Construction element

A construction element comprises a ribbed sheet metal core whose ribs are of trapezoidal cross section, at least partially embedded in plastic foam. Fretwork extends along the tops of the ribs, transversely or longitudinally thereof. Transversely, the fretwork can be spaced metal straps or wooden slats. Longitudinally, the fretwork can be undulant or twisted metal strips. The fretwork can be embedded in the plastic foam, or can disposed outside and spaced from the plastic foam so as to serve to improve the connection between the construction element and a layer of concrete cast thereon. The construction elements have overlapping edges of reduced thickness into which the metal core extends. The ends of the construction elements have Z-shaped members one wing of which is secured to the core and the other wing of which serves to secure the element to a support.

The present invention relates to a construction element of many uses, which 
can be used in any type of construction such as walls, sheathing, exterior 
insulating panels for existing constructions, ceilings, floors, etc. 
Insulating construction panels are already known that have many uses, 
generally constituted by two skins between which an insulating material is 
confined. However, these panels have certain drawbacks, among which is the 
fact that their possible number of uses is limited because of the 
unavoidable presence of the two external skins, which constitutes a double 
disadvantage both from the point of view of appearance and from the point 
of view of cost. Moreover, thermal bridges may be provided by these known 
constructions when mounted in place, and this greatly decreases their 
thermal insulation characteristics. 
It is an object of the present invention to overcome these difficulties. To 
do this, the present invention provides a construction element 
characterized by the fact that it comprises a rigid core which is at least 
partially embedded in an insulating material, each of the faces of the 
construction element being at least partially formed by the insulating 
material. 
The accompanying drawings show schematically and by way of example several 
embodiments of construction element acccording to the invention as well as 
their possible uses.

Referring now to the drawings in greater detail, and first to the 
embodiments of FIGS. 1-3, it will be seen that the construction element 
according to the present invention comprises a metallic core providing a 
rigid armature and constituted by a ribbed metal profile 1 (FIGS. 1 and 2) 
or by several ribbed profiles 1' (FIG. 3). These profiles may be formed of 
rolled sheet steel, aluminum, lead, or any other suitable metallic alloy 
according to the envisioned use; and the parallel ribs have in cross 
section a substantially trapezoidal configuration, the depth of the ribs 
being in this case substantially equal to the width of their tops. 
According to other embodiments which are not shown, the rigid armature 
functioning as the core of the construction element may also be provided 
in other rigid materials, such as wood, plastics, etc. Of course, the 
characteristics of the metallic or nonmetallic core will be chosen as a 
function of the moment of inertia sought for the particular use in 
question. 
The metallic core 1, 1' is embedded in a synthetic insulating material 2, 
for example a rigid or flexible cellular foam, such as polyurethane, or 
bonded fibers or any other thermal and/or sound insulating material. This 
covering material is disposed on both sides of the metallic core 1, 1' so 
as to form at least partially the two exposed faces 3 of the panel. These 
two faces 3 may be constituted entirely by the covering material 2 (FIGS. 
1 and 3) or else one of the faces 3 is entirely constituted by that 
material, the other face 4, 4' being only partially constituted by that 
material (FIG. 2). In this latter case, the surface of the panel has 
portions 4 of covering material and portions formed by a part 4' of the 
metallic profile. 
According to alternative embodiments which are not shown, a portion of the 
longitudinal throats of the profiles may be replaced by an inexpensive 
filling material which is then embedded in the covering material. 
According to the uses foreseen for the construction element of the present 
invention, the metallic core 1, 1' may be provided with a protective 
coating or a coating to improve its adherence with the insulating material 
2. It can also have perforations or embossing so as mechanically to 
reinforce the bond between the core and its cladding. 
The apices of the ribs of the profiles 1, 1' may be interconnected, on one 
or both faces of the construction element, by cross pieces 5 that extend 
transversely and are suitably spaced apart from each other. The cross 
pieces 5 may be constituted for example by metallic strips fixed by 
welding or crimping, or by wooden slats, etc., and serve on the one hand 
to increase the rigidity of the element, and on the other hand as 
connectors useful for handling the construction element, for securing its 
facings, for bonding to cladding material, etc. 
One of the important advantages of the construction element according to 
the invention resides in the fact that one or both of its faces may be 
provided with any kind of covering, according to the desired utilization. 
The "hot" face of the panel may be covered by a so-called "vapor barrier", 
for example of kraft paper, aluminum, aluminum paper, a film of 
polyvinylchloride or of polyethylene, etc. As to the "cold" face, this may 
be likewise provided, according to the intended use of the panel, with a 
decorative or finishing or protective coating. 
Thus, thanks to the possibility of combining the construction element 
according to the present invention with an almost unlimited range of 
functional or aesthetic facings, this element may have multiple uses in 
all fields and types of architecture. Among others could be mentioned the 
use of this construction element for providing insulating panels for 
industrial sheathing, waterproof or covering supports, walls, floors, 
external insulating panels for existing constructions, walls for 
refrigerator chambers, bathrooms, etc. Some of these recited uses will now 
be described in greater detail by way of example with reference to FIGS. 
4-11. 
The first use, shown in FIGS. 4-6, is as sheathing comprising a vertical 
series of construction elements (P.sub.1, P.sub.2, P.sub.3, etc.), the 
ribs of the profiles being disposed horizontally, fixed to upright beams 
6. At each end 2', each panel P.sub.1, P.sub.2, P.sub.3, etc. comprises a 
Z-shaped closure profile 7, for example of galvanized steel, whose one 
flange 7' is secured, by crimping, spot welding, etc., on the tops of the 
ribs of the metallic core 1, the other flange 7" serving as a lip for 
securement to the vertical beam 6. At the vertical junction of two 
horizontal panels P.sub.1, P.sub.3, a filler 8 is provided between the two 
end profiles 7, this filler being for example a flexible joint, a rigid 
foam, a pad of glass fiber, etc. (FIG. 6). 
The horizontal joint between two horizontal panels P.sub.1, P.sub.2 is 
formed by the superposition of the side edges 2'. 
A sealing joint material may also be provided at 9 between the panels. 
When a panel must be secured to more than two vertical supports, the 
intermediate connectors may be provided externally or internally, for 
example by means of self-tapping screws. When the securement is external, 
the head of the fastener will be covered by an insulating plug, for 
example of foam, so as to preserve the continuity of the thermal 
insulation. 
Thanks to the fact that it permits obtaining sheathing with no thermal 
bridge, the construction element according to the invention, used as 
sheathing, has with respect to known sandwich panels the advantage of 
being adaptable for many uses and of being useful under all climatic or 
aesthetic conditions. 
Thus, the "hot" face of the element may be covered by a material dictated 
by the use of the internal wall of the construction and particularly 
according to aesthetic standards. The interior covering therefore may be 
plain, grained, striated, of metallic appearance or not, etc., in 
contradistinction to known panels in which the interior covering must also 
function as the rigid armature and may display ribs or reinforcements as 
the case requires. 
The external covering, which will preferably be water-tight, is also chosen 
according to the type of construction as well as according to economic, 
aesthetic, climatic and other considerations. In the example illustrated 
in FIGS. 4-6, a metallic or plastic profile 10 is used as external facing 
and is fixed to the construction element according to the invention for 
example by securement to the tops of the ribs of the metallic core 1. In 
the case of horizontal sheathing, the external covering may also be fixed 
to the transverse cross pieces. 
All types of external covering may be used, thanks to the metallic 
profiles, for example asbestos cement slabs, slate shingle, plastic 
profiles, face coats, etc. It is also possible to provide, as external 
facings, elements of low moment of inertia, which thus permit increasing 
in an important way the possibilities of architectural style. 
Moreover, such a construction imparts protective characteristics, for 
example acoustic, shock absorbing, etc., at selected portions of the 
facing, which accordingly do not affect the entire construction. 
Finally, thanks to the profiled core of the construction elements when used 
as sheathing, the bracing of the latter is ensured without the need to use 
other rigidifying or reinforcing elements. 
For providing an insulating support for coverings with construction 
elements according to the invention, these may be assembled and secured to 
the joists of the roofing in the same manner as described above for the 
emplacement of sheathing on upright beams. Once installed, the 
construction elements according to the present invention are ready to 
receive any kind of traditional covering. 
FIGS. 7 and 8 show the use of construction elements according to the 
invention as exterior insulating panels for existing constructions. The 
construction elements are thus fixed to the facade by means of Z-shaped 
purlins 11. These purlins 11 may be secured by means of pins, nails, 
screws or crimping, vertically or horizontally as desired, against the 
brick wall 12 or against a concrete wall 13 (FIGS. 7 and 8). In the first 
case, the construction elements are assembled with the ribs of profile 1 
disposed horizontally; while in the second case, the ribs of profile 1 are 
disposed vertically. The securement of the elements of construction on 
Z-shaped purlins is effected by nailing, screwing or crimping on the tops 
of the ribs of profile 1. The assembly of the construction elements with 
each other is effected in the same manner as described in connection with 
FIGS. 4-6 showing the use of industrial sheathing. 
As to the external face of the construction elements, this may be provided 
for example with screen 14 to receive a cement layer 15 (FIG. 7) or else 
glass fiber or other support material designed to receive a plaster layer 
16. 
When designed for use as a simple external insulating panel to be secured 
to the facade, the construction element according to the present invention 
need not have itself a high moment of inertia other than that necessary to 
resist climatic chances at the work site without substantially sagging. 
However, the presence of an armature even of low moment of inertia 
suffices to confer on the insulating panel sufficient rigidity so that it 
can be stocked in large units and will nevertheless remain easy to handle. 
This is a great advantage when compared to other products in actual use 
for external insulation of existing buildings, which generally must be 
sold in the form of small sheets, which undesirably increases the number 
of needed joints. 
In the case of existing buildings, the construction elements according to 
the invention may also be secured as insulation, for example by nailing or 
crimping, to the interior or the exterior of existing sheathing. 
As already mentioned above, the construction element according to the 
invention may also be used for the construction of flooring. To this end, 
the insulating elements are assembled and arranged on horizontal supports, 
so as to constitute a surface adapted to receive either wooden flooring or 
a covering layer for example in the form of a concrete slab 17. So as to 
obtain effective connection between the construction element and the 
concrete, the former is preferably provided with cross members such as 
were previously described with reference to FIGS. 1-3, which may be 
transverse (FIG. 9) or longitudinal (FIGS. 10 and 11), and thus serve as 
anchors in addition to their rigidification function. 
As transverse connectors can be used for example as metal straps 18 
connecting the tops of the ribs of profile 1, these straps having 
securement portions 18' crossing the longitudinal throats of profile 1 
(FIG. 9). 
The longitudinal connectors may also be constituted by metal sheets 19 
disposed longitudinally on the lateral edges of the tops of the ribs of 
profile 1, such that a portion of these sheets overlies the longitudinal 
valleys of profile 1, these overhanging portions being preferably undulant 
so as to provide better engagement with the concrete (FIG. 10). 
The longitudinal connectors may also be constituted by metal rods 20 
preferably twisted and disposed longitudinally along the tops of the ribs 
of profile 1, on the side intended to receive the concrete (FIG. 11) 
As to the distribution of the synthetic insulating material in the 
embodiments of the construction element according to the invention, on the 
side of profile 1 opposite that intended to receive the concrete, the 
insulating material 2 need not completely fill the longitudinal valleys of 
the profile, the space 21 between the bottom of the valleys and the 
insulating material 2 being empty or filled with inexpensive filling 
material. 
Moreover, and this is a very important advantage of the construction 
element according to the invention, the height of filling (h) of the 
synthetic insulating material 2 of the longitudinal valleys of profile 1 
on the side intended to receive the concrete and thus to serve as a form 
for the latter, may be selected so that the neutral axis of the finished 
panel (insulating material plus concrete) will be approximately at the 
level of the upper connectors. Thus, the construction element according to 
the invention serves not only as formwork but also as a variable shape 
which can be selected so as to perform other desirable functions. 
To illustrate the wide variety of uses possible for the construction 
element according to the invention, one can also mention that it is 
equally adaptable to be used for the construction of portable insulating 
walls, for example anti-noise walls, closure walls, bathroom walls, bomb 
shelter walls, etc. 
A portable wall may be provided by the assembly of construction elements 
which themselves serve as reinforcement, their lower end being fixed to a 
base by simple securement in the concrete of a slab. The elements are in 
this case provided if desired with external and internal facings according 
to the type of construction in question. On the other hand, the assembly 
of construction elements may be used, as described in connection with 
FIGS. 9-11, for the production of flooring, as scaffolding for concrete 
construction, and as an insulating plate for supporting closures. 
In addition to the numerous advantages of the construction element 
according to the invention already set forth in the preceding, it may also 
be noted that such elements are easy to construct and that they are 
therefore inexpensive and particularly suited for low-cost construction, 
especially in developing countries, while at the same time fulfilling all 
of the technical and architectural requirements. 
From a consideration of the foregoing disclosure, therefore, it will be 
evident that the object of the present invention has been achieved. 
Although the present invention has been described and illustrated in 
connection with preferred embodiments, it is to be understood that 
modifications and variations may be resorted to without departing from the 
spirit of the invention, as those skilled in this art will readily 
understand. Such modifications and variations are considered to be within 
the purview and scope of the present invention as defined by the appended 
claims.