Prefabricated building element, prefabricated wall and building element production system.

Abstract

Prefabricated building element (E) for the construction of a wall (1) comprising first and second external walls (E1, E2) and a first mechanical connecting piece (11), the first and second external walls (E1, E2) being spaced apart and rigidly connected to each other by means of said at least one first mechanical connecting piece (11). The first external wall (E1) is molded around a first portion of the first connecting piece (11) and the second external wall (E2) is molded around a second portion of the first connecting piece (11). [Figure in the abbreviation: Fig. 10]

Description

Title of the invention: Prefabricated building element, prefabricated wall and system for producing building elements.

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

[0002] BACKGROUND OF THE INVENTION

[0003] It is known to produce prefabricated concrete construction elements by molding.

[0004] Such a construction element is generally single-piece and has first and second external walls parallel to each other and internal partitions for connecting these external walls.

[0005] These internal concrete partitions make the construction element heavier, which is detrimental to its transport and handling.

[0006] Due to the single-block concrete appearance, such a prefabricated construction element also has significant thermal bridges.

[0007] SUBJECT OF THE INVENTION

[0008] An object of the present invention is to provide a prefabricated construction element making it possible to resolve or at least minimize at least some of the aforementioned drawbacks of the prior art. Summary of the invention

[0009] To this end, according to a first aspect, the invention relates to a prefabricated construction element for wall construction, the element comprising first and second external walls and a first mechanical connecting piece, the first and second external walls being spaced apart from each other and being rigidly connected to each other by means of said at least one first mechanical connecting piece.

[0010] The construction element according to the invention is essentially characterized in that the first external wall is molded around a first part of the first connecting piece and in that the second external wall is molded around a second part of the first connecting piece.

[0011] The construction element according to the invention is thus particularly economical to produce since the external walls are directly formed by molding around parts of the first connecting piece which makes it possible to maintain the spacing between these first and second external walls (these external walls spaced apart from each other do not touch).

[0012] Since the connection between an outer wall and the connecting piece is formed during the molding of the outer wall, a particularly effective embedding connection is obtained. durable and economical.

[0013] This contributes to the robustness of the building element.

[0014] Unlike the construction elements of the prior art whose internal partitions are necessarily made of the same material as the first and second external walls, thanks to the invention, the connecting piece(s) connecting the external walls can be made of different materials.

[0015] The particular design of the prefabricated construction element according to the invention makes it possible to choose connecting parts adapted (in terms of materials and shape) to the expected technical specifications of the construction elements.

[0016] Thus, the thermal bridges, the mechanical resistance and the dimensions of the construction element can be optimized / adapted simply according to the characteristics of the chosen connecting parts.

[0017] According to a second aspect, the invention relates to a wall comprising several rows of construction elements according to the invention, said rows being superimposed on one another and each row being formed from an alignment of several of said construction elements, the wall comprising a first external face formed with the first external walls of the construction elements and comprising a second external face formed with the second external walls of the construction elements, each construction element of a given row being connected to at least one other adjacent construction element belonging to at least one other adjacent row by means of an assembly binder / adhesive binder.

[0018] The wall according to the invention has the advantages inherent in prefabricated construction elements according to the invention.

[0019] All adjacent rows of the wall are connected to each other by means of assembly binder / adhesive binder applied to the interface between the construction elements of the wall.

[0020] According to a third aspect, the invention relates to a method of manufacturing a prefabricated wall using construction elements according to the invention, comprising:

[0021] - the manufacture in a factory of a prefabricated wall comprising several rows of construction elements, said rows being superimposed on each other and each row being formed from an alignment of several of said construction elements, each given construction element of a given row being connected to at least one construction element of an adjacent row of the given row by means of an assembly binder / adhesive binder, the prefabricated wall having an internal volume 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;

[0022] - filling said internal volume of the wall with a thermal insulating material of so as to form a single block of thermal insulating material molded against all the first and second external walls of the entire wall construction elements.

[0023] Thanks to the block of thermal insulating material which extends continuously between the different construction elements, the wall has reduced thermal bridges.

[0024] The method according to the invention is also very economical to implement since the insulation of the wall can be carried out in a single operation.

[0025] According to a first variant of this method, the filling of the internal volume is done in the factory, then the prefabricated wall with its thermal insulating material is transported to a storage area.

[0026] According to an alternative variant of the method, the prefabricated wall is transported and fixedly installed on a construction site of a building which is to incorporate the prefabricated wall and said filling of the internal volume of the wall with the insulating material is carried out on the construction site of the building while the wall is fixedly installed.

[0027] According to a fourth aspect, the invention relates to a system for the production of wall construction elements, comprising a mold comprising a plurality of molding units, each molding unit comprising a hollow zone of a first type shaped to mold therein a first external wall of a given construction element and a hollow zone of a second type shaped to mold therein a second external wall of the given construction element and at least one central hollow zone extending between said hollow zones of the first and second types of the molding unit.

[0028] This system according to the fourth aspect of the invention is essentially characterized in that said central hollow zone is shaped to: - on the one hand positioning a first mechanical connecting part passing through said central hollow zone and having a first part placed in said hollow zone of the first type of the molding unit and a second part placed in said hollow zone of the second type of the molding unit; and for - on the other hand, creating a seal between said hollow zones of the first and second types.

[0029] In this way, the first outer wall is directly molded around said first part of the first connecting piece and the second outer wall is directly molded around said second part of the first connecting piece.

[0030] The first and second external walls thus molded in the molding unit are then precisely spaced from one another and are from the outset rigidly connected to one another by means of said at least one first mechanical connecting part.

[0031] This system for the production of construction elements according to the invention is part particularly advantageous because it allows the mechanical connecting part to be simply positioned relative to the hollow zones of the first and second types while preserving a central sealed hollow zone between these hollow zones of the first and second types.

[0032] This system according to the invention makes it possible to easily produce construction elements according to the invention, the first and second external walls of which are firmly connected to each other via the connecting pieces while being precisely positioned relative to each other and preserving a space (internal volume) between these first and second walls suitable for receiving a layer of thermal insulating material.

[0033] In this way, the geometry of the space between the walls of the construction element is easily and precisely defined to limit thermal bridges between these walls.

[0034] In summary, the system according to the invention makes it possible, at low cost, to easily manufacture construction elements whose dimensional, geometric and thermal characteristics are precisely defined and identical between the construction elements produced in the same molding unit. Brief description of the drawings

[0035] 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:

[0036] [Fig.l] [Fig.l] is a perspective view of the system according to the invention for the production of wall construction elements before placing a plurality of connecting pieces in the mold;

[0037] [Fig.2] [Fig.2] is a perspective view of the system according to the invention shown in [Fig.l] while a gripping device of a robot is used to position several connecting parts in the mold;

[0038] [Fig.3] [Fig.3] is a perspective view of a movable sealing surface for selectively sealing lower openings of the mold of the production system according to the invention;

[0039] [Fig.4] [Fig.4] is a perspective view of a mold of the production system according to the invention which comprises several molding units, each molding unit being arranged to manufacture therein a construction element according to the invention, the connecting parts of these construction elements being positioned in the mold awaiting the molding of the walls of the construction elements;

[0040] [Fig.5] [Fig.5] is a sectional view in a VV plane of the mold illustrated in [Fig.4], before carrying out the molding of the walls of the construction elements in the mold ;

[0041] [Fig.5a] [Fig.5a] is a detail view of a mold area M showing a mode particular embodiment of the positioning surfaces SI of connecting pieces 11, 12, in this embodiment, a part of the positioning surfaces SI specific to the molding unit are supported on either side of lateral edges of a central part of the positioned connecting piece (in this case on either side of opposite lateral edges of the plate 113 to achieve longitudinal wedging of the connecting piece thus positioned) while another part of these positioning surfaces SI specific to the molding unit is supported on one side against a lateral face of the connecting piece and on the other side against a longitudinal end of the tab L1 of this connecting piece (to achieve lateral wedging of the connecting piece while achieving sealing between the zones Z1 and Z2 of the molding unit concerned of the mold);

[0042] [Fig.6] [Fig.6] is a perspective view of the mold shown in [Fig.4], after first and second walls of several construction elements according to the invention have been molded, the first and second walls of each of the construction elements are connected to each other by connecting pieces 11, 12 prepositioned in the mold;

[0043] [Fig.7] [Fig.7] is a sectional view in a plane VII-VII of the mold illustrated in [Fig.6], the construction elements according to the invention always being present in the mold where they are manufactured;

[0044] [Fig.8] [Fig.8] is a perspective of the mold of the system according to the invention while the sealing surface S seals the lower openings of the mold M and that pins PI, P2 penetrate inside the corresponding hollow zones of the mold to press the material constituting the walls of the construction elements according to the invention;

[0045] [Fig.9] [Fig.9] is a perspective of the mold of the system according to the invention presented in [Fig.8] while the sealing surface S is moved away from the lower openings of the mold M to allow the demolding of the construction elements according to the invention, these elements being pushed out of the mold under the effect of the pins PI, P2 (the mold M being moved relative to the pins PI, P2 and relative to the sealing surface S so that the construction elements thus produced are extracted from the mold while remaining supported by the sealing surface S);

[0046] [Fig. 10] [Fig. 10] is a perspective view of the sealing surface S supporting the construction elements according to the invention after they have been extracted from the mold M, this figure also shows a detailed view of a connecting piece 11 used to connect walls E1 and E2;

[0047] [Fig. 11] [Fig. 11] is a perspective view of part of a row of elements of construction E according to the invention;

[0048] [Fig. 12] [Fig. 12] is a perspective view of a prefabricated wall 1 according to the invention comprising several superimposed rows of construction elements E according to the invention, the internal volume Ev of the prefabricated wall 1 being left empty to be able to admit a thermal insulator, this prefabricated wall 1 being carried by a shutter 4 providing a seal in the lower part of said internal volume Ev of the wall 1 to maintain the thermal insulator in the internal recess Ev;

[0049] [Fig. 13] [Fig. 13] is a perspective view of the prefabricated wall 1 of [Fig. 12] while its internal volume Ev is filled with insulating material forming a continuous block of thermal insulation Eth;

[0050] [Fig. 14] [Fig. 14] is a perspective view of a part of a prefabricated wall 1 according to the invention showing a detail of a connecting piece 11, according to a first embodiment of connecting piece 11 according to which each connecting piece 11 comprises a single tab L1;

[0051] [Fig. 15] [Fig. 15] is a perspective view of a part of a prefabricated wall 1 according to the invention showing a detail of a connecting piece 11 according to a second embodiment of connecting piece 11 according to which each connecting piece comprises several parallel tabs L1;

[0052] [Fig. 16] [Fig. 16] is a top view of a construction element E according to the invention in an embodiment where the first and second walls E1 and E2 are connected to each other via first and second connecting pieces 11, 12 conforming to the X-shaped connecting piece shown in [Fig. 17];

[0053] [Fig. 17] [Fig. 17] is a perspective view of an X-shaped connecting piece 11, the connecting piece 11 comprises tabs L1 parallel to each other and arranged to be on either side of a male part of the mold forming a core in the mold M to define the recess Ev between the walls El, E2 (during molding, these tabs L1 are on either side of the male part of the mold to position the connecting piece and provide a seal, on either side of this male part, between the hollow zones Zl, Z2). DETAILED DESCRIPTION OF THE INVENTION

[0054] As indicated previously, according to a first aspect, the invention relates to a prefabricated construction element E for the construction of wall 1.

[0055] Several examples of construction elements E according to the invention are illustrated in Figures 6, 7, 10 to 16.

[0056] The wall 1 according to the invention is produced by stacking several rows of prefabricated elements E according to the invention, these elements being glued together by a bonding binder spread between the rows.

[0057] The bonding binder may be a mastic or a mortar, this binder, before its crosslinking, being in the form of a gel or foam, this binder is preferably of the polymer type.

[0058] Generally speaking, a construction element E according to the invention comprises first and second external walls E1, E2, a first mechanical connection part 11 and a second mechanical connection part 12.

[0059] The first and second external walls E1, E2 are spaced apart from each other (i.e. they do not touch) and are rigidly connected to each other by means of said first and second mechanical connecting parts 11 and 12.

[0060] The first external wall E1 is molded around a first part of the first connecting piece 11 and around a first part of the second connecting piece 12.

[0061] Similarly, the second external wall E2 is molded around a second part of the first connecting piece 11 and around a second part of the second connecting piece 12.

[0062] The first part of a connecting piece 11 or 12 is located at a first end of this piece.

[0063] The second part of a connecting piece 11 or 12 is located at a second end of this piece 11 or 12, these first and second ends being on either side of the piece.

[0064] The construction element E according to the invention is particularly robust since the first and second external walls are directly molded around the first and second parts of the connecting pieces 11, 12 while preserving a spacing between these first and second walls E1, E2, that is to say a thermal decoupling space between these walls of the construction element.

[0065] Each connecting piece thus makes it possible to mechanically connect the walls of the construction element together while limiting thermal bridges between walls since thermal conduction can only take place through the connecting pieces 11, 12.

[0066] In order to limit thermal conduction, it is preferentially ensured that: - 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, preferentially less than 0.4 W*m-1*K-1; and that - the second connecting piece 12 has, at least between its 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.

[0067] In this way, each connecting piece forms a thermal breaker to limit the transfer of heat by conduction between the walls E1 E2.

[0068] For this, the connecting parts 11, 12 are preferably made of molded polymer material with thermal conductivity less than 0.5 W*m-1*K-1, preferably Typically less than 0.2 W*m-1*K-1. Typically, this polymer material is a molded thermoplastic polymer (amorphous or crystalline) and possibly containing reinforcing fibers.

[0069] Preferably, the parts 11, 12 are made of polyamide PA reinforced with glass fibers.

[0070] As illustrated in the various figures 6, 7, 10 to 15, the first and second walls E1, E2 and the first and second mechanical connecting parts together define an internal volume Ev of the construction element.

[0071] This volume Ev is intended to receive a thermal insulating material preferably molded between the first and second external walls E1, E2, against internal faces of these walls E1, E2 and against the first and second mechanical connection parts 11, 12.

[0072] This internal volume Ev forms a passage passing through the construction element E and opening on the one hand onto a lower face Fi and on an upper face Fs of the construction element E.

[0073] In this way the internal volume Ev forms a molding formwork for the insulation.

[0074] The construction element E comprises a first longitudinal end face Fl and a second longitudinal end face F2.

[0075] The first end face F1 is solid and partly constituted by the first mechanical connecting part 11.

[0076] The second end face F2 is also solid and partly constituted by the second mechanical connecting part 12.

[0077] In other words, the first and second longitudinal end faces F1, F2 of the construction element E are partly formed by the connecting pieces 11, 12.

[0078] Each at least one mechanical connecting part 11, 12 contributes to maintaining a fixed spacing between the walls E1, E2 and a fixed positioning of these walls E1, E2 relative to each other.

[0079] These walls E1, E2 are parallel to each other and form front and rear faces of the construction element E.

[0080] The arrangement of the connecting pieces 11, 12 at the level of the first and second longitudinal end faces F1, F2 is favorable to the stiffening of the construction element.

[0081] The dimensions of the construction element E are such that it can extend entirely within a maximum parallelepiped volume of length 600 mm, height 450 mm and thickness 450 mm.

[0082] The construction element E (including when filled with thermal insulation) has a unit mass preferably less than 30 kg to be transportable manually.

[0083] The first and second external walls E1, E2 have respective thermal conductivities X1, X2 greater than 0.7 W*m-1*K-1.

[0084] Typically, the material constituting the first and second walls is concrete, terracotta, cellular concrete.

[0085] The thermally insulating material placed between the walls E1, E2 has a thermal conductivity of less than 0.2 W*m-1*K-1, preferably less than 0.05 W*m-1*K-1.

[0086] The thermally insulating material here takes the form of a continuous layer Eth.

[0087] This insulating material preferably contains bulk material such as particles and / or fibers, these particles and / or fibers preferably being a bio-sourced material such as a plant material.

[0088] Preferably, said bio-sourced 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.

[0089] Preferably, the insulating material comprises a binder of said particles and / or fibers.

[0090] Preferably, the binder contains, predominantly by mass, a mineral material, this material being preferentially selected from cement, meta kaolin, clay.

[0091] 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.

[0092] Thus, the binder is preferably an insulating mineral foam, for example of the type of foam sold under the brand name AIRIUM ®.

[0093] By insulating mineral foam is meant a mineral foam with its own thermal conductivity of less than 0.05 W*m-1*K-1.

[0094] It should be noted that in non-preferred embodiments, the fibers and / or particles of said insulating material may contain a mineral material of the rock wool or glass wool or exfoliated perlite 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 thermoplastic polymers), synthetic textiles or a mixture of these materials.

[0095] In all cases, the molded layer of insulating material Eth has an overall thermal conductivity of less than 0.2 W*m-1*K-1, preferably less than 0.05 W*m-1*K-1.

[0096] [Fig. 11] illustrates a particular embodiment of the construction element which is pre-insulated before the wall is assembled.

[0097] In this particular embodiment, the layer of thermal insulating material Eth is molded against the external walls El, E2 and extends between the upper external face Fs and lower Fi.

[0098] A portion of the upper external face Fs is defined by an upper surface of the Eth layer and a portion of the lower external face Fi is defined by a lower surface of the Eth layer.

[0099] These upper and lower external faces Fs, Fi are preferably ground to improve the flatness of these faces, their parallelism and to guarantee a constant height between the construction elements.

[0100] In this embodiment, a construction element E is obtained which comprises its own layer of thermal insulating material Eth.

[0101] This construction element can be used by masons to build walls by superimposing several rows of construction elements according to the invention.

[0102] These elements being glued together, for example using a glue, a mastic, a mortar which is, before solidification / crosslinking, in the form of a gel, a foam, this glue, this mastic or this mortar being preferably of the polymer type.

[0103] In an alternative embodiment illustrated in figures 10, 12, 13, 14, 15, the internal volumes Ev of the construction elements E can be left empty to allow them to be filled by insulating once on the construction site of the wall while the elements E are already glued together.

[0104] In this case, the assembled wall 1 comprises a continuous layer of insulating material Eth extending over all the rows of the wall.

[0105] The upper external faces Fs and lower Fi may respectively have complementary upper and lower external profiles.

[0106] These 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.

[0107] Typically, each upper external profile may comprise a groove and a tongue and each lower external profile may comprise a groove and a tongue. 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. 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.

[0108] Such 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.

[0109] As understood from Figures 7 and 11, 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.

[0110] In this way, as illustrated in [Fig.l 1], 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.

[0111] The interlocking between ends of construction elements is useful for positioning construction elements of the same row relative to each other.

[0112] Preferably, as understood from [Fig. 11], 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 facing each other.

[0113] 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.

[0114] Preferably, the construction elements of the wall are mostly (in number) identical to each other.

[0115] Particular embodiments of the connecting pieces will now be described in relation to figures 5, 10, 14 to 16.

[0116] These first and second connecting pieces 11, 12 are geometrically identical to each other.

[0117] The first part of the first connecting piece 11 comprises pads 111 and the second part of the first connecting piece 11 also comprises pads 112.

[0118] These first and second parts of the first connecting piece 11 are connected to each other by a central part of the first connecting piece 11 which comprises a plate 113.

[0119] This plate 113 extends perpendicularly to a main face of the first wall E1 and perpendicularly to a main face of the second wall E2.

[0120] The main face of a wall E1, E2 is flat and oriented outside the construction element.

[0121] The main faces of the walls E1 and E2 are parallel to each other.

[0122] The first part of the second part 12 comprises studs.

[0123] Similarly, the second part of the second part 12 comprises studs.

[0124] These first and second parts of the second connecting piece 12 are connected to each other by a central part of the second piece which comprises a plate.

[0125] The plates 113 of the first and second connecting pieces 11, 12 are parallel to each other.

[0126] The pads of the first and second connecting pieces 11, 12 extend here along longitudinal directions of these pads which are substantially perpendicular to a main plane of the plate 113 of the first connecting piece 11.

[0127] Of course, the orientation of the longitudinal directions of the pads may be non-parallel to each other so as to reinforce the mechanical connection with the molded walls around these pads.

[0128] Each of the pads shown here has a uniform cross-section along the entire length of the pad.

[0129] However, it is also possible that at least some of the pads have a variable cross-section depending on the length of the pad so that wall material is interposed between one end of the pad and a plane in which the plate of the connecting piece extends.

[0130] For example, the section of the pad may increase as it approaches the end of the pad.

[0131] As understood from the different embodiments illustrated in figures 5, 10, 14 to 16, the internal volume Ev of the construction element E is on one side delimited by the plate 113 of the first connecting piece 11 and on another opposite side delimited by the plate 123 of the second connecting piece 12.

[0132] In these embodiments where the connecting pieces 11, 12 each define a part of the solid faces F1, F2, the construction element has a constant tubular section over more than 90% of its height, which facilitates its manufacture by molding process and demolding along the direction Ds.

[0133] The first and second external walls E1, E2 are U-shaped profiles, the hollow parts of the U-shaped profiles being oriented towards the inside of the construction element. Each of these U-shaped profiles has two lateral edges.

[0134] The lateral edges of said U-shaped profiles face each other two by two.

[0135] The pads 111, 112 of the first and second connecting pieces 11, 12 extend ex exclusively in the side edges of said U-shaped profiles.

[0136] The first connecting piece 11 connects a first edge of the U-shaped profile forming the first wall E1 with a first edge of the U-shaped profile forming the second wall E2, these first edges facing each other.

[0137] The second connecting piece 12 connects a second edge of the U-shaped profile forming the first wall E1 with a second edge of the U-shaped profile forming the second wall E2, these second edges facing each other.

[0138] Thus, for each given connecting piece 11, 12, the dimensions necessary to connect the first and second walls E1, E2 together are minimal.

[0139] By reducing the dimensions of the connecting parts, the quantity of material for the manufacture of these connecting parts is reduced.

[0140] This is advantageous because it minimizes the amount of polymer material contained in a construction element (the connecting parts are usually made of polymer material which is much more expensive than the material constituting the first and second walls).

[0141] The manufacturing cost of the construction element can thus be minimized.

[0142] Each connecting piece 11, 12 connecting the first and second external walls between it is preferably equipped with at least one flat tongue L1 having a free tongue end, the tongue L1 being located at a distance from the first and second walls E1, E2 of the construction element and being parallel to a median plane of the construction element.

[0143] Such a tab which extends between the walls E1, E2 makes it possible to guarantee a minimum distance between these walls. This tab makes it possible to avoid contact between these walls which would cause a thermal bridge.

[0144] The use of such a tab L1 may also be of interest for positioning the connecting piece in the mold M where the first and second walls E1, E2 are molded.

[0145] As can be seen in particular in [Fig.5], or in [Fig.5a], which show the mold M and the connecting pieces 11, 12 in cross-section along a plane VV perpendicular to the tabs L1, each tab L1 bears against a tab positioning surface SI which belongs to the mold M.

[0146] The positioning of the tab L1 parallel to the vertical median plane of the construction element is advantageous for allowing the demolding of the construction element by translating the mold M parallel to the plane of the tabs L1, i.e. in the direction Ds.

[0147] The tabs L1 may be, as in the embodiments of FIGS. 5 and 5a, oriented towards the inside of the construction element E so as to extend into the internal volume Ev intended to receive the thermal insulation Eth.

[0148] As a result, each tab L1 helps to promote the mechanical connection with the insulator Eth.

[0149] Alternatively, a tab may extend towards the outside of the construction element, which may be of interest in ensuring a minimum distance between two construction elements of the same row, this minimum distance being greater than or equal to the length of a tab.

[0150] Such a minimum distance may be of interest for injecting thermal insulating material between the adjacent ends of two construction elements of the same row.

[0151] Several examples of walls in accordance with the second aspect of the invention are shown in Figures 12, 13, 14 and 15.

[0152] This wall 1 comprises several rows of construction elements E according to the invention.

[0153] These rows are superimposed on each other and each row is formed of a alignment of several of said construction elements following an alignment direction which is preferably common to all of the rows, this direction being substantially horizontal.

[0154] The wall 1 comprises a first external face formed with the first external walls E1 of the construction elements E and comprising a second external face formed with the second external walls E2 of the construction elements E.

[0155] Each construction element E of a given rank is connected to at least one other adjacent construction element belonging to at least one other adjacent rank by means of an assembly binder / adhesive binder.

[0156] In a particular embodiment of the wall according to the invention, the latter comprises an internal volume Ev delimited on one side by all the first external walls E1 of said construction elements of the wall and on the other side by all the second external walls E2 of said construction elements of the wall, this internal volume Ev being filled with a single continuous block of thermal insulating material Eth molded against all the first and second external walls of all the construction elements of the wall 1.

[0157] In other words, according to this particular embodiment, firstly, the different rows of the wall 1 are mounted on top of each other while binding them together with the bonding / assembly binder, which makes it possible to obtain the wall with the empty internal volume Ev.

[0158] In a second step, this internal volume Ev is filled with the thermal insulating material Eth molded against all the first and second external walls El, E2 of the construction elements of the wall.

[0159] This simplifies the implementation of the insulation in wall 1 while limiting the areas of the wall that are not insulated between the internal and external faces of the wall.

[0160] With the wall according to the invention, the insulation layer can be continuous over the entire height of the wall and the thermal resistance of the wall is improved.

[0161] According to the third aspect of the invention, the invention relates to the method of manufacturing a prefabricated wall using construction elements according to the invention.

[0162] This manufacturing process is illustrated by Figures 11 to 15 and comprises:

[0163] - the manufacture in a factory of said prefabricated wall 1, this prefabricated wall 1 having said internal volume Ev delimited on one side by all the first external walls of said construction elements E of wall 1 and on the other side by all the second external walls E2 of said construction elements of the wall;

[0164] - filling said internal volume Ev of the wall with a thermal insulating material so as to form a single block of thermal insulating material Eth molded against all first and second external walls of all the construction elements of the wall.

[0165] Preferably, as illustrated in Figures 12 and 13, the filling of the internal volume Ev of the wall 1 is carried out at least in part, using an injection pipe 3 opening into a lower zone of said internal volume Ev of the wall and passing through one of the walls of one of the prefabricated construction elements E or through a shutter 4 providing a seal between a lower part of the internal volume Ev of the wall and a zone external to the wall.

[0166] Here the injection pipe 3 is shown diagrammatically in dotted lines and it passes through a shutter 4 used to close a lower zone of the internal volume Ev.

[0167] In the illustrated mode, the injection pipe 3 opens towards the internal volume Ev via three nozzles respectively shown diagrammatically by dotted arrows.

[0168] The shutter is used to close the lower area of ​​the internal volume Ev in order to be able to inject the insulating material.

[0169] After filling said internal volume Ev with the thermal insulating material Eth, the injection pipe 3 can be detached from the wall.

[0170] 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.

[0171] Depending on the case, this shutter 4 may or may not be used for transporting the prefabricated wall with its solidified thermal insulation Eth.

[0172] Depending on the case, the shutter 4 can be a fixed piece of equipment in the factory or mobile with the prefabricated wall 1.

[0173] In the case where the shutter 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.

[0174] 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).

[0175] This lifting system is adapted to lift the shutter 4 and the prefabricated wall 1 carried by the shutter 4.

[0176] The shutter 4 here takes the form of a rigid beam on which the prefabricated wall 1 is formed.

[0177] In these embodiments, the wall is directly prefabricated on the shutter 4 which is transportable using a lifting system.

[0178] The shutter 4 may or may not be reusable to make another prefabricated wall.

[0179] In a particular case, the shutter 4 is for single use and it forms a system of 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 to integrate wall 1.

[0180] 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 volume Ev to inject the insulation therein, to locate the insulation injection pipe in the internal volume Ev, to support the wall during its transport and to assemble the wall on the supporting structure of the building.

[0181] 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.

[0182] For the implementation of the manufacturing process, the thermal insulating material Eth can be composed of: - on the one hand, bulk material; and - on the other hand, a binder of this bulk material.

[0183] Here, the filling of the internal volume with the thermal insulating material Eth is carried out by first positioning said bulk material in said internal volume of the wall Ev and then injecting said binder of this bulk material while it is in a non-crosslinked state.

[0184] The binder of this material is crosslinked / solidified in the internal volume Ev to bind the bulk material there and thus form said block of insulating material Eth.

[0185] By introducing separately, on the one hand the bulk material and on the other hand the binder, free placement of the bulk material in the volume Ev is allowed without this placement depending on the weight or viscosity of the binder.

[0186] 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.

[0187] Preferably, the bulk material is inserted into the internal volume of the wall via a pipe passing through an upper zone of said internal volume 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.

[0188] The binder gradually rises in the internal volume of the wall, passing through the bulk material, which limits the compaction effect of this material.

[0189] As indicated previously, this bulk material may be in the form of particles and / or fibers, these particles and / or these fibers preferably being made of bio-sourced 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.

[0190] The use of a bulk material of the bio-sourced material type as a material plant material allows carbon to be stored inside the layer of insulating material of the building element / prefabricated wall.

[0191] Massive carbon storage in buildings is favorable to a reduction of the volume of CO2 in the atmosphere.

[0192] As indicated previously, the binder of the bulk material preferably contains, and predominantly by mass, a mineral material, this material being preferably selected from cement, meta kaolin, clay, this mineral material being preferably in the form of foam.

[0193] Preferably, this binder of the bulk material is in the form of a foam containing cells of dimensions infra centimeters, preferably infra millimeters, these cells preferably containing a gaseous fluid.

[0194] Thus, the binder of the bulk material is preferably an insulating mineral foam, for example of the type of foam sold under the brand name AIRIUM ®.

[0195] By insulator, it is meant that the insulator, here the insulating mineral foam, has a thermal conductivity of less than 0.05 W*m-1*K-1.

[0196] In some cases, the binder of the bulk material could be arranged to contain at least one thermoplastic polymer.

[0197] In a preferred embodiment, the method for manufacturing a prefabricated wall 1 according to the invention is implemented using an automaton / robotic system installed in the factory and ensuring on the one hand the stacking of the construction elements E in superimposed rows of the wall and on the other hand the distribution of binder on upper faces of rows of the wall to connect adjacent rows of the wall together (the binder distributed on an already formed row), the automaton is arranged to press the binder between these adjacent rows so as to distribute it between the elements E to be glued.

[0198] The system for the production of construction elements according to the aforementioned fourth aspect of the invention will now be described with reference to Figures 1 to 10.

[0199] This system 0 for the production of wall construction elements E, comprises a mold M comprising several molding units M1, M2, M3, M4, M5, each molding unit comprising a hollow zone Z1 of a first type shaped to mold therein a first external wall El of a given construction element E and a hollow zone Z2 of a second type shaped to mold therein a second external wall E2 of the given construction element E and at least one central hollow zone Z3 extending between said hollow zones Z1, Z2 of the first and second types of the molding unit.

[0200] The central hollow zone Z3 is shaped to position a first mechanical connecting piece 11 passing through said central hollow zone Z3 while a first part of this first connecting piece 11 is placed in the hollow zone Z1 of the first type and a second part of this connecting piece 11 is placed in the hollow zone Z2 of the second type.

[0201] The central hollow zone Z3 of the molding unit is also shaped to provide a seal between said hollow zones Z1, Z2 of this molding unit so that the first external wall E1 is molded around said first part of the first connecting piece 11 and the second external wall E2 is molded around said second part of the first connecting piece 11 while keeping these first and second molded external walls E1, E2 spaced apart from each other (i.e. avoiding any contact between these walls E1, E2).

[0202] The central hollow zone Z3 of the molding unit is also shaped to position a second mechanical connecting piece 12 passing through said central hollow zone Z3 while a first part of the second connecting piece 12 is placed in said hollow zone Z1 of the first type of the molding unit and a second part of the second connecting piece 12 is placed in said hollow zone Z2 of the second type of the molding unit ML

[0203] In this way, still maintaining the seal between the hollow zones Z1 and Z2, the central hollow zone Z3 is arranged so that the first and second molded external walls E1, E2 in the molding unit can be rigidly connected to each other by means of said second mechanical connecting piece 12 so that the first external wall E1 is directly molded around said first part of the second connecting piece 12 and the second external wall E2 is directly molded around said second part of the second connecting piece 12.

[0204] Each molding unit M1, M2, M3, M4, M5 of the production system 0 corresponds to a compression unit Cx equipped with: - a first ram PI for selectively penetrating into the hollow zone of the first type Zl and compressing the material constituting the first wall El during its molding; and - a second ram P2 to selectively penetrate into the hollow zone Z2 of the second type and compress the material constituting the second wall E2 during its molding.

[0205] The first and second rams PI, P2 of the compression unit Cx correspond here to the molding unit ML

[0206] These rams PI, P2 are mechanically connected to each other and are moved in translation relative to the corresponding molding unit M1 under the effect of at least one actuator such as a jack Vx in order to selectively penetrate into the molding unit ML.

[0207] Preferably, as illustrated in [Fig.7], the first ram PI is shaped to form an upper face of the first wall El and possibly mold one or more recesses Elx in the thickness of the first wall EL.

[0208] Preferably, as illustrated in [Fig.7], the second pestle P2 is shaped to form an upper face of the second wall E2 and possibly mold one or more recesses E2x in the thickness of the second wall E2.

[0209] 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.

[0210] In the example illustrated in [Fig.5] (cross-sectional view of the construction element E in a plane VV) and in [Fig.7] (cross-sectional view of the construction element E in a plane VILVII), the first wall El has 3 recesses Elx and the second wall E2 has 3 recesses E2x.

[0211] These recesses Elx and E2x each have an oblong shape extending in length along the length of the construction element.

[0212] These recesses Elx, E2x have the function of reducing the thermal conductivity through the wall while lightening the wall via a reduction in the quantity of material.

[0213] A given 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.

[0214] To enable the demolding of the construction elements E molded in the mold M, the mold M has lower openings which are selectively closed by a closing surface S movable relative to the mold M.

[0215] Thus, the hollow zones of the first and second types Z1, Z2 and the central hollow zone Z3 of each of the molding units M1, M2, M3, M4, M5 are open in the lower part of the mold M to allow the demolding of the construction elements E molded in the mold M via the lower openings of the mold M selectively closed by the closing surface S.

[0216] System 0 selectively adopts: - a molding configuration (illustrated in figures 4, 5, 6, 7 and 8) in which the mold M is supported against the sealing surface S to seal the hollow zones Z1, Z2, Z3 of the mold at the level of the lower part of the mold M in order to allow the compression, by the pins PI, P2, of the material constituting the walls against said sealing surface S; and

[0217] - a demolding configuration (illustrated in [Fig.9]) in which the mold M is away from the sealing surface S to free the openings of the hollow areas Zl, Z2, Z3 of the mold at the level of the lower part of the mold and allow the exit from the mold M of the construction elements E thus produced / molded.

[0218] Preferably, the sealing surface S is also arranged to form a support for the construction elements E thus produced and demolded.

[0219] This closure surface S extends here along a plane but it could take a other than flat shape.

[0220] Depending on the case, the obturation surface S can belong to a tray Px or a conveyor belt Rx.

[0221] As is apparent from Figures 1 and 2, the system 0 also comprises a gripping device R for connecting pieces 11, 12 arranged to simultaneously support and move a plurality of connecting pieces 11, 12 and to simultaneously insert the connecting pieces of this plurality of connecting pieces into the corresponding hollow zones Z1, Z2, Z3 of the molding units M1, M2, M3.

[0222] The gripping device R for connecting pieces 11, 12 is arranged to insert said connecting pieces into the corresponding hollow zones Z1, Z2, Z3 by moving them towards the mold from an area external to the mold located above the mold.

[0223] The gripping device R comprises a gripper Pi selectively adopting a clamping configuration in which the gripper Pi clamps each of the plurality of connecting pieces and a releasing configuration in which each connecting piece is released from the gripper Pi.

[0224] To facilitate the gripping of the connecting pieces by the clamp, the system 0 according to the invention may also comprise a pre-positioning plate 5 for the connecting pieces of the plurality of connecting pieces.

[0225] The connecting pieces positioned on the pre-positioning plate 5 are arranged to be simultaneously gripped by the clamp Pi of the gripping device R.

[0226] An operator can thus manually place the connecting pieces 11, 12 of the plurality of connecting pieces on the pre-positioning plate 5, which makes it possible to simultaneously grasp, then simultaneously move, then simultaneously introduce the connecting pieces into the corresponding molding units M1, M2, M3, M4, M5 of the mold M using the same clamp Pi.

[0227] The time required to refill the mold M with connecting parts 11, 12 is thus optimized.

[0228] Furthermore, the operator in charge of positioning the connecting parts on the pre-positioning plate 5 can be located in a secure working area, at a distance from the gripping device R and the mold M.

[0229] For this purpose, the pre-positioning plate 5 can be mounted movably on a guide between the area for gripping connecting parts by the gripping device and the secure working area where the operator is.

[0230] The safe working area is defined outside a possible movement space of the Pi gripper.

[0231] The gripper Pi is here carried by a 6-axis robot to be moved between the area where the pre-positioning plate(s) 5 are located and the molding area where the mold M is located.

[0232] It should be noted that the pins PI, P2 are movable to be selectively moved away from the mold M and to allow the passage of the clamp Pi necessary for positioning the connecting parts 11, 12 in the molding units of the mold M.

[0233] Once the parts 11, 12 are placed in the mold, the clamp Pi can be moved away from the mold to begin molding the walls E1, E2 of the construction elements.

[0234] As shown diagrammatically in [Fig. 4], the system 0 according to the invention also comprises a distribution device Dx to the molding units M1 to M5, of a material intended to constitute in the mold, by molding, walls of construction elements E.

[0235] This distribution device Dx comprises a plurality of distribution nozzles 6 each arranged to come opposite one of the hollow zones of a molding unit Ml which corresponds to it.

[0236] Each dispensing nozzle 6 is selectively closed via at least one valve A2 / one dispensing actuator.

[0237] This distribution device Dx is movable relative to the mold M under the effect of at least one actuator Al for moving the distribution device Dx, between: - a first position where the distribution device is placed opposite the mold M to distribute the material constituting the walls of construction elements there; and - a second position where the distribution device Dx is moved away from the mold M to allow the introduction of the pestles PI, P2 into the hollow zones Zl, Z2 of the corresponding molding units and / or to allow the passage of the gripping device Pi of the connecting pieces to position the connecting pieces in the different corresponding hollow zones Zl, Z2 of the molding units.

[0238] The distribution device Dx may comprise a tank containing the material intended to constitute the walls E1, E2.

[0239] This tank can carry said distribution nozzles 6 which are openings formed through a bottom of the tank, these openings being selectively closed via a selective closing mechanism which can be a valve A2 / a closing actuator A2 shown diagrammatically in Figures 4 and 5.

[0240] The tank can be movable between the first and second positions under the effect of said at least one actuator A1 for moving the dispensing device.

[0241] The movement of the distribution device Dx between its first and second positions can be done by translation in a horizontal plane while the respective movements of the mold M and the rams PI, P2 can be done by translation in a direction which is in an exit direction Ds of the construction elements from the mold.

[0242] This exit direction Ds is preferably vertical.

[0243] The movement of the mold M in the direction Ds is controlled by one or more Vy actuators (illustrated in figures 1, 6, 8, 9).

[0244] The system 0 according to the invention also comprises a control unit UC (shown diagrammatically in FIGS. 1 and 2) connected to the various actuators Vx, Vy, A1, A2, to at least one actuator Vz for moving the closure surface S (for example an actuator for moving the plate Px or a flat conveyor belt Rx), to the gripping device R and to its gripper Pi to control them.

[0245] The control unit UC is arranged to control the different actuators Vx, Vy, Vz Al, A2 of the system 0 to have an automated production of the construction elements E according to the invention.

[0246] In relation to figures 5 to 7, we will now specify the manner in which the connecting pieces 11, 12 are respectively positioned in the molding units of the mold M.

[0247] As indicated previously, each central hollow zone Z3 of a given molding unit M1, M2, M3, M4, M5 comprises first positioning surfaces SI of a corresponding connecting part with respect to the hollow zone Z3.

[0248] The first positioning surfaces SI are oriented so that the connecting piece bearing against the first positioning surfaces SI can be translated in a rectilinear translational movement from a first position in which the connecting piece is positioned inside the mold M to a second position in which the connecting piece is outside the mold M, the translational movement being in an exit direction Ds of the construction elements outside the mold.

[0249] As indicated previously, each connecting piece connecting the first and second external walls together is equipped with at least one flat tab LL

[0250] These flat tabs L1 have flat faces each parallel to the exit direction Ds of the construction elements from the mold M.

[0251] Thus, any connecting piece of which a tab L1 is in abutment against at least some of the first connecting piece positioning surfaces SI can slide in the exit direction Ds to pass through the mold until it is extracted from it.

[0252] Preferably, the first positioning surfaces SI for positioning a given connecting piece extend over the entire height of the corresponding molding unit to form a seal between the hollow zones Z1, Z2 of the first and second types of the molding unit by continuous support over the entire height of the molding unit against one or more tabs L1 of the given connecting piece.

[0253] In a particular embodiment, an example of which is illustrated in [Fig.15], the connecting piece comprises a pair of tabs L1 parallel to each other.

[0254] The first positioning surfaces of such a given connecting piece may form a male part positioned sealingly between the tabs of the pair of tabs coming to bear against the plate 113 which is perpendicular to these tabs Ll.

[0255] In another particular embodiment, an example of which is illustrated in Figures 5 (see detail of [Fig.5]), 10 and 14, the connecting piece comprises a tab L1 which may be unique and the first positioning surfaces SI of the given connecting piece form a female part positioned in a sealed manner against this tab L1, on either side of this tab LL.

[0256] This embodiment is preferred because, as illustrated in the detail view of [Fig. 5], when the material is pressurized by the pins PI, P2 inside the hollow zones of the first and second types Z1, Z2, this material exerts pressure against the first positioning surfaces SI which are rigid and placed on either side of the tab LL.

[0257] The risk of the tongue L1 becoming stuck between these first positioning surfaces SI is thus minimized.

[0258] In the case where the tabs L1 are on either side of the positioning surfaces SI, there is then a risk of deformation / jamming of the tabs in the mold M under the effect of the pressure in the hollow zones Z1, Z2.

[0259] Preferably, the mold M is made of metal, preferably steel.

[0260] Preferably, each given pestle PI, P2 is made of metal, and at least one peripheral seal of the pestle is arranged around the pestle to provide a seal between the mold and the pestle while the pestle slides in the mold.

[0261] Such a peripheral seal is advantageous because it makes it possible to avoid direct friction between the metal of the pestle and the metal of the mold in order to preserve them.

[0262] As is clear from Figures 4 to 7, each given molding unit Ml, M2, M3, M4, M5 comprises an external female part Mx defining a main recess of the given molding unit and a male part Myl, My2, My3, My4, My5 arranged inside this main recess to form a core of the given molding unit.

[0263] Preferably, each main recess of a given molding unit M1, M2, M3, M4, M5 passes through the mold M right through between an upper face of the mold and a lower face of the mold.

[0264] Each given male part Myl, My2, My3, My4, My5 is arranged inside the main recess of the external female part Mx of the corresponding molding unit Ml, M2, M3, M4, M5 to define therein: - on a first side of the given male part, the hollow zone of the first type Zl (the hollow zone of the first type Zl is defined between this given male part and a first internal surface of the main recess); and - on a second side of the given male part, the hollow zone of the second type Z2 (the hollow zone of the second type Z2 is defined between this male part and a second internal surface of the main recess).

[0265] Preferably, each given male part Myl, My2, My3, My4, My5 is arranged in a removable manner inside the main recess of the corresponding molding unit Ml, M2, M3, M4, M5.

[0266] This makes it possible to replace portions of the mold, for example, to meet a need for maintenance or development of the mold (for example to change a dimension or shape of the mold).

[0267] Each at least central hollow zone Z3 of a given molding unit M1, M2, M3, M4, M5 is at least partially defined by an external face of the male part My1, My2, My3, My4, My5 of the given molding unit M1, M2, M3, M4, M5 and possibly by an internal face of the main recess of the molding unit.

[0268] Preferably, each given male part Myl, My2, My3, My4, My5 is constituted by a plurality of plates, for example flat sheets, assembled to each other to form a hollow zone inside the male part.

[0269] Preferably, the hollow zone of a given male part is preferably completely closed to prevent, during the molding of the construction element, material from penetrating into the hollow zone of the male part.

[0270] The plates of the same male part can be assembled together by welding and / or screwing and / or assembly by tenons and mortises.

[0271] Preferably, as illustrated in Figures 4 to 7, each external female part of one of the given molding units M1, M2, M3, M4, M5 of the mold M is formed in a single-piece external part Mx surrounding all the molding units M1 to M5, the molding units being separated from each other by separation partitions Mxl, Mx2, Mx3, Mx4 arranged inside the single-piece external part Mx.

[0272] These separating partitions Mxl, Mx2, Mx3, Mx4 make it possible to delimit said main recesses of the molding units.

[0273] These partitions Mxl, Mx2, Mx3, Mx4 are preferably parallel to each other and are possibly removable from the external single-piece part Mx.

[0274] Each given partition wall forms a partition between two of said adjacent molding units of that given partition wall.

[0275] The single-piece part Mx may have internal grooves for guiding the partitions which are arranged so that each given separation partition has: - a first terminal end positioned / guided in one of the internal grooves; and - a second terminal end positioned / guided in another of the internal grooves.

[0276] Of course, the partition walls Mxl, Mx2, Mx3, Mx4 could also make integral part of the single-piece part Mx of the mold by being either directly machined in this single-piece part Mx or added by welding.

[0277] The invention is not limited to the examples described above and it encompasses any variant falling within the scope defined by the claims.

[0278] Thus, although the construction elements E illustrated here comprise only two external walls E1, E2, they could also comprise intermediate walls located between these external walls, these external and intermediate walls being parallel to each other.

[0279] In such a case, each connecting piece is then arranged to connect two or more of these walls together.

[0280] In such a case, the system for producing building elements would comprise at least as many hollow molding zones as there are walls to be formed and it would also comprise several central hollow zones to separate these hollow molding zones from each other.

[0281] Furthermore, depending on the penetration height of the ram into the mold, the final height of the construction element thus molded can be fixed.

[0282] Thus, specific stops can be used to define the maximum depth of penetration of the pins into the mold and thus fix the height of the construction elements produced.

[0283] The connecting pieces can take different shapes such as the X-shaped one illustrated in [Fig. 17] or any other shape adapted to the function of connecting between external walls.

Claims

Claims

1. Prefabricated building element (E) for the construction of a wall (1) comprising first and second external walls (El, E2) and a first mechanical connecting piece (11), the first and second external walls (El, E2) being spaced apart from each other and being rigidly connected to each other via said at least one first mechanical connecting piece (11), characterized in that the first external wall (El) is molded around a first part of the first connecting piece (11) and in that the second external wall (E2) is molded around a second part of the first connecting piece (11), the building element comprising a second mechanical connecting piece (12), the first and second external walls (El, E2) being rigidly connected to each other via the first and second mechanical connecting pieces (11, 12),the first external wall (El) being molded around a first part of the second connecting piece (12) and the second external wall (E2) being molded around a second part of the second connecting piece (12), characterized in that the first part of the first connecting piece (11) comprises studs (111), the second part of the first connecting piece also comprises studs (112), these first and second parts of the first connecting piece (11) being connected to each other by a central part of the first connecting piece which comprises a plate (113) which extends perpendicularly relative to a main face of the first wall (El) and relative to a main face of the second wall (E2); and in that - the first part of the second connecting piece (12) comprises studs, the second part of the second connecting piece also comprises studs,these first and second parts of the second connecting piece being connected to each other by a central part of the second connecting piece which comprises a plate, the plates of the first and second connecting pieces being parallel to each other, the pads of the first and second connecting pieces extending in longitudinal directions of these pads which are substantially perpendicular to a main plane of the plate (113) of the first connecting piece (11).,

2. Construction element (E) according to claim 1, 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.

3. Construction element (E) according to any one of claims 1 or 2, in which the second connecting piece has, at least between its first and second parts, a thermal conductivity which is strictly less than 0.5 W*m-1*K-1.

4. Construction element according to any one of claims 1 to 3, in which the first and second walls and the first and second mechanical connecting pieces define an internal volume (Ev) of the construction element (E) for receiving a thermal insulating material preferentially molded against internal faces of the first and second walls and against the first and second mechanical connecting pieces, this internal volume (Ev) forming a passage passing through the construction element (E) and opening onto a lower face (Fi) and onto an upper face (Fs) of the construction element (E).

5. Construction element according to claim 4, comprising a first longitudinal end face (F1) of the construction element and a second longitudinal end face (F2) of the construction element, the first end face (F1) being solid and partly constituted by the first mechanical connection part (11) and the second end face (F2) being solid and partly constituted by the second mechanical connection part (12).

6. Construction element according to any one of claims 1 to 5, having dimensions such that the construction element (E) can 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.

7. Construction element according to any one of claims 1 to 6, in which the first and second external walls (El, E2) have respective thermal conductivities greater than 0.7 W*m-1*K-1 and in which at least one thermally insulating material is placed between these first and second walls, this insulating material having a thermal conductivity less than 0.2 W*m-1*K-1, preferably less than 0.05 W*m-1*K-1.

8. A construction element according to claim 7, wherein the first and second external walls (E1, E2) are U-shaped profiles, the hollow parts of the U-shaped profiles being oriented towards the inside of the construction element, the studs (111, 112) of the first and second connecting pieces (11, 12) extending exclusively in lateral edges of said U-shaped profiles.

9. Construction element according to claim 8, in which each connecting piece (11, 12) connecting the first and second external walls together is equipped with at least one flat tongue (L1) having a free tongue end, the tongue being located at a distance from the first and second walls (El, E2) of the construction element and being parallel to a median plane of the construction element.

10. A building element according to any one of claims 1 to 9, wherein a layer of thermal insulating material molded (Eth) against the first and second outer walls (El, E2) extends between the first and second outer walls, this layer of insulating material (Eth) extending between an upper outer face (Fs) and a lower outer face (Fi) of the building element, a portion of the upper outer face (Fs) being defined by an upper surface of the layer of thermal insulating material (Eth) and a portion of the lower outer face (Fi) being defined by a lower surface of the layer of thermal insulating material (Eth).

11. Construction element according to claim 10, in which said layer of molded insulating material (Eth) is composed on the one hand of bulk material and on the other hand of a binder of this bulk material, this binder containing predominantly by mass a mineral material, this material being preferentially selected from cement, meta kaolin, clay.

12. A building element according to any one of claims 10 or 11, wherein the molded insulating material contains a material selected from wood, wood wool, hemp, hemp wool, flax, flax 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 or a mixture of these materials.

13. Wall (1) comprising several rows of construction elements (E) according to any one of claims 1 to 9, said rows being superimposed on each other and each row being formed from an alignment of several of said construction elements, the wall comprising a first external face formed with the first external walls of the construction elements and comprising a second external face formed with the second external walls of the construction elements, each construction element of a given row being connected to at least one other adjacent construction element belonging to at least one other adjacent row by means of an assembly binder / adhesive binder.

14. Wall (1) according to claim 13 having an internal volume (Ev) delimited on one side by all the first external walls (El) of said construction elements of the wall and on the other side by all the second external walls (E2) of said construction elements of the wall, this internal volume (Ev) being filled with a single continuous block of thermal insulating material (Eth) molded against all the first and second external walls of all the construction elements of the wall (1).

15. A method of manufacturing a prefabricated wall using construction elements according to any one of claims 1 to 9, comprising: - manufacturing in a factory a prefabricated wall (1) comprising several rows of construction elements, said rows being superimposed on each other and each row being formed by an alignment of several of said construction elements (E), each given construction element of a given row being connected to at least one construction element of an adjacent row of the given row by means of an assembly binder / adhesive binder, the prefabricated wall (1) having an internal volume (Ev) 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;- filling said internal volume (Ev) of the wall with a thermal insulating material so as to form a single block of thermal insulating material (Eth) molded against all the first and second external walls of all the construction elements of the wall.;

16. A method of manufacturing a prefabricated wall according to claim 15, in which the filling of said internal volume (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 said internal volume (Ev) of the wall and passing through one of the walls of one of the prefabricated construction elements or through a shutter (4) providing a seal between a lower part of the internal volume (Ev) of the wall and a zone external to the wall.

17. A method of manufacturing a prefabricated wall according to claim 16, wherein after filling said internal volume (Ev) of the wall with the thermal insulating material (Eth) said injection pipe (3) is detached from the wall.

18. A method of manufacturing a prefabricated wall according to any one of claims 15 to 17, 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 said internal volume of the wall with a thermal insulating material (Eth) being carried out by first positioning said bulk material in said internal volume of the wall (Ev) and then injecting said binder of this bulk material while it is in an uncrosslinked state, the binder of this material being crosslinked in said internal volume (Ev) to bind the bulk material therein and thus form said block of insulating material (Eth).

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