DK201800307A1

DK201800307A1 - Composite thermal wall element

Info

Publication number: DK201800307A1
Application number: DKPA201800307A
Authority: DK
Inventors: Gorm Hilding Rasmussen Elith
Original assignee: H+H Danmark A/S
Priority date: 2017-11-24
Filing date: 2018-06-29
Publication date: 2019-09-27
Also published as: EP3714111A4; DK180181B1; EP3714111A1

Abstract

A composite thermal wall element for new buildings and extentions are disclosed. The composite thermal wall element comprises as an example a foam layer and two CSH-component layers, one CSH-component layer on each side of the foam layer. Methods for its preparation are also disclosed.

Description

Composite thermal wall element

Description

The present invention relates to a wall element for new buildings and extensions, methods for preparation of the wall element, and a use of said wall element.

More specifically it relates to a wall element comprising an insulation material and a calcium silicate hydrate (CSH)-component material on both sides of the insulation material, and methods for preparation of the wall element.

The governments around the civilized world face the consumers of energy for heating both in private housings and in industrial buildings with still higher requirements to lower heat loss to the environment in order to save energy and thus decrease CO2 emission. The purpose is to mitigate the increasing average temperatures and consequences of the climate change caused by e.g. increased concentration of CO₂ in the air.

New buildings and extensions have today and for many years been built the same way. First the foundation is made, then the walls are set up. Subsequently, the walls are insulated in order to avoid loss of heat through the walls,

One traditional construction method for external walls comprises the following steps:

Firstly, the inner wall of e.g. either 63 clay bricks and 40-50 kg masonry mortar or light weight concrete blocks laid in masonry mortar, layer by layer, is built. Secondly, mineral insulation is mounted on the outside on the inner wall.

Thirdly, the wall ties are mounted evenly distributed into the inner wall, through the insulation layer.

Fourthly, the outer wall is built of 63 clay bricks and 40-50 kg masonry mortar, layer by layer.

DK 2018 00307 A1

All external joints are manually scratched clean on the face side for preparing final filling,

Fifthly, then the surface is brushed clean manual with a stiff brush for cleaning of loose mortar remains.

Then all joints in the brickwork are manual sealed with compacting weather resistant compacted mortar.

Finally, all surfaces are cleaned in a 1,5 % solution of HCI.

The disadvantages of the method of prior art are that the total building process requires several steps and the insulation of the walls are not very effective, and because it is a construction with so many parts and processes, there always is many risks of failures e.g. air tightness, waterproofness, frost damages and failures in mortar cohesion in between the bricks/blocks and the mortar, which can result in failure.

Thus, it is highly desirable to provide a wall material for new buildings and extensions whereby the heat loss and construction costs are lowered by less parts lowering the risks for failure e.g. airtightness, waterproofness, frost damages and failures in mortar cohesion, while the fabrication process of the wall materials is not more expensive than the total costs of the wall and insulation materials of prior art.

Summary of the invention.

The present invention solves the problem above by providing a wall material for construction and insulation of new buildings and extensions according to claim 1 wherein said wall material is a composite comprising an insulating layer and two diffusive open calcium silicate hydrate (CSH) layers, e.g. hydrothermal hardened, on each side of the insulating layer.

The layers are by the adhesive character of the insulating layer or, optionally, by an adhesive diffusive open layer, attached to each other.

Two embodiments where the CSH-component layers are further specified are

DK 2018 00307 A1 claimed in claim 2 and 3.

Further embodiments are claimed in claim 4 to 9.

A method for preparation of the composite thermal wall element is claimed in claim 10 and further methods in claims 11 to 18.

In order that the invention may be well understood, some non-limiting examples will now be described in which:

Fig. 1 shows a cross-section of a building and where a composite wall element of the invention is intended for use.

Fig. 2 shows a composite wall element of the invention comprising three layers.

Fig. 3 shows a composite wall element of the invention comprising five layers.

Fig. 4 shows a composite wall element of the invention comprising seven layers.

Fig. 5 shows a cross-section of a composite wall element of the invention intended for plastering.

Fig. 6 shows a cross-section of a composite wall element of the invention intended for a raw appearance or for paint.

Fig. 7 shows an example of wall made from composite thermal wall elements of the invention.

Fig. 8 shows an example of a wall made from composite thermal wall elements of the invention for a window opening.

The advantages of the present invention are now described and where possible by referring to the figures above.

Fig. 1 shows a cross-section of a building. The arrows point to where the composite thermal wall element of the invention may be applied, i.e. for the external structural walls, in the basement, at first or higher floors, or in the middle of the house in-between rooms that needs thermal or acoustic insulation. The wall has a low thermal conductivity and is noise reducing as well. It is very effective for thermal insulation.

DK 2018 00307 A1

Referring to Fig. 2 the composite thermal wall element according to the invention comprises at least three layers. The foam layer, 1, is attached on each face side, 11, visible on the figure and 12, not visible, to a CSH-component layer, 2. Either, the foam layer is sticking to the CSH-component layer, 2, or an adhesive layer (not shown) joins the foam, 1, and CSH-component layer, 2, see Fig. 3.

An advantage of the composite of the invention is improved construction speed, fire protection and thermal insulation. The thermal insulation properties are improved by lowering the thermal conductivity while maintaining good fire resistance properties. Both the insulation material and the mineral CSHcomponent have high resistance to fire.

The construction speed and the working environment regarding healthy and safety is improved, because is the walls are installed by using technical lifting tools and lees manual handling.

Fig. 3 shows another composite thermal wall element according to the invention. It has five layers. The foam layer, 1, is attached to an adhesive layer, 3, on both face sides, 11 and 12, and the adhesive layers, 3, are each attached to a CSHcomponent layer, 2.

Fig. 4 shows a composite thermal wall element according to the invention. It has seven layers. The foam layer, 1, is in the middle and by the adhesive characteristic of the foam layer, 1, attached on each face side, 11 and 12, to a protective glass-fibre fabric layer, 4. The protective layers, 4, are each on their other face sides, 41, one is not visible, attached to an adhesive layer, 3, and the adhesive layers, 3, are each attached to a CSH-component layer, 2.

The above composite is prepared directly from products available on the market.

Fig. 5 shows a cross section of joined composite thermal wall elements as in Fig.

2. The wall elements are covered with a layer of plaster that can be reinforced by a mesh of glass fibre fabric on the whole surface. 5. The outmost layer is typically a voluntary optical layer of paint, 6.

DK 2018 00307 A1

Fig. 6 shows a cross section of a joined composite thermal wall elements as in Fig. 2. The edges are chamfered. The outmost layer is a layer of paint, 6. As seen, the edges are chamfered, 7, and the joint sealed, 8. The paint covers both the CSH-component and the joint.

Fig. 7 shows an example of how composite thermal wall elements are installed. In between the complete thermal wall elements in the vertical joints, there is used an adhesive layer of thin layer mortar, synthetic glue or other practical functioning adhesive.

Fig. 8 shows an example of how composite thermal wall elements can be installed around windows. In between the complete thermal wall elements in the vertical joints, there is an adhesive layer of thin layer mortar, synthetic glue or other practical functioning adhesive.

Fig. 2 to 7 show all an embodiment of a thermal wall element according to the invention. The insulating phenolic foam is commercially available. It is anticipated that the foam layer may be made from a resole. This has a composition, if it includes a facing material, of:

About 70% resole resin, about 15% additives, 9% facing material and a propellant with no depletion potential 5%.

It is made from a liquid resole resin, calcium carbonate as filler, additives and a blowing agent. The foam is rigid and has 90% or more closed cells. Examples are published in EP1922356 B1 and EP1922357 B1.

The CSH-component of the claimed embodiments of the composite thermal wall element may deviate in its composition as follows:

DK 2018 00307 A1

Basic performance	Value	Unit
Density	250-2500	kg/m³
Compressive strength	1,5-40	MPa

It is anticipated that e.g. a light weight aircrete for the CSH-component may have the following composition:

Base materials 1 Auxiliaries Description	Value	Unit
Sand	40-72	%
Cement	9-45	%
Caustic lime	10-20	%
Anhydrite 1 Gypsum	2-5	%
Aluminium	0.01-0.4	%

The traditional manufacturing of the phenolic foam needs a surface covering to prevent the foam from sticking to the production equipment but also a firm support layer or surface to form the foam. So, on the market the foam layer is sold sticking on both sides to a glass fibre fabric. A thermal wall element of the invention may or may not comprise the support layer.

Examplei.

Two CSH-component boards are provided from H+H Deutschland GmbH. They have been prepared according to a well-known method, see Environmental Product Declaration of Non-reinforced autoclaved aerated concrete, 2014.

A foam product similar to phenol foam, polyurethane foam, is used in investigating tests to prove the adhesion of the formed foam to the CSHcomponents.

The CSH-components are placed aligned and plan parellely at a distance of 10 cm and the polyurethane foam is raised and filled up the cavity. No glue layer is

DK 2018 00307 A1 used as the freshly formed foam itself between the CSH-components established the necessary cohesion to the CSH-components. A composite with good insulation properties was obtained.

Example 2.

Two autoclaved aerated concrete CSH-component boards are provided from H+H Deutschland GmbH. They have been prepared according to a well-known method published in Environmental Product Declaration of Non-reinforced autoclaved aerated concrete, 2014.

The two concrete CSH-component boards are aligned plan parallelly at a distance of 5 to 20 cm. A phenol resole resin composition comprising 240 g of the commercially available liquid phenol formaldehyde resin supplied by Sumikomo Bakelite, R330, having a viscosity of 8000-10000 cP at 25°C, weight average molecular weight 600-1200 and pH 5,3 to 6,3, containing from 2 to 4% free phenol and 3 to 4% free formaldehyde, with a phenol/formaldehyde molar ratio of 1:2 and a water content of 11 to 13%, is mixed at 15°C with 12,0 g powdered urea and 6,0 g of a castor oil-ethylene oxide adduct as plasticiser and allowed to stand 14 hours. Then 12 g calcium carbonate is added and mixed into the resin until uniformly dispersed. Finally, 20 g of blended isopropyl chloride/isopentane 85/15 parts by weight as blowing agent is mixed at 1°C into the resin. Once a uniform suspension is formed the resin mixture is cooled to 8°C. Then 40,0 g liquid para-toluene sulfonic acid/xylene sulfonic acid blend 65/35 parts by weight at 92% concentration at 8°C is quickly mixed in. 200 g of the resin mix is quickly poured in between the boards, and then cured at elevated temperature 70°C. 50kPa is applied to a lid over the casing with the two concrete boards. The foam is cured for 10 minutes and cured in an oven afterwards for another 2 hours.

A composite having very good thermal insulation properties and good fire resistance is obtained.

DK 2018 00307 A1

Example 3.

The two concrete CSH-component boards are aligned plan parallelly at a distance of 5 to 20 cm, preheating the CSH-component layers to 50°C to 80°C, and filling in between a liquid phenol resin with calcium carbonate as filler, an acid catalyst and a blowing agent, forming an insulation material layer, 1, in between the preheated CSHcomponent layers, by applying the liquid phenol resin with calcium carbonate as filler, an acid catalyst and a blowing agent and wait until the curing step has finished.

As a preferred example the preheating step is performed to 60°C to 70°C.

As a preferred example the phenol resin is the phenol resole resin in Example 2.

Example 4.

An anticipated method of preparing the composite of the invention comprises, to prepare the composite by preparing a foam layer with the preferred characteristics of claim 2, according to standard methods on a support layer which also serves as a first protective layer, placing a second protective layer on the other side of the foam layer, provide at least two CSH-component layers pre-prepared using standard methods,

DK 2018 00307 A1 applying a suitable adhesive layer to each protective layer’s face side or to one side of each CSH-component layer, which have been cooled down from production, and combining the layers, thereby attaching the protective layers to the CSHcomponent layers and allowing the resulting composite to be diffusive open.

A suitable adhesive is an air-hardening moistens fast synthetic aqueous copolymer dispersion, in German called a “Kunststofharzdispersion”, based on styrene and an acrylic acid ester with a solid content of 20-80%, preferably 50% +/- 1%.

Example 5.

Yet another anticipated method comprises providing two CSH-component layers, each layer may be prepared by using standard methods as e.g. published in Environmental Product Declaration of Non-reinforced CSH-component, and wait until the CSH-component layers have cooled down, fill onto one of the CSH-component layers a composition comprising a phenol resin, using a standard method for preparing foam boards, e.g. as published in Environmental Product Declaration Kingspan Kooltherm K5, or EP1922356B1 or EP1922357B1, except for that the curing process is postponed as the next step is placing on the other side a second CSH-component layer as a second foam support layer or carrier and then performing a curing step for the foam forming process above , , applying the adhesive property of the formed foam for attaching the layers of CSH-component, one on each side of the foam layer.

DK 2018 00307 A1

The phenolic foam may, preferably, be formed from a liquid resole resin comprising calcium carbonate as filler, an acid catalyst and a blowing agent. An additive may also be present.

For walls of buildings if the wall is made from a CSH-component the amount of glue for the attachment of a CSH-component to the foam layer is 5 kg/m² CSHcomponent.

Claims

1. A thermal wall element for a building characterised in that it is a composite comprising at least three layers, where a first layer, 1, is a diffusive open rigid insulation material, and a second layer, 2, attached to and a third layer, 2, are diffusive open calcium silicate hydrate layers, the first, 1, and second layer, 2, being attached to each other, and the first, 1, and third layer, 2, being attached to each other, any of these layers by an adhesive diffusive open layer, 3, or by the adhesive character of the first layer, 1.

2. A thermal wall element according to claim 1 wherein the first layer,1, is a rigid phenol resin foam with more than 70%, preferable more than 90%, closed cells and the second layer, 2, and third layer, 2, are CSH-component layers having a density of 250-2500 kg/m³ and a compressive strength of 1,5-40 MPa.

3. A thermal wall element according to claim 1 or 2 wherein at least one CSHcomponent layer, 2, is a structural layer e.g. reinforced with e.g. steel rods, synthetic, organic, inorganic, mineral, or metallic fibres.

4. A thermal wall element according to any of the claims 1 to 3 wherein the rigid phenol foam is prepared from a composition comprising a liquid resole resin and calcium carbonate as filler using an acid catalyst and a blowing agent.

5. A thermal wall element according to any of the claims 1 to 3 wherein the composition further comprises a plasticiser.

6. A thermal wall element according to any of the claims 1 to 5 wherein said adhesive diffusive open layer, 3, is a layer of glue such as a non-plasticized aqueous copolymer dispersion based on styrene and an acrylic acid ester.

7. A thermal wall element according to claim 6 wherein said glue is an air

DK 2018 00307 A1 hardening moistens fast synthetic aqueous copolymer dispersion based on styrene and an acrylic acid ester with a solid content of 20-80%, preferably 50% +/- 1%.

8. A thermal wall element according to claim 7 wherein said synthetic aqueous copolymer dispersion is a styrol acrylic acid esters.

9. A thermal wall element according to any of the claims 6 to 8 wherein the amount of the glue is 5 kg/m² for a thermal wall element.

10. A thermal wall element according to any of the claims 1 to 3 wherein the rigid phenol foam is prepared from a phenolic resin composition comprising a phenolic resin, a blowing agent comprising at least one of butane, hexane and isomers thereof, an acid catalyst and a metal hydroxide or metallic carbonate with an Equilibrium Solubility (Ksp) less than 10'⁸ when measured at 25 °C and is present in an amount of from 1 to 10 parts per weight per 100 parts by weight of phenolic resin, and wherein the phenolic foam comprises a plasticiser for the phenolic resin wherein the plasticiser has a molecular structure containing both an ester backbone and a hydroxyl group, an organic modifier for co-reacting with the phenolic resin, the phenolic foam having a pH of 5 or more.

11. A method for preparing a composite thermal wall element characterised in, that it comprises the steps, provide a first layer made from a diffusive open rigid insulation material, 1, if it is a foam material having above 90% closed cells, optionally, covered on one or both sides with a glass-fibre layer or another carrier layer, provide a first and a second diffusive open CSH-component layer, 2, and either attaching on top of each side of the insulation material

DK 2018 00307 A1 layer, 1, one of the diffusive open CSH-component layers, 2, applying the adhesive character of the foam for the attachment, or provide a layer of a glue, 3, by applying the layer of a glue, 3, to the first layer, 1, one on each face side of the first layer, 1, and attaching on top of each one of the layers of glue, 3, one of the diffusive CSH-component layers, 2.

12. A method for preparing a composite thermal wall element according to claim 11 where the hardening of the glue takes place at a film forming temperature of above 5 °C.

13. A method for preparing a composite thermal wall element according to claim 11 or 12 wherein the diffusive open rigid insulation material is a diffusive open rigid phenol resin foam with closed cells, optionally prepared on a diffusive open glass fibre support layer.

14. A method for preparing a composite thermal wall element characterised in, that it comprises the steps, providing a first and a second diffusive open CSH-component layer, 2, forming an insulation material layer, 1, on top of one side of the first diffusive open CSH-component layer, 2, by applying a liquid phenol resin with calcium carbonate as filler, an acid catalyst and a blowing agent, foaming and curing the phenolic resin, thereby providing a diffusive open rigid insulation material, 1, having above 70%, preferably above 90% closed cells, and attaching before the curing has finished the second diffusive open CSH-component layer, 2, applying the adhesive character of

DK 2018 00307 A1 the foam for the attachment, into a composite.

15. A method for preparing a composite thermal wall element characterised in, that it comprises the steps, providing a first and a second diffusive open CSH-component layer,2 placing the second diffusive open CSH-component layer, 2, plan parallelly at a distance from the first diffusive open CSH-component layer, preheating the CSH-component layers and a composition comprising a liquid phenol resin, calcium carbonate as filler, an acid catalyst and a blowing agent to 50°C to 80°C, forming an insulation material layer, 1, in between the preheated CSH-component layers, by applying the composition comprising a liquid phenol resin, calcium carbonate as filler, an acid catalyst and a blowing agent, and curing the foam, thereby providing a diffusive open rigid insulation material, 1, having above 70%, preferably above 90% closed cells, thereby obtaining a composite by applying the adhesive character of the foam for the attachment.

16. A method according to claim 15 wherein the preheating is performed at temperature of 60°C to 70°C.

17. A method according to claim 15 or 16 wherein the liquid phenol resin composition comprises a plasticiser.

18. A method according to any of the claims 15 to 17 wherein the liquid phenol resin is a resole resin.