Composite Panel for a Wall and Method for Making Same

• US 20110277407A1
• Filed: 03/11/2009
• Published: 11/17/2011
• Est. Priority Date: 10/10/2008
• Status: Active Grant

• Current Assignee: ArcelorMittal Construction France (ArcelorMittal SA)
• Original Assignee: ArcelorMittal Construction France (ArcelorMittal SA)
• Inventors: Masure, David, Moum, Chantha
• Granted Patent: US 8,833,023 B2
• Time in Patent Office: Days
• US Class Current: 52/309.4
• CPC Class Codes: E04C 2/296 composed of insulating material and non-metallic or unspecified sheet-material E04C2/288 takes precedence
• CPC Class Codes: E04C 2/384 with a metal frame
• CPC Class Codes: Y10T 29/49629 Panel

Abstract

A composite panel for making a wall of a building includes an outer cladding plate, an inner wall plate, and a supporting structure provided between the outer cladding plate and the inner wall plate and which is partially embedded in a polymer foam.

Claims

1-32. -32. (canceled)

33. A composite panel for making a wall of a building, comprising:

an outer cladding plate;

an inner wall plate; and

a supporting structure provided between the outer cladding plate and the inner wall plate and at least partially embedded in a polymer foam;

wherein the polymer foam includes a polyurethane foam having a density greater than 30 Kg/m³.

34. The composite panel according to claim 33, further comprising at least one panel made from mineral wool housed in the supporting structure.

35. The composite panel according to claim 33, wherein the supporting structure includes a metal frame including at least two side posts, an upper crosspiece, and a lower crosspiece.

36. The composite panel according to claim 35, wherein the side posts include two C-shaped profiles that are alongside each other in different orientations relative to each other.

37. The composite panel according to claim 36, wherein the two C-shaped profiles each include a bottom connecting two parallel side wings and are arranged perpendicular to each other so that a side wing of one of the profiles is alongside the bottom of the other profile.

38. The composite panel according to claim 35, wherein the supporting structure includes a central post.

39. The composite panel according to claim 40, wherein the central post includes two C-shaped profiles alongside each other back to back.

40. The composite panel according to claim 34, further comprising a mineral wool panel arranged in a volume defined by the supporting structure, ends of the panel being housed in a bottom of two facing C-shaped profiles of two adjacent posts.

41. The composite panel according to claim 35, wherein the upper and lower crosspieces include U-shaped profiles covering free ends of the side posts.

42. The composite panel according to claim 41, wherein the U-shaped profile that makes up the lower crosspiece includes a bottom that includes a longitudinal rib extending over an entire length of the profile.

43. The composite panel according to claim 35, wherein the frame includes a wind bracing.

44. The composite panel according to claim 43, wherein the wind bracing includes a St Andrew'"'"'s cross.

45. The composite panel according to claim 43, wherein the wind bracing includes a metal plate secured to at least the side posts.

46. The composite panel according to claim 45, wherein the metal plate is also secured to the central post.

47. The composite panel according to claim 33, wherein the inner wall plate includes an outer plaster plate.

48. The composite panel according to claim 47, wherein the inner wall plate includes a steam-impermeable membrane alongside or secured to an inner or an outer surface of the outer plaster plate.

49. The composite panel according to claim 33, further comprising a device adapted to run cables inside the panel.

50. The composite panel according to claim 49, wherein the device includes a raceway adapted to run cables extending over a height of the panel and located close to an outer plaster plate so as to make it easy to access to run cables.

51. The composite panel according to claim 50, wherein the raceway is incorporated into the supporting structure extending from a bottom of a U-shaped profile of a lower crosspiece to a bottom of a U-shaped profile of an upper crosspiece, the upper and lower crosspieces including openings allowing access to an inside of the raceway.

52. The composite panel according to claim 33, further comprising a finishing plate kept, by a device for keeping the finishing plate, at a certain distance from the outer wall plate on a side opposite the supporting structure, so as to define a volume to run cables between the plates.

53. The composite panel according to claim 52, further comprising spacers made from C-shaped profiles, branches of the C secured to the finishing plate and the outer wall plate, respectively.

54. The composite panel according to claim 52, further comprising at least one mineral wool panel arranged in a volume for running cables between the finishing plate and the inner wall plate, ends of the panel being housed in a bottom of two adjacent C-shaped profiles.

55. The composite panel according to claim 33, further comprising a layer of rock wool adhered to the outer cladding plate.

56. The composite panel according to claim 33, further comprising two side edges, at least one of the two edges configured to cooperate with the side edge of an adjacent panel configured in a complementary manner.

57. The composite panel according to claim 56, wherein at least one of the two side edges includes a tab made from a fire-resistant material extending along a side edge of an outer plaster plate arranged against an inner wall of the plaster plate and extending beyond the side edge so that when the side edge of the panel cooperates with the complementary side edge of an adjacent panel, the plaster tab covers a seam between the respective outer plaster plates of the adjacent panels.

58. The composite panel according to claim 56, wherein at least one side edge is formed by the polymer foam gripped between the outer cladding plate and the inner wall plate.

59. The composite panel according to claim 57, wherein the outer plaster plate includes, on an outer face, at least one thinner strip retracted towards an inside of the panel extending over an entire height of the plaster plate along a side edge.

60. The composite panel according to claim 56, wherein along at least one of the two side edges, the outer cladding extends laterally beyond the supporting structure and the inner wall plate, over a distance adapted to cover the side edge of an adjacent panel perpendicular to the composite panel, the outer cladding being covered on the inner face with a polymer foam configured to cooperate in a complementary manner with the side edge of the adjacent panel.

61. The composite panel according to claim 33, wherein along a lower edge of the panel, the outer cladding plate extends downwards beyond a lower edge of the supporting structure to form a covering skirt.

62. The composite panel according to claim 33, wherein the outer cladding plate includes at least one of (a) a metal cladding plate and (b) a lacquered galvanized steel cladding plate.

64. The method according to claim 63, wherein the composite panel is arranged as recited in claim 33.

65. The composite panel according to claim 33, wherein the composite panel is made according to the method recited in claim 63.

63. A method for making a composite panel, comprising:

arranging at least one inner wall plate, on which a supporting structure is placed or secured, in a molding frame;

positioning side crosspieces with shapes complementary to those of the side edges of the panel to be made;

positioning polymer foam wedges placed on the inner wall plate or the supporting structure;

positioning an outer cladding panel placed on the foam wedges so that the outer cladding panel is at a certain distance from the supporting structure;

inserting an assembly of the inner wall plate, the supporting structure, the side crosspieces, the polymer foam wedges, and the outer cladding panel into a conformator;

hot injection of polymer foam is injected hot; and

stripping the panel after cooling.