GB1602856A – Building panel
– Google Patents
GB1602856A – Building panel
– Google Patents
Building panel
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Publication number
GB1602856A
GB1602856A
GB4207777A
GB4207777A
GB1602856A
GB 1602856 A
GB1602856 A
GB 1602856A
GB 4207777 A
GB4207777 A
GB 4207777A
GB 4207777 A
GB4207777 A
GB 4207777A
GB 1602856 A
GB1602856 A
GB 1602856A
Authority
GB
United Kingdom
Prior art keywords
resin
slips
layer
battens
panel
Prior art date
1978-05-30
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
GB4207777A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
FARQUHARSON I S R
Original Assignee
FARQUHARSON I S R
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
1978-05-30
Filing date
1978-05-30
Publication date
1981-11-18
1978-05-30
Application filed by FARQUHARSON I S R
filed
Critical
FARQUHARSON I S R
1978-05-30
Priority to GB4207777A
priority
Critical
patent/GB1602856A/en
1981-11-18
Publication of GB1602856A
publication
Critical
patent/GB1602856A/en
Status
Expired
legal-status
Critical
Current
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Classifications
E—FIXED CONSTRUCTIONS
E04—BUILDING
E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
E04C2/40—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of a number of smaller components rigidly or movably connected together, e.g. interlocking, hingedly connected of particular shape, e.g. not rectangular of variable shape or size, e.g. flexible or telescopic panels
Description
(54) BUILDING PANEL
(71) I, IAN STUART REID FARQUHAR
SON, a British subject, of Malindi, Craigavad, Holywood, Co. Down, Northern
Ireland, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: – This invention relates to a building panel which can be manufactured in a number of sizes and can be used either as a cladding panel or as a structural component in all types of buildings and can be adapted for all types of decorative and ornamental work, whether internal or external.
According to the present invention, I provide a method of manufacturing a building panel comprising the steps of: – providing a backing plate and placing an edge trim defining the required size of the panel around the periphery of the backing plate;
setting out on the backing plate with battens the position and profile of joints required in the facing layer of the final
laying up the backing plate and battens with a first layer of curable resin; panel;
embedding a plurality of slips of facing materials into the or a layer of uncured resin, the slips being of a predetermined size corresponding to the spacing between the battens such that the uncured resin penetrates into the joint between adjacent slips; and
allowing the uncured resin to cure.
Preferably, the resin is glass-fibre reinforced polyester resin and the slips are of brick, stone tile or other approved material, so arranged in the eventual panel that they resemble traditional brickwork, stonework, tiling, or any other known finish.
Preferably, the slips are of the same order of thickness as traditional roofing tiles and the joints between the slips in the eventual building panel are recessed.
Preferably, the battens are formed of timber and when the slips are, for example, brick slips, the battens are dimensioned such that the resin overlying them and penetrating the joints between the slips has a width, e.g. or about 10mum, and at the same time forms a fully pointed joint of traditional appearance.
The method may comprise the additional steps, prior to the embedding step, of allowing the first layer of resin to cure, and laying up on the first layer a further layer or layers of curable resin. The first layer may be removed from the battens before the second laying up step.
With this latter method, it is possible to achieve dimensional flexibility for similarly shaped modules by cutting the lightweight formers so produced to reduce the size of the eventual panel, or by placing them alongside each other to increase the size of the eventual panel before laying up as previously described. It is also possible to store large quantities of formers for future use.
In an alternative method according to the present invention, a backing layer of curable resin is layed up on the backing plate prior to the setting out step, and the backing layer is allowed to cure after the battens are set out thereon, eventually to form a building panel which incorporates the battens between the first layer and the backing layer.
The invention is now described by way of example with reference to the schematic drawings accompanying the provisional specification, in which: – Figure 1 is a plan view of a part of a building panel during the course of its manufacture;
Figure 2 is a section on the line A-A of Figure 1, and
Figure 3 is a further section to an enlarged scale through a mould showing how slips are embedded in position in a backing member.
Referring to the drawings, building panels are manufactured using a basic mould 1 having a timber frame 3 to which is fixed a backing plate 5, preferably of timber. The positions of joints for the
eventual finished panel are then set out on the backing plate 5 by means of suitably spaced timber battens 7 at an edge trim 8 is then made up, for example of timber or glass fibre reinforced polyester resin, the edge trim being generally L-shaped in cross-section and having a facing flange 9 which, as shown in the drawings, is projected to match the batten pattern to define the outer periphery of the building panel and a depending flange 11 profiled if required for weathering or interlock purposes which extends around the periphery of the frame 1.
It is envisaged that the frame could be made of other materials, such as glass fibre reinforced polyester resin or even metal, but its basic outline and function would be the same as those of the timber frame described above.
In order to manufacture the building panels, glass fibre reinforced polyester resin 13 is laid or sprayed onto the frame within the area defined by the edge trim 8, over the backing plate S and over all the battens 7, including the facing flange of the edgetrim. While the resin 13 is still tacky, i.e.
before it has cured, facing slips 15 of a size corresponding to the areas defined by the battens 7 are located face upwards in the said areas and embedded firmly in the resin 13. Because of the presence of the battens 7, the facing slips 15 will have a good mechanical bond with the resin 13 over the whole of their base area and around about half the area of their four sides. After all the facing slips 15 have been placed in position, the resin is allowed to cure and a rigid lightweight building panel representing an area, e.g. of brickwork, results. Of course, the facing slips 15 need not be brick slips; they could be tile slips, stone slips or slips of any other material.
In accordance with a modified method, lightweight formers of glass fibre reinforced polyester resin are formed on the frame 1 and are then removed from the mould after the resin has gelled. These can then be stored and they can subsequently be laid up or sprayed with further resin and the slips then then be embedded into this further laminate or resin.
Alternatively, if desired, a layer of glass reinforced polyester resin may be laid-up or sprayed on to a frame to which an edge trim has been applied, wherein battens, e.g. of timber, hardboard or other suitable materials, are bedded into the wet glass reinforced polyester resin. When the latter has gelled, thus fixing the battens in position, another layer of glass reinforced polyester resin is located over the battens, whereupon the remainder of the process described with reference to Figures 2 and 3 is carried out.
Although the invention is particularly designed for use with glass fibre reinforced polyester resins, it will be appreciated that other resins could perhaps be used.
Regardless of how the panels are manufactured, they can be strengthened structurally to suit any particular specification requirement either by laminating or spraying further layers of glass fibre reinforced polyester resin to the back face of the panels or by other known means.
The building panels of the present invention would normally be made in several different sizes, e.g. 8 ft. x 4 ft., 8 ft. x 3 ft., etc., and they can be fixed in position on internal or external faces of building structures by any known technique.
Also according to the present invention we provide a method of manufacturing a building panel comprising the steps of providing a mould comprising a surface which is provided with ribs in the positions of the joints required in the facing layer of the final panel, and an edge trim to define the periphery of the required panel; laying up the mould with a layer of curable resin; embedding a plurality of slips of facing material into the uncured resin, the slips being of a predetermined size corresponding to the spacing between the ribs such that the uncured resin penetrates into the joint between adjacent slips; and allowing the cured resin to cure.
WHAT I CLAIM IS: – 1. A method of manufacturing a building panel comprising the steps of: – providing a backing plate and placing an
edge trim defining the required size of
the panel around the periphery of the
backing plate;
setting out on the backing plate with
battens the position and profile of joints
required in the facing layer of the final
panel;
laying up the backing plate and battens
with a first layer of curable resin;
embedding a plurality of slips of facing
material into the uncured resin, the slips
being of a predetermined size corre
sponding to the spacing between the
battens such that the uncured resin
penetrates into the joint between ad
jacent slips; and
allowing the uncured resin to cure.
2. A method according to Claim 1 comprising the additional steps, prior to said embedding step, of: – allowing the first layer of resin to cure;
and
laying up on said first layer a further
layer or layers of curable resin.
3. A method according to Claim 2 corn prising the additional step, prior to said second laying up step, of: –
**WARNING** end of DESC field may overlap start of CLMS **.
Claims (12)
**WARNING** start of CLMS field may overlap end of DESC **. eventual finished panel are then set out on the backing plate 5 by means of suitably spaced timber battens 7 at an edge trim 8 is then made up, for example of timber or glass fibre reinforced polyester resin, the edge trim being generally L-shaped in cross-section and having a facing flange 9 which, as shown in the drawings, is projected to match the batten pattern to define the outer periphery of the building panel and a depending flange 11 profiled if required for weathering or interlock purposes which extends around the periphery of the frame 1. It is envisaged that the frame could be made of other materials, such as glass fibre reinforced polyester resin or even metal, but its basic outline and function would be the same as those of the timber frame described above. In order to manufacture the building panels, glass fibre reinforced polyester resin 13 is laid or sprayed onto the frame within the area defined by the edge trim 8, over the backing plate S and over all the battens 7, including the facing flange of the edgetrim. While the resin 13 is still tacky, i.e. before it has cured, facing slips 15 of a size corresponding to the areas defined by the battens 7 are located face upwards in the said areas and embedded firmly in the resin 13. Because of the presence of the battens 7, the facing slips 15 will have a good mechanical bond with the resin 13 over the whole of their base area and around about half the area of their four sides. After all the facing slips 15 have been placed in position, the resin is allowed to cure and a rigid lightweight building panel representing an area, e.g. of brickwork, results. Of course, the facing slips 15 need not be brick slips; they could be tile slips, stone slips or slips of any other material. In accordance with a modified method, lightweight formers of glass fibre reinforced polyester resin are formed on the frame 1 and are then removed from the mould after the resin has gelled. These can then be stored and they can subsequently be laid up or sprayed with further resin and the slips then then be embedded into this further laminate or resin. Alternatively, if desired, a layer of glass reinforced polyester resin may be laid-up or sprayed on to a frame to which an edge trim has been applied, wherein battens, e.g. of timber, hardboard or other suitable materials, are bedded into the wet glass reinforced polyester resin. When the latter has gelled, thus fixing the battens in position, another layer of glass reinforced polyester resin is located over the battens, whereupon the remainder of the process described with reference to Figures 2 and 3 is carried out. Although the invention is particularly designed for use with glass fibre reinforced polyester resins, it will be appreciated that other resins could perhaps be used. Regardless of how the panels are manufactured, they can be strengthened structurally to suit any particular specification requirement either by laminating or spraying further layers of glass fibre reinforced polyester resin to the back face of the panels or by other known means. The building panels of the present invention would normally be made in several different sizes, e.g. 8 ft. x 4 ft., 8 ft. x 3 ft., etc., and they can be fixed in position on internal or external faces of building structures by any known technique. Also according to the present invention we provide a method of manufacturing a building panel comprising the steps of providing a mould comprising a surface which is provided with ribs in the positions of the joints required in the facing layer of the final panel, and an edge trim to define the periphery of the required panel; laying up the mould with a layer of curable resin; embedding a plurality of slips of facing material into the uncured resin, the slips being of a predetermined size corresponding to the spacing between the ribs such that the uncured resin penetrates into the joint between adjacent slips; and allowing the cured resin to cure. WHAT I CLAIM IS: –
1. A method of manufacturing a building panel comprising the steps of: – providing a backing plate and placing an
edge trim defining the required size of
the panel around the periphery of the
backing plate;
setting out on the backing plate with
battens the position and profile of joints
required in the facing layer of the final
panel;
laying up the backing plate and battens
with a first layer of curable resin;
embedding a plurality of slips of facing
material into the uncured resin, the slips
being of a predetermined size corre
sponding to the spacing between the
battens such that the uncured resin
penetrates into the joint between ad
jacent slips; and
allowing the uncured resin to cure.
2. A method according to Claim 1 comprising the additional steps, prior to said embedding step, of: – allowing the first layer of resin to cure;
and
laying up on said first layer a further
layer or layers of curable resin.
3. A method according to Claim 2 corn prising the additional step, prior to said second laying up step, of: –
removing said first layer from said back
ing plate and battens.
4. A method according to claim 3 wherein dimensional flexibility is achieved by cutting the first layer of cured resin to reduce the size of the eventual panel or by placing them alongside each other to increase the size of the eventual panel before adding said further layer or layers of resin.
5. A method according to claim 1 comprising the additional step, prior to said setting out step, of laying up on said backing plate a backing layer of curable resin, and wherein said backing layer is allowed to cure after said battens are set out thereon, eventually to form a building panel which incorporates said battens between said first layer and said backing layer.
6. A method of manufacturing a building panel comprising the steps of providing a mould comprising a surface which is provided with ribs in the positions of the joints required in the facing layer of the first panel, and an edge trim to define the periphery of the required panel; laying up the mould with a layer of curable resin; embedding a plurality of slips of facing material into the uncured resin, the slips being of a predetermined size corresponding to the spacing between the ribs such that the uncured resin penetrates into the joint between adjacent slips; and allowing the uncured resin to cure.
7. A method according to any one of claims 1-6 wherein the resin is glass fibre reinforced polyester resin.
8. A method according to any of claims 1-7 wherein the slips are of brick, stone, tile or other approved materials and are so arranged in the eventual panel that they resemble traditional brickwork, stonework, tiling or any other known finish.
9. A method according to any of claims 1-8 wherein the slips are of the same order of thickness as traditonal tiles and the joints between the slips in the eventual building panel are recessed.
10. A method of manufacturing a building panel substantially as hereinbefore described with reference to the drawings accompanying the provisional specification.
11. A method of manufacturing a building panel substantially as hereinbefore described.
12. A building panel when manufactured by a method according to any of claims 1-11.
GB4207777A
1978-05-30
1978-05-30
Building panel
Expired
GB1602856A
(en)
Priority Applications (1)
Application Number
Priority Date
Filing Date
Title
GB4207777A
GB1602856A
(en)
1978-05-30
1978-05-30
Building panel
Applications Claiming Priority (1)
Application Number
Priority Date
Filing Date
Title
GB4207777A
GB1602856A
(en)
1978-05-30
1978-05-30
Building panel
Publications (1)
Publication Number
Publication Date
GB1602856A
true
GB1602856A
(en)
1981-11-18
Family
ID=10422737
Family Applications (1)
Application Number
Title
Priority Date
Filing Date
GB4207777A
Expired
GB1602856A
(en)
1978-05-30
1978-05-30
Building panel
Country Status (1)
Country
Link
GB
(1)
GB1602856A
(en)
Cited By (1)
* Cited by examiner, † Cited by third party
Publication number
Priority date
Publication date
Assignee
Title
GB2244501A
(en)
*
1990-05-17
1991-12-04
Kent County Council
Relocatable building system and cladding panel
1978
1978-05-30
GB
GB4207777A
patent/GB1602856A/en
not_active
Expired
Cited By (1)
* Cited by examiner, † Cited by third party
Publication number
Priority date
Publication date
Assignee
Title
GB2244501A
(en)
*
1990-05-17
1991-12-04
Kent County Council
Relocatable building system and cladding panel
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Legal Events
Date
Code
Title
Description
1982-02-10
PS
Patent sealed
1987-01-28
PCNP
Patent ceased through non-payment of renewal fee
