Prefabricated insulating panel for cladding buildings, insulating cladding obtained therefrom and corresponding manufacturing method

Abstract

 A prefabricated insulating panel (1) for cladding buildings, an insulating cladding obtained therefrom and a corresponding manufacturing method, the prefabricated insulating panel comprising a structural slab (2) made of thermally insulating material are provided with a first face and a second face (2a,2b) which are mutually opposite and at least one reinforcement element (3) which is associated and superimposed so as to cover the first face (2a), the exposed and laying surfaces (1b,1a) of the panel being formed respectively by the second face (2b) of the structural slab (2) and the reinforcement element (3); the exposed surface (1a) is shaped to form at least one recessed band (4), arranged at at least one perimetric region and having a substantially lower thickness than the remaining portion of the panel.
Further an insulating cladding (8) for buildings comprising such panels and a method of manufacturing a prefabricated insulating panel (2) are described.

Description

[0001] The present invention relates to a prefabricated insulating panel for cladding buildings, an insulating cladding obtained therefrom and a corresponding manufacturing method.

[0002] In the construction field different techniques are known for obtaining thermal insulation of buildings by way of cladding with insulating panels, so as to reduce the exchange of heat from the inside and outside. In particular the thermal insulation technique known as external insulation has been known for some time, that consists in externally cladding the building structures. In this case the cladding is, generally, obtained directly from the construction site covering the supporting surfaces to be insulated, appropriately prepared, with slabs made of insulating material, by way of gluing and fixing with nails or plugs. The exposed surfaces of such slabs are then smoothed and a net is applied that acts as reinforcement for the adhesion of one or more finishing layers.

[0003] To more easily provide insulating cladding, a system is also known for cladding building structures that uses a plurality of prefabricated insulating panels, arranged so that they are mutually adjacent and in reciprocal contact and fixed to the structure by way of plugs to obtain a modular cladding. Such panels are, substantially, constituted by a structural slab made of thermally insulating material, by a net laid flat and glued to such slab and by a layer of plaster spread on the net and firmly attached to the structural slab. The structural slab has a rectangular shape and is provided with a protruding rib that runs along two consecutive sides and a receiving groove, having a profile that is complementary to such rib, that runs along the other two sides. When laying panels, each panel is positioned with the corresponding protruding rib accommodated in the receiving groove of the adjacent panel.

[0004] Further, the flat net is provided with a flap which protrudes from the shape of the slab at two consecutive sides and the slab has an exposed band, free from the net and plaster, at the other two sides. While the panels are being laid, each panel is positioned with the corresponding protruding flap leaning against the exposed band of the adjacent panel; the free bands on which the protruding flaps of the net are superimposed are finally covered with a layer of plaster to obtain a continuous cladding.

[0005] This system of cladding with prefabricated panels, however, is not free from drawbacks, which include the fact that it is rather difficult to obtain an exposed surface of the cladding that is uniform and completely flat; in some areas, in fact, the net flaps of two or three mutually adjacent panels can overlap, producing different thicknesses that are difficult to level with the application of plaster.

[0006] Moreover, the interlocking reference system of adjacent panels implicates knowing the correct orientation and subsequent positioning, which slows down the operation of laying the panels.

[0007] Also, in the case that one or more of the prefabricated panels must be cut to reduce the size while they are being laid, it is necessary to cut a portion of the panel at the sides provided with the protruding net flap, in order to allow the correct positioning and fixing to the adjacent panels.

[0008] Moreover, such panels provide for the insertion of plugs for fixing to the building structure at certain positions, which are not always available when the panels are cut to size, which can make fixing the panels to the building structure difficult.

[0009] Further, such panels are rather laborious to provide, as they need particular care when providing the grooves and ribs for the reference and positioning while the panels are being laid.

[0010] Moreover, the storage and the transport of the known prefabricated panels are awkward due to the presence of the protruding net flaps that must not be damaged until the panels are laid.

[0011] The aim of the present invention is to eliminate the above mentioned drawbacks of the known art, by providing a prefabricated insulating panel for cladding buildings that allows to obtain a cladding whose exposed surface is perfectly flat and without discontinuity, in order to facilitate the subsequent application of the desired finish.

[0012] Within this aim, an object of the present invention is to provide a prefabricated insulating panel that can be laid in any orientation, regardless of the positioning of the adjacent panels.

[0013] Another object of the present invention is to provide a prefabricated insulating panel that is easy to lay even when cut to size, without needing any particular solutions.

[0014] Another object of the present invention is to provide a prefabricated insulating panel that can be used for the cladding of any building surface and, in particular, to provide cladding for external insulation.

[0015] Another object of the present invention is to obtain a cladding that guarantees a correct thermal insulation for the buildings on which it is used and that makes it easy to apply the subsequent layers of finish and with high quality results.

[0016] Another object of the present invention is to provide a prefabricated insulating panel that is easy and fast to manufacture in a factory, with a limited number of production steps, and that can be easily stored and transported.

[0017] Another object of the present invention is to provide an insulating panel that is simple, relatively easy to provide in practice, safe and efficient in use, as well as of low costs.

[0018] This aim and these and other objects that will become better apparent hereinafter, are achieved by the present prefabricated insulating panel for cladding buildings comprising a structural slab made of thermally insulating material and provided with a first and second face, which are mutually opposite, and at least one reinforcement element, which is associated and superimposed so as to cover said first face, the laying and exposed surfaces of said panel being formed respectively by the second face of the structural slab and by the reinforcement element, characterized in that said exposed surface is shaped so as to form at least one recessed band, which is arranged at at least one perimetric region and has a substantially lower thickness than the remaining portion of said panel.

[0019] This aim and these objects are also achieved by the present insulating cladding for building structures characterized in that it comprises a plurality of panels according to the invention that are mutually juxtaposed so that their respective recessed bands are adjacent so as to cover at least a portion of the building, the means for fixing said panels to the building and the means for joining mutually adjacent panels, which fill said recessed bands so as to obtain an exposed surface without discontinuity.

[0020] This aim and these objects are also achieved by the present method for manufacturing a prefabricated insulating panel characterized in that it comprises the steps of:

• providing a structural slab made of thermally insulating material which has a first face and a second face, which are mutually opposite;
• providing at least one shaped reinforcement element that mates with said first face;
• covering said first face with at least one continuous layer of adhesive material;
• superimposing said reinforcement element so that it adheres to said continuous layer to obtain a panel whose laying and exposed surfaces are formed, respectively, by said second face and by said reinforcement element;

said structural slab and/or said continuous layer and/or said reinforcement element being further shaped so as to form, on said exposed surface, one recessed band, which is arranged at at least one perimetric region and/or a recessed sector, which is arranged in a central position with respect to said panel and has a substantially lower thickness than the remaining portion of said panel.

[0021] Further characteristics and advantages of the present invention will become better apparent from the following detailed description of a preferred but not exclusive embodiment of a prefabricated insulating panel for cladding buildings, the insulating cladding obtained therefrom and the corresponding manufacturing method, illustrated by way of a non-limitative example in the accompanying drawings, wherein:

Figure 1 is a schematic perspective view of a first embodiment of the panel according to the invention;

Figure 2 is a schematic front view of the panel of Figure 1;

Figure 3 is a schematic sectional view taken along the line III-III of Figure 2;

Figure 4 is a schematic perspective view of a second embodiment of the panel according to the invention;

Figure 5 is a schematic plan view of the panel of Figure 4;

Figure 6 is a schematic sectional view taken along the line VI-VI of Figure 5;

Figure 7 is a schematic perspective view of an insulating cladding using the panels according to the invention;

Figure 8 is a schematic plan view of another insulating cladding using the panels according to the invention, where the means for joining the panels have not been shown;

Figures 9 and 10 are two schematic perspective views that show the steps for obtaining a panel according to the invention by way of a first manufacturing method;

Figures 11-13 are schematic perspective views that show the steps for obtaining a panel according to the invention by way of a second manufacturing method.

[0022] With reference to the figures, the reference numeral 1 designates a prefabricated insulating panel for cladding building.

[0023] The panel 1 comprises a structural slab 2 made of thermally insulating material and provided with a first face and a second face, respectively 2a and 2b, which are mutually opposite and at least one reinforcement element 3 which is associated and superimposed so as to cover the first face 2a. The exposed surface 1a and the laying surface 1b of the panel 1 are formed by, respectively, the reinforcement element 3 and the second face 2b.

[0024] The exposed surface 1a is shaped to form at least one recessed band 4, arranged at at least one perimetric region where the panel 1 has a substantially lower thickness than the remaining portion of the panel. Preferably the band 4 runs along the whole perimeter of the panel 1.

[0025] The figures show panels 1 with a rectangular shape, but the possibility of providing panels according to the invention with different geometric shapes, sizes and proportions is not excluded.

[0026] In another embodiment (Figures 4-6) the exposed surface 1a can be shaped to form at least one recessed sector 5, at which the panel has a thickness substantially equal to the thickness at the recessed band 4. Such sector 5 is positioned in the central area of the panel 1.

[0027] The structural slab 2 is provided with at least one material chosen from the group comprising polystyrene, polystyrene with graphite, polyurethane, rock wool, extruded polystyrene, wood fiber, cork, coconut fiber, hemp, and can be made by way of cutting to size or by pressing, according to the material used.

[0028] Advantageously, the reinforcement element 3 is shaped so that it mates with the first face 2a and covers it completely, so as to obtain a uniform exposed surface 1a.

[0029] The reinforcement element 3 is, preferably, constituted by an aggregated system of filaments and/or fibers to obtain a paper-like material, a fabric or a nonwoven fabric.

[0030] Further, the reinforcement element 3 has the mutually opposite surfaces provided with geometric irregularities, not shown in the figures, that facilitate the adhesion to the structural slab 2 and to the layer of finish applied after the panels have been laid.

[0031] Such geometric irregularities can be of the type of through holes provided on the reinforcement element, or can be obtained by way of embossing.

[0032] The structural slab 2 can have at least one and more preferably a plurality of elongated notches 6 that affect a portion of the slab thickness so as to avoid deformation over time after it has been laid. Preferably, the structural slab 2 is rectangular in shape and is provided with a plurality of notches 6 arranged parallel to the short ends of the shape of the slab and distributed along its length.

[0033] The panel 1, finally, comprises at least one continuous layer 7 of adhesive material interposed between the first face 2a and the reinforcement element 3; such adhesive material can be constituted by glue of the type conventionally used for external insulation cladding or by mortar.

[0034] Usually (Figures 3 and 6) the continuous layer 7, at the band 4 and at the sector 5 if provided, has a reduced thickness compared to the remaining portion of the layer, as the structural slab 2 has a substantially constant thickness. In this case the desired profile of the exposed surface 1a is provided by way of the shape of the continuous layer 7.

[0035] In an alternative embodiment, details of which are found below, it is possible that the structural slab 2 has the first face 2a shaped in such a way as to form the band 4 and the possible sector 5 and in this case the continuous layer 7 has a uniform thickness.

[0036] It should be noted that the panel 1 takes up minimal space within the shape of the structural slab 2 and can be easily stored and transported until it is laid.

[0037] To provide an insulating cladding 8 that uses the panels according to the invention, a plurality of panels 1 should be arranged so that they are mutually juxtaposed with the respective bands 4 adjacent so as to cover at least one portion of a building to be thermally insulated.

[0038] The cladding 8 requires the use of means 9 for fixing the panels 1 to the building and means 10 for joining mutually adjacent panels 1, which fill the bands 4 so as to obtain an exposed surface 1a without discontinuity.

[0039] The joining means 10 must guarantee the insulation and the flatness of the exposed surface of the cladding 8.

[0040] The joining means 10 (Figure 7) provides for the use of pieces of adhesive tape made of glass fibers or strips of reinforcement net 11 cut to size to cover the bands 4 so that two by two are adjacent. The joining means 10 further comprise at least one layer 12 of filler material, such as mortar or plaster, for covering the adhesive tape or the reinforcement net 11 to obtain a cladding 8 whose exposed surface is continuous and flat.

[0041] The fixing means 9 are constituted by plugs or nails for the thermal insulation of a conventional type that can, conveniently, be positioned along the bands 4 and at possible sectors 5. The fixing means 10 can affect one single panel, or can be positioned at the contiguous sides of two adjacent panels 1 or where three or four mutually juxtaposed panels 1 come into contact.

[0042] The plugs or nails 9 positioned along the bands 4 are superimposed by the joining means 10, the layer 12 being conveniently smoothed at the heads of the plugs or nails to obtain a continuous and flat exposed surface of the cladding 8.

[0043] Means 13 for covering the relative plugs or nails 9 are provided at the sectors 5 (Figure 8) to obtain a cladding 8 with a uniform thickness, and consist of a layer of mortar or plaster that fills such sectors.

[0044] Figures 7 and 8 show claddings 8 using different arrangements of the panels 1.

[0045] Advantageously, the panels 1 can be manufactured in factories or other dedicated areas and transported to the construction site ready to be laid.

[0046] The manufacturing method of a panel 1 comprises the steps of:

• providing a structural slab 2 made of thermally insulating material with a first face and a second face, 2a and 2b, which are mutually opposite;
• providing at least one shaped reinforcement element 3 that mates with the first face 2a;
• covering the first face 2a with at least one continuous layer 7 of adhesive material;
• superimposing the reinforcement element 3, so that it adheres to the continuous layer, to obtain a panel 1 whose laying and exposed surfaces, 1b and 1a, are formed, respectively, by the second face 2b and by the reinforcement element 3;

the structural slab 2 and/or the continuous layer 7 and/or the reinforcement element 3 being further shaped so as to form, on the exposed surface 1a, a recessed band 4, which is arranged at at least one perimetric region, and/or a recessed sector 5, which is arranged in a central position with respect to the panel and has a substantially lower thickness than the remaining portion of the panel.

[0047] In a first embodiment (Figures 11-13) the above mentioned step of shaping comprises a preliminary pressing step (Figure 11) of the structural slab 2 to shape the first face 2a according to the profile that mates with the profile of the exposed surface 1a and a final pressing step (Figure 13) to compact the structural slab 2, the continuous layer 7 and the reinforcement element 3 which are mutually superimposed. In this case the continuous layer 7 has a substantially constant thickness.

[0048] In an alternative embodiment (Figures 9-10), the step of shaping (Figure 10) consists of pressing the structural slab 2, the continuous layer 7 and the reinforcement element 3 which are mutually superimposed to shape the continuous layer 7 according to the profile that mates with the profile that one wants to confer to the exposed surface 1a. In this case the structural slab 2 maintains a substantially uniform thickness.

[0049] In practice, it has been found that the invention thus described achieves the intended aims and in particular the fact is underlined that the panel according to the invention allows to obtain cladding whose exposed surfaces are uniform and flat, ready for the application of further layers of finish. Further, the panel according to the invention can be laid with any orientation and also in the case of cutting to size it does not need any particular solutions to be placed near the adjacent panels and fixed to the building.

[0050] The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims.

[0051] All the details may also be replaced with other technically equivalent elements.

[0052] In practice, the materials employed, as well as the shapes and the dimensions, may be any according to requirements without thereby abandoning the scope of the protection of the appended claims.

[0053] The disclosures in Italian Patent Application N. M02008A000300, from which this application claims priority are incorporated herein by reference.

[0054] Where technical features mentioned in any claim are followed by reference numbers and/or signs, those reference numbers and/or signs have been included for the sole purpose of increasing intelligibility of the claims and accordingly, such reference numbers and/or signs do not have any effect on the interpretation of each element identified by way of example by such reference numbers and/or signs.

Claims

1. A prefabricated insulating panel (1) for cladding buildings, comprising a structural slab (2) made of thermally insulating material and provided with a first face and a second face (2a, 2b) which are mutually opposite, and at least one reinforcement element (3), which is associated and superimposed so as to cover said first face (2a), the laying and exposed surfaces (1b, 1a) of said panel being formed respectively by the second face (2b) of the structural slab (2) and by the reinforcement element (3), characterized in that said exposed surface (1a) is shaped so as to form at least one recessed band (4), which is arranged at at least one perimetric region and has a substantially lower thickness than the remaining portion of said panel.

2. The panel (1) according to claim 1, characterized in that said band (4) runs along the entire perimeter of said panel.

3. The panel (1) according to one or more of the preceding claims, characterized in that said exposed surface (1a) is shaped so as to form at least one recessed sector (5) whose thickness is lower than that of said remaining portion of said panel.

4. The panel (1) according to claim 3, characterized in that said sector (5) is arranged at the central region of said panel.

5. The panel (1) according to one or more of the preceding claims, characterized in that said structural slab (2) is made of at least one material chosen within the group that comprises polystyrene, polystyrene with graphite, polyurethane, rock wool, extruded polystyrene, wood fiber, cork, coconut fiber, hemp.

6. The panel (1) according to one or more of the preceding claims, characterized in that said reinforcement element (3) is shaped so as to mate with said first face (2a) so as to cover it completely.

7. The panel (1) according to one or more of the preceding claims, characterized in that said reinforcement element (3) comprises at least one aggregated system of filaments and/or fibers so as to obtain a paper-like material, a fabric or a nonwoven fabric.

8. The panel (1) according to one or more of the preceding claims, characterized in that said reinforcement element (3) has mutually opposite corresponding surfaces provided with geometric irregularities.

9. The panel (1) according to claim 8, characterized in that said geometric irregularities are formed by a plurality of through holes provided in said reinforcement element (3).

10. The panel (1) according to claim 8, characterized in that said geometric irregularities are formed by embossing.

11. The panel (1) according to one or more of the preceding claims, characterized in that it comprises at least one elongated notch (6) formed on said second face (2b).

12. The panel (1) according to one or more of the preceding claims, characterized in that it comprises at least one continuous layer (7) of adhesive material that is interposed between said first face (2a) and said reinforcement element (3).

13. The panel (1) according to one or more of the preceding claims, characterized in that said continuous layer (7) has a substantially constant thickness, the structural slab (2) having its first face (2a) shaped so as to form said band (4) and/or said sector (5).

14. The panel (1) according to one or more of claims 1 to 12, characterized in that said continuous layer (7), at said band (4) and/or said sector (5), has a substantially lower thickness than the remaining portion of said layer, the structural slab (2) having a substantially constant thickness.

15. An insulating cladding (8) for buildings, characterized in that it comprises a plurality of panels (1) according to one or more of claims 1 to 14, which are mutually juxtaposed so that the respective bands (4) are adjacent so as to cover at least one portion of a building, means (9) for fixing said panels (1) to said building, and means (10) for joining mutually adjacent panels, which fill said bands (4) so as to obtain an exposed surface without discontinuity.

16. The cladding (8) according to claim 15, characterized in that said joining means (10) comprise at least one portion of adhesive tape made of glass fiber which is associated so as to be superimposed on at least two of said bands (4) of respective panels (1) which are arranged adjacent to each other, and at least one layer (12) of filler material for covering said portion so as to obtain a uniform thickness of said cladding.

17. The cladding (8) according to claim 15, characterized in that said joining means comprise at least one strip of reinforcement net (11), which is superimposed so as to cover at least two of said bands (4) of respective panels (1) which are adjacent to each other, and at least one layer (12) of filler material for covering said strip (11) so as to obtain a uniform thickness of said cladding.

18. The cladding (8) according to one or more of claims 15 to 17, characterized in that said fixing means (9) are positioned at least at said band (4), said joining means (10) being superimposed on the fixing means (9).

19. The cladding (8) according to one or more of claims 15 to 18, characterized in that said fixing means (9) are also positioned at said sector (5), means (13) for covering the fixing means (9), arranged at the recessed sector, being further provided so as to obtain a uniform thickness of said cladding.

20. A method for manufacturing a prefabricated insulating panel (1), characterized in that it comprises the steps of:

- providing a structural slab (2) made of thermally insulating material, which has a first face and a second face (2a, 2b) which are mutually opposite;

- providing at least one shaped reinforcement element (3) that mates with said first face (2a);

- covering said first face (2a) with at least one continuous layer (7) of adhesive material;

- superimposing, so that it adheres to said continuous layer (7), said reinforcement element (3) to obtain a panel (1) whose laying and exposed surfaces (1b, 1a) are formed respectively by said second face (2b) and the reinforcement element (3); said structural slab (2) and/or said continuous layer (7) and/or said reinforcement element (3) being shaped so as to form, on said exposed surface (1a), a recessed band (4), which is arranged at at least one perimetric region, and/or a recessed sector (5), which is arranged in a central position with respect to said panel and has a substantially lower thickness than the remaining portion of said panel.

21. The method according to claim 20, characterized in that said shaping comprises a step for preliminary pressing of said structural slab (2) so as to shape said first face (2a) according to a profile that matches the profile of said exposed surface (1a) and a step for final pressing so as to compact said structural slab (2), said continuous layer (7) and said reinforcement element (3), which are mutually superimposed.

22. The method according to claim 20, characterized in that said shaping comprises a step for pressing said structural slab (2), said continuous layer (7) and said reinforcement element (3), mutually superimposed so as to shape said continuous layer (7) according to a profile that mates with the profile of said exposed surface (1a).

Drawing