LU81463A1 - CONSTRUCTION PROCESS, PREFABRICATED PRODUCT FOR IMPLEMENTING SAME AND MANUFACTURING METHOD THEREOF - Google Patents

Description

C.3465 2.4211 ow

Τ ~ Δ T GRAND DUCHY OF LUXEMBOURG

».... .. y ....... p V ...

of ..... 4 .......... Minister, 1¾¾¾ of the National Economy and the Middle Classes

Book title: ........................................: 5 V * 17?

LUXEMBOURG Industrial Property Service

Patent Application I. Application

The company in Ç omm a nd it e ... Syrup on: B .., .. M. # CQ SLA MAG NA ...................... ....... d)

Boulevard ..... JF ...... Kennedy, ...... Building ...... "Le ..... Galion" ..... 06800 ..... Çaanes / Sea.........

France, represented by Monsieur ..... Charles München. ,, counsel ...... in (¾ ..b.re.ve.ts.J [..... Lu.xembo.ur.g. , ..... acting in ..... capacity ..... as an agent ............................. .........

0 ^ pose ........ ce ..............., 9.pptr.0 ..... lylllçi .....!.?. 00 ...... sqix ^ .......................... (3) to ............ ....... * .......... hours) to the Ministry of National Economy and the Middle Classes, in Luxembourg: 1. this request for obtaining a patent invention relating to: "Method ..... of ..... construction ....... product ...... prefabricated ..... for ..... its ..... implementation ..... in ......... ") work ..... and ... mode ..... of manufacture of said ..... product .." .., .. .................................................. ................................

declares, assuming responsibility for this declaration, that the inventor (s) is (are): ......................... .................................................. .................................................. .................................................. .................................................. .................................................. .... (5) 2. the delegation of power, dated .................................. .................................... the ________________________________________-........... .....

3. description in language .......... ί.ΓΑϋÇ ä1 SJB ............................. ..... of the invention in two copies; 4 ................................. drawing boards, in two copies; 5. the receipt of the fees paid to the Luxembourg Registration Office, on ....... 4 July 1979 claims for the above patent application the priority of one (s) request (s) from (6) ..brevet ... d ...... i nyen tl.on ............. deposited® in (7) ............ France_____________________________________________________________________________________________ the J..i „Ju.tl..l.et .... l.?7.8.....sous.....le no ..... 78 ..... 213.6.9. .................................................. .................................................. ........ (8) * on behalf of ..1.4 ...... applicant, ........................ .................................................. .................................................. .................................................. ............. (9) elect domicile for him / her and, if appointed, for their proxy, in Luxembourg ................ ........................

lia, boulevard Prince-Henri ....... (10) requests the issue of a patent for the invention for the subject described and represented in the appendices „above-mentioned, - with -alouement of this issue to ... ............. LL______________________ .. month.

The ........................

IT Minutes of Filing

The above patent application has been filed with the Ministry of National Economy and the Middle Classes, Industrial Property Service in Luxembourg, dated: July 4, 1979 _ _. _ Pr. The Minister at ...... hours \ of the National Economy and the Middle Classes, \ p-d · f 0 (t A 68007 * “.....‘ i.:: Ί IC. 8465 ___________

Revendic2t: cn in: - :: - :: ¾ de (s)! S d: ·. · ^:!:; 0 ei po ^ i. '.Λ en ---- L ^ aja ^ t ---- P * ·} δ ____ „i under the number> 8 i Λ% & ¾ // / \ patent d1 invention CONSTRUCTION PROCESS, PREFABRICATED PRODUCT FOR SA ^ * IMPLEMENTATION AND MANUFACTURING OF SAID PRODUCT.

J B.M. COSTAMAGNA and CIE.

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It is currently recognized that to properly carry out thermal insulation of a building, it is preferable to! place the insulating material on the external wall of this building.

! The advantages are indeed very clear both in terms of inertia; Thermal tie, the carrier material being included in the insulated volume, only in terms of condensation and resistance to! bad weather, and on that of energy saving.

However, despite this theoretical knowledge and the number of methods already proposed, a very small part of the construction currently carried out comprises external insulation.

This is due in particular to the large thickness which must be given to the external insulation and to the construction and safety problems (fire resistance) which result therefrom. This also holds

In addition to the difficulty of achieving a resistant and -, durable outer skin on the outer face of the insulation. Besides these difficulties j; technical intervene price problems. The realization || a wall or a supporting structure, then its insulation followed by the production of the external and internal conduit facing; at high cost prices which hamper the development of this technique.

The subject of the invention is a construction method, a prefabricated product and its embodiment, studied with a view to solving this problem.

The construction method according to the invention consists in producing a wall which is both load-bearing and insulating by assembling i & of composite prefabricated elements formed from a thickness of carrier material assembled to a thickness of insulating material based on rigid foam forming binder and light aggregates, the ex-ί dull skin being reinforced with fiberglass, these elements being i - 30 of reduced dimensions, rectified in their four fields to standard dimensions and to a rigorous rectangularity, with an I 'low tolerance, of the order of a millimeter; the assembly being carried out by gluing in a thin layer over at least part of the thickness of the element and with alignment means in themselves known, this gluing being followed by the crushing of the excess glue of so as to putty the joints.

It therefore only remains to carry out an appropriate internal and external coating. ✓

By reduced dimensions is meant dimensions / 40 allowing the manipulation by hand of each element, without lifting means. These dimensions will vary depending on the thickness of the material, but in general, less than 60cm X 40cm approximately for a thickness of carrier material from 10cm to 20cm approximately.

One of the advantages of the invention is that it allows a construction of the conventional type with regard to its implementation, that is to say by simple assembly of portable elements by hand, such as concrete blocks but with great rapid installation due to the rectification of the products and alignment mcyens, simultaneously obtaining a load-bearing wall and insulation, without any additional jointing operation.

The composite prefabricated element according to the invention is characterized in that it consists of an external skin of rigid plastic material reinforced with glass fiber, followed by a thickness of rigid foam with closed cells, loaded with light aggregates, itself followed by a thickness of carrier material, such as brick or agglomerated cement, the whole being of reduced dimensions and of rigorous rectangular shape rectified with a tolerance of the order of millimeter.

The expression reduced dimensions has been defined above. The thickness of the carrier material may be of the order of 10 to 20 cm for constructions of height from 1 to 2 floors.

The thickness of rigid foam will be defined by the isolation conditions to be fulfilled; it will normally be of the order of 5 to 20 cm also.

^ 25 The rigid foam loaded with light aggregates will, for example, be of the type known under the trademark ISOBETON.

It is a closed cell polyurethane foam, the outer skin of which is densified and reinforced with fiberglass.

30 Alignment means will advantageously be provided, such as grooves provided on the fields and intended to cooperate with keys according to French patent n ° 76.08568 filed on March 15, 1976 in the name of the Company known as: The Industrial Regional Building.

35 It is also possible to use the means described in French patent n ° 76.22447 filed on July 16, 1976 in the name of the same Company.

In the case of grooves cooperating with keys, ✓ these grooves may be provided, either in the thickness isola ^ C? T / e, 40 -or in the carrier thickness, or both. / j // I. . 3 {'* * »' The element of the invention will be corrected by any appropriate means, for example, with a grinding wheel or a saw. At least the face i of the carrier thickness opposite to the insulating thickness will preferably be of a rigorous flatness, so as to constitute an internal facing not requiring any leveling.

The invention also relates to the method of manufacturing such elements consisting in placing in a mold the carrier thickness as well as the light aggregate and the external glass fiber and then, after closing the mold, injecting the polyu-10 rethane foam which, both impregnates the glass fiber and forms the external skin of the product, constitutes the insulating thickness in association with the light aggregate (expanded glass ball, expanded clay, etc.) and ensures perfect adhesion from the insulating thickness to Q 'the carrier thickness; after demolding the assembly thus obtained is J IS rectified by any means, so as to provide a rigorously rectangular element with the indicated tolerances.

In practice the tolerance may be lower and go down to 0.2mm or 0.5mm.

I When the product is manufactured in accordance with the invention! 20 tion, just for the load-bearing thickness, only one side ver-

Itably flat, namely the facing face of the element: the flatness defects of the other face are in fact caught up with the molding and the injection of the insulating thickness.

When the load-bearing thickness is constituted by a square tile 25 of brick or refractory earth, the molding and injection operation will preferably be carried out on the tiles leaving the oven, that is to say dry and hot, this ensures better adhesion of the foam and a reduction in the consumption of resin, the latter being made more fluid and better filling the spaces between aggregates.

It would not, however, depart from the scope of the invention by operating the injection on dry but cold tiles.

Due to the need to operate on a dry product, the use of cooked load-bearing materials such as brick is preferred.

In the case where the composite material is manufactured as described above, it is preferred to provide the alignment grooves on the carrier material and in the vicinity of the internal facing. In fact, the tolerances for positioning the grooves, / relative to the internal facing are then better respected at l // z 40 "manufacture of the carrier material, and the defects compared to 1/1 ·" "ί the other facing are made up during molding.

It should also be noted that the manufacturing method thus described involves cutting the light aggregates during the operation, which provides a good surface for the assembly by bonding and makes it possible to avoid subsequent joining.

It will also be noted that the insulating thickness of the product being a rigid foam with closed cells, the water tightness of the product obtained is ensured during manufacture. It is therefore sufficient.

10 due to rectification, gluing in a thin layer with crushing of the surplus to seal the building.

The invention also relates to the arrangement according to which the fields of the product, both on the load-bearing thickness and on the insulating thickness, include a groove or recesses for the expansion of the assembly adhesive; The product fields are thus presented as having edges parallel to the sides of the product and it is these edges which are the subject of the correction.

In addition, the insulating part may comprise one or more internal masses of very light cellular foam such as polystyrene foam, these masses being embedded in the product at a distance from the facings and fields at least equal to approximately 4 cm.

The invention is illustrated by the appended drawing in which: FIGS. 1 and 2 illustrate the prefabricated building element according to the invention.

As can be seen, it consists of the external facing 1 to the internal facing 2 of the succession of a layer of glass fiber 30 (glass mat for example) impregnated with densified rigid foam followed by an insulating thickness 4 formed rigid closed-cell foam, loaded with light aggregates, of the type known commercially under the trade mark ISOBETON, followed by a thickness of carrier material 5, for example, a hollow brick tile 35 from 10 to 20 cm thick; the set is relatively small, so that it can be carried by hand. The weight of the insulating part 4 is negligible compared to that of the supporting part 5. The element may reach. dre lengths and widths of the order of 60 to 40 cm for a / 40. thickness of 15 to 40 cm. The element according to the invention is in ovitÆfc 5 ι · '/! of rigorous rectangular shape rectified with a tolerance of I on the order of a millimeter.

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Any tolerance representing a maximum variation in dimensions, it is clear that the element can be manufactured 5 with a lower tolerance, for example 0.2 mm, without departing from the scope of the invention.

Thanks to the combination of its characteristics of composite element and of reduced and rigorous dimensions, the element according to the invention allows the construction method according to FIG. 3 in which a building or part of a building is made by gluing in . thin layer on at least the external and internal zones of the thickness of the element with the use of alignment means:, such as the keys 6 (FIG. 3), (French patent n ° q __ 76.08568 filed on March 15, 1976 in the name of the Company: the Industri-; 15 it Regional Building) cooperating with the grooves 7 (Figure 1) or the bars 16 of length equal to the thickness of the element, these bars being terminated by parallel cheeks (Figure 6 -I 0: French patent n 76.22447 filed July 16, 1976 with the same name) i or any other equivalent means, and crushing of excess glue! 20 so as to putty the joints.

ij After these operations, due to the characteristics of (3 | the prefabricated element of the invention, the only operations that remain to be done consist of exterior and interior finishes: 25 For the exterior in the form of a plaster or d '' a paint compatible with the external layer 3 reinforced with fiberglass and a coating, paint or wallpaper on the internal face 2 • of the load-bearing part.

i, y The supporting part 5 is preferably made of hollow brick.

30 This material in fact makes it possible to produce elements having at least I a genuinely flat face and capable of directly receiving a finishing material, such as wallpaper, without any additional leveling work. It is also possible to use an element based on cement mortar, of the concrete block type, possibly provided on one side with a wall forming a facing.

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The rectification of the fields of the element consists of a grinding or sawing operation schematically represented in FIG. 4. The element 1 is first rectified on two fields pa- /

Irallèles 8 and 9 which gives the falls 10 and 11, by means of sc ^ ê / s 40 or grinding wheels 12. It is then turned over to 90 ° and rectified on the / jf / ο * * "Λ '" two other fields parallels 13 and 14, which gives the falls 15.

Such a correction is already provided for in the aforementioned French patent n ° 76.0856¾. But in this case it relates only '5 on a tile constituting a partition. In the case of the invention, it relates to the whole of the composite element formed of an insulating thickness and a load-bearing thickness. Thereby . the fields of the insulating part are cut as well as the light aggregates located in these fields, which provides an over-face suitable for assembly by gluing without the need for subsequent jointing.

A prefabricated carrier rectified element could also be combined with an insulating facing element rectified to the same dimensions and with the same tolerances, for example by bonding. However, this solution has the disadvantage of an additional operation, which must be carried out with precision and introduces a source of defects, and it does not make it possible to make up for the flatness defects of the internal face of the carrier element.

As shown in FIG. 1, the key alignment groove 7 is preferably located on the supporting part ‘and close to the facing 2, (of the order of 5 cm). A better alignment of the internal planar faces 2 is thus obtained, and the external faces 1 are also better aligned because of this! 25 their position is defined relative to the face 2 by the molding operation.

As also shown, it is preferred that the rectification relates to edges 18, 19 leaving between them expansion channels 20, 21 for the assembly adhesive.

As can be seen in the section of FIG. 5, the insulating part 4 based on rigid closed-cell foam loaded with light aggregates 24 can include masses 22 of ordinary light foam of the polystyrene type. This arrangement makes it possible to lighten the element and reduce its price. The thickness of 35 rigid foam 4 should not drop below about 4 cm on the external face and the fields of the element. -

The method for manufacturing the element is illustrated in FIG. 5. It consists in placing in a shaping mold 23, the carrier thickness 5 and the light aggregate 24 and the outer layer / 40 of fiberglass 3, as well as, possibly the massa (ies) // '.

4 * 7 '♦ · 22, then inject the resin. Channels 25 will advantageously be provided on the face of the masses 22 in contact with the carrier thickness 5 to facilitate the expansion of the resin between mass 22 and part 5 and the adhesion between carrier part 5 rigid foam 5 4.

After this operation, the element is removed from the mold and rectified as explained above with reference to FIG. 4. Different variants can be adopted for carrying out the invention. Thus, the external face 1 may not be planar but may include reliefs, for example, decorative. It can be the same for the internal face 2 provided that the tops of these reliefs define a precise reference plane for compliance, of the tolerances provided and that the bottom of the mold 23 is produced / taking these reliefs into account. / (// VS (/

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Claims (2)

7. Element according to any one of the preceding claims 33, characterized in that the fields of the element have grooves or hollows for the expansion of the assembly glue. blage. 8, - Method of construction of the element according to any one of claims 1 to 7i characterized in that pla I · * 9 / in a shaping mold, 1 * carrier thickness and the approved—! light gat, the outer layer of fiberglass and possibly I or the masses of ordinary foam then, after closing the slack, the polyurethane foam is injected, the whole obtained being! 5 then rectified to the selected tolerances and to the strictly rectangular 1. shape. 9. Method according to claim 8, characterized in that the load-bearing thickness is of fired ceramic and the operation of!> | molding is carried out on ceramic coming out of the oven and still hot. I „10 10.- A method of constructing a wall which is both load-bearing and insulating, characterized in that it consists in assembling P; I by gluing in a thin layer of the prefabricated composite elements according to any one of claims 1 to 7, using any suitable alignment means, this gluing being followed by the crushing of the excess glue so as to putty the joints. | Drawings: - 2— Penches ^ r.?c*e J '-AJ ....... P £ -'3- "................ * r. ... - / ci3crip * ion j ......... £ ..... r: * indication:. λ ... o-scrip-if i * 1 -i * -! i I 1 ; i; '!:. i! i; î! / ii.