EP0059119B1 - 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 construction element, in particular for the production of isothermal walls, comprising a central part disposed between two finishing coatings and consisting of a load-bearing wall of cavernous or other concrete and an insulation layer. thermal, this load-bearing wall being reinforced by a three-dimensional framework in one piece, formed by a number of straight and parallel ribbons which are connected by several substantially sinusoidal ribbons whose vertices define the two longitudinal faces of the framework and are grouped in at least two parallel rows, the first of these rows also being slightly spaced from the tops of the tangles which are substantially sinusoidal defining a first longitudinal face of the framework. Such construction elements are described in the French utility certificate No. 2,243,602 and in the Belgian patent No. 774,295.

The present invention also relates to a method for producing such a building element.

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 area has shown that by creating a vacuum or an air space in the exterior walls of a dwelling, it was achieved, in combination with a layer of thermal insulation, effective thermal and acoustic damping between the exterior and interior thereof (German Patent No. 505,122). 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 construction element of the type specified in the preamble, which is characterized in that the framework projects on a first face of the load-bearing wall in such a way that its first row of straight struts is located outside of this wall and at a certain distance from the first face of the latter, in that the thermal insulation layer is formed of solid insulation wedged, in the projecting part of the framework, between the first face of the load-bearing wall, the first row of straight lines and the sinusoidal lines, and in that a first finishing covering is fixed on the tops of the substantially sinusoidal lines forming said first longitudinal face of the framework, so that this first coating delimits an air space with the thermal insulation layer.

In addition, the vertices of the sinusoidal struts, which form the second face of the framework, preferably extend flush with the second face of the load-bearing wall and carry the second finishing coating.

The primary advantage of this construction element lies in the fact that it is produced from a three-dimensional framework which, by virtue of its particular positioning, serves both to carry the two finishing coatings, to maintain the one of these slightly spaced from the central part for the delimitation of the air space, to reinforce or reinforce the concrete load-bearing wall and to support the thermal insulation layer formed of solid insulation.

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.

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

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 straight lines of the framework are oriented in a vertical direction and in this that the first finishing coating constitutes the exterior coating of the wall. In this way, the thermal insulation layer extends over the external face of the load-bearing wall and the air space is formed all along the external covering in contact with the thermal insulation layer.

Thanks to these provisions, one can achieve, on the wall, thermal insulation from the outside which is much more efficient than thermal insulation from the inside, in particular because it makes the wall play the role of a steering wheel thermal capable of radiating the colors it stores towards the interior of the home. In addition, the outer thermal insulation layer protects the wall from damage such as cracks, normally caused by large variations in outside temperature between summer and winter. Finally, in combination with the external air space, it contributes to the acoustic insulation of the interior of the house and maintains a certain degree of freshness when the outside temperature is high.

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 outer covering, that is to say protection of the latter against thermal shock. In addition, this ventilated air layer permanently evacuates the moisture present in the thermal insulation layer and thus protects it from rotting which could affect its properties over time.

According to an important characteristic of this construction 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 streaks of the frame to play the role of wooden battens in the delimitation of the additional air layers.

The construction element of the invention can be produced from a three-dimensional framework whose straight lines forming the second row are fixed to the tops of the sinusoidal lines which form the second longitudinal face of the framework, so that, on the straight lines of this second row, can be fixed a tight mesh screen on which the second finishing coating is formed, for example by spraying a plaster coating.

Likewise, this construction element can be produced from a three-dimensional framework, which includes a third row, parallel to the first two, of rectilinear and parallel ropes, fixed on the vertices of the sinusoidal ropes which form the first longitudinal face of the frame, 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.

As a variant, however, when the first finishing covering must consist of wooden, aluminum or slate cladding, it is advantageous to block inside each group of superimposable vertices sinusoidal strands, forming the first face of the frame, wooden battens on which can be nailed this cladding.

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

The primary advantage of this construction process lies in the fact 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 de l'ossature utilisée pour la réalisation de cet élément de construction;
• - la figure 2 est une vue en plan de cette ossature;
• - les figures 3 et 4 sont des vues en coupe transversale de 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 construction 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.

Several embodiments of the construction element that is the subject of the invention will be described below by way of nonlimiting examples with reference to the appended drawings in which:

• - Figure 1 is a perspective view of the frame used for the realization of this building element;
• - Figure 2 is a plan view of this frame;
• - Figures 3 and 4 are cross-sectional views of two embodiments of the construction element made 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 a building element similar to that of Figure 3, but having several air spaces; and
• - Figure 7 shows schematically a phase of the manufacture of the construction element of the invention.

The three-dimensional metal framework 9, shown in FIGS. 1 and 2, comprises a certain number of straight lines 14a, 14b, 14c welded, parallel to each other, on several substantially sinusoidal or zigzag folded wires 15, which are superimposable and are extend in stepped planes perpendicular to the straight lines.

The vertices 15a and 15b of the sinusoidal streaks 15 are located in two parallel planes and a portion of the straight streaks is grouped in a first row 14a and a second row 14b, parallel to these two planes and delimiting between them a space of width L. The first row 14a of rectilinear streaks is also slightly distant 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 between them, on the vertices 15b located in said foreground.

The struts 14 and 15 constituting the framework 9 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 the straight streaks 14, and 4 mm for sinusoidal threads 15.

To manufacture the framework which has just been described, we begin by making a sort of flat lattice with wide meshes by spot welding of threads 14 on longer threads that are arranged perpendicularly to the threads 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 runners 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 3 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 framework 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 carrier wall 4 and the first row 14a of straight lines 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 finishing coating 3a or 3b, while their vertices 15b carry the internal finishing coating 2a or 2b. Thus, the outer covering 3a or 3b defines with the central part 1 an air space 7 which corresponds to the space of width 1 mentioned above.

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 aforementioned 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 larger 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.

It is quite obvious that, in place of these cleats, provision can be made on the framework 9 for 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 several air knives of this type in order to increase the power accordingly. of thermal insulation of the building element.

The building element which is the subject of the present invention can be produced in different ways. However, in the case where it constitutes an exterior wall of a dwelling, it is advantageous to build it according to the method 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 frame 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 (13)

1. A constructional element, more especially for erecting isothermic walls, comprising a central part disposed between two finishing coverings (2a, 2b; 3a, 3b) and formed by a bearing wall (4) made from cavernous concrete or similar and a heat insulating layer (5), this bearing wall being reinforced through a three-dimensional framework in one piece (9) comprising a plurality of rectilinear parallel rods (14) which are interconnected by several substantially sinusoidal wires (15), the tips (15a, 15b) of which define the both longitudinal faces of the framework, the rectilinear rods (14) being grouped in at least two parallel rows (14a, 14b), the first row (14a) being further slightly spaced apart from the tips (15a) of the substantially sinusoidal wires, defining a first longitudinal face of the framework, characterized in that the framework (9) projects from a first face (8) of the bearing wall (4) such that its first row of rectilinear rods (14a) is disposed outside this wall and is spaced from said first face (8) thereof, in that the heat insulating layer (5) is made of solid insulating material clamped inside the projecting part of the framework, between said first face (8) of the bearing wall (4), said first row of rectilinear rods (14a) and said sinusoidal wires (15), and in that a first finishing covering (3a, 3b) is secured to the first tips (15a) of the substantially sinusoidal wires (15), defining said first longitudinal face of the framework, so that this first covering (3a, 3b) defines an air space (7) with the heat insulating layer (5).

2. A constructional element according to claim 1, characterized in that the tips (15b) of the sinusoidal wires (15), defining said second face of the framework, are flush with the second face of the bearing wall (4) and support the second finishing covering (2a; 2b).

3. A constructional element according to claim 1 or 2, forming an outer isothermic wall of a dwelling, characterized in that the rectilinear rods (14) of the framework (9) are orientated in a vertical direction and in that said first finishing covering (3a, 3b) forms the external covering of the wall.

4. A constructional element according to claim 3, characterized in that the air space (7) is open at its base and communicates at the top, for example through a ventilation aperture, with the outer air.

5. A constructional element according to anyone of claims 1 to 4, characterized in that at least one additional air space (21) is provided inside the heat insulating layer (5), this additional air space (21) being defined by two adjacent insulating panels, maintained spaced apart from each other by wooden battens (22) clamped therebetween and parallel to the rectilinear rods (14).

6. A constructional element according to anyone of claims 1 to 5, characterized in that the rectilinear rods (14b) of the framework (9), which form said second row, are fixed to the tips (15b) of the sinusoidal wires (15), defining said second longitudinal face of the framework (9).

7. A constructional element according to claim 6, characterized in that, to the rectilinear rods (14b) of the second row, there is fixed a close mesh latticework (10) on which the second finishing covering (2a, 2b) is formed, for example by projecting a plaster coating.

8. A constructional element according to anyone of claims 1 to 7, characterized in that the framework (9) comprises a third row (14c), parallel to the first two ones, of rectilinear and parallel rods, which are fixed to the tips (15a) of the sinusoidal wires, which form said first longitudinal face of the framework.

9. A constructional element according to claim 8, characterized in that, to the rectilinear rods (14c) of the third row, there is fixed a close mesh latticework (13) serving as a support for the first finishing covering (3a, 3b).

10. A constructional element according to anyone of claims 1 to 9, characterized in that a wooden batten (12) is clamped inside each group of superimposable tips (15a) of the sinusoidal wires, forming said first face of the framework, a wooden (3a), aluminium or slate covering being nailed to these battens (12).

11. A constructional element according to anyone of claims 1 to 10, characterized in that the framework (9) is strengthened by at least one armature (16) resting on one of the sinusoidal wires (15) and clamped between the first and second rows (14a, 14b) of rectilinear rods.

12. A constructional element according to claim 11, characterized in that the armature is formed by two parallel bars (17) connected together by tie- rods (18).

13. A process for constructing an external isothermic wall of a dwelling, such as defined in anyone of claims 7 to 12, characterized in that it consists in clamping heat insulating panels between the sinusoidal wires (15) of the framework and in parallel relation with the rectilinear rods (14) thereof so as to form the heat insulating layer (5), in clipping the latticework (10) to the rectilinear rods (14b) of the second row, in fitting the inner finishing covering (2a, 2b) to this latticework, in fitting the external finishing covering (3a, 3b) to the corresponding tips of the sinusoidal wires, in fixing the framework (9) to a retaining wall while orientating its rectilinear rods in a vertical direction and disposing the third row (14c) of these rods on the outer side of the wall, and in pouring concrete between the inner covering (2a, 2b) and the insulating layer (5) so as to form the bearing wall (4).

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