ES2802902A2 - SANDWICH PANEL AND ASSOCIATED ASSEMBLY PROCEDURE (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

Sandwich panel and associated assembly procedure. The invention relates to a panel comprising an insulation material sandwiched between an inner metal tray and an outer metal sheet, wherein the inner tray comprises in cross section an inner recess that extends inwardly from a first end of the inner central part and a U-shaped fold that forms an inner tab that extends inwardly from a second end of the inner central part, the inner recess and the inner tongue have interlocking conformations, where the outer sheet comprises a first lateral rib extending from a first end of the outer central part and comprising a first lower part that clamps and an outer recess, a second lateral rib which extends from a second end of the outer central part and comprising a second lower part which is pinched, the first lateral rib and the second lateral rib have conformations that allow their e interlocking. (Machine-translation by Google Translate, not legally binding)

Description

DESCRIPTION

Sandwich panel and associated assembly procedure

The present invention refers to a sandwich panel, intended for the construction of building envelopes and, more particularly, intended for the construction of building roofs, without being limited thereto.

It is known to assemble sandwich panels comprising an insulation layer between two metal sheets to build roofs. In general, each sandwich panel comprises on one of its longitudinal edges a male interlocking part and, on its other longitudinal edge, a female interlocking part, so that the male and female interlocking parts are interlocked when two are assembled. panels.

Wall construction by mounting sandwich panels is also known where the fasteners used to secure a panel to the building structure are hidden when the adjacent panel is positioned. However, these concealed fasteners are not resistant enough to wind suction to use these sandwich panels for roof construction.

Therefore, the object of the present invention is to overcome the drawbacks of the prior art by providing a sandwich panel with hidden fastening that provides improved resistance to wind suction.

For this purpose, a first object of the present invention consists of a panel comprising an insulation material sandwiched between an inner metal tray and an outer metal sheet where the inner metal tray comprises in cross section:

- an inner central portion lying substantially in a plane P, - a first inner rim extending inwardly from a first end of the inner central portion and comprising an inner recess extending parallel to the plane P and inward ,

- a second inner rim extending inwardly from a second end of the inner central portion and comprising a U-shaped fold forming an inner tongue extending parallel to plane P and towards outside, the interior recess and the interior tongue have conformations that allow their interlocking,

where the outer metal sheet comprises in cross section:

- an outer central part,

- a first outer rim extending from a first end of the outer central part, substantially above the first inner rim and successively comprising:

or a first lateral rib extending substantially perpendicular to the plane P and outward, and comprising a first lower part and a first upper part, the first lower part is at least partially thinner than the first upper part,

or an outer recess extending inwardly parallel to plane P, - a second outer rim extending from a second end of the outer central portion and comprising a second lateral rib extending substantially perpendicular to plane P and outward , and comprising a second lower part and a second upper part, the second lower part is at least partially thinner than the second upper part, the first lateral rib and the second lateral rib have conformations that allow the second lateral rib to interlock in the first lateral nerve.

The panel according to the invention can also have the optional features listed below, considered individually or in combination:

- the inner recess comprises an inner shoulder extending substantially perpendicular from the inner central part and a flat portion,

- the inner tab comprises a lower branch and an upper branch joined by a U-turn, the upper branch is inclined towards the U-turn, - the first lateral fin comprises two lateral fins that are substantially in contact in at least a portion of the first bottom part,

- the outer recess comprises an L-shaped portion with the short side of the L that is an extension of the first lateral rib and the long side of the L that extends parallel to the plane P,

- the long side of the L comprises a longitudinal groove,

- the second outer rim successively comprises an outer flat portion projecting from the insulation material and the second lateral rib,

- the first inner rim and the first outer rim delimit a first lateral side of the insulation material which forms an acute angle with the inner central part,

- the second inner edge and the second outer edge delimit a second lateral side of the insulation material that has the same inclination as the first lateral side,

- the first lateral side comprises a seal.

A second object of the invention consists of an assembly of at least a first and a second panel according to the invention, where the second lateral rib of the second panel is interlocked in the first lateral rib of the first panel and the inner tab of the second panel is inserted in the interior recess of the first panel.

A third object of the invention consists of a process for assembling a first and a second panel according to the invention, comprising:

- (i) tilt the second panel transversely at an angle a, with the plane P of the first panel, between 10 ° and 50 °,

- (ii) locking the second lateral rib of the second panel into the first lateral rib of the first panel,

- (iii) turn the second panel until the inner tab of the second panel engages with the inner recess of the first panel.

Other features and advantages of the invention will be described in more detail in the following description.

The invention will be better understood by reading the following description, which is provided purely for explanatory purposes and is in no way intended to be restrictive, with reference to:

- figure 1, which is a perspective view of a sandwich panel according to the invention,

- figure 2, which is a cross section of the sandwich panel of figure 1, figure 3, which is a cross section of the first longitudinal edge of a sandwich panel of figure 1,

figure 4, which is a cross section of the second longitudinal edge of a sandwich panel of figure 1,

- figure 5, which is a cross section of the panel assembly according to the invention,

- figure 6, which represents details of the panel assembly according to figure 5, - figure 7, which is a cross section of the first longitudinal edge of a first sandwich panel and of the second longitudinal edge of a second sandwich panel in a stage of the assembly procedure.

It should be noted that the expressions "inward" and "outward" used in this application refer to the positions and orientations of the different constituent elements of the panel with respect to the position of the insulation material. Consequently, if an element extends inward, it extends in the direction of the insulation panel. Similarly, if the element extends outward, it extends in the opposite direction from the insulation panel.

It should also be noted that "interior" and "exterior", as used in this application, refer to the position of the panels in a building. Consequently, the outer sheet is facing outward and the inner tray is facing into the building. Accordingly, the inner flange refers to the flange of the inner tray and the outer flange refers to the flange of the outer sheet.

It should be noted that the expressions "lower", "upper", "above", "below", etc., as used in this application, refer to the positions and orientations of the different constituent elements of the panel when the latter it lies in a horizontal plane.

Throughout the text, sheet metal is understood to be an element that has a flat conformation, that is, its thickness is low compared to its other dimensions. Generally speaking, its thickness is 500 to 4000 times less than its width. The sheet can be made of a single material or a set of composite materials. In the latter case, the sheet is a stack of a plurality of layers of the same material or different materials. The material in question may be, among others, a metallic material or a polymer. Steel, aluminum, copper, and zinc can be cited as non-limiting examples of metallic materials. The sheet is preferably a metal sheet. Preferably, it is made of pre-galvanized and pre-coated steel to protect against corrosion. The inner tray and the outer sheet are examples of sheets.

Within the scope of the invention, the sheet will preferably have been previously formed with the aid of any known forming process, including, by way of non-restrictive examples, bending, forming, stamping and molding. In particular, the U-shaped fold described below is a panel element whose manufacturing process is not limited to bending.

This formation leads, among other things, to the formation of ribs, stiffeners or grooves in the surface of the sheet. Throughout the text, a rib is understood as an extension formed on the surface of the sheet. The rib may have a trapezoidal shape or a rectangular, corrugated, sinusoidal or even omega shape, for example. It includes a central upper part and two side flanges. A stiffener is a rib of limited height, generally 10 to 30 times lower than a rib. The ribs and stiffeners are generally placed parallel to the longitudinal edges of the sheet, especially to make the sheet more rigid.

With reference to Figures 1 and 2, the panel 1 according to the invention first comprises an insulation material 2 sandwiched between an inner metal tray 3 and an outer metal sheet 4. The sides of the insulation material thus form the sides of the panel .

Insulation material 2 can be any material that provides some insulation to the panel. It can be, by way of non-restrictive examples, polyurethane foam, polyisocyanurate foam, phenolic foam, mineral wool. According to a variant of the invention, the insulation material is a composite material comprising a lower layer of mineral wool and an upper layer of foamed material.

The inner metal tray 3 is a metal sheet of rectangular shape, comprising longitudinal edges and transverse edges, which have been formed in a previous stage. It comprises, in cross section perpendicular to its longitudinal axis, an inner central part 5 and two inner ridges 6, 7 extending inwardly from each end of the inner central part. The inner central part is located substantially flat in a plane P. According to a variant of the invention, the inner central part 5 comprises longitudinally extending stiffeners to increase the rigidity of the metal sheet.

As illustrated in Figure 3, the first inner rim 6 extends inwardly from a first lateral end of the inner central portion 5 and comprises an S-shaped fold forming an inner recess 8 that extends parallel to the plane P and inward. Preferably, the inner recess comprises an inner shoulder 9 and a flat portion 10. The inner shoulder may extend substantially perpendicularly from the inner central portion or it may slope towards the flat portion. The latter can be parallel to the plane P or be slightly inclined towards the inner central part to facilitate the interlocking of two adjacent panels.

Preferably, the first inner flange 6 comprises a first inner stiffener 11 extending from the inner recess. According to a variant of the invention, the first inner stiffener extends substantially perpendicular to the inner central part to facilitate the manufacture of the inner metal tray. According to another variant, the first inner stiffener extends at least partially and substantially along the edge of the insulation material to facilitate the interlocking of two adjacent panels. According to a variant of the invention, the first inner stiffener comprises a first inner fin 12 which extends parallel to the plane P and inwardly towards the insulation material 2. This helps to stiffen the first inner flange.

As illustrated in Figure 4, the second inner flange 7 extends inwardly from a second lateral end of the inner central portion 5 and comprises a U-shaped fold and forms an inner tab 13 that extends substantially parallel to the plane. P and out. Preferably, the inner tab comprises a lower branch 14 and an upper branch 15 joined by a U-turn 16. More preferably, the upper branch 15 is slightly inclined towards the U-turn to facilitate interlocking of two adjacent panels. According to another variant, leads 14 and 15 are parallel. More preferably, the radius of the U-turn is such that the space between the branches is filled with the insulation material 2 which helps to stiffen the inner tongue. According to another variant, the radius of the U-turn is such that the two branches are in contact with each other.

Preferably, the second inner flange 7 comprises a second inner stiffener 17 that extends from the inner tongue, in particular, from the upper branch 15. According to a variant of the invention, the second inner stiffener extends substantially perpendicular to the inner central part to facilitate the manufacture of the inner metal tray. According to another variant, the second inner stiffener extends at least partially and substantially along the edge of the insulation material to facilitate the interlocking of two adjacent panels. According to a variant of the invention, the second inner stiffener 17 comprises a second inner fin which extends parallel to the plane P and inwardly towards the insulation material 2. This helps to stiffen the first inner rim.

Inner recess 8 and tongue 13 have shapes that allow interlocking when one panel is mounted with an adjacent panel. Preferably, their conformations are substantially complementary and their dimensions are such that:

- the height of the inner recess (measured along the Y axis) is greater than the height of the inner tongue,

- the width of the inner recess (measured along the X axis) is greater than the width of the inner tongue.

Preferably, the shape and dimensions of the inner tongue are such that it fits perfectly into the inner recess, which further improves the resistance to wind suction. "Perfect fit" means that the inner tongue and inner recess are substantially in contact with each other except in areas where a possible gasket is added for sealing purposes, such as airtightness or thermal insulation. In particular, the width of the upper branch 15 (measured along the X axis) is equal to the width of the flat portion 10 (measured along the X axis) and the height of the inner shoulder 9 is equal to the height of the U-turn 16. More preferably, the inclination of the upper branch 15 of the inner tongue engages the inclination of the flat portion 10 of the inner recess

As illustrated in Figures 1 and 2, the outer metal sheet 4 is a metal sheet of rectangular shape, comprising longitudinal edges and transverse edges, which have been formed in an earlier stage. It comprises, in cross section perpendicular to its longitudinal axis, an outer central part 18 and two flanges outer 19, 20 extending inward and / or outward from each end of the outer central portion. Preferably, most of the outer central part lies in a plane parallel to the plane P. In the variant illustrated in Figures 1 and 2, where panel 1 is intended to be used for ceilings, the outer central part comprises at least a central rib 21 that mimics a vertical seam. In particular, the lateral fins of the midrib are substantially parallel and close to each other. According to another variant, the outer central part comprises, in combination with the central rib 21 or not, longitudinally extending stiffeners to further increase the rigidity of the metal sheet.

As illustrated in Figure 3, the first outer rim 19 extends from a first end of the outer central portion 18, substantially above the first inner rim 6 and successively comprises a first lateral rib 22 extending substantially perpendicular to the plane P and outwardly, and an outer recess 23 extending parallel to the plane P and inwardly. By "outer recess", it is meant that this portion of the outer sheet metal lies in a plane located below the plane of the outer central portion 18.

The first lateral rib 22 comprises a first lower part 24 that is clamped, that is, its lower part is at least partially thinner than its first upper part 25. Thanks to this configuration, when a second lateral rib is clamped on the first rib side 22, the upper part prevents the second side rib from unexpectedly unlocking. In particular, in at least a portion of the first lower part 24, the two lateral fins of the first lateral rib are substantially in contact. In particular, the upper part has substantially the shape of a rectangle or an ellipse whose main axis is substantially perpendicular to the plane P or a circle. This conformation acts as a closure. The upper part is delimited by the upper central part of the first lateral rib 22 and the upper portion of the two lateral ribs.

The main purpose of the exterior recess is to hide the cast plates and fasteners used to secure the sandwich panel to the building structure. Preferably, the outer recess 23 comprises an L-shaped portion with the short side of the L 26 as an extension of the first lateral rib and the long side of the L 27 extending parallel to the plane P. The outer recess is the deep enough, in In particular, the short side of the L is long enough so that a distribution plate 36 and the heads of fasteners 37 can be positioned in the outer recess without jeopardizing the interlocking of two adjacent panels, as illustrated in Figures 5 and 6.

More preferably, the long side of the L comprises a longitudinal slot 28. This assists in locating the fastener and drilling through the outer sheet metal.

Preferably, the first outer flange 19 comprises a first outer stiffener 29 extending from the outer recess 23, in particular from the long side of the L 27. This helps to stiffen the outer sheet metal and the first outer flange. According to the illustrated variant, the first outer stiffener 29 schematically has the shape of a hook.

As illustrated in Figure 4, the second outer rim 20 extends from a second end of the outer central portion 18, substantially above the second inner rim 7 and comprises a second lateral rib 30 extending substantially perpendicular to the plane P and out.

Preferably, the second outer rim 20 successively comprises an outer flat portion 31 projecting from the lateral side of the insulation material and the second lateral rib 30. In particular, the outer flat portion lies in the plane of the outer central portion 18 The main purpose of this flat outer portion is to cover the outer recess of an adjacent panel when the two panels are interlocked.

The second lateral rib 30 comprises a second lower part 32 that is clamped, that is, the second lower part is at least partially thinner than the second upper part 33. Thanks to this configuration, when the second lateral rib is clamped on the first lateral rib 22, the impingement prevents the second lateral rib from unexpectedly unlocking. In particular, in at least a portion of the second lower part 32, the two lateral fins of the second lateral rib are substantially in contact. In particular, the second upper part has substantially the shape of a rectangle or an ellipse whose main axis is substantially perpendicular to the plane. P or a circle. The second upper part is delimited by the upper central part of the second lateral rib 30 and the upper portion of the two lateral ribs.

The shape of the second lateral rib 30 is such that it can be interlocked with the first lateral rib 22, as illustrated in Figure 6. In particular:

- in at least a portion of the second lower part 32, the two lateral fins of the second lateral rib are separated by twice the thickness of the outer metal sheet, so that the second lower part 32 fits above the first lower part 24 and

- the second upper part 33 has substantially the same conformation as the first upper part 25, but slightly larger, so that the second upper part 33 fits over the first upper part 25. "Slightly larger" means that the difference in width of the second upper part 33 and the first upper part 25 is substantially equal to twice the thickness of the outer metal sheet and that the difference in height of the second upper part 33 and the first upper part 25 is substantially equal to twice the thickness of the outer sheet metal.

One of ordinary skill in the art can easily design other geometries of the first and second lateral ribs that interlock with each other while avoiding unexpected unlocking.

The first outer flange 19 is located on the same lateral side, hereinafter referred to as the first lateral side 34, of the panel as the first inner flange 6 so that, when the second lateral rib 30 of a second panel is engaged in the first lateral rib 22 of a first panel already attached to the building structure, the inner tab 13 of the second panel is inserted into the inner recess 8 of the first panel. Consequently, the connection between the two panels is very strong. In particular, as the inner tab of the second panel locks under the first panel, the wind suction resistance of the panel assembly is greatly improved.

Preferably, the outer recess 23 is located substantially above the first end of the inner central portion. Preferably, the long side of the L 27 is located in front of the first inner rim 6 (along the X axis), so that the fasteners that pass through the outer recess do not pass through the first inner rim.

Preferably, the first inner flange 6 and the first outer flange 19 are positioned so that the first lateral side 34 of the insulation material is inclined towards the outer metal sheet, that is, the inner central part 5 and the first lateral side 34 form an acute angle.

Symmetrically, the second inner flange 7 and the second outer flange 20 are preferably positioned so that the second lateral side 35 of the insulation material has the same inclination as the first lateral side 34. Thanks to this symmetrical inclination, when a first panel is interlocked in a second panel, the second lateral side of the first panel is in contact substantially over its entire surface with the first lateral side of the second panel. This improves the thermal efficiency and the airtightness of the panel assembly. If one of the lateral sides comprises a gasket 38, then the latter is uniformly compressed. More preferably, when the first lateral side of the insulation material is inclined towards the outer metal sheet, the compression of the gasket is even greater.

The gasket 38 can be, among others, an elastomeric material, PVC foam, PU foam, PVC hollow section gasket or an intumescent material, such as a mineral fiber based mat incorporating phosphate or exfoliating graphite. Preferably, the gasket forms part of the second lateral side of the insulation material so that it is protected by the second inner flange 7 and the second outer flange 20 during transportation and handling of the panel. However, it may be preferred to have the gasket on the first lateral side of the insulation material to make it easier to place the gasket on the panel.

To form a roof or facade, the panels 1 are assembled by marginal overlapping of their longitudinal and / or transverse edges and are attached to the supporting structure of the building by means of fastening elements such as screws, nails or rivets.

The first stage of the assembly procedure consists of placing a first panel on the building structure and fixing it to the structure by means of a fixing element 37 that passes through the outer edge 23 of the outer metal sheet 4, the material of insulation 2 and inner metal tray 3, as illustrated in Figure 5. Preferably, a cast plate 36 is positioned in the outer recess before clamping the panel to limit deformation of the outer sheet metal and to improve transmission of loads between the panel and the fixing element and therefore improve the resistance to wind suction.

The second stage of the assembly procedure consists of inclining a second panel transversely at an angle with the plane P of the first panel, hereinafter called angle a, between 10 ° and 50 °, preferably between 20 ° and 40 °, as illustrated in figure 7.

The third stage of the assembly procedure consists of locking the second lateral rib 30 of the second panel to the first lateral rib 22 of the first panel.

The fourth stage of the assembly procedure consists of rotating the second panel in the direction of the building structure until the inner tongue 13 of the second panel engages with the inner recess 8 of the first panel.

Subsequently, the second panel can be attached to the building structure in a similar way to what has been done for the first panel.

Claims (12)

1. Panel (1) comprising an insulation material (2) sandwiched between an inner metal tray (3) and an outer metal sheet (4), where the inner metal tray comprises in cross section: - an inner central part (5) lying substantially in a plane P, - a first inner rim (6) extending inwardly from a first end of the inner central part and comprising an inner recess (8) which is extends parallel to plane P and inward, - a second inner rim (7) extending inwardly from a second end of the inner central part and comprising a U-shaped fold that forms an inner tab (13) extending parallel to plane P and outward , the inner recess and the inner tongue have conformations that allow their interlocking, where the outer metal sheet (4) comprises in cross section: - an outer central part (18), - a first outer rim (19) extending from a first end of the outer central part, substantially above the first inner rim and successively comprising: or a first lateral rib (22) extending substantially perpendicular to plane P and outward, and comprising a first lower part (24) and a first upper part (25), the first lower part is at least partially thinner than the first top, or an outer recess (23) extending inward and parallel to plane P, - a second outer rim (20) extending from a second end of the outer central part and comprising a second lateral rib (30) extending substantially perpendicular to the plane P and outward, and comprising a second lower part (32 ) and a second upper part (33), the second lower part is at least partially thinner than the second upper part, the first lateral rib and the second lateral rib have conformations that allow the second lateral rib to interlock on the first lateral rib . Panel according to claim 1, wherein the inner recess (8) comprises an inner shoulder (9) extending substantially perpendicular from the inner central part (5) and a flat portion (10). Panel according to any of claims 1 or 2, wherein the inner tab (13) comprises a lower branch (14) and an upper branch (15) joined by a U-turn (16), the upper branch is inclined towards the U-turn. Panel according to any of the preceding claims, wherein the first lateral rib (22) comprises two lateral fins which are substantially in contact in at least a portion of the first lower part (24). Panel according to any of the preceding claims, wherein the outer recess (23) comprises an L-shaped portion with the short side of the L (26) being an extension of the first lateral rib and the long side of the L ( 27) extending parallel to plane P. Panel according to claim 5, wherein the long side of the L (27) comprises a longitudinal groove (28). Panel according to any of the preceding claims, wherein the second outer flange (20) successively comprises an outer flat portion (31) projecting from the insulation material and the second lateral rib (30). Panel according to any of the preceding claims, wherein the first inner flange (6) and the first outer flange (19) delimit a first lateral side (34) of the insulation material that forms an acute angle with the inner central part (5 ). Panel according to claim 8, wherein the second inner flange (7) and the second outer flange (20) delimit a second lateral side (35) of the insulation material having the same inclination as the first lateral side (34). Panel according to any one of claims 8 or 9, wherein the first lateral side (34) comprises a gasket (38). Assembly of at least a first and a second panel (1) according to any one of claims 1 to 10, wherein the second lateral rib (30) of the second panel is interlocked in the first lateral rib (22) of the first panel and the inner tab (13) of the second panel is inserted in the inner recess (8) of the first panel. 5 12. Method for assembling a first and a second panel (1) according to any of claims 1 to 10, comprising: - (i) tilt the second panel transversely at an angle a, with the plane P of the first panel, between 10 ° and 50 °, q - (ii) interlock the second lateral rib (30) of the second panel in the first lateral rib (22) of the first panel, - (iii) turn the second panel until the inner tab (13) of the second panel engages with the inner recess (8) of the first panel.