FR2895001A1 - Isolating structural floor unit fabricating method for floor, involves forming two parts, of structural floor unit respectively forming supporting structure and filling structure, and connecting structures for forming monobloc piece - Google Patents

Abstract

The method involves forming two parts of a structural floor unit (10) by molding alveolar plastic materials, where one part forms a supporting structure (11) and other part forms a filling structure (12). The supporting and filling structures are connected for forming a monobloc piece. The plastic material utilized for the part forming the supporting structure has a density higher than that of the material utilized for the part forming the filling structure. Independent claims are also included for the following: (1) a structural floor unit (2) a floor constituted of a set of beams and a set of structural floor units.

Description

METHOD FOR MANUFACTURING INSULATING CARRIERS FOR FLOOR FLOORS,

  INSULATING CARRIER AND FLOOR OBTAINED, Technical field:

  The present invention relates to a method of manufacturing an insulating interjoists for floor beams, 1 insulating insulation obtained by this method of manufacture and the floor incorporating a plurality of insulating interjoists. Prior art:

  In the field of the manufacture of joist floors, there are different types of interjoches whose mechanical and thermal characteristics vary according to their geometry and the materials in which they are manufactured, such as concrete, terracotta agglomerated wood fibers, plastics such as polypropylene, polystyrene, etc.

  Expanded polystyrene interjoists are appreciated for their lightness, maneuverability and insulating power. Nevertheless, they present a major drawback related to their mechanical fragility. To solve this problem, some interjoists are reinforced by the addition of reinforcing members reported or integrated, in their support zones and / or in the underside, such as for example a sheet or a resin reinforcement film (FR). 2,626,030; FR-2,751,356; EP-1,371,792), a metal profile (FR25 2,560,258), a sole made of wood concrete (FR-2,635,548). Other interjoists are reinforced by their structure by means of grooves, ribs, alveoli, etc. (WO-03/025301), which have the disadvantage of considerably increasing their bulk and the material coat.

  It is, therefore, difficult to find a compromise between mechanical resistance and insulating power, using only one material such as expanded polystyrene.

  The aim of the invention is to propose a new insulating interjoists, entirely made from synthetic materials, designed to meet the standards in force in terms of mechanical and thermal stresses, by optimizing functions and material, for reduced weight, bulk and wilt. The objective is to obtain an interjoists insulating, light, easy to handle even in large dimensions, mechanically resistant to support the weight of the workers during the realization of the floor then the concrete flows from the floor itself and the load supported by this floor, fireproof and weatherproof, aesthetic on the underside, adapted to different widths of beams, easy to cut on site to adapt its length and width to the dimensions of the trenches, also facilitating the installation of thermal breakers along the walls external.

  This object is achieved by a manufacturing method characterized in that by molding a first synthetic material, at least a first part of the interstage arranged to form a supporting structure, in that it is made by molding a second synthetic material, at least a second part of the interstage arranged to form a filling structure, and in that a connection is made between the supporting structure and the filling structure to form a monobloc piece.

  The first synthetic material may be chosen from a first alveolar plastic material and, for the second synthetic material, a second alveolar plastic material, or, for the first and second synthetic materials, the same alveolar plastics material, with or without a plastic material. different density, the higher density being reserved for the bearing structure, with or without the same hue or color.

  The filling structure can be molded onto the load-bearing structure by overmoulding so as to obtain a single piece or mold the structure of the filling structure separately from the supporting structure and assembled by a chemical and / or mechanical connection.

  This object is also achieved by a interjoists characterized in that it is obtained by the manufacturing method (Merit above and in that it comprises at least one bearing structure and a Rees filling structure.

  The supporting structure may constitute an open or closed shell containing the filling structure. In a preferred embodiment, the supporting structure 15 is an open shell and forms the top of the interjoists and the filling structure is disposed within the shell and forms, at least in part, the underside of the shell. between you. In an alternative embodiment, the supporting structure is a fennee shell and forms the top and bottom of the interjoists and the filling structure is disposed within the closed shell. Preferably, the supporting structure comprises two opposing and parallel support spoilers, intended to bear on the heel of the beams, as well as the other mechanical supports.

  This goal is finally achieved by a floor is at least a set of beams defining between them travees and a set of interjures as defined above agencies to fill the travees.

  BRIEF DESCRIPTION OF THE DRAWINGS The present invention and its advantages will become more apparent in the following description of an embodiment, given by way of non-limiting example, with reference to the accompanying drawings, in which: FIGS. 1A and 1B are respectively a view from above and a sectional view along AA of a floor form of beams, interjoists according to the invention and thermal breakers, FIGS. 2A and 2B are perspective views of a interjoists associated with two different types 3A and 3B are respectively a bottom view and a sectional view according to BB of the supporting structure of the interjoists according to the invention, FIG. 4 is a perspective view of the filling structure which completes FIGS. 3, FIGS. 5A, B, C and D are plan views of the interiors according to the invention respectively in plan view, in section CC, in section DD and in section EE, FIGS. Figures 6A and 6B are enlarged views of the details F and G of Figure 1B, and Figures 7A, B and C are views of a interjoists according to the invention, for a basement, respectively in section, from below and detail H .

  Best way to achieve the invention:

  Referring to the figures, the invention relates to a floor interjoists 1 to 25 beams 2 made entirely of synthetic materials, by means of a method in which this interjoists 10 is made at least in two parts: • a first part forming the supporting structure 11 of the invention 10 in a first synthetic material, this bearing structure 11 being arranged to meet the imposed mechanical and thermal stresses, and • a second part forming the filling structure 12 of 1'invous 10 in a second materiau synthetically, this filling structure 12 being arranged to complete the bearing structure 11 by adding thermal and mechanical performance, • the two parts being intimately linked to form a piece mannobloc.

  The number of parts is not necessarily limited to two and depends on the design of the interiors.

  The synthetic materials used to manufacture the supporting structure 11 and the filling structure 12 of the interwoven 10 can be identical materials with different densities, materials of the same family with different treatments or different materials, compatible or not chemically . These are preferably alveolar plastics selected from the group consisting of expanded polystyrenes, expanded polystyrene copolymers, expanded polyvinyl chlorides, foamed polyurethanes, or the like. These plastics may or may not be loaded with carbon particles, glass fibers, or the like, to enhance their mechanical strength and / or improve their thermal performance. Whether identical or not, these plastics may have different densities. We will choose a higher density for the bearing structure 11 than that for the filling structure 12, this higher density contributing to increase both the mechanical strength of the piece and its thermal performance. This difference in density also makes it possible to optimize the amount of raw material required for the manufacture of interiors by concentrating the high density in the supporting structure 11.

  For example, the supporting structure 11 and the filling structure 12 are both made of expanded polystyrene with a high density of between 15 and 25 and preferably 20 for the supporting structure 11, and a low density of between 7 and 17 and preferably 12 to the filling structure 12.

  It is also possible to introduce into the raw material, pigments for different tinting of the supporting structure 11 of the filling structure 12, this difference of shade which can then be used as a visual reference on the building site when the interjoists 10 are to be cut, as explained. further.

  This interjoists can be made according to different manufacturing methods. One of the most efficient methods in terms of profitability consists in using a mold with two cavities in which is molded, in a first imprint, the bearing structure 11, transferring the bearing structure 11 obtained in the second imprint, in which the mold is overmolded. filling structure 12, while in the first cavity, a new supporting structure 11 is molded.

  This overmoulding technique intimately allows the two parts of the interlayer to each other, by heat-sealing or heat-sealing, without addition of binder, provided that the selected synthetic materials are chemically compatible.

  Of course, it is also possible to make the two parts of the overmold 10 in molding in a mold with a single impression but with two dies, or separately in separate molds. In this case, the two parts are assembled by any suitable means as well chemical bonding for example, that mechanics by clipping for example, or a combination of both.

  This method of manufacturing by molding allows interjoists 10 of varying shapes and sizes, incorporating complex shapes impossible to achieve in extrusion. In addition, this method of manufacture makes it possible to include, in the form of overmoulding of the filling structure 12, an aspect film 46 (see FIG 7B) in the underside to give the interlock 10 an appearance which enables it to to remain visible. An example of interjoists 10 is described with reference to the figures. It has a substantially rectangular periphery comprising two support spoilers 13, longitudinal and opposite, intended to bear on the heel 20 of the beams 2, and two transverse ends 14 for cooperating with the transverse ends 14 of interjoists 10 end to end . The interjoists 10 are made up of two parts having different and complementary properties, namely a supporting structure 11 and a filling structure 12. In the example shown, the supporting structure 11 forms an open shell defining the top of the interiors. 10 and includes all the technical parts and mechanical supports, and the filling structure 12 completes the shell defining the underside of you 10 to give the final shape at 10 among you, but does not include any mechanical support.

  In other non-Must-6-es embodiments, the supporting structure 11 can be sandwiched between two filling structures 12 forming the top and the bottom of the middle 10. Conversely, the filling structure 12 can be sandwiched between two load-bearing structures 11 forming the top and the bottom of you 10. In this case, the supporting structure can form a closed shell. The supporting structure 11 may also form the underside of each of you 10, the filling structure 12 forming the top. Any other combination may be suitable, the essential being that the supporting structure 11 supports the mechanical supports. When the supporting structure 11 and the filling structure 12 are manufactured separately, they can also be used sepal-anent as needed.

  The bearing structure 11 of the invention as illustrated is described in more detail with reference to FIGS. 3 and 5. Elie comprises a median wall 15 substantially flat, of which extend two longitudinal wings 16, inclined and open forming between they an obtuse angle. These longitudinal wings 16 are terminated by the spoilers 13 defining the rebate 17 capable of receiving the heel 20 of the beams 2.

  The supporting structure 11 comprises beneath the spoilers 13, covering means for cooperating with the covering means of an adjacent interjoists 10 to cover the sole 21 of a beam 2 arranged between them and thus ensure a continuity thermal insulation. These recovery means comprise, in the example shown, a cover tab 18, provided on one side, which extends over a width at least equal to that of the sole 21 of a beam 2, and a zone of receiving 19, provided on ratite side, intended to receive the end zone of the cover tab 18 of 1'entrevous 10 adjacent. In this case, the junction zone is located on one side of the beam 2. It is also possible to provide a split splitter tab provided on each side of the interjoists 10, the junction zone being substantially in the middle of the beam 2.

  The cover tongue 18 and the receiving zone 19 comprise complementary shapes, such as a shoulder on each, delimiting two bearing planes 18 '. A double support or a double door is thus obtained, which makes it possible to eliminate the thermal beams between two adjacent interjoists 10 disposed on either side of a beam 2. In addition, these support planes 18 'allow a displacement transversal relative between two adjacent interjoists 10 to adjust their spacing at different widths of beam 2, such as beams of 95 and 115 mm. The clearance between the two support planes of the two adjacent interjoists 10 is filled by a trapped air gap which allows the maintenance of the thermal performance of the assembly regardless of the width of the beams 2.

  The supporting structure 11 comprises reinforcing ribs 30 which extend from its median wall 15 inwardly of the interjoices 10, oriented transversely from one longitudinal side to the other, whose function is to stiffen the interiors 10. by increasing its mechanical resistance to flexion. These reinforcing ribs 30 are four in number, this figure is not limiting, and are spaced regularly, which is not mandatory. Reinforcing ribs oriented in the other direction or in a grid pattern or the like can be provided.

  The supporting structure 11 also comprises interlocking means for mechanically assembling identical end-to-end interstices 10 to form a row extending over the entire length of a beam 2. In the example shown, these means of interlocking comprise a male part provided at a transverse end 14 and a female part 32 provided at the other transverse end 14. The male part is constituted by three lugs 31, a central lug at the top and two lateral lugs at the bottom. In correspondence, the female part has three recesses 32, one obviously central in the upper part and two lateral recesses in the lower part. These male and female parts are formed of pins 31 and recesses 32 opening on the upper and lower faces of the supporting structure 11 to allow its molding in a fixed impression without removable pin. Of course, all other male and female forms are possible. It is also possible to provide male and female combinations at each transverse end.

  The bearing structure 11 comprises, in its median wall 15, a central hole 33 opening, through which the filling structure 12 will be visible, the central hole 33 may be used for passage of ducts, for example. Elie comprises on the outer face of its median wall 15 two parallel, longitudinally oriented longitudinal grooves 34 and two longitudinal grooves 35 along a longitudinal flange 16. The grooves 34 are intended to receive ducts and, as the point grooves 35 form means for indexing the position of the thermal breakers, as will be explained later. This bearing structure 11 also has on its outer face cutting edges 36, in the easily traversable zones of lesser thickness, between the reinforcing ribs 30, in the form of oblongs, cercias, etc., and locating pins. 37 of frame, like arrows or other.

  The general section of the supporting structure 11 is substantially trapezoidal and all its parts are profiled to facilitate its molding and its molding. The only part that requires a removable pin is the rebate 17 between the spoiler 13 and the cover tab 18.

  The filling structure 12 according to the invention as illustrated is described in more detail with reference to FIGS. 4 and 5. It comprises a body of variable thickness extending inside and over the entire length of the supporting structure 11 Its upper face 40 is curved and has transverse grooves 41 in correspondence of the reinforcing ribs 30, a central stud 42 bearing a logo in correspondence of the central hole 33, recesses 43 and reliefs 44 at its transverse ends in correspondence of the parts. Male and female of the supporting structure 11. Its lower face 45 gives the shape of the intervous 10. It can tapped flat or slightly recessed, especially shaped open trapeze, to facilitate its dumoulage and allow the storage and transport of between you 10 identical stacks.

  The interjoists 10 according to the invention small title used to achieve a floor 1 above a crawl space called high vacuum, >> a basement called o high basement >>, or the like. In the first case, the underside of the interiors 10 is not visible and its appearance is of little importance while, in the second case, it can remain visible. The manufacturing method as described hereinabove makes it possible to integrate, easily and without extra cost, an appearance film 46, made of plastics materials such as polypropylene, such as that illustrated in FIG. 7B, directly by thermoforming and heat-sealing at the moment. overmoulding of the filling structure 12 or by any other suitable means. Similarly, this method of manufacture allows to integrate an insert (not shown), made of thermosetting plastics for example or other, for the fixing of false ceilings by screwing, nailing, stapling, etc.30 The shape and dimensions of 1 Interships 10 according to the invention are not restrictive and are adapted according to the type of floor 1 to be made. For example, for a floor high crawl space, the beams 2 have a height greater than the beams 2 for a floor o high basement >>. The angle of inclination of the longitudinal wings 16 and the thickness of the spoilers 13 are therefore different. For a high basement floor, the underside of the interiors 10 is preferably flat, which is aesthetic but is more expensive given the amount of raw material required. Conversely, for the interjoices intended for a floor high crawl space >>, the bottom recessed is not embarrassing and saves raw material. The realization of a floor o high basement requires the use of struts to the right of the beams 2 and thus to the right of the cover tongue 18 interjoists 10. To prevent any risk of crushing or punching of the tongue 18, it is possible to add a support 50, like that shown in Figures 7A and 7C, in the form of a triangular plate 51 carried by three support rods 52. Before the installation of 1, the support rods 52 of this support 50 are inserted through the cover tongue 18 of a interlock 10 until they come into abutment against the sole 21 of the beam 2. so that it is the beam 2 which supports the load and not the interjoists 10. Of course, any other form of strut support 50 may be suitable. Once the floor 1 is finished and the straps removed, we can remove these supports 50. The example of film 46 of FIG illustrates in Figure 7B, by regularly distributed points, allows both to serve as a reel during the installation of the struts 50 and conceal the holes 53 left by the support rods 52 during the withdrawal of these struts 50. This example is not exhaustive. 25 Industrial Application Possibilities:

  The interjoists 10 as designed greatly facilitates the production of a floor 1, an example of which is illustrated in Figures IA and 1B. This floor 1 is delimited peripherally by walls 3, defining two load-bearing banks on which the ends of eight parallel beams 2 and two non-bearing edges rest. These beams 2 are positioned at regular intervals and delirnite between them identical travees T except a T 'along a non-bearing bank which is less wide.

  The interiors 10 amens on site, stacked on each other for example on a pallet, are set up manually by the workers to fill the trenches T. Its are placed in the longitudinal direction so that the spoilers support 13 rest on the heel 20 of the beams 2 and are nested end to end, the lugs 31 of a interjoists 10 entering the recesses 32 of 1'avant previous 10 to form a row of interjoists 10 connected to each other mechanically. Since the length of a gap T is generally not a multiple of the length L of the interjoists 10, the last interjoists 10 must be shortened over a length L '. Since it is made of alveolar plastics, it can be easily truncated with a hand saw or the like.

  The design of the interjoist 10 makes it possible to remove the beams along the non-bearing edges. In fact, the shoulder provided in the reception zone 19 of the cover tongue 18 makes it possible to rest the interjoist 10 on the edge of the edge, as shown in detail in FIG. 6A. For false entry T ', located along a non-load-bearing road, the same procedure is carried out by inverting the inlet 10 to use the side comprising the shoulder of the reception zone 19. For this purpose, the intersections are truncated. 10 Bans in the longitudinal direction, it removes the side with the cover tab 18 and is formed in the slice a spoiler support 13 and a slope equivalent to the inclination of the longitudinal wings 16. To facilitate the work, we use a mark The boundary formed by the boundary between the supporting structure 11 and the filling structure 12 may be marked by a difference in hue or color between the two-structure plastics used for the two structures. When the traves T, T 'are equipped by the interjoists 10, one can set up thermal switches 6 in the periphery of the floor 1 to remove the thermal bridges. These thermal breakers 6 are forms of insulating blocks, for example expanded polystyrene mono or bi-density, complete or not a rock wool plate or the like, whose shape is complementary to that interjoists 10 to facilitate their implementation. place and their positioning. The thermal breakers 6 disposed at the ends of the trenches T, T ', said end switches 60, are substantially rectangular blocks, of length substantially equal to the width of the median wall 15 of the interjoists 10. It comprises two transverse ribs 62 of complementary shape to the two wire grooves 34 provided on the top of 1'entrevous 10. The thermal breakers 6 arranged along the non-bearing banks, said edge breakers 61, are substantially rectangular blocks whose base is cut at an angle to embracing part of the medial wall 15 and the longitudinal wing 16. They comprise a longitudinal rib 63 of complementary shape to the point grooves 35 (see Figure 6B). In the example shown, there are provided two edge breakers 61 by interjoists 10, positioned between the locating pins 37. When the installation of the thermal breakers 6 is completed, it is possible to add a peripheral chaining by laying steels 7 year-level Locating cues 37. A beton said keying concrete 8 is cast in the periphery to lock this structure. Then, the floor 1 is finished by placing for example a lattice (not shown) of steel forming the armature of the floor 1 before casting the concrete slab, or any other type of floor 1. According to the thickness of the floor 1, we can also add on the interjoists 10 blocks forming extensions.

  It is clear from this description that the invention achieves the fixed goals. In particular, the manufacturing process makes it possible to optimize the quantity of raw material required for the realization of the interiors 10 and therefore its cost price. The interjoists obtained with the advantage of meeting the mechanical and thermal stresses, of saving the beams 2 along the non-load bearing shores, of adapting in length and width to the dimensions of the trenches T, T 'and of facilitating laying thermal breakers 6.

  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.

Claims (10)

claims   1. Process for the manufacture of an insulating interjoist (10) for floor (1) with beams (2), characterized in that it is made by molding a first synthetic material, at least a first part of the interjoists (10) arranged to form a supporting structure (11), in that a second synthetic material is produced by molding, at least a second portion of the interjoists (10) arranged to form a filling structure (12); ), and in that a connection is made between the supporting structure (11) and the filling structure (12) to form a single piece.   2. Method according to claim 1, characterized in that one chooses, for the first synthetic material, a first alveolar plastic material.   3. Method according to claim 1, characterized in that one chooses, for the second synthetic material, a second plastic alveolar material.   4. Method according to claim 1, characterized in that one chooses, for the first and second synthetic materials, the same plastic material alveolar. 20   5. Process according to any one of claims 2 to 4, characterized in that one chooses the alveolar plastics material (s) in the group comprising expanded polystyrenes, expanded polystyrene copolymers, expanded polyvinyl chlorides, foamed polyurethanes, with or without carbon charge, a combination of these plastics. 25   6. Method according to any one of claims 2 to 4, characterized in that, in order to produce the supporting structure (11), an alveolar plastic material having a first density is chosen and in order to produce the filling structure (12), a alveolar plastic material having a second density, less than the first density.   7. Method according to claim 6, characterized in that the first density is between 15 and 25 and preferably equal to 20 and in that the second density is between 7 and 17 and preferably equal to 12.   8. Method according to claim 1, characterized in that the filling structure (12) is molded on the supporting structure (11) by overmoulding so as to obtain a monobloc piece. 10   9. Method according to claim 1, characterized in that one molds the filling structure (12) separately from the supporting structure (11) and in that they are assembled by a chemical bond and / or mechanical.   10. Intervals (10) for floor (1) with beams (2), characterized in that it is 15 & btenu by the manufacturing method according to any one of the preceding claims and that it comprises at least one structure bearing (11) and a filling structure (12) connected. 1. An interlock according to claim 10, characterized in that the supporting structure (11) constitutes an open or closed shell containing the filling structure (12). 12. Interlocks according to claim 11, characterized in that the supporting structure (11) is an open shell and forms the top of the interjoists (10) and in that the filling structure (12) is arranged at the interior of the shell and form, at least in part, the underside of the intervous (10). 13. Interlocks according to claim 11, characterized in that the supporting structure (11) is a closed shell and forms the top and the bottom of the interjoists (10) and in that the filling structure (12) is arranged a Inside the closed hull. An interlock according to claim 11, characterized in that the supporting structure (11) carries two opposite and parallel support spoilers (13) for resting on the heel (20) of the beams (2). 15. Interlocks according to claim 11, characterized in that the supporting structure (11) carries reinforcing ribs (30) extending inside the interjoists (10). 16. Interlocking according to claim 14 comprising, under the spoilers (13), covering means (18, 19) for cooperating with the covering means (18, 19) of an adjacent interjoists (10) in to cover the sole (21) of a beam (2) arranged between them, characterized in that the supporting structure (11) comprises said covering means comprising on one side a cover tongue (18) and 1 ' on the other side a receiving area (19) for receiving the covering tab (18) of the adjacent interjoists (10). 17. Interlocks according to claim 16, characterized in that the cover tongue (18) and the receiving zone (19) comprise complementary shapes able to create at least two support planes (18 '). 18. Entrevous according to claim 11 having, at its transverse ends (14), interlocking means agencies to assemble end A. bout identical interjoists (10), characterized in that the bearing structure (11) comprises said means d interlocking forms of lugs (31) and recesses (32). 19. Interlocks according to claim 11, characterized in that it comprises in its upper face grooves (34, 35) for indexing the position of thermal breakers (6) .20. Interlocking according to claim 11, characterized in that the supporting structure (11) and the filling structure (12) have a different color. 21. Floor (1) constitutes at least one set of beams (2) defining between them traves (T, T ') and a set of intervous (10) agencies to fill the trenches (T, T '), characterized in that said interjoists (10) are made according to any one of claims 10 to 20. 22. Floor according to claim 21, characterized in that the latching tongue (18) and the receiving zone (19) ) interjoists (10) are arranged to allow the recovery of beams (2) of different widths. 23. Floor according to claim 21, characterized in that it comprises thermal breakers (6) disposed on the periphery of said floor (1) and having ribs (62, 63) adapted to be housed in the grooves (34, 35) of corresponding interjoists (10).