Method of manufacturing a wall.

Abstract

A method for manufacturing a wall using rigid building elements (E) comprising: - assembling a wall (1) having several courses of said building elements (E), each building element of a given course being bonded to at least one other building element of an adjacent course by means of a bonding agent, the wall (1) having an internal recess (Ev) extending through said building elements and delimited between external walls (E1, E2) of said building elements of the wall; and comprising - filling the internal recess (Ev) with a thermal insulating material so as to form a single molded block of thermal insulating material (Eth) extending against the first and second external walls of building elements of several courses of the wall. Figure from the abstract: Fig. 1a

Description

Title of the invention: Method of manufacturing a wall.

[0001] The present invention relates to the field of manufacturing walls using prefabricated construction elements.

[0002] BACKGROUND OF THE INVENTION

[0003] Traditionally, walls are formed using rigid building elements which are arranged in rows of building elements and which are bonded together via / by a bonding binder such as mortar.

[0004] Such walls are insulated by positioning, after construction of the wall, thermal insulation panels against at least one of the external faces of this wall.

[0005] It is also known to use construction elements which each have a specific block of insulation positioned inside the construction element.

[0006] Such thermally pre-insulated building elements are subsequently glued together and insulating foam joints are formed at the interface between these building elements.

[0007] These operations are expensive to implement and complex to ensure that thermal bridges through the wall are limited.

[0008] SUBJECT OF THE INVENTION

[0009] An object of the present invention is to provide a method of manufacturing a wall which resolves, at least in part, at least some of the aforementioned drawbacks of the prior art. Summary of the invention

[0010] To this end, the invention relates to a method of manufacturing a wall using rigid construction elements each comprising first and second external walls located on either side of the construction element, a lower face, an upper face and a passage internal to the construction element formed between said first and second external walls and opening onto each of the lower and upper faces of the construction element, the method comprising: - assembling the wall in such a way that it comprises several rows of said construction elements, said rows being superimposed on each other and each row being formed from an alignment of several of said construction elements, each construction element of a given row being glued to at least one other construction element of a row adjacent to the given row by means of a bonding binder, said internal passages of said construction elements being connected to each other to define an internal recess of the wall; - filling the internal recess of the wall with thermal insulating material so as to form a block of molded thermal insulating material which extends between the first and second external walls of building elements of several rows of the wall.

[0011] Preferably, the internal recess of the wall is delimited on one side by all the first external walls of said construction elements of the wall and on the other side by all the second external walls of said construction elements of the wall.

[0012] In this way, the internal recess extends through all the superimposed rows of the wall, passing through each of the construction elements of these rows.

[0013] The advantages of the present invention are thus maximized over the entire surface of the wall.

[0014] Preferably, said block of molded thermal insulating material extends against the first and second external walls of the construction elements of several rows of the wall.

[0015] The manufacturing method according to the invention is advantageous in that it makes it possible to obtain a wall provided with a block of insulating material which extends continuously between the rows, inside the wall, that is to say inside said construction elements which make up the wall.

[0016] This block thus passes through several rows of construction elements while passing through several of the aligned construction elements of each given row.

[0017] As the block of insulating material extends continuously in the internal recess of the wall, in several of the construction elements against the walls of which it is molded, this block allows: - to ensure thermal continuity within the wall, including at the interface between construction elements of adjacent rows; and - to promote mechanical cohesion between the construction elements in which this block of insulation extends.

[0018] If thermal bridges exist at the interfaces between adjacent rows, they are largely minimized by the presence of the insulating block which extends through the construction elements of several rows of the wall.

[0019] This method according to the invention is particularly economically advantageous since the insulation of the wall is simply carried out by filling the internal recess with thermal insulation.

[0020] By maximizing the volume of the internal passages of the construction elements, the volume of the internal recess obtained during the assembly of the wall is maximized.

[0021] It should be noted that networks, for example network ducts, can be positioned in the internal recess of the wall before filling it with thermal insulation.

[0022] Preferably, the assembly of the wall is carried out by automated equipment which is arranged to position construction elements according to rows of superimposed construction elements and which is arranged to distribute said bonding binder of the construction elements.

[0023] The automated equipment is preferably arranged to press the bonding binder between adjacent rows so as to improve its distribution between the construction elements.

[0024] According to a first variant of the method according to the invention, the filling of the internal recess is done in a factory, then the wall thus prefabricated in the factory is transported with its thermal insulating material to a storage area.

[0025] According to a second variant, the prefabricated wall is transported and fixedly installed on a construction site of a building which is to integrate the prefabricated wall and said filling of the internal recess with the insulating material is carried out on the construction site of the building while the wall is fixedly installed on a load-bearing structure belonging to the building.

[0026] In this second variant, the wall can be: - either assembled in the factory before being transported to the building construction site where it is installed and then insulated (by filling its internal cavity with insulation); - or directly assembled on site (for example, assembled manually by a mason or assembled using automated equipment) so as to constitute an integral part of the building, then the wall is insulated (by filling its internal cavity with insulation).

[0027] With this second variant, the wall can be insulated at the same time as other walls whose internal recesses communicate with each other.

[0028] This allows thermal continuity to be obtained between the internal recesses of the adjacent walls.

[0029] This second variant can be useful for passing building ducts into the recesses before filling them.

[0030] According to a second aspect, the invention relates to a prefabricated wall using rigid construction elements each comprising first and second external walls located on either side of the construction element, a lower face, an upper face and a passage internal to the construction element formed between said first and second external walls and opening onto each of the lower and upper faces of the construction element, the wall comprising several rows of said construction elements, each row being formed by an alignment of several of said construction elements, said rows being superimposed on each other, each construction element of a given row being bonded to at least one other construction element of a row adjacent to the given row by means of a bonding binder, said internal passages of said construction elements being connected to each other to define an internal recess of the wall; - the internal recess of the wall containing a block of thermal insulating material molded into the internal recess, this block extending between the first and second external walls of construction elements of several rows of the wall.

[0031] Preferably, said internal recess of the wall passes through all of the rows of the wall and the block of insulating material also extends over all of the rows of the wall.

[0032] Thus, the effect of the invention is maximized over the entire height of the wall. Brief description of the drawings

[0033] Other characteristics and advantages of the invention will emerge clearly from the description given below, for information purposes only and in no way limiting, with reference to the appended drawings, in which:

[0034] [Fig. la] [Fig.la] is a perspective view of a wall 1 according to the invention during manufacture using the method according to the invention, this wall comprising several superimposed rows of construction elements E, the internal recess Ev of the wall 1 which extends over the entire height of the wall being left empty to admit the thermal insulation, this wall 1 being carried by a shutter 4 providing a seal between a lower part of said internal volume Ev of the wall 1 and an area external to the wall;

[0035] [Fig.lb] [Fig.lb] is a perspective view of wall 1 of [Fig.la] while its internal volume Ev has been filled with thermal insulating material, thus forming a continuous block of thermal insulation Eth extending through several rows of construction elements and through all the construction elements E constituting these rows. DETAILED DESCRIPTION OF THE INVENTION

[0036] As indicated previously, with reference to figures 1a and 1b, the invention relates to a method of manufacturing a wall 1 using rigid construction elements E.

[0037] The invention also relates to the wall resulting from the method according to the invention.

[0038] Each of these construction elements E comprises: - first and second external walls E1, E2 located on either side of the construction element; - a lower face Fi; - an upper face Fs; and - an internal passage Px to the construction element E formed between said first and second external walls El, E2 and opening onto each of the lower faces Fi and upper faces Fs of the construction element E.

[0039] In this case, this internal passage Px comprises a lower end of the passage opening onto the lower face Fi and an upper end of the passage opening onto the upper face Fs.

[0040] Said walls E1, E2 are parallel to each other and form front faces Fp and rear faces of the construction element E.

[0041] The construction element E has a substantially rectangular parallelepiped shape, two opposite faces of which are respectively constituted by the walls E1, E2.

[0042] The construction element E comprises a first longitudinal end face F1 and a second longitudinal end face F2 which are substantially parallel to each other.

[0043] The first end face F1 is preferably solid but it could also be hollowed out, the same applies to the second end face F2.

[0044] Each end face F1, F2 is substantially perpendicular to a main plane of the wall E1 and to a main plane of the wall E2, and it extends from the lower face F1 to the upper face Fs of the construction element E.

[0045] In the illustrated embodiments, the internal passage Px is on one side delimited by a face of the first wall E1 and on the other side delimited by a face of the second wall E2, these faces being opposite each other.

[0046] It would however be possible for the construction element to have an intermediate wall parallel to the first and second walls E1, E2 and located between these walls E1, E2 while being at a distance from these walls E1, E2.

[0047] In such a particular embodiment, the internal passage would be constituted by a first part of the internal passage arranged between the first wall E1 and the intermediate wall and by a second part of the internal passage arranged between the second wall E2 and the intermediate wall.

[0048] Said lower face Fi of the given construction element is the face intended to support this construction element while it is carried by an adjacent lower row of the wall.

[0049] In this case, the lower face Fi is constituted at least by: - ​​a longitudinal lower edge of the first external wall El; and by - a longitudinal lower edge of the second external wall E2.

[0050] Said upper face Fs of the given construction element is the face of the given construction element which is intended to carry at least one other construction element belonging to an upper adjacent row of the wall.

[0051] In this case, the upper face Fs is constituted at least by: - a longitudinal upper edge of the first external wall El; and by - a longitudinal upper edge of the second external wall E2.

[0052] These upper external faces Fs and lower Fi can be rectified to improve the flatness of these faces, their parallelism and to guarantee a homogeneous height between the construction elements constituting the wall.

[0053] The upper external faces Fs and lower Fi may respectively have complementary upper and lower external profiles.

[0054] These complementary upper and lower external profiles allow two identical construction elements to be stacked on top of each other while fitting together at their respective upper and lower external faces.

[0055] Typically, each upper external profile may comprise a groove and a tongue and each lower external profile may comprise a groove and a tongue, these upper and lower external profiles being of complementary shapes.

[0056] For example, the first external wall E1 of the construction element may comprise a groove in the upper part and a tongue in the lower part, this groove and this tongue extending lengthwise in a longitudinal direction of the construction element which passes through the first and second end faces F1, F2 of the element E.

[0057] In the same way, the second external wall E2 of the construction element may comprise a groove in the upper part and a tongue in the lower part, this groove and this tongue extend lengthwise in a longitudinal direction of the construction element which passes through the first and second end faces F1, F2 of the element E.

[0058] Such complementary upper and lower external profiles of the construction element E can be obtained during the molding of the walls E1, E2 and / or by machining the molded walls.

[0059] The bonding binder may preferably be applied in a groove of the upper external profile to promote its distribution along a tongue of an element E of the adjacent row.

[0060] Each construction element E may comprise a first end having an external profile of a first type and a second end having an external profile of a second type of shape complementary to the shape of the external profile of the first type.

[0061] In this way, the external profile of the first end of a construction element of a given row can be fitted with the external profile of the second end of another construction element.

[0062] The interlocking between ends of construction elements is useful for positioning and aligning the construction elements of the same row relative to each other. This external profile of the first end of the element E can thus have a tongue Lx complementary to a groove shape of the external profile of the second end of the element E.

[0063] Preferably, these external profiles of the first and second types are such that when two construction elements identical to each other are aligned in a construction row with their ends in contact with each other, then an empty space Esp exists over the entire height of the construction elements between the connecting parts of these construction elements which are opposite each other.

[0064] This empty space Esp makes it possible to guide insulating material between these connecting pieces, for example when injecting insulation between the faces of the wall.

[0065] As can be understood from the detail of the connecting piece 11 illustrated in [Fig.1a], the connecting piece 11 may comprise a tongue L1 extending over the entire height of the connecting piece 11 and penetrating between the first and second walls E1, E2 of the element E.

[0066] This tab L1 is located on a central part of the connecting piece.

[0067] The tongue has a terminal end which is preferably located in the passage Px to promote the connection with the thermal insulation. However, this terminal end of the tongue could also be located outside the construction element.

[0068] This tab L1 is useful for preventing the material constituting these walls from flowing into the empty space between these walls during the molding of the first and second walls E1, E2.

[0069] The thickness of this tab L1 is chosen according to the minimum distance that we wish to guarantee between the walls E1 and E2 (we seek to guarantee that these walls are everywhere, at all points, far from each other).

[0070] It is also possible that in addition to the tab L1, the connecting piece 11 comprises a second tab parallel to the tab L1, this second tab also extending over the entire height of the connecting piece and penetrating between the first and second walls E1, E2 of the element E.

[0071] The advantage of having a second tab is still to guarantee a minimum empty space between the walls E1, E2 but by having tabs L1 individually thinner which requires less material than to manufacture a single thick tab.

[0072] Of course, the connecting piece 11 could also include stiffening ribs to connect these two parallel tabs L1 together and thus ensure resistance to the pressure of the material during the molding of the walls E1 and E2.

[0073] This or these tabs L1 preferably extend perpendicularly relative to a plate 113 of the connecting piece 11 which will be described below.

[0074] As indicated previously, the second connecting part 12 is preferably identical to the first part 11.

[0075] Thus, the second connecting piece 12 can also have one and / or two tabs L1 and / or a plate 113 to obtain the same advantages as those relating to the first connecting piece 11.

[0076] Preferably, the construction elements E of the wall are mostly (in number) identical to each other.

[0077] The construction element E is preferably dimensioned to be able to extend entirely within a maximum parallelepiped volume of length 600 mm, height 450 mm and thickness 450 mm, the construction element E preferably having a unit mass of less than 30 kg to be transportable manually.

[0078] The first and second external walls E1, E2 are spaced apart from each other and are rigidly connected to each other to ensure the rigidity of the construction element used for mounting the wall while forming said internal passage Px of the element E.

[0079] This rigid connection can be made in different ways.

[0080] For example, this connection can be made via transverse partitions to the first and second walls E1, E2 (these transverse partitions and the first and second walls forming a single-piece assembly).

[0081] However, such partitions create thermal bridges.

[0082] Preferably, the first and second walls E1, E2 are held fixedly relative to each other by a first mechanical connecting piece 11 and / or a second mechanical connecting piece 12.

[0083] In this case, the first external wall E1 can be molded around a first part of the first connecting piece 11 and the second external wall E2 can be molded around a second part of the first connecting piece 11.

[0084] These walls E1, E2 can be molded in a mold having molding zones of the first and second walls E1, E2 sealed relative to each other while the connecting parts are positioned in the mold, a part of the mold allowing the formation of the internal passage Px between these first and second walls.

[0085] Ideally, rammers can be used to compress the material constituting these walls E1, E2 into the mold.

[0086] This makes it possible to obtain compacted, homogeneous and mechanically resistant walls E1, E2.

[0087] Preferably, each wall E1 and E2 comprises internal recesses E1x, E2x.

[0088] The recesses Elx and E2x formed in a given wall El, E2 of a given construction element E are separated from each other by a partition internal to this given wall.

[0089] The first wall El has 3 recesses Elx and the second wall E2 has 3 recesses E2x.

[0090] These recesses Elx and E2x each have an oblong shape extending in length along the length of the construction element.

[0091] These internal recesses Elx, E2x of the walls have the function of reducing the thermal conductivity through the walls while lightening these walls.

[0092] A given internal recess Elx, E2x formed in one of the first or second walls may, depending on the case, open out on only one side of the construction element or open out on both sides of the construction element on the lower Fi and upper Fs faces.

[0093] Similarly, the first outer wall E1 may be molded around a first portion of the second connecting piece 12 and the second outer wall E2 may also be molded around a second portion of the second connecting piece 12.

[0094] In section planes of the construction element parallel to the plane of the upper face Fs and over at least 90% of the height of the construction element, each of the first and second external walls E1, E2 has a constant external profile.

[0095] This external profile can be of different shapes and here it is U-shaped, the central part of which forms the main external face Fp of the construction element E.

[0096] According to an observation direction perpendicular to a plane of the upper face Fs of the construction element, the first and second external walls E1, E2 are U-shaped profiles.

[0097] The hollow parts of the U-shaped profiles are oriented towards the inside of the construction element E to define at least in part the contours of the internal passage Px to the construction element E.

[0098] The connections between the connecting pieces 11, 12 and the U-shaped profiles are respectively located at the lateral edges of these U-shaped profiles.

[0099] These side edges of the U-shaped profiles are located at the terminal ends of the construction element.

[0100] The connections between the walls E1, E2 and the connecting pieces 11, 12 are thus made at the location where these walls E1, E2 are closest to each other, which makes it possible to minimize the quantity of material used to manufacture the connecting pieces 11, 12.

[0101] The manufacturing cost of the construction element can thus be minimized.

[0102] The first and second parts of the first connecting piece 11 (i.e. the parts around which the walls E1, E2 are respectively molded) are here connected to each other by a central part of the first connecting piece 11 which comprises a plate 113, this plate 113 extends perpendicularly relative to a main face of the first wall E1 and relative to a main face of the second wall E2.

[0103] Similarly, the first and second parts of the second connecting piece 12 (i.e. the parts around which the walls E1, E2 are respectively molded) are connected to each other by a central part of the second connecting piece 12 which comprises a plate.

[0104] The plates of the first and second connecting pieces 11, 12 are parallel to each other.

[0105] The end face F1 of the construction element is partly defined by the first connecting piece 11 while the end face F2 of the construction element is partly defined by the second connecting piece 12.

[0106] The first and second end faces F1, F2 of the construction element are solid.

[0107] In this way, the first and second walls E1, E2 and the first and second mechanical connecting pieces 11, 12 with their plates which extend between the walls E1, E2 together define said internal passage Px of the construction element E.

[0108] The internal volume Ev which includes the internal passages Px forms a molding formwork for the insulation.

[0109] As this passage Px opens on the one hand onto a lower face Fi and on the other hand onto an upper face Fs of the construction element E, the thermal insulation, when it is molded in the internal recess Ev, will pass through the different passages Px of the construction elements which belong to several rows of construction elements.

[0110] Depending on the geometry of the connecting pieces, it can be ensured that a space Esp exists between connecting pieces belonging to two adjacent construction elements of the same row to guide the insulating material in this space Esp.

[0111] In this case, the internal recess of the wall Ev also includes the spaces Esp formed between connecting pieces of adjacent construction elements of the same row, the non-crosslinked / non-solidified insulating material thus passing between the terminal ends of the construction elements to fill the space Esp between the connecting pieces of the adjacent construction elements on the row.

[0112] Thus, each connecting piece is caught in the insulation block, which contributes to limiting thermal bridges and the rigidity of the wall.

[0113] Such a wall is particularly effective from a thermal and acoustic point of view.

[0114] The first part of the first connecting piece 11 may have studs 111 and the second part of the first connecting piece 11 may also have studs 112.

[0115] The pads 111, 112 are shown here in [Fig.1a] in the form of straight cylinders but they could take any other form preventing the pads from being torn away from the walls E1, E2.

[0116] Each of these pads 111, 112 extends lengthwise from the plane of the plate 113 of the first connecting piece towards the wall E1, E2 in which it is mechanically engaged.

[0117] The first part of the second connecting piece 12 may also have studs and the second part of the second connecting piece 12 may also have studs.

[0118] Each of these pads extends lengthwise from the plane of the plate of the second connecting piece towards the wall E1, E2 in which it is mechanically engaged.

[0119] Each stud is used to mechanically anchor the connecting piece inside the walls which receive it.

[0120] Thus the connections between the connecting piece and the external wall are particularly robust.

[0121] The construction element E is particularly robust because the first and second external walls are directly molded around the first and second parts of the connecting pieces 11, 12.

[0122] This connection method guarantees rigidity and thermal decoupling between the walls E1, E2 which are completely separated from each other.

[0123] The first and second connecting pieces 11, 12 are preferably identical to each other, both in geometric aspects and in material aspects.

[0124] In this case, these connecting pieces 11, 12 each have, at least between their first and second parts, a thermal conductivity which is strictly less than 0.5 W*m-1*K-1, preferably less than 0.4 W*m-1*K-1.

[0125] Preferably, the connecting pieces 11, 12 are made at least partially of a molded polymer material with a thermal conductivity of less than 0.5 W*m-1*K-1, preferably less than 0.2 W*m-1*K-1.

[0126] Typically, this polymer material is a molded thermoplastic polymer (amorphous or crystalline) and optionally containing reinforcing fibers.

[0127] Preferably, the parts 11, 12 are made of polyamide PA reinforced with glass fibers.

[0128] The use of thermoplastics is not only useful to facilitate the production of connecting parts but also to facilitate their recycling.

[0129] With this low thermal conductivity, the connecting piece plays the role of a thermal breaker between the walls E1, E2.

[0130] In addition to the construction elements conforming to the construction elements described above, the wall may also include accessory elements intended to create particular technical areas of the wall, such as chains, lintels, opening transoms, opening thresholds, load-bearing posts, floor departures perpendicular to the walls, expansion joints.

[0131] Although such accessory elements may be an integral part of the wall, the wall according to the invention is essentially composed on the surface of the stacking of several rows formed of the aforementioned construction elements.

[0132] A given row of construction elements is made up of several construction elements aligned in an alignment direction common to the different rows and substantially horizontal.

[0133] The wall manufacturing method according to the invention comprises: - the assembly of the wall 1 in such a way that the wall comprises several rows of said construction elements E, said rows being superimposed on each other and each row being formed by an alignment of several of said construction elements E, each construction element of a given row being glued to at least one other construction element of a row adjacent to the given row by means of a bonding binder (the rows being glued together by means of the bonding binder), said internal passages Px of the construction elements being connected / put into communication with each other to define an internal recess Ev of the wall 1; - filling the internal recess Ev of the wall 1 with a thermal insulating material so as to form a block of molded thermal insulating material Eth which extends between the first and second external walls El, E2 of the construction elements which belong to several rows of the wall.

[0134] The bonding binder may be a mastic or a mortar, this binder being in the form of mastic, gel or foam, this binder is preferably of the polymer type.

[0135] This adhesive binder is for example applied in the form of a layer or bead along the upper face Fs of each construction element of a row of construction elements before forming a row of construction elements whose lower faces Fi come into contact against this adhesive binder.

[0136] The bonding binder is applied in a non-crosslinked / non-solidified form (fluid, mastic or gel or foam form) and then crosslinks / solidifies after application (for example under the effect of contact with air or with humidity or under the action of a hardener for this binder).

[0137] Before crosslinking the binder, pressure can be exerted on the construction elements to compress the bonding binder and improve its distribution between / against the adjacent construction elements.

[0138] This increases the bonding surface.

[0139] Said filling of the internal recess Ev of the wall with a thermal insulating material is preferably carried out at least in part, using an injection pipe 3 opening into a lower zone of the internal recess Ev of the wall 1.

[0140] Such a pipe may for example pass through one of the walls of one of the construction elements E or through a shutter 4 providing a seal between a lower part of the internal recess Ev of the wall and an area external to the wall.

[0141] Here the injection pipe 3 is shown diagrammatically in dotted lines and it passes through a shutter 4 serving to close a lower zone of the internal recess Ev.

[0142] The injection pipe 3 opens towards the internal recess Ev via three nozzles respectively shown diagrammatically by dotted arrows.

[0143] A shutter 4 is used to close the lower area of ​​the internal recess Ev in order to be able to admit / inject the insulating material Eth.

[0144] After filling the internal recess Ev with the thermal insulating material Eth, the injection pipe 3 can be detached from the wall 1.

[0145] To this end, the injection pipe 3 can, for example, be carried by the shutter 4, this shutter 4 itself being removable from the prefabricated wall 1.

[0146] Depending on the case, this shutter 4 may or may not be used for transporting the wall with its solidified thermal insulation Eth.

[0147] Depending on the case, the shutter 4 can be a fixed piece of equipment in the factory or mobile with the prefabricated wall 1.

[0148] In the case where the shutter 4 is a mobile equipment, it can be used to move the wall and its insulation Eth to a storage area in the factory and / or to the construction site of the building to integrate the prefabricated wall 1.

[0149] It should be noted that the shutter 4 can be equipped with lifting interfaces 5 arranged to be mechanically connected to an external lifting system (for example via slings).

[0150] This lifting system is adapted to lift the shutter 4 and the prefabricated wall 1 carried by the shutter 4. The shutter 4 here takes the form of a rigid beam on which the prefabricated wall 1 is mounted / formed.

[0151] In these embodiments, the wall is directly prefabricated on the shutter 4 which is transportable using a lifting system.

[0152] The shutter 4 may or may not be reusable to make another prefabricated wall.

[0153] In a particular case, the shutter 4 is for single use and it forms a system chaining fixed to the prefabricated wall, this chaining system having the function of creating an interface for fixing the prefabricated wall 1 to a supporting structure of the building which is to integrate the wall 1.

[0154] In this particular mode, the shutter 4 serves both for the manufacture of the wall 1 by allowing the wall to be supported during its assembly in the factory, to close the internal recess Ev to inject the insulation therein, to locate the insulation injection pipe 3 in the internal volume Ev, to support the wall during its transport and to assemble the wall on the supporting structure of the building.

[0155] Depending on the case, the injection pipes 3 may or may not be removable from the shutter 4 to remain permanently in the factory or be moved with the shutter and the wall 1.

[0156] The thermal insulating material Eth is preferably composed on the one hand of bulk material and on the other hand of a binder of this bulk material.

[0157] According to a first option, the bulk material is inserted into each of said internal passages Px of the construction elements E before said assembly of the wall so that the internal recess Ev of the wall obtained after assembly of the wall already contains said bulk material, then the filling of the internal recess Ev with the thermal insulating material Eth is carried out, finalized, by injecting said binder of this bulk material while it is in a non-crosslinked state, the binder of this material being crosslinked / solidified in the internal recess (Ev) to bind the bulk material there and thus form said block of insulating material Eth.

[0158] This first option facilitates the distribution of the bulk material in the internal recess Px since this bulk material is prepositioned in each of the internal passages Px of the construction elements, before the assembly of the wall, that is to say before the internal recess Ev of the wall 1 is formed.

[0159] The binder of the bulk material, in its non-crosslinked (non-solidified) and fluid state, can diffuse through the bulk material pre-positioned in the Px passages.

[0160] This ensures thermal continuity between the rows of construction elements while facilitating the distribution of bulk material in the internal recess EV.

[0161] According to a second option, said filling of the internal recess Ev with the thermal insulating material Eth is preferably carried out: - by first positioning said bulk material in the internal recess Ev; then - by injecting said binder of this bulk material while it is in a non-crosslinked / non-solidified state, the binder of this material being crosslinked / solidified in the internal recess Ev to bind the bulk material there and thus form said block of insulating material Eth.

[0162] By introducing the bulk material and then the binder separately into the recess Ev, the distribution of the bulk material is facilitated without this distribution depending on the weight or viscosity of the binder.

[0163] The thermal insulation is thus more homogeneous over the height of the prefabricated wall, the bulk material is less compacted under the weight of the binder.

[0164] Preferably, the bulk material is inserted into the internal volume of the wall via a pipe passing through an upper zone of the internal recess Ev while the binder of this bulk material is at least partly injected via said at least one injection pipe 3 opening into the lower zone of said internal volume of the wall.

[0165] The binder gradually rises in the internal recess Ev, passing through the bulk material without generating a compaction effect.

[0166] The insulating block thus molded in the internal recess Ev which extends through several rows makes it possible to limit thermal bridges at the interface between the rows while improving the mechanical connection between these rows.

[0167] It should be noted that the presence of bulk material containing fibers is favorable to improving the mechanical structure of the thermal insulation block and the wall.

[0168] The bulk material is preferably of the type material selected from wood, wood wool, hemp, hemp wool, linen, linen wool, cork, recycled textiles, sheep wool, feather, coconut wool, straw, hemp shiv, cotton, cotton wool, bamboo, cellulose, cellulose wadding and a mixture of these materials.

[0169] The use of bulk material of plant or animal origin makes it possible to store carbon inside the layer of insulating material of the construction element / prefabricated wall.

[0170] Massive carbon storage in buildings is favorable to a reduction of the volume of CO2 in the atmosphere.

[0171] Preferably, the binder of this bulk material is mainly in mass, a mineral material, this material being preferentially selected from cement, meta kaolin, clay, this mineral material being preferentially in the form of foam.

[0172] Preferably, this binder is in the form of a foam containing cells of dimensions infra centimeters, preferably infra millimeters, these cells preferably containing a gaseous fluid.

[0173] Thus, the binder is preferably an insulating mineral foam, for example of the type of foam sold under the brand name AIRIUM ®.

[0174] By insulating mineral foam is meant a mineral foam with its own thermal conductivity of less than 0.05 W*m-1*K-1.

[0175] In some cases, the binder of the bulk material could be arranged to contain at least one thermoplastic polymer.

[0176] It should be noted that in particular embodiments the fibers and / or particles of said insulating material may contain a mineral material of the rock wool, glass wool, perlite (exfoliated) type, expanded clay, vermiculite, cellular glass, insulating mineral foam with a specific thermal conductivity of less than 0.05 W*m-1*K-1, one or more polymers (for example a thermoplastic polymer such as resol or phenolic foam, PIR, PUR, XPS Polystyrene, EPS polystyrene, synthetic textiles) and a mixture of these materials.

[0177] In all cases, the thermally insulating material constituting the block of insulating material placed in the internal recess Ev has a thermal conductivity of less than 0.2 W*m-1*K-1, preferably less than 0.05 W*m-1*K-1.

[0178] The first and second external walls E1, E2 have respective thermal conductivities X1, X2 greater than 0.7 W*m-1*K-1.

[0179] Typically, the material constituting the first and second walls is chosen from concrete, terracotta or cellular concrete.

[0180] The method according to the invention is advantageous in that it simplifies the implementation of the insulation in the wall 1 while limiting the areas of the wall that are not insulated.

[0181] The wall thus obtained preferably has a layer of single-piece insulation extending over the entire height of the wall, passing through each of the construction elements E of the wall.

[0182] In one embodiment of the method according to the invention, said assembly of the wall is carried out in a factory, the method then comprising the transport of said wall thus assembled to a site of construction of a building and the installation of said wall by fixing the wall to a supporting structure belonging to said building.

[0183] Said filling of the internal recess with the thermal insulating material can be carried out in the factory and then the wall thus insulated is moved to a storage area.

[0184] This produces a prefabricated and insulated wall that can be stored and moved before being fixed to the supporting structure of the building.

[0185] Such a prefabricated insulated wall is particularly quick to produce and inexpensive.

[0186] Alternatively, the filling of the internal recess Ev is carried out at the place of construction of the building, at a distance from the place of assembly of the wall, i.e. at a distance from the factory.

[0187] In this embodiment, the filling of the internal recess with the thermal insulating material is carried out after fixing the wall on said supporting structure belonging to said building.

[0188] This can be advantageous to allow the passage of networks in the wall before filling with insulation.

Claims

Claims

1. A method of manufacturing a wall using rigid construction elements (E) each comprising first and second external walls (El, E2) located on either side of the construction element, a lower face (Fi), an upper face (Fs) and an internal passage (Px) to the construction element (E) formed between said first and second external walls (El, E2) and opening onto each of the lower (Fi) and upper (Fs) faces of the construction element (E), the method comprising: - mounting the wall (1) such that it comprises several rows of said construction elements (E), said rows being superimposed on each other and each row being formed by an alignment of several of said construction elements (E), each construction element of a given row being bonded to at least one other construction element of a row adjacent to the given row by means of a bonding binder,said internal passages of said construction elements being connected together to define an internal recess (Ev) of the wall (1); - filling the internal recess (Ev) of the wall (1) with a thermal insulating material so as to form a block of molded thermal insulating material (Eth) which extends between the first and second external walls of construction elements of several rows of the wall, in which the filling of the internal recess (Ev) of the wall with a thermal insulating material is carried out at least in part, using an injection pipe (3) opening into a lower zone of the internal recess (Ev) of the wall and passing through a shutter (4) providing a seal between a lower part of the internal recess (Ev) of the wall and a zone external to the wall, the shutter (4) is a mobile equipment forming a rigid beam on which the wall (1) is mounted.,

2. A method of manufacturing a wall according to claim 1, wherein after filling the internal recess (Ev) of the wall with the thermal insulating material (Eth), said injection pipe (3) is detached from the wall.

3. A method of manufacturing a wall according to any one of claims 1 or 2, wherein said thermal insulating material (Eth) is composed on the one hand of bulk material and on the other hand of a binder of this bulk material, said filling of the internal recess (Ev) with the thermal insulating material (Eth) being carried out by first positioning said bulk material in the internal recess (Ev) and then injecting said binder of this bulk material while it is in a non-crosslinked state, the binder of this material being crosslinked in the internal recess (Ev) to bind the bulk material there and thus form said block of insulating material (Eth).

4. A method of manufacturing a wall according to any one of claims 1 or 2, wherein said thermal insulating material (Eth) is composed on the one hand of bulk material and on the other hand of a binder of this bulk material, the bulk material being inserted into each of said internal passages (Px) of the construction elements (E) before said assembly of the wall so that the internal recess (Ev) of the wall obtained after assembly of the wall contains said bulk material, then the filling of the internal recess (Ev) with the thermal insulating material (Eth) being carried out by injecting said binder of this bulk material while it is in a non-crosslinked state, the binder of this material being crosslinked in the internal recess (Ev) to bind the bulk material therein and thus form said block of insulating material (Eth).

5. A method of manufacturing a wall according to any one of claims 3 or 4, wherein the bulk material is of a material type selected from wood, wood wool, hemp, hemp wool, linen, linen wool, cork, recycled textiles, sheep wool, feather, coconut wool, straw, hemp shiv, cotton, cotton wool, bamboo, cellulose, cellulose wadding and a mixture of these materials.

6. Method of manufacturing a wall according to any one of claims 3 to 5, in which the binder of this bulk material is predominantly in mass, a mineral material, this material being preferentially selected from cement, meta kaolin, clay.

7. A manufacturing method according to any one of claims 1 or 2, wherein said thermal insulating material is selected from wood, wood wool, hemp, hemp wool, linen, linen wool, cork, recycled textiles, sheep wool, feather, coconut wool, straw, hemp shiv, cotton, cotton wool, bamboo, cellulose, cellulose wadding, rock wool, glass wool, exfoliated perlite, expanded clay, vermiculite, cellular glass, insulating mineral foam with a specific thermal conductivity of less than 0.05 W*m-1*K-1, one or more polymers, synthetic textiles and a mixture of these materials.

8. A method of manufacturing a wall according to any one of claims 1 to 7, wherein said mounting of the wall is carried out in a factory, the method comprising transporting said wall to a building construction site and installing said wall by fixing the wall to a supporting structure belonging to said building.

9. A method of manufacturing a wall according to claim 8, wherein the filling of the internal recess with the thermal insulating material is carried out at the construction site of the building.

10. A method of manufacturing a wall according to claim 9, wherein the filling of the internal recess with the thermal insulating material is carried out after fixing the wall to said supporting structure belonging to said building.

11. A method of manufacturing a wall according to claim 8, wherein the filling of the internal recess (Ev) with the thermal insulating material is carried out in the factory and then the wall thus insulated is moved to a storage area.

12. A method of manufacturing a wall according to any one of claims 1 to 11, wherein the first and second external walls (E1, E2) of each given building element are rigidly connected to each other by means of first and second mechanical connecting pieces (11, 12), - the first external wall (E1) being molded partly around a first part of the first connecting piece (11) and around a first part of the second connecting piece (12); and - the second external wall (E2) being molded around a second part of the first connecting piece (11) and a second part of the second connecting piece (12).

13. Method of manufacturing a wall according to claim 12, in which the first connecting piece (11) has, at least between its first and second parts, a thermal conductivity which is strictly less than 0.5 W*m-1*K-1.

14. A method of manufacturing a wall according to any one of claims 1 to 13, wherein the first and second external walls (El, E2) have respective thermal conductivities greater than 0.7 W*m-1*K-1 and wherein said thermally insulating material has a thermal conductivity less than 0.2 W*m-1*K-1, preferably less than 0.05 W*m-1*K-1.

15. A method of manufacturing a wall according to any one of claims 1 to 14, wherein the internal recess (Ev) of the wall is delimited on one side by all the first external walls (El) of said building elements of the wall and on the other side by all the second external walls (E2) of said building elements of the wall and said block of molded thermal insulating material extends against the first and second external walls of the building elements of several rows of the wall.

16. A method of manufacturing a wall according to any one of claims 1 to 15, wherein the shutter (4) is equipped with lifting interfaces (5) arranged to be mechanically connected to an external lifting system.

17. A method of manufacturing a wall according to any one of claims 1 to 16, wherein the shutter (4) forms a chaining system fixed to the wall, the shutter (4) being single-use.

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