GB2474382A

GB2474382A - Coated construction component

Info

Publication number: GB2474382A
Application number: GB1100069A
Authority: GB
Inventors: Kelvin Wayne Willis
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-12-14
Filing date: 2007-12-07
Publication date: 2011-04-13
Anticipated expiration: 2027-12-07
Also published as: GB0723965D0; GB2474382B; GB2474382A8; GB2445930B; GB2445930A; GB0625056D0; GB2474382B8; GB201100069D0; GB2444711A

Abstract

A construction component for use on the exterior of a building includes a wooden base having a first surface that in use comprises an exterior surface and a second surface that comprises an interior surface. The first surface is covered by a protective polymeric film that is secured to the surface by a layer of adhesive, said polymeric film having a thickness in the rauzge 10011, na to 500Ftm and an elongation at break of at least 10%. The second surface of the wooden base is only partially uncovered. The component may be cladding, a fascia board or a roofing trim component or a sill or cill component.

Description

CONSTRUCTION COMPONENT

The present invention relates to a construction component for use on the exterior of a building, and in particular but not exclusively in a roofline system or a cladding system. The invention also relates to a roofline system and a cladding system.

Construction components used in roofline systems and cladding systems have for many years been made from wood. While wood is an ideal material in many ways, when used on the exterior of a building it has to painted or varnished to protect it from the elements. If the wood is allowed to become wet for prolonged periods due to contact with rain or snow it may expand, split or rot. However, wooden components need to be repainted or revarnished at regular intervals to maintain the necessary protection from the elements. This is an expensive and labour intensive process. If it is not carried out at regular intervals, the wood may be irreparably damaged and have to be replaced.

To avoid the problems associated with wooden components, it is also known to manufacture equivalent components from polyvinyl chloride (PVC). PVC components are long lasting and do not need painting. They are therefore essentially maintenance free. However, the extensive use of PVC is not environmentally friendly and this is therefore generally unfavourable.

DE 3510837 Al describes a wooden structural part, for example a window or door, in which S.....

* the exterior surfaces are protected by a plastic layer that is moulded to match the contour of * S....

* the wooden component. The plastic layer is attached to the surface of the wooden component * : : 20 with an adhesive. However, as the plastic layer is relatively thick (typically 1.2mm) it requires a significant quantity of the plastic material and so is not environmentally friendly. *.S.

* .. : EP 0343491 A2 describes a multi-layer surface film for coating plastics, metals, wood and the * * like, having a pigmented or patterned base film and a clear top film. Polymers of the methacrylate group are used for the base film and the top film may be a polyacrylate film or film of PVDF or PVF.

US 4503115 describes a decorative moulded article for use as a constructional panel, comprising of a core of wood fibres and/or cellulose fibres pressed together with a thermo-setting resin, and having a decorative foil or coating applied to one or both surfaces of the core.

EP 0841158 A describes a building element having a veneered wood backing with a pressed varnish film applied to its outer surface.

JP 200 1232720A describes a method of providing a grain decorative material in which a transparent or translucent decorative sheet is laminated to the surface of a woody base material using a transparent or translucent adhesive layer.

It is an object of the present invention to provide a construction component for use on the exterior of a building that mitigates at least some of the aforesaid problems.

According to the present invention there is provided a construction component for use on the exterior of a building, including a wooden base having a first surface that in use comprises an exterior surface and a second surface that comprises an interior surface, wherein the first surface is covered by a protective polymeric film that is secured to the surface by a layer of adhesive, said polymeric film having a thickness in the range 100pm to 500Lm and an elongation at break of at least 10%, and wherein the protective film is wrapped around the wooden base and partially covers the second surface, and the second surface of the wooden base is partially uncovered.

The polymeric film protects the exterior surface of the wooden base from exposure to the * 20 elements, preventing it from splitting or rotting. The component does not require painting or * : * varnishing and it therefore remains virtually maintenance free for many years. As the component is mainly wood with only a very small quantity of plastic material used in the film, ****.* * it is much more environmentally friendly than PVC construction components. The product is also aesthetically pleasing, having a natural appearance. **** * * *

: 25 Advantageously, the wooden base is made of solid timber or plywood.

****** * * The wooden base is preferably made of wood from a needleleaf tree, which is naturally relatively knot-free and rot-resistant.

The polymeric film preferably has an elongation at break of at least 20%, more preferably at least 50%, thus ensuring that it does not split or break even in extreme conditions.

The polymeric film preferably has a thickness in the range 2001.tm to 30Oitm.

Preferably, the polymeric film is a multi-layer film having a printed lower layer and a clear upper layer. Preferably, the lower layer comprises a PVC material and the upper layer comprises a polyacrylate material. Alternatively, the lower layer comprises a PMMA material and the upper layer comprises a PVDF material. This latter material has the advantage of being resistant to graffiti and easy to clean.

The adhesive is preferably a PU-based hot melt adhesive. Preferably, the adhesive is pitch resistant, so that it is not affected by resin in the wood.

The protective film is wrapped around the wooden base and partially covers the second surface, to prevent any ingress by water that seeps around the edges of the component.

The construction component preferably has sealed ends. The ends may for example be sealed with a water-based silicone sealant.

The construction component preferably comprises a roofing fascia board, a bargeboard, a soffit, a cladding board or a window sill.

According to another aspect of the invention there is provided a roofline system including at construction component according to any one of the preceding statements of invention, said * construction component comprising at least one of a fascia board, a bargeboard and a soffit.

* ***s* * 20 Advantageously, the roofline system includes a fascia board having a groove on its interior surface for receiving an edge of a soffit.

The roofline system preferably includes a fascia board and a fascia joiner having an exterior * *** : plate that is shaped to match the exterior surface of the fascia board, and a web that extends * : * inwards from the plate so that, in use, it is located between the ends of adjacent fascia boards, said web being constructed and arranged to be secured to the end of a fascia board.

The roofline system preferably includes a fascia corner element andlor a soffit joiner element.

Advantageously, at least one of the fasciajoiner, the fascia corner element and the soffit joiner element comprises a rnoulded plastics component. Preferably, the moulded plastics component has an exterior surface covered with a polymeric film matched to that covering the wooden construction components.

According to another aspect of the invention there is provided a cladding system including a plurality of cladding boards, wherein at least one of said cladding boards comprises a construction component according to any one of the preceding statements of invention.

Certain embodiments of the invention will now be described by way of example with reference to the accompanying drawings, wherein: Figures Ia, lb and Ic are front, end and back views of a wooden fascia board for a roofline system, and Figure id is an enlarged end view showing part of the fascia board; Figures 2a, 2b and 2c are back, end and front views of a wooden soffit board for use in the roofline system; is Figures 3a, 3b and 3c are plan, side and end views of a corner element for the fascia board; Figures 4a, 4b and 4c are plan, side and end views ofajoiner for the wooden fascia board; Figures 5a and 5b are end and side views of a sofflt joiner; *: * Figures 6a, 6b and 6c are plan, side and end views of a corner for a bulinose fascia board; * Figures 7a, 7b and 7c are plan, side and end views of a joiner for a bulinose fascia board; : 20 Figures 8a, 8b and 8c are front, end and back views of a bullnose fascia board, and Figure 8d is an end view of the builnose fascia board at an enlarged scale; 0s** : Figures 9a, 9b and 9c are front, plan and end views of a cladding board; S.....

* Figures 1 Oa, I Ob and 1 Oc are front, top and end views of a second cladding board having an alternative profile; Figure 11 is a perspective view showing two fascia boards aligned with a fascia joiner; Figure 12 is an end view of a roofline system, showing a bargeboard, a fascia board and a soffit; Figure 13 shows a fascia corner element aligned with two fascia boards, and Figure 14 shows a soffit joiner aligned with two soffits.

S The fascia board shown in Figures 1 a -1 d includes a wooden base 4 having an exterior surface 4a and an interior surface 4b. The base is made of solid timber, which is preferably made of wood from a needleleaf tree, for example a Russian Redwood. It is selected to have a low knot content.

The exterior surface 4a is covered by a protective polymeric film or foil 6, which is wrapped around the upper and lower edges of the wooden base 4 so that it also partially covers the interior surface 4b of the base. However, the majority of the interior surface 4b is left uncovered. This allows the wood to breathe. The polymeric film preferably has a thickness in the range 100-400tm. Typically, it may have a thickness of either 200im or 300im. The polymeric film has an elongation at break of at least 10%, preferably at least 20% and more preferably at least 50%. This ensures that the film does not split during the normal expansion and contraction of the wood.

The polymeric film is preferably a multi-layer film having a printed lower layer and a clear upper layer. For example, the film may include a lower layer of a PVC material and an upper layer of a polyacrylate material. For example, we use Renolit MBAS film from Renolit AG.

* 20 Alternatively, it may for example include a lower layer of a polymethyl methacrylate (PMMA) * and an upper layer of polyvinylidene fluoride (PVDF). For example, the film may be Renolit * FAST film from Renolit AG. **SSs * *

The film 6 is preferably secured to the wooden base 4 with a polyurethane (PU) based hot melt *: :: : adhesive. This adhesive is preferably pitch resistant, to prevent it being attacked by resin in the wooden base. For example, we use pitch resistant PURHM adhesive from Kleiberit. The **.**I * film is applied to the wooden base 4 using a standard foiling process.

The ends of the fascia board are not covered with the foil. These ends are sealed with a suitable sealant, for example a water-based silicone sealant.

The fascia board includes a slot 8 in its interior surface, towards the lower edge of the board.

This slot 8 is designed to receive the edge of a soffit board, as described below.

Figures 2a, 2b and 2c show a soffit board for use with the fascia board described above in a roofline system. The soffit board includes a wood base 12 made of an external grade plywood.

The board has an exterior surface 1 2a which, in use, forms the lower surface of the board, and an interior surface 12b that forms the upper surface of the board. The exterior surface of the board is covered with a protective polymeric film of the type as described above. The film 14 is wrapped around the edges of the wooden base 12 and partially covers the interior surface I 2b of the base. However, the interior surface 1 2b is mostly uncovered, to allow the wood to breathe. The polymeric film or foil 14 is adhered to the board with an adhesive, preferably a pitch resistant polyurethane-based hot melt adhesive. The film 14 is applied to the wooden base 12 using a standard foiling process.

Figures 3a to 3c show a corner element forjoining wooden fascia boards. The corner element is made of a plastics material, for example PVC, by a suitable moulding method, for example injection moulding. It includes two elongate side pieces 22 that are connected to one another at right angles. An L-shaped end plate 24 is provided at the lower end of the corner element.

As shown in Figure 13, in use the corner element 20 is aligned with two fascia boards 2, which are set at 900 to each other. The plates 22 are located adjacent the exterior surfaces of the fascia boards, and the end plate 24 is positioned beneath the two fascia boards. It is secured in place by nailing through the walls 22 into the ends of the fascia boards 2.

* The exterior surface of the corner element 20 is covered with a polymeric film that matches ****.* * the colour and pattern of the film on the fascia boards 2.

***.** * Figures 4a, 4b and 4c shows a joiner for joining two fascia boards end to end. The joiner 30 includes an exterior plate 32 that is shaped to match the exterior surface of the fascia board, * *** * .. : 25 and a web 34 that extends inwards from the plate so that, in use, it is located between the ends * : * * of adjacent fascia boards 2, as shown in Figure 11. At its lower end, the fascia joiner 30 includes an inwards extending plate 36 that is located beneath the lower edges of the fascia boards 2. The joiner 32 is secured to one of the fascia boards 2 by nailing through holes in the web 34 into the end of the fascia board 2. The other fascia board is not connected to the joiner, so as to allow for expansion and contraction.

A rectangular slot 38 is provided in the web 34 towards the lower end of the joiner. This slot 38 is aligned with the slot 8 in the fascia board to accommodate the edge of a soffit board 10.

The fascia joiner 32 is a moulded plastic component, made for example of PVC by injection moulding. The exterior surfaces of the fascia joiner 30 are covered with a polymeric film matching the colour and pattern of the film on the fascia boards 2.

A soffit joiner for joining soffit boards end-to-end is shown Figures 5a and 5b. The soffit joiner is of uniform cross-section, comprising parallel exterior and interior plates 42,44 joined by a perpendicular web 46. In use, the ends of the soffit boards are located within the slots formed between the exterior and interior plates 42,44 as shown in Figure 14. The soffit joiner is made of a plastics material, for example of PVC, by injection moulding. The exterior surface of the soffitjoiner 14 is covered with a polymeric film matching the colour and pattern of the film on the soffit boards 10.

The roofline system also includes a bargeboard 50 for use at the gables of a roof. In construction, the bargeboard 50, shown in Figure 12, is similar to the fascia board shown in Figures la -id, comprising a wooden base, the exterior surface of which is covered by a polymeric protective film.

Figure 12 illustrates how the components of the roofline system are joined together in use.

The fascia board 12 is located in an upright position so that it extends horizontally under the * eaves of the roof (not shown), parallel to the wall 16 of the building. The gap between the wall 16 and the interior surface of the fascia board is closed by the soffit board 10. The outer *. .*..

* edge of the soffit board 10 is located in the slot 8 on the interior surface of the fascia board, while the inner edge of the soffit board is nailed to a batten 62 that is attached to the exterior .. : 25 surface of the wall 60. The bargeboard 50 extends at an angle underneath the gable end of the roof and is connected at its lower end to the fascia board 2.

Various modifications of the components of the roofline system are of course possible, some of which are illustrated in Figures 6a -6c, 7a -7c and 8a -8d. Figures 8a -8d show a bulinose fascia board 2' that is similar to the fascia board shown in Figures 1 a -1 d, except that the lower edge of the fascia board has a bulinose profile. In all other respects it is similar to the first fascia board shown in Figures 1 a -1 d and it will not therefore be described further. The corner element shown in Figures 6a -6c and the joiner element shown in Figures 7a -7c are shaped to match the builnose fascia board and therefore have a corresponding bullnose profile at their lower ends. In all other respects, they are similar to the corner and the joiner elements shown in Figures 3a -3c and 4a -4c, and will not therefore be described further.

Figures 9a -9c show a cladding board for use in a cladding system. The cladding board 70 includes a wooden base 72 having an exterior surface 72a and an interior surface 72b. The board also has an upper edge 74 that supports a tongue 76, and a lower edge 78 that has a groove 80, which is shaped to receive the tongue 76 of an adjacent cladding board. Jn use, the boards are arranged horizontally and are joined by the tongue and groove connectors.

The exterior surface 72a of the cladding board is covered with a protective polymeric film 82 similar to that described above in relation to the fascia board. The polymeric film 82 is attached to the exterior surface of the wooden base 72 with an adhesive, for example a pitch resistant polyurethane-based hot melt adhesive. The film 82 extends over the upper and lower edges of the wooden base 72 to protect the board from water. The interior surface 72b is mainly or entirely uncovered. The ends of the cladding board are sealed with a suitable sealant, for example a water-based silicone sealant.

Figures 1 Oa, 1 Ob and 1 Oc show a second cladding board having an alternative profile. In this * case, the cladding board 70' has a tongue 84 at its upper end and a grove 86 at its lower end * : * that receives the tongue of an adjacent board. In all other respects the cladding board is similar * to the first cladding board shown in Figures 9a -9c and it will not therefore be described * * further.

The invention described herein is also applicable to other wooden construction components that require protection from the elements, including for example window sills. *