Sandwich panels and their building envelopes

Abstract

The present invention relates to a sandwich panel, wherein the sandwich panel comprises a photovoltaic active area positioned on an outer sheet, and upper and lower electrical connectors are each positioned in upper and lower cavities, respectively, wherein the upper cavity is positioned within the insulating material in the upper half of the sandwich panel, and the lower cavity is positioned within the insulating material in the lower half of the sandwich panel, and the upper cavity and the lower cavity are adjacent to the longitudinal groove in the inner central portion of the inner sheet, and both are adjacent to the first longitudinal side of the insulating material or both are adjacent to the second longitudinal side of the insulating material, so that the first upper and lower electrical connectors can be accessed from the upper cavity and the lower cavity, respectively, along one of the longitudinal sides of the insulating material and can be connected through the longitudinal groove.

Description

Technology Field

[0001] The present invention relates to, but is not limited to, sandwich panels intended for the construction of building envelopes, and more specifically, sandwich panels intended for the construction of building roofs, walls, exteriors, and claddings. In particular, the present invention relates to building-integrated photovoltaic (BIPV) sandwich panels. Background Technology

[0002] It is known that roof coverings are manufactured as sandwich panels comprising an inner sheet, an outer sheet, and an insulating material sandwiched between the inner and outer sheets. Both sheets are typically made of metal, and the insulating material is typically polyurethane (PUR) foam, polyisocyanurate (PIR) foam, or mineral wool.

[0003] From WO2012 / 120489, it is known that different layers of photovoltaic solar collector units are laminated together on a sandwich panel by heat supplied by a temperature chamber and pressure applied by a roll, as illustrated in FIG. 8 of this patent. During this process, films surrounding the solar cells are fused to embed them in the collector unit. Nevertheless, the temperature reached during the lamination of the photovoltaic solar collector units on the sandwich panel damages the insulating material of the sandwich panel, thereby compromising the adhesion between the insulating material and the metal sheet.

[0004] Meanwhile, improvements in the way photovoltaic functions are integrated into sandwich panels must not jeopardize the manufacturing process of sandwich panels in existing manufacturing facilities or impair other functions of sandwich panels. The problem to be solved

[0005] Accordingly, the present invention aims to solve the disadvantages of the prior art by providing a building-integrated photovoltaic sandwich panel with improved photovoltaic integration without substantially changing the process for manufacturing the sandwich panel. means of solving the problem

[0006] To this end, the first subject of the present invention comprises a sandwich panel for a building envelope comprising an inner sheet, an outer sheet, and an insulating material sandwiched between the inner sheet and the outer sheet, wherein the insulating material has a first longitudinal side, a second longitudinal side, an upper transverse side, and a lower transverse side, and the sandwich panel has an upper half and a lower half.

[0007] The inner sheet comprises an inner central portion including a longitudinal groove extending from the upper transverse side of the insulating material to the lower transverse side, and

[0008] The above outer sheet is:

[0009] - 1st longitudinal outer flange,

[0010] - As an outer central portion extending from the first longitudinal outer flange:

[0011] o First upper perforation through which the first upper electrical conductor passes,

[0012] o The outer central portion including a first lower perforation through which a first lower electrical conductor passes,

[0013] - A first photovoltaic active zone positioned on the outer central portion and electrically connected to the first upper electrical conductor and the first lower electrical conductor;

[0014] - Includes a second longitudinal outer flange extending from the above outer central portion, wherein the first longitudinal outer flange and the second longitudinal outer flange have shapes that allow vertical overlap with each other,

[0015] The rear side of the above outer sheet is:

[0016] - A first upper cable connecting a first upper electrical conductor to a first upper electrical connector located in an upper cavity,

[0017] - Includes a first lower cable connecting a first lower electrical conductor to a first lower electrical connector positioned in a lower cavity, wherein the first lower electrical connector and the first upper electrical connector are corresponding male and female connectors;

[0018] The upper cavity is located within the insulating material in the upper half of the sandwich panel, and the lower cavity is located within the insulating material in the lower half of the sandwich panel.

[0019] The upper cavity and the lower cavity are adjacent to the longitudinal groove, and both are adjacent to the first longitudinal side of the insulating material or both are adjacent to the second longitudinal side of the insulating material, so that each of the first upper electrical connector and the first lower electrical connector can be accessed from each of the upper cavity and the lower cavity along one of the longitudinal sides of the insulating material and can be connected through the longitudinal groove.

[0020] The first subject of the present invention may also have the optional features listed below, individually or in combination:

[0021] - The above outer sheet additionally includes an upper transverse outer edge in contact with the upper overlap area, and

[0022] - The outer sheet further includes a lower transverse outer edge extending beyond the lower transverse side of the insulating material to form a lower overlap zone, and the upper overlap zone and the lower overlap zone have a shape that allows the lower overlap zone to overlap on the upper overlap zone.

[0023] - Electrical conductors are conductive ribbons, and

[0024] - The above longitudinal groove further includes an upper opening adjacent to the upper cavity and a lower opening adjacent to the lower cavity, and

[0025] - The upper cavity and the lower cavity are open along the longitudinal side of the insulating material, and

[0026] - Each of the above upper cavity and the above lower cavity is bounded by a casing embedded in the insulating material, and

[0027] - The above upper cavity prevents the first upper electrical connector from being trapped within the insulating material, and

[0028] - The above lower cavity prevents the first lower electrical connector from being trapped within the insulating material, and

[0029] - The first photovoltaic active zone comprises a layer capable of converting solar energy into electricity, and the first upper perforation and the first lower perforation are substantially located below the layer, and

[0030] - The rear side of the above outer sheet further includes a first upper junction box connecting the first upper electrical conductor to the first upper cable and a first lower junction box connecting the first lower electrical conductor to the first lower cable, and

[0031] - Each of the above first upper cable and the above first lower cable extends through the insulating material until it enters the upper cavity and the above lower cavity, respectively, and

[0032] - Each of the first upper cable and the first lower cable is substantially embedded in the insulating material between each of the first upper electrical conductor and the first lower electrical conductor and each of the upper cavity and the lower cavity, and

[0033] - The above outer central part additionally,

[0034] o Second upper perforation through which the second upper electrical conductor passes,

[0035] o Includes a second lower perforation through which a second lower electrical conductor passes, and

[0036] - The above outer sheet further includes a second photovoltaic active zone positioned on the outer central portion and electrically connected to the second upper electrical conductor and the second lower electrical conductor, and

[0037] - The rear side of the outer seat additionally:

[0038] o A second upper cable connecting the second upper electrical conductor to the second upper electrical connector located within the upper cavity,

[0039] o Includes a second lower cable connecting the second lower electrical conductor to a second lower electrical connector positioned within a lower cavity, wherein the second lower electrical connector and the second upper electrical connector are corresponding male and female connectors;

[0040] - The first upper electrical connector and the second upper electrical connector are corresponding male and female connectors, and the first lower electrical connector and the second lower electrical connector are corresponding male and female connectors.

[0041] A second subject of the present invention comprises a sandwich panel for a building envelope, comprising an inner sheet, an outer sheet, and an insulating material sandwiched between the inner sheet and the outer sheet, wherein the insulating material has a first longitudinal side, a second longitudinal side, an upper transverse side, and a lower transverse side, and the sandwich panel has an upper half and a lower half.

[0042] The inner sheet comprises an inner central portion including a longitudinal groove extending from the upper transverse side of the insulating material to the lower transverse side, and

[0043] The above outer sheet is:

[0044] - 1st longitudinal outer flange,

[0045] - As an outer central portion extending from the first longitudinal outer flange:

[0046] o First upper perforation through which the first upper electrical conductor passes,

[0047] o The outer central portion including a first lower perforation through which a first lower electrical conductor passes,

[0048] - A first photovoltaic active zone positioned on the outer central portion and electrically connected to the first upper electrical conductor and the first lower electrical conductor;

[0049] - Includes a second longitudinal outer flange extending from the above outer central portion, wherein the first longitudinal outer flange and the second longitudinal outer flange have shapes that allow vertical overlap with each other,

[0050] The rear side of the above outer sheet is:

[0051] - A first upper cable extending from the first upper electrical conductor to the first upper electrical connector, through at least the upper opening in the longitudinal groove and the upper cavity,

[0052] - A first lower cable extending from the first lower electrical conductor to the first lower electrical connector through a lower opening and a lower cavity in at least a longitudinal groove, wherein the first lower electrical connector and the first upper electrical connector are corresponding male and female connectors, and

[0053] The upper cavity is located within the insulating material in the upper half of the sandwich panel, and the lower cavity is located within the insulating material in the lower half of the sandwich panel.

[0054] The upper cavity and the lower cavity are adjacent to the longitudinal groove and are both open along the first longitudinal side of the insulating material or both open along the second longitudinal side of the insulating material.

[0055] The second subject of the present invention may also have the following optional features listed below, individually or in combination:

[0056] - The above outer sheet additionally includes an upper transverse outer edge in contact with the upper overlap area, and

[0057] - The outer sheet further includes a lower transverse outer edge extending beyond the lower transverse side of the insulating material to form a lower overlap zone, and the upper overlap zone and the lower overlap zone have a shape that allows the lower overlap zone to overlap on the upper overlap zone.

[0058] - The portion of the first upper cable having the first upper electrical connector and the portion of the first lower cable having the first lower electrical connector are housed in the longitudinal groove.

[0059] The third subject of the present invention consists of a process for manufacturing a sandwich panel according to the present invention, and said process,

[0060] - As a step of providing an external sheet: the external sheet is,

[0061] o As an external central part:

[0062] ■ First upper perforation through which the first upper electrical conductor passes,

[0063] ■ The outer central portion including a first lower perforation through which a first lower electrical conductor passes,

[0064] o Includes a first photovoltaic active zone positioned on the above-mentioned outer central portion and electrically connected to the first upper electrical conductor and the first lower electrical conductor;

[0065] The rear side of the above outer sheet is:

[0066] ■ A first upper cable connecting a first upper electrical conductor to a first upper electrical connector located in an upper cavity,

[0067] ■ Includes a first lower cable connecting a first lower electrical conductor to a first lower electrical connector positioned within a lower cavity, wherein the first lower electrical connector and the first upper electrical connector are corresponding male and female connectors;

[0068] The above upper cavity is positioned in the upper half of the outer sheet, and

[0069] The step of providing the outer sheet, wherein the lower cavity is positioned in the lower half of the outer sheet,

[0070] - A step of providing an inner sheet including an inner central portion including a longitudinal groove,

[0071] - Step of placing the insulating material in place,

[0072] - Includes the step of maintaining the inner sheet at a given distance from the outer sheet so that the upper cavity and the lower cavity are adjacent to the longitudinal groove.

[0073] The third subject of the present invention may also have the optional features listed below, individually or in combination:

[0074] - The upper cavity is attached to the rear side of the outer sheet at the upper half of the outer sheet, and

[0075] - The lower cavity is attached to the rear side of the outer sheet at the lower half of the outer sheet, and

[0076] - The inner sheet is cut and shaped to size to include an upper transverse inner edge and a lower transverse inner edge, and the longitudinal groove extends from the upper transverse inner edge to the lower transverse inner edge, and

[0077] - The above outer sheet and the above inner sheet are positioned in the mold at a given distance from each other, and

[0078] - The reaction mixture is injected into the mold between the inner sheet and the outer sheet, and the reaction mixture reacts and expands to fill the gap between the inner sheet and the outer sheet and form the insulating material.

[0079] - The inner sheet is provided in the form of an inner strip shaped such that its inner central portion includes the longitudinal groove, and the inner strip enters a double belt conveyor of a manufacturing line, and

[0080] - The above outer sheet is part of the continuous feeding of the manufacturing line from the outer sheets, and

[0081] - The reaction mixture is applied to the rear side of the outer sheet or the rear side of the inner strip so that the reaction mixture reacts and expands on the double belt conveyor to fill the gap between the inner strip and the outer sheet and form the insulating material,

[0082] - The above process further includes the step of opening the upper cavity to provide access to the first upper electrical connector and opening the lower cavity to provide access to the first lower electrical connector, and

[0083] - The above process further includes the step of opening the upper cavity (44) and the lower cavity (45), and then passing the first upper electrical connector and the first lower electrical connector and possibly a portion of their cables through the longitudinal groove.

[0084] - The above process further includes a step of preparing the external sheet according to the following steps before providing the external sheet:

[0085] o Step of cutting the outer sheet from the strip to the appropriate length,

[0086] o A step of creating the first upper hole and the first lower hole in the outer central portion,

[0087] o Step of positioning a first photovoltaic active zone on the above outer central part,

[0088] o A step of preparing the outer sheet according to the step of providing the first upper cable, the first upper electrical connector, the first lower cable, the first lower electrical connector, the upper cavity, and the lower cavity on the rear side of the outer sheet,

[0089] - A step in which a first photovoltaic active zone is stacked on an outer central part,

[0090] - A step in which the lower cavity is positioned on the lower half of the outer sheet on the outer side of the lower overlap area.

[0091] The fourth subject of the present invention consists of a process for assembling a building envelope on a building structure, and said process,

[0092] - (i) a step of providing a first sandwich panel and a second sandwich panel according to the present invention,

[0093] - (ii) A step of fastening the first sandwich panel to the building structure,

[0094] - (iii) positioning the second sandwich panel such that the lower transverse side of the insulating material of the second sandwich panel is adjacent to the upper transverse side of the insulating material of the first sandwich panel, and fastening the second sandwich panel to the building structure,

[0095] - (iv) includes the step of connecting the first upper electrical connector of the first sandwich panel to the first lower electrical connector of the second sandwich panel.

[0096] The fourth subject of the present invention may also have the optional features listed below, individually or in combination:

[0097] - The outer sheet of the first sandwich panel further includes an upper transverse outer edge in contact with an upper overlap zone, and the outer sheet of the second sandwich panel further includes a lower transverse outer edge extending beyond the lower transverse side of the insulating material to form a lower overlap zone, and the upper overlap zone and the lower overlap zone have a shape that allows the overlap of the lower overlap zone on the upper overlap zone,

[0098] - The second sandwich panel is positioned so that its lower overlap area covers the upper overlap area of ​​the first sandwich panel.

[0099] As is evident, the present invention is based on using a traditional, semi-continuous, or discontinuous method for manufacturing sandwich panels, wherein the laying of insulating material is one of the final steps of the method, even if not the final step. Since these traditional methods are substantially unchanged, both standard sandwich panels and BIPV sandwich panels can be manufactured using the same existing line or press. Accordingly, before the outer sheet is provided for the manufacture of the sandwich panel, the photovoltaic active zone is positioned exclusively on the outer sheet. In particular, electrical conductors connected to the photovoltaic active zone pass through the outer sheet before lamination in a manner that does not impair the flatness of the lamination. Furthermore, with the exception of the photovoltaic active zone itself, no protrusions exist on the upper side of the outer sheet, so the laying of insulating material is not compromised in existing manufacturing facilities. Additionally, the sandwich panel is pre-wired in such a way that the cables necessary to electrically connect adjacent panels are within the boundaries of the sandwich panel before the insulating material is placed in place. In particular, cables required to electrically connect adjacent panels are embedded in the insulating material and subsequently housed in cavities that can be opened to access the cables and, if possible, to pull them out and connect the panels. Furthermore, because the sandwich panels are pre-wired before the insulating material is placed in position, the sandwich panels do not contain any holes manufactured simultaneously in the outer sheet, insulating material, and inner sheet. This improves the watertightness of the sandwich panels. Similarly, cavities are not open along the outer sheet, but are closed along the outer sheet.

[0100] Other features and advantages of the present invention will be described in more detail in the following description.

[0101] The present invention is provided by reference and solely for illustrative purposes, and will be better understood by carefully reading the following description, which is intended to be non-limiting. Brief explanation of the drawing

[0102] - FIG. 1 shows a perspective view of a sandwich panel according to the present invention, and - FIG. 2 shows a perspective view of a sandwich panel according to the present invention, and - FIG. 3 shows a perspective view of a sandwich panel according to the present invention, and - FIG. 4 shows a perspective view of a sandwich panel according to the present invention, and - FIG. 5 illustrates a cross-sectional view of a sandwich panel according to the present invention, and - FIG. 6 illustrates a perspective view of a sandwich panel according to the present invention, and - FIG. 7 illustrates a drawing of the upper side of an outer sheet of a sandwich panel according to the present invention, and - FIG. 8 illustrates a grommet of a sandwich panel according to the present invention, and - FIG. 9 illustrates a cross-sectional view of a sandwich panel according to a first embodiment of the present invention, and - FIG. 10 illustrates a rear side view of the outer sheet of a sandwich panel according to the first embodiment of FIG. 9, and - FIG. 11 shows a perspective view of an inner sheet of a sandwich panel according to a first embodiment, and - FIG. 12 illustrates a perspective view of a lower portion of a sandwich panel according to a first embodiment of the present invention, and - FIG. 13 shows a perspective view of the upper portion of a sandwich panel according to a first embodiment of the present invention, and - FIG. 14 illustrates a cross-sectional view of a sandwich panel according to a second embodiment of the present invention, and - FIG. 15 illustrates a rear side view of an outer sheet of a sandwich panel according to a second embodiment, and - FIG. 16 illustrates a perspective view of a lower portion of a sandwich panel according to a second embodiment of the present invention, and - FIG. 17 shows a perspective view of the upper portion of a sandwich panel according to a second embodiment, and - FIG. 18 shows a perspective view of four sandwich panels according to the present invention assembled on a building structure, and - FIG. 19 shows a perspective view of two sandwich panels assembled according to a first embodiment, and - FIG. 20 illustrates a perspective view of two sandwich panels according to a first embodiment assembled on a building structure, and - FIG. 21 shows a cross-sectional view of a sandwich panel according to a second embodiment of an inner sheet and an outer sheet. Specific details for implementing the invention

[0103] It should be noted that the terms "inward" and "outward" as used in this application are used to refer to the position and orientation of different components of the panel relative to the position of the insulating material. Consequently, if an element extends inward, it extends in the direction of the insulating material. Similarly, if an element extends outward, it extends in the direction opposite to the insulating material.

[0104] Additionally, for the sake of ease of explanation, it should be noted that the panels will be described in relation to their general position on the roof of the building. Consequently, the terms "inside" and "outside" used in this application refer to these general positions. Thus, the outer sheet faces outward, and the inner sheet faces inward. Accordingly, the inner flange refers to the flange of the inner sheet, and the outer flange refers to the flange of the outer sheet. Similarly, spatially relative terms used in this application, such as "above," "below," "upper," "lower," etc., refer to the position and orientation of different components of the sandwich panel when the sandwich panel is positioned on the roof. Thus, "below" does not mean "immediately underneath."

[0105] Throughout this specification, the photovoltaic active region is understood to mean a stack of multiple layers comprising the following layers: said layers,

[0106] - Can convert solar energy into electricity and

[0107] - It is protected from the outside by an insulating layer.

[0108] Such a stack generally comprises a foil of insulating material called a backsheet, a first layer of encapsulating material, solar cells connected via ribbons and busbars, a second layer of encapsulating material, and a transparent foil of insulating material called a frontsheet. The solar cell itself is generally composed of multiple layers, including a substrate, a back-electrode, a pn junction (which can convert solar energy into electricity), and a front-electrode. The solar cell may be, in particular, a wafer-based crystalline silicon cell or a thin-film cell. The solar cells may be grouped into modules. The photovoltaic active zone may generally include bypass diodes placed every 18 to 24 cells, which prevent the destructive effects of hot-spot heating when the cell or module is shaded or defective. Each photovoltaic active zone has a first polarity and a second polarity for connection to other photovoltaic active zones or the grid. More preferably, each photovoltaic active zone does not have more than a single pair of first and second polarities. When two or more photovoltaic active zones are positioned side by side, they may have their own backsheet and frontsheet, or they may share a single backsheet and / or a single frontsheet.

[0109] Throughout this specification, the term "sheet" is understood to mean an element having a flat shape, that is, its thickness is smaller than its other dimensions. Generally, its thickness is 500 to 4,000 times smaller than its width. The sheet may be manufactured from a single material or as a composite assembly. In the latter case, the sheet is a stack of multiple layers of the same or different materials. The materials discussed may be, in particular, metallic materials or polymers. Non-limiting examples of metallic materials may include steel, aluminum, copper, and zinc. The sheet is preferably a metal sheet. The sheet is preferably manufactured from steel that has been pre-galvanized and pre-coated to protect it against corrosion. An inner sheet and an outer sheet are examples of the sheet.

[0110] In the context of the present invention, the sheet will preferably be pre-formed by any known forming method, including bending, forming, stamping, and molding, as non-limiting examples. In particular, the U-shaped bend described below is an element of a panel whose manufacturing process is not limited to bending.

[0111] Such formations may lead, among other things, to the formation of longitudinal flanges, ribs, stiffeners, grooves, mortises, tenons, tongues, and edge rabbits on the surface of the sheet. Throughout this specification, a rib is understood to mean a protrusion formed on the surface of the sheet. A rib may have, for example, a trapezoidal shape, or a rectangular, wavy, sinusoidal, or even omega shape. It includes an upper central portion and two lateral wings. A stiffener is a rib of limited height, generally 10 to 30 times lower than a rib. A rib or stiffener is generally placed parallel to the longitudinal edge of the sheet, particularly to make the sheet more rigid, and is defined as a longitudinal rib or longitudinal stiffener. Throughout the text, a groove is understood to mean a recess formed on the surface of the panel. A groove may have a shape similar to that provided in a rib.

[0112] Referring to FIGS. 1 through 5, a sandwich panel (1) according to the present invention first comprises an insulating material (2) sandwiched between an inner sheet (3) and an outer sheet (4). The insulating material is bordered by a first longitudinal side (5), a second longitudinal side (6), an upper transverse side (7), and a lower transverse side (8). The inner sheet is laid substantially flat on a plane (P).

[0113] The insulating material (2) may be any material that provides some insulating material to the sandwich panel (1). As a non-limiting example, it may be polyurethane foam, polyisocyanurate foam, phenolic foam, mineral wool, wood wool, and mixtures thereof. It is preferably a foamed insulating material.

[0114] Some of the sides of the insulating material, particularly the longitudinal sides, may include an edge band (9) covering the insulating material. The edge band extends along a given side. The edge band prevents the insulating foam from expanding beyond the sandwich panel, particularly during manufacturing, and prevents the equipment from being contaminated by the foam. The edge band may be made of foamed plastic, plastic film, kraft paper, or cardboard as non-limiting examples.

[0115] Some of the sides, particularly the transverse sides, may include caps (10) covering the insulating material. The caps substantially close the gap between the inner sheet (3) and the outer sheet (4). Such caps are generally used in discontinuous manufacturing methods to prevent the insulating foam from expanding beyond the sandwich panel during manufacturing. They may be made of foamed plastic, plastic film, kraft paper, or cardboard as non-limiting examples.

[0116] Referring to FIGS. 2, 4 and 5, the outer sheet (4) is a rectangular sheet comprising a first longitudinal outer edge (11), a second longitudinal outer edge (12), an upper transverse outer edge (13) and a lower transverse outer edge (14). The first longitudinal outer flange (15) extends along the first longitudinal outer edge (11), and the second longitudinal outer flange (16) extends along the second longitudinal outer edge (12). The first longitudinal outer flange (15) and the second longitudinal outer flange (16) are connected by an outer center portion (17). Preferably, the latter is laid substantially flat in a plane parallel to plane (P).

[0117] Sandwich panels are designed as follows:

[0118] - The first longitudinal outer flange (15) of the first sandwich panel may overlap with the second longitudinal outer flange (16) of the second sandwich panel adjacent laterally, and the second longitudinal outer flange of the first sandwich panel may overlap with the first longitudinal outer flange of the third sandwich panel adjacent laterally, or

[0119] - The first longitudinal outer flange (15) of the first sandwich panel may overlap with the second longitudinal outer flange (16) of the second sandwich panel adjacent laterally, and the second longitudinal outer flange of the first sandwich panel may overlap with the first longitudinal outer flange of the third sandwich panel adjacent laterally.

[0120] Consequently, in the first embodiment illustrated in FIGS. 1 to 5, the first longitudinal outer flange (15) of the outer sheet includes a first longitudinal rib (18) as defined above, which protrudes from the first longitudinal side (5) of the insulating material. "Protruding" means that the first longitudinal outer flange extends beyond the first longitudinal side of the insulating material, particularly beyond the plane of the first longitudinal side. In the illustrated example, the first longitudinal rib (18) has a trapezoidal shape having an upper central portion (19) and two lateral wings (20). As the first longitudinal rib (18) protrudes from the insulating material, its lower side is therefore not covered by the insulating material. Thus, the first longitudinal rib (18) can overlap with the second longitudinal outer flange (16) of the laterally adjacent sandwich panel without a discontinuity of the insulating material.

[0121] Accordingly, the second longitudinal outer flange (16) of the outer sheet includes a second longitudinal rib (21), and the first longitudinal rib (18) and the second longitudinal rib (21) have shapes that allow the first longitudinal rib to overlap on the second longitudinal rib. In the illustrated example, the second longitudinal rib (21) has a trapezoidal shape having an upper center portion (19) and two lateral wings (20) that have substantially the same shape as the first longitudinal rib (18). It provides efficient watertightness. The lower side of the second longitudinal rib is preferably completely covered with an insulating material. This further improves the thermal insulation of the assembly.

[0122] Similarly, the sandwich panel can be designed so that the lower part of the first sandwich panel partially overlaps the upper part of the second sandwich panel positioned lower along the roof slope, and the upper part of the first sandwich panel partially overlaps the lower part of the third sandwich panel positioned higher along the roof slope.

[0123] Consequently, the lower transverse outer edge (14) of the outer sheet may extend beyond the lower transverse side (8) of the insulating material. The corresponding protrusion, that is, the portion of the outer sheet extending from the lower transverse outer edge (14) to the lower transverse side (8) of the insulating material, is defined as the lower overlap area (22). Since the lower side is not covered by the insulating material, the lower overlap area of ​​one sandwich panel may cover the upper portion of the lower adjacent sandwich panel. The upper portion of the sandwich panel that can be covered by the lower overlap area is defined as the upper overlap area (23). It is contacted by the upper transverse outer edge (13), and its height (taken parallel to the longitudinal edge of the outer sheet) is substantially equal to the distance between the lower transverse outer edge (14) of the outer sheet and the lower transverse side (8) of the insulating material (i.e., the height of the lower overlap area) because the sandwich panel is assembled without discontinuities in the insulating material. The height of the upper overlap zone and the lower overlap zone is generally between 150 mm and 500 mm, especially depending on the loop pitch.

[0124] The lower overlap zone (22) and the upper overlap zone (23) have a shape that allows the lower overlap zone to overlap on the upper overlap zone. This means that, apart from the portions of the first longitudinal rib (18) and the second longitudinal rib (21) present in the upper and lower overlap zones, the lower overlap zone (22) and the upper overlap zone (23) do not include shaped zones that prevent overlap. Such zones may be, for example, grooves in the lower overlap zone that do not match the grooves in the upper overlap zone. Preferably, apart from the portions of the first longitudinal rib (18) and the second longitudinal rib (21) present in the upper and lower overlap zones, the lower overlap zone (22) and the upper overlap zone (23) are preferably flat.

[0125] In the second embodiment of the outer sheet illustrated in FIG. 21, the first longitudinal outer flange (15) of the outer sheet includes an outer mortise (102) that extends inwardly. In the illustrated example, the outer mortise is in the form of a U-shaped bend that extends substantially parallel to the outer center portion (17). In particular, the outer mortise includes two branches that are substantially parallel and connected by a U-turn. More preferably, the two parallel branches have substantially the same length. Other designs of the outer mortise are possible. It may have a V shape, in particular, having two branches that converge toward a U-turn. It may also have an L shape having branches and a sheet.

[0126] According to a variation of the second embodiment, the first longitudinal outer flange (15) includes a first outer riser (104) extending between the first longitudinal end of the outer center portion and the outer mortise, as illustrated in FIG. 21. The first outer riser may extend substantially perpendicularly to the outer center portion, i.e., perpendicularly to the plane (P), or may be inclined toward the outer mortise, or may be inclined toward the outer center portion.

[0127] According to another variation of the second embodiment, the first longitudinal outer flange (15) includes a first extension (105) that extends inwardly between the first longitudinal end of the outer center portion, or, if applicable, between the first outer riser and the outer mortise, or, if applicable, between the first outer riser and another outer riser, as illustrated in FIG. 21. Preferably, the first extension is substantially flat. Preferably, the first extension extends substantially parallel to the outer center portion (17). It forms a male projection (106) that is designed to cover and can cover the head of a fastener inserted into the second longitudinal outer flange (16) of an adjacent panel together with the outer center portion.

[0128] According to the outer mortise, the second longitudinal outer flange (16) of the outer sheet includes an outer tenon (103) that extends outwardly, and the outer tenon and the outer mortise have a shape that allows one longitudinal outer flange to overlap the other, i.e., the outer tenon and the outer mortise to interlock. In the illustrated example, the outer tenon protrudes from the second longitudinal side (6) of the insulating material. “Protrudes” means that the second longitudinal outer flange (16) extends beyond the second longitudinal side (6) of the insulating material, particularly beyond the plane of the second longitudinal side.

[0129] In the example illustrated, the outer tenon is in the form of a U-shaped bend that extends substantially parallel to the outer center portion (17). In particular, the outer tenon includes two branches that are substantially parallel and connected by a U-turn. More preferably, the two parallel branches have substantially the same length. Other designs of the outer tenon are possible. It may have a V shape, in particular, having two branches that converge toward the U-turn. It may also have an L shape with branches and a sheet.

[0130] According to a variation of the second embodiment, the second longitudinal outer flange (16) includes a second outer riser (107) extending between the second longitudinal end of the outer center portion and the outer tenon, as illustrated in FIG. 21. The second outer riser may extend substantially perpendicularly to the outer center portion, i.e., perpendicularly to the plane (P), or may be inclined toward the outer tenon or inclined toward the outer center portion.

[0131] According to another variation of the second embodiment, the second longitudinal outer flange (16) includes an outer edge rabbit (108) that extends inwardly between the second longitudinal end of the outer center portion and the outer tenon, as illustrated in FIG. 21. The outer edge rabbit forms a recess into which a fastener head can be received. Preferably, the head of the fastener can be covered and thus concealed by a male projection (106) of the first longitudinal outer flange (15) of the adjacent sandwich panel. Accordingly, the shapes of the outer edge rabbit and the male projection are adjusted so that the fastener head can be positioned between them.

[0132] Preferably, the outer edge rabbit (108) extends substantially parallel to the outer center portion (17). Preferably, the outer edge rabbit includes a second outer riser (107) and a second extension (109), starting from the second longitudinal end of the outer center portion and continuing as described above. The second outer riser may extend substantially perpendicularly to the outer center portion or extend obliquely toward the second extension. The latter is preferably parallel to the plane (P) to facilitate screw fastening of the fastener in this portion of the sandwich panel.

[0133] The outer mortise (102) and outer tenon (103) have a shape that allows one longitudinal outer flange to overlap over the other when one sandwich panel is assembled with a laterally adjacent sandwich panel. Preferably, their shapes are substantially complementary and their dimensions are as follows:

[0134] - The height of the outer mortise (measured along the vertical axis (Z)) is higher than the height of the outer tenon

[0135] - The width of the outer mortise (measured along the transverse axis (Y)) is greater than or equal to the width of the outer tenon.

[0136] This interlocking of the outer mortise and outer tenon improves the resistance of the envelope composed of sandwich panels, particularly resistance to wind suction.

[0137] The sandwich panel is divided into an upper half and a lower half. The upper half starts from the upper transverse side (7) of the insulating material (which corresponds to the upper transverse outer edge (13) of the outer sheet) and extends to half the length of the outer sheet (the length is taken parallel to the longitudinal edge of the outer sheet). Thus, the upper half of the sandwich panel corresponds to the upper half of the outer sheet. The lower half starts from the lower transverse outer edge (14) of the outer sheet and extends to half the length of the outer sheet. Thus, the lower half of the sandwich panel corresponds to the lower half of the outer sheet.

[0138] Referring to FIGS. 1 and 2, the sandwich panel (1) is a BIPV (Building Integrated Photovoltaic) sandwich panel. Accordingly, it includes a first photovoltaic active zone (24) positioned on an outer central portion (17) as defined above, and components for electrical connection of the first photovoltaic active zone to another sandwich panel or grid are integrated within the thickness of the sandwich panel.

[0139] In particular, the first photovoltaic active zone (24) is formed directly on the outer center portion of the outer sheet before the sandwich panel is manufactured. In particular, it is laminated on the outer center portion of the outer sheet. This greatly improves the watertightness of the sandwich panel.

[0140] The first photovoltaic active zone (24) is preferably dimensioned such that, on one hand, a portion thereof is not covered by an adjacent sandwich panel when the panel is assembled, and on the other hand, the active surface is maximized. Accordingly, the upper transverse edge of the first photovoltaic active zone is preferably positioned as close as possible to the upper transverse outer edge (13) of the outer sheet or, if applicable, as close as possible to the upper overlap zone, and the lower transverse edge of the first photovoltaic active zone is preferably positioned as close as possible to the lower transverse outer edge (14) of the outer sheet. Similarly, in a variation of the invention having only one photovoltaic active zone, the first longitudinal edge of the first photovoltaic active zone is as close as possible to the first longitudinal outer flange (15), and the second longitudinal edge of the first photovoltaic active zone is as close as possible to the second longitudinal outer flange (16). The first polarity of the first photovoltaic active zone is preferably positioned adjacent to the upper transverse outer edge (13) in the upper half of the first photovoltaic active zone, more preferably below the upper overlap zone if applicable. The second polarity of the first photovoltaic active zone is preferably positioned adjacent to the lower overlap zone (22) of the sandwich panel if applicable, in the lower half of the first photovoltaic active zone.

[0141] The first photovoltaic active zone (24) is electrically connected to the first upper electrical conductor (25) and the first lower electrical conductor (26). In particular, the first polarity of the first photovoltaic active zone is connected to the first upper electrical conductor, and the second polarity of the first photovoltaic active zone is connected to the first lower electrical conductor. Since the first photovoltaic active zone (24) is on the upper side of the outer sheet and the electrical connection is within the thickness of the sandwich panel, the first upper and first lower electrical conductors extend through the outer sheet. In the variation illustrated in FIG. 6, the first upper electrical conductor (25) and the first lower electrical conductor (26) are conductive ribbons also known as conductive busbars. They are part of the first photovoltaic active zone. They are preferably connected directly to the PV cell of the first photovoltaic active zone. They all extend over the surface of the outer sheet and then pass through the outer sheet. In another variant (not exemplified), the first upper electrical conductor (25) and the first lower electrical conductor (26) are intermediate electrical conductors connected to the conductive ribbon of the first photovoltaic active zone. The first upper electrical conductor (25) and the first lower electrical conductor (26) may be embedded in a non-conductive grommet (29) described particularly later. In such a case, the conductive ribbon of the first photovoltaic active zone may extend over the surface of an outer sheet and may be connected to the first upper electrical conductor (25) and the first lower electrical conductor (26) passing through the outer sheet.

[0142] Consequently, and referring to FIG. 7, the outer central portion (17) includes a first upper perforation (27) through which a first upper electrical conductor passes and a first lower perforation (28) through which a first lower electrical conductor passes. The positions of the first upper perforation and the first lower perforation may be dependent, in particular, on the positions of the first and second polarities of the photovoltaic active zone and the positions of the electrical connections in the thickness of the sandwich panel. Generally speaking, the first upper perforation is preferably located in the upper half of the sandwich panel, and the first lower perforation is, if applicable, preferably located in the lower half of the sandwich panel outside the lower overlap zone (22). Since the first photovoltaic active zone (24) preferably has a first polarity adjacent to its upper transverse end and its second polarity adjacent to its lower transverse end or, if applicable, the lower overlap zone, below (i.e., adjacent to) the upper overlap zone (23), if applicable, the first upper perforation (27) is preferably positioned adjacent to the upper transverse end of the first photovoltaic active zone, below (i.e., adjacent to) the upper overlap zone, if applicable, and the first lower perforation (28) is preferably positioned adjacent to the lower transverse end of the first photovoltaic active zone or, if applicable, the lower overlap zone. Preferably, the first upper perforation and the first lower perforation are substantially aligned along the longitudinal axis (X).

[0143] Preferably, the width of the hole (i.e., the longest length measured in the XY plane) is approximately the size of the diameter of the electrical connector, as described below. In particular, the width is less than 3 cm, and more preferably less than 2 cm. In other words, the hole cannot accommodate the electrical connector housing. This width further minimizes the negative impact of the hole on the lamination of the photovoltaic active zone on the outer sheet and further improves the watertightness of the sandwich panel.

[0144] For waterproofing reasons, the first upper and first lower perforations are preferably covered by at least one layer of the first photovoltaic active zone. More preferably, the first upper and first lower perforations are covered by a front sheet. Even more preferably, they are covered by a front sheet, a layer of encapsulation material, and possibly at least partially by a back sheet. Additionally, the first upper and first lower perforations may exist substantially below a layer capable of converting solar energy into electricity. "Substantially below" means that, even if the PV cells do not exist strictly above the perforations, they may be located below this layer. The first upper and first lower perforations may also be substantially covered by the first photovoltaic active zone. "Substantially covered" means that even if the perforations are not strictly covered by all layers of the photovoltaic active zone, they exist entirely below the photovoltaic active zone.

[0145] Preferably, the inward end of the first upper electrical conductor is adjacent to the first upper hole. This inward end may also be substantially vertically aligned with the first upper hole. Preferably, the inward end of the first lower electrical conductor is adjacent to the first lower hole. This inward end may also be substantially vertically aligned with the first lower hole.

[0146] It is advantageous to allow the first upper electrical conductor to pass through the first upper perforation and the first lower electrical conductor to pass through the first lower perforation. Since there are no junction boxes or other protrusions on the upper side of the outer sheet, the step of forming the insulating material in the existing manufacturing equipment is not affected. Furthermore, in the case of electrical conductors in the form of conductive ribbons or electrical conductors integrated into non-conductive grommets, because they are thin, their ends placed against the rear side of the outer sheet during the lamination of the photovoltaic active zone do not affect the flatness of the outer sheet. Accordingly, the lamination of the photovoltaic active zone can be efficiently performed solely on the outer sheet without modifying the existing lamination equipment to accommodate parts protruding from the surface of the rear side of the outer sheet. Additionally, in the case of electrical conductors in the form of conductive ribbons, the connection of the conductive ribbon to the rest of the electrical circuit is not made between the outer sheet and the photovoltaic active zone. Such a connection tends to be thick relative to the thickness of the photovoltaic active zone and tends to jeopardize the lamination of the latter.

[0147] Referring to FIGS. 8, 9 and 14, for electrical safety reasons, and where the outer sheet is made of a conductive material, the first upper electrical conductor (25) and the first lower electrical conductor (26) are each electrically insulated from the edges of the first upper perforation (27) and the first lower perforation (28), respectively, by a non-conductive grommet (29) inserted into the first upper perforation and the first lower perforation, respectively. First, the non-conductive grommet may include an opening (30) for the passage of the electrical conductor. The size of the opening is customized to the size of the electrical conductor. The non-conductive grommet may further include an upper portion (31) larger than the perforation. Thus, the non-conductive grommet can be seated on the outer sheet. The upper portion may be thin enough to further avoid stacking problems of the photovoltaic active zone. The non-conductive grommet may additionally include a lower portion (32) that is narrower than the perforation and includes a plurality of serrated projections (crenellation: 321). If the lower portion is narrower than the perforation, the non-conductive grommet can be easily positioned in the perforation. The serrated projections extend the surface distance between the opening (30) and the periphery of the grommet, and thus extend the creepage distance between the electrical conductor and the outer sheet. These are preferably concentric. Thanks to the serrated projections engraved on the lower portion, the electrical conductor coming from the non-conductive grommet on the rear side of the outer sheet is maintained at a safe surface distance from the conductive metal. The non-conductive grommet may include another opening (30) adjacent to the first opening for the passage of the second electrical conductor.

[0148] Preferably, the thickness of the grommet is approximately equal to the thickness of the outer sheet (0.5 - 1 mm). In particular, the thickness of the grommet is less than 2 mm, and more preferably less than 1 mm. Preferably, the grommet does not substantially protrude below the surface of the rear side of the outer sheet, particularly the rear side of the outer center portion. In particular, the grommet does not protrude more than 1 mm below the surface of the rear side of the outer sheet. In other words, the surface of the bottom portion of the grommet is substantially flush with the surface of the rear side of the outer sheet. Thanks to this design, the lamination of the photovoltaic active zone can be efficiently performed solely on the outer sheet without modifying existing lamination equipment to accommodate the portion protruding from the surface of the rear side of the outer sheet. Additionally, the grommet does not affect the flatness of the outer sheet.

[0149] Preferably, the width of the grommet (i.e., the longest length measured in the XY plane) is approximately the same size as the electrical connector, as described below. In particular, the width is less than 3 cm, and more preferably less than 2 cm. Such a width further improves the quality of lamination of the photovoltaic active area on the outer sheet.

[0150] Preferably, the first upper hole (27) is not crossed by anything other than the first upper electrical conductor, and, if present, a non-conductive grommet and, if present, a second electrical conductor. Preferably, the first lower hole (28) is not crossed by anything other than the first lower electrical conductor, and, if present, a non-conductive grommet and, if present, a second electrical conductor.

[0151] Referring to FIGS. 7, 10, and 15, the outer central portion (17) of the outer sheet (4) may additionally include a bypass perforation (33). The latter allows for the addition of a bypass diode (34) of the first photovoltaic active zone on the rear side of the outer sheet. Since the bypass diodes are thicker than the layers of the first photovoltaic active zone, inserting them directly into the first photovoltaic active zone tends to compromise the integrity of the latter. Due to the bypass perforation, a conductive ribbon from the first photovoltaic active zone can pass through the outer sheet, connect to the bypass diode, and pass through the outer sheet again.

[0152] Bypass holes are preferably positioned regularly along the longitudinal direction of the first photovoltaic active zone. They are preferably positioned as far as possible from the edge of the front sheet of the photovoltaic active zone in the transverse direction to prevent water leakage.

[0153] Preferably, the width of the bypass hole (i.e., the longest length measured in the XY plane) is approximately the size of the diameter of the electrical connector, as described below. In particular, the width is less than 3 cm, and more preferably less than 2 cm. In other words, the bypass hole cannot accommodate the electrical connector housing. This width further minimizes the negative impact of the hole on the lamination of the photovoltaic active zone on the outer sheet and further improves the watertightness of the sandwich panel.

[0154] When the outer sheet is made of a conductive material, a non-conductive grommet (29) is preferably inserted into the bypass hole to insulate the conductive ribbon from the bypass hole. These grommets have the same features as described above, except that they include two openings: namely, one for the conductive ribbon coming out of the first photovoltaic active zone and one for the conductive ribbon returning to the first photovoltaic active zone.

[0155] According to one variant of the present invention illustrated in FIGS. 1, 2, 6 and 7, the sandwich panel (1) includes a second photovoltaic active zone (35) positioned on an outer central portion (17). The second photovoltaic active zone (35) is positioned next to the first photovoltaic active zone (24). Preferably, the first photovoltaic active zone and the second photovoltaic active zone extend along a longitudinal axis parallel to each other. The outer sheet may include a third longitudinal rib positioned between the first photovoltaic active zone and the second photovoltaic active zone.

[0156] In particular, the first polarity of the second photovoltaic active zone is positioned adjacent to the upper transverse end of the second photovoltaic active zone, in the upper half of the second photovoltaic active zone, more preferably below the upper overlap zone (23) if applicable. This first polarity is preferably opposite to the first polarity of the first photovoltaic active zone. In particular, the second polarity of the second photovoltaic active zone is positioned within the lower half of the second photovoltaic active zone, more preferably at the lower transverse end of the first photovoltaic active zone, or adjacent to the lower overlap zone (22) of the sandwich panel if applicable. This second polarity is preferably opposite to the second polarity of the first photovoltaic active zone. The second photovoltaic active zone (35) is electrically connected to the second upper electrical conductor (36) and the second lower electrical conductor (37). Consequently, the outer central portion (17) includes a second upper perforation (38) through which a second upper electrical conductor passes and a second lower perforation (39) through which a second lower electrical conductor passes. Features and variations described in detail with respect to the first photovoltaic active zone and the corresponding features of the outer sheet are applied herein. Alternatively, the second upper electrical conductor passes through the first upper perforation (27), and the second lower electrical conductor passes through the first lower perforation (28).

[0157] As previously described in relation to the first photovoltaic active zone (24), the first upper electrical conductor (25) and the first lower electrical conductor (26) pass through the outer sheet (4). On the rear side of the outer sheet, the first upper electrical conductor (25) is electrically connected directly or indirectly to the first upper cable (42), and the first lower electrical conductor (26) is electrically connected directly or indirectly to the first lower cable (43). The method of electrical connection is not limited. It may be done by welding. The upper cable and the lower cable are preferably insulated. The upper cable and the lower cable may include a sleeve in at least one part.

[0158] For electrical safety reasons, to facilitate the integration of photoelectric functions in the sandwich panel, the first upper electrical conductor and the first lower electrical conductor are preferably insulated from the insulating material (2). In the variations shown in FIGS. 9, 10, 14, and 15, the first upper electrical conductor is preferably connected to the first upper cable at the first upper junction box (40), and the first lower electrical conductor is preferably connected to the first lower cable at the first lower junction box (41). A junction box is an electrical enclosure in which electrical wiring connections are securely made. The first upper junction box (40) and the first lower junction box (41) are part of the rear side of the outer sheet. Both junction boxes preferably include a casing. The casing preferably includes a conductor opening or ribbon opening and a cable opening. In the variations, the junction boxes (40, 41) include a non-conductive grommet (29) as described above.

[0159] Each of the first upper junction box (40) and the first lower junction box (41) is preferably positioned to contact the rear side of the outer sheet and substantially aligned vertically with each of the first upper hole (27) and the first lower hole (28), so that there is no gap between the outer sheet and the junction boxes. The junction boxes can be attached to the rear side of the outer sheet, for example, by gluing.

[0160] Thanks to this configuration, the connection of electrical conductors on the rear side of the outer sheet does not compromise the integrity and quality of the first photovoltaic active zone. In addition, the junction box can further improve watertightness at the perforation level.

[0161] The first upper cable (42) and the first lower cable (43) pass through insulating material until they enter the cavity. The first upper cable (42) enters the upper cavity (44), and the first lower cable (43) enters the lower cavity (45).

[0162] The portion of the cable passing through the insulating material may include a sleeve. "Passing through the insulating material" means that this portion of the cable, possibly including a sleeve, is tightly enclosed by the insulating material. This is the result of the insulating material being placed after the cable is positioned.

[0163] Between the cavity and its respective electrical conductor, or between each junction box where applicable, each cable, possibly including a sleeve, is preferably substantially embedded within the insulating material. In other words, this part of the cable is not removable. The substantial embedding of this part of the cable within the insulating material may result from foaming of the insulating material around the cable or from the attachment of the cable to the insulating material, for example by gluing, when the insulating material is placed. This substantial embodiment facilitates the process for manufacturing sandwich panels because there is no need to perform a specific step to insulate this part of the cable from the insulating material before the insulating material is placed in place.

[0164] In each joint, each cable is connected to an electrical connector. The first upper cable is connected to the first upper electrical connector (46), and the first lower cable is connected to the first lower electrical connector (47). The first upper electrical connector and the first lower electrical connector are corresponding male and female connectors. The first upper electrical connector may be a male connector and the first lower electrical connector may be a female connector, or vice versa.

[0165] These first electrical connectors allow electrical connection of the first photovoltaic active zone to other photovoltaic active zones and / or a grid. In particular, one polarity of the first photovoltaic active zone may be connected to one polarity of the first photovoltaic active zone of the second sandwich panel, such that its lower transverse side (8) of the insulating material is positioned adjacent to the upper transverse side (7) of the first sandwich panel by directly or indirectly connecting the first upper electrical connector (46) of the first sandwich panel to the first lower electrical connector (47) of the second sandwich panel. Similarly, the other polarity of the first photovoltaic active zone may be connected to one polarity of the first photovoltaic active zone of the third sandwich panel, such that its upper transverse side (7) of the insulating material is positioned adjacent to the lower transverse side (8) of the first sandwich panel by directly or indirectly connecting the first lower electrical connector (47) of the first sandwich panel to the first upper electrical connector (46) of the third sandwich panel. Alternatively, the first upper electrical connector (46) or the first lower electrical connector (47) of the sandwich panel may be connected to the grid. The joint role and features will be explained in detail later.

[0166] Referring to FIG. 9, FIG. 10, FIG. 14 and FIG. 15, according to a variation of the present invention in which a sandwich panel (1) comprises a second photovoltaic active zone (35) positioned on an outer central portion (17), the rear side of the outer sheet (4) comprises a second upper cable (50) electrically connected directly or indirectly to a second upper electrical conductor (36) and a second lower cable (51) electrically connected directly or indirectly to a second lower electrical conductor (37). In the illustrated variation, the second upper cable (50) is connected to the second upper electrical conductor (36) at a second upper junction box (48), and the second lower cable (51) is connected to the second lower electrical conductor (37) at a second lower junction box (49). Features and variations described in detail with respect to the first junction box apply herein. Alternatively, the second upper cable (50) is connected from the first upper junction box (40) to the second upper electrical conductor (36), and the second lower cable (51) is connected from the first lower junction box (40) to the second lower electrical conductor (37).

[0167] Each second cable passes through an insulating material until it enters a cavity. The second upper cable enters an upper cavity (44) into which the first upper cable (42) also enters. The second lower cable enters a lower cavity (45) into which the first lower cable (43) also enters. Between the cavity and its respective electrical conductor, or, where applicable, each junction box, each second cable, possibly including a sleeve, is preferably embedded substantially within the insulating material. The cable is preferably insulated for this purpose. In each cavity, each second cable is connected to an electrical connector. The second upper cable is connected to the second upper electrical connector (52), and the second lower cable is connected to the second lower electrical connector (53). The second upper electrical connector and the second lower electrical connector are corresponding male and female connectors. The second upper electrical connector may be a male connector and the second lower electrical connector may be a female connector, or vice versa.

[0168] These second electrical connectors allow for electrical connection of the second photovoltaic active zone to another photovoltaic active zone and / or to a grid. In particular, one polarity of the second photovoltaic active zone may be connected to one polarity of the second photovoltaic active zone of the second sandwich panel, such that its lower transverse side (8) of the insulating material is positioned adjacent to the upper transverse side (7) of the first sandwich panel by directly or indirectly connecting the second upper electrical connector (52) of the first sandwich panel to the second lower electrical connector (53) of the second sandwich panel. Similarly, the other polarity of the second photovoltaic active zone may be connected to one polarity of the second photovoltaic active zone of the third sandwich panel, such that its upper transverse side (7) of the insulating material is positioned adjacent to the lower transverse side (8) of the first sandwich panel by directly or indirectly connecting the second lower electrical connector (53) of the first sandwich panel to the second upper electrical connector (52) of the third sandwich panel. Alternatively, the second upper electrical connector (52) or the second lower electrical connector (53) of the sandwich panel can be connected to the grid.

[0169] The first upper electrical connector (46) and the second upper electrical connector (52), both located in the upper cavity (44), are preferably corresponding male and female connectors. Similarly, the first lower electrical connector (47) and the second lower electrical connector (53), both located in the lower cavity (45), are preferably corresponding male and female connectors. Due to this configuration, each cavity includes a male connector and a female connector. Consequently:

[0170] - Through connectors in the upper cavity, the first photovoltaic active zone (24) can be connected to the first photovoltaic active zone of the second sandwich panel, the lower transverse side (8) of the insulating material being positioned adjacent to the upper transverse side (7) of the first sandwich panel, while the second photovoltaic active zone (35) can be connected to the second photovoltaic active zone of the second sandwich panel without mismatch,

[0171] - Through connectors in the lower cavity, the first photovoltaic active zone (24) can be connected to the first photovoltaic active zone of the third sandwich panel, the upper transverse side (7) of the insulating material being positioned adjacent to the lower transverse side (8) of the first sandwich panel, while the second photovoltaic active zone (35) can be connected to the second photovoltaic active zone of the third sandwich panel without mismatch,

[0172] - Through connectors within the upper cavity, the first photovoltaic active zone (24) can be connected to the second photovoltaic active zone (35), so that the electrical circuit forms a loop, for example, at one end of the building envelope, particularly at the roof ridge, and

[0173] - Through connectors within the lower cavity, the first photovoltaic active zone (24) can be connected to the second photovoltaic active zone (35), so that the electrical circuit forms a loop, for example, at one end of the building envelope, particularly at the loop ridge.

[0174] Referring to FIGS. 3 through 5 and FIG. 11, the sandwich panel (1) further comprises an inner sheet (3). It is a substantially rectangular sheet comprising a first longitudinal inner edge (61), a second longitudinal inner edge (62), an upper transverse inner edge (63), and a lower transverse inner edge (64).

[0175] As illustrated in FIG. 5, the first longitudinal inner flange (65) extends along the first longitudinal inner edge (61), and the second longitudinal inner flange (66) extends along the second longitudinal inner edge (62). The first longitudinal inner flange (65) and the second longitudinal inner flange (66) are connected by an inner center portion (67).

[0176] The inner center portion (67) is shaped to allow access to electrical connectors along the inner sheet, so that the electrical connectors remain accessible from the inside of the building, particularly after the sandwich panels are assembled. For this reason, as illustrated in FIGS. 5, 11 and 21, it includes a longitudinal groove (85) extending from the upper transverse inner edge (63) of the inner sheet to the lower transverse inner edge (64), that is, from the upper transverse side of the insulating material to the lower transverse side. The longitudinal groove preferably has a trapezoidal shape with an upper center portion (86) and two lateral wings (87). This shape facilitates profiling of the inner sheet.

[0177] The longitudinal groove is positioned adjacent to the upper cavity (44) and the lower cavity (45). Thus, electrical connectors can be connected through the longitudinal groove. This means that they can be drawn out of their cavities through the longitudinal groove for connection to other cables, or connected within their cavities for additional connecting cables passing through the longitudinal groove.

[0178] To facilitate the extraction or connection of electrical connectors, the longitudinal groove preferably includes an upper opening (88) and a lower opening (89). The openings are preferably positioned on the lateral wing (87) of the longitudinal groove closest to the longitudinal side of the insulating material. The upper opening is located in the upper half of the sandwich panel, and the lower opening is located in the lower half of the sandwich panel. In particular, the upper opening is adjacent to the upper cavity, and the lower opening is adjacent to the lower cavity. According to a variation of the present invention comprising a second photovoltaic active zone (10) positioned on the outer central portion (17) of the sandwich panel (1), the longitudinal groove may include two upper openings (88) and two lower openings (89).

[0179] The longitudinal groove is preferably dimensioned so as to allow easy access to the electrical connectors. In one variation, the height of the lateral wings (87) of the longitudinal groove (taken along the Z-axis) is greater than or equal to the diameter of the electrical connector (46, 47, 52, or 53). In another variation, the width of the top center portion (86) of the longitudinal groove (taken along the Y-axis) is greater than or equal to the diameter of the electrical connector (46, 47, 52, or 53).

[0180] Since the longitudinal groove (85) is open to the inside of the building, it can be used to route cables, particularly to route a portion of the first upper cable (42) having a first upper electrical connector (46) and a portion of the first lower cable (43) having a first lower electrical connector (47), and, if applicable, to route a portion of the second upper cable (50) having a second upper electrical connector (52) and a portion of the second lower cable (51) having a second lower electrical connector (53). It can also be used to secure equipment, for example, lighting. It can also be closed with decorative capping and / or fireproof capping.

[0181] In particular, the longitudinal groove is dimensioned to allow routing of cables. In particular, the height of the longitudinal groove (taken along the Z-axis) is greater than or equal to the diameter of the electrical connector (46, 47, 52, or 53). More specifically, the width of the longitudinal groove (taken along the Y-axis) is greater than or equal to the diameter of the electrical connector (46, 47, 52, or 53). More specifically, the width of the longitudinal groove is at least twice the diameter of the electrical connector (46, 47, 52, or 53).

[0182] In particular, the upper opening (88) and the lower opening (89) are dimensioned to allow electrical connectors to pass through. More specifically, they are dimensioned to allow up to two electrical connectors to pass through or up to one electrical connector to pass through. Their length is preferably less than 6 cm, and more preferably less than 3 cm. That is, the upper and lower openings cannot accommodate an electrical connector housing. This width facilitates the setup of the insulating material, particularly foaming, and improves the watertightness of the sandwich panel.

[0183] On the outer side of the longitudinal groove, the inner central portion (67) is positioned substantially flat on the plane (P). According to a variation of the present invention, the inner central portion (67) additionally includes longitudinal reinforcing members to increase the rigidity of the metallic sheet.

[0184] In the first embodiment of the inner sheet illustrated in FIG. 5, in a cross-section perpendicular to the longitudinal axis (X), the first longitudinal inner flange (65) extends inward from the first longitudinal end (83) of the inner center portion (67) and forms an inner edge rabbit (68) in the insulating material along the first longitudinal side (5) of the insulating material. Preferably, the inner edge rabbit includes an inner riser (69) and an upper portion (70) starting from the first longitudinal end of the inner center portion and continuing therefrom. The inner riser may extend substantially perpendicular to the inner center portion, i.e., perpendicular to the plane (P), or may be inclined toward the upper portion. The latter may be parallel to the plane (P) or slightly inclined toward the inner center portion to facilitate interlocking of two adjacent panels.

[0185] Preferably, the first longitudinal inner flange (65) further includes a first inner reinforcement (71) extending from the inner edge rabbit (68), particularly from the upper portion (70). According to one variation of the invention, the first inner reinforcement extends substantially perpendicularly to the inner center portion along the first longitudinal side (5) of the insulating material. It improves sealing between two panels.

[0186] The first longitudinal inner flange (65) is located on the longitudinal side of the same insulating material as the first longitudinal rib of the outer sheet, protruding from the longitudinal side of the insulating material as illustrated in FIG. 5. It facilitates the lateral assembly of two adjacent panels. More preferably, the first longitudinal inner edge (61) is substantially vertically aligned with the first longitudinal end of the outer center portion (17) of the outer sheet (4). That is, the inner edge rabbit (68) is positioned below the outer center portion (17) of the outer sheet (4).

[0187] The second longitudinal inner flange (66) extends from the second longitudinal end of the inner central portion (67) by forming an inner tongue (73) that protrudes from the second longitudinal side (6) of the insulating material and extends outwardly and substantially parallel to the plane (P). Preferably, the inner tongue is in the form of a U-shaped bend comprising a lower branch (74) and an upper branch (75) connected by a U-turn (76). More preferably, the branches (74 and 75) are parallel. More preferably, the radius of the U-turn is such that the space between the branches is filled with insulating material (2) to help reinforce the inner tongue. According to another variation, the radius of the U-turn is such that the two branches are in contact with each other.

[0188] Preferably, the second longitudinal inner flange (66) includes a second inner reinforcement (77) extending from the inner tongue (73), particularly from the upper branch (75). According to one variation of the invention, the second inner reinforcement extends substantially perpendicularly to the inner center portion (67) along the second longitudinal side (6) of the insulating material. It improves sealing between two panels. According to one variation of the invention, the second inner reinforcement (77) includes a second inner wing (90) extending inwardly into the insulating material (2) parallel to the plane (P). This helps reinforce the first inner flange.

[0189] The inner edge rabbit (68) and the inner tongue (73) have a shape that allows their interlocking when one sandwich panel is assembled with a laterally adjacent sandwich panel. Preferably, their shapes are substantially complementary and their dimensions are as follows:

[0190] - The height of the inner edge rabbit (measured along the vertical axis (Z)) is higher than the height of the inner tongue, and

[0191] - The width of the inner edge rabbit (measured along the transverse axis (Y)) is greater than or equal to the width of the inner tongue.

[0192] These interlocking of the inner edge rabbits and inner tongues improves the resistance to wind suction of the envelope made of sandwich panels.

[0193] In the modified example of the inner sheet, the shapes of the first longitudinal inner flange (65) and the second longitudinal inner flange (66) are reversed.

[0194] In the second embodiment of the inner sheet illustrated in FIG. 21, in a cross-section perpendicular to the longitudinal axis (X), the first longitudinal inner flange (65) includes an inner mortise (110) that extends inwardly. In the illustrated example, the inner mortise is in the form of a U-shaped bend that extends substantially parallel to the plane (P). In particular, the inner mortise includes two branches that are substantially parallel and connected by a U-turn. More preferably, the two branches have substantially the same length. Other designs of the inner mortise are possible. It may have a V shape, in particular, having two branches that converge toward a U-turn. It may also have an L shape having branches and a sheet.

[0195] The first longitudinal inner flange (65) may include a first inner riser (69) extending between the first longitudinal end (83) of the inner center portion and the inner mortise. The first inner riser may extend substantially perpendicularly to the inner center portion, i.e., perpendicularly to the plane (P), or may be inclined toward the inner mortise.

[0196] Preferably, the first longitudinal inner flange (65) further includes a first inner reinforcement (71) extending from the inner mortise. According to one variation of the invention, the first inner reinforcement extends substantially perpendicularly to the inner center portion along the first longitudinal side (5) of the insulating material. It improves sealing between two panels.

[0197] The inner mortise (110), as illustrated in FIG. 21, is preferably located on the longitudinal side of the same insulating material as the outer mortise (102) of the outer sheet. It facilitates the lateral assembly of two adjacent panels. More preferably, the inner mortise is substantially vertically aligned with the outer mortise.

[0198] According to the inner mortise, the second longitudinal inner flange (66) of the inner sheet includes an inner tenon (111) that extends outwardly, and the inner tenon and the inner mortise have a shape that allows one longitudinal inner flange to overlap the other, i.e., the interlocking of the inner tenon and the inner mortise. In the illustrated example, the inner tenon protrudes from the second longitudinal side (6) of the insulating material. “Protrudes” means that the second longitudinal inner flange (66) extends beyond the second longitudinal side (6) of the insulating material, particularly beyond the plane of the second longitudinal side.

[0199] In the illustrated example, the inner tenon (111) is in the form of a U-shaped bend that extends substantially parallel to the inner central portion (67). In particular, the inner tenon includes two branches that are substantially parallel and connected by a U-turn. More preferably, the two parallel branches have substantially the same length. Other designs of the inner tenon are possible. It may have a V shape, in particular, having two branches that converge toward the U-turn. It may also have an L shape with branches and a sheet.

[0200] The second longitudinal inner flange (66) may include a second inner riser (72) extending between the second longitudinal end (84) of the inner center portion and the inner tenon. The second inner riser may extend substantially perpendicularly to the inner center portion, i.e., perpendicularly to the plane (P), or may be inclined toward the inner tenon or inclined toward the inner center portion.

[0201] Preferably, the second longitudinal inner flange (66) includes a second inner reinforcement (77) extending from the inner tenon (111). According to one variation of the invention, the second inner reinforcement extends substantially perpendicularly to the inner center portion (67) along the second longitudinal side (6) of the insulating material. It improves sealing between two panels.

[0202] The internal mortise (110) and internal tenon (111) have a shape that allows one longitudinal internal flange to overlap over the other, i.e., interlock them, when one sandwich panel is assembled with a laterally adjacent sandwich panel. Preferably, their shapes are substantially complementary and their dimensions are as follows:

[0203] - The height of the inner mortise (measured along the vertical axis (Z)) is higher than the height of the inner tenon, and

[0204] - The width of the inner mortise (measured along the transverse axis (Y)) is greater than or equal to the width of the inner tenon.

[0205] This interlocking of the internal mortise and internal tenon improves the resistance of the envelope composed of sandwich panels, particularly resistance to wind suction.

[0206] In the modified example of the inner sheet, the shapes of the first longitudinal inner flange (65) and the second longitudinal inner flange (66) are reversed.

[0207] As previously described with respect to the electrical connector, the sandwich panel further includes an upper cavity (44) and a lower cavity (45). "Cavity" refers to a hollow space within the insulating material. This hollow space is dimensioned to accommodate a first electrical connector and a portion of the first cable, and possibly a second electrical connector and a portion of the second cable.

[0208] The cavity may substantially be a rectangular prism. It may extend in the longitudinal or transverse direction. The cavity preferably comprises a casing embedded in the insulating material. "Embedded" means that the casing is firmly fixed within the insulating material and intricately connected to it. This embedding is the result of foaming of the insulating material around the casing, or the result of the attachment of the casing to the insulating material, for example by gluing, when the insulating material is placed. The cavity may be completely enclosed by the casing. Alternatively, it may be partially enclosed by the casing and partially enclosed by other components of the sandwich panel, such as, for example, the edge band (9), cap (10), outer sheet (4), and inner sheet (3).

[0209] The material used for the casing is not limited. It can be, for example, plastic, foam material, mineral wool, or wood wool. In the case of the insulating material formed by the expansion of the reaction mixture, the material is preferably selected so that the cavity does not shrink significantly during the expansion of the reaction mixture.

[0210] Both cavities are located within the insulating material. Such representation means that no single part of the cavity, particularly any single part of the casing, extends beyond the boundaries of the insulating material. In particular, no single part of the cavity protrudes from the first longitudinal side (5) or the second longitudinal side (6), or the upper transverse side (7) or the lower transverse side (8) of the insulating material. With this configuration, the sandwich panel can be manufactured as a standard sandwich panel in an existing manufacturing facility.

[0211] Referring to FIGS. 9 and FIGS. 14, the upper cavity (44) includes a first upper electrical connector (46) and a portion of the first upper cable (42). Preferably, this portion of the first upper cable is long enough so that the first upper electrical connector can be drawn out of the upper cavity. More preferably, this portion of the first upper cable is folded within the upper cavity. This folding facilitates drawing out. In a variant of the invention in which the sandwich panel (1) includes a second photovoltaic active zone (35), the upper cavity (44) further includes a second upper electrical connector (52) and a portion of the second upper cable (50). This portion is preferably folded within the upper cavity. Each, the lower cavity (45) includes a first lower electrical connector (47) and a portion of the first lower cable (43). Preferably, this portion of the lower cable is long enough so that the first lower electrical connector can be drawn out of the lower cavity. More preferably, this portion of the first lower cable is folded within the lower cavity. In a variation of the present invention in which the sandwich panel (1) includes a second photovoltaic active zone (35), the lower cavity (45) further includes a second lower electrical connector (53) and a portion of a second lower cable (51). This portion is preferably folded within the lower cavity.

[0212] To facilitate the insertion of an upper or lower cable into the cavity, the cavity casing preferably includes an inlet for cable insertion. The casing may also include an outlet for accessing electrical connector(s). Alternatively, the electrical connector may be accessed by cutting the cavity casing.

[0213] The first purpose of both cavities is to prevent the electrical connectors of the photovoltaic active zone(s) from being trapped in the insulating material during the manufacturing process of the sandwich panel. The second purpose is to allow easy access to the electrical connectors after the sandwich panel is manufactured. Thus, above all, the upper cavity (44) is positioned in the upper half of the sandwich panel, and the lower cavity (45) is positioned in the lower half of the sandwich panel. In this way, there is no risk of cables crossing when the photovoltaic active zones of adjacent panels are electrically connected. Secondly, the cavities are positioned, on one hand, adjacent to the longitudinal groove (85), and on the other hand, adjacent to the first longitudinal side (5) of both insulating materials or adjacent to the second longitudinal side (6) of both insulating materials. In particular, the cavities, more preferably one side of the casing, are positioned adjacent to the longitudinal groove, and the cavities, more preferably the opposing side of the casing, are positioned adjacent to the first longitudinal side of the insulating material or adjacent to the second longitudinal side of the insulating material.

[0214] Due to this positioning of the above cavities, the first upper electrical connector and the first lower electrical connector, respectively, can be accessed along one of the longitudinal sides of the insulating material from the upper cavity and the lower cavity, respectively. “Accessed” means that the electrical connectors can be reached by an operator and manipulated by an operator within their cavities. Consequently, and possibly after opening the cavities, the operator can connect the electrical connectors through the longitudinal grooves. In particular, these are:

[0215] - Electrical connector(s) are drawn out through a longitudinal groove, that is, they and possibly a portion of their cables are passed through the longitudinal groove, preferably through an upper opening (88) or a lower opening (89), so that the electrical connector(s) can subsequently be connected to another cable(s), and / or

[0216] - Additional connecting cables can be passed through the longitudinal groove, preferably through the upper opening (88) or lower opening (89), and connected to electrical connectors within the cavity.

[0217] As a result, cables and electrical connectors do not hinder adjacent sandwich panels from being assembled in a connected manner.

[0218] As described above, the upper and lower cavities (44, 45) are adjacent to the longitudinal groove. Preferably, each cavity is positioned at a distance of less than 1 cm from the longitudinal groove, more preferably at a distance of less than 0.5 cm. Preferably, the upper cavity is adjacent to the upper opening (88) within the longitudinal groove. Preferably, the lower cavity is adjacent to the lower opening (89) of the longitudinal groove. In particular, the casing of the cavity is positioned adjacent to the longitudinal groove. More specifically, the wall of the casing is positioned adjacent to the longitudinal groove. It may be a wall or a flat wall that includes an outlet for connecting electrical connectors through the longitudinal groove. The wall may be in contact with the longitudinal groove.

[0219] Preferably, the upper cavity is positioned along the longitudinal axis (X) of the sandwich panel between the upper transverse side (7) of the insulating material and the first upper hole (27). This position limits the length of the cable required to connect the photovoltaic active zone.

[0220] Preferably, the lower cavity is positioned along the longitudinal axis (X) of the sandwich panel between the lower transverse side (8) of the insulating material and the first lower hole (28). This position limits the length of the cable required to connect the photovoltaic active zone.

[0221] The upper cavity (44) may be opened along the longitudinal side (5, 6) of the insulating material, possibly through a cut in the insulating material and / or through a cut in the edge band (9) and / or through a cut in the casing of the upper cavity. Accordingly, the longitudinal side of the insulating material may include an upper cutout (91) extending from the upper cavity to the longitudinal side.

[0222] The lower cavity (45) may be open along the longitudinal sides (5, 6) of the insulating material, possibly through a cut in the insulating material and / or through a cut in the edge band (9) and / or through a cut in the casing of the lower cavity (45). Accordingly, the longitudinal side of the insulating material may include a lower cutout (92) extending from the lower cavity to the longitudinal side.

[0223] According to the first embodiment of the invention illustrated in FIGS. 9 through 13, the upper cavity (44) and the lower cavity (45) are positioned adjacent to the second longitudinal side (6) of the insulating material. Preferably, each cavity is positioned at a distance of less than 1 cm from the second longitudinal side, more preferably at a distance of less than 0.5 cm. In particular, the casing of each cavity is positioned adjacent to the second longitudinal side. More specifically, the wall of the casing is positioned adjacent to the second longitudinal side. It may be a wall or a flat wall containing an outlet for accessing the electrical connector(s). Such a wall may be in the plane of the second longitudinal side. In such a case, such a wall and, if applicable, the outlet for accessing the electrical connector(s) do not come into contact with the insulating material. Each cavity, in particular its casing, may be adjacent to the edge band (9).

[0224] In this embodiment, when a sandwich panel is positioned on a building structure by overlapping the first longitudinal outer flange (15) of the sandwich panel with the second longitudinal outer flange (16) of an adjacent panel, the second longitudinal side of the insulating material is kept accessible to an operator. The latter, therefore, can easily open the cavities if they were not opened in the previous step, access the connector(s), and connect the connector(s) to the electrical connector(s) or grid of the adjacent sandwich panels through the longitudinal groove.

[0225] According to a second embodiment of the invention illustrated in FIGS. 14 to 17, the upper cavity (44) and the lower cavity (45) are positioned adjacent to the first longitudinal side (5) of the insulating material. Preferably, each cavity is positioned at a distance of less than 1 cm from the first longitudinal side, more preferably at a distance of less than 0.5 cm. In particular, the casing of each cavity is positioned adjacent to the first longitudinal side. More specifically, the wall of the casing is positioned adjacent to the first longitudinal side. It may be a wall or a flat wall containing an outlet for accessing the electrical connector(s). Such a wall may be in the plane of the first longitudinal side. In such a case, such a wall and, if applicable, the outlet for accessing the electrical connector(s) do not come into contact with the insulating material. Each cavity, in particular its casing, may be adjacent to the edge band (9).

[0226] In this embodiment, when a sandwich panel is positioned on a building structure by overlapping the first longitudinal outer flange (15) of the sandwich panel with the second longitudinal outer flange (16) of an adjacent panel, the first longitudinal side of the insulating material is no longer accessible to the operator. Nevertheless, the latter can easily open the cavities in the previous step, pull out electrical connector(s) through the longitudinal groove and / or pass additional connecting cable(s) through the longitudinal groove and connect them to the electrical connector(s) within the cavity.

[0227] From the perspective of the manufacturing process, there can be three main ways to manufacture sandwich panels.

[0228] The first method is a discontinuous process in which an inner sheet and an outer sheet are first cut to size and shaped (or vice versa). In the first variation, they are then held in a mold at a given distance from each other, and the gap between them is filled with a reaction mixture that expands to form an insulating material. In the second variation, one of the sheets is positioned in the mold and is preferably covered by an insulating material in the form of a slab, also known as a batt or lamella. A layer of adhesive is applied between the slab of insulating material and the sheet, and another layer of adhesive is applied on the insulating material. Then, the second sheet is positioned on the insulating material, and the stack is pressed and heated to cure the adhesive.

[0229] The second method is a continuous process in which the inner facing and outer facing are provided in the form of coils. The coils are unwound, and the strips move one above the other through a profiling station where they are shaped. In the first variant, the reaction mixture is then applied to the inner surface of the lower strip or the inner surface of the upper strip, and the two strips enter a double belt conveyor. The latter includes two consecutive conveyor belts aligned one above the other, extending parallel to each other and capable of absorbing or applying a predetermined amount of pressure to maintain the gap between the two strips. The gap between the two belts is adjustable, allowing for adjustment of the panel thickness. On the double belt conveyor, the reaction mixture expands and fills the gap between the two strips to form an insulating material. Side walls prevent lateral escape of the foam. Different panel designs and modes of operation require appropriate side seals in each case. The side walls may be in the form of accompanying side sealing chains manufactured as blocks. After the composite material formed from two strips and insulating material exits the double belt conveyor, the composite material is cut to a desired length to obtain a sandwich panel. In the second variant, a layer of adhesive is applied to the inner surface of the lower strip, and a slab of insulating material is positioned. Another layer of adhesive is applied on the insulating material or on the inner surface of the upper strip. On the double belt conveyor, the strips are pressed and the adhesive is cured. Other features of the first variant are applied to the second variant.

[0230] The third method is a semi-continuous process. It differs from a continuous process in that only the inner facing is supplied in the form of a coil and enters a double belt conveyor as a strip—in this case, as an inner strip, preferably as a higher strip on the manufacturing line. The outer facing is in the form of a sheet that has been cut to size and shaped (or vice versa) in the previous step. The outer sheet is supplied continuously to the manufacturing line, preferably without a gap, instead of the lower strip. Then, in the first variation, a reaction mixture is applied to the inner side of the outer sheet or the inner side of the upper strip, and the inner strip and outer sheet enter a double belt conveyor. On the conveyor, the reaction mixture reacts and expands to fill the gap between the inner strip and the outer sheet, thus forming an insulating material. In the second variation, layers of adhesive are applied and slabs of insulating material are positioned on the outer sheets, and then the inner strip and outer sheets enter a double belt conveyor where they are pressurized. At the exit of the conveyor, the inner strip and insulating material are cut along the length of the outer sheet to obtain a sandwich panel.

[0231] Although the manufacturing of the sandwich panel according to the present invention is described with respect to discontinuous and semi-continuous processes, those skilled in the art can easily customize other methods of manufacturing sandwich panels to manufacture the sandwich panel according to the present invention.

[0232] In the first stage, an outer sheet (4) is prepared.

[0233] In the first stage, the outer sheet is cut to length. Optionally, it is cut to length from a strip and then shaped, or the strip is first shaped on a profiling line and then cut to length. The shaping step includes shaping the first longitudinal outer flange (15) and shaping the second longitudinal outer flange (16).

[0234] In the second step, prior to, together with, or after the first step, a first upper hole (27) and a first lower hole (28) are formed in the outer central portion (17). If applicable, a second upper hole (38) and a second lower hole (39) and / or a bypass hole (33) are also formed in the outer central portion. Optionally, non-conductive grommets are positioned within the upper and lower holes and, possibly, attached thereto.

[0235] In the third step, following the first and second steps, the first photovoltaic active zone (24) is positioned on the outer central portion and preferably stacked. If applicable, the second photovoltaic active zone (35) is also simultaneously positioned on the outer central portion and preferably stacked. In particular, positioning the photovoltaic active zone involves stacking different components of the photovoltaic active zone. In particular, during the positioning step, the first upper electrical conductor (25) is inserted into the first upper hole and the first lower electrical conductor (26) is inserted into the first lower hole. More specifically, a non-conductive grommet (29) is inserted into the first upper and lower holes. If applicable, the second upper electrical conductor (36) is inserted into the second upper hole and the second lower electrical conductor (37) is inserted into the second lower hole. When the stack is ready, it is heated and pressurized in the stacking device so that the films surrounding the solar cells fuse and the cells are embedded. At the end of these steps, if the outer sheet has not been previously shaped, its formation is performed.

[0236] When the photovoltaic active region is laminated onto the outer sheet, the latter does not include any portion that substantially protrudes from the surface of the rear side of the outer sheet, particularly from the surface of the rear side of the outer central portion. In particular, there is no portion that protrudes more than 2 mm, more preferably more than 1 mm, below the surface of the rear side of the outer sheet or below the surface of the rear side of the outer central portion. In other words, the surface of the rear side of the outer central portion, or the surface of the rear side of the outer sheet, is substantially flat. Thanks to this design, the lamination of the photovoltaic active region can be efficiently performed solely on the outer sheet without modifying existing lamination equipment to accommodate portions protruding from the surface of the rear side of the outer sheet.

[0237] In the fourth step, after the third step, the outer sheet is positioned upside down, and on its rear side, as illustrated in FIGS. 10 and 15, a first upper cable (42), a first upper electrical connector (46), a first lower cable (43), a first lower electrical connector (47), an upper cavity (44), and a lower cavity (45) are provided. Optionally, it is also provided with a first upper junction box (40) and a first lower junction box (41). If applicable, it is additionally provided with a second upper cable (50), a second upper electrical connector (52), a second lower cable (51), and a second lower electrical connector (53) and / or bypass diodes (34), as illustrated in FIGS. 10 and 15. Optionally, it is also provided with a second upper junction box (48) and a second lower junction box (49). The junction boxes are preferably positioned substantially vertically aligned with the perforations. An electrical conductor is electrically connected to one end of the cable, possibly inside the junction box. The other end of the cable is inserted into the cavity and electrically connected to an electrical connector (or vice versa).

[0238] The upper cavity is positioned in the upper half of the outer sheet facing the rear side of the outer sheet, and the lower cavity is positioned in the lower half of the outer sheet facing the rear side of the outer sheet, if applicable, outside the lower overlap area.

[0239] The upper cavity is preferably attached directly or indirectly to the rear side of the outer sheet, and the lower cavity is preferably attached directly or indirectly to the rear side of the outer sheet. The upper and lower cavities, in particular their casings, may be attached directly to the rear side of the outer sheet, for example by gluing, or they may be attached to one shim (82) or multiple shims that are attached to the rear side of the outer sheet, as illustrated in FIGS. 9 and FIGS. 14. By the shim(s), the position of the cavity along the vertical axis (Z) in the insulating material can be adjusted according to the thickness of the insulating material. The shim thickness (taken along the vertical axis (Z)) can be adjusted so that the sum of the shim thickness and the cavity thickness is equal to the thickness of the insulating material of the sandwich panel. The shim(s) can also facilitate the positioning of the upper and lower cavities on one lateral wing (20) of the second longitudinal rib (21) of the outer sheet.

[0240] Alternatively, the upper cavity and / or lower cavity may be attached to a pre-positioned edge band (9) either previously or simultaneously along the second longitudinal outer edge (12) or adjacent to the first longitudinal outer flange (15). This facilitates the positioning of the cavity along the edge band during the placement of the insulating material.

[0241] According to the first variant, the upper cavity and the lower cavity are positioned along the second longitudinal outer edge (12). In this way, at the end of the manufacturing process, the cavity is adjacent to the second longitudinal side of the insulating material.

[0242] According to the second variant, the upper cavity and the lower cavity are positioned adjacent to the first longitudinal outer flange (15) or along the first longitudinal outer edge (11). In this way, at the end of the manufacturing process, the cavity is adjacent to the first longitudinal side of the insulating material.

[0243] In the second stage, after the first stage, an external sheet is provided.

[0244] In the third stage, prior to, simultaneously with, or after the second stage, an inner sheet comprising a longitudinal groove (85) in an inner central portion (67) is provided. In a first variant corresponding to a discontinuous process, an inner sheet that is cut and shaped to size is provided. In such a case, the inner sheet comprises an inner central portion (67) comprising an upper transverse inner edge (63), a lower transverse inner edge (64), and a longitudinal groove (85) extending from the upper transverse inner edge to the lower transverse inner edge. In a second variant corresponding to a semi-continuous process, the inner sheet is provided in the form of a strip shaped to have a longitudinal groove (85) in an inner central portion (67).

[0245] In the fourth stage, after the second stage and before or simultaneously with or after the third stage, the insulating material is placed in position. It may be placed in position in the form of a reaction mixture applied to the rear side of the outer sheet or injected between the inner and outer sheets, or in the form of a slab of insulating material (2) applied to the rear side of the outer sheet. In the case of a reaction mixture, it expands to form the insulating material (2). The outer sheet is preferably positioned upside down. In such a case, if the outer sheet was not already positioned upside down in the first stage, it is positioned upside down before the insulating material is placed in position.

[0246] In the fifth stage, after the second stage, simultaneously with or after the third stage, and before the fourth stage, simultaneously with or after, the inner sheet is maintained at a given distance from the outer sheet so that the upper cavity and the lower cavity are adjacent to the longitudinal groove. At the end of the manufacturing process, the longitudinal groove is positioned so that the upper cavity and the lower cavity are adjacent to the longitudinal groove and positioned between the longitudinal groove and either the first or second longitudinal side of the insulating material. The distance between the inner sheet and the outer sheet can be maintained in a mold, a press, or a double belt conveyor. The outer sheet is preferably positioned upside down. In such cases, if the outer sheet was not already positioned upside down in the first stage, it is positioned upside down before the inner sheet is positioned. The given distance corresponds to the set thickness of the sandwich panel.

[0247] Stages 4 and 5 are described below in relation to discontinuous and semi-continuous processes. Overall, during these two stages, the insulating material is placed in position and the inner sheet is maintained at a given distance from the outer sheet so that the upper cavity and the lower cavity are adjacent to the longitudinal groove or vice versa.

[0248] Regarding the discontinuous process, in the first variation, the outer sheet and the inner sheet are positioned within the mold at a given distance from each other. The outer sheet is preferably positioned upside down at the bottom of the mold, and the inner sheet is positioned at the top of the mold. The distance between the inner sheet and the outer sheet can be adjusted by a shim. The mold maintains the distance between the inner sheet and the outer sheet. An edge band (9) is preferably added along the longitudinal side of the mold between the inner sheet and the outer sheet, unless the edge band has already been positioned along the second longitudinal outer edge in the previous step. In other words, the edge band is preferably positioned along the first longitudinal inner edge and the second longitudinal inner edge of the inner sheet. A cap is preferably positioned along the transverse side of the mold between the inner sheet and the outer sheet. That is, the cap is preferably positioned along the upper transverse inner edge (63) and the lower transverse inner edge (64) of the inner sheet between the inner sheet and the outer sheet.

[0249] Subsequently, the reaction mixture is injected into the mold between the inner sheet and the outer sheet. The reaction mixture reacts and expands to fill the gap between the inner sheet and the outer sheet, thereby forming an insulating material. The expansion of the reaction mixture can be performed in a press or on a conveyor, possibly on a double belt conveyor.

[0250] In a second variation of the discontinuous process, the outer sheet is positioned upside down in the mold, and a slab of insulating material (2) is positioned on the outer sheet. A layer of adhesive is applied between the slab of insulating material and the outer sheet, and another layer of adhesive is applied on the insulating material. An edge band (9) and a cap (10) may be added as described in relation to the first variation. Then, the inner sheet is positioned on the insulating material and maintained at a given distance from the outer sheet. The stack is pressed and heated to cure the adhesive. Pressing and heating may be performed in a press or on a conveyor, possibly on a double belt conveyor.

[0251] For a semi-continuous process, the inner sheet enters the double belt conveyor as an inner strip shaped so that its inner central portion (67) includes a longitudinal groove (85). The inner strip is the higher strip on the manufacturing line. The outer sheet is fed continuously without gaps on the manufacturing line. These replace the second strip on the manufacturing line, the lower strip. Thus, each outer sheet is part of the continuous feeding of the manufacturing line.

[0252] In the first variation of the semi-continuous process, if the outer sheet is not already in that position, it is positioned upside down, and the reaction mixture is applied to its rear side or the rear side of the inner strip. The inner strip and the outer sheet enter a double belt conveyor, where the distance between them is maintained by the double belt conveyor. In the latter, the reaction mixture reacts, expands, and fills the gap between the inner strip and the outer sheet to form an insulating material. The edge band (9) is positioned along the first longitudinal inner edge and the second longitudinal inner edge of the inner sheet, unless the edge band has already been positioned in the previous step. The edge band is preferably a coil unwound in the form of a strip that enters the double belt conveyor.

[0253] In a second variation of the semi-continuous process, the outer sheet is positioned upside down if it is not already in such a position, and a slab of insulating material (2) is positioned on the outer sheet. A layer of adhesive is applied between the slab of insulating material and the outer sheet, and another layer of adhesive is applied on the insulating material. Then, the inner strip and the outer sheet enter a double belt conveyor, where the distance between them is maintained by the double belt conveyor. In the latter, the stack is pressed and heated to cure the adhesive.

[0254] After the insulating material is placed in position, the sandwich panel manufactured through a discontinuous process can be removed from the mold. Regarding the discontinuous process, at the exit of the conveyor, the inner strip and insulating material are cut along the length of the outer sheet to obtain the sandwich panel.

[0255] After the sandwich panel is manufactured, the upper cavity (44) may be opened to provide access to the first upper electrical connector (46) and, if applicable, to the second upper electrical connector (52). Similarly, the lower cavity (45) may be opened to provide access to the first lower electrical connector (47) and, if applicable, to provide access to the second lower electrical connector (53). This is illustrated in FIGS. 12, 13, 16, and 17.

[0256] The upper cavity and the lower cavity may be opened by a cut on the first or second longitudinal side of the insulating material. Depending on the nature and position of the cavity, the cut may be made through different materials. The cut may be made in the insulating material. If the cavity includes a casing having a planar wall adjacent to the longitudinal side, the cut is made in the insulating material and the casing. If the planar wall of the casing exists within the plane of the longitudinal side, there is no cut through the insulating material. If the wall of the casing already has an outlet for accessing the electrical connector(s) in the plane of the longitudinal side, there is no cut through the casing. If the longitudinal side includes an edge band, the cut may be made in the edge band. The cut may be formed with any suitable tool, such as a cutter, saw, or chisel, for example.

[0257] The upper and lower cavities may also be opened along the longitudinal groove by cutting in the longitudinal groove. Depending on the nature and position of the cavity, the cut may be made through different materials. If the upper opening (88) and lower opening (89) were not formed in the longitudinal groove in the previous step, the cut is performed in the longitudinal groove. If the cavity includes a casing having a flat wall adjacent to the inner sheet, the cut is made in the insulating material and the casing. If the flat wall of the casing contacts the longitudinal groove, there is no cut through the insulating material. If the wall of the casing contacting the longitudinal groove already has an outlet for accessing the electrical connector(s), there is no cut through the casing. The cut may be made with any suitable tool, such as a drill, cutter, saw, or chisel, for example.

[0258] Openings of the upper and lower cavities along the first or second longitudinal side of the insulating material and / or along the longitudinal groove may be formed immediately after or after the manufacture of the sandwich panels. To limit work during the installation of the sandwich panels on the building structure and to better control the quality of the cut, the latter is preferably performed at the manufacturing site.

[0259] After both the upper cavity and the lower cavity are opened along the longitudinal groove and either the first longitudinal side or the second longitudinal side of the insulating material is opened, the first upper electrical connector and the first lower electrical connector, and if applicable, the second upper electrical connector and the second lower electrical connector, can be set up to subsequently connect to the electrical connectors and / or grid of adjacent sandwich panels. In the first variant, the electrical connectors and, in some cases, a portion of their cables pass through the longitudinal groove, preferably through the upper opening (88) or the lower opening (89). In another variant, additional connecting cables pass through the longitudinal groove, preferably through the upper opening (88) or the lower opening (89), and are connected to the electrical connector(s) within the cavity.

[0260] This setup of the electrical connectors can be performed immediately after or after the manufacture of the sandwich panels. To limit work and better control quality during the installation of the sandwich panels on the loop, the setup is preferably performed at the manufacturing site. In such a case, a portion of the first upper cable having a first upper electrical connector and a portion of the first lower cable having a first lower electrical connector, and, if applicable, a portion of the second upper cable having a second upper electrical connector and a portion of the second lower cable having a second lower electrical connector are preferably housed in the longitudinal groove. The electrical connectors and portions of the cables may preferably be temporarily attached to the longitudinal groove, for example, with adhesive tape or clips.

[0261] After the sandwich panels are manufactured, they can be delivered to a construction site to assemble a building envelope on a building structure. Referring to FIGS. 18 through 20, the assembly process of the building envelope includes a first step in which a first sandwich panel (1a) is fastened to a building structure. In particular, it is fastened to a purlin (58). More specifically, the lower half of the first sandwich panel is fastened to the lower purlin. In particular, the upper half of the first sandwich panel is placed on the first upper purlin (58a). More specifically, the upper overlap area (23) of the first sandwich panel is placed on the first upper purlin.

[0262] In the second step, the second sandwich panel (1b) is positioned on the building structure adjacent to the first sandwich panel, such that the lower transverse side (8) of its insulating material is adjacent to the upper transverse side (7) of the insulating material of the first sandwich panel. In particular, the lower overlap area (22) covers the upper overlap area (23) of the first sandwich panel if applicable. In particular, the lower half of the second sandwich panel is placed on the first upper purlin. In particular, the upper half of the second sandwich panel is placed on the second upper purlin (58b) which is positioned higher than the first upper purlin. More specifically, the upper overlap area (23) of the second sandwich panel is placed on the second upper purlin. The second sandwich panel is fastened to the building structure. In particular, it is fastened to the first upper purlin. More specifically, the lower overlap area of ​​the second sandwich panel is fastened to the first upper purlin simultaneously with the fastening of the upper overlap area of ​​the first sandwich panel to the first upper purlin.

[0263] In the third stage, the first upper electrical connector (46) of the first sandwich panel is connected to the first lower electrical connector (47) of the second sandwich panel. This step can be performed immediately after the second sandwich panel is fastened. It can also be performed once the rows of all sandwich panels are positioned and fastened. It can also be performed once the envelopes (or envelope sides) of all sandwich panels are positioned and fastened. Since the electrical connectors are accessible from the inside of the building, the presence of an electrician is not required during the installation of the sandwich panels.

[0264] According to the first variant example illustrated in FIGS. 19 and 20, a portion of the first upper cable (42) of the first sandwich panel and the first upper electrical connector (46) are inserted into the longitudinal groove (85) of the first sandwich panel and slide over the purlin (58a), and the first upper electrical connector is connected to the first lower electrical connector (47) of the second sandwich panel. Alternatively, a portion of the first lower cable (43) of the second sandwich panel and the first lower electrical connector (47) are inserted into the longitudinal groove (85) of the second sandwich panel and slide over the purlin (58a), and the first lower electrical connector is connected to the first upper electrical connector (46) of the first sandwich panel.

[0265] If applicable, the second upper electrical connector (52) of the first sandwich panel and the second lower electrical connector (53) of the second sandwich panel are connected in a similar manner.

[0266] According to a second variant in which electrical connectors are connected to additional connecting cables within the cavities, a first upper additional connecting cable connected to a first upper electrical connector (46) of a first sandwich panel is inserted into a longitudinal groove (85) of the first sandwich panel and slides over a purlin (58a), and the first upper additional connecting cable is connected to a first lower electrical connector (47) of a second sandwich panel directly or through a first lower additional connecting cable. Alternatively, a first lower additional connecting cable connected to a first lower electrical connector (47) of a second sandwich panel is inserted into a longitudinal groove (85) of the second sandwich panel and slides over a purlin (58a), and the first lower additional connecting cable is connected to a first upper electrical connector (46) of the first sandwich panel directly or through a first upper additional connecting cable.

[0267] If applicable, the second upper electrical connector (52) of the first sandwich panel and the second lower electrical connector (53) of the second sandwich panel are connected in a similar manner.

Claims

Claim 1 A sandwich panel (1) for a building envelope comprising an inner sheet (3), an outer sheet (4), and an insulation material (2) sandwiched between the inner sheet and the outer sheet, wherein the insulation material has a first longitudinal side (5), a second longitudinal side (6), an upper transverse side (7), and a lower transverse side (8), and the sandwich panel has an upper half and a lower half, and the inner sheet comprises an inner central portion (67) including a longitudinal groove (85) extending from the upper transverse side of the insulation material to the lower transverse side, and the outer sheet comprises: - a first longitudinal outer flange (15), - an outer central portion (17) extending from the first longitudinal outer flange: o First upper perforation (27) through which the first upper electrical conductor (25) passes, o The outer central portion (17) comprising a first lower perforation (28) through which a first lower electrical conductor (26) passes, - a first photovoltaic active zone (24) positioned on the outer central portion and electrically connected to the first upper electrical conductor and the first lower electrical conductor; - a second longitudinal outer flange (16) extending from the outer central portion, wherein the first longitudinal outer flange and the second longitudinal outer flange have shapes that allow one above the other to overlap each other, and the rear side of the outer sheet comprises: - a first upper cable (42) connecting the first upper electrical conductor to a first upper electrical connector (46) positioned in the upper cavity (44), - a first lower cable (43) connecting the first lower electrical conductor to a first lower electrical connector (47) positioned in the lower cavity (45), wherein the first lower electrical connector and the first upper electrical connector are corresponding male and female connectors, and the upper cavity is of the sandwich panel A sandwich panel for a building envelope, wherein the upper half is positioned within the insulating material, the lower cavity is positioned within the insulating material in the lower half of the sandwich panel, the upper cavity and the lower cavity are adjacent to the longitudinal groove, both adjacent to the first longitudinal side of the insulating material or both adjacent to the second longitudinal side of the insulating material, and each of the first upper electrical connector and the first lower electrical connector can be accessed from each of the upper cavity and the lower cavity along one of the longitudinal sides of the insulating material and can be connected through the longitudinal groove. Claim 2 A sandwich panel for a building envelope according to claim 1, wherein the longitudinal groove further comprises an upper opening (88) adjacent to the upper cavity and a lower opening (89) adjacent to the lower cavity. Claim 3 A sandwich panel for a building envelope, wherein, in claim 1 or 2, the upper cavity (44) and the lower cavity (45) are open along the longitudinal side (6) of the insulating material. Claim 4 A sandwich panel for a building envelope, wherein, in any one of claims 1 to 3, the upper cavity (44) and the lower cavity (45) are each separated by a casing embedded in the insulating material. Claim 5 A sandwich panel for a building envelope, wherein, in any one of claims 1 to 4, the first photovoltaic active zone (24) comprises a layer capable of converting solar energy into electricity, and the first upper perforation (27) and the first lower perforation (28) are substantially located below the layer. Claim 6 A sandwich panel for a building envelope, wherein, in any one of claims 1 to 5, the rear side of the outer sheet further comprises a first upper junction box (40) connecting the first upper electrical conductor (25) to the first upper cable (42) and a first lower junction box (41) connecting the first lower electrical conductor (26) to the first lower cable (43). Claim 7 A sandwich panel for a building envelope, wherein in any one of claims 1 to 6, the first upper cable (42) and the first lower cable (43) each extend through the insulating material (2) until they enter the upper cavity (44) and the lower cavity (45), respectively. Claim 8 A sandwich panel for a building envelope, wherein, in any one of claims 1 to 7, the first upper cable (42) and the first lower cable (43) are each substantially embedded in the insulating material between the first upper electrical conductor (25) and the first lower electrical conductor (26) and the upper cavity (44) and the lower cavity (45) respectively. Claim 9 In any one of paragraphs 1 through 8, - the outer central part (17) additionally: o Second upper hole (38) through which the second upper electrical conductor (36) passes, o including a second lower perforation (39) through which a second lower electrical conductor (37) passes, - the outer sheet (4) further includes a second photovoltaic active zone (35) positioned on the outer central portion and electrically connected to the second upper electrical conductor and the second lower electrical conductor, - the rear side of the outer sheet further includes: o A second upper cable (50) connecting the second upper electrical conductor to the second upper electrical connector (52) positioned in the upper cavity (44), A sandwich panel for a building envelope, comprising a second lower cable (51) connecting the second lower electrical conductor to a second lower electrical connector (53) positioned in the lower cavity (45), wherein the second lower electrical connector and the second upper electrical connector are corresponding male and female connectors. Claim 10 In claim 9, the first upper electrical connector (46) and the second upper electrical connector (52) are corresponding male and female connectors, and the first lower electrical connector (47) and the second lower electrical connector (53) are corresponding male and female connectors, for a sandwich panel for a building envelope. Claim 11 A sandwich panel (1) for a building envelope comprising an inner sheet (3), an outer sheet (4), and an insulating material (2) sandwiched between the inner sheet and the outer sheet, wherein the insulating material has a first longitudinal side (5), a second longitudinal side (6), an upper transverse side (7), and a lower transverse side (8), and the sandwich panel has an upper half and a lower half, and the inner sheet comprises an inner central portion (67) including a longitudinal groove (85) extending from the upper transverse side of the insulating material to the lower transverse side, and the outer sheet comprises: - a first longitudinal outer flange (15), - an outer central portion (17) extending from the first longitudinal outer flange: o First upper perforation (27) through which the first upper electrical conductor (25) passes, o The outer central portion (17) comprising a first lower perforation (28) through which a first lower electrical conductor (26) passes, - a first photovoltaic active zone (24) positioned on the outer central portion and electrically connected to the first upper electrical conductor and the first lower electrical conductor; - a second longitudinal outer flange (16) extending from the outer central portion, wherein the first longitudinal outer flange and the second longitudinal outer flange have shapes that allow vertical overlap with each other, and the rear side of the outer sheet comprises: - a first upper cable (42) extending from the first upper electrical conductor to the first upper electrical connector (46) through at least the upper opening (88) in the longitudinal groove and the upper cavity (44), - a first lower cable (43) extending from the first lower electrical conductor to the first lower electrical connector (47) through at least the lower opening (89) in the longitudinal groove and the lower cavity (45), and the A sandwich panel for a building envelope, wherein the first lower electrical connector and the first upper electrical connector are corresponding male and female connectors, the upper cavity is located within the insulating material in the upper half of the sandwich panel, the lower cavity is located within the insulating material in the lower half of the sandwich panel, the upper cavity and the lower cavity are adjacent to the longitudinal groove and are both open along the first longitudinal side of the insulating material or both open along the second longitudinal side of the insulating material. Claim 12 A sandwich panel for a building envelope, wherein, in claim 11, the portion of the first upper cable having the first upper electrical connector and the portion of the first lower cable having the first lower electrical connector are reserved in a longitudinal groove. Claim 13 A process for manufacturing a sandwich panel (1) according to any one of claims 1 to 12, comprising: - a step of providing an outer sheet (4), wherein the outer sheet (4) is: o As an outer central part (17): ■ First upper perforation (27) through which the first upper electrical conductor (25) passes, ■ The outer central portion (17), including a first lower perforation (28) through which a first lower electrical conductor (26) passes, o Includes a first photovoltaic active zone (24) positioned on the outer central portion and electrically connected to the first upper electrical conductor and the first lower electrical conductor; and the rear side of the outer sheet is: ■ A first upper cable (42) connecting a first upper electrical conductor to a first upper electrical connector (46) located in the upper cavity (44), A process for manufacturing a sandwich panel comprising: a first lower cable (43) connecting a first lower electrical conductor to a first lower electrical connector (47) positioned in a lower cavity (45), wherein the first lower electrical connector and the first upper electrical connector are corresponding male and female connectors; a step of providing an outer sheet (4) wherein the upper cavity is positioned in the upper half of the outer sheet and the lower cavity is positioned in the lower half of the outer sheet; a step of providing an inner sheet (3) comprising an inner central portion (67) including a longitudinal groove (85); a step of placing an insulating material in place; and a step of maintaining the inner sheet at a given distance from the outer sheet so that the upper cavity and the lower cavity are adjacent to the longitudinal groove. Claim 14 A process for manufacturing a sandwich panel according to claim 13, wherein the inner sheet (3) is cut and shaped to size to include an upper transverse inner edge (63) and a lower transverse inner edge (64), and the longitudinal groove (85) extends from the upper transverse inner edge to the lower transverse inner edge, and the outer sheet (4) and the inner sheet are positioned in a mold at a given distance from each other, and a reaction mixture is injected into the mold between the inner sheet and the outer sheet so that the reaction mixture reacts and expands to fill the gap between the inner sheet and the outer sheet and form the insulating material (2). Claim 15 A process for manufacturing a sandwich panel, wherein, in paragraph 13, the inner sheet (3) is provided in the form of an inner strip shaped such that its inner central portion (67) includes the longitudinal groove (85), the inner strip enters a double belt conveyor of a manufacturing line, the outer sheet (4) is part of a continuous feeding of the manufacturing line from the outer sheets, and a reaction mixture is applied to the rear side of the outer sheet or to the rear side of the inner strip so that the reaction mixture reacts and expands on the double belt conveyor to fill the gap between the inner strip and the outer sheet and form the insulating material (2). Claim 16 A process for manufacturing a sandwich panel, wherein, in any one of claims 13 to 15, the upper cavity (44) is opened to provide access to the first upper electrical connector (46), and the lower cavity (45) is opened to provide access to the first lower electrical connector (47). Claim 17 A process for manufacturing a sandwich panel according to claim 16, further comprising the step of opening the upper cavity (44) and the lower cavity (45), and then passing the first upper electrical connector and the first lower electrical connector and possibly a portion of their cables through the longitudinal groove. Claim 18 A process for manufacturing a sandwich panel, wherein, in any one of claims 13 to 17, before providing the outer sheet (4), the following steps are further included: - cutting the outer sheet to length from a strip; - creating the first upper perforation (27) and the first lower perforation (28) in the outer center portion (17); - positioning the first photovoltaic active zone (24) on the outer center portion; and - providing the first upper cable (42), the first upper electrical connector (46), the first lower cable (43), the first lower electrical connector (47), the upper cavity (44), and the lower cavity (45) on the rear side of the outer sheet. Claim 19 A process for assembling a building envelope on a building structure, comprising: (i) providing a first sandwich panel and a second sandwich panel according to any one of claims 1 to 12; (ii) fastening the first sandwich panel to the building structure; (iii) positioning the second sandwich panel such that the lower transverse side (8) of the insulating material of the second sandwich panel is adjacent to the upper transverse side (7) of the insulating material of the first sandwich panel, and fastening the second sandwich panel to the building structure; and (iv) connecting the first upper electrical connector (46) of the first sandwich panel to the first lower electrical connector (47) of the second sandwich panel.

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