EP0130921B1 - Supporting composite panel - Google Patents

Description

The present invention relates to a new load-bearing or self-supporting composite panel, and in particular a new insulating cover support component, and to its manufacturing process.

For the sake of simplification, the following description will essentially refer to an insulating cover support component, it being understood that other load-bearing composite panels are included within the scope of the invention.

By performing several functions simultaneously, the insulating roof support component is used more and more in the building, in particular in the detached house with creeping ceiling or habitable roof space.

• - Fonction de portance : le composant assure la portance entre les éléments de charpente.
• - Fonction d'isolation thermique : le composant comprend un isolant thermique.
• - Fonction de parement intérieur : le composant est prêt à recevoir les finitions intérieures.
• - Fonction de contre liteaunage : le composant doit pouvoir recevoir les liteaux pour répondre à tous les types de couvertures en petits éléments.
• - Fonction d'étanchéité : le composant doit assurer les fonctions de pare-pluie et pare-neige.

The component generally performs the following functions:

• - Lift function: the component provides lift between the structural elements.
• - Thermal insulation function: the component includes thermal insulation.
• - Interior facing function: the component is ready to receive interior finishes.
• - Counter litage function: the component must be able to receive the battens to meet all types of cover in small elements.
• - Sealing function: the component must perform the functions of rain and snow shields.

Insulating cover support components are known. These components generally comprise, on the side facing inwards, an interior facing ready to finish, an insulating cellular core, and possibly on the side facing outwards, an outside facing sometimes ensuring the sealing function, and generally equipped. of contrelattes.

The interior siding generally consists of a panel of wood particles. As for the insulating core, it generally consists of a panel made of cellular material such as expanded or extruded polystyrene, polyurethane, expanded polyvinyl chloride. The exterior facing is also generally a panel of wood particles or a sheet of plastic material or based on a kraft-polyethylene complex for example.

One of the drawbacks of these known components is their sensitivity to variations in humidity resulting in significant dimensional variations, in particular bulging of the component, causing movement of the joints bringing together two neighboring components, detrimental to the appearance of the final coating.

Another drawback lies in the weight and the difficulties of implementing the component when it comprises two panels of wood particles as facings.

Document DE-A-1 659 019 discloses a composite element comprising a core of insulating cellular material coated on at least one face with a composite layer of plastic material reinforced with glass fibers. The composite layer is produced at the same time as the composite element by a single pressing operation.

The invention provides a new load-bearing composite panel, in particular an insulating cover support component free of the cited drawbacks.

The panel according to the invention, load-bearing or self-supporting, comprises a cellular insulating core, in particular in expanded or extruded polystyrene, in polyurethane, in polyvinyl chloride, of variable thickness according to the desired insulation, and, bonded to the insulating core , an inner facing formed of a sheet based on discontinuous mineral fibers, linked together by a polymerized binder, having a fiber content greater than 70% of the total weight of the fibers and of the binder, the rest of the panel consisting essentially of polymerized binder, this sheet having a high density, between 400 and 1500 kg / m ³ , and being obtained from at least one mattress of mineral fibers very highly hot pressed, and on the other side of the insulating core an external element ensuring the mechanical balance of the panel. The interior facing has very interesting mechanical properties despite its small thickness, generally of the order of 0.1 to 10 mm and preferably 2 to 4 mm.

In one embodiment, the load-bearing or self-supporting composite panel comprises, as an external element ensuring mechanical balance, an external facing of the same type as the internal facing, that is to say formed of a sheet based on staple mineral fibers as described above.

In a variant, the external element is a counterattack consisting of wooden counter-battens or of a panel derived from wood, these counter-battens being dimensioned and spaced apart according to the mechanical performance desired for the composite.

In another embodiment of the composite panel, the external element ensuring the mechanical balance consists of an external facing of the type described above, associated with a counterattack. In this embodiment, advantageously, the contrelats are arranged between the insulating core and the external facing which for this purpose takes an appropriate geometric shape. Indeed, the very good moldability of the sheets based on mineral fibers constituting the facings makes it possible to give them adapted, very varied geometric shapes, making it possible to insert, between the insulating core and the thermoformed sheet, contrelattes as described above. , or possibly other inserts intended to facilitate the implementation of the panel.

The very high density for a product based on staple fibers, of the order of 400 to 1500 kg / m ³ and preferably from 600 to 1100 kg / m ³ is obtained by thermocompression of one or more fiber mats mineral before polymerization, mattresses used in a known manner for the manufacture of thermal insulating felts.

This sheet has excellent dimensional stability to humidity variations and good water resistance.

Although having an apparent density substantially equal to that of a wood particle board, the interior and possibly exterior facing sheet can be used in a thickness of 2 mm in an equivalent manner to a wood particle board of 12 mm of thickness necessary for a load-bearing component panel to be usable in the building because of the fire resistance problem of said panel, which allows a considerable weight gain for the component panel according to the invention, hence an ease of implementation and a possibility of lightening the frame. In addition, the facing (s) according to the invention undergo a kind of sintering under the effect of the temperature due to the fire and generally remain in place.

To further improve certain properties of the facing, the sheet may advantageously contain adjuvants, for example silicone oils such as polydimethylsiloxane, these adjuvants being generally introduced into the binder.

One of the advantages of the facing (s) according to the invention is that all kinds of structural adhesives can be used, compatible with the insulating core, known from conventional assembly techniques. Adhesives based on polyurethane mono or two-component, contact adhesives of the polychloroprene type, etc. can be used, for example.

In one embodiment, the interior and / or exterior facing sheet, as the case may be, is provided on the visible side with a covering sheet or film of kraft paper, plastic, metal, fabric, peeled wood, etc. .., for example. The inner facing sheet can also be provided on its face oriented towards the insulating core with a sheet of one of the types described above and in particular made of kraft paper, for example acting if necessary as a vapor barrier.

Another advantage of using sheets based on mattresses of thermocompressed mineral fibers is the easy production of the thinned edges of the component.

Indeed, one of the problems posed by the use of multifunctional components of sub-roofing is the joint between two neighboring components and in particular the realization of the interior jointing. The sheet used as facing according to the invention does not undergo any dimensional variation due to the variations in air humidity. We can therefore consider a classic type of joint between panels, with a more coated strip. In addition, the facings according to the invention offer various possibilities for thinning the edges of the component in order to achieve correct and easy jointing. The thinning of the edges of the component can be obtained directly by thinning the edges of the sheet by molding at the time of its manufacture, or by machining. Thinning can still be obtained on the component itself, thanks to the good deformability of the facing sheet. It is thus possible to create a thinned edge on the core by molding or machining and to assemble the interior facing by pressing - bonding and compression of the insulating core. In the case where a contact adhesive is used, when the compression is released, the facing sheet remains in the profile of the core.

In a preferred form, the edge of the interior facing is not glued to the insulating core and can retain its flexibility. In the event of differential movement of two neighboring components, jointing can thus be preserved.

In accordance with claims 11 and 12, to manufacture the load-bearing composite panel according to the invention, the various constituent elements are superimposed, by interposing a layer of adhesive as described above between them. The sheet used as a facing according to the invention is made from one or more primitives of mineral insulating fibers, for example glass fibers, rock fibers, that is to say staple fibers whose the average diameter is generally between 2 and 15 micrometers. These primitives contain an unpolymerized, thermosetting binder such as a formophenolic resin, melamine-formaldehyde, urea-formaldehyde at a rate of approximately 20% of the total weight of the fibers and the binder. Primitives are strongly compressed with pressures of the order of 10 to 100 bars at the same time as heating in order to polymerize the binder, however avoiding a prepolymerization of the binder before final dimensioning.

The composite panels according to the invention can be assembled together by a socket of the tenon-mortise type, or by grooves and tongues, or by other systems well known to those skilled in the art.

• La figure 1 représente une réalisation d'un panneau composite porteur selon l'invention.
• La figure 2 représente une réalisation d'une variante avec contrelattage selon l'invention.
• La figure 3 représente une réalisation d'une autre variante avec bords amincis.
• La figure 4 représente un joint entre deux panneaux assemblés.
• Les figures 5 et 6 représentent une réalisation dans laquelle les bords du parement intérieur sont libres au droit du joint.

Other characteristics and advantages of the load-bearing composite panel according to the invention will appear in the following description of exemplary embodiments.

• FIG. 1 represents an embodiment of a load-bearing composite panel according to the invention.
• FIG. 2 represents an embodiment of a variant with counterattacking according to the invention.
• Figure 3 shows an embodiment of another variant with thinned edges.
• Figure 4 shows a joint between two assembled panels.
• Figures 5 and 6 show an embodiment in which the edges of the interior facing are free in line with the joint.

FIG. 1 represents a composite panel according to the invention comprising a cellular core 1 120 mm thick in expanded polystyrene with a density of approximately 25 kg / m ³ , an interior facing 2 2 mm thick formed from a thermocompressed glass fiber mattress with a density of 700 kg / m ³ , an exterior facing 3, of the same kind, 2 mm thick.

• On fabrique le parement intérieur à partir d'un primitif de fibres de verre discontinues d'isolation, d'une masse surfacique de 1400 g/m² obtenu par les méthodes de fibrage classique et pour lequel le liant représentant 20 % en poids est une résine formo-phénolique. Le primitif est placé entre les plateaux d'une presse. L'ensemble est comprimé fortement en exerçant une pression de 10 bars, à une température de 200° C pendant une minute. Le parement obtenu aux dimensions déterminées est démoulé.

To manufacture this component, we operate as follows:

• The interior facing is manufactured from a primitive of discontinuous insulating glass fibers, with a surface mass of 1400 g / m ² obtained by conventional fiberizing methods and for which the binder representing 20% by weight is a formo-phenolic resin. The primitive is placed between the plates of a press. The whole is compressed strongly by exerting a pressure of 10 bars, at a temperature of 200 ° C. for one minute. The facing obtained at the determined dimensions is removed from the mold.

We make the exterior siding in the same way.

The facings are glued to the cellular core in expanded polystyrene. A polychloroprene contact adhesive is used.

FIG. 2 represents an insulating cover support component according to the invention comprising a core 1, an interior facing 2 formed from a sheet obtained from a mattress of thermocompressed glass fibers, a counter-lattice consisting of counter-battens 5 made of wood or panel derived from wood, these counter laths being dimensioned and spaced from one another according to the desired mechanical performance. To manufacture this component, the facing is assembled to the core in the same way as in Example 1, and the counterparts are bonded to the other side of the core using an appropriate adhesive, for example a contact adhesive or based on polyurethane.

FIG. 1 represents a covering support component comprising a core 1, an interior facing 2, a counterattacking of wooden contrelattes 5, an exterior facing 3 having a thermoformed structure allowing the contrelattes 5 to be inserted between it and the soul two facings 2 and 3 being provided on their outer face with a sheet of Kraft paper 4. The core 1 has on one side a groove 6 and on the other a tongue 7 allowing the assembly of two neighboring panels. The panel also has thinned edges 8 and 9 facilitating jointing.

FIG. 4 represents the connection between two components of the type described in relation to FIG. 3. The assembly at the level of the core is carried out by tongue 7 and groove 6. The external seal 10 is an aluminum strip or the like, self-adhesive. The interior jointing 11 is produced by a strip 12 and a coating 13 which are applied to the thinned edges of the two components to fill the recess 14.

FIG. 5 represents the assembly between two components for which the end portions 15 and 16 of the interior facing corresponding to the thinned portions 8 and 9 of the components of the type described in FIG. 3, are free, that is to say not bonded on the insulating core. The jointing 11 is carried out in the same way as described above with a strip 12 and a coating 13 which fills the hollow 14 corresponding to the joint.

FIG. 6 represents this same joint when the two components have undergone differential movements with respect to each other. The free edges, thanks to their deformability and their elasticity, preserve the jointing.

The load-bearing composite panels according to the invention have other advantages than those described above. Thus they have good joinability, that is to say that they can be sawn, drilled, nailed easily without the formation of splinters or deformations. The elastic modulus of the sheet with a value of around 40,000 daN / cm ² is higher than that of a particle board which is around 15,000 to 25,000 daN / cm ² , which provides the component according to the invention a resistance to bending at least equivalent as demonstrated below.

A comparative test of resistance to bending between a load-bearing component panel according to example 1 described above in accordance with the invention and a known component panel using 12 mm thick particle board panels as internal facing and exterior facing and an insulating core 120 mm thick is produced in the manner described below.

A load of 500 kg per m ^{2 is} evenly distributed on panels 2 meters long arranged between free supports and the deflection is measured in the middle of the panels. The deflection for the panel according to the invention is 12 mm, equivalent to that of the component panel using particle board panels.

Claims (13)

1. A composite support or self-supporting panel comprising an insulating cellular core (1), for example of polystyrene, an interior covering (2) based on mineral fibres and a polymerised binder, characterised in that the covering (2) is formed of a sheet based on discontinuous mineral fibres bound to each other by a polymerised binder, having a content of fibres greater than 70 % of the total weight of fibres and binder, the remainder of the covering (2) being constituted essentially of polymerised binder, the sheet having a density from 400 to 1500 Kg/m³ and being obtained from at least one hot-pressed mat of mineral fibres, the covering (2) being adhered to the insulating core by a structural adhesive and in that an exterior element (3), (5) ensuring mechanical equilibrium of the panel is provided on the other side of the insulating cellular core.

2. A composite panel according to claim 1, characterised in that the covering sheet bas a density from 600 to 1100 Kg/m³.

3. A composite panel according to claim 1 or 2, characterised in that the exterior element is a covering (3) similar to the interior covering (2).

4. A composite panel according to claim 1 or 2, characterised in that the exterior element is a counter-lathing (5) formed of counterlaths of wood or of a panel derived from wood.

5. A composite panel according to claim 1 or 2, characterised in that the exterior element comprises an exterior covering (3) and a counter-lathing (5).

6. A composite panel according to claim 2 or 3, characterised in that the exterior covering has geometrical shapes allowing positioning of counter-lathings (5) or inserts between the covering and the insulating core (1).

7. A composite panel according to any one of claims 1 to 6, characterised in that the edge parts (8, 9) of its surface directed towards the interior are thinned to facilitate jointing (11).

8. A composite panel according to any one of claims 1 to 7, characterised in that the part of the interior covering corresponding to the thinned edge parts is not adhered to the core.

9. A composite panel according to any one of claims 1 to 8, characterised in that the interior and/or the exterior covering is provided with a coating sheet (4).

10. A composite panel according to claim 9, characterised in that the coating sheet (4) is assembled with the covering during manufacture of the latter.

11. A composite panel according to one of claims 1 to 10, characterised in that the thickness of the interior and exterior coverings is from 0.1 to 10 mm and preferably from 2 to 4 mm.

12. A method of making a composite panel according to one of claims 1 to 11, characterised in that there is first formed the covering sheet, optionally provided with a coating sheet, by pressing of at least one blank of insulating mineral fibres containing an unpolymerised binder, associated if required with the coating sheet, and polymerising the binder and the elements of the panel are assembled by adhesion.

13. A method according to claim 12, characterised in that the elements are assembled together by adhesion by compressing the assembly and then releasing it.

Images