ES2802902B2 - SANDWICH PANEL AND ASSOCIATED ASSEMBLY PROCEDURE - Google Patents

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.

The assembly of sandwich panels comprising an insulation layer between two metal sheets to build roofs is known. 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 interlock when two are assembled. panels.

It is also known to build walls by assembling sandwich panels where the fasteners used to fix one panel to the building structure are concealed when the adjacent panel is positioned. However, these concealed fixings are not sufficiently resistant to wind suction to use these sandwich panels for roof construction.

Therefore, the aim of the present invention is to overcome the drawbacks of the prior art by providing a concealed fastening sandwich panel 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 part lying substantially in a plane P, - a first inner rim extending inwardly from a first end of the inner central part and comprising an inner recess extending parallel to the plane P and inwardly ,

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

where the outer metal sheet comprises in cross section:

- an outer central part,

- a first outer rim that extends 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 being at least partly thinner than the first upper part,

^or an outer recess extending parallel to the plane P and inward, - a second outer rim extending from a second end of the outer central part and comprising a second lateral rib extending substantially perpendicular to the 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 interlocking of the second lateral rib 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 side flap comprises two side flaps that are substantially in contact in at least a portion of the first bottom,

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

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

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

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

- the second inner rim and the second outer rim 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 joint.

A second object of the invention consists in assembling at least one first and one second panel according to the invention, where the second lateral rib of the second panel is embedded in the first lateral rib of the first panel and the inner tab of the second panel is inserted in the inside 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 that comprises:

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

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

- (iii) rotating 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 given 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 assembly of panels according to the invention,

- figure 6, which represents details of the assembly of panels 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 "inwards" and "outwards" used in this application refer to the positions and orientations of the different constitutive 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 out, it extends in the opposite direction of the insulation board.

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 oriented towards the outside and the inner tray is oriented towards the interior of the building. Accordingly, the inner rim refers to the rim of the inner tray and the outer rim refers to the rim of the outer plate.

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 lies in a horizontal plane.

Throughout the text, sheet metal is understood to mean 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 or different materials. The material in question can be, among others, a metallic material or a polymer. Steel, aluminum, copper and zinc can be cited as non-restrictive 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 outer veneer are examples of veneers.

Within the framework 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 bend 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, rib is understood to mean an extension formed on the surface of the sheet. The nerve may have a trapezoidal or rectangular, corrugated, sinusoidal or even omega shape, for example. It includes a central upper part and two lateral flanges. A stiffener is a rib of limited height, typically 10 to 30 times lower than a rib. 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 insulating material 2 sandwiched between an inner metal tray 3 and an outer metal sheet 4. The sides of the insulating material thus form the sides of the panel .

The insulation material 2 can be any material that provides some insulation to the panel. It can be, by way of non-limiting 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 with a rectangular shape, comprising longitudinal edges and transverse edges, which have been formed in a previous phase. It comprises, in cross section perpendicular to its longitudinal axis, an inner central part 5 and two inner ridges 6, 7 which extend inwardly from each end of the inner central part. The inner central part is 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 part 5 and comprises an S-shaped bend forming an inner recess 8 extending parallel to the plane P. and inward. Preferably, the inner recess comprises an inner shoulder 9 and a flat portion 10. The inner shoulder can extend substantially perpendicular from the inner central part or can be inclined towards the flat portion. The latter can be parallel to the plane P or slightly inclined towards the inner central part to facilitate the interlocking of two adjacent panels.

Preferably, the first inner rim 6 comprises a first inner stiffener 11 extending from the inner recess. According to a variant of the invention, the first internal stiffener extends substantially perpendicular to the internal central part to facilitate the manufacture of the internal metal tray. According to another variant, the first internal 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 flange 12 which extends parallel to the plane P and inwards towards the insulation material 2. This helps to stiffen the first inner rim.

As illustrated in Figure 4, the second inner rim 7 extends inwardly from a second lateral end of the inner core 5 and comprises a U-shaped bend and forms an inner tab 13 extending 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 angled toward 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 tab. 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 rim 7 comprises a second inner stiffener 17 which 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 internal 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 inwards towards the insulation material 2. This helps to stiffen the first inner rim.

The inner recess 8 and the tongue 13 have shapes that allow them to interlock when a panel is assembled 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 tab,

- 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 tab are such that it fits perfectly into the inner recess, which further improves 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 slope of the upper branch 15 of the inner tab engages with the inclination of the flat portion 10 of the inner recess

As illustrated in Figures 1 and 2, the outer sheet metal 4 is a rectangular shaped sheet metal, comprising longitudinal edges and transverse edges, which have been formed at an earlier stage. It comprises, in cross section perpendicular to its longitudinal axis, an outer central part 18 and two ridges 19, 20 extending inward and/or outward from each end of the outer core. Preferably, most of the outer central part is in a plane parallel to the plane P. In the variant illustrated in figures 1 and 2, where the panel 1 is intended to be used for ceilings, the outer central part comprises at least a midrib 21 imitating a vertical seam. In particular, the lateral midrib fins 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, stiffeners that extend longitudinally 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 part 18, substantially above the first inner rim 6 and successively comprises a first lateral rib 22 extending substantially perpendicular to the plane P. and outward, and an outer recess 23 extending parallel to the plane P and inward. 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 center part 18.

The first lateral rib 22 comprises a first lower part 24 that is clamped, that is to say its lower part is at least partly thinner than its first upper part 25. Thanks to this configuration, when a second lateral rib is clamped on the first rib lateral 22, the upper part prevents the second lateral rib from unlocking unexpectedly. In particular, in at least a portion of the first lower part 24, the two lateral wings 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 bounded by the upper central part of the first lateral rib 22 and the upper portion of the two lateral rib wings.

The main purpose of the external recess is to hide the distribution plates and the fixing elements used to fix the sandwich panel in 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 as deep enough, in In particular, the short side of the L is long enough so that a baffle plate 36 and fastener heads 37 can be placed 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 in drilling through the outer sheet metal.

Preferably, the first outer rim 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 rim. According to the illustrated variant, the first external 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 part 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 part 18 The main purpose of this outer flat 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 partly thinner than the second upper part 33. Thanks to this configuration, when the second lateral rib is clamped in the first lateral nerve 22, the impingement prevents the second lateral nerve from unblocking unexpectedly. In particular, in at least a portion of the second lower part 32, the two lateral wings 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 bounded by the upper central part of the second lateral rib 30 and the upper portion of the two lateral rib wings.

The conformation of the second lateral rib 30 is such that it can be interlocked in 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 wings 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 the outer sheet metal.

The person skilled 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 rim 19 is located on the same lateral side, hereinafter referred to as the first lateral side 34, of the panel as the first inner rim 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 fixed in the structure of the building, the inner tongue 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 is locked under the first panel, the windage resistance of the panel assembly is greatly improved.

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

Preferably, the first inner rim 6 and the first outer rim 19 are positioned so that the first lateral side 34 of the insulation material slopes 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 edge 7 and the second outer edge 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 embedded 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 tightness of the panel assembly. If one of the lateral sides includes a gasket 38, then the latter is evenly compressed. More preferably, when the first lateral side of the insulation material is inclined towards the outer metal sheet, the compression of the joint is even greater.

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

To form a roof or façade, 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 fixing elements such as screws, nails or rivets.

The first stage of the assembly procedure consists in locating a first panel in the structure of the building and fixing it to the structure by means of a fixing element 37 that passes through the outer rim 23 of the outer metal sheet 4, the material of insulation 2 and the inner metal tray 3, as illustrated in figure 5. Preferably, a distribution plate 36 is placed in the outer recess before fastening the panel to limit the deformation of the outer metal sheet and to improve the 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 in transversely inclining a second panel 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 It is illustrated in figure 7.

The third stage of the assembly procedure consists in nailing 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 in turning the second panel in the direction of the building structure until the inner tab 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 insulating 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) extending extends parallel to the plane P and inwards, - a second inner rim (7) extending inwards from a second end of the inner central part (5) and comprising a U-shaped fold forming an inner tongue (13) extending parallel to the plane P and towards the outside, the inner recess (8) and the inner tongue (13) have shapes that allow their interlocking, where the outer metal sheet (4) comprises in cross section: - an outer central part (18), - a first outer rim (19) that extends from a first end of the outer central part (18), substantially above the first inner rim (6) and successively comprising: ^or a first lateral rib (22) extending substantially perpendicular to the plane P and outward, and comprising a first lower part (24) and a first upper part (25), the first lower part (24) being at least partially thinner than the first top (25), ^or an outer recess (23) that extends parallel to the plane P and inwards, the outer recess (23) being in a plane located below the plane of the outer central part (18), - a second outer rim (20) which extends from a second end of the outer central part and comprises a second lateral rib (30) which extends substantially perpendicular to the plane P and outwards, and which comprises a second lower part (32 ) and a second upper part (33), the second lower part (32) is at least partially thinner than the second upper part (33), the first lateral rib (22) and the second lateral rib (30) have conformations that they allow the second lateral rib (30) to engage in the first lateral rib (22), the first lower part (24) being clamped and the second lateral rib (30) being adapted to engage in the first lateral rib (22), the first upper part (25) preventing the second lateral rib (30) from unlocking unexpectedly. Panel according to claim 1, wherein the internal recess (8) comprises an internal ridge (9) extending substantially perpendicular from the internal 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 bypass (14) and an upper bypass (15) joined by a U-turn (16), the upper bypass is inclined towards the u turn Panel according to any of the preceding claims, wherein the first lateral rib (22) comprises two lateral flaps that 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) that extends parallel to the 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 rim (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 rim (6) and the first outer rim (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 edge (7) and the second outer edge (20) define a second lateral side (35) of the insulation material that has the same inclination as the first lateral side (34). Panel according to either of claims 8 or 9, wherein the first lateral side (34) comprises a joint (38). Assembly of at least one first and one second panel (1) according to any of claims 1 to 10, wherein the second lateral rib (30) of the second panel is embedded in the first lateral rib (22) of the first panel and the inner tab (13) of the second panel is inserted into the inner recess (8) of the first panel. 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°, - (ii) interlocking the second lateral rib (30) of the second panel in the first lateral rib (22) of the first panel, hooking the second lateral rib (30) in the first lateral rib (22), the first upper part (25) preventing the second lateral rib (30) from unlocking unexpectedly, - (iii) rotate the second panel until the inner tab (13) of the second panel engages with the inner recess (8) of the first panel.