Conformable sheet material comprising two faces connected by a uniform connection structure

Abstract

The present invention relates to a sheet material comprising a first fabric (1), a second fabric (3) and a connecting structure comprising a support (4) connecting the first fabric to the second fabric, wherein the rest length of each support (4) is substantially equal to the average rest length of the support (4), and the first fabric (1) is plastically deformable in at least one principal direction.

Description

Technical Field

[0001] The present invention relates to a board comprising two woven fabrics connected by a load-bearing structure, and the use of such a board as a building material. Background Technology

[0002] A wide variety of panels are used in the construction industry. Among these panels, structural panels such as concrete panels or gypsum boards can be mentioned, as can thermal insulation panels such as polyurethane panels, rock wool panels, or wood fiberboard.

[0003] These boards can be made from a single type of material, such as plaster, and are therefore often referred to as “solid” boards. They can also be made from a combination of several different materials to enhance one or more specific qualities, and are therefore often referred to as “composite” boards.

[0004] Therefore, document US2017 / 0044766 describes a composite floor covering made of a so-called three-dimensional woven fabric, which comprises two planar fabrics connected by spacer elements that make the two surfaces parallel and spaced apart. This three-dimensional woven fabric is mesh-like, through which cement can be poured to form a reinforced floor. This structure requires laying on horizontal supports because the board cannot accommodate infill material.

[0005] Document WO2019 / 197319 describes a composite material consisting of a three-dimensional woven fabric and polyurethane foam, wherein the three-dimensional woven fabric comprises two faces, the separation between which is regulated by spacers, and the material is designed to form a sole. The spacers provide mechanical integrity by maintaining a certain space between the two faces of the woven fabric, thereby providing resistance to continuous compression experienced by the sole.

[0006] Documents US2010 / 0233417 and WO2015 / 053842 describe a flexible fabric composite material capable of "solidification" (in a manner similar to cement "solidification"). This composite material can become rigid or semi-rigid by applying a liquid or radiation. It is made of a three-dimensional woven fabric containing powder and having two planes and spacers. The powder is introduced through one face of the woven fabric, which is deformable to form the space required to introduce the powder and contracts to contain it. One or more faces of the woven fabric can also be permeated with the liquid or radiation required to solidify the powder, thus hardening the composite material. The faces are separated by spacers, which can be composed of a single set of fibers or monofilaments. Although, according to US2010 / 0233417, there is theoretically no limitation on the thickness of the composite material, the listed constraints, particularly the ability of the liquid to penetrate into the core of the powdered material before the outer portion hardens, the ability of the surface to support the weight of the powder, and the constraints on the rigidity of the spacer to enable it to properly function in maintaining the space between the two inner surfaces of the composite material, therefore limit the thickness of these composite materials to a relatively small amount, typically a few millimeters, as indicated by the “typically…” example shown in the embodiments of WO2015 / 053842.

[0007] Document WO2015 / 187826 describes a fabric composite material comprising a nonwoven fabric, one side of which is liquid-permeable and the other side is impermeable, the fabric being filled with a material that hardens upon contact with the liquid. The two sides of the fabric are separated by a set of self-supporting fibers, which generally maintain the spacing between the two sides and resist compressive mechanical forces. When this composite material is bent, wrinkles form on its surface before the filler material hardens.

[0008] Regardless of the function or location of these panels, efforts should be made to ensure ease of implementation and maintain their integrity. While it is easy to create or cover flat surfaces, it can be particularly challenging when constructing or covering complex surfaces such as curved surfaces or even irregular surfaces.

[0009] Therefore, there is a need for boards with complex shapes, simple use, and the ability to meet a variety of requirements. Summary of the Invention

[0010] To meet these needs, the applicant company has developed a sheet material having a first woven fabric and a second woven fabric, the second woven fabric being connected to the first woven fabric via a connecting structure, the first woven fabric being deformable in at least one principal direction of the first woven fabric. The sheet material may be filled with a filler material, the properties of which depend on the intended use of the sheet material.

[0011] definition

[0012] The carbon-containing compounds mentioned in this specification can be of fossil or bio-based origin. In the case of bio-based origin, the carbon-containing compounds can be partially or wholly derived from biomass, or obtained from renewable raw materials derived from biomass. In particular, this relates to polymers, plasticizers, fillers, etc.

[0013] "Approximately parallel" or "generally extending along" means that the angle formed by the two directions in question is less than 10°, preferably less than 5°, more preferably less than 2°, and even more preferably less than or equal to the error of the angle measured by appropriate methods.

[0014] If two lengths are equal within the usual measurement tolerances for measuring such lengths, or within the tolerances of manufacturing methods that use elements with substantially the same lengths, then the two lengths are substantially equal.

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

[0016] A woven fabric is called a deformable woven fabric if at least one surface portion of the fabric is deformable.

[0017] Woven board

[0018] This invention relates to a sheet material, the sheet material comprising:

[0019] • A first woven fabric comprising filamentary elements (C1) referred to as warp elements and filamentary elements (T1) referred to as weft elements, the warp elements being generally parallel to each other and extending in a direction referred to as the warp direction, the warp direction constituting a first principal direction of the first woven fabric, the weft elements being generally parallel to each other and extending in a direction referred to as the weft direction, the weft direction constituting a second principal direction of the first woven fabric, the second principal direction being different from the first principal direction of the first woven fabric;

[0020] • A second woven fabric comprising filamentary elements (C2) referred to as warp elements and second filamentary elements (T2) referred to as weft elements, the warp elements being generally parallel to each other and extending in a direction referred to as the warp direction, which constitutes a first principal direction of the second woven fabric, the weft elements being generally parallel to each other and extending in a direction referred to as the weft direction, which constitutes a second principal direction of the second woven fabric, the second principal direction being different from the first principal 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 the rest length of each support member in the connecting structure is substantially equal to the average rest length of the support members. m represents the total number of supporting members of the connecting structure, and the first woven fabric is plastically deformable in at least one of the first and second main directions of the first woven fabric.

[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 woven fabric in at least one main direction of the first woven fabric can cause the sheet to conform to or define a complex non-planar surface after forming, such as a cylindrical surface or a wavy surface, or even a non-uniform surface, such as a hemispherical surface.

[0025] Forming or conforming refers to shaping a sheet material by deforming the woven fabric. For example, forming can be achieved by injecting a filler material between the inner surfaces of the first and second woven fabrics, or by injecting pressurized gas (e.g., air or an inert gas such as nitrogen) between the inner surfaces of the first and second woven fabrics of the sheet material. Therefore, those skilled in the art can ensure that the surface cannot be permeated by such pressurized gas by coating or calendering a suitable material.

[0026] Filler material

[0027] Preferably, the sheet material according to the invention includes a filling material between the inner surface of the first woven fabric and the inner surface of the second woven fabric.

[0028] The filler material can be any material capable of enabling the sheet material according to the invention to achieve its intended function. The shape of the filler material must allow it to be incorporated between the two inner surfaces of the woven fabric constituting the sheet material of the invention. When incorporated between the inner surfaces of the sheet material, the filler material can be in the form of a gas, liquid, or dispersed solid. Therefore, the filler material can preferably be any powder, gas, or liquid derived from natural or recycled materials, or it can be pulverized or incorporated into the sheet material according to the invention in a molten state.

[0029] When the sheet material is intended to be used as a structural component, the filler material can be a cement, cement-based foam, or concrete-type material.

[0030] The filler material can also be an insulating material (such as expanded polyurethane foam) or a dispersed solid material (such as polystyrene particles, cork, or clay).

[0031] The filler material can also be selected from waste materials: waste, crushed building gravel or infrastructure gravel.

[0032] Therefore, the filler material can preferably be selected from sand, cement, cement-based foam, gypsum, soil, clay, natural fibers, inorganic fibers, polystyrene, polyurethane, cork, waste and crushed building gravel or infrastructure gravel.

[0033] When the sheet material according to the present invention is used in a pipe, the filling material can also be pressurized gas, possibly pressurized circulating gas.

[0034] In another arrangement, the filler material may preferably be an expanding material, preferably an expanding foam, and more preferably an expanding polyurethane foam. The advantage of the sheet material filled with expanding material according to the invention is that the sheet material can be shaped as the expanding material expands.

[0035] The filler material can be injected in a variety of ways. For example, one or more nozzles can be used to inject the filler material through at least one end of the three-dimensional braid, with the material gradually flowing into the three-dimensional braid under the influence of gravity or "driven" by the flow of filler material.

[0036] This allows for the production of thermal insulation panels suitable for fitting curved or complex-shaped walls.

[0037] Woven fabric for the sheet metal according to the invention

[0038] The first woven fabric of the sheet metal according to the invention comprises filamentary elements (C1) referred to as warp elements and filamentary elements (T1) referred to as weft elements, the warp elements being generally parallel to each other and extending in a direction referred to as the warp direction, which constitutes a first principal direction of the first woven fabric, and the weft elements being generally parallel to each other and extending in a direction referred to as the weft direction, which constitutes a second principal direction of the first woven fabric, the second principal direction being different from the first principal direction of the first woven fabric.

[0039] The first woven fabric is characterized by its plastic deformation in at least one principal direction. Deformability means that the woven fabric can be extended along at least one principal direction without breaking.

[0040] By plastically deforming the first braid, the sheet material according to the invention can be shaped and maintain its shape. This is particularly advantageous when the sheet material according to the invention contains a filler material, especially when such filler material is a material capable of hardening. The plastic deformation of the first braid of the sheet material according to the invention can harden the filler material without requiring tension to be maintained on the first braid of the sheet material according to the invention, which would not occur if the first braid underwent elastic deformation.

[0041] Preferably, the second woven fabric is deformable in at least one main direction of the second woven fabric.

[0042] In a preferred arrangement, the second fabric undergoes plastic deformation. In another preferred arrangement, the second fabric undergoes elastic deformation.

[0043] Deformable woven fabrics are well known to those skilled in the art. The deformability of a woven fabric can be achieved in various ways. For example, deformability can be achieved through the weaving process of the fabric. It can also be achieved through the properties of the warp and / or weft filaments.

[0044] Therefore, the deformability of woven fabrics can be achieved by using wavy filaments (which are therefore stretchable), elastic filaments, filaments capable of plastic deformation without breaking, or filaments that partially break. For example, one could mention coated filaments that, when stretched, break at the core while the rest of the filament remains intact.

[0045] Preferably, at least one woven fabric selected from the first woven fabric and the second woven fabric includes at least one deformable region that is deformable in at least one main direction of the woven fabric and at least one non-deformable region that is not deformable in at least one main direction of the woven fabric.

[0046] There are deformable regions and non-deformable regions, such that the shape of the fabric surface can be adjusted after the sheet according to the present invention is formed. Thus, the sheet according to the present invention can, for example, exhibit a planar region and a deformed region after being formed.

[0047] In a preferred arrangement, at least one of the first fabric and the second fabric includes at least one deformable region that is deformable in the main direction of the fabric and non-deformable in the second main direction of the fabric.

[0048] In such a preferred arrangement, the fabric can be deformed in the first main direction and remain unchanged in the second main direction, so that a surface with a sinusoidal profile can be formed in the first main direction while substantially maintaining its length in the second main direction.

[0049] Preferably, at least one of the first fabric and the second fabric includes at least one deformable region, and the deformable region includes at least one filamentary element ED that is deformable under traction. For any filamentary element ED that can be deformed by traction, there is an elongation rate AED < ARED, such that M1ED / M2ED < 1, where M1ED represents the modulus of the deformable filamentary element ED when any elongation rate is less than or equal to K1×AED%, M2ED represents the modulus of the deformable filamentary element ED when any elongation rate is greater than or equal to K2×AED%, ARED represents the breaking elongation rate of the element ED in %, and the modulus values M1ED, M2ED and the breaking elongation rate ARED are measured according to the standard ASTM D885-03.

[0050] Such a filamentary element ED has the so-called "bi-modulus" behavior known to those skilled in the art from other places. When the elongation rate of the element ED is greater than AED, the element exhibits greater resistance to elongation compared to when the elongation rate is less than AED.

[0051] Such an element can obtain a deformable fabric. This deformable fabric has less deformation resistance during the forming process and greater deformation resistance after the fabric is formed, so that a sheet that is both easy to form and has good geometric stability after being formed can be obtained. Therefore, even if the formed sheet has a complex shape, before being formed, it has a very simple shape close to a planar fabric and can be easily stored and transported in the form of sheet stacking or wound around a reel most compactly.

[0052] Preferably, each filamentary element ED includes a first filamentary member and a second filamentary member. Preferably, in order to obtain such a bi-modulus behavior, for a given length of the filamentary element ED, each filamentary member has a different modulus and / or a different length.

[0053] Preferably, the second filamentary member is generally straight, and the first filamentary member is generally spirally wound around the second filamentary member.

[0054] Preferably, for each filament element ED, the elongation before break of the second filament member within the filament element ED is greater than A. ED %, while the elongation before fracture of the first filamentary member within the filamentary element ED is less than A. ED %.

[0055] Preferably, the first and second woven fabrics independently comprise materials selected from polyester, polyamide, polyketone, polyurethane, natural fibers, inorganic fibers, cellulose fibers, and combinations thereof, more preferably selected from polyester, polyamide, polyketone, polyurethane, natural fibers, cellulose fibers, and combinations thereof, and more preferably selected from polyester, natural fibers, cellulose fibers, and combinations thereof.

[0056] In a preferred arrangement, at least one woven fabric comprises a flame-retardant material, which is either a natural flame-retardant material or a flame-retardant treated material.

[0057] Preferably, when the sheet material according to the invention includes a filler material, at least one of the first and second braids is arranged in a manner that prevents the filler material from permeating. Thus, the filler material cannot flow through the non-permeable braids. Preferably, neither of the two braids of the sheet material according to the invention is permeable to the filler material.

[0058] Connection structure

[0059] The sheet material according to the invention includes a connecting structure comprising 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 braid to the attachment point with the second braid, the rest length of each support member of the connecting structure is substantially equal to the average rest length of the support member.

[0060] The rest length of a support member refers to its length along the longitudinal direction when no external stress load (except atmospheric pressure) is applied to it. A support member at rest in the longitudinal direction is subjected to neither tension nor compression in that direction, and therefore its elongation in that direction is zero. Similarly, the rest length of a filament element generally refers to its length along the longitudinal direction when no external stress load (except atmospheric pressure) is applied to it.

[0061] A filamentous element refers to any long, straight element whose length is greater than its cross-section, regardless of the shape of the cross-section, such as circular, elliptical, rectangular, or square, or even flat. The filamentous element may be twisted or wavy, for example. When its cross-section is circular, the diameter of the cross-section is preferably less than 5 mm, more preferably in the range of 10 μm to 1.2 mm.

[0062] The geometry of each filamentary element of the connecting structure (particularly each support connecting the inner surfaces of the first and second braids) can be characterized by its rest length LP and its average cross-section SP, which is the average value of cross-sections obtained by cutting the support on all surfaces parallel to and between the first and second braids. In the most common case where the filamentary elements and supports have constant cross-sections, the average cross-section SP is equal to that constant cross-section.

[0063] For each filamentary element of the connecting structure, particularly each support member, the minimum characteristic dimension E of its average cross-section SP is generally preferably at most equal to the average rest length of the support member. The aspect ratio R of its average cross-section SP is preferably at most 3, which is 0.02 times that of the average cross-section SP of the load-bearing element. The smaller characteristic dimension E of the average cross-section SP of the load-bearing element is at most equal to the average static length of the support. The 0.02 times rule out any large load-bearing components with a large volume.

[0064] The aspect ratio R of the average cross-section SP is at most equal to 3, meaning that the maximum characteristic dimension V of the average cross-section SP is at most equal to 3 times the minimum characteristic dimension E of the average cross-section SP. For example, the aspect ratio R of the average cross-section SP of a circle with a diameter of d is 1; the aspect ratio R of the average cross-section SP of a rectangle with a length of V and a width of V' is V / V'; and the aspect ratio R of the average cross-section SP of an ellipse with a major axis of B and a minor axis of B' is B / B'.

[0065] Average static length of support Preferably, the length is greater than 8 mm, preferably between 10 mm and 2000 mm, preferably between 10 mm and 1000 mm, preferably between 10 mm and 500 mm, and the height is preferably between 30 mm and 100 mm, and very preferably between 40 mm and 70 mm. This average static length can be adjusted according to the intended use of the sheet material according to the invention.

[0066] The support members have filament-like mechanical properties, meaning they can only be subjected to tensile or compressive forces along their mean line. Each support member of the connecting structure is flexible. This means it can bend without breaking and will not undergo plastic deformation. The connecting structure itself cannot support the gap between the two faces of the sheet metal according to the invention. Without any filler or internal pressure, the two faces can move closer to each other without being loaded.

[0067] In a preferred embodiment, each filamentary element of the connecting structure is a fabric element. Fabric means that each filamentary element of the connecting structure is non-metallic, for example made of a material selected from: polyester, polyamide, polyketone, polyvinyl alcohol, cellulose, mineral fibers, natural fibers, elastomer materials, or mixtures of these materials. Among polyesters, for example, PET (polyethylene terephthalate), PEN (polyethylene naphthalate), PBT (polybutylene terephthalate), PBN (polybutylene naphthalate), PPT (polypropylene terephthalate), or PPN (polypropylene naphthalate) may be mentioned. Among polyamides, aliphatic polyamides such as polyamide 4-6, 6, 6-6 (nylon), 11, or 12 may be mentioned, as well as aromatic polyamides such as aramid.

[0068] For example, each filamentary element of the connecting structure is a fabric assembly comprising one or more monofilaments or multifilaments twisted or untwisted together. Thus, in one embodiment, an assembly with fibers substantially parallel to each other can be used. In another embodiment, an assembly with fibers spirally 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 can range from a few hundredths of a millimeter to a few millimeters, typically between 0.001 mm and 5 mm, preferably between 5 μm and 50 μm, and more preferably between 10 μm and 40 μm.

[0069] In a preferred arrangement, each filamentary element of the connecting structure is a multifilament fabric fiber, with the diameter of each fiber constituting the fabric fiber ranging from 0.001 mm to 0.5 mm, preferably from 5 μm to 50 μm, and more preferably from 10 μm to 40 μm. The advantage of such filamentary elements is their greater flexibility compared to monofilamentary elements. Therefore, by bringing the inner surfaces of the first and second braids together, the braided fabric according to the invention, including such filamentary elements, can be stored in a very compact manner. Preferably, in this arrangement, when the sheet is subjected to a compressive load (i.e., a force applied to the sheet perpendicular to its surface and along its direction), the arrangement of the filamentary elements prevents the support itself from maintaining the spacing between the inner surfaces of the two braids. This arrangement is achieved by adjusting the density of the support (expressed as the number of support elements per square meter) and / or by adjusting the flexibility of the support through the yarn count or the chemical properties of the filamentary elements. However, when a filler material is introduced between the two inner surfaces of the sheet material according to the invention, the support does need to have sufficient strength to maintain the spacing between the two inner surfaces of the woven fabric to withstand the pressure generated by the introduction of the filler material, i.e., sufficient tensile strength. This strength can be adjusted by the density and / or toughness and / or chemical properties of the support.

[0070] In another embodiment, each filamentary element of the connecting structure is made of metal, such as a single metal filament or an assembly of single metal filaments, with the diameter of each filament ranging from a few hundredths of a millimeter to a few millimeters, typically between 0.01 mm and 5 mm. In one embodiment, each filamentary element of the connecting structure consists of an assembly of several single metal filaments. In another embodiment, each filamentary element is composed of a single metal filament.

[0071] In one embodiment, as the filaments extend along the length of the filaments, each filament of the connecting structure extends alternately from the first braid toward the second braid and from the second braid toward the first braid.

[0072] In one embodiment, each filamentary element of the connecting structure includes a first filamentary portion for anchoring each filamentary element of the connecting structure in a first braid, extending the support into the first braid.

[0073] Preferably, each first anchoring filament is interlaced with the first braid. The advantage of this assembly is that it can be manufactured in a single stage. However, it is also conceivable to manufacture the sheet according to the invention in two stages: a first stage manufacturing the first braid, and a second stage interlacing one or more filament elements of the connecting structure with the first braid. In both cases, the interlacing of each filament element of the connecting structure with the first braid ensures that each filament element of the connecting structure is mechanically anchored in the first braid, thereby imparting the required mechanical properties to the connecting structure.

[0074] In one embodiment, 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.

[0075] Preferably, the first woven fabric comprises:

[0076] • Filament-like elements referred to as warp elements, which are generally parallel to each other and extend along a first direction referred to as the warp direction, which is generally parallel to a first principal direction of the first weave.

[0077] • A filamentous element referred to as a weft element, which is generally parallel to each other and extends along a second direction referred to as the weft direction, and the weft element is interwoven with a filamentous warp element.

[0078] Each first filamentary anchoring portion is at least partially wound around at least one filamentary weft element of the first weave, preferably around at least two adjacent filamentary weft elements in the first main direction of the first weave.

[0079] In one embodiment, the extension direction of each first filamentary anchoring portion is substantially parallel to the first principal direction of the first braid.

[0080] Preferably, each first filamentary anchor portion alternately passes between two adjacent filamentary weft elements from one side of the first weave to the other side of the first weave, and the first filamentary anchor portion is wrapped around the two filamentary weft elements.

[0081] Preferably, when the sheet material according to the invention includes a filler material, at least one of the first and second braids is arranged in a manner that prevents the filler material from permeating. Thus, the filler material cannot flow through the non-permeable braids. Preferably, neither of the two braids of the sheet material according to the invention is permeable to the filler material.

[0082] Deformable and non-deformable areas of woven fabrics

[0083] In a preferred embodiment where a first woven fabric of the sheet metal according to the invention can be effectively shaped, the first woven fabric comprises:

[0084] • A first group of regions, comprising at least one transverse straight section (Z1), each transverse straight section (Z1) in the first group of regions being arranged to allow at least one transverse straight section (Z1) of the first group of regions to extend in a first principal direction (G1) of the first knitted fabric, preferably each transverse straight section (Z1) of the first group of regions extending in the first principal direction (G1) of the first knitted fabric.

[0085] • A second set of regions, which includes at least one transverse straight region (Z2), each transverse straight region (Z2) in the second set of regions being arranged to prevent the transverse straight region (Z2) from elongating.

[0086] By definition, the transverse straight zone of a woven fabric is defined longitudinally by two imaginary straight lines that are approximately perpendicular to the first principal direction of the first knit. The transverse straight zone spans the entire width of the woven fabric, meaning it is defined transversely by the longitudinal edge of the fabric.

[0087] Preferably, in an arrangement in which each filamentary element ED includes a first filamentary member and a second filamentary member, each transverse straight section in the first group of regions is arranged to allow each filamentary meridional element to extend along a first principal direction in each transverse straight section of the first group of regions.

[0088] The elongation of each filamentary radial element ED can be obtained in any way, for example by the first filamentary element described in applications WO2018 / 130782 and WO2018 / 130783.

[0089] In an embodiment where an indeformable second set of regions can be obtained, each transverse straight region (Z2) in the second set of regions is arranged to prevent each filamentary meridional element from elongating along a first general direction in each transverse straight region (Z2) of the second set of regions.

[0090] In the preferred embodiment described above, each transverse straight zone (Z1) in the first group of regions is a so-called deformable zone. These zones are deformable under molding conditions, contributing to the conformability of the first woven fabric. Each transverse straight zone (Z2) in the second group of regions is a so-called unbreakable zone. Optionally, in one embodiment, each transverse straight zone (Z2) in the second group of regions is undeformable. In another embodiment, each transverse straight zone (Z2) in the second group of regions is deformable, but to a much lesser extent than each transverse straight zone (Z1) in the first group of regions. These zones are unbreakable under molding conditions and contribute little or no to the conformability of the first woven fabric. Therefore, each so-called deformable transverse straight zone (Z1) in the first group of regions undergoes sufficient deformation to shape the component and compensate for the lack of elongation or slight elongation of the unbreakable transverse straight zones (Z2) in the second group of regions. The greater the elongation of all transverse straight zones in the first group of regions under maximum force, the shorter and fewer the so-called deformable transverse straight zones in the first group of regions compared to the unbreakable transverse straight zones in the second group of regions. At the scale of the filamentary warp element, the portion of each first filamentary warp element located in each so-called deformable transverse straight zone (Z1) in the first set of regions undergoes sufficient deformation to shape the assembly and compensate for the non-elongation or slight elongation of those portions of each first filamentary warp element located in the indestructible transverse straight zone (Z2) in the second set of regions.

[0091] Furthermore, each so-called deformable region in the first group of regions is deformable under relatively low stress, which allows for the use of appropriate forming stress in the method of forming the sheet according to the invention, such stress corresponding, for example, to the stress when inserting filler material between the two inner surfaces of the first and second braids of the sheet according to the invention.

[0092] In a preferred embodiment, each carrier filament element includes a first filament portion for anchoring each carrier filament element in a first braid, extending the carrier filament portion in the first braid:

[0093] • Each transverse straight zone (Z1) in the first group of regions has no first filamentary anchoring portion.

[0094] • Each transverse straight zone (Z2) in the second group of regions includes at least one first filamentary anchoring portion.

[0095] Preferably, each transverse straight zone (Z1) in the first group of regions alternates with the transverse straight zone (Z2) in the second group of regions in the first main direction of the first weave.

[0096] Therefore, at the scale of the first knitted fabric, to achieve uniform deformation of the first knitted fabric as a whole, the shorter the rest length of each transverse straight zone in the first principal direction of the first knitted fabric, the more uniform the deformation. The rest length of the transverse straight zone in the first principal direction refers to the length of the region along the longitudinal direction when no external stress load (except atmospheric pressure) is applied to the region. The transverse straight zones at rest in the first principal direction are subjected to neither tension nor compression in that direction, and therefore have zero elongation in that direction.

[0097] The features described above relating to the transverse straight zones (Z1) and (Z2), after appropriate adjustments, are preferably applicable to the second weave of the sheet material according to the present invention.

[0098] Board manufacturing

[0099] In the step of forming the sheet according to the invention, first filament elements 64, 66 are assembled in a manner to form a first braid 26, and second filament elements 68, 70 are assembled in a manner to form a second braid 28. A carrier element 32, which may be coated with an adhesive composition (preferably a crosslinked composition), is also assembled with the first braid 26 and the second braid 28. In an illustrative embodiment, the first filament elements 64, 66 and the second filament elements 68, 70 are assembled with the carrier element 32 simultaneously in a single step to form the sheet 24. In another embodiment, the first braid 26 and the second braid 28 are first formed separately, and then the first braid 26 and the second braid 28 are joined using the carrier element 32, which may be coated with an adhesive composition, preferably a crosslinked composition. The steps of forming the sheet 24 according to the invention are performed in a manner well known to those skilled in the art of weft-knitted fabrics.

[0100] Components

[0101] The present invention also relates to an assembly comprising at least one sheet material according to the invention. An assembly is an assembled entity that can combine any elements comprising at least one sheet material according to the invention. Such an assembly can be, for example, a building structure (but not limited thereto), such as a warehouse, building, house, aircraft, ship, or land vehicle. The assembly can also be a cable tray, pipe, or container. Attached Figure Description

[0102] [ Figure 1 According to the schematic general arrangement of the sheet metal of the present invention, the sheet metal includes a first woven fabric, the first woven fabric including deformable regions.

[0103] [ Figure 2 According to the schematic general arrangement of the sheet metal of the present invention, the sheet metal includes a first woven fabric and a second woven fabric, the first woven fabric including a deformable region and the second woven fabric including a deformable region.

[0104] [ Figure 3 A top view of the plate material according to the present invention.

[0105] [ Figure 4 A cross-sectional view of the plate according to the present invention on the cross-sectional plane P-P'. Detailed Implementation

[0106] Figure 1A schematic general arrangement of the cross-section of a sheet material (10) according to the invention is depicted, the sheet material (10) comprising a first braid (1), a second braid (3), and a connecting structure, the first braid (1) comprising a deformable region (2), the connecting structure comprising filamentary elements connecting the first braid to the second braid, each filamentary element comprising at least one filamentary portion referred to as a support (4), the support (4) connecting the first braid (1) to the second braid (3), the rest length of each support of the connecting structure being substantially equal to the average rest length of the support. The deformable region (2) is depicted thicker, simply to make the diagram easier to understand. Figure 1 The preferred filling material between the inner surface of the first woven fabric (1) and the inner surface of the second woven fabric (2) is not described. It can be seen that the surface can be conformally bent without using a large amount of flat sheet material to approximate the curvature of the surface, thus greatly simplifying the work.

[0107] Figure 2 A schematic overall arrangement of a sheet material (11) is depicted, the sheet material (11) including a deformable area (A) of a first weave and a deformable area (B) of a second weave. This figure illustrates how complex shapes can be obtained using the sheet material according to the invention.

[0108] Figure 3 A top view of the plate (10) according to the present invention is depicted. Figure 4 A cross-sectional view of the plate (10) is depicted. In both figures, the same components are numbered in the same way.

[0109] The first knit 26 includes two longitudinal edges 26A and 26B. The first knit 26 extends along a first principal direction G1, generally parallel to each longitudinal edge 26A, 26B. The first knit 26 includes filamentary elements 64, referred to as warp elements, and filamentary elements 66, referred to as weft elements. The warp elements 64 of the first knit 26 are generally parallel to each other and extend along a direction referred to as the warp direction C1, generally parallel to the first principal direction G1. The weft elements 66 of the first knit 26 are generally parallel to each other and extend along a direction referred to as the weft direction T1, interlacing with the warp elements 64. The warp elements 64 extend continuously along the entire length of the first knit 26.

[0110] Here, each filament element 64, 66 is, for example, a fabric filament element.

[0111] The filamentary elements 64 are substantially all identical. Each filamentary warp element 64 includes a first filamentary member 65 and a second filamentary member 67. The second filamentary member 67 is generally straight and the first filamentary member 65 is generally spirally wound around the second filamentary member 67. Here, the first filamentary member 65 is a multifilamentary strand made of PET with a count of 110 tex, and the second filamentary member 67 is a multifilamentary strand made of rayon with a count of 23 tex.

[0112] Here, the filamentary element 66 includes two filamentary members, the second filamentary member being generally straight and the first filamentary member being generally spirally wound around the second filamentary member. Here, the first filamentary member is a multifilamentary strand made of PET with a count of 110 tex, and the second filamentary member is a multifilamentary strand made of rayon with a count of 23 tex.

[0113] Figure 4 The depicted second knit 28 extends along a first principal direction G2. The second knit 28 includes filamentary elements 68, referred to as warp elements, and filamentary elements 70, referred to as weft elements. The warp elements 68 of the second knit 28 are generally parallel to each other and extend in a direction referred to as the warp direction C2, which is generally parallel to the first principal direction G2 of the second knit. The weft elements 70 of the second knit 28 are generally parallel to each other and extend in a direction referred to as the weft direction T2, which interweaves with the warp elements 68. The warp elements 68 extend continuously along the entire length of the second knit 28.

[0114] Here, each filament element 68, 70 is, for example, a fabric filament element.

[0115] The filamentary elements 68 are essentially all the same, and here they are multifilament strands made of PET with a count of 110 tex.

[0116] The filamentary elements 70 are essentially all the same, and here they are multifilament strands made of PET with a count of 167 tex.

[0117] 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 supporting filamentary 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 supporting filamentary element 32 is a fabric supporting filamentary element made of PET with a yarn count of 55 tex.

[0118] 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.

[0119] 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.

[0120] Each of the first filamentary anchoring portions 76 and the second filamentary anchoring portions 78 extends in directions substantially parallel to the first principal direction G1 of the first braid and the first principal direction G2 of the second braid, respectively.

[0121] Each first filamentary anchoring portion 76 alternates between faces 41 and 42 between two adjacent filamentary weft elements 66, and the first filamentary anchoring portion 76 is wrapped around these two filamentary weft elements 66. Similarly, each second filamentary anchoring portion 78 alternates between faces 46 and 49 between two adjacent filamentary weft elements 68, and the second filamentary anchoring portion 78 is wrapped around these two filamentary weft elements 68.

[0122] Figure 3 and Figure 4The depicted first woven fabric 26 includes a first set of transverse straight zones Z1, each transverse straight zone Z1 having a stationary length Ld1 in the first principal direction G1 of the first woven fabric and extending over the entire width of the first woven fabric 26. All transverse straight zones Z1 in the first set of transverse straight zones may be identical or may vary depending on the desired shape after the molding sheet is formed.

[0123] Figure 3 and Figure 4 The depicted first woven fabric 26 includes a second set of transverse straight zones Z2, each transverse straight zone Z2 having a stationary length Ld2 in the first principal direction G1 of the first woven fabric and extending over the entire width of the first woven fabric 26. All transverse straight zones Z2 in the second set of transverse straight zones may be identical or may vary depending on the desired shape after the molding sheet is formed.

[0124] Each transverse straight zone Z1 in the first group of regions alternates with the transverse straight zone Z2 in the second group of regions in the first main direction of the first weave.

[0125] Example

[0126] Two sheets are manufactured. The first sheet corresponds to... Figure 3 and Figure 4 The depicted sheet material. The second sheet material has the same first and second braids as the first sheet material, but without the connecting structure. The characteristics of the first and second braids and the connecting structure (if any) are shown in Table 1 below.

[0127] [Table 1]

[0128]

[0129] The two plates have the following geometric characteristics:

[0130] Thickness: 40mm

[0131] Width: 150mm

[0132] • Length: 500mm

[0133] 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.

[0134] [Table 2]

[0135] First Board Second board <![CDATA[E mod (kPa)]]> 8788 5450 <![CDATA[F max (N)]]> 326 135 <![CDATA[Under F max (kPa) of σ M > 427 177

[0136] The sheet material according to the present invention, in addition to being able to be formed into complex surface shapes, also has excellent structural strength.

Claims

1. A sheet material, the sheet material comprising: • A first woven fabric comprising filamentary elements (C1) referred to as warp elements and filamentary elements (T1) referred to as weft elements, wherein the warp elements of the first woven fabric are generally parallel to each other and extend in a direction referred to as the warp direction, which constitutes a first principal direction of the first woven fabric, and the weft elements of the first woven fabric are generally parallel to each other and extend in a direction referred to as the weft direction, which constitutes a second principal direction of the first woven fabric, wherein the second principal direction of the first woven fabric is different from the first principal direction of the first woven fabric; • A second woven fabric comprising filamentary elements (C2) referred to as warp elements and second filamentary elements (T2) referred to as weft elements, the warp elements of the second woven fabric being generally parallel to each other and extending in a direction referred to as the warp direction, which constitutes a first principal direction of the second woven fabric, the weft elements of the second woven fabric being generally parallel to each other and extending in a direction referred to as the weft direction, which constitutes a second principal direction of the second woven fabric, the second principal direction of the second woven fabric being different from the first principal direction of the second woven fabric; • 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; The characteristic feature is that the rest length of each support member in the connecting structure is substantially equal to the average rest length of the support members. m represents the total number of supporting members of the connecting structure, and the first woven fabric is plastically deformable in at least one of the first and second main directions of the first woven fabric.

2. The sheet material according to claim 1, wherein a filling material is included between the inner surface of the first woven fabric and the inner surface of the second woven fabric.

3. The sheet metal according to claim 2, wherein, The filler materials are selected from sand, cement, cement-based foam, gypsum, soil, clay, natural fibers, inorganic fibers, polystyrene, polyurethane, and cork.

4. The sheet metal according to claim 2, wherein, The filler material is an expanding material.

5. The sheet metal according to claim 1, wherein, The second woven fabric is deformable in at least one of the first and second principal directions of the second woven fabric.

6. The sheet metal according to claim 5, wherein, The second type of woven fabric undergoes plastic deformation.

7. The sheet metal according to claim 5, wherein, The second type of woven fabric undergoes elastic deformation.

8. The sheet metal according to claim 1, wherein, At least one of the first and second woven fabrics includes at least one deformable region, said deformable region comprising at least one filamentary element ED that is deformable under tension, wherein for any deformable filamentary element ED, there exists an elongation A. ED <AR ED This makes M1 ED / M2 ED <1, where M1 ED This means any elongation less than or equal to K1×A ED The modulus of deformable filamentary element ED at % M2 ED This means any elongation greater than or equal to K2×A ED The modulus of deformable filamentary element ED at % AR ED The component ED represents the elongation at break as a percentage, with K1 ranging from 0.8 to 0.95 and K2 ranging from 1.05 to 1.

2. The modulus value M1 is measured according to standard ASTM D885-03. ED M2 ED and elongation at break AR ED .

9. The sheet metal according to claim 1, wherein, The first and second woven fabrics independently comprise materials selected from: polyester, polyamide, polyketone, polyurethane, natural fibers, inorganic fibers, cellulose fibers, and combinations thereof.

10. The sheet metal according to claim 1, wherein, At least one woven fabric includes a flame-retardant material, which is either a natural flame-retardant material or a material that has been treated with flame retardancy.

11. The sheet metal according to claim 1, wherein, Each filamentary element in the connecting structure is a fabric element.

12. The sheet metal according to claim 11, wherein, Each filamentary element of the connecting structure is a multifilament fabric fiber, and the diameter of each fiber constituting the fabric fiber is between 0.001 mm and 0.5 mm.

13. The plate according to any one of claims 1 to 10, wherein, Each filamentary element in the connecting structure is a metal element.

14. The sheet metal according to claim 1, wherein, Average static length of support Greater than 8mm.

15. An assembly comprising at least one sheet material according to any one of claims 1 to 14.

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