WO2013026172A1 - Construction board with defined air permeability - Google Patents

Construction board with defined air permeability Download PDF

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Publication number
WO2013026172A1
WO2013026172A1 PCT/CH2012/000163 CH2012000163W WO2013026172A1 WO 2013026172 A1 WO2013026172 A1 WO 2013026172A1 CH 2012000163 W CH2012000163 W CH 2012000163W WO 2013026172 A1 WO2013026172 A1 WO 2013026172A1
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WO
WIPO (PCT)
Prior art keywords
construction board
panel
construction
dapa
cellulose
Prior art date
Application number
PCT/CH2012/000163
Other languages
French (fr)
Inventor
Jan RUDOLF
Jan KNIZE
Original Assignee
Kronoplus Technical Ag
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Publication date
Application filed by Kronoplus Technical Ag filed Critical Kronoplus Technical Ag
Publication of WO2013026172A1 publication Critical patent/WO2013026172A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/06—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
    • E04B2/70—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood
    • E04B2/706—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function
    • E04B2/707—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function obturation by means of panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0866—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the present invention relates to a construction board, to methods of use of such a construction board, to a wall, wall cladding or building employing such a construction board, and to a method of manufacturing a construction board.
  • US 2004/0226247 Al discloses prefabricated construction boards for roofing systems. These boards may be prefabricated from OSB (Oriented Strand Board) panels with tar- coated paper bound to one side, in order to prepare a weather-resistant and cost effective roof. The tar-coated paper causes a complete stop of air and vapor exchange through the panels.
  • OSB Oriented Strand Board
  • US 5,231,814 discloses a decking or sheeting material including a sheet of plywood or OSB with a reflective layer of foil material adhered thereto, the foil material including a layer of metallic foil such as aluminum and a kraft paper backing. To ensure moisture escape, the metallic foil may be perforated. This however leads to a largely undefined rate of air and moisture diffusion through the material.
  • DE 100 01 227 CI discloses an OSB board which is covered by a transparent paper attached to the board by a thermoplastic adhesive and covered by a lacquer. The aim of this treatment is to generate a wood-like protected surface for the interior covering of walls or ceilings. The air and vapor diffusion through such a panel is largely undefined.
  • EP 0 122 905 describes a wood based panel based on fibers or particles, which is coated on one side by an aluminum foil or a paper-aluminum laminate in order to prevent the basic wood based panel from influence of moisture. The panel is completely impermeable to air or moisture.
  • Ueno et al. 2008 ACEEE Sumer Study on Energy Efficiency in Buildings, pp. 1 -306 - 321) tested the performance of a variety of vapor control layers in a full-scale test facility in the marine climate of Olympia, WA, USA.
  • the test materials comprised, inter alia, an asphalt-coated Kraft paper which is essentially impermeable for air and water vapor.
  • P. Mukhopadhyaya et al. J.ASTM Int.
  • a rigid wood-based panel having a first surface and a second surface opposite said first surface
  • the construction board has an air permeability between 0.002 m 3 /(m 2 -h-daPa 2 3 ) and 0.2 m 3 /(m 2 -h-daPa 2/3 ), preferably between 0.01 m 3 /(m 2 -h-daPa 2 3 ) and 0.1 nrVim ⁇ h-daPa 273 ).
  • air permeability can be precisely adjusted to a preselected value by a careful choice of properties of the panel (panel type, material, density, thickness etc.) as well as by a careful choice of the cellulose-based layer (generally a paper layer) and of the adhesive. In this manner a construction board is obtained which exhibits reduced air permeability, leading to improved insulation properties, while ensuring that controlled air exchange remains possible through the board.
  • the prior art has failed to realize that air permeability (as well as water vapor diffusion) through a wood-based panel can be precisely controlled simply by application of a paper layer, without stopping air and water diffusion completely.
  • the properties of the panel, of the cellulose-based layer and of the adhesive are chosen such that not only air permeability is controlled, but also water vapor diffusion is controlled simultaneously, without stopping vapor diffusion completely.
  • the finished construction board has a water vapor diffusion resistance factor ⁇ between 50 and 1000, more preferably between 100 and 700 and still more preferably between 200 and 500. This will generally ensure that vapor exchange can take place to an extent necessary to avoid accumulation of moisture in constructions employing the board.
  • the water vapor diffusion resistance factor ⁇ is determined as defined in norm DIN EN 12752.
  • the water vapor diffusion resistance factor or ⁇ -factor is a dimensionless number describing how many times better a material or product is at resisting the passage of water vapor, compared with an equivalent thickness of air.
  • the water vapor diffusion resistance factor ⁇ is obtained by dividing the water vapor diffusion coefficient in air by the moisture permeability of a porous material.
  • the wood-based panel can be any type of veneer-, particle- or strand-based panel, e.g., a plywood panel or a chipboard panel, preferably an OSB panel, as it has been known for a long time.
  • the basic production procedure of such panels has been extensively described in the literature, see, e.g., . Dunky and P. Niemz: Leime und Holzwerkstoffe (Adhesive resins and wood based panels), Springer, 2002.
  • the adhesive may e.g. be a dispersion adhesive or a thermoplastic adhesive.
  • the adhesive is a polyvinyl acetate-based dispersion adhesive, which ensures a relatively high air and vapor permeability through the adhesive layer.
  • the construction board is preferably substantially free of any synthetic or metallic foil layers.
  • substantially free means that no synthetic or metallic foil layer is applied to a significant portion of the surfaces of the panel so as to influence the diffusion properties of the board.
  • that layer shall cover only such a small portion of the surface that the layer will not substantially influence the diffusion properties.
  • the board may of course comprise one or more small stickers or labels which clearly would not interfere with the overall air and vapor diffusion through the board.
  • the first cellulose-based layer will generally be a paper layer having a thickness of typically less than 0.5 mm, often less than approximately 0.3 mm.
  • the layer will generally have a mass per unit area of less than approximately 300 g/m 2 , preferably less than approximately 150 g/m 2 .
  • the layer should preferably have a mass per unit area of at least approximately 20 g/m 2 , preferably at least approximately 40 g/m 2 .
  • the construction board may comprise a second cellulose-based layer attached to the second surface of the panel by an adhesive, i.e., it may be coated by a cellulose-based layer on both sides of the panel. It is also conceivable that the board comprises two or more cellulose-based layers on the same side of the panel.
  • the construction board of the present invention is preferably used for manufacturing an external wall of a building or for manufacturing a cladding for an external wall of a building. It may, however, be used also for other purposes, such as for manufacturing a roofing construction.
  • An external wall construction or a cladding for an external wall construction will generally comprise further elements, such as a rigid frame construction, e.g. a timber frame construction, to which the construction board is directly or indirectly attached, and or at least one thermal insulation layer.
  • the present invention also encompasses a building comprising a wall or a cladding constructed in this manner.
  • the present invention further provides a method of manufacturing a construction board having a well-defined air permeability, the method comprising:
  • the panel, the adhesive and the first cellulose-based layer being selected such that the finished construction board has an air permeability between 0.002 m in ⁇ -h-daPa 273 ) and 0.2 mV(m 2 -h-daPa 2 3 ), preferably between 0.01 m 3 /(m 2 h-daPa 2/3 ) and 0.1 m 3 /(m 2 -h-daPa 2/3 ).
  • the panel, the adhesive and the cellulose-based layer are preferably selected such that the finished construction board further has a water vapor diffusion resistance factor ⁇ between 50 and 1000, preferably between 100 and 700, more preferably between 200 and 500.
  • the wood-based panel is preferably treated by sanding on the side(s) to which one or more cellulose-based layers are to be applied, before attaching the cellulose-based layers, so as to improve adhesion and to achieve a more homogeneous distribution of the diffusion properties across the surface of the panel.
  • Fig. 1 shows a highly schematic cross sectional sketch of a construction board according to a first embodiment of the present invention
  • Fig. 2 shows a highly schematic cross sectional sketch of a construction board according to a second embodiment of the present invention
  • Fig. 3 shows a first example of an external wall cladding employing a construction board according to the present invention.
  • Fig. 4 shows a second example of an external wall cladding employing a construction board according to the present invention.
  • Figure 1 illustrates, in a highly schematic manner and not to scale, a construction board according to a first embodiment of the present invention.
  • An OSB panel 1 is covered on one side by a paper layer 3, which is attached to the panel by means of an adhesive layer 2.
  • FIG. 2 A second embodiment is schematically illustrated in Fig. 2.
  • the OSB panel is additionally covered by a second paper layer 3' attached to the other side of the panel by means of an adhesive layer 2'.
  • one or more further layers may be added on top of layers 3 and/or 3'.
  • Example 1 Wall cladding
  • FIG. 3 A first example of application is illustrated in Fig. 3, illustrating an external wall cladding for a passive house construction.
  • a timber framed construction 15 forms a structural frame for the cladding.
  • a thermal insulation 14 formed of a material such as glass or mineral wool is disposed. Both sides of the construction 15 with the thermal insulation 14 are covered by a first construction board 13 and a second construction board 16 according to the present invention.
  • Second construction board 16 is mounted to wood battens 18. Additional thermal insulation 17 is provided between the wood battens 18.
  • a gypsum plasterboard 19 is mounted to the wood battens on the side facing away from board 16. Further thermal insulation boards 12 are connected to first construction board 13.
  • the outermost thermal insulation board 12 is covered with a thin layer of mineral plaster 11.
  • FIG. 4 A second example of a wall cladding is illustrated in Fig. 4.
  • this construction employs a diffusion open fiberboard panel.
  • a frame construction 26 is provided, either made of solid timber beams or of OSB with I-hoists.
  • the frame construction is covered by a diffusion open fiberboard 24.
  • the frame construction is covered by a construction board 27 according to the present invention.
  • the interspace is again filled with insulation material 25, such as mineral or glass wool.
  • a softwood fiberboard 23 covers fiberboard 24.
  • Wood battens 22 are attached to softwood fiberboard 23 and carry a finished wood siding 21.
  • Construction board 27 is mounted to wood battens 28 covered by a gypsum plasterboard 30. Additional thermal insulation 29 is provided between construction board 27 and gypsum plasterboard 30.
  • Example 3 Combination of an OSB/3 board (12 mm) and different types of papers as coating
  • the table illustrates the big differences in diffusion which can be achieved by a paper coating using various types of papers.

Abstract

A construction board comprises a rigid wood-based panel (1) and a paper layer (3) attached to the panel by an adhesive (2) so as to yield a well-defined air permeability and a well-defined water vapor diffusion resistance factor. The wood-based panel may be an OSB panel. Diffusion control is achieved without the necessity to apply metallic or plastic foil layers.

Description

TITLE
Construction board with defined air permeability
TECHNICAL FIELD The present invention relates to a construction board, to methods of use of such a construction board, to a wall, wall cladding or building employing such a construction board, and to a method of manufacturing a construction board.
PRIOR ART
The need of saving energy has led to attempts in reducing air permeability of walls of prefabricated houses. Traditionally this has been achieved by employing completely air- and vapor-tight materials like plastic foils or aluminum foils within the wall construction. In this way a complete stop of any air movement as well as a complete stop of vapor diffusion is obtained. This, however, imparts the risk of accumulation of moisture within the wall construction. For achieving a certain extent of vapor permeability, it has been suggested to employ, e.g., microporous synthetic films or synthetic or metallic films with microperforations, applied to a non-rigid substrate, such as a fabric. Such materials are generally handled independently from structural elements such as construction boards.
US 2004/0226247 Al discloses prefabricated construction boards for roofing systems. These boards may be prefabricated from OSB (Oriented Strand Board) panels with tar- coated paper bound to one side, in order to prepare a weather-resistant and cost effective roof. The tar-coated paper causes a complete stop of air and vapor exchange through the panels.
US 5,231,814 discloses a decking or sheeting material including a sheet of plywood or OSB with a reflective layer of foil material adhered thereto, the foil material including a layer of metallic foil such as aluminum and a kraft paper backing. To ensure moisture escape, the metallic foil may be perforated. This however leads to a largely undefined rate of air and moisture diffusion through the material. DE 100 01 227 CI discloses an OSB board which is covered by a transparent paper attached to the board by a thermoplastic adhesive and covered by a lacquer. The aim of this treatment is to generate a wood-like protected surface for the interior covering of walls or ceilings. The air and vapor diffusion through such a panel is largely undefined. EP 0 122 905 describes a wood based panel based on fibers or particles, which is coated on one side by an aluminum foil or a paper-aluminum laminate in order to prevent the basic wood based panel from influence of moisture. The panel is completely impermeable to air or moisture. . Ueno et al. (2008 ACEEE Sumer Study on Energy Efficiency in Buildings, pp. 1 -306 - 321) tested the performance of a variety of vapor control layers in a full-scale test facility in the marine climate of Olympia, WA, USA. The test materials comprised, inter alia, an asphalt-coated Kraft paper which is essentially impermeable for air and water vapor. P. Mukhopadhyaya et al. (J.ASTM Int. JAI 8 (2011) 3, 1-14) compared water vapor permeability and air permeability for various materials. Only for some material classes a correlation could be found between these permeabilities. For wood a very good correlation could be found at low moisture content of the material. This document shows that air permeability and vapor permeability are not necessarily correlated.
J. Langmans et al. (Energy and Buildings 42 (2010) 2376-2385) investigated the air tightness of a wood-frame passive house during the consecutive construction stages. The aim was to investigate whether acceptable air tightness can be achieved by the external wind barrier only. This is to be seen in view of the fact that energy consumption and sustainability is a growing priority for house owners, so, particularly in the last decade, considerable progress has been made to improve efficiently the energy behavior of buildings. Compared to conduction through building components, the convective heat transfer as a result of air movement through the building envelope becomes relatively more important in well-insulated buildings (C.Bankvall, The effect and cost impact of poor air tightness - information for developers and clients, in: Proceedings of Thermal Performance of the Exterior Envelopes of Whole Buildings X International Conference, Clearwater Beach, FL, 2007).
While an increase in the density of a wood-based panel, in particular, an OSB panel, can lead to higher air tightness without a complete stop of air and vapor diffusion, this implicates higher mass of these panels, hence higher costs in production and transport and higher effort in use.
SUMMARY OF THE INVENTION
It is an object of the present invention to control the air permeability of a wood-based panel, in particular, of an OSB panel, without increasing its density and without imparting a complete stop of air and vapor diffusion.
This object is achieved by a construction board according to claim 1. Further embodiments of the invention are laid down in the dependent claims. The present invention thus provides a construction board comprising:
a rigid wood-based panel having a first surface and a second surface opposite said first surface; and
at least a first cellulose-based layer attached to said first surface by an adhesive, wherein the construction board has an air permeability between 0.002 m3/(m2-h-daPa2 3) and 0.2 m3/(m2-h-daPa2/3), preferably between 0.01 m3/(m2-h-daPa2 3) and 0.1 nrVim^h-daPa273).
It has been found that air permeability can be precisely adjusted to a preselected value by a careful choice of properties of the panel (panel type, material, density, thickness etc.) as well as by a careful choice of the cellulose-based layer (generally a paper layer) and of the adhesive. In this manner a construction board is obtained which exhibits reduced air permeability, leading to improved insulation properties, while ensuring that controlled air exchange remains possible through the board. The prior art has failed to realize that air permeability (as well as water vapor diffusion) through a wood-based panel can be precisely controlled simply by application of a paper layer, without stopping air and water diffusion completely. Such precise control is not possible with standard wood-based panels: The composition of a standard wood-based panel, in particular, of an OSB panel, is very heterogeneous. The application of a defined homogenous flat material like a paper layer leads to a reduction in the heterogeneity and allows for a defined adjustment of air permeability and vapor diffusion resistance. By this defined and exact adjustment all other preferred properties of the wood-based panel, such as high strength values at low density, can be retained. The reduction of air permeability therefore does not come at the price of an increased weight or thickness of the board. Manufacture of such boards is extremely simple and cost-efficient once the properties of the panel, of the cellulose-based layer and of the adhesive have been selected. In particular, it is not necessary to employ any expensive synthetic foil materials or metallic layers, which are difficult to handle, for achieving control of air diffusion.
Preferably the properties of the panel, of the cellulose-based layer and of the adhesive are chosen such that not only air permeability is controlled, but also water vapor diffusion is controlled simultaneously, without stopping vapor diffusion completely. Preferably the finished construction board has a water vapor diffusion resistance factor μ between 50 and 1000, more preferably between 100 and 700 and still more preferably between 200 and 500. This will generally ensure that vapor exchange can take place to an extent necessary to avoid accumulation of moisture in constructions employing the board.
In the context of the present invention, the water vapor diffusion resistance factor μ is determined as defined in norm DIN EN 12752. The water vapor diffusion resistance factor or μ-factor is a dimensionless number describing how many times better a material or product is at resisting the passage of water vapor, compared with an equivalent thickness of air. The water vapor diffusion resistance factor μ is obtained by dividing the water vapor diffusion coefficient in air by the moisture permeability of a porous material.
The wood-based panel can be any type of veneer-, particle- or strand-based panel, e.g., a plywood panel or a chipboard panel, preferably an OSB panel, as it has been known for a long time. The basic production procedure of such panels has been extensively described in the literature, see, e.g., . Dunky and P. Niemz: Leime und Holzwerkstoffe (Adhesive resins and wood based panels), Springer, 2002.
Depending on the desired air and vapor permeability, the adhesive may e.g. be a dispersion adhesive or a thermoplastic adhesive. Preferably the adhesive is a polyvinyl acetate-based dispersion adhesive, which ensures a relatively high air and vapor permeability through the adhesive layer.
The construction board is preferably substantially free of any synthetic or metallic foil layers. In this context, "substantially free" means that no synthetic or metallic foil layer is applied to a significant portion of the surfaces of the panel so as to influence the diffusion properties of the board. In other words, if there is any synthetic or metallic foil layer present, that layer shall cover only such a small portion of the surface that the layer will not substantially influence the diffusion properties. Just by the way of example, the board may of course comprise one or more small stickers or labels which clearly would not interfere with the overall air and vapor diffusion through the board.
The first cellulose-based layer will generally be a paper layer having a thickness of typically less than 0.5 mm, often less than approximately 0.3 mm. The layer will generally have a mass per unit area of less than approximately 300 g/m2, preferably less than approximately 150 g/m2. For strength reasons the layer should preferably have a mass per unit area of at least approximately 20 g/m2, preferably at least approximately 40 g/m2.
The construction board may comprise a second cellulose-based layer attached to the second surface of the panel by an adhesive, i.e., it may be coated by a cellulose-based layer on both sides of the panel. It is also conceivable that the board comprises two or more cellulose-based layers on the same side of the panel.
The construction board of the present invention is preferably used for manufacturing an external wall of a building or for manufacturing a cladding for an external wall of a building. It may, however, be used also for other purposes, such as for manufacturing a roofing construction. An external wall construction or a cladding for an external wall construction will generally comprise further elements, such as a rigid frame construction, e.g. a timber frame construction, to which the construction board is directly or indirectly attached, and or at least one thermal insulation layer. The present invention also encompasses a building comprising a wall or a cladding constructed in this manner. The present invention further provides a method of manufacturing a construction board having a well-defined air permeability, the method comprising:
providing a rigid wood-based panel having a first surface and a second surface opposite said first surface; and
attaching at least a first cellulose-based layer to at least said first surface by an adhesive,
the panel, the adhesive and the first cellulose-based layer being selected such that the finished construction board has an air permeability between 0.002 m in^-h-daPa273) and 0.2 mV(m2-h-daPa2 3), preferably between 0.01 m3/(m2 h-daPa2/3) and 0.1 m3/(m2-h-daPa2/3).
As detailed above, the panel, the adhesive and the cellulose-based layer are preferably selected such that the finished construction board further has a water vapor diffusion resistance factor μ between 50 and 1000, preferably between 100 and 700, more preferably between 200 and 500.
The wood-based panel is preferably treated by sanding on the side(s) to which one or more cellulose-based layers are to be applied, before attaching the cellulose-based layers, so as to improve adhesion and to achieve a more homogeneous distribution of the diffusion properties across the surface of the panel.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described in the following with reference to the drawings, which are for the purpose of illustrating the present preferred embodiments of the invention and not for the purpose of limiting the same. In the drawings,
Fig. 1 shows a highly schematic cross sectional sketch of a construction board according to a first embodiment of the present invention; Fig. 2 shows a highly schematic cross sectional sketch of a construction board according to a second embodiment of the present invention;
Fig. 3 shows a first example of an external wall cladding employing a construction board according to the present invention; and
Fig. 4 shows a second example of an external wall cladding employing a construction board according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS Figure 1 illustrates, in a highly schematic manner and not to scale, a construction board according to a first embodiment of the present invention. An OSB panel 1 is covered on one side by a paper layer 3, which is attached to the panel by means of an adhesive layer 2.
A second embodiment is schematically illustrated in Fig. 2. Here the OSB panel is additionally covered by a second paper layer 3' attached to the other side of the panel by means of an adhesive layer 2'.
In both embodiments, one or more further layers may be added on top of layers 3 and/or 3'.
Areas of application of such a construction board are passive and low-energy houses, load- bearing elements of wall and roof structures, structures of external envelope in diffusion- open constructions, as well as final lining in attic space, just to mention some of the possible applications.
Example 1 : Wall cladding
A first example of application is illustrated in Fig. 3, illustrating an external wall cladding for a passive house construction. A timber framed construction 15 forms a structural frame for the cladding. Between the timber beams of the construction 15, a thermal insulation 14 formed of a material such as glass or mineral wool is disposed. Both sides of the construction 15 with the thermal insulation 14 are covered by a first construction board 13 and a second construction board 16 according to the present invention. Second construction board 16 is mounted to wood battens 18. Additional thermal insulation 17 is provided between the wood battens 18. A gypsum plasterboard 19 is mounted to the wood battens on the side facing away from board 16. Further thermal insulation boards 12 are connected to first construction board 13. The outermost thermal insulation board 12 is covered with a thin layer of mineral plaster 11.
Example 2: Wall cladding
A second example of a wall cladding is illustrated in Fig. 4. Instead of a second construction board according to the present invention, this construction employs a diffusion open fiberboard panel. Again, a frame construction 26 is provided, either made of solid timber beams or of OSB with I-hoists. To one side, the frame construction is covered by a diffusion open fiberboard 24. To the other side, the frame construction is covered by a construction board 27 according to the present invention. The interspace is again filled with insulation material 25, such as mineral or glass wool. A softwood fiberboard 23 covers fiberboard 24. Wood battens 22 are attached to softwood fiberboard 23 and carry a finished wood siding 21. Construction board 27 is mounted to wood battens 28 covered by a gypsum plasterboard 30. Additional thermal insulation 29 is provided between construction board 27 and gypsum plasterboard 30.
Example 3: Combination of an OSB/3 board (12 mm) and different types of papers as coating
Various paper layers were applied to an OSB/3 panel according to EN 300 having a thickness of 12 mm. Two different types of paper were used. Both paper types had a mass per unit area of 90 g m2. The first paper type (type„Backing paper") did not include any surface treatment; the second paper type (type 90B paper) had experienced a surface treatment. The sanded OSB/3 panel without any paper layer as well as the sanded OSB/3 panel with a single paper layer applied to one side were tested. The results of these tests are summarized in Table 1. Table 1: Diffusion measurements on different construction boards
Figure imgf000010_0001
The table illustrates the big differences in diffusion which can be achieved by a paper coating using various types of papers.

Claims

1. A construction board comprising:
a rigid wood-based panel (1) having a first surface and a second surface opposite said first surface; and
at least a first cellulose-based layer (3) attached to said first surface by an adhesive (2),
wherein the construction board has an air permeability between 0.002 nvV n^h-daPa273) and 0.2 m^m^h-daPa273), preferably between 0.01 m3/(m2 h daPa2/3) and 0.1 m3/(m2 h daPa2/3).
2. The construction board of claim 1 , having a water vapor diffusion resistance factor μ between 50 and 1000, preferably between 100 and 700, more preferably between 200 and 500.
3. The construction board of claim 1, wherein the panel (1) is an OSB panel.
4. The construction board of any of the preceding claims, the construction board being substantially free of any metallic foil layers.
5. The construction board of any of the preceding claims, wherein the first cellulose- based layer (3) has a mass per unit area of less than approximately 500 g/m2, preferably less than approximately 200 g/m2.
6. The construction board of any of the preceding claims, further comprising a second cellulose-based layer (3') attached to the second surface of the panel by an adhesive (2').
7. Use of a construction board according to any of the preceding claims for manufacturing an external wall of a building or for manufacturing a cladding for an external wall of a building.
8. A external wall of a building or a cladding for an external wall of a building, comprising a construction board according to any of claims 1-7.
9. The wall or cladding of claim 8, further comprising:
a rigid frame construction (15; 26), preferably a timber frame construction, the construction board being directly or indirectly attached to said frame construction; and
at least one thermal insulation layer (14; 25).
10. A building comprising a wall or a cladding according to claim 8 or 9.
11. A method of manufacturing a construction board having a well-defined air permeability, the method comprising:
providing a rigid wood-based panel (1) having a first surface and a second surface opposite said first surface; and
attaching at least a first cellulose-based layer (3) to at least said first surface by an adhesive (2),
the panel (1), the adhesive (2) and the first cellulose-based layer (3) being selected such that the finished construction board has an air permeability between 0.002 m3/(m2-h-daPa2 3) and 0.2 m^m^h-daPa273), preferably between 0.01 m3/(m2-h-daPa2/3) and 0.1 m3/(m -h-daPa2/3).
12. The method of claim 11, wherein the panel (1), the adhesive (2) and the cellulose- based layer (3) are selected such that the finished construction board has a water vapor diffusion resistance factor μ between 50 and 1000, preferably between 100 and 700, more preferably between 200 and 500.
13. The method of claim 11 or 12, wherein the wood-based panel (1) is treated by sanding before attaching the first cellulose-based layer (3) to the first surface.
14. The method of any of claims 11-13, wherein the finished construction board is substantially free of any metallic foil layers.
PCT/CH2012/000163 2011-08-23 2012-07-12 Construction board with defined air permeability WO2013026172A1 (en)

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US11697939B2 (en) 2004-02-23 2023-07-11 Huber Engineered Woods Llc Panel for sheathing system and method
US11536028B2 (en) 2004-02-23 2022-12-27 Huber Engineered Woods Llc Panel for sheathing system and method
US9546479B2 (en) 2004-02-23 2017-01-17 Huber Engineered Woods Llc Panel for sheathing system and method
US9689159B2 (en) 2004-02-23 2017-06-27 Huber Engineered Woods Llc Panel for sheathing system and method
US9695588B2 (en) 2004-02-23 2017-07-04 Huber Engineered Woods Llc Panel for sheathing system and method
US9702140B2 (en) 2004-02-23 2017-07-11 Huber Engineered Woods Llc Panel for sheathing system and method
US10415245B2 (en) 2004-02-23 2019-09-17 Huber Engineered Woods, Llc Panel for sheathing system and method
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US10711453B1 (en) 2015-12-29 2020-07-14 Georgia-Pacific Panel Products Llc Building panel with a weather barrier
US11634903B2 (en) 2015-12-29 2023-04-25 Georgia-Pacific Panel Products Llc Building panel with a weather barrier
JP2019163654A (en) * 2018-03-20 2019-09-26 パナソニックホームズ株式会社 Interior base panel and outer wall structure

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