EP2374957B1 - Process for manufacturing an insulating composite building block and block produced by this process - Google Patents

Description

The present invention relates to the field of block-shaped building elements, including bancher blocks of the crawling type, and relates to a composite building block of the block-type insulation.

It is known that the conventional blocks used in construction for the realization in particular of external walls have a generally parallelepiped shape and are intended to be stacked on top of each other in successive rows.

Among these blocks made entirely of a carrier material, are particularly known those which are in the form of a shaped hollow body of parallelepiped shape, whose side walls define at least two cells, open towards the top and towards the bottom of this block.

After stacking, a fluid material incorporating a hydraulic binder, for example of the concrete type, is injected into the cell alignments resulting from the superimposed rows of blocks, in order to create the framework of the resulting wall after solidification.

It is also currently known to use, for better acoustic and thermal insulation of walls, insulating blocks which are generally constituted by a structure consisting of an assembly of two constituent elements, one of which, located on the internal side of the construction, is a block of carrier material (concrete, wood-cement or other) and the other, located on the outer side of the construction, is a rigid insulating member, usually expanded polystyrene or the like.

Such a concrete block constituting an insulating block generally comprises one or more assembly sites with an insulating element which consist of one or more male parts or tenons, intended to fit tightly in a complementary female part or mortise, formed in the corresponding insulating element, and the shape of said male / female parts, for example dovetail, is determined so that their mechanical connection can oppose their separation when subjected to a force of external traction.

In addition, one or more cells, formed by joining the concrete part with the corresponding complementary insulating element, constitute, when assembling the blocks on top of each other for the construction of a wall and as indicated above for conventional blocks, vertical compartments in said wall which are intended to be filled with concrete, so as to auto locking said blocks on each other and to achieve a succession of concrete posts constituting, with the horizontal chaining, the frame of said wall.

By the documents FR 2 597 907 , EP 0 882 850 , DE 295 10 640 and DE 296 01 827 in particular, composite blocks of the aforementioned type formed by over-molding of the insulating component on the carrier component and / or by bonding of the two components at sites of complementary shapes are known.

However, these achievements of known insulating blocks necessarily require the development of new molds for the carrier component and the delicate molding of complex shaped fastening sites. In addition, the resistance of the assembly between the two components is often limited, which can result in a recess or separation of the two components under the pressure of the concrete injected into the cells, or in the rupture of one of the two components. components.

Moreover, we know from the document US 4,380,887 an insulating building block constituted, on the one hand, by a first element of a carrier material and which forms the structural body of the block and, on the other hand, by insulating secondary elements, made in the form of platelets and intended to be inserted in special dwellings positioned in the first element.

The object sought in this prior document is to subdivide the structural body of the building block into parts thermally insulated from one another by one or more insulating inserts.

For this purpose, the insulating elements in the form of platelets are arranged to be arranged entirely inside the building block, as inserts, that is to say without being in contact with the outer faces of these blocks. of construction and a fortiori without forming an outer side of these blocks. In particular, the inner and outer faces of this building block are always formed by the structural body.

Finally, the document FR 2,567,177 discloses, for its part, building blocks comprising a first structural part (agglomerated block) and a second insulating part (plate), the latter being arranged to be mounted / fixed on the first part by an insertion of T-section tabs in adapted grooves formed in the wall of a side face of the first structural part.

The walls of the block forming the structural part have a double and multi-cellular constitution around central cells and the grooves are formed by a plurality of slit-like cuts in the thickness of the outer skin of the wall of the first part. structural.

The complex constitution of the structural part (double and multi-cellular walls) leads to a relatively delicate fabrication and a significant additional cost for the building block.

In addition, the peripheral attachment of the insulating part in small grooves and with a recovery at an outer skin only of the wall, does not lead to a resistant assembly between the two components and limit of this also the thickness of the insulating plate that can be secured and the stresses to which it can be subjected and can be transmitted to the structural part.

The present invention aims to overcome at least some of the aforementioned drawbacks of existing solutions, while preferably having at least equivalent performance at the level of the final product.

For this purpose, it relates to a method of manufacturing a composite building block of the block-insulating type, according to the preamble of claim 1 and having in combination the characteristics of the characterizing part of this claim.

The invention also relates to a building block of the type mentioned in the preamble of claim 10 and having in combination the characteristics of the characterizing part of this claim.

• la figure 1 est une vue de dessus d'un bloc de construction composite selon un premier mode de réalisation de l'invention ;
• la figure 2 est une vue éclatée en perspective du bloc de construction de la figure 1, séparé en ses deux composantes ;
• la figure 3 est une vue de dessus d'un bloc de construction composite selon un second mode de réalisation de l'invention ;
• la figure 4 est une vue en perspective d'un bloc de construction creux en un matériau porteur formant la première composante du bloc composite de la figure 3 ;
• la figure 5 est une vue en élévation latérale du bloc composite représenté figure 3 ;
• la figure 6 est une vue de dessus d'une partie de mur réalisée par juxtaposition de deux blocs courants selon la figure 1 et d'un bloc d'angle selon la figure 3 ;
• les figures 7 à 9 sont des vues de dessus de trois variantes de réalisation du bloc composite représenté figure 1 ;
• la figure 10 et une vue en élévation latérale d'un bloc de construction composite selon un troisième mode de réalisation de l'invention ;
• la figure 11 est une vue de dessus d'une partie de mur formée par deux blocs tels que représentés sur la figure 10 disposés attenants côte à côte, et,
• les figures 12A à 12C sont des vues respectivement de dessus, en élévation frontale et en élévation latérale de la première composante porteuse faisant partie du bloc représenté figure 10.

The invention will be better understood from the following description, which refers to preferred embodiments, given by way of non-limiting examples, and explained with reference to the appended diagrammatic drawings, in which:

• the figure 1 is a top view of a composite building block according to a first embodiment of the invention;
• the figure 2 is an exploded perspective view of the building block of the figure 1 separated into its two components;
• the figure 3 is a top view of a composite building block according to a second embodiment of the invention;
• the figure 4 is a perspective view of a hollow building block made of a carrier material forming the first component of the composite block of the figure 3 ;
• the figure 5 is a side elevational view of the composite block shown figure 3 ;
• the figure 6 is a top view of a wall portion made by juxtaposing two current blocks according to the figure 1 and a corner block according to the figure 3 ;
• the Figures 7 to 9 are top views of three alternative embodiments of the composite block shown figure 1 ;
• the figure 10 and a side elevational view of a composite building block according to a third embodiment of the invention;
• the figure 11 is a top view of a wall portion formed by two blocks as shown in FIG. figure 10 arranged side by side, and,
• the Figures 12A to 12C are views respectively from above, in front elevation and in lateral elevation of the first carrier component forming part of the block shown figure 10 .

The invention relates to a method for manufacturing a block 1 of composite construction of the insulating block blocking type, comprising a first component or component part 2 of a carrier material and a second component or component part 3 made of a rigid insulating material, the two components being at least partially nested within each other and each component forming a clean volume portion of the composite block 1, and at least one outer face thereof.

This method consists in providing,
on the one hand, a hollow building block 2 made of a carrier material of generally parallelepipedal shape with an upper face 4, a lower face 4 'and lateral faces 4 ", said block consisting of portions of profiled lateral walls 5 delimiting together at least one cell 6 open at the above-mentioned upper and lower faces and the wall portion or portions 5 of at least one lateral face 4 ", or, where appropriate, of two mutually adjacent side faces 4" being provided with at least one profile cut 7, 7 'extending in a direction DP perpendicular to the upper 4 and lower 4 'faces, where appropriate over the entire height of the or at least some of said wall portions 5 concerned, and,
on the other hand, a block 3 of rigid insulating material shaped to come into intimate application against or be positioned at a distance from the outer lateral face (s) 8 of the hollow building block 2 comprising the the cutouts 7, 7 'and having one or more projecting formations 9 intended to anchor, by cooperation of complementary shapes, in the cell or the cells 6, this through one or more openings in the one or more portion (s) of wall (s) 5 corresponding to the cut-out (s) 7, 7 ',
and then, to assemble the two components 2 and 3 above to produce a composite building block 1, by a mutual interlocking movement in a direction perpendicular to the DP 4 upper and lower 4 'of the block 2 of material construction carrier forming the first component.

The composite building block 1 may be in the form of a "current" block, as shown in FIGS. figures 1 and 7 to 12 , or in the form of a corner block, as shown on the figure 3 .

Thanks to the direct anchoring of the block of rigid insulating material 3 (for example expanded polystyrene) in the cell or cells 6 central (s) of block 2, intended (s) to receive the binder forming the frame of the wall it is possible to dispense with the creation of additional hooking sites of complex shape in order to assemble the two blocks.

In addition, the assembly itself is facilitated since it can be achieved by simple interlocking with a significant mutual interlocking of the two components, if necessary without requiring any other locking or locking means (a glue point or a slight compression may be considered).

Finally, it leads to a high structural cohesion of the composite block 1 and to a high strength of the assembly of the two components 2 and 3, because of the importance of the masses of different materials nested interlocking, the importance of the surfaces in question. contact at the interfaces of the two components and the large size of the protruding formation (s) 9 extending into the cell or the cells 6.

Finally, the final blocking of the two components of each composite block between them occurs during the injection of the hydraulic binder in the cell alignments to form the frame of the wall and thus the three materials are found in direct and intimate contact, on important surfaces and in a mutually overlapping manner, with a final self-leveling and an automatic locking compensating for possible games or sizing defects of the two components of the composite block at their mutually interleaved parts.

This anchoring at the heart of the insulating block 3 in the hollow carrier block 2 allows said block 3 to withstand significant stresses, especially in both directions perpendicular to the face considered.

In particular, the block 3 may have a large thickness, making it possible to achieve a high degree of thermal insulation even with carrier blocks 2 with a single wall (solid), easy to manufacture, instead of carrier blocks 2 to double wall for multi-cellular.

Preferably, the hollow carrier block 2 comprises at least two cells 6 which are only partially filled by the projecting formations 9 and the insulating block 3 is pressed against the outer face of said block 2.

As shown by Figures 10 to 12 , the blocks 2 may also comprise only one complete cell 6 in which is introduced a projecting formation 9, through a partial cutout 7 'or through 7. The formation 9 will then advantageously occupy the entire volume of the cell 6, free volumes (half-alveoli), in the form of lateral recesses, forming cells 6 by association of two blocks 1 being created between the two blocks 2 and 3.

According to a preferred embodiment, the method according to the invention may consist of producing beforehand a hollow construction block 2 made of carrier material with portions of solid side walls, then to provide the partial cut-out (s). or through (s) 7, 7 'in the portion (s) wall (s) 5 (s) concerned, this through a subsequent machining operation or the like.

In a practical way and according to a particularly advantageous variant of implementation, particularly from the economic point of view, it may be envisaged that the initial hollow construction block 2, with integral or full side wall portions 5, is obtained by molding, by example of a wood-cement mixture, in an existing mold used for the realization of hollow cell building blocks.

According to another alternative embodiment of the method, it may be provided to manufacture the hollow construction block 2 of carrier material, provided with its or its cutout (s) 7, 7 ', by molding in an existing mold, used for the production of hollow building blocks with portions of full or entire side walls, but provided with one or more additional internal formations, protruding into the internal volume of the mold and of complementary shape to the cutout (s) 7, 7 .

Additional internal formations may consist of inserts positioned in the existing mold or of modified or additional drawers forming part of an existing drawer mold.

In order to reinforce the structure of the composite building block 1, and in particular to ensure a spacing or prevent a rupture of the wall portions 5 adjacent to the cuts 7, 7 'during the casting of the concrete in the cells 6, the process can also provide to provide, simultaneously or not with the cutouts 7, 7 ', attachment sites 10, 10' for the block of insulating material 3 at the side or sides 8 of the hollow construction block carrier material 2 which comes or comes into contact with said block of insulating material 3, for example in the form of grooves 10 ', rabbets 10 and / or profiled recesses (e) s, and to form on the block of insulating material 3, from molding or foaming in a suitable mold, profiled projections 11, 11 'respectively compliant shapes with respect to said attachment sites 10, 10'.

This cooperation between sites 10, 10 'and projections 11, 11' also makes it possible to guarantee a more intimate connection between the two constituent blocks 2 and 3, as well as blocking of the block 3 in the directions perpendicular to the direction DP of the figure 1 .

The hollow building block 2 made of a carrier material forming the first component and the block of rigid insulating material 3, preferably solid, forming the second component, may be provided in a number of variant embodiments with particular regard to the location, the size and the shape of the cutouts 7, 7 ', protruding formations 9, attachment sites 10, 10' and projections 11, 11 ', thereby resulting in as many alternative embodiments of the composite building block 1.

Thus, as shown for example by figure 4 the hollow building block made of carrier material 2 may comprise at least one partial cutout 7 'extending only over part of the height of the wall portion 5 considered and at least one through cutout 7 extending over the entire height of the wall portion 5 considered, preferably located respectively on faces 8 different side, the widths of said cuts 7, 7 'being smaller than the widths of cells respectively concerned. Similarly, the width of the partial cutouts 7 'may be smaller than that of the through cuts 7, so as not to weaken too much the wall portion 5 concerned.

As a variant, all the cut-outs 7 made in the respective wall portions 5 of the hollow construction block made of carrier material 2 extend over the entire height of said wall portions 5 and are present only on a single lateral face 8 of said block 2 ( figure 2 ).

According to another variant, all the cuts 7 'formed in the wall portion (s) 5 concerned (s) of the hollow building block of carrier material 2 is (are) partial in nature and extends (ent) ) at a part of the height of the at least one wall portion 5 ( Figures 10 to 12 ).

Another advantage of the method according to the invention is to be able to easily manufacture, without modifying or modifying only slightly the manufacturing mold of the carrier building block 2, composite building blocks 1 of thicknesses and sound insulation coefficients and / or different thermal, this by providing composite building blocks 1 with thicknesses of layer or wall of different rigid insulating material, at the side (s) side (s) 8 of the hollow building block in carrier material 2 and / or in the cells 6 concerned (s).

As shown in particular figure 6 In the accompanying drawings, the hollow building blocks of carrier material 2 will advantageously comprise ribs and grooves for making an assembly of adjacent blocks 2 by nesting at their mutually adjacent side faces.

The subject of the present invention is also a composite building block 1 of the insulating block-type type, comprising a first constituent component or component 2 made of a carrier material and a second component or constituent part 3 made of a rigid insulating material, the two components 2 and 3 being at least partially nested one inside the other.

This composite building block 1 is constituted by two mutually nested parts 2 and 3, namely,
on the one hand, a hollow building block 2 made of a generally parallelepipedal shaped material with an upper face 4, a lower face 4 'and lateral faces 4 ", said block consisting of portions of profiled lateral walls delimiting together at least one cell 6 open at the above-mentioned upper and lower faces and the wall portion or portions 5 of at least one lateral face 4 ", or, if appropriate, of two mutually adjacent side faces 4" being provided with cut-outs 7 , 7 'sections extending in a direction DP perpendicular to the upper 4 and lower 4' faces, where appropriate over the entire height of at least some of said wall portions 5 concerned, and,
on the other hand, a block 3 of rigid insulating material shaped to come into intimate application against or being positioned at a distance from the outer side face (s) 8 of the hollow building block 2 having the cutouts 7, 7 'and having protruding formations 9 anchoring, by cooperation of complementary shapes, in the cell or cells 6, ce through one or openings (s) in the portion (s) of walls 5 corresponding to the one or more cuts 7, 7 '.

According to an advantageous characteristic of the invention, the hollow building block of carrier material 2 comprises, at its or its lateral face (s) 8 in contact with the block of rigid insulating material 3, preferentially to solid structure, advantageously at least at the ends of said face or faces 8 and / or at the portions 5 'of the wall portions 5 flanking the cuts 7, 7', attachment sites 10, 10 'for projections profiles 11, 11 'of complementary shapes, formed on the block of insulating material 3.

Preferably, the composite building block 1 is obtained, as a finished product, by the manufacturing method described above, the interlocking between the two components 2 and 3 possibly being locked by bonding and / or blocked by a stop .

The Figures 1 to 9 represent blocks 1 with double nesting (of the insulating material in the carrier block 2), with covering of one or two faces of the block 2 by the material of the block 3, while the Figures 10 to 12 show blocks with simple nesting.

Of course, the invention is not limited to the embodiments described and shown in the accompanying drawings. Modifications are possible, particularly from the point of view of the constitution of the various elements or by substitution of technical equivalents, without departing from the scope of protection of the invention.

Claims (12)

1. Method for manufacturing a composite building block (1) of the insulating block type, comprising a first component or constituent part (2) of a load-bearing material and a second component or constituent part (3) of a rigid insulating material, the two components being at least partially imbricated in one another and the first component (2) having one or more cells (6) intended to receive the hydraulic binder forming the framework of the wall, the method consisting in providing,
   on the one hand, a hollow building block (2) of a load-bearing material of parallelpipedal general shape with an upper face (4), a lower face (4') and lateral faces (4''), said block being constituted by profiled lateral wall portions (5) together delimiting at least one cell (6) open at the aforementioned upper and lower faces, and the wall portion (s) (5) of at least one lateral face (4"), or, where appropriate, of two mutually adjoining lateral faces (4"), being provided with at least one profiled cutout (7, 7') extending in a direction (DP) perpendicular to the upper (4) and lower (4') faces, where appropriate over the entire height of the or of at least certain of said wall portions (5) in question, and,
   on the other hand, a block (3) of rigid insulating material shaped to be intimately applied against, or be positioned at a distance from, the outer lateral face(s) (8) of the hollow building block (2) comprising the cutout (s) (7, 7'), and having one or more projecting formations (9) intended to be anchored, by cooperation of complementary shapes, in the aforementioned cell or cells (6) intended to receive the hydraulic binder, this taking place through one or more openings in the wall portion(s) (5) corresponding to the cutout(s) (7, 7'),
   and, then, in assembling the aforementioned two components (2 and 3) to produce a composite building block (1), this taking place by a mutual nesting movement in a direction (DP) perpendicular to the upper (4) and lower (4') faces of the building block (2) of load-bearing material forming the first component, the block (3) of insulating material forming the external side of the composite building block (1).
2. Method according to Claim 1, characterized in that it also consists in forming coupling sites (10, 10') for the insulating material block (3) at the lateral face(s) (8) of the hollow building block (2) of load-bearing material which comes or come into contact with said insulating material block (3), for example in the form of profiled grooves (10'), rebates (10) and/or recesses, and in forming on the insulating material block (3), by moulding or foaming in a suitable mould, profiled projections, (11, 11') of shapes respectively complementary with respect to said coupling sites (10, 10').
3. Method according to Claim 1 or 2, characterized in that it consists in manufacturing a hollow building block (2) of load-bearing material with solid lateral wall portions (5), then in forming the partial or through-going cutout(s) (7, 7') and possibly the coupling sites (10, 10') in the wall portion(s) (5) in question, this taking place by means of a subsequent machining operation or the like.
4. Method according to Claim 2, characterized in that the initial hollow block (2), with solid or whole lateral wall portions (5), is obtained by moulding, for example a wood-cement mixture, in an existing mould used for the production of cellular hollow building blocks.
5. Method according to Claim 1 or 2, characterized in that it consists in manufacturing the hollow building block (2) of load-bearing material, provided with its cutout(s) (7, 7'), and possibly the coupling sites (10, 10'), by moulding in an existing mould, used for the production of hollow building blocks with solid or whole lateral wall portions (5), but provided with one or more additional internal formations which project into the internal volume of the mould and are complementary in shape to the cutout(s) (7, 7').
6. Method according to any one of Claims 1 to 5, characterized in that the hollow building block (2) of load-bearing material comprises at least one partial cuout (7') extending only over a part of the height of the wall portion (5) in question and at least one through-going cutout (7) extending over the entire height of the wall portion (5) in question, which are preferably situated respectively on different lateral faces (8), the widths of said cutouts (7, 7') being less than the widths of the cells (6) respectively in question.
7. Method according to any one of Claims 1 to 5, characterized in that all the cutouts (7) formed in the wall portions (5) in question of the hollow building block (2) of load-bearing material extend over the entire height of said wall portions (5) and are present only on a single lateral face (8) of said block (2).
8. Method according to any one of Claims 1 to 5, characterized in that the or all the cutout (s) (7') formed in the wall portion (s) (5) in question of the hollow building block (2) of load-bearing material is (are) of partial nature and extends (extend) only over a part of the height of said wall portions (5).
9. Method according to any one of Claims 1 to 8, characterized in that it consists in providing composite building blocks (1) with different layer or wall thicknesses of rigid insulating material at the lateral face(s) (8) of the hollow building block (2) of load-bearing material and/or in the cells (6) in question.
10. Composite building block (1) of the insulating block type, comprising a first component or constituent part (2) of a load-bearing material and a second component or constituent part (3) of a rigid insulating material, the two components being at least partially imbricated in one another, and the first component (2) having one or more cells (6) intended to receive the hydraulic binder forming the framework of the wall, said composite building block (1) being constituted by two parts (2 and 3) mutually nested in a direction (DP) perpendicular to the upper (4) and lower (4') faces of the block (2), namely,
    on the one hand, a hollow building block (2) of a material of parallelpidal general shape with an upper face (4), a lower face (4') and lateral faces (4"), said block being constituted by profiled lateral wall portions (5) together delimiting at least one cell (6) open at the aforementioned upper and lower faces, and the wall portion (s) (5) of at least one lateral face (4''), or, where appropriate, of two mutually adjoining lateral faces (4"), being provided with at least one profiled cutout (7, 7') extending in a direction (DP) perpendicular to the upper (4) and lower (4') faces, where appropriate over the entire height of the or of at least certain of said wall portions (5) in question, and,
    on the other hand, a block (3) of rigid insulating material intimately applied against, or being positioned at a distance from, the outer lateral face(s) (8) of the hollow building block (2) comprising the cutout (s) (7, 7'), and having one or more projecting formations (9) which are anchored, by cooperation of complementary shapes, in the aformetioned cell or cells (6) intended to receive the hydraulic binder, this taking place though one or more openings in the wall portion(s) (5) corresponding to the cutout (s) (7, 7'), the block (3) of insulating material forming the external side of the composite building block (1).
11. Composite building block according to Claim 10, characterized in that the hollow building block (2) of load-bearing material comprises, at its lateral face(s) (8) in contact with the rigid insulating material block (3), preferably of solid structure, advantageously at least at the ends of said face (s) (8) and/or at the parts (5') of the wall portions (5) framing the cutouts (7, 7'), coupling sites (10, 10') for profiled projections (11, 11') of complementary shapes formed on the insulating material block (3).
12. Composite building block according to Claim 10 or 11, characterized in that it is obtained by the manufacturing method according to any one of Claims 1 to 9, the nesting engagement between the two components (2 and 3) being possibly locked by adhesive bonding and/or immobilized by abutment.

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