EP0059119A1 - Building element such as an isothermal wall made with a threedimensional reinforcement and process for making this wall - Google Patents

Abstract

The present invention relates to a three dimensional metal framework, designed for forming isothermic walls of buildings, which comprise an inner air cavity in form of a blade along one of its faces. This framework (9) comprises rectilinear and parallel rods (14) which are welded, in at least two parallel rows (14a, 14b), on sinusoidal wires (15) which extend in planes perpendicular to the rectilinear rods and whose tops (15a, 15b) are situated in two planes parallel with the two rows of rectilinear rods, the first row (14a) of rectilinear rods being furthermore slightly spaced apart from a first one of the planes containing the tops (15a) of the sinusoidal wires. The invention also relates to a constructional element built from this framework and comprising a bearing wall (4) and a heat insulating layer (5) both disposed between the two rows (14a, 14b) of the rectilinear rods of the framework (9) as well as two finishing coverings (2b, 3b) formed on the tops (15a, 15b) of the sinusoidal wires of the latter. An air cavity in form of a blade is therefore formed along one of the finishing coverings. The invention also relates to a process for constructing a constructional element of this type which constitutes an external wall of a house.

Description

The present invention relates to a three-dimensional metal frame designed for the production of isothermal building walls. It also relates to a building element produced using this framework, and more particularly to an isothermal exterior wall of a dwelling provided with an outside air space, as well as to a process for the construction of 'such a wall.

To meet the growing demand of the customers and to satisfy the official regulations currently in force in the field of construction, building contractors devote more and more efforts to improving the interior comfort of habitable premises and, more specifically , thermal and acoustic insulation, mainly by their exterior walls, individual houses and collective buildings.

Theoretical research carried out in this field has shown that by creating a vacuum or an air space in the exterior walls of a dwelling, one achieves, in combination with a layer of thermal insulation, a suitable thermal and acoustic damping between the outside and inside of it. To date, however, it has not been possible to develop means enabling this air space to be produced in a practical and simple manner.

Furthermore, the thermal stabilization of the walls, that is to say their protection against thermal shocks resulting for example from a significant variation in temperature between summer and winter, has never been able to be controlled in a manner satisfactory.

Finally, it is difficult at present to construct isothermal walls which are sufficiently robust to constitute the load-bearing structure of a building and light enough not to cause too great damage, both on a human and material level, when they collapse following, for example, an earthquake.

On the basis of these observations, the present Applicant has designed a three-dimensional metal framework which makes it possible to produce, in a simple and economical manner, robust and light building walls having an interior air space along one of their faces and having a good thermal and acoustic insulation power, which can be even improved compared to that of the walls that we currently know how to manufacture.

According to the invention, this framework is characterized in that it comprises a certain number of rectilinear and parallel ropes welded on several substantially sinusoidal and overlapping ropes which extend in planes perpendicular to the rectilinear ropes and whose vertices are located in two parallel planes, the straight lines being wholly or partly grouped in a first and a second row parallel to these two planes and delimiting between them a space of a certain width, the first row of straight lines also being slightly away from a first of the plans containing the vertices of the sinusoidal streaks.

From this framework, it is possible to manufacture, still according to the invention, a construction element, such as a wall, a ceiling or a partition, of the type comprising a central part disposed between two finishing coatings and constituted by a wall. carrier in cavernous concrete or other covered, on one of its faces, with a layer of thermal insulation, and characterized in that the three-dimensional framework is partially embedded in the carrier wall and in that said central part occupies the space delimited by the first and second rows of straight lines, the tops of the sinusoidal lines situated in said first plane carrying a first finishing coating while those which are located in said second plane carrying the second finishing coating, so that the first at least of these coatings defines an air space with the central part.

The primary advantage of the framework of the invention, in its application to the manufacture of a construction element of this type, lies in the fact that it serves both to wear the two finishing coatings, to hand keep one of these slightly away from the central part for the delimitation of the air space, reinforce or reinforce the concrete load-bearing wall and support the thermal insulation layer when it is formed by solid insulation plates.

It will also be observed that this framework can be manufactured using small diameter struts which makes it very light and therefore perfectly suitable for the construction of buildings in seismic zones. Its construction is also very simple and its airy structure allows easy transport of several of these frames stacked flat on top of each other.

In the building element produced using this framework, the air space formed flush with one of the finishing coatings, as is known, is a thermal and acoustic damper.

According to an important characteristic of this building element, one or more additional air spaces can be produced inside the thermal insulation layer and, when this consists of solid insulating plates extending in planes parallel to the rows of straight lines, this or these air knives are preferably formed by placing wooden battens parallel to the straight lines of the frame, between the insulating plates. This arrangement improves the insulating power of the building element. It will be noted here that, as a variant, additional rectilinear strands can be welded to the sinusoidal struts of the frame to play the role of wooden battens in the delimitation of the additional air knives.

The building element of the invention can be produced from a framework as defined above, in which the second row of straight lines extends in the second of the planes containing the vertices of the sinusoidal lines, so that , on the straight lines of this second row, can be fixed a tight mesh screen serving as a support for the second finishing coating.

Likewise, this construction element can be produced from a three-dimensional framework according to the invention, which comprises a third row, parallel to the first two, of straight and parallel strands, this third row extending in said first plane containing the peaks of the streaks sinusoidal so that, on the straight lines of this third row, it is possible to fix a tight mesh screen serving as support for the first finishing coating.

Alternatively, however, when the first finishing covering is made of wooden cladding, it is advantageous to block, inside each group of superimposable vertices, sinusoidal strands, located in said foreground, wooden battens on which can -be nailed this siding.

The building element according to the invention is more particularly intended to constitute an external wall of a dwelling and, in this case; it is characterized in that the rectilinear struts of the framework are oriented in a vertical direction and in that said first finishing coating constitutes the exterior coating of the wall, the thermal insulation layer extending between the load-bearing wall and the air space formed flush with this outer covering. In this wall, the air space is formed all along the exterior finishing coating, in contact with the thermal insulation layer, and thus constitutes, between the interior and the exterior of the dwelling, a thermal damper. which ensures good heat conservation in winter and freshness in summer inside the house and which also contributes to its acoustic insulation.

In this wall, the air space can also be opened at its base and communicate from above, for example through a ventilation opening, with the outside air, so as to constitute an air space ventilated which provides the additional advantage of thermal stabilization of the load-bearing wall and of the external covering, that is to say of protection of the latter against internal degradations, of the cracking type, which could result significant variations in temperature between winter and summer.

The present invention also relates to an economical process for constructing such an isothermal wall, which is characterized in that it consists in blocking thermal insulating plates between the sinusoidal strands of the frame and parallel to the straight strands of this to form the thermal insulation layer, to staple the mesh on the straight lines of the second row, to lay the interior finishing coating on this mesh, to lay the exterior finishing coating on the corresponding vertices of the sinusoidal threads , to fix the framework on a retaining wall by orienting its rectilinear beams in a vertical direction and in arranging the third row of these strands on the outside of the wall and pouring concrete between the interior coating and the insulation layer so as to form the load-bearing wall.

The primary advantage of this construction process is that it allows the load-bearing wall to be made with lost formwork by pouring concrete between the second finishing coating and the solid insulation plates.

• - la figure 1 est une vue en perspective dudit mode de réalisation de l'ossature ;
• - la figure 2 est une vue en plan de cette ossature ;
• - les figures 3 et 4 sont des vues en coupe transversale des deux modes de réalisation de l'élément de construction réalisé à partir de cette ossature ;
• - la figure 5 est une vue en coupe effectuée selon la ligne V-V de la figure 3 ;
• - la figure 6 est une vue en coupe transversale d'un élément de construc⁼ tion semblable à celui de la figure ₃, mais présentant plusieurs lames d'air ; et
• - la figure 7 représente schématiquement une phase de la fabrication de l'élément de construction de l'invention.

An embodiment of the three-dimensional framework of the invention and two embodiments of the construction element manufactured using this framework will be described below by way of nonlimiting examples with reference to the accompanying drawings wherein :

• - Figure 1 is a perspective view of said embodiment of the frame;
• - Figure 2 is a plan view of this frame;
• - Figures 3 and 4 are cross-sectional views of the two embodiments of the construction element produced from this frame;
• - Figure 5 is a sectional view taken along the line VV of Figure 3;
• - Figure 6 is a cross-sectional view of an element of similar construc tion ⁼ to that of Figure ₃ but having a plurality of air knives; and
• - Figure 7 shows schematically a phase of the manufacture of the construction element of the invention.

As can be seen in FIGS. 1 and 2, the three-dimensional metal framework 9 according to the invention comprises a number of straight lines 14a, 14b, 14c welded, parallel to each other, on several substantially sinusoidal lines or folded in a zig-zag 15, which are superimposable and extend in stepped planes perpendicular to the straight lines.

The vertices 15a and 15b of the sinusoidal streaks 15 are located in two planes parallel and a part of the straight lines is grouped in a first row 14a and a second line 14b, parallel to these two planes and delimiting between them a space of width L. The first row 14a of straight lines is furthermore slightly away from the plane containing the vertices 15a so as to delimit therewith a space of reduced width 1.

As can be clearly seen in FIG. 2, the second row 14b of rectilinear streaks extends in the second plane containing the vertices 15b and, the remaining rectilinear streaks, aligned in a third row 14c parallel to the first two 14a and 14b, are welded, parallel to each other, on the vertices 15b located in said foreground.

The struts 14 and 15 constituting the framework 9 of the invention are preferably made of galvanized steel for reasons of corrosion resistance and are of a relatively small diameter, of the order of 6 mm for straight streaks 14 , and 4 mm for sinusoidal threads 15.

To make the framework which has just been described, we begin by making a sort of flat lattice with wide meshes by spot welding the strands 14 on longer strands which are arranged perpendicular to the strands 14. We fold then this accordion lattice by traditional means so as to give the struts 15 their substantially sinusoidal configuration. It goes without saying that during welding, the threads 14 are positioned on the threads 15 so as to appear in the three rows mentioned above after the folding operation.

The framework thus produced is specially designed for the production of isothermal walls of buildings. In FIGS. 3 to 6, a section of a construction element constructed from such a framework has been represented, this construction element being in the present case an exterior wall of a dwelling whose interior is referenced by A and outside by B.

More specifically, this construction element consists of a central part 1 disposed between an interior finish coating 2a or 2b and an exterior finish coating 3a or 3b. The central part 1 is more particularly constituted by a load-bearing wall 4 of cavernous concrete or the like covered, on its face turned outwards, with a layer of thermal insulation 5, formed here by plates of solid insulation such as expanded polystyrene.

In this building element, the frame 9 is partially embedded in the load-bearing wall 4, its straight struts being oriented in a vertical direction. The straight lines of the second row 14b extend flush with the inner face of the load-bearing wall 4. In addition, the framework 9 projects from the outer face 8 of the latter to serve as a support for the insulating plates 5 which are wedged between the load-bearing wall 4 and the first row 14a of rectilinear strands, extending parallel to the latter. Thus, the central part 1 of the wall as a whole occupies the space of width L delimited by the first and second rows 14a and 14b of the straight lines of the framework 9.

In FIGS. 3 to 6, it will also be observed that the vertices 15a of the sinusoidal streaks carry the external finish coating 3a or 3b, while their vertices 15b carry the internal finish coating 2a or 2b. Thus, the outer covering 3a ′ or 3 b delimits with the central part 1 an air space 7 which corresponds to the space of width 1 mentioned above.

This air gap 7 constitutes a thermal damper between the interior A and the exterior B of the dwelling.

According to a characteristic of the invention not illustrated in the figures, the air gap 7 can be open at its base and communicate from above, for example through a conventional air vent, with the external environment. A ventilated air layer is thus produced which, in cooperation with the thermal insulation layer 5, protects the concrete load-bearing wall 1 against thermal shocks resulting from large variations in the outside temperature and ensures the thermal stabilization of the external coating.

On the rectilinear struts of the framework 9 which form the second row 14b, is fixed, for example by stapling, a tight mesh screen 10 serving as a support for the inner lining finish 2a or 2b, which may be a coating layer of plaster 2a, projected onto the grid 10 (see FIG. 3) or a prefabricated panel 2b of compressed plaster, fixed to the grid 10 by means of adhesive pads 11 (see FIG. 4).

In the embodiment of the construction element of the invention shown in section in FIG. 4, a second tight mesh screen 13 is fixed to the straight lines of the frame 9, which form the third row 14c, to serve as a support for the exterior finish coating 3b generally constituted by a hydraulic coating projected onto the grid 13, which for this purpose may have a cardboard or plastic underside.

As a variant, however, and as shown in FIG. 3, a wooden batten 12 is locked inside each group of superimposable external vertices 15a of the sinusoidal strands 15 of the framework, these batts receiving by nailing the external covering 3a constituted in this case by wooden cladding. Instead of wooden cladding, one can also nail on the battens 12, clains made of slate, aluminum or wood.

It will be observed here that the above-mentioned gratings 10 and 13 can also be stapled to the vertices 15a and 15b of the sinusoidal struts 15 of the framework 9 and, to provide a greater fixing surface, these vertices are flattened.

It will also be added that the framework 9 is consolidated by a plane reinforcement 16 resting on one of the sinusoidal streaks 15, and wedged between the two rows of straight streaks 14a and 14b. This frame consists of two parallel rules 17 connected by spacers 18.

Figure 6 shows an embodiment of the building element of the invention in the thermal insulation layer which is formed an additional closed air gap 21, which improves the insulating power of the building element.

More specifically, the additional air space 21 is delimited by two neighboring insulating plates, kept at a distance from one another by wooden battens 22, locked together and parallel to the straight lines 14.

• utre, il est bien sur possible de ménager entre les plaques d'isolants eurs lames d'air de ce type afin d'augmenter d'autant le pouvoir d'isola- thermique de l'élément de construction.
  • ent de construction qui fait l'objet de la présente invention peut être de différentes manières. Toutefois, dans le cas où il constitue un mur
• extérieur d'une habitation, il est avantageux de le construire selon le procédé décrit ci-dessous.

'1 is quite obvious that in place of these cleats, one can provide on the frame 9 two additional rows of straight lines, not shown, which would delimit the air space 21.

• In addition, it is of course possible to provide between the insulating plates their air knives of this type in order to increase all the more the thermal insulation power of the building element.
  • The construction object which is the subject of the present invention can be in different ways. However, in the event that it constitutes a wall
• outside a house, it is advantageous to build it according to the process described below.

We start, in the workshop, by fixing the frame 9 against a fixed table 19 as shown in FIG. 7. Then, we introduce laterally the frame 16 in the frame, above a sinusoidal strand 15 thereof. ci, and it is put in place by blocking between the straight lines of the first and second rows 14a, 14b, as shown in broken lines in FIG. 7. The plates 20 d are introduced, on the other side of the framework. thermal insulator which is erected by blocking between the sinusoidal strands, as shown in broken lines in FIG. 7. The grid 10 is then fixed on the internal vertices 15b of the sinusoidal streaks of the framework 9. After having removed the latter from the table, the battens 12 are fixed, as the case may be, in its external vertices 15a or the grid 13 on the latter. The interior and exterior coverings 2a, 2b, 3a, 3b are then laid. The following operation consists in bringing the assembly thus produced on the site where it is fixed to a retaining wall, constituted for example by the foundations of the building to be constructed, by orienting the straight lines 14 of the framework 9 in a direction vertical and placing the third row of these strands on the outside of the wall. Finally, cavernous concrete or any other concrete is poured into the space delimited by the interior finishing coating 2a or 2b and the thermal insulating plates, so as to form the load-bearing wall 4 of the wall.

It will be observed that this construction method makes it possible, in an economical manner, to cast the load-bearing wall 4 of the lost formwork wall and to quickly make the major part of the wall in the workshop, sheltered from the weather.

If the foregoing description has been made with reference to an isothermal exterior wall of a dwelling, it goes without saying that the framework according to the invention makes it possible to produce all other isothermal walls of buildings and in particular ceilings and interior partitions.

To be complete, it should be specified that the building element according to the invention can be produced in the form of prefabricated panels.

• Epaisseur de la couche isolante : 8 à 12 cm
• Epaisseur de la paroi porteuse : 16 cm
• Epaisseur de la lame d'air : 3 cm
• Distance entre 2 filants sinusoïdaux : 25 cm
• Distance entre les filants rectilignes de la troisième rangée : 34 cm

By way of examples, the preferred dimensions of the different parts of the construction element according to the invention are given below:

• Insulation layer thickness: 8 to 12 cm
• Thickness of the load-bearing wall: 16 cm
• Air knife thickness: 3 cm
• Distance between 2 sinusoidal streaks: 25 cm
• Distance between the straight rows in the third row: 34 cm

An exterior wall of a dwelling, dimensioned in this way, has a thermal transmission coefficient of 0.29. This coefficient, which is much lower than those obtained in conventional isothermal walls, can be lowered to 0.27 if several indoor air spaces are provided.

Claims (15)

1. Three-dimensional metal frame (9), designed for the production of isothermal walls of buildings, characterized in that it comprises a number of rectilinear and parallel wires (14) welded on several substantially sinusoidal and superimposable wires (15) which are '' extend in planes perpendicular to the straight lines and whose vertices (15a, 15b) are located in two parallel planes, the straight lines being wholly or partly grouped in a first and a second row (14a, 14b) parallel to these two planes and delimiting between them a space of a certain width (L), the first row (14a) of rectilinear streaks being in addition slightly at a distance from a first of the planes containing the vertices (15a) of the sinusoidal streaks. 2. Three-dimensional metal frame according to claim 1, characterized in that the vertices (15a, 15b) of the sinusoidal streaks (15) are flattened. 3. Three-dimensional metal frame according to claim 1 or 2, characterized in that the second row (14b) of straight lines extends in the second of the planes containing the vertices (15b) of sinusoidal lines. 4. Three-dimensional metal frame according to any one of claims 1 to 3, characterized in that it comprises a third row (14c), parallel to the first two, of straight and parallel ribbing, this third row extending in said first plane containing the vertices (15a) of the sinusoidal streaks. 5. Construction element, in particular isothermal wall, constructed from a three-dimensional framework according to any one of claims 1 to 4 and comprising a central part (1) disposed between two finishing coatings (2a, 2b; 3a, 3b ) and constituted by a load-bearing wall (4) of cavernous concrete or other covered, on one of its faces, with a layer of thermal insulation (5), characterized in that the three-dimensional framework is partially embedded in the load-bearing wall and in that said central part occupies the space delimited by the first and second rows (14a, 14b) of straight lines, the vertices (15a) of the sinusoidal lines located in said first plane, carrying a first finishing coating ( 3a, 3b), while those (15b) which are located in said second plane carry the second finishing coating (2a, 2b), so that at least the first of these coverings delimits an air space (7) with the central part (1). 6. Building element according to claim 5, constituting an isothermal wall outside of a house, characterized in that the straight lines (14) of the frame (9) are oriented in a vertical direction and in that said first coating finishing (3a, 3b) constitutes the external coating of the wall, the thermal insulation layer (5) extending between the load-bearing wall (4) and the air space (7) formed flush with this external coating. 7. Building element according to claim 6 ^- , characterized in that the air space (7) is open at its base and communicates from above, for example through an air vent, with the air outside. 8. Building element according to any one of claims 5 to 7, characterized in that at least one additional air space (21) is provided in the thermal insulation layer (5). 9. Building element according to claim 8, characterized in that the thermal insulation layer (5) is formed by several plates of solid insulation extending parallel to the rows of straight lines (14) and in that the blade additional air (21) is delimited by two neighboring insulating plates, kept at a distance from each other by wooden battens (22) locked together and parallel to the straight lines (14). 10. Building element according to any one of claims 5 to 9, constructed from a frame as defined by claim 3, characterized in that, on the straight lines of the second row (14b), is fixed a tight mesh screen (10) serving as a support for the second finishing coating (2a, 2b). 11. Building element according to any one of claims 5 to 10, constructed from a three-dimensional framework as defined by claim 4, characterized in that, on the straight streaks of the third row (14c) is fixed a tight mesh screen (13) serving as a support for the first finishing coating (3a, 3b). 12. Construction element according to any one of claims 5 to 10, characterized in that a wooden cleat is blocked inside each group of overlapping vertices (15a) of the sinusoidal streaks, located in said foreground, these cleats (12) receiving by nailing a wooden covering (3a), aluminum or slate. 13. Construction element according to any one of claims 5 to 12, characterized in that the frame (9) is consolidated by at least one flat frame (16) resting on one of the sinusoidal strands (15) and wedged between the first and second rows (14a, 14b) of straight lines. 14. Building element according to claim 13, characterized in that the frame is constituted by two parallel rules (17) connected by spacers (18). 15. A method of constructing an isothermal wall outside a dwelling, as defined by any one of claims 10 to 14, characterized in that it consists in blocking thermal insulation plates between the sinusoidal strands ( 15) of the framework and parallel to the straight lines (14) thereof to form the thermal insulation layer (5), stapling the mesh (10) on the straight lines of the second row (14b), lay the interior finish covering (2a, 2b) on this grid, lay the exterior finish covering (3a, 3b) on the corresponding vertices of the sinusoidal strands, fix the framework (9) on a retaining wall by orienting its straight lines in a vertical direction and by placing the third row (14c) of these lines on the outside of the wall and pouring concrete between the interior coating (2a, 2b) and the insulation layer (5) so as to form the supporting wall (4).

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