WO2004057127A1

WO2004057127A1 - Panel for wall thermoacoustic insulation

Info

Publication number: WO2004057127A1
Application number: PCT/FR2003/003754
Authority: WO
Inventors: Eric Perrot; Basile Maissonneuve; Jean-François DOUILLET
Original assignee: Saint-Gobain Isover
Priority date: 2002-12-17
Filing date: 2003-12-16
Publication date: 2004-07-08
Also published as: EP1573147B1; FR2848582A1; AU2003300635A1; RU2352731C2; FR2848582B1; ATE351953T1; DK1573147T3; ES2280847T3; DE60311310D1; SI1573147T1; EP1573147A1; DE60311310T2; RU2005122468A

Abstract

The invention concerns a panel (1) comprising a mineral, glass or rock wool mat (2) coated with a binder, said panel including at least at one of its longitudinal edges an raised zone, said raised zone being adapted to receive a flap (5) integral with a covering (3) adhering to its surface.

Description

The present invention relates to a primitive for a panel intended to provide thermo-acoustic insulation, in particular under waterproofing and / or under finishing, of walls made up of load-bearing elements or support elements made of steel sheets, ribs, of wood or concrete. .

These panels are essentially formed from a primitive formed from a mattress of mineral wool, rock or glass, of high density (density between 50 to 400 kg / m ³ ), according to ranges of thickness between 20 and 300 mm and a facing disposed on a main face of said primitive. These panels are generally positioned and secured by gluing, by mechanical fixing to support elements or horizontal or vertical walls, inclined or even curved, which are more particularly intended for buildings of an industrial or residential nature, in an application relating to works. new or renovation. Significantly of rectangular shape, these panels have two main faces and four longitudinal edges respectively two by two parallel, generally perpendicular to these main faces; these panels are intended to be juxtaposed with similar panels, along their longitudinal edges so as to compose an insulation system for an industrial, residential, tertiary or agricultural building.

There is a first family of panels made from a primitive formed from a mineral wool mattress and a facing disposed on one of the main faces of said primitive. The main drawback of this type of panel lies in the fact that it offers reduced resistance to tearing, in particular, the facing, following a gust of wind, can tend to dissociate from the primitive.

To solve this problem of resistance to tearing, we were led to design a second family of panels which is distinguished from the previous one by the fact that the facing is folded down or flipped over the other main face of the panel (this other main face is that which is opposite to that which is coated by the facing); in this way the flaps do not offer wind resistance, and the resistance to tearing is clearly improved.

This type of panel is described for example in European patent EP 0 109 879 or in French patent FR 2 679 279. However, in order to anticipate the requirements of regulatory provisions, both in terms of their mechanical resistance as well as their acoustic and / or thermal insulation properties, as well as their performance against fire, even more efficient materials are desirable Indeed, among the most severe and most restrictive standards, we note the regulatory provisions in terms of safety with regard to fire risk, whether it is a fire originating from inside or outside. A fire is said to be "a fire coming from inside" when the flames originate or propagate inside an enclosure, and on the contrary, a fire is said "a fire coming from the outside" when on the contrary flames are located outside the enclosure.

However, for panels coated with bituminous facing, compliance with these normative conditions, especially in terms of fire resistance, is problematic, bituminous facing, especially when it is folded down or folded over the face of the panel which is directed inward, is likely to constitute a vector for the propagation of the flame.

The object of the present invention is to propose a primitive making it possible to manufacture an insulating panel capable of playing the role of fire barrier, this panel being covered with a facing, said facing being also capable of withstanding a tearing force ( especially that of the wind).

In the present invention, a covering is defined as any coating which is in the form of a thin sheet the thickness of which is less than 5 mm, and in particular close to 1 mm, and which has a capacity for folding, bending, a deformation allowing it to marry one of the faces of the panel. The substantially parallelepipedic panel according to the invention comprises a primitive essentially consisting of a mineral wool or rock mattress, substantially parallelepipedic, consisting of a plurality of fibers coated with a binder, said primitive having at the level of the at least one of its longitudinal edges a raised area, said raised area being adapted to receive a flap portion coming from a facing adhering to its surface, which is characterized in that the raised area is formed on a fraction of the thickness of the mattress, in line with a main face of said mattress, this raised zone delimiting two contiguous zones.

The raised area, which in the present invention can be constituted by a hollow area or a bump area is large enough in section and in depth to allow the flap to be embedded within the raised area so that there is no over-thickness of material on the longitudinal edge of said panel. For a better definition of the invention, the following terms will also be defined:

Exterior: is used when the panel is secured to a support element of an enclosure, one of its main faces (the one coated with the facing) is then directed towards the outside of the enclosure. Interior: is used when the panel is secured to a support element of an enclosure, one of its main faces (the one which is in contact with the support) is then directed towards the interior of the enclosure.

In preferred embodiments of the invention, it is possible optionally to have recourse to one and / or the other of the following arrangements:

the raised area is produced over a fraction of the thickness of the mattress, in line with a main face of said mattress, this raised area delimiting two contiguous areas,

the mattress is provided with at least two raised zones, each of these zones being positioned on a longitudinal edge of said mattress,

the longitudinal edge comprising the raised area is inclined relative to the main face of the mattress to be coated with the facing, at an angle greater than 90 °,

- the raised zone is produced in the form of a material recess, - the raised zone is produced in the form of a protuberance of material.

According to another aspect of the invention, it relates to a panel consisting essentially of a primitive as previously described and of a facing,

Advantageously, the panel facing has at least one flap, said flap being received in at least one raised area produced at a longitudinal edge of said panel, said flap being intended to cooperate at said raised area at the using an adhesion medium, in particular bitumen.

According to another preferred embodiment, the panel has two raised areas, each of these raised areas receiving a flap of said facing.

According to another advantageous characteristic, the facing is essentially constituted by a glass veil coated with bitumen, said facing possibly being reinforced, by a glass grid.

According to another preferred variant, the facing consists essentially of a kraft. According to yet other advantageous characteristics, the kraft comprises at least one water-repellent treated face and has, on the one hand, a smooth appearance and, on the other hand, a better distribution of the mechanical stresses.

According to yet another preferred variant, the facing is a reagent support for bonding. This reagent support is a chemical agent (for example a bonding primer in particular) which makes it possible to improve adhesion with a coating which will be added later to the facing.

The present invention also relates to a roof made up of load-bearing elements made of ribbed steel sheets, of wood or concrete, on which is fixed a plurality of panels as previously described.

It also relates more generally to any wall of an industrial, residential, tertiary or agricultural building forming a support on which is fixed a plurality of panels in accordance with the preceding provisions.

Other characteristics and advantages of the invention will appear during the following description of several of its embodiments, given by way of nonlimiting example. In the figures: FIG. 1 is a view illustrating an embodiment of a panel belonging to a first known family of panels; FIG. 2 is a view illustrating an embodiment of a panel belonging to a second known family of panels; Figure 3 is a perspective view of a panel according to the invention; Figure 4 is a perspective view illustrating the juxtaposition of a plurality of panels according to Figure 3, in order to make a roof; Figures 5 to 7 illustrate various embodiments of a panel according to the invention.

The known panel shown in FIG. 1 is of substantially parallelepiped shape, it essentially consists of a mattress 2 of mineral wool or rock wool, agglomerated by a binder, and one of its main faces is covered by a facing 3 which is made integral with this face by any known means, in particular by bonding or using an impregnation with bitumen. The facing of this panel has a very limited resistance to tearing, particularly due to wind.

The known panel shown in Figure 2 differs from that of Figure 1 in that the side flaps 5 from the facing are secured to the other main face of the panel (this other main face being that which is opposite to that on which the facing 3 is fixed, this other main face also corresponding to the face which is intended to be in contact with a support element). This panel, at the level of its facing, sees its resistance to tearing improved, on the other hand it still has a lower resistance to fire risk.

The panel 1 shown in Figure 3 is formed of a primitive consisting essentially of a rock wool mattress 2 whose binder rate is of the order of 3 to 4% by weight, this rate being one of the characteristics of the primitive. It has a density of the order of 140 kg / m ³ and a thickness of 80 mm. Of course, the dimensional and structural characteristics of the mattress 2 are given for information only, and these may vary depending on the desired applications. Thus the invention can be applied to panels whose density range is between 50 to 400 kg / m ³ and in particular from 70 to 200 kg / m ³ , and preferably close to 140 kg / m ³ , for thicknesses can vary from 30 to 300 mm.

One of the main faces of the primitive of the mattress 1 is intended to receive, by bonding or any other means making it possible to ensure adhesion between two materials, a facing 3. This facing 3 may consist of several elements such as for example a glass veil, bituminized or not, or a sheet of kraft or any other type of material, these elements are possibly associated with a glass grid to reinforce the facing.

Glass veil is understood to mean any support produced from a glass nonwoven. The facing is applied directly after impregnation of the veil with bitumen or another bonding means, so that the means which must ensure adhesion can penetrate one of the main faces of the mattress 2, at least on a small thickness of the latter.

In order to improve the anchoring of the facing 3 on the upper face of the mattress 2, a plurality of recesses obtained by punching, such as those described for example in patent FR 2 679 279, can be produced on the surface of the latter.

As a variant, the facing 3 is not a glass veil, possibly reinforced, and coated with a bituminous material but a kraft facing.

In this case, this facing 3 made of kraft can act as finishing facing.

According to an example of kraft facing which can be used as a finishing facing, it may be a kraft, one of the faces of which is treated with water repellency (which supports wetting by a cooling fluid (water)). In addition, this face thus treated has on the one hand, a smooth surface, which will minimize the quantities of glue used subsequently, and on the other hand a better distribution of the mechanical stresses. The kraft manufactured by the Canadian company Cascades Sainte Marie (ARJISO 200 ™) is an example of an embodiment having these properties.

In the table below, we give some characteristics of this kraft

These characteristics are determined by standard tests in the paper industry.

This insulating panel 1 can be used for roof insulation systems 4 horizontal, vertical or inclined, or even curved, by juxtaposing the at their longitudinal edges a plurality of panels, the panels being secured and mechanically fixed to the metal frame roof, horizontal, formed of metal profiles by means of screws or washers. Alternatively, the panels could be glued to the supports. Of course, the facing 3 is oriented towards the outside of the enclosure thus covered, as opposed to the face of the panel which is devoid of facing which is directed towards the inside of the enclosure and which is in contact with the framework of the roof 4 or any other wall linked to the support of the industrial, residential, tertiary or agricultural building. In FIG. 3, it can be seen that the facing 3 is not rimmed on the main face of the panel which is intended to be directed towards the interior of the enclosure and more particularly that at least one flap 5 of the facing 3 n 'is fixed only on a fraction of the thickness of one of the longitudinal edges of the panel (we say then that the panel is semi-rimmed). This panel 1 is semi-rimmed on two of its four edges, more particularly at the level of two substantially parallel longitudinal edges

By “semi-rimmed” is meant the fact that the main face of the panel (interior face) which is intended to be directed towards the support is not covered in whole or in part by a flap from the facing, in this configuration the flap (s) 5 issuing from the face of the facing 3 directed towards the outside of the enclosure is (are) semi-pleated so that the fibers of the panel are directly at the contact of the roof framework covering the enclosure.

In Figures 4 and following, there are shown different embodiments of a panel according to the invention. Thus, in Figure 4 in particular, there is shown a roof formed by the juxtaposition of a plurality of panels 1. Each of the flaps 5 of the facing 3 is fixed (by gluing or by another equivalent process for ensuring the adhesion between two surfaces) within a raised area 6 formed in the thickness of the panel. This raised area 6 (recessed or protruding) delimits two contiguous areas

7, 8, one of which forms an outgrowth of material 9 (visible in FIGS. 6 and 7). In this example of FIG. 4, the protuberance of material 9 is positioned in line with the main face of the panel 1 which is intended to be directed towards the interior of the enclosure, the contiguous part 8 being in this example (the part in relief is hollow) to the right of the other main face of the panel 1, that which is intended to be directed towards the outside of the enclosure.

Thus, by juxtaposing at least two panels 1 according to the embodiment described above, the respective raised portions 6 cooperate so as to conform to the level of the main faces of the panels intended to be in contact with the support, a uniform layer forming a barrier, this barrier may be acoustic and / or thermal and / or vis-à-vis the fire.

It may be noted that by carrying out a surface heating of the bituminous facing, very particularly at the level of the semi-pleated zones, these bitumen zones will merge locally and after cooling, produce a sealing barrier.

In Figure 5, there is shown a semi-rimmed panel 1 that on one of the four sides of the panel.

In FIG. 6, at least one of the edges comprising the raised area 6 is inclined relative to one of the main faces of the panel 1. In this case in this example of embodiment, the semi-rimmed edge is inclined at an angle α greater than 90 ° relative to the face of the panel which is intended to be directed towards the outside of the enclosure.

FIG. 7 illustrates another embodiment of a panel according to the invention. On one of the edges of the panel, the raised area 6 intended to cooperate with the flap 5 coming from the facing 3 is protruding while the raised area 6 located at the opposite edge is hollow.

By juxtaposing at least two panels 1 according to this embodiment according to their respective longitudinal edges by associating on the one hand a projecting zone 6 of a first panel 1 with a hollow zone 6 ′ coming from a second panel 1 ′, an insulating system is produced, the face directed towards the inside of the enclosure forms an acoustic and / or thermal barrier. The flaps 5.5 ′ of the facing 3.3 ′ are “protected” either by a projecting area or by a recessed area. Whatever the embodiment, the presence of flaps at the longitudinal edges of the panels considerably increases both the resistance to tearing (this tearing can be consecutive to a gust of wind) and the resistance to of the fire risk of the panels according to the invention compared to those of the prior art. The invention also relates to a method and a device for the continuous production of the panels described above.

According to the process, a rigid insulation blanket is made continuously of high density mineral fibers, by the conventional processes for rock wool or glass wool, recesses are created if necessary by punching the surface intended for receive the facing, in order to form anchor points regularly distributed over the surface for the glue (or other) used for fixing the facing on one of the faces of the panel.

The mattress of mineral fibers previously coated with binder is conveyed by conveyor belts within a heat treatment chamber (oven) in which the binder polymerizes and consolidates the mattress by giving it, thanks to pressure rollers, its dimensional characteristics. and thus conforming a primitive.

Downstream of this enclosure, the relief areas (recessed or projecting) are produced on at least one of the longitudinal edges of the mattress.

The removal of material over a fraction of the thickness of the mattress is carried out by a cutting member (saw, cutter) or by any other equivalent means, such as for example using a pressurized fluid (jet of water for example).

The cutting member is integrated into the panel manufacturing process. It is located downstream of the oven and upstream of the final cutting unit. As a variant, it is nevertheless possible to provide for this operation within a recovery operation, either for example after cutting in the direction of travel of the mattress, and / or either for example after cutting in the transverse direction (relative to the direction ) of the mattress. The glue or the like is then applied and the facing on the face possibly provided with recesses.

In a preferred form, the adhesive is applied to the mattress simultaneously with the facing. This is particularly the case when the facing uses bitumen as an adhesive and it is impregnated before it is applied to the mattress.

It can be noted that when the facing is a kraft of which one of the faces is treated with water repellency, the cooling necessary for the solidification of the bitumen situated at the interface between the primitive and the facing is improved.

In fact, this cooling is generally carried out wet, the cooling fluid which is in contact with the water-repellent face of the facing makes it possible to cool the bitumen without damaging the latter.

However, with traditional facings (without hydrophobic treatment), due to wet cooling, there is a risk of deterioration of the latter (swelling, surface defect ...).

The facing which is applied continuously has a width corresponding to the width of the mattress increased by at least one flap, the dimension of which corresponds to the depth of the cutting line previously operated, which allows covering only on at least one fraction of the thickness of the mattress.

The facing may include a sheet of plastic material called separation as in the case of the panel described in EP-A-0 109 879 already cited. The facing can itself provide this separation function if the latter is made of kraft or other material. The invention also relates to a device for implementing the method and manufacturing the insulating panel.

The device comprises the known manufacturing means for producing the insulating panel, that is to say a fiberizing device with incorporation of the binder at the time of fiberizing, a conveyor receiving the fibers, means bringing the mattress to the thickness desired and an oven for the polymerization of the binder, means for supplying the facing and its adhesion to the underside of the panel, cutting means. These cutting means consist of first cutting means for dimensioning in the transverse direction (relative to the direction of travel of the mattress), second means for dimensioning in the longitudinal direction (parallel to the direction of travel of the mattress), and finally third means for producing the raised areas in a fraction of the thickness of the mattress.

It also comprises a system arranged between the station for cutting the raised areas within a fraction of the thickness of the mattress and the station for bonding the facing, which comprises a pressing member making it possible to apply constant pressure to the minus a flap of the facing that we want to adhere to the level of the raised area previously removed.

Claims

1. Primitive essentially consisting of a mattress (2) of mineral wool or rock, substantially parallelepiped, consisting of a plurality of fibers coated with a binder, said primitive having at least one of its longitudinal edges a raised area (6), said raised area (6) being adapted to receive a flap portion (5) coming from a facing (3) adhering to its surface, characterized in that the raised area (6) is carried out on a fraction of the thickness of the mattress, in line with a main face of said mattress (2), this raised area delimiting two contiguous areas (7, 8).

2. Primitive according to one of claims 1, characterized in that the mattress (2) is provided with at least two raised areas (6, 6 '), each of these areas being positioned on a longitudinal edge of said mattress.

3. Primitive according to one of claims 1 to 2, characterized in that the longitudinal edge comprising the raised area (6) is inclined relative to the main face of the mattress (2) to be coated with the facing (3), at an angle α greater than 90 °.

4. Primitive according to one of claims 1 to 3, characterized in that the raised area (6) is made in the form of a material recess.

5. Primitive according to one of claims 1 to 3, characterized in that the raised area (6) is produced in the form of a protuberance (9) of material.

6. Panel (1) consisting essentially of a primitive according to any one of claims 1 to 5 and a facing (3) having a folding ability.

7. Panel according to claim 6, characterized in that the facing (3) comprises at least one flap (5), said flap (5) being received in at least one raised area (6) made at a longitudinal edge of said panel (1). J

8. Panel according to one of claims 6 or 7, characterized in that it comprises two raised areas (6, 6 '), each of these raised areas receiving a flap (5, 5') of said facing (3 ), these flaps (5, 5 ′) being intended to cooperate at the level of the raised zones (6, 6 ′) using an adhesion means, in particular bitumen.

9. Panel according to one of claims 6 to 8, characterized in that the facing (3) consists essentially of a glass veil coated with bitumen, said facing being optionally reinforced, in particular by a grid of glass.

10. Panel according to one of claims 6 to 8, characterized in that the facing (3) consists essentially of a kraft comprising a means of adhesion to said primitive.

11. Panel according to claim claim 10, characterized in that the kraft comprises at least one surface treated with water repellency.

12. Panel according to any one of claims 6 to 11, characterized in that the facing (3) is a reagent support for bonding

13. Roof made up of supporting elements made of ribbed steel sheets, of wood or concrete, on which a plurality of panels (1) is fixed according to any one of claims 6 to 12.

14. Industrial, residential, tertiary or agricultural building wall forming a support on which a plurality of panels (1) is fixed according to any one of claims 6 to 12.

15. A method for manufacturing a primitive according to any one of claims 1 to 5, characterized in that a mattress (2) is formed continuous of mineral wool coated with a binder, which is created on the at least one of the longitudinal edges a raised area (6).

16. A method for obtaining a panel from a primitive produced according to claim 15, characterized in that a facing (3) is applied to the face of the mattress situated in line with said raised area (6) ), that at least one flap (5) from said facing (3) is pressed within said raised area (6).

17. The method of claim 16, characterized in that the raised area (6) is obtained by a material removal operation performed by a cutting member.

18. Device for manufacturing a panel according to one of claims 6 to 12, characterized in that it comprises a manufacturing line for the production of the insulating panel (1), namely a fiberizing device with incorporation of '' a binder at the time of drawing, a conveyor receiving the fibers, means bringing the mattress to the desired thickness and an oven for the polymerization of the binder, means for providing a facing (3) and its adhesion to the underside of the panel, cutting means.

19. Device according to claim 18, characterized in that the cutting means consist of first cutting means for setting dimensions in the transverse direction (relative to the direction of travel of the mattress), second means for dimensioning in the longitudinal direction (parallel to the direction of travel of the mattress), and finally third means for producing the raised areas in a fraction of the thickness of the mattress.

20. Device according to one of claims 18 or 19, characterized in that it further comprises a system arranged between the station for cutting the raised areas within a fraction of the thickness of the mattress and the station for fixing the facing, which comprises a pressing member making it possible to apply constant pressure to at least one flap of the facing that is to be adhered to the level of the previously removed raised area.