GB2447375A

GB2447375A - A composite acoustic panelling system

Info

Publication number: GB2447375A
Application number: GB0810286A
Authority: GB
Inventors: Gerard Curtenat; Ludovic Hareele; Martin F Reimers
Original assignee: Dow Global Technologies LLC
Current assignee: Dow Global Technologies LLC
Priority date: 2007-09-21
Filing date: 2008-06-05
Publication date: 2008-09-10
Also published as: GB0810286D0

Abstract

A method of manufacturing a composite system involves adhering a panel to a surface of a building structure, using a foam adhesive applied in such a pattern that at least a portion of the air layer between the surface of the building structure and the panel is entrapped and thus separated from the surrounding air. Pressure equalization between adjacent panels may be provided for. The adhesive may be applied in strips and may be provided as a closed loop or as zigzag strips. A covering or finishing system may be provided over the panel. The panel may be a gypsum plasterboard laminate. The covering layer may comprise a render layer. The dynamic stiffness of the system and the dynamic modulus of elasticity of the system are of significance.

Description

IIectuaI D.iperty Office For CreatrvIy an nnOvaIOn Application No.

GB0810286.5 RTM Date:4 August 2008 The following terms are registered trademarks and should be read as such wherever they occur in this document:

INSTA STIK

STYROFOAM

UK Intellectual Property Office is an operaling name of The Patent Office

USE OF A FOAM ADHESIVE FOR INTERIOR BUILDING INSULATION

FIELD OF THE INVENTION

The present invention relates to a method for manufacturing a composite system by adhering one or more panel(s) to a surface of a building structure, preferably for interior fmishing or interior insulation purposes, wherein a foam adhesive is applied in a defined pattern or patterns, one of them being that at least a portion of the air layer between the surface of the building structure and the panel is entrapped and thus separated from the surrounding air.

The present invention further relates to a composite system manufactured according to the inventive method and to the specific use of a foam adhesive when manufacturing a composite system useful for the interior finishing or interior insulation of a surface of a building structure.

BACKGROUND OF THE INVENTION

Interior finishing or interior insulation composite systems and construction techniques therefore were known in the art. In general, these systems comprise a panel, for example a plasterboard laminate typically made of a foam insulation material, like expanded polystyrene (EPS), extruded polystyrene foam (XPS), mineral fiber or PU foam, and an adhesive system which is normally a standard mineral-based adhesive system. The standard * * mineral-based adhesive systems currently used to adhere plasterboard laminates are cement-based and are applied in dots. These adhesives have a relatively high weight having an effect on transportation costs and have a relatively short curing time having an effect on the : : : .25 installation process of the insulation and finishing composition system. Furthermore, these *:. adhesives require spreading the cement adhesive dots with relatively high force onto the plasterboard laminate. However, when using softer insulation material, such as elastified ::: EPS, the insulation material can be damaged if the spreading force is too high. Furthermore, * cement dots when cured are very rigid and act as a sound bridge in the wall and the adhered plasterboard laminate. This is particularly critical for sound insulation when a rigid insulation product which has no sound insulation properties, like XPS, PUR, PIR, is laminated to a plasterboard.

A further main problem which is accompanied with interior insulation systems is that there exists a significant condensation risk. When an exterior wall is insulated from the inside then the wall will be on the cold side of the insulation, meaning the wall will be cold itself.

If air circulation behind the insulation, i.e. between insulation and the wall, is not properly suppressed then humidity will be carried into this cavity behind the insulation and may cause condensation on the wall. This accumulation of humidity will consequently cause damages and mould formation. In addition this air circulating behind the insulation will negatively affect the thermal performance of the system. Therefore, it is required to have the boards properly sealed around the circumference. This requires additional attention to details during the installation process of the composite system. Insulation of exterior walls from the inside is broadly practiced e.g. in France, but this method is also particularly used in renovation projects of old historical buildings where the façade must not be changed, where inside insulation remains the only solution.

So, in the light of the above mentioned properties of currently used cement based adhesives there is a need for a composite system which requires an easy installation process, which avoids the risk of damages when applying the adhesive to the panels which have to be adhered to a wall or the like, and which provides good acoustic properties and good impact resistant properties in case rigid panels are used for the manufacturing of the composite system. It is a further object of the invention to provide a composite system having * *, improved insulation properties, especially when the composite system is used for the * interior insulation of a building. S... * * * S*S

::::. 25 Furthermore, since mortar based adhesives are usually quite thick, e.g. 2 cm, it would be an *:. additional benefit if the new system would be of a thinner thickness and then, e.g. in case of * building renovation, allows to save living surface. However, especially in renovation, thicker adhesive layers may often be necessary because of uneven base wall structure.

* Therefore, it would be desirable if the new system allows this also.

DETAILED DESCRIPTION OF THE INVENTION

The above object of the present invention is met by a method for manufacturing a composite system by adhering one or more panel(s) to a surface of a building structure, the method comprising the steps of: a) providing one or more panel(s) and a surface of a building structure on which the panel(s) is/are to be adhered, the surface being selected from the group consisting of a wall, floor and ceiling, b) applying a foam adhesive in individually appropriate patterns i) to each of the one or more panel(s), or ii) to an area of the surface of the building structure, or iii) to one or more panel(s) and an area of the surface of the building structure, c) adhering the one or more panel(s) to the surface of the building structure such that the foam adhesive is between the one or more panel(s) and building structure while retaining an air layer between the one or more panel(s) and the building structure, and d) curing the foam adhesive, wherein the pattern(s) in step b) is/are appropriate if at least a portion of the air layer between the one or more panel(s) and the building structure is entrapped and thus separated from the surrounding air.

The inventive combination of using a foam adhesive and applying this foam adhesive in an appropriate pattern wherein the pattern is considered as being appropriate if at least a . portion of the air layer between the surface of the building structureand the panel is entrapped and thus separated from the surrounding air provides desirable properties for insulation properties, acoustic performance, easiness of manufacturing the composite 25 system, and allows a careful handling of the panels when adhering them to the surface of the building structure. The insulation performance improvement is because the entrapped air is * *** *: separated from the surrounding air whereby circulation of humidity from the warm inside of the building to the cavity behind the insulation panel is suppressed. The suppression of circulation of humid air avoids the accumulation of humidity behind the panel and avoids consequently damages and mould formation.

In a preferred embodiment of the invention there is adhered more than one panel to the surface of the building structure in an adjacent manner. In this case the pattern of the foam adhesive is applied in such a maimer that pressure equalization between all or some of the adjacent panels is possible. This means, for example, that an area defined by more than one panels is separated from the surrounding air but that between the single panels defining this area air flow is possible. This, of course, requires that the gaps between the adjacent panels are sealed by appropriate means, for example by a closed render layer or by an airtight wallpaper in order to avoid air flow through the gaps into the cavities behind the insulation panels.

In a particularly preferred embodiment of the invention the panel used for the composite system is an interior fmishing or interior insulation panel adhered to the interior surface of a building structure. As mentioned above the possibility to apply the foam adhesive in an appropriate pattern to the panel or the wall offering the possibility to entrap at least a portion of the air layer between the surface of the building structure and the panel and thus separating from the surrounding air is a superior advantage which is especially relevant when the finishing or insulation has to be performed in the inside of the building structure.

This is due to the fact that warm humid air from the inside of the building structure circulates to the compartment between the panel and the inner side of the outer wall which is cold resulting in condensation of the humid air which may cause damage and mould formation in case the circulation to behind the panel is not suppressed. * S.

:::::: In a particularly preferred embodiment of the invention the foam adhesive is selected from the group comprising silicone adhesives and hot melt or cold melt adhesives, polyurethane ::. 25 foam adhesives, polyurethane one-component foam adhesives, and 1NSTA-STll( brand *. polyurethane adhesive from The Dow Chemical Company (INSTA-STIK is a trademark of The Dow Chemical Company) or is based on the afore-mentioned adhesives. S... * S * ..*

S

Furthermore, the acoustic performance of the composite system can be improved if the foam adhesive which is used has a low dynamic modulus of elasticity Ed (see below for more details) which means that the adhesive is flexible or soft. In this case the foam adhesive decouples the panel, which is preferably a rigid board, acoustically from the building structure. This can be understood when one imagines a mass-spring-mass system as explained below. Furthermore, the flexibility of the adhesives also enhances the impact resistance, especially if a rigid board is used as panel. Further advantages are involved in with the present invention and are mentioned below when discussing the preferred embodiments of the invention.

The mass-spring-mass principle is a well known physical principle. It can be illustrated by two steel balls separated through a spring. If one takes this system up by holding one ball and slowly moving it up and down, both balls will move at the same speed. When increasing the moving frequency, both balls will hit at a certain frequency (i. e. the "resonance frequency"). This is, for example, known when soldiers walk in a defined walking frequency over a bridge which could cause collapse of the bridge. Now, moving the balls quicker and quicker it will become obvious that the movement of the second ball will be more and more reduced which means that the system becomes decoupled. Transferring this principle to the inventive system, the first mass is the building wall, the foam adhesive represents the spring and the rigid board represents the second mass. Depending on the hardness of the spring, the resonance frequency will be higher or lower. The lower the dynamic stiffness S', the lower the resonance frequency will be. The lower the resonance frequency, the better the acoustic decoupling function.

The measurement of the dynamic stiffness S' of a material is defmed according to EN29052- * * 1. According to this standard, the dynamic stiffness S is defmed as the quotient of the dynamic modulus of elasticity Ed>,, divided by the thickness of the substrate and the lower the dynamic stiffness, the better the acoustic performance is going to be. * ** * * * S...

*:. With respect to the sound dampening properties of the composite system manufactured by * the inventive method it is preferred that the foam adhesives after the steps of adhering and curing has a dynamic modulus of elasticity Ej of less than 1.5 N/mm2, preferably of less than 1.2 N/mm2, more preferably less than 1.0 N/mm2, even more preferably less than 0.8 N/mm2 and most preferably of less than 0.6 N/mm2.

As mentioned above the dynamic stiffness S is defined as a quotient of the dynamic modulus of elasticity E divided by the thickness of the related mass. Therefore, in a preferred aspect of the invention the panel is a rigid board and the whole composite system has a dynamic stiffness after the steps of adhering and curing of less than 250 MN/rn3, preferably less than 200 MN/rn3, more preferably 150 MN/rn3, even more preferably 100 MN/rn3, and most preferably of less than 70 MN/rn3.

In case that a rigid board is used which provides only a little contribution to the dynamic modulus of elasticity to the whole composite system the dynamic modulus of elasticity of the whole composite system is virtually identical with the dynamic modulus of elasticity of the foam adhesives.

The correlation between the dynamic stiffness S' of the composite system, of the foam adhesive and of the rigid board is as follows: 1/S'totai = (1/Soar,i + 1/S'acsive).

As it is apparent from this correlation the contribution of the rigid board having very high degree of dynamic stiffness (i. e. being very rigid) is very small compared to the contribution of the dynamic stiffness of the foam adhesive. The dynamic modulus of an elasticity which is selected to define the foam adhesive properties directly correlates with the dynamic stiffness via the formula: = S' thickness. * ..

In the preferred embodiments of the invention the appropriate pattern which entraps at least a portion of the air layer between the surface of the building structure and the panel in the ::::. 25 fmished composite system comprises one or more strips of the applied foam adhesives.

*:. These strips of applied foam adhesives constitute a barrier which at least reduces or even suppress the circulation of humid air within or into the compartment between the panel and S...

the surface of the building structure.

In a particularly preferred embodiment the pattern comprises at least one Continuous enclosed strip of the applied foam adhesive near the circumference of the panel. In this embodiment the applied foam adhesive fully suppresses circulation of humid air from the inside of the building into the compartment which is enclosed behind the panel and the surface of the building structure.

Additionally, the pattern may comprise one or more zigzag strips of the applied foam adhesives in the center of the panel. These zigzag strips further suppress the circulation of air within the compartment which is entrapped behind the panel, especially in case that a continuous enclosed strip of the applied foam adhesive is near the circumference of the panel.

The width of the strips is typically up to 8 cm, preferably 1-6 cm, and more preferably 2-5 cm.

In any case the foam adhesive covers less than 100%, preferably 5 to 80%, more preferably to 70%, and most preferably 30 to 60% of the surface of the panel. It is preferred to not cover the entire back side surface of the panel with the foam adhesive in order to save adhesive material and to reduce installation costs. In case that sound dampening is an issue it is desirable to use a foam adhesive having a dynamic modulus of elasticity as low as reasonably possible in order to save as much as possible of the foam adhesive. The lower the dynamic modulus of elasticity of the adhesive andIor the thicker the layer of foam adhesive that is applied to the rigid board, the lower is the dynamic stiffness of the layer defined by the foam adhesive as well as the lower is the dynamic stiffness of the whole *: : :* composite system.

As mentioned above, the foam adhesive may be any kind of silicon adhesives and the like, ::::. 25 but preferably a polyurethane one-component foam adhesive. In order to permit a safe and *:. proper application of the foam adhesive onto the surface of the building structure or the panel all of the aforementioned uncured adhesives should have sufficient bond strength with I...

the substrate and an appropriate viscosity so that the applied uncured adhesive will not drop *..: or drain off from the panel, wall or ceiling.

Now, in order to achieve the desired dynamic modulus of elasticity, Ed, of the composite system the foam adhesive is typically applied to the panel or the surface of the building structure, respectively, in a thickness so that after the steps of adhering and curing the layer defined by the foam adhesive has a thickness of 1-30 mm, preferably 1-20 mm, more preferably 2-15 mm, and most preferred 2-10 mm.

In a preferred embodiment of the invention the curing time of the foam adhesive is such that the step of adhering the panel may start 1-15 minutes, preferably 1-10 minutes, more preferably 2-8 minutes, and most preferably 3-6 minutes, after the step of applying the foam adhesive to the wall, floors, ceiling or panel, respectively, has been finished. The step of curing lasts normally 5-30 minutes, preferably 10-25 minutes, and more preferably 15-20 minutes.

Typically, the panel is held in place by appropriate means during the step of curing.

Appropriate means for holding the panel in place may be a bar, or the like.

The panel used according to the inventive method may be either a rigid board or a non-rigid product. In case a rigid board is used it is selected from the group comprising XPS boards, EPS boards, XPS plasterboard laminates, EPS plasterboard laminates, mineral fiber plasterboard laminates, chip boards, any kind of wooden boards, boards made of plastics, metal sheets and boards, any kind of laminate boards, and oriented strand boards (OSB); preferably XPS boards.

In case a non-rigid product is used as panel it is selected from the group comprising mineral * ** wool, elastified EPS, wood fiber and hemp. S... * . *

: ** 25 In case that a good impact resistance is an issue the composite system, according to the *.

invention, comprises a rigid board as the panel preferably having a compressive strength of more than 80 kPa, more preferably more than 100 kPa, even more preferably more than 150 S...

kPa, and most preferably more than 200 kPa. S. * * .. * *.

Then the rigid board preferably has a thickness of 1 to 300 mm. in one aspect of the invention the rigid board may be an insulation board having a density of less than 500 kg/rn3. In this case the rigid board may have a thickness of 10 to 300 mm, preferably of 20 to 200 mm, more preferably of 30 to 150 mm, and most preferably of 40 to 100 mm.

Insulation boards may have thermal and/or acoustic insulating properties. Examples for such boards are XPS boards, EPS boards, XPS plasterboard laminates, EPS plasterboard laminates or the like. A preferred rigid board used as a component of the inventive composite system is an XPS board, especially due to its rigidity.

In another aspect of the invention the rigid board has a density of 500 kg/rn3 or more. in these cases, thermal insulation is typically not an issue or may be an issue of lesser priority.

Typical examples for rigid boards having a higher density are wood particle-boards, any kind of wooden boards, boards made of plastics, metal sheets and boards, any kind of laminate boards, and oriented strand boards (OSB). However, also XPS boards, EPS boards, and the corresponding plasterboard laminates may be useful examples if these boards have higher densities. In these cases the rigid boards may have a thickness of 1 to 50 mm, preferably of 2 to 40 mm, more preferably of 3 to 30 mm, and most preferably of 4 to 20 mm.

In a further embodiment of the invention, the composite system is especially useful for acoustic insulation of the inner surface of a building structure and the panel is a rigid board, i.e. a plasterboard laminate, comprising: a) a plaster board, preferably a paper faced gypsum * board, having a thickness of 4 to 20 mm, preferably of 8 to 16 mm, and b) a rigid insulation board having a thickness of ito 20 cm, preferably of 2 to 15 cm, more preferably of 3 to 12 cm. This is a type of insulation system which is predominant in some locations (e.g. France) : *, 25 where it is fixed to the inner side of a building wall which faces the outside. In such a system the same acoustic principles will apply as explained above.

In a further aspect of the invention a covering layer covers the front side of the panel. The * covering layer may be selected from the group comprising a render layer, a metal layer, a wooden layer, a plastic layer or a composite layer. The covering layer may be applied to the panel before or after the installation of the composite system. In case that the covering layer is a render layer it is preferred to apply the render layer after the panel has been installed in order to have the opportunity to close the gaps between two or more adjacent panels.

In an alternative aspect of the invention the composite system may further comprise a finishing system which covers the front side of the panel. The finishing system may comprise a Layer selected from the group comprising a render layer, a wall paper layer, and a textile layer. The render layer again may comprise a first render layer, a reinforcement mesh layer, and a second render layer wherein each of said layers may have a thickness of independently typically 1 to 5 mm, but such thickness can be more. In a preferred embodiment the first and/or the second render layer is a cement-or gypsum based render layer and more preferably a polymer modified cement-or gypsum based render layer while the reinforcement mesh layer is preferably a polymer coated glass-fiber mesh fabric having a weight of 100 to 220 g/m2, more preferably having a weight of 140 to 180 g/m2.

In preferred embodiments of the invention the covering layer or the fmishing system may have a thickness of 0.5 to 20 mm, preferably 0.5 to 15 mm, more preferably of 1 to 10 mm and most preferably of 1 to 8 mm.

In a further aspect of the invention the panel and the optional covering layer or the finishing system may have a total weight of I to 40 kg/rn2, preferably of 2 to 30 kg/rn2, more preferably of 3 to 20 kg/rn2 and most preferably of 4 to 10 kg/rn2. The involved mass of the * panel and the optional fmishing system influences the acoustic benefit which can be achieved by the composite system according to the present invention. The higher the mass * of the panel and the optional covering layer, or fmishing system, adhered by the foam ::. 25 adhesives to the, for example, building wall, the greater will be the acoustic benefit. On the *:. other hand, the higher the mass of the panel and the optional finishing system is the more weight has to be held by the foam adhesive. This could make it necessary to use anchors **.* * ** which fix the rigid board to the, for example, building wall, thereby assisting the holding *:*. force of the foam adhesive.

A further aspect of the invention is a construction comprising a) a substrate, preferably the interior surface of an exterior wall of a building structure; b) a composite system as described above which is adhered by the foam adhesive to the substrate in appropriate pattern(s) as described above; and c) optionally, one or more functional layers and/or interspaces being located between the substrate and the composite system.

EXAMPLES

Example 1:

INSTASTIKTM brand polyurethane adhesive in small cans (750 ml) was successfully used to fix EPS plasterboard laminates on a brick wall. INSTA-STIK brand adhesive was applied in strips according to a specific pattern, wherein the INSTA-STIK brand adhesive bead was applied around the perimeter of the board and in the center following a "M" shape.

The INSTA-STIK brand adhesive can be applied on the board or on the wall. See figure la and lb. Figure 2 illustrates how MAP adhesives dots are typically applied on the panel.

The width of the strips was 2 cm. The PU foam was given from 2 to 10 minutes to react before the panel was pressed on the wall. Under the effect of warpage and weight the board had a tendency to detach itself from the wall. Therefore, a bar was used to hold the panel in place until the adhesion strength was enough to keep the board in place. The bar was kept in place for up to 10 minutes. See figure 3.

Examples 2 and 3: * **

These examples relate to the acoustic and impact properties of composite systems where the *1** panel is a rigid board. The systems were prepared with the following build-ups: * ** * S * *** * Example 2 (comparative example): S..

a) 6 mm of a mineral adhesive layer, mostly cement based, with 100% of the adhesion *::::* surface covered; *: * 30 b) 8 cm STYROFOAM" LB board (STYROFOAM is extruded polystyrene (XPS) and available from The Dow Chemical Company, Midland, U.S.A.), planed product; c) Ca. 2 mm of a first cement-based render layer; d) Ca. 0.5 mm of an embedded reinforcement mesh; e) Ca. 2 mm of a second cement-based render layer; and f) Ca. 1mm of a finishing layer (colour and grain).

Example 2 represents the standard fixation of thermally insulating materials to a wall.

Example 3 (according to the invention): a) 10 mm of a foam adhesive layer (INSTA-STIK brand polyurethane adhesive, available from The Dow Chemical Company, Midland, U.S.A.). INSTA-STIK brand adhesive is a one component polyurethane adhesive having the approximate composition as follows: 10 to 30 weight % of polymethylene polyphenyl isocyanate containing 4,4'-methylene bisphenyl isocyanate at approximately 40-50 %; 30 to 60 weight % of prepolymer of 4,4'-methylene bisphenyl isocyanate and polyether polyol; chlorodifluoromethane; and morpholine, 4,4'-(oxydi-2, 1 -ethanediyl)bis). Of the foam adhesive layer, only 50% of the potential adhesion surface is covered; b) 8 cm STYROFOAM' LB board, planed product; c) Ca. 2 mm of a first cement-based render layer; d) Ca. 0.5 mm of an embedded reinforcement mesh; e) ca. 2 mm of a second cement-based render layer; and f) Ca. 1mm of a finishing layer (colour and grain).

Two specimens of each of the examples (specimens 2A, 2B, 3A, 3B) were prepared in order to test the acoustic performance and the impact resistance of the systems. * *e

The dynamic stiffness S' and the dynamic modulus of elasticity of the specimens were tested according to EN 29052-1 with the results as shown in Table 1. Dynamic stiffness is an acoustic property, measured on a special measurement device, using a vibration table, an accelerometer and an analysis tool. The top steel plate was 0.2 x 0.2 m in size and had a mass of 8 kg, with a surface weight of 200 kg/rn2. Out of the masses in the system and the measured resonance of the system the properties can be measured. The lower the dynamic * stiffness, the better the acoustic performance is going to be.

TABLE 1: Acoustic performance of the composite systems

S

Ex. specimen thickness of resonance dynamic dynamic adhesive layer frequency modulus Efj stiffness S ______ _________ (mm) (Hz) (N/mm2) (MN/mm3) 2* 2A* 6 207 2.03 338 2B* 6 174 1.43 239 _____ average 6 191 1. 73 289 3 3A 10 80.5 0.51 51 3B 10 79.0 0.49 49 ______ average 10 80 0.50 50 * comparative examples The final acoustic performance of the composite systems will depend on further element characteristics, such as the mass of the supporting wall structure, and the type and mass of render being applied. The measured properties mainly relate to the elasticity of the adhesive layer in combination with the rigid XPS board.

The impact resistance of the specimens was also tested using the method described below with the results axe shown in Table 2. The impact tests have been carried out in line with ETA0004, Guideline for European Technical Approval of External Thermal Insulation Composite Systems with Rendering, chapter 5.1.3.3. Iso 7892 is a standard referenced in ETAGOO4. During those tests an impactor with a diameter of 4 cm was dropped onto the * S. render with different impact energies. The energy levels were 3 Joules, 6 Joules and 10 *..S * . Joules.

* s. 15 TABLE 2: Impact resistance of the composite systems 558S S.. _____________ ___________ _________________ Ex. specimen # impact diameter(s) of depth of comment energy (J) indentation indentation * (cm) (mm) _____________________ 2 2A 3 2.30 1.3 circular crack 6 2.50 2.5 circular crack1 2.5 / 4.7 3.1 double circular crack2 2B* 3 2.60 1.2 circular crackt w 6 2.2 / 4.0 2.7 double circular crack2 2.3 / 4.4 3.3 double circular crack2 3 3A 3 2.10 0.8 circular crack' 6 2.0 I 2.6 2.3doubLe circular crack2 2.5 /4.0 2.8 double circular crack2 3B 3 2.20 0.7 circular crack' 6 3.2 1.8 circular crack' 2.8 / 4.4 2.9 double circular crack2 * comparative examples "Circular crack" means circular crack without damage of reinforcement mesh 2 "Double circular crack" means double circular crack without damage of reinforcement mesh The test results were consistent on all load levels. The composite systems according to the invention having a foam adhesive layer showed an average indentation of 1.88 mm and the mineral adhesive bonded systems showed an indentation of 2.35 mm, meaning 25% greater indentation. Comparing only the 3 Joule impact values, the impact depth of the mineral adhesive bonded systems was 65 % greater than the impact depth of the composite systems according to the invention using the foam adhesive. This is clear evidence for the impact strength improvement through the foam adhesive. * *. S... * * *... * .. * S S S... **.

S * S*I * S S... S. * S S * S S.

Claims

WHAT IS CLAIMED IS: I. A method for manufacturing a composite system by

adhering one or more panel(s) to a surface of a building structure, the method comprising the steps of: a) providing one or more panel(s) and a surface of a building structure on which the panel(s) is/are to be adhered, the surface being selected from the group consisting of a wall, floor and ceiling, b) applying a foam adhesive in individually appropriate patterns i) to each of the one or more panel(s), or ii) to an area of the surface of the building structure, or iii) to one or more panel(s) and an area of the surface of the building structure, c) adhering the one or more panel(s) to the surface of the building structure such that the foam adhesive is between the one or more panel(s) and building structure while retaining an air layer between the one or more panel(s) and the building structure, and d) curing the foam adhesive, wherein the pattern(s) in step b) is/are appropriate if at least a portion of the air layer between the one or more panel(s) and the building structure is entrapped and thus * 20 separated from the surrounding air. * ** *S..
2. A method according to claim 1, wherein in case of at least two adjacent panels the : *, pattern of the foam adhesive is applied in such a manner that pressure equalization e.** between all or some of the adjacent panels is possible.
3. A method according to claim 1 or 2, wherein the panel is an interior finishing or interior insulation panel adhered to the interior surface of the building structure.
4. A method according to any of the preceding claims, wherein the foam adhesive is selected from the group comprising silicone adhesives1 aftd-hot melt adhesives, of-cold melt adhesives, polyurethane foam adhesives, polyurethane one-component foam adhesives, and ENSTA ST1K brand polyurcthane adheiive from The Dow Cheniiea1 Company-or is based on one such an the afore mentioned adhesives.
5. A method according to any of the preceding claims, wherein the pattern comprises one or more strips of the applied foam adhesive.
6. A method according to any of the preceding claims, wherein the pattern comprises at least one continuous and closed strip of the applied foam adhesive near at the circumference of the panel.
7. A method according to any of the preceding claims, wherein the pattern comprises one or more zigzag strips of the applied foam adhesive in the center of the panel.
8. A method according to any of the claims 5 to 7, wherein the width of the applied strips before adhering the panel(s) is up to 8 cm.
9. A method according to any of the claims 5 to 7, wherein the width of the applied strips before adhering the panel(s) is 1 to 6 cm.
10. A method according to any of the preceding claims, wherein the step of adhering the panel starts 1 to 15 minutes after the step of applying the foam adhesive has been * *.

* * * finished. * ** **S. * * * Sb.

*
11. A method according to any of the preceding claims, wherein the step of adhering the 5:: 25 panel starts Ito 10 minutes after the step of applying the foam adhesive has been a..

* finished. S... * I II..

* .
12. A method according to any of the preceding claims, wherein the step of adhering the panel starts 2 to 8 minutes after the step of applying the foam adhesive has been finished.
13. A method according to any of the preceding claims, wherein the step of adhering the panel starts 3 to 6 minutes after the step of applying the foam adhesive has been finished.
14. A method according to any of the preceding claims, wherein during the step of curing the panel is hold in place by appropriate means.
15. A method according to any of the preceding claims, wherein the step of curing lasts 5 to 30 minutes. I0
16. A method according to any of the preceding claims, wherein the step of curing lasts 10 to 25 minutes.
17. A method according to any of the preceding claims, wherein the step of curing lasts 15 to 20 minutes.
18. A method according to any of the preceding claims, wherein after the steps of adhering and curing the layer defined by the foam adhesive has a thickness of I to 30 nun.
19. A method according to any of the preceding claims, wherein after the steps of *:*:* adhering and curing the layer defmed by the foam adhesive has a thickness of ito 20 *S..

*....I irun. * **
20. A method according to any of the preceding claims, wherein after the steps of *e* * adhering and curing the layer defined by the foam adhesive has a thickness of 2 to 15 *I**S. nun. ** * * * * * **
21. A method according to any of the preceding claims, wherein after the steps of adhering and curing the layer defined by the foam adhesive has a thickness 2 to 10 mm.
22. A method according to any of the preceding claims, wherein the panel is a rigid board or a non-rigid product.
23. A method according to claim 22, wherein the rigid board is selected from the group comprising XPS boards, EPS boards, XPS plasterboard laminates, EPS plasterboard laminates, mineral fiber plasterboard laminates, chip-boards, any kind of wooden boards, boards made of plastics, metal sheets and boards, any kind of laminate boards, and oriented strand boards (OSB); preferably XPS boards.
24. A method according to claim 22, wherein the non-rigid product is selected from the group comprising mineral wool, elastifled EPS, wood fiber, and hemp.
25. A method according to any of the preceding claims, wherein after the steps of adhering and curing the foam adhesive has a dynamic modulus of elasticity Ed of less than 1.5 N/mm2.
26. A method according to any of the preceding claims, wherein after the steps of adhering and curing the foam adhesive has a dynamic modulus of elasticity Ed of less than 1.2 N/mm2.
27. A method according to any of the preceding claims, wherein after the steps of adhering and curing the foam adhesive has a dynamic modulus of elasticity Ed of *.. less than 1.0 N/mm2. * **

*::s 25
28. A method according to any of the preceding claims, wherein after the steps of *.* adhering and curing the foam adhesive has a dynamic modulus of elasticity Ed of ** less than 0.8 N/mm2. S... * S * S * S *s
29. A method according to any of the preceding claims, wherein the panel is a rigid board and wherein after the steps of adhering and curing the composite system has a dynamic stiffness S' of less than 250 MN/rn3.

L
30. A method according to any of the preceding claims, wherein the panel is a rigid board and wherein after the steps of adhering and curing the composite system has a dynamic stiffness S' of less than 200 MN/rn3.
31. A method according to any of the preceding claims, wherein the panel is a rigid board and wherein after the steps of adhering and curing the composite system has a dynamic stiffness S' of less than 150 MN/rn3.
32. A method according to any of the preceding claims, wherein the panel is a rigid board and wherein after the steps of adhering and curing the composite system has a dynamic stiffness S' of less 100 MN/rn3.
33. A method according to any of the preceding claims, wherein the panel is a rigid board having a compressive strength of more than 80 kPa. is
34. A method according to any of the preceding claims, wherein the panel is a rigid board having a compressive strength of more than 100 kPa.
35. A method according to any of the preceding claims, wherein the panel is a rigid board having a compressive strength of more than 150 kPa.
36. A method according to any of the preceding claims, wherein the panel is a rigid board *:::* having a compressive strength of more than 200 kPa. * S.

*:: 25
37. A method according to any of the preceding claims, wherein the panel is a rigid board S..

having a thickness of 1 to 300 mm. S... * .
38. A method according to claim 37, wherein the rigid board is an insulation board having a density of less than 500 kg/rn3 and having a thickness of 40 to 100 mm.
39. A method according to claim 37, wherein the rigid board has a density of 500 kg/m3 or more and a thickness of 3 to 30 mm.
40. A method according to claim 37, wherein the composite system is useful for the acoustic insulation of the inner surface of a building structure and the rigid board is a plasterboard laminate comprising: a) a plaster board having a thickness of 4 to 20 mm, and b) a rigid insulation board having a thickness of I to 20 cm.
41. A method according to claim 37, wherein the composite system is useful for the acoustic insulation of the inner surface of a building structure and the rigid board is a plasterboard laminate comprising: a) a paper faced gypsum board, having a thickness of 4 to 20 mm, and b) a rigid insulation board having a thickness of 1 to 20 cm.
42. A method according to any of the preceding claims, wherein the composite system further comprises a covering layer or a finishing system over the rigid board.
43. A method according to claim 42, wherein the covering layer or the finishing system has a thickness of 0.5 to 20 mm.
44. A method according to claim 42, wherein the covering layer or the finishing system has a thickness of 1 to 8 mm. * ** U. * * S.

*:*
45. A method according to any of the preceding claims, wherein the panel is a rigid board * * and the rigid board and the optional covering layer or finishing system have a total weightof 1 to40kg/m2. **S

S
46. A method according to any of the claims 42 to 45, wherein the covering layer is selected from the group comprising a render layer, a metal layer, a wooden layer, a plastic layer, and a composite layer.
47. A method according to any of the claims 42 to 45, wherein the finishing system comprises a layer selected from the group comprising a render layer, a wall paper, and a textile layer.
48. A composite system manufactured according to the method of any of the claims I to 47.
49. Use of a composite system according to claim 48 for the interior finishing or interior insulation of a surface of a building structure.
50. Use of a foam adhesive or an adhesive which is based thereon for the manufacture of a composite system by adhering one or more panel(s) to an interior surface of a building structure by said foam adhesive or the adhesive which is based thereon.
51. Use according to claim 50, wherein the foam adhesive is a polyurethane one-component foam adhesive or an adhesive which is based thereon.
52. Use according to claim 50, wherein the foam adhesive is lNSTA-STll( brand polyurethane adhesive from The Dow Chemical Company or an adhesive which is based thereon.
53. A construction comprising: *1 a) a substrate; * b) a composite system according to claim 48 adhered by the foam adhesive to the *.::. 25 substrate in the appropriate pattern(s).

S
54. A construction comprising: a) the interior surface of an exterior wall of a building structure; b) a composite system according to claim 48 adhered by the foam adhesive to the substrate in the appropriate pattern(s), and c) one or more functional layers or interspaces being located between the building structure and the composite system.