PREFABRICATED INSULATION PANEL

• US 20100257800A1
• Filed: 04/08/2010
• Published: 10/14/2010
• Est. Priority Date: 04/08/2009
• Status: Abandoned Application

• Current Assignee: Richard Cassells
• Original Assignee: Richard Cassells
• Inventors: Cassells, Richard
• Application Number:
  US12/756,350
• Publication Number:
  US 20100257800A1
• Time in Patent Office: Days
• US Class Current: 52/309.130
• CPC Class Codes: E04B 1/762 Exterior insulation of exterior walls
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material

Abstract

A prefabricated insulation panel is disclosed. To improve the insulation of existing buildings by applying materials to the exterior elevation the invention provides a prefabricated insulation panel comprising a layer of insulation material, two layers of render and a layer of reinforcing. The invention also provides a method of prefabricating an insulation panel, a method of insulating a building, and a building insulated with prefabricated insulation panels.

Claims

1. A substantially rectangular prefabricated insulation panel comprising a layer of insulation material, at least a first and second layer of render, a reinforcing layer located substantially between the at least first and second layers of render, and a connection means for connecting adjacent panels in use, wherein the connection means is a tongue and groove system and the panel includes a groove on two of its sides and a tongue on two of its other sides, and wherein the panel has two substantially parallel sides of relatively large surface area and a relatively thin thickness, the layer of insulation material and the first layer of render being coterminous having the same perimeter in the plane of the relatively large surface area, the second layer of render covering an area smaller than the relatively large surface area to form rebates around its perimeter on the relatively large surface area and immediately adjacent the sides of the panel, wherein two first rebates are formed adjacent two adjacent sides of the panel and two second rebates are formed adjacent the two other adjacent sides of the panel, and wherein the second rebates are significantly narrower, in the plane of the relatively large surface area, than the first rebates, the reinforcing layer having a perimeter which is coterminous with the perimeter of the second layer of render within the perimeter of the relatively large surface area of the panel and which extends beyond the perimeter of the relatively large surface area along only the two other adjacent sides of the panel.

2. The prefabricated insulation panel of claim 1, wherein the reinforcing layer extends beyond the perimeter of the relatively large surface area of the panel along the two sides of the panel comprising grooves.

3. The prefabricated insulation panel of claim 1, wherein the reinforcing layer is a mesh.

4. The prefabricated insulation panel of claim 1, wherein the reinforcing layer comprises fibre-glass.

5. The prefabricated insulation panel of claim 1, wherein the layer of insulation comprises one or more of polystyrene, cork, glass-fibre, phenolic foam and mineral wool.

6. The prefabricated insulation panel of claim 1, wherein the at least first and second layers of render comprise a polymer and/or a silicon and/or sand and cement.

7. The prefabricated insulation panel of any claim 1, wherein one of the two relatively large external surface areas of the panel includes channels.

8. The prefabricated insulation panel of claim 7, wherein the external surface of the panel including channels is the rear surface, in use.

12. A method of insulating a building comprising the steps of fixing at least one prefabricated insulation panel, according to claim 1, and/or prefabricated according to claim 9, to the external elevation of said building.

13. The method of insulating a building according to claim 12, further comprising the steps of arranging adjacent panels such that each rebate on each panel is adjacent a portion of the reinforcing layer, which extends beyond the perimeter of the panel, of another adjacent panel;

placing said portion of the reinforcing layer onto said adjacent rebate;

fixing said two adjacent panels to the building through the rebate area; and

applying a layer of render to said rebate such that its finished surface is substantially flush with the outer surface of the said second layer of render.

9. A method of prefabricating an insulation panel, comprising the steps of providing a layer of insulation, applying a first layer of render to substantially all of one side of said insulation layer, applying a reinforcing layer to said first layer of render and applying a second layer of render to said reinforcing layer, wherein the panel has two substantially parallel sides of relatively large surface area and a relatively thin thickness, the layer of insulation material and the first layer of render being coterminous having the same perimeter in the plane of the relatively large surface area, the second layer of render covering an area smaller than the relatively large surface area to form rebates around its perimeter on the relatively large surface area and immediately adjacent the sides of the panel, wherein two first rebates are formed adjacent two adjacent sides of the panel and two second rebates are formed adjacent the two other adjacent sides of the panel, and wherein the second rebates are significantly narrower, in the plane of the relatively large surface area, than the first rebates, the reinforcing layer having a perimeter which is coterminous with the perimeter of the second layer of render within the perimeter of the relatively large surface area of the panel and which extends beyond the perimeter of the relatively large surface area along only the two other adjacent sides of the panel.

10. The method of prefabricating an insulation panel of claim 9, including the step of providing connecting means along the sides of said layer of insulation.

11. The method of prefabricating an insulation panel of claim 10, wherein the connecting means is a tongue and groove system.