FR3124406A1 - Crystallization support, crystallization assembly comprising a frame and such a support, salt panel comprising such a support and method of manufacturing such a salt panel - Google Patents

Abstract

The invention relates to a crystallization support (200) comprising a support wall (201) having at least one face (202) configured to be covered with crystallized salt, the support wall (201) further comprising openings ( 205) configured to anchor the crystallized salt on at least the face (202) of the support wall (201). It also relates to a crystallization assembly comprising a frame and such a crystallization support (200), a salt panel comprising such a support and a method of manufacturing such a salt panel. Abstract Figure: Figure 2

Description

Crystallization support, crystallization assembly comprising a frame and such a support, salt panel comprising such a support and method of manufacturing such a salt panel

The present invention relates to the field of coatings for an element, in particular a wall, for example a wall or a ceiling.

In the construction industry, various materials (wood, glass, etc.) are used to produce coverings, in particular wall coverings. The coverings can take various forms, including a panel form.

In addition, it is interesting to be able to use a natural material.

In this context, salt shows interesting properties.

The present invention thus aims to use a natural material, in particular salt, as coating material.

More specifically, an object of the present invention is to create a salt-based panel which can serve as a covering for an element, such as a wall such as a wall or a ceiling.

To this end, according to a first aspect, the invention relates to a crystallization support comprising a support wall having at least one face configured to be covered with crystallized salt, the support wall further comprising openings configured to anchor the crystallized salt on at least the face of the support wall.

Thanks to such a structure, it is possible to obtain a crystallization of the salt on the crystallization support. Indeed, the openings form housings which allow the anchoring of the salt crystals on the support wall.

According to one characteristic, the openings are holes passing through the support wall. For example, the apertures are perforations formed in the support wall.

According to another exemplary embodiment, the support wall comprises a set of intersecting bars forming between them the openings. The support wall comprises for example a lattice. The support wall thus comprises openings formed by the empty spaces between the bars.

According to an exemplary embodiment, the openings are distributed over the face of the support wall.

Such an arrangement of the openings thus favors the generation of the layer of salt over the entire wall.

For example, at least some openings are positioned close or even tangent to an edge of the wall.

This makes it possible to promote anchoring of the layer of salt at the edge of the wall, and/or coating of the edge of the wall.

The support wall here has on the one hand the face configured to be covered with crystallized salt, and on the other hand a so-called rear face; the face configured to be covered with salt and the rear face defining between them a thickness of the support wall.

Thus, the openings pass through the thickness of the support wall.

The salt crystals can thus develop on two faces of the support wall. This contributes to good bonding of the crystals to the crystallization support.

According to one characteristic, the openings represent between 20% and 50% of a surface of the face of the support wall. Preferably the openings represent at least 30% of the surface of the face of the support wall.

Such a configuration allows enough support wall surface to support the salt crystals and enough openings to support their anchoring to the support wall. It is thus a compromise between mechanical resistance and a robust attachment of the salt to the support wall.

According to one characteristic, the crystallization support further comprises at least one fixing system configured to fix the support wall to an element to be coated.

After crystallization of the salt on the crystallization support, it is thus possible to use the latter to coat an element.

According to one characteristic, at least the support wall comprises a metallic material, preferably titanium.

For example, the support wall is formed from titanium and/or is coated with a layer of titanium. It is for example a titanium support covered with titanium oxide.

Titanium has a very good resistance to corrosion, especially in the presence of salt. It is in particular one of the rare metals with very little, if any, degradation in a saline environment.

In addition, it has interesting mechanical resistance characteristics, as well as fire resistance.

According to one characteristic, each opening of the support wall has a characteristic dimension of between 0.5 millimeters and 2 millimeters, for example of the order of one millimeter.

Such values for the characteristic dimension were chosen in relation to the dimensions of the salt crystals to ensure their good anchoring on the support wall.

For example, when the openings are circular, the characteristic dimension is the diameter.

According to a second aspect, the invention relates to a crystallization assembly comprising a frame and a crystallization support having all or part of the preceding characteristics.

The frame includes a partition configured to surround the support wall.

Such a frame has for example a closed position in which it has a shape complementary to a perimeter of the support wall.

The crystallization assembly thus has at least one closed configuration in which said partition is tangent to the periphery of the support wall of the crystallization support.

The crystallization can thus be delimited laterally using the frame.

This frame makes it possible to obtain a salt panel with defined dimensions with controlled tolerances.

Such a frame is preferably translucent, even transparent.

Thus, it makes it possible to identify the thickness of salt formed during crystallization on the support wall, which makes it possible to identify when to stop the crystallization step.

For example, the frame comprises at least one side, preferably several sides, making it possible to surround a polygonal support wall.

A pan is for example a straight pan, which facilitates the production of a panel with a regular edge.

The frame can also be easily separated from the support wall after each crystallization and cleaned for later use, especially with another crystallization support.

When the frame is separated from the support wall, the assembly is said to be in the open configuration.

For this purpose, the frame can have an open position.

According to a third aspect, the invention relates to a salt panel comprising a crystallization support having all or part of the preceding characteristics, and a layer of crystallized salt coating at least the face of the support wall and which is anchored to the wall of support of the crystallization support.

Such a panel, taking advantage of the properties of salt, thus has an interesting fire resistance, in particular for use in a building. The salt panel achieves in particular the category of resistance to the bottom M0 according to the French classification of reaction and resistance to fire.

The use of salt in panels also makes it possible to lower the heat loads of a building and/or to regulate the level of ambient humidity.

According to a particularly interesting exemplary embodiment, the salt comprises sodium chloride (NaCl), for example at least 75% sodium chloride, or even at least 80%, even preferably at least 90% sodium chloride.

Such a salt is thus naturally readily available.

They are usually at least translucent and generally white in color, although the color can vary from white to pink.

A pink tint may be due to the presence of Dunaliella salina, a micro-algae often developed in saline.

However, it is possible to vary the translucency depending on the immersion time and the temperature of the fluid in which the panel is immersed to generate the salt layer, as described below.

NaCl salt crystals are naturally cubic in shape.

However, also by varying the immersion time and/or the fluid temperature, it is possible to vary the form of aggregation of the crystals, for example even making it possible to give at least certain zones of the salt layer a more rounded or more pointed shape.

This makes it possible to confer different aesthetic aspects and/or give the salt panel a “natural” effect.

For example, more rounded and smaller crystals can form on the upper part of the panel, close to the surface of the fluid when the support is submerged, this part of the fluid then being more subject to currents or movements of greater fluids.

Sodium chloride, for example, has a deliquescence point at 75% relative humidity at 25°C.

According to one characteristic, the layer of salt covers the edge of the support wall and/or extends at least in part over the rear face of the support wall of the crystallization support, in particular by passing through the openings.

This promotes better anchoring of the layer of salt on the support wall, and therefore better robustness of the panel obtained.

This further promotes encapsulation of the support wall, which allows a more aesthetic rendering when several panels are juxtaposed, for example to cover an element, such as a wall.

According to a fourth aspect, the invention relates to a method for manufacturing a salt panel having all or part of the preceding characteristics.

The manufacturing process includes the following steps:

• immersion of at least the support wall of the crystallization support in a fluid containing salt;
• crystallization of the salt contained in the fluid on the support wall for a period, called the immersion time, configured to coat the face of the support wall;
• removal of the crystallization medium from the fluid after the immersion time.

The salt crystals grow on the face of the support wall and lodge in the openings.

The salt crystals are thus “mechanically” attached, which anchors the layer to the support wall.

For example, during the immersion time, the layer of crystallized salt develops in thin layers of salt which are deposited at least on part of the face.

The immersion time is defined according to the thickness of the layer of salt desired for the salt panel, and environmental conditions, such as for example the weather conditions, a salt content of the fluid, a temperature of the fluid, a current or movement of the fluid, etc.

According to one characteristic, the salt crystallization step includes a step of housing and anchoring salt crystals in the openings of the crystallization support.

According to one characteristic, the salt crystallization step includes a step of developing the layer of crystallized salt on the salt panel by overlapping and superimposing the salt crystals during the immersion time.

According to one characteristic, the support wall is immersed in the fluid vertically.

The vertical orientation of the support wall during crystallization makes it possible to obtain a better anchoring of the crystals on the support wall.

Vertical positioning also makes it possible to benefit from the effects of any currents in the fluid, which make it possible to generate different forms of crystal growth, and thus confer different aspects on the panel.

According to one characteristic, the crystallization assembly, in particular the assembly as described above, is placed in the fluid and then removed after said immersion time.

Crystallization taking place with the frame surrounding the support wall, the salt panel obtained has well-defined dimensions and shapes. Indeed, the crystallization is stopped by the partition of the frame, thus making it possible to obtain a salt panel according to the dimensions, in addition to a thickness, desired.

It is also possible to obtain a salt panel with straight edges, by using a frame whose partitions are flat.

According to one characteristic, the method further comprises a drying step, during which the panel is dried, for a determined period, for example depending on the dryness level of the salt in question.

According to one characteristic, the method further comprises a demolding step in which a frame is separated from the crystallization support, if necessary after the drying step.

According to one characteristic, at least one crystallization support, or even at least one crystallization assembly which comprises such a support, is placed beforehand in a holding device comprising immobilization elements configured to immobilize at least the crystallization support in a position storage, in particular vertical, in the holding device.

Other particularities and advantages of the invention will appear further in the description below with reference to the appended drawings, given by way of non-limiting examples:

- there shows in a perspective view a salt panel according to an exemplary embodiment;

- there separately represents a crystallization support of the salt panel of the ;

- there represents a sheet for the manufacture of the crystallization support of the ;

- there schematically represents a laser cutting step of the sheet metal of the ;

- there schematically represents a step of punching a plate;

- there represents the plate obtained by laser cutting and punching;

- there represents the plate of the with some portions folded;

- there represents a frame according to an exemplary embodiment in an open position;

- there represents a crystallization assembly according to an exemplary embodiment;

- there represents a holding device immersed in a fluid and comprising several crystallization assemblies; And

- there represents a step of attaching a salt panel to a rail, according to one mode of implementation of the invention.

There represents salt panel 100 according to one embodiment of the invention.

The salt panel 100 includes a crystallization medium 200, shown separately in and described below, as well as a layer of crystallized salt 101.

The crystallized salt layer 101 is here formed of NaCl crystals.

NaCl crystals are naturally cubic in shape. They are for example translucent and white in color.

The layer of salt 101 is anchored on the crystallization support 200.

In particular, as shown by the , the layer of salt 101 covers at least one face 202, here an upper face, of a support wall 201 of the crystallization support 200, and also covers an edge 203 of the support wall 201.

Thus, if several salt panels 100 are juxtaposed, they make it possible to provide coating continuity.

Although not visible on the , the layer of crystallized salt can also cover at least part of a rear face 204 of the support wall.

To make the 100 salt panel shown , that comprises the crystallization support 200 shown .

The crystallization support 200 is further configured to allow the production of the salt panel 100 according to a method described below.

The crystallization support 200 comprises the support wall 201.

The support wall 201 here comprises the face 202, which is configured to be coated with the layer of salt 101, and a rear face 204 (visible in FIGS. 6 and 7 for example).

The face 202 and the rear face 204 thus define between them a thickness of the support wall 201.

The support wall 201 is configured to allow the anchoring of the layer of salt crystals.

For this purpose, the support wall 201 comprises openings 205 which pass through the thickness of the support wall 201.

The openings 205 preferably represent between 20% and 50% of a surface of the support wall 201. Preferably, the openings 205 represent 30% of the surface of the support wall 201.

Such a choice of surface ratio of openings 205 relative to the surface of the support wall 201 makes it possible not to weaken the mechanical strength of the support wall 201 while ensuring good crystallization of the salt on the support wall 201 .

It has been observed that a minimum value of 30% of the presence rate of the openings 205 is preferred since this makes it possible to obtain a good compromise between the crystallization of the salt and the mechanical resistance of the support wall 201.

Apertures 205 are configured to accommodate salt crystals. In particular, the openings 205 are sized to allow salt crystals to lodge in them and thus anchor themselves to the crystallization support 200.

The openings 205 can have any shape; here they have a circular shape with a diameter “d”.

Preferably, each opening 205 has a characteristic dimension of between 0.5 millimeters and 2 millimeters. For example, here each opening 205 has a diameter "d" of approximately 1 mm.

The openings 205 are distributed over the face 202 of the support wall 201.

As seen on the , at least some openings 205 are positioned close or even tangent to the edge 203 of the support wall 201.

Such a device of openings 205 promotes the generation of the layer of salt over the entire support wall 201 and in particular at the edge 203.

The support wall 201 here has a generally rectangular shape. Other shapes are of course possible.

Its edge 203 is therefore formed by four sides.

The crystallization support 200 further comprises here a fixing system 220. The fixing system 220 is configured to fix the crystallization support to an element 700 to be coated, as for example illustrated by the .

In the embodiment shown, the fixing system 220 comprises a fixing wall 221, and in this case two fixing walls 221.

In particular, each fixing wall 221 extends from one side of the support wall 201; and here the two fixing walls 221 extend on two opposite sides.

Each fixing wall 221 is for example an extension of the support wall 201 which is folded with respect to the support wall 201.

The fixing wall 221 includes notches 222, 223.

The notches 222, 223 are configured to cooperate with hooks of the element 700 to be coated on which the crystallization support 200 is fixed.

In this case, a first of the notches 222, 223 is here a wide notch 222 and a second of the notches is here a narrow notch 223.

Thus, the wide notch 222 has a larger lateral dimension than the narrow notch 223, while their transverse dimensions are preferably equal.

The narrow notch 223 is thus configured to correspond in size to a hook 703 of an interface system fixed to the element to be coated, while the wide notch 222 is configured to make up for or compensate for a manufacturing tolerance of the support. of crystallization 200 and/or a tolerance for fitting hooks 703.

The wide notch 222 has for example here a substantially square shape. The narrow notch 223 has a substantially rectangular shape.

Of course, the shape of the notches and their number may be different.

The crystallization support 200 further comprises here a reinforcement 224, which is for example here a curved part of the fixing wall 221.

In particular, the curved part forming the reinforcement 224 borders the notches 222, 223.

The crystallization support 200 can be at least partially metallic, for example titanium. The support wall 201 can be formed from titanium and/or coated with a layer of titanium.

For example, a layer of paint can be applied to the crystallization support 200 to reinforce its resistance to corrosion. By way of example, the paint layer may be a titanium oxide paint.

Figures 3 to 7 illustrate a method of manufacturing the crystallization support 200 as shown .

In particular, the crystallization support is here formed from a metal sheet 300, as illustrated by the .

The sheet 300 is first cut according to the desired dimensions for the crystallization support 200 so as to form a plate 301, shown schematically .

The cutting is for example carried out by means of a laser, as schematically illustrated in .

For this, each plate is perforated and punched, for example by means of a punch illustrated schematically in before being folded.

The plate 300 is perforated so as to form the openings 205, for example by means of the punch.

Further, notches 222, 223 are also formed.

The plate obtained is then represented , before bending.

The plate comprises two concentric rectangles, hereinafter internal rectangle and external rectangle, shown in broken lines. The internal rectangle is of smaller dimensions than the external rectangle, which is itself smaller than an outline of the plate.

Four slots are also shown schematically in solid lines, said slots connecting a corner of the internal rectangle to a corner closest to the plate.

On the other hand, the plate is punched along the internal rectangle and the external rectangle. The punching forms a marking facilitating the bending of the plate 301.

The plate 301 is then folded, in particular along the punched lines, possibly using known means, for example as illustrated .

The punching along the internal rectangle makes it possible to bend the plate so as to form the support wall 201, and four walls extending laterally around the support wall 201, including the two fixing walls 221.

The punching along the outer rectangle makes it possible to bend the plate so as to form a rim, in particular the rim 224 of the crystallization support 200.

The four walls are then possibly welded together.

The crystallization support as represented is then obtained.

There shows a frame 400 configured for use with the crystallization support 200 as explained below.

The frame 400 and the crystallization support 200 form a crystallization assembly 500.

Frame 400 includes partition 401. Partition 401 is configured to surround support wall 201.

The partition 401 comprises at least one side 402.

When the partition has at least two, or even at least three sections, at least two adjacent sections are possibly articulated with respect to each other. According to one option, at least two adjacent sections are detachable from each other so that the frame can be opened and unfolded.

The sections 402 make it possible to surround the support wall 201.

The support wall 201 having a rectangular shape, the partition 401 advantageously comprises here four sides 402.

A 402 panel is for example a straight panel, which facilitates the production of a salt panel with a regular edge.

A face 402 of the partition 401 comprises at least one undercut 403, and an adjacent face comprises at least one stud 404. The stud 404 and the undercut 403 have a complementary shape. The tenon 404 and the undercut 403 are thus configured to cooperate together by interlocking.

In the illustrated embodiment, a panel 402 of the frame partition includes two recesses 403 and an adjacent panel 402 includes two tenons 404.

However, two adjacent sections 402 could be connected by a hinge.

On the , the frame is thus shown in an open position.

In the closed position, the frame has a general shape similar to those of the crystallization support. The frame here therefore has a generally rectangular shape.

The crystallization assembly 500 thus has at least one closed configuration, visible at , in which the partition 401 is tangent to the periphery of the support wall 201 of the crystallization support 200.

The crystallization can thus be delimited laterally using the frame 400.

Crystallization assembly 500 also has an aperture configuration in which frame 400 is separated from crystallization support 200.

Frame 400 is then in the open position.

When the crystallization assembly 500 is in the closed configuration, each stud 404 cooperates with a corresponding clearance 403.

When the crystallization assembly 500 is in the open configuration, the tenon 404 of at least one side is disengaged from the clearance 403 corresponding to the adjacent side.

The frame 400 is preferably translucent, even transparent.

It is thus possible to identify the thickness of salt formed during the crystallization on the support wall 201 and therefore to identify when to stop the crystallization step.

For example, the frame is made of poly(methyl methacrylate), more commonly known as plexiglass.

The manufacture of the salt panel is done according to the following manufacturing process, as for example illustrated .

At least the support wall 201 of the crystallization support 200 is immersed in a fluid containing salt.

For example, at least the support wall 201 of the crystallization support 200 is immersed in a saline, that is to say at least one basin containing a fluid containing salt. In a saline, the crystallization support can be immersed in strategic places depending on the currents and the salinity of the basins.

Preferably, the support wall 201 is immersed vertically in the fluid.

In the illustrated embodiment, the crystallization assembly 500 in its closed configuration is immersed in the fluid.

In particular, several crystallization assemblies 500 are placed in a holding device 600. The holding device 600 containing the crystallization assemblies 500 is then immersed in the fluid.

The holding device 600 comprises immobilization elements configured to immobilize the crystallization assemblies 500. In particular, the immobilization elements are configured to immobilize the crystallization assemblies in a vertical position.

After immersion of the crystallization assembly 500 in the fluid, the crystallization of the salt contained in the fluid can then start.

The salt contained in the fluid is anchored on the support wall 201 so as to coat at least one face of the support wall 201.

Salt crystals become lodged in the openings 205 of the support wall 201. The salt crystals continue to overlap and possibly overlap each other on at least one face of the support wall 201 so as to form the layer of salt 101.

Salt crystals can form on both sides of support wall 201 so that salt layer 101 encapsulates support wall 201.

The crystallization step has a duration, called immersion time. The immersion time depends, among other things, on the thickness of the desired layer of salt 101, the surface of the support wall 201 to be coated, the salt content of the fluid and the meteorological and/or environmental conditions.

Under ideal conditions (high temperatures for water evaporation) during summer, and for a thickness of the salt layer between 10 mm and 35 mm, the immersion time is between 5 and 12 days in an outdoor pool, for example in a saline.

At the end of the immersion time, the crystallization assemblies 500 are extracted from the fluid.

The salt crystallized on the crystallization supports 200 is then dried.

The drying of the salt is carried out, for example, directly under the effect of solar radiation. Better drying efficiency is thus obtained in summer.

The drying step preferably lasts at least 4 hours, and is generally between 4 and 12 hours.

The method for manufacturing the salt panel 100 finally includes a demolding step in which the frame 400 is separated from the crystallization support 200.

The demoulding of the frames is preferably carried out when the salt is dry.

The frames 400 and the holding devices 600 can be reused for the manufacture of other salt panels 100, with other crystallization support such as that of the For example.

There illustrates a salt panel 100 being mounted on an element 700 to be coated. The salt panel 100 is fixed to the element 700, which here is a wall, by means of a fixing interface 701.

The fixing interface 701 is here a rail. In particular, the rail is a U-section comprising two wings 702.

The rail is for example made of stainless steel.

Each wing 702 comprises hooks 703, for example of the hook type, configured to cooperate with the fixing system 220 of the crystallization support 200.

In particular, each wing 702 comprises a notch 703 configured to cooperate with a notch 222, 223 of the fixing walls 221 of the crystallization support.

The narrow notch 223 is more precisely adapted to the thickness of the rail. The wide notch 222 thus makes it possible to compensate for the manufacturing tolerances of the crystallization support and the laying of the rails.

The notches 703 of the rails thus serve as a "hook" to support the salt panels 100.

A clip not visible on the can be used to lock the salt panel 100 to the rail. The notches and the clips thus prevent the salt panel from coming out of its fixed position on the element 700.

This system for fixing salt panels 100 allows easy and precise assembly on the element 700.

In addition, it is a modular fixing system so that the panels can be fixed on the 700 element according to a desired layout.

The fixing system also makes it possible to replace or change a 100 salt panel fixed to the 700 element if necessary. This is particularly useful when a 100 salt panel is damaged.

Claims (10)

Crystallization support comprising a support wall (201) having at least one face (202) configured to be covered with crystallized salt, the support wall (201) further comprising openings (205) configured to anchor the crystallized salt on at least minus the face (202) of the support wall (201). Crystallization support according to claim 1, in which the openings (205) represent between 20% and 50% of an area of the face (202) of the support wall (201). A crystallization support according to claim 1 or claim 2, further comprising at least one attachment system configured to attach the support wall to an element to be coated. Crystallization support according to one of Claims 1 to 3, in which at least the support wall (201) comprises a metallic material, preferably titanium. Crystallization assembly comprising a frame (400) and a crystallization support (200) according to one of claims 1 to 4, said frame (400) comprising a partition (401) configured to surround the support wall (201), the crystallization assembly (500) having at least one closed configuration in which said partition (401) is tangent to a perimeter of the support wall (201) of the crystallization support (200). Salt panel comprising a crystallization support (200) according to one of Claims 1 to 4, and a layer of crystallized salt (101) coating at least the face (202) of the support wall (201) and which is anchored on the support wall (201) of the crystallization support (200). A method of making a salt panel (100) according to claim 6, said method of making comprising the following steps:

• immersing at least the support wall (201) of the crystallization support (200) in a fluid containing salt;
• crystallization of the salt contained in the fluid on the support wall (201) for a period, called the immersion time, configured to coat the face of the support wall (201);
• removing the crystallization medium (200) from the fluid after the immersion time.

Manufacturing process according to claim 7, in which the salt crystallization step comprises a step of housing and anchoring salt crystals in the openings (205) of the crystallization support (200), and a step of developing the layer of salt (101) crystallized on the salt panel (100) by overlapping and superposition of the salt crystals during the immersion time. A manufacturing method according to claim 7 or claim 8, wherein the support wall (201) is immersed in the fluid vertically. Manufacturing process according to one of Claims 7 to 9, further comprising a demolding step in which a frame (400) is separated from the crystallization support (200) after the drying step.