Prefabricated insulation panel, particularly for covering buildings, and associated production method

Abstract

 A prefabricated insulation panel, particularly for covering buildings, that comprises a base slab (2) made of insulating material and a covering slab (3) made of fibrous material. The two slabs (2, 3) which are substantially quadrangular are connected to each other and respectively define, on two opposing faces (4, 5), which are not connected to each other, a laying surface (6) and a visible surface (7).
Furthermore, the panel (1) perimetrically is provided with a plurality of lowered band portions (8) which have a substantially smaller thickness than that of the remaining central portion (9) of the panel (1).
The peculiarity of the invention consists in that the panel (1) comprises at least two non-consecutive band portions (10) which have at least one guide (11) that runs along the entire length of the panel (1). The covering slab (3) is provided, on the visible surface (7), with at least one first gripping layer (12).

Description

[0001] The present invention relates to a prefabricated insulation panel, particularly for covering buildings, and its associated production method.

[0002] In the construction sector the use is known of insulating elements which are aimed at minimizing the heat exchange between the inside of a building and the surrounding environment, thus optimizing the energy consumption inside the building itself.

[0003] Such insulating elements are sold, in order to facilitate the laying thereof, in quadrangular panels which are mainly constituted by two layers of which a first layer, of substantial thickness, is placed in direct contact with the wall of the building and acts as the proper insulation, while a second layer, considerably thinner than the first, is designed to protect the first layer against accidental impacts and the weather.

[0004] Such panels are normally applied to the outside of the building, i.e. on the external surface of the perimeter walls, according to a known technique called "coat" insulation. According to this technique, the panels are connected to the walls by means of adhesives or more commonly with fixing elements, such as for example nails or inserts, and subsequently covered by a net that acts as a reinforcement for at least one first rough layer of plaster and subsequent layers of finishing.

[0005] Laying the net and applying the subsequent plaster, over all of the outer surface of the panels, makes it possible to obtain a wall that is completely planar, by englobing in the plaster all the imperfections of the outer surface of the panels and the protruding portions of nails or inserts, i.e. the head, that hold the panel against the wall.

[0006] This procedure however requires very lengthy timescales and very high costs.

[0007] In order to reduce the costs and timescales of laying the net and applying the subsequent plaster, panels are known, fully described in European patent application no. EP 09176235, which require the application of the plaster only on part of the outer surface, and more specifically such panels have, in their perimeter regions, a slight depression in which the heads of the inserts and the net for the plaster are accommodated.

[0008] Such panels of known type are not free from drawbacks, including the fact that the outer surface of the panel has some imperfections and/or deformations, such that an additional layer of finishing is required to even out all the surface irregularities. Indeed, these panels are made by overlaying the second layer of the panel, for example fiberglass, on the first base layer of insulating material, for example rock wool. The overlaying occurs by pressing the second layer on the completely planar surface of the first layer, which at first deforms and, subsequently, tends to return to its original shape, thus slightly deforming the second layer, i.e. the visible surface of the panel.

[0009] Another drawback of conventional panels consists in that the external surface of the panel, which comprises the second layer, is fragile and therefore not very resistant to accidental impacts both during the step of transport and laying to which the panel is subjected, and also to accidental impacts to which the wall is subjected after installation of the panel.

[0010] In order to prevent this drawback, the surface that is subjected to accidental impacts is strengthened, by increasing the thickness of the second layer. This increase in thickness irremediably increases the weight of the panel, thus requiring the installation of inserts which are larger and more expensive.

[0011] Another drawback of conventional panels can be found during application of the plaster, and particularly at the corners of the panels.

[0012] Specifically, the central regions of the panels are arranged on a higher level than the perimetric regions and when laying two or more adjacent panels a small channel is created, the bottom of which is formed by the two perimetric strips of the panels and which is delimited laterally by one side of the central portions 9 of the panels 1.

[0013] The application of plaster in this channel, and especially the subsequent smoothening, is rapid, since the sides of the central portion 9 of the adjoining panels 1 are used as a geometric reference upon which the operator slides the spatula, or any other tool adapted to smoothening.

[0014] This advantage is not found when multiple panels have more than two adjacent corners, since in such particular configuration the central portions 9 of the panels 1 are not present for use as a reference for the subsequent smoothening of the plaster, and the operator takes a longer time to achieve the same smoothening result that is present in the central part of the panel 1.

[0015] The aim of the present invention is to provide a prefabricated insulation panel, particularly for covering buildings, which resolves the drawbacks and overcomes the limitations of the known art by making it possible to obtain an external surface that is completely planar without imperfections and without deformations.

[0016] Within this aim, an object of the present invention is to provide a panel that is resistant to accidental impacts both during transport and laying, and also after installation.

[0017] Another object of the invention consists in providing a panel that is resistant, but which is low in weight.

[0018] A further object of the invention consists in that each panel, independently of the position of the adjoining panels, has a geometric reference for the smoothening of the plaster.

[0019] Another object of the invention consists in providing a panel that is easy to make and economically competitive when compared to the known art.

[0020] The aim and the objects specified, as well as others which will become better apparent hereinafter, are achieved by a prefabricated insulation panel, particularly for covering buildings, comprising a base slab made of insulating material and a covering slab made of fibrous material, said slabs being substantially quadrangular, connected to each other and respectively defining, on two opposing faces which are not connected to each other, a laying surface and a visible surface, said panel having perimetrically a plurality of lowered band portions which have a substantially smaller thickness than that of the remaining central portion of the panel, characterized in that it comprises at least two of said band portions, non-consecutive, which have at least one guide that runs along the entire length of the panel, said covering slab having on said visible surface at least one first gripping layer.

[0021] This aim and these objects, as well as others which will become better apparent hereinafter, are also achieved by the present method for manufacturing a prefabricated insulation panel, characterized in that it comprises the steps of:

• providing a covering slab comprising polypropylene and fibrous material, having on a visible surface and on an opposing face to said visible surface, at least one first and one second gripping layer;
• forming plastically and under a partial vacuum said covering slab in order to obtain a central portion having a grid in relief, a plurality of band portions arranged perimetrically and lying on a plane that is substantially parallel to and spaced from the plane of said central portion, and a plurality of guides interposed between said plurality of band portions and said central portion, said plurality of guides having a substantially curvilinear profile along a plane substantially perpendicular to said covering slab;
• cutting said covering slab perimetrically;
• machining said base slab in order to obtain a central part and a plurality of strips arranged perimetrically and lying on a plane substantially parallel to and spaced from the plane of said central part;
• uniformly spreading a layer of adhesive on said central part and said plurality of strips;
• overlaying said central portion so as to adhere to said central part, and said plurality of band portions so as to adhere to said plurality of strips;
• compressing said base slab on said covering slab.

[0022] Further characteristics and advantages of the invention will become better apparent from the description of a preferred, but not exclusive, embodiment of a prefabricated insulation panel, particularly for covering buildings, illustrated by way of non-limiting example in the accompanying drawings, wherein:

Figure 1 is a plan view from above of a panel, according to the invention;

Figure 2 is a cross-sectional schematic view of the panel in Figure 1 taken along a plane at right angles to the covering slab;

Figure 3 is an enlarged scale perspective view of the panel in Figure 1;

Figure 4 is a perspective view of two panels during the laying step, according to the invention;

Figure 5 is a schematic view of a base layer of the panel during a machining step, according to the invention;

Figure 6 is a schematic view of the base layer in Figure 5 to which a layer of adhesive is applied, according to the invention;

Figure 7 is a schematic view of the panel during a final compression step, according to the invention.

[0023] With reference to the figures, the prefabricated insulation panel, particularly for covering buildings, generally designated by the reference numeral 1, comprises a base slab 2 made of insulating material and a covering slab 3 made of a fibrous material. The slabs 2, 3 which are substantially quadrangular, are connected to each other and respectively define, on two opposing faces 4, 5 which are not connected to each other, a laying surface 6 and a visible surface 7.

[0024] Advantageously, the panel 1 has, along its perimeter, a plurality of lowered band portions 8 which have a substantially smaller thickness than that of the remaining, non-lowered central portion 9 of the panel 1.

[0025] According to the invention, the panel 1 comprises at least two band portions 10 of the plurality of lowered band portions 8, not mutually consecutive, which are provided on one side with at least one rectilinear guide 11 which, conveniently, runs along the entire length of the panel 1.

[0026] In more detail, the guide 11 has a substantially curvilinear profile along a plane that is substantially perpendicular to the covering slab 3 and is specifically perpendicular to the direction of extension of the guide 11. The panel 1, furthermore, has a thickness along the guide 11 that is substantially identical to the thickness that can be measured in the central portion 9.

[0027] The covering slab 3, which is provided with the guides 11, is composed of polypropylene and a fibrous material comprising an aggregate system of fibers chosen from the group comprising fiberglass, corn fibers or hemp fibers. In this particular embodiment the covering slab 3 is composed of fiberglass-reinforced polypropylene.

[0028] As well as the guide 11, the covering slab 3, particularly on the visible surface 7, is provided with geometric irregularities 14 in relief on the plurality of lowered band portions 8, and a grid 15, also in relief, on the central portion 9.

[0029] Advantageously, the covering slab 3 is provided with at least one first gripping layer 12 arranged on the visible surface 7 and at least one second gripping layer 13 on the opposing face to the visible surface 7, i.e. on the face interposed between the covering slab 3 and the base slab 2.

[0030] Furthermore, interposed between the two slabs 2, 3 is a layer of polyurethane-based adhesive 16; specifically the layer of adhesive is interposed between the second gripping layer 13 and the base slab 2.

[0031] The gripping layers 12, 13 are thin and light and are composed of non-woven fabric or polyethylene terephthalate.

[0032] The layers are advantageously covered by antipyretic additives, known to the technician skilled in the art, or by amorphous technopolymers like polyetherimide, commonly known as ULTEM®.

[0033] Lastly, the base slab 2 comprises an insulating material chosen from the group comprising rock wool, wood fiber, polystyrene with or without graphite, cork, wood-cement or recycled rubber.

[0034] The panel 1, thus described, is brought to the place of installation and firmly fixed by means of nails or inserts 19 that are known to the technician skilled in the art and illustrated in Figure 4.

[0035] Advantageously, the nails or inserts 19 are accommodated between the corners of the panels, so as to be able to fix four corners of four panels with a single head of an insert.

[0036] Conveniently, the panels 1 have a central depression 20 in order to accommodate the head of a further insert and firmly fix the panels 1 to the wall.

[0037] Subsequently the grid is laid on the plurality of lowered band portions 8, which acts as a grip for laying the plaster. Smoothening the laid plaster is extremely rapid given that, advantageously, the operator positions the spatula, or any other device adapted to smoothening, on the lateral guides 11 and quickly removes the excess plaster located on the lowered band portions 8 in a single pass and perfectly coplanar with the central portions 9 of the adjoining panels.

[0038] Similarly, the central depression 20 is also covered by plaster, or mortar, and the excess plaster is rapidly removed, by considering the central portion 9 of the panel 1 as a reference or guide.

[0039] Advantageously, the presence of at least one first gripping layer 12 on the covering slab 3 facilitates the adhesion of the finishing mortar to the panel 1.

[0040] The method for making the panel according to the invention comprises a step of providing the base slab 2 made of insulating material and a step of providing the covering slab 3 which comprises polypropylene and fibrous material, and is provided, on a visible surface 7 and on an opposing face 5 to the visible surface 7, with at least the first and the second gripping layer 12, 13.

[0041] The covering slab 3 is subjected to a step of forming under a partial vacuum, which takes place in a special heated press in which the temperature interval can fluctuate between 180° Centigrade and 300° Centigrade.

[0042] The forming step makes it possible to obtain, due to a base shape (not shown), a specific geometric shape of the covering slab 3, in particular the central portion 9 upon which the grid 15 is in relief which, in the embodiment shown, is comprised by a grille of squares; other, different shapes in relief are not ruled out, however.

[0043] Advantageously, the covering slab 3 is perimetrically provided with the plurality of lowered band portions 8 which, with respect to the central portion 9, are arranged on a plane that is parallel and slightly lowered. Between the central portion 9 and the plurality of lowered band portions 8 a connection with curvilinear profile is provided. In particular, on two non-consecutive sides of the central portion 9, the connection proceeds in a linear fashion until the end of the panel 1, thus defining the guide 11.

[0044] During the step of forming, the adjustment of the temperature and the time for which the temperature is applied, as well as the pressure applied, define the final thickness of the covering slab 3, preferring a slab of limited thickness for extremely resistant bodies and a slab of greater thickness for extremely sound-absorbent bodies.

[0045] The covering slab 3 thus formed is subjected to a step of perimetric cutting that can be advantageously executed by milling cutters, by shears applied directly to the forming die, or by means of devices of known type that execute water-jet cutting.

[0046] Subsequently, the base slab 2 is also subjected to a machining step that is adapted to obtain the central part 17 that is elevated with respect to the plurality of strips 18 arranged perimetrically and on a plane that is substantially parallel to and lowered with respect to the central part 17.

[0047] Advantageously, this machining can be done with digitally-controlled machines on which adapted milling cutters are installed, as shown in Figure 5, which are adapted to the specific machining of the insulating materials.

[0048] The geometric shape obtained on the base slab 2 matches with the covering slab 3. In addition, on an opposing face of the base slab 2 to the laying surface 6, a step of spreading the layer of adhesive 16 is executed. The polyurethane-based adhesive 16, specifically polyol and isocyanate, is sprayed by adapted nozzles uniformly on the central part 17 and on the plurality of strips 18, as shown in Figure 6.

[0049] There follows a step of adhesive overlaying between the central portion 9 and the central part 17 and between the plurality of lowered band portions 8 and the plurality of strips 18.

[0050] The final compression step is executed in a dedicated press where a determined pressure is applied directly to the covering slab 3 and consequently to the base slab 2.

[0051] The compression step can last for almost an hour, but the compression time can be drastically reduced to a few minutes if the press used is conveniently heated.

[0052] In the embodiment shown, the press is heated with oil with a temperature that fluctuates from 50°-60° Centigrade.

[0053] Advantageously, the presence of at least one second gripping layer 13 facilitates the adherence of the layer of adhesive 16 to the covering slab 3.

[0054] In practice it has been found that the prefabricated insulation panel, particularly for covering buildings, according to the invention, achieves the intended aim and objects since it makes it possible to obtain an external surface that is completely planar, without imperfections and without deformations.

[0055] Another advantage of the panel according to the invention consists in that it is particularly resistant to accidental impacts both during the step of transport and laying and also after installation, and it is low in weight.

[0056] A further advantage of the panel according to the invention consists in that it has a geometric reference that speeds up the smoothening of the plaster.

[0057] It should be noted that the final geometry of the covering slab, thus described, confers a particular resistance to the panel. In particular, the grid 15 in relief distributes the mechanical forces applied to the panel 1 over all of the central portion 9, and conveniently the profile of the guides 11 with curvilinear profile, i.e. free from corners, does not concentrate the forces applied to the band portions 10 directly at a single point, but instead distributes the forces over all of the profile, thus making all of the covering slab 3 particularly resistant, notwithstanding its thickness of just a few millimetres.

[0058] Furthermore, the panel 1 does not have residual tensions that are adapted to deform the visible surface 7, given that the base slab 2 geometrically conforms to the covering slab 3 thanks to the removal of excess material and not because of pressure of the insulating material.

[0059] Due to the geometry of the covering slab 3 and the materials used, the panel 1 is particularly light and resistant, so as to be capable of being used for different uses than the known technique of "coat" insulation. Conveniently the panels can be installed on the inner surface of walls without requiring further protective layers, such as for example plasterboard walls, thanks to the particular surface resistance, or advantageously they can be applied to ceilings, thanks to their particular lightness, as an acoustic aid.

[0060] The panel, thus conceived, is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims.

[0061] In addition, all the details may be replaced by other, technically equivalent elements.

[0062] In practice the materials employed, provided they are compatible with the specific use, as well as the contingent dimensions and shapes, may be any according to the requirements.

[0063] Where the technical features mentioned in any claim are followed by reference numerals and/or signs, those reference numerals and/or signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference numerals and/or signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference numerals and/or signs.

Claims

1. A prefabricated insulation panel (1), particularly for covering buildings, comprising a base slab (2) made of insulating material and a covering slab (3) made of fibrous material, said slabs (2, 3) being substantially quadrangular, connected to each other and respectively defining, on two opposing faces (4, 5) which are not connected to each other, a laying surface (6) and a visible surface (7), said panel (1) being provided perimetrically with a plurality of lowered band portions (8) which have a substantially smaller thickness than that of the remaining central portion (9) of the panel (1), characterized in that it comprises at least two band portions (10), non-consecutive, which have at least one guide (11) that runs along the entire length of the panel (1), said covering slab (3) having on said visible surface (7) at least one first gripping layer (12).

2. The panel (1) according to claim 1, characterized in that said at least one guide (11) defines one side of said central portion (9) and said panel (1) has a substantially identical thickness between said at least one guide (11) and said central portion (9).

3. The panel (1) according to claim 1 and 2, characterized in that said at least one guide (11) has a substantially curvilinear profile along a plane that is substantially perpendicular to said covering slab (3).

4. The panel (1) according to claim 1, characterized in that it comprises at least one second gripping layer (13) interposed between said base slab (2) and said covering slab (3).

5. The panel (1) according to claim 1, characterized in that said base slab (2) is made with at least one material chosen from the group comprising rock wool, wood fiber, polystyrene with graphite, polystyrene without graphite, cork, wood-cement, recycled rubber.

6. The panel (1) according to claim 1, characterized in that said covering slab (3) comprises polypropylene.

7. The panel (1) according to claim 1, characterized in that said covering slab (3) comprises an aggregate system of fibers chosen from the group comprising fiberglass, corn fibers, hemp fibers.

8. The panel (1) according to one or more of the preceding claims, characterized in that said at least one first gripping layer (12) and said at least one second gripping layer (13) are made with a material chosen from the group comprising non-woven fabric and polyethylene terephthalate.

9. The panel (1) according to claim 1, characterized in that said plurality of band portions (8) has geometric irregularities (14) in relief and said central portion (9) has a grid (15) in relief that corresponds to said visible surface (7).

10. The panel (1) according to one or more of the preceding claims, characterized in that it comprises a layer of adhesive (16) between said base slab (3) and said at least one second gripping layer (13), said layer of adhesive (16) comprising a polyurethane-based adhesive.

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

- providing a covering slab (3) comprising polypropylene and fibrous material, having on a visible surface (7) and on an opposing face (5) to said visible surface (7), at least one first and one second gripping layer (12, 13);

- forming plastically and under a partial vacuum said covering slab (3) in order to obtain a central portion (9) having a grid (15) in relief, a plurality of band portions (8) arranged perimetrically and lying on a plane that is substantially parallel to and spaced from the plane of said central portion (9), and a plurality of guides (11) interposed between non-consecutive band portions (10) of said band portions (8) and said central portion (9), said plurality of guides (11) having a substantially curvilinear profile along a plane substantially perpendicular to said covering slab (3);

- cutting said covering slab (3) perimetrically;

- machining said base slab (2) in order to obtain a central part (17) and a plurality of strips (18) arranged perimetrically and lying on a plane substantially parallel to and spaced from the plane of said central part (17);

- uniformly spreading a layer of adhesive (16) on said central part (17) and said plurality of strips (18);

- overlaying said central portion (9) so as to adhere to said central part (17), and said plurality of band portions (10) so as to adhere to said plurality of strips (18);

- compressing said base slab (2) on said covering slab (3).

12. The method for producing a panel (1) according to claim 11, characterized in that said step of forming under a partial vacuum comprises a simultaneous step of heating said covering slab (3).

Drawing