FR2931496A1 - Prefabricated multi-layer monoblock panel e.g. wall panel, for forming e.g. wythe of modular dwelling, has core formed by ultra high performance fiber concrete with ribs, and thermo-acoustic insulant placed inside ribs - Google Patents

Abstract

The panel e.g. wall panel (PM), has a rigid core (1) placed between two parallel lower and upper layers (2, 3) forming entire or part of upper and lower faces of the panel and formed by an ultra high performance fiber concrete with a rib (10) and three ribs. The ribs perpendicularly extend to the layers, and a thermo-acoustic insulant (5) is placed inside the ribs. A metallic armature (4) is molded in the concrete that is constituted by metallic fibers. The layers (3, 2) are respectively made of self-leveling gypsum plaster and ultra high performance fiber concrete with organic fibers. Independent claims are also included for the following: (1) a method for manufacturing a prefabricated multi-layer monoblock panel (2) a modular dwelling comprising habitable lateral modules.

Description

Monobloc prefabricated multilayer panel for the realization of the walls of a house, a method of manufacturing such a panel and housing equipped with such panels.

Description Technical Field of the Invention The present invention relates to a prefabricated multilayer monobloc panel for the realization of the walls of a house. It also relates to a method of manufacturing such a panel. It also relates to a dwelling equipped with such panels.

The invention relates to the general technical field of the building and more specifically that of prefabricated building elements used to directly produce residential walls.

State of the art Nowadays, it is necessary, for economic reasons, that the construction times of a house be as small as possible.

Patent documents CH 690 689 (MARCHISELLA et al.), WO 84/01975 (GOETAVERKEN MADUL AB), US Pat. No. 6,122,473 (PINGEL) or EP 1,564,337 (ALGECO) disclose dwellings composed of several habitable modular elements. juxtaposed, the number of which varies according to the living space sought. Each modular element generally comprises a metal structure forming a framework that can receive a floor-type cladding, walls and roof. These homes have 2931496 -2

the advantage of having a short manufacturing time, because the execution of most of the work is done directly in the factory. The modular elements are then transported directly to the site and set up using a crane. Once the modular elements are installed, workers seal them together and perform the twinning finishes. The installation time is extremely reduced compared to the construction of a conventional house since in general, one day is sufficient for the establishment of the various modular elements and the delivery of the keys.

The walls of such dwellings are generally in the form of prefabricated monobloc panels which are fixed on the metal structure forming a framework. These panels usually comprise a rigid core disposed between two parallel layers forming the faces of said panel. They have good acoustic and thermal resistance. However, their mechanical strength is limited so that it is necessary to fix these panels on the metal frame structure. The latter is indeed able to cash in most efforts and solicitations.

In practice, the assembly of the metal frame structure and the laying of the panels on said structure are costly steps in time and labor.

In view of this state of affairs, the main objective that the invention aims to achieve is to propose a multilayer prefabricated monoblock panel having a structure enabling it to absorb most of the forces and stresses so that it is no longer necessary to use a metal structure forming a framework. Another object of the invention is to provide a method for making such a panel quickly and simply. 2931496 -3

Yet another object of the invention is to provide a dwelling, in particular, but not exclusively a modular dwelling, whose construction times are reduced compared to homes known from the prior art. Disclosure of the invention. The solution proposed by the invention is a multilayer prefabricated monobloc panel for producing the walls of a house, said panel having a rigid core disposed between two parallel layers forming all or part of the upper and lower faces of said panel, the core being constituted by an ultra-high performance fiber-reinforced concrete structure having ribs extending perpendicularly to said two parallel layers of said panel and within which a thermo-acoustic insulation is disposed. Such a panel has not only good acoustic and thermal resistance, but the specific design of the core allows to achieve good mechanical strength. This panel is thus likely to be used alone to collect the stresses and stresses of a home, without the need to provide a metal frame structure usually used in the techniques of the prior art.

According to an advantageous characteristic of the invention making it possible to optimize the distribution of forces in the panel, a metal reinforcement 25 is molded into the ultra-high-performance fiber-reinforced concrete structure constituting the core.

According to another advantageous characteristic of the invention making it possible to increase the mechanical strength of the panel, the ultra-high-performance fiber-reinforced concrete used to produce the structure constituting the core, is a concrete comprising metallic fibers. According to yet another advantageous characteristic of the invention, the constituent material of the lower layer of the panel is an ultra-high performance fiber-reinforced concrete comprising organic fibers. Such concrete has improved properties over conventional concretes and reduced corrosion effects compared to ultra high performance fibered concretes having metal fibers.

According to yet another advantageous characteristic of the invention, the constituent material of the upper layer of the panel is a self-leveling plaster. This feature provides a panel requiring virtually no finishing once it is in place.

According to yet another advantageous feature of the invention, a thermoacoustic insulation layer is disposed between the core and one of the upper or lower layers of the panel, so that there is no bridge thermal between the two said layers.

In an alternative embodiment for using the panel to directly form the floor of a dwelling, the upper face of the panel has a tile and / or floor and / or polished concrete portion. And preferably, a layer of thermoacoustic insulation is disposed between the core and the tile and / or floor and / or waxed concrete part, the surface of said insulation being at least equal to the surface of said tile and / or said floor and / or said waxed concrete.

Another aspect of the invention relates to a method of manufacturing the panel described above, said method consisting in: placing at the bottom of a horizontal mold a first layer of a material forming all or part of the first face of said panel, - 5

- Making a core by casting a layer of ultra high performance fiber concrete, said layer being cast so as to have ribs extending perpendicular to said first layer and within which there is a thermo-acoustic insulation, - arrange a second layer of a material forming all or part of the second face of said panel, said second layer being parallel to said first layer. This process makes it possible to industrially produce finished panels that can be quickly assembled in the factory or directly on site. According to an advantageous characteristic of the invention enabling the structure of the core to be produced simply and quickly: thermo-acoustic insulation elements are provided in the mold, the latter being: positioned at a distance from the lateral walls of the mold; mold, so as to form an empty frame around said insulating elements, • separated from each other so as to form empty ribs communicating with said empty frame, - the empty layer and the empty ribs are poured into the empty frame; of ultra-high performance fiber-reinforced concrete.

According to another advantageous characteristic of the invention, before casting the ultra-high performance fiber-reinforced concrete layer, a metal reinforcement is placed in the empty frame and in the empty ribs. According to yet another advantageous characteristic of the invention making it possible to save time during the design of a dwelling, one or more conduits for the passage of electrical cables and / or one or more pipes are molded directly into the panel. And / or one or more heating elements. 2931496 -6

Yet another aspect of the invention relates to a dwelling where one or more of its walls are formed by panels conforming to some of the features described above.

Yet another aspect of the invention relates to a modular dwelling formed by two habitable side modules connected by one or more habitable central modules, the connection between the different modules being made by means of a removable fastening structure allowing adding or removing one or more central modules between said lateral modules, the various modules being structurally independent and each formed by one or more roof panels, one or more floor panels and vertical panels forming the walls, said dwelling being remarkable in that said vertical panels, possibly said roof panels and possibly said floor panels are in accordance with some of the previously described features.

According to an advantageous characteristic of the invention for rapidly building the dwelling, the roof panels, the floor panels and the vertical panels forming the walls are directly secured to each other by gluing and by means of mechanical connections.

According to another advantageous characteristic of the invention facilitating the placement of the wall panels, one of the lower edges of the latter comprises a projecting centering element, said centering element being configured to be positioned in a hollow centering element. of complementary shape, disposed at the periphery of the upper face of the floor panel.

Description of the figures. Other advantages and characteristics of the invention will appear better on reading the description of a preferred embodiment which will follow, with reference to the appended drawings, made as indicative and non-limiting examples and on which FIG. 1 is a perspective view of a panel according to the invention, such a panel being in particular intended for making walls of a dwelling, FIG. 2 is a sectional view along AA of the panel of the FIG. 3 is a sectional view along BB of the panel of FIG. 1; FIG. 4 is a perspective view of a panel according to the invention in an alternative embodiment, such a panel being in particular intended to form the floor of a dwelling, - Figure 5 is a sectional view along CC of the panel of Figure 4, - Figure 6 is a sectional view along DD of the panel of Figure 4, - Figures 7a at 7th show schematically the different stages of a n method for manufacturing the panel shown in Figures 1, 2 and 3, - Figures 8a to 8e show schematically the various steps of a method for manufacturing the panel shown in Figures 4, 5 and 6, - Figures 9a, 9b and 9c are schematic horizontal sectional views, respectively of a first lateral module, of a central module, of a second lateral module, of a dwelling according to the invention, - Figure 10 shows schematically. the assembly of the panel shown in Figure 3 and the panel shown in Figure 5.

Embodiments of the invention 1. Description of the panels. The panels of the invention are prefabricated multi-layer monobloc panels for the realization of the walls of a dwelling: walls of wall, roof or floor. For the purposes of the present invention, monoblock means integral panels in which the various constituent layers are held in position relative to one another. Prefabricated means panels made in the factory, prior to their use. Multilayer means panels composed of a succession of 10 layers, each layer may be made of a specific material having particular properties.

1.1. Wall panel and / or roof PM. Figure 1 shows a PM panel according to the invention, particularly for use in realizing the walls of a dwelling. Such a panel can however also be used as a roof panel. The PM panel is generally in the form of a rectangular plate having an upper face and a lower face. In the horizontal position, this plate has a length of between 1 m and 3 m, a width of between 0.5 m and 2 m and a thickness of between 10 cm and 1 m. However, the plate may have another shape and dimensions more or less important as needed.

The PM panel can directly integrate during its manufacture, locations for doors, French windows, windows, half-moon openings, etc. Similarly, one or more conduits for the passage of electrical cables and / or one or more pipes and / or one or more heating elements can be directly integrated in the PM panel. Each PM panel is advantageously pre-equipped to receive TV, computer and Internet power outlets, etc. According to the invention, the PM panel comprises a rigid core 1 disposed between two parallel layers 2, 3 respectively forming all or part of the upper and lower faces of said panel. As described later in the description, a greater number of layers can be provided depending on the desired thermal, acoustic and / or mechanical characteristics. The rigid core 1 is constituted by an ultra-high performance fiber-reinforced concrete structure having a thickness of between 5 cm and 1 m. Ultra-high performance fibered concretes (hereinafter referred to as UHPCF) are understood to mean materials with a cementitious matrix, with characteristic compressive strength greater than 150 MPa, and up to 250 MPa. Among the UHPCs known to those skilled in the art, mention may be made by way of non-limiting example: the DUTAL, the BSI, the CERACEM or the CEMTEC MULTISCALE. The methods for characterizing UHPCs are, for example, described in: AFG and SETRA. Scientific and technical document. Fiber concrete with ultra-high performance. Provisional recommendations. January 2002.

The UHPC used is preferably added with metal fibers 20 in order to obtain an improved mechanical behavior. Such a metal fiber concrete is for example described in patent EP 1.034.148 (BOUYGUESLAFARGE-RHODIA), the technical elements of which are incorporated herein by reference. In order to optimize the distribution of forces in the PM panel, a metal frame 4 can be molded in the UHPC. Referring to FIGS. 2 and 3, the structure of the core 1 has ribs 10, 11, 12, 13 extending perpendicularly to the two parallel layers 2, 3. In practice, the ribs have a width varying from 1 cm to 50 cm. The weft of the ribbing will respond to the structural and external stresses: load descent, handling and transport efforts, wind effects and non-deformability in the event of earthquakes, etc. Ribbing may be similar 2931496 - 10-

to a hexagonal honeycomb structure, to a star structure, or, as shown schematically in Figures 2 and 3, a simple structure where the ribs are parallel to each other. Advantageously, a metal reinforcement 4 is molded in each of the ribs 10, 11, 12, 13. With reference to FIGS. 2 and 3, a thermoacoustic insulation 5 is disposed inside the ribs 10, 11, 12, 13, said insulator filling the space defined by each rib. By thermo-acoustic insulation is meant a material able to limit the spread of cold, heat and noise. Lean concrete, rigid polystyrene, rock wool or other similar insulating materials suitable for the skilled person may be used. In an alternative embodiment, it can simply provide to leave a layer of air between the ribs 10, 11, 12, 13, said air layer acting as an insulator.

In the case where the PM panel is used as a dwelling wall or as a roof, the two parallel layers 2, 3 forming the upper and lower faces of said panel are in practice visible layers once said panel is put in place. For example, the upper layer 2 will be visible from inside the dwelling and the lower layer 3 will be visible from outside said dwelling. These two layers are therefore not subject to the same stresses and stresses and are therefore advantageously made from different materials.

In order to produce the lower layer 3 visible from outside the dwelling, it is preferred to use a UHPC of the type previously described to a thickness of between 0.5 cm and 10 cm. However, the Applicant has found that it is particularly advantageous to use a UHPC containing organic fibers. In addition to having improved properties over conventional concretes and a reduction in the effects of corrosion compared to UHPCs comprising metallic fibers, such concrete can be easily tinted in the mass and structured on the surface in view of it. -11-

give a particularly attractive aesthetic appearance. Indeed, the lower layer 3 may have the appearance of plaster, stone, timber, tile, etc.. For example, a DUCTAL -FO concrete described in patent EP 1.080.049 (BOUYGUES-LAFARGE-RHODIA) may be used, the technical elements of which are incorporated herein by reference. Those skilled in the art will still be able to refer to the technical evaluation of DUCTAL -FO prepared by CSTB on September 27, 2005, the technical elements of which are also incorporated herein by reference. However, it will be possible to use other materials such as wood or bricks to make the lower layer 3 visible from outside the house, the important thing being to be able to ensure a certain tightness and withstand external aggressions (wind, rain, sun, ...).

To achieve the upper layer 2 visible from the interior of the house, it is preferred to use a self-leveling plaster to obtain a panel 15 requiring virtually no finishing once it is in place. In practice, the plaster layer has a thickness of between 0.1 cm and 10 cm. It may be expected to use other plaster or type of cladding to hide the structure of the soul 1.

Referring to Figures 1 to 3, a thermoacoustic insulation layer 6 is disposed between the core 1 and the top layer 2, so that there is no thermal bridge between said top layer and the layer lower 3 of the PM panel and more generally between the two faces of the latter. In an alternative embodiment not shown, it is possible to arrange the insulating layer 6 between the core 1 and the lower layer 3. In practice, the insulating layer 6 covers the entire surface of the PM panel or, at minima, the surface of the upper layer 2 and the lower layer 3. In a manner well known to those skilled in the art, the thickness of the insulating layer 6 will depend on the material used. In practice, it varies from 1 cm to 20 cm. It will be possible to use as insulation: lightweight concrete, rigid insulation type 2931496 -12-

polystyrene, rockwool or other similar insulating materials suitable to those skilled in the art.

In order to secure the insulating layer 6 to the core 1 on the one hand and to the upper layer 2 (or to the lower layer 3) on the other hand, it will be advantageous to use connectors 7 made of plastic or metal in the form of a rod having at its ends lugs or fixing heads. As shown in FIGS. 2 and 3, these connectors 7 are fixed at one of their end to the core 1 (in particular in the ribs 10, 11, 10, 12, 13), at their other end to the upper layer. 2 (or at the bottom layer 3), the rod of said connectors passing through the insulating layer 6.

1.2. PP floor panel.

Figure 4 shows a PP panel for use in making the floor of a dwelling. This panel PP is generally in the form of a rectangular plate having an upper face and a lower face. In the horizontal position, this plate has a length of between 2 m and 10 m, a width of between 2 m and 10 m and a thickness of between 10 cm and 1 m. However, the plate may have another shape and dimensions more or less important as needed.

Referring to FIG. 6, the PP panel may directly integrate during its manufacture one or more conduits 109 for the passage of electrical cables and / or one or more pipes and / or one or more heating elements.

Referring to Figures 4 to 6, the panel PP comprises a rigid core 101 disposed between two parallel layers 102, 103 respectively forming all or part of the upper and lower faces of said panel, a greater number of layers can be provided. In the same way as 2931496 -13-

described above, the rigid core 101 is constituted by a UHPC structure, advantageously added with metal fibers, a metal reinforcement 104 can be provided in said structure. The core 101 has a thickness of between 5 cm and 1 m. The core structure 101 has ribs 110, 111, 112, 113 extending perpendicular to the two layers 102 and 103. In practice, the ribs have a thickness ranging from 1 cm to 50 cm. The frame of the ribbing will respond to structural and external stresses: load descent, 10 handling and transport efforts, non-deformability in the event of earthquakes, etc. The rib may be similar to a honeycomb hexagonal structure, a star structure, or, as shown schematically in Figures 5 and 6, a simple structure where the ribs are parallel to each other. Advantageously, a metal frame 104 is molded into each of the ribs 110, 111, 112, 113.

Referring to Figures 5 and 6, a thermo-acoustic insulation 105 is disposed within the ribs 110, 111, 112, 113, said insulation filling the space defined by each rib. In an alternative embodiment, it will be possible simply to leave an air layer between the ribs 110, 111, 112, 113, said air layer acting as insulator.

At least one of the two parallel layers 102, 103 forming the faces of the panel PP will in practice be visible from the inside of the house once said panel is put in place. For example, referring to Figures 5 and 6, the top layer 102 will be the one on which we will walk and will be visible from inside the house. The lower layer 103 will be not visible because vis-à-vis the ground. It should be noted that in the case where the PP panel is used for the manufacture of a mezzanine floor or another floor, the lower layer 3 will also be visible as a ceiling. In all cases, these two layers 102 and 103 are not subject to the same conditions.

the same stresses and constraints and are therefore advantageously made from different materials.

To achieve the top layer 102, it is preferred to use a tile and / or floor and / or waxed concrete material. It is not necessary that the entire upper face of the panel is covered with tiled and / or floor and / or waxed concrete. Indeed, as is explained in FIG. 10, the periphery of the upper face of the panel PP is intended to receive the wall panel PM or another partition, this part not being visible from the inside of the panel. housing and does not require the installation of a tiled floor and / or a floor and / or polished concrete. In practice, the tile and / or floor and / or waxed concrete portion covers between 80% and 100% of the upper face of the PP panel. As shown in FIGS. 5 and 6, the tile and / or floor and / or waxed concrete portion is preferably framed by the upper distal portion 1010 of the core structure 101, said distal portion having a greater thickness than the rest of said structure. As shown diagrammatically in FIG. 10, the PM wall panel or any other partition resting on this upper distal portion 1010.

The constituent material of the lower layer 103 may vary depending on the use of the PP panel. If the latter is used for the manufacture of a floor located on the ground floor of the dwelling, that is to say that the lower layer 103 is located outside said dwelling, it is preferred to use a UHPC of the type described above over a thickness of between 0.5 cm and 10 cm. The UHPC used may comprise metallic fibers, in which case the lower layer 103 is a continuity of the structure of the core 101 (FIGS. 4 to 6). In an alternative embodiment, it is also possible to use a UHPC containing organic fibers so as to reduce the effects of corrosion, for example the concrete DUCTAL -FO described above. In an alternative embodiment, it is still possible to use other materials 2931496 -15-

suitable for the skilled person and to ensure a certain tightness and withstand external aggression.

When the PP panel is used for the manufacture of a mezzanine floor or other floor, the bottom layer 103 is visible as a ceiling and must therefore have a neater finish. To do this, you can use a self-leveling plaster to obtain a panel requiring virtually no finishing once it is put in place. In practice, the plaster layer has a thickness of between 0.1 cm and 10 cm. It is possible to use other plaster or wallboard type coatings in order to hide the structure of the core 1. For the same reasons as those mentioned above, it is not useful for the whole of the lower face the PP panel is covered with plaster. Indeed, the periphery of the latter does not require a neat finish since it will rest on the upper part of the wall panels PM or any other partition. In practice, the plaster part will cover between 80% and 100% of the total underside of the PP panel. As previously described for the upper layer 102, the plaster part will in this case preferably be framed by the lower distal part of the core structure 101. Referring to FIGS. 5 and 6, a thermoacoustic insulation layer 106 is disposed between the core 101 and the upper layer 102 tiled and / or floor and / or waxed concrete. In an alternative embodiment not shown, it is possible to arrange the insulating layer 106 between the core 101 and the lower layer 103. In practice, the surface of the insulating layer 106 is at least equal to the surface area. tiling and / or floor and / or waxed concrete (or on the surface of the lower layer 103). The insulation used may be lightened concrete, rigid polystyrene type insulation, rock wool or other similar insulating materials suitable for those skilled in the art. In a manner well known to those skilled in the art, the thickness of the insulating layer 106 will depend on the material used. In 2931496 -16-

practical, it varies from 1 cm to 20 cm. Similarly, to limit the thermal bridges, provision may be made to provide a thermal breaker 120 between the inner edge of the upper distal portion 1010 of the core structure 101 and the outer edge of the upper layer 102 of tiling and / or floor and / or 5 polished concrete. The thermal breaker 120 is made of a thermally insulating material, preferably of expanded polystyrene to facilitate its handling.

With reference to FIGS. 5 and 6, a layer of UHPC 108 is advantageously disposed between the thermo-acoustic insulation layer 106 and the upper layer 102 of tiling and / or floor and / or waxed concrete. The UHPC layer 108 makes it possible to take up the stresses exerted on the upper layer 102 and to protect the thermoacoustic insulation layer 106. The BFU used is of the type described above and comprises metal or organic fibers.

In order to secure the insulating layer 106 to the core 101 and to the upper layer 102 (or to the lower layer 103), connectors 107 made of plastic or metal in the form of rod having at its ends lugs or fixing heads. As shown in FIGS. 5 and 6, these connectors 107 are attached at one end to the core 101 (in particular in the ribs 110, 111, 112, 113), at their other end to the upper layer 102. (or at the lower layer 103), the rod of said connectors passing through the insulating layer 106.

2. Houses equipped with panels.

Another object of the invention relates to a dwelling of which one or more of the walls are formed by panels previously described. In particular, the walls and possibly the roof of this house are made 2931496 -17-

by the PM panels object of the invention. Similarly, the floor of this house is made using one or more PP panels according to the invention.

More particularly and with reference to FIGS. 9a to 9c, the panels PM and PP according to the invention are preferably used in a modular dwelling formed by two living MLa, MLb side modules connected by one or more habitable central modules MC. These modules are configured to form one or more living rooms once they are together. The two side modules MLa, MLb can be connected by one or more similar central modules MC side by side. By adding or removing one or more central modules, you can modulate the volume of the home from the inside, not the outside. The connection between the different modules is achieved by means of a removable fastening structure for adding or removing one or more central modules between said side modules. Such attachment structures are for example described and shown in the patent documents CH 690.689 (MARCHISELLA et al), WO 84/01975 (GOETAVERKEN MADUL AB), US 6,124,473 (PINGEL) or EP 1,564,337 (ALGECO) . The lateral modules MLa and MLb are advantageously of polygonal and preferably trapezoidal shape. However, other forms can be envisaged and in particular rounded shapes. In practice, these two modules are complementary and symmetrical. These modules have a net surface area (or living space) of between 10 m2 and 12 m2 so as to have a satisfactory living space to be easily transportable by truck. However, other dimensions may be considered depending on the type of dwelling desired. Cl partitions equipped with P doors are advantageously reported to form different living rooms. The P-doors will benefit from the composite structure of the Cl partitions to be laid in pocket and will have a sliding opening function. 2931496 -18-

releasing the maximum of living space. In the embodiment shown in Figure 9a, the rear portion of the right side module MLa comprises a first piece Chi of about 5 m2 and a free space Ch2 of about 6 m2. The rear part of the left side module MLb has a toilet area Ch3 arranged in a room Ch4 of about 7 m2 and a free space Ch5 of about 4 m2.

The central module MC is advantageously of rectangular shape. However, other shapes can be envisaged including rounded shapes. In practice, this module has a shape complementary to the side modules MLa and MLb so as to preserve the aesthetics. The central module MC has a net floor area of between 15 m2 and 25 m2 so as to have a satisfactory living space and be easily transportable by truck. However, other dimensions may be envisaged depending on the type of dwelling desired. The central module MC may also comprise Cl partitions reported equipped with P door so as to form one or more parts. In the exemplary embodiment shown in FIG. 9b, the rear part of the central module MC comprises a water room Ch6 of approximately 4 m2 and a free space Ch7 of approximately 17 m2, which can, for example, be used for landscaping. a kitchen area and the living room.

The various modules MLa, MLb, MC are structurally independent to allow an industrialization cycle directly in the factory, the inner elements of said modules being mounted at the factory, so that at the end of the chain, they come out completely finished. These different modules are each formed by one or more roof panels, one or more floor panels and vertical panels forming the walls. According to the invention, the vertical panels and / or the roof panels are PM panels previously described. The 30 PM wall panels advantageously incorporate spaces for P doors, PF windows, glass windows, etc. 2931496 -19- The various roof panels, floor and wall, are directly secured to each other by gluing and through mechanical connections. No metal structure forming framework is provided in contrast to the dwellings described in the patent documents CH 690.689 (MARCHISELLA et al), WO 84/01975 (GOETAVERKEN MADUL AB), US 6,124,473 (PINGEL) or EP 1,564,337 ( ALGECO). This is possible thanks to the particular structure of the soul of the panels adapted to cash the various stresses and stresses. With reference to the accompanying figures and more particularly to FIG. 10, the lower edges of the PM wall panels comprise a projecting centering element 14, the latter being configured to be positioned in a recessed centering element 140 of complementary shape. disposed at the periphery of the upper face of the floorboard PP.

In practice, the projecting centering element 14 is an integral part of the structure of the core 1 of the wall panel PM and is formed during the molding of the latter. However, provision may be made to use one or more centering studs attached to the lower edges of the PM wall panels.

Similarly, the hollow centering element 140 is an integral part of the core structure 101 of the floor panel PP and is formed during the molding of the latter. This hollow centering element is preferably made in the upper distal portion 1010 of the core structure 101. It can also be provided to use one or more centering elements reported or directly molded in the upper distal portion 1010, said centering elements being configured to receive any centering studs attached to the lower edges of the PM wall panels. 30 2931496 - 20 -

It is advantageous to have a flat seal at the junction between the PM and PP panels so as to seal. The position of the PM wall panels on the floor panels PP is directly made by bolting and gluing (it will be possible to use a two-component adhesive for concrete). However, other equivalent mechanical bonds may be provided by those skilled in the art.

Referring to Fig. 10, it will be appreciated that the thermal breakers 120 of the board panel PP are arranged to coincide with the insulating layer 6 of the wall panel PM. This configuration allows for continuity of insulation and eliminates any thermal bridge.

In practice, the roof panels are bonded to the wall panels in a similar manner. To facilitate the design, however, it is preferred to use centering elements reported rather than directly provided during molding. The holding in position of these panels is directly achieved by bolting and gluing. However, other equivalent mechanical bonds may be provided by those skilled in the art. 20

3. Panel manufacturing processes.

According to the invention, a method of manufacturing the walls and roof panels PM or PP floor panels described above consists of: placing at the bottom of a horizontal mold a first layer of a material forming all or part of of the first face of said panel, - making a core by casting a layer of ultra-high performance fiber concrete, said layer being cast so as to have ribs 2931496 - 21 -

extending perpendicularly to said first layer and within which a thermoacoustic insulation is provided; - arranging a second layer of a material forming all or part of the second face of said panel, said second layer being parallel to said first layer.

This method will now be described in more detail depending on whether it is a wall panel and / or PM roof or a PP floor panel.

3.1. Method of manufacturing a wall panel and / or roof PM.

Figures 7a to 7e show schematically the various steps of a method for manufacturing the wall panel and / or roof PM shown in Figures 1, 2 and 3 and described above. A horizontal mold M is preferably used, the side walls M1, M2 of which are removably mounted on a base M3 forming the bottom of the mold, by means of removable mechanical connections M5 of the screw type. The fact of having removable side walls M1, M2 makes it possible to easily unmold the PM panel once the various layers have sufficiently hardened. In a first step shown in FIG. 7a, a first layer 3 is formed at the bottom of the mold M, which will form all or part of the lower face of the PM panel. In practice, a UHPC containing organic fibers is poured into the bottom of the mold M. The bottom M3 of the mold M is advantageously shaped so that the layer 3 has the appearance of plaster, stone, timber, tile, etc.

With reference to FIGS. 7b and 7c, the core 1 is then made by casting a layer of UHPCF onto the first sufficiently hardened layer 3, said layer being cast so as to have ribs 10, 11, 12, 13 extending perpendicularly to said first layer and to the interior 2931496 - 22 -

of which there is a thermo-acoustic insulation 5. More particularly, the structure of the core 1 is made by: - disposing in the mold M thermo-acoustic insulation elements 5, the latter being: 5 • positioned at a distance from the side walls M1, M2 of the mold M, so as to form an empty frame 1 'around said insulation elements, • separated from each other so as to form empty ribs 10', 11 ', 12', 13 'communicating with said empty frame (FIG. 7b), flowing in the empty frame 1 'and in the empty ribs 10', 11 ', 12', 13 ', the UFUP layer (FIG. 7b). The UHPCF is stopped as soon as it reaches the same level as the upper part of the insulation elements 5.

Before pouring the layer of UHPC, it will be possible to have a metal reinforcement 4 in the empty frame 1 'and in the empty ribs 10', 11 ', 12', 13 '. Similarly, one or more ducts may be arranged in the mold M for the passage of electrical cables and / or one or more pipes and / or one or more heating elements.

It is then possible to place on the structure of the core 1, a second layer 2 forming all or part of the upper face of the PM panel, said second layer being parallel to the first layer 3. In practice, a plaster is cast on the soul structure 1.

However, if it is useful, and as shown in FIG. 7d, a layer of thermoacoustic insulation 6 may be previously disposed on the structure of the core 1. Referring to FIG. then to have the second layer 2 on the insulating layer 6 (in practice we cast a plaster) to complete the PM panel. Equivalently, provision could have been made to place the insulating layer 6 on the first layer 3, before making the structure of the core 1. 2931496 - 23 -

In order to secure the insulating layer 6 to the core 1 on the one hand and to the second layer 2 on the other hand, it will be possible: - to pass through the insulating layer 6 and to fix a first end of the rod connectors 7 on the structure of the core 1 (or in said structure before 5 that it hardens), - pouring the second layer 2 on the insulating layer 6 and on the second end of the connector rod 7 , so as to maintain the latter position when said second layer cures. A similar method would make it possible to secure the insulating layer 6 to the core 1 on the one hand and to the first layer 3 on the other hand.

In the case where the projecting centering element 14 is an integral part of the structure of the core 1, the side walls M1 and / or M2 of the mold M are shaped to obtain said element during demolding. 3.2. Method of manufacturing a floorboard PP

Figures 8a to 8e show schematically the various steps of a method for manufacturing the floorboard PP shown in Figures 4 to 6 and previously described. Using a horizontal mold M similar to that described above that is to say whose side walls M1, M2 are removably mounted on the base M3 forming the bottom of the mold.

In a first step shown in FIG. 8a, at the bottom of the mold M, the first layer 102 is formed which will ultimately form part of the upper face of the panel PP. In practice, the bottom of the mold M, the tile and / or the floor and / or polished concrete. These elements are centered at the bottom of the mold M and positioned at a distance from the side walls M1, M2 of said mold M so as to form a void space 1010 'around the first layer 102. At the same time, the molds M can be thermal breakers 120 and one or more conduits for the passage of cables 15 2931496 - 24 -

and / or one or more pipes and / or one or more heating elements.

Referring to Fig. 8b, if useful, an intermediate layer of BFUP 108 may be cast onto the tile and / or floor and / or waxed concrete. In practice, this intermediate layer is stopped from running as soon as it has reached the same level as the upper part of the thermal breakers 120.

Referring to FIG. 8c, if this proves useful, a thermoacoustic insulation layer 106 may then be placed above the first layer 102 of tiling and / or floor and / or waxed concrete. In practice, the thermoacoustic insulation layer 106 also covers the thermal breakers 120. Referring to FIGS. 8d and 8e, the core 101 is then made by casting a layer of UHPC on the first layer 102 (or on the other layers covering the latter), said layer being cast so as to have ribs 110, 111, 112, 113 extending perpendicularly to said first layer and inside which there is a thermoacoustic insulation 105. More particularly, the structure of the core 101 is made by: - disposing in the mold M thermo-acoustic insulation elements 105, the latter being: • positioned at a distance from the lateral walls M1, M2 of the mold M, 25 so as to form an empty frame 101 'around said insulation elements, • separated from each other so as to form empty ribs 110', 111 ', 112', 113 'communicating with said empty frame (FIG. 8d), - flowing in the it and in the empty ribs 110 ', 111', 112 ', 113', the UHPC layer (FIG. 8d). The UHPCF is stopped as soon as the latter reaches the same level as the upper part of the insulation elements 105. It may be noted that the UHPC which is sunk in the space 2931496 - 25 -

Vacuum 1010 'allows forming the upper distal portion 1010 of the core structure 101, said distal portion flanking thermal breakers 120 and the first layer 102 tiled and / or floor and / or polished concrete.

A second layer 103 may then be directly disposed on the core structure 101, which will ultimately form the underside of the panel PP, said second layer being parallel to the first layer 102. In practice, the layer is still cast. of UHPCF forming the structure of the core 101, or casting a plaster on said structure. For the purpose of securing the insulating layer 106 to the core 101 on the one hand and the first layer 102 (or possibly to the UFUP layer 108) on the other hand, it will be possible: - to cross the layer of insulator 106 and attach a first end of the connector shaft 107 to the first layer 102 (or possibly to the UFUP layer 108), - arrange the other end of the connector rod 107 at the empty ribs 110 ' , 111 ', 112', 113 ', - flow in the empty frame 101' and in the empty ribs 110 ', 111', 112 ', 113', the layer of UHPC, so as to hold in position the rod of connectors 107 when said layer of BFUP hardens.

In the case where the hollow centering element 140 is an integral part of the structure of the core 101, the bottom wall M3 of the mold M is shaped so as to obtain said element during demolding.

Claims (17)

Revendications1. Multilayer prefabricated monoblock panel for producing the walls of a dwelling, said panel comprising a rigid core (1, 101) disposed between two parallel layers (2, 3, 102, 103) forming all or part of the upper and lower faces of said panel characterized by the fact that the core (1, 101) is constituted by an ultra-high performance fiber-reinforced concrete structure having ribs (10, 11, 12, 13, 110, 111, 112, 113) extending perpendicular to the two said parallel layers of said panel and inside which is disposed a thermoacoustic insulation (5, 105). 2. Panel according to claim 1, wherein a metal frame (4, 104) is molded into the ultra-high performance fiber concrete structure constituting the core (1, 101). 3. Panel according to one of the preceding claims, wherein the ultra-high performance fiber concrete used to achieve the structure constituting the core (1, 101), is a concrete comprising metal fibers. 4. Panel according to one of the preceding claims, wherein the material constituting the lower layer (2) of said panel is an ultra-high performance fiber concrete comprising organic fibers. 5. Panel according to claim 4, wherein the material constituting the upper layer (3) of said panel is a self-leveling plaster. 2931496 - 27 - 6. Panel according to one of claims 4 or 5, wherein a layer of thermo-acoustic insulation (6) is disposed between the core (1) and one of the upper layer (2) or lower (3) said panel, so that there is no thermal bridge between the two said layers. 7. Panel according to one of claims 1 to 3, wherein the upper face of said panel comprises a portion (102) of tile and / or floor and / or polished concrete. 10 8. Panel according to claim 7, wherein a thermoacoustic insulation layer (106) is disposed between the core (101) and the portion (102) of tile and / or floor and / or polished concrete, the surface of said insulator being at least equal to the surface of said tile and / or said floor and / or said waxed concrete. 15 9. A method of manufacturing a panel according to claim 1, comprising: - placing at the bottom of a horizontal mold (M) a first layer (3, 102) of a material forming all or part of the first face; of said panel, 20 - making a core (1, 101) by casting a layer of ultra high performance fiber concrete, said layer being cast so as to have ribs (10, 11, 12, 13, 110, 111, 112, 113) extending perpendicularly to said first layer and within which a thermoacoustic insulation (5, 105) is provided, - disposing a second layer (2, 103) of a material forming all or part of the second face of said panel, said second layer being parallel to said first layer. 10. The method according to claim 9, wherein for producing the structure of the core (1, 101): thermoacoustic insulation elements (5, 105) are provided in the mold (M). , the latter being: • positioned at a distance from the side walls (Ml, M2) of the mold, so as to form an empty frame (1 ', 101') around said insulating elements, 5 • separated from each other forming empty ribs (10 ', 11', 12 ', 13', 110 ', 111', 112 ', 113') communicating with said empty frame, - pouring into the empty frame and into the empty ribs, layer of ultra-high performance fiber-reinforced concrete. 10 11. The method of claim 10, wherein before casting the ultra-high performance fibered concrete layer, there is a metal frame (4, 104) in the empty frame (1 ', 101') and in the empty ribs ( 10 ', 11', 12 ', 13', 110 ', 111', 112 ', 113'). 15 12. Method according to one of claims 9 to 11, wherein is molded directly in the panel one or more conduits for the passage of electrical cables and / or one or more pipes and / or one or more heating elements. 20 13. Housing characterized in that one or more of its walls are formed by panels (PM, PP) according to one of claims 1 to 8. 14. Modular dwelling formed by two habitable side modules 25 (MLa, MLb) connected by one or more habitable central modules (MC), the connection between the different modules being made by means of a removable fastening structure allowing adding or removing one or more central modules between said side modules, the different modules being structurally independent and each formed by one or more roof panels (PM), one or more floor panels (PP) and vertical panels forming the walls (PM), characterized in that said vertical panels forming the walls and possibly said roof panels are in accordance with one of claims 1 to 6. 5 15. The dwelling of claim 14, wherein the floor panels (PP) are according to one of claims 7 or 8. 16. Housing according to one of claims 14 or 15, wherein the roof panels (101), the floor panels (102) and the vertical panels (103) forming the walls are directly secured to each other by gluing. and through mechanical linkages. The dwelling according to one of claims 14 to 16, wherein one of the edges of the wall panels (PM) includes a projecting centering element (14), said centering element being configured to position itself in an element of centering recess (140) of complementary shape, disposed on the periphery of the upper face of the floor panel (PP). 20