EP2920377B1 - Method for constructing a building having strong thermal insulation and building constructed by means of said method - Google Patents

Description

The present invention relates to a new building construction method with high thermal insulation, and a building constructed by this method.

Building construction methods are already known in particular for improving thermal insulation. In general, the concepts developed consist in using essentially panels of low heat transfer coefficient material, such as for example expanded polystyrene. In some cases, these panels serve only to constitute the walls of a construction whose structure is a framework that alone ensures the required mechanical strength, the insulating panels whose only function is the realization of walls and partitions and thermal insulation , thus without ensuring structural function from the point of view of the mechanical strength of the building.

Other processes have also been developed, aiming at maximizing the use of lightweight insulating panels as structural elements. It has already been proposed to build buildings only by assembling polystyrene panels glued together. However, in this type of construction, it is commonly expected to coat the walls thus formed by a layer of reinforced mortar, used as a mechanical reinforcement to withstand the descents of load and also serving as facing resistant to shocks, weather, etc.

It has also been proposed to produce panels or blocks of light insulating material incorporating such facings, and to assemble them by gluing or other processes. For example, it has already been proposed to make such thick-core polystyrene panels and thin resin facings, and to assemble them by a resin joint covering the edges of the panels and solidarisant the facings of adjacent panels.

The document US3755982 describes in particular a panel system of lightweight material having high insulation characteristics and whose edges have longitudinal grooves. These panels can in particular be assembled by a wide joint of hardenable material, poured between the edges of two adjacent panels and thus penetrating into the grooves, and thus ensuring a tight and resistant seal. In addition, this curable material forms, once cured, a pole providing resistance to loads.

US3254464 shows polyurethane insulating cellular panels covered with a skin and connecting keys between the panels, fitting into the recessed half-cells formed on the edges of the panels. But this system requires panels of complex shape, and the use of wooden poles inserted into at least some of the cells to ensure the mechanical strength of the partitions thus formed.

EP0190818 shows a similar assembly system, but for insulating panels of simpler shape, solid and flat faces. In this system, the panels are assembled with interpositions of posts, the connections between the panels and the posts being also made by longitudinal keys. CA1116371 also shows a similar system, but in which the posts located at each junction between panels are replaced by simple keys, the reduced resistance thereof being compensated by the insertion of stiffeners in grooves formed in the faces of said panels. EP0294079 also discloses an assembly system by keys or grooves and tongues.

These different systems have the particular disadvantage of having to perform on the songs of panels grooves or other forms necessary for interlocking. GB 2440803 A discloses a building with high thermal insulation with the features of the preamble of claim 1.

The present invention aims to solve the problems mentioned above, and aims in particular to simplify the construction of walls, ceilings and floors, and to ensure the thermal insulation of buildings using only lightweight building elements.

With these objectives in view, the subject of the invention is a method of constructing a building with high thermal insulation, at least some of whose walls consist essentially of panels of thermally insulating low density material as defined in claim 9. The construction method thus greatly simplifies the construction, using panels with flat edges, which can be obtained by a simple straight cut, and requiring no particular shaping of the edges such as making grooves or tongues, etc..

According to the invention, the panels are assembled by being clamped between the two boards located on opposite sides of the panels. The assembly can be achieved by screwing one board to the other across the width of the panel sandwiched between said boards, by means of long wood screws, or by strapping surrounding both the boards and the panel sandwiched between said boards.

The invention also relates to a building with high thermal insulation, at least some of the walls consist essentially of panels of thermally insulating material of low density, as defined in claim 1. By wall, here should be understood both vertical walls constituting supporting walls or other partitions, horizontal walls constituting slabs or ceilings, or also inclined walls may for example be building covers. The junction areas are formed between the edges of two panels assembled side by side in the same plane, or between the edge of a panel and a side of another panel, in the case of corner assembly. It is also possible, depending on the geometry of the buildings, to have bevelled joints, on the edges or even on the edges of the faces, to achieve all the desired angles.

The invention makes it possible to ensure very good thermal insulation of buildings by using only lightweight building elements in high thicknesses, typically 150 to 500 mm or more, preferably about 300 mm. The lightness of the elements and their strong resistance resulting from their thickness facilitate their implementation and their transport, and gives the construction good mechanical and seismic properties. These different advantages help to reduce manufacturing time and costs. The width of the junction zones, and therefore the width of the boards, being at least equal to the thickness of the panels, or greater in the case of assemblies of bevel angles, results in a high resistance to bending of the boards in the sense of their plan. Moreover, despite the relatively small thickness of the boards, the connection of the latter with the panels also prevents their bending deformation transverse to their plane or torsion, and thus eliminates any risk of buckling under vertical load when the boards are vertical. When the panels are horizontal, for slabs, or sloping, for roofs, again the panels ensure that the boards will remain flat, in a vertical plane, without possibility of torsion, and therefore with the best possible resistance in bending thanks to the relatively large width of the boards.

It is therefore the combination and the rigid assembly of the boards and panels that ensure the overall strength of the walls thus formed, whether they are arranged vertically, horizontally or inclined, as long as the boards themselves are in a plane substantially vertical. Note also that, as a result, the boards can be used advantageously for fixing heavy elements on walls or ceilings, for example cumulus or any other conventional large mass accessory.

Another advantage of the invention is the safety in case of fire, compared to constructions insulating panels according to the prior art, despite the use of insulating materials such as expanded polystyrene. Indeed, in case of fire, the polystyrene will melt, but the boards will withstand fire longer and, remaining assembled between them, continue to ensure some resistance of the structure despite the disappearance of insulation panels.

It should also be noted that, thanks to the lightness of the materials used, a building formed by these partitions can be easily assembled on site, but it is also possible to prefabricate complete walls in the workshop, then to transport these prefabricated walls and assemble them on the site, which allows the realization of a building in a very short time.

Whatever the embodiment, we can also use boards attached to the free edges of the panels, either on a end end of a wall or in the corners where a song is visible on the side out of the angle, to strengthen these abouts or angles.

The panels are preferably expanded foam of the type: expanded polystyrene, extruded polystyrene, polyurethane foam, resole foam. We can also use wood fiber panels, compact rock wool, compact glass wool, or cork. In general, materials will be used having the best possible characteristics in terms of thermal insulation, and low density, so that even large panels can be handled with the minimum of transport and lifting equipment and the minimum of manpower, in particular be handled and implemented by one or two people.

The boards are preferably in lumber, plywood, plywood, lamibois, etc., with the possibility of fireproofing treatment.

They could also be rigid material, having a fire resistance, for example in the form of composite wood or metal blades.

The boards have a width substantially equal to the thickness of the panels, and a small thickness relative to their width, in a ratio typically between 1/8 and 1/15. For example, the section of these boards may be 30 cm X 3 cm, a ratio of the order of 10 between width and thickness.

The small thickness of the boards also has the advantage of a low weight, to be easily manipulated by a single person. Thus, a building according to the invention can be made with a minimum of material handling and very little labor.

Despite the small thickness of the boards, the assembly clamping panels between two boards, provides a very good mechanical strength. Indeed, in the first place, the panels brace the different walls, and thus prevent the overall deformation of the construction. By being clamped between two planks, the panels also prevent the deformations of the planks, in particular in bending and torsion, and compensate in some way so the relative flexibility of the boards resulting from their small thickness, to maintain and improve their compressive strength along the longitudinal direction. The panels thus prevent the buckling of the boards even under heavy axial load. They also prevent the twisting of planks, from which it also results, thanks to the relatively large width of the planks, a great resistance also to bending in the general plane of the planks. This compensates, in the assembly of planks and panels, the relatively low flexural strength of insulating panels which have a thickness substantially equal to the drop planks. This high resistance to bending thus obtained by the assembly of boards and panels allows the realization of slabs and roofs.

Insofar as the boards have a width equal to or greater than the thickness of the panels, it is possible to fix on the edges boards, on the inside or outside of the partition or on both sides, cleats or other profiles allowing to attach protective or decorative coatings of all known types. Cleats or similar profiles, fixed on the edges of the boards can also be used to bind together distant boards and consolidate the assembly of boards and panels. These cleats may be arranged perpendicularly to the boards, or also obliquely to achieve bracing complementary to that which is generally obtained by the panels themselves.

A conventional coating, for example of reinforced, composite, etc., type may be applied to the walls thus formed according to the invention, that is to say applied directly on the panels and on the songs planks. Typically, such a coating may be applied to the outer faces of the walls, and a decorative coating, gypsum board, paneling, etc. will be fixed on horizontal cleats connecting the boards and fixed on the edges of them, as indicated previously. Other coatings may also be fixed in a similar way: wood panels, fibered sheets, metal cladding, rainscreen, etc. When the invention is used to make a slab, a floor can be placed in a conventional manner on joists fixed on the edges of the boards, or even directly on the boards if their spacing allows such use of the boards directly as joists. Similarly, if the invention is used to make a ceiling, can be fixed on the edges of the boards of the conventional ceiling suspension profiles, or possibly fix boards gypsum board directly on the lower edge of the boards.

Other features and advantages will appear in the description that will be made of a building according to the invention, and its method of production.

• la figure 1 est une vue en perspective d'un tel bâtiment,
• la figure 2 est une vue similaire, avec une partie de l'étage supprimée pour montrer la structure des murs, plancher et toiture,
• la figure 3 est une vue en perspective montrant un exemple d'assemblage des panneaux et planches selon un exemple non visé par l'invention mais utile à sa compréhension,
• la figure 4 est une vue en perspective montrant un exemple d'assemblage des panneaux et planches selon un exemple non visé par l'invention mais utile à sa compréhension,
• la figure 5 est une vue en perspective montrant un exemple d'assemblage des panneaux et planches selon un premier mode de réalisation.
• la figure 6 est une vue en perspective montrant un exemple d'assemblage des panneaux et planches selon un deuxième mode de réalisation.

Reference is made to the accompanying drawings in which:

• the figure 1 is a perspective view of such a building,
• the figure 2 is a similar view, with part of the floor removed to show the structure of the walls, floor and roof,
• the figure 3 is a perspective view showing an example of assembly of panels and boards according to an example not covered by the invention but useful for its understanding,
• the figure 4 is a perspective view showing an example of assembly of panels and boards according to a example not targeted by the invention but useful for its understanding,
• the figure 5 is a perspective view showing an example of assembly of panels and boards according to a first embodiment.
• the figure 6 is a perspective view showing an example of assembling panels and boards according to a second embodiment.

The building represented Figures 1 and 2 is a simple, one-story house. The basic and high slabs 1a, 1b, the walls 2 and the roof 3 are made according to the invention, by assembling polystyrene panels of dimensions typically 2.6 m × 1.2 m × 0.3 m. thickness and boards 20 plywood thickness 3 cm.

On the figure 2 , we see in particular the realization of the upper slab 1b and the roof according to the invention, the boards 20 'of the slab and the roof resting respectively on the ends of the boards 20 "of the walls.

The walls can be pre-assembled on the ground before being erected and linked to walls already mounted, by gluing, or screwing for example, at the corners.

The figure 3 shows the assembly of the panels and boards in an example not covered by the invention but useful for its understanding, in which the edges of the panels 10 are glued to the boards 20. At the corners, the boards of the vertical partition rest on the side of the boards constituting the slab, and can be fixed by any conventional fastening means. The panels constituting the walls are also glued on those constituting the slab.

The figure 4 shows the assembly of panels and boards according to an example not covered by the invention but useful for its understanding, in which blades 30 are fixed on the edges of the boards 20 to form I-shaped profiles, and the edges 11 of the panels are inserted by force between the wings of said profiles. This results in an interlocking edges of the panels in said profiles, ensuring the rigid assembly of the panels with the boards. This assembly by embedding may be completed by gluing the panels on the webs or between the wings of the profiles. In the case where the panels are not glued on the profiles, it will be possible to ensure the interlocking of the panels in the profiles by interconnecting the profiles of the same set of coplanar panels, for example by cleats like this. will be indicated later. An advantage of this assembly by embedding, without bonding, is that it allows easy disassembly of the construction, and easy recycling of materials in case of deconstruction. The figure 4 also shows the use of horizontal clamps 40 fixed by screws on the blades 30 and the edges of the boards 20. These brackets 40 connect together several boards 20, as explained above, and also allow to fix an inner lining, such as for example plasterboard. Electrical conduits may be placed between the panels 10 and these plates or any other finishing coating, and held by the cleats 40.

The figure 5 shows the assembly of panels and boards according to a first embodiment, wherein the boards are assembled by screwing, so as to grip a panel between two boards. For this purpose, special wood screws 50, of great length and having a diameter of the order of 6 mm, for example, whose length is adapted to traverse, from a last laid board 20a, all the width of the panel 10, and screw into the previously laid board 20b, located on the other side of the panel 10. This assembly mode has the facility to cross the light insulating panels by the screws 50. In addition, the tightening of the screws ensures a very good contact, under pressure, boards with the edges of the panels. This improves the resistance of the whole, favored by the presence of the screws forming a kind of reinforcement in the thickness of the wall and by the friction, resulting from the tightening of the screws, between the boards 20 and the edges of the panels 10.

The mounting of a wall according to this embodiment is done simply by first assembling a first panel between two planks screwed one on the other. Then we add a second panel whose song is placed against one of the boards and we place a third board that is screwed on the board already in place through the second panel, and so on. For disassembly and recycling of this construction, simply unscrew the screws 50, to separate the boards and panels, beginning disassembly by the last board set up during assembly.

The figure 6 shows the assembly of panels and boards according to a second embodiment, wherein the boards are assembled by strapping, by means of steel strip 60 for example. For editing, as seen on the figure 6 it is sufficient to place the strips 60a, which are used to assemble a panel and a new board on a board 20b already in place, between said board 20b and the board 10a before definitively circling said board 20b on the board 10a, and and so on.

In the case of the embodiments of Figures 5 and 6 cleats, in particular horizontal cleats, can also be fixed directly on the edges of the boards 20, to serve as a support for a covering, as explained above, by allowing ducts, ducts or cables to pass between said covering and the surface of the panels .

Claims (9)

1. High thermal insulation building where at least some of the walls (1a, 1b, 2, 3) are mainly constructed of low-density thermally insulating materials, the panels (10) comprising uniformly flat edges over their complete thickness and being assembled together with inserted boards (20) at the junction zones between two adjacent panels, the boards (20) being joined in contact with the panels (10) over the complete length and width of the edges of the panels at said junction zones so that the connection of the boards with the panels prevents the bending deformation of the boards transversally to their planes and their twisting deformation and ensures the bracing of the walls, the building being characterised in that the panels (10) are assembled by clamping, each panel being clamped between the boards (20) on the opposite edges of said panel.
2. Building according to claim 1, characterised in that the assembly is achieved by screwing one board (20a) to the other board (20b) through the width of the panel (10) clamped between said boards, by means of long wood screws (50).
3. Building according to claim 1, characterised in that the assembly is achieved by strappings (60) around both the boards (20) and the panel (10a) clamped between said boards.
4. Building according to any one of claims 1 to 3, characterised in that the boards (20) are connected by battens (40).
5. Building according to claim 4, characterised in that the battens (40) act as support for an inner or outer cladding.
6. Building according to claim 1, characterised in that the panels (10) are made of a material chosen from among: expanded foams, expanded polystyrene, extruded polystyrene, polyurethane foam, resolic foam, wood fibre, rock wool, glass wool, cork, with a thickness from 150 to 500 mm.
7. Building according to claim 1, characterised in that the boards (20) are made of timber or plywood or multilayer wood, laminated wood, composite wood.
8. Building according to claim 1, characterised in that the boards (20) have a width substantially equal to the thickness of the panels (10) and a thickness in a ratio included between 1/8 and 1/15 of the width.
9. Construction process for a high thermal insulation building where at least some of the walls (1a, 1b, 2, 3) are mainly constructed of low-density thermally isolating materials where the panels (10) are cut to the required dimensions with edges uniformly flat over the complete thickness of the panels and the panels are assembled together with inserted boards (20) at the junction zones between two adjacent panels, the boards being joined in contact with the panels over the complete length and width of the edges of the panels at said junction zones so that the connection of the boards with the panels prevents the bending deformation of the boards transversally to their planes and their twisting deformation and ensures the bracing of the walls, said process characterised in that the panels (10) are clamped between the two boards (20) located on opposite edges of the panels, by screwing one panel to the other through the width of the panel clamped between said boards, or by strapping around both the boards and the panel clamped between said boards.

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