FR2904015A1 - PROCESS FOR PRODUCING ACOUSTIC COMPOSITE PANELS - Google Patents

Abstract

The present invention relates to the creation of a new system for manufacturing and assembling acoustic composite panels in order to have a reduction in the weight of the panels, their reversibility, an improvement in acoustic performance by reducing and absorbing the propagation of sound waves within the sandwich panel, and a reduction of the bimetallic phenomenon of the sandwich panels.A method for manufacturing and assembling sandwich-type acoustic composite panels comprising an elastic median insulating core (2) made of organic material, elastomeric or mineral, arranged between two rigid insulating cores (3), (6) of organic material, or mineral, the assembly being disposed between two rigid faces (1) that can be assembled by means of a junction device comprising a junction profile (5) intended to be embedded in the longitudinal grooves (7) of the panel, characterized in that the medial insulating core iane (3) is elastic and is taken between two rigid webs (2) and / or (6), and such that these souls are assembled to provide symmetry (4) of the acoustic sandwich panel.

Description

1 Method of manufacturing acoustic composite panels. The current

  The invention relates to a device for providing sound insulation while integrating a thermal function, reversibility and reduction of the bimetallic phenomenon, sandwich panels composite to the same device. The invention is applicable when using composite sandwich panels used for the realization of insulating roof of veranda, roofing house, balconies, terraces, kiosks, galleries, cladding, industrial building, etc.. The invention relates to the realization of roofing at one or more slopes provided with this acoustic insulation device composite sandwich panels interconnected by a junction system or taken by profiles metal clamps. Composite sandwich panels consist of a core of organic or mineral material more or less rigid having thermal functions, lightness, rigidity, etc., disposed between two rigid composite facings, metallic or mineral. It is known (FR 2 780 334) and (FR 2 816 240) that composite panels comprise a core disposed between two rigid facings characterized in that said core is partly cellular or even attached to viscoelastic, and whose thermo-acoustic is Acoustic damping is made of a heavy material material and properties of this core to improve the level especially to impact noises. However, the acoustic insulation of this device is poor because although this system avoids the outer facing to be too strong acoustic resonance during impacts, it no longer has any influence on the further propagation of the acoustic wave in the soul which often can play the role of a resonator due to the use of rigid foam core. In addition, this system is positioned only on one side of the panel, which corresponds to the external face capable of receiving, for example, raindrops, which makes it impossible to use the panels in both directions and to have a reversibility. In addition this device 10 also imposes constraints for the use of the falls when corner shot, by the use that on the same side of the panels, this acoustic panel does not allow to recover the falls in any direction and face. It is also known (FR 2 849 460) to have an acoustic and / or thermal panel characterized in that the core consists of a plasterboard or gypsum sandwiched between two facings. By cons this system is very heavy and allows its use on very small format and does not allow to have 20 panels self-supporting. This system also generates handling problems for operators. In addition, the load bearing structure of this type of panel must be oversized to support this overweight, thus generating additional costs of the structure. This system also generates several problems namely the core formed of a gypsum board gives a fragile panel to external impacts but also during mechanical stress for example during sunshine or during the weight surcharge related to snow for example. In addition, this system 30 does not reduce the bimetallic phenomenon because the core is very rigid. It also does not have good thermal insulation properties due to the low thermal insulation properties of the plasterboard. Finally, the plaster is hydrophobic and can be loaded with water in comparison with the condensation phenomena on the siding on the outer side, generating a problem of overweight of the panel 2904015 3 but also by a crumbling of the gypsum plasterboard water can generate in the end the ruin of the panel. It is still known (FR 2 847 919) to have an acoustic absorbent between two walls characterized in that between the acoustic absorbent and the first wall are arranged spacer elements creating an air gap. In this configuration, we have several problems, namely that this air gap can be more or less loaded with moisture, which can generate condensation phenomena on the cold external surface with problems of delamination and mildew. In addition, this vacuum of air has no thermal insulation properties. And finally the spacer elements have very weak bonding bond between the outer facing and the acoustic absorbent which is very problematic when loading snow or bimetallic effect related to sunlight, which can generate in final ruin more or less dangerous panel. This weak bonding bonding also does not allow to have a self-supporting panel, and allows only one use of these panels between pressure profiles. Finally, WO 2005082986 discloses another device for disposing an acoustic absorption agent composed of loose foam between a back plate and a front plate. In this case the mechanical performance of the sandwich panel are poor because the bulk foam has no shear strength performance which is very problematic when loading snow or wind 30 or even a bimetallic effect related to sunshine, can also generate the ruin of the panel. In addition this loose foam has air gaps that can generate a condensation phenomenon on the siding on the outside, in fact these air voids can be more or less loaded with moisture which can generate the winter of 2904015 4 condensation phenomena on the cold outside surface with problems of delamination, mold. The implementation of these acoustic systems of composite panels thus have some disadvantages, especially sandwich panels consisting of a cellular core and / or a heavy material attached to the outer facing do not allow to be used in any what sense and face. The 10 metal facings of a few tenths of a millimeter (0.7mm for aluminum, and 0.5mm for steel) of these panels are fragile to impacts, and during their handling it is possible to create a deformation, a depression. irreversible metal siding following a blow (hammer, screwdriver, foot, impact between panels, etc.). If the interior facing is impacted it is not possible to turn the panel and put the area with this defect outside, partly not visible and thus avoid putting this panel away. In addition, when cutting sandwich panels on a roof with, for example, a valley, a victorian, particular geometric shapes, etc., it is not possible to use the falls by turning the panel over, to reduce these falls that are on average more than 15%. the sandwich panels consisting of a honeycomb core and / or a heavy material attached to the outer facing supplemented with a thermal insulating core do not make it possible to limit or reduce the propagation of sound inside the sandwich panel because of a phenomenon often resonant of these same insulating cores. - The sandwich panels consisting of a core of a heavy material are generally very heavy and can cause handling problems, the risk of work accident, and length constraints. - The sandwich panels consisting of a cellular core such as cellular polypropylene or a heavy material (plaster, ...) generally have low thermal insulation performance. - Sandwich panels consisting of a rigid hard core such as a core of plaster or rigid foam, generates on the sandwich panels a bimetallic phenomenon resulting in the curvature of the panel subjected to sunshine which then creates an elongation of the siding sunny exterior which translates as well by this bending phenomenon of the panel, thus generating cracks in the roof and aesthetic disorders. the sandwich panels consisting of air void such as a honeycomb core, for example a polypropylene honeycomb or a loose foam or any other spacing system creating an air gap, can generate a phenomenon of condensation on the siding on the outside. Indeed, these air voids can be more or less loaded with moisture which can generate condensation phenomena on the cold outer surface with problems of delamination, mold, modification of thermal properties, etc. The sandwich panels consisting solely of a flexible core may be sensitive to punching phenomena, that is to say to a mechanical stress which deforms the facing because the core is flexible, it does not allow the give sufficient rigidity to prevent it from sinking under contact pressure. The object of this invention is in particular to provide the users with a device enabling: the use of the panels in any direction and face, an improvement of the acoustic performances by reducing and absorbing the propagation of the sound waves at the Even inside the sandwich panel, a reduction in the weight of the panels - to avoid the punching phenomena of the external siding during a one-time crushing an improvement in thermal performance using a set of highly thermally insulating materials 25 - to avoid condensation phenomena under the outer facing a reduction of the bimetallic phenomenon of the sandwich panels and, lacking all the aforementioned disadvantages. The invention relates to a method of assembling insulating cores of the sandwich panel with intrinsic sound velocity properties and very different Young's Modules, such that these cores each have distinct sound propagation velocities between them. they, and between two collateral souls the difference in speed of sound within each of the souls is as great as possible. The multiplicity of large sound velocities between the souls reduces the propagation of sound in the composite sandwich panel accordingly, and thus improves these acoustic properties to impact noise and even to other types of noise such as noise. pink or road noise. In all cases it is absolutely necessary to have a break in sound propagation speed between two adjacent materials constituting the inner core of the sandwich panel. This method of assembling insulating cores will be realized while ensuring a symmetrical shape of the sandwich panel, which thus enables said acoustic composite panels to be assembled by placing each of their rigid facing indifferently towards the climatic environment or towards space. to protect.

A characteristic feature of the invention is that the medial insulating core will be elastic, it will have some flexibility (a complex Young's modulus having the high imaginary part, ie the higher viscous modulus by relative to the actual part 25 of the elastic module) thus making it possible to absorb the differential thermal expansions of the external facing subjected to sunshine, for example, in order to reduce the bimetallic phenomenon of the sandwich panel, the bending of the sandwich panel. This feature of the invention of a resilient medial insulating core will also improve acoustic performance when coupled with a rigid insulating core by creating the break in sound propagation.

Another characteristic feature of the invention is that the insulating core in contact with the outer facings will have a certain rigidity (a high elastic Young's modulus) to reduce the punching phenomena of the panels during their handling, their set up or during any specific crush. These two characteristic features of the invention make it possible to have a mass-spring-mass system, which is the best mechanical system for the absorption of acoustic waves. Indeed, during the propagation of the sound in the sandwich panel, the sound will encounter materials with very different propagation speeds in the two cores, which will considerably slow the propagation of the sound and will improve the acoustic performance of the panel sandwich. Another characteristic feature of the invention applicable to acoustic sandwich panels, comprising an insulating core assembly, is that these insulating cores will be assembled to provide symmetry of the acoustic sandwich panel. This symmetry will be compatible with the characteristics for the reduction of the bimetallic effect and the improvement of the acoustic performance of the composite panels.

The realization of roofing in the case of verandas for example, uses in more than 80% of cases the white color on both sides, which allows thanks to this assembly of insulating cores having a symmetrical shape: 30 of not more impose on the user a direction of installation of the panels, for a composite panel having an impacted, damaged interior facing, to put the zone with this defect outside, in part not 2904015 9 visible and thus avoid to reject this panel, to be able to recover the falls of the corner cuts in any direction and face, 5 when cutting at an angle of the sandwich panels for a roof having for example a valley, a Victorian, specific geometry shapes, to use the panels sandwiches in any direction and face, etc. In order to comply with these latter provisions, this will impose an odd number of insulating cores constituting the sandwich panel, which thus allows to have a panel with for example three different minimum cores, called three-layer or more such as five different cores. In the arrangement of a five-layer system, the characteristic of the invention makes it possible to have an even more elaborate mass-spring-mass-spring-mass system for the absorption of acoustic waves.

According to another characteristic feature of the invention applicable to sandwich panels comprising an insulating core assembly, the insulating core materials are made of lightweight isotropic organic materials having good values of the thermal insulation coefficient, in order to to allow an improvement of the thermal performances, and to avoid the phenomena of condensation on the external facing. The foregoing and other objects, features and advantages will become more apparent from the following description and accompanying drawings, in which: FIG. 1 is a perspective and cross-sectional view of an insulating sandwich panel and illustrating the tri-layer insulating core assembly having in its central portion an elastic core and on the outer portions a rigid insulating core to allow mass-spring-mass functionality to improve acoustic performance and reduction of the bimetallic effect. Outwardly, in an exploded manner, is shown the outer facings which may be metallic or composite. FIG. 2 is a cross-sectional view of an insulating sandwich panel and illustrating the multi-assembly of possible insulating cores generating either a tri-layer system having in its central portion an elastic core and on the outer portions a rigid insulating core or or a five-layer system having an elastic core between two rigid webs to allow the alternation of the mass-spring function, which is reflected in this figure by a mass-springmass-spring-mass system. Outwardly, in an exploded way, is also represented, the external siding which can be metallic or composite. FIG. 3 is a perspective and cross-sectional view of a sandwich panel and illustrating the insulating core assembly when a junction system is used, for example between the panels. In this example, the elastic central core may be of equal width, greater or less than the thickness of the junction of the panels between them. Referring to said drawings to describe an advantageous example, although not limiting, the method and the device according to the invention. Figure 4 is a cross-sectional perspective view of a sandwich panel and illustrating the insulating core assembly when the panels are used between pressure profiles. In the drawings, a very interesting application of the invention is shown for sandwich panels consisting mainly of core (3) of organic material such as insulating foam of polystyrene, polyurethane, melamine, polyvinyl chloride, elastomer, etc. or mineral such as rock wool, glass wool, but this soul must possess elasticity; and other cores (2) and (6) can be made of the same basic materials but must be rigid. These webs (2), (3), (6) are arranged between two rigid facings (1) composites such as a fiberglass, carbon, aramid complex with a polyester, epoxy, phenolic resin, etc .; or two rigid metal claddings (1) such as sheets of aluminum, steel, stainless steel, etc. ; or two rigid sidings (1) minerals such as plasterboards, concrete, gypsum, etc. The junction between the rigid facings (1) and the core (2) or between the cores (2), (3), (6) can be performed by a bonding assembly using a polyurethane type glue epoxide, cyanoacrylate, neoprene, etc. ; or using thermo-fusion by surface melting of the core (2) hot creating a bond after cooling between the core (2) and the facing (1). The facings (1) of the panels P1 and P2 have folded and folded edges (1A) and (1B) against the edges of the web (2), in order to mechanically maintain the web. These composite sandwich panels P1 and P2 are assembled together in pairs by means of either a clamping junction device (8) or a junction device having grooves (7) made in the at least one core ( 2), (3), (6) of the two adjacent panels and a junction profile (5) which is encased by its ends in the grooves (7) of the panels.

In the side edges of the panels P1, P2 for producing the assembly, there is provided a groove (7), preferably having a parallelepiped or rectangular section. In view of the most common use of the panels, the grooves (7) are formed by grooves made in the 5 or souls (2), (3), (6) panels P1 and P2. The assembly of the panels P1 and P2 obtained by means of a junction profile (5) shaped gutter or cylindrical plastic or metal such as aluminum.

The acoustic sandwich panels, comprising an assembly of insulating cores (2), (3), (6), provides a symmetry (4a) and (4b) with respect to a median plane (4). This symmetry will be compatible with the features for reducing the bimetallic effect and improving the acoustic performance of the composite panels. 13

Claims (9)

  1. A method for manufacturing and assembling sandwich-type acoustic composite panels, one face of which is intended to be exposed to a climatic environment (rain, wind, heat such as heat and cold, noise) and the other side facing the inside a space to be protected, and comprising at least one core (2, 3, 6) having at least one acoustic functionality and fixed against at least one rigid facing (1) constituting the face exposed to the climatic environment, characterized in that: - a sandwich of at least three insulating cores is made of which at least one is elastic (3) and interposed between at least two rigid webs (2, 6), - there is a second rigid facing (1 ) against the other side of the composite panel facing the interior of the space to be protected.   2. A method of manufacturing and assembling sandwich type acoustic composite panels according to claim 1, characterized in that the panels are assembled together in pairs by means of a junction system comprising grooves in the insulating cores. (2, 3, 6) panels and a joining piece (5) panels between them.   3. Method according to any one of claims 1 or 2, characterized in that a complex of insulating cores of an odd number is produced.   4. Method according to any one of claims 1 to 3, characterized in that said acoustic composite panels are assembled by placing each of their rigid facing (1) indifferently towards the climatic environment or towards the space to protect   5. Sandwich acoustic composite panel, one face of which is intended to be exposed to a climatic environment (rain, wind, heat such as heat and cold, noise) and the other face is intended to be turned towards the inside a space to be protected, and comprising at least one core (2, 3,   6) having at least one acoustic feature and fixed against at least one rigid facing (1) intended to constitute the face exposed to the climatic environment, characterized in that it comprises: at least three insulating cores, at least one of which one is resilient (3) and disposed between at least two rigid webs (2, 6), - a second rigid web (1) disposed against the other side of the composite panel and intended to face the interior of the web. space to protect. 6. acoustic composite panel according to claim 5, characterized in that the elastic insulating core (3) elastic disposed between two rigid webs (2, 6), has a high elasticity, with a complex Young module having the part high imaginary, that is to say a higher viscous modulus with respect to the real part of the elastic modulus.   7. acoustic composite panel according to any one of claims 5 or 6, characterized in that the insulating core in contact with the outer faces (2, 6) has a high rigidity that is to say a module of Young high elastic.   Acoustic composite panel according to any one of claims 5 to 7, characterized in that the insulating cores (2, 3, 6) and the rigid facings (1) are assembled symmetrically with respect to the median plane of the panel. acoustic sandwich, which is thus reversible. 5   Acoustic composite panel according to any one of claims 5 to 8, characterized in that the materials of the insulating core consist of light isotropic organic materials having good values of the thermal insulation coefficient, in order to allow improvement of the thermal performance, and to avoid condensation phenomena on the exterior facing.