WO2012038295A1

WO2012038295A1 - Modular construction block

Info

Publication number: WO2012038295A1
Application number: PCT/EP2011/065782
Authority: WO
Inventors: Philippe Cha
Original assignee: Pigeon Entreprises
Priority date: 2010-09-20
Filing date: 2011-09-12
Publication date: 2012-03-29
Also published as: FR2957371A1; FR2957371B1; EP2619378B1; EP2619378A1

Abstract

The invention relates to a modular construction block. According to the invention, the modular construction block includes an injected-plastic structure (10) having an overall parallelepiped rectangular shape comprising two longitudinal walls (11, 12), two transverse walls (13, 14), and one substantially planar upper wall (15), said longitudinal walls (11, 12) defining, together with said transverse walls (13, 14) and said upper wall (15), at least one inner recess (16), wherein each of said longitudinal walls includes: a plurality of profiles (P1 to P4) extending over the largest portion of the height of the longitudinal wall (11, 12); and at least one lug (T1 to T3) extending from the base of the longitudinal wall up to a predetermined height h of the longitudinal wall.

Description

Modular building block.

1 FIELD OF THE INVENTION

The invention relates to the field of modular construction. The invention relates more particularly to a modular building block for the construction of residential, industrial, agricultural buildings, ...

2 SOLUTIONS OF THE PRIOR ART

Of all the known modular building blocks, the concrete block or manufactured concrete block (abbreviated BBM) is a molded masonry element that is used in a large majority of current constructions. It is usually a molded concrete block, gray, shaped hollow parallelepiped.

It is one of the cheapest building materials on the market. On the other hand, it has a low thermal resistance compared to the standards currently imposed for the construction of buildings. For example, for 20 cm thick, the thermal resistance of a block is R = 0.22 m ² .K / W, whereas RT2005 for walls in contact with the outside requires an R between 2, 5 and 2.7 m2.K / W. It is therefore absolutely necessary to provide additional insulation.

Many alternatives to the concrete block have been proposed to overcome the problems presented by this one. Indeed the concrete block is considered to be a poor thermal insulation. In addition, the construction of a wall or a building using such a concrete block must be carried out in successive stages. Indeed, insofar as it is necessary to have a thickness of mortar (usually 1.5 cm) between each row of concrete block, it is imperative to wait for the drying of several rows before starting the assembly of the following rows . But this operation greatly increases the time of assembly of the building or wall. In addition, the installation of adhesive mortar generates the creation of thermal bridge, which greatly reduces the energy efficiency of the building constructed with the concrete block.

Thus, to overcome the disadvantages of the concrete block, other types of modular building blocks have been proposed, among which hollow brick rectified terra cotta. Brick is generally considered to have good insulating properties. It is also lighter than the concrete block and allows quick assembly of walls due to the use of a simple special glue to attach the bricks to the lower and adjacent bricks. It is however larger and has a greater footprint.

This can be problematic in some cases: in fact, it is not uncommon for municipalities to define a town plan imposing a maximum surface area for the footprint of a building or a house. One understands then that the objective is to have the maximum of useful surface considering the imposed footprint. However, a too thick wall results in a significant decrease in the useful area, which is difficult for owners to accept.

Other modular building blocks, particularly well suited to the implementation of low-energy buildings (BBC) and buildings "passive" (that is to say, producing more energy than they consume) have also been proposed. These building blocks are however very thick (often double the thickness of a concrete block, about forty centimeters) and very expensive. Their uses are therefore at present relatively marginal with regard to all the constructions made. Thus, modular building blocks pose problems both in terms of thermal resistance (for the concrete block) and in terms of price (for solutions offering increased thermal resistance).

3 SUMMARY OF THE INVENTION

The invention does not pose these problems related to modular building blocks of the prior art. Indeed, the invention relates to a modular building block.

According to the invention, such a modular building block comprises an injected plastic structure of generally rectangular parallelepipedic shape having two longitudinal walls, two transverse walls and one wall. upper substantially flat, said longitudinal walls defining with said transverse walls and said upper wall, at least one inner recess, each of said longitudinal walls comprising:

a plurality of profiles that extend over most of the height of the longitudinal wall;

at least one lug extending from the base of the longitudinal wall to a predetermined height h of the longitudinal wall.

Thus, the invention offers a compromise between thermal resistance, price and thickness of the building material. Indeed, the use of an insulating plastic structure makes it possible to greatly increase the thermal resistance of the building block. In addition, the use of the profiles and tenons ensures greater grip of the concrete when the modular building block is poured and thus prevent deterioration of the wall by time. In addition, the use of traditional concrete offers the advantage of allowing the implementation of traditional facing, on the side of the wall that is in contact with the outside.

According to a particular feature, characterized in that a plastic profile defines a spacing of at least 17 mm with said side wall on which it is molded.

Thus, the concrete can flow uniformly during the manufacture of the building block while ensuring a good grip and thus a building block resistant to weathering.

According to a particular characteristic, a concrete wall is cast on at least one of said longitudinal walls. Thus it is possible to have a building block with a concrete face and to implement another facing on the other side, for example after the implementation of the wall or building.

According to a particular characteristic, a concrete wall is cast on each of said longitudinal walls. According to a particular feature, said transverse walls are shaped such that a transverse wall of said building block fits into a transverse wall of another building block.

According to a particular characteristic, gripping means are arranged at the ends of said upper wall.

According to a particular characteristic, said upper wall comprises graduation marks.

According to one particular characteristic, said plastic structure comprises a plurality of cells.

According to another aspect, the invention also relates to a method of manufacturing a modular building block as previously described. According to the invention, such a method comprises the steps of:

injection and molding of a plastic structure, delivering a bare structure.

placing the bare structure in a concrete block mold, casting the concrete in locations left free by said plastic structure.

compressing the concrete by vibrating the mold containing the plastic structure and the cast concrete.

In general, the invention also relates to the plastic structure as previously described, intended to construct a modular building block.

4 LIST OF FIGURES

Other characteristics and advantages of the invention will appear more clearly on reading the following description of a preferred embodiment, given as a simple illustrative and nonlimiting example, and the appended drawings, among which:

Figure 1 shows a perspective view of a modular building block in a first embodiment;

FIG. 2 presents a perspective view, without concrete, of a structure plastic of the modular building block of the first embodiment;

Figure 3 shows a side view, without concrete, of the female side wall of the plastic structure of the modular building block of the first embodiment;

Figure 4 shows a side view, without concrete, of the male side wall of the plastic structure of the modular building block of the first embodiment;

Figure 5 shows a side sectional view of the plastic structure of the modular building block of the first embodiment;

Figure 6 shows a longitudinal sectional view of the plastic structure of the modular building block of the first embodiment;

Figure 7 shows a bottom view of the plastic structure of the modular building block of the first embodiment;

Figures 8 to 15 show views of a modular building block in a second embodiment adapted to a construction of wall corners;

Figures 16 to 21 show views of a modular building block in a third embodiment in the form of a planelle.

DETAILED DESCRIPTION OF THE INVENTION

5.1 Recall of the principle of invention

The invention relates to modular building blocks for the construction of a building wall. The invention also relates to constructions obtained by stacking such modular building blocks, as well as a method of manufacturing such modular blocks. The invention therefore proposes a modular building block comprising an insulating plastic structure. The invention also relates to an insulating plastic structure as described below. Thus, the modular building block according to the invention offers numerous advantages and makes it possible in particular to to meet the necessary evolutions that face the traditional concrete block, without however having the disadvantages of alternative solutions of the prior art namely the price and thickness of the modular building block.

An object of the invention is also to provide a modular building block that does not require the addition of concrete or other material to be cast, within the core of the block, to ensure rigidity and sealing. Indeed, the object of the invention is to make the construction based on more ecological concrete. The inventors have therefore made sure to solve on the one hand the stability and rigidity problems of the modular building blocks of the invention and on the other hand to reduce the amount of concrete used.

To do this, the modular building block according to the invention thus comprises an insulating structure of injected plastic structure generally having a rectangular parallelepiped shape. On at least one wall of this structure, concrete is poured and compressed to form a planelle. The assembly thus formed constitutes the modular building block of the invention. The plastic used in this insulating structure is for example recycled polystyrene. The use of such a material has many advantages. On the one hand polystyrene is unanimously recognized for its insulating qualities. On the other hand this opens a new way of reusing polystyrene. In addition, when injected into a mold to form the plastic structure of the building block of the invention, the polystyrene provides rigidity essential to the construction of a wall.

Indeed, one of the main technical difficulties that the inventors have encountered is the level of rigidity and stability of the building block. For a modular building block to be used in building construction, it is necessary that the building block is rigid on one hand and stable on the other. Rigidity is necessary for maintaining the block as such. Stability is required to mount multiple blocks on top of each other without the risk of the wall being erected. To increase the stability characteristics, the injected plastic structure of the invention further comprises means for vertical interlocking of modular building blocks of the invention. These vertical interlocking means thus make it possible to mount a plurality of modular building blocks according to the invention, for example in overlap. In addition, such a vertical interlocking system reduces the amount of adhesive mortar to be applied between the building blocks.

The modular building block of the invention also comprises horizontal interlocking means for interlocking the building blocks horizontally with one another.

Thus, when the horizontal and vertical interlocking means are combined, the invention makes it possible to mount much more simply than the existing techniques, a wall whose horizontal plumb and the vertical plumb are much simpler to implement. . This is made possible, as will be explained later, through the use of the injected plastic structure.

Many embodiments of the modular building block of the invention are conceivable and three of them will be presented later.

One of the objects of the invention is to propose a modular building block having good insulation properties without excessively high cost, while keeping a footprint identical or equivalent to the footprint of a concrete block. To do this concrete is poured and compressed on at least one of the walls of the injected plastic structure to form a concrete wall.

Preferably, the concrete is poured and compressed on the two longitudinal walls of the building block. The thickness of the resulting wall is substantially the same as the thickness of a longitudinal wall of a conventional concrete block.

In another embodiment of the invention, it is possible to cast and compress the concrete on the four walls of the injected plastic structure.

In general, the method of manufacturing a modular building block according to the invention is as follows: injection and molding of the plastic structure, delivering a bare structure.

setting up the bare structure in a concrete block mold. This installation allows to leave free locations for pouring concrete. The locations in which the concrete is not required are either solid or covered after placement of the plastic structure in the mold.

concrete pouring in the spaces provided for this purpose.

compressing the concrete by vibrating the mold containing the plastic structure and the concrete.

As explained below, the walls of the plastic structure that are intended to be in contact with concrete are specially configured to allow the grip of the concrete when it is dry and thus ensure that the plastic concrete assistant does not come off and therefore prevent degradation of the outer facing of the building mounted with modular blocks object of the invention.

In addition to the configuration of the walls, the plastic used is also likely to allow or not a good grip of the concrete. Thus, after several tests, the inventors have found that the use of recycled polystyrene has all the characteristics required for the grip on concrete. Of course, it is possible to use other plastics, such as polypropylene. But such use will require special treatment of this polypropylene.

Subsequently, there are presented in particular three embodiments of a modular building block according to the invention. It is clear however that the invention is not limited to these particular embodiments, but can also be implemented in many other embodiments and more generally in all cases where the advantages provided by the invention are interesting. . 5.2 Description of an embodiment

The modular building block object of the present invention is described, in a general embodiment, with reference to FIGS. 1 to 7.

The modular building block B l comprises an injected plastic structure 10 of generally rectangular parallelepiped shape having two longitudinal walls (11, 12), two transverse walls (13, 14) and a substantially flat upper wall (15), said longitudinal walls. (11, 12) defining with said transverse walls (13, 14) and said upper wall (15) at least one inner recess (16). On this plastic structure, two concrete walls are adjoined (20, 30).

At least one of the longitudinal walls (1 1, 12) comprises a plurality of profiles (PI to P4) which extend over most of the height of the longitudinal wall (11, 12). As will be explained later, these profiles are used to allow the grip of the concrete after the concrete has been poured and compressed on the injected plastic structure (10) to form the modular building block B1 according to the invention. The profiles are extensions of the wall, and may for example take the form of T to allow the passage of concrete during the manufacture of the building block. The profile may also have a contained dovetail shape or a contained dovetail. In this particular embodiment, the profile is an integral part of the wall. It may also, in another embodiment, be reported later thereto, by fixing means.

Between the profiles (PI to P4) having at least one tenon (T1 to T3) extending from the base of the longitudinal wall to a predetermined height h of the longitudinal wall corresponding to the total height of the wall to which are subtracted a particle size (for example 17 mm), a function of the concrete which is used for the manufacture of the modular building block and an interlocking height (for example 19.24 mm) which makes it possible to fit a block of modular construction of the invention on another as will be explained later. In this particular embodiment, the transverse walls (13, 14) are in turn shaped so that they fit into one another. In other words, the shapes of the transverse walls are created such that for a given modular building block, there is a female transverse wall (13) and a male transverse wall (14). Thus, when a building block Β is mounted next to a building block B1, the female transverse wall 13 'of the building block Β engages with the male transverse wall 14 of the building block B1. Mature mounted using the building blocks of the invention is rectilinear, because of the alignment achieved automatically during the insertion of the transverse wall maie 14 in the female transverse wall 13 '.

More specifically, as illustrated in the figures, the transverse male wall 14 comprises tabs (14-1, 14-2) extending over the entire height of the wall 14. These tabs are located on each side of a shoulder ( 14-3) also extending the full height of the male transverse wall 14.

For its part, the female transverse wall 13 comprises tabs (13-1, 13-2) configured to guide the tongues (14-1, 14-2) during nesting and slitting (13-3, 13-2). 4) configured to house the tabs (14-1, 14-2). These tongues and these grooves extend over the entire height of the wall 13.

As will be described later, the internal recess (16) formed inside the plastic structure by the longitudinal (11, 12), transverse (13, 14) and upper (15) walls is configured to fulfill certain particular functions.

It should be kept in mind that, on the one hand, this configuration is only one of the possible embodiments for the implementation of the transverse walls. On the other hand, these configurations and the resulting benefits (rigidity, stability, interlocking), are directly related to the use of plastic injected structure 10. Indeed, these configurations and advantages would be more difficult to obtain using for example clay (as cala is done for the brick making) or non-rigid insulating materials (hemp for example).

The advantage provided by the invention is to implement a rigid insulating material and injectable (in a mold) which ensures, as soon as the manufacture of the plastic structure, that the ribs required for implementation, for example vertical nesting (one block over another) or horizontal nesting (one block next to another) will be possible. In addition, horizontal interlocking and vertical interlocking saves a large amount of glue. The inventors have estimated that it is possible to save a very large quantity of adhesive mortar by using the modular building blocks of the invention in place of traditional concrete blocks, without it being necessary to modify the type of adhesive used. For example, it is not necessary to introduce adhesive mortar between two blocks nested side by side.

In addition, the horizontal interlocking and the vertical interlocking prevent the formation of thermal bridges.

The modular building block which is the subject of the present invention is described, in a particular embodiment, adapted for use at the end of a wall, in relation to FIGS. 8 to 15.

The modular building block B2 comprises, as for the previous embodiment, an injected plastic structure 10 of generally rectangular parallelepiped shape having two longitudinal walls (11, 12), two transverse walls (13, 14) and an upper wall ( 15) substantially flat, said longitudinal walls (11, 12) defining with said transverse walls (13, 14) and said upper wall (15), at least one inner recess (16).

The plastic structure is substantially identical, in its external form, to that described in relation with the block B1. However, this plastic structure comprises a cylinder (17) extending vertically from the base to the top of the structure. The diameter of this cylinder is 155 mm. It is a standard diameter. The object of this embodiment of the building block is to have a building block that allows to mount the corners of the walls of the buildings. dwellings. Thus, in addition to the nesting characteristics already described above, this building block B2 makes it possible to scrap and cement the corners of the walls, in the usual way. Thus, according to the invention, it is not necessary to modify the construction habits of those skilled in the art.

In addition, the block B2 further comprises a third concrete wall, which takes place at one of the lateral ends. In return, the concrete walls of the longitudinal walls are small. To allow lateral nesting (on the left or right side of block B2).

Incidentally, the modular building block B2 can be used outside the corners, for example for the passage of pipes or fluids in general.

The modular building block object of the present invention is described, in a particular embodiment in connection with Figures 16 to 21. In this embodiment, the building block of the invention offers the planelle function. A planelle is a building block located on the periphery of a floor and of the same nature as the material used for vertical walls. One of the problems with planelles is that they are usually a source of thermal bridges created by the wall / floor junction.

This embodiment of the invention does not have these disadvantages. Indeed, it is imposed in the construction standards that the planelles are made of the same material as that used for walls and floors. But it is this identity of material which is at the origin of the thermal bridges. The modular building block B3 of the invention does not have these disadvantages.

The modular building block B3 comprises, as for the previous embodiment, an injection-molded plastic structure 10 in the shape of an "L" (AA section) having two longitudinal walls (11, 12), two transverse walls (13, 14). and two substantially planar upper walls (15, 15 '), said longitudinal walls (11, 12) defining with said transverse walls (13, 14) and said upper walls (15, 15'), at least one inner recess (16) . Thus, in addition to the nesting characteristics already described previously, this B3 building block avoids the formation of thermal bridges during the construction of the building. Indeed, thanks to this block B3, the external environment, with which the longitudinal wall 11 is in contact, is not contact with the inside (the longitudinal wall 12). There is therefore no creation of thermal bridge and therefore no need to add thermal bridge breakers, as is frequently encountered. In addition, the slab that is cast or mounted subsequently is also not in contact with the outside of the building. Thus, the insulation of the building is total.

5.3 Other optional features and benefits

As already mentioned, the plastic structure has a substantially flat upper wall (15) extending longitudinally from one end to the other of the modular building block. At the ends of this wall, gripping means are arranged (PI, P2) to allow on the one hand a simplified handling of the building block and on the other hand a simpler installation for adjusting the male part of the block. laying on the female part of the already laid block and vice versa.

According to one particular characteristic, the upper wall (15) comprises graduation markings. These graduation pens make it possible to cut the modular building block more easily.

According to a particular embodiment, the upper wall (15) comprises a marking of direction of laying. This marking makes it possible, under certain laying conditions, to orient the building blocks in the same direction. This is particularly useful when, as is the case in some embodiments of the invention, the external surfaces (ExtA, ExtB) of the building block have different properties and that one of the surfaces must imperatively be in contact with the outside.

The plastic structure 10 comprises cells (Alv1 to Alv5). These cells are recesses of the plastic structure. They are used to define volumes in which the air is trapped at the time of mounting the wall. Once the building block is placed, the air present in the cells does not not move in the wall. The air thus trapped thus participates passively in the thermal resistance offered in fine by the modular building block of the invention.

According to a particular embodiment, additional insulating elements are added inside the cells of the plastic structure: complementary sound-insulating elements, complementary elements of thermal insulation. These complementary elements may be, in a first embodiment, in the form of square pyramids which are arranged inside the modular building block. The size and orientation of these pyramids are calculated so that the block allows a sound insulation of the wall when it is mounted.

According to a particular embodiment, the profiles (PI to P4) and the tenons (T1 to T3) are configured according to the particle size of the concrete used in the manufacture of the building block of the invention. More specifically, the section of the profiles is 17 mm for a standard concrete. Similarly, the width of the base of a stud is 17 mm (see section A-A).

The invention also relates to a plastic structure as defined previously. The injected plastic structure 10 is of generally rectangular parallelepipedal shape and has two longitudinal walls (11, 12), two transverse walls (13, 14) and a substantially flat upper wall (15), said longitudinal walls (11, 12) defining with said transverse walls (13, 14) and said upper wall (15), at least one inner recess (16). According to the invention each of said longitudinal walls comprises:

a plurality of profiles (P1-P4) that extend over most of the height of the longitudinal wall (11,12);

at least one tenon (T1 to T3) extending from the base of the longitudinal wall to a predetermined height h of the longitudinal wall. According to a particular embodiment, not shown, the cells (Alvl to Alv5) are filled with an insulating material, which is substituted for air to provide better insulation to the final modular building block. Such filling of the cells can be achieved using the aid of glass, rock wool, expanded polyurethane foam.

Claims

Modular constmction block characterized in that it comprises an injected plastic structure 10 of generally rectangular parallelepiped shape having two longitudinal walls (11, 12), two transverse walls (13, 14) and a substantially flat upper wall (15), said longitudinal walls (11, 12) defining with said transverse walls (13, 14) and said upper wall (15), at least one inner recess (16), each of said longitudinal walls comprising:

at least one tenon (T1 to T3) extending from the base of the longitudinal wall to a predetermined height h of the longitudinal wall.

Building block according to claim 1, characterized in that a plastic profile (PI to P4) defines a spacing of at least 17 mm with said side wall on which it is molded.

Building block according to claim 1, characterized in that a concrete planelle is cast on at least one of said longitudinal walls (11, 12).

Building block according to claim 1, characterized in that a concrete planelle is cast on each of said longitudinal walls (11, 12).

Building block according to any one of claims 1 to 3, characterized in that said transverse walls (13, 14) are shaped such that a transverse wall (13) of said building block fits into a transverse wall (14 ') of another building block.

Building block according to any one of claims 1 to 4, characterized in that gripping means (PI, P2) are arranged at the ends of said upper wall 15.

Building block according to any one of claims 1 to 5, characterized in that said upper wall 15 comprises graduation marks.

Building block according to any one of claims 1 to 6, characterized in that said plastic structure 10 comprises a plurality of cells (Alvl to Alv5).

A method of manufacturing a modular building block according to claim 1, characterized in that it comprises the steps of:

injection and molding of a plastic structure, delivering a bare structure.

An injected plastic structure 10 of generally rectangular parallelepiped shape having two longitudinal walls (11, 12), two transverse walls (13, 14) and a substantially flat upper wall (15), said longitudinal walls (11, 12) defining with said walls transverse (13, 14) and said upper wall (15), at least one inner recess (16), characterized in that each of said longitudinal walls comprises: