Self-supporting Thermo-acoustic Composite Panel

Abstract

Thermo-acoustic composite panel. The invention relates to a device comprising, on the one hand, an insulating core comprising recesses (3A, 3B) arranged on at least one face of the core, and on the other hand, a layer of hydraulic binder, covering at least one face of the core and comprising projections of hydraulic binder engaging in, and filling, the recesses arranged on the face of the insulating core. The insulating core (2) comprises from 1 to 100,000 recesses (3A, 3B) per m², preferably between 10 and 100,000 recesses per m2, and the layer of hydraulic binder comprises from 1 to 100,000 corresponding projections (4A, 4B) per m², preferably between 10 and 100,000 corresponding projections per m2. The thermo-acoustic composite panel (1A) has a sound transmission attenuation, measured by a sound level meter according to IEC 61672, of at least 58 dBA. Figure for abstract: Fig. 1

Description

Title of the invention: Self-supporting thermo-acoustic composite panel

[0001] The present invention relates to a self-supporting thermo-acoustic composite panel, configured and adapted for use as a structural panel in the construction of buildings and other self-supporting structures. The assembly of several of these panels together, therefore in a homogeneous manner, or in combination with other construction elements, in a heterogeneous manner, is also envisaged.

[0002] There are two main methods of building construction today, namely on the one hand on-site construction, whereby each element of the building is constructed in stages, starting with the structural work, then the finishing work, and on the other hand, factory prefabrication of all or part of a building comprising a structural work component, and one or more finishing work components, the final product in this case generally being in the form of panels, then the assembly of these panels to form a complete construction.

[0003] A large part of current constructions is made with construction materials allowing to obtain acoustic and thermal performance, the construction then being composed of several elements, namely and in particular, a first element responsible for the acoustic performances, such as concrete block, brick, cellular concrete, formwork concrete, etc., and a second element responsible for the thermal insulation performances, such as polystyrene, rock wool, glass wool or any other insulator playing a role of thermal insulation.

[0004] Also known from the prior art are various methods of constructing prefabricated buildings, for example, the prefabrication in the factory of a concrete or wooden wall, onto which thermal insulation is applied directly in the factory.

[0005] One of the known advantages of prefabricated concrete walls is its acoustic performance, which is linked to the mass of the wall, this performance being counterbalanced by a lack of adequate thermal performance, on the one hand, and the weight, on the other hand. Indeed, for concrete walls 20 cm thick, or sandwich walls comprising two concrete walls a few centimeters thick, the resulting prefabricated walls weigh several tons, which requires the use of large lifting equipment to load them for transport, unload them once on the construction site, and handle them for installation.

[0006] Another problem associated with prefabricated walls is the incorporation of electrical conduits and fluid conduits into these walls. Indeed, in order to be able to incorporate conduits into prefabricated walls comprising two concrete walls, for example, 5 to 7 cm thick, an even greater thickness of concrete is required to be able to encase these ducts, and especially to fix them well in order to avoid any rise of ducts when pouring the additional concrete. For very long panels, for example, 8 to 12 meters long, the use of telescopic forklifts is impossible due to the excessive weight, the only solution then being the use of a crane truck, or a crane, as an effective means of lifting such panels.

[0007] The common element therefore in prefabricated panels of known types is the thickness of the walls. Indeed, to obtain acoustic performance, all without exception use a physical effect based on the principle of mass, and consequently, the thicker the panel, the more acoustically efficient it is, but with the major disadvantage of being heavier, linked to a large quantity of concrete, steel or wood.

[0008] It has been common practice, especially for several decades, to use mass in construction materials to stop sound. The problem with such an approach is that a concrete wall thickness of, for example, 10 cm, has an acoustic attenuation of 48 dB, or a dB / mass ratio of 0.24, whereas a concrete wall 20 cm thick has an acoustic attenuation of 60 dB. Despite doubling the thickness of the concrete, and increasing the weight of the panel by 100%, it is found that the acoustic attenuation value increases by only 25%, or a dB / mass ratio of 0.15. We can therefore see that the dB / mass ratio is not very effective.

[0009] On the other hand, for lighter prefabricated panels that are installed with forklifts on site, these panels only transfer the problem to the sound level. Indeed, after having installed them, these panels are then filled with concrete in the form of a concrete veil, in order to obtain mass to be efficient in terms of acoustics, but the dB / mass ratio remains identical, and the solution also presents an overconsumption of concrete. These types of lighter panels then contain very large quantities of concrete, while the concrete requirement on the structural level represents barely 20% for the solidity of the structure, and the surplus concrete only serves as filling to improve the sound performance.

[0010] The quantities of concrete used in the panels known so far then pose a real problem in relation to the weight / acoustic efficiency approach, and in addition, the massive use of concrete contributes to the reduction of raw material resources, in particular sand, without forgetting its energy cost of manufacture, as well as its environmental impact, taken into account in the FDES (Environmental and Health Declaration Sheet). This FDES risks downgrading the classification of all products having a significant quantity of concrete, and making them obsolete, or even unsaleable.

[0011] According to a first aspect, the present invention aims to propose multi-use thermo-acoustic structuring prefabricated construction panels which do not have the aforementioned drawbacks.

[0012] The applicant has in fact found that it is possible to obtain a prefabricated panel similar to, but different from, those already known, and which exhibits more than acceptable acoustic performance, by intervening on the reverberation time of a sound wave. Indeed, reverberation time refers to the time required for a sound to disappear inside an enclosed space. Sounds inside a room can reverberate when the sound waves are not absorbed by the surfaces with which they come into contact, creating a return of the wave inside the enclosed space, more commonly called an echo. This reverberation time can be reduced by modifying the surfaces and the material of the panels, so that the sound is in a more absorbable frequency range and so that reflections of the sound waves are thus minimized.

[0013] According to another aspect, the present invention aims to provide a panel of the type indicated above comprising means for attenuating and fragmenting sounds of frequencies included in the range of 100 to 3000 Hz.

[0014] Thus, according to one aspect, the invention relates to a thermoacoustic composite panel, comprising: an insulating core made of a material selected from the group consisting of polystyrenes, an inorganic, organic, mineral, vegetable, synthetic composition or a mixture of several of these, the insulating core comprising recesses arranged on at least one face of the core; and a layer of hydraulic binder, covering at least one face of the insulating core having the recesses, and comprising projections of hydraulic binder engaging in, and filling, the recesses arranged on the face of the insulating core, characterized in that: the insulating core comprises from 1 to 100,000 recesses per m2, preferably between 10 and 20,000 recesses per m2, and the layer of hydraulic binder comprises from 1 to 100,000 corresponding projections per m2, preferably between 10 and 20,000 corresponding projections per m2; and The thermo-acoustic composite panel has a sound transmission attenuation, measured by a sound level meter according to IEC 61672, of at least 58 dBA.

[0015] For informational and non-limiting purposes, a panel according to the invention allows: - to guarantee standardized acoustic performance without resorting solely to the mass effect, and in particular, without resorting to a significant quantity of concrete; - to present an ultra-efficient dB / mass ratio; - to reduce concrete consumption by 5 on a structural level while respecting European and international construction standards; - to guarantee very high thermal performance, in particular an R of at least 7; - to offer ultra-light panels, with a surface mass of 20 kg / m2 to 100 kg / m2, for a thickness of 30 cm; - to build the walls of a 100 m2 building in less than 4 hours; - to use the panels for the construction of both load-bearing and non-load-bearing walls, or for floors or as roof panels.

[0016] According to another aspect, each projection of the hydraulic binder layer and each recess arranged on the face of the insulating core has a polyhedral or conical shape, in particular a geometric shape composed of one or more vertices, one or more edges, and one or more faces, and preferably the polyhedral shape is chosen from the group consisting of dihedra, and / or tetrahedra. Thus, the recesses and the projections have polyhedral or conical shapes complementary to each other, so that the projections fill the recesses, the recesses fit the projections, and vice versa. It will be understood from the above that the insulating core then also has projections, of a shape complementary to the projections of the hydraulic binder layer, and the hydraulic binder layer for its part also has recesses, which will be filled by the projections of the insulating core.Thus the hydraulic binder layer and the insulating core form a single consolidated unit inseparable from each other.

[0017] According to another aspect, the recesses of the core and the projections of the hydraulic binder layer have, respectively, dimensions lying in the range of 5 to 20,000 millimeters long, 5 to 200 millimeters high, and 5 to 200 millimeters wide. The length of the recesses and / or projections is understood here to mean the dimension corresponding to the length of the panel, which can generally extend from 1 meter to 20 meters, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 meters long, which means that the recesses and projections can extend from one edge of the panel to the other, advantageously continuously, but also advantageously discontinuously from one edge of the panel to the other.Similarly, herein the height of the recesses and / or projections is understood to mean the dimension corresponding to the height of the panel, from a first edge to a second opposite edge, or vice versa, the height of the panel generally being between 0.5 meters and 5 meters, for example, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5 or 5 meters high, the recesses and / or projections then being . distributed, arranged or shaped, at equal spacing, or in groups separated from an adjacent neighboring group, depending on the height of the panel. Similarly, herein the width of the recesses and / or projections is understood to mean the depth to which these recesses and / or projections extend from, or are hollowed out in, the material forming the core and / or the layer of hydraulic binder.

[0018] According to another aspect, the panel comprises at least one excess thickness covering the layer of hydraulic binder comprising the projections, and consisting of a material chosen from the group of inorganic, organic, mineral, and plant materials, separately or as a mixture. This excess layer or excess thickness may also cover one or more of the faces of the insulating core on which the layer of hydraulic binder is not present, for example, the faces of the core considered to be the edges of the insulating core.

[0019] According to another aspect, the hydraulic binder layer comprising the projections and / or the at least one excess thickness comprises fibers, chosen from the group of metallic, inorganic, organic, synthetic, vegetable, and mineral fibers, separately or as a mixture.

[0020] According to another aspect, the insulating core further comprises recesses formed inside the material of the core, in the shape of a rectangle or in the shape of a C-shaped, T-shaped, H-shaped profile, or in any other geometric shape.

[0021] According to another aspect, the internal recesses of the insulating core are dimensioned to receive a hardenable hydraulic binder or a mechanical reinforcing element, this hydraulic binder or mechanical reinforcing element being made of a material chosen from the group of inorganic, organic, mineral, vegetable, synthetic, metallic or mixed materials, forming structural reinforcing elements. The internal recesses of the core are therefore configured to receive these reinforcing elements which will reinforce the panel, and / or the assembly in which the panel is integrated to form a construction, such as a wall, building, roof, fence, etc.

[0022] According to another aspect, the projections and the excess thicknesses are in the form of formwork reinforcements at the level of the internal recesses, that is to say perpendicular to the internal recesses of the insulating core.

[0023] According to a particularly advantageous aspect, the hydraulic binder, whether used to form the projections, or the extra thickness layer(s), or the reinforcements filling the internal recesses of the insulating core, is an ultra-high performance fiber-reinforced concrete (UHPC).

[0024] According to yet another aspect, the invention relates to an assembly of a plurality of thermo-acoustic composite panels according to the invention, the assembly being in the form of a wall, barrier, partition, false ceiling, and / or roof.

[0025] The accompanying drawings are provided by way of example and serve to illustrate the invention: [Fig. 1] represents a cross-section of a panel according to the invention; [Fig. 2] represents an exploded sectional view of a panel according to the invention; [Fig. 3] represents an enlarged sectional view of a panel according to the invention; [Fig.4] illustrates the principle of manu-portability of a panel according to the invention; [Fig.5] shows the panel in longitudinal section, and including integrated reinforcing elements; [Fig.6] represents an isometric view of a panel according to the invention comprising vertical recesses in the shape of C, T, and H; [Fig.7] shows a plan view of the path of a hot wire cutting a recess, with the cutting starting on the outer face of the panel and returning to its starting point; [Fig.8] represents a plan view of the internal recess of the insulating core (2), as well as the direction of the concrete thrust, demonstrating the principle of mechanical weakening of the recess during the pouring of the cement binder, the directions of deterioration of the insulating core being indicated by arrows; Figures 9, 10 and 11 represent a series of graphs highlighting the acoustic performance of a panel according to the invention.

[0026] The invention will be described in more detail in the following.

[0027] A thermo-acoustic composite panel according to the invention is illustrated by [Fig.l], and the general reference numeral 1A. The panel (1A) as illustrated comprises a core (2) of insulating material, such as polystyrene, for example in the form of polystyrene beads expanded by steam and compressed or constrained during expansion in order to limit the expansion of the beads on the one hand, and to form a cohesive and resistant integral block, on the other hand. Such blocks of expanded EPS are known as such and commercially available. The insulating core (2) comprises one or more recesses (3A, 3B), formed or arranged on at least one face of the core, for example, one or both of the largest faces of the core in terms of surface area. In [Fig.l] and [Fig.2], it can be seen that the recesses are provided on the two largest opposite faces of the block of insulating material constituting the core (2). The number of recesses can range from 1 to 100.000 per m2, but the applicant has established that good results can be obtained with 20,000 recesses per m2 organized or arranged on the surface of the core (2). These recesses can be obtained, for example, by cutting the insulating material forming the core, such as polystyrene, with a hot wire. Alternatively, the recesses can be formed at the same time as the formation of the block of insulating material intended to constitute the core (2), for example, by molding, with or without compression. The panel (IA) also comprises a layer . hydraulic binder (4), for example based on cement or concrete or any other suitable hydraulic binder, for example mortars, ceramics, lime, plasters or any other hydraulic or aerial binder. This hydraulic binder may also and advantageously comprise fibers. A particularly advantageous hydraulic binder for producing the hydraulic binder layer of the thermo-acoustic composite panels according to the invention is ultra-high performance fiber-reinforced concrete, otherwise known under the designation BFUP.

[0028] As can be seen in [Fig. 1] and [Fig. 2], the layer of hydraulic binder (4A, 4B) covers the insulating core, for example, at the time of its casting in liquid or pasty form, on the faces of the core having the recesses. In doing so, the layer of hydraulic binder (4A, 4B), once hardened or set, forms projections (5A, 5B), which extend from an internal face of the layer of hydraulic binder (4A, 4B), towards, and into, the recesses formed on the surface of the insulating core (2). It will then be easily understood that the recesses (3A, 3B) of the insulating core (2) alternately define a corresponding number of projections (6A, 6B) of insulating core material (2) which are inserted into corresponding recesses (7A, 7B) of the hydraulic binder layer, as illustrated in the figures, to form a composite integral assembly.

[0029] In terms of the number of projections (5A, 5B) of the hydraulic binder layer extending towards the insulating core, it will be equivalent to the number of recesses arranged on the surface of the insulating core, namely from 1 to 100,000 per m2, and advantageously 20,000 per m2. The recesses (3A, 3B, 7A, 7B) and the projections (5A, 5B, 6A, 6B), on either side of the thermo-acoustic panel, together play a role of attenuation and reflection of waves, linked not only to their respective compositions, but also linked to the choice of a geometric shape of these respective recesses and projections.To this end, each projection (5A, 5B) of the hydraulic binder layer (4A, 4B) and each recess arranged on the face of the insulating core (3A, 3B) has a polyhedral or conical shape, in particular a geometric shape composed of one or more vertices, one or more edges, and one or more faces, and preferably the polyhedral shape is chosen from the group consisting of dihedrons, and / or tetrahedrons. For example, the polyhedrons have a pyramidal shape, which allows dispersion of sound waves and efficient acoustic attenuation comprising a preferred dispersion angle of between 20° and 110°. Furthermore, another advantage of the pyramidal shape of the polyhedra is that it allows to increase the contact surface when pouring the hydraulic binder layer to form the projections, which results in an advantageous increase in the bonding surfaces between the hydraulic binder and the insulating core, resulting in . greater tear-off performance. In addition, an unexpected effect observed by the implementation of polyhedral projections in pyramidal form was an increase in the fire performance of the composite panel according to the invention, because the pyramidal shape allows it to act as a heat diffuser within the composite panel. In contact with the fire, the layers (4A, 4B) transmit the heat to the projections (5A, 5B), the latter in turn diffusing this energy over their entire surfaces. As the contact surfaces of the recesses (3A, 3B) are greater than the surface area of ​​the layers (4A, 4B), by around 349%, the projections of the hydraulic binder layer allow heat dissipation 3.49 times greater than if they were not present in the panel.

[0030] As indicated above, the projections are advantageously composed of hydraulic binder, and in particular cementitious, for example ultra-high performance fiber-reinforced concretes. According to another advantageous embodiment, the performance of the panel may be further increased by using two hydraulic binders or different compositions for the projections of the hydraulic binder layer, for example, by providing that one of the faces of the insulating core is covered with a layer of hydraulic binder having projections based on a first hydraulic material, for example concrete, and the other face of the insulating core is covered with a layer of hydraulic binder having projections based on another hydraulic material, for example plaster or lime.The use of two different materials, each forming a different, opposite layer covering the recesses of the insulating core, increases acoustic performance by at least 16% compared to the basic acoustic performance.

[0031] As illustrated in [Fig.l] and [Fig.2], the panel further comprises an excess thickness, or overlayer (8A, 8B), covering the hydraulic binder layers (4A, 4B). The excess thicknesses (8A, 8B) cooperate with, and adhere to, the hydraulic binder layer (4A, 4B) during the pouring of the hardenable hydraulic binder.

[0032] According to an advantageous embodiment, the excess thickness or overlayer (8A, 8B) is an integral part of the hydraulic binder layer (4A, 4B). The excess thicknesses are then calculated to define the thickness of the area covering the projections (5A, 5B), depending on the application of an aesthetic coating that may be desired. These excess thicknesses can vary from 1 mm to several centimeters in addition to the dimensions of the projections (5A, 5B).

[0033] The overthicknesses or overlayers (8A, 8B) can be cast at the same time as the casting of the hydraulic binder layer (4A, 4B) forming the projections (5A, 5B). Alternatively, the overlayer (8A, 8B) can be cast in a second step, and in another hydraulic binder composition, in order to obtain additional performance. The extra thickness (8A, 8B) can also be sprayed on site for various reasons. This extra thickness (8A, 8B) can then be a decorative element such as paint or a thin organic coating such as RPE. The combined use of an inorganic hydraulic binder in the projections (5A, 5B) and the extra thicknesses (8A, 8B) makes it possible, for example, to make the panel fire-resistant with fire-resistant performance of at least 30 minutes to 4 hours.

[0034] It is also possible to play with the excess thicknesses (8A, 8B), using them for architectural motifs or reliefs, either by molding or by impression preferably made in the factory for practical reasons. Furthermore, the composition of the excess thickness (8A, 8B) may be different from the hydraulic binder used to form the projections (5A, 5B), the difference being in particular at the level of a characteristic chosen from among the granulometry, the density, the composition of the hydraulic binder, and the color, or a combination of one or more of these characteristics. By way of non-limiting example, the overlayers (8A, 8B) may be composed of a hydraulic binder lightened with polystyrene, while the projections (5A, 5B) may be composed of an ultra-high performance concrete (UHPC), or vice versa.

[0035] According to another embodiment, and as illustrated in [Fig. 3], some of the projections have dimensions such that projections of two opposite faces join at their internal ends to form a connection (9). This possibility makes it possible to stiffen the composite panel without disturbing the performance of the panel.

[0036] In the panel according to the invention, the recesses of the insulating core (3A, 3B) have a spring function and the projections (5A, 5B) of the hydraulic binder layer have a mass function. This organization makes it possible to significantly weaken and deflect sound waves, but also to combine a second function based on the principle of the effect: mass <> spring <> mass.

[0037] Indeed, the pooling of the recesses and projections simultaneously allows a gain in acoustic attenuation of the order of 30 to 120 decibels, depending on one or more elements chosen from the dimensions, the material compositions, the spacings, and the geometric shapes, of the recesses (3A, 3B, 7A, 7B) and projections (5A, 5B, 6A, 6B).

[0038] As an example, a panel (IA) as illustrated in [Fig.2], comprising a polystyrene core, with a thickness of 27.4 cm, the panel comprising respective recesses and projections with a length of 25 mm, and 8 mm of hydraulic binder forming each overlayer or overthickness (8A, 8B), allows an acoustic attenuation of the sound transmission of at least 37 decibels for a panel measuring 1 m wide by 1 m high, and 49.7 kg / m2 of surface weight, i.e. a dB / mass ratio of 0.74 (37 / 49.7), compared to 48 dB for a concrete wall 10 cm thick and of 230 kg / m2 of surface weight, i.e. a dB / mass ratio of 0.20 (48 / 230). For comparison, a 1 mm thick steel plate with an 8 kg / m2 surface weight has an attenuation of 32 dB, i.e. a dB / mass ratio of 4 (32 / 8), this shows that mass is not an absolute criterion of efficiency.

[0039] The panels according to the present invention also make it possible to solve the problem of implementing ducts or reservations in prefabricated walls. In fact, the ducts are directly incorporated into a clip-on groove (10), cf. [Fig.2], made almost flush with the insulating core (2) and no longer in the concrete part as in usual prefabricated walls, this reservation is then covered by the hydraulic binder with a thickness of only a few millimeters, unlike the minimum thickness of 5 to 7 cm known from usual prefabricated concrete panels.

[0040] It has already been indicated that the panel may comprise fibers, integrated into the hydraulic binder composition forming the projections (5A, 5B) and / or the overlayers (8A, 8B). These fibers may be chosen from one or more of the following types of fibers, namely metallic, inorganic, organic, vegetable, synthetic, and / or in mixture. For example, on one side of the panel, metallic fibers may be used in a first layer (4A) of hydraulic binder forming the projections (5A) and a corresponding first overlayer (8A), and on the opposite side of the panel, basalt fibers may be used in the hydraulic binder layer (4B) forming opposite projections (5B) and the second overlayer (8B).

[0041] Optionally, and advantageously, woven or non-woven reinforcements, either metallic or otherwise, may be incorporated into the core of the layers (4A, 4B) and / or (8A, 8B), or a mixture of several reinforcements in each layer may be used to increase the mechanical, acoustic and thermal performance of the panel. Referring to [Fig. 3], for example, the projections (5A, 5B) may be composed of a lightweight hydraulic binder, with a density in the range of 150 kg / m3 to 1,800 kg / m3. A cementitious hydraulic binder may then be produced with polystyrene beads, forming a lightweight concrete, with a preferred density of 350 kg / m3 to 1,100 kg / m3, or in another method of preparation, with a cementitious binder in which a foaming agent is incorporated into the hydraulic binder or any other agent making it possible to lighten this hydraulic binder.By proceeding in this way, it is possible to obtain a thermo-acoustic composite panel according to the invention with a dimension of 1 meter wide by 1 meter high having a thickness of 30 cm, and comprising projections (5A, 5B) and overlayers (8A, 8B), composed of a polystyrene concrete, making it possible to obtain a panel with a surface weight of 22 kg / m2.

[0042] The panel according to the invention makes it possible to obtain assemblies of panels forming an entire construction, for example a building, or even building substructures, such as walls. For example, and as illustrated by [Fig. 4], it is possible to produce an ultra-light wall (14), with dimensions that can exceed 8 meters in length, heights greater than 3 meters and wall thicknesses between 5 and 100 cm. For example, a lightweight wall with recesses and projections according to the invention, measuring 8 meters in length by 3 meters in height and 30 cm thick, will have a total weight of 528 kg. For comparison, for a prefabricated concrete wall of the same dimensions and 20 cm in thickness, i.e. 10 cm less, the latter has a weight of 11,040 kg, i.e. 20.9 times heavier.

[0043] Similarly, the panel according to the invention can be used as an interior partition wall. For example, this wall can be composed of an insulating core (2), layers of hydraulic binder (4A, 4B) forming projections (5A, 5B), and plaster over-thicknesses (8A, 8B), for a total surface weight of 18 kg / m2, compared to 23 kg / m2 for existing systems. A notable advantage of the invention is that the panel forming a partition wall can also have very long dimensions, for example, a dimension of 4 meters long by 3 meters high and 10 cm thick, the panel then weighing only 218 kg, and what is more, can be installed at the same time as the base walls.

[0044] The thermo-acoustic panel according to the invention can also be used as a floor, or as a roof panel. For example, and as illustrated by [Fig.5], such an element is composed of an insulating core (2), recesses (3A, 3B), and projections (5A, 5B) in a BFUP type composition, panel in which metal profiles (15) will have been introduced into the core (2), to increase the mechanical resistance and the span between two supports of the panel (IA). Such a structure has a major advantage, namely, it can be installed at the same time as the walls. Another advantage is that this panel can also have very large length dimensions.

[0045] Due to its construction, the panel according to the invention can do without rendering on its outer face when it is assembled to make a building, and without a plaster facing plate on its inner face of a building, the set of extra thicknesses (8A, 8B) also playing the role of facing, which in fact allows a wall, or a wall component, to be entirely finished.

[0046] The mechanical resistance of the panel makes it possible to envisage the construction of small single-story structures, without resorting to the use of load-bearing structures at the heart of the panel, for example, small chalets, garages, pool houses, garden sheds or garden offices.

[0047] As illustrated in [Fig.6], the construction and structural organization of the panel also makes it possible to dig other recesses (16) into the heart of the insulating core (2), which will be used to receive a sand-hardened cementitious binder, for example poured concrete, these recesses making it possible to create a post / beam type framework which serves as a load-bearing structure for the work and which has the advantage of being economical in concrete with a concrete / structure ratio of 100%, and presenting an efficiency without waste or superfluity of raw material. The cutouts of the recesses (16) are not limiting, neither in shape nor in size, and can have shapes related to the binder to be poured, for example, by retaining the BFUP, the recesses (16) can be optimized and have a more dynamic shape in the form of a “C” (11), “H” (12), or “T” (13) profile, optimized for the structural study.These optimized recesses (16) thus make it possible to reduce the quantities of concrete to be used by at least 40%. The recesses (16) inside the insulating core can be made by using a hot wire, the principle of which is known in the art, and which consists of inserting the hot wire into the material to cut it, to produce the desired shape and to come out exactly at the entry point. Then it is sufficient to eject the cutting. This cutting technique nevertheless has disadvantages, since it has the effect of weakening the cut shape from a mechanical point of view. [Fig.7] illustrates, via arrows, in a top view, the path (17) of the cutting wire.

[0048] [Fig.8] provides a better understanding of the problem of weakening of the recess (16). As can be seen, the entry and exit of the cutting wire creates an area where there is no longer any connection of the insulating material, since the latter has been cut from top to bottom by the entry of the hot wire. When pouring the cementitious hydraulic binder, a unidirectional thrust is created on this area (18) and deforms the recess (16) until it bursts when the concrete is poured. This problem is fairly widely known, and as a general rule, to prevent bursting from occurring, formwork elements must be used.

[0049] The panel according to the invention makes it possible to avoid the problem described above. The recesses (11, 12, 13, 16) dug in the insulating core (2) dedicated to the casting of the concrete structure remain very advantageous, despite their low resistance to pressure. In the case of the panel which is the subject of the invention, the cementitious hydraulic binders forming the projections (5A, 5B) and / or the excess thicknesses (8A, 8B), and which are cast in the factory during the manufacture of the panel, make it possible to play the role of structural reinforcement at the right angles to these internal recesses (16) of the insulating core (2). Indeed, the counter dihedrals (4A) also play a jaw role and make it possible to mechanically block the recesses (16), and consequently, it is no longer necessary to resort to separate formwork when pouring the concrete into the internal recesses.

[0050] One way of manufacturing the panel according to the invention will now be briefly described, by way of example: - manufacturing by molding an insulating core panel having dimensions of 3 meters high, 1.2 meters wide, 0.3 meters thick, the surface recesses (3A, 3B) of the core being obtained during molding; - alternatively, hot wire cutting of the recesses on the surface of the insulating core; - optional gluing or nesting of several core panels together to obtain the desired length; - production of the internal recesses (16) of the core, for example, with hot wire, according to the calculation of the structural plan; - pouring the layer of hardenable hydraulic binder (4A) forming the projections (5A) on a first face of the wall; - after drying the first face, pour the layer of hardenable binder (4B) forming the projections (5B) onto the opposite face of the insulating core; - incidentally, pouring the two opposite layers of hydraulic binder (4A, 4B) forming the projections (5A, 5B) at the same time, for example, via a semi-closed molding device.

[0051] The acoustic performance of a thermo-acoustic composite panel according to the invention, and obtained as indicated above, was tested according to the IEC 61672 standard with a PCE 322A sound level meter. The hydraulic binder layers forming the projections were made of UHPFRC, and the insulating core was made of steam-expanded polystyrene beads compressed during expansion. This panel had a surface weight of 22 kg / m2 and the following dimensions: 1m x 1m x 0.30m. The sound propagated for the tests had a frequency of 0 to 20,000 Hz. The tests were carried out as follows: - measurement of the initial surrounding sound; - measurement of sound transmission in dBA without panel; - measurement of sound transmission in dBA with panel.

[0052] The results of this test are illustrated by Figures 9, 10 and 11 respectively. [Fig. 9] shows that the ambient test sound was on average 39 db. Then, as illustrated in [Fig. 10], a sound transmission test, without a panel, over the range of propagated test frequencies indicated above indicated a maximum sound transmission of 108 dBA, and a minimum transmission of 41 dBA, which therefore varied quite significantly over time, with an average of 65 dBA. The test with the panel according to the invention, illustrated by [Fig. 1 1], still showed a sound transmission profile significantly lower than that of the test without a panel, the profile being particularly flatter and less heterogeneous in terms of transmission. sound, with a maximum transmission established at 49.5 dBA. From this profile, there results a sound attenuation, or weakening, which is of the order of -58 dBA, at least, for example, by comparing the 2 most important peaks at approximately the same time of the measurement due to the passage through the panel according to the invention. This shows the interesting and advantageous acoustic performances of the panel.

Claims

Claims

1. Thermo-acoustic composite panel (IA), comprising: an insulating core (2) made of a material selected from the group consisting of polystyrenes, an inorganic, organic, mineral, vegetable, synthetic composition or a mixture of several of these, the insulating core comprising recesses (3A, 3B) arranged on at least one face of the core; and a layer of hydraulic binder, covering at least one face of the insulating core having the recesses (3A, 3B), and comprising projections of hydraulic binder engaging in, and filling, the recesses arranged on the face of the insulating core, characterized in that: the insulating core (2) comprises from 1 to 100,000 recesses (3A, 3B) per m2, preferably between 10 and 20,000 recesses per m2, and the layer of hydraulic binder comprises from 1 to 100,000 projections (4A, 4B) corresponding to the m2, preferably between 10 and 20.000 corresponding projections per m2; and the thermo-acoustic composite panel (IA) has a sound transmission attenuation, measured by sound level meter according to standard IEC 61672, of at least 58 dBA.

2. Thermo-acoustic composite panel (IA) according to claim 1, characterized in that each projection (4A, 4B) of the hydraulic binder layer and each recess arranged on the face of the insulating core (3A, 3B) has a polyhedral or conical shape, in particular a geometric shape composed of one or more vertices, one or more edges, and one or more faces, and preferably the polyhedral shape is chosen from the group consisting of dihedrons, and / or tetrahedrons.

3. Thermo-acoustic composite panel (IA), according to claim 1 or claim 2, characterized in that the recesses of the core (3A, 3B) and the projections of the hydraulic binder layer (4A, 4B) have, respectively, dimensions lying in the range of 5 to 20,000 millimeters long, 5 to 200 millimeters wide, and 5 to 200 millimeters high.

4. Thermo-acoustic composite panel (IA), according to any one of the preceding claims, characterized in that the panel comprises at least one excess thickness (5A, 5B) covering the layer hydraulic binder comprising projections, and consisting of a material chosen from the group of inorganic, organic, mineral, and plant materials, separately or in a mixture.

5. Thermo-acoustic composite panel (1 A), according to claim 4, characterized in that the layer of hydraulic binder comprising the projections (4A, 4B) and / or the at least one extra thickness (5A, 5B) comprise fibers, chosen from the group of metallic, inorganic, organic, synthetic, vegetable, and mineral fibers, separately or as a mixture.

6. Thermo-acoustic composite panel (IA), according to any one of the preceding claims, characterized in that the insulating core (2) further comprises recesses formed inside the material of the core, in the shape of a rectangle (7) or in the shape of a C-shaped profile (13), T-shaped profile (14), H-shaped profile (15) or any other geometric shape.

7. Thermo-acoustic composite panel (IA), according to claim 6, characterized in that the internal recesses (7, 13, 14, 15) of the insulating core are sized to receive a sand-hardened hydraulic binder (6) or a mechanical reinforcement element (9), this hydraulic binder or mechanical reinforcement element being made of a material chosen from the group of inorganic, organic, mineral, vegetable, synthetic, metallic or mixed materials, forming structural reinforcement elements.

8. Thermo-acoustic composite panel (IA), according to any one of the preceding claims, characterized in that the projections (4A, 4B) and the excess thicknesses (5A, 5B) are in the form of formwork reinforcements at the level of the internal recesses (7, 13, 14, 15).

9. Thermo-acoustic composite panel (IA), according to any one of the preceding claims, characterized in that the hydraulic binder is an ultra-high performance fiber-reinforced concrete (UHPC).

10. Assembly of a plurality of thermoacoustic composite panels according to any one of claims 1 to 9, the assembly being in the form of a wall, barrier, partition, false ceiling, and / or roof.

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