INSULATED ROOFING PANEL WITH A REDUCED CARBON FOOTPRINT

Abstract

The invention relates to a composite panel (1) for structural and / or roofing and / or decorative purposes, comprising a core (2) sandwiched between two metal plates (3). The bond between the core (2) and each of the metal plates (3) is achieved by means of an adhesive layer forming the interface between said core (2) and each of said metal plates (3). According to the invention, the core (2) comprises at least one mixture or combination of at least one material from a first family of materials including cork and mycelium, and at least one material from a second family of materials including hydraulic lime, vermiculite, calcium silicate, calcium carbonate, and cement. Figure for the abstract: [Fig 2]

Description

Title of the invention: Insulating roofing panel with a reduced carbon footprint technical field

[0001] The present invention relates to the general technical field of construction and more particularly to the field of building facade or roof coverings. The invention also relates to all technical or industrial fields in which the use of thermal and / or acoustic insulation is necessary.

[0002] The invention relates in particular to the design and manufacture of cladding elements, roofing panels and composite panels that can be used to cover large areas of facades, for example of high-rise buildings.

[0003] The invention also relates to interior sound and / or thermal insulation panels for buildings. The invention also relates to recreational vehicles, cruise ships, transport trucks and trailers, as well as the manufacture of any wall requiring specific mechanical, thermal and / or acoustic properties. Previous technique

[0004] For example, panels shaped into cladding cassettes for covering building facades are known. These panels have a polyethylene core sandwiched between two aluminum sheets. The use of polyethylene makes it possible to substantially reduce the weight of the composite panels, but presents some drawbacks.

[0005] Indeed, such composite panels with a polyethylene core or any other petroleum-based material provide little or no protection against heat and / or cold. Therefore, the thickness of a thermal insulation layer on the facade, positioned between the facade and the cladding panels, must be sufficient to achieve good thermal performance.

[0006] Furthermore, a polyethylene core does not offer sufficient fire resistance. This is why fire safety standards in various countries no longer permit the use of composite roofing panels with a polyethylene core, particularly on buildings exceeding 8 m in height.

[0007] In addition, a polyethylene material, with a usual thickness, does not allow for satisfactory sound and thermal insulation.

[0008] It should also be noted that known materials may contain a resin-type binder, which is combustible at high temperatures, even if it remains non-flammable. This type of product therefore cannot be used on high-rise buildings. Presentation of the invention

[0009] The object of the invention is therefore to overcome the disadvantages of the prior art by proposing a new composite panel for structure, covering or decoration, exhibiting thermal and acoustic insulation properties and meeting new environmental and global warming constraints and standards.

[0010] Another object of the invention aims to propose a new composite roofing panel with greatly improved fire-resistant properties compared to known composite panels.

[0011] Another object of the invention aims to propose a new composite panel made at least partly with natural and / or bio-based materials to reduce the carbon footprint of said panel.

[0012] Another object of the invention aims to propose a new composite roofing panel having a low weight, while exhibiting satisfactory mechanical strength.

[0013] Another object of the invention aims to propose a new composite roofing panel, incorporating a natural or bio-based product, whose industrial manufacture is simple and efficient.

[0014] Another object of the invention aims to provide a new fully recyclable composite panel.

[0015] Another object of the invention aims to propose a new composite roofing panel, for example for a facade, which can easily serve as a support for an added technology, such as solar panel glass or paint, sprinkler system or additional insulation.

[0016] The objects assigned to the invention are achieved by means of a composite structural and / or covering and / or decorative panel, comprising a core sandwiched between two metal plates, the bond between the core and each of the metal plates being obtained by means of an adhesive layer forming the interface between said core and each of said metal plates, characterized in that the core comprises at least one mixture or combination of at least one material from a first family of materials comprising cork and mycelium and at least one material from a second family of materials comprising the hydraulic lime, vermiculite, calcium silicate, calcium carbonate and cement.

[0017] According to one embodiment, the core is a compressed mixture of materials in granular or powder form. The granular materials advantageously have a particle size between 0.1 mm and 4 mm.

[0018] According to one embodiment, the proportion by volume relative to the total volume of the core of material or mixture of materials of the first family is between 40% and 90%.

[0019] According to one embodiment, the core has a thickness between 2 mm and 100 mm.

[0020] According to one embodiment, the metal plates have a thickness of between 0.2 mm and 3 mm.

[0021] According to one embodiment, the adhesive layer is a hot-melt adhesive film.

[0022] According to another embodiment, the adhesive layer is a double-sided adhesive strip, allowing for cold bonding.

[0023] According to one embodiment, the metal plates have at least one powder-coated face.

[0024] According to one embodiment, the metal plates comprise at least one plate made of aluminium, steel, stainless steel or titanium.

[0025] The objects assigned to the invention are also achieved using a thermal and acoustic building insulation element comprising at least one composite panel as shown above.

[0026] The objects assigned to the invention are also achieved using a cladding cassette for covering an exterior facade of a building, comprising at least one composite panel as presented above, the metal plate intended to make the exterior side of said cladding cassette and the facade covering having larger dimensions than the other metal plate so as to have edges folded at right angles towards said other metal plate to form said cladding cassette, the edges folded on each lateral side of the composite panel having notches for mounting on a support structure attached to a facade.

[0027] The objects assigned to the invention are also achieved using a cladding cassette to cover an exterior facade of a building, comprising at least one composite panel as presented above, said composite panel comprising metal plates of the same dimensions and having edges folded at right angles, to form said cladding cassette, the folded edges on each lateral side of the composite panel having notches for mounting on a support structure attached to a facade.

[0028] The objects assigned to the invention are also reached using a roof covering comprising an assembly of composite panels as shown above.

[0029] The objects assigned to the invention are also achieved using a method for manufacturing a composite panel as described above, characterized in that it comprises the following steps: - mix materials from the first and second families of materials or use a pre-prepared mixture of materials, - extrude a continuous strip of the constituent materials of the core, - apply an adhesion film to one upper and one lower face of the continuous strip at the inlet of a laminating unit, - feed the laminating unit with a continuous strip of metal on the top and bottom faces, each covered with an adhesion film, - compress the assembly thus made in the laminating unit, - deliver a composite strip at the output of the laminating unit, - cut the composite strip into composite panels.

[0030] According to one example of implementation, the manufacturing process comprises: - upon exiting the lamination unit, the composite strip is introduced into a furnace to be heated to a temperature between 75°C and 220°C for a predetermined time, in order to melt the adhesion films and establish adhesion between the base material and the continuous metal strips, and - Cooling the composite strip thus produced in ambient air at the oven outlet.

[0031] A remarkable advantage of the composite panel according to the invention lies in the increase in its thermal and acoustic performance thanks to the use of an optimized insulating core. In addition, the composite panel according to the invention is characterized by increased fire resistance properties.

[0032] Indeed, the core of a panel according to the invention exhibits enhanced fire-resistant properties due to the use of a non-combustible material (hydraulic mineral binder) mixed with a natural or bio-based material. Depending on the required level of fire resistance performance, it is possible to select an appropriate mass proportion of the non-combustible material, for example calcium silicate, to mix with the natural or bio-based material comprising cork and / or mycelium.

[0033] Furthermore, the thermal inertia of cork makes it possible to create an effective weather barrier. It is therefore possible to reduce the thickness of the thermal insulation layer placed between a facade and the composite panels according to the invention.

[0034] Another significant advantage is obtained by using a natural and / or bio-based material, in particular cork or mycelium, of which a substantial renewable supply is available throughout the Mediterranean region. Such materials make it possible to avoid the use of petroleum products.

[0035] Cork is a bio-based material, but also rot-proof.

[0036] Another advantage lies in the rigidity and strength obtained for composite panels according to the invention, despite their lightness.

[0037] Another advantage of the composite panel according to the invention lies in its remarkable sound insulation properties. The sound insulation performance obtained is far superior to that obtained with petroleum products of similar thickness.

[0038] The use of materials incorporating or containing cork or bio-based mycelium makes it possible to substantially reduce the carbon footprint for such composite panels.

[0039] The composite panel according to the invention is also made entirely of non-polluting materials. These materials are fully recyclable and can be reused to manufacture new identical or similar composite panels.

[0040] Another advantage of the composite panel according to the invention lies in the possibility of using it for or integrating it into countless architectural or industrial applications.

[0041] For this purpose, we can cite the field of architecture and in particular the cladding of buildings, curtain walls and shading elements, roofs and coverings, canopies, house gables, ceilings, walls, mobile or fixed partitions for isolating workspaces, decorative panels, interior lining panels, doors, site site fencing, industrial buildings, agricultural sheds, construction components, prefabricated buildings, window sills and frames, tiles for buildings and houses, sandwich panels or composite panels, gutters, drainage pipes.

[0042] We can also mention the field of signage and advertising and in particular totems, car dealerships, service stations, restaurant chains, advertising panels, road signs.

[0043] We can also mention the field of packaging, in particular pharmaceutical or food packaging.

[0044] We can also mention the automotive sector, and in particular bodywork, caravans, motorhomes and, more broadly, the transport sector. For example, we can cite interior partitions for recreational vehicles. (caravans, motorhomes), cruise ships, but also the interior / exterior partitions of transport trucks and refrigerated trucks.

[0045] We can also mention the field of household appliances and in particular household appliances, refrigerators, freezers.

[0046] We can also mention the industrial field in the broad sense, namely elements used and / or manufactured industrially and in particular machine protection, containers, heat pumps, vehicles, public transport vehicles, lighting fixtures, kitchen splashbacks, computer equipment, suitcases, in-ground or above-ground swimming pools, protective devices.

[0047] The composite panel according to the invention therefore constitutes a kind of raw material whose transformation and adaptation for the different intended uses are extremely varied. Brief description of the drawings

[0048] Other features and advantages of the present invention will become more apparent upon reading the following description, made with reference to the accompanying drawings, given by way of non-limiting examples, in which:

[0049] [Fig-1] [Fig. 1] is a perspective view of an example embodiment of a composite roofing panel according to the invention,

[0050] [Fig.2] [Fig.2] schematically illustrates an example of a manufacturing unit for a composite roofing panel according to the invention,

[0051] [Fig.3] [Fig.3] schematically illustrates another example of a manufacturing unit for a composite roofing panel according to the invention,

[0052] [Fig.4] [Fig.4] represents an example of an embodiment of a cladding cassette according to the invention, made with a roofing panel of [Fig.1], and

[0053] [Fig.5] [Fig.5] illustrates an example of mounting discount cassettes according to the invention on a facade. Detailed description of the invention

[0054] Structurally and functionally identical elements present on several distinct figures are assigned the same numeric or alphanumeric reference.

[0055] Fig. 1 is a perspective view of an example of an embodiment of a composite panel 1. The composite panel 1 comprises a core 2 sandwiched between two metal plates 3.

[0056] The bond between the core 2 and each of the metal plates 3 is obtained by means of an adhesive layer in the form of an adhesion film 4, creating the interface between said core 2 and each of said metal plates 3. The adhesive layer is for example a hot-melt adhesion film 4.

[0057] According to another embodiment, the adhesive layer is an industrial double-sided adhesive tape enabling cold bonding.

[0058] The core 2 comprises in part a base material, preferably bio-based, chosen from a family of materials including cork and mycelium or an association or combination of said materials.

[0059] The core 2 advantageously comprises a mixture of at least one material from a first family of materials comprising cork and mycelium and at least one material from a second family of materials comprising hydraulic lime, vermiculite, calcium silicate, calcium carbonate and cement.

[0060] This second family of materials advantageously includes any other material constituting a hydraulic binder obtained from a mineral material.

[0061] According to one embodiment, the core 2 is a compressed mixture of materials in the form of beads, grains or powders. The grains then advantageously have a particle size between 0.1 mm and 4 mm.

[0062] According to one embodiment, the proportion by volume relative to the total volume of the core 2, of material or mixture of materials of the first family (natural or bio-based materials) is between 40% and 90%.

[0063] Figure 2 schematically illustrates an example of a manufacturing unit for a composite panel 1. In such a manufacturing unit, the core 2 is pre-conditioned into a continuous strip 6, for example by extrusion. According to one embodiment, the continuous strip is unwound from a roller 7.

[0064] In this example, the core 2 is obtained from a mixture of base materials transformed into a continuous strip 6 by extrusion and then packaged in a roll 7. The base material is a mixture of extruded and stiffened materials, for example from cork beads and calcium silicate grains or powders, transformed into a continuous strip 6.

[0065] The metal plates 3 advantageously have faces coated with a corrosion protection varnish, applied by powder coating. Depending on the intended use of the composite panel 1, at least one of its faces may be coated with a special varnish, also applied by powder coating, giving it a particular color and / or appearance.

[0066] The core 2 advantageously has a thickness of between 2 mm and 100 mm. The metal plates 3 advantageously have a thickness of between 0.2 mm and 3 mm.

[0067] According to the manufacturing process, an adhesion film 4, from a roll 8a and 8b, is applied respectively to an upper face 6a and to an lower face 6b of the continuous strip 6, at the inlet of a laminating unit 10.

[0068] According to the manufacturing process, the laminating unit 10 is fed with two continuous metal strips 11, for example continuous aluminum strips, to deposit them respectively on the upper face 6a and on the lower face 6b, each covered with the adhesive film 4. The continuous metal strips 11 will form the aluminum plates 3 of the composite panel 1.

[0069] According to the manufacturing process, the assembly thus produced is compressed in the laminating unit 10. By way of example, the laminating unit 10 comprises two compression rollers 10a and 10b for compressing the continuous aluminum strips 11, the core 2 and the superimposed adhesion films 4.

[0070] According to the manufacturing process, a continuous composite strip 12 is delivered from the laminating unit 10. This strip is then conveyed into an oven 13 to be heated to a temperature between 75°C and 220°C for a predetermined period. This period is, for example, between 20 and 30 minutes. The oven 13 is used to melt the adhesion films 4 and, by hot cross-linking, establish the necessary adhesion and mechanical cohesion between the continuous strip 6 and the continuous metal strips 11.

[0071] The process then consists of cooling the composite strip 12 thus produced in ambient air, at the exit of the oven 13.

[0072] According to another example of implementing the manufacturing process, the adhesive film 4 is a double-sided industrial adhesive applied to the upper face 6a and the lower face 6b of the continuous strip 6. The double-sided adhesive is advantageously unwound from rolls 8a and 8b. The necessary adhesion and mechanical cohesion between the continuous strip 6 and the continuous metal strips 11 are then obtained by cold bonding.

[0073] According to the manufacturing process, the composite strip 12 is cut into composite panels 1, according to the desired dimensions, by all known means.

[0074] Figure 3 schematically illustrates another example of a manufacturing unit for a composite panel 1. This manufacturing unit illustrates another embodiment of the manufacturing process, differing from the one described above in that the continuous strip 6 is extruded from a mixture of materials. This mixture includes, for example, cork and / or mycelium beads and calcium silicate grains. In this other embodiment, the roller 7 is replaced by an extruder 14.

[0075] The various feed rollers 8a, 8b, lia, 11b, 7 are advantageously duplicated to prevent a break in the feed and an interruption of the manufacturing process. An empty roller 8a, 8b, lia, 11b, 7 is then automatically replaced by a full roller 8a, 8b, lia, 11b, 7.

[0076] Fig. 4 represents an example of the realization of a cladding cassette 16, made with a composite panel 1 and Fig. 5 illustrates an example of mounting cladding cassettes 16 on a support structure 20.

[0077] The cladding cassette 16 preferably comprises a composite panel 1. The metal plate 3, intended to form the exterior side of the cassette and the facade covering, has larger dimensions than the other metal plate 3, so as to have edges 17 folded at right angles towards said other metal plate 3. The edges 17 folded at least on each lateral side of the composite panel 1 have notches 18 for mounting said cladding cassette 16 on the support structure 20 attached to a facade.

[0078] According to another embodiment, the composite panel 1 comprises metal plates 3 of the same dimensions and has edges 17 folded at right angles to form the cladding cassette. In order to be able to fold the edges 17, which are made of the base material sandwiched between two aluminum plates 3, V-shaped ribs are machined on the outer face of the aluminum plate 3 located on the inner side of said cladding cassette 16, to form the fold lines.

[0079] The folded edges 17 on each lateral side of the composite panel have notches 18 for mounting on the support structure 20.

[0080] According to another example of use, the composite panel 1 is intended for use in roofing. This roofing then comprises an assembly of composite panels 1 equipped with a fastening system. This fastening system is then customized according to each roofing or tile manufacturer that uses composite panels 1.

[0081] Depending on the intended use, the composite panel 1 can have significant dimensions, for example up to a length of ten meters and a width of two meters.

[0082] The composite panel 1 is therefore a sandwich material used for example as sound insulation, to insulate meeting rooms, separate workspaces in a mobile or fixed manner, partition interior spaces of motorhomes, caravans, or cruise ships.

[0083] It is evident that the present description is not limited to the explicitly described examples, but also includes other embodiments or implementations. Thus, a technical feature or implementation step described may be replaced by an equivalent technical feature or step, respectively, without departing from the scope of the invention as defined by the claims.

Claims

Demands

1. Composite panel (1) for structure and / or covering and / or decoration, comprising a core (2) sandwiched between two metal plates (3), the bond between the core (2) and each of the metal plates (3) being obtained by means of an adhesive layer forming the interface between said core (2) and each of said metal plates (3), characterized in that the core (2) comprises at least one mixture or combination of at least one material from a first family of materials comprising cork and mycelium and at least one material from a second family of materials comprising hydraulic lime, vermiculite, calcium silicate, calcium carbonate and cement.

2. Composite panel (1) according to claim 1, characterized in that the core (2) is a compressed mixture of materials in the form of grains or powders, the grains having a particle size between 0.1 mm and 4 mm.

3. Composite panel (1) according to claim 1 or 2, characterized in that the proportion by volume relative to the total volume of the core (2) of material or mixture of materials of the first family is between 40% and 90%.

4. Composite panel (1) according to any one of claims 1 to 3, characterized in that the core (2) has a thickness between 2 mm and 100 mm.

5. Composite panel (1) according to any one of claims 1 to 4, characterized in that the metal plates (3) have a thickness of between 0.2 mm and 3 mm.

6. Composite panel (1) according to any one of claims 1 to 5, characterized in that the adhesive layer is a hot-melt adhesive film (4).

7. Composite panel (1) according to any one of claims 1 to 5, characterized in that the adhesive layer is a double-sided adhesive strip.

8. Composite panel (1) according to any one of claims 1 to 7, characterized in that the metal plates (3) have at least one powder-coated face.

9. Composite panel (1) according to any one of claims 1 to 8, characterized in that the metal plates (3) comprise at least one plate of aluminium, steel, stainless steel or titanium.

10. Thermal and acoustic insulation element for building comprising at least one composite panel (1) conforming to any one of claims 1 to 9.

11. Cladding cassette (16) for covering an exterior facade of a building, comprising at least one composite panel (1) according to any one of claims 1 to 9, the metal plate (3) intended to form the exterior side of said cladding cassette (16) and the facade covering having larger dimensions than the other metal plate (3) so as to have edges (17) folded at right angles towards said other metal plate (3) to form said cladding cassette (16), the edges (17) folded on each lateral side of the composite panel (1) having notches (18) for mounting on a support structure (20) attached to a facade.

12. Cladding cassette (16) for covering an exterior facade of a building, comprising at least one composite panel (1) according to any one of claims 1 to 9, said composite panel (1) comprising metal plates (3) of the same dimensions and having edges (17) folded at right angles, to form said cladding cassette (16), the edges (17) folded on each lateral side of the composite panel (1) having notches (18) for mounting on a support structure (20) attached to a facade.

13. Roofing comprising an assembly of composite panels (1) conforming to any one of claims 1 to Q

14. y. A method for manufacturing a composite panel (1) according to any one of claims 1 to 9, characterized in that it comprises the steps: - mixing the materials of the first and second family of materials or using a mixture of materials already prepared, - extruding a continuous strip (6) of the constituent materials of the core (2), - apply an adhesion film (4) on an upper face (6a) and on an lower face (6b) of the continuous strip (6) at the inlet of a laminating unit (10), - feed the laminating unit (10) with a continuous metal strip (11) on the upper face (6a) and on the lower face (6b) each covered with an adhesion film (4), - compress the assembly thus made in the laminating unit (10), - deliver at the outlet of the laminating unit (10) a composite strip (12), and - cut the composite strip (12) into composite panels (1).

15. A method for manufacturing a composite panel (1) according to any one of claims 1 to 5 or 7 to 9 and according to claim 6, characterized in that it comprises the steps: - mixing the materials of the first and second families of materials or using a pre-prepared mixture of materials, - extruding a continuous strip (6) of the constituent materials of the core (2), - applying an adhesion film (4) to an upper face (6a) and a lower face (6b) of the continuous strip (6) at the inlet of a laminating unit (10), - feeding the laminating unit (10) with a continuous strip of metal (11) on the upper face (6a) and the lower face (6b), each covered with an adhesion film (4), - compressing the assembly thus formed in the laminating unit (10), - delivering a composite strip at the outlet of the laminating unit (10). (12), - at the output of the complexing unit (10),the introduction of the composite strip (12) into a furnace (13) to raise it to a temperature between 75°C and 220°C for a specified period, in order to melt the adhesion films (4) and establish adhesion between the base material and the continuous metal strips (11), - the cooling of the composite strip (12) thus produced in ambient air upon exiting the furnace, and - cutting the composite strip (12) into composite panels (1).

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