Building panel

Abstract

A building panel has a substrate having a first surface formed with guide means to define a guide or pathway across the surface for location or alignment of elements ofrming a facade to a building. An

Description

FIELD OF THE INVENTION

[0001] This invention relates to a building panel. More especially, the invention relates to a building panel to which tiles or brick slips can be secured offsite. BACKGROUND TO THE INVENTION

[0002] The construction of brick walls can be troublesome, particular in temperate climates. Adverse weather, dry or hot, can adversely affect the efficiency of construction and there is a need fora more reliable way of constructing brick or brick effect walls.

[0003] Brick tiles (referred to as “brick slips”) are commonly used to clad buildings with a brick-effect faqade. A back panel is fixed to the vertical wall substrate and permanent bond adhesive is applied to the top of the course. The brick slips are then pushed into place and mortar is applied between the brick joints. Once the mortar has set, but not dried, the brickwork is brushed to finish.

[0004] Modular brick slip cladding systems are also known. These typically require stainless steel vertical rails and panels to be fixed to a wall. Brick slips may be secured to the panels prior to fixing of the panels but gaps need to be provided to allow securement of the panels to the wall. Further brick slips are then secured over the screw locations to provide a seamless brickwork finish ready to be pointed with mortar.

[0005] The modular-style of the cladding systems requires each section to be fixed to the wall. The securement mechanisms, typically utilising low profile stainless steel screws, need to be accessible when the frames are placed against the vertical wall for securement, thereby requiring any pointing of the brickwork to be carried out on site only after the frames have been secured to the wall.

[0006] The present invention seeks to provide an improved system and method of applying brick slips to a building in which all the manufacture and preparation and finishing of the brickwork, including pointing, is carried out off site in an environmentally controlled location.

[0007] The brick slips and pointing mortar are applied to insulation panels in controlled factory conditions, ensuring consistent quality. This process eliminates weather-related delays and reduces labour costs, providing an efficient and reliable alternative to conventional brickwork. STATEMENT OF THE INVENTION According to a first aspect of the invention, there is provided a building panel comprising a substrate, a first surface of the substrate having guide means to define a guide or pathway across the substrate surface configured for location and alignment of the material forming a faqade to a building; and a second surface opposed to the first surface having a securement mechanism to secure the substrate to a wall of the building. Preferably, at least part of the securement mechanism extends beyond at least part of the periphery of the substrate. Preferably, the substrate comprises a layer of extruded polystyrene reinforced on both sides with a cement layer. Preferably, the substrate comprises a layer of mineral board reinforced on both sides with a cement layer. Preferably, one or both cement layers have a fibreglass mesh superimposed thereon. Preferably, the guide means comprises a plurality of spaced spacers extending across the substrate. Preferably, the guide means comprises a plurality of spaced grooves extending across the substrate. Preferably, at least one of surfaces of the substrate include at least two vertically orientated braces. Preferably, the plates include a plurality of apertures extending between the intersection of the first and second sections and through the distal edge of the second section. Preferably, the first surface of the building panel has a frame secured thereto. Preferably, the frame comprises two spaced brace members and a plurality of spacers extending therebetween, the spacers forming the guide means. According to a second aspect of the invention, there is provided a building panel system comprising: at least one panel according to the first aspect of the invention; guide means located on, or connectable to, the first surface of the panel; securement means on, or connectable to, the second surface of the panel. According to a third aspect of the invention, there is provided a method of preparing and installing a building panel according to the first aspect of the invention, the method comprising the steps of: locating and aligning brickslips on the first side of the substrate using the guide means; adhering the brickslips to the substrate; applying pointing mortar to brickslips; and securing the second side of the substrate to a building wall using the securement means. BRIEF DESCRIPTION OF DRAWINGS

[0008] The invention will now be described with reference to the accompanying drawings in which:-

[0009] Figure 1 is a plan schematic view of a building panel substrate constructed in accordance with a first embodiment of the invention;

[0010] Figure 2 shows two panels interlocking;

[0011] Figure 3 shows a schematic plan view of a panel constructed in accordance constructed in accordance with a further embodiment of the invention;

[0012] Figure 4 shows two interlocking brick fapade panels;

[0013] Figure 5 shows schematic perspective view of two corner panels constructed in accordance with the invention;

[0014] Figure 6 shows the front surface of a panel of figure 1 including alignment spacers;

[0015] Figure 7 shows the rear surface of the panel of figure 6 with wall fixing means;

[0016] Figure 8A shows a top-down perspective view of a frame suitable for being secured to the front surface of a building panel;

[0017] Figure 8B shows a perspective view of a frame suitable for being secured to the rear surface of a building panel;

[0018] Figure 9A shows the front surface of a panel constructed in accordance with another embodiment;

[0019] Figure 9B shows the front surface of the panel of figure 9A, arranged in a reverse orientation;

[0020] Figure 10A shows the rear surface of the panel of figure 9A, showing the securement mechanism in accordance with another embodiment;

[0021] Figure 10B shows the rear surface of the panel of figure 19B, showing the securement mechanism of figure 10A;

[0022] Figure 11A shows the front surface of two panels of Figure 9 interlocking;

[0023] Figure 11B shows the rear surface of the interlocked arrangement of Figure 11 A;

[0024] Figure 12 shows a plan view of the frame of Figure 8B;

[0025] Figure 13 shows a rear plan view of the upper panel plate of the frame of Figure 8B;

[0026] Figure 14 shows a rear perspective view of the upper plate portion of figure 13;

[0027] Figure 15 shows two interlocked brick facade panel having the securement mechanism of figure 10, secured to a substrate; showing the corresponding wall plate portion;

[0028] Figure 16A is a plan view of the arrangement of the securement mechanism when secured to a substrate, showing a weep hole;

[0029] Figure 16B shows a rear perspective view of the arrangement of 16A;

[0030] Figure 17 shows the brick fapade panel of figure 15 being further secured to a substrate via a securing means;

[0031] Figure 18 shows a perspective view of the L-shaped bracket of figure 9;

[0032] Figure 19 shows a plan view of a single vertical brace. DETAILED DESCRIPTION OF THE INVENTION

[0033] Referring to figure 1, the brick slip panel system of the invention comprises at least one panel section 2 having a generally rectangular profile with an array of spaced rectangular recesses 4 formed in opposing side walls 6. The side walls 6 extend between first and second end walls 8, 10. The first end wall 8 extends along the entire length of the panel 2 and has a length of typically around 650mm. The second wall 10 opposing the first, extends only between the bases of end recesses 4A formed in the side walls 6. The second end wall 10 has a length of typically 450mm. The total length of each side wall 6 is typically 600mm.

[0034] The profiled shape of the panel 2 is such that two panels 2A, 2B can be placed in reverse orientation with respect to each other such that their side walls 6 interlock to form a single substate panel structure, as shown in figure 2.

[0035] The panel sections 2 are constructed from a solid material middle layer reinforced on both sides with a cement layer.

[0036] The middle layer may for example be made from extruded polystyrene (PS). Alternatively, the middle layer may be made for example from a mineral board. A mineral board, would more appropriate for the construction of higher buildings for example.

[0037] The outer cement layers have a fiberglass mesh 12 superimposed on them to add strength.

[0038] Other materials may be used, with a preference for lightweight solid materials that are durable and able to withstand transport and assembly rigours. The boards should achieve A1 and A2 fire rating performance. Panel thickness can be varied to achieve required insulation values, ranging from 12-100mm, typically.

[0039] Once the required number of panels 2 have been selected and locked together to form the overall substrate for securement to outside wall of a building, the substrate is laid flat and faqade material is adhered its front surface, being the surface that will face outwardly from the building wall.

[0040] The faqade material typically comprises brick slips (tiles) or bricks. Other materials may be secured depending on the type of faqade required by the end user. The adhesion of the bricks to the substrate is carried out in in controlled factory conditions, ensuring consistent quality. This process eliminates weather-related delays and reduces labour costs. Adhesion is far quicker in climate-controlled environment and with the bricks being applied on a flat horizontal surface.

[0041] Application of mortar and pointing of the brickwork is also carried out at this time to provide a complete finished brick faqade. More efficient mortar application and accurate pointing is achieved due to the substrate being on a flat horizontal surface allowing for mortar to be simply poured over the bricks to flow therebetween.

[0042] In one embodiment, shown in figure 3, spaced lengthwise grooves 14 are provided, which in turn, define guides or pathways 16 extending longitudinally across the panel section 2. The guides 16 provide location and alignment of the faqade materials such as brick slips, onto the substrate. The grooves 14 are configured to capture and retain the flow of the mortar between the bricks. The grooves 14 may typically have a width of 10mm and depth of 5mm.

[0043] Should one panel 2 be required to form a straight end to the substrate, the panel 2 can be cut widthwise along or near its centre to form one straight side wall with the opposing side wall remaining recessed to interlock with another panel 2, the result of which can be seen in figure 4. Figure 4 also shows a corner panel section 18 configured to connect an adjacent “straight” panel section 2.

[0044] Examples of profiled corner panels 18 can be seen in figure 5.

[0045] Figure 6 illustrates a further embodiment of the invention. In this embodiment the substrate structure is the same, but the guides or pathways 16 are defined by spacers 18 that are secured to and upstand from the surface of the panel section 2. The spacers 18 are formed from sheet metal, for example steel, and included spaced apertures 20 along their length to provide an array of locating holes to allow fastening of the spacer 18 to the surface, and to increase the mortar binding.

[0046] Figure 7 shows the rear surface of the substrate. By “rear” it is meant the surface opposed to the front surface and which faces the building wall for securement.

[0047] The edges of the end walls 8, 10 have a plurality of spaced fixings 22 secured thereto to provide securement means to secure the substrate panel 2 to the outside wall of a building. The number and location of the fixings 22 shown in the figure are shown as an example; the number of fixings 22 and their location along the side edges is variable depending on the application.

[0048] The fixings 22 extend outwardly from the periphery of the substrate panel 2 such that the fixings 22 remain accessible after the substrate faqade has been completed. Locating the securement mechanism outside the panel profile allows the brickworkadhered to the substrate to be finished (mortared and pointed) off site prior to installation.

[0049] Stainless steel elongate spacers 24 are provided which extend along the width of the panel 2. The spacers 24 between the first and second ends 8, 10. The spacers 24 provide a gap between the substrate and building wall when the substrate is secured, to allow for ventilation and drainage.

[0050] Figures 8 to 19 show an alternative embodiment of the invention. In this embodiment, the substrate is the same in terms of its profile and structure. The guide or pathways for the brick slips are provided by a framework 26 that is secured on to the front face of the substrate, as will be explained below.

[0051] The framework 26 is shown in figure 8. The frame comprises least two parallel and spaced braces 28, which are orientated vertically when on the substrate and in use. A plurality of spacers 30 extending lengthwise between the braces 28. As can be seen in Figures 18 and 19, the braces 28 and spacers 30 are formed from a thin metal sheet and include a plurality of apertures 32, which provide a location to secure the braces 28 to the front surface of the panel 34A via a suitable securing means. A suitable securing means may include, without limitation a screw or a nail. A suitable metal for the braces 28 may include, without limitation stainless steel. The spacers 30 may also be secured to the panel in the same way.

[0052] Figure 9B shows the first framework 26, in use being secured to the front surface of a building panel 34B, which is arranged in a reverse orientation. The panel 34B includes the same features as the panel 34A, however, as can be seen in the figures, the top and bottom edges of the panel 34B are flipped, such that the top edge 36 is equal in length to the bottom edge 38 of the panel 34A; whilst the bottom edge 40 is equal in length to the top edge 42 of the panel 34A.

[0053] In use, the side walls 44 of the panels 34A and 34B interlock in use to form a single substrate panel structure 46, the front surface of which can be seen in figure 11 A. Figure 11B shows the rear surface of the panel structure 46.

[0054] As can be seen on figure 15, to secure the panel 34 to a wall or substrate, at least an upper substrate plate 48A and a lower substrate plate 48B are required. As can be seen in Figure 15, the substrate plates 48 are arranged adjacently along the length of the substrate to form a ‘substrate rail’ 50.

[0055] As seen in Figure 16B, the substrate plates 48 have a generally J-shaped profile in an inverted orientation, having a first section 52A, which abuts the surface of the substrate. Outwardly and upwardly extending from the top-most edge of the first section 52A is a second section 52B. Extending between the intersection between the first and second sections 52 and the distal edge of the second section 52B is a plurality of apertures 54 which extend through the face of the substrate plates 48. The purpose of the apertures 54 will be explained later. In the embodiment shown in the figures, the apertures 54 are pill-shaped, however it can be envisaged that alternative geometries may be used, for example without limitation circle or square-shaped. The first section 52Aalso includes a plurality of apertures 56, which enable the substrate plates 48 to be secured to a substrate via a suitable securing means. Suitable securing means may include, without limitation, a screw or a nail.

[0056] The upper and lower substrate plates 48 form one half of a “French cleat” securement mechanism 58.

[0057] Figure 8B shows a second frame 60, having an upper panel plate 62 and a lower panel plate 64 extending lengthwise across the frame 60. The upper panel plate 62 and the lower panel plate 64 are secured to the front surface of at least two vertically orientated braces 28 via a suitable securing means being located through the apertures 66. A suitable securing means may include, without limitation a screw or a nail. The braces 28 are formed from a thin metal sheet and includes a plurality of apertures 30. A suitable metal for the braces 28 may include, without limitation stainless steel.

[0058] Figure 10A shows the second frame 60, in use being secured to the rear surface of the building panel 34A. In use, the braces 28 aid in providing increased stability and structure to the panel 34A. The upper panel plate 62 and the lower panel plate 64 compliment the substrate plates 48, forming the other half of the French cleat mechanism 58.

[0059] Figure 10B shows the second frame 60, in use being secured to the rear surface of a building panel 34B, which is arranged in a reverse orientation. The panel 34B includes the same features as the panel 34A, however, as can be seen in the figures, the top and bottom edges of the panel 34B are flipped, such that the top edge 36 is equal in length to the bottom edge 38 of the panel 34A; whilst the bottom edge 40 is equal in length to the top edge 42 of the panel 34A.

[0060] Both the panel plates 62 and 64 are formed of a first section 68A which abuts the rear surface of the panel 34. The first section 68A includes a plurality of apertures 70, which enable the panel plates 62 and 64 to be secured to a panel 34 using a suitable securing means. Suitable securing means may include, without limitation a screw or a nail. As can be seen in figure 12, the apertures 70 may be used to secure the panel plates 62 and 64 to the vertical braces 28. At one end of the first section 68A is a second section 68B which extends downwardly and outwardly at an angle from the first section 68A. Ascan be seen in the figures, when in use, the second section 68B extends from the bottommost edge of the first portion 68A.

[0061] In the embodiment shown in the figures, the upper panel plate 62 further includes a third section 68C, which is located distally from the second section 68B and extends from the opposing end of and perpendicular to the first section 68A. As can be seen in figure 14, the perpendicular distance from the first section 68A to the distal edge of the second section 68B is equal to the distance from the first section 68Ato the distal edge of the third section 68C. In use, this serves several purposes, firstly, it ensures that the first section 68A and thus the panel 34 remains parallel to the substrate. Secondly, it distributes pressure, prevents overtightening and flexing of the panel plate 62. As can be seen the figures, located proximal to the third section 68C, the first section 68A further includes a fixing means 72.

[0062] As can be seen from figure 9A, the fixing means 72 extends through the first section 68A. The fixing means 72 are located above the top edge of the panel 34 and aids the securement mechanism 58 by securing the panel 34 to a substrate. As can be seen in Figure 9A, the fixing means 72 are a plurality of apertures 72. In the embodiment shown in figure 9A, the number of apertures 72 is three, however it can be appreciated that, without limitation, the number of apertures 72 can exceed three, depending on the length and size of the panel 34. In use, the apertures 72 are suitable for receiving a suitable securing means for securing the panel in the desired location. Suitable securing means may include, without limitation, screws or nails. The building panel 34B also includes a fixing means 72, due to the increased length of the top edge 36, the number of apertures 72 provided are four.

[0063] Extending between the intersection between the first and second sections 68, and the distal edge of the second section 68B is a plurality of apertures 74. In the embodiment shown in the figures, the apertures 74 are pill-shaped, however it can be envisaged that alternative geometries maybe used, for example without limitation circle or square-shaped. As can be seen in Figure 16A and 16B, when then the securement mechanism 58 is engaged, the apertures 54 and 74 overlap to form a plurality of weep holes 76. In use, the weep holes 76 allow for ventilation and drainage of any moisture behind the panel 34. As seen in figure 12, extending downwardly through the third section 68C is a plurality of weep holes 78.

[0064] Figure 12 illustrates that two substrate plates 48 correspond with two panel plates 62 and 64 to secure the panel 34 to a substrate. In alternative embodiments (not shown), additional substrate plates and corresponding panel plates may be used to secure the panel to the substrate. As can be seen in figure 11B, when panels 34A, 34B and additional subsequent panels (not shown) interlock, they form a panel rail 80. In use, the substrate rail 50 engages with the panel rail 80, when being installed, the panels 34 are slid along the rail 50. Once the panel is in the desired location, a suitable securing means is located within the fixing means 72 to prevent the panel 34 from sliding along the rails 50.

Claims

1. A building panel comprising a substrate, a first surface of the substrate having guide means to define a guide or pathway across the substrate surface configured for location and alignment of the material forming a fapade to a building; and a second surface opposed to the first surface having a securement mechanism to secure the substrate to a wall of the building.

2. A building panel according to claim 1, wherein at least part of the securement mechanism extends beyond at least part of the periphery of the substrate.

3. A building panel according to claim 1 or claim 2, wherein the substrate comprises a layer of extruded polystyrene reinforced on both sides with a cement layer.

4. A building panel according to claim 1 or claim 2, wherein the substrate comprises a layer of mineral board reinforced on both sides with a cement layer.

5. A building panel according to claim 3 or 4, wherein one or both cement layers have a fibreglass mesh superimposed thereon.

6. A building panel according to any one of claims 1 to 6, wherein the guide means comprises a plurality of spaced spacers extending across the substrate.

7. A building panel according to any one of claims 1 to 6, wherein the guide means comprises a plurality of spaced grooves extending across the substrate.

8. A building panel according to claim 1, wherein at least one of surfaces of the substrate include at least two vertically orientated braces.

9. A building panel according to claim 4, wherein the plates include a plurality of apertures extending between the intersection of the first and second sections and through the distal edge of the second section.

10. A building panel according to claim 1, wherein the first surface of the building panel has a frame secured thereto.

11. A building panel according to claim 10, wherein the frame comprises two spaced brace members and a plurality of spacers extending therebetween, the spacers forming the guide means.

12. A building panel system comprising:at least one panel according to claim 1;guide means located on, or connectable to, the first surface of the panel;securement means on, or connectable to, the second surface of the panel.

13. A method of preparing and installing a building panel according to claim 1, the method comprising the steps of:locating and aligning brickslips on the first side of the substrate using the guide means;adhering the brickslips to the substrate;applying pointing mortar to brickslips; andsecuring the second side of the substrate to a building wall using the securement means.A

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