Patent Publication Number: US-11661748-B2

Title: Method for producing a facing

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is the U.S. National Stage of PCT/FR2019/051494, filed Jun. 19, 2019, which in turn claims priority to French patent application number 1855395 filed Jun. 19, 2018. The content of these applications are incorporated herein by reference in their entireties. 
     TECHNICAL FIELD 
     The present description relates to a method for producing a facing, in particular a facing of a room partition or of a lining partition of a structure such as a wall, a partition, a ceiling, a rake. 
     BACKGROUND OF THE INVENTION 
     As is well known, a room partition is generally formed of two facings fastened on either side of a framework comprising a plurality of metal members, generally equidistant, disposed vertically between and nested in two horizontal members, also referred to as top rail and bottom rail, fastened to the ceiling and to the floor, respectively. 
     A lining partition is made up for example of a facing, attached to a framework comprising a plurality of bracing devices fastened to the structure to be lined and metal members of the type described above, which are fastened to these bracing devices and nested in two horizontal members fastened to the ceiling and to the floor, respectively. 
     In the case of a room partition and of a lining partition of the abovementioned type, each facing is formed by a juxtaposition of panels having a width corresponding to a multiple of the distance between two adjacent vertical metal members. The lateral edges of a panel are thus in continuous contact, over their entire height, with a vertical metal member, ensuring the planarity of the facing at the junction between panels. 
     In order to make it easier to fit partitions and reduce the associated costs, the applicant is currently developing a new type of framework, which makes it possible to produce room partitions and lining partitions that do not have vertical metal members or, at the very least, does not require any screwing of panels in such vertical members. This new type of framework employs a plurality of point support elements, disposed at a distance from the top and bottom rails, for example half-way up, configured such that the panels can be fastened directly thereto without interposition of metal members. With such a system, the lateral edges of the facing panels are supported only at points, in zones known as support zones, by point support elements. Between two support zones, the edges of the panels are free. There is then a risk of two adjacent panels not being at the same level (meaning that their front faces are not locally coplanar), impairing the esthetic finish of the facing. Moreover, the facing, which is not very rigid, can be deformed between two support zones, when a force is applied orthogonally to the panel, for example by a person pressing on the partition. 
     OBJECT AND SUMMARY OF THE INVENTION 
     One of the objectives of the present invention is to remedy the abovementioned drawbacks of the prior art. 
     This objective is achieved by a method for producing a facing, in particular a facing of a room partition or of a lining partition, said facing comprising at least one first panel and one second panel that are each delimited by a front face and a rear face connected by a lateral edge, the method comprising at least the following steps: 
     a) a first panel is fitted, 
     b) a first part of a connector is fastened to the first panel such that a second part of the connector projects beyond said first panel, 
     c) a second panel is fitted next to the first panel and fastened to the second part of the connector. 
     The method according to the invention makes it possible to locally connect two adjacent panels that are not supported by a metal member. It is particularly suitable for the production of a facing in front of a framework comprising individual point support elements instead of vertical metal members, in line with the junctions between panels (it should be noted that a vertical member is understood here to be a member orthogonal to the horizontal direction, which may optionally be inclined). 
     The method according to the invention ensures better rigidity and durability of the facing and avoids level unevenness at the junction between panels, which make the finish unattractive and sometimes impossible. 
     A panel may be for example a plasterboard sheet, which is or is not provided with a decorative coating, is in one piece or has a sandwich structure or a laminated structure made of several sheets bonded together. 
     A panel may also be a sheet of cement board, of timber, of wood composite (agglomerate, OSB). It may also be made from a plastics material or a metal material, or from any other suitable material. 
     The material of which it is made (plaster, plastic, etc.) may optionally be reinforced with fibers (mineral fibers, cellulosic fibers, etc.). 
     In one example, the first panel is fastened to a framework before the connector is fitted. 
     The framework may for example comprise: 
     at least one point support element provided, at a first end, with an overall planar surface for the direct support of a panel and, at a second end, with means for fastening it to an adjacent structure, for example an opposite facing or a structure to be lined (it should be noted that “direct support” means direct support or support via a thin layer of glue or a thin adhesive element), 
     and/or 
     top and bottom horizontal members that are fastened to the ceiling and to the floor, respectively. These may be for example C profiles, also known as rails, or simple angle bars. 
     It will be understood that, in contrast to such a framework, the connector is intended to be connected only to the panels that it links, and to no other structural element, in particular the structure to be lined (in the case of a lining partition), the adjacent facing (in the case of a room partition, the floor, the ceiling etc.). The connector is therefore normally fastened only to the first and second panels. 
     In one example, in step b), the connector is fastened to the first panel such that the rear face of the latter is placed against the first part of the connector. 
     In one example, the first part of the connector comprises a main face and at least one lug comprising a wedging wing extending from said main face, and during step b), the main face of the first part is fitted on the rear face of the first panel and the wedging wing is wedged against the edge of the first panel. 
     In the present application, the main face is understood to be the face of an element intended to be oriented toward the room to be delimited by the facing, after it has been mounted. 
     In one exemplary embodiment, the first part is provided with clamping means designed to cooperate with the edge of the first panel. 
     For example, the lug also comprises a projection extending from the wedging wing and forming a receiving part with the main face of the first part and the wedging wing, and during step b), the receiving part is engaged over the edge of the first panel. 
     The connector is thus mounted on the first panel, either by force if the lug is rigid and the width of the receiving part is equal to or slightly less than the width of the panel, or by elastic deformation of the lug, the U-shaped receiving part forming a clip that clamps the panel. 
     In one example, the lug is cut or broken at the end of step b) or c). This prevents it from impeding the production of the joint between panels, or from remaining visible after jointing. Generally, the connector is preferably not visible following the production of the facing, meaning that it is not visible from the room that the facing delimits. 
     In some cases, the facing is not linear. The first panel and the second panel then form a salient or reentrant angle. In this case, the connector is folded before it is fastened to the first panel, by an angle corresponding to the desired angle between the first panel and the second panel. 
     In one example, in step c), the second panel is fitted next to the first panel such that its rear face is placed against the second part of the connector. 
     The connector can for example be fastened to the first and/or the second panel by screwing. In one variant or in addition, it can be fastened to the first and/or the second panel by adhesive bonding, in particular by means of a glue or an adhesive element of the film or tape type, or by a combination of screwing and adhesive bonding. In another variant, the first part and/or the second part of the connector can be fastened to the first and/or to the second panel only by clamping (of the edge of the panel in a receiving part in particular). 
     The invention also relates to a connector for implementing the method as defined above, comprising a first part for fastening it to the first panel and a second part for fastening it to the second panel. 
     In one example, at least one of the first and the second part of the connector, preferably the first and the second part of the connector, comprises an overall planar main face. The connector preferably comprises an overall planar main face. 
     In one example, the connector is such that the ratio between the largest transverse dimension and the smallest transverse dimension of the or each main face is at most 3, in particular at most 2. The connector can then be fastened quickly and easily to the first panel after the latter has been fitted and the second panel can be fastened quickly and easily to the connector, while preventing the deformation of the facing. 
     In one example, the or each main face is textured. A “textured face” means that the face in question has a relief, made up of a succession of peaks and troughs. This relief may be periodic or random. The texturing of the surface may also have a plurality of different reliefs that are distributed regularly or randomly. By way of example, the contact face may be provided with concentric and/or honeycomb ribs and/or grooves. 
     In one example, the first part has at least one lug provided with a wedging wing extending from its main face, orthogonally to said main face. 
     In one example, the lug also comprises a projection extending from the wedging wing and forming a receiving part with the main face of the first part and the wedging wing. 
     Advantageously, the lug is designed to be entirely or partially removable. In order to make it easier to take hold of the lug in order to remove it, the projection may bear gripping means such as a gripping tab. 
     In one example, the connector comprises, extending perpendicularly to the face on the opposite side from the main face of the connector, gripping means in order to make it easier to take hold of the connector while it is being fitted and fastened to the first panel. 
     In one particular exemplary embodiment, the connector comprises means for pivoting the first and the second parts with respect to one another. To this end, the first part and the second part can be connected for example by at least one metal core, the metal core forming a foldable intermediate part between the first and the second part. 
     Finally, the invention relates to a kit comprising at least one connector as defined above and at least one point support element provided, at a first end, with an overall planar surface for the direct support of a panel and, at a second end, with means for fastening it to an adjacent structure, for example an opposite facing or a structure to be lined. 
     A number of exemplary embodiments are described in the present description. However, unless specified to the contrary, the features described in relation to any one exemplary embodiment can be applied to another exemplary embodiment. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be understood better and the advantages thereof will become clearer on reading the following detailed description of a number of exemplary embodiments depicted by way of nonlimiting examples. The description refers to the appended drawings, in which: 
         FIG.  1    illustrates a connector according to a first exemplary embodiment of the invention (front face); 
         FIG.  2    illustrates the connector from  FIG.  1    in side view; 
         FIGS.  3  to  8    illustrate, step by step, the production of a facing according to a first implementation example of the method of the invention, with the aid of connectors according to  FIGS.  1  and  2   :  FIGS.  3 ,  4  and  8    are front views of the facing being produced, and  FIGS.  5  to  7    are views on the section plane V in  FIG.  4   ; 
         FIG.  9    illustrates a connector according to a second exemplary embodiment of the invention (front face); 
         FIG.  10    illustrates the rear face of the connector from  FIG.  9   , and shows, by dashed lines, the internal structure thereof; 
         FIGS.  11  and  12    illustrate the production of a facing according to a second implementation example of the method of the invention, with the aid of a connector according to  FIGS.  9  and  10   , 
         FIGS.  13  and  14    illustrate a variant of the connector according to the first exemplary embodiment, showing the rear face and the front face, respectively, of the connector. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       FIG.  1    illustrates a connector  100  according to a first exemplary embodiment of the present invention, which is intended to locally form the link between two panels  91 ,  92  of a facing P, as illustrated in  FIG.  8   . 
     Hereinbelow, the following are defined for each panel  91 ,  92 : 
     a front face  91   a ,  92   a  oriented toward the interior of the room intended to be at least partially delimited by the facing P, 
     a rear face  91   b ,  92   b  on the opposite side from the front face  91   a ,  92   a , and 
     an edge  91   c ,  92   c.    
     More generally, the terms front and rear are used, throughout the description, with reference to the location of the components on the final facing, the front being oriented toward the interior of the room intended to be at least partially delimited by the facing P, the rear being oriented away from said room. 
     With reference to  FIG.  7   , the general principle of the method according to the invention is as follows: 
     the connector  100  is fastened by a first part (referenced  111  below) to a first panel  91  such that a second part of the connector (referenced  112  below) projects beyond said first panel  91 , 
     a second panel  92  is fitted next to the first panel  91  and fastened to the second part  112  of the connector  100 , and so on for the following panels. 
     In this first exemplary embodiment, the connector  100  is a one-piece element made of a thermoplastic material such as a polyamide filled or not filled with glass fibers, polypropylene, or the like. 
     As illustrated in  FIG.  1    and  FIG.  14   , the connector  100  comprises a main part  110  exhibiting the overall form of a mounting plate, in this case generally circular of central axis X. In a variant, the connector  100  may, however, exhibit any other suitable section, for example square, rectangular, hexagonal, octagonal, etc. 
     In the example, and as will become apparent from the rest of the description, the limit between the first part  111  of the connector, which is intended to be fastened to the first panel  91 , and the second part  112  of the connector, which is intended to be fastened to the second panel  92 , corresponds to a transverse plane of the main part  110 , in this case its plane of symmetry S. 
     As illustrated in more detail in  FIG.  2   , the main part  110  is in this case delimited, in the direction X, by two faces: a front face  114 , known as the main face of the connector, formed by main faces  111   a ,  112   a  of the first and second parts  111 ,  112 , and a rear face  116  of the connector, formed by the rear faces  111   b ,  112   b  of the first and second parts  111 ,  112 . In the example, the main faces  111   a ,  112   a  are coplanar, as are the rear faces  111   b ,  112   b.    
     In the example, the main face  114  of the connector is entirely textured, meaning that it has a relief made up of a succession of peaks and troughs. This is a periodic relief, formed of a plurality of parallel ribs  118  with the same height and the same width. In the variant shown in  FIG.  14   , the relief also comprises, in the central part of the main face  114 , a plurality of parallel ribs  119  that are arranged perpendicularly to the ribs  118  and have a smaller height than the latter. This configuration makes it possible, in the case of screwing the panels, to prevent the screw from turning the connector or from being inserted at an angle. 
     The texturing of the main face  114  allows improved coupling of the fastening screws or, in the case of fastening by means of a glue, increases the contact area of the glue with the mounting plate. 
     In the example, the main face  114  of the connector remains overall planar, however, in order to be able to be in stable contact with the rear faces  91   b ,  92   b  of the first and the second panel  91 ,  92 , as described in more detail below. Overall planar means that the top points of this face are situated substantially in a single plane, or more generally that its envelope surface is substantially planar. 
     The minimum transverse dimension of the main face  114 , denoted D here, is greater than or equal to 30 mm, preferably greater than or equal to 45 mm. The minimum transverse dimension means the smallest dimension of the connector measured in a plane orthogonal to the axial direction X. The maximum transverse dimension of the main face  114  is preferably less than or equal to 600 mm, in particular less than or equal to 400 mm, and even less than or equal to 200 mm. 
     In addition, the total surface area of the main face  114  of the connector is preferably greater than at least 900 mm 2 , preferably greater than 2025 mm 2 . The total surface area of the main face  114  of the connector is preferably less than 3000 cm 2 , in particular less than 1000 cm 2 , and even less than 300 cm 2 . The total surface area means here the surface area of the envelope surface of the contact face  114 . 
     In the example illustrated, it has an axial section with a diameter D equal to 8 cm. 
     As illustrated in  FIG.  2   , the rear face  116  of the connector  100  may also be planar or more or less planar. 
     In a variant illustrated in  FIG.  13   , the rear face  116  is also provided with gripping means  130  that make it easier to position and fasten the connector, in particular by allowing it to be taken hold of at the time it is fitted on the first panel and while it is being screwed thereto. These gripping means are in this case in the form of two mutually parallel wings that extend toward the rear in the axial direction X. 
     In the example in  FIGS.  1  and  2   , the first part  111  of the connector  100  is provided with a lug  120  extending toward the front from its main face  111   a . In the example in  FIGS.  13  and  14   , the first part  111  is provided with two lugs  120 . 
     The or each lug  120  comprises a wedging wing  122  extending from the main face  111   a  and orthogonal to this main face  111   a . It extends at the periphery of the main part  111 , along the transverse plane S of the main part  110 . 
     The or each lug  120  also comprises a projection  124  that defines, with the wing  122  and the main face  111   a , a U-shaped receiving part  126 , the receiving part  126  being open next to the main part  111  of the connector. 
     Finally, the or each lug comprises gripping means  128 , on the projection  124 , in this case in the form of a tab protruding toward the front. 
     In a variant, the or each lug  120  could also have only the wedging wing  122 , or only the wedging wing  122  and the projection  124 , without gripping means  128 . 
     Advantageously, the or each lug  120  is designed to be able to be removed after the connector  100  has been fastened to the first panel  91  and before or after it has been fastened to the second panel. For example, the wedging wing  122  may be sufficiently thin to be able to be detached under the effect of a sufficient pulling force, the application of which can be made easier by the gripping means. In a variant, precut lines can also be made at the base of the wedging wing  122  or of the projection  124 . 
       FIGS.  3  to  8    illustrate the production of the facing of a lining partition attached to the front of an existing wall M, according to one implementation example of the present invention using the connector from  FIGS.  1  and  2   . 
     As is well known, the facing P is formed by the juxtaposition of a plurality of panels  91 ,  92 , etc. 
     In the example, the facing P is attached to a framework comprising a plurality of bracing devices  94  fastened to the wall to be lined, and two horizontal metal members  96 ,  98  fastened to the ceiling and to the floor, respectively. 
     The bracing devices  94  are in this case point support elements provided, at a first end (front), with an overall planar surface  94   a  for the direct support of a panel and, at a second end  94   b , with means for fastening it to the wall to be lined M, for example a mounting plate for screwing or means for clip-fastening to a metal member. 
     In a first step, illustrated in  FIG.  3   , the first panel  91  is fitted in its final position and then fastened, generally by screws  93 , to the horizontal metal members  96 ,  98  and to the point support elements  94 . At the end of this first step, the lateral edges of the panel  91  are not supported in the intermediate zones between the metal members  96 ,  98  and the bracing devices  94 . 
     In a second step, illustrated in  FIG.  4   , connectors  100  are fitted on the panel  91 , preferably at the center of each intermediate zone, by engaging their receiving part  126  over the edge of the panel  91 . Each connector  100  is in this case mounted on the edge of the panel  91 , either by force if the lug  120  is rigid and the width of the receiving part  126  is equal to or slightly less than the thickness of the panel  91 , or by deformation of the lug. In the latter case, with the lug being returned elastically into its initial position, the U-shaped receiving part forms a clip that clamps the panel. 
     Each connector  100  is thus positioned such that the main face  111   a  of its first part is in contact with the rear face  91   b  of the first panel  91 , that a first face of the wedging wing  122  is in contact with the edge  91   c  of the first panel  91 , and that the second part  112  of the connector projects laterally beyond the first panel  91 , thus remaining free, in the continuation of the first panel. 
     In a third step illustrated in  FIG.  5   , the connector  100  is fastened to the first panel  91 , for example by screwing through the first panel  91  and the first part  111 . 
     Following this third step, as illustrated in  FIG.  6   , the lug  120  is optionally cut or broken, preferably at its base or optionally at the junction between the wing  122  and the projection  124 . This then prevents it from impeding the production of the joint between panels, or from remaining visible after jointing. In a variant, if, however, the projection  124  is sufficiently thin and has a substantially planar front surface, the lug can also remain in place and be covered by the jointing product. 
     In a fifth step, illustrated in  FIG.  7   , the second panel  92  is fitted next to the first panel  91 , with its edge  92   c  in contact with the edge  91   c  of the first panel  91  and with the right-hand face of the wedging wing  122  and with its rear face  92   b  in contact with the main face  112   a  of the second part  112  of the connector. 
     In a sixth step ( FIG.  8   ), the second panel  92  is finally fastened to the second part  112  of the connector  100 , for example by screwing through the second panel  92  and said second part  112 . 
     At the same time, the second panel  92  is also fastened to the framework formed here by the horizontal members  96 ,  98  and the bracing devices  94 . 
     According to one variant, the framework could for example be formed only of horizontal members  96 ,  98 , or only of point support elements, or of a combination of horizontal members and/or point support elements with vertical members. 
     Furthermore, while  FIGS.  3  to  8    illustrate the production of a facing attached to the front of an existing wall M, the method according to the invention can be implemented in the same way to produce any facing comprising at least two panels, in particular a facing for lining a ceiling, a rake, or for producing a room partition. 
       FIGS.  9  and  10    illustrate a connector  200  according to a second exemplary embodiment of the invention. 
     The connector  200  differs from the one in the first embodiment in that it comprises a first part  211  (intended to be fastened to the first panel  91 ) and a second part  212  (intended to be fastened to the second panel  92 ) that are movable with respect to one another about an intermediate part forming a hinge  213 . 
     The connector  200  is thus designed to pass from a non-folded state, as illustrated in  FIGS.  9  and  10   , to a folded state, illustrated in  FIGS.  11  and  12   . It can therefore be used to locally link two panels  91 ,  92  that form a salient or reentrant angle with one another. 
     In the example, each part  211 ,  212  form a substantially semicircular mounting half-plate delimited by a front face (known as the main face)  211   a ,  212   a , respectively, and a rear face  211   b ,  212   b , respectively. The main faces  211   a ,  212   a  of the two mounting half-plates jointly form the main face  214  of the connector  200 , and their rear faces  211   b ,  212   b  form the rear face  216  of the connector  216 . 
     Furthermore, an inner edge  211   c ,  212   c , respectively, and an outer edge  211   d ,  212   d , respectively, are defined for each mounting half-plate  211 ,  212 , with the inner edges oriented toward the intermediate part  213 . 
     In the non-folded state illustrated in  FIGS.  9  and  10   : 
     the main faces  211   a ,  212   a , respectively, of the two parts  211 ,  212  are situated in one and the same plane. 
     The inner edges  211   c ,  212   c  face one another and are spaced apart by a preferably small distance of between 0.5 and 3 mm. 
     In the example, the first and second parts  211 ,  212  are connected by a metal core in the form of a plate  230 , which is preferably made of galvanized steel and has typically a thickness of between 0.3 mm and 0.6 mm. 
     As illustrated in more detail in  FIG.  10   , the plate  230  is secured in part to the first part  211  and in part to the second part  212 , a thin strip of plate  230 , free between the first and second parts  211 ,  212 , forming the intermediate part  213 . This part, which is deformable, forms a hinge for folding the connector  200 . 
     The connector  200  is manufactured for example by overmolding the metal plate  230 . To this end, said plate  230  has, in the example, two holes  232   a ,  232   b  that are intended to cooperate with stems for keeping it in position inside the injection mold. These holes may optionally serve for the introduction of screws when the connector  200  is fastened to the panels  91 ,  92 , but this implementation is not limiting. 
     In order to ensure that the plate  230  is anchored properly on the first and second parts  211 ,  212 , it is advantageously provided with a plurality of further through-holes  234 , into which the material forming said parts  211 ,  212  passes during the injection. 
     As in the first exemplary embodiment, the connector has the main faces  211   a ,  212   a  of its first and second parts textured by a plurality of parallel ribs  218 . These main faces remain overall planar, however. 
     The first part  211  of the connector is also provided with two lugs  220 , which are each similar to the one  120  described in connection with the first exemplary embodiment and each have: 
     a wing  222  extending from the edge  211   c  of the first part  211  that is adjacent to the second part  212  and orthogonally to the front face  211   a  of said first part  211 , 
     a projection  224  that defines a U-shaped receiving part  226  with the wing  222  and the face  211   a,    
     gripping means  228 , on the projection  224 , in this case in the form of a tab protruding toward the front. 
     According to a variant of this second embodiment that is not shown, the intermediate part forming a hinge is positioned perpendicularly to the intermediate part  213  shown in  FIGS.  9  and  10   . The intermediate part is therefore situated between the wings  222 , along the axis of symmetry of the connector. Such a configuration makes it possible to manage the (reentrant or salient) angles and to produce window sills. 
       FIGS.  11  and  12    illustrate the use of a connector  200  according to  FIGS.  9  and  10    for producing a facing P′ having at least two joined panels  91 ,  92  forming a right angle. 
       FIG.  11    illustrates the connector  200  fastened to the first panel  91 . Before being fitted, the connector  200  was folded such that the main face  211   a  of the first part  211  and the main face  212   a  of the second part  212  form an angle of 90° between one another. 
     Once the lug  220  has been removed, the second panel  92  is fitted against the edge  91   c  of the first panel  91  and the main face  212   a  of the second part of the connector  200 , and is then fastened to this second part  212 , for example by screwing. 
     In the present case, in order to produce a facing with a salient angle, the first and second parts  211 ,  212  were folded toward the rear (so as to move their rear faces  211   b ,  212   b  toward one another). In order to produce a reentrant angle, the first and second parts  211 ,  212  should simply be folded forward (so as to move their main faces  211   a ,  212   a  toward one another).