Modular insulating block

Abstract

The present invention relates to a modular filler block comprising a plurality of sub-units held together by means of a holding product (103). The present invention also relates to a method for producing such modular blocks.

Description

Modular insulating block technical field

[0001] The present invention relates to the field of construction. In particular, the present invention relates to a filling block for ensuring the technical equipment of a building after the construction of its concrete structure. The filling block also makes it possible to protect workers during construction, notably by preventing falls into the hollow spaces created in the concrete structure. The present invention further relates to a method for producing such filling blocks. State of the art

[0002] Fill blocks such as those described in application EP3730722 are often used to create gaps in a concrete structure. They are placed before the concrete is poured. Such blocks often need to be profiled to ensure they are properly embedded in the concrete, which requires specific manufacturing steps to produce the appropriate three-dimensional geometry.

[0003] Document US2016090738 proposes modular, fire-resistant backfill blocks. Different subunits can be assembled according to field requirements. The assembly of the subunits also requires a suitable three-dimensional profile. In particular, grooves or notches are provided to prevent transverse misalignment of the subunits.

[0004] Three-dimensional profiles are generally fitted onto the edges of the infill blocks, allowing them to be modulated within a plane. The subunits remain free to separate within their assembly plane. The entire assembly must therefore be held together by concrete. The sub- Firesy-7-PCT units cannot generally be assembled in thickness, for example to allow adaptation to different thicknesses of concrete slab.

[0005] There is therefore room for improvement in the infill blocks, so that they offer greater modularity. Furthermore, it is advantageous to offer modular blocks that are less expensive than those currently in use. Brief summary of the invention

[0006] One aim of the present invention is to provide a modular filling block, allowing its dimensions, particularly its thickness, to be adapted. Another objective is to provide a block whose properties are either alternatively or additionally modular. A further objective is to provide a block whose properties, such as mechanical strength, fire resistance, and density, can be adjusted.

[0007] Another objective of the present invention is to provide a method for manufacturing such a filling block. In particular, it is desirable to provide a method that is easy to implement and inexpensive.

[0008] According to the invention, these goals are achieved in particular by means of the modular block which is the subject of the main claim, the manufacturing process which is the subject of claim 10 and detailed in the claims which depend on it.

[0009] The block described here offers several advantages over previous designs, including greater modularity and easier implementation. Furthermore, production costs are lower compared to existing blocks. FIRESY-7-PCT Brief description of the figures

[0010] Examples of implementation of the invention are shown in the description illustrated by the following figures: • Figure 1: Schematic perspective view of a block according to an embodiment of the present invention, and its use in the construction of a building, • Figure 2: Schematic cross-sectional and exploded view of a block according to an embodiment of the present invention, • Figure 3: Schematic cross-sectional view of a block according to an embodiment of the present invention, • Figure 4: Schematic cross-sectional and exploded view of a block according to another embodiment of the present invention, • Figure 5: Schematic cross-sectional view of a set of blocks according to an embodiment of the present invention, • Figure 6: Deformation test diagram (in millimeters) of a block according to the present invention as a function of the pressure exerted (in Newtons) Example(s) of an embodiment of the invention

[0011] With reference to Figure 1, the filling block 100 according to the present invention is intended to fill a space 10 provided in a solid structure 1 of a building. Such a solid structure 1 refers in particular to a horizontal slab or a vertical partition, which may be made of concrete or any other construction material. The structure FIRESY-7-PCT For example, "solid" can refer to a wall, load-bearing or not, or a partition, which can be made of rubble, plaster, aerated concrete, brick, stone, or any equivalent material. The modular block according to the present invention is also applicable to structures made of wood, metal, and / or composite or polymer materials.

[0012] Space 10 refers to an opening, generally passing completely through the solid structure 1. Space 10 can be prepared for future installation of equipment such as doors and windows, service ducts, ventilation shafts, electrical cables, or any other equipment necessary for the use of the building.

[0013] The block 100 according to the present invention can be designed to be placed in a predetermined location before the concrete is poured, thus avoiding the need to drill into the structure 1 after its construction. Alternatively, the block according to the present invention can be fixed afterward in the space 10, replacing a previous infill element and / or serving as an initial device before construction continues.

[0014] The modular design of the 100 infill block allows for optimal adaptation to site conditions. Indeed, the dimensions of the spaces 10 created within architectural structures are not always standard and require adapting the systems installed within them. Prefabricated infill blocks may not be suitable. Depending on the application, the materials of existing infill blocks may also be unsuitable. For example, insulating or fire-resistant blocks may lack robustness and not provide sufficient safety for construction workers. This is particularly crucial for spaces 10 located within horizontal slabs, where workers and sometimes loads pass through. The modular block according to the present invention allows for the combination of several materials as needed.

[0015] A block according to the present invention consists of several subunits combined together. The different subunits may have FIRESY-7-PCT Different dimensions, in terms of thickness, width, or length, allow the block dimensions to be adapted to specific needs. Furthermore, the various subunits can be made of different materials, or alternatively, allowing for a combination of advantages.

[0016] According to one embodiment, a block 100 comprises a first subunit 101 and one or more other subunits 102, 102', as illustrated in detail in figures 2 to 5.

[0017] The subunits are preferably in the form of square or rectangular plates of constant thickness, which facilitates their manufacture and storage. Triangular plates may nevertheless be considered as needed. Other geometries are also possible. The first subunit 101 has a first thickness E101. Here, "thickness" is understood in its usual sense. It refers, for example, to the smallest dimension of the parallelepiped-shaped subunit. The first subunit 101 also has a transverse dimension D101. For the sake of simplicity, the transverse dimension refers to either the width or the length of the subunit. However, it is possible to specifically define a transverse dimension and a longitudinal dimension, designating the width and length of the subunit, respectively.

[0018] A subunit according to the present invention comprises at least one contact surface. As such, the first subunit, for example, comprises a first contact surface 111. A contact surface, in this context, refers to the surface in contact with another subunit. Contact surfaces are preferably planar. They may be the largest faces of the parallelepiped formed by the subunits. This does not preclude the fields of the subunits from serving as contact surfaces.

[0019] According to one embodiment, the first contact surface 111 of the first subunit 101 designates one of the wider faces. The filling block 100 comprises a second subunit 102, comprising a FIRESY-7-PCT second contact surface 112, which is placed opposite the first contact surface 111. The second subunit 102 can be of the same size and composition as the first subunit 101. In this sense, two first subunits 101 can be associated with each other to form a plate of greater thickness but of the same transverse dimensions, or of the same thickness as the subunits but of greater transverse dimension.

[0020] This arrangement, however, allows the subunits to be offset from one another, producing a 200° offset, visible, for example, in Figure 3. Alternatively, this arrangement allows subunits made of different materials to be combined. For example, the first subunit could be made of glass wool, providing optimal sound and thermal insulation, and the second subunit of a stronger material such as rock wool, compacted cellulose, or a composite material, ensuring greater robustness for the block. Alternatively, a subunit made of a hydrophobic or waterproof material could be combined with a subunit containing an insulating material.

[0021] The second subunit may have a second thickness E102. The second thickness may be identical to or different from the first thickness E101. The second subunit 102 may also have a second transverse dimension D102 that is identical to or different from the first transverse dimension D101. The second contact surface 112 of the second subunit 102 is positioned opposite the first contact surface 111.

[0022] In one embodiment, the first 101 and second 102 subunits are superimposed, meaning that one of their largest surfaces is used as the contact surface. The resulting filling block 100 then has a thickness E100 greater than the first E101 and second E102 thicknesses of the subunits that compose it. In this case, the thickness E100 of the block corresponds approximately to the sum of the first E101 and second E102 thicknesses. FIRESY-7-PCT

[0023] Alternatively, or in addition, the second subunit may have a second transverse dimension D102 that differs from the first transverse dimension D101. The superposition of the first 101 and second 102 subunits then results in a block 100 with a transverse dimension D100. The transverse dimension D100 of block 10 may, for example, correspond to the larger transverse dimension of the two subunits, or to an even larger transverse dimension if the two subunits are assembled in a staggered manner. The resulting offset 200 (Figure 3) can be located on either or both edges of block 100, as required. Naturally, such an arrangement applies whether the transverse dimensions refer to width or length.

[0024] Between the first 111 and second 112 contact surfaces, at least one holding agent 113 is placed to bond the first 101 and second 102 subunits together. Such a holding agent may be an adhesive, such as a liquid adhesive applied to a surface before the two subunits are brought into contact. This adhesive may be a multi-component adhesive, an air-curing adhesive, or any other suitable type of adhesive. For example, such adhesives may be based on neoprene, epoxy, or isothiazole derivatives. Bringing the contact surfaces into contact with the adhesive then permanently bonds the two subunits together. Alternatively, or in addition, the holding agent may be in the form of a film, which is sometimes easier to handle than a liquid or paste adhesive. Such a film may also provide greater strength to the block 100 resulting from the combination of the subunits.The film (not shown) can be made of a non-stretch polymer, for example, and thus acts as reinforcement. Such a film can be pre-glued so that it can be applied to the contact surface and adhere to it. In one embodiment, the film can be glued on both sides, forming a double-sided adhesive.

[0025] In another embodiment, the contact surfaces of two subunits can be equipped with mechanical retaining elements, such as plugs or inserts embedded in the subunits. Specifically, when the subunits are composed of soft materials such as rock wool, glass wool, or polystyrene, FIRESY-7-PCT Inserts can be easily embedded in them. Such inserts can, for example, have anti-return points, shaped like a harpoon or an arrow, thus preventing the subunit from being pulled out. Plugs with anti-return points at each end allow two subunits to be joined per anchor point. The inserts can be used alone or in combination with adhesive or a retaining film.

[0026] The combination of subunits to form block 100 can be carried out at the factory, either during the manufacturing of block 100 or when preparing an order, using the available subunits. In addition to gluing the contact surfaces 111, 112, the combination of subunits may involve pressing, heating, drying, or any other necessary step. This does not preclude subunits from being independently delivered to the field and assembled on-site.

[0027] In one embodiment, more than two subunits are combined to form a block 100, as illustrated in Figure 4. This makes it possible, in particular, to produce filling blocks 100 with a suitable three-dimensional profile without having to machine a block of raw material. A first subunit 101 can be placed between a second 102 and a third 102' subunits whose second D102 and third D102' transverse dimensions are greater than the first transverse dimension D101 of the first subunit 101. The block 100 thus obtained forms on its edge a groove or longitudinal recess with a width corresponding to the first thickness E101 of the first subunit 101. Such a profile is sometimes necessary to stabilize the block 100 within the rigid structure 1. Such a block can, for example, be inserted between two bars or two solid surfaces via these grooves and thus fill an open space 10.One advantage is that the dimensions of the lateral groove can easily vary by selecting the dimensions of the subunits, both in their thickness and in their transverse dimension.

[0028] In such a configuration, a subunit can have more than one contact surface. This is the case here for the first subunit 101 which FIRESY-7-PCT It comprises two initial contact surfaces 111, 111', opposed to each other. In one embodiment, the retaining agent 103 is the same for all subunits. This arrangement is not, however, essential. Indeed, depending on the materials used, several retaining agents can be selected. As illustrated in Figure 4, a first retaining agent 103 can be placed between the first subunit 101 and the second subunit 102. A second retaining agent 103' can be placed between the first subunit and the third subunit 102'. If, for example, the first 101 and second 102 subunits are made of rock wool, a suitable adhesive can be used between these two subunits.If the third subunit is a composite material, for example to give the block greater robustness or to waterproof it, a special adhesive can be used as a second retaining product, placed between the first subunit and the third subunit.

[0029] The modular block according to the present invention is not limited to adjusting its thickness. Since the contact surfaces can be the fields of the subunits, the total surface area of ​​the block can be extended by combining several subunits.

[0030] According to an embodiment detailed in Figure 5, several 100, 100' infill blocks as described herein can be combined so as to remain permanently assembled. The assembly thus forms a single-piece device that can be easily handled. A first block 100 can be designed to include at least one first notch 200. A second block 100' can be designed similarly, with a second notch 200' complementary to the first notch. The surfaces of the first 200 and second 200' notches can be provided with a retaining agent such as an adhesive or the inserts described above. In particular, inserts 104 can be inserted into either of the notches 200, 200' so as to join the two blocks. The notch thus provides a larger contact surface between the two assembled blocks and consequently greater robustness.Although Figure 5 depicts blocks formed from two subunits, this does not exclude blocks with more than two subunits, as illustrated in the. FIRESY-7-PCT Figure 4, are also assembled. The longitudinal groove of a block 100 can serve as a notch to insert the offset of an adjacent block. The transverse dimension D200 of the assembly of blocks 100 is thus enlarged compared to those of the subunits used.

[0031] Since the subunits are in the form of plates, they can easily be cut on site before assembly. Specific three-dimensional profiles can then be produced easily and without machining.

[0032] The thickness of the subunits can range from 10 mm to 300 mm. For example, it could be approximately 10 mm, 25 mm, 50 mm, 75 mm, 100 mm, or 125 mm, or any intermediate value. The thickness of a block 100, comprising two superimposed subunits, can range from 20 mm to 600 mm. For example, it could be approximately 530 to 550 mm. Superimposing more than two subunits results in greater thicknesses.

[0033] The modular blocks according to the present invention can meet a variety of requirements. For example, they can be fire-resistant, with a fire resistance of at least 30 minutes, or even 60 minutes, or 90 minutes or more. Fire resistance is determined, for example, according to the provisions of the applicable AEAI standard. For this purpose, at least one of the subunits can be made of rock wool, an RF1 material as defined in the currently applicable fire protection directive "Building Materials and Elements," and is particularly suitable for this purpose. The density is preferably at least 150 kg / m³. 3 even 170 kg / m 3 .

[0034] Alternatively or in addition, a block according to the present invention can meet static mechanical strength requirements, in particular crushing strength. In particular, at least one of the subunits constituting the block can withstand a pressure of more than 100 kg or 200 kg, or even more than 300 kg, or even more than 400 kg or 500 kg, for a surface area of ​​1 m². 2 or 1.5m 2 , or even 2 m 2 . FIRESY-7-PCT

[0035] According to one embodiment, a block according to the present invention, comprising two superimposed subunits, resists pressure exceeding 200 kg, or even exceeding 300 kg, or even exceeding 400 kg or 500 kg for a surface area of ​​1 m² 2 or 1.5m 2 , or even 2 m 2 and resists fire for at least 30 minutes, or even 60 minutes, or even 90 minutes and more.

[0036] According to one embodiment, the material of block 100 according to the present invention, or of at least one of its subunits, is sufficiently malleable to be hollowed out by hand, or with the aid of a hand tool such as a blade or a trowel. In this way, it can be hollowed out at least partially to allow the passage of equipment such as a pipe or a technical duct.

[0037] According to one embodiment, the block 100 according to the present invention is covered on at least one of its faces with a layer of waterproof material. Such a waterproof layer may be a layer of aluminum, or a polymer layer such as a plastic material, or a mixture of several layers of different materials.

[0038] Alternatively or in addition, block 100 can be coated with fire-retardant paint.

[0039] According to one embodiment, a block according to the present invention comprises one or more fastening devices (not shown) for attaching it to a solid structure 1. Such fastening devices include mounting brackets, angle brackets, slides, lugs, or any suitable element. The fastening devices may have recesses or holes for the passage of screws, bolts, or rivets. The fastening devices may be present on the subunits prior to their assembly. Alternatively, they may be added to the block 100 as required. For example, fastening devices may be arranged on the edges of the block 100 to hold it to the solid structure 1 once it is placed in the hollow space 10. FIRESY-7-PCT

[0040] For the purposes of the present invention, the terms "horizontal" and "vertical," as well as related terms, shall have their usual meanings. Thus, in the field of construction to which the present invention relates, a slab is usually arranged horizontally and a wall vertically.

[0041] Depending on the requirements, the properties of block 100 can be adjusted across several levels of performance, including sound insulation, thermal insulation, fire resistance, pressure resistance, tensile strength, density, and cost. These properties can be adjusted using selected subunits.

[0042] The present invention also covers a method for manufacturing a block 100 as described herein. The manufacturing process includes a step of selecting a first subunit 101 and at least one second subunit 102. The selection of a subunit relates, for example, to dimensions such as its thickness or its cross-sectional dimension. Alternatively, or in addition, the selection may relate to the material constituting the subunit. The manufacturing process may include a step of adjusting one or more of the dimensions of the subunits. Preferably, the thickness is not adjusted, but one or more of the cross-sectional dimensions can easily be adjusted, for example, by sawing or any other cutting operation.

[0043] The manufacturing process includes a step of applying a bonding agent to at least one of the contact surfaces of the first subunit and another subunit to be joined. The contact surfaces are identified beforehand according to the block to be produced. The bonding agent can be applied using a method appropriate to its nature, for example, by spraying, by application with a roller or spatula, or by deposition using a dispenser or cartridge when it is a fluid product such as an adhesive. It can be applied by applying a film to the contact surface in question. It can be applied by dot-tapping or pressing in the case of inserts. Other suitable methods may be considered. FIRESY-7-PCT

[0044] The process includes a step of combining the first subunit with another subunit, via the retaining agent, so as to bond the subunits together by contact. In addition to bringing the contact surfaces of the two subunits into contact, the process may include pressing, heating, drying, or any other operation useful for finalizing the combination of the subunits.

[0045] The process may involve combining a third or more subunits by iterating the steps previously described.

[0046] The process may also include a step of combining several blocks thus produced, according to the same operations as those described here. The blocks are preferably designed with recesses to facilitate their combination.

[0047] The process may also include one or more coating steps. In particular, a block or a set of blocks thus obtained may be coated with paint, especially fire-retardant paint. Alternatively, they may be coated with a water-repellent or waterproofing agent. Alternatively, a block or a set of blocks may be coated with a chemical treatment such as an antifungal or stabilizing agent. Example A crush test of a block of rock wool with a density of 170 kg / m³ 3 The sample, consisting of two superimposed and glued subunits, is made. The sample has a width of 400 mm and a length of 1200 mm. The rock wool panels are set in concrete within a concrete frame (1400 x 650 x 250 mm). FIRESY-7-PCT The load is applied cyclically with an articulated test punch (500 cycles, maximum load per cycle: 2.5 kN, cycle duration: 5 seconds). The test parameters are as follows: Maximum load per cycle [kN] 2.5 Number of cycles [-] 500 Cycle duration [s] 5 Maximum load [kN] 12.4 Once the 500th cycle is completed, the force is progressively increased (speed: 50 mm / min) until the end of the test. The observed deformation occurs due to the continuous indentation and tearing of the rock wool around the test punch. At maximum load, the piston stroke is approximately 72 mm. The test ends when the rock wool plate, which flares out at the bottom, comes into contact with the test table. The deformation and force are recorded and represented by the graph in Figure 6. FIRESY-7-PCT Reference numbers used in the figures 1 Slab 10 Space 100 Filling block 101 First subunit 111 First contact surface 102, 102' Second subunit 112 Second contact surface 112' Third contact area 103, 103' Maintenance product 104 Insert 200, 200' Detachment E100 Block thickness E101 First layer E102 Second thickness E102' Third layer D101 First transverse dimension D102 Second transverse dimension D102' Third transverse dimension D200 Total transverse dimension FIRESY-7-PCT

Claims

Demands 1. Modular backfill block comprising a first subunit (101) of first thickness (E101) and first transverse dimension (D101), and at least one second subunit (102) of second thickness (E102) and second transverse dimension (D102), the first (101) and second (102) subunits each comprising a first contact surface (111) and a second contact surface (112) and being held together by means of a retaining product (103) disposed in contact with said first (111) and second (112) contact surfaces.

2. Filling block according to claim 1, said first (111) and second (112) contact surfaces being flat.

3. Block according to any one of claims 1 and 2, said first and at least one second subunit being superimposed, so as to produce a filling block (100) of thickness (E100) greater than each of the first (E101) and second (E102) thicknesses.

4. Block according to any one of claims 1 to 3, said first (D101) and second (D102) having different transverse dimensions, so as to produce a filling block (D100) of which at least one of the slices has a step (200).

5. Block according to any one of claims 1 to 4, comprising a third subunit (102') of third thickness (E102') and third transverse dimension (D102') and comprising at least a third contact surface (112').

6. Block according to claim 5, the third subunit (102') being associated with one of the first (101) or second (102) subunits by means of said retaining product (103'). FIRESY-7-PCT 7. Block according to any one of claims 1 to 6, said retaining product (103, 103') being selected from an adhesive, an adhesive film, a double-sided adhesive film, inserts or a combination thereof.

8. Block according to any one of claims 1 to 7, the material of said first (101) and at least one second (102, 102') subunits being independently selected from rock wool, glass wool, compacted glass wool, a cellulosic material such as cardboard, an expanded polymer such as polystyrene, a composite material.

9. Block according to any one of claims 1 to 8, further comprising a device for fixing to a solid structure.

10. Method of manufacturing a block (100) according to any one of claims 1 to 9, comprising a step of selecting a first subunit (101) and at least one second subunit (102, 102') according to their size and / or composition, of identifying at least one contact surface on the first subunit and on at least one second subunit, of applying a retaining agent (103, 103') to said contact surfaces, and of combining said subunits so as to make them bonded.

11. Method according to claim 10, further comprising a step of combining several blocks, said blocks each comprising several subunits arranged so as to provide at least one step (200, 200') on each of the blocks.

12. A method according to any one of claims 10 and 11, further comprising a step of treating the block(s) obtained, such as a waterproofing coating, a fire-retardant paint or a chemical treatment. FIRESY-7-PCT

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