PREFABRICATED BUILDING PANEL WITH A RESERVATION FRAME, BUILDING AND METHOD FOR MANUFACTURING A PREFABRICATED BUILDING PANEL

Abstract

PREFABRICATED BUILDING PANEL WITH A RESERVATION FRAME, BUILDING AND METHOD FOR MANUFACTURING A PREFABRICATED BUILDING PANEL A prefabricated building panel (1) comprises a body (6) made of a body material comprising a mineral binder. The body (6) extends in longitudinal (XX), transverse (YY) and thickness (ZZ) directions. The body (6) delimits a through hole in the thickness direction (ZZ). A reservation frame (4) has a shape complementary to the through hole in the longitudinal direction (XX) and in the transverse direction (YY). The reservation frame (4) delimits a through orifice in the thickness direction (ZZ). One or more of the external walls of the reservation frame (4) has a surface texture forming a locking member preventing separation between the reservation frame (4) and the body (6).The reservation frame (4) is a foam which has a thermal conductivity at least twice lower than the thermal conductivity of the body material.

Description

Title of the invention: PREFABRICATED BUILDING PANEL WITH A RESERVATION FRAME, BUILDING AND METHOD FOR MANUFACTURING A PREFABRICATED BUILDING PANEL Technical field

[0001] The invention relates to a prefabricated building panel, a building and to a method of manufacturing a prefabricated building panel. Prior art

[0002] To make construction panels, it is common to use a mold and then pour concrete into the mold. The concrete can be replaced by a composite based on a binder that hardens with time, heat or humidity in the air. Once the concrete is in the hardened state, the future construction panel is separated from the mold. The mold can be used again in whole or in part to form a new panel.

[0003] It is also common to make walls with through holes, for example a hole intended to receive a window, a door or the passage of a technical duct. In order to facilitate the production of this type of panel, it is common to place a reservation frame in the mold. The reservation frame delimits an area inside the mold where the concrete will not be present. The shape of the mold can be any. Once the concrete is in the hardened state, the reservation frame and the mold are separated from the construction panel.

[0004] The through hole that has been created is then functionalized with a door, window or other element before or after its installation with other panels.

[0005] Conventionally, the reservation frames are made of wood, metal or another material that is particularly well suited to this use. The material(s) forming the reservation frame are economical and preferably reusable in order to further reduce manufacturing costs. In addition, the material used must be able to withstand the thrust forces associated with the volume of concrete introduced into the mold.

[0006] It is also known to make reservations by means of a solid element which is made of foam. The concrete is poured around the foam pad and the latter is destroyed in order to form a through hole, for example to define a passage hole for a hydraulic pipe or to pass electrical cables.

[0007] Once the building panels have hardened and the building masonry is finalized, foam pre-frames can be installed in the openings. The pre-frames are thermally insulating to prevent the formation of thermal bridges. The rigid foam pre-frames will not only provide insulation and break thermal bridges but also allow the fixing of joinery and additional joinery cladding (sill, apron, etc.). To achieve these results, the dimensions of the pre-frames are adapted to the size of the opening as well as the size of the windows, which requires taking measurements on site and cutting the foam to size to form the pre-frame. The pre-frame can then be glued or screwed to the construction wall.

[0008] It appears that this implementation method is not entirely satisfactory because there are too many manual interventions and there are regular adaptation operations on the foam frame to better adapt to the dimensions of the hole in the construction panel and thus ensure airtightness, breaking of thermal bridges, watertightness while being compatible with the other components of the structure, in particular the coatings, the cladding, possible external thermal insulation and roller shutters. Subject of the invention

[0009] An object of the invention is to provide a building panel which is more efficient than prior art configurations and which allows a window to be installed more quickly and efficiently in a through hole of the building panel.

[0010] We tend to solve this problem by means of a prefabricated construction panel comprising: - a body made of a body material comprising a mineral binder, the body extending in a longitudinal direction, a transverse direction and a depth direction, the body delimiting a through hole in the depth direction; - a reservation frame provided with several side walls assembled in the form of a ring, the ring having an external face having a shape complementary to the through hole perpendicular to the depth direction, the reservation frame having an internal face delimiting a through opening which is through in the depth direction.

[0011] The construction panel is remarkable in that the external face of several of the side walls of the reservation frame has one or more projecting elements defining a surface texturing forming a locking member preventing detachment between the reservation frame and the body; in that the projecting elements are elements present only on the external face and / or are partially recessed according to the thickness of the side wall; and in that the reservation frame is a foam which has a conductivity thermal conductivity at least twice as low as the thermal conductivity of the body material.

[0012] According to one aspect of the invention, the foam of the reservation frame has a modulus of elasticity greater than 75Mpa and a compressive strength greater than IMpa.

[0013] Preferably, a window is only attached to the reservation frame.

[0014] Advantageously, the side walls extending mainly in a vertical direction have a rupture joint which has a Young's modulus less than or equal to 80% of the Young's modulus of the foam and less than the Young's modulus of the body.

[0015] In a particular configuration, the body material comprises at least 30% by mass of particles of an element of plant origin.

[0016] Preferably, the body material is a porous material. The body material has a porosity at the interface with the reservation frame which is less than a porosity at the core of the body.

[0017] The invention also relates to a building which is capable of providing better management of the thermal resistance of the joinery to be installed.

[0018] This result is tended to be achieved by means of a building which comprises at least one wall formed by a construction panel according to any one of the preceding configurations.

[0019] The invention also relates to a method of manufacturing a construction panel which is easier to implement than the methods of the prior art while facilitating the installation of the joinery.

[0020] This result is achieved by means of a method of manufacturing a prefabricated construction panel comprising the following steps: - provide a mold and a reservation frame formed by several side walls assembled in the form of a ring; - pouring a body material comprising a mineral binder into the mold around the reservation frame to form a body, the mineral binder partially filling the mold and being in contact with the external faces of the reservation frame; - solidify the mineral binder before removing the mold.

[0021] The method is remarkable in that the external face of several of the side walls of the reservation frame has one or more projecting elements defining a surface texture and forming a blocking member preventing separation between the reservation frame and the body when the mineral binder is solidified; in that the projecting elements are elements present only on the external face and / or are partially recessed according to the thickness of the side wall; in that the reservation frame is made of a foam which has a thermal conductivity at least twice as low as the thermal conductivity of the body material.

[0022] Advantageously, the manufacturing method comprises a step of fixing a window with the body. Preferably, the window is fixed only to the reservation frame.

[0023] Preferably, a metal keyway is attached to said one or more external faces to form the surface texturing, the metal keyway being embedded in the body material.

[0024] In an advantageous embodiment, one or more of the external faces of the reservation frame have a surface roughness, the mineral binder filling the surface roughness. Summary description of the drawings

[0025] 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:

[0026] [Fig.l] schematically illustrates a perspective view of a mold containing a reservation frame and cast body material;

[0027] [Fig.2] schematically illustrates a construction panel separated from the mold and retaining the reinforcing element inside the reservation frame;

[0028] [Fig.3] schematically illustrates a view of a horizontal section of a ground floor of a building provided with several construction panels;

[0029] [Fig.4] schematically illustrates a view of a vertical section of an intermediate floor of a building provided with several construction panels;

[0030] [Fig.5] schematically illustrates a view of a vertical section of a top floor of a building provided with several construction panels;

[0031] [Fig.6] schematically illustrates a view of a cavity delimited in part by a reservation frame supporting a window, the cavity housing a roller shutter;

[0032] [Fig.7] schematically illustrates a view of a part of the reservation frame provided with different surface textures;

[0033] [Fig.8] schematically illustrates a view of a reservation frame provided with a rupture joint

[0034] [Fig.9] schematically illustrates a construction with windows installed in the reservation frames. Description of the embodiments

[0035] Figures 1 and 2 illustrate two steps of a method of manufacturing a construction panel 1. Figures 3, 4, 5, 6, 7, 8 and 9 illustrate different embodiments of a construction panel 1 installed in a building 2. The construction panel construction 1 extends mainly along longitudinal XX and transverse YY directions. It also extends along a depth direction ZZ which is perpendicular to the longitudinal XX and transverse YY directions.

[0036] As illustrated in [Fig.l], the method for manufacturing a construction panel 1 comprises a first step of providing a mold 3 and a reservation frame 4 arranged inside the mold 3. The mold can have any shape and the reservation frame 4 can also have any shape. In the example illustrated in [Fig.l], the mold 3 has a rectangular section. In the example illustrated in Figures 1 and 2, the reservation frame 4 has a rectangular section.

[0037] The mold 3 has a bottom and side walls 3a. The side walls 3a may be reinforced by reinforcing elements 3b. The reinforcing elements 3b make it possible to maintain the inclination of the side walls 3a relative to a vertical direction. The reinforcing elements 3b may make it possible to ensure the dimensions are maintained by ensuring the non-deformation of the mold 3 or the reduction of the deformation of the mold 3 during the manufacturing process of the construction panel 1, in particular in response to the thrust forces generated during the casting of the material intended to form the construction panel 1.

[0038] The reservation frame 4 has side walls 4a. Depending on the embodiments, the reservation frame 4 may be provided with or without a bottom. In the illustrated example, the reservation frame 4 has no bottom. It is advantageous to provide a reservation frame 4 which is associated with reinforcements 5. For example, the reinforcements 5 may comprise reinforcement plates 5a which have an external wall intended to be in contact with the side walls 4a of the reservation frame 4. The reinforcement plates 5a may have any shape and preferably the shape is identical or substantially identical to the internal wall of the reservation frame 4. In the illustrated example, the internal walls of the reservation frame 4 are rectilinear and the reinforcement plate 5a has a rectilinear face. Some of the internal walls of the reservation frame 4 are planar and the reinforcement plate 5a is also planar.The reinforcement plate 5a is removable from the reservation frame 4 and from the mold 3. The reinforcement plate 5a makes it possible to temporarily stiffen all or part of the reservation frame 4 in order to allow the reservation frame 4 to better withstand the forces applied by the material poured into the mold 3. If necessary, the reinforcements 5 make it possible to maintain the internal shape of the reservation frame 4, the dimensions of which are chosen for the fixing of equipment, for example joinery.

[0039] The reservation frame 4 advantageously has a compressive strength at least equal to IMPa, preferably at least equal to 2MPa and more preferably at least equal to 2.5MPa in the direction XX or in the direction YY. compressive strength allows the reservation frame 4 to resist the thrust forces associated with casting.

[0040] The reservation frame 4 may also cooperate with a reinforcement 5 in the form of a position locking system 5b which is configured to lock the position of all or part of the reservation frame 4. The position locking system 5b may be configured to lock the position of a side wall 4a of the reservation frame 4 relative to the mold 3 and / or of a side wall 4a of the reservation frame 4 relative to another side wall 4a of the reservation frame 4. In the illustrated embodiment, the position locking system 5b is in the form of one or more rods which connect and fix the separation distance between two side walls 4a. In the illustrated embodiment, the position locking system 5b is in the form of several rods extending in intersecting directions to fix the position of the longitudinal side walls and the transverse side walls.In this case, the position locking system 5b does not necessarily attach to the mold 3.

[0041] Other embodiments of the position locking system 5b are possible, for example with one or more parts of the position locking system 5b which are fixed to the mold 3. If the bottom of the mold 3 is metallic, the position locking system 5b can be provided with a magnet which makes it possible to fix the position of the magnetized part. If the side wall 4a is pressed against the magnetized part, the side wall 4a remains fixed despite the force applied by the cast material. An identical result can be obtained with a bottom which makes it possible to attach the position locking system 5b by screwing or by any other technique.

[0042] Once the mold 3 is installed and the reservation frame 4 is arranged in the mold 3, possibly with the reinforcement, a body material is poured into the mold 3 in order to form a body 6 of the construction panel 1. The material is poured in the liquid or pasty state. The body material hardens so as to form a self-supporting construction panel 1 and more preferably a construction panel 1 capable of supporting the weight of a roof or a ceiling and possibly the weight of one or more floors surmounted by a roof or a ceiling.

[0043] Once the body material is harder and / or in a hardened state, the mold 3 is separated from the body 6 of the building panel 1. Once the material is harder and / or in a hardened state, the reinforcement 5 is separated from the body 6 of the building panel 1. Depending on the configurations, the reinforcement 5 is removed before, after or at the same time as the mold 3. The position locking systems 5b can be quickly dismantled before complete drying of the body material which is retained by the reservation frame 4. The position locking system 5b can be used in another mold before complete drying. The reinforcement 5 can be made of wood or metal.

[0044] [Fig. 2] illustrates a particular embodiment where the mold 3 is removed before removing the reinforcement 5. It is advantageous to remove the reinforcement 5 as late as possible in order to avoid damaging the reservation frame 4. The reinforcement 5 can also serve as mechanical reinforcement during the stages of transport and / or handling of the construction panel 1.

[0045] Whereas in prior art configurations the reservation frame was removed in order to install a window therein or possibly to install a foam frame and a window therein in the workshop or on site, the manufacturing method retains the reservation frame 4 and a window 7 or other element is installed inside the reservation frame 4. The reservation frame 4 used during casting of the body material is used to place a window 7 in the building panel 1 and mechanically support the window 7. Depending on the implementation methods, the window is fixed to the reservation frame 4 in the workshop or on site.

[0046] The use of a foam to form the reservation frame 4 allows for a better compromise between thermal performance and mechanical performance. The foam is not suitable for reusing the reservation frame in another mold. The foam reservation frame 4 is retained for the installation of the joinery.

[0047] The internal dimensions of the reservation frame 4 are defined to receive equipment, for example joinery. The mechanical characteristics of the material forming the reservation frame 4 are chosen so that, during casting, the dimensions of the internal opening do not change or change little so as to accept the installation of the joinery. Preferably, the thickness of the reservation frame 4 is greater than 2 cm, more preferably greater than 4 cm and even more preferably greater than 6 cm to form good thermal resistance between the joinery and the body 6 without excessively reducing the usable surface area.

[0048] The reservation frame 4 has been installed in the mold 3 before casting the body material, which allows the reservation frame 4 to be positioned precisely. The body material is then cast into the mold 3. During its hardening, the body material is in contact with the reservation frame 4 so that the shape of the body 6 is perfectly adapted to the shape of the external walls of the reservation frame 4. The body 6 and the reservation frame 4 define two complementary surfaces. The reservation frame 4 is specific to an opening in the building panel 1. The dimensional variations that may exist with respect to the external walls of the reservation frame 4 are absorbed by the body material cast in the liquid or pasty state, which adapts to the shape of the reservation frame 4 arranged in the mold 3. The reservation frame 4 is in the form of a ring with an external face and an internal face.

[0049] It is particularly advantageous to provide that, in the thickness direction, the reservation frame 4 has one or more non-smooth walls, i.e. a wall with projecting elements that define a surface texture. The use of non-smooth walls makes it possible to prevent the reservation frame 4 from sliding relative to the body 6 in the hardened state in the depth direction. The risk of loss of a reservation frame 4 during transport of the building panel 1 becomes low or even zero. This also facilitates the installation of the window 7 in the reservation frame 4 before its fixing and this allows the direct fixing of the window 7 with the reservation frame 4 possibly without direct fixing with the body 6. The direct fixing of the window 7 can be carried out by screws.The direct fixing represents less than 10% in volume compared to the volume of the reservation frame 4, more preferably less than 5%, more preferably less than 2% and even more preferably less than 1%.

[0050] The use of a reservation frame 4 of which several of the side walls 4a are provided with projecting elements which define a texturing on its external surface makes it possible to fixably mount the reservation frame 4 and the body 6 without having to use a layer of glue. The difference in coefficient of thermal expansion between the body 6 and the reservation frame 4 will induce repeated shear forces on the layer of glue which reduces its service life. The use of a reservation frame 4 provided with a texturing on its external surface makes it possible to fixably mount the reservation frame 4 and the body 6 without having to fix the reservation frame 4 by screwing or any other equivalent means. The screw which extends through the entire thickness forms a thermal bridge which degrades the performance of the reservation frame 4.

[0051] The non-smooth outer wall of the reservation frame 4 represents a surface texturing which forms a locking member preventing detachment between the reservation frame 4 and the body 6. The protruding elements may come from a rough outer wall with holes and bumps. The bumps form the protruding elements. The roughness of the outer surface may be achieved by cutting holes, for example grooves in the side walls 4a.

[0052] The texturing may be the presence of one or more protruding patterns which may be in the form of one or more fins extending in the longitudinal and / or transverse direction. It is also possible to provide a texturing made of a material different from the reservation frame 4, for example in the form of an additional texturing 8. [Fig. 7] illustrates different embodiments of a surface texturing of a part of a reservation frame 4 which may comprise an additional texturing in the form of a screw or a nail 8a, or in the form of a pin 8b stuck in the reservation frame 4. In the example illustrated, the pin 8b is introduced into a recess in the reservation frame 4 and it has a section increasing away from the reservation frame 4. It is also possible that the reservation frame 4 has a hole and preferably a groove 8c whose width increases in the direction from the external face towards the internal face. When the additional texturing 8 is a screw, it is advantageous to screw the screw directly into the reservation frame 4. The material of the reservation frame 4 is chosen accordingly. It is advantageous for the projecting element to extend over a distance of at least 3 cm inside the body and for the projecting element to have an area with a larger section inside the body 6 which prevents its removal without destruction of the projecting element or degradation of the body 6.

[0053] In order to have better resistance over time of the reservation frame 4, it is advantageous to have a single material which extends over the entire thickness from the interface with the body 6 to the joinery.

[0054] Preferably, the reservation frame 4 has a roughness which is greater than the roughness of the walls 3a and the bottom of the mold 3 so as to make the reservation frame 4 non-removable from the body 6 and to facilitate the dissociation between the body 6 and the mold 3.

[0055] For example, [Fig.6] illustrates a protruding element fixed to the reservation frame 4 before casting the body material. In the illustrated example, the protruding element of the additional texturing 8 may be a screw or a nail. When casting the body material, the protruding element is embedded in the body material before the latter hardens.

[0056] The projecting element does not extend over the entire thickness of the reservation frame 4, that is to say over the entire dimension which extends from the internal face of the ring, that is to say the periphery, to the external face of the ring. This precaution makes it possible to avoid forming a thermal bridge inside the reservation frame 4 and this also makes it possible to avoid forming a zone of differential expansion over the entire thickness of the ring.

[0057] It is advantageous to form protruding elements which make it possible to define a retention resistance which is greater than 50kN / linear meter of side wall 4a for a side wall which has an interface with the body 6 which extends over a depth at least equal to 5cm. More preferably, the retention resistance is greater than 100kN / linear meter.

[0058] It has been observed that a roughness with hollows of at least 0.5 mm on the external wall of the reservation frame 4 makes it possible to ensure the immovability of the reservation frame 4 with respect to the body 6. Such a result can be obtained with a body 6 whose mineral binder is liquid enough to be introduced into the hollows. For example, a body material which is made exclusively of concrete or by means of a concrete which is loaded with particles of material of plant origin makes it possible to have a very good cohesion between the body 6 and the reservation frame 4 even when the particles of material of plant origin represent a greater volume than the volume of mineral binder, preferably concrete.

[0059] The surface texturing makes it possible to form a reservation frame 4 which is irremovable relative to the body 6 and which makes it possible to provide good thermal resistance between the joinery and the body 6.

[0060] To increase the retention resistance value, it is possible to increase the roughness value and / or to increase the interface surface between the reservation frame 4 and the body 6. It is particularly advantageous to have an outer wall that is rough, i.e. with holes and bumps distributed over the entire interface because the forces are better distributed over the entire surface between the reservation frame 4 and the body 6. When the building panel 1 is devoid of protruding elements that sink inside the reservation frame 4, the thermal resistance between the inner wall of the reservation frame 4 and the outer wall of the reservation frame 4 is maximum. To improve the retention resistance value at specific points, it is possible to install a protruding element such as a nail or a screw to fix more securely to the body 6. However, this results in a decrease in thermal performance.

[0061] Since the reservation frame 4 is intended to be arranged between the body 6 and the window 7, it is particularly advantageous to have a reservation frame 4 which is made of a material which has a thermal conductivity lower than the thermal conductivity of the material forming the body 6. More preferably, the material of the reservation frame 4 has a thermal conductivity which is at least two times lower than the thermal conductivity of the material forming the body 6, more preferably at least four times lower. The further the conductivity ratio is from unity, the more it is possible to eliminate thermal bridges with a small quantity of reservation frame material 4. The quantity of material is measured in the longitudinal and transverse directions. Advantageously, the material of the reservation frame 4 has a thermal conductivity of between 0.025 W / (mK) and 0.05 W / (mK).

[0062] It is therefore particularly advantageous to use a body material whose density is lower than the density of the concrete, in order to have a better compromise between the mechanical performance of the body 6, the thermal performance of the body 6 and the size of the reservation frame 4.

[0063] In one embodiment, the body material comprises a mineral binder and particles of a plant material embedded in the mineral binder. The use of particles of a plant material makes it possible to form a body 6 whose capacity to store heat is lower than for an equivalent made of cement, concrete, reinforced concrete or in any other mineral binder. The use of particles of a plant material embedded in the mineral binder makes it possible to have particles that are fully coated by the mineral binder, which ensures mechanical cohesion between the particles and protects the particles against external aggressions. The use of particles of plant material makes it possible to produce a material with an improved carbon footprint and which allows the woodwork to be screwed through the reservation frame 4 directly into the body 6 without making a pre-hole. In this configuration, the reservation frame 4 being fixed to the body 6 by the surface texturing, only a few screws are necessary to fix the woodwork to the body 6. The configuration has better airtightness than the configurations of the prior art as well as a better reduction of thermal bridges.

[0064] Preferably, the body material is a porous material with open pores. The body material has a first value of mass content of plant material particles of between 30% and 70% and preferably with a volume content of plant material particles of between 30% and 95%, more preferably the plant material particles represent a greater volume than the mineral binder. The mass content of plant material particles corresponds to the mass of the plant material particles relative to the total mass of the body material 6 after drying. The volume content of plant material particles corresponds to the volume of the plant material particles relative to the total volume of the other materials of the body 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 1 in comparison with an equivalent panel made exclusively of concrete or reinforced concrete.

[0065] Preferably, the majority in number of the particles 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 body 6 with significant surface roughness.Even more preferably, the particles are wood chips which have a thickness mainly (in number) between 1mm and 5mm. Such a distribution in length and thickness makes it possible to form a support material. 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 on the surface.

[0066] The body 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. The mineral binder may comprise fly ash or "Pulverized Fuel Ash" which is waste from the combustion of carbon. The binder is preferably a binder which hardens after the addition of water. 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.

[0067] The particles of plant element 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 body 6.

[0068] 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 body material is preferably between 600 and 1200 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 wood elements and whose density is approximately 2300 kg / m3.

[0069] During casting, the particles of plant material are distributed randomly. However, in contact with the side wall 3a of the mold 3 and in contact with the side wall 4a of the reservation frame 4, the particles tend to align parallel to the face of the side wall, which has the effect of reducing the surface porosity. In addition, the roughness is lower than casting without a side wall, which increases the surface cohesion value between the body 6 and the reservation frame 4.

[0070] When a body material containing at least 30% by mass of plant material particles is used, it appears that the side walls are sensitive to impacts and deteriorate quickly. This problem is all the more important since the construction panel 1 is intended to be moved because it is prefabricated. It is therefore particularly advantageous to keep the reservation frame 4. This also makes it possible to avoid moving the reservation frames 4 to the place where the windows 7 are installed, generally on the final construction site, and then bringing the reservation frames 4 back to the place where the construction panels 1 are manufactured.

[0071] Furthermore, it is advantageous to place the reservation frame 4 against the bottom wall of the mold 3 so that the bottom wall of the mold 3 is intended to represent the interior face of the building 2 comprising the construction panel 1. The bottom of the mold 3 can form a flat wall and the end of the reservation frame 4 is flush which makes it possible to precisely place the window 7 relative to the face of the body 6 in the thickness direction.

[0072] When the body material comprises at least 30% by mass of plant material particles, the density of the material in the liquid or pasty state decreases significantly in comparison with pure concrete or reinforced concrete. The thrust force applied by the material in the liquid state on the reservation frame 4 is much lower. It is possible to have a more flexible foam which promotes filtering of the forces between the window 7 and the construction panel 1.

[0073] It is advantageous to use a foam whose compressive strength is between IMPa and 5MPa. Such a value makes it possible to support a very large number of materials capable of forming the body material in the liquid or pasty state and in various configurations, in particular for materials containing at least 30% by mass of plant material particles. For a reservation frame 4 intended to be used with pure concrete, a concrete having less than 20% by mass of plant material particles, a material having a compressive strength greater than or equal to 5Mpa will be preferred.

[0074] It is also advantageous to use a modulus of elasticity which is between 75Mpa and 275Mpa. Such a material is particularly interesting for carrying out the fixing of the window with the separation frame 4 possibly without fixing directly to the body 6.

[0075] The reservation frame 4 serves to support a window 7. The material of the reservation frame 4 must be rot-proof and maintain its mechanical and thermal performance well over time, particularly for a period of at least 10 years, preferably at least 25 years.

[0076] The foam forming the reservation frame 4 has a surface roughness which is significantly less than the surface of the body 6 formed by a material containing at least 30% by mass of plant material particles. The installation surface is better defined.

[0077] In an advantageous embodiment illustrated in [Fig.9], it is advantageous to limit the absorption of forces by the reservation frame 4. This configuration is part This is particularly advantageous when the body 6 is made of a body material whose compressive strength is close to the compressive strength of the material forming the reservation frame 4 and more particularly when the Young's modulus of the body material approaches the Young's modulus of the foam which forms the reservation frame 4. The values ​​of Young's modulus and compressive strength become closer when the content of plant material particles is increased. It is advantageous for the reservation frame 4 to have side walls 4a extending mainly in a vertical direction and which has a rupture joint 4b which has a Young's modulus less than or equal to 80% of the Young's modulus of the foam and less than the Young's modulus of the body 6. The material forming the rupture joint 4b will deform preferentially to avoid overstressing the reservation frame 4.In this case, the use of a reinforcement 5 is preferred to ensure good control of the dimensions of the reservation frame 4.

[0078] It is possible to use a polyethylene terephthalate foam which is capable of exhibiting mechanical and thermal performances in accordance with what has been stated above. For example, the polyethylene terephthalate foam may exhibit a thermal conductivity which is 4 to 6 times lower than the thermal resistivity of a body material whose mineral binder is concrete and whose plant material particles are particles of wood or another plant element. The polyethylene terephthalate foam is advantageous because it is economical. It is also possible to use another foam, for example a polyurethane foam.

[0079] Figures 3 to 6 illustrate a building 2 which comprises several construction panels 1. The construction panels 1 define through openings 9 delimited by a reservation frame 4.

[0080] [Fig.3] illustrates a building 2 of which two construction panels 1 form two walls. A first wall defines a single through opening 9 intended to receive a window 7 while the other wall defines several through openings 9, here two through openings intended to receive windows 7. By window 7, we mean any type of window including French windows, bay windows, windows with one, two, three or more openings as well as windows 7 which do not open.

[0081] Figures 3, 4 and 5 illustrate reservation frames 4 whose section is not constant along the thickness direction. The hollows and / or the projecting zones can be used to precisely position the windows 7 along one or more directions. The frames of the windows 7 have complementary shapes or an inhomogeneous section to fix the position of the window 7 along the depth direction ZZ.

[0082] Figures 3 and 8 illustrate an embodiment where the building panels 1 form a ground floor. A building panel 1 may define a through opening 9 intended to receive a door. The other building panels 1 end with through openings 9 intended to receive a window 7.

[0083] [Fig.4] illustrates an embodiment where the building panels 1 form an intermediate floor of a building 2. A building panel 1 defines a through opening 9 intended to receive a window 7. The building panel 1 is fixed or can be fixed to a floor slab 10 and a ceiling slab 11. Each of the floor and ceiling slabs is supported by beams 12.

[0084] [Fig. 5] illustrates an embodiment where the building panels 1 form a top floor of a building 2 supporting a roof. Two walls define a through opening 9 intended to receive a window 7. The wall is fixed or can be fixed to a floor slab 10 and a ceiling slab 11. Each of the floor slabs 10 and ceiling slabs 11 is supported by beams 12.

[0085] [Fig.5] illustrates an embodiment where the wall 4a defines a recess capable of receiving a roller shutter 13.

[0086] [Fig. 6] illustrates, in sectional view, an embodiment where the wall 2a defines a recess capable of receiving a roller shutter 13. The external face of the construction panel 1 is covered by a layer of insulation 14, for example glass wool or rock wool, and by a protective layer 15, for example a metal sheet, a polymer sheet or wooden cladding. The internal face of the construction panel 1 is covered by a facing layer 16, for example a plasterboard. [Fig. 6] also illustrates the fixing of the frame 7' and the opening 7” of a window 7.

[0087] The construction panel 1 was prefabricated, i.e. manufactured on a manufacturing site and then moved to its place of use.

[0088] [Fig.8] illustrates an embodiment of a building panel 1 with a window.

Claims

Claims

1. Prefabricated construction panel (1) comprising: - a body (6) made of a body material comprising a mineral binder, the body (6) extending in a longitudinal direction (XX), a transverse direction (YY) and a depth direction (ZZ), the body (6) delimiting a through hole in the depth direction (ZZ); - a reservation frame (4) provided with several side walls (4a) assembled in the form of a ring, the ring having an external face having a shape complementary to the through hole perpendicular to the depth direction (ZZ), the reservation frame (4) having an internal face delimiting a through opening (9) which is through in the depth direction (ZZ);characterized in that the outer face of several of the side walls (4a) of the reservation frame (4) has one or more projecting elements defining a surface texture (8, 8a, 8b, 8c) forming a locking member preventing detachment between the reservation frame (4) and the body (6); in that the projecting elements are elements present only on the outer face and / or are partially sunk according to the thickness of the side wall (4a); and in that the reservation frame (4) is a foam which has a thermal conductivity at least twice lower than the thermal conductivity of the body material.;

2. Prefabricated building panel (1) according to claim 1 wherein the foam of the reservation frame (4) has a modulus of elasticity greater than 75Mpa and a compressive strength greater than IMpa.

3. Prefabricated building panel (1) according to claim 2 wherein a window (7) is only fixed to the reservation frame (4).

4. Prefabricated construction panel (1) according to any one of claims 1 to 3 in which the side walls (4a) extending mainly in a vertical direction have a rupture joint (4b) which has a Young's modulus less than or equal to 80% of the Young's modulus of the foam and less than the Young's modulus of the body (6).

5. A prefabricated building panel (1) according to any one of claims 1 to 4 wherein the body material comprises at least 30% by mass of particles of an element of plant origin (1).

6. A prefabricated building panel 1 according to claim 4 wherein the body material is a porous material and wherein the body material has a porosity at the interface with the reservation frame (4) which is less than a porosity at the core of the body (6).

7. Building comprising at least one wall formed by a building panel according to any one of claims 1 to 6.

8. A method of manufacturing a prefabricated building panel (1) comprising the following steps: - providing a mold (3) and a reservation frame (4) formed by a plurality of side walls (4a) assembled in the form of a ring; - casting a body material comprising a mineral binder into the mold (3) around the reservation frame (4) to form a body (6), the mineral binder partially filling the mold (3) and being in contact with the outer faces of the reservation frame (4); - solidifying the mineral binder before removing the mold (3); characterized in that the outer face of several of the side walls of the reservation frame (4) has one or more projecting elements defining a surface texturing (8, 8a, 8b, 8c) and forming a locking member preventing detachment between the reservation frame (4) and the body (6) when the mineral binder is solidified;in that the protruding elements are elements present only on the external face and / or are partially recessed according to the thickness of the side wall (4a) in that the reservation frame (4) is made of a foam which has a thermal conductivity at least twice lower than the thermal conductivity of the body material.;

9. Manufacturing method according to claim 8 comprising a step of fixing a window (7) with the body (6).

10. Manufacturing method according to one of claims 8 and 9 in which the window (7) is fixed only to the reservation frame (4).

11. A manufacturing method according to any one of claims 8 to 10 wherein a metal keyway is attached to said one or more outer faces to form the surface texturing, the metal keyway being embedded in the body material.

12. Manufacturing method according to one of claims 8 to 11 in which one or more of the external faces of the reservation frame (4) have a surface roughness, the mineral binder filling the surface roughness.

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