FR2899259A1 - Sandwich panel for e.g. building field, has one roof element with roof plate and spacing unit for maintaining plate remote from insulant material layer for forming space deprived of insulant material between plate and layer - Google Patents

Abstract

The panel (100) has roof elements (110, 120) and a core formed of an insulant material layer (130) extending between the elements, where the elements are exposed to sunlight and protected from radiation, respectively. The element (110) has a roof plate (111) and a spacing unit (113) for maintaining the plate remote from the layer for forming a space (115) deprived of an insulant material between the plate and the layer, where the space is filled with air. An independent claim is also included for a method for fabricating a roof panel.

Description

The invention relates to the field of sandwich panels. These panels are

  used for many applications.

  They are used in particular in the field of building and construction, to form partitions, cladding, roofing or floors for example. These panels must be both insulating, resistant to aging, light and economical.

  The sandwich panels generally comprise two facing plates and a layer of insulating material extending between the two facing plates. Depending on the types of application for which they are intended, different structures of sandwich panels have already been proposed.

  When sandwich panels are used in applications that require good impact resistance, such as floor panels, the panels have a reinforced structure. For this purpose, they comprise thick facing plates or include a honeycomb structure disposed between the facing plates. These panels have the disadvantage of being relatively expensive. In particular, the manufacture of panels which include a honeycomb structure requires the bonding of the honeycomb structure on the facing plates by means of specific glues which are relatively expensive and which require a drying time which increases the manufacturing time of the panel. Some sandwich panels are used in outdoor applications where they are subject to climate action. Sandwich panels that include composite facing boards, such as polyvinyl chloride (PVC), are sensitive to thermal shock. Indeed, these thermal shocks cause a detachment of the facing plates of the layer of insulating material. To limit the risks of peeling or blistering of the facing plates, one solution is to make metal cladding plates.

  However, the metal facing plates have the disadvantage of being sensitive to corrosion, of having a significant weight which makes their handling difficult. In addition, in the case where the panel is cut, the fields of metal cladding plates must be treated.

  Another solution is to install protective structures near the panel to protect it. An object of the invention is to provide a sandwich panel having improved strength. This problem is solved in the context of the present invention by means of a sandwich panel comprising a facing element and a layer of insulating material, the facing element comprising a facing plate and spacing means able to hold the cladding plate. remotely facing the layer of insulating material so as to form a space free of insulating material between the facing plate and the layer of insulating material. Due to the presence of the space devoid of insulating material, the layer of insulating material is set back from the facing plate. The layer of insulating material is thus protected by the space separating it from the facing plate.

  In addition, the space devoid of insulating material provides a panel having improved thermal or acoustic insulation properties. The panel may advantageously have the following characteristics: the space formed between the facing plate and the layer of insulating material is filled with air, the facing plate and the spacing means are formed in one piece by extrusion the facing plate and the spacing means are formed by extrusion in a direction parallel to a plane in which the facing plate extends, the layer of insulating material is continuous, the layer of insulating material present, a microcellular structure, that is to say that the insulating material contains small cells regularly distributed in the material so that the material has the structure of a foam, the layer of insulating material is formed of expanded polymer, the cladding element comprises an intermediate plate extending between the cladding plate and the layer of insulating material, in contact with the layer of insulating material; The facing means comprises anchoring means 10 extending inside the layer of insulating material for fixing the facing plate to the layer of insulating material, the anchoring means comprise protrusions extending from the panel comprises connecting means for joining the panel to another similar panel, the connection means comprise a female member and a male member having a shape complementary to the female member so that that the female member is adapted to cooperate with a male member of an adjacent panel 20 - the facing plate comprises perforations capable of absorbing acoustic waves, - the facing element constitutes a first facing element and presents a first extrusion direction, the panel comprising a second facing member having a second extrusion direction, the first and second members being arranged relative to each other so that the first and second extrusion directions form a non-zero angle. The invention also relates to a method of manufacturing a facing panel, comprising the steps of: - forming a facing element comprising a facing plate and spacing means, - forming a layer of material insulation, the spacing means holding the layer of insulating material away from the facing plate so as to form a space free of insulating material between the facing plate and the layer of insulating material. Other features and advantages will become apparent from the description which follows, which is purely illustrative and non-limiting and should be read with reference to the appended figures, in which: FIG. 1 schematically represents a sandwich panel structure conforming to FIG. In a first embodiment of the invention - Figure 2 schematically shows a sandwich panel structure according to a second embodiment of the invention - Figure 3 schematically shows a sandwich panel structure according to the invention. In a third embodiment of the invention, FIG. 4 schematically shows a sandwich panel structure according to a fourth embodiment of the invention, FIG. 5 schematically shows a sandwich panel structure. comprising assembly means, FIG. 6 schematically shows a structure of Sandwich lamb with acoustic absorption ports; FIG. 7 schematically shows a sandwich panel structure comprising inserts for attaching equipment; FIG. 8 schematically shows a sandwich panel structure comprising anchoring means adapted to receive tubes or circulation ducts; FIG. 9 schematically shows a sandwich panel structure comprising anchoring means formed by assembly of modules; FIGS. 10 and 11 schematically represent a sandwich panel structure comprising two-piece anchoring means; - Figure 12 schematically shows a sandwich panel structure comprising cavities for receiving reinforcing elements; - Figure 13 schematically represents a structure sandwich panel comprising orthogonal oriented facing panels to each other. In Figures 1 to 5, the sandwich panels are shown in section along an X-Y plane, so that the internal structure of the panels is visible. In Figure 1, the sandwich panel 100 shown includes a first facing member 110, a second facing member 120, and a core formed of a layer of insulating material 130 extending between the facing members 110 and 120. first facing element 110 comprises a cladding plate 111, an intermediate plate 112, spacing means 113 and anchoring means 114. The first cladding element 110 which extends on one side of the cladding layer insulating material 130, is formed in one piece, by extrusion of a composite material, preferably polyvinyl chloride (PVC). The facing plate 111 is intended to be visible. It extends parallel to the intermediate plate 112, at a distance from the latter. The intermediate plate 112 extends between the cladding plate 111 and the layer of insulating material 130, in contact with the layer of insulating material 130. The cladding plate 111 is kept away from the intermediate plate 112 and the diaper of the insulating material 130 by the spacing means 113. The spacing means 113 comprise ribs of rectilinear shape, parallel to each other and extending in a general direction perpendicular to the plates 111 and 112. The spacing means 113 allow to provide a space free of insulating material between the facing plate 111 and the intermediate plate 112. More specifically, the facing plate 111, the intermediate plate 112 and the spacer means 113 define a plurality of cavities 115 extending between the spacing means 113. The first facing element 110 is held on the layer of insulating material 130 on the one hand by adhesion of the insulating material on r the intermediate plate 112 and secondly through the anchoring means 114. The anchoring means 114 comprise protuberances extending inside the layer of insulating material 130. The protuberances form a relief fastening means that the first facing member 110 is engaged with the layer of insulating material 130. Each protrusion comprises a rib 114 projecting from the intermediate plate 112. The ribs 114 are parallel to one another and have a generally T-shaped cross-section.

  More specifically, each rib 114 comprises a rectilinear central portion 1141 and an anchor head formed by two wings 1142 extending from the central portion 1141, on either side of the central portion 1141 and perpendicular to it. this. Specifically, the central portion 1141 comprises a first end fixed to the intermediate plate 112 and a second end, supporting the wings 1142. The wings 1142 form an anchoring portion opposing the separation of the first facing element 110 of the layer In the embodiment illustrated in FIG. 1, the anchoring means 114 extend in the extension of the spacing means 113. In addition, the first cladding element 110 is formed of a profile obtained by extrusion. The first facing element 110 thus has a constant section in an extrusion direction Z of the first element. In the embodiment illustrated in FIG. 1, the second cladding element 120 comprises only a cladding plate 121. The second cladding element 120 is formed in one piece, by extrusion of a composite material, preferably of polychloride of vinyl (PVC).

  In the embodiment of the panel 100 shown in Figure 1, the first cladding element 110 is intended to be exposed to climatic actions while the second cladding element 120 is rather intended to be protected. This type of panel is for example adapted to be used as a partition, with an outer face exposed to sunlight (or weather) and an inner face to be preserved from this radiation. The layer 130 of insulating material has a microcellular structure. The layer 130 is preferably formed of expanded polymer, such as a polymer comprising starch, polyethylene (PE), polyvinylidene fluoride, polyurethane or polyvinyl chloride (PVC). In particular, the polyurethane foam has adhesion qualities on many supports. It also has the advantage of being easy to implement and have a moderate cost.

  Due to the presence of the space comprising the cavities 115 between the facing plate 111 and the intermediate plate 112, the panel 100 has improved thermal or acoustic insulation properties. In addition, because it comprises several plates (facing plate 111 and intermediate plate 112) and T-shaped anchoring means 114, the first facing element 111 can easily be provided with attachment pieces, such as screws or nails. Typically, the method of manufacturing the sandwich panel 100 comprises the following steps. In a first step, the first cladding element 110 and possibly the second cladding element 120 are produced by extrusion. In a second step, the two facing elements 110 and 120 are arranged in a mold. The two facing members 110 and 120 are held at a predetermined distance from each other by means of formers disposed in the mold, so as to provide a space between the two facing elements 110 and 120. According to a third step, polymeric material is injected into the space between the two facing elements 110 and 120. The polymeric material expands, so that it fills the space between the two facing elements 110 and 120. In particular, during its expansion, the polymeric material is introduced between the anchoring means 114, so that the anchoring means are in engagement with the polymeric material. In a fourth step, when the polymeric material is solidified, thereby forming the layer of insulating material 130, the sandwich panel is extracted from the mold. Shapers maintain the facing elements 110 and 120 in place during the injection and drying of the polymeric material until the panel is removed. The third step of injecting polymeric material has the effect of adhering together the various components of the panel (facing elements 110 and 120, and layer of insulating material 130). This method of manufacturing the sandwich panel is simple and fast. In a variant of the manufacturing method, during the third step, the facing elements 110 and 120 are held under pressure so as to improve the adhesion between the different elements 20 of the panel and to limit the deformation of the facing elements 110 and 120 due to the expansion of the polymeric material. In FIG. 2, the sandwich panel 200 shown comprises a first cladding element 210, a second cladding element 220 and a core formed of a layer of insulating material 230 extending between the cladding elements 210 and 220. first facing element 210 is identical to the first facing element 110 of the panel 100 of FIG. 1. The second facing element 220 comprises a cladding plate 221 and anchoring means 224. The anchoring means 224 of the second cladding element 224. facing element 220 are identical to the anchoring means 214 of the first facing element.

  The anchoring means 224 comprise protuberances extending inside the layer of insulating material 230. The protuberances form a hooking relief which has the effect that the second facing element 220 is in engagement with the layer 230. Each protuberance comprises a rib 224 projecting from the cladding plate 221. The ribs 224 are mutually parallel and have a generally T-shaped cross-section. Similar to the first cladding element 210 , the second facing element 220 is formed of a profile obtained by extrusion. The second facing element 220 thus has a constant section in an extrusion direction Z. It will be noted that the anchoring means 214 of the first cladding element 210 and the anchoring means 224 of the second cladding element 220 are arranged in alternating (or staggered) on either side of the layer of insulating material 230, so as not to weaken the layer of insulating material 230 and to obtain a minimum thickness of this layer 230 over the entire extent of the panel. In FIG. 3, the sandwich panel 300 shown comprises a first facing element 310, a second facing element 320 and a core formed of a layer of insulating material 330 extending between the facing elements 310 and 320. The facing element 310 and the second facing element 320 are identical to the first facing element 110 of FIG. 1. The first facing element 310 and the second facing element 320 respectively comprise a cladding plate 311 and 321, a plate intermediate 312 and 322, spacing means 313 and 323 extending between the cladding plate 311, 321 and the intermediate plate 312, 322 and anchoring means 314 and 324 extending from the intermediate plate 312, 322. As in the embodiment of Figure 2, the anchoring means 314 of the first cladding element 310 and the anchoring means 324 of the second cladding element 320 are arranged e n alternating (or staggered) on either side of the layer of insulating material 330, so as not to weaken the layer of insulating material 330 and to obtain a minimum thickness of this layer 330 throughout the entire panel . The panel shown in Figure 3 is particularly suitable for use in applications where each facing element 310, 320 is subject to climate actions. The panel of Figure 3 is also suitable for use as flooring, for example sports floor. Indeed, the panel 300 has good rebound and shock absorption properties. Because it has two gaps 315 and 325 free of insulating material, the panel of Figure 3 is also suitable for use in sound insulation applications. In FIG. 4, the sandwich panel 400 shown comprises a first cladding element 410, a second cladding element 420 and a core formed of a layer of insulating material 430 extending between the cladding elements 410 and 420. first cladding element 410 is identical to the first cladding element 110 of the panel 100 of FIG. 1. The second cladding element 420 comprises a cladding plate 421, an intermediate plate 422 and spacing means 423. siding 421 extends parallel to the intermediate plate 422, at a distance from the latter. The intermediate plate 422 extends between the cladding plate 421 and the layer of insulating material 430, in contact with the layer of insulating material 430. The cladding plate 421 is kept away from the intermediate plate 422 and the diaper of the insulating material 430 by the spacing means 423. The spacing means 423 comprise ribs of rectilinear shape, parallel to each other and extending in a general direction perpendicular to the plates 421 and 422. The spacing means 423 allow to provide a space free of insulating material between the cladding plate 421 and the intermediate plate 422. The cladding plate 421, the intermediate plate 422 and the spacing means 423 define a plurality of cavities 425 extending between the means 423. In the embodiment of the panel 400 shown in FIG. 4, the first cladding element 210 is intended to be exposed to the air conditioning actions. while the second facing element 420 is rather intended to be protected. This type of panel is for example adapted to be used as a partition, with an outer face exposed to sunlight and an inner face to be preserved from this radiation. Panel 400 provides good insulation.

  FIG. 5 schematically represents a sandwich panel 500 comprising a first facing element 510, a second facing element 520, a core formed of a layer of insulating material 530 and connection means 540. the assembly of several sandwich panels together. In the embodiment illustrated in FIG. 5, the connection means 540 comprise a female member 541 and a male member 542 having a shape complementary to the female member 541. Thus, each female member 541 is adapted to cooperate with an organ male 25 542 of an adjacent panel. More specifically, the members 541 and 542 are each formed on a wafer of the sandwich panel 500, on either side of the sandwich panel 500. The female member 541 is adapted to be fitted with a male element 542 formed on a wafer. an adjacent panel. For this purpose, the female member 541 has a cavity of generally trapezoidal shape. The male element 542 has a corresponding protrusion, also of generally trapezoidal shape, adapted to be inserted into the cavity of the female member so as to achieve an assembly of two adjacent panels by mechanical attachment. The members 541 and 542 may comprise inserts on the sandwich panel 500 or may be integrally formed with one of the facing members 510 or 520 during extrusion thereof. Because the members 541 and 542 are part of the panel 500, the assembly of panels together does not require additional connecting parts. Thus the assembly of several panels can be simple and fast.

  The connection means 540 are preferably made of plastic so as to limit the thermal conduction of the connection means 540 and preserve the insulation properties of the assembly. For some applications, it may be useful to provide specific panels having only one connection member 541 or 542 or having additional connecting members that can be used as corner panels, edge or connection. It may further be provided to add flexible lips or seals to seal the assembly of the panels at the connecting members. According to a variant of the embodiment of Figure 5, the connecting members comprise grooves and ribs adapted to cooperate to achieve an assembly of several panels together, and a self-tightening cam system capable of preventing spacing 25 panels when assembled, while allowing disassembly of the panels if necessary. According to this variant, the female member comprises the grooves while the male member comprises the ribs adapted to be inserted into the grooves of the female member. According to yet another variant of the embodiment of FIG. 5, the connection members 541 and 542 may have shapes such that when the female member 541 is inserted into the male connection member 542, the connecting members 541 and 542 define a cavity adapted to receive a seal. Such a cavity has the advantage that the seal is protected and can not be removed from the cavity, especially under the action of a high pressure jet projected on the panels for cleaning for example. In Figure 6, the facing panel 600 shown is similar to the panel 100 of Figure 1. One of the facing plates 111 is provided with perforations 116. These perforations can improve the sound absorption properties of the panel. 100. In FIG. 7, the facing panel 700 shown is similar to the panel 100 of FIG. 1, except that it comprises inserts 117.

  Each insert 117 is fixed on an anchoring element 114. These inserts form supports intended to receive fastening means 118, such as for example screws, for fastening inserts on the panel 100, such as for example clappers. , tiles, or plates. As illustrated in FIG. 7, each insert can be attached to the anchoring head of the anchoring elements 114. In FIG. 8, the panel 800 shown is similar to the panel 100 of FIG. 1, except that it comprises anchoring elements 114 which have a shape adapted to receive equipment, such as for example tubes or ducts for the circulation of fluids or for the passage of cables. As illustrated in FIG. 8, the anchoring elements 114 have an anchoring head whose flanges 1142 are curved, thus forming a half-cylinder. The half-cylinder anchoring head is adapted to receive a tube 140. Each tube 140 is held on an anchoring element 1114 between the wings 1142 of the anchoring element 114. On FIG. 900 shown is similar to panel 100 of FIG. 1, except that each anchor element 114 comprises a module assembly 1143. Each module 1143 comprises a central portion 1141, an anchor head 30 with wings 1142 and a portion of coupling 1144. The coupling portion 1144 is adapted to be coupled to an anchor head 1142 of another identical module 1143. More specifically, the coupling portion 1144 has a shape complementary to the shape of the anchor head, so that the coupling portion 1144 is adapted to receive the anchor head of another identical module 1143. It is thus possible to assemble by coupling a plurality of modules 1143 to produce an anchoring element 114 having desired dimensions. In particular, the assembly of the modules makes it possible to extend the anchoring element 114, in particular according to the thickness of the sandwich panel 900. Advantageously, it is possible to fix each module on another module by threading (according to the extrusion direction Z) of the coupling portion of one of the modules on the anchoring head of the adjacent module. Thus, it is possible to realize on demand panels of different thicknesses, from identical modules. In Fig. 10, the panel 1000 shown is similar to the panel 10C) of Fig. 1, except that each anchor 114 is formed of two pieces 1145 and 1146. Each anchor member 114 comprises a first piece 1145. extending from the intermediate plate 112 and a second part 1146 adapted to be fixed on the first part 1145. As is more specifically illustrated in FIG. 11, the first part 1145 comprises a first coupling portion. The first coupling portion comprises a central portion 1147 and a plurality of sawtooth reliefs 1148 extending along the central portion 1147 on either side thereof. The second piece 1146 comprises a second coupling portion and an anchor head with two wings 1142. The second coupling portion comprises an opening 1157 provided with a plurality of saw-tooth reliefs 1158. The first coupling portion is adapted to receive the second coupling portion so that the sawtooth reliefs 1148 and 1158 engage with each other to secure the second piece 1146 to the second piece 1145. 1148 and 1158 allow to adjust the position of the anchoring element relative to the cladding panel 1000.

  Indeed, the first part 1145 can be inserted more or less deeply into the second part 1146. Thus, it is possible to produce on request panels of different thicknesses, from identical parts.

  In Fig. 12, the panel 1200 shown is similar to the panel 200 of Fig. 2 except that it includes cavities 227 for receiving reinforcing members 228. As shown in Fig. 12, the cavities 227 may be formed between two anchoring elements 224.

  In Figure 13, the panel 1300 shown is identical to the panel 30C) of Figure 3, except that the cladding elements 310 and 320 are oriented orthogonally with respect to each other. Indeed, the first cladding panel 310 has a constant section in a first extrusion direction Z, while the second cladding element 320 has a constant section in a second extrusion direction X, orthogonal to the first direction Z. As a result, the spacing means 313, the cavities 315 and the anchoring means 314 of the first panel 310 are oriented in a direction orthogonal to the direction in which the spacing means 323, the cavities 325 and the anchoring means 324 of the second panel 320. This has the advantage that the panel 1300 is particularly suitable for use as flooring, for example sports floor. Indeed, because of the orientation of the elements 310 and 320, the panel 1300 has good strength properties. Note that the profiles forming the sandwich panel may include if necessary equipment such as reinforcements made of metal, plastic or wood, tubes or ducts for the circulation of fluids or for the passage of cables.

  The sandwich panels proposed can be used for multiple applications, such as the realization of industrial warehouses, including refrigerated warehouses, cold rooms or storage structures of agro-food products, the realization of clean rooms or clean rooms, the construction of hospital operating theaters, the production of vehicle cases for the transport of goods or passengers, the insulation of swimming pools, the construction of light homes, mobile homes, prefabricated housing units, floating houses or house-boats, the production of machine tools, shower cabins, toilets, fitting rooms, construction cabins. The thermal and acoustic insulation properties, the sealing, the corrosion resistance, the thermal resistance, the resistance to the climatic conditions, the ease of assembly / disassembly, and the economic nature of the panels which have just been described make these particularly attractive panels for uses in the aforesaid different fields. In particular, the resistance of the panels to ultraviolet thanks to the space between the outer plate and the layer of insulating material increases the service life of the panel compared to the panels of the prior art.

Claims (15)

  A sandwich panel (100, 200, 300) comprising a facing member (110, 210, 310) and a layer of insulating material (130, 230, 330), the facing member (110, 210, 310) comprising a facing plate (111, 211, 311) and spacing means (113, 213, 313) capable of holding the facing plate (111, 211, 311) away from the layer of insulating material (130, 230 , 330) so as to form a space (115, 215, 315) free of insulating material between the facing plate (111, 211, 311) and the layer of insulating material (130, 230, 330).   2. Panel according to claim 1, wherein the space (115) formed between the facing plate (111) and the layer of insulating material (130) is filled with air.   3. Panel according to one of claims 1 or 2, wherein the facing plate (111) and the spacer means (113) are formed in one piece, by extrusion. 20   4. Panel according to one of claims 1 to 3, wherein the facing plate (111) and the spacing means (113) are formed by extrusion in a direction (Z) parallel to a plane in which extends the facing plate (111). 25   5. Panel according to one of claims 1 to 4, wherein the layer of insulating material (130) is continuous.   6. Panel according to one of claims 1 to 5, wherein the layer of insulating material (130) has a microcellular structure.   7. Panel according to one of claims 1 to 6, wherein the layer of insulating material (130) is formed of expanded polymer. 30   8. Panel according to one of claims 1 to 7, wherein the facing element (110) comprises an intermediate plate (112) extending between the facing plate (111) and the layer of insulating material (130). in contact with the layer of insulating material (130).   9. Panel according to one of claims 1 to 8, wherein the facing element (110) comprises anchoring means (114) extending inside the layer of insulating material (130) for fixing the facing element (110) on the layer of insulating material (130).   10. Panel according to claim 9, wherein the anchoring means (114) comprise protrusions extending from the facing element (110). 15   11. Panel according to one of claims 1 to 10, comprising connecting means (540) for assembly of the panel with another similar panel.   The panel of claim 11, wherein the connecting means (540) comprises a female member (541) and a male member (542) having a shape complementary to the female member (541) so that the member female (541) is adapted to cooperate with a male member (542) of an adjacent panel. 25   13. Panel according to one of claims 1 to 12, wherein the facing plate (111) comprises perforations (116) capable of absorbing acoustic waves.   14. Panel according to one of claims 1 to 13, wherein the facing element (310) constitutes a first facing element (310) and has a first extrusion direction (Z), the panel comprising a second a facing member (320) having a second extrusion direction (X), the first and second members (310, 320) being arranged relative to each other so that the first and second directions extrusion form a non-zero angle.   A method of manufacturing a cladding board (100), comprising the steps of: - forming a cladding member (110) comprising a cladding board (111) and spacing means (113), - forming a layer of insulating material (130), the spacer means (113) holding the layer of insulating material (130) away from the facing plate (111) to form a space (115) free of material insulation between the facing plate (111) and the layer of insulating material (130).