FAÇADE ORNAMENT AND METHOD FOR MANUFACTURING THE SAME

Abstract

The present application related to a method for manufacturing a façade ornament. The method comprises forming an ornament core enveloped by one or more resin impregnated fibre sheets, in an ornament-shaped cavity, substantially filling said cavity. The method further comprises forming an ornament shell by hardening, when in the cavity, the one or more resin impregnated fibre sheets. The present application further relates to a facade ornament comprising a core and a shell. The shell comprises one or more fibre sheets at least partially impregnated with a resin. The shell envelops the core.

Description

The invention relates to a façade ornament, such as a window sill, window frame, lintel, or chimney cover, comprising a core and a shell enveloping said core. The invention also relates to a method for manufacturing such a façade ornament. Façade ornaments, such as window sills, window frames, lintels, and chimney covers, have long been staple components in building construction, serving both functional and aesthetic purposes. Traditionally, these elements have been manufactured using materials like concrete and natural stone, which are known for their durability and strength. In recent years, there has been a shift towards using synthetic materials such as artificial plastics for facade ornaments. These materials offer advantages in terms of weight and durability, but they are derived from non-renewable resources and some have a significant environmental impact during production and disposal. These concerns have, in turn, led to a growing demand for sustainable building materials. However, existing eco-friendly alternatives often struggle to match the aesthetic qualities of traditional materials, or the performance of synthetic materials. Additionally, many of these materials are flammable and have poor fire-resistance properties. Also, state of the manufacturing techniques still struggle with consistently producing ornaments with complex geometries or intricate details, limiting the range of designs that can be efficiently produced at scale. It is an object of the invention to provide a facade ornament and a method for manufacturing the same in which the abovementioned disadvantages are at least less prevalent. The present invention thereto provides a method for manufacturing a facade ornament, comprising: - forming an ornament core enveloped by one or more resin impregnated fibre sheets, in an ornament-shaped cavity, substantially filling said cavity, - forming an ornament shell by hardening, when in the cavity, the one or more resin impregnated fibre sheets. This method provides a lightweight yet structurally sound facade ornament. The use of resin impregnated fibre sheets allows for precise shaping and containment of the core material, ensuring the uniform distribution and filling of the cavity, and a facade ornament of the desired shape and / or size. Additionally, forming the shell by hardening the resin impregnated fibre sheets in the cavity creates a seamless, weather-resistant outer layer that enhances durability and longevity of the ornament, solving the problem of degradation due to environmental exposure. The resin impregnated fibre sheets are also fire-resistant and fire retardant. The ornament core may otherwise be referred to as a core. The ornament shell may otherwise be referred to as a shell. The one or more resin impregnated fibre sheets may be considered enveloping the core when they cover a substantial part of the core, preferably all of the core. The sheets may be considered enveloping the core when they cover multiple of the cores surfaces, preferably all of the cores surfaces. The sheets may be considered enveloping the core when they are wrapped and / or folded around the core. The sheets may also be considered enveloping the core when separate surfaces of the core are each covered by initially separate sheets that are later fused into one shell. The cavity may be said to be ornament shaped in the sense that it has the shape that the façade ornament or more specifically the ornament shell should have. This ornament shape of the cavity may at least partially be defined by a shape-retaining and / or dimensionally stable product said cavity is provided in, for example by a mould. This ornament shape of the cavity may also at least partially be defined by the ornament core. The cavity itself may be provided by a more form-free product, for example a pouch, a sack or a bag, of which at least a part can urged to take the shape of the enveloped ornament core in it. For example by providing a vacuum in said form-free product. The form-free product may be said to then fit around the core, for example with a tight or snug fit. The method of forming the ornament core can be achieved through different approaches. ln some embodiment, forming the ornament core enveloped by one or more resin impregnated fibre sheets in an ornament-shaped cavity comprises: - shaping core material to form the ornament core; - enveloping the ornament core with the one or more resin impregnated fibre sheets; - arranging the ornament core and the enveloping one or more resin impregnated fibre sheets in said cavity. This approach allows for precise control over the core material and shape before insertion into the cavity. ln further embodiments, forming the ornament core enveloped by one or more resin impregnated fibre sheets in an ornament-shaped cavity comprises: - arranging the one or more resin impregnated fibre sheets in said cavity; - inserting core material in between the one or more resin impregnated fibre sheets, substantially filling the cavity; - hardening, when in the cavity, the core material to form the ornament core. ln some embodiments, hardening, when in the cavity, the core material comprises heating the core material. The step of hardening, when in the cavity, the one or more resin impregnated fibre sheets and the step of hardening, when in the cavity, the core material, may be performed at the same time. This approach allows for efficient filling of complex cavity shapes and ensures a tight bond between the core and shell. According to other aspects of the present disclosure, the ornament-shaped cavity may be provided using a mould. According to other aspects of the present disclosure, hardening, when in the cavity, the one or more resin impregnated fibre sheets comprises heating the one or more resin impregnated fibre sheets. Heating may comprises subjecting the one or more resin impregnated fibre sheets to electromagnetic radiation, such as microwaves or radio waves. This method of heating allows for rapid and uniform heat distribution throughout the foil sheets, ensuring consistent shell formation and reducing production time. According to other aspects of the present disclosure, the method may further comprise sanding the ornament shell. According to other aspects of the present disclosure, the method may further comprise coating the facade shell, to form a coating layer, such as a paint layer or a lacquer. Said coating layer may be a bio- based coating. These additional steps may contribute to the overall durability and appearance of the façade ornament. According to other aspects of the present disclosure, the method may further comprise attaching a first mounting part to the ornament shell, said first mounting part being configured to be fixedly attached to a second mounting part. The first and second mounting parts may be velcro, a snap-fit profile or a sliding profile. This feature significantly reduces installation time and complexity compared to traditional facade ornaments. According to other aspects of the present disclosure, the resin may be a crosslinked polymeric resin system, preferably comprising polyfurfuryl alcohol (PFA) resins. According to other aspects of the present disclosure, the fibre sheet may be a fibre mesh and / or may comprise fibres, such as inorganic fibres, preferably glass fibres, metal fibres, or polyester fibres, or organic fibres, preferably hemp, jute, or flax. According to other aspects of the present disclosure, the core may comprise at least one of one or more types of foamed polymers, such as PET, polyurethane, polyisocyanurate, expanded polypropylene (EPP), polyether sulfone, polyethylene, polystyrene, polymethacrylimide (PMI), one or more thermosetting-based materials, thermoplastic-based materials, or closed-cell thermoplastic polymer foams, or organic materials, preferably expandable organic material, such as corn and / or popcorn. According to other aspects of the present disclosure, the shell may comprise a bottom surface, and the method may further comprise attaching an adjustable support element to the bottom surface, said adjustable support element comprising a support surface facing away from said bottom surface and wherein the adjustable support element is configured for adjusting a distance between the bottom surface and support surface. This feature allows for precise adjustment during installation, ensuring proper alignment and fit. The facade ornament may be a window sill, a window frame, a lintel or chimney cover According to another aspect of the present disclosure, a facade ornament manufactured according to the method described above is provided. According to another aspect of the present disclosure, a facade ornament is provided, comprising a core and a shell. The shell comprises one or more fibre sheets at least partially impregnated with a resin. The shell envelops the core. According to other aspects of the present disclosure, the fibre sheet may comprise fibres, such as inorganic fibres, preferably glass fibres, metal fibres, or polyester fibres, or organic fibres, preferably hemp, jute, or flax. According to other aspects of the present disclosure, the resin may be a crosslinked polymeric resin system, preferably comprising polyfurfuryl alcohol (PFA) resins. According to other aspects of the present disclosure, the facade ornament may further comprise a coating layer, such as a paint layer or a lacquer. Preferably, the coating layer is a bio-based coating. According to other aspects of the present disclosure, the facade ornament may further comprise a first mounting part fixedly attached to the shell, the first mounting part configured to be fixedly attached to a second mounting part. The first and second mounting parts may be velcro, a snap-fit profile or a sliding profile. The facade ornament may further comprise the second mounting part. This second mounting part may also be provided separately. This feature significantly reduces installation time and complexity compared to traditional facade ornaments. According to other aspects of the present disclosure, the shell may comprise at least one surface, the ornament further comprising an adjustable support element attached to said at least one surface, said adjustable support element comprising a support surface facing away from said at least one surface and wherein the adjustable support element is configured for adjusting a distance between the at least one surface and the support surface. According to other aspects of the present disclosure, the façade ornament may be a window sill, a window frame, a lintel or chimney cover. In a specific embodiment, in which the façade ornament is a window sill, the shell comprises a bottom section, comprising a front end and a rear end, a substantially vertical front section, extending from said front end, perpendicularly to the bottom section, a substantially vertical rear section, extending from said rear end, perpendicularly to the bottom section, and / or parallel to the front section, extending farther upward from the bottom section than the front section, and a top section, at least partially inclining upwards from the front section towards the rear section. According to other aspects of the present disclosure, an upper part of the rear section may extend upwards beyond a highest point of the top section, wherein said upper part does comprise a double shell layer, does comprise two layers of shell adjacent and preferably directly attached to each other, and / or does not comprise a part of the core. This embodiment is particularly advantageous as this extending double shell layer forms a part where the rear section of the shell and the top section of the shell are attached to one another, without having to introduce overlapping sheets in either of those sections. Overlapping sheets can create parts of shell 3 that are thicker than other parts. This may be considered aesthetically unpleasing. This, while at the same time forming this extending double shell layer that may also be used to form a mechanical and / or structural connection between the ornament and its environment. According to other aspects of the present disclosure, the bottom section may comprise a groove extending in a longitudinal direction along the ornament. According to other aspects of the present disclosure, the core may comprise at least one of one or more types of foamed polymers, such as PET, polyurethane, polyisocyanurate, expanded polypropylene (EPP), polyether sulfone, polyethylene, polystyrene, polymethacrylimide (PMI), one or more thermosetting-based materials, thermoplastic-based materials, or closed-cell thermoplastic polymer foams, or organic materials, preferably expandable organic material, such as corn and / or popcorn. The invention will be further elucidated by means of non-limiting exemplary embodiments illustrated in the following figures, in which: - figure 1 shows a façade ornament according to an embodiment of the present invention, - figure 2 shows a flow chart for a method for manufacturing such a façade ornament, - figure 3 shows various types of weaves that may be used to form the one or more resin impregnated fibre sheets, - figure 4 shows a flowchart for a specific embodiment of step 81, - figure 5 shows an intermediate product as may be formed during the method of figure 4, - figure 6 shows an intermediate product as may be formed during the method of figure 4, - figure 7 shows a flowchart for a further specific embodiment of step 81, - figure 8 shows a cross-section of a mould, fibre-sheets and core material as may occur during the method shown in figure 7, - figure 9 shows a mould that may be used during the method of figure 2 and an ornament core therein, - figure 10 shows the mould of figure 9 without said ornament core therein, - figure 11 shows a cross-section of the mould shown in figures 9 and 10, - figure 12 shows a cross-section of a part of a wall in which a façade ornament according to the invention is incorporated; and - figures 13a, 13b, and 13c each show cross-sections of façade ornaments according to further embodiments of the present invention; - figures 14a-14f show various embodiments of façade ornaments according to the invention. Within these figures, similar reference numbers correspond to similar or equivalent elements or features. Figure 1 shows a façade ornament according to an embodiment of the present invention. 8pecifically, figure 1 shows a window sill including a body 10, a groove 11 on the bottom of body 10, and a top ridge 12. The body 10 may form most of the desired shape and aesthetic appeal of the window sill. Groove 11 may serve to channel water away from the building. Top ridge 12 may assist, as a structural element, in incorporating the window sill in a wall. For example by being inserted in a bottom groove of a window frame. Other façade ornaments also according to the invention are shown in figures 14a-14f. Figure 2 shows a flow chart for a method for manufacturing such a façade ornament according to the invention. The method includes forming an ornament core 2 enveloped by one or more resin impregnated fibre sheets in an ornament-shaped cavity 100, substantially filling said cavity 100 (81). The method further includes forming an ornament shell 3 by hardening, when in the cavity 100, the one or more resin impregnated fibre sheets (82). Ornament core 2 may be made of a number of materials. For example, core 2 maybe made of a foamed polymer. This type of material is lightweight yet strong. The foamed polymer may include one or more types of polymers, such as PET, polyurethane, polyisocyanurate, expanded polypropylene (EPP), polyether sulfone, polyethylene, polystyrene, thermosetting-based materials, thermoplastic-based materials, polymethacrylimide (PMI), or closed-cell thermoplastic polymer foams. The polymers may also be recycled, either from industrial processes or from consumer products. These polymers offer a combination of strength, flexibility, and resistance to weathering, making them suitable for use in the facade ornament 1. In a further example, core 2 may be made of organic materials, such as cork. 8pecifically, core 2 may be at least partially made of a compound based on an expandable organic material. In the context of this application, organic materials are considered expandable when, under the effects of heat and / or pressure, they can be urged to increase in size, up to a multitude of times their original size. Said multitude being, for example, at least 1.5 times their original size, preferably at least 2 times. An example of an expandable organic material is corn. ln some embodiments, ornament core 2 is made from a corn-based composite. Such a composite may include at least 30 percent corn and / or popcorn fragments, and preferably at least 50 percent. Compounds based on an expandable organic material may further include binding agents, either synthetic and / or natural. Compounds based on an expandable organic material may also further include filler materials, preferably organic filler materials. Examples thereof are lignocellulose material such as wood, straw, hemp or flax. Such filler materials may be included to reduce costs, or if sufficient expansion can be achieved with less than 100 percent expandable organic material. The resin impregnated fibre sheets that are to be hardened to form shell 3 can also be made of a number of materials. Alternatively phrased, shell 3 can also be made of a number of materials. ln some embodiments, the resin impregnated fibre sheets are a fibre sheets at least partially impregnated with a resin. ln some embodiments, the resin is specifically a bio-based resin. A shell made with such resins is not very flammable and generally has good fire-retardant and fire-protective properties. The resin serves to bind the fibres together and form a solid, cohesive structure. ln some embodiments, the resin is a crosslinked polymeric resin system. 8pecifically, the resin system may comprise polyfurfuryl alcohol (PFA) resin. PFA resins have a high thermal stability and resistance to chemicals. The fibre sheet may include inorganic fibres, such as glass fibres, metal fibres, or polyester fibres. These inorganic fibres provide strength and rigidity to the resin impregnated fibre sheets, enhancing the structural integrity of the façade ornament 1. ln other cases, the fibre sheet may include organic fibres, such as hemp, jute, or flax. These organic fibres offer a sustainable and eco-friendly alternative to inorganic fibres, without compromising the strength and durability of the façade ornament 1. The use of organic fibres also contributes to the lightweight nature of the façade ornament 1, making it easier to handle and install. Figure 3 shows a number of ways that fibres may be combined to form a fibre sheet. The act of combining fibres this way may be referred to as enmeshing, weaving and / or interlacing. The resulting sheet may be referred to as a particular weave. The sheets discussed in relation to figure 3 are considered woven sheets. The skilled person will appreciate that for the invention, non-woven fibre sheets may also be used. In this application, sheets are described having two fibre directions. Each of the weaves shown in figure 3 does, and more specifically, therein these directions are perpendicular to each other. The skilled person will appreciate that sheets can also have one fibre direction, which are called unidirectional. ln such sheets, the resin assists in keeping the fibres together. Sheets can also have more than two fibre directions. The skilled person will also appreciate that it is also possible to have weaves with fibre directions that are not perpendicular to each other. ln some embodiments, in a fibre sheet with two fibre directions, these two fibre directions are at about a 45 degree angle with respect to each other. In a directional weave, one fibre direction is formed with more and / or stronger fibres are used. In a uniform weave, an equal amount and / or equally strong combination of fibres is used for each direction. Further characteristics may depend on how the fibres (or strands made of those fibres, for that matter) are interlaced. If the fibres are interlaced in pairs, for example, that is referred to as a basket weave. The orientation of the fibre directions in façade ornament 1, or, alternatively phrased, the orientation of the fibre directions with respect to ornament core 2, also influence the strength of facade ornament 1. ln some embodiments, one of the fibre directions is aligned with an edge of ornament core 2. Preferably, the desires alignment is considered with respect to the longest edge or edges of core 2. The other fibre direction is then perpendicular to this edge. Alternatively phrased, the fibre directions may be said to be at 0 and 90 degrees with respect to an edge of ornament core 2. ln further embodiments, the sheets may be arranged on ornament core 2 in such away that the fibre directions are at an angle with the edges, such as at a 45 degree angle. Alternatively phrased, the fibre directions may be said to be at -45 and 45 degrees with respect to an edge of ornament core 2. ln embodiments in which core 2 is enveloped by two layers of fibre sheets, said sheets may be arranged at an angle with respect to each other. The fibre directions of the layers may be, for example, at a 45 degree angle with respect to each other. The abovementioned alignments may assist in providing a shell 3 for ornament 1 that is more resilient against bending, breaking, kinking or rotating. The skilled person will appreciate that, instead of aligning the fibre directions with an edge of the ornament core, it is also possible to align them with other identifiable axes and / or dimensions. The fibre directions may also be aligned with respect to a lengthwise axis of core 2, or the longest dimension of core 2, for example. Alignments between two layers of fibre sheets may be combined with the abovementioned alignments of a layer with respect to the ornament core. ln some embodiments, individual resin impregnated fibre sheets comprise more than one layer of fibres. These layers may be the same or may be different. These layers may have different thicknesses, types of weaves, or coarseness. For example, a sheet may have a first layer that is coarser than a second layer. Alternatively phrased, the second layer may be finer than the first layer. In this case, it is preferred that the sheet is arranged on core 2 such that coarser layer is adjacent to core 2 and / or that the finer layer is arranged outward i.e. away from the core material. In a further example, a sheet may have a first layer having more fibre directions than the second layer. For example, the first layer may have four fibre directions and the second layer may have one or two. It is preferred that the sheet is arranged on core 2 such that the layer with the least fibre directions is arranged outward. The skilled person will appreciate that how the resin impregnated fibre sheets hardens or can be hardened, depends on the resin used. Throughout the description, hardening will be mostly discussed as hardening through heating of the resin impregnated fibre sheets. The skilled person will appreciate that some resins set over time, in which case heating can still be useful but is not necessary. Waiting may suffice. Sometimes, multiple component resins are used which also harden over time, but only once mixed. Step S1, forming an ornament core 2 enveloped by one or more resin impregnated fibre sheets in an ornament-shaped cavity 100, substantially filling said cavity 100, may be implemented in various ways. Specific embodiments thereof are shown in figures 4 and 7. Figure 4 shows an embodiment of step S1. In this embodiment, the ornament core is formed by shaping core material (81 a-1 ). The ornament core is then enveloped with one or more resin impregnated fibre sheets (S1a-2). Ornament core 2 and enveloping one or more resin impregnated fibre sheets are then arranged in ornament-shaped cavity 100 (S1a3). lntermediate products that may be present when performing the method shown in figure 4 are shown in figures 5 and 6. Therein, ornament core 2 and the resin impregnated fibre sheets ultimately forming shell 3 are shown. Shaping of the core material (S1a-1) can be achieved in various ways. ln some embodiments, a previously manufactured body of core material is provided and parts thereof are removed such that the desired shape of ornament core 2 remains. ln some embodiments, core material itself may be shaped as described in steps 81 b-2 and S1b-3 of figure 7, without fibre sheets present. This approach is also called pre- moulding. Enveloping the ornament core (S1a2) can also be implemented in a number of ways. Resin impregnated fibre sheets are generally flexible and can be wrapped and / or folded around core 2. ln some embodiments, a resin impregnated fibre sheets is cut in the shape of a contour blank or a blank, and folded around the ornament core. The skilled person will appreciate that a blank is a piece of fibre sheet that includes the shapes of surfaces of ornament core 2, connected to each other such that it can be folded around core 2 such that these shapes cover the corresponding core surfaces. (The blank can include all surfaces of the ornament core, some of them but not all, or just one surface of the ornament core.) The blank, when folded around the ornament core 2, may at various positions overlap with itself. These overlapping portions allow for the blank to merge with itself when being hardened in step S2. Enveloping core 2 can also be achieved using multiple blanks that overlap with themselves and with each other. ln specific embodiments, overlap between the individual blanks is not necessary. Abutting edges of fibre sheets 3 may also merge together to form shell 3. ln specific embodiments, blanks are at least partially pre-hardened before being arranged on core 2. This gives the blank more structural integrity and makes them easier to handle. This is particularly advantages to cover surfaces that are flat. Such structural integrity may also be achieved by attaching blanks to support plates, for example plates made of wood, or fully hardened resin impregnated fibre sheets. Other organic materials may also be used for the support plates ln some embodiments, these support plates are then also enveloped by the fibre sheets, along with core 2, and end up as part of facade ornament 1. ln further embodiments, the support plates are merely used to assist in enveloping core 2 in the sheets and removed before the sheet is hardened to form the shell. ln specific embodiments, blanks are both pre-shaped and pre-hardened. That is, blanks may be folded and at least partially hardened before being arranged on core 2. As shown in figure 5, in the example where the façade ornament is a windowsill, blanks may be cut, folded and hardened to form a cap or cover for a distal end. lnstead of cutting, the caps may also be manufactured by deep drawing and then hardening the resin impregnated fibre sheet. Deep drawing may be used with both woven and non-woven sheets but is better suited for non-woven fibre sheets, as these stretch more and / or in more directions than woven sheets. These pre-made caps or covers can be made-to-shelf, and therefore reduce the amount of time necessary to complete made-to-order components in which they can be used. These pre-made caps are also convenient because they can be made before the final design of the facade ornament is known. In the example that the façade ornament is a window sill, pre-made caps, such as the one shown in figure 5, can be used regardless of the length of the window sill core that is to be covered. Embodiments are also conceivable in which such pre-made caps or covers are made of other materials than the resin impregnated fibre sheets. The caps may also be made of a fire retardant and / or heat resistant organic or inorganic material. The caps may also be injection moulded. In a specific embodiment, in which the façade ornament is a windowsill, ornament core 2 may be enveloped by three blanks: One for each of the distal ends and a third for the rest of core 2. The two blanks covering the distal ends include parts with the same shape and size as the distal ends and may include sections extending from said part, intended to be folded around core 2 to overlap with the third blank. These two blanks used to cover the distal ends may be pre-processed e.g. pre-hardened, etc. in the manners discussed above. The third blank includes parts with the same shape and size as the remaining surfaces of core 2. The third blank is wrapped and / or folded around core 2, arounds its longitudinal axis. . In this embodiment specifically, the third blank is effectively a rectangle and therefore easier to manufacture. Embodiments are also conceivable in which these overlapping extensions are included in the third blank, or both the two blanks used for the distal ends, as well as the third blank. In a specific embodiment in which these overlapping extensions are included in said blank, the two blanks covering the distal ends may also be implemented as just the support plates. In this case, the ornament core is enveloped using both the resin impregnated fibre sheets and support plates. The support plates may be made of a material that can merge and / or fuse with the resin impregnated fibre sheets, other than said sheet itself. During the step of hardening the one or more resin impregnated fibre sheets, said sheet(s) may fuse and / or merge with the support plates to create shell 3. This fusing and / or merging may create a seamless shell 3 similar to the one created when only resin impregnated fibre sheets are used. In a further specific embodiment, in which ornament cores are used that have, along an axis, such as the lengthwise axis, a continuous cross-section, ornament cores are provided that are elongated along said axis. 8ides of the elongated core parallel to said axis may be covered with fibre sheets, for example by application of rolls. This partially enveloped elongated core can be made ready-to-shelf. When an enveloped ornament core, for example for step S1 a-3, is to be provided, this partially enveloped elongated core can be cut to the desired lengths. Then, only the distal ends of said ornament 2 still have to be covered. This may be done, for example, using one of the approaches mentioned above. This approach reduces the time necessary to create a made-to-order product. An example of a facade ornament for which this approach is particularly advantageous is the window sill. In the above example, discussing step 81a-2, ornament core 2 is provided with sheets that are already impregnated with resin. Such sheets are also referred to as pre-impregnated fibre sheets, or prepreg for short. Prepreg is sold on rolls per linear metre, which makes it convenient to use. The skilled person will appreciate that it is also possible to envelop ornament core 2 with just fibre sheets, meaning fibre sheets that are not yet impregnated. Such sheets are also referred to as naked fibre sheets. These fibre sheets are then impregnated with resin after being arranged on core 2. For example by arranging the enveloped core 2, together with an adequate amount of resin, in a vacuum bag. By applying a vacuum, the resin is urged into the space between the fibres of the fibre sheet. Alternatively phrased, vacuum may be used to impregnate the fibre sheets with resin. This approach may be used for any type of facade ornament but is particularly useful for complex shapes, around which prepeg may be difficult to wrap. Figure 7 shows a further an embodiment of step S1. In this embodiment, the one or more resin impregnated fibre sheets are arranged in the ornament-shaped cavity (81b-1). The core material is inserted in between the one or more resin impregnated fibre sheets, substantially filling the cavity (81b-2). The ornament core is then formed by hardening, when in the cavity, the core material (81b-3). A schematic representation of this process is shown in figure 8. Therein, a cross-section is shown of a two-piece mould 20, including a bottom part 24 and an upper part 23, which provides the ornament shaped cavity. Inside mould 20, one or more resin impregnated fibre sheets 3 are arranged. A core material 2-1 is injected between said one or more resin impregnated fibre sheets 3. The core material 2-1 may also be inserted between said sheets using other techniques. When the core material 2-1 fills the ornament shaped cavity, it pushes the sheets 3 outward and against the mould 20. This assists in bringing and / or keeping the sheets 3 in position for when they are eventually hardened in step S2. Hardening of the core material may cause it to bond together and harden, forming the ornament core. Having substantially filled the cavity, the ornament core takes on the shape of said cavity. Hardening of the core material may be achieved by heating it. It will be discussed throughout this description mostly as such. However, the skilled person will appreciate that other approached to hardening the core material are possible as well. Depending on the core material, it may also be hardened by letting it set over time. The skilled person will appreciate that what other ways of hardening may also be used depends on the core material. The core material may be a granular and / or particulate core material 2-1, or may even be fluid. Each of these forms allow for the core material, when being injected in between the resin impregnated fibre sheets in mould 20, to the shape of the cavity 100, ensuring a precise fit for the resulting the ornament core. In a preferred embodiment, the core material is an expandable material. The core material may be any one of the earlier mentioned a foamed polymers, for example. The core material may also be the earlier mentioned expandable organic material, or any one of the specific embodiments thereof. During step 82, when hardening, when in the cavity, the one or more resin impregnated fibre sheets, the sheets bond together, forming the shell 3 that envelops the ornament core 2. The shell 3 may provide structural integrity, as well as a durable and weather-resistant exterior for the façade ornament 1. Step S2, forming the ornament shell 3 by hardening, when in the cavity, the one or more resin impregnated fibre sheets, may be implemented using various techniques. These techniques may rely on conduction, convection or radiation. These techniques may include the use of ovens and / or steam. In a preferred embodiment, the sheets are heated by subjecting them to electromagnetic radiation, such as radio waves (with frequencies below about 300 MHz) or microwaves (with frequencies between about 300 MHz and about 300 GHz). The electromagnetic waves penetrate and heat the resin impregnated fibre sheets. This technique provides relatively uniform heating of the sheets, ensuring a consistent and high-quality result. ln some embodiments, the heating of the one or more resin impregnated fibre sheets and the heating of the ornament core 2 are performed at the same time. This allows the sheets and core to melt together and form a strong bond. This simultaneous heating may also improve processing time as well as energy efficiency. Figures 9 and 10 show a mould 20, including a bottom part 21 and upper part 22, that may be used to provide the ornament-shaped cavity. The skilled person will appreciate that this is a mould for manufacturing a window sill and that for other specific shapes of the façade ornaments other moulds may be provided. On opposite ends of mould 20, separation panels 26 may be included. These may assist in removing the facade ornament from mould 20, for example when multiple enveloped cores are arranged inside mould 20 at the same time, side to side. The skilled person will appreciate that the ornament core 2 and one or more resin impregnated fibre sheets may be said to substantially fill cavity 100 when they snugly fit therein. A snug fit means that there is some clearance around facade ornament 1, or at least enough to remove it from bottom part 21, but not so much that the resin impregnated fibre sheets can sag, peel away, or otherwise separate from ornament core 2. ln some embodiments, mould 20 comprises adjustable inner surfaces. Such adjustable inner surfaces may be used to form the desired ornament shaped cavity. ln some embodiments, these inner surfaces can also be used to press the fibre sheets against the ornament core and / or core material, preferably when said sheets are hardening and / or being heated. Providing pressure from one or more sides may improve the attachment of shell 3 onto core 2. In a preferred embodiments, the fibre sheets are pressed onto core 2 from at least two opposing sides. In a more preferred embodiment, the fibre sheets on all sides are pressed onto core 2. Adjustable inner surfaces may also be used to form and / or adjust the ornament shaped cavity. ln some embodiments, this function of the mould is assisted by applying pressure to the mould from one or more outsider sides. This may be done mechanically, or achieved using a vacuum. In a specific embodiment, mould 20 is arranged inside a vacuum bag. By providing a vacuum in this way, the parts 21 and 22 are pushed together. The vacuum bag with the mould inside, may, in turn, also be placed in a high-pressure environment such as an autoclave. Alternatively and / or additionally, some or all of the individual walls or wall parts of the mould may be adjustable to press the resin impregnated fibre sheets against the ornament core. Said mould 20 with a facade ornament 1 in the making arranged therein, is shown in figure 9. A cross-section of mould 20 of figures 9 and 10 is shown in figure 11. In some embodiments, the step of forming an ornament shell 3 by heating, when in the cavity 100, the one or more resin impregnated fibre sheets, is applied to more than one enveloped ornament core at the same time. A plurality of enveloped ornament shells may be arranged, side by side, in mould 20 and divider panels may be arranged in between adjacent enveloped ornament cores 2. This may, for example, be applied when relatively short facade ornaments are made. This improves the throughput of this method and thereby its efficiency. Embodiments are also conceivable in which the ornament shaped cavity is provided without a mould and with a vacuum bag. Specifically, in embodiments in which the ornament body is shaped before being wrapped in the one or more resin impregnated fibre sheets, the structural integrity of such an ornament body, in combination with the inward pressure of the vacuum bag, keep the resin impregnated fibre sheets in place. The vacuum bag then shapes itself around the core and the resin impregnated fibre sheets to form the ornament shaped cavity. The vacuum bag with ornament core and resin impregnated fibre sheets may, in turn, also be placed in a high-pressure environment such as an autoclave and / or be heated. Facade ornament 1 according to the invention may also be a combined ornament, such as a corner element. The invention further provides for a method for manufacturing a combined ornament and, specifically, for a corner element. The method includes manufacturing at least two intermediate ornament parts, each using a method also disclosed in the application for example the method shown in figure 2 - and attaching these intermediate ornament parts to each other preferably at an angle. In a specific embodiment, one or both of the intermediate parts may be cut, such that a section thereof is removed, resulting in a side via which the core material is exposed. These cut open intermediate parts may then be attached to each other by, for example, use of a glue, a tape, or a kit. These cut open intermediate parts may also be attached to each other by adjoining the exposed core material sides, covering the resulting seam in one or more sections of resin-impregnated fibre sheets, and heating said sections of sheet. By heating said sections of sheet, they may attach to and / or fuse with both of the shells of the intermediate ornament parts. These cut open intermediate parts may also be attached to each other by adjoining the exposed core material sides and arranging a section of resin impregnated fibre sheet in between. In a further specific embodiment, the intermediate ornament parts may be manufactured such that one or both of them already has a surface at a desired angle. This may be achieved by forming ornament core 2 in the corresponding shape and forming shell 3 around said core 2. As alternative or in addition to the earlier mentioned use of a mould 20 with adjustable inner sides, which can be adjusted to form ornaments 1 with sides at the desired angle, it is also possible to provide the ornament shaped cavity by placing an insert in mould 20. Said insert may then define at least a part of the ornament shaped cavity. Use of such inserts reduced the different types of mould necessary to create multiple types of facade ornaments 1. In these embodiments specifically, the angled surfaces of the intermediate ornaments that are to be adjoined are already covered in resin impregnated fibre sheets. These intermediate ornaments may be attached by adjoining said angled surfaces and heating said angled surfaces. By heating said angled surfaces, they may attach to and / or fuse with the fibre sheet 3 / shell 3 of the other intermediate ornament part. Facade ornament 1 may be finished with various further steps. A possible further step is sanding of the ornament shell 3 to smoothen its surface, removing any irregularities or imperfections that may have formed. This results in a smooth and aesthetically pleasing surface, enhancing the overall appearance of the facade ornament 1. Another possible further step is colouring the ornament shell 3. This may be achieved by applying a coating to shell 3, ideally with a bio-based coating derived from renewable resources. Such coatings are sustainable and eco- friendly choices for the façade ornament 1. The coating may be a paint layer or a lacquer, depending on the desired appearance and performance characteristics of the façade ornament 1. The coating may also be a direct to metal or DTM paint. A specific example of a possible coating is plaster, which provides a possibly desired colour and also a structure, resulting in a façade ornament with specifically a concrete look. Other coatings that provide both colour and structure are also possible. ln some embodiments, a coating layer is applied to the façade shell 3 after sanding. Coatings might be applied by spraying them onto shell 3. Alternatively and / or additionally, what is sometime called a gelcoat may be provided on the inside of the cavity before the one or more resin impregnated fibre sheets are arranged therein. When said sheets are hardened during step S2, they may at least partially absorb the gelcoat, resulting in a coating layer on the outside of facade ornament 1. Alternatively and / or additionally, dyes and / or pigments may be included in the resin with which the fibre sheets are impregnated. The skilled person will appreciate that it is possible to combine the various colouring methods, and that it is also possible to include just one or even none of them in the method. In a specific embodiment, the façade ornament comprises a core made of a corn- based composite, said composite comprising corn and / or popcorn fragments, and a shell, made of a fibre sheet at least partially impregnated with a resin, wherein the shell envelops the core. This type of ornament may be manufactured especially efficiently. Heating of the core material and the resin impregnated fibre sheets that are to form the shell may be performed simultaneously. Said heating urges the corn-based composite to expand, pushing the resin impregnated fibre sheets outward, against whatever surfaces are used to provide the ornament-shaped cavity. The heat hardens the resin impregnated fibre sheets at the same time, so it is more likely that the resulting shell attaches to the core and / or is one that snugly fits the ornament-shaped cava. It is possible to use a previously provided body of corn-based composite and shape it, similar to what is described in relation to step 81a-1. Such a core, while already a stable product in itself, when heated, or alternatively said, reheated, during step S2 may also provide some expansion, and albeit less, sufficient for some applications. It is also possible to inject corn-based composite as particulate material in between the one or more resin impregnated fibre sheets to fill the cavity (i.e. implement step 81 using the method of figure 9). Using this method, the core material may expand more and may provide more outward pressure on the resin impregnated fibre sheets. For this embodiment specifically, it is preferred to implement the heating step(s) (i.e. steps 81 b-3 and S2) by applying radio waves to the ornament core 2 and resin impregnated fibre sheets that are to form the shell when inside said cavity. This ensures a relatively uniform heating within the core material and therefore a relatively uniform outward expansion. In addition to the above, façade ornament 1 may be provided with further components assisting its incorporation into a wall or window. Figures 13a shows an embodiment in which the facade ornament 1 includes an adjustable support element 4. Said element includes an adjustable leg, itself attached to a bottom surface of the shell 3, and a support surface 4-2, facing away from the bottom surface of the shell 3, and in turn attached to the leg 4-1. This allows for fine- tuning of the position of the facade ornament 1, ensuring a perfect fit on the building facade. ln some embodiments, the length of leg 4-1 can be adjusted and as such the distance between the support surface 4-2 and shell 3 may be changed. ln some embodiments, the orientation of support surface 4-2 with respect to leg 4-1 and / or the orientation of leg 4-1 with respect to shell 3 can be adjusted and as such the mutual alignment between the support surface 4-2 and shell 3 may be changed. ln some embodiments, the adjustable support element 4 may be configured to pivot or rotate relative to the shell 3. This adjustable support element allows the facade ornament 1 to conform to irregular or curved surfaces on the building facade, providing a secure and aesthetically pleasing installation. Embodiments are also conceivable in which the adjustable support element is provided on the rear, or on the side of the ornament. The ornament 1 may also comprise a plurality of support elements, arranged all on the same side or on varying sides of the ornament. The skilled person will appreciate that it is possible to provide a support element to the facade ornament 1 at various stages of the manufacturing process. The element 4 may be provided after the steps shown in figure 2. The support element may, for example, be attached by drilling a hole in the shell and anchoring one end of leg 4-1 therein. Alternatively one end of leg 4-1 may be glued to the shell. Providing element 4 after the steps shown in figure 2 allows for somewhat better control of placement of the element 4, as the manufacturing of the other components is then already complete and the result unlikely to change. Embodiments are also conceivable in which at least part of the support element 4 is provided during the steps shown in figure 2. ln some embodiments, at least a part of element 4 e.g. leg 4.1 or possibly all of element 4 is arranged in cavity 100 together with the resin impregnated fibre sheets and ornament core, when said sheets are being hardened. The sheets may harden around part of element 4 and provide a strong connection between said part of element 4 and shell 3. In this way, element 4 can be connected to shell 3 without risking negatively affecting the structural integrity of the latter. Figure 13b shows an embodiment in which the facade ornament 1 is provided with two pairs of Velcro layers 5-1, 5-2, 5-3, 5-4. ln each of these pairs, the inner Velcro layers 5-2 or 5-3 are fixedly attached to the facade ornament 1. The outer Velcro layers may be fixedly attached to surfaces surrounding the installation side of the facade ornament 1, and be removeably attached, via their Velcro side, to the inner Velcro layers. Figure 13c shows an embodiment in which the facade ornament 1 is provided with two pairs of snap-fit mounting parts 6-1, 6-2, 6-3, 6-4. ln each of these pairs, the inner snap-fit mounting parts 6-2 or 6-3 is fixedly attached to the facade ornament 1. The outer snap-fit mounting parts 6-1 or 6-4 may be fixedly attached to surfaces surrounding the installation side of the facade ornament 1, and be removeably attached, via their snap-fit side, to the inner snap-fit elements. Embodiments are also conceivable in which the inner mounting part is provided during the steps shown in figure 2. For example the inner snap-fit mounting part 6-2 may be arranged in cavity 100 together with the resin impregnated fibre sheets and ornament core, when said sheets are being hardened. The sheets may harden around this mounting part and provide a strong connection between said mounting part and shell 3. In this way, mounting parts can be connected to shell 3 without risking negatively affecting the structural integrity of the latter. The skilled person will appreciate that all kinds of tabs, hooks, eyelets, and other fastening components, suitable for fixing the ornament to its surroundings, may be arranged in the cavity when the fibre sheets are hardening. These fastening components may be considered baked into the shell. Use of other mounting parts is also conceivable, such as slide-in mounting parts. Use of such mounting parts allows for further pre-manufacturing, also called pre-fab, of the façade ornament itself, as well as the architectural structure it is to be incorporated in. Fixedly attaching a mounting part with, e.g. an adhesive or a screw, can take more time and is therefore preferably performed in an environment more controlled than the average building site, such as a factory hall or workshop. Fixedly attaching the mounting parts there reduced the time spend assembling on the building site. Figure 12 shows a cross-section of a part of a wall in which a façade ornament according to the invention is incorporated. 8pecifically, figure 12 shows a section of a wall construed of an outer wall 101 also called a façade wall or façade for short, a middle wall 102, and an inner wall 103. Also shown in figure 12 are a window frame 105, a horizontal indoor sill 104, and a window pane 106. In this figure specifically it is shown that the window sill may include a bottom section 31, a rear section 32, a front section 33, and a top section 34. The bottom section 31 extends between its front end and its rear end, providing a stable base for the window sill. The front section 33 extends perpendicularly from the front end of the bottom section 31, while the rear section 32 extends perpendicularly from the rear end of the bottom section 31. The rear section 32 extends farther upward from the bottom section 31 than the front section 33. The section 34 of the window sill inclines downwards from the rear section towards the front section. Alternatively said, the top section 34 inclines upwards from the front section 33 towards the rear section 32. This inclined design aids in directing water away from the window, preventing water damage to the building's interior. A part of the rear section 32 that extends upwards beyond the highest point of the top section 34 is referred to as the upper part of the window sill or the top ridge 12. In this embodiment specifically, this upper part 35 does not include a part of the core. It is simply formed by a double shell layer. This double layer may be formed from one outer end of the sheet covering the top section and one outer end of the sheet covering the rear. ln some embodiments, this double layer is formed from two outer ends of one contour blank that is wrapped around the ornament core 2. Alternatively phrased, the double shell layer is formed by two layers of shell adjacent and directly attached to each other. As shell 3 is hardened, making this upper part 35 therefrom does not weaken the structural integrity while requiring less core and / or a less complex shape of core. Therefore a window sill with this type of upper part or top ridge 12 can be manufactured with method according to the invention more reliably. This upper part may function as the aforementioned top ridge 12. While in this figure the window sill is attached to facade wall 101 via an adhesive layer 7, other approaches to incorporating this façade ornament into a wall are also possible, as was also discussed in relation to figures 13b and 13c. The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts, including inventive details, may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application and / or alternative embodiment. It will also be apparent that the invention is not limited to the working examples 5 shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.

Claims

1. A method for manufacturing a façade ornament, comprising: the formation of an ornamental core encased by one or more with resin impregnated fiber sheets, in an ornamental cavity, with which the cavity is mainly filled; the formation of an ornamental shell by hardening one or more resin-impregnated fiber sheets, when in the cavity.

2. The method according to conclusion 1, whereby the formation of the ornamental core enveloped by one or more resin-impregnated fiber sheets in the ornamental cavity comprises: shaping core material to form an ornamental core; the encasing of the ornamental core with one or more with resin impregnated fiber sheets; arranging the ornamental core and the surrounding one or more with resin impregnated fiber sheets in a hot cavity.

3. The method according to claim 1 or 2, whereby the formation of the ornamental core encased by one or more resin-impregnated fiber sheets in the ornamental cavity comprises: arranging the one or more resin-impregnated fiber sheets in the cavity; the insertion of core material between the one or more with resin impregnated fiber sheets, with which the hot cavity is mainly filled is becoming; the hardening of the core material to form an ornamental core, when in the cavity.

4. The method according to conclusion 3, whereby the hardening of the core material, when in the cavity, involves heating the core material.

5. The method according to conclusion 3 or 4, whereby the hardening step of the one or more resin-impregnated fiber sheets, when in the cavity, and the hardening step of the core material, when in the cavity, simultaneously are carried out.

6. The method according to one of conclusions 1-5, whereby the ornamental cavity is provided by the use of a mold.

7. The method according to one of conclusions 1-6, whereby the hardening of the one or more resin-impregnated fiber sheets, when in the cavity, the involves heating one or more resin-impregnated fiber sheets.

8. The method under claim 7, whereby the heating of one or more resin-impregnated fiber sheets the exposure of one or more resin-impregnated impregnated fiber sheets to electromagnetic radiation, such as microwaves or radio waves, includes.

9. The method in accordance with one of claims 1-8, further comprising the sanding the ornamental shell.

10. The method in accordance with one of conclusions 1-9, further comprising the coating the facade shell to form a coating layer, such as a paint layer or a lacquer coating 11. The method according to claim 10, whereby the coating layer a coating on is based on organic ingredients.

12. The method in accordance with one of conclusions 1-11, further comprising the attaching a first fastening part to the facade shell, whereby the first fastening part is designed to be securely attached to a second mounting part 13. Ornament according to claim 12, whereby the first and second fastening parts are Velcro, a click profile, or a sliding profile.

14. The method according to one of conclusions 1-13, whereby the resin a crosslink polymer resin system is, preferably comprising polyfurfuryl alcohol (PFA) resins.

15. The method according to one of conclusions 1-14, where the fiber sheet a is a fiber mat and / or comprises fibers, such as: inorganic fibers, preferably glass fibers, metal fibers, or polyester fibres; organic fibers, preferably hemp, jute, or flax.

16. The method according to one of conclusions 1-15, whereby the core at least one of the following includes: one or more types of foamed polymers, such as PET, polyurethane, polyisocyanurate, expanded polypropylene (EPP), polyethersulfone, polyethylene, polystyrene, polymethacrylamide (PMI), one or more thermosetting materials, thermoplastic materials, or closed-cell thermoplastic polymer foams, or organic materials, preferably expandable organic material, such as corn and / or popcorn.

17. The method according to one of conclusions 1-16, where the shell a includes the subsurface, and the method further includes: attaching an adjustable support element to the underside, where the adjustable support element comprises a support surface that of the the underside is turned away and where the adjustable support element is designed for adjusting a distance between the bottom surface and the support surface.

18. The method according to one of conclusions 1-17, whereby the a façade ornament is a windowsill, a window frame, a lintel, or a chimney cap.

19. A façade ornament manufactured according to the method of one of the conclusions 1-18.

20. A gable ornament, comprising: a core; a peel, comprising one or more fibrous sheets that are at least partially be impregnated with a resin; where the shell envelops the core.

21. Ornament according to claim 20, where the fiber sheet comprises fibers, such as: inorganic fibers, preferably glass fibers, metal fibers, or polyester fibers; organic fibers, preferably hemp, jute or flax.

22. Ornament according to claim 20 or 21, where the resin a is a crosslink polymer resin system, preferably comprising polyfurfuryl alcohol (PFA) resins.

23. Ornament according to one of claims 20-22, further comprising a coating layer, such as a paint layer or an lacquer layer.

24. Ornament according to claim 23, where the coating layer is a coating on is based on organic ingredients.

25. Ornament according to one of claims 20-24, further comprising a first fastening part that is permanently attached to the shell, whereby the first fastening part is designed to be permanently connected to a second mounting part 26. Ornament according to claim 25, where the first and second fastening parts are Velcro, a click profile, or a sliding profile.

27. Ornament according to claim 25 or 26, further comprising the second mounting part 28. Ornament according to one of claims 20-27, where the shell at least comprises a surface, the ornament further comprises an adjustable support element that is connected to at least one surface, whereby it is adjustable supporting element comprises a supporting surface that is turned away from at least one surface and where the adjustable support element is designed for adjustment of a distance between at least one surface and the support surface.

29. Ornament according to one of conclusions 20-28, where the facade ornament is a windowsill, a window frame, a |atei or chimney cap.

30. Ornament according to claim 29, where the facade ornament is a window frame is, where the shell comprises: a lower section, comprising a front end and a rear end; a substantially vertical front section, extending from the front end, Perpendicular to the subsection; a predominantly vertical rear section, extending from the rear end, perpendicular to the lower section, and / or parallel to the front section, extending further upwards from the lower section than the front section; an upper section, which slopes at least partially upwards from the front section to rear section.

31. Ornament according to claim 30, involving an upper part of the rear section extends upwards beyond a highest point of the upper section, whereby it above all comprises a double layer of skin, two layers of shell comprising those adjacent and preferably directly to each other are connected, and / or does not comprise part of a core.

32. Ornament according to claim 30 or 31, where the lower section has a groove includes that extends in a longitudinal direction along the ornament.

33. Ornament according to one of claims 20-32, where the core is at least includes one of the following: one or more types of foamed polymers, such as PET, polyurethane, polyisocyanurate, expanded polypropylene (EPP), polyethersulfone, polyethylene, polystyrene, polymethacrylamide (PMI), one or more thermosetting materials, thermoplastic materials, or closed-cell thermoplastic polymer foams, or organische materialen, bij voorkeur expandeerbaar organisch materiaal, zoals maïs en / of popcorn. 1 / 8 12 10 11 Fig. 1 Forming an ornament core enveloped by one or more resin impregnated fibre sheets S1 in an ornament-shaped cavity, substantially filling said cavity. Forming an ornament shell by hardening, when in the cavity, the one or moren resin S2 impregnated fibre sheets. Fig. 2

Images