Cover panel and method for manufacturing same

Abstract

The invention relates to a composite structural and / or cover and / or decorative panel (1) comprising a core (2) sandwiched between two metal plates (3), the connection between the core (2) and each of the metal plates (3) being obtained by means of an adhesive layer providing the interface between the core (2) and each of the metal plates (3). According to the invention, the core (2) comprises at least one bio-based material chosen from a family of materials comprising cork and mycelium or an association or combination of those materials.

Description

[0001] ROOFING PANEL AND METHOD FOR MANUFACTURING THE SAME

[0002] Technical field

[0003] The present invention relates to the general technical field of construction and more particularly to the field of covering facades or roofs of buildings. The invention also relates to all technical or industrial fields in which the use of thermal and / or sound insulation is necessary.

[0004] The invention relates in particular to the design and manufacture of cladding elements which can be used to cover large areas of facades, for example of high-rise buildings. The invention also relates to internal sound and / or thermal insulation panels for buildings. The invention also relates to recreational vehicles, cruise ships, trucks and transport trailers as well as the manufacture of any wall which must have specific mechanical, thermal and / or sound properties.

[0005] Prior art

[0006] For example, we know of panels shaped into cladding cassettes for covering building facades. These panels have a polyethylene core sandwiched between two aluminum plates. The use of polyethylene makes composite panels substantially lighter, but they have drawbacks. Indeed, such composite panels with a core of polyethylene or any other petroleum-based material provide little or no protection from heat and / or cold. The thickness of a thermal insulation layer on the facade placed between the facade and the cladding cassettes must therefore be sufficient to achieve the desired thermal performance.

[0007] Furthermore, a polyethylene core does not provide sufficient fire resistance. This is why fire standards in various countries no longer allow the use of composite roofing panels with a polyethylene core, for example on buildings whose height exceeds 8 m. Presentation of the invention

[0008] The object of the invention therefore aims to overcome the drawbacks of the prior art by proposing a new composite structural, covering or decorative panel, having thermal and / or sound insulation properties.

[0009] Another object of the invention is to propose a new composite roofing panel having improved fire-resistant properties.

[0010] Another object of the invention aims to propose a new composite panel made at least in part with natural and / or bio-sourced materials.

[0011] The objects assigned to the invention are achieved using a composite structural and / or covering and / or decorative panel, comprising a core sandwiched between two metal plates, the connection between the core and each of the metal plates being obtained by means of an adhesive layer providing the interface between said core and each of said metal plates, characterized in that the core comprises at least one natural material chosen from a family of materials including cork and mycelium or an association or combination of said materials.

[0012] The natural material is advantageously expanded.

[0013] According to an exemplary embodiment, the core has a thickness of between 2 mm and 10 mm and the metal plates have a thickness of between 0.2 mm and 2 mm.

[0014] According to an exemplary embodiment, the adhesive layer is a hot-melt adhesion film.

[0015] According to an exemplary embodiment, the metal plates have at least one thermo-lacquered face. The metal plates are or preferably comprise aluminum plates. According to another exemplary embodiment, the metal plates are advantageously made of steel or stainless steel. The metal plates may also be made of or comprise other metals or alloys for specific applications.

[0016] The objects assigned to the invention are also achieved using a thermal and / or sound insulation element for a building comprising at least one composite panel as presented above.

[0017] The objects assigned to the invention are also achieved using a cladding cassette for covering an exterior facade of a building, comprising at least one composite panel as presented above, the metal plate intended to produce the exterior side of the facade covering having larger dimensions than the other metal plate so as to have edges folded at right angles towards said other metal plate to form said cladding cassette, the edges folded on each lateral side of the composite panel comprising notches for mounting on a support structure secured to a facade.

[0018] The objects assigned to the invention are also achieved using a cladding cassette for covering an exterior facade of a building, comprising at least one composite panel as presented above, said composite panel comprising metal plates of the same dimensions and having edges folded at right angles, to form said cladding cassette, the edges folded on each lateral side of the composite panel comprising notches for mounting on a support structure secured to a facade.

[0019] The objects assigned to the invention are also achieved using a roof covering comprising an assembly of composite panels such as those presented above.

[0020] The objects assigned to the invention are also achieved using a method of manufacturing a composite panel as presented above, characterized in that it comprises the steps:

[0021] - unroll a continuous strip of a base material comprising cork and / or mycelium,

[0022] - applying an adhesion film to an upper face and to a lower face of the continuous strip of base material at the entrance to a complexing unit,

[0023] - feed the laminating unit with a continuous strip of aluminum on the upper face and on the lower face, each covered with an adhesion film,

[0024] - compress the assembly thus produced in the complexing unit,

[0025] - deliver a composite strip at the output of the complexing unit,

[0026] - introduce the composite strip into an oven to bring it to a temperature between 75°C and 220°C, for a determined period and to melt the adhesion films and establish adhesion between the base material and the continuous aluminium strips,

[0027] - cool the composite strip thus produced in ambient air at the outlet of the furnace, and

[0028] - cut the composite strip into composite panels.

[0029] The objects assigned to the invention are also achieved using a method of manufacturing a composite panel as presented above, characterized in that it comprises the steps:

[0030] - extruding a continuous strip of a base material comprising cork and / or mycelium,

[0031] - applying an adhesion film to an upper face and to a lower face of the continuous strip of base material at the entrance to a complexing unit,

[0032] - feed the laminating unit with a continuous strip of aluminum on the upper face and on the lower face, each covered with an adhesion film,

[0033] - compress the assembly thus produced in the complexing unit,

[0034] - deliver a composite strip at the output of the complexing unit,

[0035] - introduce the composite strip into an oven to bring it to a temperature between 75°C and 220°C, for a determined period and to melt the adhesion films and establish adhesion between the base material and the continuous aluminium strips,

[0036] - cool the composite strip thus produced in ambient air at the outlet of the furnace, and

[0037] - cut the composite strip into composite panels.

[0038] A remarkable advantage of the composite panel according to the invention lies in the increase in its thermal performance thanks to the use of an insulating core and in the increase in its fire-resistant properties. For example, the thermal inertia of cork makes it possible to create an efficient weather strip. It is therefore possible to reduce the thickness of the thermal insulation layer placed between a facade and the composite panels.

[0039] Another remarkable advantage is obtained by using a natural and / or bio-sourced material, in particular cork or mycelium, a significant renewable production of which is available throughout the Mediterranean region. Such materials make it possible to avoid the use of petroleum products. In addition, cork is advantageously bio-sourced, but also rot-proof.

[0040] Another advantage is the rigidity and strength of composite panels, despite their lightness.

[0041] Another advantage of the composite panel according to the invention lies in its sound properties.

[0042] Another advantage of the composite panel according to the invention lies in the possibility of using it for or integrating it into countless architectural or industrial applications.

[0043] For this purpose, we can cite the field of architecture and in particular building cladding, curtain walls and shading elements, roofs and coverings, awnings, house gables, ceilings, walls, movable or fixed partitions to isolate work spaces, decorative panels, interior lining panels, doors, construction site fencing, industrial buildings, agricultural sheds, construction components, prefabricated buildings, window sills and frames, tiles for buildings and houses, sandwich panels or composite panels, gutters, drainage pipes.

[0044] We can also mention the field of signage and advertising, including totems, car dealerships, gas stations, restaurant chains, billboards, road signs.

[0045] We can also mention the field of packaging, particularly pharmaceutical or food packaging.

[0046] We can also cite the automotive sector, particularly bodywork, caravans, motorhomes and, more broadly, the transport sector. For example, we can cite the interior partitions of recreational vehicles (caravans, motorhomes), cruise ships, but also the interior / exterior partitions of transport trucks and refrigerated trucks.

[0047] We can also mention the field of household appliances, particularly household appliances, refrigerators and freezers.

[0048] We can also mention the industrial field in the broad sense, namely elements used and / or manufactured industrially and in particular the protection of machines, containers, heat pumps, vehicles, public transport vehicles, lighting, kitchen splashbacks, computer equipment, suitcases, in-ground or above-ground swimming pools, protective devices. The composite panel in accordance with the invention therefore constitutes a type of raw material whose transformation and adaptation for the different intended uses is extremely varied.

[0049] Brief description of the figures

[0050] Other characteristics and advantages of the present invention will appear more clearly on reading the description which follows, given with reference to the appended drawings, given as non-limiting examples, in which:

[0051] • figure 1 is a perspective view of an exemplary embodiment of a cover panel according to the invention,

[0052] • figure 2 schematically illustrates an example of the manufacture of a covering panel in accordance with the invention,

[0053] • figure 3 schematically illustrates another example of manufacturing a cover panel in accordance with the invention,

[0054] • figure 4a represents an example of the embodiment of a cladding cassette in accordance with the invention, produced with a covering panel of figure 1, and

[0055] • Figure 5 illustrates an example of mounting brading cassettes in accordance with the invention on a facade.

[0056] Detailed description of the invention

[0057] Structurally and functionally identical elements present in several distinct figures are assigned the same numerical or alphanumeric reference.

[0058] Figure 1 is a perspective view of an exemplary embodiment of a composite panel 1. The composite panel 1 comprises a core 2 sandwiched between two metal plates 3.

[0059] The connection between the core 2 and each of the metal plates 3 is obtained by means of an adhesive layer in the form of an adhesion film 4, providing the interface between said core 2 and each of said metal plates 3. The adhesive layer is for example a hot-melt adhesion film 4.

[0060] The core 2 comprises at least one base material, preferably bio-sourced, chosen from a family of materials including cork and mycelium or a combination or association of said materials. The mycelium can advantageously be packaged.

[0061] For example, the base material is a raw material processed into a continuous strip. In another example, the base material is an extruded material, for example from cork beads, processed into a continuous strip of expanded cork.

[0062] The metal plates 3 advantageously have faces covered with a corrosion protection varnish, applied by powder coating. Depending on the intended use for the composite panel 1, at least one of its faces may be covered with a particular varnish, also applied by powder coating, giving it a particular color and / or appearance.

[0063] The core 2 advantageously has a thickness of between 2 mm and 10 mm and the metal plates 3 have a thickness of between 0.2 mm and 2 mm.

[0064] Figure 2 schematically illustrates an example of manufacturing a composite panel 1 according to the invention.

[0065] The manufacturing method consists of unrolling a continuous strip 6 of a base material, constituting the core 2, comprising cork and / or mycelium, from a roll 7.

[0066] According to the manufacturing method, an adhesion film 4, coming from a roller 8a and 8b, is applied respectively to an upper face 6a and to a lower face 6b of the continuous strip 6, at the entrance to a complexing unit 10.

[0067] According to the manufacturing method, the laminating unit 10 is supplied with two continuous strips of metal 11, for example continuous strips of aluminum, to deposit them respectively on the upper face 6a and on the lower face 6b each covered with the adhesion film 4. The continuous strips of metal 11 will form the aluminum plates 3 of the composite panel 1.

[0068] According to the manufacturing method, the assembly thus produced is compressed in the laminating unit 10. For example, the laminating unit 10 comprises two compression rollers 10a and 10b for compressing the continuous aluminum strips 11, the core 2 and the superimposed adhesion films 4.

[0069] According to the manufacturing method, a continuous composite strip 12 is delivered at the outlet of the laminating unit 10. The latter is then conveyed into an oven 13 to bring it to a temperature between 75°C and 220°C, for a determined period. The oven 13 is used to melt the adhesion films 4 and establish the necessary adhesion and mechanical cohesion between the continuous strip 6 and the continuous metal strips 11.

[0070] The process then consists of cooling the composite strip 12 thus produced in ambient air at the outlet of the furnace 13.

[0071] According to the manufacturing process, the composite strip 12 is cut, by any known means, into composite panels 1 according to the desired dimensions.

[0072] Figure 3 schematically illustrates another example of manufacturing a composite panel 1. This other mode of implementation of the manufacturing method differs from the mode described above in that the continuous strip 6 is extruded from a base material comprising, for example, cork and / or mycelium beads. The roller 7 is, in this other mode of implementation, replaced by an extruder 14.

[0073] The various feed rollers 8a, 8b, 11a, 11b and 7 are advantageously split to avoid a feed break and an interruption of the manufacturing process. An empty roller is then automatically replaced by a full roller.

[0074] Figure 4 represents an example of the embodiment of a cladding cassette 16, produced with a composite panel 1 and Figure 5 illustrates an example of the mounting of cladding cassettes 16 on a support structure 20.

[0075] The cladding cassette 16 preferably comprises a composite panel 1. The metal plate 3, intended to form the outer side of the cassette and the facade covering, has larger dimensions than the other metal plate 3, so as to have edges 17 folded at right angles towards said other metal plate 3. The edges 17 folded at least on each lateral side of the composite panel 1 comprise notches 18 for mounting said cladding cassette 16 on the support structure 20 secured to a facade. According to another embodiment, the composite panel 1 comprises metal plates 3 of the same dimensions and has edges 17 folded at right angles to form the cladding cassette.In order to be able to fold the edges 17, which are made of the base material sandwiched between two aluminum plates 3, V-shaped ribs are machined on the outer faces of the aluminum plates 3 to form the folding lines.

[0076] The folded edges 17 on each lateral side of the composite panel have notches 18 for mounting on the support structure 20.

[0077] According to another example of use, the composite panel 1 is intended to produce a roof covering. The latter then comprises an assembly of composite panels 1 provided with a hanging system. The latter is then customized according to each roof or tile manufacturer, which uses composite panels 1.

[0078] Depending on the intended use, the composite panel 1 may have significant dimensions, for example up to a length of ten meters and a width of two meters.

[0079] Composite panel 1 is therefore a sandwich material used, for example, as sound insulation, to insulate meeting rooms, separate work spaces in a mobile or fixed manner, partition interior spaces of camper vans, caravans, or cruise ships.

[0080] It is obvious that the present description is not limited to the examples explicitly described, but also includes other embodiments or implementations. Thus, a described technical characteristic or implementation step may be replaced by an equivalent technical characteristic, or step, without departing from the scope of the invention as defined by the claims.

Claims

CLAIMS 1. Composite panel (1) for structure and / or covering and / or decoration, comprising a core (2) sandwiched between two metal plates (3), the connection between the core (2) and each of the metal plates (3) being obtained by means of an adhesive layer providing the interface between said core (2) and each of said metal plates (3), characterized in that the core (2) comprises at least one natural material chosen from a family of materials including cork and mycelium or an association or combination of said materials.

2. Composite panel (1) according to claim 1, characterized in that the natural material is expanded.

3. Composite panel (1) according to claim 1 or 2, characterized in that the core (2) has a thickness of between 2 mm and 10 mm and that the metal plates (3) have a thickness of between 0.2 mm and 2 mm.

4. Composite panel (1) according to any one of claims 1 to 3, characterized in that the adhesive layer is a hot-melt adhesion film (4).

5. Composite panel (1) according to any one of claims 1 to 4, characterized in that the metal plates (3) have at least one thermo-lacquered face.

6. Composite panel (1) according to any one of claims 1 to 5, characterized in that the metal plates (3) comprise at least one plate made of aluminum, steel or stainless steel.

7. Thermal and / or sound insulation element for a building comprising at least one composite panel (1) conforming to any one of the claims 1 to 6.

7. Cladding cassette (16) for covering an exterior facade of a building, comprising at least one composite panel (1) according to any one of claims 1 to 6, the metal plate (3) intended to produce the exterior side of said cladding cassette (16) and of the facade covering having larger dimensions than the other metal plate (3) so as to have edges (17) folded at right angles towards said other metal plate (3) to form said cladding cassette (16), the edges (17) folded on each lateral side of the composite panel (1) comprising notches (18) for mounting on a support structure (20) secured to a facade.

8. Cladding cassette (16) for covering an exterior facade of a building, comprising at least one composite panel (1) according to any one of claims 1 to 6, said composite panel (1) comprising metal plates (3) of the same dimensions and having edges (17) folded at right angles, to form said cladding cassette (16), the edges (17) folded on each lateral side of the composite panel (1) comprising notches (18) for mounting on a support structure (20) secured to a facade.

9. Roof covering comprising an assembly of composite panels (1) according to any one of claims 1 to 6.

10. Method for manufacturing a composite panel (1) according to any one of claims 1 to 6, characterized in that it comprises the steps: - unrolling a continuous strip (6) of a base material comprising cork and / or mycelium, - applying an adhesion film (4) to an upper face (6a) and to a lower face (6b) of the continuous strip (6) of the base material at the entrance to a complexing unit (10), - feed the complexing unit (10) with a continuous strip of metal (11) on the upper face (6a) and on the lower face (6b) each covered with a film adhesion (4), - compress the assembly thus produced in the complexing unit (10), - deliver a composite strip (12) at the output of the complexing unit (10), - introducing the composite strip (12) into an oven (13) to bring it to a temperature between 75°C and 220°C, for a determined period and to melt the adhesion films (4) and establish adhesion between the base material and the continuous metal strips (11), - cool the composite strip (12) thus produced in ambient air at the outlet of the furnace (13), and - cut the composite strip (12) into composite panels (1).

11. Method for manufacturing a composite panel (1) according to any one of claims 1 to 6, characterized in that it comprises the steps: - extruding a continuous strip (6) of a base material comprising cork and / or mycelium, - applying an adhesion film (4) to an upper face (6a) and to a lower face (6b) of the continuous strip (6) of the base material at the entrance to a complexing unit (10), - feeding the complexing unit (10) with a continuous strip of metal (11) on the upper face (6a) and on the lower face (6b) each covered with an adhesion film (4), - compress the assembly thus produced in the complexing unit (10), - deliver a composite strip (12) at the output of the complexing unit (10), - introducing the composite strip (12) into an oven (13) to bring it to a temperature between 75°C and 220°C, for a determined period and to melt the adhesion films (4) and establish adhesion between the base material and the continuous metal strips (11), - cool the composite strip (12) thus produced in ambient air at the outlet of the furnace, and - cut the composite strip (12) into composite panels (1).

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