AU2016226160B9

AU2016226160B9 - Panel

Info

Publication number: AU2016226160B9
Application number: AU2016226160A
Authority: AU
Inventors: Yaron GOLDSMITH
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-03-04
Filing date: 2016-03-03
Publication date: 2018-11-08
Anticipated expiration: 2036-03-03
Also published as: AU2016226160A1; US20180051471A1; GB2554207A; WO2016141212A1; GB201716036D0; AU2016226160B2

Abstract

The present invention relates to panels, panel systems and panel sealing elements, and may be useful for panels used in building. The invention may be particularly useful for panels used on existing walls to provide a desired structural appearance or effect. According to an aspect, the present invention provides a panel for providing a selected structural appearance, the panel comprising a support layer formed from a rigid material, an outer layer comprising elements which provide the selected structural appearance, the outer layer formed from a material different from the support layer material, and a mid-layer between the support layer and the outer layer, wherein the mid-layer allows for different thermal expansion and contraction rates of the support layer material and the outer layer material.

Description

US 2014/0134392 A1 US 2013/0097950 A1 US 3994105 A (12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT) (19) World Intellectual Property Organization

International Bureau (43) International Publication Date 9 September 2016 (09.09.2016)

(10) International Publication Number

International Patent Classification:

E04F13/08 (2006.01) B32B 3/10 (2006.01) E04B 1/61 (2006.01) E04B 2/92 (2006.01)

WIPOIPCT

WO 2016/141212 A1

E04C 2/284 (2006.01) E04F13/076 (2006.01) E04F13/14 (2006.01) (21) International Application Number:

PCT/US2016/020740 (22) International Filing Date:

March 2016 (03.03.2016) (25) Filing Uanguage: English (26) Publication Uanguage: English (30) Priority Data:

62/128,121 4 March 2015 (04.03.2015) US (72) Inventor; and (71) Applicant: GOLDSMITH, Yaron [US/US]; 2009-B Via Mariposa W., Laguna Woods, California 92637 (US).

HN, HR, HU, ID, IL, IN, IR, IS, JP, KE, KG, KN, KP, KR, KZ, LA, LC, LK, LR, LS, LU, LY, MA, MD, ME, MG,

MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO, NZ, OM, PA, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW, SA, SC, SD, SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, TN, TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW.

(84) Designated States (unless otherwise indicated, for every kind of regional protection available)·. ARIPO (BW, GH, GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, ST, SZ, TZ, UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU, TJ, TM), European (AL, AT, BE, BG, CH, CY, CZ, DE, DK, EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, LU,

LV, MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM, TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW, KM, ML, MR, NE, SN, TD, TG).

Declarations under Rule 4.17:

— as to applicant's entitlement to apply for and be granted a patent (Rule 4.17(H)) (74) Agent: ADEBIYI, Adenike; PO Box 1017, Cypress, Texas 77410 (US).

as to the applicant's entitlement to claim the priority of the earlier application (Rule 4.17(iii)) — (81) Designated States (unless otherwise indicated, for every kind of national protection available)·. AE, AG, AL, AM, = AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY, BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, DO, ^DZ’ ^EC’ ^EE> ^EG> ^ES’ ^FI> ^GB> ^GD’ ^GE> ^GH’ ^GM> ^GT’

Published:

— with international search report (Art. 21(3)) — before the expiration of the time limit for amending the claims and to be republished in the event of receipt of amendments (Rule 48.2(h)) (54) Title: PANEL

WO 2016/141212 A1 (57) Abstract: The present invention relates to panels, panel systems and panel sealing elements, and may be useful for panels used in building. The invention may be particularly useful for panels used on existing walls to provide a desired structural appearance or effect. According to an aspect, the present invention provides a panel for providing a selected structural appearance, the panel com prising a support layer formed from a rigid material, an outer layer comprising elements which provide the selected structural ap pearance, the outer layer formed from a material different from the support layer material, and a mid-layer between the support layer and the outer layer, wherein the mid-layer allows for different thermal expansion and contraction rates of the support layer material and the outer layer material.

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PCT/US2016/020740

PANEL

FIELD [0001] The present invention relates to panels, panel systems and panel sealing elements, and may be useful for panels used in building. The invention may be particularly useful for panels used on existing walls to provide a desired structural appearance or effect.

BACKGROUND [0002] Panels are used in building to provide a structural appearance or effect, for example, a weather board wall can be made to look like a brick wall by attaching panels having a brick or brick-like appearance or effect. Such panels may have a substrate onto which there is attached a number of brick or brick-like elements which are arranged to resemble a laid brick wall. In other examples, the appearance or effect may be for a regular or irregular stone wall, or other types of wall structure. Other types of panels may have a structural appearance or effect printed on them, or represented some other way. Often the structural appearance or effect can seem artificial as the material used for appearance or effect or the technique of applying the material can be inferior. An artificial looking appearance or effect is undesirable as many people want to have something closely approximating the real appearance of a particular structure.

[0003] Such panels are typically regularly shaped, for example, squarely or rectangularly shaped, to allow a number of panels to be readily used together to cover a wall surface. The panels abut each other so as to try to form a continuous structural pattern. However, the seams between each of the panels are usually readily visible so that the appearance or effect is negatively impaired. This may be particularly problematic where the structural appearance or effect is for a brick pattern, for example, an alternating off-set row pattern, such as a stretcher bond laid brick pattern. At the juncture of two half bricks along the seam, there will be an appearance of a split brick.

[0004] A similar problem arises where the panels meet at a corner. For example, the corner bricks will appear as if they have a split due to the seam between a panel on

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PCT/US2016/020740 the wall on one side adjacent the corner and another panel on the wall on the other side adjacent the corner. The split appearance can worsen with time, as the gap along the seam can widen or become uneven.

[0005] Another problem with existing panels is that the substrate and the elements making the structural appearance or effect have different thermal expansion and contraction rates. The substrate may be subject to faster expansion in hot conditions, or may be subject to greater overall expansion in such conditions than the structural elements. Conversely, the substrate may be subject to faster contraction in cold conditions, or may be subject to greater overall contraction in such conditions than the structural elements. This can lead to cracking and other failures in the panels.

[0006] A further problem with existing panels is a lack of structural integrity, or a weak attachment to the wall. In harsh weather conditions, such as very high winds, the panels can snap, delaminate, bend, or become partially or fully detached from the wall. This lack of structural integrity can be due to inferior materials, or inferior structure of materials. The detachment from the wall may be due to poor attachment mechanisms, poor adhesive, or adhesive being poorly applied to the panels.

[0007] Some existing panels have tried to solve problems with strength by using stronger materials, but this may unacceptably increase the weight of such panels, thus limiting their use in many circumstances.

[0008] Some methods of attaching panels have problems, including lack of strength and/or durability. Some attachment methods can be difficult to use, unreliable or messy. Further, the existing attachment methods may have the problem that the panels are subject to reproducing defects in the wall to which they are attached. Such defects include unevenness of the wall surface or curvature. The panels are attached to the wall using means that are independent of attachment means for others of the panels. This results in the panels being subject to local defects in the wall. This can cause the panel to be misaligned from other adjacent panels. Where the wall has sufficiently localized curvature, the panels may also repeat this defect, and this can also cause misalignment.

[0009] Yet another problem in existing panels is the inability to choose an alternative appearance for the structural appearance or effect in a given panel. The panels will be provided in a given colour and pattern, but this colour and pattern is not

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PCT/US2016/020740 alterable by a user at time of installation. This can be limiting where it is desired to have new and varied structural appearances or effects where using a given panel.

[0010] Other problems with some existing panels include flammability (or lack of ability to retard fire), colour fading, corrosion, lack of resistance to scratching, lack of resistance to impact damage, and lack of resistance to other physical damage, lack of flexibility (not appropriate for areas prone to seismic activity or high wind), or too much flexibility (these panels have a tendency to bend in high wind conditions, and do not provide any structural strengthening to a wall), along with other structural and aesthetic defects and shortcomings.

[0011] Further problems exist with panel systems, for example panel systems for forming wall structures in buildings, where the seals between the panels in the structure are prone to leak when subjected to precipitation, or are not sufficiently windtight, and therefore cannot provide adequate wind protection. Moreover, unsealed or inadequately sealed panels may not provide thermal and/or sound insulation, which may be required in areas where a building is located, such as particularly hot or cold areas, or areas subject to a lot of noise.

[0012] Previously, panels used, for example, to form structures in buildings, may have seals between those panels which are obvious to an observer when the panels have been installed. Such obvious seals between panels may create an unacceptable and unsightly appearance to a building. It may therefore be desirable to have a sealing system, suitable for panels, which allows for panels to be adequately sealed for protection against, for example, precipitation, wind, thermal leaking, and noise, and wherein the sealing system for the panels is not obvious to an observer looking at the installed panel system.

[0013] There is a need to overcome, or at least ameliorate, at least one of the abovementioned problems in the prior art, and/or to overcome, or at least ameliorate, at least one problem in the prior art, which has not been mentioned above and/or to provide at least useful alternative to prior art devices, systems and/or methods.

BRIEF SUMMARY OF THE INVENTION [0014] According to an aspect, the present invention provides a panel for providing a selected structural appearance, the panel comprising a support layer formed from a

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PCT/US2016/020740 rigid material, an outer layer comprising elements which provide the selected structural appearance, the outer layer formed from a material different from the support layer material, and a mid-layer between the support layer and the outer layer, wherein the mid-layer allows for different thermal expansion and contraction rates of the support layer material and the outer layer material.

[0015] In an embodiment, the support layer includes a honeycomb substrate and a backing sheet for the honeycomb substrate.

[0016] In an embodiment, the backing sheet and honeycomb substrate are formed from aluminum.

[0017] In an embodiment, the mid-layer includes a fiberglass sheet.

[0018] In an embodiment, the mid-layer includes an aluminum sheet.

[0019] In an embodiment, the selected structural appearance comprises a plurality of regular shaped elements having a periodic tessellated pattern.

[0020] In an embodiment, the elements are rectangular brick-like shapes and the pattern comprises an alternating off-set row brick pattern.

[0021] In an embodiment, the pattern comprises a brick stretcher bond pattern.

[0022] In an embodiment, two opposing sides of the panel comprise complementary toothed shapes such that, when one panel is placed next to another like panel the shape of adjacent sides of the panels form a finger joint to provide a continued alternating offset row brick pattern.

[0023] In an embodiment, the panel is configured so that the finger joint comprises a gap, wherein the gap is adapted to be fillable to produce a grout-like or mortar-like line. [0024] In an embodiment, the grout-like or mortar-like lines comprise a polymer.

[0025] According to an aspect, the present invention provides a panel including at least a support layer and an outer layer comprising elements which provide a selected structural appearance, the selected structural appearance comprising a plurality of regular shaped elements having a periodic tessellated pattern, a first side of the panel comprises at least one row where, at least a part of an end element of the row protrudes outwardly, and at a second side of the panel opposite the first side, an end element of the row forms a part element space, such that, when two panels are to be placed side4

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PCT/US2016/020740 by-side, the protruding end element of one panel is to be placed in the corresponding part element space of the other panel.

[0026] In an embodiment, alternating rows of elements include at least a part of an end element of each row protruding outwardly of the first side, and an end element of each row forming a part element space, wherein at the first side of the panel the support layer is shaped to correspond with the end elements of each row.

[0027] According to an aspect, the present invention provides a panel system including at least a first panel and a second panel each configured according to the panel of paragraph [0026], wherein the first panel and second panel are placed side-byside such that the protruding end element of one panel is to be placed in the corresponding part element space of the other panel to form a finger joint.

[0028] In an embodiment, the first panel is a wall panel and the second panel is an adjacent wall panel.

[0029] In an embodiment, the first panel is a wall panel and the second panel is a corner piece for use at a junction between two walls, the corner piece being configured similarly to said first wall panel in that the corner piece also includes at least a support layer and an outer layer comprising elements which provide the selected structural appearance of a plurality of regular shaped elements having a periodic tessellated pattern.

[0030] According to an aspect, the present invention provides a panel including at least a support layer and an outer layer comprising elements which provide a selected structural appearance, the selected structural appearance comprising a plurality of regular shaped elements having a periodic tessellated pattern, wherein alternating rows of elements include at least a part of an end element of each row protruding outwardly of the first side, and an end element of each row forming a part element space, wherein the support layer includes a straight side edge along at least one side of the panel which is aligned with an outer edge of the end elements that protrude outwardly of the side, thereby exposing the support layer in each of the part element spaces.

[0031] In an embodiment, when two panels are to be placed side-by-side so as to cause abutment between the straight side edge of each panel, end elements in alternate rows of each panel form two adjacent part element spaces to accommodate a separate

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PCT/US2016/020740 element which substantially corresponds to the size and shape of the adjacent part element spaces such that the separate element spans across adjacent panels when affixed to the exposed support layer.

[0032] In an embodiment, a first side of the panel includes the support layer having a straight side edge aligned with an outer edge of the end elements that protrude outwardly of the first side, and a second side of the panel includes a support layer having a straight side edge aligned with an outer edge of the end elements that form a part element space such that the end elements which protrude outwardly of the second side protrude beyond the support layer straight side edge.

[0033] According to an aspect, the present invention provides a panel system including at least a first panel and a second panel each configured according to the panel of paragraph [0031], wherein the first panel and second panel are placed side-byside to cause abutment between the support layer straight side edge of each panel.

[0034] In an embodiment, one or more separate elements for affixing to the exposed support layer across the adjacent first and second panels.

[0035] In an embodiment, the first panel is a wall panel and the second panel is an adjacent wall panel.

[0036] In an embodiment, the first panel is a wall panel and the second panel is a corner piece for use at a junction between two walls, the corner piece being configured similarly to said first wall panel in that the corner piece also includes at least a support layer and an outer layer comprising elements which provide the selected structural appearance of a plurality of regular shaped elements having a periodic tessellated pattern.

[0037] According to an aspect, the present invention provides a panel system including at least a first panel and a second panel each panel configured according to the panel of paragraph [0032], wherein the first panel and second panel are placed side by-side such that the protruding end element of one panel that extends beyond the support layer straight side edge is to be placed in the corresponding part element space of the other panel and affixed to the exposed support layer to form a finger joint.

[0038] In an embodiment, the first panel is a wall panel and the second panel is an adjacent wall panel.

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PCT/US2016/020740 [0039] In an embodiment, the first panel is a wall panel and the second panel is a corner piece for use at a junction between two walls, the corner piece being configured similarly to said first wall panel in that the corner piece also includes at least a support layer and an outer layer comprising elements which provide the selected structural appearance of a plurality of regular shaped elements having a periodic tessellated pattern.

[0040] In an embodiment, the pattern includes a grout-like or mortar-like line between each of the elements.

[0041] In an embodiment, the grout-like or mortar-like lines comprise a polymer.

[0042] In an embodiment, the panel system according to each of the above aspects comprises one or more rails for attachment to a surface to be panelled, wherein the panels include clips for attachment to the one or more rails.

[0043] In an embodiment, if the surface is a substantially vertical wall, the one or more rails are attached horizontally to the surface.

[0044] In an embodiment, the panel system further includes one or more backer rods for placement between adjacent panels, the backer rods having a shape and size to maintain a selected separation between the adjacent panels.

[0045] In an embodiment, the panel according to each of the above aspects including a mid-layer which allows for different thermal expansion and contraction rates of the support layer material and the outer layer material.

[0046] According to an aspect, the present invention provides a sealing element adapted to be fixed to at least one side of an object, and so as to present a sealing surface outwardly facing with respect to the object, wherein the sealing surface has a periodic non-planar shape.

[0047] In an embodiment, the periodic non-planar shape is a sinusoidal or sinusoidal-like curved shape.

[0048] In an embodiment, the sinusoidal or sinusoidal-like curved shape includes more than half of one sinusoidal or sinusoidal-like cycle.

[0049] In an embodiment, the sealing surface is adapted to meet with a corresponding sealing surface of at least one other sealing element to form a seal.

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PCT/US2016/020740 [0050] In an embodiment, the object is a panel adapted to be used with other like panels to form a structure.

[0051] In an embodiment, a bracket for fixing the sealing element to an object.

[0052] In an embodiment, the bracket is elongate and has an L-shape cross-section.

[0053] In an embodiment, the object is a panel adapted to be used with other like panels to form a structure, each panel including an elongated edge to which the LShaped bracket is to be attached.

[0054] In an embodiment, at least a part of the sealing element is formed from a rubber or rubber-like compound.

BRIEF DESCRIPTION OF THE DRAWINGS [0055] For a better understanding of the invention and to show how it may be performed, embodiments thereof will now be described, by way of non-limiting examples only and with reference to the drawings in which:

[0056] FIG. 1 is a perspective view of a part of a panel according to an embodiment of the present invention, a mid-layer and outer layer are shown as cut away to more clearly reveal the structure of the panel;

[0057] FIG. 2 is a perspective view of a panel attached to a wall, along with a corner piece, the panel and corner piece forming an embodiment of one as aspect of the present invention;

[0058] FIG. 3 is a similar view to FIG. 2 showing the corner piece joined to the panel;

[0059] FIG. 4 is a rear perspective view of a panel including clips according to an embodiment of the present invention;

[0060] FIG. 5 is a side cross-sectional view of two panels configured as per the panel of FIG.l attached to a wall with rails mounted, the panels forming an embodiment of one as aspect of a system of the present invention;

[0061] FIG. 6 is a perspective view of FIG. 5 of two panels joined and mounted on a wall;

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PCT/US2016/020740 [0062] FIG. 7 is a perspective view of two panels each configured according to an embodiment, joined and using a separate element to fill spaces in the outer layer of the joined panels;

[0063] FIG. 8 is a perspective view of another embodiment of a corner piece in a panel system;

[0064] FIG. 9 is a detailed perspective view of the part of FIG. 8 circled in a dashed line and labelled nine (9);

[0065] FIG. 10 is a perspective view of another embodiment of a panel of the present invention;

[0066] FIG. 11 is a side elevation view of a part panel and a full panel configured as per the panel of FIG. 10 and a corner configured as per the corner of FIG. 8, in an embodiment of an aspect of a system of the present invention;

[0067] FIG. 12 is a rear side elevation view of a panel in accordance with an embodiment of the present invention;

[0068] FIG. 13 is a side cross-sectional view of two vertically disposed panels including a sealing element in accordance with an embodiment of the present invention for sealing objects; and [0069] FIG. 14 is a perspective and partial cross-sectional view of corner edges of two sealed panels configured as per the panels in FIG. 13.

DETAILED DESCRIPTION OF THE EMBODIMENT(S) OF THE INVENTION [0070] For a better understanding of the invention it will now be described in some of its aspects and embodiments. This detailed description is intended to be nonlimiting, and there are other aspects and embodiments which fall within the scope of the invention defined in the claims.

[0071] FIG. 1 shows a part of a panel 10 according to an embodiment including a support layer 12, a mid-layer 14 and an outer layer 16. The support layer may include a rigid material comprising a honeycomb patterned substrate 22, which may be made from a metal such as aluminum. Advantages of using aluminum include it being light weight and non-corrosive. It is to be understood that whilst reference is made to a layer throughout this document, any one of the support layer 12, mid-layer 14 and

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PCT/US2016/020740 outer layer 16 may themselves comprise two or more layers or sub-layers. For example, the honeycomb substrate 22 may have a backing sheet 23 which together with the substrate 22 forms the support layer 12. In one embodiment, the panel 10 includes a 1.0 mm anodized sheet of aluminum 23 as a backing, on the back face of the honeycomb 22.

[0072] The honeycomb structure 22 allows the support layer 12 to be rigid. It will be understood that the rigidity is sufficient to support the panel 10 with its layers, but the rigidity is limited so that the support layer has some flexibility in circumstances such as when the panel is in a high speed and variable direction wind. It will also be understood that the rigidity can be selectively altered by varying the structure of the panel, such as using a thicker honeycomb substrate or using a more rigid material to form same.

[0073] The outer layer 16 comprises the selected structural appearance, which, in this embodiment, is a brick wall having off-set alternating rows, also known as a stretcher bond brick laying pattern. The brick wall includes brick elements 18, which may be formed from various materials.

[0074] In this embodiment, the brick elements 18 are formed from a porcelain or ceramic type material. In other embodiments, the bricks elements 18 may be formed from a material more closely resembling real bricks, such as baked clay. In yet other embodiments, different structural appearances or effects can be achieved by using real or artificial sandstone elements, so as to resemble a dressed sandstone wall. It is also possible to use irregularly shaped materials such as stone or the like to produce the effect of rustic constructions.

[0075] In different weather conditions, the panels will be subject to hot and cold conditions, and transitions between the two temperature extremes. It will be understood that an aluminum substrate 22 in the support layer 12 and a ceramic or porcelain brick-like element 18 in the outer layer 16 will have different rates of expansion or contraction in hot or cold conditions. The present invention provides a mid-layer 14 to negate or ameliorate the effects of this differential expansion and contraction between the support layer 12 and the outer layer 16. In an embodiment, the mid-layer 14 may be formed from fiberglass in the form of a fiberglass sheet. In an alternate embodiment, the mid-layer 14 may be formed from an additional sheet of metal (not shown), such as aluminium, which together with the aluminium backing

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PCT/US2016/020740 sheet encloses the honeycomb substrate 23 in a sandwich configuration. Due to its physical properties, the fiberglass sheet will stop or substantially lessen the risk of cracking of the outer layer elements 18 due to a more rapid expansion in the aluminum substrate 22 of the support layer 12 in hot or increasing temperature weather conditions. Accordingly, the fibreglass sheet is appropriate as a middle layer 14 when the panel is used in warmer outdoor environments. In indoor environments, it may be sufficient to use an additional aluminum sheet (not shown) in the middle layer 14, in place of the fibreglass, as an aluminium sheet (on its own or in combination with the substrate) will still allow for different thermal expansion and contraction rates of the support layer material and the outer layer material. The present invention is not limited to the use of any one particular material in the middle layer 14, or in any of the support or outer panel layers for that matter.

[0076] The elements 18 of the outer layer 16 have gaps between them, which may be filled with a polymer 20 to mimic the appearance of grout or mortar. The grout-like or mortar-like effect can be achieved with a polymer substance. The polymer has the added benefit that it can maintain elasticity when cured, and this elasticity allows for a certain amount of expansion and contraction between the elements and also assists with negating or ameliorating the effect of differential expansion between the outer layer 16 and the support layer 12.

[0077] In one technique of manufacturing a panel 10 according to the embodiment, the porcelain brick elements 18 are directly adhered to the middle layer sheet 14 using an epoxy under an industrial vacuum table for a minimum of four hours and up to eight hours, depending on environmental conditions and temperature. In some embodiments, the middle layer sheet 14 is already bonded to the honeycomb substrate 22 before the brick elements 18 are attached to it.

[0078] Although the invention may have a considerable number of variations and changes without effecting its essential nature, it has been found that using different backing panels instead of the aluminium honeycomb 22 may result in a lower performance rating for the impact and flexural strength. It has also been found that use of porcelain for the brick-like elements provides a superior performance over stone or masonry brick, as the porcelain is less subject to fading, discolouring, or an inconsistent colour range between the elements.

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PCT/US2016/020740 [0079] Furthermore, it has been found that using traditional grout or mortar results in cracking and inconsistent coverage in the spaces between the elements 18 of the outer layer 16. Using the polymer mortar-like or grout-like substance 20 provides a superior performance in changeable weather condition and makes for easier manufacture, and is less likely to be damaged during transportation of panels from manufacture to installation.

[0080] Although there may be a number of adhesives to be used in bonding the porcelain brick to the fiberglass sheet, it has been found that an epoxy adhesive provides superior performance.

[0081] Further advantages of panels in accordance with the invention and its embodiments are easier installation as the panels are significantly lighter than other panelling/cladding options. Lighter panels also contribute to a reduction in cost for transportation. The panels have a high impact rating and have been tested to MiamiDade Notice of Acceptance (NOA) and High Velocity Hurricane Zone (HVHZ) ratings. Other advantages are that the porcelain used for the brick elements 18 is resistant to fading and staining. The porcelain is also graffiti resistant.

[0082] As mentioned above, the panels are rigid, but have sufficient flexibility so that they can be used in areas with regular and/or high seismic activity. The flexibility also allows for the panels to be made in larger sizes. This cuts down on installation costs as more area can be covered more quickly. The flexibility also allows for a high wind load capability.

[0083] Furthermore, due to the materials being used in such an embodiments, the panels are resistant to rust and corrosion. Moreover, the panels are suitable for a great range of climate conditions and have been tested from -40 degrees Celsius to 150 degrees Celsius. The panels are also non-combustible, which provide fire resistance and heat resistance.

[0084] Referring to FIG. 2, there is shown an embodiment of the panel 10 attached to a wall 40. As previously described, the panel has a support layer 12, which may include an aluminum honeycomb layer 22, a mid-layer 14, which may be formed from a fiberglass sheet, and an outer layer 16, which may be formed from brick elements 18 and mortar-like or grout-like lines formed from a polymer 20.

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PCT/US2016/020740 [0085] The particular panel 10 shown in FIG. 2 has a first side 24 and a second side 26, each side has a toothed shape, wherein a half-brick element size protrudes forming the teeth 32 with recesses 34 in between. The toothed shape 28 of the first side 24 is offset by one row of brick-like elements from the toothed shape 30 of the second side

26. This allows adjacent panels to be easily fitted together so as to maintain a consistent laid brick pattern.

[0086] The panel 10 shown also has an upper straight side 36 and a lower straight side 38, thus allowing the panel to abut adjacent upper and lower panels. The upper and lower straight sides 36, 38 may also have a lip formed from a protrusion of the support layer (and, optionally, the mid-layer). The lip may meet with a corresponding lip of an upper or lower panel to form a channel between corresponding brick-like elements 18, and the channel can be filled with a polymer similar or same as the polymer 20 used in manufacture of the panel 10. These features and construction techniques allow for a continued and consistent appearance or effect of the panels when forming a wall or other structure.

[0087] Also shown in FIG. 2 is a corner piece 42. It will be understood that corner pieces can be formed at a variety of angles to suit corresponding angles on a structure to which the panels are attached. In FIG. 2, the corner piece 42 is shown as having an obtuse angle. In other embodiments, the angle may be acute or a right angle (90 degrees).

[0088] Similarly to the panel 10, the corner piece 42 has a first side 44 with a toothed shape and a second side 46 with a toothed shape. The toothed shape of the first side 44 is offset from the toothed shape of the second side 46 by one brick-like row, such that the first side 44 cooperates with the second side 26 of the panel 10, and the second side 46 of the corner piece 42 can cooperate with a first side 24 of another panel 10 (not shown). In these embodiments, the side edge of the support layer 12 and midlayer 14 terminate at where each brick-like row terminates, but variations are possible where the support layer 12 (and also the middle layer 14 where appropriate extend further beyond or short of where each brick-like row terminates, and will become apparent from a reading of the further embodiments.

[0089] FIG. 3 shows the panel 10 and the corner piece 42 joined together in an installation on a wall 40. The toothed shape 30 of the second side 26 of the panel 10

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PCT/US2016/020740 cooperates with the toothed shape of the first side 44 of the corner piece 42 so as to form a finger joint 48. The panel 10 and corner piece 42 are formed so as to leave a gap 50 between the two, which may be filled with the mortar-like or grout-like polymer material 20.

[0090] FIG. 4 shows a rear of a wall panel forming part of an embodiment of a wall panel system 58 shown in FIG. 5 for attaching panels 10 to a wall. The system includes clips 52 which are affixed to the back of the panel 10, and, in this embodiment, are affixed to the aluminum sheet 23 on the back of the honeycomb structure 22 in the support layer 12. Each clip 52 has an upper hook 54 and a lower hook 56, which are designed to cooperate with a rail 60 (see FIG. 5).

[0091] The clip and rail system 58 for attaching panels to walls has a number of advantages, including ease of installation. The clip and rail system may also provide an easily reversible installation, so panels 10 can be swapped out and in very readily.

[0092] FIG. 5 shows details of the clip and rail system 58 for attaching panels to walls. In a typical installation process, the rails 60 are mounted to the wall 40 and may also use a spacer 68. In this embodiment, the rails consist of an upper bar 62 and a lower bar 64, which cooperate, respectively with the upper hook 54 and lower hook 56 of the clip 52. The rail 60 also has a back plate 66 which abuts the wall 40 or spacer 68 and it can be affixed thereto using screws 70. The rails 60 and clips 52 form an embodiment of the mounting system 58.

[0093] During installation, the clips 52 are moved towards the rails 60, such that the upper hook 54 is able to move over and towards the rear side of the upper bar 62, and the lower hook 56 is able to move over and towards the rear side of the lower bar 64. The panel 10 is then moved downwardly so that the upper hook engages in a snug fit with the upper bar and lower hook engages in a snug fit with the lower bar.

[0094] Also shown in FIG. 5 is a rod or backer rod 71, which can be placed between panels 10 during installation. The rod may be formed from a material that allows for expansion and contraction of the panels in varying weather conditions. It should be understood that the rod is an alternative to having lips on the panels as previously described. In an installation process, a rod 71 is placed between adjacent panels and

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PCT/US2016/020740 then the grout-like or mortar-like polymer 20 is placed between the adjacent panels and over the rod 71.

[0095] The rod 71 may also be formed of a material or to have structures, such that it keys into the grout-like or mortar-like polymer 20. This assists in maintaining structural integrity of the installation.

[0096] FIG. 6 show two laterally adjacent panels 10 installed on a wall 40 using the clip 52 and rail 60 of system 58. The panels 10 join together to form a finger joint 72, and in which there is formed a grout-like or mortar-like line 74 from a polymer at installation.

[0097] FIG. 6 shows that the rails 60 run continuously along the wall 40, which provides a consistent and straight line attachment point for all the panels 10 along the rails. This can help to ameliorate or eliminate the effect of defects in the wall 40, such as local or large curvatures in the wall or unevenness of other kinds on the surface. The spacers 68 used in cooperation with the clip and rail system 58 can be used selectively to pad out the wall so that the rail 60 is able to form a straight edge. The spacers 68 can be formed from a material which is able to be sanded back or otherwise altered, which enables a finer adjustment of curvatures or other defects in the wall to provide a straight line when attaching the rail 60.

[0098] Although FIG. 6 shows only an upper and lower rail 60, it will be understood that the attachment system may have a greater number of rails to increase structural integrity of the panels. For example, having a mid-rail in such an installation would help to prevent flexing towards the centre of the panel between the two rails shown in FIG. 6.

[0099] FIG. 7 shows panels 10A and 10B configured according to an alternate embodiment and an embodiment for joining two panels 10A and 10B together. In this embodiment, the left-most panel 10A is shown with a first side 76 having a tooth pattern which is different from the tooth pattern shown in previous embodiments of the corresponding side 24 of panels 10. In this regard, it will be noted that the tooth pattern of the side 76 has recesses 34 both at the top and bottom thereof. A similar tooth pattern appears at the side 78 of the right-most panel 10B.

[0100] On the right side 78A of the left-most panel 10A, the support layer 12 (and optionally the mid-layer 14) include a straight side 79 instead of a tooth pattern as per

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PCT/US2016/020740 the panel in FIG.6. Instead of the tooth pattern, the support layer 12 and mid-layer 14 at this side 78A of panel 10A has spaces or gaps 82 corresponding to a half brick-like element shape and size in alternating rows in the outer layer 16 of the panel 10A. There is a corresponding pattern of spaces on the left-most side 76A of the right-most panel 10B. The combined spaces 82, in this embodiment, expose the mid-layer 14 in the panels 10A and 10B in the shape of a brick element.

[0101] During installation, the panels 10A and 10B are placed next to each other such that their straight sides 79 directly abut, or can be spaced with a rod 71. When in place, the corresponding half spaces 82 will form a full size brick-like element space, which can then be filled with a separate brick-like element 84, which may also be made of porcelain. The separate brick-like element 84 may be the same as the brick-like elements 18 in the panels 10A, 10B. Alternatively, to provide a special structural effect, the separate elements 84 can be of a different colour and/or texture, or could be of a different thickness, so as to provide a variation in the pattern of the structural appearance or effect produced by the panels.

[0102] When the panels 10A and 10B are installed, and the separate elements 84 are affixed to the panel (this can be by use of a same or similar epoxy as used in manufacture of the panels), there will be left a gap 80 forming a space for the grout-like or mortar-like line to be placed using a polymer substance.

[0103] The panels, in other embodiments, may have spaces in the outer layer 16 in different positions than those shown in FIG. 7. This can allow variations of the appearance or effect according to aesthetic taste.

[0104] In another use scenario, it may be desired to end a panel installation at the end of a wall 40, or at an internal corner where it is desired to panel one wall adjacent the corner, but not the other wall adjacent the corner. For example, if a wall 40 ends on a left side, then a panel such as 10B can be used so that the left-most side 79 of the panel 10B corresponds with the end of the wall on its left side. In this scenario, the panel 10B will have a series of alternating spaces 82, which correspond approximately to the size and shape of a half brick-like element 18. When the panel 10B is installed, the spaces 82 can be filled with a separate half-size brick-like element so as to form a consistent appearance of the structural appearance or effect at the end of the wall 40 in the panel 10B.

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PCT/US2016/020740 [0105] A corner piece 42 was detailed earlier with reference to FIGS. 2 and 3, in accordance with an embodiment. FIG. 8 shows another embodiment of a corner piece 100 in a panel system that may be suitable for use at a wall corner having panels 10A and/or 10B affixed. The corner piece 100 has a first side 101 and a second side 103. It will be understood that the corner piece 100 can be formed at a variety of angles to suit corresponding angles on a structure to which panels are to be attached. In FIG. 8, the corner piece 100 is shown as having an obtuse angle. In other embodiments, the angle may be acute or right angle (90 degrees).

[0106] The first side 101 of the corner piece 100 has a tooth-shaped pattern, including an outer layer 102 comprising a selected structural appearance, in this case brick pieces which protrude 104, forming gaps 110 therebetween. Similarly, the second side 103 of the corner piece 100 has top layer brick elements, alternately protruding 104 so as to form gaps 110 therebetween. In this way, the corner piece 100 shown in FIG. 8 is similar to the corner piece 42 depicted in FIGS. 2 and 3.

[0107] The corner piece 100 depicted in FIG. 8 also includes a support layer (not shown) which may be configured in accordance with the previously described support layer 12, and a mid- layer 105, wherein the mid-layer 105 may be configured in accordance with the previously described mid-layer 14 and allow for different thermal expansion and contraction rates of the support layer material and the outer layer material.

[0108] FIG. 9 is a detail of FIG. 8 towards the top of the corner piece 100. Moreclearly shown in FIG. 9 is the configuration of brick elements comprising the outer layer 102 wherein, in alternate rows, a brick element has a half brick end 108 and a full brick end 106. The top-most depicted brick element has the full-length brick end 106 protruding outwardly from the second side 103 of the corner piece 100 and the half brick end 108 located on the first side 101 of the corner 100. The next brick row reverses the top brick row pattern, such that the brick element half end 108 is located on the second side 103 of the corner 100, and the full length brick end 106 is located on and protrudes from the first side 101 of the corner piece 100. The difference between corner piece 100 and that previously described is that the side edges of the corner piece 100 do not extend out with the protruding elements but fall short to form a straight line edge in alignment with the half-brick ends 108.

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PCT/US2016/020740 [0109] Panels 10,10A and 10B were described earlier, with reference to FIGS. 1-7, in accordance with embodiments. FIG. 10 shows another embodiment of a panel 120. Similarly to the embodiment of the panel 10, the panel 120 in FIG. 10 includes a support layer 122 formed from a rigid material, and an outer layer 132 formed from a material different from the support layer material and comprising the selected structural appearance, which, in this case, is a stretcher bond brick pattern. The panel 120 also includes a mid-layer 124 between the support layer 122 and the outer layer 132, wherein the mid-layer 124 allows for different thermal expansion and contraction rates of the support layer material and the outer layer material.

[0110] The panel 120 has a first side 125, which includes brick elements at an end of each alternate row of bricks that protrude 130 from an edge 136 in alternate rows to form gaps 134 therebetween, such that the protruding brick elements and the gaps form a tooth shaped pattern.

[0111] The second side 123 of panel 120 is shown with the top row of bricks, for example, having the end brick 129 set back from an edge 137 the second side 123. In the second row of bricks an end brick 131 on the second side 123 extends to the side line 137.

[0112] The alternate rows of bricks that protrude 131 from the second side 123 of the panel 120 form gaps 126 between the bricks 131 which extend to the side edge. In some embodiments, the surface of the gap 126 is formed from the mid-layer 124. In other embodiments, the surface of the gaps 126 is formed from the support layer 122 of the panel 120.

[0113] It will be understood that, in the embodiment depicted in FIG. 10, the sides 125 and 123 are defined by where the support layer 122 or a combination of support layer 122 and the mid-layer 124 of the panel 120 end. This panel 200 is thus similar to panel 10A depicted in FIG. 7, except the top end brick 129 on the second side 123 is set back instead of protruding out, and likewise on the other side is protruding out instead of setback.

[0114] FIG. 11 shows a panel system including a partially-depicted face of a first panel 120A and a fully depicted face of a second panel 120B which are configured

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PCT/US2016/020740 according to the previously described panel 120. FIG. 11 also shows a corner piece 100, as previously described and depicted in FIGS. 8 and 9.

[0115] It should be readily understood that when installing a panel system as shown in FIG. 11, an installer may first install the first panel 120A, and when the first panel is sufficiently secured, the installer can then position the second panel 120B for installation. The protruding brick elements 130 associated with the first side 125 of the second panel 120B will be located in the corresponding gaps 126 of the first panel 120A.

[0116] When the second panel 120B is sufficiently securely installed, the installer may then position the corner piece 100 for installation, wherein protruding brick elements 104 associated with the corner piece 100 are positioned into the gaps 126 associated with the second side 123 of the second panel 120B.

[0117] It will be understood by those skilled in the art that there may be many different types of brick pattern that can be applied to embodiments of the panel, or the panel system in accordance with the present invention. The stretcher bond pattern of bricks is merely one example pattern used to exemplify the present invention. It will also be understood that the tooth shaped pattern depicted at the first side 125 of the panel 120 in FIG. 10 may have a different kind of pattern to suit the brick laying pattern used on the panel.

[0118] Further, it is contemplated within the scope of the present invention that non-regular shape elements, such as rocks, could be used to form the selected structural appearance for the outer layer of the panel. In such cases where the structural appearance is made from irregularly shaped objects, it is possible to configure the first side 125 and second side 123 of the panel 200 so as to form joints between a first panel and a second panel which are adequately sealed. It will be understood that, though the pattern of the structural appearance may be composed of irregular elements, the joints will include irregular shaped protrusions on a first panel, with corresponding substantially same irregular shaped gaps or spaces on a second panel.

[0119] FIG. 12 shows the rear face 150 of a panel 120 having the first side 125 and the second side 123 reversed from the depictions in FIGs 10 and 11.

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PCT/US2016/020740 [0120] The panel 120 of FIG. 12 is shown in use with another aspect of the invention, being the means and method for sealing between panels.

[0121] The panel 120 may have attached around the sides of the support layer 122 four sealing elements 152, including a top, bottom, first side, and second side sealing element 152. The sealing elements 152 will be described in more detail in the description below relating to FIG. 13 and FIG. 14.

[0122] In this embodiment, the sealing elements include brackets 153 for assisting in attaching each sealing element to a side edge of the panel 200, which can comprise the support layer 122, or a combination of a support layer 122 and mid-layer 124. In this embodiment, the brackets 153 have an L-shaped cross-section, and may be affixed to the support layer 122 by screws 154.

[0123] FIG. 12 also shows positions 155 adapted to allow affixing of mounting brackets for the panel to allow the panel to be mounted to a wall using, for example, rails as depicted by feature 60 in FIG.6 for another embodiment of the invention.

[0124] FIG.13 shows a first panel 120C and a second panel 120D where, when installed, panel 120C is located vertically above panel 120D. Each panel includes a support layer 122, a mid-layer 124 and an outer layer 132. The outer layer 132 may be a brick or brick stretcher bond pattern as previously depicted in various embodiments.

[0125] Panel 120C has a sealing element 152 attached thereto via a bracket 153. The bracket has an L-shaped cross-section, with a first arm 156 of the L-shape abutting the rear face of the support layer 122 and a second arm 158 of the L-shape abutting a side edge of the support layer 122. The L-shaped bracket 153 may be affixed to the support layer 122 via a number of screws 154 which in the embodiment shown are inserted into the rear face of the support layer 122 but may equally be screwed into the side edge of the support layer 122.

[0126] Each sealing element (one sealing element located on panel 120C and the other corresponding sealing element located on panel 120D) includes a part 160 which may be formed from a sufficiently flexible, yet sufficiently durable material, such as rubber or a rubber-like compound.

[0127] Each sealing part 160 has a sealing surface 162. The sealing surfaces of the seal elements 152 may have a complementary shaping allowing the sealing surfaces of

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PCT/US2016/020740 respective sealing parts 160 to meet and to form a sufficiently water and wind resistant seal.

[0128] In the embodiment depicted in FIG. 13, for example, the shape of the sealing surface is sinusoidal or includes a sinusoidal-like curved shape. The sinusoidal or sinusoidal-like curved shape extends for approximately two sinusoidal or sinusoidallike cycles on each respective sealing surface 162. In other embodiments, the sinusoidal or sinusoidal-like curve shape may include different integer or non-integer sinusoidal or sinusoidal-like cycles. However, it will be appreciated that a greater number of sinusoidal or sinusoidal-like cycles may produce better precipitation and wind resistance, better noise and thermal resistance, and better structural integrity of objects to be sealed.

[0129] FIG. 14 shows the two panels depicted in FIG. 13,120C and 120D, moved together so that the respective sealing surfaces 162 of the sealing elements 152 meet with each other and form a seal 200.

[0130] In various other embodiments, the sealing surfaces 162 may have other types of periodic non-planar shapes, such as saw toothed shaped, square-wave shapes, and periodic shapes having peaks and troughs in the periodicity, which are different from cycle to cycle. It will be readily appreciated that a vast number of shapes are contemplated within the scope of the term periodic non-planar shape.

[0131] Although, in FIGS. 13 and 14, the seal elements are exemplified as being attached to panels 120C and 120D, it will be appreciated that in other circumstances a seal element may be attached to other objects or surfaces in a building structure. For example, an installer may wish to install a bottom row of panels to form a wall structure, and a sealing element 152 or row of sealing elements may be placed along a ground or a foundation (not shown) in order to form the bottom most seal of the wall structure between the bottom line of panels and the ground or foundation. Similarly, where panels are installed along a wall at a 2-wall corner junction, a sealing element or row of sealing elements may be placed along one of the walls in order to form the side seal of the wall structure between the side edge of panels mounted to the wall structure and the other wall.

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PCT/US2016/020740 [0132] The invention is susceptible to variations, modifications and/or additions other those specifically described, and yet it to be understood that the invention includes all such variations, modifications and/or additions, which fall within the scope of the following claims.

[0133] Throughout this specification and the claims which follow, unless the context requires otherwise, the word comprise, and variations such as comprises and comprising, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0134] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that the prior art forms part of the common general knowledge.

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Claims

The Claims:

1. A panel for providing a selected structural appearance, the panel including:

a support layer formed from a rigid material;

an outer layer including elements which provide the selected structural appearance, the outer layer formed from a material different from the support layer material; and, a single mid-layer between the support layer and the outer layer, wherein the mid-layer includes at least one sheet of material which compensates for differences in thermal expansion and contraction rates of the support layer material and the outer layer material, and wherein the support layer includes a honeycomb substrate.
2. The panel according to claim 1, wherein the support layer further includes a backing sheet for the honeycomb substrate.
3. The panel according to claim 2, wherein the backing sheet and honeycomb substrate are formed from aluminum.
4. The panel according to any one of claims 1 to 3, wherein the mid-layer includes a fiberglass sheet.
5. The panel according to any one of claims 1 to 3, wherein the mid-layer includes an aluminum sheet.
6. The panel according to any one of claims 1 to 5, wherein the selected structural appearance includes a plurality of regular shaped elements having a periodic tessellated pattern.
7. The panel according to any one of claims 1 to 6, wherein two opposing sides of the panel include complementary toothed shapes such that, when one panel is placed next to another like panel the shape of adjacent sides of the panels form a finger joint to provide a continued alternating off-set row brick pattern.

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8. The panel according to claim 7, wherein the panel is configured so that the finger joint includes a gap, wherein the gap is adapted to be fillable to produce a groutlike or mortar-like line.
9. The panel according to claim 6, wherein a first side of the panel includes at least one row where at least a part of an end element of the row protrudes outwardly, and at a second side of the panel opposite the first side, an end element of the row forms a part element space, such that, when two panels are to be placed side-by-side, the protruding end element of one panel is to be placed in the corresponding part element space of the other panel.
10. The panel according to claim 9, wherein alternating rows of elements include at least a part of an end element of each row protruding outwardly of the first side, and an end element of each row forming a part element space, wherein at the first side of the panel the support layer is shaped to correspond with the end elements of each row.
11. The panel according to claim 6, wherein alternating rows of elements include at least a part of an end element of each row protruding outwardly of the first side, and an end element of each row forming a part element space, wherein the support layer includes a straight side edge along at least one side of the panel which is aligned with an outer edge of the end elements that protrude outwardly of the side, thereby exposing the support layer in each of the part element spaces.
12. The panel according to claim 11, wherein a first side of the panel includes the support layer having a straight side edge aligned with an outer edge of the end elements that protrude outwardly of the first side, and a second side of the panel includes a support layer having a straight side edge aligned with an outer edge of the end elements that form a part element space such that the end elements which protrude outwardly of the second side protrude beyond the support layer straight side edge.
13. The panel according to any one of claims 6 to 12, wherein the pattern includes a grout-like or mortar-like line between each of the elements.

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14. The panel according to any one of claims 6 to 13, further including a sealing element adapted to be fixed to at least one side of the panel, and so as to present a sealing surface outwardly facing with respect to the panel, wherein the sealing surface has a periodic non-planar shape.
15. The panel according to claim 14, wherein the periodic non-planar shape is a sinusoidal or sinusoidal-like curved shape.
16. The panel according to either claim 14 or claim 15, wherein at least a part of the sealing element is formed from a rubber or rubber-like compound.
17. A panel system, including:

a first panel and a second panel, each of the first panel and second panel including:

a support layer formed from a rigid material, the support layer including a honeycomb substrate, an outer layer including elements that provide a selected structural appearance, the outer layer formed from a material different from the support layer material, and a single mid-layer between the support layer and the outer layer, wherein the mid-layer includes at least one sheet material which compensates for differences in thermal expansion and contraction rates of the support layer material and the outer layer material;

wherein each of the panels has a first side and a second side opposite the side, the first side including at least one row where at least part of an end element of the row protrudes outwardly, the end element of the row forming a part element space at the second side such that when the two panels are placed side-by-side the protruding element of one panel is placed in the corresponding part element space of the other panel.
18. The panel system according to claim 17, wherein the first side of each panel includes a plurality of rows where at least part of an end element on alternating rows protrudes outwardly, wherein an end element of each row forms a part element space,

2016226160 05 Aug 2018 wherein at the first side of each panel the support layer of the panel is shaped to correspond with the elements of each row.
19. The panel system according to claim 18, wherein the first panel and second are placed side-by-side such that protruding end element of one panel is placed in the corresponding part element space of the other panel to form a finger joint.
20. The panel system according to claim 19, wherein the first side of each panel includes a plurality of rows where at least part of an end element on alternating rows protrudes outwardly, wherein an end element of each row forms a part element space, wherein the support layer of each panel includes a straight side edge along at least one side of the panel that is aligned with an outer edge of the protruding end elements, thereby exposing the support layer in each of the part element spaces.
21. The panel system according to claim 20, wherein end elements in alternate rows of each panel form two adjacent part element spaces to accommodate a separate element that substantially corresponds to the size and shape of the adjacent part element spaces such that the separate element spans across adjacent panels when affixed to the exposed support layer, wherein the first panel and second panel are placed side-by-side to cause abutment between the support layer straight side edges of the panels.
22. The panel system according to claim 21, further including one or more separate elements for affixing to the exposed support layer across the adjacent first and second panels.
23. The panel system according to claim 22, wherein the support layer of each panel includes a straight side edge along the second side of the panel that is aligned with an outer edge of the elements that form a part element space such that the end elements that protrude outwardly of the second side protrude beyond the support layer straight side edge, wherein the first panel and second panel are placed side-by-side such that the protruding end element of the second panel that extends beyond the support

2016226160 05 Aug 2018 layer straight side edge is placed in the corresponding part element space of the first panel and affixed to the exposed support layer to form a finger joint.
24. The panel system according to any one of claims 17 to 23, further including one or more rails for attachment to a surface to be paneled, wherein the panels include clips for attachment to the one or more rails.
25. The panel system according to any one of claims 17 to 23, further including one or more backer rods for placement between adjacent panels, the backer rods having a shape and size to maintain a selected separation between the adjacent panels.

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