HEAT-INSULATING-MATERIAL MAT, IN PARTICULAR FOR BUILDING CONSTRUCTION, AND METHOD FOR PRODUCING THE SAME
The present invention relates to a heat-insulating-material mat (10) in particular for building construction, which is formed from layers (1, 2, 3, 4, etc.) which are arranged loosely one above the other and are made of insulating materials which fuse together exclusively under the heat of a standard flame of a fire test conducted in accordance with standard DIN EN ISO 11925-2 and are held together by means of at least one seam (31, 32, 33) which is configured in undulating form in the longitudinal direction (X) and/or transverse direction (Y) of the mat (10) and in the case of which at least one thread (20, 21, 22) is guided through the layers (1, 2, 3, 4, etc.), wherein the undulating form of the seam (31, 32, 33) is dimensioned such that, constantly changing in position in relation to the local surface area of the standard flame, it moves out of the local flame-treatment surface area. A method for producing heat-insulating-material mats (10) making use of a multi-needle sewing machine is also claimed. The heat-insulating-material mat (10) according to the invention, which can be supplied in a variant which is closed to diffusion and in a variant which is open to diffusion, is suitable for insulating static objects such as roofs, walls/facades or floors and also for lining, for example, drivers' cabs, caravans and other means of transport.
The present invention relates to a heat-insulating-material mat, in particular for building construction, which is formed from layers which are arranged one above the other, which are held together by means of at least one seam which is configured in undulating form in the longitudinal direction (Y) and/or transverse direction (X) of the mat and in the case of which at least one thread is guided through the layers, as well as the method of producing same heat-insulating-material mats.
There are diverse heat-insulating-material mats known, which are formed particularly from composite layers which are arranged and combined one above the other made out of different materials.
For example the DE 101 01 966 B4 manifests a heat-insulating-material mat and/or sound proofing material for the building construction, which is formed of composite materials with layers arranged one above the other, whereas one composite material is minimum one layer of metalized layer, minimum one Polyolefin-layer and minimum a layer of air cushion, whereas one Polyolefin layer is made of a high density Polyethylene foil and minimum one Polyolefin layer is made of foamed Polyethylene foil, after it was discovered, that foamed Polyethylene foil in combination with metalized foil, high density Polyethylene foil and/or air cushions have proven to have very good insulating properties.
In order to handle all layers it is known, that these, especially in the corner margins, have to be hold together/connected by means of seams and/or welds and/or staples.
The DE 100 01 7781 A1 reveals a compound system, including one or multiple sheets of poly foam panels which are open celled, flexible and include good sound-proofing properties, which are made of a mix of melamine and formaldehyde resin and one or more layers of fiber fleece or fiber fabric, whereas the sheets and layers are connected mechanically through stitching, quilting, stapling, nailing and riveting.
It is known from the DE 42 42 261 A1 that this is a procedure of coating plastic foam sheets with mortar or similar, especially for structural wall panels used as tile backer board, whereas in order to improve the mechanical integrity a fabric is intended in the mortar layer, which is sewn onto the plastic foam sheet or the fabric texture is evolving through the stitching together of the plastic foam sheet.
The DE 600 26 541 T2 reveals a procedure for production of a coating for an insulation material, whereas a layer of synthetic material, which includes a polyamide, is extruded onto a surface of a metal layer in such a way that the synthetic material and the metal layer are fused together, and whereas after the fusion of the metal layer and the synthetic material layer the coating is heated in a certain way between 100 and 160° C., in order to crystallize the polyamide.
It is known from the DE 1 778 733 U that there is a sheet for floor- or wall covering, in which strips of felt are connected through zig-zag-seams, whereas zig-zag-seams are described as patterns of short distances, which are arranged in always the same angles towards each other, and whereas the felts which are connected through these zig-zag-seams are fastened differently onto a slip resistant sub structure, f.e. made out of foamed material.
In the course of the approval certification have mats of a similar category according to the standard DIN EN ISO 11925-2:20111-02 (“tests for fire behavior—inflammability of products under direct flame impact—part 2: single flame test”) to pass various fire tests in which the mats and their connecting material (seams) are exposed to defined localized flames (norm flames).
In order to adhere to the current fire protection regulations, it is known, that at least one layer or all layers have to be flame retarding, whereas the for this purpose appropriate method for the coating respective inclusion of flame retardant chemicals onto the respective foils is being known and therefore is not to be mentioned here in detail.
For the protection against tearing of the metalized outer layers of similar categorized mats during the installation f.e. in the attic of a building the DE 101 01 966 B4 resorts to the use of relatively thick outer layers with a thickness of 0.03 mm and 0.2 mm, because known alternatives such as very thin metalized outer foils with a thickness of f.e. 0.012 mm and reinforced by glued textile grits are constantly run contrary to the fire certification, because glue usually works as a fire accelerant.
The problem with this is that mats with metalized outer foils with a thickness of more than 0.03 mm usually do not melt under the heat of a localized (norm) flame, but they continuously transfer the heat into the mat, which starts to burn after reaching the lowest level of flash point of one of the used materials.
Based thereof the underlying purpose of the invention at hand is, compared to the current state-of-heat-insulation-mat-technology, to supply an improved heat-insulating-material mat, which in particular avoids the aforementioned drawbacks and at the same time fulfills the required fire protection regulations.
This task is resolved through a heat-insulating-material mat, in particular for building construction, based upon the attributes of the independent patent requirement 1 and also through the method of producing heat-insulating-material mats according to the attributes of the patent requirement 14.
The subject of the attached claims is the beneficial developments and development advancements which are to be used individually or in conjunction.
Compared to heat-insulating-material mats in the similar category the invented heat-insulating-material mat is different such as that all layers are loosely arranged above each other, which are solely made out of materials which melt (fuse) together onto themselves under the norm flame, whereas said norm flame conforms to the testing procedure of DIN EN ISO 11925-2:2011-02.
It was discovered that if you resort to solely materials which melt (fuse) together onto themselves, the norm flame is just burning a hole in the mat, which results in an advantageous prevention of a continuously induction of heat into the mat and thus the ignition of the mat at the lowest flash point is avoided.
Although, with such a test configuration it showed that if you use straight lines of thread on the edges and in the middle, of which one thread is going straight through all layers, this thread stimulates the ignition of the heat-insulating-material mat like a wick, and therefore the striven certification “normal inflammable” (“B2” after DIN 4102-1 respective “E” after the European classification DIN EN 13501-1) was denied.
Compared to similar category heat-insulating-material mats the accomplished invented heat-insulating-material mats have at least one seam in undulating form in the longitudinal direction (Y) and/or transverse direction (X) wherein the undulating form of the seam is dimensioned such that, constantly changing in position in relation to the local surface area of the norm flame, it moves out of the local flame-treatment surface area.
The undulating form of the seam has therefore the advantage, that this undulating seam does not—contrary to straight seams—stay within the local area of the norm flame or springs back therein—as zig-zag-seams—, but is dimensioned such that, constantly changing position in relation to the local surface of the area of the norm flame, it moves out of the local flame-treatment surface, this in consequence avoids a wick effect of the seam thread and ignition of the used materials, which fuse together within the scope of the test norm.
Depending on the width of the mat, which is assembled assimilated upon the usage and/or building construction possibilities and f.e. is approximately 120 cm for consumers (private) or approximately 150 cm for commercial users, mats have proved themselves, which have in particular at least two, preferably three or maximum five undulating seams going through the layers, whereas neighbouring of the transverse edge of the mat, preferably with a distance of approximately 20 mm to the transverse edge, an undulating outer seam and/or right in the center of the transverse edge of the mat an undulating center seam and/or between the transverse edges of the mat and the center of the mat each an undulating inner seam has to be guided through the layers.
An undesirable wick effect is avoided, if the distance between two undulating seams is a minimum of 90 mm. Through compliance of a minimum distance there is the advantageous formation of air layers in between the single layers which are held together by the seams. Through the formation of air layers between the single layers it is possible that an inflation between the undulating seams is accomplished, so that in practice a significant raise in the heat transfer resistance is to be seen, which is usually only theoretically to be calculated.
An undesirable wick effect is also been avoided, if the repeat length (y) is f.e. approximately 150 mm, which is defined by the distance of two consecutive maximum or minimal undulations, the undulation amplitude (x) which is also called peak-to-valley ratio, and is defined through the distance between maximum and minimum, should be minimum approximately 40 mm, preferably approximately 50 mm.
For the formation of air layers between the single layers it is supportive, if based on a f.e. undulating seam of approximately 180 mm (the real length of the undulating seam) preferably not more than approximately 36 needle stitches are guided through the layers, so that this results in a preferred stitch length of 5 mm for each undulating seam, so that the loosely arranged layers on top of each other are adequately permeable to air and at the same time are held together.
From the invention side it is preferred to have minimum one, particularly two, preferably four, rows of perforation holes guided though the layers, where the course of each row of the perforation holes preferably have the same undulating form as the corresponding undulating seam. The perforation holes guarantee a diffusion openness of the mat and the advantageous usage in an outside section before the vapour barrier with an otherwise identical configuration.
Alternatively or accumulatively it has been proven to use threads with capillary effects in order to avoid a moisture build up.
Claimable is also a method of producing heat-insulating-material mats, especially present invention related mats, with the use of a multi-needle sewing machine.
From the invention side it is preferred to stitch the seams and/or rows of perforation holes via needles from a multi-needle sewing machine, preferably during the same work process, which permits the inexpensive production of the invented mats. Thereby with the diffusion open version of the mat it is possible to implement additional needles without thread in the sewing machine, which can punch the holes during the same work cycle as the stitching is done.
The high thermal insulation effect of the present invented heat-insulating-material mats is achieved thus heat and cold reflects on metalized, f.e. vapour coated with aluminum and/or bronze and ergo silver—and or gold colored mirroring occurs, outer layers made out of polyester foil, which is made preferably flame retardant, f.e. through a coating of LDPE (“low density polyethylene”). Alternatively a coated, fabric reinforced aluminum composite foil can be used as outer layer as well.
In order to have the metalized outer layers or aluminum composite foils of the mat fused together under the heat of the norm flame they have a preferred thickness of f.e. only 0.012 mm. To protect from ripping through the material when installed it is preferably intended by invention a strengthening of the polyester foil through a textile printing process.
Advantageously this eliminates the use of fire accelerant glues and ensures at the same time a sufficient stability of the outer layers of the mat during installations.
Depending on requirement and place of application it is possible to have multiple inner layers between the outer layers, whereas it is preferred, if at least one inner layer of the mat is made out of flame retardant polyester fleece; and/or a soft foam made out polyethylene; and/or one inner layer is made out of a double-sided aluminum and/or bronze vapour coated polyester foil, whereas the latter has to be stored over 48 hours at 70° C. and 50% humidity and then preferably and irreversibly is undulating in the direction of the thickness (z) of the mat and beneficially supports the forming of air layers between the single layers and ergo supports the inflation between the undulating seams.
In order to install/use the mat left- or right sided a layer formation of the mat has proven to be best in which the layers are arranged symmetrically from the outside to the inside.
Because the crucial characteristic of the high thermal insulation effect of the present invented heat-insulating-material mat is its reflection effect and not the thickness of the material, it has proven best to be made out of fourteen layers, which has the following assembly of layers seen from the outside to the inside: one first layer, one second layer, one third layer, two fourth layers, one third layer, two fourth layers, one third layer, two fourth layers, one third layer, one second layer and one first layer.
In order for the present invented heat-insulating-material mat to be used easily by both consumers (private) and commercial applicants it has proved to be the best to compile the materials and thicknesses of the layers as follows: the heat-insulating-material mat has a delivered thickness of a minimum of 7 mm, preferably an average of 11 mm and maximum 20 mm, and also a total area weight of a minimum of 436 g/m2+/−10%.
The heat-insulating-material mat according to the invention is suitable for insulating static objects such as roofs, walls/facades or floors and also for lining f.e. drivers' cabs, caravans (RV's) and other means of transport.
Additional details and more advantages of the present invention are described in the following application example and the supplied drawing of the multilayer heat-insulating-material mat, which does not mean that the present invention is limited to the described installation.
It is shown schematically:
In the following description of one preferable composition of the present invention the same reference signs are standing for the same or comparable components.
Outside
Inside
In order to affix the layers 1,2,3,4 . . . together these layers are attached on both transverse corners respective transverse edges 11 of the mat 10 to each other with an undulating outer seam 31 and also with an undulating middle seam 32 in the middle of the mat 12, especially sown together with the help of a multi-needle sewing machine (not shown). As shown it is possible to include an inner seam 33 between the outer seam 32 and the middle seam 32.
Firstly it is visible, how the undulating form, looking like a sinusoid curve, of each of the seams 31, 32 or 33 do not stay in the local area of the norm flame—which in
The present invented heat-insulating-material mat 10 is suitable in particular for the insulation of roofs, walls/facades or floors, which is described as follows:
A thermal loss, which is caused by wind or wide area air movements (called convection), can be achieved through a separation of an interior room from the exterior room (air and wind tightness). The same applies for water permeation. This separation is achieved by installing the present invented heat-insulating-material mat 10 at its interfaces, usually at the transverse edges 11, with a minimum overlap of 50 mm. In an application of a steep roof with a low roof pitch less than 20° the overlap should be 80 mm. The minimum installation temperature should be at least 10° C., with a maximum humidity of 65%. Ergo the present invented heat-insulating-material mat 10 can either be used as roof underlay in order to achieve wind proofing or as means to achieve air impermeability as air tightness foil.
The—preferably laid out in rows—heat-insulating-material mats 10 are sealed together afterwards with the use of an adhesive aluminum or bronze tape centered on top of the interface/overlap (top and bottom and sides). In this process the outside edges 31 are sealed as well. As soon as the center seam 32 and any possible inner seams 33 are sealed with the adhesive tape, you will achieve a diffusion closed surface, which is comparable advantageously to a vapour barrier, which f.e. is intended beneath the roof trusses, in order to prevent the penetration of moisture from the interior (f.e. any wet cells) into the roof structure.
In an alternative diffusion open variant of the present invented heat-insulating-material mats 10 it is intended to have rows of perforation holes 40 besides the undulating seams, which allow the application of the otherwise similar heat-insulating-material mats 10 as vapour permeable mats above the roof trusses. In this application the center seam 32 and any possible inner seams 33 do not have to be sealed with tape.
Based upon the low grade of emissions and the related high grade of reflection of the surface of the heat-insulating-material mat in the infrared sector the heat transfer mechanism is almost fully eliminated within the bordering air layers. In practice the heat transfer takes place only through heat conduction and convection. Therefore the anyway construction wise necessary air layers and installation levels can be used as thermo-technically relevant layers. If the present invented heat-insulating-material mat 10 is visible from the inside or outside or is used in ventilated air spaces, then the internal or external heat transfer resistance is raised, therefore the thermal insulation performance is enhanced additionally.
Based upon the considerably larger dependency of convection towards non-reflective insulating materials the results for the thermal insulation ratings are varied depending on the direction of thermal energy flow. Therefore the heat protection of a flat roof in summer is considerably higher than in winter.
The—preferably laid out in rows—heat-insulating-material mats 10 should be fastened onto the fastening surface (mostly battens) approximately every 80 mm with at least 20 mm deep/long staples or roof nails.
A nail strip has to be used at the nail holes respective staple holes. All surfaces, which are forming a heat loss zone, should be covered in present invented heat-insulating-material mat 10.
The heat-insulating-material mat 10 according to the invention, which can also be seen as almost diffusion closed in combination with the taped seams, is rendered diffusion open through micro perforation. Depending on the numbers and size of the micro pores which thus create the thermal diffusion behavior, it is then possible that the mat 10 is used diffusion open.
The heat-insulating-material mats 10 according to the invention is therefore suitable for insulating roofs, walls/facades, floors and ceilings and also can be used in f.e., drivers' cab, caravans (RV's), container, cold storages (refrigerated ware houses), technical facilities etc. and the mat can use the surrounding air layers as additional thermal insulation.
Based upon the multi layer composition and the chosen materials there is a good shielding effect against high frequency waves. It is also possible to have a shielding against low frequency waves through a grounding of the mats 10.
LIST OF REFERENCE SIGNS
- 1 first layer, outer layers, in particular: coated, fabric reinforced aluminum composite polyester foil
- 2 second layer, inner layer, in particular: flame retardant polyester fleece
- 3 third layer, inner layer, in particular: double sided aluminum and/or bronze vapour coated polyester foil
- 4 fourth layer, inner layer, in particular: polyethylene soft foam
- 10 heat-insulating-material mat
- 11 transverse edges of the heat-insulating-material mat 10
- 12 center of the mat
- 20 thread
- 21 top thread
- 22 bottom thread
- 31 outer seam
- 32 center seam
- 33 inner seam
- 40 rows of perforation holes
- 50 pressure applied fabric reinforcement
- 60 burn hole inflicted by norm flame
- X transverse direction of heat-insulating-material mat 10
- Y longitudinal direction of heat-insulating-material mat 10
- Z thickness direction of heat-insulating-material mat 10
- y repeat length of the seams 31, 32, 33 respectively the row of perforation holes 40
- x undulating amplitude of the seams 31,32,33 respectively of the rows of perforation holes 40
Claims
1. a heat-insulating-material mat (10) in particular for building construction, which is formed from layers (1,2,3,4... etc.) which are arranged loosely one above the other and are made of insulating materials which fuse together exclusively under the heat of a norm flame of a fire test conducted in accordance with standard DIN EN ISO 11925-2 and are held together by means of at least one seam (31,32,33) which is configured in undulating form in the longitudinal direction (X) and/or transverse direction (Y) of the mat (10) and in the case of which at least one thread (20,21,22) is guided through the layers (1,2,3,4,... etc), wherein the undulating form of seam (31,32,33) is dimensioned such that, constantly changing in position in relation to the local surface area of the norm flame, it moves out of the local flame-treatment surface area.
2. heat-insulating-material mat (10) of claim 1, that a minimum of two (31,31), preferably three (31,32,31) and maximum five (31,33,32,23,31) undulating seams are guided through the layers (1,2,3,4... etc), whereas particularly
- neighbouring to the transverse edge (11) of the mat (10), preferably with a distance of approximately 20 mm to the transverse edge (11), an undulating outer seam (31) and/or
- centered between the transverse edges (11) of the mat (10) an undulating center seam (32) and/or
- between the transverse edges (11) of the mat (10) and the center of the mat (12) each an undulating inner seam (33) are guided through the layers (1,2,3,4... etc.).
3. heat-insulating-material mat (10) of claim 2, that the distance between the undulating seams (31,32,33) is a minimum of 90 mm
4. heat-insulating-material mat (10) of claim 1, that the repeat length (y) of f.e. approximately 150 mm of the undulating amplitude (x) of each of the undulating seams (31,32,33) is a minimum of approximately 40 mm, preferably approximately 50 mm.
5. heat-insulating-material mat (10) of claim 1, that with an undulating seam of approximately 180 mm preferably not more than approximately 36 needle stitches are guided through the layers (1,2,3,4,... etc), so that this results in a preferred stitch length of 5 mm for each undulating seam (31,32,33)
6. heat-insulating-material mat (10) of claim 1, that between two seams (31,32,33) a minimum of one, particularly two, preferably four, rows of perforation holes (40) are guided through the layers (1,2,3,4,... etc) whereas the course of each row of perforation holes (40) has to be preferably of the same undulating form corresponding to the seams (31,32,33).
7. heat-insulating-material mat (10) of claim 1, that the threads (20,21,22), with which the layers (1,2,3,4,... etc) are held together, exhibit capillary effects.
8. heat-insulating-material mat (10) of claim 1, that the seams (31,32,33) and/or the rows of perforation holes (40) are executed with needles of a multi-needle sewing machine, preferably during the same work process
9. heat-insulating-material mat (10) of claim 1, that the outer layer (1) of the mat (10) is a coated, fabric reinforced aluminum composite polyester foil (1)
10. heat-insulating-material mat (10) of claim 1, that at least one inner layer (2,3,4... etc) of the mat (10)
- is a flame retardant polyester fleece (2); and/or
- is a double sided aluminum or bronze vapour coated polyester foil (3), which has to be stored over 48 hours at 70° C. and 50% humidity and then preferably and irreversibly is undulating in the direction of the thickness (z) of the mat (10); and/or
- is a soft foam (4) made out of polyethylene
11. heat-insulating-material mat (10) of claim 1, that the layers (1,2,3,4,4,3,4,4,3,4,4,3,2,1) of the mat (10) are assembled symmetrically from the outside to the inside.
12. heat-insulating-material mat (10) of claim 1, that the mat (10) encompassed fourteen layers (1,2,3,4,... etc), which are assembled from the outside to the inside as follows: one first layer (1), one second layer (2), one third layer (3), two fourth layers (4), one third layer (3), two fourth layers (4), one third layer (3), two fourth layers (4), one third layer (3), one second layer (2) and one first layer (1).
13. heat-insulating-material mat (10) of claim 1, that materials and thickness of the layers (1,2,3,4,... etc) are put together such as, that the mat (10) has a minimum thickness at least 7 mm, preferably of an average of 11 mm and a maximum of 20 mm, as well as a total area weight of a minimum of 436 g/m2+/−10%.
14. a method of producing heat-insulating-material mat (10) of claim 1 with a multi needle sewing machine
15. a method of claim 14, in which the seams (31,32,33) and/or the rows of perforation holes (40) are executed, preferably during the same production process, through needles of the multi needle sewing machine, whereas in the case of production of the diffusion open variant of the mat (10) additional needles with no thread are inserted in the sewing machine, which can punch the extra holes (40) through the layers (1,2,3,4... etc) in the same work process when making the seams (31,32,33)
Type: Application
Filed: May 7, 2012
Publication Date: Mar 20, 2014
Inventor: Oscar Riccardo Rombolotto (Meerbusch)
Application Number: 14/115,864
International Classification: E04B 1/76 (20060101); D05B 55/00 (20060101); D05B 37/00 (20060101);
