Thermal insulation process for building blocks.

Abstract

A method for the thermal insulation of building blocks (3), each block (3) having upper (Fs) and lower (Fi) faces and at least one internal recess (31) opening onto said lower face (Fi) and said upper face (Fs), the method comprising introducing a material into at least some of the internal recesses (31) of the building blocks (3) to form masses (M) of thermally insulating material, each mass (M) being molded and solidified in one of said internal recesses (31), the method comprising stacking several layers (C1, C2, Cn) of building blocks on a transportable support (1) to constitute a transportable stack (2). The layers (C1, C2, Cn) of the stack (2) are separated from each other by separators (4), each mass (M) being molded against at least one of said separators (4). FIGURE IN ABRIDGED DIAGRAM: Fig. 1K

Description

Title of the invention: Method for thermal insulation of building blocks.

[0001] The present invention relates to the field of manufacturing insulated building blocks.

[0002] BACKGROUND OF THE INVENTION

[0003] It is known in the field of building construction to use building blocks to build walls.

[0004] Each wall is made up of several rows of building blocks, these rows being superimposed on each other and the building blocks of adjacent rows of the wall being bound together with glue or masonry mortar.

[0005] In order to improve the thermal insulation characteristics, some building blocks are provided with at least one internal recess in which there is a mass of thermal insulating material, these are then referred to as insulated building blocks.

[0006] The thermal insulation mass is either introduced into the building block during the manufacture of the building block, for example by inserting into the recess, a solid block of insulation preformed to the dimensions of the recess.

[0007] This solution is advantageous because the wall is directly assembled using insulated building blocks, which facilitates the organization of the masonry site.

[0008] A disadvantage of this solution is that it induces an additional production cost of the isolated building blocks.

[0009] It is also possible to insert the thermal insulation into the internal recesses of the building blocks after they have been assembled to form the wall.

[0010] This solution complicates the construction of the wall since it is necessary to manage the introduction of the insulation not in the building block production plant but on the building construction site.

[0011] A qualified workforce must be specifically trained for the implementation of insulation on site.

[0012] SUBJECT OF THE INVENTION

[0013] An object of the present invention is to provide isolated building blocks solving all or part of the drawbacks of the prior art. Summary of the invention

[0014] To this end, according to a first aspect of the invention, a method is proposed for thermally insulating building blocks, each building block having an upper face, a lower face and at least one recess internal to the building block which opens onto said lower face of the building block and onto said upper face of the building block, the method comprising introducing a material into at least some of the internal recesses of the building blocks to form masses of thermal insulating material, each mass of thermal insulating material being molded and solidified in one of said internal recesses of the building blocks which corresponds to it, the method comprising superimposing on a transportable support several layers of building blocks to constitute a transportable stack of building blocks.

[0015] The method for thermally insulating building blocks according to the first aspect of the invention is essentially characterized in that the layers of building blocks of the stack are separated from each other by separators, each of the masses of thermal insulating material being molded against at least one of said separators.

[0016] Thanks to the invention, the solidification of the masses of thermal insulating material occurs directly against the separators placed between the layers of building blocks which form the stack of blocks while this stack is carried by the transportable support.

[0017] As a result, the solidification of the masses of insulating material occurs, in the stack, after the transportable stack of blocks has been formed.

[0018] In a conventional production line, the stacking of building blocks is carried out with already insulated building blocks, i.e. after complete solidification of the masses of insulating material in the blocks.

[0019] With the method according to the invention the stack of blocks can be transported and stored while the masses of insulating material have not yet solidified.

[0020] Thus, the solidification of the thermal insulation masses can be done in a hidden time directly at the storage location of the stacks of blocks.

[0021] Thanks to the invention, the storage area for blocks awaiting solidification of the masses is located downstream of the last station of the production line, that is to say downstream of the station where the stacks of blocks are formed.

[0022] Thus the blocks waiting for solidification of masses do not clutter the production line.

[0023] The invention allows a significant saving of space in the block production plant since the insulation of the blocks ends in a specific storage area, downstream of the last station of the production line.

[0024] The invention also makes it possible to increase the production capacity in isolated blocks of a given factory since the filling operations can be carried out, if necessary, outside the block production factory.

[0025] The solidification of the masses of insulating material can be done in a less expensive storage area, outside the area where the production line is located, if necessary. necessary outside the factory.

[0026] It should be noted that the invention also makes it possible to eliminate a step consisting of stacking building blocks that are already thermally insulated (by insulated block, we mean a block whose mass of insulating material is solidified) which limits the risks of degradation of the insulated blocks during a stacking operation.

[0027] As a result, the method of thermal insulation of blocks according to the invention provides a qualitative advantage to the insulated blocks thus produced.

[0028] These various advantages contribute to limiting the production cost of isolated building blocks.

[0029] According to another aspect, the invention relates to an assembly comprising a transportable support carrying a stack of insulated building blocks, the stack comprising several layers of insulated building blocks, each insulated building block having an upper face, a lower face and at least one recess internal to the building block which opens onto said lower face of the building block and onto said upper face of the building block, a mass of thermal insulating material being molded and solidified in said internal recess of the building block.

[0030] The assembly according to the invention is essentially characterized in that the layers of building blocks of the stack are separated from each other by separators, each of the masses of thermal insulating material being molded against at least one of said separators.

[0031] In other words, each given mass of insulating material is molded against at least one of the separators which is used to separate two layers of the stack from each other and which is in contact with the block in which the given mass is molded.

[0032] The assembly according to the invention can be stored in a specific storage area where the masses of thermal insulating material contained in the different blocks of the stack can solidify, this storage area being located downstream of the block production line.

[0033] The cost price of an isolated block from the assembly according to the invention is also minimized because the isolated blocks belonging to this assembly do not have to be stored in buffer stocks (block steaming stocks) of the production line before being stacked. Brief description of the drawings

[0034] 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:

[0035] [Fig.lA] [Fig.lA] shows a perspective view of a transportable support 1 used for implementing the method according to the invention and used in the assembly 0 according to the invention, this transportable support 1 here being a handling pallet0;

[0036] [Fig.lB] [Fig.lB] illustrates the transportable support 1 of [Fig.lA] on which is positioned a lower plate 40 intended to carry the stack 2 of layers C1, C2, Cn of blocks 3, in this case this lower plate 40 is intended to receive in support the lower layer C1 of building blocks of the stack 2 to close a lower side of the recesses 31 of these blocks 3 of the lower layer C1 to be able to mold in recesses of the lower layer C1 masses of thermal insulation M respectively molded against the lower plate 40;

[0037] [Fig.lC] [Fig.lC] illustrates the transportable support 1 and the lower plate 40 of [Fig.lB] as well as the lower layer of non-insulated blocks (it can be seen that the blocks of the lower layer have their respective lower faces Fi in contact against the upper face of the lower plate 40 to provide a seal against the lower faces Fi of the building blocks, which makes it possible to close the sides of the internal recesses 31 of the blocks which open towards this lower plate 40), this [Fig.lC] also shows a perspective view of a non-insulated building block with its internal recess 31 opening onto the lower faces Fi and upper faces Fs of the block 3;

[0038] [Fig.lD] [Fig.lD] illustrates a step in which an insulating material injection mechanism 50 introduces a material into the internal recesses 31 of the blocks of the lower layer C1 of blocks of [Fig.lC], this material being molded into the internal recesses 31 of the blocks into which it is introduced and against the lower plate 40 which is in sealing contact against the lower faces Fi of these blocks 3 of the lower layer C1, this molded material, once solidified in the recesses, will form a mass M of thermal insulating material in each internal recess 31 where it is introduced / molded;

[0039] [Fig.lE] [Fig.lE] illustrates the moment when, after introduction of the material into the recesses 31 of the blocks 3 of the lower layer C1, a plate-shaped separator 4 (but which could be in the form of a film preferably tensioned so that it extends along a plane) is about to be positioned against an upper face of this layer of blocks C1, in other words against the upper faces Fs of the blocks 3 of the layer C1, to close an upper side of the internal recesses 31 of these blocks, this separator 4 has the function of separating two adjacent layers of blocks from the stack 2 of blocks while making it possible to mold the masses M of insulating material present in the recesses against the separator 4;

[0040] [Fig.lF] [Fig.lF] illustrates a step of the method according to the invention in which the plate-shaped separator 4 (visible in [Fig.lE]) has been positioned in contact with the upper faces of the blocks of a layer of blocks C1 of the stack (this separator prevents insulating material from escaping from the internal recesses of these blocks of the stack). layer Cl);

[0041] [Fig.lG] [Fig.lG] illustrates a step of the method according to the invention in which, the separator 4 which is wedged between the first layer C1 of blocks of the stack 2 (lower layer C1 of the stack) and the new layer C2 of blocks (in this case a second layer C2 of the stack) closes a lower side of the internal recesses of the new layer C2, the injection mechanism 50 introduces the material into the internal recesses of the new layer C2 to mold masses M of insulating material against this separator 4 (the material of the lower plate 40 and of the separators 4 is chosen so that, under the sole weight of a given building block, there is a sealed contact between the lower face Fi of this block and the lower plate 40 or the separator 4, this sealed contact opposing the passage of the insulating material between the given block 4 and the plate 40 or the separator 4);

[0042] [Fig.lH] [Fig.lH] illustrates a step of the method according to the invention immediately after the step of [Fig.lG], in which the plate-shaped separator 4 has been positioned in contact with the upper faces Fs of the blocks of the second layer C2 of blocks of the stack 2 in order to oppose the exit of insulating material from the internal recesses 31 of these blocks of the second layer C2, pending the addition of a third layer C3 to this stack 2;

[0043] [Fig.II] [Fig.II] illustrates the stack of six layers C1, C2, C3, Cn of building blocks identical to each other, a separator 4 being positioned between all pairs of adjacent layers of the stack 2 to close the lower sides of the internal recesses 31 of these blocks which open onto the lower faces Fi of these blocks, the recesses 31 of all blocks of all the layers of the stack containing the material, only the recesses of the upper layer Cn, that is to say the highest layer of the stack, being still free of insulating material;

[0044] [Fig.U] [Fig.U] illustrates a step of the method according to the invention subsequent to that of [Fig.II], in which a separator 4, also called upper plate, has been positioned on the upper faces Fs of the blocks of the upper layer Cn of the stack 2, after filling the recesses of this upper layer Cn with the material, this [Fig.U] illustrates an assembly 0 according to the invention while the blocks of the stack 2 all contain a material intended to form masses of insulation M molded against the separators 4 respectively placed between adjacent layers of the stack 2;

[0045] [Fig.lK] [Fig.lK] illustrates the assembly 0 according to the invention with the isolated blocks 3 and their solidified masses M of insulating material, these isolated blocks being obtained by implementing the method according to the invention, here the assembly 0 has been transported to the place of use of the building blocks and the upper separator 4 (upper plate) located at the top of the stack is being removed to be able to extract the isolated building blocks, a detailed isolated building block is also shown in perspective;

[0046] [Fig.2] [Fig.2] illustrates an exploded view of an isolated building block obtained in implementing the method according to the invention, that is to say a block of set 0 according to the invention. DETAILED DESCRIPTION OF THE INVENTION

[0047] The assembly 0 according to the invention as illustrated in Figures 1J and 1K comprises: - a transportable support 1 carrying a stack 2 of isolated building blocks 3; - stack 2 comprises several layers Cl, C2, C3, Cn of isolated building blocks 3, each layer Cl, C2, C3, Cn comprising several building blocks 3.

[0048] Each isolated building block 3 (by isolated, we mean thermally insulated, and containing a solidified mass M) of the assembly 0 according to the invention comprises: - an upper face Fs; - a lower face Fi; - at least one internal recess 31 in the building block 3 which opens only onto said lower face Fi of the building block 3 and onto said upper face Fs of the building block 3; and - a mass M of thermal insulating material which is molded against surfaces of this internal recess 31 and which is solidified in said internal recess 31 of the building block.

[0049] In other words, each building block 3 comprises at least one internal recess 31 which opens onto only two faces of the block, in this case on one side onto said upper face Fs of the block and on the other side onto said lower face Fi of the block, the molded mass M in the block matching the internal surfaces of the internal recess going to the limit of the upper face Fs and lower face Fi. At least one separator 4 or a lower plate 40 being adjacent to the block is in leaktight support against the lower face Fi, the mass M contained in the block being molded against this separator 4 or this lower plate 40.

[0050] The assembly 0 may also comprise a lower plate 40 interposed between an upper face of the transportable support 1 and a lower face of the stack 2.

[0051] The masses of the blocks of the lower layer C1 of the stack 2 are respectively molded against this lower plate 40.

[0052] It should be noted that such a lower plate 40 may be optional in the case where the upper face of the support 1 is itself flat and continuous over the entire lower layer of the stack 2 to allow the molding of the masses M of the in- lower Cl directly against the upper face of the support 1.

[0053] As understood from the building blocks detailed in figures IC (non-isolated block), 1K (isolated block) and 2 (exploded view of an isolated block), the building blocks 3 of the stack 2 are geometrically identical to each other and are of rectangular parallelepiped shape.

[0054] The lower faces Fi and / or the upper faces Fs of the blocks are preferably ground so that the lower and upper faces of each given block are flat and parallel to each other.

[0055] To limit the heat flows through the building blocks, each building block comprises first and second planes P1, P2 parallel to each other and first and second transverse walls P3, P4, the first and second transverse walls P3, P4 forming longitudinal end faces of the block.

[0056] Each of these first and second transverse walls P3, P4 preferably comprises first and second portions connected to each other by a thermal breaker P5, P6 comprising a polymer material, possibly made of a composite material combining fibers, such as glass fibers, and a binder of these fibers made of polymer material.

[0057] The polymer used in the thermal breaks P5, P6 of the first and second transverse walls P3, P4 is useful for minimizing thermal conduction via the transverse walls P3, P4.

[0058] The recess 31 of the block is thus partly delimited by the thermal breakers P5, P6.

[0059] Consequently each mass M is partly molded against the breakers P5, P6.

[0060] The thermal breaker P5 of the first transverse wall P3 extends between the first and second portions of the first transverse wall P3 so as to assemble them together while keeping them distant from each other, the thermal breaker P5 of the first transverse wall P3 occupying a free space between these first and second portions of the first transverse wall P3.

[0061] Similarly, the thermal breaker P6 of the second transverse wall P4 extends between the first and second portions of the second transverse wall P4 so as to assemble them together while keeping them distant from each other, the thermal breaker P6 of the second transverse wall P4 occupying a free space between these first and second portions of the second transverse wall P4.

[0062] The first and second transverse walls P3, P4 form connecting interfaces each integrating a thermal breaker and making it possible to keep the first and second plates PI, P2 parallel to each other and distant from each other.

[0063] Said internal recess 31 of the block 3 is delimited at its periphery by the first and second planes PI, P2 which face each other and by the first and second transverse walls- versales P3, P4 which also face each other.

[0064] The planes PI, P2 have main flat faces oriented towards the outside of the block 3.

[0065] These main flat faces of the planes are full and parallel to each other.

[0066] Similarly, the first and second transverse walls have main faces oriented towards the outside of the block 3, these main faces being solid and parallel to each other.

[0067] The slabs PI, P2 are made at least partly of concrete or fiber-reinforced concrete (for example with plant or mineral fibers such as fiberglass or polymer fibers or metal fibers) or of terracotta or cellular concrete, these materials having the advantage of being able to withstand significant compressive forces applied to the block 3 in directions parallel to the main flat faces of the slabs PI, P2.

[0068] When observed in a direction perpendicular to the upper face Fs of the block, the block includes: - a first longitudinal end of the block having a profile comprising at least one male tongue and at least one female groove; and - a second longitudinal end of the block having a profile comprising at least one male tongue and at least one female groove.

[0069] These profiles of the first and second longitudinal ends of the block are geometrically complementary.

[0070] Thus, when two identical blocks are aligned on the same row of blocks of a construction, their geometrically complementary profiles allow a tongue of one of these blocks to fit into the groove of the other of these blocks and vice versa.

[0071] This characteristic of geometrically complementary profiles is useful for facilitating the alignment of the blocks following a construction direction of the row while reinforcing the masonry structure thus constructed.

[0072] In the embodiment illustrated in Figures IC, 1K and 2, the first portion of the first transverse wall P3 is an outgrowth of the first plane PL

[0073] Similarly, the first portion of the second transverse wall P4 is an outgrowth of the first plane PL

[0074] The second portion of the first transverse wall P3 is an outgrowth of the second plane P2.

[0075] The second portion of the second transverse wall P4 is an outgrowth of the second plane P2.

[0076] Thus, the first plane PI, the first portion of the first transverse wall P3 and the first portion of the second transverse wall P4 belong to the same one-piece molded part.

[0077] This molded single-piece part which comprises the first plane PI, when observed from a direction perpendicular to the upper face Fs of the block 3 has a U shape, a part of the recess 31 being in the U shape.

[0078] Similarly, the second plate P2, the second portion of the first transverse wall P3 and the second portion of the second transverse wall P4 belong to the same molded single-piece part.

[0079] This molded single-piece part which includes the second plane P2, when observed from a direction perpendicular to the upper face Fs of the block 3 has a U shape, a part of the recess 31 being in the U shape.

[0080] These U-shaped single-piece parts are connected to each other by thermal breakers P5, P6.

[0081] To this end, each of these single-piece parts is molded around protrusions of these thermal breaks P5, P6 to create rigid assemblies between single-piece parts.

[0082] Preferably, the dimensions of a building block 3 are such that it can extend entirely within a maximum parallelepiped volume of length 600 mm, height 450 mm and thickness 450 mm.

[0083] The building block 3, the recess 31 of which contains a mass M of thermally insulating material, has a unit mass preferably less than 30 kg to be transportable manually.

[0084] The planes PI, P2 of the building block 3 have respective thermal conductivities XI, X2 which can be respectively greater than 0.7 W*m-1*K-1.

[0085] The mass M of thermal insulating material solidified in the recess 31 of a block 3 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 layers C1, C2, Cn of building blocks 3 of the stack 2 of the set 0 according to the invention are separated from each other by separators 4.

[0087] Each of said masses M of thermal insulating material is molded against at least one of said separators 4.

[0088] In this case, each of the masses M is molded at least against a separator 4 which is adjacent to it and which is located under the mass M.

[0089] In some cases, it is also possible that each mass M is molded against a second separator which is adjacent to the mass M and which is located above this mass M.

[0090] The molding of the masses M of thermal insulating material of several layers C1, C2, Cn against the separators 4 makes it possible to simplify the molding operations of the masses M since these masses M are directly molded and solidified while the blocks 3 are in stack 2 carried / supported by transportable support 1.

[0091] This makes it possible to limit the production cost of the building blocks 3 while making it possible to store these blocks 3 in the form of a stack 2 even before the masses M have solidified.

[0092] This optimizes the storage space in the production line by allowing the blocks to be stored in stacked form even though their masses M have not yet solidified.

[0093] The solidification / drying time of the insulating material is therefore not a penalty in the production process since the solidification takes place in hidden time in a stock, downstream of the station where the stacking is carried out, while retaining the possibility of transporting this stack.

[0094] The assembly 0 according to the invention is also advantageous because adhesion forces between the molded masses M and the separators 4 are created which generates, via the separators 4, mechanical connections between the isolated blocks of the stack.

[0095] The stability of the assembly 0 is thus improved, which facilitates its transport by reducing the relative movements between the blocks in the stack.

[0096] Each separator 4 arranged between two adjacent layers C1, C2 of blocks of the stack 2 extends on one side against the entirety of an upper side of one of the adjacent layers and against the entirety of a lower side of the other of the adjacent layers, each separator having the form of a film or preferably of a plate.

[0097] The use of a plate 4 rather than a film is preferable because the geometric tolerances of the surfaces molded against a plate are generally more precise than if these surfaces were molded against a film which is more deformable than a plate.

[0098] In a preferred embodiment, it is ensured that each mass M of solidified thermal insulating material contains, predominantly by mass, a mineral material selected from cement, meta kaolin, clay, the thermal insulating material preferably being in the form of a foam containing cells of dimensions infra centimeters, preferably infra millimeters, these cells containing a gaseous fluid.

[0099] Preferably, this thermal insulating material contains an insulating mineral foam, for example of the type of foam sold under the brand name AIRIUM ® or under the brand name AIRCIMAT ®.

[0100] By insulating mineral foam is meant a mineral foam with its own thermal conductivity of less than 0.05 W*m-1*K-1.

[0101] The mass of thermal insulating material may optionally contain bulk material in the form of fibers and / or particles, this bulk material being agglomerated in a binder, said fibers and / or particles preferably being a material bio-sourced as a plant material.

[0102] This binder of the fibers and / or particles is for example said mineral material, selected from cement, meta kaolin, clay possibly in the form of a foam.

[0103] This type of thermal insulation has the advantage of being introduced in the form of viscous foam into the recesses and of quickly generating a rigid insulating mass which is structurally resistant and improves the fire resistance of the insulated block.

[0104] Preferably, the bulk material is selected from wood, wood wool, miscanthus, hemp, hemp wool, hemp shiv, flax, flax wool, cork, recycled textiles, sheep wool, feather, coconut wool, straw, hemp shiv, cotton, cotton wool, bamboo, cellulose, cellulose wadding, mineral fibers such as 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 (for example thermoplastic polymers), synthetic textiles or a mixture of some of these materials.

[0105] In all cases, the mass M of thermal insulating material 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.

[0106] The transportable support 1 on which the stack 2 is formed comprises lower supports arranged to come into contact against a ground plane and an upper face of the transportable support 1 arranged to carry the stack 2 by raising the stack to a fixed minimum distance from a support plane defined by said supports (When the supports are on the ground plane, the fixed minimum distance between the support plane and the stack is equal to the minimum distance between the ground plane and the stack).

[0107] This transportable support 1 is arranged to allow handling means to extend between the support plane and the upper face of the transportable support 1 in order to be able to lift the transportable support 1 with the stack 2.

[0108] Thus, the transportable support 1 allows the load of the stack to be taken up such that the stack 2 can either be placed on the ground, the transportable support 1 maintaining the stack 2 at a minimum distance from the ground plane, or placed on a handling means passing through the transportable support 1 between the support plane and the stack 2.

[0109] The transportable support 1 is a support having a mass less than 30 kg, preferably less than 25 kg and adapted to carry on its own a stack 2 of layers of blocks with a maximum total stacking mass greater than 300 kg and less than 1500 kg.

[0110] The transportable support 1 has four lateral sides forming a rectangular parallelogram and comprising first and second pairs of passages fork there, 1b.

[0111] Each pair of fork passages 1a, 1b allows the passage of a lifting fork of a handling means (forklift or pallet truck) to lift the support 1 with the stack 2 carried by the transportable support.

[0112] The lifting fork having two parallel arms spaced apart from each other by a distance such that one of these arms can extend into one of the fork passages of one of the pairs of passages 1a while the other of these arms extends into the other of the fork passages of this same pair of passages 1a.

[0113] Typically, the transportable support 1 may be a pallet, preferably a pallet conforming to the UNE-EN 13698-1 standard, i.e. a European EPAL standard pallet.

[0114] Thus, a transportable stack 2 is a stack entirely carried and formed on a transportable support 1 and having a maximum total mass of less than 1500 kg.

[0115] The stack 2 of layers of building blocks comprises at least two layers C1, C2 of blocks, preferably at least three layers C1, C2, C3, preferably less than 10 layers, the maximum total mass of the stack 2.

[0116] The number of building blocks of each layer of blocks C1, C2, C3, Cn is preferably between 6 and 12 building blocks.

[0117] In the present case, the stack comprises 6 layers of blocks, each layer comprising 10 building blocks distributed over two rows of five blocks.

[0118] The building blocks belonging to a given layer are arranged in the given layer in the form of rows of building blocks.

[0119] The building blocks of the same rank of the given layer are placed against each other with their planes PI, P2 parallel to each other.

[0120] The building blocks 3 belonging to a given layer C1, C2, Cn are oriented in length following a common direction of orientation of the blocks which is specific to the given layer.

[0121] The common direction of orientation of the blocks of a given layer is perpendicular to a common direction of orientation of the blocks of the layer adjacent to the given layer.

[0122] By having block orientation directions in adjacent layers that are perpendicular to each other, crossings are created between the blocks of the different layers which promote the cohesion of the stack by limiting the relative movements between the layers of the stack.

[0123] The stacking thus produced makes it possible to preserve the integrity of the masses of thermal insulating material since these masses are protected by the separators arranged between the layers.

[0124] Therefore, this stack is easy to transport to the place of use. blocks where these blocks are used to build masonry assemblies such as building walls.

[0125] The protection of the masses M of insulating material by the separators 4 makes it possible, throughout the transport of the stack 2, to preserve the geometry of the upper and lower faces of the masses.

[0126] Preserving the geometry of the masses M is favorable to an improvement in the thermal insulation of the masonry assembly which will be constructed with the insulated blocks according to the invention.

[0127] Indeed, any degradation of the geometry of the masses can generate, at the interface between the building blocks, thermal leaks through the masonry assembly.

[0128] In this sense, the insulated blocks obtained by implementing the method of the invention allow an improvement in the thermal quality of the masonry assembly made with these blocks.

[0129] Preferably, the separators 4 and the transportable support 1 are designed to be reusable to form other stacks of layers of isolated building blocks. To promote the reuse of the separators 4 and the transportable support 1, these can be returned.

[0130] Preferably, all the blocks of a given layer of the stack are brought together on the stack using a robotic mechanism.

[0131] To this end, the robotic mechanism comprises a gripper capable of clamping all the blocks of the same layer against each other in order to lift the layers of blocks to be isolated one after the other to form the stack of layers.

[0132] The robotic mechanism is preferably arranged to position the separator 4 on the layer of blocks of the stack whose recesses 31 have been filled with the material intended to form the masses M.

[0133] The robotic mechanism is also arranged to grip the separators one by one so that adjacent layers of the stack are separated from each other by at least one separator positioned by the robotic mechanism.

[0134] Typically, the blocks to be isolated may arrive in the form of stacks of non-insulated blocks, each layer of the stack of non-insulated blocks being taken by the robotic mechanism and moved to be positioned on the stack 2 carried by the transportable support 1 while being above and in contact with a separator 4.

[0135] Preferably, the introduction of the material into the recesses of the blocks of a given layer of the stack is carried out by an injection mechanism 50 having a reserve R of material to be injected fluidically connected to one or more nozzles 501.

[0136] Depending on the case, the injection mechanism 50: - has several nozzles 501 arranged to simultaneously introduce the material in the recesses 31 of several of the blocks of the given layer; or - has a single nozzle arranged to introduce the material into the recesses 31 by being successively moved from one recess 31 to another.

[0137] In the present case, as illustrated in Figures 1D and 1G, the injection mechanism 50 has a reserve R fluidly connected to several nozzles 501 arranged to simultaneously inject the material into all the internal recesses 31 of the blocks 3 of the current upper layer of the stack 2.

[0138] To allow the injection of material, the nozzles 501 can be orientable according to the current orientation of the blocks of the current upper layer of the stack whose blocks are to be isolated.

[0139] Alternatively, a pivoting conveyor supporting the transportable support 1 can be used to orient the transportable support 1 and the stack 2 so that the nozzles 501 are respectively placed opposite the recesses 31 of the blocks to be isolated from the current upper layer of the stack.

[0140] The injection mechanism is preferably vertically movable to adjust the vertical position of the nozzles 501 according to the current height of the stack.

[0141] According to another aspect, the invention relates to said method of thermal insulation of said building blocks 3.

[0142] This method comprises the superposition on a transportable support 1 of several layers C1, C2, C3, Cn of building blocks to constitute the transportable stack 2 of building blocks 3, these layers C1, C2, C3, Cn of building blocks 3 of the stack 2 are separated two by two from each other by said separators 4.

[0143] This method also comprises the introduction of said material into at least some of the internal recesses 31 of the building blocks 3 to form therein masses M of thermal insulating material, each mass M of thermal insulating material being molded and solidified in one of said internal recesses 31 of the building blocks which corresponds to it and also being molded against at least one of said separators 4.

[0144] As understood from Figures 1A to 1J which show the succession of steps implemented in accordance with the method according to the invention.

[0145] According to this method, the layers of the stack are positioned one after the other so that all the blocks of each given layer are positioned in abutment against the same given separator 4 adjacent to the given layer, the lower sides of the recesses 31 of the blocks of this given layer opening towards this given separator 4.

[0146] After positioning each given layer of the stack against a given separator adjacent to it, the method comprises introducing the material into the internal recesses 31 of the blocks 3 of this given layer so that this material is on the one hand molded into these recesses 31 of the given layer and on the other hand molded against the adjacent given separator 4 which carries this given layer.

[0147] These operations are repeated for each layer of blocks in the stack by positioning a separator on a previously formed layer of the stack, then forming a new layer of the stack and introducing the material into the recesses of this new layer of the stack.

[0148] Thus, each separator 4 is located between two successive layers of the stack which are adjacent to it.

[0149] One face of the separator closes an upper side of the internal recesses 31 of the blocks 3 of the layer adjacent to the separator C1 and another face of the separator 4 closes or is intended to close a lower side of the internal recesses 31 of the blocks 3 of the layer of blocks C2 which is supported above the separator 4.

[0150] It is conceivable that this separator 4 is deformable in the direction of its thickness to provide a sealed support against all the lower and upper faces of the blocks which are in support against this separator. This sealed support makes it possible to maintain the insulating material in hermetic recesses 31 of the blocks even when these blocks have slightly different heights. The deformation of a given separator according to its thickness is preferably such that it is less than 2 mm under the effect of the weight of a single isolated block.

[0151] Here, each separator 4 arranged between two adjacent layers of blocks 3 of the stack 2 extends on one side against the entirety of an upper side of one of the adjacent layers C1 and against the entirety of a lower side of the other of the adjacent layers C2.

[0152] Thanks to the method according to the invention, as indicated above, the solidification of the masses of thermal insulating material occurs directly in the stack and against the separators placed between the layers of the stack.

[0153] The material constituting the separators 4 is chosen to provide an adhesion capacity between the separators and the masses M of thermal insulating material such that - each mass of insulating material solidified and molded against a separator can be detached / detached from the separator, while preserving the integrity of the mass and the separator, by simply applying a force to separate the mass from the separator; and / or such that - each separator 4 is peelable relative to a mass M of thermal insulating material molded against this separator (thus the separator is peelable relative to the layer of building blocks which supports it).

[0154] As an example, [Fig. 1K] shows a separator 4 against which the masses M of a layer of isolated blocks Cn have been molded, this separator being detached from these masses M and removed to release the isolated blocks.

[0155] To facilitate the detachment of the masses molded against the separators, each separator comprises main faces respectively in contact with layers adjacent to the separator 4, each main face being made of a polymer material chosen for example from a polyethylene, an epoxy polymer, a phenolic polymer, a polyester, a vinyl ester polymer VE, a urethane polymer, a polyimide, a polyamide PA, a polypropylene, a polytetrafluoroethylene PTFE, a polysiloxane (i.e. a silicone).

[0156] This choice of materials reduces the risk of degradation of the separators or masses of insulating material when the building blocks are removed.

[0157] Preferably, each given mass M of thermal insulating material is: - on a lower side of the given mass M, molded against a separator 4 placed below the given mass; and - on an upper side of the given mass, molded against a separator placed above the given mass.

[0158] The material introduced into the internal recesses 31 thus occupies the entirety of the internal recess 31 going from the lower face Fi to the upper face Fs of the building block in which said given mass M is molded.

[0159] Preferably, the introduction of said material into the internal recesses 31 of the building blocks is carried out only in blocks carried by said transportable support 1.

[0160] Although it is possible for the material intended to form the insulating masses to be introduced into the recesses 31 of a layer of blocks carried by a separator 4, before this layer is positioned above the transportable support 1 and forms part of the stack, it is preferable for the material to be introduced into the recesses 31 while these blocks are already carried by the transportable support 1, that is to say while these blocks form an upper layer of the stack 2.

[0161] This limits the risk of the material spilling.

[0162] The invention is not limited to the examples described above and it encompasses any variant falling within the scope defined by the claims.

[0163] In particular, it is possible that the material introduced into at least some of the internal recesses of the building blocks to form masses of thermal insulating material is an expansive material which, in its expanded state, constitutes the solidified thermal insulating material. For example, such an expansive material could be a polymeric material such as expanding polyurethane foam.

[0164] Such an expansive material can, for example, be introduced into the recesses in liquid, foam, gel or paste form, to form there, after expansion and solidification, the masses of insulating material.

Claims

Claims

1. A method of thermally insulating building blocks (3), each building block (3) having an upper face (Fs), a lower face (Fi) and at least one internal recess (31) in the building block (3) which opens onto said lower face (Fi) of the building block and onto said upper face (Fs) of the building block, the method comprising introducing a material into at least some of the internal recesses (31) of the building blocks (3) to form masses (M) of thermally insulating material, each mass (M) of thermally insulating material being molded and solidified in one of said internal recesses (31) of the building blocks which corresponds to it, the method comprising superimposing on a transportable support (1) several layers (Cl, C2, Cn) of building blocks to constitute a transportable stack (2) of building blocks (3), characterized in that the layers (Cl, C2,Cn) of building blocks (3) of the stack (2) are separated from each other by separators (4), each of the masses (M) of thermal insulating material being molded against at least one of said separators (4), the transportable support 1 is a handling pallet having four lateral sides forming a right-angled parallelogram and having first and second pairs of fork passages (la, 1b), each pair of fork passages (la, 1b) being arranged to allow the passage of a lifting fork of a handling means for lifting the support 1 with the stack (2) carried by the transportable support, the stack (2) being transported and stored while the masses of insulating material are not yet solidified.,

2. A method of thermally insulating building blocks according to claim 1, wherein each separator (4) disposed between two adjacent layers (Cl, C2) of building blocks (3) of the stack (2) extends on one side against the entirety of an upper side of one of the adjacent layers (Cl) and against the entirety of a lower side of the other of the adjacent layers (C2).

3. A method of thermally insulating building blocks according to claim 2, wherein each separator is in the form of a plate or film.

4. A method of thermally insulating building blocks according to claim 3, wherein each separator (4) has faces main faces respectively in contact with layers of building blocks adjacent to the separator, each main face being made of a polymer material chosen from a thermoplastic polymer, a thermosetting polymer, a polyethylene, an epoxy polymer, a phenolic polymer, a polyester, a vinyl ester polymer VE, a urethane polymer, a polyimide, a polyamide PA, a polypropylene, a polytetrafluoroethylene PTFE, a polysiloxane.

5. A method of thermally insulating building blocks according to claim 4, wherein each given mass (M) of thermally insulating material is: - on a lower side of the given mass, molded against a separator placed below the given mass; and - on an upper side of the given mass, molded against a separator placed above the given mass.

6. A method of thermally insulating building blocks according to any one of claims 1 to 5, wherein the introduction of said material into the internal recesses (31) of the building blocks is carried out only in blocks carried by said transportable support (1).

7. A method of thermally insulating building blocks according to any one of claims 1 to 6, wherein said material introduced into the internal recesses (31) occupies the entire internal recess from the lower face (Fi) to the upper face (Fs) of the building block in which said given mass (M) is molded.

8. A thermal insulation method according to any one of claims 1 to 7, wherein each solidified mass of thermal insulating material (M) contains a mineral material.

9. Thermal insulation method according to claim 8, wherein said mineral material of the masses of thermal insulating material (M) is selected from cement, meta kaolin, clay.

10. Thermal insulation method according to any one of claims 8 or 9, in which said thermal insulating material is in the form of a foam containing cells of dimensions infra centimeters, preferably infra millimeters, these cells containing a gaseous fluid.

11. A thermal insulation method according to any one of claims 1 to 10, wherein each mass of thermal insulating material (M) contains bulk material in the form of fibers and / or particles, this bulk material being agglomerated in a binder.

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