FIELD OF THE INVENTION
[0001] The invention relates to construction industry, namely, to structural element of
building walls and other partition structures. More specifically, the invention relates
to an exterior wall element with excellent thermal insulation properties.
BACKGROUND OF THE INVENTION
[0002] Requirements for energy efficiency of buildings are becoming ever stricter, creating
a need for new structural solutions for exterior walls of buildings. A wide range
of materials and solutions are available for installing walls and other partition
structures, which are characterised with increased thermal insulation properties and
are also easy to manufacture without requiring any complex equipment for installation.
US9163397 describes a wall element made of several rectangular cross-section wooden bars with
insulating cavities between them, sheathing panels fixed to the bars on the outer
wall side, and insulation material filling the cavities between the bars; these insulation
materials are directed to the inside of the wall element over the entire width of
the bars. An inner side of the wall element is covered with plasterboard, which is
used for interior wall decoration. A vapour barrier creating metal foil or film is
installed between the thermal insulation and the inner side of the plasterboard.
[0003] The closest prior art is described in
Slovakian Patent No. 6285. The invention relates to a wooden wall panel, which is made of two side bars and
one central bar with attached oriented strand boards (OSB) on both sides, covered
with vapour barrier film on the inner side. The internal cavity between OSB sheets
is filled with thermal insulation made of extruded polystyrene (EPS).
SUMMARY OF THE INVENTION
[0004] The goal of the present invention is to expand the range of products intended for
this purpose by offering an alternative structural version for wall or other partition
structural elements, characterised by excellent thermal insulation properties; such
product shall be easy to manufacture in advance or
in situ without any complex construction equipment. According to the invention, the wall
element is made of plurality rectangular cross-section glued timber vertical bars
of 2000-3500 mm in height, which are arranged in a single line at a distance of 600-700
mm apart, interconnected by horizontal beams of the same cross-section, which are
attached to the top and bottom of vertical bars and together with the bars form the
frame of the wall element; this frame is covered on both sides with OSB sheets and
contains many thermal insulating air chambers between those sheets formed by rolling
continuous metallised oriented polypropylene (OPP) film multiple times up and down
parallel to the OSB sheets through the entire height and width of the vertical bars,
by maintaining a gap of 10-15 mm between the adjacent films; spacing between the adjacent
films is formed by interconnected polystyrene strips of 10-15 mm in width and 30-40
mm in height, which are fixed at the top and bottom of the frame. A vapour barrier
is additionally installed between the inner OSB sheet and the metallised film.
[0005] It has been unexpectedly discovered that such wall element has excellent thermal
insulation properties. The calculated value of heat transfer coefficient U of such
structural wall element is 0.10-0.14 W/(m
2K), depending on films used as well as number of air chambers inside the wall element.
A current valid passive house standard is granted to products with the U value not
higher than 0.15 W/(m
2K).
BRIEF DESCRIPTION OF FIGURES
[0006] Further, the invention is described with reference to the following figures:
Fig. 1 presents a perspective view of the wall element frame;
Fig. 2 is a perspective view of the wall element with unrolled OPP film in the partial
cut between the adjacent vertical bars of the frame;
Fig. 3 is a cross-sectional view through the line A-A of Fig. 2;
Fig. 4 - Fig. 15 present steps of assembly of the wall element.
DETAILED DESCRIPTION OF THE INVENTION
[0007] As shown in Fig. 1, the frame of this wall element is made of plurality of glued
timber vertical bars 1 of 2000-3500 mm in height, with preferable cross-section of
45x300 mm; bars are arranged in one line with a gap of 600-700 mm between the adjacent
bars 1. Height and number of vertical bars 1 depend on dimensions of the designed
wall. Vertical bars 1 are interconnected with the top and bottom horizontal beams
2 and 3 of the same cross-section; these beams are attached to the top and bottom
ends of vertical bars 1.
[0008] As further shown in Fig. 2 and 3, cavities between adjacent vertical bars 1 are filled
with continuous oriented metallized (OPP) film 4 which is rolled up and down multiple
times over the entire height and width of vertical bars 1, by maintaining a 10-15
mm gap between adjacent OPP films 4, thus forming many thermal-insulating air chambers
5. Gaps between adjacent OPP films 4 are formed using 10-15 mm in width and 30-40
mm in height polystyrene strips 6, which are inserted into grooves 7 between the adjacent
bars 1 and their side surfaces are interconnected with metal clamps 8. OPP films are
stretched in a way so that these OPP films would not touch each other under their
own gravity when the wall element is in a horizontal position.
[0009] Both sides of the frame are covered with oriented strand boards (OSB) 9, fixed to
the bars 1 and beams 2 and 3. On every side of the wall element, between the inner
side of the OSB sheet 9 and the first OPP film 4, an additional vapour barrier 10
is installed.
[0010] This structural wall element is assembled as follows: first of all, bars 1 are fixed
to the inner side of the first OSB panel 9, which is covered with a vapour barrier
10, by maintaining 600-700 mm gaps between the bars (Fig. 4). The height of the OSB
panel is estimated to cover the top and bottom beams 2 and 3, which will be fixed
to the bars 1 later.
[0011] The first polystyrene strips 6 are inserted into the each groove 7 at the top and
bottom ends of the adjacent bars 1 and attached to the OSB panel 9 using metal clamps
(Fig. 5).
[0012] The first end of the unrolled OPP film 4 is fixed to the first polystyrene strip
6 inserted into the first end of the bar 1 using clamps 8; then OPP film 4 is unrolled
over the entire length of the bars 1; stretched film is attached to the second polystyrene
strip 6 located in grooves 7 on the opposite ends 7 of the adjacent bars 1 using clamps
8 (Fig. 6).
[0013] Yet other polystyrene strips 6 are inserted into each groove 7 at the opposite ends
of the adjacent bars 1 on top of previously unrolled and stretched OPP film 4; both
strips are attached to the first polystyrene strips 6 with metal clamps (Fig. 7).
[0014] The OPP film 4 is rolled to the opposite end of the bars 1 thus covering both of
previously attached and fixed polystyrene strips 6 (Fig. 8).
[0015] Yet other polystyrene strips 6 are inserted into each groove 7 of the adjacent bars
1 on the opposite sides; both strips are attached to the previously installed polystyrene
strips 6 with metal clamps (Fig. 9).
[0016] The OPP film 4 is rolled to the opposite end of the bars 1 by covering both of the
previously attached and fixed polystyrene strips 6 (Fig. 10).
[0017] The process is repeated until the entire cavity between the adjacent bars 1 is filled
with OPP films 4 (Fig. 11). When the width of the bars is 300 mm, the optimum amount
of OPP films is 20-24 units.
[0018] The process is repeated until all cavities between the adjacent bars 1 are packed
with OPP films 4 (Fig. 12). The excess film 4 is cut along the sides of polystyrene
strips 6 (Fig. 13).
[0019] Then beams 2 and 3 are fixed to the top and bottom ends of the bars 1 (Fig. 14).
[0020] Finally, the frame filled with OPP films 4, is covered with the second OSB sheet
9 (the inner side of which is coated with vapour barrier 10); this results in the
final wall element depicted in Fig. 15.
[0021] As shown in Fig. 3, which is a cross-sectional view through the line A-A of Fig.
2, the thermal insulation layer of the wall element contains plurality of air chambers
5, which are formed by unrolling the OPP film multiple times up and down over the
entire length and width of vertical bars 1, maintaining 10-15 mm gaps between the
adjacent OPP films 4. The thermal insulation assessment performed in the laboratory
showed that the calculated value of heat transfer coefficient U of such structural
wall element is 0.10-0.14 W/(m
2K), depending on used films 4 as well as number of air chambers 5 inside the wall
element.
1. A wall element consisting of plurality of vertical bars (1) arranged in a single line
with gaps between them, closed from both sides with oriented strand boards (OSB) (9)
coated with vapour barrier film (10) on the inner surface, where gaps between the
vertical bars and OSB sheets are packed with thermal insulation, characterized in that the thermal insulation is made of continuous oriented metallized polypropylene (OPP)
film (4), which is rolled up and down multiple times through the entire height and
width of the bars (1) by maintaining a 10-15 mm gap between the adjacent metallized
OPP films (4) thus forming a plurality of thermal insulating chambers (5), where the
gaps between the adjacent metallized OPP films (4) are formed by polystyrene strips
(6) of 10-15 mm in width and 30-40 mm in height, which are interconnected and fixed
at the top and bottom of the bars (1).
2. The wall element according to claim 1, characterized in that the polystyrene strips (6) are inserted into grooves (7) between the adjacent bars
(1) and are connected to each other with their external surfaces with metal clamps
(8).
1. Wandelement bestehend aus einer Vielzahl von senkrechten Stäben (1), die in einer
einzigen Reihe mit Zwischenräumen dazwischen angeordnet sind und von beiden Seiten
mit Oriented Strand Boards (OSB) (9) geschlossen sind, die auf der Innenoberfläche
mit Dampfsperrfolie (10) beschichtet sind, wobei Zwischenräume zwischen den vertikalen
Stäben und OSB-Platten mit Wärmedämmung gefüllt sind, dadurch gekennzeichnet, dass die Wärmedämmung aus kontinuierlicher orientierter metallisierter Polypropylenfolie
(OPP) (4) gefertigt ist, die über die gesamte Höhe und Breite der Stäbe (1) durch
Aufrechterhalten eines Abstands von 10 bis 15 mm zwischen den benachbarten metallisierten
OPP-Folien (4) mehrfach auf- und abgerollt wird, wodurch eine Vielzahl von wärmeisolierenden
Kammern (5) gebildet wird, wobei die Zwischenräume zwischen den benachbarten metallisierten
OPP-Folien (4) durch Polystyrolstreifen (6) von 10 bis 15 mm Breite und 30 bis 40
mm Höhe gebildet werden, die miteinander verbunden und an der Ober- und Unterseite
an den Stäben (1) befestigt sind.
2. Wandelement nach Anspruch 1, dadurch gekennzeichnet, dass die Polystyrolstreifen (6) in Rillen (7) zwischen den benachbarten Stäben (1) eingefügt
und mit ihren Außenoberflächen mit Metallklammern (8) miteinander verbunden sind.
1. Élément mural consistant en une pluralité de barres verticales (1) agencées en une
seule ligne avec des espaces entre elles, fermées des deux côtés avec des panneaux
à copeaux orientés (OSB) (9) recouverts d'un film pare-vapeur (10) sur la surface
intérieure, où des espaces entre les barres verticales et des feuilles OSB sont comblés
par une isolation thermique, caractérisé en ce que l'isolation thermique est constituée d'un film continu orienté de polypropylène métallisé
(OPP) (4), lequel est roulé vers le haut et vers le bas plusieurs fois sur toute la
hauteur et la largeur des barres (1) en maintenant un espace de 10 à 15 mm entre les
films OPP métallisés (4) adjacents, formant ainsi une pluralité de chambres d'isolation
thermique (5), où les espaces entre les films OPP métallisés (4) adjacents sont formés
par des bandes de polystyrène (6) de 10 à 15 mm de largeur et de 30 à 40 mm de hauteur,
lesquelles sont interconnectées et fixées sur le haut et sur le bas des barres (1).
2. Élément mural selon la revendication 1, caractérisé en ce que les bandes de polystyrène (6) sont insérées dans des rainures (7) entre les barres
adjacentes (1) et sont reliées entre elles par leurs surfaces extérieures à l'aide
de fixations métalliques (8).