Method for forming a masonry-effect composite product

Abstract

A method of forming a masonry-effect composite product comprises the steps of: providing a substrate 6 having a frangible porous structure; providing a layer comprising a sheet-form curable material 2

Description

Field of the invention This invention relates to methods of forming a masonry-effect composite product and composite products having masonry-effect surfaces. In particular, the invention relates to methods and composite products having masonry surfaces for use, for example, in building, furniture and as architectural components. Background to the Invention Panels and other elements used in building have traditionally been made of natural materials. For example, structures formed from masonry have traditionally been constructed from masonry blocks which are generally laid in and bound together by mortar, in some cases with steel reinforcement. Such structures are generally highly durable, resistant to weathering, have good weight-bearing properties, and are also visually appealing, making masonry a widely-used construction material. However, masonry does have the disadvantages that masonry blocks are heavy, time-consuming to install, and can be extremely costly. Particularly in the case of stone blocks, such as granite or marble, only a small portion of the costly stone is visible in use, making the use of entire blocks of such stone types unnecessary and economically prohibitive. Furthermore, traditional masonry construction techniques do not have the architectural flexibility that is found with more modern construction techniques, such as steel or concrete frame buildings. For instance, masonry construction techniques are generally unsuited to the construction of very tall buildings due to the weight of the masonry blocks. There has been interest in developing techniques to overcome the disadvantages of traditional masonry techniques, whilst maintaining the visual appeal and durability of traditional masonry in the completed structures. Generally, these techniques involve some kind of masonry cladding or siding. The terms “cladding” or “siding” are used to refer to a non-structural layer of masonry that is added to a pre-existing structure, such as a wall or building, usually to imitate the appearance of a traditional masonry structure. The masonry layer is generally substantially thinner than traditional masonry building blocks, being required only for visual and non-structural purposes. Thus, siding materials often take the form of a tile or slip having the surface dimensions of a brick or stone block on the visible surface but are typically between 10 to 50 mm in depth. For example, brick siding is generally applied by using individual brick slips and applying them to structures (such as building facades) by being embedded in a layer of mortar coating the surface of the structure or otherwise attached using adhesives, occasionally with the use of guide rails (such as a plastic or metal frame) to maintain even spacing between the brick slips. Mortar is then pointed around and between the brick slips to provide a brickwork pattern. The use of siding materials, whilst having some advantages over traditional masonry construction techniques, nonetheless has the disadvantages that the installation of large numbers of separate siding tiles remains comparatively time consuming. In addition, the need for the installation of the siding materials to take place entirely in situ can add significantly to the duration of construction projects. Recently, there has been further development into the production of panels that can be used in the place of brick slips and mortar. However, these panels often fail to properly replicate the visual aesthetic of traditional masonry. Therefore, there remains a need in the art for an alternative process for the provision of masonry surfaces, to alleviate or reduce one or more of the issues discussed above. Summary of the Invention The present invention provides the particular advantage of being able to produce siding materials in the form of a composite product where the masonry tile and grouting can be formed in situ, and where the profile of the grouting can be controlled. Such a process significantly reduces the duration for formation of siding panels, and indeed the duration of construction projects whilst additionally providing for various different design patterns. According to the present invention, there is provided a method of forming a masonry-effect composite product, the method comprising: i) providing a substrate having a frangible porous structure; ii) providing a layer comprising a sheet-form curable material having reinforcing fibres; iii) providing a masonry tile; and iv) providing a template comprising a plurality of openings shaped to receive a masonry tile; the method comprising the steps of: a) applying the sheet-form curable material to a surface of the frangible porous substrate; b) placing the template on the sheet-form curable material; c) applying the masonry tile in the openings of the template and onto the layer of sheet-form curable material; d) applying pressure to press the masonry tile, the template, the sheet-form curable material and the frangible porous substrate together whereby the template and masonry tile cause shaping of the frangible porous substrate; and e) removal of the template. In this way, a composite product comprising a masonry surface effect can be formed. The masonry surface effect can provide a desirable aesthetic finish to the product and / or provide durability to the product. The methods of the present invention may be advantageous in a number of respects. For instance, it has surprisingly been found that the use of a template during the pressing step can advantageously control the depth and / or shape of the gaps between the masonry tiles. This allows for a multitude of designs to be readily available without having to provide a multitude of different pressing moulds. Additionally, the use of a template provides a better finish because the bonding of the sheet-form curable material and the substrate is improved across the profile of the indentation formed due to the template forcing the sheet-form curable material into the substrate. This, therefore, removes potentially points of weakness in the final composite structure. The template is used to define a pattern to be formed by the masonry tiles. Such a template may be used to help position the masonry tiles when forming the composite product. In particular, the template is used to control the profile of the composite product between the masonry tiles. Such control allows the position of the grout or render lines between the masonry tiles to be controlled. In certain countries, it is known for the grout or render to be lower than the upper surface of the masonry (i.e., the grout or render is sunken compared to the masonry). In other countries, it is preferred for the grout or render to be at a height similar to that of the upper surface of the masonry, or even extend above the masonry. It will be appreciated that the use of a template enables the present invention to be used to produce a wide range of different styles without needing complicated mould systems or multiple processes. The template according to the present invention is configured so as provide a plurality of openings shaped to receive a masonry tile. For example, the template may be provided by a plurality of blocks positioned to provide an internal space between the blocks that is sized to fit a masonry tile. By using a plurality of blocks, the template can be easily arranged to provide different sizes or different arrangements as required. Alternatively, unitary templates may be used. Unitary templates are more sturdy and are less likely to move during application of pressure. In some embodiments, the height of the spaces between adjacent masonry tiles is controlled to adjust the height of the rendering or grouting substance between the masonry tiles. Preferably, the height of the spaces is controlled by the means of pressing with a template and / or the height of the template. For example, to provide a profile in the composite product that is sunken compared to the masonry, the height of the template must be greater than that of the masonry tile. Thus, during the application of pressure, the template will be pressed deeper into the frangible substrate than the masonry tile and therefore create a deeper grout line. On the other hand, where it is preferred for the grout to be at a height similar to that of the masonry tile, the height of the template and the height of the masonry tile should also be similar. However, it may be necessary for the template to be greater in height than the masonry tile where a bulky grouting substance is preferred. Where it may be desirable for the height of the grout line to vary, for example with a stone wall, the height of the template may also vary. Alternatively, the depth of the profile in the composite material created by pressing with the template may be controlled by adjusting how far the template is pressed into the substrate. Thus, the means of pressing can adjust the height of the indentations formed by stamping the substrate with the template. Additionally, the template may provide the grout or render line with a specific shaped profile. For example, where a curved grout line is desired, the template may have a curved surface, along the edge that is in contact with the sheet-form curable material. Alternatively, if other shapes are desirable, the template surface can be modified accordingly. Furthermore, the template may be used to vary the thickness of the grout or render lines by varying the thickness of the template between the masonry tiles, i.e. increasing the size of the gap between the plurality of openings in the template. It is known that different grout thicknesses may be preferrable depending on the final desired pattern. The plurality of openings in the template, and thus the plurality of masonry tiles, may be desirably arranged so as to imitate the arrangement of masonry building blocks found in traditional masonry construction techniques, for example, the traditional brickwork bonds (e.g., Flemish bond, stretcher bond, English bond, header bond, herringbone bond and basket bond). The openings of the template may form a regular repeating pattern to allow a plurality of masonry tiles to be positioned regularly, to form a pattern such as that formed by a brick wall. Alternatively, the openings of the template may form an irregular repeating pattern, to form a pattern such as that formed by a stone wall or mosaic. Preferably, the template is configured such that each opening may be sized to accommodate a single masonry tile. Furthermore, in preferred embodiments a masonry tile is provided for each respective opening of the template. Preferably, the plurality of openings of the template may substantially cover the surface of the substrate and / or the sheet-form curable material. Preferably, a plurality of masonry tiles may be provided within the template openings which collectively extend over substantially the sheet-form curable material and / or the substrate area. In this way, the plurality of masonry tiles may be rigidly bonded onto the surface of the sheet-form material and the substrate in any desired arrangement. As used herein, the term “masonry tile” is intended to refer to a tile formed, at least in part, from concrete, clay, natural stone, artificial stone, ceramic, glass, ora combination thereof. For example, the masonry tile may be formed from brick, marble, granite, limestone, travertine, sandstone, slate, cast stone, porcelain, earthenware, glass, or other similar materials, or a combination thereof. Where the masonry tile is formed from a porous material such as clay, porcelain or earthenware, it may be at least partially glazed. For example, the visible surface may be glazed, with the surface that contacts the sheet-form material remaining unglazed. As will be appreciated by persons of skill in the art, an unglazed surface provides a better key for attachment to the sheet-form material and is therefore preferable to form a strong bond. The depth of the masonry tile is preferably less than 50 mm, more preferably less than 30 mm, and still more preferably less than 20 mm. Generally, a depth of at least 5 mm is preferred for reasons of durability, although with smaller masonry tiles the depth may be less than 5 mm, for example from 2 to 5 mm, e.g., 3 mm or 4 mm. Suitably, the masonry tile has a depth in the range of from 3 to 50 mm, more preferably from 3 to 30 mm, for example from 5 to 30 mm, or 5 to 20 mm. Generally, the surface area of the masonry tile will not be greater than about 500 mm by 500 mm. However, the exact size of the masonry tile depends on the type of material used to form the masonry tile and the desired visual effect of the composite product. For instance, where the composite product is intended to look like a brick wall, the masonry tiles advantageously have a surface area of from about 190 mm to about 250 mm by about 55 to about 75 mm to simulate the dimensions of a major side face of a standard building brick. Alternatively, the masonry tile may have a surface area of from about 95 to about 125 mm by about 55 to about 75 mm to simulate the dimensions of an end face of a standard building brick. For example, the masonry tile could be cut from a standard building block, such as a standard building brick. Alternatively, the masonry tile could be a brick slip of the type known in the art. In some embodiments, the masonry tile may be sized to fill the dimensions of the template openings. In the United Kingdom a standard size building brick generally has a major side face of about 65 mm by about 215 mm and an end face of about 65 mm by about 102.5 mm. In the United States a standard size building brick generally has a major side face of about 57 mm by about 203 mm and an end face of about 57 mm by about 102.5 mm. Where the composite product is intended to look like a stone wall, a larger masonry tile size may be appropriate. The surface of the masonry tile that contacts the sheet-form material may be provided with surface indentations or protrusions to form a key to ensure a strong bond is formed between the sheet-form material and the masonry tile. For example, a series of parallel or crossed grooves may be provided. In some cases, however, the masonry material may have a sufficiently coarse structure that the provision of surface indentations or protrusions is unnecessary for a strong bond to be formed between the sheet-form material and the masonry tile. In accordance with the present invention, the sheet-form curable material having reinforcing fibres preferably may comprise a curable polymer material. Preferably, the sheet-form curable material comprises a thermosetting polymer resin matrix. For example, the thermosetting polymer resin matrix may be selected from polyester resins, vinyl ester resins, epoxy resins, phenolic resins, bismaleimide resins or polyimide resins. The layer of sheet-form curable material may comprise SMC (sheet moulding compound). The SMC preferably may include a thermosetting resin, preferably a polymer matrix as defined above, and reinforcing fibres. For example, the SMC may include a thermosetting resin, for example a polyester resin, together with reinforcing fibres, for example glass fibres. The thermosetting polymer may further comprise additives, for example minerals, inert fillers, pigments, stabilizers, inhibitors, release agents, catalysts, thickeners, hydrating additives and / or suitable materials. There are benefits in using SMC. For example, SMC has a low density, but favourable mechanical properties compared with other sheet-form materials, and also exhibits good thermal properties. Of particular importance for some applications, for example building applications, resistance to fire is good. SMC also shows good chemical resistance. The sheet-form curable material may also include melamine, which is useful as a fire retardant. The sheet-form curable material may further include additives selected from hardeners, accelerators, fillers, pigments, stabilizers, inhibitors, release agents, catalysts, thickeners, hydrating additives and / or any other components as required. With regard to the use of phenolic resins, the prior art (see for example US3,005,798, US3,663,503 and US4,369,259) teaches that in order to produce a phenolic resin with limited or reduced colour change, both a colour-stabilising agent and an acid catalyst must be present. Clearly, the requirement of both reactants will increase the costs of producing lighter coloured resins. Furthermore, as shown in some of the above mentioned documents, the colour stabilising agent may be required to be added at a specific point in the reaction process (i.e. whilst the phenol resin is still in water-soluble form) in order to achieve the colour-stabilising effect throughout the resin formed. This creates a more complex reaction process, which will inevitably affect time efficiency and therefore, once again, cost efficiency of producing such resins. In addition, many of the methods available for producing lighter coloured phenolic resins require the presence of strong acids or bases to catalyse the reaction process. It is known that the use of such chemicals causes corrosion of equipment which will therefore need to be replaced more frequently. Therefore, in preferred embodiments, the sheet-form curable material comprises a phenolic resin sheet comprising: - uncured phenolic resin, such as a phenol-formaldehyde resin; - filler; - a catalyst in an amount of less than 2wt.% relative to the content of phenolic resin; and wherein the filler is present in a ratio of filler to uncured phenolic resin in an amount of 2.5:1 and greater, and further wherein the filler comprises a transition metal hydroxide and / or aluminium hydroxide in a ratio of metal hydroxide to uncured phenolic resin in an amount of 1:1.5 to 3:1. The uncured phenolic compositions described herein are particularly concerned with phenol-formaldehyde resins. It has been surprisingly found that the addition of a metal hydroxide compound within the filler allows forthe amount of catalyst present to be significantly reduced, and even possibly avoided altogether. Without wishing to be bound by any particular theory, it is believed that the addition of the metal hydroxide compound allows forthe uncured phenolic material to reach an equivalent of B-stage curing without the need for a catalyst to be present in any significant quantity, or even at all. As would be fully understood by persons of skill in the art, the B-stage refers to a partially cured state which allows for increased processability of such phenolic resins, for example, allowing them to be formed into sheets which may then be applied to a substrate and / or surface. The stability is such that the formed sheets can be formed into rolls for storage and later use. Such materials can then be fully cured by the application of heat and pressure. As discussed above, a problem with the use of traditional catalysts is the discolouration of the cured resin produced, and therefore the ability to produce composites of different colour finishes and patterns. By use of the material disclosed herein, it is possible to reduce or even alleviate such issues as the amount of catalyst can be used, and in some embodiments avoided altogether. Preferably, the amount of catalyst that is present may be less than 1 wt.% relative to the content of the phenolic resin, more preferably less than 0.5 wt.% relative to the content of the phenolic resin, such as less than 0.2 wt.%. In some embodiments, the uncured material may be substantially free of catalyst. By substantially free, it is meant that the amount of any catalyst present is negligible in terms of the overall effect that it has on uncured material, and its ability to reach a B-stage equivalent of curing. For the avoidance of any doubt, the term catalyst is intended to refer to additives which are known to catalyse the curing of such phenolic resins, and are known to aid B-stage curing. Traditionally, such catalysts fall into two main categories, namely acidic and basic. Examples of acidic catalysts include, but are not limited to, one or more of hydrochloric acid, sulphuric acid and oxalic acid. Examples of basic catalysts include, but are not limited to, one or more of ammonia, sodium hydroxide, potassium hydroxide, lithium hydroxide, rubidium hydroxide, caesium hydroxide, barium hydroxide, calcium hydroxide and ethylamine. It will also be appreciated that by reducing the presence of the catalyst material, or even avoiding its presence altogether, it is possible to avoid discolouration issues without the need to add colour-stabilising agents, for example, glyoxal, thiones, phosphinic acid salts or phosphonic acid salts. In accordance with the uncured materials described herein (including sheet-form curable materials in general), the filler may be present in an amount of 3:1 and greater, and preferably in an amount of 3.5:1 and greater. It will be appreciated that the amount of filler which is added is dependent, in some instances on the intended use of the composite being prepared. It will also be appreciated that there is a significant economic advantage in being able to increase the amount of filler whilst still being able to meet the stringent requirements for such composites, such as strength, modulus, fire resistance, weathering resistance etc. Accordingly, the amount of filler present may also be in an amount of 5:1 and greater where applicable. The fillers used may be organic or inorganic materials. For some embodiments, it is preferable for the filler to be an inorganic material. Suitable fillers for use in the sheet-form curable materials include particulate solids which are insoluble in the thermosetting material, such as filler selected from one or more of clays, clay minerals, talc, vermiculite, metal oxides, refractories, solid or hollow glass microspheres, fly ash, coal dust, wood flour, grain flour, nut shell flour, silica, ground plastics and resins in the form of powder, powdered reclaimed waste plastics, powdered resins, pigments, and starches. In preferred embodiments of the materials described herein, the fillers do not substantially comprise silicates and / or carbonates of alkali metals. This is due to the fact that solids having more than a slightly alkaline reaction, for example silicates and carbonates of alkali metals, are preferably avoided because of their tendency to react with acid hardeners. However, solids such as talc, which have a very mild alkaline reaction, in some cases because of contamination with more strongly alkaline materials such as magnesite, are acceptable for use as fillers. In accordance with the uncured materials described herein (which includes in general the sheet-form curable materials described herein), the amount of filler may be present in an amount of 20:1 and less, such as in an amount of 10:1 and less. In general, the fillers used in the sheet-form curable materials described herein may be any particulate solid which is insoluble in the resin mixture. As will be appreciated, it is preferable that the filler is inert to the rest of the uncured material. As discussed above, the use of the transition metal and / or aluminium hydroxide compound allows for the amount of catalyst used to be reduced, or even avoided altogether. A significant benefit of this is that issues known in the art associated with discolouration can be avoided, thus allowing for the use of pigments which previously would not have been suitable, especially for commercial uses where finishes are of great importance. It will also be understood that suitable colours may include white, yellow, pink, red, orange, green, blue, grey or purple. The reduction in catalyst and therefore the associated discolouration means that lighter colours may now be produced, for example, white, yellow, pink, red, orange, as well as light green, blue, grey and purple. The ability to produce finishes having such light colours greatly improves the commercial applications of such materials. Preferably, the transition metal or aluminium hydroxides are selected from compounds of formula M(OH)3, wherein M is a metal. Suitable metals (M) may be selected from one or more of scandium, vanadium, chromium, manganese, iron, cobalt and aluminium. In a preferred embodiment, the metal hydroxide is aluminium hydroxide. In the materials described herein, the transition metal and / or aluminium hydroxide may be present in a ratio of metal hydroxide to uncured phenolic resin in an amount of 1:1.6 to 2.5:1, such as a ratio of metal hydroxide to uncured phenolic resin in an amount of 1:2 to 2:1. In addition to the transition metal and / or aluminium hydroxide in the compositions described herein, the uncured phenolic material may further comprise ethylenediaminetetraacetic acid (EDTA). However, it is not in any way essential to the present invention. Phenolic resin materials such as described herein have significant advantages over more traditional materials such as SMC. It has been found that the phenolic resin material disclosed herein generally has the following advantages over SMC: • Better temperature performance and thermal shock resilience o The phenolic materials of the present invention can be used to form brake pads, foundry moulds, aerospace heat shields etc. • Excellent resistance to chemicals, corrosives / solvents, oil and water / salt water (including acid rain) o The phenolic materials of the present invention can be used to make laboratory countertops • Improved fire, smoke and toxicity performance o The phenolic materials of the present invention can be used in mass transport and defence applications • Improved anti-microbial properties • Harder, stronger, excellent dimensional stability • Electrical resistance • Good thermal insulation • Superior workability • Low temperature processing The sheet-form curable materials described herein may further comprise a viscosity controlling agent. Suitable viscosity controlling agents may be selected from one or more of butanol, chloroform, ethanol, water, acetonitrile, hexane, and isopropyl alcohol. In a preferred embodiment, the viscosity controlling agent is water. It will be appreciated that the amount of viscosity controlling agent used is dependent on the intended use of the uncured material. It is considered that the controlling of the viscosity is within the knowledge of the person of skill in the art. The sheet-form curable materials may be produced by mixing of the components as described above so as to form a generally homogeneous distribution of the components throughout the material. Any known method may be used to produce the general homogeneous distribution, such as high-shear mixing. The length of time required to produce a generally homogeneous distribution of the components is dependent on, amongst other things, the amount of each component added, the viscosity of the components and the method of mixing used. In general, a substantially homogeneous distribution of the components can be formed within 5 minutes to 2 days, preferably within 10 minutes to 1 day, more preferably within 15 minutes to 10 hours. The sheet-form curable material of the present invention comprises reinforcement fibres. The fibres may include one or more materials. For example, the fibres may include one or more of carbon fibres, glass fibres, aramid fibres and / or mixtures thereof. Preferably, the reinforcement fibres comprise or consist of glass fibres. Alternatively, the fibres may be selected from one or more of mineral fibres (such as finely chopped glass fibre and finely divided asbestos), chopped fibres, finely chopped natural or synthetic fibres, and ground plastics and resins in the form of fibres. The fibres may be added to the uncured material in a ratio of resin to fibre of 6:1 to 1:3, such as a ratio of from 4:1 to 1:1. The reinforcing fibres may be short fibres, for example having lengths of 5.0 cm or less, or may be longer fibres. The fibres may be loose, for example, the fibres may be arranged in a uni- or multi-directional manner. The fibres may be part of a network, for example woven or knitted together in any appropriate manner. The arrangement of the fibres may be random or regular, and may comprise a fabric, mat, felt or woven or other arrangement. Fibres may provide a continuous filament winding. Optionally, more than one layer of fibres may be provided. The sheet-form curable material may extend over substantially all or only a part of the substrate area. Preferably, the sheet-form material extends over substantially all of the substrate area. The thickness of the sheet-form curable material may range from 0.3 mm to 50 mm, such as 0.5 to 10 mm, for example 1 mm to 5 mm. The thickness of the sheet-form material used depends on the type and weight of the masonry tile that is used. Generally, an increased thickness of sheet-form material is preferred when heavier masonry tiles are used. The thickness of the sheet-form material may be obtained by using a single layer of sheet-form material having the required thickness, or by assembling a plurality of layers of sheet-form material until the required thickness is obtained. In addition, a mosaic of pieces of sheet-form material may optionally be used to extend over the substrate or a part thereof. In addition to reinforcement being provided as an integral part of the sheet-form material, in the form of reinforcement fibres, reinforcement may be provided as a separate layer, for example arranged between the sheet-form material and the substrate. Where the separate layer of reinforcement is provided, it may be located across the whole of the substrate, or may be provided in only parts. For example, if there is a particular section of the product which is more susceptible to damage, for example the corners of the composite product, these areas can be selectively reinforced. Preferably at least some part of the sheet-form curable material flows into a surface of the masonry tile during pressing. Preferably, the material is keyed into the masonry tile. In this way, a strong bond between the matrix and the masonry tile can be obtained. Alternatively or in addition, adhesive material may be applied between the sheet-form material and the masonry tile to aid bonding. The substrate of the present invention has a frangible porous structure. The substrate of the present invention has a frangible structure, such that during the application of pressure, the surface can be readily crushed to be moulded to the shape of the masonry tile(s) and template. The substrate may be non-crushable in normal use of the resulting product, and thus only crushable during the pressing step. It is envisaged that the invention may be applied where the substrate comprises a material which is rigid, but which can be controllably crushed during application of pressure so that a surface of the substrate can take on the contours of the masonry tile(s) and template. Accordingly, during the step of applying pressure to press the masonry tile, the template, the sheet-form curable material and the frangible porous substrate together, the template and the masonry tile(s) cause shaping of the frangible porous substrate’s surface. This forms indentations in the substrate, where the masonry tiles are located and further provides indentations fora rendering or grouting substance. The substrate is frangible such that where the masonry tile(s) and templates are present, indentations are formed, however the remainder of the substrate retains its structure and stays intact. Furthermore, additional materials may be present to provide the substrate with additional structural support beyond the depth that the template and masonry tile(s) are located. The configuration of the substrate is such that gas and / or vapour can be displaced from the pressing region. The pressing region is defined herein as that area where the surface of the substrate and the sheet-form material are being pressed together, preferably in the region of the interface of the substrate and the sheet-form material. Preferably the substrate may be such that gas or vapour can escape from the pressing region in a direction having at least a component in a direction generally transverse to the pressing direction in which the sheet-form material is pressed to the substrate. Other formations (as an alternative or in addition) may be provided to assist the displacement of the gas. For example, grooves or channels could be formed in the substrate. The configuration of the substrate which allows for the displacement of the gas may be inherent in that it arises from the nature of the composition of the substrate itself and / or it may be provided by subsequent action, for example by machining the substrate or by chemical action on the substrate. Preferably the substrate may include a material having a cellular structure. A cellular structure of the substrate can provide the necessary displacement of the gases in some arrangements. In preferred examples, the substrate comprises a material including a substantially open-cell cellular structure. In this way, good movement of the gases away from the pressing region can be obtained. The substrate may comprise a foam material, wherein the foam material preferably has a substantially open-cell structure. For example, the substrate may comprise an open-cell polymeric foam. Said polymeric foam may be selected from phenolic resin foams, polystyrene foams, polyurethane foams, polyethylene foams, polyvinylchloride foams, polyvinylacetate foams, polyester foams, polyether foams, and foam rubber. Preferably, the polymeric foam is selected from phenolic resin foams. The open-cell polymeric foam may include a finely-divided particulate reinforcing material. Suitable particulate reinforcing materials are preferably inert and insoluble. The reinforcing material may be present in an amount of up to 10 weight percent based on the total weight of the foam, for example from 2 to 10 weight percent, or 5 to 10 weight percent based on the total weight of the foam. Suitable reinforcing materials include organic or inorganic (including metallic) particulate materials, which may be crystalline or amorphous. Even fibrous solids have been found to be effective, although not preferred. Non-limiting examples of suitable particulate materials include clays, clay minerals, talc, vermiculite, metal oxides, refractories, solid or hollow gas microspheres, fly ash, coal dust, wood flour, grain flour, nut shell flour, silica, mineral fibres such as finely chopped glass fibre and finely divided asbestos, chopped fibres, finely chopped natural or synthetic fibres, ground plastics and resins whether in the form of powder or fibres, e.g., reclaimed waste plastics and resins, pigments such as powdered paint and carbon black, and starches. Preferably, the foam has a density in the range of 100 to 500 kg-rm3, more preferably 120 to 400 kg m-3, and most preferably 120 to 250 kg m-3. The physical properties of such foams, especially the compressive strength and deflection under load are believed to be related to (amongst other factors) cell wall thickness and average cell diameter. Preferably, the average cell diameter of the solid open-cell is in the range of about 0.5 mm to 5 mm, more preferably 0.5 to 1 mm to 2 or 3 mm. The cells or pores of the foam are open to the surface of the substrate which contacts the sheet-form material, and preferably they open out below the surface to a greater width than the opening, thereby providing an undercut which can enhance the keying of the sheet-form curable material to the foam. The substrate preferably may comprise a rigid foam, for example a foam material obtained by causing or allowing a mixture of phenolic resole, acid hardener and finely divided particulate solid to cure under conditions in which foaming for the mixture is caused primarily or solely by volatilisation of small molecules present in the resole or formed as a by-product of the curing reaction. The formation of an example of such foams is described in detail in EP0010353 and foamed bodies comprising these foams can be obtained as ACELL foam from Acell Holdings Limited, UK. The composite product produced according to the method of the invention may comprise, for example, a substrate in the form of a substantially planar panel having a thickness of from 0.5 to 20 cm. It will be appreciated that the exact thickness of the substrate panel is dependent on a number of factors, including the type of substrate, the type and thickness of the masonry tile(s) used, and the end use of the composite product. However, in some embodiments, it is preferred that the substrate panel has a thickness in the range of from 0.5 to 10 cm, more preferably 0.5 to 5 cm, still more preferably 0.5 to 3 cm, for example 1 to 3 cm. By contrast, the surface dimensions of the substrate panel are not particularly limited and may vary widely depending on the end use of the composite product. Preferably, the substrate may be bonded to the sheet-form material during the pressing step. In some embodiments, the sheet-form material is pressed into the surface of the substrate during the pressing step, thus forming a strong mechanical bond between the components. More preferably, the curable material flows into the cells of the open-celled substrate during the pressing step. This can reduce the risk of delamination of the sheetform material and the masonry tile from the substrate, to provide a stable product when exposed to heating / cooling cycles and provides a unitary composite structure without the need for an adhesive to be applied or the assembly of parts. In some cases it has been found that the bond achieved at the interface of the sheet-form material and the substrate is in fact stronger than the material of the substrate itself. Alternatively, or in addition, an adhesive or other bonding agent may be used between the substrate and sheet-form curable material. Thus, in a preferred embodiment, the sheet-form curable material is pressed into the surface of the masonry tile and into the surface of the substrate during the pressing step. By applying a sheet-form curable material to a porous substrate, several advantages can be achieved. In particular, by using an open cell foam substrate, air can pass into and through the open cell structure of the foam so that the risk of the air and gases leading to flaws and other deformities in the bond between the sheet-form material and the substrate is reduced. Furthermore, by bonding the sheet-form material to the substrate and the masonry tile in the process of the invention, efficiencies in manufacture of the composite product can be achieved since a further step to adhere the components together can be avoided. After the step of applying pressure to press the masonry tile, the template, the sheet-form curable material and the frangible porous substrate together, the template is removed from the surface of the composite product, thus forming wells in the composite product, for rendering or grouting. Preferably, the template is formed from a material that is inert with respect to the sheetform curable material, or any other material used in the composite product, such that the template may be readily removed. For example, the template may be formed from steel, aluminium or another material that is stable at increased pressure. Alternatively, a protective layer may be placed between the template and the sheet-form curable material to provide a barrier between the two, such that the template may be easily removed. In some embodiments, a protective layer is placed between the sheet-form material and the masonry tile(s) and template so that the sheet-form material does not bind to the masonry tile(s) or template during the step of applying pressure to press the masonry tile, the template, the sheet-form curable material and the frangible porous substrate together. The template is then easily removed, and a further pressing step and / or heating step is performed to bind the masonry tiles to the sheet-form curable material within the indentations formed in the substrate. An advantage of using a template in the present invention during the step of applying pressure to press the masonry tile, the template, the sheet-form curable material and the frangible porous substrate, is that the template ensures that the sheet-form curable material and the substrate bind together substantially over the profile of the well formed in the substrate. The depth of the wells formed in the composite product may be controlled by pressing the substrate with the template, and / or the height of the template. Accordingly, the height of the spaces between adjacent masonry tiles may be controlled to adjust the height of the rendering or grouting substance between the masonry tiles. Any suitable grouting or rendering material may be used. The rendering or grouting may be provided by using a particulate material. Suitable particulate materials include sand, gypsum, graphite, calcium carbonate, hydrated organic salts, ceramic materials, ground glass, ground stone, clay materials, metal oxides, powdered paints, and mixtures thereof. Pigments may be added to the particulate material in order to control colour. In some embodiments, the particulate material is pressed into the sheet-form curable material after removal of the template. The particulate material may be positioned between adjacent masonry tiles to simulate the appearance of bricks bonded together by mortar, or a tiled wall or floor. The particulate material may be pressed into the sheet-form curable material in a separate step of pressing and / or heating the sheet-form material. Preferably, the sheet-form curable material may be partially liquefied during the step to allow for the particulate material to become embedded in the sheet-form curable material. In preferred embodiments, the sheet-form curable material is cured in the same step. In preferred embodiments, a rendering or grouting material is provided in the spaces between adjacent masonry tiles. The rendering or grouting material may be used to at least partially fill the indentations formed by the template within the composite product. The rendering or grouting materials may comprise sand, cement or monocouche, or mixtures thereof. Alternatively, or in addition, the rendering or grouting materials may comprise binders, for example, Portland cement, lime and / or gypsum. The step of applying pressure to press the masonry tile, the template, the sheet-form curable material and the frangible porous substrate together whereby the template and masonry tile cause shaping of the frangible porous substrate allows for the template and the masonry tile to effectively stamp the substrate creating an indentation in the substrate that matches the masonry tile and template’s outlines. This step may be achieved by using pressing plates or by the use of weighted plates. The pressing plates or weighted plates may be preferably metal, for example aluminium. Preferably the method includes applying heat to the masonry tile and the sheet-form material. Preferably, the sheet form material may be reduced in viscosity and / or at least partially liquified on the application of heat and / or pressure. This allows for easier pressing of the masonry tile and template into the substrate through the sheet-form curable material. In some embodiments, this step may also cure the sheet-form curable material to form a composite product. Preferably, heating of the sheet-form material may be performed to cure the sheet-form curable material. In this way, some flow of the material prior to curing can be achieved. In preferred embodiments, the material at least partly flows into cells of the substrate material during the application of pressure. When curing the sheet-form curable material to form a composite product is achieved within the same application of pressure as the stamping of the template and masonry tile, a grouting material may be added to the composite material after the removal of the template. In preferred embodiments, a traditional grouting material is used, such as those including sand, cement or monocouche, or mixtures thereof. In some embodiments, the step of curing the sheet-form curable material to form the composite is performed after the removal of the template. For example, the method may comprise the steps of pressing the masonry tile(s), substrate, sheet-form curable material and template together, followed by removing the template and then the step of adding a grout or render material followed by performing a final press to form the masonry-effect composite product. The final press may be performed by placing a heated weight on top of the layers. Preferably, the grout or render material may be a particulate material, such as sand, gypsum, graphite, calcium carbonate, hydrated organic salts, ceramic materials, ground glass, ground stone, clay materials, metal oxides, powdered paints, and mixtures thereof. Such a process also allows for the possibility of being able to cure multiple panels simultaneously without the need for multiple presses as the main pressing step has already been completed. When forming the composite product, preferably the pressure applied is in the range of from 1 to 20 kgcrrr3, more preferably 2 to 15 kgcm-3, and more preferably 5 to 10 kgcm-3 The temperature required during the composite product formation step is dependent on the type of sheet form material used, the type of substrate, and the type of any adhesive which may be used, and can readily be determined by persons of skill in the art by routine experimentation. However, where the sheet form material comprises or consists of SMC, a temperature in the range of from 100 to 200 °C is appropriate, for example 120 to 160 °C. Accordingly, in some embodiments, the composite forming step step comprises heating the composite member to a temperature of from 100 to 200 °C. Suitable methods of heating include microwaves, infrared, induction heating of the plates ora heating tunnel. Preferably the pressure and temperature and cycle time are chosen so that the sheet-form material cures during the pressing operation. Preferably the sheet form material is cured directly onto the masonry tile and substrate during the pressing operation. In a preferred embodiment, the masonry tile is preheated prior to the pressing step. Preheating the masonry tile reduces the necessary duration of the pressing step, enabling a faster turnover of products. Any conventional means of preheating the masonry tile could be used, for example, using hot air or infrared irradiation. Alternatively, or in addition, the template may be preheated prior to the step of forming the composite material. Preferably preheating the template is performed where the template is formed from a material that is impervious to the sheet-form curable material. Pressing of the composite material is preferably performed fora period of from 30 seconds to 20 minutes, for example 1 minute to 10 minutes. ln some embodiments, a method according to the present invention may further comprise the steps of applying a second layer of sheet-form material having reinforcing fibres to the surface of the substrate panel opposite the first layer of sheet-form material having reinforcing fibres. Therefore, the composite product produced may comprise for example a substrate panel having two “skins” of sheet-form material having reinforcing fibres and masonry tile applied to opposing surfaces or may comprise a substrate panel sandwiched between a “skin” of sheet-form material having reinforcing fibres and a second “skin” of sheet-form material having reinforcing fibres and masonry tile. The arrangement where the composite products comprise a core having a first skin including sheet-form material and an outer layer of the masonry tile, and a second skin including just the sheet-form material and no masonry tile may be preferred where only one surface of the composite product is visible in use. Alternatively, the composite product may comprise a core having a first skin including sheet-form material having reinforcing fibres and an outer layer of the masonry tile, and a second skin including sheet-form material having reinforcing fibres and the same, or a different, masonry tile to the first skin. The composite product having two skins may be formed in a single pressing operation as described above, wherein the required layers are arranged and then pressed together to bond the layers together. In this way, a two-sided composite product can be formed in a single pressing operation. A grouting material may then be placed between the adjacent masonry tiles after the removal of the template. In other embodiments, the composite product having two skins may be formed using multiple pressing operations. For example, the composite product having two skins may be formed by placing one layer of sheet-form curable material on a heated bottom pressing plate, following by the substrate and then a second layer of sheet-form curable material, arranged so that the substrate material is sandwiched between the two layers. The template and masonry tile(s) are then arranged on top of the top layer of sheet-form curable material and then the layers are pressed together. The template may then be removed and a grouting material can be positioned between adjacent masonry tiles. Finally, the composite is subjected to another pressing and / or heating step to form the masonry-effect composite product. The finally pressing and / or heating step may be performed by placing a heated weight on top of the layers. The method of the invention may further comprise providing interconnecting means to enable a series of composite product panels according to the invention to be interconnected, e.g. to cover a wall or floor. In one preferred embodiment, the interconnecting means is a tongue and groove arrangement. For instance, the tongue and groove arrangement may be provided by profiling or machining the substrate. In another embodiment, the method of the invention may comprise providing a fixing means on the surface of the composite material panels which is opposite the masonry tile, wherein said fixing means are adapted to enable the composite product panel to be attached to a wall, frame or other surface. A variety of suitable fixing means are known in the art, and include metal clips. In another aspect of the present invention, a masonry-effect composite product obtainable by a method as described herein is provided. The composite product comprises a skin of sheet-form material having reinforcing fibres, the sheet-form material comprising a masonry tile bonded to a surface of the skin of sheet-form material, and wherein at least a part of the sheet-form material has flowed into the porous structure of the substrate, and additionally comprising a substrate having a porous structure, and having an indentation formed therein, wherein the masonry tile is located in an area of the indentation formed therein, and further wherein the sheet-form material having reinforcing fibres is bonded to the substrate, and further comprising a rendering or grouting substance in spaces between adjacent masonry tiles, wherein the height of the rendering or grouting substance in spaces between adjacent masonry tiles has been adjusted. The masonry tile may extend over substantially all or only a part of the sheet-form material and / or substrate area. Preferably, a plurality of masonry tiles is provided which collectively extend over substantially all or only a part of the sheet-form material and / or the substrate area. Similarly, the sheet-form material may extend over substantially all or only a part of the substrate area. Preferably, the sheet-form material extends over substantially all of the substrate area. The grouting or rendering substance may preferably comprise sand, cement or monocouche, or mixtures thereof or binders, for example, Portland cement, lime and / or gypsum. The composite product may comprise a reinforcing layer in addition to the reinforcing fibres present in the sheet form material. For instance, the reinforcing layer may be provided between the sheet-form material and the substrate. The reinforcing layer may be located across the whole of the substrate or may, for example, be provided in only parts. For example, if there is a particular section of the product which is more susceptible to damage, for example the corners of the composite product. Preferably, the sheet-form material may be bonded to the masonry tile by way of a key. In this way, a strong bond between the matrix and the masonry tile can be obtained. More specifically, the sheet-form material may extend into grooves or around protrusions on the surface of the masonry tile, or into spaces in the coarse structure of the masonry tile thus forming a strong bond between the sheet-form material and the masonry tile. Alternatively, or in addition, a layer of an adhesive material may be provided between the sheet-form material and the masonry tile. In the present invention, the sheet-form material flows and therefore extends into the porous surface of the substrate, thus forming a strong mechanical bond between the two components. More preferably, a cured material extends into the cells of an open-celled substrate. This can reduce the risk of delamination of the sheet-form material and the masonry tile from the substrate, providing a stable product when exposed to heating / cooling cycles and provides a unitary composite structure without the need for an adhesive to be applied or the assembly of parts. In some embodiments, an additional adhesive or other bonding agent may be present between the substrate and the sheet-form material. The composite product (e.g., panel) may comprise a frame or frame members such as stiles, rails, and / or mullions. The frame members may be of wood, metal (for example, aluminium) or plastics (such as uPVC) ora combination of these, e.g. metal-reinforced plastics. The plastics material may contain filler, if desired, to improve hardness and / or rigidity. In a preferred embodiment, the substrate occupies substantially the entire volume or volumes within the frame, i.e., substantially the whole space within a panel defined by first and second skins and the components of the frame. The composite product may further comprise an interconnecting means, such as a tongue and groove arrangement. Brief Description of the Drawings Figure 1 shows an exploded cross-sectional view of the template, masonry tiles, sheetform curable material and substrate prior to being pressed together. Figure 2 shows a schematic cross-sectional view of the template, masonry tiles, sheetform curable material and substrate prior during the step of applying pressure to press the masonry tile, the template, the sheet-form curable material and the frangible porous substrate together whereby the template and masonry tile are causing shaping of the frangible porous substrate. Figure 3 shows a schematic cross-sectional view of the masonry tiles, sheet-form curable material and substrate after the removal of the template. Figure 4 shows a schematic cross-sectional view of a masonry-effect composite product according to the present invention. Figure 5 shows a process flow diagram of a method according to the present invention. Detailed Description of the Inventions In an exemplary process according to the invention, a layer of SMC (2) is laid on top of a layer of solid open-cell phenolic resin foam (6), as seen in Figure 1. A plurality of masonry tiles (4) formed from brick (brick slips) and having a depth of 10 to 15 mm are positioned in a template (8), which helps maintain the shape of a desired brickwork bond. The template (8) is configured to fill the spaces between the brick slips (4) and the resulting assembly is laid on top of the layer of SMC (2). As shown in Figure 2, a pressing plate (10) heated to 120 to 160 °C is positioned above the plurality of masonry tiles (4) and template (8) and the resulting assembly is pressed using 2 to 10 kgcm2 of pressure for a period of from 2 to 10 minutes. This caused the template (8) and the masonry tiles (4) to crush the surface of the open-cell phenolic resin foam (6). The surface of the open-cell phenolic resin foam (6) is frangible and is therefore shaped to the outline of the template (8) and masonry tiles (4). Furthermore, as illustrated in Figure 2, the SMC layer (2) is forced by the template (8) and masonry tiles (4) into the phenolic resin foam (6) also. As seen in Figure 3, the template (8) is then removed from the composite product after the upper pressing plate (10) has been removed. In this embodiment, the SMC (2) is cured during the pressing step. A cement grout (12) is then used to partially fill the wells formed by the template (8) blocks in the composite product to form a masonry-effect composite product according to the present invention, as depicted in Figure 4. A process flow diagram in illustrated in Figure 5, which outlines the steps of the methods of the present invention. As shown, the method involves the steps of providing a substrate having a frangible porous structure; providing a layer comprising a sheet-form curable material having reinforcing fibres; providing a masonry tile; and providing a template comprising a plurality of openings shaped to receive a masonry tile (20). The method further comprises the steps of applying the sheet-form curable material to a surface of the frangible porous substrate (22); placing the template on the sheet-form curable material (24); applying the masonry tile in the openings of the template and onto the layer of sheetform curable material (26); applying pressure to press the masonry tile, the template, the sheet-form curable material and the frangible porous substrate together whereby the template and masonry tile cause shaping of the frangible porous substrate (28); and removal of the template (30). In some embodiments, the method further comprises a step of providing a protective layer between the template and the sheet-form curable material. This additional step is performed prior to placing the template on the sheet-form curable material (24). The method then comprising further steps after the removal of the template (30) of removing the template, and potentially the masonry tiles depending on how the protective layer is positioned), and then removing the protective layer. The masonry tiles are then repositioned (if removed) and the composite layers are subjected to additional pressing and / or heating step to cure the sheet-form curable material to the masonry tiles. In some embodiments, the method further comprises a step of pointing a grouting material within the wells formed by the removal of the frame from the composite product. In some embodiments, the method further comprises a step of providing a particulate material between the masonry tiles. This step is performed after removal of the template. The particulate material is then pressed into the sheet-form curable material and preferably cured into the sheet-form curable material to simulate grout between the masonry tiles. In some embodiments, the method includes an additional step of curing the sheet-form curable material through an additional pressing step. In this embodiment, after the template is removed, an additional pressing step is performed by placing a heated weight on top of the layers to form the composite product. It will be appreciated that the present invention has been described by way of example. Each feature disclosed in the description, and (where appropriate) the claims and drawings may be provided independently or in any appropriate combination. Thus, it will be appreciated that the various methods described herein could be combined as appropriate to form a particular product.

Claims

1. A method of forming a masonry-effect composite product, the method comprising: (i) providing a substrate having a frangible porous structure; (ii) providing a layer comprising a sheet-form curable material having reinforcing fibres; (iii) providing a masonry tile; and (iv) providing a template comprising a plurality of openings shaped to receive a masonry tile;the method comprising the steps of: (a) applying the sheet-form curable material to a surface of the frangible porous substrate; (b) placing the template on the sheetform curable material; (c) applying the masonry tile in the openings of the template and onto the layer of sheet-form curable material; (d) applying pressure to press the masonry tile, the template, the sheet-form curable material and the frangible porous substrate together whereby the template and masonry tile cause shaping of the frangible porous substrate; and (e) removal of the template.

2. The method of Claim 1, wherein the openings form a regular repeating pattern, such as formed by a brick wall.

3. The method of Claim 1, wherein the openings form an irregular repeating pattern such as formed by a stone wall or mosaic.

4. The method of any one of Claims 1 to 3, wherein the plurality of openings substantially cover the surface of the substrate.

5. The method of any one of Claims 2 to 4, wherein a masonry tile is provided for each respective opening.

6. A method of any one of the preceding claims, wherein the masonry tile is formed, at least in part from concrete, clay, natural stone, artificial stone, ceramic, glass, or a combination thereof.

7. A method according to Claim 6, wherein the masonry tile is formed, at least in part from brick, marble, granite, limestone, travertine, sandstone, slate, cast stone,porcelain, earthenware, glass, ora combination thereof.

8. A method according to any one of the preceding claims, wherein the masonry tile is partially glazed.

9. A method according to any one of the preceding claims, wherein masonry tile has a depth in the range of from 3 to 50 mm, such as 5 to 30mm.

10. A method according to any one of the preceding claims wherein the masonry tile has dimensions of from 190 to 250 mm by 55 to 75 mm.

11. A method according to any one of Claims 1 to 9, wherein the masonry tile has dimensions of from 95 to 125 mm by 55 to 75 mm.

12. A method according to any one of the preceding claims, wherein the masonry tile is provided with surface indentations or protrusions on the surface that contacts the sheet-form material.

13. A method according to any one of the preceding claims, wherein the masonry tile is sized to fill the dimensions of the template openings.

14. A method according to any one of the preceding claims, wherein the sheet-form material comprises a thermosetting polymer resin matrix.

15. A method according to Claim 14, wherein the thermosetting polymer resin matrix is selected from polyester resins, vinyl ester resins, epoxy resins, phenolic resins, bismaleimide resins or polyimide resins.

16. A method according to Claim 14, wherein the sheet-form curable material comprises a phenolic resin sheet comprising:uncured phenolic resin, such as a phenol-formaldehyde resin;filler;a catalyst in an amount of less than 2wt.% relative to the content ofphenolic resin; andwherein the filler is present in a ratio of filler to uncured phenolic resin in an amount of 2.5:1 and greater, and further wherein the filler comprises a transition metal hydroxide and / or aluminium hydroxide in a ratio of metal hydroxide to uncured phenolic resin in an amount of 1:1.5 to 3:1.

17. A method according to Claim 14, wherein the sheet-form material comprises sheet moulding compound (SMC).

18. A method according to any one of the preceding claims, wherein the reinforcing fibres comprise or consist of carbon fibres, glass fibres or aramid fibres, and mixtures thereof, and wherein the fibres may be present in a ratio of resin to fibre of 6:1 to 1:3, such as from 4:1 to 1:1.

19. A method according to any one of the preceding claims, wherein a rendering or grouting substance is provided in the spaces between adjacent masonry tiles.

20. A method according to Claim 19, wherein the rendering or grouting materials comprise sand, cement or monocouche, or mixtures thereof.

21. A method according to Claim 19 or Claim 20, wherein the rendering or grouting materials comprise binders, for example, Portland cement, lime and / or gypsum.

22. A method according to any one of the preceding claims, wherein the height of the spaces between adjacent masonry tiles is controlled to adjust the height of the rendering or grouting substance between the masonry tiles.

23. A method according to Claim 22, wherein the height of the spaces is controlled by means of pressing with a template and / or the height of the template.

24. A method according to any one of the preceding claims, wherein the substrate includes a material having an open-cell cellular structure.

25. A method according to any one of the preceding claims, wherein the substrate comprises an open-cell polymeric foam.

26. A method according to Claim 25, wherein the open-cell polymeric foam is selected from phenolic resin foams, polystyrene foams, polyurethane foams, polyethylene foams, polyvinylchloride foams, polyvinylacetate foams, polyester foams, polyether foams, and foam rubber.

27. A method according to Claim 25 or Claim 26, wherein the open-cell polymeric foam includes a finely-divided particulate reinforcing material; and / or wherein the open-cell foam has a density in the range of 100 to 500 kgnr3;and / or wherein the open-cell foam has an average cell diameter of 0.5 mm to 5 mm; and / or wherein the substrate is in the form of a panel having a thickness of from 0.5 to 20 cm.

28. A method according to any one of the preceding claims, further comprising applying a second layer of sheet-form material having reinforcing fibres to the surface of the substrate panel opposite the first layer of sheet-form material having reinforcing fibres.

29. A method according to any one of the preceding claims, further comprising providing interconnecting means to enable a series of masonry-effect composite product according to the invention to be interconnected30. A method according to Claim 29, wherein the interconnecting means is a tongue and groove arrangement.

31. A method according to any one of the preceding claims, wherein the method further comprises a step of curing the sheet-form curable material and the pressure applied during is in the range of from 1 to 20 kg cnrr2.

32. A method according to any one of the preceding claims, wherein the method further comprises a step of curing the sheet-form curable material and further comprisingheating the composite material to a temperature of from 100 to 200 °C during the curing step.

33. A method according to any one of the preceding claims, the method further comprises a step of curing the sheet-form curable material and further comprising preheating the masonry tile prior to the curing step.

34. A masonry-effect composite product formed according to the process of any one of Claims 1 to 33, the product comprising a skin of sheet-form material having reinforcing fibres, the sheet-form material comprising a masonry tile bonded to a surface of the skin of sheet-form material, and wherein at least a part of the sheetform material has flowed into the porous structure of the substrate, and additionally comprising a substate having a porous structure, and having an indentation formed therein, wherein the masonry tile is located in an area of the indentation, and further wherein the sheet-form material having reinforcing fibres is bonded to the substrate, and further comprising a rendering or grouting substance in spaces between adjacent masonry tiles, wherein the height of the rendering or grouting substance in spaces between adjacent masonry tiles has been adjusted.

Images