FR2852041A1 - A integrated sandwich roofing panel providing a one piece roof and ceiling for houses and extensions comprising an outer layer resembling tiles or slates, an insulating core, a stiffening panel and interior decorative panel - Google Patents

Abstract

A sandwich roofing panel for private houses or extensions comprising a rigid exterior facing resembling tiles or slates, a thermal and sound insulating core, a stiffening composite or metallic facing and a decorative underface in plaster, panelling etc. The panel allows the application of a complete roof in one operation, giving weather tightness and thermal and sound insulation (with the possibility of integrating heating) and a decorative ceiling.

Description

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  The invention relates to sandwich panels used for making roofs, for example roofs for single-family homes or residential extensions.

  When such a panel constitutes a roof, there are several techniques to allow exterior insulation of roofs in new construction or in renovation, allowing to have a continuous insulation which gives better thermal performances and which also makes it possible to minimize the thermal bridges. This exterior insulation allows any type of roofing, from traditional flat mechanical tiles, channel to slate.

  One of the techniques for making roofing panels is to install one-piece panels (of the Rexotoit type from Unilin or Roofmate TGX from DOW) on the rafters, which consist of a decorative underside 15 (plaster, paneling , ...) for the interior covering of the ramps, and an insulating foam of an organic product, of polyurethane, expanded or extruded polystyrene type, etc. This insulating material can be coated with a particle facing often water repellent in order to balance the sandwich panel.

  A second technique of the sarking type allows the entrepreneur 20 to make the sandwich himself but with a constraint of implementation in several stages and the need to manage different materials (the purchase, the cutting of the interior facing, of the wall -vapor, insulation, ...).

  Other methods make it possible in certain cases to simplify the frame, bypassing the rafters, to save time and to leave the purlins in visible beams.

  This third technique consists of placing load-bearing and insulating panels on the panes (of the Pannotec or Efilate from Efisol, Trilatte from Unilin, Fibratec or Fibralatte from Knauf, Béocanal from Béopan, Soutuisol d'Eternit) types. This operating mode allows these load-bearing and insulating panels to be deposited on the panes in the direction of the ramp in a single operation, and allows to isolate and decorate without encroaching on the habitable interior volume.

  These panels are much more rigid thanks to the use of a thicker underside or by the rafting of the panels called seasoned boxes. The latter technique requires closer breakdowns. 35 These panels are characterized by their thermal resistance according to the thickness of the insulating core, the nature of the under, decorative face s- '(plaster, paneling, etc.) and the span, that is to say say the maximum admissible length between purlins.

  For all these techniques and these different types of panels relating thereto, for the constitution of the roof of an individual house or 5 of residential extension, and to secure the cover, it is first of all advisable to carry out a bedding or a counter bedding intended to support the tiles or slates, or either to install a plate whose ribs allow the direct laying of the channel tiles (Eternit, Onduline, ...). As a last step, it is then possible to lay the flat, channel or slate tiles by gluing, sealing or by mechanical fixing (hook, etc.).

  Thus all these techniques have a constraint of implementation in several stages, from the installation of the sandwich panels arranged on the rafters or the purlins, the liteaunage or the counter-liteaunage, the laying of the cover with traditional mechanical tiles plates, canal or 15 slates, as well as the need to manage these different materials (purchasing and cutting). In addition, most of these panels do not meet the new acoustic regulations (NRA) because it is used inside the panels, rigid insulating foams which have a resonant behavior towards sound waves.

  The object of the present invention is to remedy these drawbacks by considerably reducing the various stages of implementation, without this modifying the other functions of the sandwich panel, namely thermal insulation, aesthetics, sealing, resistance. mechanical, reliability, while providing better performance for sound insulation (Rw).

  This invention makes it possible to obtain a finished roof in a single laying step while having the functions of: - exterior decoration of the roof with a composite facing with geometric shape and with the same colors as the traditional tiles or slates, - thermal and sound insulation, sealing - even greater range (from 5 to 6m) with, depending on the case, the elimination of intermediate breakdowns, with participation in the bracing - interior decoration with a decorative underside (plaster, paneling, ...).

  This invention also makes it possible to offer roofing panels in a single part, monolithic, making it possible to ensure stormproof performance of the panel and total sealing with respect to traditional roofs.

  Indeed the traditional tiles or slates put in place by gluing, 5 sealing or by mechanical fixing, can be damaged during their lifetime, with respect to the external environment (sun, rain, snow, wind) or take off during a storm, and thus generate water entries when they are removed, or by cracks, or by breakages following thermal or mechanical shocks.

  These single-part, monolithic roofing panels also make it possible, by this invention, to provide an effective barrier to all insects or rodents likely to come to lodge in these roofs compared to traditional roofs even if they use sandwich panels.

  This invention of a new concept of load-bearing and insulating panel can also be completed by the integration of another innovation in order to allow the obtaining of a heating panel for the roof of a single-family house or of a residential extension. The heating function is obtained from a film 20 of a few tenths of a millimeter through which a current flows, and by Joule effect generates the temperature rise and emits its energy in the form of electromagnetic waves (short infrared). This technique uses a natural phenomenon, radiation, which is that emitted by the sun to heat the earth.

  The various current technologies make it possible to obtain heating cassettes of small dimensions (600x2400mm or 1800x1O00mm) often reported under the ceiling, with a constraint of implementation in several stages and the need to manage different materials (installation of hangers, removal of glass or rock wool, installation of the 30 heating films and then of the decorative undercoat). These radiant heating sub-ceilings are currently marketed under the Knauf sigma ranges from KNAUF, Placowatt from BPB Placo. There are other types of glued heating cassettes of 600x600mm which are also suspended and are marketed by the company SERTIM. This additional innovative character of this technology is to be able to produce heating panels for the roof of a single house or a residential extension by eliminating the creation of a sub-ceiling and to make it possible to have very large heating panels up to several meters away.

  This type of heating panel makes it possible to have radiant heating of the home with all the advantages that radiant heating provides on comfort as well as on energy savings. Advantageously, the heating film is positioned between the stiffening facing and the decorative underside (plaster, paneling, etc.), in order to offer the best heating efficiency and to allow thermal protection of the insulating core.

  To this end, the integrated composite panel according to the invention comprises the rigid exterior composite facing representing not only the geometric shapes of the flat tiles, channel or slate type but also their colors; the insulating and phonic core made of insulating and elastically deformable material based on graphite carbon in order to absorb the differences in flatness of the external facing representing the tiles; a stiffening facing to ensure the mechanical strength and give out the carrier sandwich panel; and a decorative underside (plaster, paneling, ...).

  With this arrangement, when under the action of mechanical loading according to the type of region (rain, snow, wind), it is necessary to obtain a certain rigidity of the panel, this is determined by the nature of the composite exterior facing constituted a reinforcement (fiberglass in mat, rowing or fabric, or any other fibrous reinforcing material) and an organic matrix (polyester resin, epoxy, etc.) to protect, transmit the stresses to these reinforcements .

  This composite exterior facing is balanced by a metallic or composite stiffening facing, sandwiching the insulating and sound core.

  The balance and rigidity of the panel, of the sandwich structure (its moment of inertia) will be determined according to the Young's moduli of the materials used and their thickness.

  - The thermal insulating nature of the layer of elastically deformable material based on carbon graphite between the rigid composite exterior facing 25 representing the geometric shapes of the tiles or slates and the stiffening facing, avoids the transmission of calories but also also greatly reduces the transmission sound waves.

  Advantageously, the material of the thermal and sound insulation layer is chosen from the following materials: elastified polystyrene foam based on graphite carbon, elasticized polyurethane foam or plastic, polyvinyl chloride foam elasticized or plastic, polyethylene foam plastic or any other flexible and deformable organic or mineral core such as rock wool, etc. The characteristics of flexibility and deformability in the vertical axis (z) must be determined in order to ensure on the one hand l absorption of variations in the flatness of the exterior facing representing the geometric shapes of the flat tiles, channel or slate type, and on the other hand make it possible to ensure a certain rigidity in the two other transverse axes (x, y) of the sandwich panel.

  It is possible to use different methods of manufacturing the sandwich panel. It can be used bonding technology with polyurethane, epoxy, acrylic, cyanoacrylate, neoprene, hot melt, etc. adhesives.

  but also other assembly technologies of mechanical or chemical type. The chemical assembly technology offers a wide range of processes such as the injection of foam, of polyurethane type or other organic or mineral materials, injected between the rigid exterior facing 10 composite representing the geometric shapes of the tiles and the stiffening facing. The constitution of the thermal and sound insulation layer injected, conforms to the shape of the exterior facing during the expansion of the foam in order to completely fill the cavities of the panel, but also participates in the bonding of the various constituent materials such as 15 composite rigid exterior facing representing the geometric shapes of the tiles and the stiffening facing. For the injection process, it is not necessary to have a certain elasticity of the core.

  In one embodiment of the invention, a layer of the material of the exterior facing may have the appearance of a flat mechanical tile, channel 20 or slate. This geometrical shape will have required, if necessary, a precut on the insulating core to the average shape of the tile or slate.

  This configuration of the insulating core to the shape of the tile and to its quality of being elastically deformable allows during the manufacture of the panel, an absorption of the geometric shapes of the tiles and above all an absorption of the level differences of several millimeters, linked to the aesthetic aspect of the tiles and more particularly to the representation of the junctions, of the interfaces between the mechanical, flat, canaIs or slate tiles.

  The invention will be better understood with the aid of the description, given with reference to the appended schematic drawings showing, by way of examples, several embodiments of the panel according to the invention.

  FIGS. 2,3 and 4 are side elevation views of a panel 5 constituting the roof of a house and illustrating the aesthetic appearance of the composite exterior facing representing the shapes of flat or channel tiles or also of slate type, and the elasticated insulating core allowing the different geometry of the exterior facing to be absorbed, as well as the stiffening facing and the decorative underside (plaster, paneling, etc.) FIGS. 1 is a partial view in cross section of this panel, each of the components of the panel being spaced from the juxtaposed components. f Figure 2 is a side elevation view of a panel constituting the roof, where there is shown a system for joining the insulating core between two panels with a rounded interlocking principle (6) or by an angular interlocking (7). This last angular fitting (7) is most generally used because it allows a fitting of the upper panel in the vertical axis.

  Figure 3 is a side elevational view of several panels 20 constituting the roof, where there is shown the junction of the panels together when mounting the roof by an angular interlocking. The composite exterior facings of a certain geometric shape will also provide overlap between two collateral panels (8) and (9) to allow ensuring a very good seal, for example; when the sandwich panel is formed with an exterior facing in the form of a flat or channel tile, there will be a row of tiles which will cover the collateral panel.

  Figure 4 is a side elevation view of a panel constituting the roof resting on the ridge beam (11) and on the sandpit (10).

  In the embodiment represented in FIG. 1, the sandwich panel is composed of an elasticized insulating core (2), disposed between two rigid facings, namely an external composite facing (1) representing the appearance, the shape and the color of the traditional tile and a stiffening facing (3). The stiffening facing is separated from the rigid outer facing (1) by a layer (2) forming a thermoacoustic distender made of an elastically deformable insulating material and with acoustic performance, having an elongation index without breaking greater than 6%. , and / or a Young's modulus less than 2000 mega Pascal.

  By way of example, a sandwich panel intended for the production of a house or residential extension roof shown in FIG. 1 is composed of the following elements: - composite exterior facing (1) representing the traditional flat tiles, mechanical, channel, or slate, consisting of a fiberglass reinforcement in mat or fabric, or any other fibrous reinforcing material and an organic matrix (polyester resin, epoxy,

  .). This resin should have 10 high UV resistance performance, greater than 10 years. It is recommended to use a thicker gelcoat, for example of the isophthalic polyester type (class 8 or higher) or any other organic material in order to guarantee the resistance over time and more particularly to UV of the composite facing ... DTD : - elasticized insulating core for absorbing geometric deformations (2) in the vertical axis (z) and greater rigidity in the other two transverse axes (x, y), the insulating core is made of elasticized polystyrene foam, based on graphite carbon and marketed under the name "Maxissimo" by BPB Placo from 80 to 160 millimeters or more, resulting from the transformation of unexpanded beads based on polystyrene and graphite carbon of the product marketed under the brand NEOPOR of BASF or other chemical groups such as BP or Nova marketing graphite carbon-based polystyrene beads, the elasticity being obtained only in the vertical axis (z); or else an elasticized or injected polyurethane foam, elasticized polyvinyl chloride foam or plastic, plastic polyethylene foam or any other flexible and deformable organic or inorganic core - stiffening facing (3) composite produced with mechanical fiber-fiber reinforcement glass, or mineral, or organic and of an organic matrix in polyester resin, epoxy or other organic resin from 1 to millimeters, this stiffening facing (3) can also be metallic made of steel or aluminum from 0.5 to 2 millimeters , interior decorative underside (4) consisting of plaster, paneling, or any other decorative panel having a thickness between 5 and 13 35 millimeters - Heating film (5) consisting of two polyester films or of another electrically organic material insulator, in which conductive aluminum strips or other electrically conductive material are positioned, taken in s andwich between polyester films. The heating film is sold by the companies ILO technology, ACSO, HORA, TRESCO, Sertim, Teval, Flexel .... The recommended power of the heating films is 135-140 W / m2 in order to give the best conditions of comfort and avoid overheating phenomena.

  Of course, the various layers of the panel are, in known manner, linked to each other by a layer of adhesive, the nature of which is adapted to the products to be assembled, except in the case of injection between the composite rigid exterior facing representing the geometric shapes of the tiles or slates and the stiffening facing.

  In this panel, the thermal and acoustic insulating core (2) and its respectively external (1) and stiffening (3) facings provide rigidity to the assembly, taking into account their thickness and their Young modulus so to have a balanced and almost isotropic structure. This dimensioning and the definition of the thicknesses are necessary in order to respond to external mechanical stresses.

  This layer can be combined with all the materials generally used to constitute a sandwich panel, namely: - for the exterior facing (1) representing the traditional flat, mechanical, channel or slate tiles, having a thickness of 25 to 0.5 20 millimeters or more, consisting of a composite with or without fiberglass reinforcement in mat or fabric, or any other fibrous reinforcing material, an organic matrix (polyester resin, epoxy, ...) and with or without isophthalic polyester gelcoat. This external facing (1) can also be made of another material with the geometric shape of tiles or slates made from a metal sheet of stamped steel or aluminum, polymeric material, such as a thermoformed thermoplastic or thermosetting material, or a mineral facing such as concrete, or a facing complexed and composed of different sub-sets of materials always representing the shape and color of traditional tiles or slates; - for the insulating core (2), having a thickness ranging from 80 to millimeters or more, consists of a polystyrene foam based on graphite carbon, elasticized in the vertical axis (z) and of higher rigidity in the 2 other transverse axes (x, y). It is obvious that the invention is not limited to this material given above by way of example. Indeed, this material can be replaced by an axial elasticated foam based on, polyurethane, vinyl chloride, polyethylene, or an elastomer and, in general, by any other organic material, flexible and elastic, having an index elongation greater than 6% and / or a Young's modulus less than 2000 mega Pascal in the vertical axis (z), but also capable of providing insulation. Rigid cores can also be used, such as metallic honeycombs, thermoplastic or composite honeycombs, rock wool or glass wool.

  as well as injected foams such as polyurethane foams. A variant of the foams injected to replace the flexible elasticated foams is to allow the complex shapes of the tiles to be filled and to use the adhesiveness performance of these 15 foams to catch on, stick to the exterior facings (1) and stiffening (3). On the other hand, this adhesiveness in general is not as efficient as the bonding technologies for elasticized foams ... DTD: - for the stiffening facing (3), made of a thermosetting or thermoplastic composite material produced with a mechanical reinforcement glass fiber, or mineral, or organic and an organic matrix of polyester resin, epoxy or other organic resin having a thickness between 0.3 and several millimeters. This stiffening facing (3) can also be metallic made of steel or aluminum of 0.5 to 2 millimeters or more but also with any other rigid material such as a mineral material such as concrete.

  In known manner, the material of the stiffening facing (3) is preferably of the same rigidity as that of the outer facing (1), in order to give a balanced structure to the sandwich panel formed by the elements (1), (2) , (3), (4), avoiding the twists of this structure. 30 Whatever the nature of the materials used, the addition to a sandwich panel composed of an insulating core (2) and an external facing (1) and a stiffening facing (3), further improves the capacities. acoustic absorption, since it gives the complex formed comprising a core of elasticized foam (2) a spring effect and the two facings (1) and (3) a mass function. In acoustics the mass / spring / mass functions are the best complexes for the acoustic gains for the phenomena of sound transmission.

  Whatever its embodiment, the sandwich panel 5 according to the invention improves the cost of obtaining the production of a single-family house roof by considerably reducing the different stages of implementation, allows greater speed of achievement, improves the comfort of the home by allowing continuous insulation, better thermal performance while minimizing thermal bridges. 10 This monolithic single-piece sandwich panel also ensures stormproof and total waterproofing performance with respect to traditional roofs, also ensures an effective barrier to all insects or rodents. This invention of a new concept of load-bearing and insulating panel also allows the possibility of incorporating a new function allowing the production of a heating panel.

  In another embodiment, the sandwich panel according to the invention can also be used for individual house walls where the rigid exterior composite facing representing the shapes of the tiles will in this case have a representation of the traditional brick, stone walls. , plaster, ..., and as for the inside face, it will always be a decorative under face in plaster, paneling, etc ...

Claims (6)

  1. Sandwich panel for the roof of a single-family house or of a residential extension, comprising the composite exterior rigid facing (1) 5 representing the shapes of flat, channel or slate-type tiles; a thermally insulating and phonic core (2) made of insulating and elastically deformable material in order to absorb the differences in flatness of the exterior composite facing and to give the acoustic performance; a composite or metallic stiffening facing (3) to provide mechanical strength and give the lift of the carrier sandwich panel; and a decorative subface (4) in plaster, paneling, etc.   2. Sandwich panel according to claim 1, characterized in that the panel makes it possible to obtain a finished roof in a single laying step while having the functions of exterior decoration of the roof with a composite facing with a geometric shape and with the colors of traditional tiles or slates, waterproofing, thermal and sound insulation, range, with the possibility of integrating heating, and interior decoration with a decorative underside (plaster, paneling, etc.).   3. Sandwich panel according to claim 1, characterized in that the material of the composite exterior facing (1) representing the shapes and colors of traditional tiles or slates, consists of a reinforcement (fiberglass in mat, rowing or fabric, or any other fibrous reinforcing material), an organic matrix (polyester resin, epoxy, etc.) and a gel-coat (or other organic material) to provide UV protection; this facing 25 will also provide an overlap between two panels (8) and (9) to allow ensuring a very good seal; the thickness of this composite facing and the type of reinforcement will be determined according to the desired rigidity of the panel.   4. Sandwich panel according to claim 1, characterized in that the material of the layer (2) of the insulating core, on the one hand has a certain vertical axial elasticity (z) in order to ensure the absorption of variations flatness of the exterior facing representing the shapes of flat tiles, channel or slate type, a spring function by its elasticity for performance in sound transmission with respect to the acoustic mass / spring / mass function, and on the other hand this insulating core will have a higher longitudinal rigidity in the two other transverse axes (x, y) to give the mechanical strength to the panel; the material of the layer (2) of the insulating core is chosen from the following elasticated materials: polystyrene foam based on graphite carbon, polyurethane foam, polyvinyl chloride, polyethylene, elastomeric material, mineral wool (wool rock, glass) or any other organic material, flexible and elastic, having an elongation index in the vertical axis (z) greater than 6% and / or a Young's modulus less than 2000 mega Pascal, but also suitable to provide thermal insulation; this insulating core (2) of 80 to 160 mm or more being implemented in the form of a machined block or by injection is taken between the composite exterior facing (1) representing the shapes and the 10 colors of the tiles and the stiffening facing (3) which provides the mechanical strength and gives the lift of the sandwich panel, moreover these injected foams do not necessarily require vertical axial elasticity (z).   S. Sandwich panel according to claim 1, characterized in that a stiffening facing (3) provides mechanical strength and gives the lift of the carrier sandwich panel, taking into account its thickness and its Young's modulus in order to '' have a balanced and almost isotropic structure with the composite exterior facing; this stiffening facing (3) consists of a fiberglass reinforcement, or mineral, or organic and an organic matrix in polyester resin, epoxy or other organic resin from 1 to 20 mm, this stiffening facing ( 3) can also be metallic made of steel or aluminum from 0.5 to 2 millimeters or more.   6. Sandwich panel according to claim 1, characterized in that a decorative underside (4) is constituted by a plasterboard, paneling, or with any other decorative material, is positioned against the stiffening facing.   7. Sandwich panel according to claim 1, characterized in that a heating function with a film (5) can be added between the stiffening facing (3) and the decorative underside (4), is constituted by a film of a few tenths of a millimeter with a complex of films of polyester or other electrically insulating organic material, and metal strips of aluminum or other electrically conductive material sandwiched between the polyester films.