Structural component prefabricated.

Sought at present, in the field of

the construction of dwellings, to develop types of walls or other partitions that have sound and heat insulation increased as far as possible, the solution search demands to this problem presents difficulties in that the materials which have good thermal insulating properties of often have poor sound absorbing qualities, so that their use has not reached satisfactory results standpoint of sound transmission. The BN addition, making partition walls, whether as facades, interior dividers or galling between floors of a building, involves, if it is desired to ensure good insulation properties both in the field of sound transmission that in the field of heat transmission, many operations and expensive as well as frequency of use expensive materials *

It is known that the mth materials formed of fibers have relatively high thermal insulation capacity. however, it has been found in many cases, that partitions formed of two rigid panels between which was positioned a mutuamente fibrous, had very bad insulation standpoint of sound in that air trapped between the two panels by the fibrous mass transmitted sounds of a panel to the other and that, more than the panels were rigid, and more their critical frequency was high, more the assembly had been operating as a soundboard.

It has already been proposed {Patent FR's no. 731,319) use as construction material for the assemblies formed ' mattress fiore ^. or granules disposed between two veneers of sheets of cement, wood or sheet metal. However, the insulating core provided in this type of construction, being thicker than that of the veneers containing it, the sound absorbing capacity of these assemblies are known was particularly susceptible to the above defects.

According to the Belgian Patent no. 466,039 it was envisaged that panels consisting of two or more layers of batten oriented perpendicularly to each other, and nailed across intermediate layers composed of_T- flexible impervious material such as roofing felt. Such a construction enables partitions light suitable for temporary accommodation. It has been found however that the breathable meabilisation a felt layer had the consequence of greatly reduced thermal isolation capabilities of this material.

According to the French Patent no. 23, 46 515, it is known to make composite building elements acting as pillars and formed of a nucleus of rectangular section of fibrous nonwoven bonded mineral, said core being assembled along its two opposite narrow sides, to members for wood. However, as the felt is a material having a planar structure, its mechanical behavior differs greatly depending on whether it is linked to - léments adjacent via its edge or by one or other of its main faces, and experience shows that the columns of the type described in the aforementioned Patent whose core cross-section is e.g. 5 x 15 cm, have I includes a shear strength which remains less than optimum desirable.

Finally, still known by the French Patent no. 21, 61 442 for component parts to serve as internal partitions or facings and consisting of two gypsum boards or agglomerated wood particles with a layer of fibers such as glass fiber, interposed between the two plates. The fibers may constitute a piece of felt and be bound by the means of élastomêres. The element construction known being directed primarily to facings, the idea that it was possible to use pieces of felt in prefabricated elements and carriers, it is to say having a modulus of elasticity sufficiently high to resist bending and buckling when used for the production of structural walls or floor slabs for example, does not result in an obvious manner.

Thus, the aim of the present invention is to provide prefabricated structural elements the visual level as both a high mechanical strength and thermal insulation properties and high sound-capable of providing a minimum of assembly operations, the bearing walls, floor to ceiling tiles and other supporting structures in constructing dwelling houses.

For this purpose, the present invention relates to a prefabricated element, in particular for the construction of walls or floor to ceiling tiles, characterized in that it comprises at least a carrier assembly high capacity sound and heat insulation, formed of a piece of felt and two rigid wooden plates which cover the opposite sides of the piece of felt, and are bonded thereto by gluing.

It will readily apparent that, by felt, is meant all materials that are essentially formed of fibers of limited length, bonded to one another by any means and arranged in a variety of angles relative to the yaws general of the workpiece. A piece of felt, in the sense of the present application is therefore a piece having the shape of a plate made of fibers bonded to one another, the remaining assembly air permeable. The fibers can be natural fibers, animal, vegetable or mineral, or plastic fibers ., such as the polymers used generally for the synthetic fiber for example polymers of acryl. Among the most frequently used methods for making parts of felt, known mainly for needle, as well as the fulling. The fibers may be agglomerated by bonding by means of a suitable adhesive or by partial melting. If desired, the binding fibers can be provided by a sheet of woven or monolithic support for said anchor fibers.

Similarly, for the realization of the veneer, a preferred form of solid parts. the form of boards or slats and bonded assemblies.

As it will be farther, the one or more assemblies that includes each element will be preferably carried out by a simple bonding each of two plates on both opposite sides of the piece of felt. Experience shows that obtained die this way components whose mechanical strength is perfectly adapted to the required construction.

We will describe below, by way of example, some embodiments of the object of the invention, with reference to the attached drawing of which:

fig. 1 is a perspective view torn from an embodiment wherein the member comprises a single assembly and is intended for the manufacture of door frames or windows,

fig. 2 is a sectional view of a variation on the fig. 1 erffective powerU,

figure 3 a sectional view also of another embodiment of the element of fig. 1,

fig. 4 is a perspective view broken away and exploded an embodiment wherein each element comprises two assemblies, to interlayer insulating layer, a channel for passing electrical and plumbing, a floor covering, and a headliner and constitutes an element of slab for building floor to ceiling in a building construction and

fig. 5 a. perspective view also illustrating torn performing a facade in a building construction using inventive elements each having two assemblies formed of two base members with their insulation.

Figure 1 represents a subassembly for forming of prefabricated elements according to the invention. It consists of two wooden planks 1 and 2 adhered on either side of a piece of felt 3.

The boards 1 and 2 are monolithic elements whose dimensions can be for example of the order of 15 cm in width and 10 to 50 mm in thickness, the length of up to prefabrication, e.g. two or three meters or even longer, and there by dividing into segments of the desired length at the time of manufacture. The piece of felt 3 will, according to the disclosed embodiments, between 2 and 50 mm thick. However, a thickness in the range of 3 to 7 mm and preferably 5 mm has been found to be particularly advantageous in that it gives the assembly a flexural strength and at flambageHüres. high. It is not necessary that the piece of felt is integral. It can be manufactured by any of the methods mentioned above. Portlast of making the assembly, the two boards 1 and 2 will be pressed against the piece of felt 3 after gluing boards and/or piece of felt, so as to ensure the perfect adhesion of its constituent parts. After setting of the adhesive, the construction element will be calibrated and undergo the finishing operations required as when producing * solid wood. Thus, it will be possible in ES - practised in two longitudinal edges of the member fee - - Es projection α ¾ dice groovings so - form the only; 4 and the vuregofgeûnent giving a s-type assembly current and usual, as "scored a-Crested", andc. It has been found that the machining elements 4 and e I through the piece of felt could be carried out by usual moÿeh of 1 * outillage joinery, without varying nor the cutting depths nor the operating speeds.

a TES - 1 and 2 both boards may be n * imported which quality of wood and, as the case may be, may be coated with surface layers of plastic, cloth, leather, skin, andc.

The fig. 2 and 3. - - represent elements of the same kind of fig. 1. The piece of felt 6 is here secured by bonding two wooden planks? and 8 which are themselves each constituted by two components 7a, 7b, 8a, 8b assembled in one case (7a, 7b) by grooving and crétage, and in the other case, by comb-shaped indentations, any other form of assembling proven remaining usable. The components will be assembled and/or adhesively bonded together to form the parts 7 and 8. In the case of the Figure. 2, the assembly of

•" amount1 constitutes an element of rectangular profile '; - while, in the case of the Figure. 3, is provided at each end of the profile a setback of 2 cm width which leaves visible the piece of felt 6a and 6b 6 locations, the piece of felt then being reduced in its thickness. Elements such as those of Figures 2 and 3 are suitable for the practice of doors or windows, panels, or even, if necessary, internal partitions or outer housing construction in various, e.g. in bungalows, cottages or in vacation homes.

Prefabricated structural elements, according to the invention can also be formed by combining several base assemblies face, for example by adhering the plate 1 or 2, 7 or 3 against the plate homolog of another assembly.

This application is to be preferably used in the manufacture of bearer boards of dimensions larger than heretofore contemplated for the elements and intended either for internal partitions, or facades or floor to ceiling tiles.

Thus, the fig. 4 represents a prefabricated element consisting of two base assemblies. Said plank completely prefabricated can be used to form the floor to ceiling tiles whose pose is greatly simplified. The planks will be implemented firmly by fastening between the two walls of the premises to cover.

These structures form directly. slab stage separation or exterior walls of a house. Each plank consists of two assemblies 9 and 10, a floor covering 11 and a ceiling panel 12. The two assemblies 9 and 10 are of the same structure.

U.S. each comprise two plates 13 and 14 and a piece of felt spacer 15. The dimensions may naturally vary from case in case. The boards 13 and 14 will be bonded to the spacer piece of felt glued as in assembly of Figures 1 to 3.

Provision may be providing the boards such as 13 and 14 cases in a face thereof. The

O

planks are then formed by gluing boards along the edges of the housings. Pieces of felt are placed without sticking, floating in the housings.

This solution allows, in some cases, better insulation of the building.

K the fig.. 4, the plates 14 have in their outer face a groove 16 which e¹ extends centrally of their width and over their entire length. For revising the plank described, both assemblies 9 and 10 are bonded together such that the two grooves 16 are opposite one another and form a longitudinal channel in the center left atrial plank. This channel may be log -: centeredly to water pipe or gas or to electrical conductors. It is noticed that is enclosed between two layers of insulation.

Each plank (9, 10) will form as such a slab floor to ceiling. As applicable, it will be filled at the time of manufacturing a plate 11 flooring. This flooring can be 17, with or without an insulating layer 15, made of felt or other insulating material, bonded or joined between the plank (9, 10) and the board 17. It may be of wood or a material with a different composition.

On the floor 17 may be attachable to a bottom mat 18, fastened e.g. by gluing. The bottom mat 18 may also be applied directly on the plank (9, 10).

On the board 17 can be fixed parquet exempler 19 attached by adhesive bonding. 17 Between the table and the floor 19, an insulator 15 made of felt or other insulating material can be bonded or attached. The parquet floor 19 can also be attached by gluing or any other method defined above, directly on the plank (9, 10) with or without interlayer insulating layer 15.

This flooring will be of any type, oak or other wood or can be a plastic or other material used as flooring.

Finally, the ceiling covering 12 can be formed by wood parts and glued or contreplaculamellêes AE, by plates of plastic coating had by any other structure. These elements 12 or settle AAs ^ reference by sticking under the plank (9, 10) is the board 17 of the assembly 9.

Thus, provides the floor to ceiling tiles and performing coatings become operations extremely simplified since it is enough to place the prefabricated construction elements which are in the form of planks composite partially or entirely filled.

Figure 5 represents a composition of assemblies according to another embodiment. The two prefabricated elements 20 visible to said pattern, each comprise two base assemblies 21 and 22 each formed of two plates 23 and a piece of felt spacer 24.

Each element 20 forms a plank comprising two base assemblies glued one against the other. Grooves 25, similar to the grooves 16, are machined centrally in upper and/or lower of each plank 20, so that during the manufacture of the partition by stacking the elements 20, it will be formed at the center of the partition between two pieces of felt channels directed horizontally and allowing the passage of pipes, so on the other hand, the pieces of felt 24 will be placed end to end and will build continuous thermal barriers.

To ensure the cohesion of the partition, profiles 26 will be placed between each layer of boards 20.

These profiles whose shape is visible in fig.. 5, have at their end wings 26a engaged in slots formed in the base assemblies 21, 22. In their central portion, they have a tube structure 26b which adjusts to the grooves 25, so that the channels formed by the grooves 25 are shielded by the material of the extrusion.

The profiles 26 will be aluminum or other metal 1 ℮ς·℮ - or a material exhibiting improved insulation lnermic than aluminum. The use of such a phys _ a-.u is however not absolutely necessary, since it has been found that the presence of aluminum profiles in a partition 26 built using elements 20 and that nothing - qualities of the good thermal insulation of the cloiscr by blocking joints between the 20, they PEs^-1 'ucipent heat insulation of 1' enserr>' th.

The member: icrits may also allow for

- ealise roofs. They can also be used the sheave] '. creating method of supporting pylons in constructions of Q ') - are then partitioned by walls light.

See therefore that many embodiments are possible and elements to deliver improved thermal and sound insulation that the traditional solid wood configured according to one or other of the embodiments described above can be used in all kinds of housing construction, including the farms, villas and buildings.

Experiments have shown that a plank formed of two base assemblies 9 and 10 with felt spacer bonded had a bending strength higher than that of a massive plank of the same size. These components enable partitions or load bearing structural components for buildings which, for a price of construction reduces, and a relatively small thickness, have simultaneously heat insulating ability and a very high quality sound insulation.

Of course, in other embodiments, may also be obtained planks constituting structural components for walls or slabs using more than two base assemblies as shown in Figure 1. Thus, three base assemblies bonded face likewise constitute a plank according to the invention.

It has also been found that planks which has good thermal and acoustic insulation and mechanical strength, may be formed by securing two base assemblies such as that shown in Figure 1, on either side of a plate formed of agglomerated cork, for example cork particles bonded together. The thickness of the spacer board cork can vary between 2 and 8 cm, but it will be preferably of 4 to 6 cm. Here too, the connection between the plate of agglomerated cork and the internal faces of two ' base assemblies which constitute the structure of the board, will be done preferably by gluing.

Another important element which must be taken when making the guard members described construction embodies the bonding. It has been found that the use of a glue rendered liquid by high-frequency heating has been found to allow diffusion of the binder between the fibers. Supra and assemblies in which the network of fibers constituting the felt was not blocked, so that this material as extending insulation capacity. Although the felt remains then fully permeable, the veneer which constitute the opposite sides of the building element ensure sealing while maintaining the insulation capacity.

Of course, the ends of the slabs, walls or walls will be populated with closure parts closes flush with the felt to ensure sealing of the assembly.