Insulating element for the insulation of flat roofs

Abstract

The invention relates to a thermal insulating element comprising an insulating layer having a first face and a second face, said insulating layer comprising a coherent man-made vitreous fibre-containing insulating material and at least one reinforcing element extending substantially from the first face to the second face of the insulating layer, wherein the reinforcing element comprises a polymeric foam composite material, the composite material comprising a polymeric foam and man-made vitreous fibres produced with a cascade spinner or a spinning cup, wherein at least 50% by weight of the man-made vitreous fibres present in the polymeric foam composite material have a length less than 100 micrometers.

1 . A thermal insulating element comprising an insulating layer having a first face and a second face, said insulating layer comprising a coherent man-made vitreous fibre-containing insulating material and at least one reinforcing element extending substantially from the first fact to the second face of the insulating layer, wherein the reinforcing element comprises a polymeric foam composite material, the composite material comprising a polymeric foam and man-made vitreous fibers produced with a cascade spinner or a spinning cup, wherein at least 50% by weight of the man-made vitreous fibres present in the polymeric foam composite material have a length less than 100 micrometers. 
     
     
         2 . A thermal insulating element according to  claim 1 , wherein a top plate is disposed on at least one face of the insulating layer. 
     
     
         3 . A thermal insulating element according to  claim 2 , wherein the top plate comprises man-made vitreous fibres and binder and has a density of at least 100 kg/m 3 , such as at least 150 kg/m 3 , such as around 200 kg/m 3 . 
     
     
         4 . A thermal insulating element according to  claim 2 , wherein the top plate and the reinforcing element are bonded together without any extrinsic attachments means. 
     
     
         5 . A thermal insulating element according to  claim 1 , wherein at least 60% by weight of man-made vitreous fibres present in the polymeric foam composite material have a length less than 65 micrometers. 
     
     
         6 . A thermal insulating element according to  claim 1 , wherein at least 80% by weight of the man-made vitreous fibres present in the polymeric foam composite material have a length less than 125 micrometers. 
     
     
         7 . A thermal insulating element according to  claim 1 , wherein at least 95% by weight of the man-made vitreous fibres present in the polymeric foam composite material having a length less than 250 micrometers. 
     
     
         8 . A thermal insulating element according to  claim 1 , wherein at least 0.5%, preferably at least 1% by weight of the man-made vitreous fibres present in the polymeric foam composite material have a length less than 10 micrometers. 
     
     
         9 . A thermal insulating element according to  claim 1 , wherein the man-made vitreous fibres present in the polymeric foam composite material have an average diameter of from 2 to 6, preferably from 3 to 6 micrometers. 
     
     
         10 . A thermal insulating element according to  claim 1 , wherein the man-made vitreous fibres present in the polymeric foam composite material have a content of oxides by weight as follows:
 SiO 2  25 to 50%, preferably 38 to 48%   Al 2 O 3  12 to 30%, preferably 15 to 28%   TiO 2  up to 2%   Fe 2 O 3  2 to 12%   CaO 5 to 30%, preferably 5 to 18%   MgO up to 15%, preferably 1 to 8% or 4 to 10%   Na 2 O up to 15%   K 2 O up to 15%   P 2 O 5  up to 3%   MnO up to 3%   B 2 O 3  0 to 3%   
     
     
         11 . A thermal insulating element according to  claim 1 , wherein the reinforcing elements are shaped as columns. 
     
     
         12 . A thermal insulating element according to  claim 1 , wherein the reinforcing elements are plate-shaped. 
     
     
         13 . A thermal insulating element according to  claim 1 , wherein the polymeric foam is a polyurethane foam or a phenolic foam. 
     
     
         14 . A thermal insulating element according to  claim 1 , wherein the polymeric foam composite material comprises at least 10% by weight, preferably at least 15% by weight, more preferably at least 20% by weight of man-made vitreous fibres. 
     
     
         15 . A thermal insulating element according to  claim 1 , wherein the polymeric foam composite material comprises less than 80% by weight, preferably less than 60%, more preferably less than 55% by weight of man-made vitreous fibres. 
     
     
         16 . A thermal insulating element according to  claim 1 , wherein the polymeric foam composite further comprises an additive selected from fire retardants, such as graphite powder, and surfactants, in particular cationic surfactants. 
     
     
         17 . A thermal insulating element according to  claim 1 , wherein the insulating element comprises 4 to 20% by weight, preferably 6 to 15% by weight, more preferably 8 to 12% by weight, of the polymeric foam composite material. 
     
     
         18 . A thermal insulating element according to  claim 1 , wherein the density of the coherent man-made vitreous fibre-containing insulating material is less than 60 kg/m 3 , more preferably less than 50 kg/m 3 . 
     
     
         19 . A thermal insulating element according to  claim 1 , wherein the average density of the complete element is 30 to 100 kg/m3, preferably 40 to 80 kg/m 3 , most preferably 50 to 70 kg/m 3 . 
     
     
         20 . A thermal insulating element according to  claim 1 , wherein the thickness of the insulation element is at least 50 mm, preferably at least 100 mm, more preferably at least 120 mm. 
     
     
         21 . A roof insulation system, preferably a flat room insulation system, comprising:
 a roof support,   at least one thermal insulating element according to  claim 1  arranged on top of the roof support, and   a cover layer on top of the thermal insulating element.   
     
     
         22 . A roof insulation system according to  claim 21 , wherein the cover layer comprises a bituminous sub-layer and a top layer, the top layer being a bituminous top layer of a polymeric film, preferably a PVC film. 
     
     
         23 . A roof insulation system according to  claim 21 , wherein the roof support comprises at least one corrugated steel plate or is a concrete deck. 
     
     
         24 . A roof insulation system according to  claim 23 , wherein a water vapour barrier is arranged between the roof support and the thermal insulating element. 
     
     
         25 . A roof insulation system according to  claim 24 , wherein a man-made vitreous fibre board is arranged between the roof support and the water vapour barrier layer, said man-made vitreous fibre board preferably having a density of at least 100 kg/m 3 . 
     
     
         26 . A roof insulation system according to  claim 21 , wherein the thermal insulating element is secured to the roof support by mechanical fastening means. 
     
     
         27 . Use of a thermal insulating element according to  claim 1 , in a flat roof insulation system. 
     
     
         28 . Use according to  claim 27  in a flat roof insulation system comprising:
 a roof support, 
 at least one thermal insulating element according to  claim 1  arranged on top of the roof support, and 
 a cover layer on top of the thermal insulating element. 
 
     
     
         29 . Use according to  claim 27  in a flat roof insulation system, wherein the cover layer comprises a bituminous sub-layer and a top layer, the top layer being a bituminous top layer of a polymeric film, preferably a PVC film. 
     
     
         30 . Use according to  claim 27  in a flat room insulation system, wherein the roof support comprises at least one corrugated steel plate or is a concrete deck. 
     
     
         31 . Use according to  claim 27  in a flat room insulation system, wherein a water vapour barrier is arranged between the roof support and the thermal insulating element. 
     
     
         32 . Use according to  claim 27  in a flat room insulation system, wherein a man-made vitreous fibre board is arranged between the roof support and the water vapour barrier layer, said man-made vitreous fibre board preferably having a density of at least 100 kg/m 3 . 
     
     
         33 . Use according to  claim 27  in a flat room insulation system, wherein the thermal insulating element is secured to the roof support by mechanical fastening means.