GB2173444A - Improvements in or relating to building panels - Google Patents

Abstract

A building panel (46) is formed using a demountable mould (10) of wood or other material. The mould 10 has a baseplate (11) having two flat parts (12, 13) connected by an angled part (14). The mould surface of a central portion of the part (12) is formed with an array of slightly proud beads (16) for simulating mortar joints. To manufacture the panel, the mould surface is covered with a cementitious layer (40), followed by a layer (41) of glass-reinforced plastics material. Strengthening pieces (29a) are incorporated in the panel. The panel can be further reinforced by incorporating a metallic mesh between the layers. Panels can be interconnected by internal nut and bolt assemblies, which cannot be seen from the front faces of the panels. <IMAGE>

Description

SPECIFICATION Improvements in or relating to building panels BACKGROUND TO THE INVENTION This invention relates to building panels and is concerned with the manufacture thereof by the use of moulds.

As used herein, the term "panel" includes structures such as pillars which can be joined to a panel.

SUMMARIES OF THE INVENTION According to one aspect of the invention, a method of manufacturing a building panel comprises the steps of providing a mould having a surface, applying a cementitious layer to the surface, and applying a backing layer of plastics material to the cementitious layer.

The mould surface may define a main surface and side and top surfaces upstanding from the main surface.

The method may include the further step of applying a reinforcing layer to the backing layer.

The method may comprise the further steps of forming grooves in the outer surface of the sides and top of the panel. The grooves may be formed by providing the mould side and top surfaces with upstanding elongate formations extending the length thereof.

The method may comprise the step of forming the outer surface of the panel with grooves to give a simulated brick formation.

According to another aspect of the invention, a building panel comprises an outer layer of cementitious material and a backing layer of plastics material.

The panel may have a main portion and side and top portions extending away from the main portion to form a hollow panel.

A groove may extend along the length of the top and side portion outer surfaces.

The panel may have grooves on the outer surface of the panel so as to simulate a stone, brick, or like building element formation.

Strengthening members may extend from the backing layer.

The invention also provides an assembly of two such panels, with side portions adjacent and filler or sealing material in confronting grooves formed in the side portions.

Securing means, for example bolts, may extend through adjacent side portions.

The outer surfaces of the main portions may be free from securing means.

The invention also comprises any novel subject matter or combination including novel subject matter herein disclosed, whether or not within the scope of or relating to the same invention as any of the succeeding claims.

BRIEF DESCRIPTION OF THE DRAWINGS The invention may be performed in various ways and one specific embodiment with possible modifications will now be described by way of example only, with reference to the accompanying drawings, wherein: Figure 1 is a perspective view which illustrates manufacture of a building panel, Figure la is an enlarged view of the area enclosed by the circle la of Fig. 1, Figure 2 is a perspective view of parts of two assembled panels, Figure 3 is an exploded view of an assembly of panels, Figure 4 is a view in perspective, and illustrates how a seal is provided between adjacent panels, and Figures 5 and 6 illustrate modifications.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring first to Figs. 1 and 1a, a building panel 46 is manufactured using a demountable mould 10 of wood or other suitable material.

The mould 10 has a baseplate or sheet 11 having two flat parts 12, 13 connected by an angled part 14. The (main) mould surface 15 of a central portion of the part 12 is formed with an array of slightly proud beads or the like mouldings 16 for a purpose described later.

Laterally-spaced "U"-section side pieces 18, 19 having lower edges conforming to the mould surface 15 are disposed at the ends of the mould 10. Each side piece has a flat piece 20 disposed at right angles to, and cut to conform to, the surface 15 and is provided with two strengthening lengths 21, 22 extending substantially normal to the "plane" of the piece 20. The inner face 23 of each piece 20 is provided with a part-circular section bead 24 for a purpose described later.

One end of the mould 10 is defined by a flat piece 25 having an inner surface 26 formed with a substantially parallel array of downwardly extending, slightly proud, beads 27 similar to beads 16, as well as a longitudinally-extending bead 28 similar to and coterminous with the bead 24.

Flat strengthening pieces 29 are provided, extending in substantially parallel array from the inner surface of the piece 25, each having an edge 30 conforming to the mould surface 15.

When the mould parts 11, 25, 18, 19, 29 are assembled, the inner mould surfaces defined by these parts is provided with first a cement screed layer 40. When that cementitious layer has set, or has set sufficiently, a layer 41 of G.R.P. (Glass-Reinforced Piastics), for example a layer of polyester resin reinforced by fibre glass matting, is applied, so as to form a backing and supporting layer for the layer 40. The layers 40, 41 are applied over the parts 29 also but one or more strengthen ing pieces 29a may be added after application of the layer 41 and adjacent the existing pieces 29.

The beads 16 and 27 form indentations in the layers 40, 41 which, when the mould 10 is removed, provide recesses 44 in the outer surface 45 of the moulded panel 46 (Fig. 2) so as to simulate mortar joints. Subsequently, these recesses 44 can, if desired, be filled with material to simulate mortar.

The beads 28, 24 form grooves 50 so that when two panels 46 are brought side-by-side, these grooves provide confronting recesses which can receive an - elongate weather seal of rubber. Alternatively, the grooves 50 can be filled with mortar, the recesses acting as keys for the mortar.

During moulding, the lengths 22 can be releasably secured by bolts 51 to the baseplate 11.

With reference to Fig. 2, after the panel 46 has been moulded as described, the side walls 60 and the top wall 61 are provided with reinforcing sheets 62, 63 respectively, for example of wood or expanded metal. Bolt apertures may be formed through the walls 60 and layers 62 so that adjacent panels 46 can be secured together by nut and bolt assemblies 64 from the insides only of the panels.

Hence no bolts are visible from outside the panels 46. (See Fig. 3). Bolt apertures 65 are formed in the top walls 61 and layers 63 (Fig.

3).

The beads 16, 27 produce a simulated brick face on the outer cement face 45 of a panel 46.

As is illustrated by the pillar-like panel 80 of Fig. 3, a panel need not be flat.

The pillar form of "panel" 80 is moulded in a similar way to the panels 46, and in use, protrudes outwardly from the outer face of an adjacent main panel 46, in order to eliminate a vertical butt joint in a brick facing panel.

The invention provides, by use of the mould 10, an independent building panel which is formed with a cavity into which timber or metal reinforcing structure such as 29, 62, 63 can be built in, in order to suit any required strength according to use of the panel. Also, a panel can be produced as a flat-facing sheet of any required size for use as a lining inside an existing panel, or it can be fixed as a cladding to an existing flat surface.

The cavity-formed building panel can be used for the purpose of constructing a singlestorey sectional building, either for permanent erection or of a portable nature, or for any given length or height of brick-faced fencing panels.

Fig. 4 illustrates how a weather-resisting seal is formed between one panel 100, placed on a similar panel 101. Adjacent edges of the panels 100, 101 have cooperating longitudinally-extending grooves 102, 103, which receive a rubber seal 104 of substantially circular cross-section. Alternatively, sealant can be introduced into the grooves 102, 103, using a gun 105.

The side edges of the panels 100, 101 have grooves 106, 107 for reception of a rubber seal or sealant whereby the panels can be sealed to adjacent panels.

It will be appreciated that panel 100 will not have a plinth as does a panel 46 of Fig. 3.

The method of manufacturing building panels disclosed herein allows a wide variety of size and shape to any given requirement, e.g. flat-faced sections, pier sections, corner sections, concave or radius.

The first panel or "foundation panel" of any construction is designed with a simulated cement-plinth facing, thus enabling any structure, e.g. building or brick-faced fencing, to be erected. The plinth portion 13 of the mould 10, (see Fig. 1), would then be filled with concrete on the inside region 85 thereof (Fig.

2), so as to form concrete footings.

The following details are of one method of panel manufacture.

A mixture or screed 40, consisting for example of 3 parts fine grit, 1 part cement, 1 part cement colourizer, to suit required finished colour, 1 part micro bloom powder (which improves the bond between layers 40, 41) is prepared. All the ingredients are thoroughly dry-mixed in a cement mixing machine.

Water and waterproof bonding agent are added as appropriate, so as to produce a firm screed. The face of the mould 10 is treated with mould-release agent, and the screed is applied, (as layer 40), to the mould face and up-stands 18, 19, 25 to a depth to cover simulated cement course extrusion 16, 27 and also half-round moulding 24, 28. on the upstands. The layer 40 is then left to harden.

When hardened, a mixture of, for example, 3 parts fine sand or grit to 1 part cement into recess 85 for simulated plinth is applied and allowed to harden. When this mixture has hardened, a glass-reinforced plastics (G.R.P.) bonding layer 41 comprising a mixture of polyester resin and reinforced glass fibre matting is applied to the required strength. The layer 41 is applied and rolled by hand, or, alternatively, machine sprayed. The G.R.P.

layer 41 bonds itself to the inner face of the screed layer 40, thus forming a G.R.P. inner box or cavity. A wood or metal framing comprising parts 62, 63 is then fitted to inside vertical and longitudinal cavity up-stands. The framing 62/63 is finished flush to the inside extremities 90, 91 of the cavity edging, thus forming a built-in uniform structure for fixing internal panelling, and also strengthening the cavity web. When bolting panels to one another, these reinforcing members would be bedded into position on wet fibre glass matting and internally bonded to the G.R.P. layer 41.

A large panel could comprise equal-sized panel portions, with vertical reinforcing members 29 inserted and bonded to the G.R.P.

layer 41. The members 29 would serve three purposes: (a) A reinforcing backing for the panel face.

(b) A vertical load-bearing structure to carry the weight of any additional structure formed vertically above the panel.

(c) Additional framing to carry internal panelling. The members 29 would be bonded each side to the G.R.P. layer 41.

After the G.R.P. layer 41 has cured, the panel is ready to be extracted from its mould.

To extract a panel from the mould 10, the portable up-stands 18, 19, 25 are unbolted and lifted away. The panel can now be lifted off from the mould surface 15. The face 45 of the panel is now ready for pointing in grooves 44. This pointing may be performed in a conventional way, and to any colour required. When two juxtaposed panels are bolted horizontally together, (as in Fig. 4), the intersection joint is made to follow the line of horizontal pointing. Thus when the bolting of panels is complete, the joint is subsequently pointed and thus lost to sight.

A value of the invention is in the versatility of the panels. For example, a complete sectional building could be erected inside factory premises, complete with windows, doors, floors and roof, interior fitted out to any design required, plumbing and electricity completed up to outside mains, and then transported to any required site. Alternatively, the panels can be supplied and delivered for erection on site, to any size or design shape required.

As the panels are bolted together, this enables any building using the panels to be extended as desired.

Panels manufactured according to the invention can be used for boundary fencing and structural extensions such as conservatory fronts and porches, the external brick facing of the panel being made to blend with existing brickwork.

In the modification illustrated by Fig. 5, a galvanised metal membrane 140 of expanded form is introduced on top of the cementitious layer 40. A further cementitious layer 142 is then applied, followed by the G.R.P. layer 41.

The arrangement provides the panel with further reinforcement.

Panels manufactured according to the invention need not be produced with cavities. Fig.

6 illustrates how such a "flat" panel 150 could be formed.

The demountable mould 210 of Fig. 6 has a flat surface 215 bounded by side and end members 151, 152. The surface 215 carries beads 216 for simulating cement courses. The panel 150 comprises a cementitious layer 40a, a galvanised metal membrane 140a of expanded form, a further cementitious layer 142a, and a G.R.P. layer 41a, applied in the order given.

Claims (19)

1. A method of manufacturing a building panel comprising the steps of providing a mould having a surface, applying a cementitious layer to the surface, and applying a backing layer of plastics material to the cementitious layer.

2. A method as claimed in Claim 1, wherein the mould surface defines a main surface and side and top surfaces upstanding from the main surface.

3. A method as claimed in Claim 1 or 2, including the further step of applying a reinforcing layer to the backing layer.

4. A method as claimed in Claim 1, 2 or 3, comprising the further step of forming grooves in the outer surface of the sides and top of the panel.

5. A method as claimed in Claim 4, wherein the grooves are formed by providing the mould side and top surfaces with upstanding elongate formations extending the length thereof.

6. A method as claimed in any one of Claims 1 to 5, comprising the step of forming the outer surface of the panel with grooves to give a simulated brick formation.

7. A method as claimed in any one of Claims 1 to 6, comprising the step of incorporating a metallic membrane between the cementitious and plastics material layers.

8. A building panel comprising an outer layer of cementitious material and a backing layer of plastics material.

9. A panel as claimed in Claim 8, wherein the panel has a main portion and side and top portions extending away from the main portion to form a hollow panel.

10. A panel as claimed in Claim 9, provided with a groove extending along the length of the top and side portion outer surfaces.

11. A panel as claimed in Claim 8, 9 or 10, provided with grooves on the outer surface of the panel so as to simulate a stone, brick, or like building element formation.

12. A panel as claimed in any one of Claims 8 to 11, provided with a metallic layer disposed between the layers of cementitious and plastics materials.

13. An assembly of two or more panels, each according to any one of Claims 8 to 12, with side portions adjacent and filler or sealing material in confronting grooves formed in the side portions.

14. A method of manufacturing a building panel, substantially as hereinbefore described with reference to Figs. 1 to 4 of the accompanying drawings.

15. A method of manufacturing a building panel, substantially as hereinbefore described with reference to Figs. 1 to 4 of the accompanying drawings, modified substantially as hereinbefore described with reference to Fig. 5 of said drawings.

16. A method of manufacturing a building panel, substantially as hereinbefore described with reference to Figs. 1 to 4 of the accompanying drawings, modified substantially as hereinbefore described with reference to Fig. 6 of said drawings.

17. A building panel substantially as hereinbefore described with reference to Figs. 1 to 4 of the accompanying drawings.

18. A building panel substantially as hereinbefore described with reference to Figs. 1 to 4 of the accompanying drawings, modified substantially as hereinbefore described with reference to Fig. 5 of said drawings.

19. A building panel substantially as hereinbefore described with reference to Figs. 1 to 4 of the accompanying drawings, modified substantially as hereinbefore described with reference to Fig. 6 of said drawings.