Conformable sheet material including two faces connected by a non-uniform connection structure

Abstract

The invention relates to a panel (10) comprising a first fabric (26), a second fabric (28) and a connection structure comprising a support (74) connecting the first fabric (26) to the second fabric (28), wherein at least a part of the support (74) of the connection structure has a rest length different from the average value hm of the rest lengths of the support (74) and the first fabric (26) is plastically deformable in at least one main direction thereof.

Description

TECHNICAL FIELD

[0001] The present invention relates to a panel comprising two weaves connected by a load-bearing structure, and the use of such a panel as a building material. BACKGROUND

[0002] A large number of panels are used in the construction industry. Among these panels, one can mention structural panels such as concrete panels or gypsum panels, or one can mention thermal insulation panels such as polyurethane panels, rock wool panels or wood fiber panels.

[0003] These panels can be made of a single type of material, for example gypsum, and are therefore generally referred to as "solid" panels. They can also be made of a combination of several different materials in order to improve one or more specific qualities, and are therefore generally referred to as "composite" panels.

[0004] Thus, document US2017 / 0044766 describes a composite floor covering made of a so-called three-dimensional weave comprising two planar weaves connected by spacing elements which parallelize and distance the two faces, this three-dimensional weave being meshed, cement can be poured through this meshed weave, thus forming a reinforced floor. This structure needs to be laid on horizontal supports as the panel cannot contain the filling material.

[0005] Document WO2019 / 197319 describes a composite material composed of a three-dimensional weave comprising two faces whose separation is regulated by spacers, and a polyurethane foam, this material aiming to form a shoe sole, the spacers fulfilling a mechanical integrity function by maintaining a certain space between the two faces of the weave, thus providing resistance to the continuous compression experienced by the shoe sole.

[0006] Documents US2010 / 0233417 and WO2015 / 053842 describe a flexible fabric composite material capable of "setting" (in the manner of cement "setting"), i.e. of becoming rigid or semi-rigid, by application of a liquid or radiation, this composite material being made of a three-dimensional fabric with two planes and spacers and containing a powder. The powder is introduced through one of the planes of the fabric, which is deformable to create the space required for the introduction of the powder and which shrinks to accommodate the powder, one or more of the planes of the fabric also being permeable to the liquid or radiation required for the setting of the powder, thus causing the composite material to become rigid. The planes are kept apart by a distance by means of the spacers, which can consist solely of a set of fibres or monofilaments. Although, according to US2010 / 0233417, there is theoretically no limit to the thickness of the composite material, the constraints listed, in particular the ability of the liquid to penetrate to the core of the powdered material before the hardening of the outer part, the ability of the planes to support the weight of the powder, and the rigidity of the spacers to enable them to correctly perform their function of maintaining the space between the two internal surfaces of the composite material, limit the thickness of these composite materials to relatively small values, generally of the order of a few millimetres, as indicated by the "typically..." example shown in the examples of WO2015 / 053842.

[0007] Document WO2015 / 187826 describes a fabric composite material comprising a non-woven fabric, one plane of which is permeable to a liquid and the other plane of which is impermeable, the fabric being filled with a material capable of becoming rigid on contact with the liquid. The two planes of the fabric are separated by a set of self-supporting fibres, i.e. fibres which generally maintain the spacing between the two planes and which are able to resist compressive mechanical forces. When this composite material is bent, its surface forms creases before the hardening of the filling material.

[0008] Regardless of the function or position of these panels, it is desirable to facilitate their implementation and to maintain their integrity. Although easy to create or to cover planar surfaces, they can be particularly tricky to implement when building or covering complex surfaces, such as curved surfaces, or even irregular surfaces.

[0009] There is therefore a need for panels which are complex in shape, simple to use and which can meet a variety of needs. SUMMARY

[0010] To meet these needs, the Applicant Company has developed a panel having a first fabric and a second fabric connected to the first fabric by a connection structure, the first fabric being deformable in at least one main direction of the first fabric. This panel can be filled with a filling material, the properties of which depend on the intended use of the panel.

[0011] DEFINITIONS

[0012] The carbon-containing compounds mentioned in the present description can be of fossil origin or of bio-based origin. In the case of bio-based origin, the carbon-containing compounds can be derived, partially or completely, from biomass, or obtained from renewable raw materials derived from biomass. In particular, polymers, plasticizers, fillers, etc. are concerned.

[0013] "Substantially parallel" or "extend substantially along" means that the angle formed by the two directions in question is less than 10°, preferably less than 5°, preferably less than 2°, and more preferably less than or equal to the error in measuring the angle by an appropriate method.

[0014] Two lengths are substantially equal if they are equal within the usual measurement tolerances for measuring such lengths, or within the tolerances of the manufacturing method using elements of substantially the same length.

[0015] As known to the person skilled in the art, plastic deformation of a filamentary element means that when this element is stretched along its overall direction, its deformation is irreversible. In other words, it does not return to its initial shape when the stress load is removed.

[0016] A woven fabric is said to be deformable if at least one of its surface portions is deformable.

[0017] Woven fabric panel

[0018] The present invention relates to a panel comprising:

[0019] • a first woven fabric comprising filamentary elements called warp elements (C1) and filamentary elements called weft elements (T1), the warp elements being substantially parallel to each other and extending along a direction called warp direction, the warp direction constituting a first main direction of the first woven fabric, the weft elements being substantially parallel to each other and extending along a direction called weft direction, the weft direction constituting a second main direction of the first woven fabric, the second main direction being different from the first main direction of the first woven fabric;

[0020] • a second woven fabric comprising filamentary elements called warp elements (C2) and second filamentary elements called weft elements (T2), the warp elements being substantially parallel to each other and extending along a direction called warp direction, the warp direction constituting a first main direction of the second woven fabric, the weft elements being substantially parallel to each other and extending along a direction called weft direction, the weft direction constituting a second main direction of the second woven fabric, the second main direction being different from the first main direction of the second woven fabric;

[0021] • A connecting structure comprising n filamentary elements connecting a first braid to a second braid, each filamentary element including at least one filamentary portion referred to as a support member, the support member extending between the first and second braids and connecting the first braid to the second braid, each support member i having a rest length h. i And extending from the attachment point with the first weave to the attachment point with the second weave;

[0022] The characteristic feature is that, among the m supporting members of the connecting structure, at least some of the supporting members have a rest length different from the average rest length of the supporting members. m represents the total number of supporting members in the connection structure, and h represents the static length of the longest supporting member in the connection structure. max The static length h of the shortest support member of the connecting structure min The values ​​are expressed as % and calculated as E = 100x(h) max -h min ) / h min The difference E satisfies E>A r A r The elongation at break, expressed as a percentage, represents the support member with the shortest rest length, and the first weave is plastically deformable in at least one of the first and second principal directions of the first weave, such that the distance between the two attachment points of each support member i is substantially equal to its rest length h. i .

[0023] Average value of the static length of the support This refers to the average static length of the supporting members of the connecting structure. According to the present invention, the total number of supporting members in the connecting structure of the plate is equal to m, which is a strictly positive integer. Therefore, The total number of supports is adjusted based on the geometry of the sheet, the required rigidity, and the flow characteristics of any filler materials that may be introduced into the sheet. The elongation at break of the filamentary elements is measured according to standard ASTM D885-03.

[0024] The deformation of the first braid in at least one principal direction of the first braid can cause the sheet to conform to or define a complex non-planar surface after molding, such as a cylindrical or wavy surface, or even a non-uniform surface, such as a hemispherical surface. i Therefore, by adjusting the height of each support and the distribution of the supports, complex surfaces can be defined very simply.

[0025] Shaping or conforming means that the panel is shaped by deformation of the woven fabric. Shaping can be performed, for example, by injecting a filling material between the inner surface of the first woven fabric and the inner surface of the second woven fabric, or by inflating with a pressurized gas (for example air or an inert gas such as nitrogen) injected between the inner surface of the first woven fabric and the inner surface of the second woven fabric of the panel. The person skilled in the art can thus ensure that the surfaces are not permeable to such a pressurized gas by coating or calendering with an appropriate material.

[0026] Filling material

[0027] As a preference, the panel according to the application comprises a filling material between the inner surface of the first woven fabric and the inner surface of the second woven fabric.

[0028] The filling material can be any material capable of enabling the panel according to the application to fulfil its intended function. The shape of the filling material must be such that it can be introduced between the two inner surfaces of the woven fabrics constituting the panel of the application. The filling material, when introduced between the inner surfaces of the panel, can be in the form of a gas, a liquid or a dispersed solid. The filling material can thus preferably be any powder, gas or liquid originating from natural or recycled materials, which can be introduced in a pulverized or in a molten state into the panel according to the application.

[0029] When the panel is intended to be used as a structural element, the filling material can be a material of the cement, cement-based foam or concrete type.

[0030] The filling material can also be a thermal insulating material (for example expanded polyurethane foam), a dispersed solid material (for example polystyrene granules, cork, clay).

[0031] The filling material can likewise be chosen from waste products: waste, crushed construction or infrastructure gravel.

[0032] The filling material can thus preferably be chosen from sand, cement, cement-based foam, gypsum, soil, clay, natural fibres, inorganic fibres, polystyrene, polyurethane, cork, waste and crushed construction or infrastructure gravel.

[0033] When the panel according to the application is used for piping, the filling material can likewise be a pressurized gas, possibly a pressurized circulating gas.

[0034] In another arrangement, the filling material can preferably be an expanding material, preferably an expanding foam, preferably an expanding polyurethane foam. The benefit of a panel according to the application filled with an expanding material is that the panel can be shaped as the expanding material expands.

[0035] The infill material can be injected in various ways. For example, the infill material can be injected through one or more nozzles through at least one end of the three-dimensional braid, the material gradually flowing into the three-dimensional braid under the influence of gravity or under the influence of a "drive" of the infill material flow.

[0036] Thereby a thermal insulation panel is obtained which is suitable for conforming to a curved or complex shaped wall.

[0037] Braid for a panel according to the invention

[0038] The first braid of the panel according to the invention comprises filiform elements called warp elements (C1) which are substantially parallel to each other and extend in a direction called warp direction, which constitutes a first main direction of the first braid, and filiform elements called weft elements (T1) which are substantially parallel to each other and extend in a direction called weft direction, which constitutes a second main direction of the first braid, different from the first main direction of the first braid.

[0039] The first braid is characterized in that it is plastically deformable in at least one of its main directions, so that the distance between the two attachment points of each support i is substantially equal to its rest length h i By deformable is meant that the braid can be extended in at least one of its main directions without breaking.

[0040] By plastically deforming the first braid, the panel according to the invention can be shaped and retain its shape. This is particularly advantageous when the panel according to the invention contains an infill material, in particular when this infill material is a material which can become rigid. The plastic deformation of the first braid of the panel according to the invention can cause the infill material to become rigid, without the need to maintain a tension on the first braid of the panel according to the invention, which would not be the case if the first braid were to be elastically deformed.

[0041] The first braid is deformable in at least one of its main directions to the extent that the distance between the two attachment points of each support i is substantially equal to its rest length h i The surface shape obtained after shaping thus depends on the position and height of each support.

[0042] As a preference, the second braid is deformable in at least one of its main directions.

[0043] In a preferred arrangement, the second braid is plastically deformed. In another preferred arrangement, the second braid is elastically deformed.

[0044] Deformable knits are well known to the person skilled in the art. The deformability of a knit can be obtained in various ways. For example, the deformability can be achieved by the knitting of the knit. It can also be achieved by the nature of the filamentary warp elements and / or of the filamentary weft elements.

[0045] Thus, the deformability of the knit can be obtained by using undulating filamentary elements, thus able to stretch, elastic filamentary elements, filamentary elements able to plastically deform without breaking or with partial breaking of the filamentary elements. By way of example, mention can be made of coated filamentary elements, the core of which breaks when the filamentary element is subjected to traction, while the rest of the filamentary element does not break.

[0046] As a preference, at least one knit chosen from the first knit and the second knit comprises at least one deformable zone deformable in at least one main direction of said knit and at least one non-deformable zone non-deformable in at least one main direction of said knit.

[0047] The presence of the deformable zone and of the non-deformable zone makes it possible to adjust the shape of the surface of the knit after forming of the panel according to the application. Thus, the panel according to the application can exhibit, after forming, for example, a planar zone and a deformed zone.

[0048] In a preferred arrangement, at least one knit chosen from the first knit and the second knit comprises at least one deformable zone deformable in a first main direction of said knit and non-deformable in a second main direction of said knit.

[0049] In this preferred arrangement, the knit can be deformed in the first main direction and not in the second main direction, so as to be able to form a surface having a sinusoidal profile in the first main direction, while substantially preserving its length in the second main direction.

[0050] As a preference, at least one knit chosen from the first knit and the second knit comprises at least one deformable zone comprising at least one filamentary element ED deformable under traction, in which, for any deformable filamentary element ED under traction, there is an elongation AED < ARED such that M1ED / M2ED < 1, in which M1ED represents the modulus of the deformable filamentary element ED for any elongation less than or equal to K1 x AED%, M2ED represents the modulus of the deformable filamentary element ED for any elongation greater than or equal to K2 x AED%, ARED represents the elongation at break of the element ED in %, K1 ranges from 0.8 to 0.95, K2 ranges from 1.05 to 1.2, the modulus values M1ED, M2ED and the elongation at break ARED being measured according to the standard ASTM D885-03.

[0051] The filamentary elements ED have a so-called "bi-modulus" behaviour known to the skilled person from other contexts, in that the elements exhibit a greater resistance to elongation when the elongation of the element ED is greater than AED than when it is less than AED.

[0052] The elements make it possible to obtain a deformable braid which has a low resistance to deformation during shaping and a high resistance to deformation after the braid has been shaped, thus making it possible to obtain a panel which is easy to shape and which has good geometric stability after shaping. Thus, even if the panel has a complex shape after shaping, it has a very simple shape, close to that of a planar braid, before shaping, which can be easily stored and transported in the form of a stack of panels or wound on a reel.

[0053] As a preference, each filamentary element ED comprises a first filamentary member and a second filamentary member. As a preference, in order to obtain this bi-modulus behaviour, each filamentary member has a different modulus and / or a different length for a given length of the filamentary element ED.

[0054] As a preference, the second filamentary member is substantially rectilinear and the first filamentary member is wound substantially in a spiral around the second filamentary member.

[0055] As a preference, for each filamentary element ED, the elongation to break of the second filamentary member within the filamentary element ED is greater than A ED % and the elongation to break of the first filamentary member within the filamentary element ED is less than A ED %.

[0056] As a preference, the first braid and the second braid each comprise a material selected from the group consisting of: polyester, polyamide, polyketone, polyurethane, natural fibres, inorganic fibres, cellulose fibres and combinations of these materials, preferably selected from the group consisting of: polyester, polyamide, polyketone, polyurethane, natural fibres, cellulose fibres and combinations of these materials, more preferably selected from the group consisting of: polyester, natural fibres, cellulose fibres and combinations of these materials.

[0057] In a preferred arrangement, at least one of the braids comprises a material having a fire-retardant property, which is either a naturally fire-retardant material or a material which has been treated to be fire-retardant.

[0058] As a preference, when the panel according to the application comprises a filler material, at least one of the first braid and the second braid is arranged so as to be impermeable to the filler material. In this way, the filler material cannot flow through the braid which is impermeable to said material. As a preference, both of the braids of the panel according to the application are impermeable to the filler material.

[0059] Deformable and non-deformable zones of the braid

[0060] In a preferred embodiment which can effectively shape the first braid of the sheet material according to the present application, said first braid comprises:

[0061] • a first set of zones comprising at least one transverse straight zone (Z1 ), each transverse straight zone (Z1 ) in the first set of zones being arranged to allow elongation of at least one transverse straight zone (Z1 ) of the first set of zones in the first general direction (G1 ) of the first braid, preferably each transverse straight zone (Z1 ) of the first set of zones being arranged to allow elongation in the first general direction (G1 ) of the first braid,

[0062] • a second set of zones comprising at least one transverse straight zone (Z2), each transverse straight zone (Z2) in the second set of zones being arranged to prevent elongation of said transverse straight zone (Z2).

[0063] By definition, a transverse straight zone of a braid is delimited longitudinally by two imaginary straight lines which are substantially perpendicular to the first general direction of the first braid. A transverse straight zone spans the entire width of the braid, meaning that it is delimited laterally by the longitudinal edges of the braid.

[0064] As a preference, in an arrangement in which each filamentary element ED comprises a first filamentary member and a second filamentary member, each transverse straight zone in the first set of zones is arranged to allow elongation of each filamentary element in the first general direction in each transverse straight zone in the first set of zones.

[0065] Elongation of each filamentary element ED can be obtained by any means, for example by the first filamentary element described in the applications WO2018 / 130782 and WO2018 / 130783.

[0066] In an embodiment which can obtain transverse straight zones (Z2) of the second set of zones which are non-deformable, each transverse straight zone (Z2) in the second set of zones is arranged to prevent elongation of each filamentary element in the first general direction in each transverse straight zone (Z2) in the second set of zones.

[0067] In the preferred embodiment described above, each transverse straight zone (Z1) in the first set of zones is a so-called deformable zone. These zones are deformable under forming conditions, contributing to the conformability of the first braid. Each transverse straight zone (Z2) in the second set of zones is a so-called non-breakable zone. Optionally, in one embodiment, each transverse straight zone (Z2) in the second set of zones is non-deformable. In another embodiment, each transverse straight zone (Z2) in the second set of zones is deformable, but to a much lesser extent than each transverse straight zone (Z1) in the first set of zones. These zones are non-breakable under forming conditions, contributing little or nothing to the conformability of the first braid. Thus, each so-called deformable transverse straight zone (Z1) in the first set of zones deforms sufficiently to allow the assembly to be formed and to compensate for the non-elongation or slight elongation of the non-breakable transverse straight zones (Z2) in the second set of zones. The greater the elongation of all the transverse straight zones in the first set of zones under maximum force, the shorter and the fewer the so-called deformable transverse straight zones in the first set of zones compared with the non-breakable transverse straight zones in the second set of zones. On the scale of the filamentary warp elements, the portion of each first filamentary warp element located within each so-called deformable transverse straight zone (Z1) in the first set of zones deforms sufficiently to allow the assembly to be formed and to compensate for the non-elongation or slight elongation of those portions of each first filamentary warp element located within the non-breakable transverse straight zones (Z2) in the second set of zones.

[0068] Furthermore, each so-called deformable zone in the first set of zones is deformable under relatively low stress, which makes it possible, in the method for forming a panel according to the application, to use a suitable forming stress, for example corresponding to the stress when a filler material is inserted between the two inner surfaces of the first braid and the second braid of the panel according to the application.

[0069] In one preferred embodiment, each load-bearing filamentary element comprises a first filamentary portion for anchoring each load-bearing filamentary element in the first braid, the load-bearing filamentary portion extending in the first braid:

[0070] • each transverse straight zone (Z1) in the first set of zones is devoid of any first filamentary anchoring portion,

[0071] • each transverse straight zone (Z2) in the second set of zones comprises at least one first filamentary anchoring portion.

[0072] As a preference, each transverse straight zone (Z1) in the first set of zones alternates with a transverse straight zone (Z2) in the second set of zones in the first main direction of the first braid.

[0073] Thus, on the scale of the first braid, a global uniform deformation of the first braid is obtained, the shorter the resting length of each transverse straight zone in the first main direction of the first braid, the more uniform the deformation. The resting length of a transverse straight zone in the first main direction refers to the length of the zone in the longitudinal direction in the absence of any external stress load (except atmospheric pressure) applied to the zone. A transverse straight zone at rest in the first main direction is neither in tension nor in compression in this direction, so that the elongation in this direction is zero.

[0074] The features described above in relation with the transverse straight zones (Z1) and (Z2), adjusted as appropriate, are preferably applicable to the second braid of the panel according to the application.

[0075] Connection structure

[0076] The panel according to the application comprises a connection structure comprising filamentary elements connecting the first braid to the second braid, each filamentary element comprising at least one filamentary portion called a support extending between the first braid and the second braid and connecting the first braid to the second braid, each support i having a resting length h i extending from the point of attachment with the first braid to the point of attachment with the second braid, the resting length of at least some of the supports in the connection structure being different from the average resting length of the supports the resting length of the longest support h max and the resting length of the shortest support h min the difference E expressed in % and calculated as E = 100 x (h max -h min ) / h min satisfies E > A r where A r represents the elongation at break of the shortest support in %.

[0077] The resting length of a support refers to the length of the support in the longitudinal direction in the absence of any external stress load (except atmospheric pressure) applied to the support. A support at rest in the longitudinal direction is neither in tension nor in compression in this direction, so that the elongation in this direction is zero. Likewise, generally, the resting length of a filamentary element refers to the length of the filamentary element in the longitudinal direction in the absence of any external stress load (except atmospheric pressure) applied to the filamentary element.

[0078] By filamentary element is meant any long straight element of length greater relative to its cross-section, whatever the shape of this cross-section, for example circular, oval, rectangular or square or even flat, which can for example be twisted or undulated. When its cross-section is of circular shape, the diameter of this cross-section is preferably less than 5 mm, more preferably ranging from 10 μιη to 1.2 mm.

[0079] The geometric characteristics of each filamentary element of the connecting structure, in particular each support connecting the inner face of the first braid and the inner face of the second braid, can consist in its resting length LP and in its average cross-section SP, said average cross-section SP being the average of the cross-sections obtained by sectioning the support on all the surfaces parallel to the first braid and to the second braid and interposed between the first braid and the second braid. In the most common case where the filamentary element and the support have a constant cross-section, the average cross-section SP is equal to this constant cross-section.

[0080] The minimum characteristic dimension E of the average cross-section SP of each filamentary element of the connecting structure, in particular each support, is generally preferably at most equal to 0.02 times the average resting length LP of the support, the aspect ratio R of the average cross-section SP of the support being preferably at most equal to 3. The smaller characteristic dimension E of the average cross-section SP of the support being at most equal to 0.02 times the average resting length LP of the support excludes any bulky support element having a greater volume. The aspect ratio R of the average cross-section SP of the support being at most equal to 3 means that the maximum characteristic dimension V of the average cross-section SP of the support is at most equal to 3 times the minimum characteristic dimension E of the average cross-section SP of the support. For example, the aspect ratio R of a circular average cross-section SP of diameter equal to d is R = 1 ; the aspect ratio R of a rectangular average cross-section SP of length V and width V' is R = V / V'; the aspect ratio R of an oval average cross-section SP of major axis B and minor axis B' is R = B / B'. The average resting length LP of the support being preferably greater than 8 mm, preferably ranging from 10 mm to 2000 mm, preferably ranging from 10 mm to 1000 mm, preferably ranging from 10 mm to 500 mm, highly preferably ranging from 30 mm to 100 mm, very highly preferably ranging from 40 mm to 70 mm. This average resting length can be adapted according to the intended use of the panel according to the application.

[0081] The aspect ratio R of the average cross-section SP of the support being at most equal to 3 means that the maximum characteristic dimension V of the average cross-section SP of the support is at most equal to 3 times the minimum characteristic dimension E of the average cross-section SP of the support. For example, the aspect ratio R of a circular average cross-section SP of diameter equal to d is R = 1 ; the aspect ratio R of a rectangular average cross-section SP of length V and width V' is R = V / V'; the aspect ratio R of an oval average cross-section SP of major axis B and minor axis B' is R = B / B'.

[0082] The average resting length LP of the support being preferably greater than 8 mm, preferably ranging from 10 mm to 2000 mm, preferably ranging from 10 mm to 1000 mm, preferably ranging from 10 mm to 500 mm, highly preferably ranging from 30 mm to 100 mm, very highly preferably ranging from 40 mm to 70 mm. This average resting length can be adapted according to the intended use of the panel according to the application. The average resting length LP of the support being preferably greater than 8 mm, preferably ranging from 10 mm to 2000 mm, preferably ranging from 10 mm to 1000 mm, preferably ranging from 10 mm to 500 mm, highly preferably ranging from 30 mm to 100 mm, very highly preferably ranging from 40 mm to 70 mm. This average resting length can be adapted according to the intended use of the panel according to the application.

[0083] The supports have mechanical properties of the filamentary type, i.e. they can only be subjected to tensile or compressive forces along their average line. Each support of the connection structure is flexible. This means that it can bend without breaking, nor does it undergo plastic deformation. The connection structure as such is not able to support the spacing between the two faces of the panel according to the invention. In the absence of both filler and internal pressure, the two faces can move closer to each other without the application of a load.

[0084] As a preference, the height h of the supports is distributed so as to increase in at least one of the first and second main directions of the first weave. This support height distribution aims to give the panel as a whole the shape of a prism, a cone or a pyramid. i The distribution is such that they increase in at least one of the first and second main directions of the first weave. This support height distribution aims to give the surface of one of the weaves of the panel a periodic pattern, for example a wave pattern if the distribution of the dimensions is sinusoidal in shape, or a square wave pattern if the distribution of the dimensions is square wave type.

[0085] As a preference, the height h of the supports is distributed so as to increase in at least one of the first and second main directions of the first weave. This support height distribution aims to give the panel as a whole the shape of a prism, a cone or a pyramid. i The distribution is periodic in at least one of the first and second main directions of the first weave. This support height distribution aims to give the surface of one of the weaves of the panel a periodic pattern, for example a wave pattern if the distribution of the dimensions is sinusoidal in shape, or a square wave pattern if the distribution of the dimensions is square wave type.

[0086] As a preference, the panel according to the invention comprises at least g groups G of supports j where g is greater than 1 and less than m, j is an integer between 1 and g, each group G j is characterized in that the resting length of each support of said group G j is substantially equal to the average of the resting lengths of the supports of said group G j is substantially equal to the average of the resting lengths of the supports of said group G for different integers j and k between 1 and g,

[0087] In one preferred embodiment, each filamentary element of the connection structure is a textile element. By textile is meant that each filamentary element of the connection structure is non-metallic, for example made of a material chosen from the group comprising: polyester, polyamide, polyketone, polyvinyl alcohol, cellulose, mineral fibers, natural fibers, elastomeric materials or mixtures of these materials. Among the polyesters, mention can be made for example of PET (polyethylene terephthalate), PEN (polyethylene naphthalate), PBT (polybutylene terephthalate), PBN (polybutylene naphthalate), PPT (polypropylene terephthalate) or PPN (polypropylene naphthalate). Among the polyamides, mention can be made of aliphatic polyamides such as polyamide 4-6, 6, 6-6 (nylon), 11 or 12, and aromatic polyamides such as aramid.

[0088] For example, each filamentary element of the connection structure is a fabric assembly comprising one or more monofilament or multifilament fabric fibres twisted together or not twisted together. Thus, in one embodiment, assemblies in which the fibres are substantially parallel to each other can be used. In another embodiment, assemblies in which the fibres are helically wound (e.g. twisted or overtwisted) can also be used. In yet another embodiment, each filamentary element consists of a monofilament. The diameter of each monofilament or multifilament fibre can range from a few percent of a millimetre to a few millimetres, typically between 0.001 mm and 5 mm, preferably between 5 μm and 50 μm, preferably between 10 μm and 40 μm.

[0089] In a preferred arrangement, each filamentary element of the connection structure is a multifilament fabric fibre, each fibre constituting the fabric fibre having a diameter of between 0.001 mm and 0.5 mm, preferably between 5 μm and 50 μm, preferably between 10 μm and 40 μm. Such filamentary elements have the advantage of being more flexible than monofilament filamentary elements. Thus, by bringing the inner surface of the first braid and the inner surface of the second braid together, the braid according to the application comprising such filamentary elements can be stored in a very compact manner. Preferably, in the case of such an arrangement, when the panel is subjected to a compressive load (i.e. a force applied to the panel perpendicular to its surface and in the direction thereof), the filamentary elements are arranged in such a way that the support itself is unable to maintain the spacing between the two inner surfaces of the braid. This arrangement is obtained by adjusting the density of the support (expressed in the number of supports per square metre) and / or by adjusting the flexibility of the support through the thread count or the chemical nature of the filamentary elements. However, when a filler material is introduced between the two inner surfaces of the panel according to the application, the support does need to have sufficient strength to maintain the spacing between the two inner surfaces of the braid in order to withstand the pressure generated by the introduction of the filler material, i.e. to have sufficient tensile strength. This strength can be adjusted through the density of the support and / or its flexibility and / or its chemical nature.

[0090] In another embodiment, each filamentary element of the connection structure is made of metal, for example a metal monofilament or an assembly of metal monofilaments, each metal monofilament having a diameter ranging from a few percent of a millimetre to a few millimetres, typically between 0.01 mm and 5 mm. In one embodiment, each filamentary element of the connection structure consists of an assembly of several metal monofilaments. In another embodiment, each filamentary element consists of a metal monofilament.

[0091] In one embodiment, each filamentary element of the connection structure extends alternately from the first braid towards the second braid and from the second braid towards the first braid when progressing along the length of the filamentary element.

[0092] In one embodiment, each filamentary element of the connection structure comprises a first filamentary portion for anchoring each filamentary element of the connection structure in the first braid, elongating the support into the first braid.

[0093] Preferably, each first anchoring filamentary portion is interlaced with the first braid. This assembly has the advantage of being able to be made in a single stage. However, it is also conceivable to manufacture the panel according to the application in two stages, the first stage manufacturing the first braid and the second stage interlacing one or more filamentary elements of the connection structure with the first braid. In both cases, the interlacing of each filamentary element of the connection structure with the first braid makes it possible to ensure that each filamentary element of the connection structure is mechanically anchored in the first braid, thereby imparting the mechanical properties required of the connection structure.

[0094] In one embodiment, in order to ensure mechanical anchoring of the filamentary anchoring portions, each first filamentary anchoring portion is at least partially wrapped around at least one first filamentary element of the first braid.

[0095] Preferably, the first braid comprises:

[0096] • filamentary elements called warp elements, which are substantially parallel to one another and extend in a first direction called the warp direction, which is substantially parallel to the first main direction of the first braid, and

[0097] • filamentary elements called weft elements, which are substantially parallel to one another and extend in a second direction called the weft direction, which are interwoven with the filamentary warp elements.

[0098] Each first filamentary anchoring portion is at least partially wrapped around at least one filamentary weft element of the first braid, preferably around at least two filamentary weft elements of the first braid which are adjacent in the first main direction of the first braid.

[0099] In one embodiment, the direction of extension of each first filamentary anchoring portion is substantially parallel to the first main direction of the first braid.

[0100] Preferably, each first filamentary anchoring portion alternates from one face of the first braid to the other face of the first braid between two adjacent filamentary weft elements and is wrapped around these two first filamentary weft elements.

[0101] Manufacture of the panel

[0102] In the step of forming the panel according to the present application, the first filiform elements 64, 66 are assembled in such a way as to form the first braid 26, the second filiform elements 68, 70 are assembled in such a way as to form the second braid 28. The load-bearing element 32, which can be coated with an adhesive composition, preferably a cross-linking composition, is also assembled with the first braid 26 and the second braid 28. In the embodiment illustrated by way of example, the first filiform elements 64, 66 and the second filiform elements 68, 70 are simultaneously assembled with the load-bearing element 32 in a single step, so as to form the panel 24. In another embodiment, the first braid 26 and the second braid 28 are first formed separately, then connected using the load-bearing element 32, which can be coated with an adhesive composition, preferably a cross-linking composition. The step of forming the panel 24 according to the present application is carried out in such a way as to be known to the person skilled in the art of weft knitting.

[0103] Assembly

[0104] The present application also relates to an assembly comprising at least one panel according to the present application. The assembly is an assembly entity which can combine any element comprising at least one panel according to the present application. Such an assembly can for example be a building structure (but not limited thereto), such as a warehouse, a building, a house, an airplane, a ship or a land vehicle. The assembly can likewise be a wire duct, a pipe or a container. BRIEF DESCRIPTION OF DRAWINGS

[0105] [ Figure 1 ] Schematic general arrangement of a panel according to the present application, comprising a first braid comprising a deformable zone.

[0106] [ Figure 2 ] Schematic general arrangement of a panel according to the present application, comprising a first braid comprising a deformable zone and a second braid comprising a deformable zone.

[0107] [ Figure 3 ] Schematic general arrangement of a panel according to the present application, comprising two deformable braids.

[0108] [ Figure 4 ] Top view of a panel according to the present application.

[0109] [ Figure 5 ] Cross-sectional view of a panel according to the present application in the plane of the cross-section P-P’. DETAILED DESCRIPTION

[0110] Figure 1A cross-sectional schematic overall arrangement of a panel (10) according to the present application is depicted, said panel (10) comprising a first fabric (1), a second fabric (3) and a connecting structure, said first fabric (1) comprising a deformable zone (2), said connecting structure comprising filamentary elements connecting the first fabric to the second fabric, each filamentary element comprising at least one filamentary portion, called support (4), connecting the first fabric (1) to the second fabric (3), the resting length of some supports of the connecting structure being different from the average resting length of the supports The deformable zone (2) is depicted thicker, just to make the drawing easier to understand. Figure 1 The preferred filling material, interposed between the inner surface of the first fabric (1) and the inner surface of the second fabric (2), is not depicted in the figures. It can be seen that, without using a large number of flat panels to approximate the curvature of the surface, it is possible to conform the panel to the surface, making the work easier and the shape of the inner surface different from the outer surface of the panel.

[0111] Figure 2 A cross-sectional schematic overall arrangement through a panel (11) is depicted, said panel (11) comprising a deformable zone (A) of a first fabric. This figure shows how it is possible to obtain complex shapes using the panel of the underlying application, the shape of the surface of the first fabric after shaping being determined by the distribution of the dimensions of the supports.

[0112] Figure 3 Another schematic overall arrangement of a panel (11) is depicted, said panel (11) comprising a deformable zone of a first fabric and a deformable zone of a second fabric, and two groups of supports (12), each support (13) having a length substantially equal to the average of the lengths of each support in the group.

[0113] Figure 4 A top view of a panel (10) according to the present application is depicted, Figure 5 A cross-sectional schematic view through a panel (10) is depicted. In the two figures, the numbering of the same elements is the same.

[0114] The first braid 26 comprises two longitudinal edges 26A and 26B. The first braid 26 extends along a first main direction Gl of the first braid substantially parallel to each longitudinal edge 26A, 26B. The first braid 26 comprises filiform elements 64, referred to as filiform warp elements, and filiform elements 66, referred to as filiform weft elements. The filiform warp elements 64 of the first braid 26 are substantially parallel to one another and extend along a direction referred to as warp direction Cl substantially parallel to the first main direction Gl. The filiform weft elements 66 of the first braid 26 are substantially parallel to one another and extend along a direction referred to as weft direction Tl, interlaced with the filiform warp elements 64. The filiform warp elements 64 extend continuously along the entire length of the first braid 26.

[0115] Here, each filiform element 64, 66 is for example a textile filiform element.

[0116] The filiform elements 64 are substantially all identical. Each filiform warp element 64 comprises a first filiform member 65 and a second filiform member 67. The second filiform member 67 is substantially rectilinear and the first filiform member 65 is substantially wound in a spiral around the second filiform member 67. Here, the first filiform member 65 is a multifilament thread having a count equal to 110 tex made of PET and the second filiform member 67 is a multifilament thread having a count equal to 23 tex made of rayon.

[0117] Here, the filiform elements 66 comprise two filiform members, the second filiform member is substantially rectilinear and the first filiform member is substantially wound in a spiral around the second filiform member. Here, the first filiform member is a multifilament thread having a count equal to 110 tex made of PET and the second filiform member is a multifilament thread having a count equal to 23 tex made of rayon.

[0118] Figure 4 The depicted second braid 28 extends along a first main direction G2 of the second braid. The second braid 28 comprises filiform elements 68, referred to as filiform warp elements, and filiform elements 70, referred to as filiform weft elements. The filiform warp elements 68 of the second braid 28 are substantially parallel to one another and extend along a direction referred to as warp direction C2 substantially parallel to the first main direction G2 of the second braid. The filiform weft elements 70 of the second braid 28 are substantially parallel to one another and extend along a direction referred to as weft direction T2, interlaced with the filiform warp elements 68. The filiform warp elements 68 extend continuously along the entire length of the second braid 28.

[0119] Here, each filiform element 68, 70 is for example a textile filiform element.

[0120] The filiform elements 68 are substantially all identical and here are multifilament threads having a count equal to 110 tex made of PET.

[0121] The filamentary elements 70 are essentially all the same, and here they are multifilament strands made of PET with a count of 167 tex.

[0122] The sheet material (10) includes a connecting structure comprising filamentary elements connecting a first braid (26) to a second braid (28). Each filamentary element includes at least one filamentary portion (74) referred to as a support, which extends between the first and second braids and connects the first braid to the second braid. As the material moves along the filamentary support element 32, each filamentary element 32 extends alternately from the first braid 26 toward the second braid 28 and from the second braid 28 toward the first braid 26. Here, each support filamentary element 32 is a fabric support filamentary element made of PET with a yarn count of 55 tex.

[0123] Each filament element 32 includes a carrier filament portion 74 extending between the first braid 26 and the second braid 28, particularly between the inner surfaces 42 and 46. Each carrier filament element 32 includes a first filament anchoring portion 76 and a second filament anchoring portion 78, which anchor the carrier filament element 32 in the first braid 26 and the second braid 28, respectively. Each first filament anchoring portion 76 and each second filament anchoring portion 78 extends the carrier portion 74 into each of the first braid 26 and the second braid 28. Each first filament anchoring portion 76 and each second filament anchoring portion 78 interweaves with each of the first braid 26 and the second braid 28. Each first filament anchoring portion 76 and each second filament anchoring portion 78 is at least partially wound around at least one first filament element 64, 66 of the first braid 26 and at least one second filament element 68, 70 of the second braid 28, respectively. In this way, each filamentary anchoring part 76, 78 connects two load-bearing filamentary parts 74 together, and each load-bearing filamentary part 74 connects two filamentary anchoring parts 76, 78 together.

[0124] In this configuration, each first filamentary anchoring portion 76 is at least partially wound around at least one filamentary weft element 66 of the first braid 26, and preferably around at least two adjacent filamentary weft elements 66 along the first principal direction G1 of the first braid. Similarly, each second filamentary anchoring portion 78 is at least partially wound around at least one filamentary weft element 68 of the second braid 28, preferably around at least two adjacent filamentary weft elements 66 along the first principal direction G2 of the second braid.

[0125] Each first and second filamentary anchoring portion 76, 78 extends in a direction that is respectively substantially parallel to the first main direction G1 of the first braid and to the first main direction G2 of the second braid.

[0126] Each first filamentary anchoring portion 76 alternates between two adjacent filamentary weft elements 66 from face 41 to face 42 and is wrapped around these two filamentary weft elements 66. Likewise, each second filamentary anchoring portion 78 alternates between two adjacent filamentary weft elements 68 from face 46 to face 49 and is wrapped around these two filamentary weft elements 68.

[0127] Figure 4 and Figure 5 The depicted first braid 26 comprises a first set of regions of transverse straight zones Z1, each transverse straight zone Z1 having a rest length Ld1 in the first main direction G1 of the first braid and extending over the entire width of the first braid 26. All transverse straight zones Z1 of the first set of transverse straight zones can be identical or can differ depending on the shape sought after the forming of the formed sheet.

[0128] Figure 4 and Figure 5 The depicted first braid 26 comprises a second set of regions of transverse straight zones Z2, each transverse straight zone Z2 having a rest length Ld2 in the first main direction G1 of the first braid and extending over the entire width of the first braid 26. All transverse straight zones Z1 of the second set of transverse straight zones can be identical or can differ depending on the shape sought after the forming of the formed sheet.

[0129] Each transverse straight zone Z1 of the first set of regions alternates with a transverse straight zone Z2 of the second set of regions in the first main direction of the first braid.

[0130] Embodiment

[0131] Two sheets were manufactured. The first sheet corresponds to Figure 4 and Figure 5 The depicted sheet. The second sheet has the same first and second braids as the first sheet but without the connecting structure. The characteristics of the first and second braids and of the connecting structure, if any, are shown in Table 1 below.

[0132] [Table 1]

[0133]

[0134] The two sheets have the following geometric characteristics:

[0135] • thickness: 40 mm

[0136] • Width: 150 mm

[0137] • Length: 500 mm

[0138] The panels were then filled with polyurethane foam. A so-called "three-point" measurement was performed on each panel according to standard NF EN 12089. The results are presented in Table 2.

[0139] [Table 2]

[0140] First sheet Second sheet E mod (kPa)]]> 8788 5450 F max (N)]]> 326 135 In F max σ M ]]> 427 177

[0141] The panel according to the application has, in addition to being able to be shaped into complex surface shapes, an excellent structural strength.

Claims

1. Panel comprising: • a first braid comprising filiform elements called warp elements (C1) and filiform elements called weft elements (T1), the warp elements being substantially parallel to one another and extending along a direction called warp direction, the warp direction constituting a first main direction of the first braid, the weft elements being substantially parallel to one another and extending along a direction called weft direction, the weft direction constituting a second main direction of the first braid, the second main direction being different from the first main direction of the first braid; • a second braid comprising filiform elements called warp elements (C2) and second filiform elements called weft elements (T2), the warp elements being substantially parallel to one another and extending along a direction called warp direction, the warp direction constituting a first main direction of the second braid, the weft elements being substantially parallel to one another and extending along a direction called weft direction, the weft direction constituting a second main direction of the second braid, the second main direction being different from the first main direction of the second braid; • a connection structure comprising n filamentary elements connecting the first braid to the second braid, each filamentary element comprising at least one filamentary portion called a support, the support extending between the first braid and the second braid and connecting the first braid to the second braid, each support i having a rest length h i and extending from an attachment point to the first braid to an attachment point to the second braid; characterized in that the resting length of at least some of the m supports of the connection structure differs from the average value of the resting lengths of the supports m denotes the total number of supports of the connection structure, the resting length h max of the longest support of the connection structure min is expressed in % and calculated as E = 100 x (h max -h min ) / h min The difference E in % satisfies E > A r , where A r denotes the elongation at break of the shortest support in % and the first braid is plastically deformable in at least one of the first and second main directions of the first braid, such that the distance between the two attachment points of each support i is substantially equal to its resting length h i .

2. The panel of claim 1, wherein, The height h of the support i are distributed periodically in at least one of the first and second main directions of the first braid.

3. The panel according to claim 1 or 2, comprising at least g groups G of supports j where g is greater than 1 and less than m, j is an integer between 1 and g, each group G j being characterized in that the resting length of each support of said group G j is substantially equal to the average value of the resting lengths of the supports of said group G j for different integers j and k between 1 and g, ​ 4. Panel according to claim 1, comprising a filler material between the inner surface of the first braid and the inner surface of the second braid.

5. The panel of claim 4, wherein, The filler material is chosen from gypsum, soil, clay, natural fibers, inorganic fibers, polystyrene, polyurethane, cork and crushed construction or infrastructure gravel.

6. The panel of claim 4, wherein, The filler material is chosen from sand, cement, cement-based foam.

7. The panel of claim 4, wherein, The filler material is waste.

8. The panel of claim 4, wherein, The filler material is an expanded material.

9. The panel of claim 1, wherein, The second braid is deformable in at least one of the first and second main directions of the second braid.

10. The panel of claim 9, wherein, The second braid is plastically deformed.

11. The panel of claim 1, wherein, At least one of the knitted fabrics, chosen from the first knitted fabric and the second knitted fabric, comprises at least one deformable zone comprising at least one threadlike element ED deformable under traction, wherein, for any threadlike element ED deformable under traction, there is an elongation A ED <AR ED , such that M1 ED / M2 ED <1, wherein M1 ED represents the modulus of the deformable threadlike element ED for any elongation less than or equal to K1 x A ED %, M2 ED represents the modulus of the deformable threadlike element ED for any elongation greater than or equal to K2 x A ED %, AR ED represents the elongation at break of the element ED in %, K1 ranges from 0.8 to 0.95, K2 ranges from 1.05 to 1.2, the modulus values M1 ED , M2 ED and the elongation at break AR ED are measured according to the standard ASTM D885-03.

12. The panel of claim 1, wherein, The first and second braids independently of one another comprise a material chosen from polyester, polyamide, polyketone, polyurethane, natural fibers, inorganic fibers, cellulose fibers and combinations of these materials.

13. The panel of claim 1, wherein, At least one of the braids comprises a material having a fire resistance, such a material being a naturally fire-resistant material or a material treated for fire resistance.

14. The panel of claim 1, wherein, Each filiform element of the connection structure is a textile element.

15. The panel of claim 1, wherein, Each filiform element of the connection structure is a metallic element.

16. The panel of claim 1, wherein, average resting length of the support greater than 8 mm.

17. Assembly comprising at least one panel according to any one of claims 1 to 16.

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