FIELD OF THE INVENTION

The present invention relates to vapour-permeable panels with improved insulation and their use in the building and construction industry. This invention also relates to wall sections comprising vapour-permeable panels.

BACKGROUND OF THE INVENTION

Conventionally, the walls (i.e. shells) of the majority of residential property such as houses and flats, industrial property such as warehouses and factories, retail property such as shop units and shopping centres, and indeed any other type of building structure, have been constructed from bricks and/or building blocks such as breeze blocks. The bricks and/or building blocks are adhered to one another using cement. Constructing buildings in this manner is a time consuming process which significantly contributes to the cost of a building. A skilled tradesman is also required in the construction of a brick wall.

A brick wall also tends to have imperfections such as slight curvatures and distortions which leads to, for example, difficulties when applying an outer finish such as render.

Furthermore, on the completion of a brick wall, the wall goes through a

'drying-out' process whereupon there may be some shrinkage in the wall which may lead to cracking and a loss of structural integrity.

The building of a brick wall may also be affected by bad weather such as frost and heavy rain. Additionally, brick walls may also be susceptible to dampness as bricks and cement have a tendency to retain moisture.

Building brick walls has the further disadvantage that brick walls are relatively heavy and require deep foundations to support the weight of a formed building. If deep foundations are required, this significantly adds to the cost of a building.

It is an object of at least one aspect of the present invention to obviate or mitigate at least one or more of the aforementioned problems. It is a further object of at least one aspect of the present invention to provide a vapour-permeable panel which may be used in the construction of a building which has improved insulation properties.

It is a further object of at least one aspect of the present invention to provide a wall section for efficiently and cost effectively constructing the framework of a building which has improved insulation properties.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a vapour-permeable structural panel comprising:

a central insulation layer having a first and second face;

a first panel attached to the first face of the central insulation layer;

a second panel attached to the second face of the central insulation layer; first and second insulation layers attached to the first and second panels; a honeycomb panel comprising a vapour membrane attached to the first panel;

an air-gap located adjacent the second panel; and

a plasterboard panel located opposite the second insulation layer.

The vapour-permeable structural panel provides improved insulation. The vapour-permeable structural panel can be used to minimise heat loss from a building. The vapour-permeable structural panel may be used in the construction of walls in buildings and may be fixed directly onto steel, timber or polymeric frames. The vapour-permeable structural panel may be highly breathable and may prevent or minimise the formation of dampness in a building.

The central insulation layer may be made of any suitable insulating material such as any one of or combination of the following: polyisocyanurate (PIR) insulation; glass wool; mineral wool; foam; cellular glass; shredded cellular fibres or expanded polystyrene. In particular embodiments the central insulation section may be made of PIR insulation. The thickness of the central insulation section may be about 20 - 200 mm and typically about 100 mm. The first and second panels may be bonded or mechanically fixed to the central insulation section. The first and second panels may be made from a honeycomb structure, a plywood or oriented strand board. The panels may be thin with a thickness of about 1 - 20 mm or typically about 6 mm.

The first and second insulating layers may be bonded or mechanically fixed to the first and second panels, respectively. Any suitable type of insulating material may be used such as any one of or combination of the following: glass wool; mineral wool; foam; cellular glass; shredded cellular fibres or expanded polystyrene. The first and second insulating layers may be about 10 - 200 mm thick and typically about 30 mm thick.

There may also be a small air gap separating the second panel and the second insulating panel.

There may also be a channel (e.g. a 'IT- channel) attached to a lower area of the second insulation layer. The channel may be made of a metal or alloy such as galvanised steel. The channel may be fixed substantially horizontally to the second insulation layer.

On the side of second insulation layer there may then be an air-gap 24. The air gap may be about 10 - 100 mm thick. The air gap may prevent or minimise any build up of condensation and may be used as an access point for any type of servicing and/or maintenance. Electric wiring may be run through the air gap.

There may then be an optional vapour check layer located on the opposite side of the air gap. The vapour check layer may prevent the ingress and penetration of any moisture into a lining layer.

The lining layer may be made of plasterboard and may be attached using mechanical means such as screws to the vapour check layer. The inner lining layer may form the inside surface of a building.

The vapour-permeable structural panel may also comprise a vapour membrane attached to a honeycomb panel (e.g. a honeycomb panel). The vapour membrane attached to a honeycomb panel may be located adjacent the first insulation layer. The honeycomb panel may be a cellular structure comprising a structural network with a plurality of interconnecting cell walls or edges. The interconnecting cell walls or edges may be welded or adhered together with, for example, a resin, glue or adhesive film. In use, vapour is capable of permeating substantially horizontally and vertically through the honeycomb panel through a series of substantially horizontally and vertically located apertures (e.g. perforations).

The honeycomb panel may be formed by applying adhesive in parallel lines onto sheet aluminium alloy. The aluminium alloy may then be perforated with needles, and cut and folded into layered sections so that the parallel lines of adhesive form a staggered pattern from one layer to another. The folded sections may then be heated under pressure to set the adhesive, and then pulled apart to form the cellular panel member. Reinforcing fibreglass layers in a "wet form" may then be applied using a heated set of rollers onto at least one or both the front and back surfaces of the cellular panel member forming the vapour membrane.

On the outer face of the plasterboard layer any suitable form of finish can be applied such as any of the following: traditional render; wet dash; acrylics; marble; terracotta; dry dash; tyrolean finishes; high build finishes; ceramics; timber and aluminium finished metal glass mirrors; stone; granite; and silicone based coatings.

The vapour-permeable structural panel may be wind and waterproof and will have a minimum life of at least 60 years. The vapour-permeable structural panel can be used for quick and easy construction with the result that the frame of a standard house may be built in a single day. As no cement is used the formed frame also does not need to go through a 'drying-out' process. The building process is also relatively unaffected by bad weather. A flat outer surface is also produced which makes it relatively easy to apply outer finishes.

The vapour-permeable structural panel may be used in the construction of walls in buildings and may be fixed directly onto steel, timber or polymeric frames. The vapour-permeable structural panel may be highly breathable and prevent or minimise the formation of dampness in a building. The vapour-permeable structural panel may also comprise grooves enabling any vapour to escape along the grooves and to exit through a drainage hole.

The panel of the present invention may have an excellent U-value (i.e. coefficient of heat transmission) of at least about 0.10 w/m ² k; at least about 0.15 w/m ² k, at least about 0.20 w/m ² k or at least about 0.25 w/m ² k.

The panel may also be very light weight with excellent acoustic performance. The panel can also be used as a structure element such as for walls, floors or ceilings. The panel may also have high fire resistance and also has a high impact resistance.

According to a second aspect of the present invention there is provided a method of providing an improved vapour-permeable structural panel comprising: providing a central insulation layer having a first and second face;

providing a first panel attached to the first face of the central insulation layer;

providing a second panel attached to the second face of the central insulation layer;

providing first and second insulation layers attached to the first and second panels;

providing a honeycomb panel comprising a vapour membrane is then attached to the first panel;

providing an air-gap is located beside the second panel; and

providing a plasterboard panel is then located opposite the second insulation layer.

The vapour-permeable structural panel may be as defined in the first aspect.

According to a third aspect of the present invention there is provided a wall comprising a vapour-permeable structural panel as defined in the first aspect. BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a sectional side-view of a vapour-permeable structural panel according to an embodiment of the present invention.

BRIEF DESCRIPTION

Generally speaking, the present invention resides in the provision of an improved vapour-permeable structural panel, generally designated 10, as shown in Figure 1. The vapour-permeable structural panel 10 minimises heat loss from a building and is in the form of a 'sandwich-type' structure. The vapour- permeable structural panel 10 may be used in the construction of walls in buildings and may be fixed directly onto steel, timber or polymeric frames. The vapour-permeable structural panel 10 is highly breathable and prevents or minimises the formation of dampness in a building.

The vapour-permeable structural panel 10 comprises a central insulation section 12. The central insulation section 12 is of any suitable insulating material such as any one of or combination of the following: polyisocyanurate (PIR) insulation; glass wool; mineral wool; foam; cellular glass; shredded cellular fibres or expanded polystyrene. In particular embodiments the central insulation section 12 is made of PIR insulation. The thickness of the central insulation section 12 is about 20 - 200 mm and typically about 100 mm.

As shown in Figure 1 , located on either side of the central insulation section 12 there are panels 14,16. The panels 14,16 are relatively thin and are bonded (e.g. glued with adhesive) or mechanically fixed (e.g. screws, bolts, pins and the like) to the central insulation section 12. The panels 14,16 are made from a honeycomb structure, a plywood or oriented strand board. The panels 14,16 are thin with a thickness of about 1 - 20 mm or typically about 6 mm. In particular embodiments the panels 14,16 are made of about 6 mm thick honeycomb panels. Located on the panels 14,16 there are then insulating layers 18,20, respectively. The insulating layers 18,20 are bonded (e.g. glued with adhesive) or mechanically fixed (e.g. screws, bolts, pins and the like) to the panels 14,16. Any suitable type of insulating material may be used such as any one of or combination of the following: glass wool; mineral wool; foam; cellular glass; shredded cellular fibres or expanded polystyrene. The insulating layers 18,20 are about 10 - 200 mm thick and typically about 30 mm thick. In particular embodiments the insulating layers 18,20 are made of 30 mm thick mineral wool.

Figure 1 also shows that panel 16 and insulating layer 20 are separated by a small air-gap 17 using spacers 19. The spacers create an air-gap 17 of a 0.5 - 10 mm or typically about 2 mm.

As shown in Figure 1 , there is a 'IT- channel 22 attached to a lower area of the insulating area 20. The 'IT- channel 22 is made of a metal or alloy such as galvanised steel. The 'IT- channel 22 is fixed substantially horizontally to the insulating layer 20. The 'IT- channel 22 can be used to allow any collected water to flow away.

On the other side of insulating layer 20 there is then an air-gap 24. The air gap 24 is about 10 - 100 mm thick. In particular embodiments the air-gap 24 is about 30 mm. The air gap 24 prevents or minimises any build up of condensation and may be used as an access point for any type of servicing and/or maintenance. Electrical wiring may be run through the air gap 24.

There is then an optional vapour check layer 26. The vapour check layer 26 prevents the ingress and penetration of any moisture into a lining layer 28.

The lining layer 28 may be made of plasterboard and may be attached using mechanical means such as screws 30 to the vapour check layer 26. The inner layer 28 forms the inside surface of a building.

On the left-hand side of vapour-permeable structural panel 10 there is a vapour membrane 32 attached to a panel 34 (e.g. a honeycomb panel 34). The vapour membrane may be a thin perforated sheet. Alternatively, the vapour membrane 32 may be in the form of a reinforcing layer which comprises a woven structure of interlacing fibres. The interlacing fibres of the woven structure may be substantially perpendicularly oriented forming a mesh-like structure. Typically, the apertures in the at least one reinforcing layer are formed in a substantially regular pattern, and may be in rows and columns between interlacing fibres of a woven structure. Alternatively, the vapour membrane 32 is in the form of a perforated polymeric material.

The panel 34 may be a cellular structure comprising a structural network with a plurality of interconnecting cell walls or edges. The interconnecting cell walls or edges may be welded or adhered together with, for example, a resin, glue or adhesive film. In use, vapour is capable of permeating substantially horizontally and/or vertically through the panel 34. This allows condensation/vapour to dissipate away.

The panel 34 may be formed by applying adhesive in parallel lines onto sheet aluminium alloy. The aluminium alloy is then perforated with needles, and cut and folded into layered sections so that the parallel lines of adhesive form a staggered pattern from one layer to another. The folded sections are then heated under pressure to set the adhesive, and then pulled apart to form the cellular panel member 34. Reinforcing fibreglass layers in a "wet form" may then be applied using a heated set of rollers onto at least one or both the front and back surfaces of the cellular panel member 34 forming the vapour membrane 32..

On the outer face of the panel 34 any suitable form of finish can be applied such as any of the following: traditional render; wet dash; acrylics; marble; terracotta; dry dash; tyrolean finishes; high build finishes; ceramics; timber and aluminium finished metal glass mirrors; stone; granite; and silicone based coatings.

The vapour-permeable structural panel 10 is wind and waterproof and will have a minimum life of at least 60 years. The vapour-permeable structural panel 10 can be used for quick and easy construction with the result that the frame of a standard house may be built in a single day. As no cement is used the formed frame also does not need to go through a 'drying-out' process. The building process is also relatively unaffected by bad weather. A flat outer surface is also produced which makes it relatively easy to apply outer finishes.

The vapour-permeable structural panel 10 may be used in the construction of walls in buildings and may be fixed directly onto steel, timber or polymeric frames. The vapour-permeable structural panel 10 is highly breathable and prevents or minimises the formation of dampness in a building.

Although not shown the vapour-permeable structural panel 10 also comprises grooves enabling any vapour to escape along the grooves and to exit through a drainage hole.

The insulating sections 12,18,20 have the advantageous effect of being able to surround the surface area of a metal frame cretin what is sometimes called a 'warm frame'.

The panel 10 of the present invention has an excellent U-value (i.e. coefficient of heat transmission) of at least about 0.10 w/m ² k; at least about 0.15 w/m ² k, at least about 0.20 w/m ² k or at least about 0.25 w/m ² k.

The panel 10 is also very light weight with excellent acoustic performance. The panel 10 can also be used as a structure element such as for walls, floors or ceilings. The panel 10 also has high fire resistance and also has a high impact resistance.

Whilst specific embodiments of the present invention have been described above, it will be appreciated that departures from the described embodiments may still fall within the scope of the present invention. For example, any suitable type of insulation and panel members can be used for the construction of the vapour-permeable structural panel 10. The different types of insulation and panel members can also be connected to one another using any form of mechanical and/or chemical means.