Facade Insulation Board with Inhomogeneous Binder Distribution
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Solution Overview
Problem
Thermal insulation composite systems face challenges in achieving both sufficient mechanical stability and low thermal conductivity, particularly with wind suction loads, leading to the need for a high number of plate anchors which are costly and labor-intensive, and the visibility of dowel plates in the plaster surface.
Innovation Solution
A thermal insulation composite system with a facade insulation board featuring an inhomogeneous binder distribution, combining a laminar underlayer with a top layer of mineral wool having a three-dimensional isotropic fiber orientation and increased binder content, allowing for improved stability and thermal insulation without increasing the number of plate anchors, enabling countersunk dowels with smaller diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of plate anchors is increased to improve mechanical stability against wind suction loads, then structural stability is improved, but installation costs and labor intensity increase
Solution Approach 1:
The patent changes the material parameters of the insulation board by creating an inhomogeneous binder distribution with a top layer having increased binder content. This parameter change increases the board's mechanical strength, allowing it to withstand wind suction loads with fewer anchors, thus resolving the contradiction between structural stability and installation efficiency
Solution Approach 2:
The patent creates a composite structure within the insulation board by combining a base layer with a top layer that has different material properties (increased binder content). This composite material approach enhances the overall mechanical performance of the board, enabling reduced anchor numbers while maintaining structural stability
2Reliability
If plate anchors are installed across the entire surface to ensure structural stability, then mechanical strength is improved, but thermal insulation performance deteriorates due to thermal bridges
Solution Approach 1:
The patent changes the material parameters of the insulation board to achieve higher mechanical strength through increased binder content in the top layer. This allows the use of fewer and smaller anchors, thereby reducing thermal bridge effects while maintaining mechanical strength, resolving the contradiction between these two requirements
3Loss of energy
If facade insulation panels use homogeneous single-layer mineral wool to achieve low thermal conductivity, then thermal insulation performance is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent creates a composite structure with a base layer and a top layer having different material compositions. The base layer maintains low thermal conductivity while the top layer with increased binder content provides enhanced mechanical strength. This composite approach resolves the contradiction between thermal insulation performance and mechanical strength that plagues homogeneous single-layer panels
4Reliability
If the binder content is increased throughout the entire insulation board to improve mechanical strength, then structural stability is improved, but thermal conductivity increases reducing insulation performance
Solution Approach 1:
The patent applies local quality by concentrating increased binder content specifically in the top layer where mechanical strength is most needed, while keeping the binder content in the base layer low to maintain thermal insulation performance. This localized approach resolves the contradiction between structural stability and thermal conductivity that would arise from uniform binder distribution
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design maintains excellent thermal insulation properties while enhancing mechanical strength, reducing the number of required plate anchors, and allowing for the use of smaller dowel diameters, thus lowering costs and labor, while preventing thermal bridges and ensuring stability against wind suction loads.
Implementation Method 1
a top layer (42) of mineral wool with a three-dimensional isotropic fiber orientation and an integral layer with an increased binder content in an area (41a) forming a boundary layer between the base layer (41) and the top layer (42)
Implementation Method 2
A thermal insulation composite system (1) with an adhesive mortar (3) by means of which an insulation layer formed from facade insulation panels (4) is spot-bonded to the facade (2)
Implementation Method 3
The interaction of the adhesive mortar with the plate anchors ensures the transfer of these forces and thus the stability of the ETICS
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a façade insulating board (4) for insulating exterior façades (2) of building, particularly as a component of a heat insulating composite system (1), which is made of bound mineral wool and meets a rated value of heat conductivity ? < 0.040 W/mK according to DIN EN 13162. The façade insulating board (4) has an under layer (41) and a cover layer (42). The under layer (41) is made of laminar mineral wool. The cover layer (42) comprises mineral wool having increased mechanical strength compared to the under layer. The content of binding agent is first greater in the region of a boundary layer between the cover layer (42) and the laminar under layer (41) than in the other regions. The present invention further relates to a heat insulating composite system having such a new façade insulating board. The present invention further proposes a method for producing such a façade insulating board (4).