A subject of the invention is a method for manufacturing a vapor-permeable insulation panel and a vapor-permeable insulation panel.

The vapor-permeable insulation panel is designed for use in construction as thermal and acoustic insulation, among other things.

Polystyrene boards, pasted on the building wall, are usually used for thermal insulation of buildings, including roof insulation. Of course, other materials are also considered, such as polyurethane, cork or wood. With this type of cladding of a building wall, care should be taken to ensure that no intermediate air spaces are created where outside air can circulate and where condensation can form. However, the walls of buildings tend to be uneven so that, unless additional measures are taken, such intermediate spaces between the building wall and the flat insulating fittings are unavoidable. Therefore, such insulation cladding requires special treatment of the exterior surface of the building wall.

The various types of insulation panels and boards previously used in construction are usually characterized by either high levels of thermal insulation or high levels of fire resistance. In view of the above, the technical problem to be solved, according to the invention, is the development of such a construction of layered insulation board, which will be characterized by fire resistance, thermal insulation similar to the level achieved by insulating materials in the form of foam, with simultaneous vapor-permeability allowing the drying of the wall of the building from the outside together with layers of insulation similar to the level achieved by mineral fibrous materials.

From the international application no. W02004054799, there is known a vapor-permeable heat reflecting membrane, which is preferably an aluminum foil having numerous small gaps and cracks on its surface. A vapor-permeable material, preferably in the form of a non-woven fiber, is applied to the surface of the aluminum foil.

Polish patent description No. PL192673 entitled "Thermo- insulating board" includes a thermo-insulating board made of foamed plastic of any shape. Preferably, the thermal insulation board has a cuboid shape. A thermal insulation board having two front surfaces, preferably flat, and at least one, preferably four, side surfaces, preferably flat. The faces of the thermal insulation board are connected to each other through through-holes.

European Patent No. EP2989267 entitled "Insulating panels made of mineral wool and a concrete wall equipped with such panels" includes an insulating panel comprising a body made of mineral wool, the highest density part of which is located above the lower density part, giving high crush resistance. The body consists of two layers of mineral wool. The fibers may share the same main direction. The main direction of the two layers may be parallel to the main surface. Strong attachment of the insulating panels to the underside of the concrete slab is achieved by using a limited number of profiled grooves, that is, a number of grooves less than or equal to three per 60 cm of panel dimension perpendicular to the direction of the grooves.

From Polish patent description no. PL170894 entitled "Cladding of a building wall" includes a cladding comprising prefabricated plate profiles with thermal insulating properties whereby the thermal insulating core of a single profile constitutes a main layer of brittle foamed material. The essence of this invention is that between the thermal insulation core and the building wall, there is a layer of soft foam material closely adhering to the building wall. This layer and the insulating core - forming the body of the fitting - are connected to each other by foaming.

Polish patent description no. PL230119 entitled "Composite facade-thermal insulating panel, method of its manufacture and application of the composite facade-thermal insulating panel" includes the composite facade-thermal insulating panel constructed from three elements performing three separate functions. The composite facade-thermal insulating panel is made up of a facade panel and a frame preferably made of metal, which constitutes the load-bearing structure of the panel and is part of the system for fixing the panel to the wall of the building, which are permanently connected to each other by means of an insulating layer, the insulating layer being a plastic foam, which during the foaming process, permanently connects the facade panel and the frame. The plastic foam is PSUR polystyrene-polyurethane foam, where PSUR is a composite of two plastics: rigid polyurethane foam (PUR) and expanded polystyrene (EPS). Preferably, facade panels are such as ceramic panels, panels of natural or artificial stone, glass, metals or wood and wood or wood veneer, fiber-cement panels, plasterboard or ceramic panels.

The Polish invention application No. P.416916 entitled. "Sandwich panel and method of manufacturing sandwich panel" includes a sandwich panel with a mixed core, made of a metal cladding formed of a top sheet and a bottom sheet, and the core of the panel is formed of mineral wool, polyurethane foam and an adhesive layer. The manufacturing method of the mixed- core sandwich panel is that the lower sheet and the upper sheet are developed and profiled first. Then a layer of adhesive is applied to the lower sheet successively and a layer of mineral wool is adhered and a polyurethane foam is applied between the lower sheet bonded with the wool and the upper sheet, and the bonding of the polyurethane foam with the upper sheet and the bonding of the polyurethane foam with the mineral wool is by self-adhesion.

A disadvantage of the insulation boards used today, which are installed in the curtain walls of buildings between the building wall and the outer layer, is the inability to remove water vapor created by condensation in the cavities of the building wall. Water vapor is formed by the difference in temperature of the outer and inner curtain wall and by the penetration of moisture from the atmosphere and from weathering. Although there are well-known insulation board systems, these systems do not have the ability to remove water vapor or the removal of water vapor is not very effective once it has penetrated through the supporting layer of the wall. Used in the state of the art systems of continuous layer of polystyrene foam in the insulation layer of the building built of closely adjoining panels, which are-characterized by water vapor impermeability, which is related to the properties of polystyrene foam, is unfavorable to the durability of insulation layers. Water vapor accumulating in the airtight building (thanks to modern window systems) and coming from e.g. cooking food or the human respiratory system, penetrates the load-bearing layer of the wall and then condenses between the layer of Styrofoam and the building wall layer and through the grooves is carried away to the lower parts of the building, especially near the foundations. The inability to drain water vapor from around the foundations causes them to become damp, which in turn is the cause of the development of various types of fungi on the walls of the building. These fungi cause severe allergies and various dermatoses in humans. Humidity of walls as a result of inability of water vapor removal can be prevented by using a discontinuous layer of insulation boards, however, in this case it is not possible to avoid getting into gaps between insulation boards of mortar, which in turn causes so-called thermal bridges, and the wall built in this way does not meet the standards of heat transfer .

The purpose of the invention is to develop an insulating panel whose individual components do not require adhesive bonding, and whose level of fire resistance is characteristic of mineral fibrous materials, while achieving substantial water vapor permeability and insulating performance characteristic of insulating materials in the form of polyurethane foam or polystyrenes. An additional purpose realized by the solution according to the invention is to obtain an effect in the form of sound insulation.

The method of manufacturing a vapor-permeable insulation panel according to the invention by the process of pouring into a metal mold a mixture of expanding insulation foams over a mineral wool or ceramic wool having a density of 60 to 120 kg/m ³ , lined at the bottom of the metal mold, consists in being realized in a metal mold in the shape of a cuboid. The metal mold is constructed with a rectangular bottom, each edge of which is terminated by a vertical side that forms a vertical wall perpendicular to the rectangular bottom. The metal mold is provided with a metal cover that is applied to the upper surface of the metal mold after the interior of the metal mold is filled with mineral wool or ceramic wool and expanding insulation foam. To the inside of the metal form, mineral wool or ceramic wool with a thickness of not less than 1 cm is laid on its rectangular bottom and along not less than two vertical sides. Then, no less than 2% of the necessary volume of the expanding insulation foam is applied into the central free space limited by the layer of mineral wool by means of a mixer, filling the metal mold completely, after which, before the insulation foam volume increases completely, the metal mold is closed from above with a metal cover for the time of insulation foam curing. The insulation foam curing process takes no less than 3 minutes. The expanding insulation foam has at least 80% closed air cells.

Preferably, the mineral wool or ceramic wool layer has a thickness of 1 to 8 cm.

Preferably, before the expanding insulating foam has completely increased in volume, it is covered from above with another layer of mineral wool having a thickness of not less than 1 cm, which covers the entire surface of the expanding insulating foam, after which the metal mold is closed from above for the time of curing of the expanding insulating foam with a metal cover.

Preferably, before the expanding insulation foam is completely increased in volume, it is covered from above with another layer of mineral wool not less than 1 cm thick which covers the entire surface of the expanding insulation foam, and then another layer of expanding insulating foam is applied to the next layer of mineral wool in an amount of not less than 2% of the necessary volume of the expanding insulating foam filling the space limited from the next layer of mineral wool to the upper front surface of the metal mold, after which the metal mold is closed from above for the time of curing the expanding insulating foam by a metal cover.

The mineral wool layer of the side surfaces of the vapor- permeable insulation panel seals the two adjacent panels.

Mineral wool preferably has a thermal conductivity coefficient no greater than l = 0,038 and the self-weight load is in the range from 0,5 kN/m ³ to 1,5 kN/m ³ .

Preferably, the expanding insulation foam is an expanding polyurethane foam with a thermal conductivity coefficient l of between 0.010 and 0.030 and a density of between 25 kg/m ³ and 100 kg/m ³ .

Preferably, the method of manuf cturing a vapor-permeable insulation panel according to the invention comprises arranging mineral wool in a metal mold at the bottom and along the vertical sides, whereupon the metal mold is closed from the top with a metal cover and not less than 2% of the necessary volume of expanding insulation foam is injected inside.

The vapor-permeable insulation panel according to the invention has a substantially cuboidal shape. It consists of no less than two layers permanently connected with each other, of which one layer is mineral wool or ceramic wool, and the second layer is insulation foam in which at least 80% of the cells are closed. Preferably, the second layer is an insulating material with a low thermal conductivity coefficient. The vapor-permeable insulating panel has two preferably flat surfaces, an outer surface and an inner surface, and four preferably flat side surfaces. The inner surface of the vapor-permeable insulation panel is in direct contact with the outer surface of the insulated building wall. At least two side surfaces of a vapor-permeable insulating panel are in direct contact with other side surfaces of vapor- permeable insulating panels, creating vapor-permeable ventilation spaces in the wall built of these panels, filled completely with mineral wool.

The mineral wool layer of the side surfaces of the vapor- permeable insulation panel seals the two adjacent panels.

Preferably, the vapor-permeable insulating panel having an outer surface constructed of a mineral wool layer having mineral wool spot posts built up along the central longitudinal axis of the panel on the inner side of the outer surface, and having a permanently applied insulating foam layer on the inner mineral wool layer and around the spot posts, the mineral wool layer being lined with at least two side walls.

Preferably, one of the front surfaces of the vapor- permeable insulating panel is constructed of mineral wool, on which a layer of insulating foam is permanently applied. Another layer of mineral wool is placed on top of the insulation foam layer, on top of which another layer of insulation foam is permanently applied. A layer of mineral wool also lined at least two side walls of the vapor-permeable insulation panel.

The rigidity of the vapor-permeable insulation panel is provided by a cured foam insulation layer.

The rigidity of the vapor-permeable insulation panel obtained after curing the insulation foam makes it possible to install these panels using bridgeless fasteners placed in the joints between the vapor-permeable insulation panels, which are a layer of mineral wool. The mineral wool layer, which yields when the bridgeless fasteners are inserted, seals the installation points of the bridgeless fasteners. Bxidgeless fasteners are installed on the edges of the vapor-permeable insulation panel.

The vapor-permeable insulating panel is implemented by a layer of mineral wool or a layer of ceramic wool placed in no less than two flat side surfaces of the vapor-permeable insulating panels that are in contact with each other. The vapor-permeability of the insulation panel is also achieved by a layer of mineral wool or ceramic wool outer surface built into any part of the outer surface of the vapor-permeable insulation panel, through which water vapor passes through the mineral wool or ceramic wool towards the panel surfaces, which are perpendicular to the thickness of the insulation panels.

Advantages of the vapor-permeable insulating panel according to the invention are its fire resistance ensured by the use of fire-resistant outer layers of mineral wool or ceramic wool, vapor-permeability on parts of ventilation spaces filled with mineral wool or ceramic wool, significant rigidity of the structure of the vapor-permeable insulating panel, possibility of bridgeless assembly, better thermal insulation than insulating panels known from the prior art, as well as self-sealing during assembly. In addition, the vapor- permeable insulation panel takes advantage of the phase change in thermal flow at the material interfaces which results in an increase in thermal resistance. During the formation of the vapor-permeable insulation panel, the insulation foam is self- adhered to the mineral wool without the need for gluing the layers. The layered structure of the vapor-permeable insulation panel immobilizes the gases locked in the mineral wool layer, thus improving its insulation performance. An advantage of the vapor-permeable insulating panel is also the fact that on the side of the structural wall it is made of mineral wool or of other material with low diffusion resistance and elasticity causing the vapor-permeable insulating panel to adjust to wall irregularities

An subject of the invention is further explained in the following examples of its implementation.

Example 1.

A metal mold of cuboid shape with base dimensions of 100 cm x 60 cm and height of 20 cm was prepared. The entire bottom surface of the metal mold was lined with 5 cm thick mineral wool. The mineral wool used had a density of 60 to 120 kg/m ³ . Two side walls, one shorter and one longer, were also lined with mineral wool of the same density and 2 cm thick. A two- component polyurethane foam raw material system was poured into a multi-component mixer having separate tanks for each component of the polyurethane foam at a weight ratio of 100: 120 called PUREX WG in the amount indicated by the manufacturer and the metering agitator was turned on for 6 seconds. An expanding insulating foam was obtained. To the prepared interior of the metal form lined with mineral wool, the PUREX WG = 3% of the necessary volume of the expanding insulation foam was applied with a mixer according to the PUREX WG instructions, filling the layer 15 cm thick with vapor-permeable insulation panel. Then the metal mold from the top was closed with a metal cover, and the expanding insulation foam was cured for a period of 3 minutes. Coefficient l coefficient for the cured foam was 0.024, while for mineral wool it was 0.036. After unmolding, a vapor-permeable insulating panel with dimensions of 100 cm x 60 cm x 20 cm consistent with the panel disclosed in Fig.l and Fig.2 was obtained. After laboratory tests, the following results were obtained l = 0.02905 on the "cold" side and l = 0.02633 on the "warm" side and fire resistance in accordance with the standard for fire-resistant construction elements.

Example 2.

A metal mold was prepared as in Example 1. The bottom of the metal mold and the four side walls of the metal mold were lined with a layer of mineral wool having the parameters and thickness as in Example 1. Then the expanding insulation foam prepared as in example 1 and in the quantity as in example 1 was applied from a mixer to the so prepared metal mold lined inside with mineral wool, filling the layer 10 cm thick with vapor-permeable insulation panel. During the expansion process, a 5 cm thick top layer of mineral wool was applied to the surface of the expanding insulation foam. Then the metal mold from the top was closed with a metal cover, and the expanding insulation foam was cured for a period of 3 minutes. Coefficient l coefficient for the cured foam was 0.024, while for mineral wool it was 0.036.

After unmolding, a vapor-permeable insulation panel with dimensions of 100 cm x 60 cm x 20 cm revealed in Fig.3 and Fig.4 was obtained. After laboratory tests, l = 0.02633 was obtained and the fire resistance was in accordance with the standard for fire resistant building components. Example 3.

A metal mold was prepared as in Example 1. The bottom of the metal mold and the four side walls of the metal mold were lined with a layer of mineral wool having the parameters and thickness as in Example 1. Then, the expanding insulation foam prepared as in Example 1 was applied from a mixer to the prepared metal form lined with mineral wool in the amount corresponding to the instruction PUREX WG = 3% of the minimum necessary volume of the expanding insulation foam, filling the 15 cm thick layer of the vapor-permeable insulation panel. Then the metal mold from the top was closed with a metal cover, and the expanding insulation foam was cured for a period of 3 minutes. Coefficient l coefficient for the cured foam was 0.024, while for mineral wool it was 0.036.

After unmolding, a vapor-permeable insulation panel with dimensions of 100 cm x 60 cm x 20 cm revealed in Fig.5 and Fig.6 was obtained. After laboratory tests, l = 0.02688 was obtained and the fire resistance was in accordance with the standard for fire resistant building components.

Example 4.

At the bottom of the metal mold, along the central longitudinal axis of the metal mold along the length of 100 cm, 4 point posts made of compressed mineral wool with a sguare base of 8 cm x 8 cm were built in. The height of each post was equal to the height of the vapor-permeable insulation panel and was 20 cm. As in example 1, the bottom of the metal mold and the three side walls of the metal mold - the two longer walls and the left shorter wall are lined with a layer of mineral wool having the parameters and thickness as in example 1. Then, the expanding insulation foam prepaired as in Example 1 was applied from a mixer to the interior of the metal mold lined with mineral wool in the amount corresponding to the PUREX WG = 3% of the necessary volume of the expanding insulation foam, filling the 15 cm thick layer of the vapor- permeable insulation panel. Then the metal mold from the top was closed with a metal cover, and the expanding insulation foam was cured for a period of 3 minutes. Coefficient l coefficient for the cured foam was 0.024, while for mineral wool it was 0.036.

After unmolding, a vapor-permeable insulation panel with dimensions of 100 cm x 60 cm x 20 cm revealed in Fig.7 and Fig.8 was obtained. After laboratory tests, the following results were obtained l = 0.03020 on the "cold" side and l = 0.02966 on the "warm" side and fire resistance in accordance with the standard for fire-resistant construction elements.

After laboratory tests, l = 0.026 was obtained and the fire resistance was in accordance with the standard for fire resistant building components.

Example 5.

The bottom of the metal mold as in Example 1 was lined with a 5 cm thick layer of mineral wool. The four side walls of the metal mold were lined with a 2 cm thick layer of mineral wool. Then, the expanding foam prepared as in example 1 was applied from a mixer to the metal mold prepared in this way, to its interior lined with mineral wool. The amount of expanding foam applied was a minimum of 3% of the necessary volume of the first layer of 8 cm thick vapor-permeable insulation panel. During the expansion process, a 2 cm thick layer of mineral wool was applied to the surface of the expanding foam. On this layer of mineral wool the expanding foam prepared as in example 1 was applied from a mixer. The amount of expanding foam applied was a minimum of 3% of the necessary volume of the second layer of 5 cm thick vapor- permeable insulation panel. Then the metal mold from the top was closed with a metal cover, and the expanding foam was cured for a period of 3 minutes. Coefficient l coefficient for the cured foam was 0.024, while for mineral wool it was 0.036.

After unmolding, a multilayer vapor-permeable insulation panel with dimensions of 100 cm x 60 cm x 20 cm revealed in Fig.9 and Fig.10 was obtained. After laboratory tests, the following results were obtained l = 0.02989 on the "cold" side and l = 0.0283 on the "warm" side and fire resistance in accordance with the standard for fire-resistant construction elements.

After laboratory tests, l = 0.025 was obtained and the fire resistance was in accordance with the standard for fire resistant building components.

The subject of the invention in several variants, which do not exhaust all the construction possibilities of the vapor- permeable insulating panel according to the invention, is illustrated in Fig. 1 shows a vapor-permeable insulation panel in axonometric view disclosed in a first example embodiment, Fig. 2 depicts a cross-sectional view through the vapor- permeable insulating panel disclosed in the first example of implementation, Fig.3 depicts the vapor-permeable insulating panel in axonometric view disclosed in the second example of implementation, Fig. depicts a cross-sectional view through the vapor-permeable insulating panel disclosed in the second example of implementation, Fig.5 depicts a vapor-permeable insulating panel in axonometric view disclosed in a third example of implementation, Fig.6 depicts a cross-section through the vapor-permeable insulating panel disclosed in a third example of implementation, Fig.7 depicts a vapor- permeable insulating panel in axonometric view disclosed in a fourth example of implementation, Fig.8 depicts a cross section through the vapor-permeable insulating panel disclosed in the fourth example implementation, Fig.9 depicts a cross section through the vapor-permeable insulating panel disclosed in the fifth example implementation, Fig.10 depicts a cross section through the vapor-permeable insulating panel disclosed in the fifth example implementation, while Fig.11 depicts a building wall with the vapor permeable insulating panels disclosed in the first example embodiment, and Fig.12 depicts a building wall with the vapor permeable insulating panels disclosed in the second example embodiment.

The vapor-permeable insulating panel in the first example of implementation is constructed from a mineral wool base layer 1, on which an insulating foam layer 2 is supported. A layer of mineral wool 1 is also lined on the two side walls of the vapor-permeable insulating panel - the shorter left wall 7 and the front longer wall 9. The bottom mineral wool layer 1 and the two side mineral wool layers 1 of the vapor-permeable insulation panel are permanently and inseparably bonded to the insulation foam layer 2 as a result of penetration and curing of the expanding insulation foam 2 towards the mineral wool layers 1.

The vapor-permeable insulating panel in the second example of implementation is constructed from a bottom layer of mineral wool 1 on which is a layer of insulating foam 2 covered from above by a layer of mineral wool 1. The mineral wool layer 1 is lined with the four side walls 7, 8, 9 and 10 of the vapor-permeable insulation panel. The bottom mineral wool layer 1, the top mineral wool layer 1 and the four side mineral wool layers 1 of the vapor permeable insulation panel are permanently and inseparably bonded to the insulation foam layer 2 as a result of penetration and curing of the expanding insulation foam 2 towards the mineral wool layers 1.

The vapor-permeable insulating panel in the third example of implementation is constructed from a mineral wool base layer 1, on which an insulating foam layer 2 is supported. The mineral wool layer 1 is lined with the four side walls 7, 8, 9 and 10 of the vapor-permeable insulation panel. The bottom mineral wool layer 1 and the four side mineral wool layers 1 of the vapor-permeable insulation panel are permanently and inseparably bonded to the insulation foam layer 2 as a result of penetration and curing of the expanding insulation foam 2 towards the mineral wool layers 1.

The vapor-permeable insulating panel in the fourth example of implementation is constructed from a bottom layer of mineral wool 1, wherein along the central longitudinal axis of the panel are embedded point posts 3 made of mineral wool 1. A layer of insulating foam 2 is permanently embedded on the bottom layer of mineral wool 1 and around the posts 3. The mineral wool layer 1 is lined with three side walls of the vapor-permeable insulation panel - the shorter left side 7 and the two longer side surfaces 9 and 10. The bottom mineral wool layer 1, the three side mineral wool layers 1 and the point posts 3 of the vapor-permeable insulation panel are permanently and inseparably bonded to the insulation foam layer 2 as a result of penetration and curing of the expanding insulation foam 2 towards the mineral wool layers 1.

The vapor-permeable insulation panel in the fifth example implementation is constructed from a mineral wool backing layer 1, on which an insulation foam layer 2 is deposited. A further layer of mineral wool 1 is laid on top of the insulating foam layer 2, on which another layer of insulating foam 2 is deposited. A layer of mineral wool 1 is also lined on the four side walls 7, 8, 9 and 10 of the vapor-permeable insulation panel. The bottom mineral wool layer 1 and the four side mineral wool layers 1 of the vapor-permeable insulation panel are permanently and inseparably bonded to the layers of insulation foam 2 as a result of penetration and curing of the expanding insulation foam 2 towards the mineral wool layers 1.