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 process comprising positioning the outer sheet in a mold, inserting at least one of the first upper electrical connector and the first lower electrical connector, with a downstream portion of its cable, 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, the first upper cable having:

[0014] - an upstream portion running from the first upper electrical conductor to the outer sheet and running through the insulation material,

[0015] - a downstream portion with the first upper electrical connector, freely extending from the outer sheet, the first lower cable having: - an upstream portion running from the first lower electrical conductor to either the lower transverse side of the insulation material or the outer sheet and running through the insulation material,

[0016] - a downstream portion with the first lower electrical connector, freely extending either from the lower transverse side of the insulation material or from the outer sheet.

[0017]

[0007] The sandwich panel according to the invention may also have the optional features listed below, considered individually or in combination:

[0018] - the sandwich panel comprises an upper outer groove extending from an upper transverse outer edge of the outer sheet up to at least the junction point of the upstream portion and the downstream portion of the first upper cable.

[0019] - the sandwich panel comprises a lower outer groove extending from a lower transverse outer edge of the outer sheet up to at least the junction point of the upstream portion and the downstream portion of the first lower cable.

[0020] - the outer sheet further comprises an upper transverse outer edge bordering an upper overlap area,

[0021] - 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,

[0022] - 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,

[0023] - 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, - the upstream portion of the first upper cable, respectively the upstream portion of the first lower cable, is substantially embedded in the insulation material,

[0024] - 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,

[0025] - 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,

[0026] - 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,

[0027] - the second upper cable comprising: o an upstream portion running from the second upper electrical conductor to the outer sheet and running through the insulation material, o a downstream portion with the second upper electrical connector, freely extending from the outer sheet,

[0028] - the second lower cable comprising: o an upstream portion running from the second lower electrical conductor to either the lower transverse side of the insulation material or the outer sheet and running through the insulation material, o a downstream portion with the second lower electrical connector, freely extending either from the lower transverse side of the insulation material or from the outer sheet, - the first upper electrical connector and the second upper electrical connector are corresponding male and female connectors and wherein the first lower electrical connector and the second lower electrical connector are corresponding male and female connectors,

[0029] - the sandwich panel does not comprise a cavity positioned within the insulation material that prevents the first upper electrical connector from being trapped in the insulation material,

[0030] - the sandwich panel does not comprise a cavity positioned within the insulation material that prevents the first lower electrical connector from being trapped in the insulation material.

[0031]

[0008] A second 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:

[0032] - Providing the outer sheet comprising: o an outer central part including:

[0033] ■ a first upper perforation through which a first upper electrical conductor runs,

[0034] ■ 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:

[0035] ■ a first upper cable connecting the first upper electrical conductor to a first upper electrical connector,

[0036] ■ 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, - Providing an inner sheet,

[0037] - 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,

[0038] - Inserting at least one of the first upper electrical connector and the first lower electrical connector, with a downstream portion of its cable, in a groove formed in the outer sheet,

[0039] - Putting insulation in place,

[0040] - Maintaining the inner sheet at a given distance from the outer sheet.

[0041]

[0009] The process for manufacturing a sandwich panel may also have the optional features listed below, considered individually or in combination:

[0042] - 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 and the first lower electrical connector,

[0043] - An upper outer hole is done in the outer sheet, in particular during the preparation step of the outer sheet,

[0044] - A lower outer hole is done in the outer sheet, in particular during the preparation step of the outer sheet,

[0045] - the groove in the outer sheet is an upper outer groove extending from an upper transverse outer edge of the outer sheet up to at least an upper outer hole in the outer sheet,

[0046] - the upper outer groove is positioned in a second longitudinal rib of the outer sheet, - the groove in the outer sheet is a lower outer groove extending from a lower transverse outer edge of the outer sheet up to at least a lower outer hole in the outer sheet.

[0047] - the lower outer groove is positioned in a second longitudinal rib of the outer sheet.

[0048] - the first photovoltaic active area is laminated on the outer central part,

[0049] - the mold further comprises a hole in one of its sides in the form of a hollow space in the inner surface of the side,

[0050] - the mold further comprises a hole in one of its sides in the form of a through-hole,

[0051] - the hole is positioned in either the first transverse side, or the second transverse side, or the bottom side or the top side of the mold.

[0052] - 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 the first upper cable with the first upper electrical connector or a portion of the first lower cable with the first lower electrical connector,

[0053] - 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,

[0054] - 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.

[0055]

[0010] A third subject of the invention consists of a process for the assembling of a building envelope on a building structure, comprising:

[0056] - (i) providing a first and a second sandwich panel according to the invention,

[0057] - (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,

[0058] - (iv) connecting the first upper electrical connector of the first sandwich panel to the first lower electrical connector of the second sandwich panel.

[0059]

[0011] 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, portions of the cables needed to electrically connect adjacent panels are inserted in a groove in the outer sheet so that they do not get embedded in the insulation material when the insulation is put in place. 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. Similarly, the sandwich panel does not comprise any hole in the inner sheet capable of receiving an electrical connector housing I capable of having an electrical connector housing inserted from the external surface of the inner sheet.

[0012] Other characteristics and advantages of the invention will be described in greater detail in the following description.

[0060]

[0013] 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:

[0061] - 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,

[0062] - 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,

[0063] - 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,

[0064] - 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,

[0065] - Figure 5, which is a cross-section of the sandwich panel according to a first embodiment of the outer sheet and inner sheet,

[0066] - Figure 6, which is a cross-section of the sandwich panel according to a second embodiment of the outer sheet and inner sheet,

[0067] - Figure 7, which is a perspective view of the sandwich panel according to the invention,

[0068] - Figure 8, which is a view of the upper side of the outer sheet of the sandwich panel according to the invention,

[0069] - Figure 9, which is a view of the grommet of the sandwich panel according to the invention,

[0070] - Figure 10, which is a cross-section of the sandwich panel according to the invention,

[0071] - Figure 11 , which is a perspective view of the lower part of the sandwich panel according to the first embodiment of the cable positioning,

[0072] - Figure 12, which is a perspective view of the upper part of the sandwich panel according to the first embodiment of the cable positioning,

[0073] - Figure 13, which is a perspective view of the lower part of the sandwich panel according to the second embodiment of the cable positioning, - Figure 14, which is a perspective view of the upper part of the sandwich panel according to the second embodiment of the cable positioning,

[0074] - Figure 15, which is a schematic cross-section of a first variant of a mold according to the invention,

[0075] - Figure 16, which is a schematic cross-section of a second variant of a mold according to the invention,

[0076] - Figure 17, which is a perspective view of the assembling of four sandwich panels according to the invention on a building structure.

[0077]

[0014] 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.

[0078]

[0015] 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”.

[0079]

[0016] Throughout the text, a photovoltaic active area is understood to mean a stack of a plurality of layers which comprises a layer:

[0080] - capable of converting solar energy into electricity and

[0081] - protected from the outside by insulating layers.

[0082]

[0017] 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.

[0083]

[0018] 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.

[0084]

[0019] 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.

[0085]

[0020] 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.

[0086]

[0021] 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.

[0087]

[0022] 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.

[0088]

[0023] 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.

[0089]

[0024] 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.

[0090]

[0025] With reference to Figures 2, 4, 5 and 6, the outer sheet 4 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.

[0091]

[0026] The sandwich panel is designed so that:

[0092] - 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

[0093] - 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.

[0094]

[0027] Consequently, in a first embodiment of the outer sheet illustrated on Figures 1 to 5, 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.

[0095]

[0028] 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.

[0096]

[0029] 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.

[0097]

[0030] 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.

[0031] 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.

[0098]

[0032] In a second embodiment of the outer sheet illustrated on Figure 6, 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.

[0099]

[0033] 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 6. 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.

[0100]

[0034] 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 6. 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.

[0101]

[0035] 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.

[0102]

[0036] 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.

[0103]

[0037] 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 6. 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.

[0104]

[0038] 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 6. 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.

[0105]

[0039] 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.

[0106]

[0040] 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:

[0107] - The height of the outer mortise (measured along the vertical axis Z) is superior to the height of the outer tenon,

[0108] - The width of the outer mortise (measured along the transversal axis Y) is superior or equal to the width of the outer tenon.

[0109]

[0041] Such interlocking of the outer mortise and the outer tenon improves the resistance, notably to wind suction, of the envelope made of sandwich panels.

[0110]

[0042] 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.

[0043] With reference to Figures 3 to 6, 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. Preferably, the inner sheet is substantially a flat rectangle at the size of the insulation material. It can nevertheless be shaped notably along its edges to notably facilitate the interlocking of two adjacent panels and / or to increase its stiffness.

[0111]

[0044] Preferably, 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. According to a first variant, the latter substantially lies down flat in plane P. According to a second variant illustrated on Figure 5, the inner central part comprises longitudinal stiffeners to increase the stiffness of the metallic sheet.

[0112]

[0045] According to a first embodiment of the inner sheet illustrated on Figure 5, 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. 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 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.

[0113]

[0046] 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.

[0114]

[0047] The first longitudinal inner flange 65 is 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.

[0115]

[0048] The second longitudinal inner flange 66 extends from the second longitudinal extremity of the inner central part 67 by projecting from the second longitudinal side 6 of the insulation material and forming an inner tongue 73 extending substantially parallel to plane P and outwards. 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.

[0116]

[0049] 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. According to one variant of the invention, the second inner stiffener 77 comprises a second inner wing 90 extending parallel to plane P and inwards into the insulation material 2. This helps stiffening the first inner flange.

[0117]

[0050] The inner edge rabbet 68 and the inner tongue 73 have shapes that allow 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:

[0118] - The height of the inner edge rabbet (measured along the vertical axis Z) is superior to the height of the inner tongue,

[0119] - The width of the inner edge rabbet (measured along the transversal axis Y) is superior or equal to the width of the inner tongue.

[0120]

[0051] Such interlocking of the inner edge rabbet and the inner tongue improves the resistance to wind suction of the envelope made of sandwich panels.

[0121]

[0052] In a variant of the inner sheet, the shapes of the first longitudinal inner flange 65 and second longitudinal inner flange 66 are inverted.

[0122]

[0053] In a second embodiment of the inner sheet illustrated on Figure 6, 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.

[0123]

[0054] 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.

[0124]

[0055] 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.

[0056] 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 6. It facilitates the lateral assembling of two adjacent panels. More preferably, the inner mortise is substantially plumb with the outer mortise.

[0125]

[0057] 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.

[0126]

[0058] 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.

[0127]

[0059] 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.

[0128]

[0060] 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.

[0061] 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:

[0129] - The height of the inner mortise (measured along the vertical axis Z) is superior to the height of the inner tenon,

[0130] - The width of the inner mortise (measured along the transversal axis Y) is superior or equal to the width of the inner tenon.

[0131]

[0062] Such interlocking of the inner mortise and the inner tenon improves the resistance, notably to wind suction, of the envelope made of sandwich panels.

[0132]

[0063] In a variant of the inner sheet, the shapes of the first longitudinal inner flange 65 and second longitudinal inner flange 66 are inverted.

[0133]

[0064] The embodiments of the inner sheet and the embodiments of the outer sheet can be combined.

[0134]

[0065] 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.

[0135]

[0066] 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.

[0136]

[0067] 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.

[0137]

[0068] 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 7, 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.

[0138]

[0069] Consequently, and with reference to Figure 8, 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.

[0139]

[0070] 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.

[0140]

[0071] 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.

[0141]

[0072] 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.

[0142]

[0073] 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.

[0143]

[0074] With reference to Figures 7 and 9, 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 narrower 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.

[0144]

[0075] 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.

[0145]

[0076] 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.

[0146]

[0077] 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.

[0147]

[0078] With reference to Figure 8, 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.

[0148]

[0079] 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.

[0149]

[0080] 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.

[0150]

[0081] 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.

[0151]

[0082] According to one variant of the invention illustrated on Figures 1 , 2, 7 and 8, 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.

[0152]

[0083] 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 37. 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.

[0084] 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.

[0153]

[0085] 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 Figure 10, 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

[0154] 40, 41 comprises a non-conductive grommet 29, as described above.

[0155]

[0086] The first upper junction box 40, respectively the first lower junction box

[0156] 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.

[0157]

[0087] 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.

[0158]

[0088] With reference to Figures 10 to 14, the first upper cable 42 and first lower cable 43 are now described.

[0159]

[0089] The first upper cable 42 has: o an upstream portion running from the first upper electrical conductor 25 to the outer sheet through the insulation material, o a downstream portion with a first upper electrical connector 46, freely extending from the outer sheet.

[0160]

[0090] The first lower cable 43 has: o an upstream portion running from the first lower electrical conductor 26 to either the lower transverse side of the insulation material or the outer sheet and running through the insulation material, o a downstream portion with a first lower electrical connector 47, freely extending either from the lower transverse side of the insulation material or from the outer sheet.

[0161]

[0091] 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.

[0162]

[0092] For the sake of clarity, the cables, and in particular their upstream portions, do not run through a cavity positioned within the insulation material. By “cavity”, it is meant a hollow space within the insulation material that prevents electrical connector(s) of the photovoltaic active area(s) from being trapped in the insulation material during the manufacturing process of the sandwich panel. By “positioned within the insulation material”, 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, the cables, and in particular their upstream portions, do not run through a cavity positioned within the insulation material and adjacent to either a side of the insulation material or the inner sheet. In particular, the cables, and in particular their upstream portions, do not run through a cavity positioned within the insulation material and designed for, and capable of, accommodating an electrical connector and a portion of a cable. More particularly, the cables, and in particular their upstream portions, do not run through a cavity positioned within the insulation material, adjacent to either a side of the insulation material or the inner sheet, and designed for, and capable of, accommodating an electrical connector and a portion of a cable. Even more particularly, the cables, and in particular their upstream portions, do not run through a cavity positioned within the insulation material, adjacent to either a side of the insulation material or the inner sheet, designed for, and capable of, accommodating an electrical connector and a portion of a cable and comprising 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.

[0163]

[0093] In particular, for any of the above exclusions, the upstream portion of the first upper cable 42 do not run through an upper cavity positioned in the upper half of the sandwich panel. In particular, for any of the three last above exclusions, the upstream portion of the first upper cable 42 do not run through an upper cavity designed for, and capable of, accommodating the first upper electrical connector 46 and a portion of the first upper cable 42. Similarly, for any of the above exclusions, the upstream portion of the first lower cable 43 do not run through a lower cavity positioned in the lower half of the sandwich panel. In particular, for any of the three last above exclusions, the upstream portion of the first lower cable 43 do not run through a lower cavity designed for, and capable of, accommodating the first upper electrical connector 46 and a portion of the first upper cable 42.

[0164]

[0094] More preferably, the upstream portion of the cable, possibly comprising a sleeve, is substantially embedded in the insulation material. In other words, this portion of the cable is irremovable. The substantial embedment of the upstream portion of the cable 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. Even more preferably, at least 90%, or at least 95%, of the upstream portion of the cable, possibly comprising a sleeve, is in contact with the insulation material (possible glue included).

[0165]

[0095] 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. Similarly, 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. This way, there is no risk of cable crossing 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. For the sake of clarity, each cable has no other portion than the upstream portion and the downstream portion.

[0166]

[0096] The upstream portion of the first upper cable 42 is preferably positioned in the upper half of the sandwich panel. More preferably, this 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. Similarly, the upstream portion of the first lower cable 43 is preferably positioned in the lower half of the sandwich panel. More preferably, this upstream portion 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 way, there is no risk of cable crossing 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.

[0167]

[0097] The first upper electrical connector 46 and first lower electrical connector 47 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.

[0168]

[0098] 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.

[0169]

[0099] With reference to Figure 10, 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.

[0170]

[0100] The second upper cable 50 has: o an upstream portion running from the second upper electrical conductor 36 to the outer sheet and running through the insulation material, o a downstream portion with a second upper electrical connector 52, freely extending from the outer sheet,

[0171]

[0101] The second lower cable 51 comprises: o an upstream portion running from the second lower electrical conductor 37 to either the lower transverse side of the insulation material or the outer sheet and running through the insulation material, o a downstream portion with a second lower electrical connector 53, freely extending either from the lower transverse side of the insulation material or from the outer sheet.

[0172]

[0102] The features and variants detailed in relation to the first cables apply here.

[0173]

[0103] Preferably, the junction point of the second upper cable 50 is adjacent to the junction point of the first upper cable 42. Preferably, the junction point of the second lower cable 51 is adjacent to the junction point of the first lower cable 43.

[0174]

[0104] More preferably, the upstream portion of the second upper cable 50 is adjacent to the upstream portion of the first upper cable 42. More preferably, the upstream portion of the second lower cable 51 is adjacent to the upstream portion of the first lower cable 43.

[0175]

[0105] 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.

[0176]

[0106] 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.

[0177]

[0107] 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:

[0178] - 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,

[0179] - 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,

[0180] - 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,

[0181] - 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.

[0182]

[0108] According to a first embodiment of the cable positioning illustrated on Figures 11 and 12 with the first embodiment of the outer sheet and the first embodiment of the inner sheet, the first upper cable is extracted through the outer sheet while the first lower cable is extracted through the lower transverse side of the insulation material. The upstream portion of the first upper cable 42 runs from the first upper electrical conductor 25 to the outer sheet and its downstream portion freely extends from the outer sheet. In particular, the upstream portion of the first upper cable runs from the first upper electrical conductor to the second longitudinal outer flange 16. More particularly, it runs from the first upper electrical conductor to the second longitudinal rib 21. Even more particularly, it runs from the first upper electrical conductor to the top central part 19 of the second longitudinal rib 21 . The junction point of the first upper cable is thus positioned on the outer sheet, in particular on the second longitudinal outer flange 16, more particularly on the second longitudinal rib 21 , even more particularly on the top central part 19 of the second longitudinal rib.

[0109] 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 8 of the insulation material. In particular, the upstream portion of the first lower cable runs from the first lower electrical conductor to the portion of the lower transverse side 8 covered by the second longitudinal outer flange 16. More particularly, it runs from the first lower electrical conductor to the portion of the lower transverse side 8 covered by the second longitudinal rib 21 . Even more particularly, it runs from the first lower electrical conductor to the portion of the lower transverse side 8 covered by the top central part 19 of the second longitudinal rib 21 . The junction point of the first lower cable is thus positioned on the lower transverse side 8 of the insulation material, in particular on the portion of the lower transverse side 8 covered by the second longitudinal outer flange 16, more particularly on the portion of the lower transverse side 8 covered by the second longitudinal rib 21 , even more particularly on the portion of the lower transverse side 8 covered by the top central part 19 of the second longitudinal rib 21 .

[0183]

[0110] In the variant where the sandwich panel further comprises a second photovoltaic active area 35, the upstream portion of the second upper cable 50 runs from the second upper electrical conductor 36 to the outer sheet and its downstream portion freely extends from the outer sheet. In particular, the upstream portion of the second upper cable runs from the second upper electrical conductor to the second longitudinal outer flange 16, more particularly to the second longitudinal rib 21 , even more particularly, to the top central part 19 of the second longitudinal rib 21 . The junction point of the second upper cable is thus positioned on the outer sheet, in particular on the second longitudinal outer flange 16, more particularly on the second longitudinal rib 21 , even more particularly on the top central part 19 of the second longitudinal rib.

[0184]

[0111] 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. In particular, the upstream portion of the second lower cable runs from the second lower electrical conductor to the portion of the lower transverse side 8 covered by the second longitudinal outer flange 16, more particularly, to the portion of the lower transverse side covered by the second longitudinal rib 21 , even more particularly, to the portion of the lower transverse side covered by the top central part 19 of the second longitudinal rib 21. The junction point of the second lower cable is thus positioned on the lower transverse side 8 of the insulation material, in particular on the portion of the lower transverse side 8 covered by the second longitudinal outer flange 16, more particularly on the portion of the lower transverse side covered by the second longitudinal rib 21 , even more particularly on the portion of the lower transverse side 8 covered by the top central part 19 of the second longitudinal rib 21 .

[0185]

[0112] In the variant where the sandwich panel comprises an upper overlap area 23 and a lower overlap area 22, the junction point of the first upper cable, and of the second upper cable if applicable, is preferably positioned in the upper overlap area. This improves the watertightness of the assembly of sandwich panels.

[0186]

[0113] In this embodiment, the outer sheet comprises an upper outer hole 117 for the passing of the first upper cable, possibly of the second upper cable, through the outer sheet. In particular, the upper outer hole is positioned on the second longitudinal outer flange 16, more particularly on the second longitudinal rib 21 , even more particularly on the top central part 19 of the second longitudinal rib.

[0187]

[0114] In this embodiment, the upper cable(s) along the outer sheet should not prevent adjacent sandwich panels from being assembled contiguously. Consequently, the outer sheet, in particular the second longitudinal outer flange 16, more particularly the second longitudinal rib 21 , even more particularly the top central part 19 of the second longitudinal rib, preferably comprises an upper outer groove 116 extending from the upper transverse outer edge 13 up to at least the upper outer hole 117 in the outer sheet. In other words, the upper outer groove extends from the upper transverse side 7 of the insulation material to at least the junction point of the first upper cable. If there is a second upper cable, the upper outer groove also extends to the junction point of the second upper cable. In particular, the upper outer groove extends along the longitudinal axis X. Cables can run in the upper outer groove when the two sandwich panels are positioned contiguously.

[0188]

[0115] The size of the upper outer groove is adapted to the size of the electrical connectors and cables. In one variant, the height (taken along the Z axis) of the upper outer groove is superior or equal to the diameter of the electrical connector 46, 47, 52 or 53. In another variant, the width (taken along the Y axis) of the upper outer groove is superior or equal to the diameter of the electrical connector 46, 47, 52 or 53, preferably superior or equal to the diameter of two electrical connectors.

[0189]

[0116] In the variant where the sandwich panel comprises an upper overlap area 23 and a lower overlap area 22, the upper outer groove is preferably integrally positioned in the upper overlap area. In other words, it does not extend beyond the upper overlap area. This improves the watertightness of the assembly of sandwich panels. Alternatively, if the upper outer groove extends beyond the upper overlap area, or if there are no overlap areas, once adjacent sandwich panels have been assembled or while they are being assembled, a hood can be added. The hood covers at least the portion of the upper outer groove outside of the upper overlap area or exposed to the environment.

[0190]

[0117] In a second embodiment of the cable positioning illustrated on Figures 13 and 14 with the first embodiment of the outer sheet and the first embodiment of the inner sheet, the extraction of the first lower cable 43 differs from the first embodiment. All the features and variants of the extraction of the first upper cable(s), detailed above for the first embodiment of the cable positioning, apply to the second embodiment. In particular, the outer sheet of the second embodiment can comprise an upper outer groove 116 as described above for the first embodiment of the cable positioning.

[0191]

[0118] In the second embodiment, the first lower cable 43 is extracted through the outer sheet. The upstream portion of the first lower cable runs from the first lower electrical conductor 26 to the outer sheet and its downstream portion freely extends from the outer sheet. In particular, the upstream portion of the first lower cable runs from the first lower electrical conductor to the second longitudinal outer flange 16. More particularly, it runs from the first lower electrical conductor to the second longitudinal rib 21. Even more particularly, it runs from the first lower electrical conductor to the top central part 19 of the second longitudinal rib 21 . The junction point of the first lower cable is thus positioned on the outer sheet, in particular on the second longitudinal outer flange 16, more particularly on the second longitudinal rib 21 , even more particularly on the top central part 19 of the second longitudinal rib.

[0192]

[0119] 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 outer sheet and its downstream portion freely extends from the outer sheet. In particular, the upstream portion of the second lower cable runs from the second lower electrical conductor to the second longitudinal outer flange 16, more particularly to the second longitudinal rib 21 , even more particularly to the top central part 19 of the second longitudinal rib 21. The junction point of the second lower cable is thus positioned on the outer sheet, in particular on the second longitudinal outer flange 16, more particularly on the second longitudinal rib 21 , even more particularly on the top central part 19 of the second longitudinal rib.

[0193]

[0120] In the variant where the sandwich panel comprises an upper overlap area 23 and a lower overlap area 22, the junction point of the first lower cable, and of the second lower cable if applicable, is preferably adjacent to the lower overlap area.

[0194]

[0121] In this embodiment, the outer sheet comprises a lower outer hole 119 for the passing of the first lower cable, possibly of the second lower cable, through the outer sheet. In particular, the lower outer hole is positioned on the second longitudinal outer flange 16, more particularly on the second longitudinal rib 21 , even more particularly on the top central part 19 of the second longitudinal rib.

[0195]

[0122] In this embodiment, the outer sheet, in particular the second longitudinal outer flange 16, more particularly the second longitudinal rib 21 , even more particularly the top central part 19 of the second longitudinal rib, can comprise a lower outer groove 118 extending from the lower transverse outer edge 14 up to at least the lower outer hole 119 in the outer sheet. In other words, the lower outer groove extends from the lower transverse outer edge 14 up to at least the junction point of the first lower cable. If there is a second lower cable, the lower outer groove also extends to the junction point of the second lower cable. In particular, the lower outer groove extends along the longitudinal axis X. In particular, the lower outer groove and the upper outer groove are aligned along the longitudinal axis X. Cables can run in the lower outer groove when two sandwich panels are positioned contiguously.

[0196]

[0123] The size of the lower outer groove 118 is adapted to the size of the electrical connectors and cables. In one variant, the height (taken along the Z axis) of the lower outer groove is superior or equal to the diameter of the electrical connector 46, 47, 52 or 53. In another variant, the width (taken along the Y axis) of the lower outer groove is superior or equal to the diameter of the electrical connector 46, 47, 52 or 53, preferably superior or equal to the diameter of two electrical connectors.

[0197]

[0124] The lower outer groove 118 and the upper outer groove 116 can have shapes that allow the overlapping of the lower outer groove on the upper outer groove when adjacent sandwich panels are assembled. In other words, at least a part of the lower outer groove of a first sandwich panel can be inserted in the upper outer groove of a second sandwich panel. In particular, the part of the lower outer groove positioned in the lower overlap area 22 can be inserted in the part of the upper outer groove positioned in the upper overlap area 23. Accordingly, in particular in the case where the upper outer hole 117 of a first sandwich panel is positioned below the upper overlap area as illustrated on Figure 14, once the lower overlap of a second sandwich panel has overlapped the upper overlap area of the first sandwich panel, the upper cable(s) of the first sandwich panel and the lower cable(s) of the second sandwich panel can run in the lower outer groove and the electrical connectors can be connected.

[0198]

[0125] In a variant of this embodiment, once adjacent sandwich panels have been assembled, a hood can be added. The hood covers the lower outer groove. Preferably, the hood integrally covers the lower outer groove and the upper outer groove. The hood protects the electrical connections from the environment.

[0199]

[0126] 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.

[0200]

[0127] In particular, at a first stage, the outer sheet 4 is prepared.

[0201]

[0128] 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 also comprises the forming of an upper outer groove 116 and / or the forming of a lower outer groove 118.

[0202]

[0129] In a second step, anterior to or concomitant with or posterior to the first step, a first upper perforation 27, 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 this step, an upper outer hole 117 is further done in the outer sheet. Optionally, a lower outer hole 119 is also done in the outer sheet.

[0203]

[0130] 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.

[0204]

[0131] 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.

[0205]

[0132] 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 and a first lower electrical connector 47. 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.

[0206]

[0133] At a second stage, posterior to the first stage, the outer sheet is provided.

[0207]

[0134] 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 be simply 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.

[0208]

[0135] 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.

[0209]

[0136] As illustrated on Figures 15 and 16, the mold comprises a bottom side 93, a top side 94, a first longitudinal side, a second longitudinal side, a first transverse side 126 and a second transverse side 127. 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.

[0137] 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. For the sake of clarity, if the outer sheet comprises an upper outer groove 116, the bottom side does not comprise a counterpart of the upper outer groove, so that a portion of the cables can be inserted between the outer sheet and the bottom side of the mold. Similarly, if the outer sheet comprises a lower outer groove 118, the bottom side does not comprise a counterpart of the lower outer groove, so that a portion of the cables can be inserted between the outer sheet and the bottom side of the mold.

[0210]

[0138] 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. In a variant, the shapes of the bottom side and of the top side are inverted.

[0211]

[0139] In particular, the first longitudinal side 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 of the mold can also be substantially a counterpart of the first longitudinal inner flange of the inner sheet. Accordingly, the first longitudinal side 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 of the mold can also be substantially a counterpart of the first longitudinal outer flange of the outer sheet. Accordingly, the first longitudinal side of the mold can comprise a counterpart of the external surface of the male protrusion 106, if any.

[0212]

[0140] In particular, the second longitudinal side 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 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 of the mold preferably comprises a counterpart of the external surface(s) of the inner tongue 73 and of the second inner stiffener 77, if any. In the case of the second embodiment of the longitudinal inner flanges, the second longitudinal side of the mold preferably comprises a counterpart of the external surface(s) of the second inner riser 72 and of the inner tenon 111.

[0213]

[0141] 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 of the mold can also be substantially a counterpart of the second longitudinal outer flange of the inner sheet. Accordingly, the second longitudinal side of the mold can comprise a counterpart of the external surface of the lower portion of the upper tenon 103.

[0214]

[0142] In particular, the first transverse side 126 of the mold is substantially a counterpart of the upper transverse side 7 of the insulation material and the second transverse side 127 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.

[0215]

[0143] 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 possibly once edge bands and / or caps have been positioned.

[0216]

[0144] At a fifth stage, posterior to or concomitant with the first stage and anterior to or concomitant with or posterior to any of the second, third and fourth stages, at least one of the first upper electrical connector 46 and the first lower electrical connector 47, with a downstream portion of its cable, is inserted in a groove 116, 118 in the outer sheet.

[0217]

[0145] In a first variant corresponding to the first embodiment of the cable positioning, a downstream portion of the first upper cable 42 with the first upper electrical connector 46, is inserted in the upper outer groove 116 formed in the outer sheet. They thus avoid been embedded in the insulation material. If applicable, a downstream portion of the second upper cable 50 with the second upper electrical connector 52 is inserted in the upper outer groove 116. In particular, the upper cable(s) are inserted in the upper outer groove through the upper outer hole 117 of the outer sheet.

[0218]

[0146] In this first variant, a downstream portion of the first lower cable 43 with the first lower electrical connector 47, is inserted in a hole in the second transverse side 127 of the mold. If applicable, a downstream portion of the second lower cable 51 with the second lower electrical connector 53 is inserted in a hole in the second transverse side of the mold. It can be the same hole for the first lower cable and the second lower cable.

[0219]

[0147] In a second variant corresponding to the second embodiment of the cable positioning, a downstream portion of the first lower cable 43 with the first lower electrical connector 47, is inserted in the lower outer groove 118 formed in the outer sheet. They thus avoid been embedded in the insulation material. If applicable, a downstream portion of the second lower cable 51 with the second lower electrical connector 53 is inserted in the lower outer groove 118. In particular, the lower cable(s) are inserted in the lower outer groove through the lower outer hole 119 of the outer sheet.

[0148] If the outer sheet has an upper outer groove 116, a downstream portion of the first upper cable 42 with the first upper electrical connector 46, is inserted in the upper outer groove 116. If applicable, a downstream portion of the second upper cable 50 with the second upper electrical connector 52 is inserted in the upper outer groove 116.

[0220]

[0149] If the outer sheet does not have an upper outer groove 116, a downstream portion of the first upper cable 42 with the first upper electrical connector 46, is inserted in a hole in the first transverse side 126 of the mold or in the bottom side of the mold or in the top side of the mold. If applicable, a downstream portion of the second upper cable 50 with the second upper electrical connector 52 is inserted in a hole in the first transverse side of the mold or in the bottom side of the mold or in the top side of the mold. It can be the same hole for the first upper cable and the second upper cable.

[0221]

[0150] This fifth stage can be performed while the outer sheet is being prepared or at any other time between the preparation of the outer sheet and the laying of the insulation.

[0222]

[0151] For this purpose, in a first variant illustrated on Figure 15, 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 is preferably an upper through-hole 97, for accommodating a part of the downstream portion(s) of the upper cable(s), and a lower through-hole 98, for accommodating a part of the downstream portion(s) of the lower cable(s). In particular, the upper through- hole 97 is in the first transverse side 126 of the mold or in the bottom side 93 or in the top side 94 of the mold. In particular, the lower through-hole 98 is in the second transverse side 127 of the mold.

[0223]

[0152] 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.

[0224]

[0153] 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.

[0225]

[0154] To ease the illustration of the mold, the upper through-hole 97, the lower through-hole 98 and the recess 99 have been positioned in the first transverse side 126 of the mold.

[0226]

[0155] In a second variant illustrated on Figure 16, the mold can comprise holes in the form of hollow spaces in the inner surface of the side. There is preferably an upper hollow space 100, for the downstream portion(s) of the upper cable(s) and their corresponding electrical connector(s), and a lower hollow space 101 , for the downstream portion(s) of the lower cable(s) and their corresponding electrical connector(s). In particular, the upper hollow space 100 is in the first transverse side 126 of the mold or in the bottom side 93 or in the top side 94 of the mold. In particular, the lower hollow space 101 is in the second transverse side 127 of the mold.

[0227]

[0156] To ease the illustration of the mold, the upper hollow space 100 and the lower hollow space 101 have been positioned in the second longitudinal side of the mold.

[0228]

[0157] 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 can comprise a lid that seals the hollow space once the electrical connector(s) and the downstream portion(s) of the cable(s) have been inserted.

[0229]

[0158] 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.

[0159] 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.

[0230]

[0160] The fourth, fifth, sixth and seventh stages are detailed below in relation to the nature of the insulation material. Overall, during these four stages and in no specific order, the outer sheet is positioned in the mold, at least one of the first upper electrical connector and the first lower electrical connector, with a downstream portion of its cable, is inserted in a groove formed in the outer sheet, insulation is put in place and the inner sheet is maintained at a given distance from the outer sheet.

[0231]

[0161] 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 portions of the cables are sheltered from the insulation material before injecting the reaction mix.

[0232]

[0162] In a first variant, the outer sheet is positioned upside down in the mold. The downstream portions of the cables are inserted in outer groove(s) or in hole(s) in the side(s) 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 and second longitudinal side of the mold so that it is at the given distance from the outer sheet.

[0233]

[0163] In a second variant, downstream portion(s) of cable(s) are inserted in outer groove(s) while the outer sheet is being prepared. Then, the outer sheet is positioned upside down in the mold. If appropriate, other downstream portion(s) of cable(s) are inserted in hole(s) in the side(s) of the mold. Then, the inner sheet is positioned in the mold, on the first longitudinal side and second longitudinal side of the mold so that it is at the given distance from the outer sheet.

[0234]

[0164] In a third variant, the downstream portion(s) of the cable(s) are inserted in the outer groove(s) while the outer sheet is being prepared. Then, the inner sheet is positioned upside down in the mold. Then, the outer sheet is positioned in the mold, on the first longitudinal side and second longitudinal side of the mold so that it is at the given distance from the inner sheet.

[0235]

[0165] Then, in all three variants, the top side is put in place.

[0236]

[0166] In a fourth variant, downstream portion(s) of cable(s) are inserted in outer groove(s) while the outer sheet is being prepared. Then, the inner sheet is positioned upside down in the mold. Then, the outer sheet is positioned in the mold, on the first longitudinal side and second longitudinal side of the mold so that it is at the given distance from the inner sheet. Then, while the top side is put in place, other downstream portion(s) of cable(s) are inserted in hole(s) in the top side of the mold.

[0237]

[0167] Then, in all fourth 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.

[0238]

[0168] 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.

[0239]

[0169] In a second embodiment of the manufacturing process, the insulation material is in the form of slabs.

[0240]

[0170] In a first variant, the outer sheet is positioned upside down in the mold. The downstream portions of the cables are inserted in outer groove(s) or in hole(s) in the side(s) 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.

[0241]

[0171] In a second variant, the downstream portion(s) of the cable(s) are inserted in outer groove(s) while the outer sheet is being prepared. Then, the outer sheet is positioned upside down in the mold.

[0242]

[0172] In a third variant, downstream portion(s) of cable(s) are inserted in outer groove(s) while the outer sheet is being prepared. Then, the outer sheet is positioned upside down in the mold. Then, other downstream portion(s) of cable(s) are inserted in hole(s) in the side(s) of the mold.

[0243]

[0173] In all three variants, a layer of adhesive is then applied to the backside of the outer sheet and slabs of insulation material are positioned. 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 and second longitudinal side of the mold so that it is at the given distance from the outer sheet. Then the top side is put in place. Then, 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.

[0244]

[0174] Finally, for both embodiments, the sandwich panel can be removed from the mold.

[0245]

[0175] 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 Figure 17, 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.

[0246]

[0176] 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.

[0247]

[0177] 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. In some variants, it can also take place right after the fastening of the second sandwich panel. In some variants, it can also take place once all the sandwich panels of a row have been positioned and fastened. In some variants, 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.

[0248]

[0178] According to a first variant (not illustrated), where the sandwich panel is according to the first embodiment of the cable positioning illustrated on Figures 11 and 12, while the second sandwich panel is being positioned, the first upper electrical connector 46 and part of the first upper cable 42 of the first sandwich panel are inserted in the upper outer groove 116 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 upper outer groove 116 of the first sandwich panel. The upper electrical connector and the first lower electrical connector are then connected.

[0249]

[0179] 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.

[0250]

[0180] According to a second variant (not illustrated), where the sandwich panel is according to the second embodiment of the cable positioning illustrated on Figures 13 and 14 and with an upper outer groove, the first upper electrical connector 46 and part of the downstream portion of the first upper cable 42 of the first sandwich panel are inserted in the upper outer groove 116 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 outer groove 118 of the second sandwich panel. The upper electrical connector and the first lower electrical connector are then connected. Optionally, the upper outer groove and the lower outer groove are then covered by a hood.

[0251]

[0181] 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,- 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, a second longitudinal side, a first transverse side (126) and a second transverse side (127),- Inserting at least one of the first upper electrical connector and the first lower electrical connector, with a downstream portion of its cable, in a groove (116, 118) 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) and the first lower electrical connector (47).3) Process according to any one of claims 1 or 2, wherein the groove in the outer sheet is an upper outer groove (116) extending from an upper transverse outer edge (13) of the outer sheet up to at least an upper outer hole (117) in the outer sheet.4) Process according to claim 3 wherein the upper outer groove (116) is positioned in a second longitudinal rib (21 ) of the outer sheet.5) Process according to any one of the preceding claims, wherein the groove in the outer sheet is a lower outer groove (118) extending from a lower transverse outer edge (14) of the outer sheet up to at least a lower outer hole (119) in the outer sheet.6) Process according to claim 5 wherein the lower outer groove (118) is positioned in a second longitudinal rib (21 ) of the outer sheet.7) 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).8) Process according to any one of claims 1 to 6 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.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 andthe first upper electrical connector being corresponding male and female connectors, the first upper cable having:- an upstream portion running from the first upper electrical conductor to the outer sheet and running through the insulation material,- a downstream portion with the first upper electrical connector, freely extending from the outer sheet, the first lower cable having:- an upstream portion running from the first lower electrical conductor to either the lower transverse side of the insulation material or the outer sheet and running through the insulation material,- a downstream portion with the first lower electrical connector, freely extending either from the lower transverse side of the insulation material or from the outer sheet. )Sandwich panel according to claim 9 comprising an upper outer groove (116) extending from an upper transverse outer edge (13) of the outer sheet up to at least the junction point of the upstream portion and the downstream portion of the first upper cable (42). )Sandwich panel according to any one of claims 9 or 10 comprising a lower outer groove (118) extending from a lower transverse outer edge (14) of the outer sheet up to at least the junction point of the upstream portion and the downstream portion of the first lower cable (43). )Sandwich panel according to claim 9 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 thesecond 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 comprising:- an upstream portion running from the second upper electrical conductor to the outer sheet and running through the insulation material,- a downstream portion with the second upper electrical connector, freely extending from the outer sheet, the second lower cable comprising:- an upstream portion running from the second lower electrical conductor to either the lower transverse side of the insulation material or the outer sheet and running through the insulation material,- a downstream portion with the second lower electrical connector, freely extending either from the lower transverse side of the insulation material or from the outer sheet. )Sandwich panel according to claim 12 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. )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 13,- (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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