EP1573147B1 - Panel for wall thermoacoustic insulation - Google Patents

Abstract

The mattress (2) has fibers coated with a binder. The binder has longitudinal borders for forming a relief zone. The zone is inclined with respect to a principal face of the mattress, which is covered by a facing (3). The zone is adapted to receive a part (5), which is folded back. The part arising from the facing is adhered to a surface. Independent claims are also included for the following: (a) a panel for a roof (b) a roof including mattress (c) an industrial building wall, residential wall, tertiary sector, or agricultural forming support including mattress (d) a method for manufacturing a mattress (e) a device for manufacturing a mattress.

Description

The present invention relates to a primitive for a panel intended to ensure the thermo-acoustic insulation, in particular under seal and / or under finish, of walls constituted by supporting elements or support elements made of ribbed steel sheets, of wood or concrete .

These panels consist essentially of a primitive formed from a mat of mineral wool, rock or glass, of high density (density between 50 to 400 kg / m ³ ), according to ranges of thickness between 20 to 300 mm and a facing disposed on a main face of said primitive. These panels are generally positioned and secured by gluing, by mechanical attachment to support members or horizontal or vertical walls, inclined or curved, which are more particularly intended for industrial or residential buildings, in an application of the work new or renovation.

These parallelepipedally shaped panels have two main faces and four longitudinal edges respectively parallel two by two, generally perpendicular to these main faces; these panels are intended to be juxtaposed to similar panels along their longitudinal edges so as to compose an insulation system of an industrial building, residential, tertiary or agricultural.

A first family of panels made from a primitive formed from a mineral wool mat and a facing disposed on one of the main faces of said primitive is known. The main disadvantage of this type of panel lies in the fact that it offers a reduced resistance to tearing, in particular, the facing, following a gust of wind, may have a tendency to separate from the primitive.

To solve this problem of resistance to tearing, it was necessary to design a second family of panels that differs from the previous in that the facing is folded or flanged on the other main face of the panel (this other the main face is the one opposite to that facing the facing); in this way the flaps do not offer wind resistance, and the resistance to tearing is significantly improved.

This type of panel is described for example in the European patent EP 0 109 879 or in the French patent FR 2 679 279.

However, in order to anticipate the requirements of the regulatory provisions, both in terms of their mechanical strength as well as their acoustic and / or thermal insulation properties, as well as their performance with respect to fire, even more efficient materials are desirable

Indeed, among the most stringent and most stringent standards, we note the regulatory provisions for fire safety, whether a fire from inside or outside. A fire is said to be "a fire from within" when the flames originate or spread inside an enclosure, and on the contrary, a fire is called "fire from outside" when, on the contrary, flames are located outside the enclosure.

However, for panels coated with an asphalt facing, the respect of these normative conditions, especially in terms of fire resistance, is problematic, the asphalt facing, especially when it is folded or flanged on the face of the panel which is directed inward, is likely to constitute a vector for the propagation of the flame.

The object of the present invention is to propose a primitive making it possible to manufacture an insulating panel that can act as a fire barrier, this panel being covered with a facing, said facing being moreover able to withstand a tearing force ( especially that of the wind).

In the present invention, by facing is defined any coating in the form of a thin sheet whose thickness is less than 5 mm, and in particular close to 1 mm, and having an ability to bend, bend, a deformation allowing him to marry one of the faces of the panel.

The substantially parallelepiped-shaped panel according to the invention comprises a primitive according to claim 1.

The area in relief, which in the present invention can be constituted by a hollow zone or a hump zone, is sufficiently large in section and depth to allow the flap to fit within the raised area so that there is no over-thickness of material on the longitudinal edge of said panel.

• Extérieur : est utilisé lorsque le panneau est solidaire d'un élément formant support d'une enceinte, l'une de ses faces principales (celle qui est revêtue du parement) est alors dirigée vers l'extérieur de l'enceinte.
• Intérieur: est utilisé lorsque le panneau est solidaire d'un élément formant support d'une enceinte, l'une de ses faces principales (celle qui est en contact avec le support) est alors dirigée vers l'intérieur de l'enceinte.

For a better definition of the invention, the following terms will also be defined:

• Exterior: is used when the panel is secured to a support member of an enclosure, one of its main faces (that which is coated facing) is then directed outwardly of the enclosure.
• Inside: is used when the panel is secured to a support member of an enclosure, one of its main faces (the one that is in contact with the support) is then directed towards the inside of the enclosure.

• la zone en relief est réalisée sur une fraction de l'épaisseur du matelas, au droit d'une face principale dudit matelas, cette zone en relief délimitant deux zones contiguës,
• le matelas est pourvu d'au moins deux zones en relief, chacune de ces zones étant positionnée sur un bord longitudinal dudit matelas,
• le bord longitudinal comportant la zone en relief est incliné par rapport à la face principale du matelas devant être revêtue du parement, selon un angle supérieur à 90 °,
• la zone en relief est réalisée sous la forme d'un évidement de matière,
• la zone en relief est réalisée sous la forme d'une excroissance de matière.

In preferred embodiments of the invention, one or more of the following may also be used:

• the zone in relief is made on a fraction of the thickness of the mattress, to the right of a main face of said mattress, this zone in relief delimiting two contiguous zones,
• the mattress is provided with at least two zones in relief, each of these zones being positioned on a longitudinal edge of said mattress,
• the longitudinal edge comprising the raised area is inclined relative to the main face of the mattress to be coated facing, at an angle greater than 90 °,
• the area in relief is made in the form of a recess of material,
• the area in relief is made in the form of an outgrowth of material.

According to another aspect of the invention, it relates to a panel consisting essentially of a primitive as described above and a facing,

Advantageously, the facing of the panel comprises at least one flap, said flap being received in at least one raised area made at a longitudinal edge of said panel, said flap being intended to cooperate at said raised area at the using a means of adhesion, including bitumen.

According to another preferred embodiment, the panel comprises two raised areas, each of these raised areas receiving a flap of said facing.

According to another advantageous characteristic, the facing is essentially constituted by a veil of glass coated with bitumen, said facing being optionally reinforced by a glass grid.

According to another preferred variant, the facing is essentially constituted by a kraft.

According to still other advantageous characteristics, the kraft comprises at least one water-repellent treated surface and presents, on the one hand, a smooth appearance and, on the other hand, a better distribution of the mechanical stresses.

According to another preferred variant, the facing is a reagent support for bonding.

This reagent support is a chemical agent (for example a primer in particular) which improves the adhesion with a coating that will be reported later on the facing.

The present invention also relates to a roof consisting of load-bearing elements of ribbed steel sheets, wood or concrete, on which is fixed a plurality of panels as previously described.

It also aims and more generally any wall of industrial building, residential, tertiary or agricultural forming support on which is fixed a plurality of panels in accordance with the preceding provisions.

• la figure 1 est une vue illustrant un mode de réalisation d'un panneau appartenant à une première famille connue de panneaux ;
• la figure 2 est une vue illustrant un mode de réalisation d'un panneau appartenant à une deuxième famille connue de panneaux ;
• la figure 3 est une vue en perspective d'un panneau selon l'invention ;
• la figure 4 est une vue en perspective illustrant la juxtaposition d'une pluralité de panneaux selon la figure 3, en vue de réaliser une toiture ;
• les figures 5 et 6 illustrent divers modes de réalisation d'un panneau selon l'invention. La figure 7 illustre un mode de réalisation qui ne fait pas partie de l'étendue de la protection de l'invention revendiquée.

Other features and advantages of the invention will become apparent from the following description of several of its embodiments, given by way of non-limiting example. In the figures:

• Figure 1 is a view illustrating an embodiment of a panel belonging to a first known family of panels;
• Fig. 2 is a view illustrating an embodiment of a panel belonging to a second known family of panels;
• Figure 3 is a perspective view of a panel according to the invention;
• Figure 4 is a perspective view illustrating the juxtaposition of a plurality of panels according to Figure 3, to achieve a roof;
• Figures 5 and 6 illustrate various embodiments of a panel according to the invention. Fig. 7 illustrates an embodiment that does not fall within the scope of protection of the claimed invention.

The known panel shown in FIG. 1 is of substantially parallelepipedal shape, it consists essentially of a mattress 2 of mineral wool or rockwool, agglomerated by a binder, and one of its main faces is covered by a facing. who is made supportive of this face by any known means, in particular by gluing or by impregnation with bitumen. The facing of this panel has a resistance to tearing, especially following the wind, very limited.

The known panel shown in FIG. 2 differs from that of FIG. 1 in that side flaps coming from the facing are secured to the other main face of the panel (this other main face being that opposite to that on which is fixed the facing 3, this other main face also corresponding to the face which is intended to be in contact with a support member). This panel, at the level of its facing, sees its resistance to tearing improved, against it still has a lower resistance to fire risk.

The panel 1 represented in FIG. 3 is formed of a primitive consisting essentially of a rock wool mattress 2 whose binder content is of the order of 3 to 4% by weight, this rate being one of the characteristics structural aspects of the primitive. It has a density of the order of 140 kg / m ³ and a thickness of 80 mm. Of course, the dimensional and structural characteristics of the mattress 2 are given for information only, and these may vary depending on the desired applications. Thus the invention can be applied to panels whose density range is between 50 to 400 kg / m ³ and in particular 70 to 200 kg / m ³ , and preferably close to 140 kg / m ³ , for thicknesses ranging from 30 to 300 mm.

One of the main faces of the primitive of the mattress 1 is intended to receive by gluing or any other means for ensuring adhesion between two materials, a facing 3. This facing 3 may consist of several elements such as for example a glass veil, bituminous or not, or a sheet of kraft or any other type of material, these elements are optionally associated with a glass grid to reinforce the siding.

Glass mat is any support made from a non-woven glass.

The facing is applied directly after the impregnation of the veil by bitumen or other means of bonding, so that the means to ensure adhesion can penetrate one of the main faces of the mattress 2, at least on a small thickness of the latter.

In order to improve the anchoring of the facing 3 on the upper face of the mattress 2, it is possible to realize on the surface of the latter a plurality of recesses obtained by punching, such as those described for example in patent FR 2 679 279.

Alternatively, the facing 3 is not a glass veil, possibly reinforced, and coated with a bituminous material but a kraft facing.

In this case, this facing 3 consisting of kraft can be used as finish facing.

According to an example of kraft facing that can be used as a finishing facing, it may be a kraft whose one side is treated water-repellent (which supports wetting with a cooling fluid (water)). In addition, this face thus treated has on the one hand a smooth surface, which will minimize the amounts of glue used later, and on the other hand a better distribution of mechanical stresses. The kraft manufactured by the Canadian company Cascades Sainte Marie (ARJISO 200 ^™ ) is an example of an embodiment possessing these properties.

In the table below, we give some characteristics of this kraft Feature units mini values max values weight G / m ² 185 215 Thickness 1/100 mm 22 28 Breaking SM (Sens Machine) Kg / 1.5cm 9.0 Rupture ST (Transverse Sens) Kg / 1.5cm 4.5 Wet stability % 0.30 Rigidity Taber SM Taber 8 20 Rigidity Taber ST Taber 5 15 Water splash FF Level 1 2 Porosity 150 WG MI / min 10 300 COBB 1 min G / m ² 10 28 Scott Bond 800 1/1000 ft.Lbs.in 320 These characteristics are determined by usual tests in the paper industry.

This insulating panel 1 can be used for roof insulation systems 4 horizontal, vertical or inclined, or curved, by juxtaposing the at their longitudinal edges a plurality of panels, the panels being secured and mechanically fastened to the roof with a metal frame, horizontal, formed of metal sections by means of screws or washers. Alternatively, the panels could be glued to the supports.

Of course, the facing 3 is oriented towards the outside of the enclosure thus covered, as opposed to the face of the panel which is devoid of facing which is directed towards the interior of the enclosure and which is in contact with the framework of the roof 4 or any other wall connected to the support of the industrial building, residential, tertiary, or agricultural.

In FIG. 3, it will be noted that the facing 3 is not flanged on the main face of the panel which is intended to be directed towards the inside of the enclosure and more particularly that at least one flap 5 of the facing 3 n It is fixed only on a fraction of the thickness of one of the longitudinal edges of the panel (it is said that the panel is semi-flanged). This panel 1 is semi-flanged on two of its four edges, more particularly at two substantially parallel longitudinal edges.

The term "semi-flange" means that the main face of the panel (inside face) which is intended to be directed towards the support is not covered in whole or in part by a flap from the facing, in this configuration the flap (s) 5 (s) coming from the face of the facing 3 directed towards the outside of the enclosure is (are) semi-flanged (s) so that the fibers of the panel are directly at the contact of the roof frame covering the enclosure.

FIGS. 4 and following show different embodiments of a panel according to the invention.

Thus, in FIG. 4 in particular, a roof consisting of the juxtaposition of a plurality of panels 1 is shown. Each of the flaps 5 of the facing 3 is fixed (by gluing or by another equivalent method making it possible to ensure adhesion between two surfaces) within a relief zone 6 made in the thickness of the panel.

This raised zone 6 (recessed or protruding) delimits two contiguous zones 7, 8, one of which forms an outgrowth of material 9 (visible in FIGS. 6 and 7). In this example of FIG. 4, the protrusion of material 9 is positioned to the right of the main face of the panel 1 which is intended to be directed towards the inside of the enclosure, the contiguous part 8 being in this example (FIG. raised portion is recessed) to the right of the other main face of the panel 1, that which is intended to be directed towards the outside of the enclosure.

Thus, by juxtaposing at least two panels 1 according to the embodiment previously described, the respective raised parts 6 cooperate to form at the level of the main faces of the panels intended to be in contact with the support, a uniform barrier layer, this barrier that can be acoustic and / or thermal and / or fireproof.

It may be noted that by performing a surface heating of the bituminous coating, particularly in the semi-flanged areas, these bitumen areas will fuse locally and after cooling, provide a sealing barrier.

In Figure 5, there is shown a panel 1 semi-flanged on one of the four sides of the panel.

In FIG. 6, at least one of the edges comprising the raised zone 6 is inclined with respect to one of the main faces of the panel 1. In this example, in this embodiment, the semi-flanged edge is inclined. an angle α greater than 90 ° with respect to the face of the panel which is intended to be directed towards the outside of the enclosure.

Figure 7 illustrates another embodiment of a panel. On one of the edges of the panel, the raised area 6 intended to cooperate with the flap 5 from the facing 3 is projecting while the raised area 6 located at the opposite edge is recessed.

By juxtaposing at least two panels 1 according to this embodiment according to their respective longitudinal edges by associating on the one hand a protruding zone 6 of a first panel 1 with a hollow zone 6 'coming from a second panel 1', an insulating system is produced whose face directed towards the interior of the enclosure forms an acoustic and / or thermal barrier. The flaps 5, 5 'of the cladding 3, 3' are "protected" either by a protruding zone or by a hollow zone.

Whatever the embodiment, the presence of the flaps at the longitudinal edges of the panels considerably increases both the tear resistance (this tearing may be consecutive to a gust of wind) and the resistance vis-à-vis fire risk of the panels according to the invention compared to those of the prior art.

The invention also relates to a method and a device for continuously manufacturing the panels described above.

According to the method, a rigid high-density mineral fiber insulation mat is continuously manufactured by conventional methods for rockwool or glass wool, puncturing recesses of the surface for receive the facing, to form anchoring points evenly distributed on the surface for the glue (or other) used for fixing the facing on one side of the panel.

The mat of mineral fibers previously coated with binder is conveyed by conveyor belts in a heat treatment chamber (oven) in which the binder polymerizes and consolidates the mattress by giving it, thanks to pressure rollers, its dimensional characteristics. and thus conforming a primitive.

Downstream of this chamber, it proceeds to the realization of the raised areas (hollow, or protruding) on at least one of the longitudinal edges of the mattress.

The removal of material over a fraction of the thickness of the mattress is performed by a cutting member (saw, milling cutter) or by any other equivalent means, such as for example using a fluid under pressure (jet of water for example).

The cutter is integrated in the manufacturing process of the panels. It is located downstream of the oven and upstream of the final cutting unit. As a variant, it is nevertheless possible to provide this operation within a recovery operation, for example after cutting in the direction of travel of the mattress, and / or, for example, after cutting in the transverse direction (with respect to the direction scroll) of the mattress.

The glue or the like and the facing are then applied to the face optionally provided with the recesses.

In a preferred form, the glue is provided on the mattress simultaneously to the facing. This is particularly the case when the facing uses bitumen as glue and is impregnated before its application on the mattress.

It may be noted that when the facing is a kraft whose one face is treated water-repellent, the cooling necessary for the solidification of the bitumen located at the interface between the primitive and the facing is improved.

Indeed, this cooling is generally carried out wet, the cooling fluid which is in contact with water-repellent face of the facing makes it possible to cool the bitumen without damaging the latter.

However, with traditional facings (without hydrophobic treatment), due to wet cooling, there is a risk of deterioration of the latter (swelling, surface defect ...).

The facing which is applied continuously has a width corresponding to the width of the mattress increased by at least one flap, the size of which corresponds to the depth of the cut line previously made, which allows a covering that on at least one fraction of the thickness of the mattress.

The facing may comprise a so-called separation sheet of plastic as in the case of the panel described in EP-A-0 109 879 already cited.

The siding can ensure itself this separation function if the latter is made of kraft or other material.

The invention also relates to a device for implementing the method and the manufacture of the insulating panel.

The device comprises the known manufacturing means for producing the insulating panel, that is to say a fiberizing device incorporating the binder at the time of drawing, a conveyor receiving the fibers, means bringing the mattress to the thickness desired and an oven for the polymerization of the binder, means for the contribution of the facing and its adhesion on the underside of the panel, cutting means. These cutting means consist of first cutting means for dimensioning in the transverse direction (with respect to the running direction of the mattress), second means for dimensioning in the longitudinal direction (parallel to the direction of travel of the mattress), and finally third means for producing relief areas in a fraction of the thickness of the mattress.

It further comprises a system disposed between the cutting station of the raised areas within a fraction of the thickness of the mattress and the siding bonding station, which comprises a pressing member for applying a constant pressure on to minus a flap of the facing that one wants to adhere to the level of the raised area previously removed.

Claims (15)

1. An element essentially consisting of a substantially parallelepiped of mineral or rockwool mat (2) having two main surfaces and longitudinal edges, consisting of a plurality of fibres coated with a binder; at least one of the longitudinal edges of said intermediate product has a relief (6); said relief is created over a fraction of the thickness of the mat, in line with a main surface of said mat (2); said relief delimits two contiguous areas (7, 8) and this said relief (6) is for receiving a flap portion (5) of a covering (3); said flap portion (5) of the covering (3) covers a portion of the longitudinal edge of said relief (6); said covering (3) is bonded to a first main surface of the mat, is not folded back onto the second main surface of the mat (2), and is a thin sheet less than 5 mm thick; and this said relief (6) is a concave area of sufficient cross-section and depth to enable the flap (5} to be inserted therein so that there is no excess thickness of material on the longitudinal edge of the panel including the mat (2) and the covering (3), and so that the flap (5) of the covering (3) and the portion of the longitudinal edge of the mat (2) that is not covered by the flap (5) forms a continuous flat outer surface of the panel.
2. Element as claimed in claim 1, characterized in that the longitudinal edge having the relief (6) is inclined at an angle α of greater than 90° to that main face of the mat (2) which has to be clad with the covering (3).
3. Panel (1) essentially consisting of an element as claimed in claim 1 or 2 and of a covering (3) being able to be bend.
4. Panel as claimed in claim 3, characterized in that it has two reliefs (6, 6'), each of these reliefs accommodating a flap (5, 5') of said covering (3), these flaps (5, 5') being designed to cooperate with the reliefs (6, 6') with the aid of an adhesion means, especially bitumen.
5. Panel as claimed in one of claims 3 to 4, characterized in that the covering (3) essentially comprises of a bitumen-coated glass veil, said covering being optionally reinforced, especially by a glass mesh.
6. Panel as claimed in claims of claims 3 to 4, characterized in that the covering (3) essentially comprises of a kraft paper that includes a means of adhesion to said element.
7. Panel as claimed in claim 6, characterized in that the kraft paper has at least one face treated so as to be non-beading.
8. Panel as claimed in one of claims 3 to 7, characterized in that the covering (3) is a reactive substrate for adhesive bonding
9. A roofing structure comprising of load-bearing elements made of ribbed steel sheet, wood or concrete, to which a plurality of panels (1) according to any one of claims 3 to 8 is fixed.
10. A wall of an industrial, residential, services or agricultural building forming a support to which a plurality of panels (1) as claimed in any one of claims 3 to 8 is fixed.
11. A process for manufacturing an element as claimed in one of claims 1 to 2, characterized in that a continuous mat (2) of mineral wool coated with a binder is formed and in that a relief (6) is created along at least one of the longitudinal edges.
12. Process as claimed in claim 11, characterized in that a covering(3) is applied to that face of the mat which is in line with said relief (6) and at least one flap (5) made as one piece with said covering(3) is pressed into said relief (6).
13. Process as claimed as claimed in claims 11 or 12, characterized in that the relief (6) is obtained by a material removal operation carried out by a cutting device.
14. Device for the manufacture of a panel as claimed in one of claims 3 to 8, characterized in that it comprises a manufacturing line for producing the insulating panel (1), namely a fiberizing apparatus with incorporation of a binder during the fiberizing, a conveyor that receives the fibers, means that bring the mat to the desired thickness and an oven for curing the binder, means for supplying a covering(3) and for making it adhere to the lower face of the panel, and cutting means, said cutting means comprising a first cutting means for cutting to the dimensions in the transverse direction relative to the run direction of the mat, second means for cutting to the dimensions in the longitudinal direction parallel to the run direction of the mat and, finally, third means for producing the reliefs over a fraction of the thickness of the mat.
15. Device claimed in claim 14, characterized in that it furthermore includes a system placed between the station for cutting the reliefs into a fraction of the thickness of the mat and the station for fixing the facing, which system comprises a press for applying constant pressure on at least one flap of the covering that it is desired to adhere to the relief removed beforehand.

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