EP2488707B1 - Modular construction element made of carton - Google Patents

Description

The present invention relates to a building module based on cardboard especially for the manufacture of buildings.

Prior art:

Cardboard is widely used in the packaging field being an inexpensive, lightweight product that is easy to produce, cut and handle, and fully recyclable. In the specific area of the building, it can be used for its thermal insulation properties in combination with other materials. The publication FR 2 546 449 illustrates an example of a panel formed of several layers of corrugated board assembled by gluing and surrounded by a plastic film to make this panel waterproof, which is intended in particular for the manufacture of packaging, advertising media or wall coverings. The publication EP 0 957 214 proposes a building board made of corrugated cardboard and covered with a plastic film. However, it is not designed to be freestanding, nor to be assembled to other identical panels on the one hand and a floor or a floor on the other hand.

In general, building a building requires combining different products such as bricks and plaster, wood and glass wool, and so on. to achieve the various functions of mechanical strength and thermal and sound insulation, the implementation of which is often complex and whose materials used are often expensive and difficult to recycle.

Presentation of the invention

The present invention aims to provide a solution to the problems mentioned above by proposing a building module based on cardboard, which is designed to allow its assembly to other identical or similar modules and a screed, a floor or any foundation, preserving its mechanical characteristics, and that can meet the specifications in the field of the construction of buildings, in particular in terms of mechanical resistance, thermal insulation, sound insulation, seismic resistance, windshield -vapeur, fire resistance, etc., this module can be achieved at reduced costs, allowing a modular construction and in fact easily configurable for any type of architecture, and can be easily recycled if necessary.

For this purpose, the invention relates to a building module of the kind indicated in the preamble, characterized in that it comprises a central cardboard core defining at least the height, the width and the section of said module, this central core consisting of a plurality of layers of corrugated cardboard and / or cellular, sealing means arranged to protect said central core from moisture, at least two holding and protection panels arranged on either side of said central core of so as to cover at least two of its faces respectively outer and inner, and at least two frames superimposed on said holding and protection panels forming a load bearing frame and delimiting a free internal volume for the passage of technical elements, said frames being fixed to each other by fasteners passing right through said holding panels and protection and said central core.

Thus, the module as defined combines alone all the functions necessary for the construction of a building and is advantageously reversible up / down, right / left. The flutes of the corrugated layers constituting the central core may be oriented in the direction of the height or width of said module, or in a cross configuration, depending on the desired mechanical characteristics. The thickness of the central core may vary depending on the characteristics imparted to the module and the corrugated board layers may be assembled by a bonding process or any other suitable assembly method such as a mechanical assembly.

The sealing means may comprise at least one tight film made from an extruded or stretched polymer disposed around said central core. They may also consist of a hydrophobic product coated or impregnated with a cardboard / plastic film complex forming said central core, or by any other equivalent method.

The building module may comprise two other spacer and protection panels arranged on either side of the central core so as to cover respectively its upper and lower faces.

These panels can be made from agglomerated wood fibers or any other type of panels and frames from treated or untreated wood profiles, or any other material such as metal, composite materials.

It may advantageously comprise spacers arranged through at least the central core to ensure a constant thickness of the central core without risk of crushing due to tightening fasteners.

The frames may consist of at least two parallel uprights flush with the side edges of said module. They may also consist of at least two parallel uprights interconnected by two parallel cross members flush with the lower and upper edges of said module. Alternatively at least one of the lower or upper cross members may be recessed relative to the corresponding lower or upper edge of the module.

The building module may be completed by an additional beam disposed between the frame and the lower or upper edge of said module. It may also include at least one additional frame disposed within said module between the central core and at least one of said panels.

The central core or the cardboard constituting said central core may comprise an additive selected from the group comprising a fungicide, an insecticide, a fireproof product, a water-repellent product.

The inner and / or outer faces of said module may be covered respectively with an inner and / or outer facing.

This freestanding building module may have a section selected from the group consisting of a square, a rectangle, a right angle bracket. Its lateral edges may be straight to allow a juxtaposed assembly of several modules without overlap, or comprise complementary interlocking forms so as to allow a juxtaposed assembly of several modules with overlap. Its lateral edges may also include at least one U-shaped notch arranged to receive a complementary shaped pole to lock said assembly and resume the loads.

The object of the invention is also achieved by a building, characterized in that at least one of the elements selected from the group comprising the external walls, the floors, the roof, and the internal partitions, is made by juxtaposed assembly of several building modules as defined above.

Brief description of the drawings:

• la figure 1 est une vue de dessus éclatée d'un premier module de construction selon l'invention,
• la figure 2 est une vue de dessus du premier module de la figure 1,
• la figure 3 est une vue de dessus d'un deuxième module de construction selon l'invention,
• la figure 4 est une vue de dessus d'un troisième module de construction selon l'invention,
• la figure 5 est une vue en coupe longitudinale d'une variante d'un des modules des figures précédentes, complété par des entretoises et revêtu d'un parement intérieur et d'un parement extérieur,
• la figure 6 est une vue de dessus d'un exemple de construction d'un mur extérieur d'un bâtiment comportant un ouvrant
• la figure 7 est une vue de dessus agrandie de deux modules assemblés, montrant le passage d'éléments techniques, et les organes de fixation,
• la figure 8 est une vue de face des modules assemblés de la figure 7,
• les figures 9A-E représentent différentes formes du module de construction de l'invention, et
• la figure 10 est une vue de dessus de deux modules assemblés selon la figure 9D.

The present invention and its advantages will appear better in the following description of an embodiment given by way of non-limiting example, with reference to the appended drawings, in which:

• the figure 1 is an exploded top view of a first building module according to the invention,
• the figure 2 is a top view of the first module of the figure 1 ,
• the figure 3 is a view from above of a second building module according to the invention,
• the figure 4 is a view from above of a third building module according to the invention,
• the figure 5 is a longitudinal sectional view of a variant of one of the modules of the preceding figures, completed by spacers and coated with an inner facing and an outer facing,
• the figure 6 is a view from above of an example of construction of an exterior wall of a building comprising an opening
• the figure 7 is an enlarged top view of two assembled modules, showing the passage of technical elements, and the fasteners,
• the figure 8 is a front view of the assembled modules of the figure 7 ,
• the Figures 9A-E represent different forms of the building module of the invention, and
• the figure 10 is a top view of two modules assembled according to the Figure 9D .

Illustrations of the invention and best way to achieve it:

With reference to the figures, the building module 10, 20, 30, 50 according to the invention is made from cardboard and intended in particular for the manufacture of buildings such as detached houses, collective, or the like. With particular reference to the figure 1 , which represents an exploded view from above of a first module 10, it essentially comprises a central core 1 defining at less the height, the width and the section of the module 10, this central core consisting of a plurality of layers of single or multi-corrugated corrugated cardboard. Depending on the desired mechanical characteristics, the splines can be oriented in the direction of the height or width of the module, or in a cross configuration. Similarly, the corrugated cardboard can be replaced or supplemented by cellular cardboard, for example in honeycombs. The layers of cardboard are assembled for example by means of a hot or cold bonding process. Any other method of assembly may also be suitable, such as in particular a mechanical assembly by connecting pins, rivets, bolts or the like. The number of fasteners and their distribution are determined by the dimensions of said building module 10. The thickness of the central core 1 is variable and determined according to the load to be supported and the quality of the desired insulation . The central core 1 or the cardboard constituting this central core may undergo treatment by any means and / or any additive product adapted according to the desired properties, for example a treatment by impregnation, spraying, misting or the like, of a fungicidal product. , insecticide, water repellent, fireproof, or other.

The central core 1 is protected against moisture by any appropriate sealing means. These sealing means may be at least one tight film 2, made from at least one polymer or the like, extruded and / or stretched, arranged around the central core 1 to cover all its faces. They may also be a coating or an impregnation of a hydrophobic product, such as an aqueous acrylic emulsion, a paraffin, a wax, a resin, or the like. In the case of the sealed film 2, it can be assembled to the central core 1 by bonding with an adhesive to cover all its faces or any equivalent assembly method. This film serves as a vapor barrier and rain barrier, it prevents the creation of a dew point. This waterproof film 2 is a removable product in the event that the building module 10 must be recycled.

The building module 10 comprises at least two holding and protection panels 3 arranged on either side of the central core 1 so as to cover at least two of its faces respectively outer FE and inner FI. For optimum protection of the central core 1, it is possible to add two spacer and protection panels 3a on the respectively high FH and low FB faces of the central core 1 ( figure 5 ). In this case, these high and low protection panels 3a play the role of spacers guaranteeing the regular and precise thickness of the building module 10 while maintaining the insulating and mechanical qualities of the central core 1. It is specified that the module of construction 10 according to the invention is reversible as well up / down as right / left. Thus, the faces of the module designated external face FE and internal face FI, as well as the high faces FH and low FB, are arbitrary and can be reversed. The building module 10 may be completed by one or more spacers 3b (cf. Fig. 5 ) distributed in said module according to its surface and passing through at least the central core 1, to ensure a constant thickness of the central core 1 without crushing of the cardboard layers during screwing of the various organs Fixing 40, 73. If the spacers 3b through only the central core 1, they are covered by the panels 3 which abut against them. If they pass right through the central core 1 and the panels 3, they serve as a transverse stop for fasteners. These spacers 3b can be made in various forms such as for example solid or hollow tubes, wood, metal or the like. In the case of hollow tubes, fasteners such as threaded rods or the like may be accommodated therein.

The holding and protection panels 3, as well as the spacer and protection panels 3a, may be made from agglomerated fibreboard such as, for example, OSB-type panels or the like, having a thickness of a few millimeters or even centimeters. In the example made, the protective panels 3 have a thickness of about 9mm. They preferably extend over the entire surface of the outer faces FE and inner FI of the central core 1 in order to maintain and protect its faces possible shocks during storage, transport and handling of the building module 10. In addition, they allow to achieve the assemblies and provide a gripping surface and / or screwing for any fastener.

The building module 10 of the invention is completed by at least two frames 4 superimposed on said protection panels 3. These frames 4 fulfill several functions: they form a reinforcement or load-bearing structure, delimit a free internal volume 5 for the passage of the technical elements of the construction, without piercing the central core 1, or the sealed film 2, and allow the assembly of the modules 10 together juxtaposed by any fastener 42 and 42a (cf. fig.7 and 8 ), without damaging or constraining the central core 1. In the examples shown, these frames 4 are arranged only outside the building module 10. For some applications, it may be envisaged to add one or two additional frames 4 inside said building module 10, that is to say between the central core 1 and the protective panels 3. In these variants not shown, the central core 1 is configured to include recesses arranged to receive the one or more additional frames 4.

These frames 4 may be open and consist only of parallel uprights, including vertical, at least two of which are flush with the side edges of the module 10. As in the examples shown, these frames 4 are closed and consist of at least two parallel uprights assembled between them by at least two parallel crosspieces, in particular horizontal crosspieces. They can be made from wood profiles or similar, assembled in their corners for closed frames, by tenon / mortise, brackets, gluing, screwing or a combination of these techniques. They may have a dimension such that they are flush with the perimeter of the module 10 or a smaller dimension in the direction of the height so that at least one of the lower or upper cross members of the frames 4 is set back with respect to the lower or upper edge corresponding part of the module 10. This recessed area may be used to provide at least one assembly area by interlocking relative to to a floor or ceiling rail, slab or the like. This recessed area can be filled by an additional beam 4a for example made of Querto® type wood or similar, which allows to create in said module a high and low belt for the recovery of loads and the maintenance of the building module.

The frames 4 are fixed to each other by fasteners 40, such as threaded rods, studs, tie rods or the like, passing right through the building module 10, namely the holding panels and protection 3 and the central core 1 (cf. Fig. 5 ). The order mentioned may vary according to the arrangement of the frames 4 in said building module 10. Depending on the dimensions of the building modules 10, 20, 30, 50, the frames 4 may be completed by vertical uprights 41 and / or horizontal crosspieces (cf. Fig. 3 and 4 ).

These frames 4 make it possible to receive an interior facing 6 and / or an external finish facing 7 fixed by any appropriate means on the frames 4 and / or in the holding and protection panels 3. The internal volume 5 defined by these frames 4 can be filled by any insulating material and in particular by a thickness of cardboard in a composition identical or different from the central core 1. An example is illustrated in the figure 5 which represents the module 10 in axial section, wherein the inner facing 6, placed on the side of the face intended to become the inner face FI, comprises a type BA13 plasterboard for interior finishing, and the outer face 7, placed on the side of the face intended to become the outer face FE, comprises a panel of compressed wood fibers or the like 70, on which is deposited a net 71 and a plaster 72. The wood fiber panel 70 can be fixed by any organ fasteners 73 such as screws, threaded rods or the like. Of course, the inner facing 6 and / or the outer facing 7 may vary depending on the specifications of the building to be made (example of a wooden cladding, etc.).

The Figures 2 to 4 represent three building modules 10, 20, 30 of different sections: the first module 10 of the figure 2 and the second module 20 of the figure 3 have a rectangular section of different length, and the third module 30 of the figure 4 has a square section at right angles. With these modules 10, 20, 30, it is possible to carry out any type of construction. However, these examples are not limiting, other sections can be imagined as needed.

The lateral edges of the building modules 10, 20, 30 and 50 comprise complementary interlocking shapes so as to allow juxtaposed assembly of several modules. In the Figures 1 to 4 , the building modules 10, 20 and 30 are assembled by juxtaposition without covering straight edges provided with a notch 11 in the form of a U. This notch 11 can receive a locking key of said assembly in the form for example of a pole 11a, for example of wood (cf. Fig. 7 ), which allows a load recovery. Other forms of assembly are also possible with reference to Figures 9A-E ; by straight edges ( Fig. 9A ) or bevelled edges ( Fig. 9B ) for non-overlapping assembly, with symmetrical L-shaped edges ( Fig. 9C ), with asymmetric L-shaped edges ( Fig. 9D ), or by tenon / mortise edges ( Fig. 9E ) for an assembly with overlap avoiding thermal bridges. The figure 10 illustrates an example of overlapping assembly of two modules with asymmetrical L-shaped edges according to the Figure 9D . The modules are fixed to one another by fasteners 42 and 42a, such as screws, bolts, threaded rods or the like, passing through the frames 4 located respectively side by side and on both sides. modules (cf. Fig. 7 and 10 ).

These building modules 10, 20, 30 and 50 are therefore reversible up / down, right / left, which limits the number of references and facilitates the management of production, storage, transport and installation.

Possibilities of industrial application:

The building modules 10, 20, 30 and 50 as described are reproducible industrially and can be used to produce slabs, external walls, interior partitions, roofs, on, between or under rafters, new construction or renovation . An example of construction is shown in figure 6 which represents a portion of an outer wall 8 having an opening 80 such as a door which fits into the mortise 11 between two building modules 10 and 30 to avoid thermal bridges. The outer wall 8 is obtained by assembling a plurality of straight construction modules 10 and / or 20 and angled modules 30. The junction areas may be covered with a gasket or the like. The free volume 5 delimited by the frames 4 allows the simple and fast implementation of all the technical part of the building, namely the technical elements 9 for the electric cables, the water pipes, the gas supply, the flows , ventilation, etc. (Cf. Fig. 7 and 8 ). The inner cladding 6 and / or the outer cladding 7 are preferably placed once the walls are finished and the technical elements placed to ensure continuity in the finish. The assembly of the building modules to a yoke 81, a slab, a floor 82 (cf. Fig. 8 ) or a roof is made by any appropriate means. If the building modules 10, 20, 30 and 50 have a frame 4 set back from their lower and / or upper edges, they can be nested between beams, beams or the like.

It is clear from this description that the invention achieves the goals set, namely a building module made from a corrugated material ecological and recyclable, easy to produce, ensuring excellent thermal insulation as well as phonic, resistant and light, easy to work and to pose without specific equipment and protection, allowing any format and any type of construction. The building thus obtained has a very great thermal inertia generating a very low energy consumption in the same way as the so-called passive houses.

The present invention is not limited to the embodiment described but extends to any modification and variation obvious to a person skilled in the art while remaining within the scope of protection defined in the appended claims.

Claims (20)

1. Modular construction element (10, 20, 30, 50) made of cardboard, in particular for the construction of buildings, comprising a central core (1) that defines at least the height, the width and the cross-section of said modular element, this central core (1) being made of a plurality of corrugated and/or honeycomb cardboard layers, sealing means (2) arranged to protect said central core (1) against humidity, at least two holding and protection panels (3) arranged on both sides of said central core (1) in order to cover at least two of its respectively external and internal sides, characterized in that said modular construction element moreover includes at least two frames (4) superimposed on said internal and external holding and protection panels (3), forming a load recovery reinforcement and delimiting an internal free space (5) intended for receiving technical elements (9), said frames (4) being fastened onto each other by fastening elements (40) that pass through said holding and protection panels (3) and said central core (1).
2. Modular construction element according to claim 1, characterized in that the flutes of said corrugated cardboard layers are oriented in the direction of the height and/or of the width of said modular element, or according to a crossed configuration.
3. Modular construction element according to any of the previous claims, characterized in that said cardboard layers are assembled by means of a gluing method.
4. Modular construction element according to any of the previous claims, characterized in that said sealing means include at least one watertight film (2) made of an extruded or drawn polymer, arranged around said central core (1).
5. Modular construction element according to any of claims 1 to 3, characterized in that said sealing means include at least one coated or impregnated hydrophobic product.
6. Modular construction element according to any of the previous claims, characterized in that it comprises two further spacer and protection panels (3a) arranged on both sides
   of said central core (1) in order to cover respectively its upper (FH) and lower (FB) sides.
7. Modular construction element according to any of the previous claims, characterized in that it comprises spacers (3b) arranged through at least said central core (1).
8. Modular construction element according to any of the previous claims, characterized in that said frames (4) include each at least two parallel uprights flush with the side edges of said modular element.
9. Modular construction element according to claim 8, characterized in that said frames (4) include each at least two parallel crossbeams connecting said uprights and flush with the lower and upper edges of said modular element (10, 20, 30, 50).
10. Modular construction element according to claim 8, characterized in that said frames (4) include each at least two parallel crossbeams connecting said uprights, at least one of said lower or upper crossbeams standing back with respect to the corresponding lower or upper edge of said modular element.
11. Modular construction element according to claim 10, characterized in that it comprises at least one additional beam (4a) arranged between said frame (4) and the lower or upper edge of said modular element.
12. Modular construction element according to any of the previous claims, characterized in that it comprises at least one additional frame (4) arranged inside said modular element, between the central core (1) and at least one of said panels (3).
13. Modular construction element according to any of the previous claims, characterized in that the central core (1) or the cardboard making up said central core comprises an additive chosen in the group including a fungicide, an insecticide, a water-repellent product, a fireproofing product.
14. Modular construction element according to any of the previous claims, characterized in that the internal (FI) and/or external (FE) sides of said modular element (10, 20, 30) are covered respectively with an internal facing (6) and/or with an external facing (7).
15. Modular construction element according to any of the previous claims, characterized in that it has a cross-section chosen in the group including a square, a rectangle, a right-angle square.
16. Modular construction element according to claim 15, characterized in that the side edges of said modular element are straight in order to allow a juxtaposed assembly of several modular elements (10, 20, 30) without overlapping.
17. Modular construction element according to claim 15, characterized in that the side edges of said modular element have complementary fitting shapes (11) in order to allow a juxtaposed assembly of several modular elements (10, 20, 30, 50) with an overlapping.
18. Modular construction element according to claim 16, characterized in that the side edges of said modular element have at least one U-shaped notch (11) arranged to receive a post with a complementary (11 a) shape to lock said assembly.
19. Modular construction element according to any of the previous claims, characterized in that it is arranged to be up/down and right/left reversible.
20. Building, characterized in that at least one of the elements chosen in the group including the exterior walls, the interior partition walls, the floors, the roofings, is made by the juxtaposed assembly of several modular construction elements (10, 20, 30, 50) according to any of the previous claims.

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