AU600116B2 - Insulating cladding - Google Patents

Description

'14 COMMONWEA H ONE UNDRED DOLS TWENTY DOLLR

COLJMP-LETES

(ORIGINAL)

011 1044 Class Application Number: PI 01162, PI 3573 PI 05327 Lodged: 31.03.1987, 6.8.1987 1.11.1987 Cosmplete Specification Lodged: Accepted: I nt. Class bielbouxr~- Priority: Published: RFelated Art T h'is docUment contains the ~ameiidments made undt,.

cc I C C I C LCCUfl 47 am, ,lsco,rrect foir printing.j Name of Applicant: BRIAN BIALOWAS Atidress of Applicant: Actual Inventor: Address for Service: 67 Queen Street, Altona, Victoria 3018, Australia.

BRIAN BIALOWAS EDWD. WATERS SONS, 50 QUEEN STREET, MELBOURNE, AUSTRALIA, 3000.

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.1 Complete Specification for the invention entitled: INSULATING CLADDING The following statement is a full description of this invention, including the best method of performing it knowne to

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-2- INSULATING CLADDING This invention relates to improvement in partitioning for use in buildings and a method of making such partitioning.

In the building industry insulating coverings are in most cases applied separately from the cladding materials used.

Of the insulating materials used, the majority are placed between the outer frame members which are often of timber. These allow little protection to the timbers between them in the event of fire and consequently do little to stop the quick spread of the flames throughout the building nor do they provide effective moisture or vapour cc r barriers.

r tT 15 Examples of these sorts of insulation fibreglass; (ii) rockwool; (iii) cellulose fluff; (iv) lead sheet for sound insulation.

Reflective thermofoil where used is generally on the outer walls and is placed over the wooden framework of most houses, usually externally.

rrr *Installation of these types of insulation involve time and labour and often lack a satisfactory level of fire retardation sound insulation and moisture/vapour barrier.

It is an object of this invention to provide a partition or panel which overcomes these difficulties and is more economical. It is a further object of the invention to provide a panel with thermal and sound insulation properties for use in internal walls and ceilings.

i To achieve these objects, the present invention ,rr 30 provides a cladding or partition panel comprising: S. a first layer of cladding material; a second thermal insulation layer of cupped, corrugated or dimpled material forming air voids; a flat sheet forming a third layer; a fourth layer consisting of a thermal insulation layer of cupped, corrugated or dimpled material; 9- L 2a a fifth layer comprising a thermal reflective or sound insulating sheet with the reflective face outwards.

Conventional plasterboard may be used but any other suitable lining material is suitable. The reflective sheet 1, k *t9 0 t 9 9 9*49 *199 *0 9 09 9 9 9*9 0 00 0 0 990* *09049 I S 3 surface is preferably the face which faces the wall studs or when used in ceiling construction the ceiling joists.

Preferably, the reflective sheet is reflective on both surfaces and is fire rated to provide adequate fire protection to the ceiling joists and wall studs. The insulating material may also be water resistant to provide additional protection particularly where plasterboards are used. S The 1r material may be adhered at spaced intervals to the cladding material to provide air spaces between the insulating sheet and the cladding panel but .oo* without affecting the strength of attachment between the cladding panel and the insulating sheet.

*te Where a double sided reflective sheet is used the insulating and fire retardant properties of the combined panel are dramatically increased.

Where sound insulation rather than heat insulation is of importance such as in office partitioning this Sinvention provides a structure incorporating one or more *I 20 layers containing air voids interleaved with one or more sound deadening layers.

Thus the present invention provides a panel for use as partitioning or cladding comprising a support panel and a sheet of thermally reflective material and/or sound deadening material separated by at least one layer of corrugated or dimpled material providing air spaces.

The insulating layer may comprise a corrugated, dimpled, cupped or similarly treated layer which provides air spaces in the depth created by the corrugations, dimples or cups. The material may be paperboard synthetic plastic or other suitable material treated to form the necessary contoured layer.

Preferred as sound deadening layers is lead sheet.

This preferred form of construction preferably provides a corrugated sheet adhered to a surface of a cladding panel and either surface of the corrugated sheet may be reflective. A further flat sheet or liner is adhered to the corrugated sheet to form a 3 ply laminate. Either :r 7: uT---Lu 4 surface of this third layer may be reflective.

Where a partition for internal walls or sound insulation is required a preferred form comprises two corrugatel paperboard sheets with a lead sheet between as a liner bonded to each corrugated layer. A cladding panel such as plasterboard may be bonded to one or both corrugated layers. Where the plasterboard is bonded to only one corrugated layer, two such partitions may be joined to form a partition having two outer plaster board layers and three ooi 1 0 or four corrugated layers with two or three lead sheet sound deadening layers. The combination of air spaces and sound o0o0 *oo.o deadening sheets provides an effective sound insulation o panel which is relatively inexpensive to manufacture compared to conventionally constructed sound proof walls.

A reflective layer may be included as may a water barrier laver. Other suitable contoured materials can be used instead of paper board.

0, ~Fire retardants may also be incorporated in the panel components.

20 The panel of this invention make it possible for a l 0 considerable saving in time and labour to be achieved, thus making it a viable economic proposition to use the panels of this invention in all internal and external walls resulting 000000 So in savings in heating and cooling and increasing safety from 25 fire hazards or excessive moisture damage plus noise reductions.

The combined insulating sheet cladding panels of this invention may be made by any suitable method.

A preferred embodiment of this invention will now be described with reference to the drawings in which: Figures 1 and 2 are side views of panels according to two embodiments of this invention.

Figure 3 and Figure 4 schematically illustrate two steps in the manufacture of the panel shown in Figure 4.

Figure 5 is a perspective view of a partition of this invention.

Figures 1 and 2 are further embodiments of this invention which improves the insulating capacity of the combined panel.

The panel 30 may be a plasterboard or other suitable internal partitioning panel having an internal face 31 and a face 32 adapted to be oriented toward the wall studs. Adhered to face 32 is a corrugated sheet 33 bonded at flute tips 34 to the face 32. Bonded to the corrugated o sheet 33 of figure 1 at flute tips 36 is a flat sheet 10 which forms the layer in contact with the wall studs.

°o The air spaces between corrugated sheet 33 and flat sheet 35 or board 30 and corrugated sheet 33 provide 000* additional insulating capacity for the combined panel.

One or both of the corrugated sheet 33 or flat sheet 35 may be reflective on one or both surfaces to provide additional insulation properties. Ideally one or S both of the corrugated sheet 33 and flat sheet 35 may be composed of paperboard or plastic or similar material.

The construction shown in figures 1 and 2 do not require the alignment of the wall studs with the adhesion points 34 or 36 and provides protection against dust build up on the reflective surface while this is on either face of corrugated sheet 33. The corrugations on the board can be aligned either vertically or horizontally when the panel is 30 c 25 in position. In figure 2 the boardA" and corrugated sheet 33 are as shown in figure i. A sound deadening layer 38 of lead is provided as a layer between sheet 33 and a second corrugated sheet 43. Both corrugated layers 33 and 43 are bonded to the sound deading sheet 38. A liner sheet (possibly water impermeable is bonded to the corrugated layer 43). The configuration of figure 2 could also be L modified by simply utilizing a reflective sheet as the interlayer 38. Further the direction of the corrugations of layers 33 and 43 may be arranged at right instead of parallel as shown. Any other convenient form of contoured layer other than corrugated layers are also suitable.

In some applications of the present invention the i rT~ ll-- lrrr~'--n~rrrrr~-ra*a~ll~- 6 fastening of the panel to wall studs may result in deformation of the corrugations. A modification of this invention provides a means of maintaining the shape of the corrugated layer. As shown in figure 3 by extruding ribbons of a plastic substance such as adhesive or wet plaster (in the case of plasterboard) which are the height of the flutes in the corrugated sheet this may not only provide bonding between the board and the corrugated sheet but will fill up 90 the space between the flute and the board along the line of et 10 the ribbon and when the ribbon hardens, will prevent ~collapse of the corrugations.

0990 Ribbons 37 of plaster are applied from nozzles 41 30 to each board= 4 and the corrugated sheet is laid so that eoe ~the flutes lie at right angles to the plaster ribbons. In assembling the panel onto wall studs, the flutes will lie S 1, vertically and the hardened ribbons of adhesive effectively act as spacers to keep the plasterboard a flute height from I 1 Sthe stud. Further, the air spaces formed by the flutes are interrupted by the adhesive ribbons to form enclosed air spaces.

In a continuous manufacturing operation the ribbons of adhesive are applied after the plasterboard is dried.

S, Referring to figure 4 the corrugated sheet 33 and liner are unrolled from roll 40 and the roller 42 presses the corrugations into the ribbon so that the full height of each flute is filled by the ribbon.

Figure 5 is a perspective view of the partition panel of figure 2 made by the method of figures 3 and 4.

The outer layer 45 may be a reflective foil. Tests of the thermal insulation capability of panels according to this invention are set out below with the figures for A conventional plasterboard.

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Sample Thermal resistance (m 2

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Plaster, reflective corrugations 0,19 two paper corrugations, paper separator 0.21 Plaster, two paper corrugations, foil separator 0.23 t ii

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"4 7 Sound insulation where a lead sheet is used as a flat layer between two corrugated paperboard layers is as effective as conventionally hung lead sheet in fully lined internal walls. The advantage of using this invention is the savings in labour costs.

From the above it can be seen that this invention provides a labour saving means of insulating buildings and improving fire protection in a unique way.

9 9. I1 I tr t It 91 t St 949*99 4 9 45 449 4 C 4 1

Claims (3)

1. A cladding or partition panel comprising: a first layer of cladding material; a second thermal insulation layer of cupped, corrugated or dimpled material forming air voids; a flat sheet forming a third layer; a fourth layer consisting of a thermal insulation layer of cupped, corrugated or dimpled material; a fifth layer comprising a thermal reflective or ,0 'sound insulating sheet with the reflective face outwards. T

2. A panel as claimed in claim 1 in which said thermal insulation layer is corrugated and the corrugated sheet is Ssupported on the layer of cladding material by lines of support material which fill the void formed by flutes of the corrugated layer to provide spaced lines of support for the corrugated layer. I

3. A panel as claimed in claim 1 wherein the thermal insulating layer is corrugated paperboard. I DATED this 8th day of May, 1990. BRIAN BIALOWIS WATERMARK PATENT TRADEMARK ATTORNEYS, 290 Burwood Road, 7 HAWTHORN. VIC. 3122 AUSTRALIA DBM:jl(9.16) -V* C"Ri~ i "tT