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
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
  • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
  • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material
• • 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
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
  • E04C2/388—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a frame of other materials, e.g. fibres, plastics
• • 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
  • E04F13/0875—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 having a basic insulating layer and at least one covering layer
  • E04F13/0878—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 having a basic insulating layer and at least one covering layer the basic insulating layer comprising mutual alignment or interlocking means

Definitions

• the invention relates to insulating multilayer panels essentially made of plastic.
• the invention also relates to a manufacturing method for such panels and their use.
• V layers ensure the mechanical strength of the assembly and possibly allow it to adapt its external appearance.
• US Patent US 5,842,315 describes a three-layer panel, the upper layer of which is made of plastic or metal is corrugated, the lower layer consists of a PNC film and the central layer is of injected polyurethane foam.
• the upper layer of these panels is extended beyond the foam layer to allow overlapping of the junction of different panels between them.
• During assembly such panels are in fact simply juxtaposed. They must therefore be fixed to a supporting structure, using screws, bolts or 'nails which perforate the panel.
• This type of mounting has many disadvantages: risk of corrosion, handling necessary for their fixing, loss of tightness following the perforation of the panels, loss of insulating power following thermal bridges constituted by nails or bolts.
• due to mounting imperfections there is a risk that the foam layers of adjoining panels are not perfectly contiguous. The insulation properties of the panels will then be greatly reduced.
• the invention relates to a multilayer insulating panel comprising a layer of expanded plastic material located between two layers of unexpanded plastic material and comprising an integrated system making it possible to assemble said panel in at least two dimensions of space. at least one other complementary panel, said integrated system consisting of profiles having a grooved or ribbed shape provided with a self-locking cam.
• the multilayer panels according to the present invention are essentially planar. The word essentially refers in particular to the case where the panels have a surface relief. According to the embodiments, the panels will possibly have a certain flexibility which will make it possible to bend them when they are used.
• expanded plastic material is meant a plastic material whose density has been reduced by the addition of additives known under the name of "foaming agents".
• additives are well known in the plastics industry. They can be of various types often grouped into two families: chemical foaming agents and physical foaming agents. You can also mix them. Information can be found on this subject in numerous technical works.
• the density reductions vary greatly depending on the foaming agent and the amount used.
• expanded plastic is meant a plastic whose density has been reduced by more than 5%, or even more than 10%, compared to its value without foaming agents, for identical pressure and temperature conditions. .
• unexpanded plastic is meant a plastic whose density is close to its value without foaming agents, for identical pressure and temperature conditions. It may or may not contain foaming agents. If it does, it must be in small quantities or the action of the foaming agent must have been prevented, for example by applying pressure.
• unexpanded plastic material means a plastic material whose density has been reduced by less than 5%, possibly less than 10%, compared to its value without foaming agents and for pressure and temperature conditions identical.
• the transition between the expanded layer and the unexpanded layer can be very abrupt, that is to say that one passes directly from the density of the expanded material to that of the material unexpanded.
• the unexpanded layers may or may not be reinforced by any well-known technique (for example fibers or fabrics of glass, polyester, etc.). They may include any type of additives well known in plastics to improve certain properties (such as impact resistance, fire resistance, etc.). They may also have undergone a surface treatment or even have been coated or covered with outer layers, for example protective thin layers, in particular protections against solar radiation. These thin layers may also have a decorative purpose.
• any well-known technique for example fibers or fabrics of glass, polyester, etc.
• They may include any type of additives well known in plastics to improve certain properties (such as impact resistance, fire resistance, etc.). They may also have undergone a surface treatment or even have been coated or covered with outer layers, for example protective thin layers, in particular protections against solar radiation. These thin layers may also have a decorative purpose.
• the panels include an assembly system.
• This system is integrated into the panel.
• the component parts of the system are already part of the panel before it is attached to other panels. It is therefore not necessary to have additional separate parts.
• the assembly can therefore be done quickly and simply.
• the assembly system will consist of two complementary parts, for example one of the "male” type and one of the "female” type.
• the panels will be provided with this system on two of their opposite ends, each end carrying one of the two complementary parts.
• the complementary panels will therefore generally be similar.
• Some panels may even include complementary parts of the assembly system on more than two of their ends.
• the additional panels may also be corner, edge, connection, ...
• the panels will be assembled in two or three dimensions of space.
• the word dimension is understood here in the geometric sense of directions perpendicular two by two: a plane has two dimensions and space has 3 dimensions.
• these dimensions are the dimension perpendicular to the panels and the dimension perpendicular to the assembly system.
• the panels will then be assembled in such a way that they can neither be separated from one another nor lifted one relative to the other in the dimension perpen-dicular to the plane of the panels.
• the integrated assembly system can be made for example of metal (aluminum, in particular), of plastic material, etc. Plastics are preferred. Indeed, given the low thermal conductivity of these materials, thermal bridges are avoided. It is indeed well known in the field of thermal insulation that even a small element of the structure whose thermal conductivity is high can deteriorate the insulation properties of the entire structure.
• the integrated assembly system consists of profiles.
• profile is well known in the art (parts defined geometrically by the translation of a two-dimensional contour).
• the profiles may possibly also include additional periodic patterns, such as notches or protuberances formed at regular intervals on the profile.
• the profile may consist of a part produced separately from the other elements of the panel and assembled during the manufacture of the latter. It can also consist of the ends of the layers of unexpanded material.
• the profiles have a grooved or ribbed shape provided with a self-tightening cam, i.e. a device which prevents the spacing of the panels when they are assembled but whose design is such that it nevertheless allows the disassembly of the panels if necessary.
• a self-tightening cam i.e. a device which prevents the spacing of the panels when they are assembled but whose design is such that it nevertheless allows the disassembly of the panels if necessary.
• One end of the panel will be provided with the rib ("male" side) while its opposite end will be provided with the groove (“female” side).
• the penetration of the rib in the groove assembles the panels in the dimension which is perpendicular to them.
• the self-locking cam prevents the spacing of the panels when they are assembled either by its shape only, or by the fact that it is provided with a reversible clipping device. The latter variant is preferred.
• the integrated system allows the said panel and at least one other complementary panel to be assembled in the three dimensions of the space.
• the assembly system consists of profiles provided with grooves, ribs and self-locking cams, the assembly will be obtained in the third dimension by providing the profiles with the additional periodic patterns mentioned above.
• the integrated assembly system according to the invention makes it possible in most cases to avoid using additional fastening systems.
• locations may be provided in the assembly system for having there screws, nails or other well-known fixing device.
• these housings for additional fastenings will be arranged so as to be invisible after assembly of the panels together and to avoid thermal bridges.
• one -for example can fix some in this way. This will ensure the entire assembly exceptional stability, while greatly reducing the number of fasteners, compared to an assembly according to the prior art.
• Polyethylene polypropylene
• polyvinylidene fluoride polyurethane
• Polyurethane foam is preferred for its adhesion qualities on many supports (plastic materials, metals, wood, %), its ease of implementation and its moderate cost.
• the layers of unexpanded material can be made of polyethylene, polypropylene or PVC, to cite only so-called convenience polymers.
• the PNC is nevertheless preferred, given its widespread use, especially in the building sector, for which grades resistant to bad weather and solar radiation exist.
• flexible or rigid PNC may be used. It is also very advantageous to combine these two materials, one non-expanded layer being made of flexible PNC, the other of rigid PVC.
• the use of flexible PNC in the outer layer makes it possible to take advantage of the renovation possibilities offered by flexible PNC membranes. During a renovation, the entire panel should not be replaced. It will suffice to cover it by well-known techniques for these products with a new membrane layer.
• the rigid PVC layer placed on the inside of the panel, will ensure the rigidity of the panel.
• the expanded plastic material is polyurethane and the two layers of unexpanded plastic material are made of flexible PVC and / or rigid PVC.
• the two layers of unexpanded plastic material of the insulating panel according to the invention may have various reliefs. These reliefs can be the well-known undulations (rounded, of Greek form, etc.), or any periodic form which can be obtained by hot forming techniques. It is in fact known that such reliefs increase the overall rigidity of the panel. All combinations between these reliefs are possible for the two layers. One can thus combine by way of example two Identificationa undulations or a Totala undulation and a thermoformed relief. It is also possible to use layers whose • outer face is flat and the inner face has a relief, for example rib, or even the opposite situation. Depending on the technique for producing the panel, it may be that the foam layer follows these various reliefs or that, on the contrary, it remains flat.
• At least one of the two layers of unexpanded plastic material is planar. Indeed, thanks to the good performance of the assembly system according to the invention and thanks to the rigidity provided by the foam layer, a panel of which one of the layers of unexpanded material is flat will already be sufficiently rigid for many applications. All other things being equal, such a panel will require less material, will be lighter and simpler to produce, a forming operation being able to be avoided. It will also be easier to install. In a particularly advantageous manner, the two layers of unexpanded plastic material will be flat.
• such panels can be more easily bent, in order to obtain rounded shapes.
• the concepts of relief, undulation, layer of plane plastic material which are discussed here are understood on a centimeter scale and do not relate to the surface condition of the materials.
• the surface condition also concerns reliefs but which have a smaller characteristic size.
• the surface condition of a layer of flat plastic can therefore have reliefs intended to improve, for example, its adhesion to the foam or the adhesion of a finishing layer which would be applied to the panel.
• An example of such relief is the "graining" which is often given to plastic sheets and plates.
• the invention also relates to a method for manufacturing a multilayer insulating panel according to the invention as defined above, according to which the layer of expanded plastic is injected.
• the panels according to the invention can be produced by many well-known techniques in plastics.
• the panel when the assembly system is made up of plastic profiles, the panel can be coextruded directly in a block, by means of a coextrusion die, the different segments of which are supplied with the different necessary materials (expanded, unexpanded , material for the profiles).
• the extradate must be cut periodically at the outlet of the die.
• this step will be delicate.
• the expanded plastic material is injected. If the panel is made of a single material, it is possible to advantageously use the well-known techniques of “structured foams”.
• the interface between the expanded and unexpanded layers is of the "progressive" type.
• Several well-known implementation techniques are available in this context in order to release the action of the foaming agent present in the material only in the desired layer of the panel.
• the profiles of the assembly system can be made as separate parts also or, on the contrary, they can be made in one piece with the layers of unexpanded material.
• the method of manufacturing the panel according to the invention will advantageously include the following steps:
• the integrated panel assembly system according to this variant of the invention can be produced by any implementation technique (molding, overmolding, thermoforming, compression, extrusion, etc.). It is advantageously produced by extrusion. If the profiles are provided with additional periodic patterns, such as notches or protuberances formed at regular intervals, the extrusion die will be provided with a mobile device, actuated periodically.
• thermoforming is meant any forming technique during which the material undergoes heating.
• the thermoforming of the assembly system may be carried out separately or else when the panel itself is made up. A panel produced in the latter way will be particularly economical.
• the panel manufacturing method according to the invention advantageously comprise the steps of: '
• the panel is extracted from the mold as well as a step of thermoforming the ends of at least one layer of unexpanded plastic material produced separately or during the constitution of the panel in order to produce an integrated assembly system for said panel.
• the invention also relates to the use of the insulating multilayer panel according to the invention as defined above, for the insulation of premises or parts of vehicles whose interior temperature is controlled.
• the multilayer insulating panels according to the invention can be used for extremely varied applications, such as: production of refrigerated warehouses, cold rooms, storage of food products, construction of operating theaters for hospitals, production of vehicle cases for transport, insulation of swimming pools, construction of light and inexpensive dwellings, etc.
• the multilayer insulating panels according to the invention will advantageously be used for the insulation of premises or parts of vehicles whose interior temperature is controlled.
• the excellent thermal and sound insulation properties, the sealing, the corrosion resistance, the ease of assembly (and disassembly) and finally the economic nature of the panels according to the invention allow a particularly competitive use in these applications.
• the assembly system ensures that the panels according to the invention keep these properties for a long period of use.
• FIG. 1 represents an exemplary embodiment of the panel according to the invention.
• FIGS. 2a, 2b, 2c illustrate the operation of the assembly system according to the invention in the case of the panel illustrated in FIG. 1.
• FIG. 2a shows the assembly systems of the panels before their coupling, in particular the sections 4 and 5. It can be seen that the self-tightening cam 8 prevents the panels from being brought together completely by translation.
• FIG. 2b illustrates the inclination or the bending which it is necessary to give to the panel provided with the male part of the assembly system so that it can penetrate the groove of the complementary part.
• Figure 2c shows the assembled system.
• the self-locking cam 8 assembles the panels in the X dimension of the space.
• the penetration of the rib 6 in the groove 7 assembles the panels in the dimension Y of the space.
• the dimensions X and Y • are perpendicular.
• a screw 11 has been placed in the housing 10 provided for this purpose. The presence of this screw is optional.
• the housing for fixing 10 makes the screw 11 invisible after assembly of the panels.
• the space provided above the screw 11 by this housing 10 also prevents the screw from forming a thermal bridge.
• the contact surfaces 12a and 12b ensure the seal of the assembly. They can be covered with a seal, not shown. The presence of the screw 11 will therefore not affect the tightness of the assembled panels.
• Figure 3 Figure 3 shows an embodiment of the panel according to the invention, particularly suited to the case where they must be bent.
• the panel comprises a flexible PVC membrane 13, a rigid PVC plate 14, a layer of polyurethane foam 15, an upper part 16 of the assembly system according to the invention and its lower complementary part 17.
• FIG. 4a and 4b illustrate the operation of the assembly system according to the invention, in the case of a panel well suited to bending.
• Figure 4a shows the positioning of the panels before their assembly.
• Figure 4b illustrates the relative arrangement of the panels after assembly. We can see that thanks to the angle 18 made by the sides 19 to 24 with the dimension Y, the panels are assembled in the two perpendicular dimensions X and Y.
• Figure 5
• FIG. 5 represents a particularly advantageous variant embodiment of the panel according to the invention which allows particularly easy mounting with an additional panel.
• the panel has a female end A and a male end B.
• the female end A of the panel is shown. fitted into the male end B of an additional panel.
• These panels include a flexible PVC membrane (1), a PUR insulating foam (2), a rigid PVC plate (3), a female junction profile (4) comprising a flexible lip (7) and an opening (rib ) upper edge (8), a male junction profile (5) comprising a rigid lip (6) and a stud (groove) (9).
• the two complementary panels To assemble the two complementary panels, they are brought together laterally and the post (9) is slid under the edge (8) of the opening, ensuring that the end of the rigid PVC plates (10) overlap .
• the rigid lip (6) comes into contact with the flexible lip (7), deforms it by flattening it and then marries it by clipping.
• the flexibility of the lip (7) is relative, i.e. that it is sufficient to allow its deformation during assembly / disassembly with a reasonable effort in the lateral direction, but insufficient for an accidental dislocation can occur during assembly.

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• 2000
  • 2000-09-11 FR FR0011684A patent/FR2813927B1/fr not_active Expired - Fee Related
• 2001
  • 2001-09-10 WO PCT/EP2001/010410 patent/WO2002020915A1/fr not_active Application Discontinuation
  • 2001-09-10 AU AU2001295549A patent/AU2001295549A1/en not_active Abandoned
  • 2001-09-10 EP EP01976206A patent/EP1319106A1/de not_active Withdrawn

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