Roof insulation panel with enhanced fire resistance

Abstract

The invention relates to a composite panel (1) for structural and / or cladding 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 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 bio-based material selected from a family of materials including cork and mycelium or an association or combination of said materials. Figure for the abstract: [Fig 1]

Description

Title of the invention: Roof insulation panel with enhanced fire-resistant properties 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 desired.

[0002] The invention relates in particular to the design and manufacture of roofing or cladding elements that can be used to cover large facade areas, for example, of high-rise buildings. The invention also relates to interior sound and / or thermal insulation panels for buildings.

[0003] The invention also relates to recreational vehicles, cruise ships, transport trucks and trailers, as well as the manufacture of any wall required to have specific mechanical, thermal and / or acoustic properties. Previous technique

[0004] Composite panels, for example, are known, formed into cladding cassettes for covering building facades. These panels have a polyethylene core sandwiched between two aluminum sheets. The use of polyethylene makes it possible to substantially lighten the composite panels, but also presents disadvantages.

[0005] Indeed, composite panels with a polyethylene core, or any other petroleum-based material, offer 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. For this reason, fire safety standards in various countries no longer permit the use of composite roofing panels with a polyethylene core on buildings exceeding 8 meters in height.

[0007] Furthermore, a panel containing polyethylene and having a standard thickness does not provide satisfactory sound insulation. Presentation of the invention

[0008] 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, offering satisfactory thermal and acoustic insulation.

[0009] Another object of the invention aims to provide a new composite roofing panel with improved fire-resistant properties.

[0010] Another object of the invention aims to propose a new composite roofing panel having a low weight, while exhibiting satisfactory mechanical strength.

[0011] The objects assigned to the invention are achieved using 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 material chosen from a family of materials including rock wool and glass wool.

[0012] According to one embodiment, the core comprises at least one layer of rock wool and / or at least one layer of glass wool.

[0013] According to one embodiment, the core has a thickness of between 2 mm and 100 mm. By way of example, the metal plates each have a thickness of between 0.2 mm and 3 mm.

[0014] According to one embodiment, the adhesive layer is a hot-melt adhesive film.

[0015] According to another embodiment, the adhesive layer is a double-sided adhesive strip.

[0016] According to one embodiment, the metal plates have at least one powder-coated face.

[0017] According to one embodiment, the metal plates comprise at least one plate made of aluminum, steel, stainless steel, or titanium. Titanium, for example, provides the panel with abrasion-resistant or scratch-resistant properties.

[0018] The objects assigned to the invention are also achieved using a thermal and acoustic building insulation element comprising at least one composite panel as presented above.

[0019] 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 described above, the metal plate intended to form 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.

[0020] 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.

[0021] The objects assigned to the invention are also reached using a roof covering comprising an assembly of composite panels as shown above.

[0022] 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: - unroll a continuous strip of the material(s) constituting 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, and - cut the composite strip into composite panels.

[0023] 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: - use a rigid or semi-rigid panel made with the same material(s) as the core, - apply an adhesive film to one upper and one lower face of the rigid or semi-rigid panel at the entrance to 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, and - cut the composite strip into composite panels.

[0024] According to an example of implementation, the manufacturing process comprises the following steps: - the introduction of the composite strip into an oven to raise it to a temperature between 75°C and 220°C for a specified period, in order to melt the adhesive films and establish adhesion between the base material and the continuous metal strips, and - cooling the composite strip thus produced at ambient air after it exits the oven.

[0025] According to another embodiment, the manufacturing process includes the use of a double-sided adhesive tape to form the adhesive layer and thus achieve cold bonding.

[0026] A notable 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 insulating core. Such a composite panel is also non-combustible.

[0027] A core made of glass wool or rock wool has the added advantage of being rot-proof.

[0028] Another advantage lies in the rigidity and strength of the composite panels, despite their lightness.

[0029] 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.

[0030] 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.

[0031] In some examples of embodiment of the composite panel according to the invention, the use of materials incorporating or containing cork or mycelium makes it possible to substantially reduce their carbon footprint.

[0032] In other embodiments, devoid of cork or mycelium, the use of rock wool or glass wool provides a non-combustible panel, which allows its use on high-rise buildings.

[0033] The use of rock wool or glass wool, having a very low density, makes it possible, where appropriate, to increase the thickness of the metal plates and consequently the mechanical resistance of the composite panel, without significantly increasing the weight of said composite panel.

[0034] For this purpose, one can cite the field of architecture and in particular building cladding, curtain walls and shading elements, roofs and coverings, canopies, house gables, ceilings, walls, movable or fixed partitions for isolating workspaces, decorative panels, interior lining panels, doors, site fences, 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.

[0035] We can also mention the field of signage and advertising and in particular totems, car dealerships, service stations, restaurant chains, advertising panels, road signs.

[0036] We can also mention the field of packaging, in particular pharmaceutical or food packaging.

[0037] We can also mention the automotive sector, particularly bodywork, caravans, motorhomes, and more broadly, the transport sector. For example, we can cite interior partitions for recreational vehicles (caravans, motorhomes), cruise ships, as well as interior / exterior partitions for transport trucks and refrigerated trucks.

[0038] We can also mention the field of household appliances and in particular household appliances, refrigerators, freezers.

[0039] 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.

[0040] The composite panel according to the invention therefore constitutes a kind of raw material whose transformation and adaptation for the different intended uses is extremely varied. Brief description of the drawings

[0041] 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:

[0042] [Fig-1] [Fig. 1] is a perspective view of an example embodiment of a cover panel according to the invention,

[0043] [Fig.2] [Fig.2] schematically illustrates an example of a manufacturing unit for a roofing panel according to the invention,

[0044] [Fig.3] [Fig.3] schematically illustrates another example of a manufacturing unit for a roofing panel according to the invention,

[0045] [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

[0046] [Fig.5] [Fig.5] illustrates an example of mounting bargain cassettes according to the invention on a facade. Detailed description of the invention

[0047] Structurally and functionally identical elements present on several distinct figures are assigned the same numeric or alphanumeric reference.

[0048] 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.

[0049] 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 or a hot-cured adhesive.

[0050] According to another embodiment, the adhesive layer is a double-sided industrial adhesive, allowing for cold bonding.

[0051] The core 2 comprises at least one basic material, chosen from a family of materials including rock wool and glass wool.

[0052] By way of example, the base material is a raw material transformed into a continuous strip and packaged in the form of rolls or rigid or semi-rigid plates.

[0053] 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.

[0054] The core 2 advantageously has a thickness between 2 mm and 100 mm. By way of example, the core 2 has a preferred thickness between 4 mm and 60 mm.

[0055] The metal plates 3 advantageously each have a thickness between 0.2 mm and 3 mm.

[0056] Fig. 2 schematically illustrates an example of a manufacturing unit for a composite panel 1 according to the invention.

[0057] The manufacturing process consists of unwinding a continuous strip 6 of a base material, constituting the core 2, comprising rock wool or glass wool, from a roll 7.

[0058] 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.

[0059] According to the manufacturing process, the laminating unit 10 is fed with two continuous strips of metal 11, for example continuous strips of aluminum, to deposit them respectively on the upper face 6a and on the lower face 6b coated each of the 4 adhesive film. The continuous metal strips 11 will form the 3 aluminum plates of the composite panel 1.

[0060] 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.

[0061] According to the manufacturing process, a continuous composite strip 12 is delivered at the output of the laminating unit 10.

[0062] According to one example of implementing the manufacturing process, the composite strip 12 is conveyed into an oven 13 to be heated to a temperature between 75°C and 220°C for a specified period. The oven 13 is used to melt the adhesion films 4 and establish, through hot cross-linking, the necessary adhesion and mechanical cohesion between the continuous strip 6 and the continuous metal strips 11.

[0063] The process then consists of cooling the composite strip 12 thus produced in ambient air, at the exit of the oven 13.

[0064] According to the manufacturing process, the composite strip 12 is cut, by all known means, into composite panels 1 according to the desired dimensions.

[0065] Figure 3 schematically illustrates another example of manufacturing a composite panel 1. In this embodiment of the manufacturing process, the continuous strip 6 is extruded from a base material comprising, for example, a mixture of glass wool or rock wool flakes mixed with cork beads or granules and / or mycelium. An extruder 14 then replaces a roll unwinder 7.

[0066] 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 corresponding full roller 8a, 8b, lia, 11b, 7.

[0067] 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.

[0068] 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 folded edges 17 have, at least on each lateral side of the composite panel 1, notches 18 for mounting said cladding cassette 16 on the support structure 20 attached to a facade.

[0069] 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 the cladding cassette 16, to form the fold lines.

[0070] The edges 17 folded over each lateral side of the composite panel 1 have notches 18 for mounting on the support structure 20.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] By way of example, the core 2 advantageously has, for a thickness of 4 mm, a mass less than or equal to 4 kg / m2.

[0075] According to an additional embodiment, the core 2 comprises at least one layer made of cork, mycelium, or a cork-mycelium mixture, which is associated with at least one layer of glass wool or rock wool. Such a solution makes it possible to reduce the carbon footprint of the core 2.

[0076] 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 material from a family of materials including rock wool and glass wool.

2. Composite panel (1) according to claim 1, characterized in that the core (2) comprises at least one layer of rock wool and / or at least one layer of glass wool.

3. Composite panel (1) according to claim 1 or 2, characterized in that the core (2) has a thickness between 2 mm and 100 mm and preferably between 4 mm and 60 mm, the metal plates (3) each having a thickness between 0.2 mm and 3 mm.

4. Composite panel (1) according to any one of claims 1 to 3, characterized in that the adhesive layer is a hot-melt adhesive film (4).

5. Composite panel (1) according to any one of claims 1 to 3, characterized in that the adhesive layer is a double-sided adhesive strip.

6. Composite panel (1) according to any one of claims 1 to 5, characterized in that the metal plates (3) have at least one powder-coated face.

7. Composite panel (1) according to any one of claims 1 to 6, characterized in that the metal plates (3) comprise at least one plate of aluminium, steel, stainless steel or titanium.

8. Thermal and acoustic insulation element for building comprising at least one composite panel (1) conforming to any one of claims 1 to 7.

9. 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 7, 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.

10. 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 7, 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.

11. Roofing comprising an assembly of composite panels (1) conforming to any one of claims 1 to 7

12. / . Method of manufacturing a composite panel (1) according to any one of claims 1 to 7, characterized in that it comprises the steps: - unwinding a continuous strip (6) of the material(s) constituting the core (2), - applying an adhesion film (4) to an upper face (6a) and to an 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 on the lower face (6b) each covered with an adhesion film (4), - compressing the assembly thus made in the laminating unit (10), - delivering at the outlet of the laminating unit (10) a composite strip (12), and - cutting the composite strip (12) into composite panels (1).

13. A method for manufacturing a composite panel (1) according to any one of claims 1 to 6, characterized in that it comprises the steps: - use a rigid or semi-rigid panel formed with the constituent material(s) of the core (2), - apply an adhesion film (4) on a top face (6a) and on a bottom face (6b) of the rigid or semi-rigid panel at the inlet of a laminating unit (10), - feed the laminating unit (10) with a continuous strip of metal (11) on the top face (6a) and on the bottom 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).

14. A method for manufacturing a composite panel (1) according to claim 13, characterized in that it comprises: - at the exit of the laminating unit (10), the introduction of the composite strip (12) into a furnace (13) to bring it to a temperature between 75°C and 220°C, for a determined time and to melt the adhesion films (4) and establish the adhesion between the base material and the continuous metal strips (11), - the cooling in ambient air at the exit of the furnace (13) of the composite strip (12) thus produced.

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