Insulation system for covering a facade of a building

Abstract

This invention relates to an improved insulation system for covering a façade of a building consisting of at least one insulation element ( 3 ), at least one mechanical fastener ( 4 ), which fastener fixes the insulation element ( 3 ) to the façade ( 2 ) of the building, and a rendering system ( 5 ) being arranged on the outer surface of the insulation element ( 3 ) whereby the insulation element has at least a first and a second layer being connected to each other; whereby the first layer being directed to the façade having a bulk density being lower than the bulk density of the second layer and whereby at least one layer is made of mineral fibres, especially stone wool fibres and a binding agent, or of cellular plastic, especially expanded polystyrene (EPS). To achieve an insulation system which has very good insulation characteristics, which can be produced for low costs and which can be fixed to the facade of a building without causing high labour costs the insulation element ( 3 ) has a third layer ( 10 ) made of mineral fibres and a binding agent, which third layer ( 10 ) has a bulk density being higher than the bulk density of the second layer ( 9 ) and which third layer ( 10 ) has a high receptiveness and/or adhesion for the rendering system ( 5 ) without using any surface primer, coating and/or an additive.

1 . An insulation system for covering a façade of a building comprising at least one insulation element, at least one mechanical fastener, which fastener fixes the insulation element to the façade of the building, and a rendering system being arranged on the outer surface of the insulation element whereby the insulation element has at least a first and a second layer being connected to each other;
 the first layer being directed to the façade having a bulk density being lower than the bulk density of the second layer; 
 at least one layer is made of mineral fibers and a binding agent or cellular plastic, characterized in that 
 the insulation element has a third layer made of mineral fibers and a binding agent, which third layer has a bulk density being higher than the bulk density of the second layer and which third layer has a high receptiveness and/or adhesion for the rendering system without using any surface primer, coating and/or an additive. 
 
     
     
         2 . The insulation system according to  claim 1 , characterized in that the adhesion between the third layer and the rendering system has a bond strength between 0.010 N/mm 2  and 0.080 N/mm 2 . 
     
     
         3 . The insulation system according to  claim 1 , characterized in that the third layer has a bulk density of 190 kg/m 3  to 390 kg/m 3 . 
     
     
         4 . The insulation system according to  claim 1 , characterized in that at least the third layer is made of mineral fibers in an amount of 90 to 99 wt % of the total weight of starting materials in the form of a collected web and a binding agent in an amount of 1 to 10 wt % of the total weight of starting materials, whereby the collected web of mineral fibers is subjected to a disentanglement process, whereby the mineral fibers are suspended in a primary air flow, whereby the mineral fibers are mixed with the binding agent before, during or after the disentanglement process to form a mixture of mineral fibers and binding agent and whereby the mixture of mineral fibers and binding agent is pressed and cured to provide a consolidated composite with a bulk density of 190 kg/m 3  to 390 kg/m 3 . 
     
     
         5 . The insulation system according to  claim 1 , characterized in that at least the third layer is made of mineral fibers in an amount of from 24 to 80 wt % of the total weight of starting materials in the form of a collected web, an aerogel particulate material in an amount of from 10 to 75 wt % of the total weight of starting materials and a binding agent in an amount of from 1 to 30 wt % of the total weight of starting materials, whereby the mineral fibers are suspended in a primary air flow, whereby the aerogel particulate material is suspended in the primary air flow, thereby mixing the aerogel particulate material with the suspended mineral fibers, whereby the mineral fibers are mixed with the binding agent before, during or after the mixing of the aerogel particulate material with the mineral fibers to form a mixture of mineral fibers, aerogel particulate material and binding agent and whereby the mixture of mineral fibers, aerogel particulate material and binding agent is pressed and cured to provide a consolidated composite with a bulk density of 190 kg/m 3  to 390 kg/m 3 . 
     
     
         6 . The insulation system according  claim 1 , wherein the first layer of the insulation element has a bulk density of from 30 kg/m 3  to 55 kg/m 3 . 
     
     
         7 . The insulation system according to  claim 1 , wherein the second layer of the insulation element has a bulk density of from 60 kg/m 3  to 85 kg/m 3 . 
     
     
         8 . The insulation system according to  claim 1 , wherein the mechanical fastener has a screw like shaft and a plug and/or a plug plate, which plug and/or plug plate is arranged in the third layer of the insulation element in that the plug and/or plug plate is flush with the outer surface of the third layer of the insulation element. 
     
     
         9 . The insulation system according to  claim 1 , wherein the third layer of the insulation element is fixed to the second layer of the insulation element. 
     
     
         10 . The insulation system according to  claim 1 , wherein the insulation element is fixed to the facade by at least one mechanical fastener per square meter of the insulation element. 
     
     
         11 . The insulation system according to  claim 1 , wherein the binding agent of the third layer is selected from the group consisting of dry dry binders, condensation resins, acrylates, epoxy polymers, sodium silicate, hot melts of polyurethane, polyethylene, polypropylene and/or polytetrafluorethylene polymers. 
     
     
         12 . The insulation system according to  claim 1 , wherein the rendering system is a multi-layer system containing at least a base coat and a finishing coat. 
     
     
         13 . The insulation system according to  claim 1 , whereby the second layer has fibers being substantially oriented parallel to the surfaces of the second layer which are connected to the first layer and third layer. 
     
     
         14 . The insulation system according to  claim 1 , wherein the mineral fibers are stone wool fibers. 
     
     
         15 . The insulation system according to  claim 1 , wherein the cellular plastic is expanded polystyrene. 
     
     
         16 . The insulation system according to  claim 2 , characterized in that the adhesion between the third layer and the rendering system has a bond strength between 0.010 N/mm 2  and 0.030 N/mm 2 . 
     
     
         17 . The insulation system according to  claim 16 , characterized in that the adhesion between the third layer and the rendering system has a bond strength between 0.015 N/mm 2  and 0.025 N/mm 2 . 
     
     
         18 . The insulation system according to  claim 3 , characterized in that the third layer has a bulk density of 250 kg/m 3  to 320 kg/m 3 . 
     
     
         19 . The insulation system according to  claim 9 , wherein the third layer of the insulation element is glued to the second layer of the insulation element. 
     
     
         20 . The insulation system according to  claim 11 , wherein the binding agent is a dry binder selected from the group consisting of phenol formaldehyde binders, phenol urea formaldehyde binders and melamine formaldehyde binders.