Insulating cover panel having enhanced fire-resistant properties

Abstract

The invention relates to a composite structural and / or cover and / or decorative panel (1) comprising a core (2) sandwiched between two metal plates (3), the connection between the core (2) and each of the metal plates (3) being provided by an adhesive layer forming the interface between the core (2) and each of the metal plates (3). According to the invention, the core (2) comprises at least one material from a family of materials including rock wool and glass wool, the core (2) having a thickness of between 2 mm and 100 mm, preferably between 4 mm and 60 mm, and the metal plates (3) each having a thickness of between 0.2 mm and 3 mm.

Description

[0001] DESCRIPTION

[0002] Title: Roof Insulation Panel Featuring

[0003] ENHANCED FIRE-RESISTANT PROPERTIES

[0004] technical field

[0005] The present invention relates to the general technical field of construction and more particularly to the field of building facades or roofs. The invention also relates to all technical or industrial fields in which the use of thermal and / or acoustic insulation is required.

[0006] The invention relates in particular to the design and manufacture of roofing or cladding elements that can be used to cover large facade surfaces, for example, on high-rise buildings. The invention also relates to interior sound and / or thermal insulation panels for buildings.

[0007] 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.

[0008] Previous technique

[0009] For example, we are familiar with composite panels, shaped into cladding cassettes for covering building facades. These panels consist of a polyethylene core sandwiched between two aluminum sheets. The use of polyethylene allows for a substantial reduction in the weight of the composite panels, but also presents some drawbacks.

[0010] Indeed, composite panels with a polyethylene core or any other petroleum-based material offer little or no protection against heat and / or cold and provide very poor sound insulation.

[0011] Furthermore, a polyethylene core offers insufficient fire resistance. This is why 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. In addition, a panel containing polyethylene and of standard thickness does not provide adequate sound insulation.

[0012] For example, US patent 2015 / 336356 A1 describes a composite cladding panel with a core sandwiched between two metal sheets. The core comprises a fiber-based material resistant to temperatures of at least 600°C. This core material consists of inorganic fibers combined with organic binders.

[0013] For example, we know of document EP 1 347 111 Al which describes a composite panel for roofing, cladding or walls, consisting of an insulating core of polyurethane foam or rock wool, sandwiched between two metal sheets. This panel, for example intended to form door sections, incorporates reinforcements.

[0014] For example, we know of document EP 0 699 256 B1, which describes a sandwich assembly structure consisting of a core and metal roofing plates. The bond between the core and the metal plates is achieved with an adhesive. The core is composed of mineral wool.

[0015] We know, for example, of the document DE 102 02 411 Al which describes a cladding cassette and more particularly its manufacturing process, including folding operations.

[0016] For example, we know of document WO 2006 / 122999 which describes a composite panel formed with a sandwich assembly comprising aluminum plates and an aluminum foam core. The latter contains a blowing agent based on a titanium hybrid.

[0017] Presentation of the invention

[0018] 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.

[0019] Another object of the invention aims to provide a new composite panel with improved fire-resistant properties.

[0020] Another object of the invention is to propose a new composite panel with a low weight, while exhibiting satisfactory mechanical strength.

[0021] 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 from a family of materials including rock wool and glass wool, the core having a thickness between 2 mm and 100 mm and preferably between 4 mm and 60 mm, the metal plates each having a thickness between 0.2 mm and 3 mm.

[0022] According to one example of implementation, the core comprises at least one layer of rock wool and / or at least one layer of glass wool.

[0023] According to one embodiment, the core is supplied by a rock wool strip supplied in roll or panel form, to form a continuous rock wool strip.

[0024] According to another embodiment, the core is provided by a strip of glass wool supplied in roll or panel form, to form a continuous strip of glass wool.

[0025] According to one embodiment, the adhesive layer is a hot-melt adhesive film.

[0026] In another example, the adhesive layer is a double-sided, water-free adhesive tape. Such an adhesive tape is offered, for instance, by the company ADHEX under the commercial names "Acrylic adhesive transfer" or "Solventless adhesive transfer." Using a water-free adhesive layer prevents air pollution from volatile organic compounds (VOCs) and water vapor, which can promote corrosion of metal building structures.

[0027] In another embodiment, the adhesive layer is a hot melt adhesive sprayed onto one upper and one lower surface of the core strip. The use of a hot melt adhesive or a double-sided adhesive thus allows for cold compression of the constituent elements of the composite panel according to the invention. An example of a hot melt adhesive is, for instance, a "Holt Melt" adhesive marketed under the acronym "PSA".

[0028] According to one example of implementation, the metal plates have at least one powder-coated, varnished or anodized face.

[0029] In one example, the metal plates include 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.

[0030] 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.

[0031] The objects assigned to the invention are also achieved using a cladding cassette, for example, to cover 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 of 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.

[0032] The objects assigned to the invention are also achieved using a cladding cassette, for example 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.

[0033] The objects assigned to the invention are also reached using a roof covering comprising an assembly of composite panels as shown above.

[0034] 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:

[0035] - use a rigid or semi-rigid roll or panel of a base material to form a continuous strip of the core constituent material(s),

[0036] - to coat one upper and one lower face of the continuous strip with an adhesive layer at the inlet of a laminating unit,

[0037] - feed the laminating unit with a continuous strip of metal on the upper and lower surfaces, each coated with an adhesive layer,

[0038] - compress the assembly thus produced in the laminating unit,

[0039] - to deliver a composite strip at the output of the laminating unit, and

[0040] - cut the composite strip into composite panels.

[0041] According to an example implementation, the manufacturing process includes the following steps:

[0042] - 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

[0043] - cooling in ambient air upon exiting the oven of the composite strip thus produced.

[0044] According to another implementation example, the manufacturing process includes the use of double-sided adhesive tape to form the adhesive layer and thus achieve cold bonding.

[0045] 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.

[0046] A core made of glass wool or rock wool has the added advantage of being rot-proof, provided it is protected from moisture. Indeed, glass wool or rock wool itself, when exposed to moisture, can age prematurely. Its use is therefore discouraged or prohibited in many buildings. Remarkably, the panel according to the invention protects the glass wool or rock wool forming the core of said panel and, thanks to its adhesive layer, prevents the glass wool or rock wool from absorbing moisture. Consequently, its thermal, acoustic, and mechanical performance is well maintained over time.

[0047] In addition, glass wool or rock wool dust or other harmful particles are trapped by the adhesive layer and in particular by the hot glue, preventing the dissemination of this dust and / or harmful particles.

[0048] Another advantage lies in the rigidity and strength of composite panels, despite their lightness.

[0049] The glass wool and rock wool used to form the core of the composite panel according to the invention are also natural mineral products devoid of any organic or mineral binding material, greatly facilitating the recycling of said composite panel.

[0050] 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.

[0051] The composite panel according to the invention is also made entirely from non-polluting materials. These materials are fully recyclable and can be reused to manufacture new, identical or similar composite panels. The panel according to the invention is made primarily from mineral products and is free of petroleum products.

[0052] Furthermore, the constituent materials of the composite panel according to the invention do not impair the health of personnel handling the composite panel from the beginning of its packaging.

[0053] It is also noteworthy that the buildings are protected against corrosion problems and that staff are not exposed to harmful particles from glass wool or rock wool or volatile organic compounds.

[0054] Remarkably, the use of rock wool or glass wool provides a non-combustible panel, which allows its use on high-rise buildings.

[0055] The use of rock wool or glass wool, which have a very low density, makes it possible, where necessary, to increase the thickness of the metal plates and consequently the mechanical strength of the composite panel, without significantly increasing the weight of said composite panel. Contrary to expectations, the mechanical strength of a panel conforming to the invention, even with a core thickness greater than 2 mm, is not affected.

[0056] 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 to isolate 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.

[0057] We can also mention the field of signage and advertising, including totems, car dealerships, service stations, restaurant chains, advertising panels, and road signs.

[0058] We can also mention the field of packaging, particularly pharmaceutical or food packaging.

[0059] We can also mention the automotive sector, particularly bodywork, caravans, motorhomes, and more broadly, the transportation sector. For example, we can cite the interior partitions of recreational vehicles (caravans, motorhomes), cruise ships, as well as the interior / exterior partitions of transport trucks and refrigerated trucks.

[0060] We can also mention the field of household appliances, particularly appliances, refrigerators, and freezers. We can also mention the industrial sector in a broader sense, namely elements used and / or manufactured industrially, including machine guards, containers, heat pumps, vehicles, public transport vehicles, lighting fixtures, kitchen splashbacks, computer equipment, suitcases, in-ground and above-ground swimming pools, and protective devices.

[0061] 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.

[0062] Brief description of the drawings

[0063] 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:

[0064] [Fig 1] Figure 1 is a perspective view of an example of an embodiment of a roof panel according to the invention,

[0065] [Fig 2] Figure 2 schematically illustrates an example of a manufacturing unit for a roofing panel according to the invention,

[0066] [Fig 3] Figure 3 schematically illustrates another example of a manufacturing unit for a roofing panel according to the invention,

[0067] [Fig 4] Figure 4 shows an example of an embodiment of a cladding cassette according to the invention, made with a roofing panel of Figure 1, and

[0068] [Fig 5] Figure 5 illustrates an example of mounting discount cassettes according to the invention on a facade.

[0069] Detailed description of the invention

[0070] Structurally and functionally identical elements present on several distinct figures are assigned the same numerical or alphanumeric reference.

[0071] Figure 1 is a perspective view of an example of the realization of a composite panel 1. The composite panel 1 has a core 2 sandwiched between two metal plates 3.

[0072] 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 crosslinked adhesive.

[0073] According to another example of implementation, the adhesive layer is a double-sided industrial adhesive, allowing for cold bonding.

[0074] Core 2 comprises at least one basic material, chosen from a family of materials including rock wool and glass wool.

[0075] As an example, the basic material is a raw material transformed into a continuous strip and packaged in the form of rolls or rigid or semi-rigid sheets.

[0076] The metal plates 3 advantageously have faces coated with a protective anti-corrosion 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.

[0077] The core 2 advantageously has a thickness between 2 mm and 100 mm. As an example, the core 2 has a preferred thickness between 4 mm and 60 mm.

[0078] The 3 metal plates each advantageously have a thickness between 0.2 mm and 3 mm.

[0079] Figure 2 schematically illustrates an example of a manufacturing unit for a composite panel 1 according to the invention.

[0080] The manufacturing process for a composite panel 1 includes:

[0081] - the use of a rigid or semi-rigid roll or panel of a base material to form a continuous strip 6 of the constituent material(s) of the core 2,

[0082] - the operation of coating an upper face 6a and a lower face 6b of the continuous strip 6 with an adhesive layer at the inlet of a laminating unit 10,

[0083] - the feeding of 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 adhesive layer,

[0084] - the operation of compressing the assembly thus produced in the complexing unit 10,

[0085] - the output from the laminating unit 10 of a composite strip 12, and

[0086] - cutting the composite strip 12 into composite panels 1.

[0087] According to an example implementation, the manufacturing process for a composite panel 1 includes:

[0088] - upon exiting the lamination unit 10, the introduction of the composite strip 12 into an oven 13 to raise it to a temperature between 75°C and 220°C for a predetermined time, in order to melt the adhesive layers and establish adhesion between the core 2 and the continuous metal strips 11, and

[0089] - the ambient air cooling of the composite strip 12 thus produced at the exit of the oven 13.

[0090] According to one implementation example, the manufacturing process consists of unwinding a continuous strip 6 of a core material 2, comprising rock wool or glass wool, from a roll 7. The glass wool or rock wool can also be supplied in the form of rigid or semi-rigid panels to provide the continuous strip 6.

[0091] As an example, 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 entrance of a laminating unit 10.

[0092] 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.

[0093] According to the manufacturing process, the assembly thus produced is compressed in the laminating unit 10. As an example, the laminating unit 10 includes two compression rollers 10a and 10b to compress the continuous aluminum strips 11, the core 2 and the superimposed adhesion films 4.

[0094] According to the manufacturing process, a continuous composite strip 12 is delivered at the output of the laminating unit 10.

[0095] According to one example of implementing the manufacturing process, the composite strip 12 is conveyed into a furnace 13 to be heated to a temperature between 75°C and 220°C for a specified period. The furnace 13 is used to melt the adhesion films 4 and, through hot cross-linking, establish the necessary adhesion and mechanical cohesion between the continuous strip 6 and the continuous metal strips 11.

[0096] The process then consists of cooling the composite strip 12 thus produced in ambient air, as it exits the oven 13.

[0097] According to the manufacturing process, the composite strip 12 is cut, by all known means, into composite panels 1 according to the desired dimensions.

[0098] Figure 3 schematically illustrates another example of manufacturing a composite panel 1. In this implementation 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 and / or perlite and / or calcium silicate and / or vermiculite. An extruder 14 then replaces a roll unwinder 7.

[0099] The various feed rollers 8a, 8b, l ia, 11b, 7 are advantageously duplicated to prevent a break in the feed and an interruption of the manufacturing process. An empty roller 8a, 8b, l ia, 11b, 7 is then automatically replaced by a corresponding full roller 8a, 8b, l ia, 11b, 7.

[0100] Figure 4 represents an example of the production of a cladding cassette 16, made with a composite panel 1 and Figure 5 illustrates an example of mounting cladding cassettes 16 on a support structure 20.

[0101] 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.

[0102] In 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, positioned on the inner side of the cladding cassette 16, to form the fold lines.

[0103] The folded edges 17 on each lateral side of the composite panel 1 have notches 18 for mounting on the support structure 20.

[0104] In another example of its use, composite panel 1 is intended for roofing. This roofing then comprises an assembly of composite panels 1 equipped with a fastening system. This system is customized according to each roofing or tile manufacturer that uses composite panels 1.

[0105] Depending on the intended use, composite panel 1 can have significant dimensions, for example up to a length of ten meters and a width of two meters.

[0106] 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.

[0107] As an example, the core 2 advantageously has, for a thickness of 4 mm, a mass less than or equal to 4 kg / m 2 .

[0108] According to an additional embodiment, core 2 comprises at least one layer made of cork, mycelium, or a cork-mycelium mixture, which is bonded to at least one layer of glass wool or rock wool. This solution reduces the carbon footprint of core 2.

[0109] It is clear 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, the core (2) having 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.

2. Composite panel (1) according to claim 1, characterized in that the core (2) is supplied by a rock wool strip conditioned in roll or panel form, to form a continuous rock wool strip.

3. Composite panel (1) according to claim 1, characterized in that the core (2) is supplied by a strip of glass wool conditioned in the form of a roll or panel, to form a continuous strip of glass wool.

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 without an aqueous base.

6. Composite panel (1) according to any one of claims 1 to 3, characterized in that the adhesive layer is a hot-spray adhesive applied to an upper face (6a) and to an lower face (6b) of the constituent strip of the soul (2).

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

8. Composite panel (1) according to any one of claims 1 to 7, characterized in that the metal plates (3) are made of aluminium, steel, stainless steel or titanium.

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

10. Cladding cassette (16) comprising at least one composite panel (1) according to any one of claims 1 to 8, the metal plate (3) intended to form the outer side of said cladding cassette (16) and of 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.

11. Cladding cassette (16) comprising at least one composite panel (1) according to any one of claims 1 to 8, 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.

12. Roof covering comprising an assembly of composite panels (1) conforming to any one of claims 1 to 8.

13. A method for manufacturing a composite panel (1) according to any one of claims 1 to 7, characterized in that it comprises the steps: - use a rigid or semi-rigid roll or panel of a base material to form a continuous strip (6) of the constituent material(s) of the core (2), - to coat with an adhesive layer one upper face (6a) and one lower face (6b) of the continuous strip (6) at the inlet of a laminating unit (10), - supply 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 adhesive layer, - compress the assembly thus produced in the complexing unit (10), - to deliver a composite strip (12) at the output of the laminating unit (10), 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, in order to melt the adhesive layers and establish adhesion between the core (2) and the continuous metal strips (11), - the ambient air cooling of the composite strip (12) thus produced at the outlet of the oven (13).

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