Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
  • E04C2/40—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of a number of smaller components rigidly or movably connected together, e.g. interlocking, hingedly connected of particular shape, e.g. not rectangular of variable shape or size, e.g. flexible or telescopic panels
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
  • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
  • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced

Definitions

• the present disclosure relates to a wall and a method for producing the wall, the wall comprising a plurality of construction elements.
• Such a wall makes it possible to manufacture a structure, preferably a residential house, but also a footbridge, a boat pontoon or the like.
• the present disclosure further relates to a construction element.
• the method comprises the following operations: a) producing a group of construction elements comprising a plurality of construction elements, the operation a) comprising the sub-operations: a1) putting on an envelope, made of fibers , in a mold having a cavity defined by an interior surface of the mold, said interior surface being cylindrical of polygonal cross section, then a2) place a foam inside the envelope to form a construction element, the element of construction being cylindrical and comprising a first end face, a second end face and side faces, the side faces defining an axis and a polygonal cross section (the first end face and the second end face being perpendicular has the axis), each construction element comprising a foam core and the envelope on the periphery (the foam passing through the envelope, so that the envelope is slightly embedded in the foam), a3) carry out operations a1) and a2) a plurality of times, b) arrange the group of construction elements with the first end face resting on a support, the construction elements being joined together
• the walls having both high mechanical resistance, very good thermal insulation and a moderate weight facilitating its implementation.
• the walls have good elastic resistance to deformation, giving the structure excellent resistance to earthquakes.
• the walls can be placed vertically to form walls or horizontally to form a floor, ceiling or platform. Openings for doors and windows can easily be made.
• the construction elements can be called rubble stones.
• operation b) comprises the sub-steps: b1) wet (impregnate) with resin at least one of the lateral faces of each construction element of said group, then b2) arrange the construction elements of said group with the first end face resting on the support.
• the resin coating makes it possible to create a sort of waterproof skin around the periphery of the construction element. This skin protects the foam core, insulating it, particularly from humidity, and also promotes the fixing of the construction element.
• operation b1) preferably includes wetting all the side faces of the construction elements of the group with resin.
• operation b1) preferably includes also wetting the first end face and the second end face of the construction elements of the group with resin.
• the skin completely insulates the foam core.
• operation b1) comprises after wetting the construction elements with resin, wringing the construction elements to remove a portion of excess resin, more preferably by rotation around the axis.
• the construction elements are uniformly wetted with resin, just the quantity necessary to form a skin impervious to humidity in gaseous (water vapor) or liquid (water) form.
• operation b1) comprises exposing the construction elements to an ultraviolet emitter after coating with resin.
• the resin is solidified quickly.
• operation b2) comprises applying the lateral faces of the construction elements against each other to obtain the panel comprising the plurality of construction elements secured to each other by their faces lateral.
• operation b) comprises the sub-steps: bi) arranging the group of construction elements in a formwork, the formwork comprising the support, the construction elements of the group being joined together by providing a spacing between the facing side faces, then bii) arranging the resin so that it flows into the formwork in the spacing between the construction elements, in order to obtain the panel comprising the plurality of elements of construction secured to each other by their lateral faces via a lacunar resin structure.
• construction elements are joined together by distributing the resin between the construction elements.
• operation b) further comprises:
• the first layer of resin reinforces the panel and protects the construction elements.
• operation b) comprises placing at least one first sheet of fibers in contact with the first layer of resin, between the support and the first end face of the plurality of elements of construction.
• the first sheet of fibers further reinforces the first layer of resin.
• operation b) further comprises placing a first plate on the support, the first plate having a first right side and a first reverse side, the first right side being supported on the support, place the first layer of resin on the first reverse side, so as to join the first end face of the plurality of construction elements to the first plate via the first layer of resin.
• the first plate constitutes a facing
• the first face has a finished appearance which can constitute an external face or internal face of the wall of a residential house.
• the method preferably further comprises bending the first plate before hardening of the first layer of resin.
• the method further comprises an operation c) comprising applying a coating to a coating face, the coating face being one of the first end face and the second face d end of the construction elements.
• This operation also makes it possible to finish the panel on the panel production site and thus reduce the production cost compared to production on the construction site of the work.
• operation c) comprises the sub-operations:
• - operation b) further comprises casting a second layer of resin on the second end face of the plurality of construction elements of said group;
• - operation d) comprises placing at least one second sheet of fibers in contact with the second layer of resin;
• - operation b) further comprises placing a second plate on the second layer of resin, so as to secure the second end face of the plurality of construction elements to the second plate via the second layer resin;
• operation a1) comprises the sub-operations: a1 i) placing the envelope on a punch, a1 ii) inserting the punch with the envelope in the cavity, and a1 iii) removal of the punch from the cavity.
• the envelope is efficiently placed repetitively in the cavity.
• sub-operation a1 ii) further comprises providing a clearance of less than 1 centimeter between the punch and the interior surface of the cavity.
• the envelope is placed in support against the interior surface of the mold.
• sub-operation a1 ii) comprises holding the envelope on the punch, preferably by suction.
• the interior surface comprises a first end surface, a second end surface and side surfaces
• operation a1) comprises covering the first end surface, the second end surface and the side surfaces of at least one layer of fibers forming the envelope
• - said interior surface of the cavity is of regular polygonal cross section
• the interior surface of the cavity is of regular hexagonal cross section.
• the method comprises: producing a series of groups of construction elements comprising a first group of construction elements and a second group of construction elements, the first group of construction elements comprising at least twenty construction elements, each group of construction elements comprising the same number of construction elements as the first group, the production of a series of panels, said panels being identical and comprising a first panel and a second panel, the first panel comprising the first group of construction elements, each panel comprising one of the groups of construction elements of said series of groups of construction elements, then e) forming the wall by attaching the panels of the series of panels to each other, parallel to each other (and coplanar).
• the panels constitute subassemblies whose assembly allows the creation of the wall. This makes it possible to produce large numbers of identical “standard” panels to build walls of different dimensions.
• the method comprises:
• the cavity has, along the mold axis, a height between a first end surface and a second end surface and constituents capable of forming the foam are arranged in a container having an opening extending a central 1/3 of the mold between the first end surface and the second end surface;
• the construction elements have a volume of between 5 dm 3 and 20 dm 3 .
• the present disclosure also relates to a wall.
• the wall comprises at least one panel, the panel comprising a plurality of construction elements, in which:
• each construction element is cylindrical and comprises a first end face, a second end face and side faces, the side faces defining an axis and a polygonal cross section (the first end face and the second face of the end being perpendicular to the axis),
• each construction element has a foam core and a fiber covering on the periphery
• the construction elements are joined together, the lateral faces extending facing (near and substantially parallel) to each other,
• the panel comprises a lacunar structure in resin, the construction elements are secured to each other by their lateral faces via the lacunar structure;
• the panel further comprises a first layer of resin covering the first end face of the plurality of elements
• the panel further comprises a first plate, the first plate having a first right side and a first reverse side, the first end face of the plurality of construction elements being secured to the first reverse side by means of the first layer of resin;
• the first facing side comprises a facing, in particular made of stone, tiles, glass, wood, metal or composite;
• the panel further comprises a second layer of resin covering the second end face of the plurality of construction elements
• the panel further comprises a second plate, the second plate having a second right side and a second reverse side, the second end face of the plurality of construction elements being secured to the second reverse side by means of the second layer of resin;
• the second face includes a facing, in particular made of stone, tiles, glass, wood, metal or composite;
• the panel comprises a coating covering a coating face, the coating face being one of the first end face and the second end face of the construction elements;
• the panel includes a frame embedded in the coating
• each construction element has a regular polygonal cross section
• each construction element has a regular hexagonal cross section
• the wall comprises a series of panels fixed to each other, parallel to each other and as an extension of each other
• each construction element is made of polyurethane foam
• the construction elements each have a volume of between 5 dm 3 and 20 dm 3 .
• the present disclosure further relates to a mold for producing a construction element used in the aforementioned method or an element of a aforementioned wall.
• the mold has the following characteristics: the mold comprises a first end part, a central part and a second end part, the central part comprises a plurality of side elements connected to each other by a hinge, each hinge comprises a first hinge element and a second hinge element rotatably movable relative to each other about a hinge axis, the plurality of side elements comprises a first end side element and a second side element end, the mold further comprises a flange having a locked state and an unlocked state, in the locked state the first lateral end element is held relative to the second lateral end element, in the unlocked state the first lateral end element is released relative to the second lateral end element, the mold has a molding configuration and a demolding configuration, in the molding configuration, the flange is in the locked state, each hinge is immobilized in rotation, the mold has a closed cavity defined by an interior surface of the mold
• the construction element does not need to have any relief to be able to be unmolded.
• the absence of undercut allows a reduction in the quantity of resin used and better wall strength.
• the mold (80) is configured to arrange the lateral surfaces (86) in the same plane in the demolding configuration; the first end part (81a) is away from the central part (81 b) and the second end part (89) is away from the central part: the flange is formed by a hinge d the end comprising a first end hinge element, a second end hinge element and an end hinge pin, in the locked state the pin connecting the first hinge element to the second hinge element and the pin end hinge being removable; the side elements are all identical.
• FIG. 1 represents a fiber envelope before shaping
• FIG. 2 represents the shaping of the envelope and its introduction into a mold
• FIG. 3 illustrates the production of a construction element by expansion of foam in the mold
• FIG. 4 illustrates in perspective the construction element produced
• FIG. 5 illustrates the construction element in section along the line marked V-V in Figure 4, after wetting of the construction element, according to a first embodiment
• FIG. 6 illustrates the production of a panel comprising a plurality of construction elements, according to the first embodiment
• FIG. 7 is a sectional view along the line marked VII-VII in Figure 6
• FIG. 8 illustrates the creation of a wall comprising two panels
• FIG. 9 is a view of the wall according to the arrow marked IX in Figure 8
• FIG. 10 illustrates the production of a panel comprising a plurality of construction elements, according to a second embodiment
• FIG. 11 is a view of the panel according to the arrow marked XI in Figure 10,
• FIG. 12 represents a variant of fiber envelope before shaping
• FIG. 13 illustrates in perspective a central part of the mold illustrated in Figure 2 and Figure 3, in a closed configuration
• FIG. 14 illustrates the central part of the mold, in an open configuration
• FIG. 15 illustrates in perspective a variant embodiment of the panel according to the first embodiment
• FIG. 16 illustrates in perspective a variant embodiment of the panel according to the second embodiment
• FIG. 17 illustrates another variant of panel construction. Detailed description of the disclosure
• FIG. 1 illustrates an envelope 20 before shaping.
• the envelope 20 comprises at least one sheet of fibers, preferably a single sheet, possibly two or three sheets of fibers (depending on the surface density of the sheet of fibers).
• the envelope 20 is substantially rectangular.
• Each sheet of fibers comprises a central portion 26, a first end portion 27 and a second end portion 28.
• the first end portion 27 extends between the central portion 26 and a first edge 27a.
• the second extreme portion 28 extends between the central portion 26 and a second edge 28a. In the illustrated embodiment, the first end portion 27 is wider than the second end portion 28.
• the envelope has slots 25 extending transversely in the first end portion 27 from the first edge 27a to the central portion 26 , and in the second extreme portion 28 of the second edge 28a up to the central portion 26.
• the first extreme portion 27 and the second extreme portion 28 thus appear to each consist of six tongues.
• the first end portion 27 and the second end portion 28 are obtained by creating cutouts forming the slots 25 (for the sake of readability, a slight gap has been shown between the edges of each slot, this gap not existing not necessarily), each sheet of fibers being initially rectangular.
• the envelope 20 is placed on a punch 70.
• the punch 70 is cylindrical of regular hexagonal cross section having an axis, so that the punch 70 has six peripheral faces 74 and one end face 72.
• the central portion 26 and the second end portion 28 of the envelope 20 are arranged around the punch 70, in contact with the peripheral faces 74.
• the central portion 26 and the second end portion 28 are therefore arranged around the punch 70.
• the first extreme portion 27 is bent at right angles to the central portion 26, so that the first extreme portion 27 comes into contact with the extreme face 72 of the punch 70.
• the six tabs of the first end portion 27 cover the end face 72 of the punch 70 by overlapping.
• the thickness of the envelope 20 is represented in an increased manner compared to its other dimensions and to the dimensions of the punch 70.
• the envelope 20 is held on the punch 70.
• the envelope 20 is held by suction, but the retention of the envelope could be achieved in a different way.
• the envelope 20 could be constituted by three strips each extending facing the first end surface 82, on two opposite side faces 86 and having free ends facing the second end surface 84, the strips being offset from each other 60 degrees around the mold axis 83.
• the envelope 20 can be produced by knitting, in particular by circular knitting, fibers.
• the envelope 20 then has a seamless tubular shape extending between the first edge 27a and the second edge 27b.
• the envelope can optionally be closed at the first edge 27a.
• the envelope can then be adjusted so as to be held by friction on the punch 70.
• the envelope 20 can be folded close to the first edge 27a against the end face 72 of the punch 70 without requiring the slots 25 described previously.
• the envelope can be obtained by winding fibers, the fibers preferably forming an angle of approximately 45 degrees relative to the axis of the punch 70.
• the envelope 20 is made from of a sheet, of strips, by circular knitting, rolling or other, the envelope can include not only fibers serving for mechanical resistance, but also thermoplastic fibers allowing by heating the envelope to give it an appropriate shape for facilitate its placement against the interior surface 88 of the mold.
• the punch 70 covered with the envelope 20 is then inserted into a mold 80 during a sub-operation a1 ii).
• the mold 80 comprises a first end part 81a, a central part 81b and a second end part 89.
• the mold 80 has an interior surface 88 delimiting a cavity 85.
• the cavity 85 is substantially cylindrical and extends along a mold axis 83. In the illustrated embodiment, the cavity 85 is hexagonal perpendicular to the mold axis 83.
• the first end part 81a comprises a first end surface 82
• the central part 81b comprises side surfaces 86
• the second end part 89 comprises a second end surface 84.
• the central portion 26 of the envelope 20 (and the second extreme portion 28) is arranged between the peripheral faces 74 of the punch and the side surfaces 86 of the mold 80. There is a clearance d between the peripheral faces 74 of the punch 70 and the lateral surfaces 86 of the mold 80.
• the first end portion 27 of the envelope 20 is between the end face 72 of the punch 70 and the first bearing surface 82 of the mold 80.
• the clearance d is less than 1 centimeter, preferably of the order of a few millimeters, to shape the envelope 20 and place it substantially in contact with the side surfaces 86 of the mold 80.
• the punch 70 is inserted into the cavity 85 until the end face 72 of the punch 70 is less than one centimeter from the first end surface 82. Then, when of a sub-operation a1 iii), the punch 70 is removed from the cavity 85.
• rods 8 are then placed in the cavity 85 inside the envelope 20.
• the rods 8 form inserts.
• the rods 8 are arranged against the envelope 20, at the level of the edges extending between the lateral surfaces 86.
• the rods 8 extend in the direction of the mold axis 83, substantially from the first surface of end 82 to the second end surface 84.
• the rods 8 may in particular have a rectangular circular section.
• the rods 8 may in particular be made of wood or metal, in particular aluminum.
• the second extreme portion 28 is then folded.
• the second edge 28a of the different tongues of the second folded extreme portion 28 provides a passage 21.
• foam 32 is then introduced through passage 21 into envelope 20, folded .
• the foam 32 preferably being polyurethane foam, we introduce through the passage 21 two constituents reacting with each other to create an expansion of the foam 32.
• the foam could be phenolic foam instead of polyurethane foam.
• the second extreme portion 28 could be made with the same width between the second edge 28a and the central portion 26 as the first extreme portion 27 between the first edge 27a and the central portion 26. In this case, the second extreme portion 28 would be folded after having introduced the foam 32 into the cavity 85. The closing portion 29 would then not be necessary.
• the envelope 20 is also devoid of slots near the second edge 28a, the flexibility provided by the knitting allowing the envelope to be folded without the need for said slots.
• the cavity 85 has, along the mold axis 83, a height between the first end surface 82 and the second end surface 84 and the constituents generating the foam 32 are arranged in a container 34 having an opening 36 extending in the central 1/3 of the height of the mold 80.
• the foam 32 is distributed more uniformly than if the constituents were poured into the bottom of the mold, at the level of the first end surface 82.
• mold 80 can be rotomolded.
• the mold 80 is then placed in a molding configuration, the cavity 85 being closed by arranging the second end portion 89 of the mold 80 with the second end surface 84 facing the second end portion 28 and the portion of closure 29 of the envelope 20.
• the mold 80 is in the molding configuration when the foam 32 expands until it substantially reaches the second extreme portion 28 of the envelope 20, if the mold 80 does not have a vent. If mold 80 has vents, cavity 85 can be closed sooner.
• the 80 mold can be placed in the configuration molding before the introduction of the foam 82, if suitable means for the introduction of the foam 32 into the envelope 20 are provided.
• the foam 32 presses the first end portion 27 against the first end surface 82, the central portion 26 against the side surfaces 86 and the second end portion 28 (as well as the closing portion 29) contains the second end surface 84.
• the foam 32 slightly passes through the envelope 20 (the first end portion 27, the second end portion 28 and the closing portion 29).
• the central part 81b comprises a plurality of side elements 182a, 182b, 182c, 182d, 182e, 182f.
• Each side element 182a, 182b, 182c, 182d, 182e, 182f comprises one of the side surfaces 86.
• the side elements 182a, 182b, 182c, 182d, 182e, 182f are all identical.
• the side elements 182a, 182b, 182c, 182d, 182e, 182f are connected to each other by a hinge 185. In the illustrated embodiment, the hinges 185 are all identical.
• Each hinge 185 comprises a first knuckle forming a first hinge element 181, a second knuckle forming a second hinge element 183 and a hinge pin 184.
• the hinge pin 184 passes through a bore of the first hinge element 181 and a bore of the second hinge element 183.
• the first hinge element 181 and the second hinge element 183 are movable in rotation relative to each other around a hinge axis 180, via the hinge pin 184.
• the mold 80 comprises six side elements 182a, 182b, 182c, 182d, 182e, 182f and six hinges 185.
• the first hinge element 181 comprises three portions spaced from each other along the hinge axis 180.
• the second hinge element 183 comprises two portions spaced from each other along the hinge axis 180.
• the portions of the second hinge element 183 are arranged between the portions of the first hinge element 181.
• each hinge pin 184 protrudes from the first hinge element 181 and the second hinge element 183 along the hinge axis, at each end, forming lugs adapted to be received in housings provided for this purpose respectively in the first end part 81a and in the second end part 89, in the molding configuration of the mold 80.
• the central part 81b is precisely positioned and maintained relative to the first end part 81a and to the second end part 89.
• the side element 182a forms a first side end element and the side element 182f forms a second side end element.
• the hinge 185 connecting the side element 182a and the side element 182f forms a flange 189.
• the flange 189 has a locked state and an unlocked state. In the locked state shown in Figure 13, the pin 184 connects the first hinge member 181 of the first end side member 182a to the second hinge member 183 of the second end side member 182f.
• the flange 189 includes the first hinge member 181 of the first end side member 182a, the second hinge member 183 of the second end side member 182f and the pin 184.
• the flange 189 is in the locked state and each hinge 185 is immobilized in rotation around the corresponding hinge axis 180.
• the hinge pins 180 extend parallel to the mold pin 83.
• the first hinge member 181 of the first end side member 182a and the second hinge member 183 of the second end side member 182a and the second hinge member 183 of the second end side member 182a end 182f are not connected by pin 184 of flange 189.
• the first lateral end element 182a is then released relative to the second lateral end element 182f.
• the central part 81 b is moved away from the second end part 82 and the first end part 81a is moved away from the central part 81 b.
• the pin 184 of the flange 189 is then removed from the bore of the first hinge member 181 of the first end side member 182a and the bore of the second hinge member 183 of the second member lateral end 182f by sliding in the direction of the hinge axis 180 of the flange 189.
• the flange 189 is then in the unlocked state, the hinges 185, other than the flange 189, are then free to pivot.
• the side elements 182a, 182b, 182c, 182d, 182e, 182f can then be placed flat, side by side.
• the side surfaces 86 are then in the same plane.
• the mold 80 is in the unmolding configuration.
• the construction element 10 is then released from the mold 80.
• the lateral elements 182a, 182b, 182c, 182d, 182e, 182f each have a first beveled portion 187a, 187b, 187c, 187d, 187e, 187f and a second beveled portion 188a , 188b, 188c, 188d, 188e, 188f arranged on either side of the lateral surface.
• the first beveled portion 187a, 187b, 187c, 187d, 187e, 187f forms an angle a with the second beveled portion 188a, 188b, 188c, 188d, 188e , 188f.
• the angle a is equal to 360 degrees divided by the number of side elements. In the illustrated embodiment, the angle a is equal to 60 degrees.
• each first beveled portion 187a, 187b, 187c, 187d, 187e, 187f is in contact with a corresponding second beveled portion 188a, 188b, 188c, 188d, 188e, 188f, so that the lateral surfaces 86 follow one another without play between them around the mold axis 83 and the hinges 185 are immobilized in rotation in the molding configuration.
• the construction element 10 comprises a core 30 of expanded material (foam) and the envelope 20 which is slightly enclosed in the core 30, the envelope 20 being on the periphery of the construction element 10.
• the container 34 is found in the core 30 and must therefore be made of material compatible with the expanded material of the core 30.
• the construction element 10 is cylindrical.
• the construction element 10 comprises a first end face 12, a second end face 14, opposite the first end face 12, and side faces 16.
• the side faces 16 defining an axis 15 and a section polygonal transverse, regular hexagonal in the illustrated embodiment.
• the rods 8, optional, extend between the first end face 12 and the second end face 14, along the edges joining the side faces 86.
• the rods 8 extend in the direction of the axis 15
• the rods 8 form reinforcements increasing the mechanical resistance of the construction elements, particularly in compression.
• Operations a1) and a2) are carried out a plurality of times so as to produce a first group 2 of a plurality of construction elements 10.
• the time for the foam to harden is relatively long (several minutes, or even several tens of minutes), operations can be carried out on a carousel in order to increase productivity.
• each construction element 10 is then wetted with resin 40, according to a first embodiment. At least one of the side faces 16 of the construction element 10 is wetted with resin. In the first embodiment, all the side faces 16, as well as the first end face 12 and the second end face 14 are wetted with resin 40.
• the resin 40 impregnates the fibers of the envelope 20 and also superficially the heart 30.
• each construction element 10 is rotated around the axis 15 to uniformly distribute the resin 40 and remove by centrifugation, in other words by spinning, the excess resin 40.
• the construction elements 10 can then be exposed to an ultraviolet emitter in order to harden the resin 40, which creates a hardened resin shell 40 at the periphery of the construction elements 10.
• This resin shell 40 is waterproof, in order to protect the foam core 30 and promotes the adhesion of resin subsequently deposited on the construction elements 10.
• the first group 2 of construction elements 10 is arranged in a formwork 90.
• the formwork 90 comprises a support 92 and a frame 94 carried by the support 92.
• the elements of construction 10 are arranged with the first end face 12 resting on the support 92 and held inside the frame 94, so that the side faces 16 of the adjacent construction elements 10 are applied (pressed) against each other others.
• the first group 2 of construction elements is maintained in this way until the resin 40 hardens and the construction elements 10 are joined to each other by their side faces 16.
• a first plate 52 is placed on the support 92 before placing the first group 2 of construction elements 10 in the formwork 90.
• the first plate 52 has a first right side 52a and a first reverse side 52b.
• the first right side 52a is arranged to rest on the support 92.
• a first layer of resin 42 is placed on the first reverse side 52b of the first plate 52.
• a first sheet of fibers 22 is then placed on the first layer of resin 42.
• the first layer of resin 42 gradually impregnates the fibers with the first sheet of fibers 22.
• the first end face 12 of the construction elements 10 is arranged on the support 92 via the first plate 52, the first layer of resin 42 and the first sheet of fibers 22.
• the support 92 is curved, as illustrated in Figure 15.
• the support 92 a convex shape on the side of the construction elements 10, so that the construction elements 10 are in contact with each other at the level of the first end face 12, and have rows slightly spaced apart from each other of the others at the level of the second end face 14.
• spacer elements 18 are preferably arranged between the rows of construction elements 10. THE principle of spacer elements is well known, particularly in the field of tiling, or the like. These spacer elements 18 act as corners. In the illustrated embodiment, they have a chevron shape, but they could have another shape. Resin 40 can, if necessary, be added between the rows of construction elements 10.
• the formwork 90 is made of a material or covered with a material on which the resin 40 and the first layer of resin 42 does not adhere to facilitate the separation of the first panel 100 and the formwork 90.
• the construction elements 10 are fixed to each other by their side faces 16 and the resin 40.
• the construction elements 10 are fixed by their first end face 12 to the first layer of resin 42 in which is embedded the first sheet of fibers 22 and which holds the construction elements 10 together.
• the first panel 100 is in particular held more firmly with the desired bend.
• Figure 8 illustrates the creation of a wall from a plurality of panels fixed in pairs.
• Figure 2 illustrates the production of a wall 1 by fixing together a first panel 100, a second panel 200 and elements assembly 110.
• the second panel 200 comprises a second group 4 of construction elements 10.
• the second panel 200 is identical to the first panel 100 and produced as described above in relation to the first panel 100.
• the assembly elements 110 are identical to the construction elements 10 of the first panel 100 and the second panel 200.
• the assembly elements 110 are wetted with resin, in a manner analogous to what has been described above in relation to the construction element 10 illustrated in Figure 5. Then, the assembly elements 110 are pressed against the first panel 100, as shown schematically by the arrows 130. Then, the second panel 200 is arranged parallel to the first panel 100, in the extension of the first panel 100, and pressed against the first panel 100 and the elements of assembly 110.
• the side faces of the construction elements 10 of the first panel 100 coming into contact with a side face of one of the construction elements 10 of the second panel have also been previously wetted with resin.
• a wall comprising the first panel 100 and the second panel 200 fixed together. By proceeding in this way with other panels, we obtain a wall 1 comprising a series of panels.
• operation e) is optional. It is possible to directly make the first panel to the desired dimensions, without having to attach it to other panels.
• Figure 8 further illustrates the optional fixing of a frame 62 on the second end face 14 of the construction elements 10 by means of screws 64.
• the screws 64 are preferably screwed into resin, either between the elements of construction 10, or on the second end face 14 of the construction elements 10. If necessary, a hollow can be formed in the construction element 10 and filled with resin to serve as a housing cooperating with the screws 64.
• a coating 60 is then applied to the second end face 14 by embedding the frame 62 in the coating 60.
• the frame 62 can be fixed during the production of each panel, before assembly of the panels to form the wall 1. Alternatively, the frame 62 and the coating 60 can be produced after assembling the panels to form the wall 1.
• the reinforcement can then be in one piece and extend over the first panel 100 and the second panel 200. To avoid overloading Figure 8, the panel 100 is shown without coating 60 and the second panel 200 is shown without reinforcement 62 nor coating 60.
• Figures 10 and 11 illustrate a second embodiment of the first panel 100 from the first group 2 of construction elements 10.
• the construction elements 10 are arranged in the formwork 90 with the first end face 12 resting on the support 12.
• the construction elements 10 may have been previously wetted with resin to form a hardened resin shell.
• a first plate 52 and/or a first layer of resin 42 and/or a first sheet of fibers 22 can be placed on the support 52 before the construction elements 10.
• a spacing e is provided between the side faces 16 facing the construction elements 10. This spacing e can easily be obtained by means of the spacer elements 18.
• the formwork 90 comprises first studs 96 and second studs 98 removably held on the frame.
• the first pads 96 and the second pads 98 are preferably removed to facilitate the installation of the first plate 52, the first layer of resin 42 and the first sheet of fibers 22 on the support 92.
• the first plate 52, the first layer of resin 42 and the first sheet of fibers 22 each have a substantially rectangular shape extending to the frame 94.
• the first pads 96 and the second pads 98 are then positioned on the frame 94, but the first pads 96 and 98 do not come into contact with the support 92, taking into account the presence of the first plate 52, the first layer of resin 42 and the first sheet of fibers 22.
• the first pads 96 and the second pads 98 make it possible to not leave that the spacing e around the construction elements 10.
• the support 92 is curved, as illustrated in Figure 16.
• the support 92 is given a concave shape on the side of the construction elements 10, so that the construction elements 10 are brought into contact with each other at the level of the second end face 14.
• the spacing e is preferably chosen according to the desired bending to bring the construction elements 10 into contact with each other at the level of the second end face 14. Spacer elements 18 of different dimensions may therefore be provided, depending on the desired bending.
• the construction elements 10 are only spaced from each other at the level of the first end face 12 in a single direction (from left to right in Figure 16). Indeed, in the perpendicular direction (substantially perpendicular to the plane of Figure 16), the construction elements 10 are in contact with each other at the level of the first end face 12. Consequently, in the alternative embodiment illustrated in Figure 16, at the first end face 12 the construction elements 10 form rows spaced apart by the spacing e and in each row, the construction elements 10 are in contact with each other.
• Resin 40 is then poured into the formwork 90, in order to fill the spacing e between the construction elements 10 with resin 40, between the first end face 12 and the second end face 14.
• resin 40 is cast to cover the end face 14 with a second layer of resin 44.
• a second sheet of fibers 24 is then placed on the second layer of resin 44.
• the second layer of resin 44 gradually impregnates the second sheet of fibers 24.
• the resin layer 40, the first resin layer 42 and the second resin layer 44 have hardened, we obtain the first panel 100 illustrated in Figure 11.
• the first panel 100 is removed from the formwork 90 with the first pads 96 and the second pads 98. Then, the first pads 96 and the second pads 98 are separated from the first panel 100.
• the first sheet of fibers 22 is included in the first layer of resin 42, as illustrated in Figure 11.
• the second sheet of fibers 24 is included in the second layer of resin 44.
• the resin 40 forms a gap structure 46 extending between the construction elements 10.
• the gap structure 46 has a honeycomb shape.
• the first layer of resin 42, the second layer of resin 44 and the gap structure 46 form a single piece, in other words in one piece.
• Aggregates can be incorporated into the second layer of resin to improve the appearance and mechanical resistance.
• the aggregates preferably include broken stone, particularly marble.
• the first layer of resin 42 and the first sheet of fibers 22 hold the construction elements 10 by their first end face 12.
• the second layer of resin 44 and the second sheet of fibers 24 hold the construction elements 10 by their second end face 14.
• the lacunar structure 46 holds the construction elements 10 by their side faces 16.
• Each construction element 10 has the shape of a cylinder with a regular hexagonal base.
• the height (in the direction of axis 15, between the first end face 12 and the second end face 14) of each construction element 10 is preferably between 150 millimeters and 250 millimeters, advantageously approximately 200 millimeters.
• the height of the construction elements 10 can be adapted according to the desired wall resistance. The more the wall needs resistance or high lift, the greater the height of the construction elements 10 must be. It could therefore be planned to produce construction elements 10 with a height of 300 millimeters for example to obtain very high resistance or lift.
• the insulation provided by the wall also increases with the increase in the height of the construction elements 10.
• different versions of the part are provided. central 81b of the mold 80 and a single version of the first end part 81a and the second end part 89 is used.
• Each side of the hexagonal base is preferably between 90 millimeters and 150 millimeters, advantageously of the order of 115 millimeters. Consequently, the distance between two opposite side faces 16 of each construction element is advantageously approximately 200 millimeters and the distance between two opposite edges is advantageously approximately 230 millimeters.
• Each construction element 10 therefore advantageously has a volume close to 6.9 dm 3 (liters).
• the density of the foam constituting the core 30 of the construction element 10 is preferably around 50 kg/m 3 .
• the mass of the core 30 of each construction element 10 is of the order of 340 grams.
• the envelope 20 corresponds substantially to a surface area of 800 millimeters by 400 millimeters.
• the envelope 20, the first sheet of fibers 22 and the second sheet of fibers 24 are preferably made of glass fibers and have a surface density preferably between approximately 300 and 450 g/m 2 .
• the envelope 20 therefore has a mass preferably of approximately 90 to 150 grams.
• the envelope 20, the first sheet of fibers 22 and the second sheet of fibers 24 may in particular be made of aramid fibers or carbon fibers.
• the envelope 20, the first sheet of fibers 22 and the second sheet of fibers 24 may also comprise a mixture comprising glass fibers and/or aramid fibers and/or carbon fibers.
• the envelope 20, the first sheet of fibers 22 and the second sheet of fibers 24 may also comprise elements other than glass fibers, aramid fibers and carbon fibers.
• the mass of resin 40 is preferably approximately 150 grams per construction element 10.
• each construction element 10 is preferably between 550 and 650 grams.
• the number of building elements 10 is preferably between 25 and 29 per square meter.
• the surface density is therefore of the order of 15 kilograms per square meter.
• the density is therefore of the order of 0.075.
• a first group 2 and a second group 4 are shown, each comprising thirteen construction elements 10.
• the first panel 100 and the second panel 200 preferably measure approximately 3 m by 1.2m.
• the first panel 100 comprising the first group 2 and the second panel 200 comprising the second group 4 each preferably comprise between eighty-five and one hundred construction elements 10, advantageously ninety-four.
• Eight assembly elements 110 are preferably used to fix the first panel 100 to the second panel 200.
• the resin 40, the first resin layer 42 and the second resin layer 44 are preferably made of epoxy or polyester.
• the thickness of the first resin layer 42, of the second resin layer 44 and the spacing e are each preferably between 1 and 3 millimeters, advantageously approximately 2 millimeters.
• the first resin layer 42 and the second resin layer 44 each have a mass preferably between 2 and 3 kilograms per square meter.
• the lacunar structure preferably has a mass of between 4 and 5 kilograms per square meter.
• the first panel 100, the second panel 200 and the wall 1 have a mass preferably d 'approximately 12 to 18 kilograms per square meter (depending on the presence or absence of the first sheet of fibers 22, the second sheet of fibers 24, the first layer of resin 42, the second layer of resin 44 and the lacunar structure 46), advantageously around 15 kilograms per square meter. Therefore, each panel preferably has a mass of between 40 and 60 kilograms.
• the insulation coefficient provided by the first panel 100, the second panel 200 and the wall 1 is approximately 13 m 2 .K/W.
• the insulation provided is excellent for a wall thickness of between 20 and 25 centimeters.
• the mechanical resistance is particularly high, so that the wall 1 is suitable for forming a bridge or the ceiling of a house.
• the wall can have a length of around ten meters or more, to obtain a span of 5 to 10 meters, while presenting minimal displacement under stress.
• the mold 80 and the formwork 90 are preferably made of pressed polyethylene or covered with polytetrafluoroethylene (PTFE).
• PTFE polytetrafluoroethylene
• the first plate 52 and the second plate 54 constitute a facing, preferably made of stone, glass, wood, plaster, plastic, in particular polyester or metal.
• the coating 60 is preferably a mineral coating, based on cement, lime sand, or plaster that can be tinted, or a plastic coating based on epoxy, acrylic or vinyl resin.
• the wall 1 has an excellent finish, so that in the case of a home, the work can be quickly completed.
• the construction elements 10 have at the level of the second end face 14 reservations 19 to allow the passage of sheaths electrical or conduit. These reservations 19 can be made by creating projections on the periphery of the second end face 84 of the mold 80.
• the section of the construction elements 10 is reduced at the level of the second end face 14.
• the section of the construction elements 10 is advantageously square at the level of the second end face 14, while the section of the rest of the construction elements 10 is hexagonal.
• construction elements 10, as well as the panels 100, 200 can easily be produced in the factory. But, manufacturing is flexible. Thus, it may also be favorable to manufacture only the construction elements 10 in the factory, transport them to site and produce the wall 1 and more generally the entire work by adding the construction elements 10 one after the other to the manner of concrete block works. And, if necessary, the manufacturing of the construction elements 10 can also be carried out on the site where the work is carried out.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Finishing Walls (AREA)

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• 2022
  • 2022-06-20 FR FR2206043A patent/FR3136800B1/fr active Active
• 2023
  • 2023-06-19 WO PCT/FR2023/050901 patent/WO2023247877A1/fr not_active Ceased
  • 2023-06-19 EP EP23744197.7A patent/EP4540475A1/de active Pending

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