EP3510211A1

EP3510211A1 - Method for assembling building elements and building thus produced

Info

Publication number: EP3510211A1
Application number: EP17768837.1A
Authority: EP
Inventors: Willem Arnold Van Willigen
Original assignee: Individual
Current assignee: Individual
Priority date: 2016-09-06
Filing date: 2017-08-28
Publication date: 2019-07-17
Anticipated expiration: 2037-08-28
Also published as: FR3055638B1; EP3510211B1; WO2018046819A1; CA3035826C; CA3035826A1; FR3055638A1; US20190203468A1

Abstract

The method for assembling a collection of building elements (1) comprises at least the following steps: –a) assembling, by bonding, two complementary external faces of two building elements (1), –b) continuing with the assembly performed in step a) by bonding other faces of the said elements (1) to complementary external faces of other building elements (1) until a predefined part of a building or of an engineering structure is obtained, –c) bonding sheets (15, 16), referred to as resetting sheets, made from a wood-based material, onto at least part of the coplanar faces of the elements (1) assembled in the preceding steps, –d) repeating steps a) to c) until the part is obtained. The invention also relates to a building produced with at least three elements assembled according to the method of the invention.

Description

METHOD FOR ASSEMBLING BUILDING ELEMENTS AND

CONSTRUCTION SO REALIZED

The present invention relates to a method of assembling building elements and a construction thus produced.

The invention relates to any type of construction, public, private, commercial, industrial, agricultural or other, regardless of the size of the construction. By construction, also designates works of art, such as bridges, bridges, canopies, retaining walls or others.

In the field of construction, it is known to use standard elements of the brick or block type, to produce the constituent walls of a building. These elements are fixed together by a binder such as mortar. Such a construction method is long and complex. In recent years, the construction of buildings has been developing using wood as the basic material. Typically, such buildings, with a so-called wood frame structure, include prefabricated wooden panels which are mounted on a framework, preferably wood.

This solution involves a custom and factory completion of wooden panels, depending on the architecture of the building to be produced, only the assembly of the building being carried out in situ. Moreover, because of the way in which the panels are connected using metal elements such as connectors or screws, the presence of thermal bridges in such buildings is observed. However, due to the introduction of relatively restrictive environmental standards and the obligation to build buildings with optimized insulation and low environmental impact, the search for new construction methods is necessary.

EP-A-861 587 discloses a wooden box containing a body of insulating material, for example polyurethane foam. It is known from WO-A-85/04922, previously filed by the applicant, a plate-shaped member formed of a polystyrene core bonded between two layers of plywood. Cutouts made in one of the plywood faces allow, if necessary, to bend the plate. WO-A-90/00474 discloses a core comprising two materials, including a transition, on which are glued plywood plates. The element thus manufactured has a shape adapted to its use, for example corner, cylinder or plate. These solutions require the realization of elements specific to each building, while being difficult to implement. Also known from FR-A-2952659 wooden building elements, shaped brick, filled with an insulating material. These elements are connected to each other by voltage elements, of the male-female type and by metal rods ensuring the tensioning of the elements stacked on the height of the walls. Such a solution is complex to achieve and does not eliminate thermal bridges. Also known from WO-A-2010/047570 are brick-shaped elements provided with a double wall of wood and whose interior is filled with an insulating material. The connection between these elements is of the mortise tenon type.

These different solutions, if they offer an advantage over traditional concrete or stone constructions, are not easy to implement. Indeed, the elements require either a carrier structure or connecting elements, generally metallic, between the elements, which de facto generates thermal bridges. In addition, in the case of construction using wood, the presence of such thermal bridges promote the spread of fire. In addition, the elements do not make it possible to realize all the architectural types of building by optimizing the insulation and the distribution of the loads, at a cost and with constraints of manufacturing mastered.

That being said, the invention aims to overcome the disadvantages of the prior art mentioned above.

To this end, the subject of the invention is a method of assembling a set of construction elements whose outer walls of each element define a receiving volume of a main body, in the form of a polyhedron, occupying the together said receiving volume and of which at least two faces are parallel, the main body being made of a rigid insulating material formed by expanded polystyrene or EPS having a density of at least 1 Qkg / m3 and each of the faces of the main body being completely covered by at least one sheet made of a material based on wood, each sheet being pressed onto said face of the main body which receives it, characterized in that it comprises at least the following steps:

-a) assembling by gluing two complementary external faces of two construction elements,

b) continuing the assembly carried out in step a) by bonding other faces of said elements with complementary external faces of other building elements until a part of a building or structure is obtained predefined art,

~ c) sticking sheets, called reset, made of a wood-based material, on at least a portion of the coplanar faces of the elements assembled in the previous steps,

-d) repeat steps a) to c) until the part of the building or predefined structure is obtained.

The invention thus achieves the objectives mentioned above. Indeed, several geometric shapes of the main body, therefore the element, all polyhedral, are easily achievable to meet the architectural needs to achieve a building or component of this building such as a beam or a wall or a book art.

Thanks to the invention, simple or complex shapes of the element are produced, provided that its main body has at least two parallel faces and this without a thermal bridge since no metallic material is used to produce the elements and to assemble them. The use only of insulating material and wood-based sheets bonded to this material guarantees the absence of thermal bridge at least without harming, if not reinforcing, the mechanical strength of the element and therefore, de facto, preserving or improving the mechanical strength of the part of the building or building constructed of such elements. The realization of the construction by gluing makes it possible to preserve this absence of thermal bridge while ensuring a distribution of the loads on the whole of the construction. This gives a self-supporting construction with optimal load distribution, which allows varied shapes and / or high heights. According to advantageous but non-obligatory aspects of the invention, such a method may comprise one or more of the following steps:

after step d), during an additional step e), a sheet of protective and / or decorative coating is bonded to at least one of the faces of the part of the building or structure of realized art.

- In step c), the reset sheets are glued on the coplanar faces of the assembled elements so that the connecting joints between two assembled elements are never aligned with the connecting joints of two abolished reset sheets.

- Each wood-based sheet is a sheet, at least 5 mm thick, strips of wood called Oriented Strand Board (OSB) or plywood.

- At least one gutter is formed in the main body of at least one element, the gutter defining a passage for conduits and ducts.

The invention also relates to a building or structure of which at least a part is made with at least three construction elements assembled according to the assembly method according to the invention characterized in that said elements are assembled so as to defining a honeycomb structure with solid cells, the outer walls of the honeycomb structure being defined by the resetting sheets.

The invention will be better understood and other advantages thereof will appear more clearly on reading the description of several embodiments of the invention which will follow, given solely by way of nonlimiting example and made with reference. in the accompanying drawings in which:

FIG. 1 is a view from above of a construction element according to an embodiment of the invention, a face being devoid of a sheet for visualizing the interior,

FIG. 2 is a view of the element of FIG. 1, in pre-assembly configuration, FIG. 3 illustrates, in a pre-assembly configuration, the embodiment of a part of a building with elements of FIG.

FIG. 4 is a schematic view of a flat wall of a building made with elements of FIG. 1, on another scale, illustrating the honeycomb configuration of this wall, the rearming sheets being illustrated, front, dotted for more readability.

FIG. 5 is a simplified perspective view of a wall of a building in progress with elements of FIG. 1,

FIGS. 6 and 7 illustrate, on the same scale, elements conforming to two other embodiments of the invention,

FIGS. 8 and 9 represent, at the same scale, wall portions of buildings respectively configured in an arc and a dome, made with elements respectively having two or four inclined faces and in accordance with two other embodiments of the invention; 'invention,

FIG. 10 illustrates, on another scale and in pre-assembly configuration, the embodiment of a part of a beam-type building, using elements of FIG. 1, according to another embodiment of the invention and

- Figure 1 1 is a perspective view, on another scale, of two beams of Figure 10 assembled at right angles.

Figure 1 illustrates a construction element 1 according to one embodiment of the invention. The element 1 is formed of a main body 2, partially visible in Figure 1. The body 2 occupies the receiving volume defined by the constituent walls of the outer faces of each element 1. Thus, each element 1 has a geometric shape corresponding to that of the body 2 that it receives.

The body 2 is made of a rigid insulating material. Here, the term insulation should be understood as relating to, at least, thermal insulation, it being understood that such a material may also have sound insulation characteristics. The insulating material is chosen by materials of plant origin, mineral or synthetic that is to say derived from petroleum. It must be rigid, insensitive to environmental conditions, especially stable dimensionally in a range of temperatures ranging typically from -80 ° C to + 80 ° C. H must also have a shear strength of at least 40 KPa and preferably close to 50 KPa. I! It is generally accepted that, at least for a rigid material, there is a relationship between its density and its mechanical strength: the higher the density of the material and the higher its mechanical strength. In the context of the invention, the minimum density is close to 10 Kg / m 3, preferably between 15 Kg / m 3 and 25 Kg / m 3, advantageously close to 18 Kg / m 3.

Thus, in the context of the invention the preferred material for forming the body 2 is, but not exclusively, expanded polystyrene or EPS. This material also offers the advantage of being easy to produce in large quantities, at a low cost, to be recyclable and easy to work. In other words, from a block of polystyrene, it is possible to realize any geometric shape. The body 2 defines not only the geometric shape of the finished element 1 but also, overall, its size and weight. Indeed, each of the different faces of the body 2 is covered over its entire surface by at least one sheet of a material based on wood.

Such a sheet must be substantially watertight and dustproof, fireproof, protect the block of polystyrene against any effect of punching or tearing. In other words, such a sheet must have a tensile strength perpendicular to its surface of at least 0.3 Newton / mm 2. In addition, such a sheet should not alter the insulation characteristics, at least thermal insulation, of the main body, and therefore do not create a thermal bridge. As a result, such a sheet is for example made of plywood, in the medium or, in a preferred embodiment, in OSB (Oriented Strand Board), that is to say in a sheet formed of strips of wood bonded together by a resin, with cross-layer orientation.

FIG. 2 illustrates such sheets in pre-assembly configuration on the faces of the body 2. Each sheet 3 to 8, here of OSB, has dimensions complementary in length and width to those respectively of the faces 9 to 14 who will receive them. The different sheets 3 to 8 here have the same thickness. This is at least 5 mm to ensure a certain rigidity to the sheet and generally between 10 mm and 40 mm. Advantageously, the preferred thickness is 10 mm.

In all cases, each sheet 3 to 8 covers, once in place on the body 2, the entire face 9 to 14 on which it is bonded. It is necessary that no part of the body 2 is visible on a finished element 1. To ensure a permanent fixation between the sheets 3 to 8 and the body 2, with regular contact between the sheet 3 to 8 and the face 9 to 14, this over the entire surface of the contact zone, so from the face 9 to 14, an adhesive is used. It is a glue chosen from structural glues based on polyurethane, epoxy, vinyl or others as long as such a glue offers impact resistance, thus shear strength of at least 10 MPa and, in this case, species, close to 16MPa.

We thus obtain a construction element 1 which is sandwich composite type. In such a type of element, a synergistic effect is associated with materials that individually have structural weaknesses. Thus, the sheets 3 to 8 are particularly resistant to bending, tearing and compression while the body 2 is remarkably resistant to shearing. Element 1 combines, with a synergetic effect, these different characteristics.

Elements 1 which have high insulation and mechanical strength characteristics are thus obtained, for elements 1 which, preferably in the case of rectangle regular polyhedra, as illustrated in FIGS. 1 to 3, are 2.50 m in length. long for a section of 0.40 m by 0.40 m. Such dimensions allow the installation of walls or part of a structure or buildings quickly, with few elements while offering optimal mechanical and insulation characteristics.

Figure 3 illustrates the assembly of several elements 1 together. Such a configuration is, for example, for mounting walls of high thickness, structural elements of beam type or pylons. In FIG. 3, twelve identical elements 1 are united, by gluing, in two rows of three pairs of elements 1. Thus, each element 1 is glued to three other elements 1 neighbors. For this, the visible faces of the sheets 3 to 8 of each element are glued to the visible faces 3 to 8 of the other neighboring elements. Visible faces denote the faces of the sheets 3 to 8 which are not bonded to the body 2.

Two sheets 15, 16 similar to the sheets 3 to 8, as regards the constituent material, are shown in the pre-assembly position. These sheets 15, 16 are called reset. It is understood that these sheets have dimensions adapted to cover, at least in part, the twelve elements 1 thus assembled. Here, for greater clarity, only two sheets are illustrated, it being understood that, in some embodiments, only some of the faces of the joined elements are covered by a sheet made of a wood-based material. In other embodiments, all the visible faces of the assembled elements are covered by sheets similar to the sheets 15, 16. In this case, six sheets must be provided to cover all the visible faces of the twelve assembled elements 1, including the end faces. In a variant, the sheets used are of a different nature.

The presence of additional sheets 15, 16 in a wood-based material, here the same as that comprising the sheets 3 to 8, and therefore in OSB, bonded to the assembled elements 1 ensure rearming of all the elements 1. From in this way, a second overlap of the main bodies of the elements, always by gluing, which reinforces the mechanical strength of the assembled elements.

The de facto presence of a double thickness on at least some of the faces of the elements assembled to form a part of a building contribute to the optimization of the insulation characteristics of the building parts thus produced. Furthermore, the bonding of these two sheets 3 to 8 and 15, 16 induces a rolling effect, namely a synergy that induces a mechanical strength of the set of two sheets greater than the sum of the unitary mechanical strengths of the two sheets. In any case, in order to preserve the evoked synergy and the insulation characteristics, the rearming sheets 15, 16 are glued and abutted so that the connecting joints between the sheets 15, 16 are never aligned with the connection joints between two assembled elements 1.

FIG. 4 illustrates an assembly of sixteen elements 1 for producing a wall P whose width corresponds substantially to that, unitary, of the elements 1. The planes of joints between the elements 1, therefore the bonding zones, are represented in bold, for more readability. It can be seen that when several rearming sheets 15, 16 are abutted and glued to each face 17, 18 of the wall P in order to completely cover the faces 17, 18, a wall P is obtained whose internal structure is formed of several blocks. solid, here the elements 1 bonded together, de facto defining a honeycomb structure whose cells are solid, the outer walls of the structure being formed by the rearming sheets 15, 16.

It is conceivable that, alternatively, these sheets may themselves be covered with another material, for example tiles, a coated type coating, paint or a cladding sheet fiber cement or metal. Figure 5 illustrates, in a simplified manner, a wall portion M which comprises elements 1 stacked and glued together. A reset sheet 20 is glued on the face 19 of the wall M intended to be oriented towards the outside of the finished building. On this sheet 20, a plate of an outer coating 21 is glued, to protect the sheet 20 external aggression while participating in the mechanical properties of the wall M and its aesthetics. Advantageously, the plate 21 is bonded offset from the sheet 20 so that the respective bonding joints between the abutting plates 21 and the abutting sheets 20 are not aligned. It is noted that the first element 1, located at the bottom of the wall M, rests on a floating slab 22. Between this slab 22 and the ground, a sealing barrier, not shown, is provided to prevent any rise in moisture.

It is noted that a wall M, and more generally a building, thus produced, has a mode of construction combining, with a synergistic effect, the advantages of a laminated wall by bonding wood-based panels with those of a structure of solid honeycomb walls. Indeed, a wall made by rolling has a high mechanical strength. A wall having a structure honeycomb has significant resistance to bending and deformation. Thus, with the implementation of the elements 1 seion the method of 1'invention, one obtains, in addition to the previously indicated effects, a sandwich effect at each element 1. The latter has a mechanical strength greater than the sum of the unit resistances of the body 2 and sheets 3 to 8. Thus, a part of a building, a building or a work of art made according to the invention combines all the advantages mentioned.

Furthermore, in addition to the absence of any thermal bridge in the construction, conlrevenlement is achieved, along three axes. Indeed, as is apparent from Figures 3 and 4 a part of a wall, or more generally a part of the construction, is formed by several connected elements, each at least two and preferably three other elements. In this way, each element forms a bracing for the elements to which it is connected. The assembly is also rearmed by a sheet 15, 16, 20. Such a construction method allows to distribute the loads, no longer on pillars upright and some so-called bearing walls but on the entire periphery of the building. In this way, a building or a structure of art meets the requirements in earthquake-proofing, while allowing the construction of multi-storey buildings or high engineering structures.

The following figures illustrate other embodiments of the invention and its implementation. FIG. 6 illustrates an element 100, globally in the shape of a rectangle polyhedron such as element 1, but in which gutters 23, 24 have been made in order to allow the passage of ducts and technical ducts. These channels 23, 24 are made in the main body of the element 100, so in the EPS and then, similarly to the element 1, are covered with OSB sheets.

FIG. 7 represents an element 200 in the form of a curved rectangle polyhedron.

Such a form of elements 200 makes it possible to produce curved wall parts, for example a curved wall or a balcony.

It is understood that the examples of Figures 6 and 7 are not limiting, many geometric shapes being achievable through the ease of machining of the constituent materials of the elements. Figure 8 illustrates a wall portion S formed of several elements 300 having two non-parallel faces, the other faces being parallel. In this case the shape of the elements 300 is frustoconical, which makes it possible, as is apparent from FIG. 8, to produce walls constituting towers or silos, or more generally walls in an arc or a vault, depending on the position final occupied in the work by the elements 300 assembled.

Figure 9 illustrates a wall portion D constituting a dome, here, the elements 400 have four non-parallel faces. In other words, they are configured globally at the corner. Of course, whether in Figure 8 or 9, the elements 300 and 400 are formed of a main body EPS covered on all sides by an OSB sheet. The elements 300, 400 are glued together before being covered by at least one reset sheet.

FIG. 10 illustrates the production of a carrier member O, such as a beam with elements 1. Thirty-eight elements 1 form here the beam O, the latter being in the form of a rectangular section polyhedron. The thirty-eight elements 1 are divided into three stacked rows. Rectangular OSB sheets 25 to 28B provide reset, and define the four faces of the member O. The central row R is devoid of element 1 in the central part, thus providing a passage for a pipe or a technical sheath . In other words, the row R here comprises eight elements, the two rows above and below the row R comprising in turn fifteen elements each. Each row is separated from the adjacent row, thus located below and / or above, by an internal rearming sheet 28A, 28B. An internal and external rearmament of the beam O is thus achieved by the sheets 25 to 28B, which contributes to the production of a honeycomb structure. In a variant, there are also fifteen elements 1 to form the row. R, the beam O being then full.

It is conceivable that the central passage made in the row R continues along the entire length of the beam O between the two ends. Of course, alternatively, the number of elements per row is different Such a member can be used as a pylon, carrier pole or lintel in different types of buildings and structures. FIG. 11 represents another embodiment of two members T, similar to the member O of FIG. 10 in their individual embodiment, here two members T are provided, in addition to the axial passage according to the length of each member T, as in the member O, of a transverse passage, substantially at half length of each member T. Such a configuration makes it possible to associate together two members T at right angles, so as to preserve the outlets of ends at the central passages of the two organs when they are glued together at right angles.

In other non-illustrated embodiments, the carrier members are H-shaped, tubes, or the like.

For the construction of a building, with or without floors, the shape and the number of elements necessary for the construction are defined beforehand by layout. The elements are assembled at the factory, routed on site and assembled on site, by gluing to form first parts of building which, connected together, constitute the building. It should be noted that, with elements according to the invention, the frames, roofs, terraces and floors are formed by the only assembled elements. Similarly, such a building is devoid of lintel. The latter are no longer necessary, the openings being delimited by the absence of elements in certain areas of the walls.

In order to facilitate the identification and thus the assembly of the elements, they are provided with a marking allowing their identification. Advantageously, it is a bar code. Alternatively, other marking means may be used, associated or not with the bar code, for example a color code. Insofar as the main body of each element, taken separately, has a high shear strength and between each main body there is a rigid zone formed by the bonding of at least two sheets of high strength material to the traction, we obtain a wall, vertical or not, or part of the building or structure, which behaves like a honeycomb structure with solid cells. De facto, the building or the structure as a whole also behaves like a honeycomb structure. This gives a homogeneous behavior of the whole building. In particular, the phenomena of diiatation are made on the whole building or the work of art, and not individually on this or that part of the building. In other words, in the case of a multi-storey building, each floor is itself structural. Such behavior of the building allows it to form a seismic construction.

Alternatively, it is possible to deliver separately the main body and the sheets that cover it, the bonding of these components to make an element being made in situ. In another embodiment, the sheets are preassembled, for example in the form of folded boxes. They are shipped with a minimum footprint in this form, for example by container. On site, or near the latter, the main body is shaped, introduced into the volume defined between the sheets in unfolded and glued configuration. Such a solution makes it possible to transport on site the elements with a minimum of transport constraints. The main body in EPS is made on site, for example from recycled polystyrene. Such a solution is particularly interesting for the construction of buildings or engineering structures in hard-to-reach areas and / or limited industrial infrastructures.

Claims

1. - A method of assembling a set of building elements (1; 100; 200; 300; 400) whose outer walls (3 to 8) of each element (1; 100; 200; 300; 400); define a reception volume of a main body (2), in the form of a polyhedron, occupying the whole of said reception volume and of which at least two faces (9 to 14) are parallel, the main body (2) being made of a rigid insulating material formed by expanded polystyrene or EPS having a density of at least 10 kg / m 3 and each of the faces (9 to 14) of the main body (2) being completely covered by at least one sheet (3 to 8, 15, 16; 20; 25 to 28B) made of a wood-based material, each sheet (3 to 8) being adhered to said face (9 to 14) of the main body (2) which receives it, characterized in that it includes at least the following steps:

-a) bonding two complementary external faces (3 to 8) of two construction elements (1; 100; 200; 300; 400);

b) continue the assembly carried out in step a) by gluing other faces (3 to

8) of said elements (1; 100; 200; 300; 400) with external faces (3 to 8) complementary to other construction elements (1; 100; 200; 300; 400) until a part is obtained; (P, M, S, D, O, T) of a predefined building or structure,

c) resurfacing sheets (15, 16; 20; 25 to 28B) made of a wood-based material on at least a portion of the co-planar faces (3 to 8; 17, 18; 19); elements (1; 100; 200; 300; 400) assembled in the preceding steps;

-d) repeat steps a) to c) until you obtain the part (P, M, S, D, O, T) of the building or the predefined structure.

2. - Method according to claim 1, characterized in that after step d), during an additional step e), a sheet (21) is glued with a protective and / or decorative coating on the at least one of the faces (20) of the portion (M) of the building or structure constructed.

3. A process according to claim 1, characterized in that, in step c), the rearming sheets (15, 16; 20; 25 to 28B) are jointed on the copial faces (3 to 8; 17; 18; 19) of the elements (1; 100; 200; 300; 400) assembled so that the joints The connection between two assembled elements (1; 100; 200; 300; 400) is never aligned with the connecting joints of two abutting resurfacing sheets (15,16; 20; 25-28).

4. - Process according to claim 1, characterized in that each sheet (3 to 8, 15, 16; 20; 25 to 28B) based on wood is a sheet, at least 5 mm thick, of lamellae OSB (Oriented Strand Board) or plywood.

5. - Method according to claim 1, characterized in that at least one gutter (23, 24) is formed in the main body of at least one element (100), the gutter defining a passage for ducts and ducts techniques.

6. - Building or structure of which at least a part (P; M; S; D; O; T) is made with at least three building elements (1; 100; 200; 300; 400) assembled according to the assembly method according to one of claims 1 to 5, characterized in that said elements (1; 100; 200; 300; 400) are assembled so as to define a honeycomb structure with solid cells (1; 100 200, 300, 400), the outer walls of the honeycomb structure being defined by the resetting sheets (15, 16; 20; 25 to 28B).