GB2346393A

GB2346393A - Building block support panel

Info

Publication number: GB2346393A
Application number: GB9902712A
Authority: GB
Inventors: John Thompson
Original assignee: Individual
Current assignee: Individual
Priority date: 1999-02-06
Filing date: 1999-02-06
Publication date: 2000-08-09
Also published as: GB9902712D0; WO2000046465A1; GB0120507D0; GB2363137A; GB2363137B; AU2555800A

Abstract

A panel comprises a plurality of ribs 14 which have a upper surface 17 for supporting building blocks 21. The ribs 14 are spaced apart by a distance greater than the height of the building blocks 21 to be supported on the panel, to allow for variations in the dimensions of the blocks.

Description

BUILDING BLOCK SUPPORT PANEL The present invention relates to a building block support panel.

Building block support panels comprising a panel including a number of spaced supports for holding thin building blocks, for example so-called brick slips, are known. Such panels may be affixed to or form part of buildings to give the appearance of a conventiona ! brick wall. The provision of spaced building block supports enables building blocks to be affixed to the panel more quickly and with less skill than is required to build a conventional brick wall.

One known arrangement is described in GB 2199352. This arrangement comprises an inner portion including insulating material which is bonded to an outer portion for supporting bricks. The outer portion has a number of equally spaced channel bars which define therebetween channels corresponding to the widths of bricks to be supported on the panel. The channel bars are so spaced that there is an interference fit between bricks and the panel, and are sufficiently resilient so that bricks are retained between adjacent channel bars by friction. To further ensure effective retention of bricks by the channel bars their side walls which, in use, contact bricks extend outwardly from the outer portion in opposite directions, at an acute angle to the outer portion, to create a dovetail appearance.

Although, as with other systems, bricks would be secured to the panel using an adhesive the provision of channel bars arranged to hold bricks by friction is thought to aid assembly of the panel.

It has been found, however, that the provision of a friction fit between bricks and channel bars causes a number of problems.

One problem arises due to the tolerances used in brick manufacture.

To obtain a good friction or interference fit requires the brick size and channel bar spacing to be carefully matched. Now, whereas the channel bar spacing may be reproduced accurately brick sizes can and do vary. For example the height of conventional bricks and brick slips sold in the U. K. with a nominal height of 65mm typically varies by j 3mm. This presents a problem in that larger bricks can be very difficult, if not impossible, to fit between the channel bars. This can result in wastage of bricks and time, and hence labour, in assembling panels.

Another problem is that once a brick has been friction fitted between channel bars it can be very difficult to subsequently move or remove that brick. This is inconvenient as once mounted on the panel it can be difficult to align a brick with other bricks already on the panel to obtain a satisfactory finish.

Yet another problem is that the dovetail appearance shape of the channel bars can be difficult to mould because of potential difficulty in removing the moulding tool.

It is an object of the present invention to overcome, or at least mitigate, these and other problems associated with known building block support panels.

It is a further object of the invention to provide a more versatile, easy to use and produce building block support panel.

According to one aspect of the present invention there is provided a moulded plastics building block support panel comprising a panel surface having a plurality of evenly spaced substantially parallel building block support ribs projecting therefrom, said ribs having an upper surface for supporting building blocks and wherein said ribs are spaced apart by a distance greater than the height of building blocks to be supported on the panel.

According to another aspect of the present invention there is provided a panel comprising building blocks mounted on a moulded plastics support panel, said panel comprising a panel surface having a plurality of evenly spaced substantially parallel building block support ribs projecting therefrom, said ribs having an upper surface for supporting said building blocks and wherein said ribs are spaced apart by a distance greater than the height of the building blocks.

By spacing the support ribs at a greater distance apart than the size of the blocks the panel is able to accommodate variations in block size.

This reduces wastage. It also allows blocks to be repositioned when placed between support ribs.

Preferably the upper surface of the ribs extends substantially perpendicularly from the panel surface. In addition it is preferred that the ribs also have a lower guide surface which extends outwardly and upwardly from the panel surface so as to form an obtuse angle with the panel surface.

The provision of a lower guide surface at an obtuse angle to the panel assists in preventing any oversize blocks becoming wedged between the ribs, strengthens the ribs and helps in revealing if any blocks have been incorrectly positioned or not properly seated on the supporting surface of the ribs.

Preferably the support ribs are of generally triangular cross-section.

The height of the ribs is preferably about half of the depth of the blocks to be supported.

The block support panel is preferably formed from a sheet of plastic, for example a high impact polystyrene sheet. The support panel may be formed by vacuum moulding. The sheet is preferably at least 0.5mm thick.

For supporting brick slips it is preferred that the sheet is between 0.5 and 4mm thick. The thickness of the sheet should be chosen having regard to the size and mass of blocks to be mounted on the panel and the type of material to which the panel is to be affixed.

The block support panel is preferably bonded to an insulating material, for example to a sheet of a synthetic foam material, for example closed cell extruded polystyrene. The bond is preferably formed by an adhesive, for example a polyurethane or a styrene butadiene rubber (SBR) adhesive. This adds rigidity to the panel which may then be affixed to an existing wall, a framework, or some other support structure.

The lateral edges of the insulating material preferably include cooperating formations to enable a number of panels to be placed in engagement with each other.

Blocks may be secured to the support panel either before or after the panel is secured to another structure. It is generally preferred, however, that the panel is first secured to some other structure, say a plywood sheet, before blocks are mounted on the panel. This allows fasteners with wide heads which will not easily pass through any insulation layer bonded to the panel and the blocks to then be affixed over the fasteners. Blocks are preferably secured to the panel using an adhesive for example a synthetic adhesive, preferably an adhesive with good'grabbing'properties. Flexible polyurethane adhesives are suitable an example is the adhesive sold under the trade mark Rallithane High Performance by Allied Signal Speciality Chemicals, Astor Ltd. of Tavistock Road, West Drayton, Middlesex, England. The panel surface preferably inclues a relief pattern, or some other key to aid bonding of the adhesive to the panel.

The distance between successive ribs preferably exceeds the nominal height of the blocks to be employed by at least 1 mm, more preferably by at least 3mm and still more preferably by at least 5mm. More clearance allows the panel to accommodate greater variations in brick size which gives the finished panel an appearance more like a conventional brick wall.

In order that the invention may be more clearly understood an embodiment thereof will now be described, by way of example, with reference to the accompanying drawings in which: Figure 1 shows a perspective view of a panel according to the present invention with two brick slips mounted thereon; Figure 2 shows an enlarged cross-sectional view of a part of the panel of Figure 1; and Figure 3 shows an enlarged cross-section through an alternative form of brick support panel having differently shaped ribs.

Referring to Figures 1 and 2 a building block support panel comprises a closed cell expanded polystyrene foam sheet 10 one end of which inclues a slot 11 and the opposite side of which includes a tongue formation 12 which is arranged to fit snugly within the slot of another panel. This allows large areas to be covered effectively with multiple panels. The tongue and groove arrangement makes the resulting structure more stable than a simple butt joint and helps prevent cold bridging. The foam sheet provides support for the block support panel 13 as well as giving the panel insulative properties.

The block support panel 13 is formed by vacuum forming a sheet of high impact polystyrene sheet to produce a series of ribs 14 on the surface of the sheet. The panel 13 is bonded to the foam sheet 10 with an SBR adhesive 15.

The block support ribs 14 extend laterally across the panel in substantially parallel and evenly spaced vertical relation to one another. A margin is provided down each edge of the panel, that is the ribs do not extend all the way to the edge of the panel. When two panels are joined there will be a break in the ribs between panels. An additional break 16 is provided approximately mid-way along each rib. These breaks allow any moisture that may become trapped between blocks and the panel to drain away. Having a gap in the ribs between panels helps to negate the effect of any misalignment between adjacent panels, although this should preferably be avoided.

The ribs 14 themselves are of generally triangular cross-section, but with one side being open since they are formed by deforming a single sheet of material. Each rib has an upper surface 17 for supporting blocks which extends substantially perpendicularly outwardly from the plane of the support panel 13. Each rib also has a lower guide surface 18 which extends outwardly and upwardly from the plane of the support panel 13 forming an obtuse angle 19 with the plane. The guide surface 18 strengthens the ribs, acting, to some extent, as a strut. For the avoidance of doubt, as used herein, upwardly and downwardly are used in relation to a panel mounted as for normal use as illustrated in the accompanying figures.

The spacing of the ribs 14 is greater than the nominal size of the blocks 21 intended for mounting on the panel. The embodiment illustrated is designed for use with brick slips of nominal height 65mm. The distance between the support surface of one rib and the underside of the rib immediately above is 70mm. The distance between the upper and lower surfaces of each rib is 15mm, therefore the ribs have a pitch of 75mm.

Thus, when using 65mm bricks there will be a standard 10mm mortar bed.

Different brick styles could also be used with different mortar bed sizes.

The surface of the support panel 13 other than where there are ribs is embossed with a relief pattern (not shown) to aid adhesion of blocks.

Any suitable pattern can be used.

The panel may be affixed to another structure using any suitable technique, for example fasteners may be passed through the panel and into an underlying structure. Ways in which building block support panels may be affixed to a surface are well known and will therefore not be described in any further detail.

Building blocks may be affixed to the panel either before, or after, it has been secured to another structure. First, a suitable adhesive 20 for example a flexible polyurethane adhesive with good"grabbing"properties is applied to the surface of the panel between ribs 14. It is preferred that adhesive is not applied in the region of the drainage gaps 16 as this can impair drainage. Building blocks may then be applied to the adhesive. Figure 2 shows a brick slip 21 bonded to the surface of the block support panel between two ribs. When the slip is inserted between the ribs and pushed home the guide surface on the underside of the upper rib helps to ensure that the brick slip is moved towards the support surface of the lower rib.

The spacing of the ribs is such that, when properly seated, there is some clearance between the top of the brick slip 21 and the next rib. This allows brick slips which exceed their nominal size to be fitted onto the support. Were an exceptionally large or incorrectly sized brick slip to be offered up to the support so that, even when seated on a brick support, the top of the slip rested on the guide surface 18 not only would it be immediately apparent that the brick slip was oversized but there would be no risk of the brick becoming wedged between adjacent ribs. This could potentially damage the panel.

Once brick slips are secured in place with the adhesive 20 the spaces between the bricks can be filled with mortar 22, polymer modified mortar being preferred, to give the completed panel the appearance of a conventional brick wall. To ensure good keying of the mortar it is desirable that the thickness of the brick slip exceeds the height of the ribs. When the ribs are of generally triangular cross-section this provides a better key for the mortar than, say, a rectangular cross-section.

Referring to Figure 3 there is shown an alternative configuration for the block support panel ribs. The essential difference compared to the embodiment illustrated in Figures 1 and 2 is that the guide surface 30 inclues a discontinuity 31. This makes little or no difference to the function of the panel but is illustrated to show a possible variation within the scope of the invention.

The above described embodiments confer numerous advantages over known systems. They allow for tolerances in brick size, allow positioning of the brick once placed adjacent the panel and prevent undesirable jamming of bricks between the ribs. Accommodating variations in brick size can give a more realistic appearance to a completed panel. The shape of the ribs also lends itself to easier moulding.

The above embodiments are described by way of example only.

Many variations are possible without departing from the invention.

Claims

CLAIMS 1. A moulded plastics building block support panel comprising a panel surface having a plurality of evenly spaced substantially parallel building block support ribs projecting therefrom, said ribs having an upper surface for supporting building blocks and wherein said ribs are spaced apart by a distance greater than the height of building blocks to be supported or supported on the panel.
2. A moulded plastics building block support panel as claimed in claim 1, wherein the upper surface of the ribs extend substantially perpendicularly from the panel surface.
3. A moulded plastics building block support panel as claimed in either claim 1 or 2, wherein the ribs have a lower guide surface which extends outwardly and upwardly from the panel surface so as to form an obtuse angle with the panel surface.
4. A moulded plastics building block support panel as claimed in any preceding claim, wherein the support ribs are of generally triangular cross-section.
5. A moulded plastics building block support panel as claimed in any preceding claim, wherein the height of the ribs is about half the depth of the blocks to be supported or supported on the panel.
6. A moulded plastics building block support panel as claimed in any preceding claim, wherein the panel is formed from a sheet of plastic.
7. A moulded plastics building block support panel as claimed in claim 6, wherein the sheet of plastic is between 0.5 and 4mm thick.
8. A moulded plastics building block support panel as claimed in any preceding claim, wherein the panel is bonded to an insulating material.
9. A moulded plastics building block support panel as claimed in claim 8, wherein the insulating material comprises a sheet of synthetic foam material.
10. A moulded plastics building block support panel as claimed in either claim 8 or 9, wherein the lateral edges of the insulating material include cooperating formations to enable a number of panels to be placed in engagement with each other.
11. A moulded plastics building block support panel as claimed in any preceding claim, wherein the distance between successive ribs exceeds the nominal height of the blocks to be supported or supported on the panel by at least 1 mm.
12. A moulded plastics building block support panel as claimed in any preceding claim, wherein the distance between successive ribs exceeds the nominal height of the blocks to be supported or supported on the panel by at least 3mm.
13. A moulded plastics building block support panel as claimed in any preceding claim, wherein the distance between successive ribs exceeds the nominal height of the blocks to be supported or supported on the panel by at least 5mm.
14. A panel comprising building blocks mounted on a moulded plastics building block support panel a$ claimed in any preceding claim.
15. A moulded plastics building block support panel substantially as herein described and illustrated.
16. A panel comprising building blocks mounted on a moulded plastics building block support panel substantially as herein described and illustrated.