Process for the production of panels with integrated insulation for the production of buildings, panels thus produced

• US 8,621,807 B2
• Filed: 07/29/2010
• Issued: 01/07/2014
• Est. Priority Date: 07/29/2009
• Status: Active Grant

• Current Assignee: Maisons Naturelles En Beton De Chanvre
• Original Assignee: Maisons Naturelles En Beton De Chanvre
• Inventors: Charvoz, Laurent
• Primary Examiner(s): KATCHEVES, BASIL S
• Application Number:
  US12/846,046
• Publication Number:
  US 20110023397A1
• Time in Patent Office: 1,258 Days
• Field of Search: 524/14, 527/451.9, 523/097, 523/091.1, 524/053, 525/831, 264/34, 264/35, 264/255, 264/256
• US Class Current: 52/414
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/12 Expanded clay
• CPC Class Codes: C04B 18/248 from specific plants, e.g. hemp fibres
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/10 Lime cements or magnesium oxide cements
• CPC Class Codes: E04C 2/044 of concrete E04C2/049 takes precedence
• CPC Class Codes: E04C 2/049 completely or partially of insulating material, e.g. cellular concrete or foamed plaster
• CPC Class Codes: E04C 2/06 reinforced
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

A process for the production of panels (10) with integrated insulation in particular for the production of buildings, includes the following stages:

• • pouring a concrete that includes natural fibers into a mold M to form an interior surface (12) of the panel,
  • pouring a light hydrophobic concrete, with reinforcements, to form an exterior surface (14) of the panel,
  • adjustment of reinforcements (28) on the edge of each panel to ensure a cottering and adjustment of chain reinforcements (32). Also described are the panels obtained by the process.

Claims

1. A process for the production of panels with integrated insulation, comprising:

pouring concrete that includes natural fibers into a mold to form an interior surface of said panel;

pouring light hydrophobic concrete, with reinforcements, to form an exterior surface of said panel; and

reinforcing an edge of each panel to ensure cottering of chain reinforcements.

2. The process for the production of panels according to claim 1, further comprising an additional stage for deposition of a silica material layer in an interface between the interior surface and the exterior surface.

3. The process for the production of panels according to claim 2, wherein mechanical connectors are inserted between the interior surface and the exterior surface during the pouring so as to connect the interior surface and the exterior surface mechanically.

4. The process for the production of panels according to claim 1, wherein mechanical connectors are inserted between the interior surface and the exterior surface during the pouring so as to connect the interior surface and the exterior surface mechanically.

5. The process for the production of panels according to claim 1, wherein the natural fibers include natural hemp fibers.

6. The process for the production of panels according to claim 1, wherein casings of door frames, sheathings of fluid and electrical networks, and connection housings are prepositioned in advance in the mold M, in the interior surface.

7. A construction panel, made from the process according to claim 1, wherein the construction panel comprises a structured insulating surface.

8. The construction panel according to claim 7, wherein hemp comprises the natural fiber and wherein the construction panel has the following composition:

interior surface;

fibrous reed;

11.0%

standard reed;

5.5%

lime binder;

34.0%

sufficient quantity of water

exterior surface;

cement;

23.0%

sand;

40.0%

0/5 expanded clay;

12.0%

5/15 expanded clay;

12.0%

sufficient quantity of water.

9. The process for the production of panels according to claim 1, wherein the panels are for the production of buildings.

10. A process for producing a panel, comprising:

forming an interior surface from a mixture of concrete and natural fibers by pouring into a mold to form a monolithic layer, the natural fibers being selected from the group consisting of hemp fibers, flax fibers, straw fibers or wood fibers;

forming an exterior surface from light hydrophobic concrete; and

reinforcing an edge of the panel to ensure cottering of chain reinforcements.

11. The process according to claim 10, further comprising an additional step of depositing a silica material layer in an interface between the interior surface and the exterior surface.

12. The process according to claim 10, wherein mechanical connectors are inserted between the interior surface and the exterior surface during the pouring so as to connect the interior surface and the exterior surface mechanically.

13. The process according to claim 10, wherein the natural fibers include natural hemp fibers.

14. The process according to claim 10, wherein casings of door frames, sheathings of fluid and electrical networks, and connection housings are prepositioned in advance in the mold M, in the interior surface.

15. A construction panel, made from the process according to claim 10, wherein the construction panel comprises a structured insulating surface.

16. The construction panel according to claim 15, wherein hemp comprises the natural fiber and wherein the construction panel has the following composition:

interior surface;

fibrous reed;

11.0%

standard reed;

5.5%

lime binder;

34.0%

sufficient quantity of water

exterior surface;

cement;

23.0%

sand;

40.0%

0/5 expanded clay;

12.0%

5/15 expanded clay;

12.0%

sufficient quantity of water.

17. The process for the production of panels according to claim 10, wherein the panels are for the production of buildings.