EP4453339A1

EP4453339A1 - Insulating element and method for manufacturing thereof

Info

Publication number: EP4453339A1
Application number: EP24700419.5A
Authority: EP
Inventors: Solenn MORO; Alice SAAD
Original assignee: Saint Gobain Isover; Saint Gobain Isover SA France
Current assignee: Saint Gobain Isover; Saint Gobain Isover SA France
Priority date: 2023-01-11
Filing date: 2024-01-10
Publication date: 2024-10-30
Also published as: WO2024149782A1

Abstract

An insulating element (2000) made of bonded mineral fibres with two main surfaces (2001a-b) which are spaced and parallel to one another, and four side surfaces (2002a-d) substantially perpendicular to the two main surfaces (2001a-b), wherein at least one or both of the two main surfaces (2001a-b) are rough surfaces with a root mean square surface roughness, Rq, below 0.1 mm, preferably below 0.08 mm, more preferably below 0.05 mm. Are also provided a method for manufacturing said insulating element, a thermal insulating system comprising said insulating element, a kit for exterior insulation finishing systems and a method for installing a thermal insulating system.

Description

Title: Insulating element and method for manufacturing thereof

Technical field

[0001 ] The invention pertains to insulating elements made of bonded mineral fibres, thermal insulating system comprising said insulating element, and method for manufacturing thereof.

Technical background

[0002] Exterior Insulation Finishing Systems (EIFS), also known as Exterior Wall Insulation Systems (EWI) or External Thermal Insulation Composite Systems (ETICS), are integrated multilayer composite cladding systems for thermal insulation of building walls, e.g., vertical envelopes of a building. They are made of many layers of different materials, usually including, among others and without limitation, an adhesive layer to be applied on the wall to be insulated, an insulating panel or board, means for fixings for said panel or board, a basecoat, e.g., mortar, a reinforcing mesh, a key coat, e.g., mortar, a finishing coat, e.g., mortar and/or plaster, and a decorative coat, mortar and/or plaster.

[0003] ETICS may be differentiated into ‘Bonded ETICS’ and ‘Mechanically fixed ETICS’ depending on the main means, i.e. , resp. adhesive fixings or mechanical fixings, for fixing onto walls. In ‘Bonded ETICS’, the adhesion to the wall is ensured by bonding or adhesives and may or may not include supplementary fixings, whereas, in ‘Mechanically fixed ETICS’, this adhesion is ensured by mechanical fixings and may or may not include supplementary bonding or adhesive.

[0004] The insulating panel or board may be made of Expanded Poly-Styrene (EPS), expanded polyurethane foam, or mineral wool, e.g., stone wool or glass wool, with equivalent thermal but not mechanical and/or acoustic performances. For instance, current ‘Bonded ETICS’ comprising insulating panels made of Expanded Poly-Styrene (EPS) offers lighter ETICS, higher bond (tensile) strength between the basecoat and the insulating panel, but lower resistance to impact, lower fire resistance and lower acoustic insulation. On the contrary, ‘Bonded ETICS’ comprising insulating panels made of mineral wool offers heavier ETICS, lower bond (tensile) strength between the basecoat and the insulating panel, but higher resistance to impact, higher fire resistance and higher acoustic insulation.

[0005] Insulating panel made of mineral wool may be differentiated into ‘lamellar panels’ or ‘non-lamellar panels’ depending on their design. In a ‘lamellar panel’, the mineral fibres are organised into lamellas or webs which are assembled to form a stack of layers within the panels. The mineral fibres are oriented within the plane of the lamellas or webs whereas the lamellas or the webs may be oriented parallel, perpendicular or oblique to the contact surface of the panels depending on the properties sought for their application.

[0006] ‘Non-lamellar panels’ encompass all panels which may be considered as not lamellar, i.e. , which do not have a structure made of stacked lamellas or webs. In non-lamellar panels, all or part of the mineral fibres may be oriented in different privileged directions depending on the process used for manufacturing the panels. Also, within a panel, the mineral fibres may have different orientations depending on their location from the contact surface of said panel, i.e., their depth within said panel. All or parts of them may be oriented parallel, perpendicular, or oblique to the contact surface of the panel. As a rule of thumb, their orientation is mainly governed by the process for manufacturing the panel.

[0007] The main benefit of using a lamellar panel instead of a non-lamellar one is to provide higher tensile strengths, up to more than 0.08 MPa, compared to non-lamellar panel, but it usually requires a lower density for higher thermal conductivity.

[0008] The European Assessment Document EAD 040083-00-0404 from the European Organisation for Technical Assessment on the external thermal insulation composite systems (ETICS) with rendering (EAD 040083-00- 0404, 2019) recommends the bond strength between the basecoat and the insulating panel ETICS, in particular Bonded ETICS, comprising insulating panel made of mineral wool to be at least 0.08 MPa for adhesive or cohesive rupture, or the rupture to occur within the insulation panel if the bond strength is less than 0.08 MPa (Table 4, § 2.2.10, § 2.2.11 .1 , EAD 040083-00-0404). [0009] However, whether the insulating panel has lamellar or a non-lamellar structure, such bond strength remains challenging and is still a major drawback for its extensive use in cladding systems. The technical field is then deprived from benefiting of their other mechanical and/or acoustic performances, e.g., higher resistance to impact, higher fire resistance and higher acoustic insulation...

[0010] Improving the mechanical properties of the insulating panel made of mineral wool for ETICS related applications or similar has already been, and is still, a subject to intensive developments, even well before the current recommendations of the EAD 040083-00-0404.

[0011] EP 0 277 500 A2, ROCKWOOL MINERALWOLLE [DE], 10.08.1988 describes a process for manufacturing of an insulating material with a lamellar core made of vertically or horizontally stacked layers of bonded mineral fibres and a denser surface layer. A continuously produced insulating material is first split into two partial webs before the curing step and one of the webs is strongly compacted. Then the compacted web is fed back onto the surface of the other web and the assembly is cured. The compacted surface provides increased mechanical strength and a better adhesion when the insulation material is applied on walls, e.g., via partial gluing.

[0012] WO 9213150 A1 , ROCKWOOL INT [DK] 06.08.1992 describes a similar process in which the compressed layer is impregnated with an impregnating agent by suction in an under-pressure chamber. The impregnating agent, e.g., colloidal silica, helps to promote the adhesion of plaster with which the insulating material may be covered.

[0013] EP 1 203 847 A1 , ROCKWOOL MINERALWOLLE [DE] 08.05.2002 describes blocks of lamellar insulating material made of bonded mineral fibres which main surfaces are coated with an impregnation agent, e.g., aqueous solution of sodium silicate, epoxy resins... , and a pressure- chargeable layer, e.g., construction adhesives, tile adhesives, adhesive mortars, polymer-cement-concrete and/or cement mortar, epoxy-cement- concrete mortar... The modified surfaces promote the adhesion of insulating block to building materials while providing high transverse tensile strength and compressive rigidity. [0014] EP 1 321 595 A2, ROCKWOOL MINERALWOLLE [DE] 25.06.2003 describes a lamellar insulating element which one of its main surfaces is coated by a binding agent, e.g., a polymer solution, before to be applied onto a wall. The binding agent may be either applied to a depth up to 10 mm with a hand-held roller or with a plurality of aligned rollers that are arranged in a trough filled with binding agent. The coated surface of the insulating element may be further coated with layer of mortar.

[0015] EP 1 559 844 A1 , ROCKWOOL MINERALWOLLE [DE] 03.08.2005 describes a lamellar insulating element which one of its main surfaces is provided with bead-like projections which promotes the adhesion of an adhesive plaster by filling the areas between the bead-like projections. The bead-like projections are obtained by compressing some areas of the main surface during the hardening step. The transverse tensile strength of the insulating element in the area under the main surface in contact with the plaster should be higher than 30 kPa, preferably higher than to 60 kPa, which is alleged to fulfil the requirement for a bond strength of 80 kPa between the adhesive layer and the building surface to be insulated.

[0016] EP 2 525 016 A1 , SAINT GOBAIN ISOVER [FR] 21 .11 .2012 describes a non-lamellar insulating element which one of its main surfaces is provided with a 3D-supporting grid to promote the adhesion of mortar or plaster.

Summary of the invention

Technical problem

[0017] A disadvantage of the current insulating panels made of mineral wool for ETICS application is that they require additional components such as adhesion-promoting agent or supporting grid, to improve the bond strength between the panels and the layers of mortar of plaster applied either as basecoats or adhesive layers. Not only these additional components may be cost intensive, but also, they may require complex modifications in the current manufacturing processes which, in turn, induces further significant costs.

[0018] For those insulating panels which may be equipped with these additional components, e.g., adhesion-promoting agent, just before their application into ETICS, they may inconveniently increase the workload on on-site operators with additional steps of preparation. [0019] Insulating panels made of mineral wool with compacted surfaces which may possibly be used without additional components still require complex manufacturing process, in particular for the superimposition of layers of mineral wool with different densities.

[0020] Another disadvantage is that the use of lamellar panels of mineral wool seems to be mandatory to achieve high levels of tensile strength within the panel and to fulfil the recommendation of bond strength of at least 80 kPa. In other words, there is no solution for non-lamellar panels which high tensile strengths are too low compared to lamellar panels.

[0021] Thus, there is a need for a cost-effective insulating panel made of mineral fibres that may fulfil the recommendations of EAD 040083-00-0404 whether its structure is lamellar or non-lamellar. Such insulating panel may also be advantageously manufactured in a cost-effective manner which is easy-to-to implement in existing manufacturing processes with limited modifications.

Solution to the technical problem

[0022] In a first aspect of the invention, there is provided an insulating element as described in claim 1 , dependant claims being advantageous embodiments.

[0023] In a second aspect of the invention, there is provided a method for manufacturing of an insulating element according to the first aspect of the invention.

[0024] In a third aspect of the invention, there is provided a thermal insulating system comprising an insulating element according to the first aspect of the invention.

[0025] In a fourth aspect of the invention, there is provided a kit for exterior insulation finishing systems comprising at least one insulating element according to the first aspect of the invention and at least one basecoat mortar to be applied on said insulating element.

[0026] In a fifth aspect of the invention, there is provided a method for installing a thermal insulating system according to the third aspect of the invention on a building wall.

Advantages of the invention [0027] A first outstanding advantage of the invention is that it may fulfil the recommendation of EAD 040083-00-0404 regarding the bond strength between the insulating panel and the basecoat, in particular for the rupture to occur within the insulation panel if the bond strength is less than 0.08 MPa.

[0028] A second advantage is that the invention may apply on any insulating panel made of mineral fibres whatever its structure, i.e. , lamellar or non- lamellar.

[0029] A third advantage is that the manufacturing process according to the invention is cost-effective and easy to implement in an existing process with very limited modifications.

[0030] Additional advantages of the certain embodiments of the invention will be set forth in the detailed description and examples, and in part will be readily apparent to those skilled in the art from that description and examples or be recognized by practicing the embodiments described herein, including the detailed description, the examples, and the drawings.

Brief description of drawings

[0031 ] [Fig. 1 ] is schematic orthographic cross-sectional representation of an external thermal insulation composite system.

[0032] [Fig. 2] is a schematic representation of insulating element according to the first aspect of the invention.

[0033] [Fig. 3] is a schematic representation of a thermal insulating system according to the third aspect of the invention.

[0034] [Fig. 4] is a plot of pull-out tensile strength of thermal insulating systems comprising insulating elements according to example embodiments and according to counterexamples.

[0035] [Fig. 5] is a plot of the percentages of the surface area of insulating element ripped out at the rupture surface of thermal insulating systems comprising insulating elements according to example embodiments and according to counterexamples.

Detailed description of embodiments

[0036] As ‘insulating element’, it is hereby referred to an insulating element, or similar, which features, and applications encompass at least those described and/or defined in the European Standard EN 13162 and/or in § 1 .3.5 of EAD 040083-00-0404.

[0037] As ‘thermal insulating system’, it is hereby referred to a thermal insulating system, or similar, which features, and applications encompass at least those described and/or defined in the EAD 040083-00-0404.

[0038] As ‘basecoat’, it is hereby referred to a base coat as defined in § 1 .1 , § 1.3.8, § 1.3.17 of EAD 040083-00-0404, i.e., a coat which is applied directly onto an insulation element and may embed a reinforcement providing most of the mechanical properties of the rendering of an ETICS.

[0039] As ‘reinforcement’, it is hereby referred to a reinforcement as defined in § 1 .1 , § 1 .3.8 and § 1 .3.17 of EAD 040083-00-0404, i.e., glass fibre mesh or grid, metal lath or plastic mesh reinforcement (embedded) as well as fibres (dispersed) in the base coat to improve its mechanical strength.

[0040] As ‘adhesive layer’, it is hereby referred to an adhesive as defined in § 1 .1 and § 1 .3.3 of EAD 040083-00-0404; i.e., a layer used to bond an insulating element to a substrate, e.g., a wall.

[0041] As ‘key coat’, ‘finishing coat’ and ‘decorative coat’, it is hereby referred to key coat’, ‘finishing coat’ and ‘decorative coat’ as defined in § § 1 .1 and § 1 .3.3 of EAD 040083-00-0404.

[0042] As ‘kit’, it is hereby referred to a kit or similar which features and applications encompass at least those described and/or defined in Guidance Paper C ‘THE TREATMENT OF KITS AND SYSTEMS UNDER THE CONSTRUCTION PRODUCTS DIRECTIVE’ from the European Commission (2002) and/or in §1 .3.15 and §1 .3.16 of EAD 040083-00- 0404.

[0043] As ‘a root mean square surface roughness’, Rq, it is hereby referred to the root mean square value of the ordinate values of the height of the surface profile within the sampling length as defined in § 4.2.2 of the International Standard ISO 4287.

[0044] As ‘mean profile element heights’, Rc, it is hereby referred to the mean value of the profile element heights, i.e., the height of peaks-valleys, within the sampling length as defined in § 4.1.4 of the International Standard ISO [0045] Rq and Rc are usually measured by laser profilometry, based on the following features:

- Measurement on a surface of 10 cm²,

- In the plane (XY): spatial resolution = 20 pm (i.e. 1 point every 20 pm),

- Out-of-plane (Z): repeatability of 0.4 pm and linearity of 16 pm,

- Treatment: a) Denoising: removal of outliers and noise reduction by a median filter (9x9 pixels) and b) Filtering (high-pass filter): gaussian filtering - sigma = 2 mm.

[0046] As ‘compressive strength’, when applied to insulating elements, it is hereby referred to the compressive strength as defined in the European Standard EN 826.

[0047] As ‘density’, applied to insulating elements, it is hereby referred to the density as defined in the European Standard EN 1602.

[0048] As ‘tensile or bond strength of the interface between the surface of an insulating element and a basecoat, e.g., mortar or plaster, of which it is coated, it is hereby referred to the tensile strength or bond strength as defined in Table 4, § 2.2.10 and § 2.2.11 .1 of EAD 040083-00-0404.

[0049] As ‘mineral wool’, it is hereby referred to mineral wool as defined in § 3.1.1.1 of the European Standard EN 13162, i.e., insulation material having a woolly consistency, manufactured from molten rock, slag or glass.

[0050] As ‘glass wool’, it is hereby referred to a mat, or the like, made of aggregated fibre materials which are formed by spinning or drawing molten glass with any modem processes as first described in US 2133235 A [OWENS ILLINOIS GLASS CO] 11 .10.1938. A glass wool may further comprise on organic binding agent to bond the fibres together.

[0051] As ‘stone wool’ or ‘rock wool’, it is hereby referred to a mat, or the like, made of aggregated fibre materials which are formed by spinning or drawing molten natural rock material, e.g., basalt.

[0052] As ‘mineral fibres’, it is hereby referred to mineral fibres as used or adapted to be used as component of thermal insulation product. In particular, the expression encompasses at least the mineral fibres for glass wool or stone wool. [0053] As ‘bonded mineral fibres’, it is hereby referred to mineral fibres which are bound or bonded to each other by use of an organic binding agent to form an insulation product or element such as a mat of glass wool or rock wool. [0054] As ‘coated abrasive’, it is hereby referred to a coated abrasive as defined by the Federation of European Producers of Abrasives, i.e. , abrasive grains bonded onto a flexible substrate, e.g., paper, textile, plastic film.

[0055] As ‘grade’, when applied to abrasives, in particular coated abrasives, it is hereby referred to the grade as defined by the Federation of European Producers of Abrasives, in particular as defined in the International Standard ISO 6344-2. Examples of coated abrasives are sandpapers and emery clothes.

[0056] With reference to fig. 1 , a common External Thermal Insulation Composite Systems (ETICS) 1000 comprise several layers 1001 of different materials which are assembled as a stack. The layers 1001 may comprise an adhesive layer 1003 to be applied on the building wall 1002 to be insulated, an insulating panel 1004, a basecoat 1005, e.g., mortar, a reinforcement 1006, e.g., a glass fibre grid, a key coat 1007, e.g., mortar, a finishing coat 1008, e.g., mortar and/or plaster, and a decorative coat 1009, mortar and/or plaster.

[0057] As previously mentioned, the ETICS as depicted in fig. 1 is commonly referred as a Bonded ETICS since it is bonded to the wall 1002 by means of the adhesive layer 1003. Optionally, it may further include supplementary fixing means, e.g., anchors, (not shown) to the wall 1002.

[0058] As previously explained, a major drawback of bonded ETICS 1000 in which the insulating panel 1004 is made of mineral wool, e.g., glass wool or stone wool, is their low bond or tensile strength, or the rupture mechanism when the bond or tensile strength between the insulating panel 1004 and the basecoat 1005 and/or the adhesive layer 1003, or the absence of rupture within the insulating panel when the bond or tensile strength is less than 0.08 MPa. Thus, the recommendations of the EAD 040083-00-0404 are not fulfilled and, consequently, despite their other advantageous properties, the use of insulating panels made of mineral wool, e.g., glass wool or stone wool is rather limited in cladding systems such as ETICS. [0059] In this respect, with a reference to fig. 2, in a first aspect of the invention, there is provided an insulating element 2000 made of bonded mineral fibres with two main surfaces 2001 a-b which are spaced and parallel to one another, and four side surfaces 2002a-d substantially perpendicular to the two main surfaces 2001 a-b, wherein at least one or both of the two main surfaces 2001 a-b are rough surfaces with a root mean square surface roughness, Rq, below 0.1 mm, preferably below 0.08 mm, more preferably below 0.05 mm.

[0060] Surprisingly, when an insulating element 2000 according to the first aspect of the invention is used as an insulating panel in an ETICS, the bond strength is measured to be less than 0.08 MPa and a rupture to occur within the insulation panel.

[0061 ] The insulating element 2000 may have a lamellar structure or a non- lamellar structure. In preferred embodiments, the insulating element 2000 may have a non-lamellar structure.

[0062] In certain embodiments, the mean height of profile elements, Rc, of the rough surface 2001a may be below 0.1 mm, preferably below 0.06 mm.

[0063] Preferably, the insulating element 2000 according to the first aspect of the invention may have a density and/or a 10% compressive strength that are both adapted for use in ETICS.

[0064] In this regard, in advantageous embodiments, the 10% compressive strength of said insulating element 2000 may be at least 10 kPa, preferably at least 12 kPa, preferably at least 15 kPa, preferably at least 20 kPa, preferably at least 25 kPa. In further advantageous embodiments, the density of said insulating element 2000 may be at least 40 kg/m3, preferably at least 45 kg/m3, more preferably at least 50 kg/m3.

[0065] In certain embodiments, the thickness of said insulating element 2000 is from 30 to 300 mm, preferably from 50 to 200 mm. The thickness corresponds herein to the minimal distance between the two main surfaces 2001a and 2001 b of said insulating element 2000. The thickness can be measured according to the standard EN ISO 29466:2022.

[0066] In certain embodiments, the bonded mineral fibres may be glass wool or stone wool. [0067] In preferred embodiments, they may be made of aluminosilicate glass, e.g., as described in WO 0017117 A1 [SAINT GOBAIN ISOVER [FR]] 30.03.2000 or in WO 2005033032 A1 [SAINT GOBAIN ISOVER [FR]] 14.04.2005.

[0068] Advantageously, the bonded mineral fibres may be made of aluminosilicate glass with an amount of aluminium oxide of at least 14 wt.%, preferably at least 16 wt.%, preferably at least 18 wt.%. Further, the amount of aluminium oxide may be preferably at most 28 wt.%, preferably at most 26 wt.%, preferably at most 24 wt.%.

[0069] In certain embodiments, the fibres of aluminosilicate glass may comprise an amount of silicon oxide may vary from 32 wt.% to 50 wt.%, preferably from 33 wt.% to 48 wt.%, preferably from 34 wt.% to 46 wt.%.

[0070] In certain embodiments, the fibres of aluminosilicate glass may content an amount of aluminium oxide and silicon oxide such as the molar ratio is AI³⁺/(AI³⁺+Si⁴⁺) is higher than 0.25, preferably higher than 0.30, preferably higher than 0.35.

[0071 ] An outstanding advantage of the fibres of aluminosilicate glass according to the afore embodiments is that they fulfil the requirements of the Regulation (EC) No 1272/2008 of the European Parliament and of the Council of 16 December 2008 for the protection of human health, in particular, regarding the classification of the fibres as non-carcinogen.

[0072] In a second aspect of the invention, there is provided a method for manufacturing an insulating element 2000 according to any of the embodiments of the first aspect of the invention, wherein said method comprises the following step:

(a) providing an insulating element 2000 made of bonded mineral fibres with two main surfaces 2001 a-b which are spaced and parallel to one another, and four side surfaces 2002a-d substantially perpendicular to the two main surfaces 2001 a-b;

(b) sanding at least one or both of the two main surfaces 2001 a-b of said insulating element 2000 so that said sanded main surfaces (2001 a, 2001 b) have a root mean square surface roughness, Rq, below 0.1 mm, preferably below 0.08 mm, more preferably below 0.05 mm. [0073] In certain embodiments, in step (a), the insulating element 2000 is provided as a continuously produced ribbon of insulating element made of bonded mineral fibres, wherein said ribbon is cut into slabs of insulating element, and wherein the sanding step (b) is performed before or after said cutting.

[0074] In certain embodiments, the continuously produced ribbon of insulating element has a longitudinal direction corresponding to the direction according to which said ribbon is continuously produced and, wherein the sanding is performed in a direction perpendicular to said longitudinal direction.

[0075] The step (b) of sanding may be performed by means of any adapted sanding method. In certain preferred embodiments, the sanding is performed by use of oscillating coated abrasive with grade below P100, preferably below P50.

[0076] An insulating element according to the first aspect of the invention may be advantageously integrated within an External Thermal Insulation Composite Systems (ETICS) or equivalent.

[0077] Accordingly, with reference to fig. 3, in a third aspect of the invention, there is provided a thermal insulating system 3000 comprising at least one insulating element 2000 according to any of embodiments of the first aspect of the invention, wherein said insulating element 2000 is arranged with its first main surface 2001 b facing a contact surface 1002a of a building wall 1002 to be insulated, wherein said first main surface 2001 b is connected to said contact surface 1002a via an adhesive layer 1003, wherein the second main surface 2001a of said insulating element 2000 is covered with a basecoat 1005, preferably a basecoat of mortar or plaster, and wherein the first and/or second main surfaces 2001a, 2001 b of said insulating element 2000 are the rough surfaces of said insulating element 2000.

[0078] The insulating element 2000 is advantageously used as is (for instance when used in a thermal insulating system 3000), in particular without any surface coating or surface facing on said rough surface(s).

[0079] As basecoat, any material, e.g., mortar or plaster that is adapted for such application in thermal insulating system may be used. Examples of basecoats made of mortar are described in EP 1 182 235 A1 [ROHM & HAAS [US]] 27.02.2002, WO 2013040788 A1 [ROHM & HAAS [US]] 28.03.2013, or WO 2013063743 A1 [ROHM & HAAS [US]] 10.05.2013.

[0080] In preferred embodiments, the tensile strength of the interface between the rough surface 2001a and the basecoat 1005 and/or the adhesive layer (1003) may be at least 3 kPa, preferably at least 5 kPa, preferably at least 10 kPa, preferably 15 kPa.

[0081] In advantageous embodiments, the basecoat 1005 may be further reinforced with a reinforcement 1006, preferably a glass fibre grid.

[0082] A thermal insulating system 3000 according to the third aspect of the invention should not be contemplated as to be limited to the afore described features. Instead, it may incorporate other layers of materials as described above in the context of the fig. 1 illustrating an ETICS. In particular, it may further comprise a key coat 1007, a finishing coat 1008, and a decorative coat 1009, mortar and/or plaster.

[0083] A thermal insulating system 3000 according to the third aspect of the invention may preferably be implemented as a bonded ETICS. Optionally, it may further include supplementary fixing means, e.g., anchors.

[0084] A thermal insulating system 3000 according to the third aspect of the invention is usually intended to cover a building surface to achieve its thermal insulation from exterior. For covering the entire wall, a layout for the pavement is drawn which requires more than one insulating element.

[0085] In this respect, in certain advantageous embodiments, the thermal insulating system 3000 may comprise a plurality of thermal insulating elements arranged and fastened to cover the contact surface (1002a) of the building wall (1002) to be insulated.

[0086] For greater convenience on a building site, a thermal insulating system according to the third aspect of the invention may be provided as a kit to be assembled on-site.

[0087] Accordingly, in fourth aspect of the invention, there is provided a kit for exterior insulation finishing systems comprising at least one insulating element 2000 according to any of the embodiment of the first aspect of the invention and at least one basecoat 1005, preferably of plaster or mortar, and/or at least one adhesive layer 1003, wherein said basecoat 1005 and/or adhesive layer 1003 are to be applied on the at least one or both rough surface 2001a of said insulating element 2000.

[0088] In preferred embodiment, the basecoat 1005 may be provided as ready-to- use premix of reactive materials to be mix with the required amount of water.

[0089] Whether a thermal insulating system 3000 according to the third aspect of the invention insulating provided as a kit or not, in a fifth aspect of the invention, with reference to fig. 3, there is provided a method for installing a thermal insulating system 3000 on a building wall 1002, the method comprising:

- providing at least one insulating element 2000 according to any of the embodiments of the first aspect of the invention;

- arranging said insulating element 2000 with its first main surface 2001 b facing a contact surface 1002a of the building wall 1002;

- connecting said first main surface 2001 b to the contact surface 1002a via an adhesive layer 1003;

- covering the second main surface 2001a of said insulating element 2000 with a basecoat 1005; wherein the first and/or second main surfaces 2001a, 2001 b of said insulating element 2000 are the rough surfaces of said insulating element 2000.

Examples

[0090] Two examples, E1-E2, according to the first aspect of the invention and two counterexamples, CE1-CE2, were prepared from three different commercially available insulating elements: Isover Clima 34®, and Isover TF36® which technical properties are reported in Table 1.

[0091] [Table 1]

[0092] The two examples, E1-E2 were prepared by sanding one of the main surfaces of the three afore mentioned insulating elements with oscillating coated abrasives with grade below P50 until the root mean square surface roughness, Rq, was below 0.1 mm, preferably below 0.08 mm, more preferably below 0.05 mm. Two Norton ® coated abrasives belts from were used: 1330mmx2620mm Norton® R817 P24 and 1330mmx2620mm Norton® R976 P36.

[0093] The two counterexamples, CE1-CE2, were the three afore mentioned insulating elements without sanding, i.e. , with their pristine main surfaces.

[0094] The root mean square surface roughness, Rq, the mean height of profile elements, Rc, of the rough surface of the examples E1-E2 and of the pristine main surface of the counterexamples CE1-CE2 was measured by laser profilometry with a Keyence LJ-V7060 profilometer, using the following features:

- Measurement on a surface of 10 cm²,

- In the plane (XY): spatial resolution = 20 pm (i.e. 1 point every 20 pm),

- Out-of-plane (Z): repeatability of 0.4 pm and linearity of 16 pm,

The results are reported in Table 2.

[0095] [Table 2]

[0096] From the examples E1-E2, two corresponding thermal insulating systems, TE1-TE2, according to the third aspect of the invention were prepared and, for comparison, other two, TCE1-TCE2, were also prepared from counterexamples CE1-CE2. The preparation was carried with the following procedure.

[0097] First, a basecoat was prepared by mixing 1 kg of Weber. therm 302 ® mortar powder and water in a planetary mixer with a dry powder I water ratio of about 0.32. The paste was then mixed for 30 seconds in the mixer, then 1 minute manually, then again 1 minute in the mixer, and let rest for 2 minutes. After the 2 minutes rest, the paste was again mixed for 15 seconds in the mixer.

[0098] The prepared basecoat was applied as a thin layer onto the rough surface of each of the examples E1-E2 to form the corresponding thermal insulating systems TE1-TE2, and one of the main pristine surfaces of the counterexamples CE1-CE2 to form the corresponding thermal insulating systems TE1-TE2. The layer was applied with a cat tongue towel and smoothed with an adapted smoothing tool to form a homogenous 4 mm thick layer. Once applied, is let to set for 14 days at 23°C under a 50% RH atmosphere.

[0099] Once the mortar was set, 20x20 cm square samples were cut perpendicular to the surface of the basecoat within the examples and counterexamples of the thermal insulating systems up to 2-3 mm depth with the insulating element. The samples are then glued to their face opposite to the basecoat onto 18 mm thick plywood board with a SABA Wellfix® epoxy glue. The bond strength of the interface between the surface of an insulating element and the basecoat for each sample were measured by submitting the samples to pull-off tests following the recommendations of the § 2.2.11 .1 of EAD 040083-00-0404, 2013 by using a ‘Haftzugprufgerat M 2015’ from BPS Wennigsten®. The results are reported on Fig. 4.

[00100] On Fig. 4, the examples TE1-TE2 and the counterexamples TCE1-TCE2 all present a bond strength lower than 0.08 MPa. However, optical observations of the rupture surfaces (not shown) showed that only the examples TE1-TE2 according to the first aspect of the invention have a cohesive rupture, i.e. , the rupture occurs within the insulating element.

[00101] On Fig.5, are plotted for the examples TE1-TE2 and the counterexamples TCE1-TCE2, the ratios (SRP), expressed in percentages, of the surface area ripped out at the rupture surface after the pull-out tests over the total surface area of said rupture surface before said pull-out tests. A ratio of 0% corresponds to a pure adhesive rupture and a ratio of 100% to a pure cohesive rupture.

[00102] The examples TE1-TE2 exhibit manly cohesive rupture profiles whereas the counterexamples TCE1-TCE2 exhibit mainly adhesive rupture profiles.

[00103] These results clearly show that the examples TE1-TE2 according to the first aspect of the invention fulfil the recommendations of EAD 040083-00- 0404.

[00104] All embodiments and examples including drawings which are described herein, whatever the aspect of the invention, which is concerned, may be combined by one skilled in the art unless they appear technically incompatible.

[00105] Further, although the invention has been described in connection with preferred embodiments, it should be understood that various modifications, additions and alterations may be made to the invention by one skilled in the art without departing from the spirit and scope of the invention as defined in claims.

Citation List

Patent Literature

[00106] US 2133235 A [OWENS ILLINOIS GLASS CO] 11.10.1938.

[00107] EP 0277 500 A2, ROCKWOOL MINERALWOLLE [DE], 10.08.1988.

[00108] WO 9213150 A1 , ROCKWOOL INT [DK] 06.08.1992.

[00109] WO 0017117 A1 [SAINT GOBAIN ISOVER [FR]] 30.03.2000.

[00110] EP 1 182 235 A1 [ROHM & HAAS [US]] 27.02.2002.

[00111 ] EP 1 203 847 A1 , ROCKWOOL MINERALWOLLE [DE] 08.05.2002. [00112] EP 1 321 595 A2, ROCKWOOL MINERALWOLLE [DE] 25.06.2003.

[00113] WO 2005033032 A1 [SAINT GOBAIN ISOVER [FR]] 14.04.2005 [00114] EP 1 559 844 A1 , ROCKWOOL MINERALWOLLE [DE] 03.08.2005. [00115] EP 2 525 016 A1 , SAINT GOBAIN ISOVER [FR] 21.11.2012.

[00116] WO 2013040788 AT [ROHM & HAAS [US]] 28.03.2013.

[00117] WO 2013063743 AT [ROHM & HAAS [US]] 10.05.2013.

Non-Patent Literature

[00118] The European Assessment Document EAD 040083-00-0404, External thermal insulation composite systems (ETICS) with rendering, European Organisation for Technical Assessment, 2019.

[00119] Guidance Paper C ‘THE TREATMENT OF KITS AND SYSTEMS UNDER THE CONSTRUCTION PRODUCTS DIRECTIVE’ from the European Commission (2002).

[00120] Geometrical Product Specification (GPS) - Surface texture: Profile method - Terms, definitions and surface texture parameters, International Standard ISO 4287, 1997.

[00121] Thermal insulating products for building applications - Determination of tensile strength perpendicular to the faces, European Standard EN 1607.

[00122] Thermal insulating products for building applications - Determination of the apparent density, European Standard EN 1602.

[00123] Thermal insulating products for building applications - Determination of compression behaviour, European Standard EN ISO 29469:2022.

[00124] ‘Thermal insulation products for buildings - Factory made mineral wool (MW) products - Specification’, European Standard EN 13162, 2001.

[00125] Coated abrasives — Determination and designation of grain size distribution — Part 2: Macrogrit sizes P12 to P220, International Standard ISO 6344-2, 2021.

[00126] Regulation (EC) No 1272/2008 of the European Parliament and of the Council of 16 December 2008 on classification, labelling and packaging of substances and mixtures, amending and repealing Directives 67/548/EEC and 1999/45/EC, and amending Regulation (EC) No 1907/2006.

Claims

Claim 1 . Insulating element (2000) made of bonded mineral fibres with two main surfaces (2001 a, 2001 b) which are spaced and parallel to one another, and four side surfaces (2002a-d) substantially perpendicular to the two main surfaces (2001 a, 2001 b), wherein at least one or both of the two main surfaces (2001 a, 2001 b) are rough surfaces with a root mean square surface roughness, Rq, below 0.1 mm, preferably below 0.08 mm, more preferably below 0.05 mm.

Claim 2. Insulating element (2000) according to claim 1 , wherein the mean height of profile elements, Rc, of said rough surfaces (2001a, 2001 b) is below 0.1 mm, preferably below 0.06 mm.

Claim 3. Insulating element (2000) according to any of claims 1 to 2, wherein the 10% compressive strength of said insulating element may be at least 10 kPa, preferably at least 12 kPa, preferably at least 15 kPa, preferably at least 20 kPa, preferably at least 25 kPa.

Claim 4. Insulating element (2000) according to any of claims 1 to 3, wherein the density of said insulating element (2000) is at least 40 kg/m3, preferably at least 45 kg/m3, more preferably at least 50 kg/m3.

Claim 5. Insulation element (2000) according to any of claims 1 to 5, wherein the bonded mineral fibres are glass wool or stone wool.

Claim 6. Method for manufacturing an insulating element (2000) according to any of claims 1 to 5, wherein said method comprises the following step:

(a) providing an insulating element (2000) made of bonded mineral fibres with two main surfaces (2001 a, 2001 b) which are spaced and parallel to one another, and four side surfaces (2002a-d) substantially perpendicular to the two main surfaces;

(b) sanding at least one of the two main surfaces (2001 a, 2001 b) of said insulating element (2000) so that said sanded main surfaces (2001a, 2001 b) have a root mean square surface roughness, Rq, below 0.1 mm, preferably below 0.08 mm, more preferably below 0.05 mm.

Claim 7. Method according to claim 6, wherein, in step (a), the insulating element (2000) is provided as a continuously produced ribbon of insulating element made of bonded mineral fibres, wherein said ribbon is cut into slabs of insulating element, and wherein the sanding step (b) is performed before or after said cutting.

Claim 8. Method according to claim 7, wherein the continuously produced ribbon of insulating element has a longitudinal direction corresponding to the direction according to which said ribbon is continuously produced and, wherein the sanding is performed in a direction perpendicular to said longitudinal direction.

Claim 9. Method according to any of claims 6 to 8 wherein the sanding is performed by use of oscillating coated abrasive with grade below P100, preferably below P50.

Claim 10. Thermal insulating system (3000) comprising at least one insulating element according (2000) to any of claims 1 to 5, wherein said insulating element is arranged (2000) with its first main surface (2001b) facing a contact surface (1002a) of a building wall (1002) to be insulated, wherein said first main surface (1001b) is connected to said contact surface (1002a) via an adhesive layer (1003), wherein the second main surface (1002a) of said insulating element (2000) is covered with a basecoat (1005), preferably a basecoat of mortar or plaster, and wherein the first and/or second main surfaces (2001a, 2001b) of said insulating element (2000) are the rough surfaces (2001a, 2001b) of said insulating element (2000).

Claim 11. Thermal insulating system (3000) according to claim 10, wherein the tensile strength of the interface between the rough surfaces (2001a, 2001 b) and the basecoat (1005) and/or the adhesive layer (1003) is at least 3kPa, preferably at least 5kPa, preferably at least 10kPa, preferably 15kPa.

Claim 12. Thermal insulating system (3000) according any of claims 10 to 11 , wherein the basecoat (1005) is further reinforced with a reinforcement (1006), preferably a glass fibre grid.

Claim 13. Thermal insulating system (3000) according to any of claims 10 to 12, wherein said system (3000) comprises a plurality of insulating elements (2000) arranged and fastened to cover the contact surface (1002a) of the building wall (1002) to be insulated.

Claim 14. Kit for exterior insulation finishing systems comprising at least one insulating element (2000) according to any of claims 1 to 5, and at least one basecoat (1005), preferably of plaster or mortar, and/or at least one adhesive layer (1003), wherein said basecoat (1005) and/or adhesive layer (1003) are to be applied on the at least one or both rough surface of said insulating element (2000).

Claim 15. Method for installing a thermal insulating system (3000) on a building wall (1002), the method comprising:

- providing at least one insulating element (2000) according to any of claims 1 to 5;

- arranging said insulating element (2000) with its first main surface (2001b) facing a contact surface (1002a) of the building wall (1002); - connecting said first main surface (2001 b) to the contact surface (1002a) via an adhesive layer (1003);

- covering the second main surface (2001a) of said insulating element (2000) with a basecoat (1005); wherein the first and/or second main surfaces (2001a, 2001 b) of said insulating element (2000) are the rough surfaces of said insulating element

(2000).