Prefabricated construction panel with a reservation frame, building and manufacturing process of a prefabricated construction 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 containing a mineral binder. The body (6) extends along the longitudinal (XX), transverse (YY), and thickness (ZZ) directions. The body (6) defines a through hole along the thickness direction (ZZ). A reservation frame (4) has a shape complementary to the through hole along the longitudinal (XX) and transverse (YY) directions. The reservation frame (4) defines a through hole along the thickness direction (ZZ). One or more of the external walls of the reservation frame (4) have a surface texture forming a locking element that prevents 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 as low as the thermal conductivity of the body material.

Description

Title of the invention: PREFABRICATED CONSTRUCTION PANEL WITH A RESERVATION FRAME, BUILDING AND METHOD FOR MANUFACTURED A PREFABRICATED CONSTRUCTION PANEL technical field

[0001] The invention relates to a prefabricated construction panel, a building and a method for manufacturing a prefabricated construction panel. Previous technique

[0002] To produce construction panels, it is common practice to use a mold and then pour concrete into the mold. The concrete can be replaced by a composite material based on a binder that hardens over time, with heat or atmospheric humidity. Once the concrete has hardened, the future construction panel is removed from the mold. The mold can then be reused, in whole or in part, to form a new panel.

[0003] It is also common to create walls with through holes, for example, a hole for a window, a door, or a service duct. To facilitate the creation of this type of panel, it is common to place a template frame in the mold. The template frame defines an area inside the mold where the concrete will not be present. The shape of the mold can be any shape. Once the concrete has hardened, the template frame and the mold are separated from the construction panel.

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

[0005] Typically, formwork frames are made of wood, metal, or another material particularly well-suited to this use. The material(s) forming the formwork frame are economical and preferably reusable in order to further reduce manufacturing costs. Furthermore, 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 create recesses using a solid element made of foam. Concrete is poured around the foam block, which is then destroyed to form a through hole, for example, to create a passage for a hydraulic pipe or for passing electrical cables.

[0007] Once the construction panels have hardened and when the building masonry Once the construction is complete, foam subframes can be installed in the openings. These subframes provide thermal insulation to prevent thermal bridging. Rigid foam subframes not only offer insulation and break thermal bridges but also allow for the attachment of the window and door frames and any additional trim (sills, drip edges, etc.). To achieve these results, the subframe dimensions are adapted to the size of the opening and the windows, which requires on-site measurements and custom cutting of the foam to form the subframe. The subframe can then be glued or screwed to the building wall.

[0008] It appears that this implementation method is not entirely satisfactory because manual interventions are too numerous and there are regular adaptation operations on the foam frame to better fit the dimensions of the hole in the construction panel and thus ensure air tightness, thermal bridge breaking, water tightness while being compatible with the other components of the structure, in particular the plaster, the cladding, any external thermal insulation and roller shutters. Object of the invention

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

[0010] This problem is to be solved by means of a prefabricated construction panel comprising: - a body made of a body material comprising a mineral binder, the body extending along a longitudinal direction, a transverse direction and a depth direction, the body delimiting a hole passing through along the depth direction; - a reservation frame with several side walls assembled in the form of a ring, the ring having an external face having a shape complementary to the hole passing through perpendicularly to the depth direction, the reservation frame having an internal face delimiting a through opening which is through along 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 protruding elements defining a surface texture forming a blocking element preventing a separation between the reservation frame and the body; in that the protruding elements are elements present only on the external face and / or are partially recessed depending on the thickness of the side wall; and in that the reservation frame is a foam which possesses conductivity thermal 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 fixed to the reservation frame.

[0014] Advantageously, the side walls extending predominantly 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 that is lower than the 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 includes at least one wall formed by a construction panel according to any of the preceding configurations.

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

[0020] This result is to be achieved by means of a process for manufacturing a prefabricated construction panel comprising the following steps: - provide a mold and a reservation frame formed by several side walls assembled in the shape of a ring; - pour a body material containing 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 process is remarkable in that the external face of several of the side walls of the reservation frame has one or more protruding elements defining a surface texture and forming a blocking element preventing a separation between the reservation frame and the body when the mineral binder is solidified; in that the protruding elements are elements present only on the external face and / or are partially recessed depending on the thickness of the lateral 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 process includes a step of attaching a window to the body. Preferably, the window is attached only to the mounting frame.

[0023] Preferably, a metal key is fixed to one or more external faces to form the surface texture, the metal key 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. Brief description of the drawings

[0025] Other advantages and features will become clearer from the following description of particular embodiments and implementations of the invention given by way of non-limiting examples and shown in the accompanying 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 equipped with several construction panels;

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

[0030] [Fig.5] schematically illustrates a view of a vertical section of the top floor of a building equipped 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 part of the reservation frame equipped with different surface textures;

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

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

[0035] Figures 1 and 2 illustrate two steps in a manufacturing process for 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 panel of Construction 1 extends mainly along the longitudinal XX and transverse YY directions. It also extends along a depth ZZ direction which is perpendicular to the longitudinal XX and transverse YY directions.

[0036] As illustrated in [Fig. 1], the manufacturing process for 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. 1], the mold 3 has a rectangular cross-section. In the example illustrated in Figures 1 and 2, the reservation frame 4 has a rectangular cross-section.

[0037] The mold 3 has a base and side walls 3a. The side walls 3a can be reinforced by reinforcing elements 3b. The reinforcing elements 3b maintain the inclination of the side walls 3a relative to a vertical direction. The reinforcing elements 3b can ensure that the dimensions are maintained by preventing deformation of the mold 3 or reducing deformation of the mold 3 during the manufacturing process of the construction panel 1, particularly in response to the thrust forces generated during the pouring of the material intended to form the construction panel 1.

[0038] The recess 4 has side walls 4a. Depending on the embodiment, the recess 4 may or may not have a bottom. In the illustrated example, the recess 4 has no bottom. It is advantageous to provide a recess 4 that is associated with reinforcements 5. For example, the reinforcements 5 may comprise reinforcement plates 5a that have an outer wall intended to be in contact with the side walls 4a of the recess 4. The reinforcement plates 5a may have any shape, and preferably the shape is identical or substantially identical to the inner wall of the recess 4. In the illustrated example, the inner walls of the recess 4 are straight, and the reinforcement plate 5a has a straight face. Some of the inner walls of the recess 4 are flat, and the reinforcement plate 5a is also flat.The reinforcing plate 5a is removable from the recess frame 4 and from the mold 3. The reinforcing plate 5a allows all or part of the recess frame 4 to be temporarily stiffened so that the recess frame 4 can better withstand the forces applied by the material poured into the mold 3. If necessary, the reinforcements 5 allow the internal shape of the recess frame 4 to be maintained, the dimensions of which are chosen for the fixing of equipment, for example, a joinery.

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

[0040] The reservation frame 4 can 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 can be configured to lock the position of one side wall 4a of the reservation frame 4 relative to the mold 3 and / or one 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 takes the form of one or more rods that connect and fix the separation distance between two side walls 4a. In the illustrated embodiment, the position-locking system 5b takes the form of several rods extending in intersecting directions to fix the position of the longitudinal and transverse side walls.In this scenario, 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 attached to the mold 3. If the bottom of the mold 3 is metallic, the position-locking system 5b can be equipped with a magnet, which allows the position of the magnetized part to be fixed. If the side wall 4a is pressed against the magnetized part, the side wall 4a remains fixed despite the force applied by the molten material. An identical result can be obtained with a bottom that allows the position-locking system 5b to be attached by screwing or by any other technique.

[0042] Once the mold 3 is installed and the retaining frame 4 is positioned in the mold 3, optionally with reinforcement, a body material is poured into the mold 3 to form a body 6 of the construction panel 1. The material is poured in a liquid or paste-like state. The body material hardens to form a self-supporting construction panel 1 and, more preferably, a construction panel 1 capable of supporting the weight of a roof or ceiling and, optionally, the weight of one or more stories surmounted by a roof or ceiling.

[0043] Once the body material has hardened and / or is in a cured state, the mold 3 is separated from the body 6 of the construction panel 1. Once the material has hardened and / or is in a cured state, the reinforcement 5 is separated from the body 6 of the construction panel 1. Depending on the configuration, the reinforcement 5 is removed before, after, or at the same time as the mold 3. The position-locking systems 5b can be quickly disassembled before the body material, which is held by the retaining frame 4, has completely dried. The position-locking system 5b can be used in another mold before it has completely dried. The reinforcement 5 can be made of wood or metal.

[0044] Figure 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 to avoid damaging the reservation frame 4. The reinforcement 5 can also serve as mechanical reinforcement during the transport and / or handling stages of the construction panel 1.

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

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

[0047] The internal dimensions of the recess 4 are defined to accommodate equipment, for example, a window or door frame. The mechanical properties of the material forming the recess 4 are chosen so that, during casting, the dimensions of the internal opening do not change, or change only slightly, to allow for the installation of the window or door frame. Preferably, the thickness of the recess 4 is greater than 2 cm, more preferably greater than 4 cm, and even more preferably greater than 6 cm to provide good thermal resistance between the window or door frame and the body 6 without significantly reducing the usable surface area.

[0048] The opening frame 4 was installed in the mold 3 before the body material was poured, allowing for precise positioning of the opening frame 4. The body material is then poured into the mold 3. During its hardening, the body material is in contact with the opening frame 4, so that the shape of the body 6 is perfectly adapted to the shape of the outer walls of the opening frame 4. The body 6 and the opening frame 4 define two complementary surfaces. The opening frame 4 is specific to an opening in the construction panel 1. Any dimensional variations that may exist with respect to the outer walls of the opening frame 4 are absorbed by the body material, which is poured in a liquid or paste-like state and adapts to the shape of the opening frame 4 in the mold 3. The opening frame 4 is in the form of a ring with an outer face and an inner face.

[0049] It is particularly advantageous to provide that, in the thickness direction, the opening frame 4 has one or more non-smooth walls, i.e., a wall with protruding elements that define a surface texture. The use of non-smooth walls prevents the opening frame 4 from slipping relative to the body 6 in the hardened state in the depth direction. The risk of losing an opening frame 4 during transport of the construction panel 1 becomes low or even zero. This also facilitates the installation of the window 7 in the opening frame 4 before it is fixed and allows for direct fixing of the window 7 to the opening frame 4, possibly without direct fixing to the body 6. The window 7 can be fixed directly with screws.Direct fixing represents less than 10% by 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 mounting frame 4, several of whose side walls 4a have protruding elements that define a texture on its external surface, allows the mounting of the mounting frame 4 and the body 6 to be fixed without the need for an adhesive layer. The difference in the coefficient of thermal expansion between the body 6 and the mounting frame 4 will induce repeated shear stresses on the adhesive layer, thus reducing its lifespan. The use of a mounting frame 4 with a texture on its external surface allows the mounting of the mounting frame 4 and the body 6 to be fixed without the need to fix the mounting frame 4 by screwing or any other equivalent means. The screw extending through the entire thickness forms a thermal bridge that degrades the performance of the mounting frame 4.

[0051] The non-smooth outer wall of the retaining frame 4 represents a surface texture that forms a locking element preventing separation between the retaining frame 4 and the body 6. The protruding elements can originate from a rough outer wall with holes and bumps. The bumps form the protruding elements. The roughness of the outer surface can be achieved by cutting holes, for example grooves, in the side walls 4a.

[0052] The texturing may consist of one or more raised patterns, which may be in the form of one or more fins extending along the longitudinal and / or transverse direction. It is also possible to provide texturing made of a material different from the reservation frame 4, for example, in the form of additional texturing 8. [Fig. 7] illustrates various embodiments of surface texturing of a portion of a reservation frame 4, which may include additional texturing in the form of a screw or nail 8a, or in the form of a pin 8b wedged into the reservation frame 4. In the illustrated example, the pin 8b is inserted into a recess in the reservation frame 4 and has a cross-section increasing in width as it extends from the recess 4. It is also possible for the recess 4 to have a hole, and preferably a groove 8c, whose width increases from the outer face towards the inner face. When the additional texture 8 is a screw, it is advantageous to screw the screw directly into the recess 4. The material of the recess 4 is chosen accordingly. It is advantageous for the protruding element to extend at least 3 cm into the body and for the protruding element to have a larger cross-sectional area inside the body 6, preventing its removal without damaging the protruding element or degrading the body 6.

[0053] In order to have better long-term stability of the reservation frame 4, it is advantageous to have a single material that extends over the entire thickness from the interface with the body 6 to the joinery.

[0054] Preferably, the reservation frame 4 has a roughness that is greater than the roughness of the walls 3a and the bottom of the mold 3 so as to make the reservation frame 4 indissoluble in relation to 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 attached to the reservation frame 4 before the body material is poured. In the illustrated example, the protruding element of the additional texture 8 can be a screw or a nail. During the pouring of the body material, the protruding element is embedded in the body material before it hardens.

[0056] The protruding element does not extend over the entire thickness of the recess 4, that is, over the entire dimension extending from the inner face of the ring, i.e., the perimeter, to the outer face of the ring. This precaution prevents the formation of a thermal bridge inside the recess 4 and also avoids the formation of a zone of differential expansion over the entire thickness of the ring.

[0057] It is advantageous to form protruding elements that allow for a retention resistance greater than 50 kN / linear meter of side wall 4a for a side wall having an interface with the body 6 extending over a depth of at least 5 cm. More preferably, the retention resistance is greater than 100 kN / linear meter.

[0058] It has been observed that a roughness with pits of at least 0.5 mm on the outer wall of the retaining frame 4 ensures the immovability of the retaining frame 4 relative to the body 6. Such a result can be obtained with a body 6 whose mineral binder is sufficiently fluid to penetrate the pits. For example, a body material made exclusively of concrete or of concrete mixed with particles of plant-based material provides a very good cohesion between body 6 and reservation frame 4 including when the particles of plant-based material represent a larger volume than the volume of mineral binder, preferably concrete.

[0059] The surface texture allows the formation of a reservation frame 4 which is immovable in relation to the body 6 and which allows good thermal resistance to be delivered between the joinery and the body 6.

[0060] To increase the retention resistance value, it is possible to increase the roughness value and / or increase the interface surface area between the retaining frame 4 and the body 6. It is particularly advantageous to have a rough outer wall, i.e., with holes and bumps distributed across the interface, because the stresses are better distributed over the entire surface between the retaining frame 4 and the body 6. When the construction panel 1 has no protruding elements embedded in the retaining frame 4, the thermal resistance between the inner and outer walls of the retaining frame 4 is maximized. To temporarily improve the retention resistance value, a protruding element such as a nail or screw can be installed to secure it more firmly to the body 6. However, this results in a decrease in thermal performance.

[0061] Since the reservation frame 4 is intended to be positioned between the body 6 and the window 7, it is particularly advantageous to have a reservation frame 4 made of a material with a thermal conductivity lower than that of the material forming the body 6. More preferably, the material of the reservation frame 4 has a thermal conductivity that is at least twice as low as that of the material forming the body 6, and more preferably at least four times lower. The further the conductivity ratio is from unity, the more thermal bridges can be eliminated with a small amount of material for the reservation frame 4. The amount of material is measured in the longitudinal and transverse directions. Advantageously, the material of the reservation frame 4 has a thermal conductivity 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 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-based material embedded in the mineral binder. The use of plant-based material particles makes it possible to form a body 6 whose heat storage capacity is lower than that of an equivalent made of cement, concrete, etc. Reinforced concrete or any other mineral binder. The use of plant-based material particles embedded in the mineral binder ensures that the particles are completely coated, guaranteeing mechanical cohesion and protecting them from external elements. This plant-based material also results in a material with an improved carbon footprint, allowing the window or door frame to be screwed directly into the body 6 through the opening frame 4 without pre-drilling. In this configuration, with the opening frame 4 fixed to the body 6 by the surface texture, only a few screws are needed to attach the window or door frame. This configuration offers better airtightness than prior art designs and significantly reduces thermal bridging.

[0064] Preferably, the body material is an open-pore porous material. The body material has a first mass content of plant material particles of between 30% and 70%, and preferably a volumetric content of plant material particles of between 30% and 95%, with the plant material particles representing a larger 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 volumetric content of plant material particles corresponds to the volume of the plant material particles relative to the total volume of the other materials in the body material after drying, without taking into account the porosity of the material.The use of such a high content of plant-based material particles allows for a significant reduction in the mass of construction panel 1 compared to an equivalent panel made exclusively of concrete or reinforced concrete.

[0065] Preferably, the majority of the plant-based material particles have a length between 1 and 100 mm. Particularly advantageously, the average particle length is between 10 and 100 mm, preferably between 10 and 60 mm, and more preferably between 20 and 60 mm. The average length can be a simple average length. Using such a length range makes it possible to form a material with better-controlled porosity and surface roughness, particularly with microcavities and, above all, cavities with a larger volume. Using a mixture comprising a majority of particles with a size preferably between 10 and 100 mm, preferably between 10 and 60 mm, and with a high mass and / or volume content of particles, makes it possible to form a porous body with significant surface roughness.Even more preferably, the particles are wood chips with a thickness predominantly (in number) between 1mm and 5mm. Such a distribution in length and thickness makes it possible to form a support material for . 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-based material. The plant-based material may be wood, straw, cellulose, hemp, or cork. The plant-based material particles are preferably wood particles. Preferably, the plant-based material particles are predominantly wood particles (by volume) and preferably wood chips. Preferably, the mineral binder is chosen from cement, clay, a clay-based material, blast furnace slag, or lime. The mineral binder may include fly ash or pulverized fuel ash, which is a waste product from carbon combustion. The binder is preferably a binder that hardens after the addition of water. It is also possible to use concrete, which is a mixture containing water, a binder (for example, cement), and other elements, such as sand and possibly gravel.It is particularly advantageous for the mineral binder to contain a significant content, and more preferably a majority, of geo-sourced material.

[0067] The plant-based particles are embedded in a mineral binder that ensures mechanical cohesion between the particles. The particles are coated with a layer of mineral binder to protect them from external aggressions. The particles are randomly assembled relative to one another and define channels and / or cavities within the body 6.

[0068] When the plant material particles are wood particles and the mineral binder is cement or concrete, the density of the porous material is preferably between 600 and 1200 kg / m³, and by varying the material composition, it is preferably equal to 800 kg / m³. This results in a material lighter than raw concrete, i.e., concrete that does not contain wood elements and whose density is approximately 2300 kg / m³.

[0069] During casting, the plant material particles are randomly distributed. However, upon contact with the side wall 3a of the mold 3 and with the side wall 4a of the retaining frame 4, the particles tend to align parallel to the face of the side wall, which reduces surface porosity. Furthermore, the roughness is lower than with a casting without a side wall, which increases the surface cohesion between the body 6 and the retaining frame 4.

[0070] When a body material containing at least 30% by mass of plant-based material particles is used, it appears that the side walls are sensitive to impacts and deteriorate rapidly. This problem is all the more significant since the construction panel 1 is intended to be moved because it is prefabricated. It is therefore It is particularly advantageous to retain the reservation frame 4. This also avoids moving the reservation frames 4 to the window installation site 7, usually on the final construction site, and then bringing the reservation frames 4 back to the construction panel manufacturing site 1.

[0071] In addition, 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 inner 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 allows the window 7 to be positioned precisely relative to the face of the body 6 along the thickness direction.

[0072] When the body material contains at least 30% by mass of plant-based material particles, the density of the material in its liquid or paste-like state decreases significantly compared to pure concrete or reinforced concrete. The thrust force applied by the material in its liquid state to the opening frame 4 is much lower. A more flexible foam is possible, which facilitates the filtering of forces between the window 7 and the construction panel 1.

[0073] It is advantageous to use a foam with a compressive strength between 5 MPa and 5 MPa. This value allows it to support a very large number of materials suitable for forming the body material in a liquid or paste-like state and in various configurations, particularly for materials containing at least 30% by mass of plant material particles. For a frame 4 intended for use with pure concrete, or concrete containing less than 20% by mass of plant material particles, a material with a compressive strength greater than or equal to 5 MPa is preferred.

[0074] It is also advantageous to use a modulus of elasticity that is between 75 MPa and 275 MPa. Such a material is particularly useful for fixing the window to the partition frame 4, possibly without fixing it 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 exhibit good maintenance of its mechanical and thermal performance over time and in particular over a period of at least 10 years, preferably at least 25 years.

[0076] The foam forming the retaining frame 4 has a surface roughness that 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 beneficial to limit the transfer of forces by the reservation frame 4. This configuration is based on This is particularly advantageous when the body 6 is made of a material whose compressive strength is close to that of the material forming the frame 4, and especially when the Young's modulus of the body material is close to the Young's modulus of the foam forming the frame 4. The Young's modulus and compressive strength values ​​become closer as the plant material particle content increases. It is advantageous for the frame 4 to have side walls 4a extending predominantly in a vertical direction and to have a rupture joint 4b with 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 excessive stress on the frame 4.In this scenario, the use of a reinforcement 5 is preferred to ensure proper control of the dimensions of the reservation frame 4.

[0078] It is possible to use polyethylene terephthalate foam that is capable of exhibiting mechanical and thermal performance in accordance with the above-mentioned specifications. For example, polyethylene terephthalate foam can have a thermal conductivity that 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 wood particles or particles of another plant element. Polyethylene terephthalate foam is advantageous because it is economical. It is also possible to use another foam, for example, 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] Figure 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 doors, 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 cross-section is not constant along the thickness direction. The recesses and / or protruding areas can be used to precisely position the windows 7 in one or more directions. The window frames 7 have complementary shapes or an inhomogeneous cross-section to fix the position of the window 7 along the depth direction ZZ.

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

[0083] Figure 4 illustrates an embodiment where the construction panels 1 form an intermediate floor of a building 2. A construction panel 1 defines a through opening 9 intended to receive a window 7. The construction 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] Figure 5 illustrates an embodiment in which the construction panels 1 form the 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 wall 4a defines a recess suitable for receiving a roller shutter 13.

[0086] Figure 6 illustrates, in cross-section, an embodiment in which the wall 2a defines a recess suitable for receiving a roller shutter 13. The outer 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 wood cladding. The inner face of the construction panel 1 is covered by a facing layer 16, for example, a plasterboard panel. Figure 6 also illustrates the fixing of the frame 7' and the sash 7" of a window 7.

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

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

Claims

Demands

1. Prefabricated construction panel (1) comprising: - a body (6) made of a body material comprising a mineral binder, the body (6) extending along a longitudinal direction (XX), a transverse direction (YY) and a depth direction (ZZ), the body (6) delimiting a hole through along the depth direction (ZZ); - a reservation frame (4) provided with several lateral walls (4a) assembled in the form of a ring, the ring having an external face having a shape complementary to the hole through perpendicular to the depth direction (ZZ), the reservation frame (4) having an internal face delimiting a through opening (9) which is through along the depth direction (ZZ);characterized in that the external face of several of the side walls (4a) of the reservation frame (4) has one or more protruding elements defining a surface texture (8, 8a, 8b, 8c) forming a locking element preventing separation between the reservation frame (4) and the body (6); 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); and in that the reservation frame (4) is a foam which has a thermal conductivity at least twice as low as the thermal conductivity of the body material.

2. Construction panel (1) prefabricated according to claim 1 in which the foam of the reservation frame (4) has a modulus of elasticity greater than 75Mpa and a compressive strength greater than IMpa.

3. Construction panel (1) prefabricated according to claim 2 in which a window (7) is only fixed to the reservation frame (4).

4. Construction panel (1) prefabricated according to any one of claims 1 to 3 wherein the side walls (4a) extending predominantly 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. Prefabricated construction panel (1) according to any one of claims 1 to 4 wherein the body material comprises at 30% mass percentage of particles of an element of plant origin (1).

6. Prefabricated construction 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 construction panel according to any one of claims 1 to 6.

8. A method for manufacturing a prefabricated construction panel (1) comprising the following steps: - providing a mold (3) and a reservation frame (4) formed by several side walls (4a) assembled in the form of a ring; - pouring 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 external faces of the reservation frame (4); - solidifying the mineral binder before removing the mold (3); characterized in that the external face of several of the side walls of the reservation frame (4) has one or more protruding elements defining a surface texture (8, 8a, 8b, 8c) and forming a locking element preventing separation 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 as low as the thermal conductivity of the body material.;

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

10. A manufacturing method according to any one of claims 8 and 9 wherein 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 key is fixed to said one or more external faces to form the surface texture, the metal key being embedded in the body material.

12. A manufacturing method according to any one of claims 8 to 11, wherein 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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