0046] In other advantageous embodiments , not illustrated, the first external layer 5 is fixed to the first polymeric film 3 with the interposition of one or more further layers , not illustrated, adapted to confer desired properties ( for example, resistance to the passage of gases such as radon or methane ) to the panel 1 .

[0047] In an advantageous embodiment , such as for example that illustrated in Figure 1 , the external surface 4a of the second polymeric film 4 , facing the side opposite to the central layer 2 , forms a second external face lb of the panel 1 ; this embodiment is particularly advantageous when only the first external face la of the panel 1 is to be covered with cement mortar or glue, while the second external face lb of such panel is to be, for example, fixed to metal or wood battens , for example, by screws or nails .

[0048] In a further advantageous embodiment , such as for example that illustrated in Figure 2 , the panel 1 comprises a second external layer 6, rigid, made of cement mortar or cement resin, superimposed on the second polymeric film 4 , on the side opposite the central layer 2 .

[0049] Advantageously, the second external layer 6 completely covers the second polymeric film .

[0050] In an advantageous embodiment , such as for example that illustrated in Figure 2 , the external surface 6a of the second external layer 6, facing the side opposite to the second polymeric film 4 , forms the second external face lb of the panel 1 .

[0051] The second external layer 6, made of cement mortar or cement resin, has excellent adhesion properties to the cement glue and cement , thereby it can face, with its external surface 6a ( corresponding in this advantageous embodiment to the second external face lb of the panel 1 ) , the screed, not illustrated, of a floor, not illustrated, on which the panel 1 can be laid, with the interposition of a layer of cement glue or mortar (not illustrated) , so as to increase the fixing between the panel 1 and the screed .

[0052] Advantageously, the second external layer 6 has a thickness comprised between 0 . 1 mm and 3 mm, more preferably between 0 . 4 mm and 2 mm .

[0053] Advantageously, the second external layer 6 is applied to cover the second polymeric film 4 in a liquid or semi-liquid state, for example by a dedicated spreading roller, not illustrated, for example similar (or even equal ) to the spreading roller 7 or other spreading or spraying system; by solidifying, such second external layer 6 becomes rigid and adheres firmly and stably to the second polymeric film 4 .

[0054] In an advantageous embodiment , such as for example that illustrated in Figure 2 , the second external layer 6 is fixed directly ( or without the interposition of further layers ) to the second polymeric film 4 .

[0055] The Applicant has found that such advantageous embodiment is particularly preferred in the case where the second polymeric film 4 is made of polyester; indeed, it is known that polyester is chemically unstable when being in a basic environment , and that cement glues , before solidification, have a typically basic pH that causes partial chemical degradation of the second polymeric film 4 . This degradation, which at first glance can appear as a disadvantage, has actually proven to be an advantage for the panel 1 according to the finding, since a partial degradation of the second polymeric film 4 leads to the formation of indented, or however non-smooth, areas thereon, which are filled by the cement mortar or cement resin of the second external layer 6 before its solidification, thus promoting gripping between the second polymeric film 4 and the second external layer 6 .

[0056] In other advantageous embodiments , not illustrated, the second external layer 6 is fixed to the second polymeric film 4 with the interposition of one or more further layers , not illustrated, adapted to confer desired properties ( for example, resistance to the passage of gases such as radon or methane ) to the panel 1 .

[0057] In advantageous embodiments , the first external layer 5 is made of a first cement mortar that comprises one or more first cement binders , one or more first inert powders , and water .

[0058] Advantageously, such one or more first cement binders comprise cement .

[0059] Advantageously, the one or more first inert powders comprise calcium carbonate and / or basalt and / or sand and / or aluminosilicates and / or oxides with colouring function, such as for example titanium dioxide .

[0060] In other advantageous embodiments , the first external layer 5 is made of a first cement resin comprising cement and a first polymeric resin .

[0061] Advantageously, the first cement resin comprises one or more second inert powders .

[0062] Advantageously, the one or more second inert powders comprise calcium carbonate and / or basalt and / or sand and / or aluminosilicates and / or oxides with colouring function, such as for example titanium dioxide . Advantageously, the first polymeric resin comprises latex and / or one or more elastomers and / or an acrylicbased and / or styrene butadiene-based polymer blend and / or a polyurethane resin and / or an aqueous polyurethane dispersion (PUD ) , and / or one or more polyester-polyether based polymers or a mixture between a polyurethane resin or aqueous polyurethane dispersion and one or more polyester-polyether based polymers , or a combination of two or more of such materials .

[0063] In advantageous embodiments , the second external layer 6, when present , is made of a second cement mortar that comprises one or more second cement binders , one or more third inert powders , and water .

[0064] Advantageously, the one or more second cement binders comprise cement .

[0065] Advantageously, the one or more third inert powders comprise calcium carbonate and / or basalt and / or sand and / or aluminosilicates and / or oxides with colouring function, such as for example titanium dioxide .

[0066] In other advantageous embodiments , the second external layer 6, when present , is made of a second cement resin comprising cement and a second polymeric resin .

[0067] Advantageously, the second polymeric resin comprises latex and / or one or more elastomers and / or an acrylicbased and / or styrene butadiene-based polymer blend and / or a polyurethane resin and / or an aqueous polyurethane dispersion (PUD ) , and / or one or more polyester-polyether based polymers or a mixture between a polyurethane resin or aqueous polyurethane dispersion and one or more polyester-polyether based polymers , or a combination of two or more of such materials .

[0068] Advantageously, the second cement resin comprises one or more fourth inert powders .

[0069] Preferably, the one or more fourth inert powders comprise calcium carbonate and / or basalt and / or sand and / or aluminosilicates and / or oxides with colouring function, such as for example titanium dioxide .

[0070] In advantageous embodiments , the first external layer 5 and the second external layer 6 have the same thickness and / or the same composition ( in this case, the cement mortars or cement resins of which they are made are equal to each other, i . e . , they are the same cement mortar or cement resin, or consist of the same components in the same percentages / proportions ) . In other advantageous embodiments , the first external layer 5 and the second external layer 6 have thicknesses and / or compositions different to each other .

[0071] Only by way of example, the Applicant has found that in order to make the first external layer 5 and / or the possible second external layer 6, it is possible to use the two-component cement mortar commercially known as "Mapelastic" , by the Italian company Mapei ( see for example the website of such company : https : / / www . mapei . com) , or the mortar used to grout ceramic tile joints , commercially known as "Fugabella" , by the Italian company Kerakoll ( see for example the website of such company : https : / / products . kerakoll . com) .

[0072] It has thus been found that the finding solves the above-stated task and objects , since the first external layer (which forms the first external face of the panel ) , made of cement mortar or cement resin, which has high adhesion properties to the cement glue and mortar, once deposited in a liquid or semi-liquid state on the first polymeric film and solidified, becomes rigid and adheres stably to such first polymeric film, without having the risk of delamination occurring in the prior art using non-woven fabric layers .

[0073] The same applies to the second external layer, made of cement mortar or cement resin, in the advantageous embodiments where the same is in the panel and its second external surface forms the second external face of the panel .

[0074] The insulating panel according to the finding therefore maintains its adhesion properties to cement glue and mortar unaltered for a relatively long time .

[0075] Furthermore, the high rigidity of the first external layer and, where present , of the second external layer, contribute to increase the flexural strength (already sufficient due to the presence of the first and second polymeric films , which are relatively low-stretchable ) and the compressive strength of the panel .

[0076] In this regard, comparative tests carried out by the Applicant have shown that even before applying the first external layer and the optional second external layer made of cement mortar or cement resin, a panel comprising a central layer according to the finding, for example, made of extruded polystyrene (XPS ) , enclosed between a first polymeric film and a second polymeric film according to the finding, has a flexural strength comparable to the known-type panels described above .

[0077] For example, the Applicant has measured, according to the ASTM C947 standard, the flexural strength of a known-type panel and of an example panel according to the finding .

[0078] Such standard provides for subjecting a panel sample of approximately 20 x 35 cm in dimensions to flexural stress , resting on a U-shaped support that holds the panel at both ends of the longer side .

[0079] A further inverted U-shaped support engraves the sample at two zones positioned at a distance from the end of the sample equal to one third of the sample ' s longer side dimension .

[0080] The selected parameter for measuring flexural strength is the force required to impress a 4-mm flexure on the vertical plane . The known-type panel used in the test has an overall thickness of 12 . 7 mm and has the following layer structure :

[0081] - external non-woven fabric layer, with a thickness of 0 . 4 mm;

[0082] - 300 g / m2polyethylene layer, with a thickness equal to 0 . 35 mm;

[0083] - extruded polystyrene (XPS ) layer, with a thickness equal to 11 . 7 mm;

[0084] - 300 g / m2polyethylene layer, with a thickness equal to 0 . 35 mm;

[0085] - external non-woven fabric layer, with a thickness of 0 . mm .

[0086] The panel according to the finding used in the test has an overall thickness of 12 . 5 mm and has the following layer structure :

[0087] - 100-micron polyester film

[0088] - extruded polystyrene (XPS ) layer, with a thickness of 12 . 3 mm;

[0089] - polyester film, with a thickness of 100 microns .

[0090] The above test has detected a flexural strength at 4 mm deflection equal to 125 N for the panel according to the prior art and 150 N for the panel according to the finding; the flexural strength values of the two panels are therefore comparable, even though the thickness of the layers of the panel according to the finding that cover the extruded polystyrene layer are thinner .

[0091] It is emphasized that , after applying the first layer and the possible second layer, made of cement mortar or cement resin, the flexural strength of the panel according to the finding further increases .

[0092] Furthermore, the relatively low cost of the polymeric films and of the cement mortar or cement resin, and the ease of spreading or spraying thereof , maintain the production cost of the panel according to the finding relatively low, and in particular lower than the known- type panels described above .

[0093] Finally, it is clear that the panel according to the finding is susceptible to numerous modifications and variants , all falling within the finding; furthermore, all the details are replaceable by technically equivalent elements . In practice, the materials used, as well as the dimensions , can be any depending on the technical requirements .

Claims

CLAIMS1) Insulating panel (1) for construction industrycomprising :- a central layer (2) , made of expanded or extruded polymeric material, enclosed between a first polymeric film (3) and a second polymeric film (4) ;- a first external layer (5) , rigid, made of cement mortar or cement resin, superimposed on said first polymeric film (3) on the side opposite to said central layer (2 ) .2) Panel (1) , as in claim 1, wherein said central layer (2) is made of expanded (EPS) or extruded (XPS) polystyrene .3) Panel (1) , as in a previous claim, wherein said first polymeric film (3) and / or said second polymeric film (4) are made of polyester (PES) or bioriented polypropylene (BOPP) , or general-purpose polystyrene (GPPS) or high impact polystyrene (HIPS) .4) Panel (1) , as in a previous claim, wherein said first polymeric film (3) and / or said second polymeric film (4) have a thickness comprised between 25 and 150 microns .5) Panel (1) , as in a previous claim, wherein said first external layer (5) is made of a first cement mortar which comprises one or more first cement binders, one or more first inert powders and water.6) Panel (1) , as in claim 5, wherein said one or more first cement binders comprise cement.7) Panel (1) , as in claim 5 or 6, wherein said one or more first inert powders comprise calcium carbonate and / or basalt and / or sand and / or aluminosilicatesand / or oxides with colouring function.8) Panel (1) , as in a claim 1 to 4, wherein said first external layer (5) is made of a first cement resin comprising cement and a first polymeric resin.9) Panel (1) , as in claim 8, wherein said first cement resin comprises one or more second inert powders.10) Panel (1) , as in claim 9, wherein said one or more second inert powders comprise calcium carbonate and / or basalt and / or sand and / or aluminosilicates and / or oxides with colouring function.11) Panel, as in claim 8 or 9 or 10, wherein said first polymeric resin comprises latex and / or one or more elastomers and / or an acrylic-based and / or styrene butadiene-based polymer blend and / or a polyurethane resin and / or an aqueous polyurethane dispersion (PUD) and / or one or more polyester-polyether based polymers or a mixture between a polyurethane resin or aqueous polyurethane dispersion and one or more polyester- polyether based polymers, or a combination of two or more of such materials.12) Panel (1) , as in a previous claim, comprising a second external layer (6) , rigid, made of cement mortar or cement resin, superimposed on said second polymer film (4) , on the side opposite to said central layer (2) .13) Panel (1) , as in claim 12, wherein said second external layer (6) is made of a second cement mortar which comprises one more second cement binders, one or more third inert powders and water.14) Panel, as in claim 13, wherein said one or more second cement binders comprise cement.15) Panel, as in claim 13 or 14, wherein said one ormore third inert powders comprise calcium carbonate and / or basalt and / or sand and / or aluminosilicates and / or oxides with colouring function.16) Panel, as in claim 12, wherein said second external layer (6) is made of a second cement resin comprising cement and a second polymeric resin.17) Panel, as in claim 16, wherein said second polymeric resin comprises latex and / or one or more elastomers and / or an acrylic-based and / or styrene butadiene-based polymer blend and / or a polyurethane resin and / or an aqueous polyurethane dispersion (PUD) and / or one or more polyester-polyether based polymers or a mixture between a polyurethane resin or aqueous polyurethane dispersion and one or more polyester- polyether based polymers, or a combination of two or more of such materials.18) Panel (1) , as in claim 16 or 17, wherein said second cement resin comprises one or more fourth inert powders .19) Panel (1) , as in claim 18, wherein said one or more fourth inert powders comprise calcium carbonate and / or basalt and / or sand and / or aluminosilicates and / or oxides with colouring function.20) Method for making a panel (1) as in one or more of the preceding claims, which provides the following steps : a) arranging a central layer (2) , made of expanded or extruded polymeric material; b) fixing a first polymeric film (3) and a second polymeric film (4) , respectively on the two larger faces of said central layer (2) ; c) applying a first external layer (5) , made of cementmortar or cement resin, in a liquid or semi-liquid state, to cover said first polymeric film (3) on the side opposite to said central layer (2) ; d) solidifying said first external layer (5) until the same becomes rigid and adheres firmly and stably to said first polymeric film (3) .21) Method, as in claim 20, which comprises the following further steps : d) applying a second external layer (6) , made of cement mortar or cement resin, in a liquid or semi-liquid state, to cover said second polymeric film (4) on the side opposite to said central layer (2) ; d) solidifying said second external layer (6) until the same becomes rigid and adheres firmly and stably to said second polymeric film (4) .

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