(12)UK Patent Application (19)GB (11)2 376 206 (13)A
`
`
`
`(43) Date of A Publication
`
`11.12.2002
`
`(51) JNT CL7
`8328 3/28// 8328 7/06 15/08, E04B 1/64
`
`(52) UK CL (Edition T )
`
`B5N N0328 N0706 N1508 N1520 N195 N196 N199
`N20Y N207 N21X N21Y N222 N223 N224 N255 N256
`N257 N258 N259 N26X N26Y N389 N46Y N477 N480
`N484 N515 N517 N524 N527 N534 N537 N552 N564
`
`N573 N58X N58Y N589 N59X N60X N648 N657 N658
`
`N66Y N661 N670 N672 N681 N682 N684 N695 N70X
`N71Y N712 N725 N76X
`E1D DCF 0106 01071 01072 02044 D401 0402 D427
`
`U1S S1405 S1707 53011
`
`(56) Documents Cited
`GB 2370049 A
`
`GB 2367839 A
`
`(58) Field of Search
`
`UK CL (Edition T) B5N
`INT CL7 8328 3/28 15/08, E04B 1/64
`Other: Online: EPODOC, WPI, JAPIO, RM2 5
`
`No 0207775.8
`(21) Application
`
`(22) Date of Filing 04.04.2002
`
`(30) Priority Data
`
`(31) 0109156
`
`(33) GB
`(32) 12.04.2001
`
`(71) Applicant(s)
`British S isalkraft limited
`(Incorporated in the United Kingdom)
`Commissioners Road, Strood,
`ROCHESTER, Kent, ME2 4ED,
`United Kingdom
`
`(72) lnventor(s)
`Stephen Waight
`
`(74) Agent and/or Address for Service
`Stevens Hewlett & Perkins
`1 St Augustine's Place, BRISTOL,
`BS1 4UD, United Kingdom
`
`(54) Abstract litle
`Cavity wall lining
`sheet
`
`(57) A cavity wall lining sheet 10 comprises a vacuum formed bubble sheet 11,12 laminated to the first face of
`metal foil 15. The bubble sheet
`
`may be constructed from polyethylene and the foil may comprise aluminium,
`
`
`with a polyethylene or lacquer corrosion resistant coating. Optionally the second face of the foil may be heat
`sheet (150) which is tinted
`bonded to a further polyethylene
`or otherwise treated to reduce glare from the
`
`
`metal foil during installation of the liner sheet. In use, vertical overlaps between adjacent lining sheets are
`sealed with tape, whereas horizontal overlaps are left unsealed. The liner provides cavity insulation with
`around bubble cells 13.
`
`improved breathability due to air circulation
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`Page 1 of 13
`
`REFLECTIX, INC.
`Exhibit 1010
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`Page 2 of 13
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`Page 3 of 13
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`Page 4 of 13
`
`

`
`2376206
`
`CAVITY WALL LINING SHEET
`
`The present invention relates to cavity wall lining sheets and
`
`
`
`cavity wall constructions incorporating such lining sheets.
`
`Cavity walls are well known and provide inner and outer walls
`
`which are spaced from each other to provide some degree of thermal
`
`
`
`insulation and a barrier to water penetrating the inner wall. The term
`
`
`
`cavity wall should, in the context of this specification, be taken to include
`
`
`
`cavity roof sections and angled walls as well as generally vertical walls.
`
`
`
`
`
`
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`According to a first aspect of the present invention there IS
`
`provided a cavity wall lining sheet comprising a bubble sheet laminated
`
`
`
`on one major side only with a metal foil, the other major side being open
`
`thereby exposing the bubbles and allowing air to flow in the spaces
`
`between the bubbles.
`
`Preferably the bubbles are circular in cross-section and also
`
`
`
`cylindrical in shape. In preferred arrangements the metal foil is a coated
`
`
`
`aluminium foil. It is a further preferred feature that the bubble sheet
`
`
`
`comprises a thermoplastic film laminated to a vacuum formed
`
`
`
`thermoplastic sheet. The thermoplastic film and sheet may, for example,
`
`
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`be made oflow-density polyethylene.
`
`
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`In preferred embodiments a further sheet is peelably attached to
`
`the exposed surface of the metal foil. With some arrangements said
`
`
`
`further sheet is made from polyethylene which is heat sealed to the
`
`
`
`exposed surface of the metal foil and also the further sheet is coloured or
`
`
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`otherwise treated whereby glare from the metal foil is reduced.
`
`
`
`According to a second aspect of the present invention there is
`
`
`
`
`
`provided a cavity wall construction having an inner wall and a spaced
`
`
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`outer wall, the inner wall having attached to its outward facing surface a
`
`
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`lining sheet as described above, the metal foil facing outwardly.
`
`
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`In some arrangements the outer wall is made of brick. In other
`
`
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`arrangements the outer wall is made of tiles or cladding which are
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`Page 5 of 13
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`

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`2
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`mounted on battens attached to the inner wall with the li11ing sheet
`
`disposed between the battens and the inner wall. With these other
`
`
`
`arrangements the battens comprise first battens and second cross battens
`
`
`
`attached to the outward facing surfaces ofthe first battens.
`
`
`
`
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`With some cavity wall constructions, the inner wall comprises a
`
`
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`structural frame of timber or other material having a sheathing board
`
`
`
`
`
`
`
`
`
`
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`secured to its outermost surface. Usually wall ties link the inner and outer
`
`walls.
`
`
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`Preferred features are that vertical joints between adjacent lining
`
`
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`sheets have an overlap and are taped with foil tape and also that horizontal
`
`
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`joints between adjacent lining sheet have an upper lining sheet
`
`
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`overlapping a lower lining sheet with the overlap left open.
`
`
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`Embodiments of the present invention will now be described
`in
`
`
`
`more detail. The description makes reference to the following drawings
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`
`
`
`
`in which:
`
`Figure 1 is a view from one side of a section of cavity wall lining
`
`
`
`sheet according to the present invention,
`
`Figure 2 is an enlarged sectional view on line II-II of figure 1,
`
`Figure 3 is a vertical section through a cavity wall construction
`incorporating the lining sheet shown in figures 1 and 2.
`
`
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`
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`cavity wall Figure 4 is a vertical section through an alternative
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`
`
`construction,
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`Figure 5 is a vertical section through a further alternative cavity
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`
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`wall construction, and
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`
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`Figure 6 is a sectional view similar to figure 2 of a modified cavity
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`wall lining sheet according to the present invention.
`
`Figures 1 and 2 show a cavity wall lining sheet 10 comprising a
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`
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`thermoplastic film 11, which in this embodiment is a low-density
`
`
`
`polyethylene film, laminated on one major side to a vacuum formed
`
`
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`thermoplastic sheet 12, which in this embodiment is also a low-density
`
`
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`Page 6 of 13
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`

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`3
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`
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`polyethylene sheet. The thermoplastic sheet is vacuum formed to provide
`
`
`generally cylindrical bubble cells 13 arranged across the surface. As is
`lrnown, the thermoplastic film 11 is laminated to those areas 14 which are
`
`
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`not formed as cells. It is clear from the figures, the areas 14 result in
`
`
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`space around the bubble cells 13 which enable passage of air/vapours
`
`around the bubble cells.
`
`
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`Laminated to the other major side of the thermoplastic film 11 is
`
`an aluminium foil 15 which has been coated, for example with
`
`
`polyethylene, to prevent corrosion. An alternative coating would be a thin
`
`
`
`
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`coating of lacquer which improves the foil reflectivity and thus improves
`
`
`
`
`
`
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`the insulation value of the construction described herein. The bubble cell
`
`
`
`side of the lining sheet 10 is, however, left open.
`
`
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`Figure 3 shows a cavity wall construction 20 comprising an outer
`wall 21 made from bricks 22 and an inner wall 23. The inner wall 23 in
`
`
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`this embodiment comprises a timber frame 24 having an inner wall lining
`
`
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`25 and a sheathing board 26 attached to the outside of the timber frame
`
`
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`24. Insulation material 27 is provided between the inner wall lining 25,
`
`
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`which may, for example, be plasterboard, and the sheathing board 26,
`
`
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`which may, for example, be plywood, oriented strand board or wood
`
`particle board.
`
`
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`On the outward facing side of the sheathing board 26 is attached
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`the cavity wall lining sheet 10, perhaps with staples or nails. The lining
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`
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`sheet 10 is attached with the bubble cells 13 against the sheathing board
`
`
`
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`26 such that the foil15 faces outwardly into the cavity 28.
`
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`It IS envisaged that wall ties would be provided at suitable
`
`locations to connect the inner and outer walls 23, 21, as is standard
`
`
`
`practise with cavity wall constructions. The wall ties are not, however,
`
`shown.
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`Page 7 of 13
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`4
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`
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`Ideally, the lining sheet 1 0 is fixed to the sheathing board 26
`
`
`
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`
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`horizontally in strips perhaps 1 000 mm wide, with each upper sheet 1 0
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`
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`overlapping a lower sheet 10 as is clearly shown in figure 3. The overlap
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`
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`is left open at its lower edge. The amount of overlap is preferably about
`
`
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`75 mm but this could be longer or shorter. If sheets 10 are to meet
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`vertically then again there should be an overlap of perhaps 100 mm and
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`preferably the overlapping edge should be taped closed with foil tape of a
`
`suitable width.
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`It will be appreciated that the lining sheet 10, by virtue of its foil
`
`
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`film 15, provides a flame retardant property for the inner wall 23. The
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`
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`lining sheet 10 also creates a wind-tight, draught-free, weather-sealed
`
`
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`
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`wall, providing a complete barrier to moisture moving inwards. However,
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`the open nature of the cell structure lying against the sheathing boards
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`26 allows any water vapour present in the inner wall to exit via the
`channels between the cells 13 and into the cavity 28. Once in the cavity,
`
`the water vapour can exit the cavity via weep vents (not shown) in the
`
`brick work.
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`When the cavity wall is being constructed, the lining sheet 10 also
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`offers some protection from the weather prior to construction of the outer
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`wall21 and the addition of a roof structure.
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`Figure 4 shows an alternative arrangement and like parts have
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`
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`been given the same reference numerals. In the alternative arrangement,
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`the outer wall 21 is not made of bricks, but comprises external cladding
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`to the timber fr ame 24 30. A set of vertical battens 31 are attached
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`through the lining sheet 1 0 at spaced locations horizontally along the wall.
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`The external cladding 30 is then attached to the vertical battens 32 thus
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`leaving a cavity 28 between the inner wall 23 and the external cladding
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`30. The lining sheet 10, therefore, performs the same functions and has
`
`
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`the same effects as in the figure 3 arrangement.
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`Page 8 of 13
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`

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`5
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`Figure 5 shows a further alternative arrangement which is similar
`
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`
`
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`in some respects to figure 4. Like reference numerals have, therefore,
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`
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`been given to like parts. However, the external cladding panels 30 have
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`been replaced by individual tiles 40 which are located on and secured to
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`spaced horizontal counter battens 32 which are attached to the vertical
`
`battens 31. Again, this results in a cavity 28 between the inner walls 23
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`and the tiles 40. The lining sheet 10, therefore, performs the same
`
`functions and has the same effects as described above.
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`Figure 6 is similar in many respects to figure 2 and so like parts
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`have been given like reference numerals with the addition of a "1" prefix.
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`A further sheet 15 0 is included in the figure 6 embodiment. The further
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`sheet 150 is made for example from polyethylene and is affixed to the
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`
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`exposed side of the foil 115 by a heat seal to form a light bond. The
`
`
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`further sheet 150 is also coloured or otherwise treated so as to reduce
`
`
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`glare from the foil surface, particularly during installation of the cavity
`
`
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`wall lining sheet 110. Once the lining sheet 110 has been installed, or
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`indeed at any other chosen time, the further sheet 150 can be peeled off
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`the surface of the foil 115 to leave the foil surface exposed save for the
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`corrosion prevention layer. Other methods of forming the peelable, light
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`bond can be envisaged but heat sealing has been found to be acceptable.
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`It will be appreciated that the lining sheet 10 can be used in other
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`
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`cavity wall constructions not described above. Also the cavity wall
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`
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`constructions need not necessarily be vertical but could be angled, for
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`example in roof situations.
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`Although the bubble cells 13 described above are cylindrical in
`
`
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`shape, it will be understood that other shapes and sections are possible.
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`
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`Also the staggered arrangement of the rows of cells 13 could be varied
`
`
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`provided there is still space around them for passage of air/vapour
`
`between the cells when the open side of the lining sheet 1 0 lies against the
`
`sheathing board 26.
`
`Page 9 of 13
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`

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`6
`
`
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`1. A cavity wall lining sheet comprising a bubble sheet laminated on
`
`one major side only with a metal foil, the other major side being
`
`open to expose the bubbles and allow air to flow in the spaces
`
`between the bubbles.
`
`2. A cavity wall lining sheet as claimed in claim 1 wherein the
`bubbles are circular in cross-section.
`
`
`
`3. A cavity wall lining sheet as claimed in claim 1 or claim 2 wherein
`
`
`
`the bubbles are cylindrical in shape.
`
`4. A cavity wall
`lining sheet as claimed in any one of claims 1 to 3
`
`
`
`wherein the metal foil is a coated aluminium foil.
`
`5. A cavity wall lining sheet as claimed in any one of claims 1 to 4
`wherein the bubble sheet comprises a thermoplastic film laminated
`
`
`
`
`
`to a vacuum formed thermoplastic sheet.
`
`6. A cavity wall lining sheet as claimed in claim 5 wherein the
`thermoplastic film and sheet are made of low-density
`
`
`
`polyethylene.
`
`7. A cavity wall lining sheet as claimed in any one of claims 1 to 6
`
`
`
`wherein a further sheet is peelably attached to the exposed surface
`
`of the metal foil.
`
`Page 10 of 13
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`

`
`7
`
`
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`8. A cavity wall lining sheet as claimed in claim 7 wherein said
`
`
`
`further sheet is made from polyethylene which is heat sealed to the
`
`exposed surface of the metal foil.
`
`9. A cavity wall lining sheet as claimed in claim 7 or claim 8 wherein
`
`
`
`the further sheet is coloured or otherwise treated whereby glare
`
`from the metal foil is reduced.
`
`10. A cavity wall lining sheet as claimed in any one of claims 1 to 9
`
`
`
`wherein the foil has a corrosion prevention coating of lacquer or
`
`polyethylene.
`
`11. A cavity wall construction having an inner wall and a spaced outer
`
`wall, the inner wall having attached to its outward facing surface a
`lining sheet as claimed in any one of claims 1 to 10, the metal foil
`
`facing outwardly.
`
`12. A cavity wall construction as claimed in claim 11 wherein the
`
`outer wall is made of bricks.
`
`
`
`13. A cavity wall construction as claimed in claim 11 or claim 12
`
`wherein wall ties link the inner and outer walls.
`
`14. A cavity wall
`as claimed in claim 11 wherein the
`construction
`
`outer wall is made of tiles or cladding which are mounted on
`
`battens attached to the inner wall with the lining sheet disposed
`
`between the battens and the inner wall.
`
`Page 11 of 13
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`

`
`8
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`
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`15. A cavity wall construction as claimed in claim 14 wherein the
`
`
`
`battens comprise first battens and second cross battens attached to
`
`
`
`the outward facing surfaces of the first battens.
`
`16. A cavity wall construction as claimed in any one of claims 1 1 to
`
`
`
`
`
`15 wherein the inner wall comprises a structural frame having a
`
`sheathing board secured to its outermost surface.
`
`17. A cavity wall was claimed m claim 16 wherein the structural
`
`frame is made oftimber.
`
`as claimed in any one of claims 11 to
`18. A cavity wall construction
`
`
`
`lining sheets have an 17 wherein vertical joints between adjacent
`
`
`
`overlap and are taped with foil tape.
`
`19. A cavity wall construction
`as claimed in any one of claims 11 to
`
`
`18 wherein horizontal joints between adjacent lining sheets have
`
`
`an upper lining sheet overlapping a lower lining sheet with the
`
`overlap left open.
`
`Page 12 of 13
`
`

`
`GB 0207775.8
`Application No:
`
`1-1'9
`Claims searched:
`
`Richard Gregson
`Examiner:
`3 October 2002
`Date of search:
`
`INVESTOR IN PEOPLE
`
`Patents Act 1977
`Search Report under Section 17
`
`Databases searched:
`
`
`
`
`
`UK Patent Office collections, including GB, EP, WO & US patent specifications,
`in:
`
`UK Cl (Ed. T): B5N
`
`Int Cl (Ed.7): B32B (3/28, 15/08) : E04B (1/64)
`
`Other: Online: EPODOC, WPI, JAPIO, RM25
`
`
`
`Documents considered t o be relevant:
`
`Category Identity
`of document and relevant
`passage
`
`E,X GB 2370049 A
`
`E,X GB 2367839 A
`
`Relevant
`to claims
`(YORKSHIRE BUILDING)-see whole document. 1,5
`(YORKSHIRE BUILDING) -see whole document. 1,2,4,5,11
`12,14,17,1
`9 at least.
`
`X
`y
`
`&
`
`A Document indicating technological background and/or state of the art.
`
`
`Document indicating lack of novelty or inventive step
`
`
`
`on or after the declared priority date but before the
`P Document published
`
`
`Document indicating lack of inventive step if combined
`filing date of this invention.
`with one or more other documents of same category.
`
`E Patent document published
`
`than, the filing date of this application.
`
`on or after, but with priority date earlier
`
`Member of the same patent family
`
`
`
`An Executive Agency of the Department of Trade and Industry
`
`
`
`Page 13 of 13