BUILDING PANEL FOR FLOOR OR WALL, METHOD FOR MANUFACTURING A PANEL AND CONSTRUCTION

Abstract

BUILDING PANEL FOR FLOOR OR WALL, METHOD FOR MANUFACTURING A PANEL AND CONSTRUCTION A building panel comprises a support (1) made of a mixture of concrete and wood and a reinforcement (2) made of reinforced concrete. The support (1) is a porous material with a mass content of wood particles of between 30 and 70%. The surface roughness of the support (1) is at least 5mm. The material of the reinforcement (2) penetrates into the surface cavities of the support (1) to a depth of between 5mm and 5cm to form a fixing interface between the support (1) and reinforcement (2) which extends over the entire longitudinal dimension (XX) of the reinforcement (2). A fixing plate (5) has one end embedded in the reinforcement (2) and one end mounted flush with a wall of the building panel projecting longitudinally from the reinforcement (2) to fix the building panel to an anchor point (6). Figure for the abstract: Figure 1

Description

Title of the invention: CONSTRUCTION PANEL FOR FLOOR OR WALL, METHOD FOR MANUFACTURING A PANEL AND CONSTRUCTION Technical field

[0001] The invention relates to a building panel intended to form at least part of a floor or a wall, a method of manufacturing such a building panel and such a construction. State of the art

[0002] For the manufacture of a building, there are different manufacturing methods and in particular the assembly of modular building blocks which are joined together and then fixed to form the structure of the building. It is known to produce building blocks in multiple materials. Pre-assembled building blocks allow the structure to be produced in better controlled conditions. The blocks are made well before assembly which allows a building to be manufactured more quickly because drying times are eliminated.

[0003] Prefabricated panels can be made of wood or metal, but they do not have the properties of concrete. In particular, wooden or metal building blocks have limited fire resistance. It also appears that these building blocks have improvable thermal comfort and lower mechanical stability than concrete. On the other hand, concrete building blocks are heavy, which complicates transport.

[0004] Document FR3036123 discloses a slab that is made from a mixture of concrete and wood. The wood is in the form of chips which are machining waste from a sawmill. The wood chips are mixed with concrete and the whole is poured to form a support defining grooves. The grooves form molds for reinforced concrete beams. The introduction of wood chips into the concrete to form a concrete-wood mixture makes it possible to reduce the density of the mixture and to improve the acoustic performance at the expense of the mechanical performance and in particular at the expense of a bending strength which is lower than its equivalent in concrete. The longitudinal ends of the slab are formed by the ends of the reinforced concrete beams so as to be secured to a reinforced concrete frame which requires pouring concrete at the last moment on site.The interest of this technical solution is limited because it requires fixing to another reinforced concrete structure.

[0005] Document FR3084092 discloses a slab which is made from a mixture of Concrete and wood. The wood is in the form of slabs. The concrete and wood support forms microcavities. The concrete is poured to form reinforced beams. The concrete penetrates the microcavities. The beams have a metal frame that is partially embedded in the concrete. Statement of the invention

[0006] An object of the invention is to overcome these drawbacks, and more particularly to provide a construction panel which has better mechanical cohesion and the forces of which are better distributed between the points of attachment to an anchor. The construction panel is compatible with dry anchoring.

[0007] These drawbacks tend to be resolved by means of a construction panel intended for the formation of a wall or a slab comprising at least one support piece and at least one reinforcement, in which: - the at least one support part is formed from a support material comprising a mineral binder and particles of a plant material embedded in the mineral binder; - the at least one reinforcement is fixed to the at least one support piece and has a bending strength greater than the bending strength of the at least one support piece, the at least one reinforcement being formed by a reinforcing material comprising a mineral binder and a metal reinforcement.

[0008] The construction panel is remarkable in that: - the support material is a porous material which has a first value of mass content of plant material particles of between 30 and 70%, the average length of the particles being between 10 and 100 mm; - the at least one support part has surface cavities defining a surface roughness at least equal to 5 mm and continuously envelops the at least one reinforcement in an observation of a section plane perpendicular to a thickness direction, the at least one support part defining at least two end walls arranged projecting from the at least one reinforcement and opposite in a longitudinal direction; - the reinforcing material penetrates into the surface cavities of the at least one support part to a depth of between 5mm and 5cm to form a fixing interface between the at least one support part and the at least one reinforcement which extends over the entire longitudinal dimension of the at least one reinforcement; - at least one fixing plate is arranged at one end of the at least one reinforcement and intended to fix the construction panel to an anchoring point, the at least one fixing plate having a first end embedded in the at least one reinforcement and another end covering one of the end walls in the direction of the thickness beyond at least one reinforcement in the longitudinal direction, the fixing plate being non-removable from the reinforcement.

[0009] According to one aspect of the invention, the at least one support part is porous through at least in the thickness direction.

[0010] Preferably, the at least one support part has a porosity value of between 30% and 70%.

[0011] Advantageously, the reinforcing material comprises particles of a plant material whose volume content is less than 20% or is free of particles of a plant material.

[0012] According to another aspect, the at least one reinforcement has a porosity of less than 15%.

[0013] Preferably, the support part comprises a core and a layer of re covering, the core being in contact with the side walls of the at least one reinforcement, the covering layer forming at least one main wall of the construction panel, said main wall being perpendicular to the thickness direction and in which the core and the covering layer are different compositions of the support material, the covering layer having a porosity lower than the porosity of the core.

[0014] Advantageously, the covering layer forms the end walls.

[0015] In a preferred development, the covering layer forms an end annular wall of the assembly formed by the at least one support piece and the at least one reinforcement in an observation along a section perpendicular to the thickness direction.

[0016] Advantageously, each fixing plate is free from contact with the main wall of the construction panel.

[0017] The invention also relates to a construction which is easy to produce while being sufficiently strong to form a wall or a slab using prefabricated construction panels.

[0018] This result is tended to be achieved by means of a construction comprising at least one construction panel according to any one of the preceding configurations, the at least one construction panel being fixed to at least two anchoring points by at least two connectors, the connectors being opposite in the longitudinal direction of the construction panel, the two connectors directly fixing one of the anchoring points to a fixing plate.

[0019] In a particular embodiment, the building panel forms a slab and / or a floor, the anchoring point being an edge wall. Alternatively, the building panel forms a wall, the anchoring point being a floor.

[0020] The invention also relates to a method which makes it possible to produce a construction panel which is more easily attached to anchors to form a construction. Such a result is achieved by means of a process which involves the following steps: - providing at least one support piece defining all or part of a mold, the mold forming at least one hole extending mainly in a longitudinal direction, the at least one support piece being formed in a support material comprising a mineral binder and particles of a plant material, the particles being embedded in the mineral binder, the support material being a porous material which has a first value of mass content of particles of plant material of between 30 and 70%, the average length of the particles being between 10 and 100mm, the support material being a porous material with opening cavities and defining a surface roughness at least equal to 5mm; - forming at least one reinforcement in the at least one hole, the at least one reinforcement extending mainly in the longitudinal direction, the at least one reinforcement being formed in a reinforcement material comprising a mineral binder, a metal reinforcement, the reinforcement material having a flexural strength greater than the flexural strength of the support material, the mineral binder being poured into the at least one hole so that the mineral binder is inserted into the opening cavities of the at least one support part, the at least one reinforcement having two opposite side walls in a transverse direction fixed to the at least one support part continuously in the longitudinal direction, a metal reinforcement being embedded in the mineral binder. Description of the drawings

[0021] Other advantages and characteristics will emerge more clearly from the following description of particular embodiments and implementations of the invention given as non-limiting examples and represented in the appended drawings, in which:

[0022] [Fig-1]: a schematic perspective view of a construction panel according to the invention; [Fig.2]: a schematic perspective view of a construction panel according to the invention with one end showing the reinforcement frame; [Fig.3]: a schematic perspective view of a construction panel according to [Fig.2] and whose support piece is a mixture of concrete and wooden plates; [Fig.4]: a schematic cross-sectional view of a construction panel according to the invention; [Fig.5]: a schematic cross-sectional view of a construction panel according to the invention according to another embodiment; [Fig.6]: a schematic front sectional view of a mold in a first stage of a method of manufacturing a construction panel; [Fig.7]: a schematic front sectional view of a second stage of a process for manufacturing a building panel, the mold being partially filled with support material; [Fig.8]: a schematic front sectional view of a third stage of a process for manufacturing a building panel, reservations being removed; [Fig.9]: a schematic front sectional view of a fourth step of a process for manufacturing a construction panel, reinforcements being formed; [Fig.10]: a schematic front sectional view of a fifth step of a process for manufacturing a construction panel, a covering layer being deposited; [Fig. 11]: a schematic front sectional view of a fifth step of a method of manufacturing a construction panel, a covering layer being deposited according to another embodiment; [Fig. 12]: a schematic view along a longitudinal section of the first stage of the manufacturing process; [Fig. 13]: a schematic view along a longitudinal section of the second stage of the manufacturing process; [Fig. 14]: a schematic view along a longitudinal section of the third stage of the manufacturing process with the installation of the fixing plates; [Fig. 15]: a schematic view along a longitudinal section of the fifth stage of the manufacturing process; [Fig. 16]: a schematic view along a longitudinal section of the fifth step of the manufacturing method in another embodiment; [Fig. 17]:, a schematic perspective view of a fixing plate; [Fig. 18]: a schematic perspective view of a construction. Detailed description

[0023] Figures 1 to 5 illustrate a building panel which is intended to form at least part of a wall or slab, for example a floor and / or a ceiling.

[0024] The construction panel has at least one support piece 1 and at least one reinforcement 2. The construction panel extends in a longitudinal direction XX and a transverse direction YY which are perpendicular to each other and perpendicular to a thickness direction ZZ. The at least one support piece 1 extends mainly in the longitudinal direction XX. The panel has a generally parallelepiped shape. Preferably, the construction panel has several reinforcements 2 which are offset from each other in the direction YY. There is an alternation, in the direction YY, between the reinforcements 2 and support pieces 1 or parts of a support part 1.

[0025] The support part 1 is made of a support material. The reinforcement 2 is made of a reinforcement material. The reinforcement 2 has a bending strength which is greater than the bending strength of the support part 1 in the ZZ direction. The reinforcement 2 is fixedly mounted to the support part 1 to improve the bending performance. The bending force is applied in the ZZ direction.

[0026] The support material is a mixture comprising a mineral binder and particles of a plant material. The plant material may be wood, straw, cellulose, hemp or cork. The particles of plant material are preferably wood particles. Preferably, the particles of plant material are predominantly wood particles (by volume) and preferably wood chips. Preferably, the mineral binder is chosen from a cement, a clay, a clay-based material, blast furnace slag or lime. It is also possible to use a concrete which is a mixture containing water, a binder for example cement and other elements, for example sand and possibly gravel. It is particularly advantageous for the mineral binder to contain a significant content and more preferably a majority of geosourced material.

[0027] The plant-based particles are embedded in the mineral binder which ensures mechanical cohesion between the particles. The particles are covered by a layer of mineral binder to protect them from external aggressions. The particles are assembled randomly with respect to each other and they define channels and / or cavities inside the support. The support material makes it possible to provide an improved fire-resistant property to the panel, particularly when it forms a floor, preferably when it uses predominantly wood particles by volume. Indeed, wood is a better thermal insulator than the sand used in conventional concrete. In addition, the mineral binder coats the elements of plant origin such as wood and protects them from flames. It has been observed that under the effect of a fire, the material formed by the first mixture expands less than its equivalent in raw concrete or a steel floor.It has also been observed that the floor does not explode under the thermal stress of fire or degrade much later. The effect is enhanced when the material is porous.

[0028] The use of such a mixture to form the support part 1 makes it possible to reduce the density of the support material compared to a material which only comprises the mineral binder. The incorporation of particles of a plant material also makes it possible to improve the acoustic performance of the material.

[0029] The support material has a first mass value in particles of plant material of between 30% and 70% and preferably with a volume content in particles of plant material of between 30 and 95%, more preferably The plant material particles represent a larger volume than the mineral binder. The mass content of plant material particles corresponds to the mass of the plant material particles in relation to the total mass of the support material after drying. The volume content of plant material particles corresponds to the volume of the plant material particles in relation to the total volume of the other materials in the support material after drying and without taking into account the porosity of the material. The use of such a content of plant material particles allows for a significant reduction in the mass of the construction panel compared to an equivalent panel made exclusively of concrete or reinforced concrete.

[0030] It is particularly advantageous to have a support material that is porous in the solid state. The particles of plant material are arranged randomly relative to each other with possibly a preferred orientation linked to the manufacturing conditions and they define pores. The support material can be open-pored or closed-pored. The pore size is greater than 1 mm and the porosity of the support material is different from the intrinsic porosity of the mineral binder. It is particularly advantageous for the support material to have a porosity of between 30% and 70%, which provides a good compromise between the density of the material, its flexural strength, its compressive strength and its thermal resistance.

[0031] Preferably, the majority in number of particles made of plant material has a length of between 1 and 100 mm. Particularly advantageously, the average length of the particles is between 10 and 100 mm, preferably between 10 and 60 mm, more preferably between 20 and 60 mm. The average length may be a simple average length. The use of such a length range makes it possible to form a material whose porosity and surface roughness are better controlled, in particular with microcavities and especially cavities whose volume is larger. The use of a mixture comprising a majority of particles whose size is preferably between 10 and 100 mm, preferably between 10 and 60 mm and whose mass and / or volume content of particles is high makes it possible to form a porous support with significant surface roughness.Even more preferably, the particles are wood chips which have a thickness mainly between 1mm and 5mm (in number). Such a distribution in length and thickness makes it possible to form a support material of reduced density, with satisfactory mechanical resistance and a good compromise between porosity and surface roughness. Roughness corresponds to the maximum height between a peak and a trough of the surface.

[0032] The porosity of the material makes it possible to form a construction panel which has good acoustic absorption and in particular better acoustic absorption than conventional solid materials regularly used in construction. This configuration is particularly advantageous when the construction panel forms a floor or a dividing wall in a residential dwelling or a commercial building.

[0033] When the particles of plant material are wood particles and when the mineral binder is a cement or a concrete, the density of the porous support material is between 600 and 1000 kg / m3, by varying the composition of the material, preferably it is equal to 800 kg / m3. This produces a material that is lighter than raw concrete, i.e. a concrete that does not contain wooden elements and whose density is approximately 2300 kg / m3.

[0034] It is particularly advantageous to have a support part 1 which has a roughness greater than 5 mm, preferably between 6 and 15 mm.

[0035] The support material makes it possible to form a porous material. The at least one support part 1 is made of a porous material which has pores extending at least along the ZZ direction. Preferably, the support part 1 has a porosity which represents between 30% and 50% of the total surface area of ​​the support part 1.

[0036] The support part 1 is in direct contact with the reinforcement 2 and they are fixed to each other by a connection interface which extends continuously over the entire length of the reinforcement, i.e. in the direction XX and which extends over the majority of the thickness of the reinforcement, for example over at least 75% of the thickness, preferably at least 90% or even 100% in the direction ZZ. The contact surface comprises at least one side wall 2a, i.e. the surface which extends in the directions ZZ and XX.

[0037] In order to ensure a good mechanical connection, the reinforcement 2 and the support piece 1 have complementary faces. The reinforcement material is introduced into the surface cavities of the porous support to fill the cavities. Preferably, the reinforcement material is introduced into the support material over a distance at least equal to 3 mm, preferably at least equal to 5 mm, even more preferably at least equal to 1 cm.

[0038] When forming a construction panel, it is advantageous to first form the support piece 1 from porous material and then form the at least one reinforcement 2. When forming the reinforcement 2, it is advantageous to have a mineral binder poured. The mineral binder penetrates inside the cavities of the porous material which fixes the at least one reinforcement 2 with the at least one support piece 1.

[0039] When pouring a mineral binder which is a cement or a concrete to form the reinforcement 2, the concrete is able to be inserted inside the support part 1 over a distance of several millimeters, for example at least 5mm, preferably at least 10mm or even at least 15mm. Such a sinking into the support part 1 allows for good mechanical cohesion between the reinforcement 2 and the support part 1. The support part 1 forms at least in part the mold which defines the shape of the reinforcement 2.

[0040] The at least one reinforcement 2 has its largest dimension in the longitudinal direction XX of the panel and it is in intimate contact with the support part 1 over the majority or all of this dimension. Depending on the performance sought for the panel, for example mechanical, thermal, acoustic and / or seismic performance, the best compromise will be chosen between the dimensions of the support part(s) 1 and the dimensions of the reinforcement(s) 2, in particular in the direction YY.

[0041] The reinforcement 2 is made of a reinforcing material comprising a mineral binder and a metal reinforcement 3. The mineral binder is preferably chosen from a cement or a concrete. The composition of the binder is adapted to the desired mechanical performance and to the dimensions of the cavities present on the surface of the support part 1. The reinforcement 2 comprises a metal reinforcement 3 which makes it possible to improve the mechanical performance of the reinforcement 2. The mineral binder may optionally be associated with particles of a plant material. The volume content of particles of plant material is less than 20%. The metal reinforcement extends in the longitudinal direction. The reinforcing material penetrates into the cavities of the material forming the support part 1. Limiting the content of particles of plant material makes it easier for the binder to penetrate into the cavities of the support part 1 over a significant distance.Alternatively or in addition, the average length of the particles of plant material may be at least 30% lower than for the support material. The binder may include a thickener or a fluidifier in order to better control the penetration distance of the binder into the cavities. Preferably, the reinforcement 2 is not porous or not as porous as the support part 1. Advantageously, the porosity is less than 15%, preferably less than 10% after 28 days of casting.

[0042] The mechanical connection between the at least one reinforcement 2 and the at least one support piece 1 makes it possible to improve the bending strength of the assembly formed by the support piece 1 and the reinforcement 2 in comparison with a support piece 1 without the reinforcement 2. The mineral binder of the at least one reinforcement 2 is introduced into the holes of the at least one support piece 1, which makes it possible to form a reinforcement 2 and a support 1 which have the most complementary shapes possible on an interface layer which extends between 5 mm and 5 cm, i.e. the depth of penetration of the reinforcement material into the support piece.

[0043] Preferably, the reinforcement 2 is in contact with two support pieces 1 which are separated by the reinforcement 2 in the direction YY or with the same support piece which at least partially covers the reinforcement in the form of a U or a ring in an observation along the ZZ direction. The reinforcement 2 has two opposite side walls 2a along a transverse direction YY, each fixed to the same support part 1 continuously along the longitudinal direction XX in the same way as previously. Such interface layers allow for good transfer of forces between the reinforcement 2 and the support 1 without having to use additional connectors, for example screws or other metal elements. This also allows for simplifying the shape of the reinforcement 2.

[0044] The construction panel has end walls 4 which are formed by the at least one support piece 1 at least along the direction XX and preferably along the directions XX and YY. In other words, the at least one support piece 1 extends the at least one reinforcement 2 at each end along the longitudinal direction XX. The reinforcement 2 does not form the end wall of the construction panel, which makes it possible to form a layer which is thermally more insulating than the reinforcement 2 so as to limit thermal conduction to the reinforcement 2 along the longitudinal direction XX. The use of the end walls 4 at both ends of the support piece 1 along the longitudinal direction XX also makes it possible to have a better adaptation of the forces between the construction panel and its anchoring points at the two opposite ends along the direction XX. This makes it possible to favor the deformation of the end walls 4 made of support material.Such deformation can occur as temperature changes throughout the year, or in response to an earthquake.

[0045] The end walls 4 made of support material arranged beyond each reinforcement 2 in the longitudinal direction XX have a length advantageously at least equal to 3 cm and preferably less than 20 cm in the direction XX. Preferably, the ends made of support material beyond each reinforcement 2 represent less than 5% of the total length of the construction panel.

[0046] When the content of plant particles is too low, the surface roughness of the support part 1 approaches the surface roughness obtained with concrete, and this is essentially the same when the average length of the particles becomes too small, for example less than 5 mm. When the average length of the plant particles becomes too large, the mechanical strength of the material decreases.

[0047] The construction panel also has at least one fixing plate 5 installed in a non-removable manner at at least one end, preferably at each end of the at least one reinforcement 2 in the longitudinal direction XX. Each fixing plate 5 is intended to fix the construction panel to an anchoring point 6, for example an anchoring point 6 of a frame made of concrete, wood or another material. The fixing plate 5 is opposite the support piece 1 in the direction of the thickness ZZ at each end of the construction panel and preferably it covers the support part 1. When fixing the building panel to the anchor point 6, the fixing plate 5 creates the mechanical connection between the anchor point 6 and the reinforcement 2.

[0048] The fixing plate 5 has a first end which is embedded in the reinforcement 2 and a second end which extends beyond the reinforcement 2 in the direction XX. Preferably, the fixing plate is wider than the reinforcement 2, in the direction YY. The fixing plate 5 extends in the direction XX. Preferably, the first end of the fixing plate 5 is arranged inside the reinforcement 3, in an observation along a section plane perpendicular to the direction XX. In one embodiment, the fixing plate 5 is distinct from the reinforcement 3. The fixing plate 5 and the reinforcement 3 are connected to each other exclusively or mainly by the reinforcement material.In one embodiment, the fixing plate 5 can be fixed to the frame 3, for example by a plastic connector or in any other material which makes it possible to impose the position of the fixing plate 5 relative to the frame 3 but the mechanical strength is provided by the reinforcing material.

[0049] The fixing between the construction panel and the anchoring point 6 can be obtained by any suitable means, in particular by a fixing 7, for example by at least one screw, at least one nail, at least one bolt, at least one rivet. The fixing 7 passes through the fixing plate 5 and the support part 1 in the ZZ direction to fix the fixing plate 5 with the anchoring point 6. The fixing 7 is adapted to the nature of the anchoring point 6. It is particularly advantageous to apply a compressive force on the support part 1 between the anchoring point 6 and the fixing plate 5 because the support material is adapted to withstand such a force with large contact surfaces between the anchoring point 6 and the support part 1.

[0050] The use of a building panel end that is terminated by the fixing plate 5 makes it possible to provide a greater variety in the means of fixing the building panel with the anchor point 6 or in the materials suitable for forming the anchor point 6. Preferably, the fixing plate 5 has one or more through holes 5a in the direction of the thickness ZZ. This makes it possible to carry out a screw fixing by means of a screw that is screwed into the anchor point 6 and into the support 1 by passing through the fixing plate 5. The screws connect a panel to an anchor point 6 by passing through the building panel. The high content of plant material particles makes it possible to carry out a screwing directly into the panel without having to first make a hole and without having to use a dowel or chemical sealing. The same applies when the anchor point 6 is made of wood.It is therefore possible to fix the panel using one or more screws without using a chemical sealant and without a dowel. In comparison, in a concrete structure, it is necessary to make a preliminary hole and then fill it. this hole with a dowel or chemical seal to ensure that the screw remains in place despite stress.

[0051] Alternatively, bolting is possible by means of a bolt passing through the anchor point 6, the fixing plate 5 and the support 1 to fix these three elements together. A hole for passing the bolts is made more easily than in a concrete wall. The shape of the anchor point 6 is suitable for fixing by a bolt.

[0052] The use of a construction panel provided with a fixing plate 5 makes it possible to fix the construction panel by dry method, that is to say without having to make and pour concrete which ensures the mechanical connection between the anchoring point 6 and the construction panel. The fixing of a construction panel to the anchoring point 6 can be carried out by a connector 7 (also called fixing) which is fixed on the one hand to the anchoring point 6 and on the other hand to the construction panel. The connector 7 can be a removable connector for example a screw or a bolt, but it is also possible to provide a non-removable connector.

[0053] The fixing plate 5 is preferably made of a metal, for example steel, more preferably a steel treated against corrosion or even a stainless steel. Alternatively, the fixing plate 5 can be made of wood or a composite material.

[0054] Preferably, the at least one support member 1 completely surrounds the or each reinforcement 2 in a view according to a cutting plane perpendicular to the ZZ direction as illustrated in Figures 4 and 5. The at least one reinforcement 2 is included in the at least one support member 1 in the cutting plane. There is a mechanical continuity of the support material all around the reinforcement 2. Preferably, the end walls 4 of the building panel in the YY direction are formed by the at least one support member 1. This allows for forming a thermal insulation in the YY direction.

[0055] Preferably, a main wall 8 of the construction panel, i.e. a wall which is perpendicular to the direction ZZ, is formed by the at least one support piece 1. The main wall 8 is in contact with the at least one reinforcement 2. Advantageously, the at least one reinforcement 2 is at least partially embedded in the support piece 1, i.e. in contact with the at least one support piece 1 on all its faces except for a single main face 8 which is perpendicular to the direction ZZ. Alternatively, the at least one reinforcement 2 is fully embedded in the at least one support piece 1, i.e. covered on all its faces in the directions XX, YY and ZZ. When the at least one reinforcement 2 is not fully embedded in the support piece 1, it is flush with a single face of the support 1 which is perpendicular or substantially perpendicular to the direction ZZ.

[0056] In an advantageous embodiment, the main wall 8 of support material is made of a material different from the material in contact with the side walls of the reinforcement 2. It is then possible to identify in the at least one support part 1 a core 1a and a covering layer 1b. The core 1a is in contact at least with the side walls 2a of the reinforcement 2. The covering layer 1b forms at least one main wall of the construction panel. The core 1a and the covering layer 1b are different compositions of the support material. The covering layer 1b has a porosity lower than the porosity of the core 1a.

[0057] The core 1a has a significant porosity which allows a significant amount of air to be stored to improve thermal resistance performance. The covering layer 1b has a lower porosity to improve mechanical performance.

[0058] In a particular embodiment illustrated in figures 1, 2, 4, 5, 16 and 17, the end walls of the construction panel in the directions XX and / or YY are made by the covering layer 1b in order to improve the mechanical performance of the construction panel.

[0059] It is preferable that the covering material has a flexural strength that is greater than the flexural strength of the core material. Preferably, the flexural strength of the covering material is greater than the flexural strength of the core material by at least 10%. The covering material is a mixture of a mineral binder and particles of a plant material according to the definition presented above to characterize the support material. The use of a layer of covering material makes it possible to improve the flexural strength of the construction panel. This configuration is particularly advantageous when the covering layer 1b forms the lower face of a slab because the bending and tensile forces are mainly applied to the lower face of the slab.Using a 1b cover layer as a lower layer allows for a greater number of accessories to be fixed to the ceiling, for example at least one of a thermal insulation layer, a hanger for fixing a false ceiling, all or part of a false ceiling, electrical cables, plumbing.

[0060] Preferably, the thickness of the covering layer 1b is at least equal to 5 cm. It is preferable that the thickness of the covering layer 1b is less than half the thickness of the construction panel, more preferably less than one third of the thickness of the construction panel. It is preferable that the thickness of the covering layer 1b is less than the thickness of the reinforcement 2 in the facing portion in the ZZ direction for the or each main wall 8.

[0061] In an advantageous embodiment, the covering layer 1b may have a lattice in order to improve the flexural strength. The lattice may be a composite material mesh. Preferably, the mesh can be a fiberglass, carbon fiber, or polyester fiber mesh.

[0062] Preferably, the fixing plate 5 defines one or more through holes which open onto the support 1 or opposite a through hole in the support 1. Alternatively, the through holes are made at the last moment during fixing.

[0063] Preferably, the covering layer 1b has a surface roughness which is less than the roughness of the core 1a. The reduction in roughness makes it easier to install a covering layer such as a coating. The covering layer 1b is preferably a layer intended to be located inside a construction and not outside. The porosity of the coating makes it possible to define the porosity of the construction panel and thus to form a breathable construction panel.

[0064] In a construction, when the construction panel forms a slab, the panel is placed on a plurality of anchoring points 6 and the panel is fixed to each of the anchoring points 6 by one or more connectors 7. The end of the construction panel made of support material forms the support zone with the anchoring point 6. In a particular embodiment, the reinforcement 2 may bear on the anchoring point 6. Alternatively, the reinforcement 2 is not bear on the anchoring point 6, it is separated by the support part 1 in the direction ZZ. The anchoring point 6 may be a wall, also called an edge wall.

[0065] It is also possible that an additional fixing plate is used in the central part of the reinforcement 2 in the direction XX.

[0066] In another embodiment, one of the main walls 8 is devoid of reinforcement 2. A thickness of support material is present facing the reinforcement 2 in the direction of the thickness ZZ to protect the reinforcement 2. This configuration makes it possible to form a layer of thermal insulation which protects the reinforcement 2. This configuration is advantageous during a fire because it delays the supply of heat to the reinforcement 2 which is formed by a reinforcement 3 and a mineral binder which have different thermal expansion coefficients.

[0067] The construction panel behaves monolithically from one end to the other in the longitudinal direction XX and the transverse direction YY. The at least one support piece 1 is preferably fixed to two reinforcements 2 which are separated in the transverse direction YY. The at least one support piece 1 takes up the bracing forces by diaphragm effect, without shearing or breaking the support piece 1. Such a configuration is capable of supporting vertical operating loads of up to 750 kg / m2 when the construction panel is used as a floor in a thickness range identical to that used in the configurations of the prior art.

[0068] The construction panel can be produced by means of the following manufacturing method and illustrated in Figures 6 to 11 in front sectional views and in Figures 12 to 16 in longitudinal sectional views. In a step S1 illustrated in Figures 8 and 14, at least one support part 1 is provided which defines a hole delimiting all or part of a mold intended to impose the shape of the at least one reinforcement 2 to be formed. As indicated previously, the at least one support part 1 is a porous part with significant surface roughness. Preferably, the support part 1 has been previously formed in a mold 9 which advantageously has one or more reservations 10 for the steps to follow. The reservation 10 is a solid or hollow part made of any suitable material and which defines a volume free of support material after casting.

[0069] In one case illustrated in Figures 6, 7, 12 and 13, the support material is cast into the mold 9 which has a reservation 10 to define one or more holes intended to at least partially define the reinforcement(s) 5. In another case, the reservations are introduced after casting to move the material and define the shape of the reinforcement part 2. Once the support material has been cast and shaped, the reservations 10 are removed as illustrated in Figures 8 and 14. The support material retains the shape imposed on it.

[0070] In a step S2 illustrated in Figures 9 and 14, a reinforcement 3 and at least one mineral binder are provided. The reinforcement 3 is arranged in the hole delimited by the support part 1 and at least one mineral binder is poured into the hole to form the reinforcement 2. As indicated above, the mineral binder can be added with particles of plant element. The mineral binder may include additives so as to control its hardening speed and / or its viscosity. It is advantageous to adjust the viscosity of the mixture intended to form the reinforcement material in order to control the depth of penetration inside the cavities present in the support part 1.

[0071] The fixing plate 5 can be installed before, after or at the same time as the reinforcement 3. In one embodiment, the fixing plate 5 is separate from the reinforcement 3. In another embodiment, the fixing plate 5 is fixed to the reinforcement 3 so as to impose the position of the fixing plate 5 relative to the reinforcement 3. This embodiment is particularly advantageous when pouring the mineral binder of the reinforcement 2. It is advantageous for at least one of the reinforcement and the fixing plate to be fixed to the mold 9 during the step of pouring the mixture intended to form the reinforcement material in order to precisely define its position.

[0072] It is preferable to provide a support piece 1 whose mineral binder has not yet completely hardened and to form the reinforcement 2 before the mineral binder hardens. It is advantageous to use the same mineral binder for the support piece 1 and the reinforcement 2 or compatible binders, for example the same cement, the same concrete, two cements or two concretes having different compositions or even a cement and a concrete. It is advantageous that the reinforcement 4 does not protrude from the reinforcement piece 1 in the ZZ direction. It is also advantageous that the reinforcement material does not protrude from the reinforcement piece 1 in the ZZ direction.

[0073] Advantageously, in a step S3 subsequent to the formation of the reinforcement 2, the covering layer 1b is cast onto the assembly formed by the reinforcement(s) 2 and the at least one support piece 1. Again, it is preferable to cast the covering layer 1b before the mineral binder of the reinforcement 2 and possibly the remainder of the support piece 1 have completely hardened. This precaution facilitates the reaction between the different mineral binders and increases the cohesion between the layers. In this scenario, it may be difficult to detect the interfaces between the different layers.

[0074] It is advantageous to deposit a covering layer 1b that is sufficiently fluid to penetrate into the cavities of the support piece 1.

[0075] The mixture forming the covering layer 1b may be identical to or different from the mixture forming the support piece 1. Preferably, the mixture forming the covering layer 1b comes from the initial mixture used to form the at least one support piece 1 to which water is added in order to make the mixture more fluid. Once dry, the mixture of the covering layer 1b has the same mass content of wood particles and the same mass content of mineral binder. However, it has a reduced porosity compared to the porosity of the support piece 1.

[0076] It is advantageous for the reinforcement 3 to be a three-dimensional reinforcement and for it to be crossed by the mineral binder in order to ensure good mechanical continuity between the reinforcement 3 and the at least one support part 1. It is also advantageous for at least a part of the fixing plate 5 to be located inside the reinforcement 3 in a section plane perpendicular to the direction XX.

[0077] Preferably, the reinforcement 3 is completely embedded in the mineral binder of the reinforcement 2. More preferably, the reinforcement 2 and the support piece 1 define a common upper plane after casting the reinforcement 2.

[0078] It is advantageous to provide a peripheral reservation 10 along the entire internal periphery of the mold 9 to form the construction panel illustrated in [Fig.5]. The support material is cast to define the support part(s) 1. The reinforcement(s) 2 are formed. The peripheral reservation 10 is removed, then the covering layer 1b is cast in order to form the end walls of the construction panel which will surround the assembly formed by the at least one support part 1 and the at least one reinforcement 2.

[0079] As an alternative to a peripheral reservation, reservations aimed at forming the end walls in the XX direction (figures 1, 2 and 4) or in the YY direction are possible.

[0080] Preferably, the fixing plate(s) 5 are arranged in the bottom of the mold 9. The bottom of the mold 9 will define a main surface of the construction panel. The support material is cast to form the at least one support part 1 which can coat a part of the fixing plate 5 as illustrated in Figures 1 to 3.

[0081] Once completed, the construction panel 1 is moved from its place of manufacture to its place of use. The construction panels 1 are arranged next to each other and fixed to the anchor points to form a wall or a slab. This saves time on the manufacture of a construction.

[0082] [Fig. 17] illustrates a particular embodiment of a fixing plate 5 which comprises an anchoring portion 5a intended to be located in the reinforcement 2 inside the volume delimited by the frame 3. The anchoring portion 5a is extended by a hooking portion 5b which passes through the reinforcement 2 and partially covers the end wall 4.

[0083] [Fig. 18] illustrates a particular embodiment of a construction where the construction panel is fixed at each of its ends, in the direction XX, to an anchoring point 6 by means of a connector 7 which passes through the fixing plate 5, the end wall 4 and which is fixed to the anchoring point 6. [Fig. 18] illustrates more particularly an assembly as a slab.

Claims

Claims

1. Construction panel intended for the manufacture of a floor or a wall comprising at least one support piece (1) and at least one reinforcement (2), in which: - the at least one support part (1) is formed from a support material comprising a mineral binder and particles of a plant material embedded in the mineral binder; - the at least one reinforcement (2) is fixed to the at least one support part (1) and has a bending strength greater than the bending strength of the at least one support part (1), the at least one reinforcement (2) being formed by a reinforcing material comprising a mineral binder and a metal reinforcement (3); characterized in that: - the support material is a porous material which has a first value of mass content of plant material particles of between 30 and 70%, the average length of the particles being between 10 and 100 mm; - the at least one support part (1) has surface cavities defining a surface roughness at least equal to 5 mm and continuously envelops the at least one reinforcement (2) in an observation along a section plane perpendicular to a thickness direction (ZZ), the at least one support part (1) defining at least two end walls (4) arranged projecting from the at least one reinforcement (2) and opposite in a longitudinal direction (XX); - the reinforcing material penetrates into the surface cavities of the at least one support part (1) to a depth of between 5mm and 5cm to form a fixing interface between the at least one support part (1) with the at least one reinforcement (2) which extends over the entire dimension of the at least one reinforcement (2) in the longitudinal direction (XX); - at least one fixing plate (5) is arranged at one end of the at least one reinforcement (2) and intended to fix the construction panel to an anchoring point (6), the at least one fixing plate (5) having a first end (5a) embedded in the at least one reinforcement (2) and another end (5b) covering one of the end walls (4) in the thickness direction (ZZ) beyond the at least one reinforcement (2) in the longitudinal direction (XX), the fixing plate (3) being independent mountable with at least one reinforcement (2).

2. Construction panel (1) according to claim 1 wherein the at least one support piece (1) is porous through at least in the thickness direction (ZZ).

3. Construction panel (1) according to claim 2 wherein the at least one support piece (1) has a porosity value of between 30% and 70%.

4. A building panel (1) according to any one of claims 1 to 3 wherein the reinforcing material comprises particles of a plant material whose volume content is less than 20% or is free of particles of a plant material.

5. Construction panel (1) according to any one of claims 1 to 4 in which the at least one reinforcement (2) has a porosity of less than 15%.

6. Construction panel (1) according to any one of claims 1 to 5 wherein the at least one support part (1) comprises a core (1a) and a covering layer (1b), the core (1a) being in contact with the side walls (2a) of the at least one reinforcement (2), the covering layer (1b) forming at least one main wall (8) of the construction panel, said main wall (8) being perpendicular to the thickness direction (ZZ) and wherein the core (1a) and the covering layer (1b) are different compositions of the support material, the covering layer (1b) having a porosity lower than the porosity of the core (1a).

7. A building panel (1) according to claim 6 wherein the covering layer (1b) forms the end walls (4).

8. Construction panel (1) according to claim 7 wherein the covering layer (1b) forms an end annular wall of the assembly formed by the at least one support piece (1) and the at least one reinforcement (2) in an observation along a section perpendicular to the thickness direction (ZZ).

9. Construction panel (1) according to one of claims 6 to 8 in which each fixing plate (5) is not in contact with the main wall (8) of the construction panel.

10. Construction comprising at least one construction panel according to any one of the preceding claims, the at least one construction panel being fixed to at least two anchoring points (6) by at least two connectors (7), the connectors (7) being opposite

11.

12.

13. along the longitudinal direction (XX) of the construction panel, the two connectors (7) directly fixing one of the anchor points (6) to a fixing plate (5). Construction according to claim 10 in which the construction panel forms a slab and / or a floor, the anchoring point (6) being an edge wall. Construction according to claim 10 in which the building panel forms a wall, the anchor point being a floor.A method of manufacturing a construction panel according to any one of claims 1 to 9 comprising the following steps: - providing at least one support part (1) defining all or part of a mold (9), the mold (9) forming at least one hole extending mainly in a longitudinal direction (XX), the at least one support part (1) being formed in a support material comprising a mineral binder and particles of a plant material, the particles being embedded in the mineral binder, the support material being a porous material which has a first value of mass content of particles of plant material of between 30 and 70%, the average length of the particles being between 10 and 100mm, the support material being a porous material with opening cavities and defining a surface roughness at least equal to 5mm;. - forming at least one reinforcement (2) in the at least one hole, the at least one reinforcement (2) extending mainly in the longitudinal direction (XX), the at least one reinforcement (2) being formed in a reinforcement material comprising a mineral binder, a metal reinforcement (3), the reinforcement material having a bending strength greater than the bending strength of the support material (1), the mineral binder being poured into the at least one hole so that the mineral binder is inserted into the opening cavities of the at least one support part (1), the at least one reinforcement (2) having two side walls (2a) opposite in a transverse direction fixed to the at least one support part (1) continuously in the longitudinal direction (XX), a metal reinforcement being embedded in the mineral binder.

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