Sandwich panel and building envelope thereof

Abstract

The invention relates to a process for manufacturing a sandwich panel comprising a photovoltaic active area positioned on the outer sheet and whose upper, respectively lower, electrical conductor is connected to an upper, respectively lower, cable at the backside of the outer sheet, the latter comprising a cavity in which one of the first upper electrical connector and the first lower electrical connector is positioned, the process comprising positioning the outer sheet in a mold, inserting the other of the first upper electrical connector and the first lower electrical connector, with a downstream portion of its cable, either in a hole in one of the sides of the mold or in a groove formed in the inner sheet or in a groove formed in the outer sheet, putting insulation in place and maintaining the inner sheet at a given distance from the outer sheet.

Description

[0001] Sandwich panel and building envelope thereof

[0002]

[0001] The present invention relates to a sandwich panel intended for the construction of building envelopes, and more particularly intended for the construction of building roofs, walls, facades and claddings, without being limited thereto. In particular, the invention relates to a building integrated photovoltaic (BIPV) sandwich panel.

[0003]

[0002] Roof coverings are known to be made of sandwich panels comprising an inner sheet, an outer sheet and an insulation material sandwiched between the inner sheet and the outer sheet. Both sheets are usually made of metal and the insulation material is usually polyurethane (PUR) foam, polyisocyanurate (PIR) foam or mineral wool.

[0004]

[0003] It is known from WO2012 / 120489 to laminate together the different layers of a photovoltaic solar collector unit, on a sandwich panel, via pressure exerted by a roll and by heat supplied by a temperature chamber as illustrated in figure 8 of this patent. During this process, the films surrounding the solar cells fuse and embed them in the collector unit. Nevertheless, the temperatures reached during the lamination of the photovoltaic solar collector unit on a sandwich panel damage the insulation material of the sandwich panel, jeopardizing the adhesion between the insulation materials and the metallic sheets.

[0005]

[0004] Meanwhile, improvements in the way the photovoltaic function is integrated in the sandwich panel should neither jeopardize the manufacturing process of sandwich panels in existing production facilities nor impair other functions of the sandwich panel.

[0006]

[0005] The aim of the present invention is therefore to remedy the drawbacks of the prior art by providing a building integrated photovoltaic sandwich panel with improved photovoltaic integration while keeping the process for manufacturing sandwich panels substantially unchanged.

[0007]

[0006] For this purpose, a first subject of the present invention consists of a sandwich panel, for building envelope, comprising an inner sheet, an outer sheet and an insulation material sandwiched between the inner sheet and the outer sheet, the insulation material having a first longitudinal side, a second longitudinal side, an upper transverse side and a lower transverse side, the outer sheet comprising:

[0008] - a first longitudinal outer flange,

[0009] - an outer central part extending from the first longitudinal outer flange, including: o a first upper perforation through which a first upper electrical conductor runs, o a first lower perforation through which a first lower electrical conductor runs,

[0010] - a first photovoltaic active area positioned on the outer central part and electrically connected to the first upper electrical conductor and to the first lower electrical conductor,

[0011] - a second longitudinal outer flange extending from the outer central part, the first longitudinal outer flange and the second longitudinal outer flange having shapes that allow the overlapping of one on the other, the backside of the outer sheet comprising:

[0012] - a first upper cable connecting the first upper electrical conductor to a first upper electrical connector,

[0013] - a first lower cable connecting the first lower electrical conductor to a first lower electrical connector, the first lower electrical connector and the first upper electrical connector being corresponding male and female connectors, one of the first upper cable and the first lower cable having:

[0014] - an upstream portion running from the respective first electrical conductor to either: o one of the first longitudinal side and the second longitudinal side of the insulation material or, o one of the upper transverse side and the lower transverse side of the insulation material or, o the inner sheet or, o the outer sheet and running through the insulation material,

[0015] - a downstream portion with the respective first electrical connector, freely extending either from the said longitudinal side of the insulation material or from the said transverse side of the insulation material or from the inner sheet or from the outer sheet, the other of the first upper cable and the first lower cable having the respective first electrical connector positioned in a cavity (44, 45) positioned within the insulation material and adjacent to either the said longitudinal side of the insulation material, or the other transverse side of the insulation material, or the inner sheet or the outer sheet.

[0016]

[0007] A second subject of the present invention consists of a sandwich panel, for building envelope, comprising an inner sheet, an outer sheet and an insulation material sandwiched between the inner sheet and the outer sheet, the insulation material having a first longitudinal side, a second longitudinal side, an upper transverse side and a lower transverse side, the outer sheet comprising:

[0017] - a first longitudinal outer flange,

[0018] - an outer central part extending from the first longitudinal outer flange, including: o a first upper perforation through which a first upper electrical conductor runs, o a first lower perforation through which a first lower electrical conductor runs,

[0019] - a first photovoltaic active area positioned on the outer central part and electrically connected to the first upper electrical conductor and to the first lower electrical conductor,

[0020] - a second longitudinal outer flange extending from the outer central part, the first longitudinal outer flange and the second longitudinal outer flange having shapes that allow the overlapping of one on the other, the backside of the outer sheet comprising:

[0021] - a first upper cable connecting the first upper electrical conductor to a first upper electrical connector, - a first lower cable connecting the first lower electrical conductor to a first lower electrical connector, the first lower electrical connector and the first upper electrical connector being corresponding male and female connectors, one of the first upper cable and the first lower cable having:

[0022] - an upstream portion running from the respective first electrical conductor to either: o one of the first longitudinal side and the second longitudinal side of the insulation material or, o one of the upper transverse side and the lower transverse side of the insulation material or, o the inner sheet or, o the outer sheet, and running through the insulation material,

[0023] - a downstream portion with the respective first electrical connector, freely extending either from the said longitudinal side of the insulation material or from the said transverse side of the insulation material or from the inner sheet or from the outer sheet, the other of the first upper cable and the first lower cable running from the respective first electrical conductor, through at least a cavity and either a cut in the said longitudinal side of the insulation material, or a cut in the other transverse side of the insulation material, or a hole in the inner sheet or a hole in the outer sheet, up to the respective first electrical connector.

[0024]

[0008] The sandwich panel according to the invention may also have the optional features listed below, considered individually or in combination:

[0025] - the outer sheet further comprises an upper transverse outer edge bordering an upper overlap area,

[0026] - the outer sheet further comprises a lower transverse outer edge extending beyond the lower transverse side of the insulation material to form a lower overlap area, the upper overlap area and the lower overlap area having shapes that allow the overlapping of the lower overlap area on the upper overlap area, - the first photovoltaic active area comprises a layer capable of converting solar energy into electricity and the first upper perforation and first lower perforation are substantially below this layer,

[0027] - the backside of the outer sheet further comprises a first upper junction box connecting the first upper electrical conductor to the first upper cable and a first lower junction box connecting the first lower electrical conductor to the first lower cable,

[0028] - the upstream portion of the first upper cable, respectively the upstream portion of the first lower cable, is substantially embedded in the insulation material,

[0029] - the longitudinal side of the insulation material comprises an upper cutout extending from the first upper cable, or from the upper cavity, to the upper transverse side of the insulation material,

[0030] - the longitudinal side of the insulation material comprises a lower cutout extending from the first lower cable, or from the lower cavity, to the lower transverse side of the insulation material,

[0031] - the inner sheet comprises an upper inner groove extending at least from the upper transverse side of the insulation material to the first upper cable, or to the upper cavity,

[0032] - the inner sheet comprises a lower inner groove extending at least from the lower transverse side of the insulation material to the first lower cable, or to the lower cavity,

[0033] - the outer central part further includes: o a second upper perforation through which a second upper electrical conductor runs, o a second lower perforation through which a second lower electrical conductor runs,

[0034] - the outer sheet further comprises a second photovoltaic active area positioned on the outer central part and electrically connected to the second upper electrical conductor and to the second lower electrical conductor,

[0035] - the backside of the outer sheet further comprises: o a second upper cable connecting the second upper electrical conductor to a second upper electrical connector, o a second lower cable connecting the second lower electrical conductor to a second lower electrical connector, the second lower electrical connector and second upper electrical connector being corresponding male and female connectors,

[0036] - the second upper cable runs at least partially adjacently to the first upper cable and the second lower cable runs at least partially adjacently to the lower cable,

[0037] - the first upper electrical connector and the second upper electrical connector are corresponding male and female connectors and the first lower electrical connector and the second lower electrical connector are corresponding male and female connectors,

[0038] - the cavity is a lower cavity positioned in the lower half of the sandwich panel and the upstream portion of the first upper cable is positioned in the upper half of the sandwich panel.

[0039] - the cavity is an upper cavity positioned in the upper half of the sandwich panel and the upstream portion of the first lower cable is positioned in the lower half of the sandwich panel,

[0040] - the cavity is delimited by a casing embedded in the insulation material,

[0041] - the cavity prevents either the first upper electrical connector or the first lower electrical connector from being trapped in the insulation material.

[0042]

[0009] A third subject of the invention consists of a process for manufacturing a sandwich panel comprising an inner sheet, an outer sheet and an insulation material sandwiched between the inner sheet and the outer sheet, the insulation material having a first longitudinal side, a second longitudinal side, an upper transverse side and a lower transverse side, the process comprising:

[0043] - Providing the outer sheet comprising: o an outer central part including:

[0044] ■ a first upper perforation through which a first upper electrical conductor runs, ■ a first lower perforation through which a first lower electrical conductor runs, o a first photovoltaic active area positioned on the outer central part and electrically connected to the first upper electrical conductor and to the first lower electrical conductor, the backside of the outer sheet comprising:

[0045] ■ a first upper cable connecting the first upper electrical conductor to a first upper electrical connector,

[0046] ■ a first lower cable connecting the first lower electrical conductor to a first lower electrical connector, the first lower electrical connector and the first upper electrical connector being corresponding male and female connectors,

[0047] ■ a cavity in which one of the first upper electrical connector and the first lower electrical connector is positioned,

[0048] - Providing an inner sheet,

[0049] - Positioning the outer sheet in a mold comprising a bottom side, a top side, a first longitudinal side, a second longitudinal side, a first transverse side and a second transverse side,

[0050] - Inserting the other of the first upper electrical connector and the first lower electrical connector, with a downstream portion of its cable, either in a hole in one of the sides of the mold or in a groove formed in the inner sheet or in a groove formed in the outer sheet,

[0051] - Putting insulation in place,

[0052] - Maintaining the inner sheet at a given distance from the outer sheet.

[0053]

[0010] The process for manufacturing a sandwich panel may also have the optional features listed below, considered individually or in combination:

[0054] - The process further comprises, before providing the outer sheet, preparing the outer sheet according to the following steps: o the outer sheet is cut to length from a strip, o the first upper perforation and the first lower perforation are done in the outer central part, o the first photovoltaic active area is positioned on the outer central part, o the backside of the outer sheet is equipped with the first upper cable, the first upper electrical connector, the first lower cable, the first lower electrical connector and the cavity,

[0055] - the first photovoltaic active area is laminated on the outer central part,

[0056] - the hole in one of the sides of the mold is a hollow space in the inner surface of the side,

[0057] - the hole in one of the sides of the mold is a through-hole,

[0058] - the side of the mold further comprises a recess in the outer surface of the side at the level of the through-hole for inserting a portion of a cable with an electrical connector,

[0059] - while the inner sheet is maintained in place at the given distance from the outer sheet, a reaction mix is injected in the mold between the inner sheet and the outer sheet so that the reaction mix reacts and expands to fill the gap between the inner sheet and the outer sheet and thus forms the insulation material,

[0060] - once the outer sheet has been positioned upside down in the mold, the insulation is put in place in the form of slabs on the backside of the outer sheet, a layer of adhesive is then applied on the insulation material, the inner sheet is then positioned in the mold at the given distance from the outer sheet and the inner sheet is maintained in place by the top side of the mold during curing of the adhesive,

[0061] - the insulation is put in place before the downstream portion of the cable is inserted in the hole or the groove.

[0062]

[0011] A fourth subject of the invention consists of a process for the assembling of a building envelope on a building structure, comprising:

[0063] - (i) providing a first and a second sandwich panel according to the invention,

[0064] - (ii) fastening the first sandwich panel to the building structure, - (iii) positioning the second sandwich panel so that the lower transverse side of its insulation material is adjacent to the upper transverse side of the insulation material of the first sandwich panel,

[0065] - (iv) connecting the first upper electrical connector of the first sandwich panel to the first lower electrical connector of the second sandwich panel.

[0066]

[0012] As it is apparent, the invention is based on the recourse to the traditional discontinuous method for manufacturing sandwich panels where the laying of the insulation material is one of the last steps of the method, if not the last one. This traditional method is substantially unchanged so that both standard sandwich panels and BIPV sandwich panels can be manufactured with the same existing line or press. Accordingly, the photovoltaic active area is positioned on the outer sheet alone, before the outer sheet is provided for the making of the sandwich panel. In particular, electrical conductors connected to the photovoltaic active area run through the outer sheet before lamination in such a way that the flatness of the lamination is not compromised. Also, except the photovoltaic active area itself, there is no protruding part on the upper side of the outer sheet so that the laying of the insulation material in existing production facilities is not compromised. Also, the sandwich panel is prewired before the insulation is put in place in such a way that the cables needed to electrically connect adjacent panels do not prevent the sandwich panel from being manufactured on existing lines or presses. In particular, a portion of one cable needed to electrically connect adjacent panels is inserted in a hole in a side of the mold or in a groove in a sheet of the sandwich panel so that it does not get embedded in the insulation material when the insulation is put in place while a portion of the other cable is reserved in a cavity that get embedded in the insulation material and which can be opened afterwards to access the cable. Also, as the sandwich panel is prewired before the insulation is put in place, the sandwich panel does not comprise any hole made, at once, in the outer sheet, the insulation material and the inner sheet. This improves the watertightness of the sandwich panel.

[0013] Other characteristics and advantages of the invention will be described in greater detail in the following description.

[0067]

[0014] The invention will be better understood by reading the following description, which is provided purely for purposes of explanation and is in no way intended to be restrictive, with reference to:

[0068] - Figure 1 , which is a perspective view of the sandwich panel according to the invention, on which the upper and lower cables are not represented,

[0069] - Figure 2, which is a perspective view of the sandwich panel according to the invention, on which the upper and lower cables are not represented,

[0070] - Figure 3, which is a perspective view of the sandwich panel according to the invention, on which the upper and lower cables are not represented,

[0071] - Figure 4, which is a perspective view of the sandwich panel according to the invention, on which the upper and lower cables are not represented,

[0072] - Figure 5, which is a cross-section of the sandwich panel according to a first variant of a first embodiment of the longitudinal inner flanges and to a first embodiment of the outer sheet,

[0073] - Figure 6, which is a cross-section of the sandwich panel according to a second variant of the first embodiment of the longitudinal inner flanges,

[0074] - Figure 7, which represents details of the assembly of sandwich panels according to the second variant of the first embodiment of the longitudinal inner flanges,

[0075] - Figure 8, which is a cross-section of the sandwich panel according to a first variant of the first embodiment of the longitudinal inner flanges,

[0076] - Figure 9, which represents details of the assembly of sandwich panels according to the first variant of the first embodiment of the longitudinal inner flanges,

[0077] - Figure 10, which is a cross-section of the sandwich panel according to a third embodiment of the inner central part,

[0078] - Figure 11 , which is a perspective view of the inner sheet of the sandwich panel according to the third embodiment of the inner central part, - Figure 12, which is a cross-section of the sandwich panel according to a second embodiment of the longitudinal inner flange and to a second embodiment of the outer sheet,

[0079] - Figure 13, which is a perspective view of the sandwich panel according to the invention,

[0080] - Figure 14, which is a view of the upper side of the outer sheet of the sandwich panel according to the invention,

[0081] - Figure 15, which is a view of the grommet of the sandwich panel according to the invention,

[0082] - Figure 16, which is a cross-section of the sandwich panel according to a first embodiment of the cable positioning,

[0083] - Figure 17, which is a cross-section of the sandwich panel according to a first embodiment of the cable positioning,

[0084] - Figure 18, which is a perspective view of the lower part of the sandwich panel according to the first embodiment of the cable positioning,

[0085] - Figure 19, which is a perspective view of the upper part of the sandwich panel according to the first embodiment of the cable positioning,

[0086] - Figure 20, which is a cross-section of the sandwich panel according to a second embodiment of the cable positioning,

[0087] - Figure 21 , which is a cross-section of the sandwich panel according to a second embodiment of the cable positioning,

[0088] - Figure 22, which is a perspective view of the lower part of the sandwich panel according to the second embodiment of the cable positioning,

[0089] - Figure 23, which is a perspective view of the upper part of the sandwich panel according to the second embodiment of the cable positioning,

[0090] - Figure 24, which is a cross-section of the sandwich panel according to a third embodiment of the cable positioning,

[0091] - Figure 25, which is a cross-section of the sandwich panel according to a third embodiment of the cable positioning,

[0092] - Figure 26, which is a perspective view of the lower part of the sandwich panel according to the third embodiment of the cable positioning,

[0093] - Figure 27, which is a perspective view of the upper part of the sandwich panel according to the third embodiment of the cable positioning, - Figure 28, which is a cross-section of the sandwich panel according to a fourth embodiment of the cable positioning,

[0094] - Figure 29, which is a cross-section of the sandwich panel according to a fourth embodiment of the cable positioning,

[0095] - Figure 30, which is a perspective view of the lower part of the sandwich panel according to the fourth embodiment of the cable positioning,

[0096] - Figure 31 , which is a perspective view of the upper part of the sandwich panel according to the fourth embodiment of the cable positioning,

[0097] - Figure 32, which is a cross-section of the sandwich panel according to a fifth embodiment of the cable positioning,

[0098] - Figure 33, which is a cross-section of the sandwich panel according to a fifth embodiment of the cable positioning,

[0099] - Figure 34, which is a perspective view of the lower part of the sandwich panel according to the fifth embodiment of the cable positioning,

[0100] - Figure 35, which is a perspective view of the upper part of the sandwich panel according to the fifth embodiment of the cable positioning,

[0101] - Figure 36, which is a cross-section of the sandwich panel according to a seventh embodiment of the cable positioning,

[0102] - Figure 37, which is a perspective view of the lower part of the sandwich panel according to the seventh embodiment of the cable positioning,

[0103] - Figure 38, which is a perspective view of the upper part of the sandwich panel according to the seventh embodiment of the cable positioning,

[0104] - Figure 39, which is a perspective view of the lower part of the sandwich panel according to a eighth embodiment of the cable positioning,

[0105] - Figure 40, which is a perspective view of the upper part of the sandwich panel according to the eighth embodiment of the cable positioning,

[0106] - Figure 41 , which is a schematic cross-section of a first variant of a mold according to the invention,

[0107] - Figure 42, which is a schematic cross-section of a second variant of a mold according to the invention,

[0108] - Figure 43, which is a perspective view of the assembling of four sandwich panels according to the invention on a building structure, - Figure 44, which is a perspective view of the assembling of two sandwich panels according to a second variant,

[0109] - Figure 45, which is a perspective view of two sandwich panels according to the second variant, assembled on the building structure,

[0110] - Figure 46, which is a perspective view of the assembling of two sandwich panels according to a third variant,

[0111] - Figure 47, which is a perspective view of two sandwich panels according to the third variant, assembled on the building structure.

[0112]

[0015] It should be noted that the terms “inwards” and “outwards” as used in this application refer to the positions and orientations of the different constituent elements of the panel in relation to the position of the insulation material. Consequently, if an element extends inwards, it extends in the direction of the insulation material. Similarly, if the element extends outwards, it extends in the opposite direction of the insulation material.

[0113]

[0016] It should also be noted that, to ease the description, the panels will be described in relation to their usual position on a building roof. Consequently, the terms “inner” and “outer” as used in this application refer to this usual position. Accordingly, the outer sheet is facing the outside and the inner sheet is facing the inside of the building. Accordingly, the inner flange refers to the flange of the inner sheet and the outer flange refers to the flange of the outer sheet. Similarly, spatially relative terms such as “above”, “below”, “lower”, “upper”... as used in this application refer to the positions and orientations of the different constituent elements of the sandwich panel when the latter is positioned on a roof. Accordingly, “below” does not mean “underneath”.

[0114]

[0017] Throughout the text, a photovoltaic active area is understood to mean a stack of a plurality of layers which comprises a layer:

[0115] - capable of converting solar energy into electricity and

[0116] - protected from the outside by insulating layers.

[0117]

[0018] Such stacks usually comprise a foil of insulating material called backsheet, a first layer of encapsulation material, solar cells connected via ribbons and busbars, a second layer of encapsulation material and a transparent foil of insulation material called frontsheet. The solar cells are usually themselves composed of several layers among which a substrate, a back-electrode, a p-n junction (which is capable of converting solar energy into electricity) and a front electrode. The solar cells can notably be waferbased crystalline silicon cells or thin-film cells. The solar cells can be grouped into modules. The photovoltaic active area can comprise bypass diodes, generally placed every 18-24 cells, which prevent the destructive effects of hot-spot heating when a cell or module becomes shaded or faulty. Each photovoltaic active area has a first polarity and a second polarity, for connection to other photovoltaic active areas or to the grid. More preferably, each photovoltaic active area does not have more than a single pair of a first polarity and a second polarity. When two or more photovoltaic active areas are positioned next to each other, they can have their own backsheet and frontsheet or they can share one single backsheet and / or one single frontsheet.

[0118]

[0019] Throughout the text, a sheet is understood to mean an element that has a flat shape, i.e. , its thickness is low compared to its other dimensions. Generally speaking, its thickness is 500 to 4000 times lower than its width. The sheet may be made of a single material or a composite assembly. In the latter case, the sheet is a stack of a plurality of layers of the same material or different materials. The material in question may be, among others, a metallic material or a polymer. Steel, aluminum, copper and zinc may be cited as nonrestricting examples of metallic materials. The sheet is preferably a metallic sheet. It is preferably made of previously galvanized and pre-coated steel to protect it against corrosion. The inner sheet and the outer sheet are examples of sheets.

[0119]

[0020] In the context of the invention, the sheet will preferably have been previously formed with the aid of any known forming method, including, by way of non-restricting examples, bending, forming, stamping and molding. In particular, the U-shaped bend described later on is an element of the panel whose manufacturing process is not limited to bending.

[0120]

[0021] This forming can lead among other things to the formation of longitudinal flanges, ribs, stiffeners, grooves, mortises, tenons, tongues, edge rabbets on the surface of the sheet. Throughout the text, a rib is understood to mean a protrusion formed on the surface of the sheet. The rib may have a trapezoidal shape or a rectangular, corrugated, sinusoidal or even omega shape, for example. It includes a top central part and two lateral wings. A stiffener is a rib of limited height, generally 10 to 30 times lower than a rib. Ribs or stiffeners are generally placed in parallel to the longitudinal edges of the sheet notably to render the sheet more rigid and are then defined as longitudinal ribs or longitudinal stiffeners. Throughout the text, a groove is understood to mean a recess formed on the surface of the panel. The groove can have shapes similar to the ones offered for ribs.

[0121]

[0022] With reference to Figures 1 to 4, the sandwich panel 1 according to the invention first comprises an insulation material 2 sandwiched between an inner sheet 3 and an outer sheet 4. The insulation material is delimited by a first longitudinal side 5, a second longitudinal side 6, an upper transverse side 7 and a lower transverse side 8. The inner sheet substantially lies down flat in a plane P.

[0122]

[0023] The insulation material 2 can be any material providing some insulation to the sandwich panel 1. It is preferably a foamed insulation material. It can be, by way of non-restricting examples, polyurethane foam, polyisocyanurate foam, phenolic foam, mineral wool, wood wool and their mixtures.

[0123]

[0024] Some of the sides of the insulation material, in particular the longitudinal sides, can comprise an edge band 9 covering the insulation material. The edge band runs along the given side. The edge band notably prevents the insulation foam from expanding beyond the sandwich panel during manufacturing and prevents the equipment from being soiled by the foam. The edge band can be made of, by way of non-restricting examples, foamed plastic, plastic film, kraft paper, cardboard.

[0124]

[0025] Some of the sides, in particular the transverse sides, can comprise a cap 10 covering the insulation material. The cap substantially closes the gap between the inner sheet 3 and an outer sheet 4. Such caps are usually used in the discontinuous manufacturing methods to prevent the insulation foam from expanding beyond the sandwich panel during manufacturing. They can be made of, by way of non-restricting examples, foamed plastic, plastic film, kraft paper, cardboard.

[0125]

[0026] With reference to Figures 2, 4, 5, 6, 8, 10 and 12, the outer sheet 2 is a sheet of rectangular shape comprising a first longitudinal outer edge 11 , a second longitudinal outer edge 12, an upper transverse outer edge 13 and a lower transverse outer edge 14. A first longitudinal outer flange 15 runs along the first longitudinal outer edge 11 and a second longitudinal outer flange 16 runs along the second longitudinal outer edge 12. The first longitudinal outer flange 15 and the second longitudinal outer flange 16 are connected by an outer central part 17. Preferably, the latter substantially lies down flat in a plane parallel to plane P.

[0126]

[0027] The sandwich panel is designed so that:

[0127] - the first longitudinal outer flange 15 of a first sandwich panel can overlap the second longitudinal outer flange 16 of a second sandwich panel laterally adjacent and the second longitudinal outer flange of the first sandwich panel can be overlapped by the first longitudinal outer flange of a third sandwich panel laterally adjacent, or

[0128] - the first longitudinal outer flange 15 of a first sandwich panel can be overlapped by the second longitudinal outer flange 16 of a second sandwich panel laterally adjacent and the second longitudinal outer flange of the first sandwich panel can overlap the first longitudinal outer flange of a third sandwich panel laterally adjacent.

[0129]

[0028] Consequently, in a first embodiment of the outer sheet illustrated on Figures 1 to 10, the first longitudinal outer flange 15 of the outer sheet comprises a first longitudinal rib 18, as defined above, projecting from the first longitudinal side 5 of the insulation material. By “projecting”, it is meant that the first longitudinal outer flange extends beyond the first longitudinal side of the insulation material, in particular beyond the plane of the first longitudinal side. In the example illustrated, the first longitudinal rib 18 has a trapezoidal shape with a top central part 19 and two lateral wings 20. As the first longitudinal rib 18 projects from the insulation material, its underside is thus not covered with the insulation material. The first longitudinal rib 18 can thus overlap the second longitudinal outer flange 16 of a sandwich panel laterally adjacent without discontinuities in the insulation material.

[0130]

[0029] Accordingly, the second longitudinal outer flange 16 of the outer sheet comprises a second longitudinal rib 21 , the first longitudinal rib 18 and the second longitudinal rib 21 having shapes that allow the overlapping of the first longitudinal rib on the second longitudinal rib. In the example illustrated, the second longitudinal rib 21 has a trapezoidal shape, with a top central part 19 and two lateral wings 20, with substantially the same shape as the first longitudinal rib 18. It provides an efficient watertightness. The underside of the second longitudinal rib is preferably fully covered with the insulation material. It further improves the thermal insulation of the assembly.

[0131]

[0030] Similarly, the sandwich panel can be designed so that the lower part of a first sandwich panel can partially overlap the upper part of a second sandwich panel positioned lower along the roof slope and so that the upper part of the first sandwich panel can be partially overlapped by the lower part of a third sandwich panel positioned higher along the roof slope.

[0132]

[0031] Consequently, the lower transverse outer edge 14 of the outer sheet can extend beyond the lower transverse side 8 of the insulation material. The corresponding projection, i.e. the portion of the outer sheet extending from its lower transverse outer edge 14 to the lower transverse side 8 of the insulation material, is defined as the lower overlap area 22. As its underside is not covered with the insulation material, the lower overlap area of one sandwich panel can cover the upper part of a lower adjacent sandwich panel. The upper part of the sandwich panel that can be covered by the lower overlap area is defined as the upper overlap area 23. It is bordered by the upper transverse outer edge 13 and its height (taken parallel to the longitudinal edge of the outer sheet) is de facto substantially identical to the distance between the lower transverse outer edge 14 of the outer sheet and the lower transverse side 8 of the insulation material (i.e. the height of the lower overlap area) since sandwich panels are assembled without discontinuities in the insulation material. The height of the upper overlap area and lower overlap area is generally comprised between 150 and 500mm, depending notably on the roof pitch.

[0032] The lower overlap area 22 and the upper overlap area 23 have shapes that allow the overlapping of the lower overlap area on the upper overlap area. This means that, apart from the portions of the first longitudinal rib 18 and second longitudinal rib 21 that are present in the upper and lower overlap areas, the lower overlap area 22 and the upper overlap area 23 do not comprise shaped areas that prevent the overlapping. Such areas might be for example, a groove in the lower overlap area that does not match a groove in the upper overlap area. Preferably, apart from the portions of the first longitudinal rib 18 and second longitudinal rib 21 that are present in the upper and lower overlap areas, the lower overlap area 22 and the upper overlap area 23 are preferably flat.

[0133]

[0033] In a second embodiment of the outer sheet illustrated on Figure 12, the first longitudinal outer flange 15 of the outer sheet comprises an outer mortise 102, extending inwards. In the example illustrated, the outer mortise is in the form of a U-shaped bend extending substantially in parallel to the outer central part 17. In particular, the outer mortise comprises two branches substantially parallel and linked by a U-turn. More preferably, the two parallel branches have substantially the same length. Other designs of outer mortise are possible. It can notably have a V-shape with two branches converging towards a U-turn. It can also have a L-shape with a branch and a seat.

[0134]

[0034] According to a variant of the second embodiment, the first longitudinal outer flange 15 comprises a first outer riser 104 extending between the first longitudinal extremity of the outer central part and the outer mortise, as illustrated on Figure 12. The first outer riser can extend substantially perpendicular to the outer central part, i.e. perpendicular to plane P, or can be inclined towards the outer mortise, or can be inclined towards the outer central part.

[0135]

[0035] According to another variant of the second embodiment, the first longitudinal outer flange 15 comprises a first extension 105 extending inwards between the first longitudinal extremity of the outer central part, or the first outer riser if applicable, and the outer mortise, or the first outer riser or another outer riser if applicable, as illustrated on Figure 12. Preferably, the first extension is substantially flat. Preferably, the first extension extends substantially in parallel to the outer central part 17. It forms with the outer central part a male protrusion 106 designed for and capable of covering the head of a fastener inserted in the second longitudinal outer flange 16 of an adjacent panel.

[0136]

[0036] In accordance with the outer mortise, the second longitudinal outer flange 16 of the outer sheet comprises an outer tenon 103 extending outwards, the outer tenon and the outer mortise having shapes that allow the overlapping of one longitudinal outer flange on the other, i.e. the interlocking of the outer tenon and the outer mortise. In the example illustrated, the outer tenon projects from the second longitudinal side 6 of the insulation material. By “projects”, it is meant that the second longitudinal outer flange 16 extends beyond the second longitudinal side 6 of the insulation material, in particular beyond the plane of the second longitudinal side.

[0137]

[0037] In the example illustrated, the outer tenon is in the form of a U-shaped bend extending substantially in parallel to the outer central part 17. In particular, the outer tenon comprises two branches substantially parallel and linked by a U-turn. More preferably, the two parallel branches have substantially the same length. Other designs of outer tenon are possible. It can notably have a V-shape with two branches converging towards a U-turn. It can also have a L-shape with a branch and a seat.

[0138]

[0038] According to a variant of the second embodiment, the second longitudinal outer flange 16 comprises a second outer riser 107 extending between the second longitudinal extremity of the outer central part and the outer tenon, as illustrated on Figure 12. The second outer riser can extend substantially perpendicular to the outer central part, i.e. perpendicular to plane P, or can be inclined towards the outer tenon, or can be inclined towards the outer central part.

[0139]

[0039] According to another variant of the second embodiment, the second longitudinal outer flange 16 comprises an outer edge rabbet 108 extending inwards between the second longitudinal extremity of the outer central part and the outer tenon, as illustrated on Figure 12. The outer edge rabbet forms a recess in which a fastener head can be accommodated. Preferably, the fastener head can be covered, and thus hidden, by the male protrusion 106 of the first longitudinal outer flange 15 of an adjacent sandwich panel. Accordingly, the shapes of the outer edge rabbet and of the male protrusion are adjusted so that a fastener head can be positioned between them.

[0140]

[0040] Preferably, the outer edge rabbet 108 extends substantially in parallel to the outer central part 17. Preferably, the outer edge rabbet comprises, successively and starting from the second longitudinal extremity of the outer central part, a second outer riser 107, as described above, and a second extension 109. The second outer riser can extend substantially perpendicular to the outer central part or can be inclined towards the second extension. The latter is preferably parallel to plane P to facilitate the screwing of a fastener in this portion of the sandwich panel.

[0141]

[0041] The outer mortise 102 and the outer tenon 103 have shapes that allow the overlapping of one longitudinal outer flange on the other when one sandwich panel is assembled with a sandwich panel laterally adjacent. Preferably, their shapes are substantially complementary and their dimensions are such that:

[0142] - The height of the outer mortise (measured along the vertical axis Z) is superior to the height of the outer tenon,

[0143] - The width of the outer mortise (measured along the transversal axis Y) is superior or equal to the width of the outer tenon.

[0144]

[0042] Such interlocking of the outer mortise and the outer tenon improves the resistance, notably to wind suction, of the envelope made of sandwich panels.

[0145]

[0043] The sandwich panel is divided into an upper half and a lower half. The upper half starts from the upper transverse side 7 of the insulation material (which corresponds to the upper transverse outer edge 13 of the outer sheet) and extends to half the length of the outer sheet (the length being taken parallel to the longitudinal edge of the outer sheet). The upper half of the sandwich panel thus corresponds to the upper half of the outer sheet. The lower half starts from the lower transverse outer edge 14 of the outer sheet and extends to half the length of the outer sheet. The lower half of the sandwich panel thus corresponds to the lower half of the outer sheet.

[0044] With reference to Figures 3 to 12, the sandwich panel 1 further comprises an inner sheet 3. It is a sheet of substantially rectangular shape, comprising a first longitudinal inner edge 61 , a second longitudinal inner edge 62, an upper transverse inner edge 63, a lower transverse inner edge 64.

[0146]

[0045] As illustrated on Figures 5, 6, 8, 10 and 12, a first longitudinal inner flange 65 runs along the first longitudinal inner edge and a second longitudinal inner flange 66 runs along the second longitudinal inner edge. The first longitudinal inner flange 66 and the second longitudinal inner flange 67 are connected by an inner central part 67. The latter has a first longitudinal extremity 83 and a second longitudinal extremity 84.

[0147]

[0046] According to a first embodiment of the inner central part illustrated on Figure 12, the latter substantially lies down flat in plane P. According to a second embodiment of the inner central part illustrated on Figure 5, the inner central part comprises longitudinal stiffeners to increase the stiffness of the metallic sheet.

[0148]

[0047] According to a third embodiment of the inner central part, the inner central part 67 is shaped so that portion(s) of the cable(s) with electrical connector(s) can be reserved between the inner sheet and the mold during the manufacturing of the sandwich panel, as detailed later. Advantageously, once the sandwich panels have been assembled, the electrical connectors remain accessible from the inside of the building and the cables can be routed along the inner sheet. For that reason, the inner central part can comprise a groove 59, 60, 85. The groove has preferably a trapezoidal shape with a top central part 86 and two lateral wings 87. This shape facilitates the profiling of the inner sheet.

[0149]

[0048] The groove is dimensioned so that portions of the cables with electrical connectors can be reserved between the inner sheet and the mold. In particular, the height (taken along the Z axis) of the groove is superior or equal to the diameter of the electrical connector. More particularly, the width (taken along the Y axis) of the groove is superior or equal to the diameter of the electrical connector. Even more particularly, the width of the groove is superior or equal to two times the diameter of the electrical connector. In one variant, the height (taken along the Z axis) of the lateral wings of the groove is superior or equal to the diameter of the electrical connector. In another variant, the width (taken along the Y axis) of the top central part of the groove is superior or equal to the diameter of the electrical connector.

[0150]

[0049] In a first variant of this embodiment illustrated on Figures 22 and 23, the inner central part comprises an upper inner groove 59 extending at least from the upper transverse side 7 of the insulation material up to an upper hole 55 in the inner central part and / or a lower inner groove 60 extending at least from the lower transverse side 8 of the insulation material up to a lower hole 57 in the inner central part. The length of the upper inner groove and the lower inner groove is along the longitudinal axis X.

[0151]

[0050] In a second variant illustrated on Figures 10 and 11 , the inner central part comprises a longitudinal groove 85 extending from the upper transverse inner edge 63 to the lower transverse inner edge 64 of the inner sheet, i.e. from the upper transverse side 7 to the lower transverse side 8 of the insulation material.

[0152]

[0051] The longitudinal groove comprises an upper opening 88 and a lower opening 89 for the routing of cables and electrical connectors. The openings are preferably positioned on the lateral wing 87 of the longitudinal groove which is farthest from a longitudinal side of the insulation material. The upper opening is located in the upper half of the sandwich panel and the lower opening is located in the lower half of the sandwich panel. According to the variant of the invention in which the sandwich panel 1 comprises a second photovoltaic active 10 area positioned on the outer central part 17, the longitudinal groove can comprise two upper openings 88 and two lower openings 89.

[0153]

[0052] In particular, the upper opening 88 and lower opening 89 are dimensioned so that electrical connectors can pass through. More particularly, they are dimensioned so that a maximum of two electrical connectors can pass through or so that a maximum of one electrical connector can pass through. Their length is preferably inferior to 6 cm, more preferably inferior to 3 cm. In other words, the upper and lower openings are not capable of receiving an electrical connector housing. Such a width facilitates the setup of the insulation, in particular the foaming, and improves the watertightness of the sandwich panel.

[0154]

[0053] According to a first embodiment of the longitudinal inner flanges illustrated on Figures 5 to 10, in cross-section perpendicular to the longitudinal axis X, the first longitudinal inner flange 65 extends inwards from the first longitudinal extremity of the inner central part 67 and forms an inner edge rabbet 68 in the insulation material along the first longitudinal side 5 of the insulation material. In the context of the invention, the inner edge rabbet is a groove in the inner sheet. Preferably, the inner edge rabbet comprises, successively and starting from the first longitudinal extremity of the inner central part, a first inner riser 69 and a top portion 70. The first inner riser is preferably substantially flat. It can comprise a longitudinal embossing for the easy clipping of a capping. It can extend substantially perpendicular to the inner central part, i.e. perpendicular to plane P or can be inclined towards the top portion. The latter can be parallel to plane P or slightly inclined towards the inner central part to facilitate the interlocking of two adjacent panels.

[0155]

[0054] Preferably the first longitudinal inner flange 65 further comprises a first inner stiffener 71 extending from the inner edge rabbet 68, in particular from the top portion 70. According to one variant of the invention, the first inner stiffener extends substantially perpendicularly to the inner central part along the first longitudinal side 5 of the insulation material. It improves the sealing between two panels.

[0156]

[0055] The first longitudinal inner flange 65 is preferably on the same longitudinal side of the insulation material as the first longitudinal rib of the outer sheet, which projects from the longitudinal side of the insulation material, as illustrated on Figure 5. It facilitates the lateral assembling of two adjacent panels. More preferably, the first longitudinal inner edge 61 is substantially plumb with the first longitudinal extremity of the outer central part 17 of the outer sheet 4. In other words, the inner edge rabbet 68 is positioned underneath the outer central part 17 of the outer sheet 4.

[0157]

[0056] According to a first variant of the first embodiment illustrated on Figures 5 and 8, the second longitudinal inner flange 66 extends from the second longitudinal extremity 84 of the inner central part 67 and comprises a second inner riser 72 extending inwards from this second longitudinal extremity 84. The second inner riser is preferably substantially flat. It can comprise a longitudinal embossing for the easy clipping of a capping. It preferably extends substantially perpendicular to plane P.

[0158]

[0057] The second longitudinal inner flange 66 further comprises a bearing area, extending from the second inner riser 72, in the form of an inner indent 81 extending substantially parallel to plane P and inwards.

[0159]

[0058] Preferably, the inner indent 81 is in the form of a substantially flat ledge projecting from the portion of the second longitudinal side 6 of the insulation material situated between the inner sheet and the outer sheet. In other words, the second longitudinal side of the insulation preferably comprises a substantially vertical portion positioned between the outer sheet and the inner sheet, then a ledge projecting from this portion and covered by the inner indent 81 , and then a substantially vertical portion covered by the second inner riser 72.

[0160]

[0059] Preferably the second longitudinal inner flange 66 comprises a second inner stiffener 77 extending from the inner indent 81 . According to one variant of the invention, the second inner stiffener extends substantially perpendicularly to the inner central part 67 along the second longitudinal side 6 of the insulation material. It improves the sealing between two panels.

[0161]

[0060] According to a second variant of the first embodiment illustrated on Figure 6, the second longitudinal inner flange 66 differs from the first variant in that the bearing area, extending from the second inner riser 72, is in the form of an inner tongue 73 extending substantially parallel to plane P and outwards.

[0162]

[0061] Preferably, the inner tongue 73 projects from the second longitudinal side 6 of the insulation material. In other words, the inner tongue extends beyond the second longitudinal side of the insulation material. Preferably, the inner tongue is in the form of a U-shaped bend comprising a lower branch 74 and an upper branch 75 linked by a U-turn 76. More preferably, the branches 74 and 75 are parallel. More preferably, the radius of the U-turn is such that the space in-between the branches is filled with insulation material 2 which helps stiffening the inner tongue. According to another variant, the radius of the U-turn is such that the two branches are in contact with each other.

[0163]

[0062] Preferably the second longitudinal inner flange 66 comprises a second inner stiffener 77 extending from the inner tongue 73, in particular from the upper branch 75. According to one variant of the invention, the second inner stiffener extends substantially perpendicularly to the inner central part 67 along the second longitudinal side 6 of the insulation material. It improves the sealing between two panels.

[0164]

[0063] In both variants, the first longitudinal inner flange 65 and the second longitudinal inner flange 66 have shapes that allow the overlapping of one on the other, i.e. their interlocking, when one sandwich panel is assembled with a sandwich panel laterally adjacent. Preferably, their shapes are substantially complementary and their dimensions are such that:

[0165] - The height of the inner edge rabbet (measured along the vertical axis Z) is superior to the height of the second inner riser,

[0166] - The width of the inner edge rabbet (measured along the transversal axis Y) is superior or equal to the width of the bearing area (inner tongue 73 or inner indent 81 ).

[0167]

[0064] In particular, the first longitudinal inner flange 65 and the second longitudinal inner flange 66 can have shapes that allow them to form a technical recess 78 when two sandwich panel laterally adjacent are assembled, as illustrated on Figures 7 and 9. In particular, it is formed when the second longitudinal outer flange 16 of a first sandwich panel is interlocked with the first longitudinal outer flange 15 of a second sandwich panel laterally adjacent.

[0168]

[0065] The second inner riser 72 of the first sandwich panel and the inner edge rabbet 68 of the second sandwich panel form the technical recess 78. In particular, the technical recess is delimited by the second inner riser 72 of the first sandwich panel, the inner edge rabbet 68, at least in part, of the second sandwich panel and the plane P. More particularly, in the case of an inner tongue 73, the technical recess is delimited by the plane P and, as for the first sandwich panel, by the second inner riser 72 and the lower branch 74 of the inner tongue and, as for the second sandwich panel, by the part of the top portion 70 not covered by the inner tongue and the first inner riser 69. More particularly, in the case of an inner indent 81 , the technical recess is delimited by the plane P and, as for the first sandwich panel, by the second inner riser 72 and, as for the second sandwich panel, by the first inner riser 69 and the part of the top portion 70 not covering the inner indent 81 .

[0169]

[0066] As the technical recess is open to the inside of the building, it can be used to route cables, in particular to route a part of the first cable 42 with the first electrical connector 46 and a part of the second cable 43 with the second electrical connector 47 and, if applicable, a part of the third cable 50 with the third electrical connector 52 and a part of the fourth cable 51 with the fourth electrical connector 53. It can also be used to fix equipment, such as lightning. The technical recess can also be closed with a decorative capping and / or a fireproof capping.

[0170]

[0067] Such overlapping of the inner edge rabbet and the bearing area improves the watertightness, airtightness and mechanical resistance of the envelope made of sandwich panels.

[0171]

[0068] In a variant of the inner sheet, the shapes of the first longitudinal inner flange 65 and second longitudinal inner flange 66 are inverted.

[0172]

[0069] In a second embodiment of the longitudinal inner flanges illustrated on Figure 12, in cross-section perpendicular to the longitudinal axis X, the first longitudinal inner flange 65 comprises an inner mortise 110 extending inwards. In the example illustrated, the inner mortise is in the form of a U- shaped bend extending substantially in parallel to plane P. In particular, the inner mortise comprises two branches substantially parallel and linked by a U-turn. More preferably, the two branches have substantially the same length. Other designs of inner mortise are possible. It can notably have a V- shape with two branches converging towards a U-turn. It can also have a L- shape with a branch and a seat.

[0173]

[0070] The first longitudinal inner flange 65 can comprise a first inner riser 69 extending between the first longitudinal extremity 83 of the inner central part and the inner mortise. The first inner riser can extend substantially perpendicular to the inner central part, i.e. perpendicular to plane P, or can be inclined towards the inner mortise.

[0174]

[0071] Preferably the first longitudinal inner flange 65 further comprises a first inner stiffener 71 extending from the inner mortise. According to one variant of the invention, the first inner stiffener extends substantially perpendicularly to the inner central part along the first longitudinal side 5 of the insulation material. It improves the sealing between two panels.

[0175]

[0072] The inner mortise 110 is preferably on the same longitudinal side of the insulation material as the outer mortise 102 of the outer sheet, as illustrated on Figure 12. It facilitates the lateral assembling of two adjacent panels. More preferably, the inner mortise is substantially plumb with the outer mortise.

[0176]

[0073] In accordance with the inner mortise, the second longitudinal inner flange 66 of the inner sheet comprises an inner tenon 111 extending outwards, the inner tenon and the inner mortise having shapes that allow the overlapping of one longitudinal inner flange on the other, i.e. the interlocking of the inner tenon and the inner mortise. In the example illustrated, the inner tenon projects from the second longitudinal side 6 of the insulation material. By “projects”, it is meant that the second longitudinal inner flange 66 extends beyond the second longitudinal side 6 of the insulation material, in particular beyond the plane of the second longitudinal side.

[0177]

[0074] In the example illustrated, the inner tenon 111 is in the form of a U- shaped bend extending substantially in parallel to the inner central part 67. In particular, the inner tenon comprises two branches substantially parallel and linked by a U-turn. More preferably, the two parallel branches have substantially the same length. Other designs of inner tenon are possible. It can notably have a V-shape with two branches converging towards a U-turn. It can also have a L-shape with a branch and a seat.

[0178]

[0075] The second longitudinal inner flange 66 can comprise a second inner riser 72 extending between the second longitudinal extremity 84 of the inner central part and the inner tenon. The second inner riser can extend substantially perpendicular to the inner central part, i.e. perpendicular to plane P, or can be inclined towards the inner tenon, or can be inclined towards the inner central part.

[0179]

[0076] Preferably the second longitudinal inner flange 66 comprises a second inner stiffener 77 extending from the inner tenon 111. According to one variant of the invention, the second inner stiffener extends substantially perpendicularly to the inner central part 67 along the second longitudinal side 6 of the insulation material. It improves the sealing between two panels.

[0180]

[0077] The inner mortise 110 and the inner tenon 111 have shapes that allow the overlapping of one longitudinal inner flange on the other, i.e. their interlocking, when one sandwich panel is assembled with a sandwich panel laterally adjacent. Preferably, their shapes are substantially complementary and their dimensions are such that:

[0181] - The height of the inner mortise (measured along the vertical axis Z) is superior to the height of the inner tenon,

[0182] - The width of the inner mortise (measured along the transversal axis Y) is superior or equal to the width of the inner tenon.

[0183]

[0078] Such interlocking of the inner mortise and the inner tenon improves the resistance, notably to wind suction, of the envelope made of sandwich panels.

[0184]

[0079] In a variant of the inner sheet, the shapes of the first longitudinal inner flange 65 and second longitudinal inner flange 66 are inverted.

[0185]

[0080] The embodiments of the longitudinal inner flanges and the embodiments of the inner central part can be combined. Any combination of an embodiment of the longitudinal inner flanges and an embodiment of the inner central part can be combined with any embodiment of the outer sheet.

[0186]

[0081] With reference to Figures 1 and 2, the sandwich panel 1 is a building integrated photovoltaic (BIPV) sandwich panel. Accordingly, it comprises a first photovoltaic active area 24, as defined above, positioned on the outer central part 17 and the components for the electrical connections of the first photovoltaic active area to other sandwich panels or to the grid are integrated in the thickness of the sandwich panel.

[0082] In particular, the first photovoltaic active area 24 is directly built on the outer central part of the outer sheet before the sandwich panel is manufactured. In particular, it is laminated on the outer central part of the outer sheet. It strongly improves the watertightness of the sandwich panel.

[0187]

[0083] The first photovoltaic active area 24 is preferably dimensioned so that, on one hand, no part of it is covered by an adjacent sandwich panel when the panels are assembled and, on the other hand, the active surface is maximized. Accordingly, the upper transverse edge of the first photovoltaic active area is positioned preferably as close as possible to the upper transverse outer edge 13 of the outer sheet, or as close as possible to the upper overlap area if applicable, and the lower transverse edge of the first photovoltaic active area is positioned preferably as close as possible to the lower transverse outer edge 14 of the outer sheet. Similarly, in the variant of the invention where there is only one photovoltaic active area, the first longitudinal edge of the first photovoltaic active area is as close as possible to the first longitudinal outer flange 15 and the second longitudinal edge of the first photovoltaic active area is as close as possible to the second longitudinal outer flange 16. A first polarity of the first photovoltaic active area is preferably positioned in the upper half of the first photovoltaic active area, more preferably adjacent to the upper transverse edge, below the upper overlap area if applicable. A second polarity of the first photovoltaic active area is preferably positioned in the lower half of the first photovoltaic active area, more preferably adjacent to the lower overlap area 22 of the sandwich panel, if applicable.

[0188]

[0084] The first photovoltaic active area 24 is electrically connected to a first upper electrical conductor 25 and to a first lower electrical conductor 26. In particular, a first polarity of the first photovoltaic active area is connected to the first upper electrical conductor and a second polarity of the first photovoltaic active area is connected to the first lower electrical conductor. As the first photovoltaic active area 24 is on the upper side of the outer sheet and the electrical connections are in the thickness of the sandwich panel, the first upper and first lower electrical conductors run through the outer sheet. In the variant illustrated on Figure 13, the first upper electrical conductor 25 and the first lower electrical conductor 26 are conductive ribbons, also known as conductive busbars. They are part of the first photovoltaic active area. They are preferably directly connected to PV cells of the first photovoltaic active area. They are both running on the surface of the outer sheet and then through the outer sheet. In another variant (not illustrated), the first upper electrical conductor 25 and the first lower electrical conductor 26 are intermediate electrical conductors connected to a conductive ribbon of the first photovoltaic active area. The first upper electrical conductor 25 and the first lower electrical conductor 26 can notably be embedded in a non- conductive grommet 29 described below. In that case, the conductive ribbons of the first photovoltaic active area can run on the surface of the outer sheet and can be connected to the first upper electrical conductor 25 and the first lower electrical conductor 26 that run through the outer sheet.

[0189]

[0085] Consequently, and with reference to Figure 14, the outer central part 17 comprises a first upper perforation 27 through which the first upper electrical conductor runs and a first lower perforation 28 through which the first lower electrical conductor runs. The positions of the first upper perforation and first lower perforation can depend notably on the positions of the first and second polarities of the photovoltaic active area and on the positions of the electrical connections in the thickness of the sandwich panel. Generally speaking, the first upper perforation is preferably positioned in the upper half of the sandwich panel and the first lower perforation is preferably positioned in the lower half of the sandwich panel, outside of the lower overlap area 22 if applicable. As the first photovoltaic active area 24 preferably has its first polarity adjacent to its upper transverse end, below (i.e. adjacent to) the upper overlap area 23 if applicable, and its second polarity adjacent to its lower transverse end or to the lower overlap area if applicable, the first upper perforation 27 is preferably positioned adjacent to the upper transverse end of the first photovoltaic active area, below (i.e. adjacent to) the upper overlap area if applicable, and the first lower perforation 28 is preferably positioned adjacent to the lower transverse end of the first photovoltaic active area or to the lower overlap area if applicable. Preferably, the first upper perforation and first lower perforation are substantially aligned in the longitudinal axis X.

[0190]

[0086] Preferably, the width of the perforations (i.e. the longest length measured in the X-Y plane) is of the order of magnitude of the diameter of an electrical connector, as described below. In particular, the width is inferior to 3 cm, more preferably inferior to 2 cm. In other words, the perforations are not capable of receiving an electrical connector housing. Such a width further minimizes the negative impact a hole can have on the lamination of the photovoltaic active area on the outer sheet alone and further improves the watertightness of the sandwich panel.

[0191]

[0087] For waterproofing reasons, the first upper and first lower perforations preferably are covered by at least one layer of the first photovoltaic active area. More preferably, the first upper and first lower perforations are covered by the frontsheet. Even more preferably, they are covered by the frontsheet, a layer of encapsulation material and possibly at least partially the backsheet. Also, the first upper and first lower perforations can be substantially below the layer capable of converting solar energy into electricity. By substantially below it is meant here that they can be below this layer even if there are no PV cells strictly above the perforations. The first upper and first lower perforations can also be substantially covered by the first photovoltaic active area. By substantially covered, it is meant here that they are overall below the photovoltaic active area even if the perforations are not strictly covered by all the layers of the photovoltaic active area.

[0192]

[0088] Preferaby, the inward end of the first upper electrical conductor is adjacent to the first upper perforation. This inward end can also be substantially plumb with the first upper perforation. Preferaby, the inward end of the first lower electrical conductor is adjacent to the first lower perforation. This inward end can also be substantially plumb with the first lower perforation.

[0193]

[0089] Having the first upper electrical conductor going through the first upper perforation and the first lower electrical conductor going through the first lower perforation is advantageous. As there are no junction boxes or other protruding parts on the upper side of the outer sheet, the step of forming the insulation material in existing production facilities is not compromised. Also, in the case of electrical conductors in the form of conductive ribbons or in the case of electrical conductors integrated in a non-conductive grommet, as they are thin, their ends lying against the backside of the outer sheet during the lamination of the photovoltaic active area have no impact on the flatness of the outer sheet. Accordingly, the lamination of the photovoltaic active area can be efficiently performed on the outer sheet alone, without modifying existing lamination equipment to accommodate parts protruding from the surface of the backside of the outer sheet. Moreover, in the case of electrical conductors in the form of conductive ribbons, the connection of the electrical conductor to the rest of the electrical circuit is not done between the outer sheet and the photovoltaic active area. Such connection tends to be thick compared to the thickness of the photovoltaic active area and to jeopardize the lamination of the latter.

[0194]

[0090] With reference to Figures 15, 16, 17, 20, 21 , 24, 25, 28, 29, 32, 33 and 36, for electrical safety reasons, and in the case where the outer sheet is made of a conductive material, the first upper electrical conductor 25, respectively the first lower electrical conductor 26, is preferably electrically insulated from the edge of the first upper perforation 27, respectively first lower perforation 28, by a non-conductive grommet 29 inserted in the first upper perforation, respectively first lower perforation. Firstly, the non- conductive grommet comprises an opening 30 for the passing of an electrical conductor. The size of the opening is adapted to the size of the electrical conductor. The non-conductive grommet can further comprise an upper part 31 larger than the perforation. The non-conductive grommet can thus rest on the outer sheet. The upper part can be thin enough to further avoid lamination issues of the photovoltaic active area. The non-conductive grommet can further comprise a lower part 32 narrower than the perforation and comprising a plurality of crenellations 321. The lower part being narrowed than the perforation, the non-conductive grommet can easily be positioned in the perforation. The crenellations extend the surface distance between the opening 30 and the periphery of the grommet and thus extend the creepage distance between the electrical conductor and the outer sheet. They are preferably concentric. Thanks to the crenellations engraved in the lower part, the electrical conductor emerging from the non-conductive grommet on the backside of the outer sheet is kept at a safe surface distance from the conductive metal. The non-conductive grommet can comprise another opening 30, adjacent to the first one for the passing of a second electrical conductor.

[0195]

[0091] Preferably, the thickness of the grommet is of the order or magnitude of the thickness of the outer sheet (0.5-1 mm). In particular, the grommet is less than 2 mm thick, more preferably less than 1 mm thick. Preferably, the grommet does not protrude substantially below the surface of the backside of the outer sheet, in particular of the backside of the outer central part. In particular, the grommet does not protrude over more than 1 mm below the surface of the backside of the outer sheet. In other words, the surface of the bottom part of the grommet is substantially flush with the surface of the backside of the outer sheet. Thanks to this design, the lamination of the photovoltaic active area can be efficiently performed on the outer sheet alone, without modifying existing lamination equipment to accommodate parts protruding from the surface of the backside of the outer sheet. Furthermore, the grommet has no impact on the flatness of the outer sheet.

[0196]

[0092] Preferably, the width of the grommet (i.e. the longest length measured in the X-Y plane) is of the order or magnitude of the diameter of an electrical connector, as described below. In particular, the width is inferior to 3 cm, more preferably inferior to 2 cm. Such a width further improves the quality of the lamination of the photovoltaic active area on the outer sheet.

[0197]

[0093] Preferably, the first upper perforation 27 is not traversed by anything other than the first upper electrical conductor, and the non-conductive grommet if any and a second electrical conductor if any. Preferably, the first lower perforation 28 is not traversed by anything other than the first lower electrical conductor, and the non-conductive grommet if any and a second electrical conductor if any.

[0198]

[0094] With reference to Figure 14, the outer central part 17 of the outer sheet 4 can further comprise by-pass perforations 33. The latter allow the addition of by-pass diodes of the first photovoltaic active area at the backside of the outer sheet. As the by-pass diodes are thicker than the layers of the first photovoltaic active area, inserting them directly in the first photovoltaic active area tends to jeopardize the integrity of the latter. Thanks to the by-pass perforations, conductive ribbons from the first photovoltaic active area can go through the outer sheet, be connected to a by-pass diode and go through the outer sheet again.

[0199]

[0095] The by-pass perforations are preferably regularly positioned along the longitudinal direction of the first photovoltaic active area. They are preferably positioned as far as possible from the edges of the frontsheet of the photovoltaic active area, in the transverse direction, to prevent water leaks.

[0200]

[0096] Preferably, the width of the by-pass perforations (i.e. the longest length measured in the X-Y plane) is of the order of magnitude of the diameter of an electrical connector, as described below. In particular, the width is inferior to 3 cm, more preferably inferior to 2 cm. In other words, the by-pass perforations are not capable of receiving an electrical connector housing. Such a width further minimizes the negative impact a hole can have on the lam ination of the photovoltaic active area on the outer sheet alone and further improves the watertightness of the sandwich panel.

[0201]

[0097] In the case where the outer sheet is made of a conductive material, non-conductive grommets 29 are preferably inserted in the by-pass perforations to insulate the conductive ribbons from the by-pass perforations. These grommets have the same features as the ones described above except in that they comprise two openings: one for the conductive ribbon coming from the first photovoltaic active area and one for the conductive ribbon going back to the first photovoltaic active area.

[0202]

[0098] According to one variant of the invention illustrated on Figures 1 , 2, 13 and 14, the sandwich panel 1 comprises a second photovoltaic active area 35 positioned on the outer central part 17. The second photovoltaic active area 35 is positioned beside the first photovoltaic active area 24. Preferably, the first photovoltaic active area and the second photovoltaic active area extend in the longitudinal axis parallel to each other. The outer sheet can comprise a third longitudinal rib positioned between the first photovoltaic active area and the second photovoltaic active area.

[0099] In particular, a first polarity of the second photovoltaic active area is positioned in the upper half of the second photovoltaic active area, more preferably adjacent to the upper transverse end of the second photovoltaic active area, below the upper overlap area 23 if applicable. This first polarity is preferably of opposite polarity to the first polarity of the first photovoltaic active area. In particular, a second polarity of the second photovoltaic active area is positioned in the lower half of the second photovoltaic active area, more preferably adjacent to the lower transverse end of the first photovoltaic active area or to the lower overlap area 22 of the sandwich panel if applicable. This second polarity is preferably of opposite polarity to the second polarity of the first photovoltaic active area. The second photovoltaic active area 35 is electrically connected to a second upper electrical conductor 36 and to a second lower electrical conductor s?. Consequently, the outer central part 17 can comprise a second upper perforation 38 through which the second upper electrical conductor runs and a second lower perforation 39 through which the second lower electrical conductor runs. The features and variants detailed in relation to the first photovoltaic active area and the corresponding features of the outer sheet apply here. Alternatively, the second upper electrical conductor runs through the first upper perforation 27 and the second lower electrical conductor runs through the first lower perforation 28.

[0203]

[0100] As mentioned above in relation to the first photovoltaic active area 24, the first upper electrical conductor 25 and the first lower electrical conductor 26 go through the outer sheet 4. On the backside of the outer sheet, the first upper electrical conductor 25 is electrically connected, directly or indirectly, to a first upper cable 42 and the first lower electrical conductor 26 is electrically connected, directly or indirectly, to a first lower cable 43. The way the electrical connections are done is not limited. It can be done by welding. The upper cable and lower cable are preferably insulated. The upper cable and lower cable can comprise a sleeve, in at least one portion.

[0204]

[0101] For electrical safety reasons and to facilitate the integration of the photovoltaic function in the sandwich panel, the first upper electrical conductor and the first lower electrical conductor are preferably insulated from the insulation material 2. In the variant illustrated on Figures 16, 17, 20, 21 , 24, 25, 28, 29, 32, 33 and 36, the first upper electrical conductor is preferably connected to the first upper cable in a first upper junction box 40 and the first lower electrical conductor is preferably connected to the first lower cable in a first lower junction box 41 . A junction box is an electrical enclosure in which electrical wiring connections are safely made. The first upper junction box 40 and the first lower junction box 41 are part of the backside of the outer sheet. Both junction boxes preferably comprise a casing. The casing preferably comprises a conductor opening or ribbon opening and a cable opening. In a variant, the junction box 40, 41 comprises a non-conductive grommet 29, as described above.

[0205]

[0102] The first upper junction box 40, respectively the first lower junction box 41 , is preferably positioned in contact with the backside of the outer sheet, substantially plumb with the first upper perforation 27, respectively first lower perforation 28, so that there is no gap between the outer sheet and the junction boxes. The junction boxes can be attached to the backside of the outer sheet, for example by gluing.

[0206]

[0103] Thanks to this configuration, the connection of the electrical conductors on the backside of the outer sheet does not jeopardize the integrity and quality of the first photovoltaic active area. Moreover, the junction boxes can further improve the watertightness at the level of the perforations.

[0207]

[0104] With reference to Figures 16 to 40, two embodiments of cables are now described.

[0208]

[0105] For the two embodiments, one of the two first cables runs through the insulation material until it enters a cavity. Either the first upper cable 42 runs through the insulation material until it enters an upper cavity 44 or the first lower cable runs through the insulation material until it enters a lower cavity 45. In the cavity, the cable is connected to an electrical connector. Either the first upper cable is connected to a first upper electrical connector 46 in the upper cavity or the first lower cable is connected to a first lower electrical connector 47 in the lower cavity.

[0209]

[0106] The portion of the cable running through the insulation can comprise a sleeve. By Tun through the insulation material”, it is meant that the cable, possibly comprising a sleeve, is closely surrounded by the insulation material. It is the result of the laying of the insulation after the cable has been positioned.

[0210]

[0107] Between its cavity and the respective electrical conductor, or respective junction box if applicable, the cable, possibly comprising a sleeve, is preferably substantially embedded in the insulation material. In other words, this portion of the cable is irremovable. The substantial embedment of this portion of cables in the insulation material is the result of the foaming of the insulation material around the cable or the result of the attachment of the cable to the insulation material, for example by gluing, when the insulation is laid. This substantial embedment facilitates the process for manufacturing the sandwich panel since no specific step has to be performed to isolate this portion of the cables from the insulation material before the latter is put in place.

[0211]

[0108] For the two embodiments, the cable among the first upper cable and the first lower cable that does not enter a cavity has:

[0212] - an upstream portion running from the respective first electrical conductor to either: o one of the first longitudinal side and the second longitudinal side of the insulation material or, o one of the upper transverse side and the lower transverse side of the insulation material or, o the inner sheet or, o the outer sheet, and running through the insulation material,

[0213] - a downstream portion with a first electrical connector, freely extending either from the said longitudinal side of the insulation material or from the said transverse side of the insulation material or from the inner sheet or from the outer sheet.

[0214]

[0109] By “run through the insulation material”, it is meant that the upstream portion of the cable, possibly comprising a sleeve, is closely surrounded by the insulation material. It is the result of the upstream portion of the cable being positioned before laying the insulation or while laying the insulation. It facilitates the process for manufacturing the sandwich panel since no specific step has to be performed to isolate the upstream portion of the cable from the insulation material before the latter is put in place. Preferably, the upstream portions of the cable run exclusively through the insulation material.

[0215]

[0110] According to a first embodiment of the cables illustrated on Figures 16 to 19 and 24 to 40, the first upper cable runs through the insulation material until it enters an upper cavity 44. In the latter, the first upper cable is connected to a first upper electrical connector 46.

[0216]

[0111] The upper cavity 44 comprises the first upper electrical connector 46 and a portion of the first upper cable 42. Preferably, this portion of the first upper cable is long enough so that the first upper electrical connector can be extracted from the upper cavity. More preferably, this portion of the first upper cable is folded in the upper cavity. This folding eases the extraction.

[0217]

[0112] As for the first lower cable 43, it has:

[0218] - an upstream portion running from the first lower electrical conductor 26 to either : o one of the first longitudinal side and the second longitudinal side of the insulation material or, o the lower transverse side of the insulation material or, o the inner sheet or, o the outer sheet, and running through the insulation material,

[0219] - a downstream portion with a first lower electrical connector 47, freely extending either from the said longitudinal side of the insulation material or from the lower transverse side of the insulation material or from the inner sheet or from the outer sheet.

[0220]

[0113] The upstream portion and the downstream portion of the first lower cable 43 join at a junction point. This junction point is preferably positioned in the lower half of the sandwich panel. More preferably, this junction point is positioned, along the longitudinal axis X of the sandwich panel, between the first lower perforation 28 and the lower transverse side 8 of the insulation material. For the sake of clarity, in this embodiment, the first lower cable has no other portion than the upstream portion and the downstream portion.

[0114] In particular, the upper cavity 44 is positioned in the upper half of the sandwich panel while the upstream portion of the first lower cable 43 is positioned in the lower half of the sandwich panel. This way, there is no risk of cable crossing between the first upper cable and the first lower cable when the photovoltaic active areas of adjacent panels are electrically connected and the length of cables needed to connect the photovoltaic active areas is limited.

[0221]

[0115] According to a second embodiment of the cables illustrated on Figures 20 to 23, the first lower cable runs through the insulation material until it enters a lower cavity 45. In the latter, the first lower cable is connected to a first lower electrical connector 47.

[0222]

[0116] The lower cavity 45 comprises the first lower electrical connector 47 and a portion of the first lower cable 43. Preferably, this portion of the lower cable is long enough so that the first lower electrical connector can be extracted from the lower cavity. More preferably, this portion of the first lower cable is folded in the lower cavity.

[0223]

[0117] As for the first upper cable 42, it has:

[0224] - an upstream portion running from the first upper electrical conductor 25 to either : o one of the first longitudinal side and the second longitudinal side of the insulation material or, o the upper transverse side of the insulation material or, o the inner sheet or, o the outer sheet, and running through the insulation material,

[0225] - a downstream portion with a first upper electrical connector 46, freely extending either from the said longitudinal side of the insulation material or from the upper transverse side of the insulation material or from the inner sheet or from the outer sheet.

[0226]

[0118] The upstream portion and the downstream portion of the first upper cable 42 join at a junction point. This junction point is preferably positioned in the upper half of the sandwich panel. More preferably, this junction point is positioned, along the longitudinal axis X of the sandwich panel, between the first upper perforation 27 and the upper transverse side 7 of the insulation material. For the sake of clarity, in this embodiment, the first upper cable has no other portion than the upstream portion and the downstream portion.

[0227]

[0119] In particular, the lower cavity 45 is positioned in the lower half of the sandwich panel while the upstream portion of the first upper cable 42 is positioned in the upper half of the sandwich panel. This way, there is no risk of cable crossing between the first upper cable and the first lower cable when the photovoltaic active areas of adjacent panels are electrically connected and the length of cables needed to connect the photovoltaic active areas is limited.

[0228]

[0120] Any embodiment of the cables can be combined with any embodiment of the longitudinal inner flanges or any embodiment of the inner central part or any embodiment of the outer sheet or any combinations of them.

[0229]

[0121] The first upper electrical connector 46 and first lower electrical connector 47 described above in relation to the first and second embodiments of the cables are corresponding male and female connectors. The first upper electrical connector can be the male connector and the first lower electrical connector the female connector or vice versa.

[0230]

[0122] These first electrical connectors allow the electrical connection of the first photovoltaic active area to other photovoltaic active areas and / or to the grid. In particular, one polarity of the first photovoltaic active area can be connected to one polarity of a first photovoltaic active area of a second sandwich panel whose lower transverse side 8 of insulation material is positioned adjacent to the upper transverse side 7 of the first sandwich panel, by connecting, directly or indirectly, the first upper electrical connector 46 of the first sandwich panel to the first lower electrical connector 47 of the second sandwich panel. Similarly, the other polarity of the first photovoltaic active area can be connected to one polarity of a first photovoltaic active area of a third sandwich panel whose upper transverse side 7 of insulation material is positioned adjacent to the lower transverse side 8 of the first sandwich panel, by connecting, directly or indirectly, the first lower electrical connector 47 of the first sandwich panel to the first upper electrical connector 46 of the third sandwich panel. Alternatively, the first upper electrical connector 46 or the first lower electrical connector 47 of the sandwich panel can be connected to the grid.

[0231]

[0123] With reference to Figures 15, 16, 17, 20, 21 , 24, 25, 28, 29, 32, 33 and 36, according to the variant of the invention in which the sandwich panel 1 comprises a second photovoltaic active area 35 positioned on the outer central part 17, the backside of the outer sheet 4 comprises a second upper cable 50 electrically connected, directly or indirectly, to the second upper electrical conductor 36 and a second lower cable 51 electrically connected, directly or indirectly, to the second lower electrical conductor 37. In the variant illustrated, the second upper cable 50 is connected to the second upper electrical conductor 36 in a second upper junction box 48 and the second lower cable 51 is connected to the second lower electrical conductor 37 in a second lower junction box 49. The features and variants detailed in relation to the first junction boxes apply here. Alternatively, the second upper cable 50 is connected to the second upper electrical conductor 36 in the first upper junction box 40 and the second lower cable 51 is connected to the second lower electrical conductor 37 in a first lower junction box 40.

[0232]

[0124] Each second cable runs at least partially adjacently to the respective first cable. In particular, the second upper cable 50 runs at least partially adjacently to the first upper cable 40 and the second lower cable 51 runs at least partially adjacently to the first lower cable 43.

[0233]

[0125] By “at least partially adjacently to”, it is meant that each second cable is positioned similarly to the respective first cable. Even if a second cable does not run exactly from the same position as the respective first cable and does not run exactly to the same position as the respective first cable, a portion of the second cable is positioned close to the respective first cable within the insulation material. In other words, if the first upper cable enters the upper cavity while the first lower cable has a downstream portion extending from a side or a sheet of the sandwich panel, then the second upper cable enters the upper cavity too while the second lower cable has a downstream portion extending from a side or a sheet of the sandwich panel adjacently to the downstream portion of the first lower cable. Inversely, if the first lower cable enters the lower cavity while the first upper cable has a downstream portion extending from a side or a sheet of the sandwich panel, then the second lower cable enters the lower cavity too while the second upper cable has a downstream portion extending from a side or a sheet of the sandwich panel adjacently to the downstream portion of the first upper cable.

[0234]

[0126] According to the first embodiment of the cables illustrated on Figures 16 to 19 and 24 to 40, the second upper cable 50 runs through the insulation material until it enters the upper cavity 44. In the latter, the second upper cable is connected to a second upper electrical connector 52.

[0235]

[0127] The upper cavity 44 thus further comprises the second upper electrical connector 52 and a portion of the second upper cable 50. Preferably, this portion of the second upper cable is long enough so that the second upper electrical connector can be extracted from the upper cavity. More preferably, this portion of the second upper cable is folded in the upper cavity. This folding eases the extraction.

[0236]

[0128] As for the second lower cable 51 , it has:

[0237] - an upstream portion running from the second lower electrical conductor 37 to either: o the same longitudinal side of the insulation material as the first lower cable, or o the lower transverse side of the insulation material or, o the inner sheet, o or the outer sheet, and running through the insulation material,

[0238] - a downstream portion with a second lower electrical connector 53, freely extending either from the said longitudinal side of the insulation material, or from the lower transverse side of the insulation material or from the inner sheet or from the outer sheet.

[0239]

[0129] The features and variants detailed in relation to the first cables apply here.

[0240]

[0130] Preferably, the junction point of the second lower cable 51 is adjacent to the junction point of the first lower cable 43. More preferably, the upstream portion of the second lower cable 51 is adjacent to the upstream portion of the first lower cable 43.

[0241]

[0131] According to the second embodiment of the cables illustrated on Figures 20 to 23, the second lower cable 51 runs through the insulation material until it enters the lower cavity 45. In the latter, the second lower cable is connected to a second lower electrical connector 53.

[0242]

[0132] The lower cavity 45 thus further comprises the second lower electrical connector 53 and a portion of the second lower cable 51 . Preferably, this portion of the second lower cable is long enough so that the second lower electrical connector can be extracted from the lower cavity. More preferably, this portion of the second lower cable is folded in the lower cavity. This folding eases the extraction.

[0243]

[0133] As for the second upper cable 50, it has:

[0244] - an upstream portion running from the second upper electrical conductor 36 to either: o the same longitudinal side of the insulation material as the first upper cable, or o the upper transverse side of the insulation material or, o the inner sheet, o or the outer sheet, and running through the insulation material,

[0245] - a downstream portion with a second upper electrical connector 52, freely extending either from the said longitudinal side of the insulation material, or from the upper transverse side of the insulation material or from the inner sheet or from the outer sheet,

[0246]

[0134] Preferably, the junction point of the second upper cable 50 is adjacent to the junction point of the first upper cable 42. More preferably, the upstream portion of the second upper cable 50 is adjacent to the upstream portion of the first upper cable 42.

[0247]

[0135] The second upper electrical connector 52 and second lower electrical connector 53 are corresponding male and female connectors. The second upper electrical connector can be the male connector and the second lower electrical connector the female connector or vice versa.

[0136] These second electrical connectors allow the electrical connection of the second photovoltaic active area to other photovoltaic active areas and / or to the grid. In particular, one polarity of the second photovoltaic active area can be connected to one polarity of a second photovoltaic active area of a second sandwich panel whose lower transverse side 8 of insulation material is positioned adjacent to the upper transverse side 7 of the first sandwich panel, by connecting, directly or indirectly, the second upper electrical connector 52 of the first sandwich panel to the second lower electrical connector 53 of the second sandwich panel. Similarly, the other polarity of the second photovoltaic active area can be connected to one polarity of a second photovoltaic active area of a third sandwich panel whose upper transverse side 7 of insulation material is positioned adjacent to the lower transverse side 8 of the first sandwich panel, by connecting, directly or indirectly, the second lower electrical connector 53 of the first sandwich panel to the second upper electrical connector 52 of the third sandwich panel. Alternatively, the second upper electrical connector 52 or the second lower electrical connector 53 of the sandwich panel can be connected to the grid.

[0248]

[0137] The first upper electrical connector 46 and the second upper electrical connector 52 are preferably corresponding male and female connectors. Similarly, the first lower electrical connector 47 and the second lower electrical connector 53 are preferably corresponding male and female connectors. Consequently:

[0249] - with the upper connectors, the first photovoltaic active area 24 can be connected to the first photovoltaic active area of a second sandwich panel whose lower transverse side 8 of insulation material is positioned adjacent to the upper transverse side 7 of the first sandwich panel, while the second photovoltaic active area 35 can be connected to the second photovoltaic active area of the second sandwich panel, without mismatch,

[0250] - with the lower connectors, the first photovoltaic active area 24 can be connected to the first photovoltaic active area of a third sandwich panel whose upper transverse side 7 of insulation material is positioned adjacent to the lower transverse side 8 of the first sandwich panel, while the second photovoltaic active area 35 can be connected to the second photovoltaic active area of the third sandwich panel, without mismatch,

[0251] - with the upper connectors, the first photovoltaic active area 24 can be connected to the second photovoltaic active area 35, so that the electrical circuit is looped for example at one extremity of the building envelope, in particular at the roof ridge,

[0252] - with the lower connectors, the first photovoltaic active area 24 can be connected to the second photovoltaic active area 35, so that the electrical circuit is looped for example at another extremity of the building envelope, in particular at the roof gutter.

[0253]

[0138] As mentioned above in relation to the two embodiments of the cables, the sandwich panel further comprises a cavity among an upper cavity 44 and a lower cavity 45. For the sake of clarity, the sandwich panel only comprises one cavity among an upper cavity 44 and a lower cavity 45. This cavity can contain either the upper electrical connector(s) or the lower electrical connector(s). The sandwich panel does not comprise an upper cavity and a lower cavity.

[0254]

[0139] By “cavity”, it is meant a hollow space within the insulation material. This hollow space is dimensioned so that it can accommodate a first electrical connector and a portion of a first cable, and possibly a second electrical connector and a portion of a second cable.

[0255]

[0140] The cavity can be a substantially rectangular parallelepiped. It can extend in the longitudinal direction or in the transverse direction. The cavity preferably comprises a casing embedded in the insulation material. By “embedded”, it is meant that the casing is fixed firmly into the insulation material and intricately linked to it. This embedment is the result of the foaming of the insulation material around the casing or the result of the attachment of the casing to the insulation material, for example by gluing, when the insulation is laid. The cavity can be fully delimited by the casing. Alternatively, it can be delimited in part by the casing and in part by other components of the sandwich panel, such as, for example, the edge band 9, the cap 10, the outer sheet 4, the inner sheet 3.

[0141] The material used for the casing is not limited. It can be, for example, plastic, a foamed material, mineral wool, wood wool. In the case of the insulation material formed by expansion of a reaction mix, the material is preferably selected so that the cavity is not significantly shrunk during the expansion of the reaction mix.

[0256]

[0142] The cavity is positioned within the insulation material. By that expression, it is meant that no single part of the cavity, and in particular no single part of its casing is outside the limits of the insulation material. In particular, no single part of the cavity protrudes from either the first longitudinal side 5 or the second longitudinal side 6, or the upper transverse side 7 or the lower transverse side 8 of the insulation material. With this configuration, the sandwich panel can be produced as a standard sandwich panel in existing production facilities.

[0257]

[0143] In order to ease the insertion of the cable(s) in the cavity, the casing of the cavity preferably comprises an inlet for cable insertion. The casing can also comprise an outlet for accessing the electrical connector(s). Alternatively, the electrical connectors can be accessed by cutting the casing of the cavity.

[0258]

[0144] The first purpose of the cavity is to prevent electrical connector(s) of the photovoltaic active area(s) from being trapped in the insulation material during the manufacturing process of the sandwich panel. The second purpose is to permit an easy access to the electrical connector(s) during the assembling of sandwich panels and, in particular, during the electrical connection of the photovoltaic active areas of adjacent panels. Accordingly, the cavity is adjacent to a side or to a sheet of the sandwich panel so that it can:

[0259] - give access to the electrical connectors, possibly after being opened,

[0260] - allow the connectors to be extracted from the cavity if the portion of the cable present in the cavity is long enough to do so.

[0261]

[0145] In particular, the cavity, which is adapted to accommodate one of the first upper cable and the first lower cable, is positioned adjacent to either: the same longitudinal side of the insulation material as the other of the first upper cable and the first lower cable or,

[0262] - the other transverse side of the insulation material compared to the other of the first upper cable and the first lower cable or,

[0263] - adjacent to the inner sheet or,

[0264] - adjacent to the outer sheet.

[0265]

[0146] Different possible positions of the cavity and of the cables are detailed in the below embodiments.

[0266]

[0147] According to a first embodiment of the cable positioning illustrated on Figures 16 to 19 with the first embodiment of the outer sheet, the second embodiment of the inner central part and the first variant of the first embodiment of the longitudinal inner flanges, the cables are accessed, and possibly extracted, along the second longitudinal side 6 of the insulation material. In other words, one of the first upper cable and the first lower cable has a downstream portion freely extending from the second longitudinal side 6 while the cavity for the electrical connector of the other cable is positioned adjacent to the second longitudinal side.

[0267]

[0148] In the variant illustrated:

[0268] - the upper cavity 44 is positioned adjacent to the second longitudinal side 6 of the insulation material and,

[0269] - the upstream portion of the first lower cable 43 runs from the first lower electrical conductor 26 to the second longitudinal side 6 of the insulation material and its downstream portion freely extends from the second longitudinal side 6 of the insulation material.

[0270]

[0149] With this cavity position, when a sandwich panel is positioned on a building structure by overlapping the second longitudinal outer flange 16 of an adjacent panel with the first longitudinal outer flange 15 of the sandwich panel, the second longitudinal side of the insulation material remains accessible to the operator. The latter can thus easily open the cavity, if it has not been done at a previous step, and access the connector(s) to connect them to the electrical connector(s) of adjacent sandwich panels or to the grid. Preferably, the upper cavity is positioned less than 1 cm from the second longitudinal side, more preferably less than 0.5 cm. In particular, the casing of the upper cavity is positioned adjacent to the second longitudinal side. More particularly, a wall of the casing is positioned adjacent to the second longitudinal side. It can be a plain wall or a wall comprising an outlet for accessing the electrical connector(s). This wall can be in the plane of the second longitudinal side. In that case, this wall and, if applicable, the outlet for accessing the electrical connector(s) are not in contact with the insulation material. The upper cavity, in particular its casing, can be adjacent to the edge band 9. Preferably, the upper cavity is positioned, along the longitudinal axis X of the sandwich panel, between the first upper perforation and the upper transverse side 7 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas. More preferably, the upper cavity is adjacent to the upper transverse side 7 of the insulation material. It further limits the length of cables running between sandwich panels and facilitates the connections between panels.

[0271]

[0150] The junction point of the first lower cable is positioned on the second longitudinal side 6 of the insulation material. Preferably, the junction point, and thus the upstream portion of the first lower cable, is positioned, along the longitudinal axis X of the sandwich panel, between the first lower perforation 28 and the lower transverse side 8 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas.

[0272]

[0151] In the variant illustrated on Figures 16 to 19, the sandwich panel further comprises a second photovoltaic active area 35. Accordingly the upstream portion of the second lower cable 51 runs from the second lower electrical conductor 37 to the second longitudinal side 6 of the insulation material and its downstream portion freely extends from the second longitudinal side 6 of the insulation material. The junction point of the second lower cable is thus positioned on the second longitudinal side 6 of the insulation material.

[0273]

[0152] In this embodiment, the cables along the second longitudinal side should not prevent the sandwich panels from being assembled contiguously. Consequently, the second longitudinal side 6 of the insulation material comprises an upper cutout 54 extending from the upper cavity to the upper transverse side 7 of the insulation material. Similarly, the second longitudinal side 6 of the insulation material comprises a lower cutout 56 extending from the first lower cable, in particular from the junction point of the first lower cable, to the lower transverse side 8 of the insulation material. If applicable, the lower cutout 56 also extends from the second lower cable, in particular from the junction point of the second lower cable, to the lower transverse side 8 of the insulation material. Consequently, the cable(s) can run in the upper and lower cutouts.

[0274]

[0153] In a second variant of the first embodiment of the cable positioning:

[0275] - the lower cavity 45 is positioned adjacent to the second longitudinal side 6 of the insulation material and,

[0276] - the upstream portion of the first upper cable 42 runs from the first upper electrical conductor 25 to the second longitudinal side 6 of the insulation material and its downstream portion freely extends from the second longitudinal side 6 of the insulation material.

[0277]

[0154] The details and features detailed in relation to the first variant apply to the second variant, with the understanding that the terms “upper” and “lower” have to be inverted.

[0278]

[0155] According to a second embodiment of the cable positioning illustrated on Figures 20 to 23 with the first embodiment of the outer sheet, the second embodiment of the inner central part and the first variant of the first embodiment of the longitudinal inner flanges, the cables are accessed, and possibly extracted, along the inner central part of the inner sheet. In other words, one of the first upper cable and the first lower cable has a downstream portion freely extending from the inner central part while the cavity for the electrical connector of the other cable is positioned adjacent to the inner central part.

[0279]

[0156] In the variant illustrated:

[0280] - The lower cavity 45 is positioned adjacent to the inner central part of the inner sheet and,

[0281] - the upstream portion of the first upper cable 42 runs from the first upper electrical conductor 25 to the inner central part 67 of the inner sheet and its downstream portion freely extends from the inner central part.

[0282]

[0157] With this cavity position, when a sandwich panel is positioned on a building structure, the cable(s) can be accessed from the inner sheet and the electrical connections can be done from the inside of the building. Preferably, the lower cavity is positioned less than 1 cm from the inner sheet, more preferably less than 0.5 cm. In particular, the casing of the lower cavity is positioned adjacent to the inner sheet. More particularly, a wall of the casing is positioned adjacent to the inner sheet. It can be a plain wall or a wall comprising an outlet for accessing the electrical connector(s). This wall can be in contact with the inner sheet. Preferably, the lower cavity is positioned along the longitudinal axis X of the sandwich panel between the first lower junction box 41 and the lower transverse side 8 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas. The lower cavity can also be positioned adjacent to the first and / or second lower junction box or even plumb with the junction box. According to a variant of the invention, the junction box is inside the lower cavity, by being for example integrated in the lower cavity casing. It eases the installation of the electrical components on the backside of the outer sheet since the junction box and the lower cavity can be installed at once. The first and / or second lower cable and the first and / or second lower electrical connector can even be pre-installed in the lower cavity, before the latter is positioned on the backside of the outer sheet.

[0283]

[0158] The junction point of the first upper cable is positioned on the inner central part. Preferably, the junction point, and thus the upstream portion, is positioned, along the longitudinal axis X of the sandwich panel, between the first upper perforation 27 and the upper transverse side 7 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas.

[0284]

[0159] In the variant illustrated on Figures 20 to 23, the sandwich panel further comprises a second photovoltaic active area 35. Accordingly, the upstream portion of the second upper cable 50 runs from the second upper electrical conductor 36 to the inner central part 67 of the inner sheet and its downstream portion freely extends from the inner central part. The junction point of the second upper cable is thus positioned on the inner central part.

[0285]

[0160] In this embodiment, the inner sheet comprises an upper hole 55 for the passing of the first upper cable, possibly of the second upper cable, and a lower hole 57 for the passing of the first lower cable, possibly of the second lower cable.

[0286]

[0161] In this embodiment, the inner sheet can comprise an upper inner groove 59 extending from the upper transverse side 7 of the insulation material to the first upper cable, in particular to the junction point of the first upper cable, in other words to the upper hole 55. If applicable, the upper inner groove 59 also extends from the upper transverse side 7 of the insulation material to the second upper cable, in particular to the junction point of the second upper cable.

[0287]

[0162] Similarly, the inner sheet can comprise a lower inner groove 60 extending from the lower transverse side 8 of the insulation material to the lower cavity 45, in other words to the lower hole 57.

[0288]

[0163] Thanks to the upper inner groove, the downstream portions of the upper cable(s) with their electrical connector(s) can be reserved between the inner sheet and the mold during the manufacturing of the sandwich panel. Thanks to the upper inner groove and the lower inner groove, the cables can run between the building structure and the sandwich panels.

[0289]

[0164] In a second variant of the second embodiment of the cable positioning:

[0290] - The upper cavity 44 is positioned adjacent to the inner central part of the inner sheet and,

[0291] - the upstream portion of the first lower cable 43 runs from the first lower electrical conductor 26 to the inner central part 67 of the inner sheet and its downstream portion freely extends from the inner central part.

[0292]

[0165] The details and features detailed in relation to the first variant apply to the second variant, with the understanding that the terms “upper” and “lower” have to be inverted.

[0166] According to a third embodiment of the cable positioning illustrated on Figures 24 to 27 with the first embodiment of the outer sheet, the second embodiment of the inner central part and the second variant of the first embodiment of the longitudinal inner flanges, the cables are accessed, and possibly extracted, along the second inner riser 72 of the second longitudinal inner flange 66 of the inner sheet. In other words, one of the first upper cable and the first lower cable has a downstream portion freely extending from the second inner riser while the cavity for the electrical connector of the other cable is positioned adjacent to the second inner riser.

[0293]

[0167] In the variant illustrated:

[0294] - the upper cavity 45 is positioned adjacent to the second inner riser 72 of the second longitudinal inner flange 66 of the inner sheet and,

[0295] - the upstream portion of the first lower cable 43 runs from the first lower electrical conductor 26 to the second inner riser 72 of the second longitudinal inner flange 66 of the inner sheet and its downstream portion freely extends from the second inner riser.

[0296]

[0168] With this cavity position, the first upper electrical connector 46, and if applicable the second upper electrical connector 52, can be accessed along the second inner riser from the upper cavity. Preferably, the upper cavity is positioned less than 1 cm from the second inner riser, more preferably less than 0.5 cm. In particular, the casing of the upper cavity is positioned adjacent to the second inner riser. More particularly, a wall of the casing is positioned adjacent to the second inner riser. It can be a plain wall or a wall comprising an outlet for accessing the electrical connector(s). This wall can be in contact with the second inner riser. In that case, this wall and, if applicable, the outlet for accessing the electrical connector(s) may not be in contact with the insulation material. Preferably, the upper cavity is positioned, along the longitudinal axis X of the sandwich panel, between the first upper perforation 27 and the upper transverse side 7 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas.

[0297]

[0169] The upper cavity 44 adjacent to the second inner riser 72 of the inner sheet can be open along the second inner riser, through an upper opening 79 in the inner riser and possibly through a cut in the casing of the upper cavity.

[0298]

[0170] The junction point of the first lower cable is positioned on the second inner riser. Preferably, the junction point, and thus the upstream portion of the first lower cable, is positioned, along the longitudinal axis X of the sandwich panel, between the first lower perforation 28 and the lower transverse side 8 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas. The second inner riser comprises a lower opening 80 for the passing of the first lower cable, possibly of the second lower cable.

[0299]

[0171] In the variant illustrated on Figures 24 to 27, the sandwich panel further comprises a second photovoltaic active area 35. Accordingly, the upstream portion of the second lower cable 51 runs from the second lower electrical conductor 37 to the second inner riser 72 of the second longitudinal inner flange 66 of the inner sheet and its downstream portion freely extends from the second inner riser. The junction point of the second lower cable is thus positioned on the second inner riser.

[0300]

[0172] Thanks to this configuration, when two sandwich panels are positioned laterally adjacent to each other on a building structure, in particular when a sandwich panel is positioned by overlapping the second longitudinal outer flange 16 of an adjacent panel with its first longitudinal outer flange 15, the second inner riser of the inner sheet remains accessible to the operator from the side of the sandwich panel. The operator can thus easily open the upper cavity, if it has not been done at a previous step, access the connector(s) and connect the electrical connectors of the sandwich panel to electrical connector(s) of adjacent sandwich panels. The cables do not prevent an adjacent sandwich panel from being positioned on the building structure by overlapping the second longitudinal outer flange 16 of the panel with the first longitudinal outer flange 15 of this adjacent panel, since the inner edge rabbet of the adjacent panel will remain above the cables. Alternatively, the electrical connectors with a portion of cable are not extracted from the upper cavity or the additional cables are not connected to the electrical connectors before the adjacent sandwich panel is positioned on the building structure and overlap the second longitudinal outer flange 16 of the panel. In that case, the electrical connectors in the upper cavity can be accessed and connected from the inside of the building through the technical recess 78.

[0301]

[0173] In a second variant of the third embodiment of the cable positioning:

[0302] - the lower cavity 45 is positioned adjacent to the second inner riser 72 of the second longitudinal inner flange 66 of the inner sheet and,

[0303] - the upstream portion of the first upper cable 42 runs from the first upper electrical conductor 25 to the second inner riser 72 of the second longitudinal inner flange 66 of the inner sheet and its downstream portion freely extends from the second inner riser.

[0304]

[0174] The details and features detailed in relation to the first variant apply to the second variant, with the understanding that the terms “upper” and “lower” have to be inverted.

[0305]

[0175] According to a fourth embodiment of the cable positioning illustrated on Figures 28 to 31 with the first embodiment of the outer sheet, the second embodiment of the inner central part and the second variant of the first embodiment of the longitudinal inner flanges, the cables are accessed, and possibly extracted, along the inner edge rabbet 68 of the first longitudinal inner flange 65 of the inner sheet. In other words, one of the first upper cable and the first lower cable has a downstream portion freely extending from the inner edge rabbet while the cavity for the electrical connector of the other cable is positioned adjacent to the inner edge rabbet.

[0306]

[0176] In the variant illustrated:

[0307] - the upper cavity 45 is positioned adjacent to the inner edge rabbet 68 of the first longitudinal inner flange 65 of the inner sheet and,

[0308] - the upstream portion of the first lower cable 43 runs from the first lower electrical conductor 26 to the inner edge rabbet 68 of the first longitudinal inner flange 65 of the inner sheet and its downstream portion freely extends from the inner edge rabbet.

[0309]

[0177] With this cavity position, the first upper electrical connector 46, and if applicable the second upper electrical connector 52, can be accessed from the upper cavity through the inner edge rabbet, in particular through the first inner riser or through the top portion. Preferably, the upper cavity is positioned less than 1 cm from the inner edge rabbet, in particular from the first inner riser or from the top portion, more preferably less than 0.5 cm. In particular, the casing of the upper cavity is positioned adjacent to the inner edge rabbet, for example adjacent to the first inner riser or adjacent to the top portion. More particularly, a wall of the casing is positioned adjacent to the inner edge rabbet, for example adjacent to the first inner riser or adjacent to the top portion. It can be a plain wall or a wall comprising an outlet for accessing the electrical connector(s). This wall can be in contact with the inner edge rabbet. In that case, this wall and, if applicable, the outlet for accessing the electrical connector(s) may not be in contact with the insulation material. Preferably, the upper cavity is positioned, along the longitudinal axis X of the sandwich panel, between the first upper perforation 27 and the upper transverse side 7 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas.

[0310]

[0178] The upper cavity 44 adjacent to the inner edge rabbet 68 of the inner sheet can be open along the inner edge rabbet through an upper opening 79 in the inner edge rabbet, in particular in the first inner riser 69 or in the top portion 70, and possibly through a cut in the casing of the upper cavity.

[0311]

[0179] The junction point of the first lower cable is positioned on the inner edge rabbet. Preferably, the junction point, and thus the upstream portion of the first lower cable, is positioned, along the longitudinal axis X of the sandwich panel, between the first lower perforation 28 and the lower transverse side 8 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas. The inner edge rabbet comprises a lower opening 80 for the passing of the first lower cable, possibly of the second lower cable.

[0312]

[0180] In the variant illustrated on Figures 28 to 31 , the sandwich panel further comprises a second photovoltaic active area 35. Accordingly, the upstream portion of the second lower cable 51 runs from the second lower electrical conductor 37 to the inner edge rabbet 68 of the first longitudinal inner flange 65 of the inner sheet and its downstream portion freely extends from the inner edge rabbet, either from the first inner riser 69 or from the top portion 70. The junction point of the second lower cable is thus positioned on the inner edge rabbet, either on the first inner riser 69 or on the top portion 70. The inner edge rabbet comprises a lower opening 80 for the passing of the first lower cable, possibly of the second lower cable.

[0313]

[0181] Thanks to this configuration, once a sandwich panel has been positioned on a building structure, in particular, by overlapping the second longitudinal outer flange 16 of an adjacent panel with the first longitudinal outer flange 16 of the sandwich panel, the upper cavity of the sandwich panel remains accessible to the operator from the inside of the building. The operator can thus easily open the upper cavity, if it has not been done at a previous step, access the connector(s) and connect the electrical connectors of the sandwich panel to the electrical connector(s) of adjacent sandwich panels or to the grid. The cables do not prevent the sandwich panel from being positioned on the building structure by overlapping the second longitudinal outer flange 16 of an adjacent panel with the first longitudinal outer flange 15 of the sandwich panel, since the inner edge rabbet remains largely uncovered by the adjacent panel.

[0314]

[0182] In a second variant of the fourth embodiment of the cable positioning:

[0315] - the lower cavity 45 is positioned adjacent to the inner edge rabbet 68 of the first longitudinal inner flange 65 of the inner sheet and,

[0316] - the upstream portion of the first upper cable 42 runs from the first upper electrical conductor 25 to the inner edge rabbet 68 of the first longitudinal inner flange 65 of the inner sheet and its downstream portion freely extends from the inner edge rabbet.

[0317]

[0183] The details and features detailed in relation to the first variant apply to the second variant, with the understanding that the terms “upper” and “lower” have to be inverted.

[0318]

[0184] According to a fifth embodiment of the cable positioning illustrated on Figures 32 to 35 with the first embodiment of the outer sheet, the third embodiment of the inner central part and the first variant of the first embodiment of the inner central part, the cables are accessed, and possibly extracted, along the longitudinal groove 85 in the inner central part 67 of the inner sheet. In other words, one of the first upper cable and the first lower cable has a downstream portion freely extending from the longitudinal groove while the cavity for the electrical connector of the other cable is positioned adjacent to the longitudinal groove.

[0319]

[0185] In the variant illustrated:

[0320] - the upper cavity 45 is positioned adjacent to the longitudinal groove 85 in the inner central part 67 of the inner sheet and,

[0321] - the upstream portion of the first lower cable 43 runs from the first lower electrical conductor 26 to the longitudinal groove 85 in the inner central part 67 of the inner sheet and its downstream portion freely extends from the longitudinal groove.

[0322]

[0186] With this cavity position, the first upper electrical connector 46, and if applicable the second upper electrical connector 52, can be accessed from the upper cavity through the longitudinal groove. Preferably, the upper cavity is positioned less than 1 cm from the longitudinal groove, more preferably less than 0.5 cm. In particular, the casing of the upper cavity is positioned adjacent to the longitudinal groove. More particularly, a wall of the casing is positioned adjacent to the longitudinal groove. It can be a plain wall or a wall comprising an outlet for accessing the electrical connector(s). This wall can be in contact with the longitudinal groove. In that case, this wall and, if applicable, the outlet for accessing the electrical connector(s) may not be in contact with the insulation material. Preferably, the upper cavity is positioned, along the longitudinal axis X of the sandwich panel, between the first upper perforation 27 and the upper transverse side 7 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas.

[0323]

[0187] The upper cavity 44 adjacent to longitudinal groove 85 can be open along the longitudinal groove through an upper opening 88 in the longitudinal groove, and possibly through a cut in the casing of the upper cavity.

[0324]

[0188] The junction point of the first lower cable is positioned on the longitudinal groove. Preferably, the junction point, and thus the upstream portion of the first lower cable, is positioned, along the longitudinal axis X of the sandwich panel, between the first lower perforation 28 and the lower transverse side 8 of the insulation material. This position limits the length of cables needed to connect the photovoltaic active areas. The longitudinal groove comprises a lower opening 89 for the passing of the first lower cable, possibly of the second lower cable.

[0325]

[0189] In the variant illustrated on Figures 32 to 35, the sandwich panel further comprises a second photovoltaic active area 35. Accordingly, the upstream portion of the second lower cable 51 runs from the second lower electrical conductor 37 to the longitudinal groove 85 in the inner central part 67 of the inner sheet and its downstream portion freely extends from the longitudinal groove. The junction point of the second lower cable is thus positioned on the longitudinal groove.

[0326]

[0190] Thanks to the longitudinal groove, the downstream portions of the cables with their electrical connectors can be reserved between the inner sheet and the mold during the manufacturing of the sandwich panel.

[0327]

[0191] In a second variant of the fifth embodiment of the cable positioning:

[0328] - the lower cavity 45 is positioned adjacent to the longitudinal groove 85 in the inner central part 67 of the inner sheet and,

[0329] - the upstream portion of the first upper cable 42 runs from the first upper electrical conductor 25 to the longitudinal groove 85 in the inner central part 67 of the inner sheet and its downstream portion freely extends from the longitudinal groove.

[0330]

[0192] The details and features detailed in relation to the first variant apply to the second variant, with the understanding that the terms “upper” and “lower” have to be inverted.

[0331]

[0193] According to a sixth embodiment of the cable positioning (not illustrated), the cables are accessed, and possibly extracted, along the first longitudinal side 5 of the insulation material. In other words, one of the first upper cable and the first lower cable has a downstream portion freely extending from the first longitudinal side 5 while the cavity for the electrical connector of the other cable is positioned adjacent to the first longitudinal side.

[0332]

[0194] Accordingly, in a first variant: - the upper cavity 44 is positioned adjacent to the first longitudinal side 5 of the insulation material and,

[0333] - the upstream portion of the first lower cable 43 runs from the first lower electrical conductor 26 to the first longitudinal side 5 of the insulation material and its downstream portion freely extends from the first longitudinal side 5 of the insulation material.

[0334]

[0195] Accordingly, in a second variant:

[0335] - the lower cavity 45 is positioned adjacent to the first longitudinal side 5 of the insulation material and,

[0336] - the upstream portion of the first upper cable 42 runs from the first upper electrical conductor 25 to the first longitudinal side 5 of the insulation material and its downstream portion freely extends from the first longitudinal side 5 of the insulation material.

[0337]

[0196] The details and features detailed in relation to the first embodiment of the cable positioning apply to this embodiment, with the understanding that the term “second longitudinal side 6” has to be replaced by the term “first longitudinal side 5”.

[0338]

[0197] According to a seventh embodiment of the cable positioning illustrated on Figures 36 to 38 with the first embodiment of the outer sheet, the second embodiment of the inner central part and the first variant of the first embodiment of the longitudinal inner flanges, the cables are accessed, and possibly extracted, along the transverse sides of the insulation material. In other words, one of the first upper cable and the first lower cable has a downstream portion freely extending from the one of the transverse sides 7, 8 while the cavity for the electrical connector of the other cable is positioned adjacent to the other transverse side.

[0339]

[0198] In the variant illustrated:

[0340] - the upper cavity 44 is positioned adjacent to the upper transverse side 7 of the insulation material and,

[0341] - the upstream portion of the first lower cable 43 runs from the first lower electrical conductor 26 to the lower transverse side 8 of the insulation material and its downstream portion freely extends from the lower transverse side.

[0342]

[0199] With this cavity position, when the lower transverse side 8 of insulation material of a second sandwich panel is positioned adjacent to the upper transverse side 7 of a first sandwich panel, the upper electrical connector(s) of the first sandwich panel can be extracted from the upper cavity, while the second sandwich panel is being positioned on the building structure, connected to the lower electrical connector(s) of the second sandwich panel and all the cables are retracted in the upper cavity when the two sandwich panels are positioned contiguously. Preferably, the upper cavity is positioned less than 1 cm from the upper transverse side 7, more preferably less than 0.5 cm. In particular, the casing of the upper cavity is positioned adjacent to the upper transverse side. More particularly, a wall of the casing is positioned adjacent to the upper transverse side. It can be a plain wall or a wall comprising an outlet for accessing the electrical connector(s). This wall can be in the plane of the upper transverse side. In that case, this wall and, if applicable, the outlet for accessing the electrical connector(s) are not in contact with the insulation material. The upper cavity, in particular its casing, can be adjacent to the cap 10 of the upper transverse side.

[0343]

[0200] The junction point of the first lower cable is positioned on the lower transverse side 8 of the insulation material.

[0344]

[0201] In the variant where the sandwich panel further comprises a second photovoltaic active area 35, the upstream portion of the second lower cable 51 runs from the second lower electrical conductor 37 to the lower transverse side 8 of the insulation material and its downstream portion freely extends from the lower transverse side 8 of the insulation material. The junction point of the second lower cable is thus positioned on the lower transverse side 8 of the insulation material.

[0345]

[0202] In this embodiment, there can be an upper indentation, in the upper transverse side 7 and / or in the upper cap 10, extending from the upper cavity to the upper transverse side 7 of the insulation material. Similarly, there can be a lower indentation, in the lower transverse side 8 and / or in the lower cap 10, extending from the first lower cable, in particular from the junction point of the first lower cable, to the lower transverse side 8 of the insulation material. Cables can run in the upper indentation and / or lower indentation so that the electrical connectors are accessible from the inside of building.

[0346]

[0203] In a second variant of the seventh embodiment of the cable positioning:

[0347] - the lower cavity 45 is positioned adjacent to the lower transverse side 8 of the insulation material and,

[0348] - the upstream portion of the first upper cable 42 runs from the first lower electrical conductor 26 to the upper transverse side 7 of the insulation material and its downstream portion freely extends from the upper transverse side.

[0349]

[0204] The details and features detailed in relation to the first variant apply to the second variant, with the understanding that the terms “upper” and “lower” have to be inverted.

[0350]

[0205] According to an eighth embodiment of the cable positioning illustrated on Figures 39 and 40 with the first embodiment of the outer sheet, the second embodiment of the inner central part and the first variant of the first embodiment of the longitudinal inner flanges, at least one of the cables is accessed, and possibly extracted, along the outer sheet.

[0351]

[0206] In the variant illustrated:

[0352] - the upper cavity 44 is positioned adjacent to the outer sheet and,

[0353] - the upstream portion of the first lower cable 43 runs from the first lower electrical conductor 26 to the lower transverse side 8 of the insulation material and its downstream portion freely extends from the lower transverse side.

[0354]

[0207] With this cavity position, when the lower transverse side 8 of insulation material of a second sandwich panel is positioned adjacent to the upper transverse side 7 of a first sandwich panel, the upper electrical connector(s) of the first sandwich panel can be extracted from the upper cavity, while the second sandwich panel is being positioned on the building structure, connected to the lower electrical connector(s) of the second sandwich panel and all the cables are retracted in the upper cavity when the two sandwich panels are positioned contiguously. Preferably, the upper cavity is positioned less than 1 cm from the outer sheet, in particular from the second longitudinal rib 21 , more preferably less than 0.5 cm. In particular, the casing of the upper cavity is positioned adjacent to the outer sheet, in particular to the second longitudinal rib 21. More particularly, a wall of the casing is positioned adjacent to the outer sheet. It can be a plain wall or a wall comprising an outlet for accessing the electrical connector(s). This wall can be in the plane of the outer sheet. In that case, this wall and, if applicable, the outlet for accessing the electrical connector(s) are not in contact with the insulation material.

[0355]

[0208] The junction point of the first lower cable is positioned on the lower transverse side 8 of the insulation material.

[0356]

[0209] In the variant where the sandwich panel further comprises a second photovoltaic active area 35, the upstream portion of the second lower cable 51 runs from the second lower electrical conductor 37 to the lower transverse side 8 of the insulation material and its downstream portion freely extends from the lower transverse side 8 of the insulation material. The junction point of the second lower cable is thus positioned on the lower transverse side 8 of the insulation material.

[0357]

[0210] In this embodiment, the cables along the outer sheet should not prevent the sandwich panels from being assembled contiguously. Consequently, the outer sheet, in particular the second longitudinal rib 21 , comprises an upper outer groove 116 extending from the upper cavity to the upper transverse side 7 of the insulation material. Cables can run in the upper outer groove when the two sandwich panels are positioned contiguously.

[0358]

[0211] From a manufacturing process perspective, the sandwich panel according to the invention can be manufactured in a discontinuous process in which the inner sheet and the outer sheet are first cut to size and shaped (or vice versa). In a first variant, they are then maintained in a mold at a given distance from each other and the gap between them is filled with a reaction mix that expands to form the insulation material. In a second variant, one of the sheets is positioned in a mold and covered by the insulation material, preferably in the form of slabs, also known as batts or lamellas. A layer of adhesive is applied between the sheet and the slabs of insulation material and another layer of adhesive is applied on the insulation material. Then the second sheet is positioned on the insulation material and the stack is pressed and heated to cure the adhesive.

[0359]

[0212] In particular, at a first stage, the outer sheet 4 is prepared.

[0360]

[0213] In a first step, the outer sheet is cut to length. Optionally, it is cut to length from a strip and then shaped or the strip is first shaped on a profiling line and then cut to length. The shaping step comprises the forming of the first longitudinal outer flange 15 and of the second longitudinal outer flange 16. The shaping step can also comprise the forming of an upper outer groove 116.

[0361]

[0214] In a second step, anterior to or concomitant with or posterior to the first step, a first upper perforation 27 and a first lower perforation 28 are done in the outer central part 17. If applicable, a second upper perforation 38 and a second lower perforation 39 and / or by-pass perforations 33 are also done in the outer central part. Optionally, non-conductive grommets are positioned in, and possibly attached to, the upper and lower perforations. In a variant, an upper outer hole is done in the outer sheet.

[0362]

[0215] In a third step, posterior to the first and second steps, a first photovoltaic active area 24 is positioned on the outer central part and preferably laminated. If applicable, a second photovoltaic active area 35 is also positioned on the outer central part at the same time and preferably laminated at the same time. In particular, positioning the photovoltaic active area comprises stacking the different components of the photovoltaic active area. In particular, during the positioning step, a first upper electrical conductor 25 is inserted in the first upper perforation and a first lower electrical conductor 26 is inserted in the first lower perforation. More particularly, non-conductive grommets 29 are inserted in the first upper and lower perforations. If applicable, a second upper electrical conductor 36 is inserted in the second upper perforation and a second lower electrical conductor 37 is inserted in the second lower perforation. Once the stack has been prepared, it is heated and pressed in a lamination device so that the films surrounding the solar cells fuse and embed the cells. At the end of this step, if the outer sheet has not been previously shaped, it is done so.

[0363]

[0216] When the photovoltaic active area is laminated on the outer sheet, the latter does not comprise any part substantially protruding from the surface of the backside of the outer sheet, in particular from the surface of the backside of the outer central part. In particular, there is no part protruding over more than 2 mm below the surface of the backside of the outer sheet, or below the surface of the backside of the outer central part, more preferably over more than 1 mm. In other words, the surface of the backside of the outer central part, or the surface of the backside of the outer sheet, is substantially flat. Thanks to this design, the lamination of the photovoltaic active area can be efficiently performed on the outer sheet alone, without modifying existing lamination equipment to accommodate parts protruding from the surface of the backside of the outer sheet.

[0364]

[0217] In a fourth step, the outer sheet is positioned upside down and its backside is equipped with a first upper cable 42, a first upper electrical connector 46, a first lower cable 43, a first lower electrical connector 47 and either an upper cavity 44 or a lower cavity 45. Optionally, it is also equipped with a first upper junction box 40 and a first lower junction box 41. If applicable, it is further equipped with a second upper cable 50, a second upper electrical connector 52, a second lower cable 51 and a second lower electrical connector 53 and / or by-pass diodes. Optionally, it is also equipped with a second upper junction box 48 and a second lower junction box 49. The junction boxes are preferably positioned substantially plumb with the perforations. The electrical conductors are electrically connected to one end of a cable, possibly inside the junction boxes. The other end of the cables is electrically connected to an electrical connector.

[0365]

[0218] The cavity is positioned on the backside of the outer sheet. It is preferably attached, directly or indirectly, to the backside of the outer sheet.

[0366]

[0219] In particular, the cavity is positioned so that, at the end of the manufacturing process, the cavity is adjacent to either one side of the insulation material or the inner sheet or the outer sheet. The cavity, in particular its casing, can be directed attached, for example by gluing, to the backside of the outer sheet or it can be attached to one shim 82 or a plurality of shims, themselves attached to the backside of the outer sheet, as illustrated on Figures 17, 21 , 25, 29, 33 and 36. With the shim(s), the position along the vertical axis Z of the cavity in the insulation material can be adjusted, depending on the thickness of the insulation material. As an alternative to the attachment to the backside of the outer sheet, in the discontinuous process, the cavity can be attached to an edge band 9 prepositioned, previously or concomitantly, along a longitudinal outer edge of the outer sheet or to a cap 10 prepositioned, previously or concomitantly, along a transverse outer edge of the outer sheet. It facilitates the positioning of the cavity along the edge band or cap during the laying of the insulation.

[0367]

[0220] At a second stage, posterior to the first stage, the outer sheet is provided.

[0368]

[0221] At a third stage, anterior to or concomitant with or posterior to the second stage, the inner sheet 3 is provided. In particular, the inner sheet cut to size and possibly shaped is provided. The inner sheet can have been previously prepared in a few steps:

[0369]

[0222] In a first step, it is cut to length. Optionally, it is cut to length from a strip and then shaped or the strip is first shaped on a profiling line and then cut to length. The shaping can comprise the forming of the first longitudinal inner flange 65 and of the second longitudinal inner flange 66. The shaping step can also comprise the forming of the longitudinal groove 85 or the forming of the upper inner groove 59 and the lower inner groove 60.

[0370]

[0223] Optionally, in a second step, anterior to or concomitant with or posterior to the first step, openings are done in the inner sheet. In a first variant, the upper hole 55 and the lower hole 57 are done in the inner central part of the inner sheet. In a second variant, the upper opening 79 and the lower opening 80 are done in either the first longitudinal inner flange 65 or second longitudinal inner flange 66 of the inner sheet. In a third variant, the upper opening 88 and the lower opening 89 are done in the longitudinal groove.

[0224] At a fourth stage, posterior to the second stage and anterior to or concomitant with or posterior to the third stage, the outer sheet is positioned in a mold.

[0371]

[0225] As illustrated on Figures 41 and 42, the mold comprises a bottom side 93, a top side 94, a first longitudinal side 95, a second longitudinal side 94, a first transverse side and a second transverse side. Each side can be formed of one single piece or of a plurality of pieces. These pieces can notably be stacked one above the other depending on the thickness of the sandwich panel. The sides are designed for, and capable of, maintaining each part of the sandwich panel in its set position during the last steps of the manufacturing process, in particular during laying of the insulation and / or during the pressing. In particular, the sides are designed for, and capable of, closing the space between the inner sheet and the outer sheet in which the reaction mix is injected and resisting the pressure of the reaction mix expansion. In order to avoid the deformation of the inner sheet and outer sheet under the pressure of the expansion and to have the longitudinal sides 5, 6 and transverse sides 7, 8 of the insulation material at the correct shape, the sides of the mold are substantially counterparts of the sandwich panel.

[0372]

[0226] In particular, the bottom side 93 of the mold is substantially a counterpart of the external surface of the outer sheet 4. Accordingly, in the case of the first embodiment of the outer sheet, as the outer sheet is substantially flat with two longitudinal ribs, the bottom side is preferably flat with two longitudinal edge rabbets. In the case of the second embodiment of the outer sheet, as the outer sheet is substantially flat with an outer mortise extending inwards and an upper tenon extending outwards, the bottom side is preferably flat and possibly comprises a counterpart of the external surface of the upper portion of the upper tenon 103 and a counterpart of the external surface of the outer edge rabbet 108, if any.

[0373]

[0227] In particular, the top side 94 is substantially a counterpart of the external surface of central inner part 67 of the inner sheet 3. As the central inner part 67 is substantially flat, the top side is preferably flat. If the central inner part comprises a groove, 59, 60, 85, the top side does not comprise a counter-rib, so that a portion of the cables can be inserted between the inner sheet and the side of the mold.

[0374]

[0228] In particular, the first longitudinal side 95 of the mold is substantially a counterpart of the first longitudinal side 5 of the insulation material. If the first longitudinal inner flange 65 of the inner sheet extends, in the final sandwich panel, along the first longitudinal side 5 of the insulation material, then the first longitudinal side 95 of the mold can also be substantially a counterpart of the first longitudinal inner flange of the inner sheet. Accordingly, the first longitudinal side 95 of the mold can comprise a counterpart of the external surface of the inner edge rabbet 68 of the inner sheet and / or a counterpart of the external surface of the first inner stiffener 71 . If the first longitudinal outer flange 15 of the outer sheet extends, in the final sandwich panel, along the first longitudinal side 5 of the insulation material, then the first longitudinal side 95 of the mold can also be substantially a counterpart of the first longitudinal outer flange of the outer sheet. Accordingly, the first longitudinal side 95 of the mold can comprise a counterpart of the external surface of the male protrusion 106, if any.

[0375]

[0229] In particular, the second longitudinal side 96 of the mold is substantially a counterpart of the second longitudinal side 6 of the insulation material. If the second longitudinal inner flange 66 of the inner sheet extends, in the final sandwich panel, along the second longitudinal side 6 of the insulation material, then the second longitudinal side 96 of the mold can also be substantially a counterpart of the second longitudinal inner flange of the inner sheet. Accordingly, in the case of the first embodiment of the longitudinal inner flanges, the second longitudinal side 96 of the mold can comprises a counterpart of the external surface(s) of the inner tongue 73, or a counterpart of the external surface(s) of the second inner riser 72 and of the inner indent 81 , if any, and a counterpart of the second inner stiffener 77, if any. In the case of the second embodiment of the longitudinal inner flanges, the second longitudinal side 96 of the mold preferably comprises a counterpart of the external surface(s) of the second inner riser 72 and of the inner tenon 111.

[0230] If the second longitudinal outer flange 16 of the outer sheet extends, in the final sandwich panel, along the second longitudinal side 6 of the insulation material, then the second longitudinal side 96 of the mold can also be substantially a counterpart of the second longitudinal outer flange of the inner sheet. Accordingly, the second longitudinal side 96 of the mold can comprise a counterpart of the external surface of the lower portion of the upper tenon 103.

[0376]

[0231] In particular, the first transverse side of the mold is substantially a counterpart of the upper transverse side 7 of the insulation material and the second transverse side of the mold is substantially a counterpart of the lower transverse side 8 of the insulation material. These transverse sides of the insulation material being preferably flat, the first transverse side and second transverse side of the mold are preferably flat.

[0377]

[0232] The way the outer sheet is positioned in the mold is not limited. In one variant, the outer sheet is preferably positioned upside down on the bottom side of the mold. Then the longitudinal and transverse sides of the mold are positioned and possibly secured in place. Edge bands 9 are preferably added along the longitudinal sides of the mold. Caps are preferably positioned along the transverse sides of the mold. In another variant, the outer sheet is positioned once the inner sheet has been positioned upside down on the bottom side of the mold and once the longitudinal and transverse sides of the mold have been positioned and possibly secured in place, and possible once edge bands and / or caps have been positioned.

[0378]

[0233] At a fifth stage, posterior to or concomitant with the fourth stage and anterior to or concomitant with or posterior to the third stage, the first cable whose electrical connector is not already positioned in the cavity is positioned in the mold. In particular, a downstream portion of the first cable with the first electrical connector is inserted in a hole in one of the sides of the mold or in a groove 59, 60, 68, 85 formed in the inner sheet or in a groove 116 formed in the outer sheet. They thus avoid been embedded in the insulation material. If applicable, a downstream portion of the second cable with the second electrical connector is inserted in a hole in one of the sides of the mold or in a groove 59, 60, 68, 85 formed in the inner sheet or in a groove 116 formed in the outer sheet. The downstream portion of the second cable with the second electrical connector can be inserted in the same hole, or in the same groove 59, 60, 68, 85, 116, as the downstream portion of the first cable with the first electrical connector. In the case where, in the sandwich panel, the downstream portions extend from the inner sheet, the downstream portions are first inserted in a hole 55, 57 in the inner central part, or in an opening 79, 80 in either the second inner riser or the inner edge rabbet, or in an opening 88, 89 in the longitudinal groove. In the case where, in the sandwich panel, the downstream portions extend from the outer sheet, the downstream portions are first inserted in a hole in the outer sheet.

[0379]

[0234] For this purpose, in a first variant illustrated on Figure 41 , the mold can comprise holes in one of the sides of the mold in the form of through-holes, i.e. holes passing through the side. There can be an upper through-hole 97, for accommodating a part of the downstream portion(s) of the upper cable(s), or a lower through-hole 98, for accommodating a part of the downstream portion(s) of the lower cable(s). The through-holes are preferably in the first longitudinal side 95 or the second longitudinal side 96 of the mold. Depending on the design of the inner sheet, the through-holes can be adjacent to either the longitudinal side 5, 6 of the insulation material or the second inner riser 72 or the inner edge rabbet 68. In a variant, the upper through-hole 97 is in the first transverse side of the mold and the lower through-hole 98 is in the second transverse side of the mold. In another variant, the through-holes are in the bottom side 93 or the top side 94 of the mold.

[0380]

[0235] Preferably, the diameter of the through-hole is substantially at the size of one electrical connector, or substantially at the size of two electrical conductors for the case where the downstream portions of the first cable and of the second cable are inserted in the same through-hole. It facilitates the sealing of the through-hole, notably before injecting a reaction mix in the mold.

[0381]

[0236] The side of the mold can further comprise a recess 99 in its outer surface at the level of the through-hole. A part of the downstream portion(s) of the upper cable(s) with the upper electrical connector(s), respectively a part of the downstream portion(s) of the lower cable(s) with the lower electrical connector(s), can be arranged in the recess.

[0382]

[0237] In a second variant illustrated on Figure 42, the mold can comprise holes in the form of hollow spaces in the inner surface of the side. There can be an upper hollow space 100, for the downstream portion(s) of the upper cable(s) and their respective electrical connector(s), or a lower hollow space 101 , for the downstream portion(s) of the lower cable(s) and their respective electrical connector(s). The hollow spaces are preferably in the first longitudinal side 95 or the second longitudinal side 96 of the mold. Depending on the design of the inner sheet, the hollow spaces can be adjacent to either the longitudinal side 5, 6 of the insulation material or the second inner riser 72 or the inner edge rabbet 68. In a variant, the upper hollow space 100 is in the first transverse side of the mold and the lower hollow space 101 is in the second transverse side of the mold. In another variant, the hollow spaces are in the bottom side 93 or the top side 94 of the mold.

[0383]

[0238] Preferably, each hollow space is dimensioned so that it can accommodate a first electrical connector and a downstream portion of a first cable, and possibly a second electrical connector and a downstream portion of a second cable. Each hollow space preferably comprises a lid that seals the hollow space once the electrical connector(s) and the downstream portion(s) of the cable(s) have been inserted.

[0384]

[0239] At a sixth stage, posterior to the fourth stage and anterior to or concomitant with or posterior to the third stage and anterior to or concomitant with or posterior to the fifth stage, insulation is put in place. It can be put in place in the form of a reaction mix injected between the inner and outer sheets or in the form of slabs of insulation material 2 applied on the backside of the outer sheet. In the case of the reaction mix, it expands to form the insulation material 2. The outer sheet is preferably positioned upside down. In that case, if it has not already been positioned upside down at a previous stage, it is positioned upside down before the insulation is put in place.

[0385]

[0240] At a seventh stage, posterior to the fifth stage, concomitant with or posterior to the third stage and anterior to or concomitant with or posterior to the sixth stage, the inner sheet is maintained at a given distance from the outer sheet. The distance between the inner sheet and the outer sheet can preferably be maintained in the mold with the top side of the mold, and / or both the bottom side and top side of the mold, and possibly in a press or in a conveyor, possibly a double-belt conveyor. The given distance corresponds to the set thickness of the sandwich panel.

[0386]

[0241] The fifth, sixth and seventh stages are detailed below in relation to the nature of the insulation material. Overall, during these three stages and in no specific order, the downstream portion of the first cable, whose electrical connector is not already positioned in the cavity, is inserted in a hole in a side of the mold or in a groove formed either in the inner sheet or in the outer sheet, insulation is put in place and the inner sheet is maintained at a given distance from the outer sheet.

[0387]

[0242] In a first embodiment of the manufacturing process, the insulation material is a foam obtained from the expansion of a reaction mix. In that case, once the outer sheet has been positioned in the mold or while it is positioned in the mold, the downstream portion of the first cable, and the downstream portion of the second cable if applicable, is sheltered from the insulation material before injecting the reaction mix.

[0388]

[0243] In a first variant, the downstream portions of the cables are inserted in hole(s) in a side of the mold, in particular in either the first longitudinal side 95 or the second longitudinal side 96, or the first transverse side or the second transverse side of the mold. The insertions can be done once the outer sheet has been positioned in the mold or while it is positioned in the mold. Then, the inner sheet is positioned in the mold, on the first longitudinal side 95 and second longitudinal side 96 of the mold so that it is at the given distance from the outer sheet.

[0389]

[0244] In a second variant, the downstream portions of the cables are inserted in groove(s) formed in the inner sheet, in particular either in the upper inner groove 59 and lower inner groove 60 or in the inner edge rabbet 68 or in the longitudinal groove 85. It is done once the inner sheet has been brought close to the mold or while the inner sheet is being positioned in the mold, as described above in relation to the first variant.

[0245] In a third variant, the downstream portions of the cables are inserted in groove(s) formed in the outer sheet, in particular in the upper outer groove 116. The insertions can be done while the outer sheet is positioned in the mold. Then, the inner sheet is positioned in the mold, on the first longitudinal side 95 and second longitudinal side 96 of the mold so that it is at the given distance from the outer sheet.

[0390]

[0246] In a fourth variant, where the inner sheet is positioned in the mold before the outer sheet, once the inner sheet has been positioned in the mold and while the outer sheet is being positioned in the mold, the downstream portions of the cables are inserted in hole(s) in the side(s) of the mold, in particular in the part of the longitudinal side 95, 96 of the mold uncovered by the inner sheet, or in the bottom side 93 of the mold, or in the first transverse side or in the second transverse side of the mold or are inserted in groove(s) formed in the inner sheet.

[0391]

[0247] Then, in all fourth variants, the top side is put in place.

[0392]

[0248] In a fifth variant, once the inner sheet has been brought close to the mold or while the inner sheet is being positioned in the mold, as described above in relation to the first variant, the downstream portions of the cables are inserted in the upper hole 55 or the lower hole 57 of the inner sheet. Then, while the top side is put in place, the downstream portions of the cables are further inserted in hole(s) in the top side of the mold.

[0393]

[0249] Then, in all five variants, the inner sheet is maintained at the given distance from the outer sheet by the bottom side and the top side and possibly in a press or in a conveyor, possibly a double-belt conveyor.

[0394]

[0250] While the inner sheet is maintained in place, a reaction mix is injected in the mold between the inner sheet and the outer sheet. The reaction mix reacts and expands to fill the gap between the inner sheet and the outer sheet and thus forms the insulation material.

[0395]

[0251] In a second embodiment of the manufacturing process, the insulation material is in the form of slabs.

[0396]

[0252] In a first variant, once the outer sheet has been positioned in the mold upside down, the downstream portions of the cables are inserted in hole(s) in a side of the mold, in particular in either the part of the first longitudinal side 95 or the part of the second longitudinal side 96 of the mold uncovered by the outer sheet, or in the first transverse side, or in the second transverse side of the mold. Then a layer of adhesive is applied to the backside of the outer sheet and slabs of insulation material are positioned.

[0397]

[0253] In a second variant, while the outer sheet is being positioned in the mold upside down, the downstream portions of the cables are inserted in groove(s) formed in the outer sheet, in particular in the upper outer groove 116. Then a layer of adhesive is applied to the backside of the outer sheet and slabs of insulation material are positioned.

[0398]

[0254] In a third variant, once the outer sheet has been positioned in the mold upside down, a layer of adhesive is applied to the backside of the outer sheet and slabs of insulation material are positioned while ensuring that the downstream portions of the cables are maintained above the insulation material. Then the inner sheet is brought close to the mold and the downstream portions of the cables are inserted. They can be inserted in a groove formed in the inner sheet, in particular either in the upper inner groove 59, or in the lower inner groove 60, or in the inner edge rabbet 68, or in the longitudinal groove 85. Alternatively, they can be inserted in holes in the side of the mold that are positioned above the resting position of the inner sheet in the mold. The holes can notably be in the first longitudinal side 95 of the mold facing the inner edge rabbet 68 or in the second longitudinal side 96 facing the second inner riser 72.

[0399]

[0255] In all three variants, another layer of adhesive is then applied on the insulation material and then the inner sheet is positioned in the mold, on the insulation material and on the first longitudinal side 95 and second longitudinal side 96 of the mold so that it is at the given distance from the outer sheet. Then the top side is put in place.

[0400]

[0256] In a fourth variant, once the outer sheet has been positioned in the mold upside down, a layer of adhesive is applied to the backside of the outer sheet and slabs of insulation material are positioned while ensuring that the downstream portions of the cables are maintained above the insulation material. Then another layer of adhesive is applied on the insulation material, the inner sheet is brought close to the mold and the downstream portions of the cables are inserted in the upper hole 55 or the lower hole 57 of the inner sheet. Then, the inner sheet is positioned in the mold, on the insulation material and on the first longitudinal side 95 and second longitudinal side 96 of the mold so that it is at the given distance from the outer sheet. Then, while the top side is put in place, the downstream portions of the cables are further inserted in hole(s) in the top side of the mold.

[0401]

[0257] Then, in all four variants, the inner sheet is maintained in place by the top side and possibly in a press or in a conveyor, possibly a double-belt conveyor. It is done so during the curing of the adhesive.

[0402]

[0258] Finally, for both embodiments, the sandwich panel can be removed from the mold.

[0403]

[0259] With reference to Figures 18 and 19, according to the variant where downstream portion(s) of the cable(s) extend from one of the longitudinal sides 5, 6 of the insulation material, once a sandwich panel has been manufactured, an upper cutout 54 and a lower cutout 56 can be done in the longitudinal side. The cutouts can be done with any appropriate tool, such as, for example, a cutter, a chisel, a grooving machine. Alternatively, the longitudinal side of the mold comprises a counterpart of the upper cutout 54 and a counterpart of the lower cutout 56.

[0404]

[0260] With references to Figures 22 and 23, according to the variant where downstream portion(s) of cable(s) extend from the inner sheet, once a sandwich panel has been manufactured, an upper inner groove 59 or a lower inner groove 60 can be done in the inner sheet and the insulation material. The grooves can be done with any appropriate tool, such as, for example, a cutter, a chisel, a grooving machine.

[0405]

[0261] With reference to Figures 37 and 38, according to the variant where downstream portion(s) of cable(s) extend from one of the transverse side 7, 8 of the insulation material, once a sandwich panel has been manufactured, an upper indentation and / or a lower indentation can be done in the transverse sides. The indentations can be done with any appropriate tool, such as, for example, a cutter, a chisel, a grooving machine.

[0262] Once sandwich panels have been manufactured, they can be shipped to a construction site for assembling of a building envelope on a building structure. With reference to Figures 43 to 47, the process for the assembling of the building envelope comprises a first step where a first sandwich panel 1 a is fastened to the building structure. In particular, it is fastened to a purlin 58. More particularly, the lower half of the first sandwich panel is fastened to a lower purlin. In particular, the upper half of the first sandwich panel rests on a first upper purlin 58a. More particularly, the upper overlap area 23 of the first sandwich panel rests on the first upper purlin.

[0406]

[0263] In a second step, a second sandwich panel 1 b is positioned on the building structure, adjacent to the first sandwich panel, so that the lower transverse side 8 of its insulation material is adjacent to the upper transverse side 7 of the insulation material of the first sandwich panel. In particular, its lower overlap area 22 covers the upper overlap area 23 of the first sandwich panel, if applicable. In particular, the lower half of the second sandwich panel rests on the first upper purlin. In particular, the upper half of the second sandwich panel rests on a second upper purlin 58b, positioned higher than the first upper purlin. More particularly, the upper overlap area 23 of the second sandwich panel rests on the second upper purlin. The second sandwich panel can be fastened to the building structure. In particular, it is fastened to the first upper purlin. More particularly, the lower overlap area of the second sandwich panel is fastened to the first upper purlin, concomitantly with the fastening of the upper overlap area of the first sandwich panel to the first upper purlin.

[0407]

[0264] In a third step, posterior to or concomitant with the second step, the first upper electrical connector 46 of the first sandwich panel is connected to the first lower electrical connector 47 of the second sandwich panel. This step can take place while the second sandwich panel is being positioned. It can also take place right after the fastening of the second sandwich panel. It can also take place once all the sandwich panels of a row have been positioned and fastened. In the case of the second, third, fourth, fifth and seventh embodiments of the cable positioning (where the downstream portions of the cable are accessible from the inside of the building), it can also take place once all the sandwich panels of the envelope (or envelope side) have been positioned and fastened. In this latter case, an electrician does not need to be present during installation of the sandwich panels.

[0408]

[0265] According to a first variant (not illustrated), where the sandwich panel is according to the first embodiment of the cable positioning illustrated on Figures 16 to 19, or according to the sixth embodiment of the cable positioning, with the downstream portion of a first cable extending from either the second longitudinal side or the first longitudinal side of the insulation material, and the cavity along the same longitudinal side of the insulation material, the first upper electrical connector 46 and part of the first upper cable 42 of the first sandwich panel are inserted in the upper cutout 54 of the first sandwich panel and the first lower electrical connector 47 and part of the first lower cable 43 of the second sandwich panel are inserted in the lower cutout 56 of the second sandwich panel. The upper electrical connector and the first lower electrical connector are then connected. Alternatively, the downstream portion of the first cable is inserted in the lower cutout and in the upper cutout and its first electrical connector is connected to the other first electrical connector in the cavity.

[0409]

[0266] If applicable, the second upper electrical connector 52 of the first sandwich panel and the second lower electrical connector 53 of the second sandwich panel are connected similarly.

[0410]

[0267] According to a second variant illustrated on Figures 44 and 45, where the sandwich panel is according to the third embodiment of the cable positioning with the downstream portion of a first cable extending from the second inner riser 72, and the cavity along the second inner riser 72, the first upper electrical connector 46 and part of the first upper cable 42 of the first sandwich panel are slid between the purlin 58a and the inner tongue of the second longitudinal inner flange or slid in the technical recess. Then the first upper electrical connector is connected to the first lower electrical connector 47 of the second sandwich panel. Alternatively, the first lower electrical connector 47 and part of the first lower cable 43 of the second sandwich panel are slid between the purlin 58a and the inner tongue of the second longitudinal inner flange or slid in the technical recess. Then, the first lower electrical connector is connected to the first upper electrical connector 46 of the first sandwich panel. In another alternative, the downstream portion of the first cable is slid between the purlin 58a and the inner tongue of the second longitudinal inner flange or slid in the technical recess. Then its first electrical connector is connected to the other first electrical connector in the cavity.

[0411]

[0268] If applicable, the second upper electrical connector 52 of the first sandwich panel and the second lower electrical connector 53 of the second sandwich panel are connected similarly.

[0412]

[0269] The same methodology applies in the fourth embodiment of the cable positioning with the downstream portion of a first cable extending from the inner edge rabbet 68 of the inner sheet, and the cavity along the inner edge rabbet 68 of the inner sheet.

[0413]

[0270] According to a third variant illustrated on Figures 46 and 47, where the sandwich panel is according to the fifth embodiment of the cable positioning with the downstream portion of a first cable extending from the longitudinal groove 85, and the cavity along the longitudinal groove 85, the first upper electrical connector 46 and part of the first upper cable 42 of the first sandwich panel are inserted in the longitudinal groove 85 of the first sandwich panel, slid over the purlin 58a and the first upper electrical connector is connected to the first lower electrical connector 47 of the second sandwich panel. Alternatively, the first lower electrical connector 47 and part of the first lower cable 43 of the second sandwich panel are inserted in the longitudinal groove 85 of the second sandwich panel, slid over the purlin 58a and the first lower electrical connector is connected to the first upper electrical connector 46 of the first sandwich panel. In another alternative, the downstream portion of the first cable is inserted in both the longitudinal groove 85 of the first sandwich panel and the longitudinal groove 85 of the second sandwich panel. Then its first electrical connector is connected to the other first electrical connector in the cavity.

[0414]

[0271] If applicable, the second upper electrical connector 52 of the first sandwich panel and the second lower electrical connector 53 of the second sandwich panel are connected similarly.

[0272] The same methodology applies in the second embodiment of the cable positioning with the downstream portion of a first cable extending from the inner central part 67 of the inner sheet, and the cavity along the inner central part 67 and when the upper inner groove 59 and / or the lower inner groove 60 are present in the inner sheet. If there are no upper inner groove and lower inner groove, the first upper electrical connector and part of the first upper cable of the first sandwich panel can go around part of the purlin and the first lower electrical connector and part of the first lower cable of the second sandwich panel can go around the rest of the purlin.

[0415]

[0273] According to a fourth variant (not illustrated), where the sandwich panel is according to the seventh embodiment of the cable positioning with the downstream portion of a first cable extending from one of the transverse side of the insulation material and the cavity along the other transverse side, at least a part, if not all, of the downstream portion of the first cable 42 of one sandwich panel is inserted in the cavity of the other sandwich panel and its first electrical connector is connected to the other first electrical connector of the other sandwich panel in the cavity. Alternatively, the first upper electrical connector 46 and part of the first upper cable 42 of the first sandwich panel are inserted in the upper indentation of the first sandwich panel and the first lower electrical connector 47 and part of the first lower cable 43 of the second sandwich panel are inserted in the lower indentation of the second sandwich panel. The upper electrical connector and the first lower electrical connector are connected either while the second sandwich panel is positioned or afterwards, from the inside of the building.

[0416]

[0274] If applicable, the second upper electrical connector 52 of the first sandwich panel and the second lower electrical connector 53 of the second sandwich panel are connected similarly.

[0417]

[0275] According to a fifth variant (not illustrated), where the sandwich panel is according to the eighth embodiment of the cable positioning with the downstream portion of a first cable extending from one of the transverse sides of the insulation material and the cavity along the outer sheet, the downstream portion of the first cable can be inserted in the upper outer groove 116 of the other sandwich panel. Then its first electrical connector is connected to the other first electrical connector of the other sandwich panel in the cavity.

[0418]

[0276] If applicable, the second upper electrical connector 52 of the first sandwich panel and the second lower electrical connector 53 of the second sandwich panel are connected similarly.

Claims

CLAIMS1 ) A process for manufacturing a sandwich panel (1 ) comprising an inner sheet (3), an outer sheet (4) and an insulation material (2) sandwiched between the inner sheet and the outer sheet, the insulation material having a first longitudinal side (5), a second longitudinal side (6), an upper transverse side (7) and a lower transverse side (8), the process comprising:- Providing the outer sheet comprising: o an outer central part (17) including:■ a first upper perforation (27) through which a first upper electrical conductor (25) runs,■ a first lower perforation (28) through which a first lower electrical conductor (26) runs, o a first photovoltaic active area (24) positioned on the outer central part and electrically connected to the first upper electrical conductor and to the first lower electrical conductor, the backside of the outer sheet comprising:■ a first upper cable (42) connecting the first upper electrical conductor to a first upper electrical connector (46),■ a first lower cable (43) connecting the first lower electrical conductor to a first lower electrical connector (47), the first lower electrical connector and the first upper electrical connector being corresponding male and female connectors,■ a cavity (44, 45) in which one of the first upper electrical connector and the first lower electrical connector is positioned,- Providing an inner sheet (3),- Positioning the outer sheet in a mold comprising a bottom side (93), a top side (94), a first longitudinal side (95), a second longitudinal side (96), a first transverse side and a second transverse side,- Inserting the other of the first upper electrical connector and the first lower electrical connector, with a downstream portion of its cable, either in ahole (97, 98, 100, 101 ) in one of the sides of the mold or in a groove (59, 60, 68, 85) formed in the inner sheet or in a groove (116) formed in the outer sheet,- Putting insulation in place,- Maintaining the inner sheet at a given distance from the outer sheet.2) Process according to claim 1 further comprising, before providing the outer sheet (4), preparing the outer sheet according to the following steps:- the outer sheet is cut to length from a strip,- the first upper perforation (27) and the first lower perforation (28) are done in the outer central part (17),- the first photovoltaic active area (24) is positioned on the outer central part,- the backside of the outer sheet is equipped with the first upper cable (42), the first upper electrical connector (46), the first lower cable (43), the first lower electrical connector (47) and the cavity (44, 45).3) Process according to any one of claims 1 or 2, wherein the hole in one of the sides of the mold is a hollow space (100, 101 ) in the inner surface of the side.4) Process according to any one of claims 1 or 2, wherein the hole in one of the sides of the mold is a through-hole (97, 98).5) Process according to claim 4, wherein the side of the mold further comprises a recess (99) in the outer surface of the side at the level of the through-hole for inserting a portion of a cable with an electrical connector.6) Process according to any one of the preceding claims wherein, while the inner sheet is maintained in place at the given distance from the outer sheet, a reaction mix is injected in the mold between the inner sheet and the outer sheet so that the reaction mix reacts and expands to fill the gap between the inner sheet and the outer sheet and thus forms the insulation material (2).7) Process according to any one of claims 1 to 5 wherein, once the outer sheet has been positioned upside down in the mold, the insulation is put in place in the form of slabs on the backside of the outer sheet, a layer of adhesive is then applied on the insulation material, the inner sheet is then positioned in the mold at the given distance from the outer sheet and the inner sheet is maintained in place by the top side of the mold during curing of the adhesive.8) Process according to claim 7 wherein the insulation is put in place before the downstream portion of the cable is inserted in the hole or the groove.9) Sandwich panel (1 ), for building envelope, comprising an inner sheet (3), an outer sheet (4) and an insulation material (2) sandwiched between the inner sheet and the outer sheet, the insulation material having a first longitudinal side (5), a second longitudinal side (6), an upper transverse side (7) and a lower transverse side (8), the outer sheet comprising:- a first longitudinal outer flange (15),- an outer central part (17) extending from the first longitudinal outer flange, including: o a first upper perforation (27) through which a first upper electrical conductor (25) runs, o a first lower perforation (28) through which a first lower electrical conductor (26) runs,- a first photovoltaic active area (24) positioned on the outer central part and electrically connected to the first upper electrical conductor and to the first lower electrical conductor,- a second longitudinal outer flange (16) extending from the outer central part, the first longitudinal outer flange and the second longitudinal outer flange having shapes that allow the overlapping of one on the other, the backside of the outer sheet comprising:- a first upper cable (42) connecting the first upper electrical conductor to a first upper electrical connector (46),- a first lower cable (43) connecting the first lower electrical conductor to a first lower electrical connector (47), the first lower electrical connector and the first upper electrical connector being corresponding male and female connectors, one of the first upper cable and the first lower cable having:- an upstream portion running from the respective first electrical conductor to either: o one of the first longitudinal side and the second longitudinal side of the insulation material or, o one of the upper transverse side and the lower transverse side of the insulation material or, o the inner sheet or, o the outer sheet and running through the insulation material,- a downstream portion with the respective first electrical connector, freely extending either from the said longitudinal side of the insulation material or from the said transverse side of the insulation material or from the inner sheet or from the outer sheet, the other of the first upper cable and the first lower cable having the respective first electrical connector positioned in a cavity (44, 45) positioned within the insulation material and adjacent to either the said longitudinal side of the insulation material, or the other transverse side of the insulation material, or the inner sheet or the outer sheet.10)Sandwich panel according to claim 9 wherein the cavity is a lower cavity 45 positioned in the lower half of the sandwich panel and wherein the upstream portion of the first upper cable 42 is positioned in the upper half of the sandwich panel.11 )Sandwich panel according to claim 9 wherein the cavity is an upper cavity 44 positioned in the upper half of the sandwich panel and wherein the upstream portion of the first lower cable 43 is positioned in the lower half of the sandwich panel.)Sandwich panel (1 ), for building envelope, comprising an inner sheet (3), an outer sheet (4) and an insulation material (2) sandwiched between the inner sheet and the outer sheet, the insulation material having a first longitudinal side (5), a second longitudinal side (6), an upper transverse side (7) and a lower transverse side (8), the outer sheet comprising:- a first longitudinal outer flange (15),- an outer central part (17) extending from the first longitudinal outer flange, including: o a first upper perforation (27) through which a first upper electrical conductor (25) runs, o a first lower perforation (28) through which a first lower electrical conductor (26) runs,- a first photovoltaic active area (24) positioned on the outer central part and electrically connected to the first upper electrical conductor and to the first lower electrical conductor,- a second longitudinal outer flange (16) extending from the outer central part, the first longitudinal outer flange and the second longitudinal outer flange having shapes that allow the overlapping of one on the other, the backside of the outer sheet comprising:- a first upper cable (42) connecting the first upper electrical conductor to a first upper electrical connector (46),- a first lower cable (43) connecting the first lower electrical conductor to a first lower electrical connector (47), the first lower electrical connector and the first upper electrical connector being corresponding male and female connectors, one of the first upper cable and the first lower cable having:- an upstream portion running from the respective first electrical conductor to either: o one of the first longitudinal side and the second longitudinal side of the insulation material or,o one of the upper transverse side and the lower transverse side of the insulation material or, o the inner sheet or, o the outer sheet, and running through the insulation material,- a downstream portion with the respective first electrical connector, freely extending either from the said longitudinal side of the insulation material or from the said transverse side of the insulation material or from the inner sheet or from the outer sheet, the other of the first upper cable and the first lower cable running from the respective first electrical conductor, through at least a cavity (44, 45) and either a cut in the said longitudinal side of the insulation material, or a cut in the other transverse side of the insulation material, or a hole in the inner sheet or a hole in the outer sheet, up to the respective first electrical connector. )Sandwich panel according to any one of claims 9 to 12 wherein:- the outer central part (17) further includes: o a second upper perforation (38) through which a second upper electrical conductor (36) runs, o a second lower perforation (39) through which a second lower electrical conductor (37) runs,- the outer sheet (4) further comprises a second photovoltaic active area (35) positioned on the outer central part and electrically connected to the second upper electrical conductor and to the second lower electrical conductor, the backside of the outer sheet further comprises: o a second upper cable (50) connecting the second upper electrical conductor to a second upper electrical connector (52), o a second lower cable (51 ) connecting the second lower electrical conductor to a second lower electrical connector (53), the second lower electrical connector and second upper electrical connector being corresponding male and female connectors,the second upper cable running at least partially adjacently to the first upper cable and the second lower cable running at least partially adjacently to the lower cable.14)Sandwich panel according to claim 13 wherein the first upper electrical connector (46) and the second upper electrical connector (52) are corresponding male and female connectors and wherein the first lower electrical connector (47) and the second lower electrical connector (53) are corresponding male and female connectors.15)A process for the assembling of a building envelope on a building structure, comprising:- (i) providing a first and a second sandwich panel (1 ) according to any one of claims 9 to 14,- (ii) fastening the first sandwich panel to the building structure,- (iii) positioning the second sandwich panel so that the lower transverse side (8) of its insulation material is adjacent to the upper transverse side (7) of the insulation material of the first sandwich panel,- (iv) connecting the first upper electrical connector (46) of the first sandwich panel to the first lower electrical connector (47) of the second sandwich panel.

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