Insulating panels made of stone wool, and concrete wall provided with such panels

Abstract

Insulating panel (10) having a top face (12) and a bottom face (14) opposite the top face, comprising a body (20) made of stone wool with a part of substantially uniform first density and a part of substantially uniform second density, different from the first density, at least one profiled groove (22) being formed in said insulating panel starting from the top face, the top face (12) being made of stone wool, the groove (22) being formed in the stone wool, the number of grooves being less than or equal to three for 60 cm of a dimension of said panel perpendicular to the direction of the grooves.

Claims

1. An insulating panel having a top face and a bottom face opposite the top face, comprising a body made of stone wool with a part of substantially uniform first density and a part of substantially uniform second density, different from the first density, at least one profiled groove being formed in said insulating panel starting from the top face, the top face being made of stone wool, the groove being formed in the stone wool, the number of grooves being less than or equal to three for 60 cm of a dimension of said panel perpendicular to the direction of the grooves, wherein the groove has a depth of from 0.5 to 6 cm, and wherein the first stone wool density is from 100 to 300 kg per cubic meter and the second stone wool density is from 60 to 120 kg per cubic meter.

2. The insulating panel of claim 1, wherein the groove has a trapezoidal profile with a small base on the side of the top face.

3. The insulating panel of claim 1, wherein the groove has a rectangular profile.

4. The insulating panel of claim 1, wherein the groove has a parallelogram-shaped profile.

5. The insulating panel of claim 1, wherein the groove has a bottom parallel to the top face and edges of unequal gradients, the width of the groove increasing towards said bottom.

6. The insulating panel of claim 1, wherein the groove has a transverse profile with a zone of smaller width close to the top face and a zone of larger width at a distance from the top face.

7. The insulating panel of claim 1, provided with one longitudinal groove for a panel width of from 50 to 70 cm.

8. The insulating panel of claim 1, provided with two longitudinal grooves for a panel width of from 50 to 70 cm.

9. The insulating panel of claim 1, wherein the depth of the groove is from 1 to 4 cm.

10. The insulating panel of claim 1, wherein the minimum width of the groove, in a zone closer to the top face than to the bottom of the groove, is greater than or equal to 15 mm.

11. The insulating panel of claim 1, wherein the first stone wool density is from 110 to 180 kg per cubic meter and the second stone wool density is from 80 to 105 kg per cubic meter.

12. The insulating panel of claim 1, wherein the panel allows reversible deformations under the application of a pressure having a value of from 1.5 to 5.0 Newtons/cm.sup.2 on the top face.

13. The insulating panel of claim 1, wherein the top face forms a face of the part of first density and the bottom face forms a face of the part of second density.

14. Concrete insulating wall, comprising a concrete slab and insulating panels according to claim 1, wherein the insulating panels are fixed to a bottom face of the slab by introducing concrete into the groove or grooves of the insulating panels.

15. Cellar ceiling comprising an insulating wall according to claim 14.

Description

(1) FIG. 1 is a transverse sectional view of an insulating panel provided with a single profiled groove that opens out into a top face of said panel;

(2) FIG. 2 shows the panel of FIG. 1 disposed horizontally on a shuttering plate, and onto which a concrete slab has been poured;

(3) FIG. 3 shows a partial view of two sides, a body made of stone wool during manufacture, in which the profiled groove is formed by means of a tool;

(4) FIG. 4 is a front view of the tool of FIG. 3;

(5) FIG. 5 is a detailed view on an enlarged scale of one embodiment of a profiled groove;

(6) FIG. 6 is a view analogous to FIG. 1 showing dimensions;

(7) FIG. 7 is a view analogous to FIG. 6 in which the insulating panel comprises two profiled grooves;

(8) FIG. 8 shows a variant embodiment in which the insulating panel comprises two profiled grooves with different profiles; and

(9) FIG. 9 shows a sectional view of an insulating panel comprising a single profiled groove with a profile different from that of FIGS. 1 and 6.

(10) Reference will first be made to FIG. 1, which shows a sectional view of an insulating panel 10 having a top face 12 and a bottom face 14 opposite the top face. The faces 12 and 14 are rectangular in shape and are parallel to one another. The insulating panel 10 has a width L between two longitudinal edges 16 and 18. The panel has a thickness E as defined by the distance between the faces 12 and 14. The top face 12 has a roughness which is a function especially of the density of the material. The top face 12 can further have longitudinal undulations, especially of amplitude less than 2 mm. The longitudinal undulations can have a wavelength of from 5 to 30 mm. Said undulations can result from the hardening of the panel during manufacture. Hardening is carried out in a baking kiln, certain elements of which can be in contact with the panel. The profile of the baking kiln can print a pattern in the panel, which pattern remains after hardening.

(11) This panel comprises a body 20 made of mineral wool, in this case stone wool.

(12) The body 20 is composed of two layers, a top layer 21 and a bottom layer 23. The top layer 21 has a density that is substantially uniform in the thickness direction, for example from 100 to 300 kg per m.sup.3 and more advantageously from 110 to 180 kg/m.sup.3 (for example 150 kg/m.sup.3) with the usual manufacturing tolerances. The bottom layer 23 has a density that is substantially uniform in the thickness direction, for example from 60 to 120 kg per m.sup.3 and more advantageously from 80 to 105 kg/m.sup.3 (for example 95 kg/m.sup.3) with the usual manufacturing tolerances. The density uniformity is within 10%. The top face 12 is made of stone wool. The top face 12 also belongs to the body 20.

(13) The body 20 can act as insulation for the panel 10. The panel 10 can further comprise a coating on the bottom face 14, for example based on plasterboard, mortar, decorative elements, etc. In one embodiment, the insulating panel 10 is a two-layer panel.

(14) The top layer 21 can have a thickness of from 10 to 30 mm (for example 25 mm). The bottom layer 23 can have a thickness of from 10 to 290 mm.

(15) The panel 10 can be produced by a known process starting from, for example, rock to form fibres which are generally oriented in a preferential direction.

(16) The width L of the panel is typically 60 cm for a length of 120 or 240 cm, or 100 cm for a length of 120 cm.

(17) As can be seen in FIG. 1, a profiled groove 22 is formed in the insulating panel starting from the top face 12. The groove 22 opens out onto this top face. The groove 22 is formed in the stone wool. The groove 22 is located in the body 20. The profiled groove 22 crosses the top layer 21 and partly enters the bottom layer 23.

(18) The thickness E of the panel can be, for example, from 40 to 300 mm and more advantageously from 50 to 300 mm.

(19) In the example shown, the insulating panel comprises a single groove for 60 cm of a dimension, that is to say for 60 cm of width.

(20) More generally, the number of grooves can be less than or equal to 3 for 60 cm of a dimension of said panel perpendicular to the direction of the grooves.

(21) There can accordingly be provided a single longitudinal groove as in the case of FIG. 1, for a width of from 50 to 70 cm.

(22) However, it is also possible to envisage, within the scope of the invention, an arrangement of grooves in the transverse direction, provided that the number of grooves is less than or equal to 3 for 60 cm of a dimension.

(23) In the example of FIG. 1, the groove 22 has a trapezoidal profile, the small base of which is on the side of the top face and the large base is on the opposite side, as will be seen in detail below.

(24) Moreover, the insulating panel 10 has a mechanical strength that is sufficient to allow reversible deformations under the application of a pressure having a value of from 1.5 to 5.0 Newtons/cm.sup.2 on the top face, considering the effect of a foot of a person walking on the panel. By way of example, the maximum value of the pressure can be from 2.6 to 3.1 Newtons/cm.sup.2.

(25) Reference will now be made to FIG. 2, which shows the use of the panel 10 of FIG. 1 as a shuttering element.

(26) The panel 10 is placed horizontally on a shuttering plate 24 formed of one or more metal plates disposed on support members (not shown) used in the conventional manner.

(27) Conventionally, such metal plates are supported by parallel girders, which are placed at the top of suitable props.

(28) After the insulating panel, which is actually a plurality of insulating panels disposed contiguously, has been put in place, concrete is poured to form a concrete slab 26 above the insulating panel. This concrete slab can have a thickness of, for example, from 14 to 23 cm, generally 14, 18 or 23 cm.

(29) Conventionally, the concrete is reinforced, that is to say reinforcements (not shown) are provided above and at a distance from the top face 12 of the panels.

(30) Because the insulating panel has suitable mechanical strength, as indicated above, the panel allows reversible deformations under the application of a pressure having the indicated value.

(31) As a result, if an operator occasionally needs to walk on the panels, for example in order to fit reinforcements, these deformations will be reversible and will subsequently not impair either the thermal insulation properties or the fire resistance properties.

(32) When the concrete is poured, it will fill the grooves 22 of the insulating panels.

(33) Accordingly, once the concrete has hardened, the shuttering plate 24 can be removed, the insulating panels 10 remaining integrally fixed underneath the concrete slab.

(34) The profiled grooves are hence each filled with a concrete bar having a complementary profile, which creates a mechanical lock by shape cooperation.

(35) Reference will now be made to FIG. 3, which shows the manufacture of a body 20 made of stone wool. The body 20 is displaced horizontally in the direction of the arrow F by suitable transport means, for example by endless conveyor belts disposed beneath and above the moving body 20.

(36) According to the invention, a cutting tool 28 carried by a support 30 is provided, the cutting tool being driven into the thickness of the insulating body in order to produce a profiled groove 22 as the body made of stone wool is displaced. For a panel having a plurality of grooves, a corresponding number of cutting tools 28 on individual supports or on one common support is employed.

(37) The cutout of the profiled groove is shown schematically by the broken line 32 in FIG. 3.

(38) Reference will now be made to FIG. 4, which shows in profile view the cutting tool 28 connected to the support 30.

(39) Here, the cutting tool 28 is to be driven into the body 20 made of stone wool, while the support 30 is disposed above the body while being connected to a suitable fixed structure.

(40) Here, the cutting tool is produced in the form of a knife having a suitable profile to give the groove 22 a trapezoidal profile. Accordingly, the tool 28 comprises a large base 32 and two sloping sides 34 which are themselves connected to the support 30. The base 32 and the sides 34 are connected by rounded portions 36.

(41) The formation of the profiled groove or grooves is preferably carried out by means of a cutting tool such as a knife, or a milling cutter.

(42) However, it is also within the scope of the invention to use other types of tool, for example saws, etc.

(43) FIG. 5 shows a groove 22 having a trapezoidal profile analogous to that of FIGS. 1 and 2.

(44) The groove has a bottom 38 parallel to the top face 12 and edges 40 with equal gradients.

(45) The groove 22 accordingly has a transverse profile having a zone of small width (d1) close to the top face 12 and a zone of large width (d2) at a distance from the top face. The distance d1 corresponds to the width of the groove in the plane of the top face, that is to say corresponding to the small base of the trapezium, while the distance d2 corresponds to the width of the groove at the bottom 38.

(46) By way of example, the value d1 can be from 1.5 to 5 cm, for example 3 cm, and the value d2 can be from 3 to 8 cm, for example 6 cm.

(47) The depth of the groove 22 is advantageously from 0.5 to 6 cm, and preferably from 1 to 4 cm.

(48) It has been found that such a depth for such a small number of grooves allowed the desired strength performances to be obtained.

(49) As can also be seen in FIG. 5, the bottom 38 is connected to the edges 40 by rounded portions 42 having a radius of from 3 to 15 mm, preferably from 5 to 6 mm.

(50) FIG. 6 is a sectional view analogous to FIG. 1. It will be seen that the profiled groove 22 is at an equal distance D1 from the edges 16 and 18 of the panel 10.

(51) It will be seen that the profiled groove 22 is at an equal distance D1 from the edges 16 and 18.

(52) This distance D1 is equal to (Ld1).

(53) FIG. 7 shows a variant embodiment in which the insulating panel comprises two profiled grooves 22 analogous to those described above. This profiled groove has the same dimensions as those of the preceding figures.

(54) Each of the grooves is situated at a distance D1 from a longitudinal edge, the distance between the two grooves being equal to D2.

(55) By way of example, D1 and D2 can have the following values, respectively: 13.5 and 27 cm for a groove width in the plane of the top face equal to 3 cm and a panel width equal to 60 cm.

(56) FIG. 8 shows a variant embodiment in which the grooves have a parallelogram-shaped profile. Each groove has a bottom 44 and two sides.

(57) FIG. 8 shows the displacements a1 and a2 of the ends of the bottom 44 relative to the opening. By way of example, a1 and a2 can be less than 1.5P, where P is the depth of the groove, advantageously less than or equal to 0.75P. Here a1=a2. In another embodiment, a1>a2.

(58) FIG. 9 shows a variant embodiment of FIG. 8 in which the panel comprises a single groove having a parallelogram-shaped profile.

(59) In general, in order to ensure good anchoring, it is preferable that the grooves have a bottom that is parallel to the top face with edges of unequal or equal gradient, the width of the groove increasing towards the bottom.

(60) Other profile shapes are possible, including a rectangular profile. The rectangular profile can be sloping relative to the top face. The rectangular profile is then truncated by the top face.

(61) In addition, the minimum width (d1) of the groove in a zone closer to the top face than to the bottom of the groove is generally greater than or equal to 15 mm.

(62) It is necessary for the minimum width of the groove to be broadly larger than the maximum size of the granules that are included in the composition of the concrete so that such granules cannot impede the introduction of the concrete into the grooves.

(63) The invention is accordingly used in the insulation of concrete walls, whether they be horizontal or sloping.

(64) Tests have been carried out on insulating panels and have yielded the following result:

(65) 1) Tensile Strength

(66) Tests have been carried out in order to compare the tensile strength of the profiled groove of the invention with anchoring members such as helical or corkscrew elements as described in publication FR 2 624 154.

(67) The minimum value obtained in these results has shown that the behaviour was at least seven times superior to that of a panel of the prior art, with only one groove per panel, that is to say one groove for a panel dimension of 60 cm perpendicular to the groove.

(68) It was also observed that, due to the shape of the profiled groove, the strength remained effective subsequently because, in addition, the sloping edges of the profile of the groove prevented the concrete from subsequently coming away after adhesion between the concrete and the insulation was lost.

(69) The tensile strength test is different from the standard test. The difference lies in the fact that, in the standard test, tension from the test equipment is exerted over the whole surface area (0.30.3 m), while in the test of the invention, the tension is exerted only over the surface area of the groove, that is to say over a smaller surface area. An attempt has therefore been made to identify and adapt the effect brought about by the groove. The minimum value obtained is therefore a lower bound of the value under real conditions. The test is carried out according to standard EN 1607. The results obtained are as follows for a ROCKFEU DUAL RAINURE (GROOVE) panel, dovetailed or parallelogram-shaped, with depths 40, 40, 60 and 40 mm, groove head widths 50, 30, 50 and 50 mm, groove bottom widths 80, 60, 80 and 50 mm (with displacements a1 and a2 of 20 mm), respectively:

(70) TABLE-US-00001 ROCKFEU DUAL RAINURE (GROOVE) Pulling load (daN/m.sup.2) Improvement factor Series 1 (ROCKFEU RAINURE Dual Queue d'Aronde (Dovetail) - 40/50/80) average 266.9 7 min 264.0 7 Series 2 (ROCKFEU RAINURE Dual Queue d'Aronde (Dovetail) - 40/30/60) average 395.9 10 min 258.0 7 Series 3 (ROCKFEU RAINURE Dual Queue d'Aronde (Dovetail) - 60/50/80) average 485.7 13 min 382.0 10 Series 4 (ROCKFEU RAINURE Dual Biseau (Bevel) - 40/50/20) average 521.0 14 min 444.0 12

(71) The density of the tested product ROCKFEU DUAL RAINURE (GROOVE) is 150 kg/m.sup.3 in the top layer and 95 kg/m.sup.3 in the bottom layer. The thermal conductivity is 36 mWm.sup.1K.sup.1.

(72) The conducted test is a suitable parameter for determining the tensile strength. Given that concrete is much stronger than mineral wool and that the horizontal surfaces constitute the weakest parts of the interface between the mineral wool and the concrete, the test can be considered to be representative and satisfactory.

(73) 2) Compressive Strength

(74) The compression value obtained on ungrooved samples is at least 20 kPa, a comparable value being expected on grooved samples. The standard test is EN 826 for a non-laminar product expressed according to a compressive stress at 10% deformation. The compression test values are measured on an ungrooved panel.

(75) 3) Concentrated Loads

(76) The usual testing tool for solid panels is found to be unsuitable for a grooved panel because the dimensions of the bearing surface of the testing tool are very similar to the width of the groove. Nevertheless, the results obtained are sufficient and convincing with a value of 213 N at the groove for a dovetailed ROCKFEU DUAL RAINURE (GROOVE) panel, depth 40 mm, groove head width 30 mm, groove bottom width 60 mm, and a value greater than 300 N outside the groove. The test was conducted according to standard EN 12430.

(77) The density of the tested product ROCKFEU DUAL RAINURE (GROOVE) is 150 kg/m.sup.3 in the top layer and 95 kg/m.sup.3 in the bottom layer. The thermal conductivity is 36 mWm.sup.1K.sup.1.

(78) 4) Flexural Strength

(79) The density of the tested product ROCKFEU DUAL RAINURE (GROOVE) is 150 kg/m.sup.3 in the top layer and 95 kg/m.sup.3 in the bottom layer. The thermal conductivity is 36 mWm.sup.1K.sup.1. The tests were carried out according to standard EN 12089.

(80) There is no significant difference between the ungrooved products of the prior art and the grooved products of the invention. The panel can be handled by an operator accustomed to conventional panels.

(81) The insulating panel of the invention can accordingly be used on undersides or on concrete, regardless of the orientation thereof. This can be not only ceilings but also sloping walls such as, for example, walls located beneath staircases, beneath tiers, etc.