PREFABRICATED INSULATION PANEL

Description

[0001] The present invention belongs to the field of prefabricated panels. Previous art

[0002] In construction, it is possible to create walls using prefabricated principles. These walls are composed of multiple prefabricated panels. Each panel consists of a frame enclosed by two plates: a front plate and a back plate made of a material such as plasterboard or wood. This frame and these plates form a cavity into which insulating material is placed. This insulating material can be mineral wool in the form of loose fill.

[0003] To achieve this, the frame is attached to the back plate, which is then placed flat / horizontally so that the insulating material can be placed in the space defined by the back plate and the frame. This horizontal position of the back plate allows the insulating material to be placed while ensuring its even distribution and therefore consistent thermal performance.

[0004] The front plate is then attached to the frame to close the panel.

[0005] The drawback of these panels is that, during transport, they are generally placed on their edge, i.e., on the frame. This positioning is a consequence of the panels' dimensions.

[0006] However, in this position on its edge, the insulating material is more susceptible to shocks occurring during transport. These shocks tend to cause the material to settle within the dwelling. Such settling is characterized by the appearance of voids (or thermal bridges) because the mineral wool flakes clump together. As a result, the flakes are no longer evenly distributed, leading to a decrease in the thermal performance of the panels.

[0007] Documents WO2017146615A1 and DE29810487U1 both disclose building elements insulated by blown flakes and held at different heights by horizontal battens.

[0008] Document EP1273730A2 discloses an insulating panel having a base and a lid in which fins hold a coherent layer of polyurethane, wood wool or mineral wool insulation. Summary of the invention

[0009] The present invention seeks to solve the problems of the prior art by providing a prefabricated wall panel whose thermal performance has less deterioration following shocks, particularly following transport.

[0010] For this purpose, the invention relates to an insulating panel according to the subject of claim 1. Optional embodiments are the subject of dependent claims.

[0011] In one example, the distance between the pins is constant.

[0012] In one example, the pegs are positioned to be aligned in the form of a grid.

[0013] In one example, the studs are positioned to be arranged in a staggered pattern.

[0014] According to one example, the spikes are made of a metallic or plastic material.

[0015] According to one example, the insulating material has a density between 15 and 45 kg / m3.

[0016] The invention further relates to a wall composed of a plurality of insulating panels according to one of the preceding claims, said insulating panels being fixed to each other.

[0017] The invention also relates to a method of assembling an insulating panel according to claim 16. Brief description of the figures

[0018] Other features and advantages will become clear from the description given below, which is indicative and in no way exhaustive, with reference to the attached drawings, in which: there figure 1 schematically represents a prefabricated panel according to the invention; the figure 2 schematically represents an open panel according to the invention; the figure 3 schematically represents an open panel equipped with retention means according to the invention; the figure 4 schematically represents a side view of an open panel equipped with retention means according to the invention; the figure 5 schematically represents a profile view of a variant of an open panel equipped with retention means according to the invention; figures 6 And 7 schematically represent variants of fixing the retention means to the prefabricated panel according to the invention; figures 8 And 9 schematically represent a variant of retention methods using a structure; the figures 10a , 10b , 11 and 12 schematically represent a variant of retention methods using a dual structure. figure 13 represents a diagram of the settlement in percentage according to the invention and according to the prior art. Detailed description

[0019] To the figure 1A panel 10 according to the invention is shown. Such a panel comprises a frame 12 or side panel, preferably rectangular or square, closed by two plates, a front plate 14 called the cover and a rear plate 16 called the base. The frame 12 and the two plates 14, 16 are arranged so that the two plates are, preferably, parallel to each other.

[0020] The frame, for example, is made of wooden battens and the panels are made from a plaster or wood-based material.

[0021] This panel has dimensions such that the panel has a height between 1 and 6m, a width between 1 and 6m and a depth between 10 and 60cm.

[0022] The frame 12 and the two plates 14, 16 form a housing 17 or space in which an insulating material 20 is placed as visible to the figure 2This insulation material, or insulator 20, is a mineral wool type material such as glass wool or rock wool, which, unlike the purely schematic mattress shown in figure 20, is not a physical material. figure 2 , according to the invention, is in the form of flakes or nodules having a density of 10 to 75 kg / m3, preferably 15 to 45 kg / m3.

[0023] To manufacture such a panel, the frame 12 and the back plate 16 are fixed together, and then the whole assembly is laid flat, resting on the back plate. This positioning allows access to the space formed by the back plate 16 and the frame 12.

[0024] This space 17 can be filled with the insulating material before it is closed by the front plate.

[0025] Ingeniously, according to the invention, the panel 10 includes retention means 30 as visible to the figure 3These retention means 30 are means of keeping the flakes in place during the transport of the panel, i.e. when it is handled, subjected to shocks and is positioned in different ways on one or the other of its faces.

[0026] These retention means 30 comprise a plurality of pins 32, that is, at least two pins. These pins 32 are in the form of rods. It is therefore understood that these pins 32 are elements whose cross-sectional diameter is negligible compared to their lengths. These pins or rods 32 are arranged in the panel so as to extend in a direction substantially orthogonal to the plane of the front plates 14 or rear plates 16, as visible to the figures 3 And 4 . This means that the 32 pins or rods extend orthogonally to the plane of the plates or are inclined at a maximum of 45 degrees with respect to an axis orthogonal to the plane of the plates.

[0027] The function of this plurality of 32 studs is to increase the friction between the flakes themselves and between the flakes and the panel structure. This increased friction tends to provide better resistance to impacts, particularly during transport.

[0028] To make this effect noticeable, the invention proposes to have a plurality of 32 studs distributed in the panel.

[0029] The 32 studs are made of a material such as metal, plastic, or wood.

[0030] Preferably, the material used has thermal properties so that the presence of the studs does not disrupt the performance of the panel.

[0031] In the example of a panel with a height of 550mm, a width of 550mm and a thickness of 165mm and 42 studs, we obtain, for an insulating material with a density of 20kg / m3, the diagram shown in the figure 13in which we can see that the settling for a panel without studs is greater than 14% whereas it is around 3% with the presence of studs.

[0032] According to the invention, the number of pins 32 is such that the spacing between two pins is between 2 and 20cm, preferably from 2 to 15cm, and preferably from 5 to 10cm.

[0033] This spacing varies depending on the density of the insulating material. Indeed, as can be seen below with a panel measuring 550 mm high, 550 mm wide, and 165 mm thick, several spacing configurations (5 and 8.5 cm) and densities (20, 30, and 40 kg / m³) were tested. The table below illustrates the settling (in mm) for different insulating material densities and for different stud spacings. Settlement in mm Spacing 5cm Spacing 8.5cm Insulation material density: 20kg / m³ 15 20-25 Insulation material density: 30kg / m³ 15 5-10 Insulation material density: 40kg / m³ 5-10 0

[0034] Consequently, for a given spacing, increasing density reduces compaction. It is also observed that compaction performance varies with density. Thus, it appears that for low density, a narrow spacing is effective, while for high density, a wider spacing may be more effective.

[0035] The spacing between the pins 32 is preferably constant, but it is entirely possible for it to vary. Thus, the spacing of the pins located in the center of the panel may differ from that of the pins located at the periphery, or simply that areas of the panel may have pins 32 with a different spacing.

[0036] The spacing between the 32 pins is such that the pins are positioned to be aligned in the form of a grid or to be staggered.

[0037] Similarly, the height of the 32 studs is an adjustable variable. It is not necessary for the studs to extend through the entire thickness of the panel. Indeed, the operation of the present invention relies on the presence of the studs or rods, which increase friction and improve the adhesion of the flakes.

[0038] Thus, 32 pins having a length at least equal to 25% of the panel's depth, as visible in the figure 5 have an effect on settlement.

[0039] Preferably, the spikes have a length equal to at least 50%, or even 75% and even more preferably 100% of the depth.

[0040] The advantage of the studs and their distribution within the panel is that they increase the retention of the loose fill within the cavity without the need for partitions, thus preventing intermediate settling. The studs are used to improve the retention of the loose fill by increasing friction between the flakes themselves and between the flakes and the panel structure. The spacing between the studs allows the flakes some freedom of movement. Therefore, the combination of the studs and their spacing allows the flakes to remain within the panel, limiting settling without the need for partitions. These retention devices are installed within the panel before it is filled with the insulating material.

[0041] Several methods are possible for integrating the pins into the panel.

[0042] In a first embodiment, the pins 32 are directly fixed to the back plate 16 as visible in the figure 6 Each pin 32 is then fixed to the plate by gluing. For this purpose, the plate is optionally marked with a plurality of blind holes 160, each corresponding to the position of a pin. Each pin is then placed in a hole and glued.

[0043] Alternatively, each pin 32 is provided with a fixing head 32a allowing said pin to be screwed onto the back plate as seen in the figure 7 .

[0044] Thus, the pins 32 according to this first embodiment are fixed to the back plate 16 before or after its assembly with the frame 12 but before filling with the insulating material.

[0045] In a second embodiment, the studs 32 are fixed to the panel via a structure 40. This structure 40 is in the form of a sheet 41 from which the studs extend. These studs 32 are elements attached to the sheet 41 but may be made of a single piece of material / be integral with the sheet 41.

[0046] In the case where the studs 32 are added elements, the studs 32 and the sheet 41 forming the structure can be made of the same material or of different materials. Thus, it is possible to have a wooden structure and metal or plastic studs, or a metal sheet and metal studs.

[0047] If the pins 32 and the sheet 41 are a single piece, the material of the pins and the sheet is identical. This allows, in the case of wood or metal, for the sheet and pins to be machined, while in the case of plastic, injection molding can be used. Of course, all possible methods for obtaining this sheet-pin assembly are applicable.

[0048] In this second embodiment, the sheet 41 fitted with the studs 32 is fixed to the rear plate 16 as visible in the figure 8 This fastening system allows the sheet to stay in place regardless of the panel's orientation. This fastening can be achieved by nailing, stapling, gluing, screwing, or using a snap-lock system.

[0049] In a variant visible at the figure 9The flexible sheet 41 from which the studs extend is perforated, that is to say, it includes a multitude of openings 42. These openings 42 are made firstly to lighten the structure 40. Indeed, this flexible sheet 41 brings an unnecessary additional weight.

[0050] Secondly, this perforation helps limit the influence of the flexible sheet 41 on thermal performance. Indeed, the material used for the flexible sheet 41 may not be a good thermal insulator, thus degrading the thermal performance of the insulation panel. To limit this degradation, the openings 42 reduce the amount of low-performance material.

[0051] In this second embodiment, the pins 32 and the flexible sheet 41 are fixed to the back plate, before or after its assembly with the frame, but before filling with the insulating material.

[0052] In a third embodiment, the pins 32 of the retention means 30 are fixed via a double structure 40'. This double structure 40' comprises two flexible sheets 41' between which pins 32 extend as visible to figures 10a And 10b These two leaves are, preferably, parallel to each other.

[0053] As with the second version, the flexible sheets 41' and the studs 32 can be made of different materials: wood, plastic, metal or be made of the same material, be made of different materials or be joined together by gluing, nailing, stapling, screwing, snapping or by any other means.

[0054] Since the insulating material is placed in the panel after the retention means are in place, these means must be designed to allow the insulating material to fill the panel. To this end, the flexible sheet that is not fixed or in contact with the back panel is perforated, i.e., it includes multiple openings allowing the insulating material to be inserted between the two flexible sheets 41'.

[0055] In a preferred design, this perforation is also applied to the 41" flexible sheet attached to or in contact with the backplate. This perforation helps to reduce the weight of the 41" flexible sheets and also to limit performance degradation. Indeed, with a solid 41" flexible sheet in contact with the backplate, there is a risk of panel performance degradation if this 41" flexible sheet is made of a material with poor thermal performance.

[0056] With a cutout, the influence of this material decreases and therefore the degradation of performance also decreases.

[0057] In the case where the two flexible sheets 41' are perforated as visible to the figure 11 that is to say include openings, it is necessary that this perforation does not disrupt the arrangement of the pins 32. For this, the two flexible sheets 41' are, preferably, perforationed in a similar way so that the openings of the two flexible sheets 41' are opposite each other in pairs.

[0058] In an even more preferred execution, the two flexible 41' sheets are each replaced by a grid formed of interwoven wires as seen in the figure 12 These two grids are connected by the studs, which extend from the wires forming the grids. The two flexible sheets and the studs form a framework like a trellis.

[0059] This grid-like configuration advantageously limits the amount of material that could degrade the panel's performance while still allowing the panel to be properly filled with the insulating material.

[0060] For this third execution, while it is possible for all the spikes to extend between the two sheets or grids, i.e. to be in contact with the two sheets or grids, it is alternatively possible that this is not the case.

[0061] Indeed, it is conceivable that some of the 32 prongs extend from both sheets or grids while others do not. Thus, it would be possible to have prongs extending from one or the other sheet or grid without being in contact with both.

[0062] The studs in contact with the two sheets or grids have an additional, structural function, which is to keep the two sheets or grids spaced apart from each other.

Claims

1. An insulating panel (10) comprising a bottom (16) and a lid (14) linked at their periphery by a side wall (12) forming a housing (17) in which an insulating material (20) is placed, said insulating panel (10) further comprising retention means (30) for retaining the insulating material (20) in said panel and preventing it from collapsing, said retention means (30) comprise spikes (32) extending from the bottom (16) of the insulating panel (10), the spikes being respectively spaced apart by a distance of 2 to 20 cm, characterized in that the insulating material is in the form of flakes and has a density of between 10 and 75 kg / m3.

2. The insulating panel (10) according to the preceding claim, wherein the spikes (32) extend from a structure (40, 40') attached to the bottom (16) of the insulating panel (10).

3. The insulating panel (10) according to the preceding claim, wherein the structure (40) comprises a flexible sheet (41), from which the spikes (32) extend, arranged in the housing (17) of the insulating panel (10).

4. The insulating panel (10) according to claim 2, wherein the structure (40') comprises two parallel flexible sheets (41'), from which the spikes (32) extend, arranged in the housing (17) of the insulating panel (10).

5. The insulating panel (10) according to claims 3 or 4, wherein the flexible sheets (41, 41') are interwoven wires forming meshes.

6. The insulating panel (10) according to the preceding claim, wherein the spikes (32) are integral with the structures (40, 40') at the interweaving of the wires.

7. The insulating panel (10) according to one of claims 1 to 6, wherein the spikes (32) extend orthogonally to the bottom (16) and to the lid (14).

8. The insulating panel (10) according to one of claims 1 to 7, wherein the spikes (32) have a length equal to at least 25% of the distance between the bottom (16) and the lid (14), preferably at least 50% of the distance between the bottom (16) and the lid (14) and even more preferably at least 75%.

9. The insulating panel (10) according to one of claims 1 to 8, wherein the spikes (32) are spaced apart by a distance of 2 to 15 cm, preferably of 5 to 10 cm.

10. The insulating panel (10) according to claim 1 to 9, wherein the distance between the spikes (32) is constant.

11. The insulating panel (10) according to one of claims 1 to 10, wherein the spikes (32) are positioned to be aligned in the form of a grid.

12. The insulating panel (10) according to claim 1 to 10, wherein the spikes (32) are positioned to be staggered.

13. The insulating panel (10) according to one of claims 1 to 12, wherein the spikes (32) are made of a metal or plastic material.

14. The insulating panel (10) according to one of the preceding claims, wherein the insulating material has a density of between 15 to 45 kg / m3.

15. A wall composed of a plurality of insulating panels (10) according to one of the preceding claims, said insulating panels (10) being attached to one another.

16. A method for manufacturing an insulating panel (10) according to one of claims 1 to 14, characterized in that it includes the following steps: - Providing the bottom (16) to which the side wall (12) has been pre-attached; - Providing retention means (30) and attaching them to the bottom (16), said retention means (30) comprise spikes (32) extending from the bottom (16) and being regularly spaced apart by a distance that can be vary of 2 to 20 cm; - Placing the panel horizontally on the bottom (16); - Providing the insulating material (20) being in the form of flakes and having a density of insulating material (20) of between 10 and 75 kg / m3 and pouring it into the space defined by the bottom (16) and the side wall (12); - Providing the lid (14) and closing the insulating panel (10) therewith.