WO2011089340A1 - Pre-manufactured device enabling creation of a construction element, and construction element including at least two such devices - Google Patents

Abstract

Said pre-manufactured device consists of at least three panels, at least two end panels (7) of which and at least one intermediate panel (6) of which are made of rigid, heat-insulating material. Said panels are assembled so that, between each pair of panels, an air space (20) makes up the main heat insulation. According to the invention, the panels (6) comprise a plurality of horizontal ribs (10) that are spaced so as to subdivide the air space (20) into bands (B) in order to limit the natural air convection. Said device has, on at least one of the side edges thereof, at least one main vertical rib for defining, with an identical device, a fitting and sealing area formed by a series of such ribs that extend, in a staggered manner, between both end panels.

Description

 Prefabricated device for creating a construction element, and construction element comprising at least two such devices

Technical field of the invention

 The present invention relates to a prefabricated device for creating a construction element, composed of at least three panels, including at least two end panels and at least one intermediate panel made of thermally insulating and rigid material, assembled in such a way that between each pair of panels, an air gap constitutes the main thermal insulation.

State of the art

 The realization of a perfectly insulated and mechanically efficient building wall today requires a lot of manual activities as well as the management of different materials on the construction site of this building.

 Even in the case of using materials such as wood there is little simplification in the design of walls and partitions.

 In fact, even though the main elements of the building's mechanical structure can be prefabricated, most of the structural materials are shaped on site generating multiple transport, high costs, long lead times and errors in construction. .

 Once the wall is completed and the shell finished, intervenes the establishment of exterior siding, insulation and interior siding. All these operations recreate the same problems and the same risks as the realization of the structural work.

 Finally this method of work generates many and different waste that must then be managed.

The different current solutions are as follows. We know first of all walls and mineral partitions (concrete, bricks, plaster, ...). Their prefabrication techniques exist in particular for concrete, but they are used only for the construction of buildings, industrial sites and offices. These techniques impose a very strong standardization incompatible with the wishes of architects and designers of individual houses. In addition, the transport of prefabricated concrete walls imposes, because of the weight, expensive transport methods that are not economically viable for large quantities.

With regard to partitions, it can be considered that most products are now prefabricated and only shaped on site (eg plaster tiles).

 We also know walls and partitions made of vegetable matter (wood, ...). Despite the existence of several proposals for industrial methods of making prefabricated walls of plant materials, they are not developed because they are not sufficiently flexible for the positioning of doors and windows. The needs of the customers finally transform the prefabrication into a specific realization which, in fact, moves the realization of the wall of the place of construction to a workshop. The advantage is to improve the working conditions, the disadvantages are the transportation of bulky sub-assemblies, the on-site assembly and the error management inherent to the realization of unique products.

The realization of wood partitions is today equivalent to the realization of partitions such as with plates composed of cardboard, plaster and insulation. To date, ready-made prefabricated plant partitions are not available.

Other solutions are known, such as metal cladding, or composite panels. Most cladding can be considered prefabricated. On the other hand, the wall itself is not prefabricated since the supporting structure on which the cladding will be fixed is often mounted on site. Cladding including insulation functions exist (composite panels). In general, cladding is cut at the place of construction for the installation of doors and windows. These technologies are mainly reserved for industrial buildings.

Finally, there is known from GB-A-2,039,601 a device of the type presented in the preamble above. In this solution, the insulation is created by the interior honeycomb structure, weakly conductive. This device uses a high amount of materials, compared to the volume of air. In addition, the junction between two adjacent devices is not very satisfactory, so that it must generally be supplemented by the use of auxiliary systems, such as a beam type IPN.

Object of the invention

 Given the above, there is a strong opportunity to create prefabricated walls in the building market. In particular, these prefabricated walls, bearing or non-bearing, are usable for homes and small buildings for residential or professional use.

That being said, the invention is remarkable in that the panels comprise a plurality of horizontal ribs which are spaced so as to subdivide the air strip into strips, so as to limit the natural convection of the air, and in that the device has, on at least one of its lateral edges, at least one main vertical rib, so as to define with an identical device an interlocking and airtight zone, formed by a succession of such ribs; , extending staggered between the two end panels.

The device may have all or some of the following features:

the panels furthermore comprise, between their lateral edges, a plurality of intermediate vertical ribs extending staggered between the two end panels, so as to reduce heat loss by conduction but also to increase the rigidity of the device, these secondary vertical ribs subdividing each band into elementary cavities - side views, the horizontal ribs extend in continuity from each other

 the horizontal ribs and / or the intermediate vertical ribs comprise at least one zone of reduced cross section, so as to limit the transfer of heat by conduction

 - there are two end panels and between three and six intermediate panels, defining between four and seven blades of air.

 - The panels are made of natural wood, or synthetic wood, or a mixture of natural wood and synthetic wood.

- At least one inner and / or outer facing is attached to at least one end panel.

 - The or each facing is made of plastic, so as to remove the installation of internal vapor barrier and / or outdoor rain cover.

- At least one additional film or layer (1c), such as vapor barrier and / or rain cover and / or reflector and / or acoustic insulation is immobilized (e) being sandwiched between two adjacent panels.

In its preferred variant, the invention mainly uses two high-performance, inexpensive and available insulators: air (more than 65% of the volume) and wood (less than 35% of the volume). These elements make it possible to quickly and easily create building elements, bearing or not. The mechanical, thermal and acoustic properties of the load-bearing walls thus created are superior in all respects to the timber load-bearing walls composed of two external faces associated with vertical and possibly horizontal frames and an integrated insulator. These building elements, object of the invention, can be dressed, inside and outside the building, as standard wood partitions, but can also be factory equipped with all or part of the siding. The wall elements may incorporate components such as vapor barrier and / or rain cover and / or heat reflector and / or noise reducer. These elements are made with standardized parts to simplify manufacturing and thus reduce production costs. Spaces for doors and windows can be cut as easily as with a cellular concrete partition. These operations can be carried out at the factory or after assembly on site. These spaces for doors and windows can also be prefabricated.

The invention also relates to a construction element, of the wall type, comprising at least two devices as above, two adjacent devices delimiting an interlocking and sealing zone.

According to an advantageous variant, this element of construction further comprises a corner post, defining two additional nesting and sealing zones, with the two devices fixed on this post.

Brief description of the drawings

 The invention will be described hereinafter with reference to the accompanying drawings in which:

 Figure 1 shows, in general view, a construction element made according to the invention.

 FIG. 2 represents, in a general view, a device according to the invention, making it possible to produce the element of FIG. 1.

 FIG. 3 represents, in a general view, a panel belonging to the device of FIG. 2.

Figure 4 shows, in exploded detail, the constituent members of the device of the invention.

 Figure 5 shows, in detail, the constituent members of Figure 4, once assembled.

 Figure 6 shows, in detail, the principle of assembling a device with another identical device.

 FIG. 7 represents, in detail, a vertical section of the device of the invention

 FIG. 8 represents, in detail and from above, the principle of transfer of heat by conduction along the device of the invention

Figures 9 and 10 show an exploded overall view and overall assembled view, a variant of the invention. FIG. 11 represents, in exploded detail view, another variant of the invention

 FIG. 12 represents, as a whole, another variant of the invention, and

Figure 13 is a top view, illustrating the mounting of two identical devices according to the invention.

Description of a preferred embodiment of the invention

 The invention relates to a prefabricated device that makes it possible very easily and very quickly to create a construction element, such as a wall, by interlocking and for example by pegging. This device is made in the factory using a plurality of standard planar components made of thermally insulating and rigid material, preferably wood.

Each prefabricated device (1) consists of two end panels respectively outer (6) and inner (6 ') and at least one intermediate panel (7). In the examples described, there are provided two intermediate panels (7) delimiting three air knives with the end panels, as will be detailed in what follows. Advantageously, the device comprises between three and six intermediate panels, thus delimiting between four and seven air knives. The height of the prefabricated device (1) and therefore that of the panels (6), (6 ') and (7) will adapt to the different construction standards of the countries or regions of the world where this product will be marketed, for example 2.7 m.

 The width of the prefabricated device (1) and therefore that of the panels (6), (6 ') and (7) will be chosen so as to simplify:

 • manipulation,

 • on-site assembly,

 • transport between the prefabrication site and the construction site.

For example, a width of 1.15 meters for the overall device (1) and 1 meter for each panel will be chosen. To create a 10 m long wall It will therefore be necessary to assemble 10 prefabricated devices, ie about 2 hours of work.

 To facilitate the assembly of prefabricated devices together, the panels are fixed together in staggered rows to generate interlocking spaces (11). More specifically, with reference in particular to FIGS. 6 and 13, the lateral edges (6-1), (6'-1) and (7-1) of the panels of the element on the left form a slot, in this sense that we find a succession of edges recessed and protruding. In these figures, IN and OUT respectively indicate the inside and the outside of the enclosure, bordered by the construction element.

 In addition, three of the four panels are provided with vertical ribs, said main (NV), which are directed transversely towards the adjacent panel, inwardly. Likewise, the other lateral edges (6-2), (6'-2) and (7-2) of the panels, belonging to a device identical on the right in FIGS. 6 and 13, form slots, however, being devoid of of rib. Finally, the facing edges (6'-1) and (6'-2) of the inner panels (6 ') are chamfered so as to bear against each other, by cooperation of forms.

 Once the two elements are assembled (Figure 13), the vertical ribs (NV) of the two projecting edges bear against the panels of the other element. There is thus an interlocking zone (11) between the two elements, in which these ribs extend between the end panels (6) in a staggered two-to-two manner, namely staggered.

Thanks to the interlocking zone (11) thus formed, the junction between two elements allows a satisfactory continuity. This nesting zone also provides an airtight function, without however creating a thermal bridge. This airtightness is conferred by the contacting of at least two main vertical ribs, with the panels of the same identical device. This is shown in Figure 13 by the references 6-1 and 7-2 on the one hand, and 7-1 and 6 -2 on the other hand. These contact areas, forming seals, are not sensitive to the relative movements of the devices between them, whether they are due to thermal expansion or movement of the building. Such contact can be provided by at least two methods, namely gluing or screw tightening, the latter ensuring sufficient pressure over the entire height of the joint. These two assembly methods also ensure the mutual attachment of two adjacent identical devices.

 This fixing devices (1) between them can be completed or replaced by an additional means, for example using dowels (3). The realization of the wall angles is possible, whatever the angle, by bevelling the prefabricated element (1) so as to obtain wall elements (4) and (5). Preferably, for the purpose of airtightness in the areas where required, corner posts will be used which reproduce the interlocking areas (11). These posts will also allow the ground fixing of the building to increase its seismic resistance. This attachment will be provided, for example, by means of a lag bolt or a metal reinforcement implanted (e) in the length of each of the poles.

The standard panels have ribs, different from those NV described above. During assembly, for example by gluing or screwing, the plurality of components constitutes a plurality of layers including air blades (20), see in particular FIG. 8. The aforementioned ribs subdivide these blades, as will be seen here. -after.

Each ribbed panel comprises a plurality of horizontal ribs (10), visible in particular in Figure 3, which participate first of all in the rigidity of the partition. However, their main function is to improve thermal insulation. It is for this purpose that these ribs advantageously have a profile having a thinned zone A. Such a profile, triangular or similar, allows to limit the transfer of heat by conduction.

This plurality of horizontal ribs creates a plurality of strips (B) in which air, one of the best insulators available (conduction of 0.024 W / m. ° C) but especially the best insulator in terms of ratio performance / cost, is imprisoned. To do this, it is advantageous that the height of the strips is sufficiently small so that the air effectively acts as an insulator. The vertical space between the horizontal ribs is calculated so as to limit natural convection and thus to create strips whose thermal resistance approaches that of a still air layer of the same thickness.

 As shown in particular in Figure 7, the different horizontal ribs are arranged in the extension of each other, viewed from the side. We therefore notice the difference with the staggered arrangement of the vertical ribs. However, it is possible to mutually offset two horizontal ribs, at a low height less than 10% of the height of the air strips. Surprisingly, this plate exchanger type arrangement, between two successive air strips, is advantageous for reducing heat exchanges between the two end panels of the device.

 There is also a plurality of vertical ribs, said secondary (9), visible for example in Figures 3 and 5, the height is equal to the thickness of the air gap, which is a vertical frame. These secondary ribs are arranged between the two opposite lateral edges, evenly over the entire width of the panels. These ribs extend between the end panels (6) and (6 ') offset in pairs, so as to form a plurality of staggered areas Q (Figure 5). This arrangement allows the plurality of vertical ribs to provide first a main function of resistance to vertical load, but also to increase the overall stiffness and the path that the heat must go through conduction.

As a variant not shown, it can be provided that at least one panel carries two vertical ribs and / or two horizontal ribs, on its opposite faces. This can, in some cases, simplify the manufacturing process. Moreover, as for the horizontal ribs, one can foresee these vertical ribs have at least one thinned section, which limits the transfer of heat by conduction.

The ribs (9) subdivide each air band (B) into a plurality of elementary cavities (C) visible in particular in FIG. 3. Advantageously, as illustrated in FIG. 8, the ribs (9) have a thickness (e9 ), which is greater than that (e7) of the intermediate panels. In this way, not only the length that the heat has to travel is increased, but also this path is narrower which increases the thermal resistance.

Note that these vertical ribs (9) advantageously equip the device of the invention, when it forms a bearing wall. On the other hand, they are optional in the case of a non-load bearing wall. It can be in this case partial in the direction of the height for the high panels to withstand high bending force (high wind) or absent for non-load bearing walls not having to withstand bending.

 The wall element will be composed of two end panels and at least one intermediate panel, so as to limit radiation heat transmission. Indeed, the amount of heat transmitted by radiation is very much divided by the number of air knives. The maximum number of panels is defined by the insulation and load resistance objectives of the building.

 Interior and / or exterior siding may be prefabricated and optionally assembled in the factory with the same methods as the wall components. The materials of the facing panels are wood or more preferably plastics that avoid the installation of vapor barrier and / or rain cover.

Other components in the form of a thin layer such as vapor barrier and / or rain and / or reflector and / or soundproofing can be sandwiched between any one or more pairs of components of the wall including the facings, so as to avoid their installation on site. The thickness of the prefabricated device (1) will be adapted on the one hand to the architects' request, on the other hand to the vertical load to be supported and finally to the thermal insulation to be achieved.

 The characteristic dimensions are for example the following:

each end panel has a thickness (e6, e6 ') of between 5 and 22 mm, in particular between 10 and 22 mm, while each intermediate panel has a thickness (e7) of between 3 and 15 mm, in particular between 3 and 15 mm; and 8 mm (Figure 8). These thicknesses do not take into account the ribs carried by these panels.

- Each vertical rib (9) has a thickness (e9) of between 5 and 25 mm, preferably between 15 and 25 mm. These different thicknesses of ribs are "average" thicknesses, taking into account ribs whose thickness is not constant.

 each air band has a height (HB) of between 50 and 300 mm, in particular between 50 and 125 mm. (Figure 3). This height corresponds to the spacing between two successive horizontal ribs.

 each air gap has a thickness (e) of between 20 and 100 mm, in particular between 50 and 100 mm (FIG. 8)

 the distance (d9) separating two intermediate vertical ribs is between 200 and 500 mm, in particular around 250 mm (FIG. 8)

This distance is taken between the middle of the two adjacent ribs.

It will be appreciated that an advantageous aspect of the invention is achieved by combining an air gap thicker than the web height, for example a value (e) of 70 mm with a value (HB) of 50 mm.

As shown in FIG. 9, it is possible to provide optional facing panels (21) whose shapes are standardized. They comprise passages (22), (23) and (24) for either wiring or recessed pipework. The passages (23) also constitute the ventilation chimneys of the exterior cladding.

The height of the cladding panels may be different from that of the partition and this according to the needs of builders and architects. For example, a shorter interior facing to take into account the thickness of the floor and the installation of the ceiling and a longer outer siding, or vice versa.

 The methods of making the panels (6), (6 ') and (7) may be as follows:

 A) For walls supporting low loads: molding of recomposed wood (wood powder).

 B) For walls with heavy loads:

 at. Recomposed wood panels (oriented slats) molded / pressed b. recomposed wood panels (wood powder) associated with cleats for (10) and vertical frames (9) of solid wood, c. recomposed wood panels (oriented slats) or sliced wood panels associated with cleats for (10) and vertical frames (9) made of steel profile.

 C) For walls supporting very large loads: solid glued laminated panels integrating the vertical frames (9) associated with cleats for (10).

 Other materials can be exploited for example compressed recycling plastics. The use of waterproof materials for the cladding panels (21) has the advantage of avoiding the installation of indoor vapor barrier and rain cover outdoors.

 The possible methods of realization for the prefabricated element (1) with or without facing are gluing, nailing and screwing. The fact that the panels (6) are offset relative to each other greatly simplifies the application of nail and / or screw assembly solutions. When integrating vapor barrier and / or rain shield and / or heat reflector and / or noise reducer in the form of layer (25) up to several centimeters thick, it will promote assembly by nail and / or or screws at least for the two adjacent panels that take this additional sandwich element.

Thermal insulation is provided in two ways: Due to the staggered arrangement, the heat transfer by conduction in the wood is considerably longer (see reference 12 in FIG. 5). Whereas in a 200 mm thick wooden wall typically having a vertical beam of 160 x 45 mm (e _p ) every 50 cm, the heat circulating through the vertical and horizontal frames travels at most 200 mm, in the case of the invention this same heat travels at least 450 mm (see reference 19 in Figure 8). Indeed, the specific profile of the horizontal ribs (10), which comprises at least a very small section, for example the triangle, reduces the conduction in the latter to a level close to zero. Any profile having at least one section close to zero can be used as a horizontal framework (10). Only conduction through vertical frames is therefore taken into account. However, along these 450 mm of travel, at least 250 mm are made through a reduced thickness as soon as e7 is less than e _p / 4. The conductive thermal resistance is thus at least doubled, which therefore reduces conductive heat loss.

 The transfer of heat by conduction and natural convection in the air is limited by the reduction of the height of the bands (B) and by the multiplication of the air knives (20). As a result, the plurality of ribs will be defined according to the desired insulation performance for a given thickness. The lower the vertical space between the ribs, the less the wall can communicate heat to the air and the more this air remains stable. The speed (see reference 17 in FIG. 7) then tends to zero and limits natural convection heat transfer.

Compared with technologies using foam insulators or fiber mattresses, radiation transfer will be more important. Note that most of the materials used to create these prefabricated walls have emissivities close to 1. The reduction in radiation heat loss (reference 18 in Figure 7) is achieved by optimizing the thickness of the panels, in order to to reduce the temperatures of the emitting surfaces, and the multiplication of the obstacles. Indeed, the radiation is proportional to the difference of the temperatures of the bodies raised to the power four. Multiplying the panels reduces the temperature differences (13) - (14), (14) - (15) and (15) - (16) by three in this example (see Figure 7). Finally, the radiation is also divided by about 3. If this technology requires more materials to achieve the same level of efficiency as a foam or a fiber mattress, ultimately this technology will be more economical when we take into account the total cost of insulation laid.

 The industrial applications of this invention relate to the manufacture of the wall or partition as well as the shell construction industry.

Claims

claims 1) Prefabricated device for creating a building element, in particular a wall, this device being composed of at least three panels, including at least two end panels (6, 6 ') and at least one intermediate panel (7) made of thermally insulating and rigid material, assembled in such a way that between each pair of panels, an air gap (20) constitutes the main thermal insulation, characterized in that the panels (6, 6 ', 7) comprise a plurality of horizontal ribs (10) which are spaced apart so as to subdivide the air gap (20) into strips (B), so as to limit the natural convection of the air, and in that the device has, on at least one of its lateral edges, at least one main vertical rib (NV), so as to define with an identical device an interlocking and airtight zone (11) formed by a succession of such ribs, extending staggered between the two panels of end. 2) Device according to claim 1, characterized in that the panels (6, 6 ', 7) further comprise, between their lateral edges, a plurality of intermediate vertical ribs (9) extending staggered between the two panels d end, so as to reduce heat loss by conduction but also to increase the rigidity of the device, these secondary vertical ribs subdividing each band (B) into elementary cavities (C). 3) Device according to claim 1 or 2, characterized in that, viewed from the side, the horizontal ribs (10) extend in continuity from one another. 4) Device according to one of the preceding claims, characterized in that the horizontal ribs (10) and / or the intermediate vertical ribs (9) comprise at least one zone of reduced section, so as to limit the heat transfer by conduction. 5) Device according to one of the preceding claims, characterized in that there is provided two end panels and between three and six intermediate panels, defining between four and seven air knives. 6) Device according to one of the preceding claims, characterized in that the panels are made of natural wood, or synthetic wood, or a mixture of natural wood and synthetic wood. 7) Device according to one of the preceding claims, characterized in that each end panel (6, 6 ') has a thickness (e6, e6') of between 5 and 22 mm, in particular between 10 and 22 mm, then each intermediate panel (7) has a thickness (e7) of between 3 and 15 mm, in particular between 3 and 8 mm. 8) Device according to one of the preceding claims, characterized in that each air band (B) has a height (HB) of between 50 and 300 mm, in particular between 50 and 125 mm. 9) Device according to one of the preceding claims, characterized in that each air gap (20) has a thickness (e) between 20 and 100 mm, in particular between 50 and 100 mm. 10) Device according to one of claims 2 to 9, characterized in that the distance (d9) separating two intermediate vertical ribs (9) is between 200 and 500 mm, in particular close to 250 mm. 11) Device according to one of claims 2 to 10, characterized in that each intermediate vertical rib (9) has a thickness (e9) of between 5 and 25 mm, preferably between 15 and 25 mm. 12) Device according to one of the preceding claims, characterized in that at least one inner and / or outer facing (21) is attached to at least one end panel. 13) Device according to claim 12, characterized in that the or each cladding (21) is made of plastic, so as to remove the installation of internal vapor barrier and / or outdoor rain cover. 14) Device according to one of the preceding claims, characterized in that at least one additional film or layer (the) (25), such as vapor barrier and / or rain cover and / or reflector and / or acoustic insulation is immobilized (e) sandwiched between two adjacent panels. 15) Element of construction, wall type, comprising at least two devices according to one of the preceding claims, two adjacent devices defining a nesting area and sealing. 16) Element of construction according to the preceding claim, further comprising a corner post, defining two additional nesting and sealing zones, with the two devices attached to this post.