GB2508975A

GB2508975A - A support panel comprising dual mesh layers for holding render material

Info

Publication number: GB2508975A
Application number: GB1319003.8A
Authority: GB
Inventors: Michael George
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-10-29
Filing date: 2013-10-28
Publication date: 2014-06-18
Anticipated expiration: 2033-10-28
Also published as: GB2508975B; GB201219427D0; GB201319003D0

Abstract

The support panel 10 comprises a number of ribs 11a defining a first mesh 11, another set of ribs 12a defining a second mesh 12 and the meshes being arranged near each other in a spaced relation and coupled together using connecting members 13. The mesh layers are preferably parallel or have a fixed separation between them. The connecting members may comprise two portions which have complimentary formations to allow coupling together. The panel is preferably attached to a wall using fasteners with a head portion that abuts the second mesh. Also claimed is an assembly where the carrier is combined with fasteners. Also claimed is a thermal insulation board for a wall wherein the board comprises the carrier and the second mesh of the panel is rigidly paired with the board. The boards ribs and mesh allow increased keying area for a cementitious mortar render when affixing an insulation board to a wall. The panel removes the need to create a key area onto which render needs to adhere to and provides an improved bond.

Description

Render Support Panel foraWall The present invention retate5 to a render support panel for a wall.

In recent years there has been a drive toimprove the thermal Insulation of houses to reduce the sc-called carbon footprlnt1e of households. This has Involved insulating attic spaces with rolls of insulathig wool and also Insulating cavity spaces within the wails of houses by injecting an Insulating foam therein.

However, many older properties do not typically comprise cavity spaces between wails and as such, the thermal insulatiott of these houses have been improved by applying insulati4n to the e4ern& walls of the houses. Such external insulation systems typically Involved securing rigid insulating boarth to the external wafts of the houses and then a$$yiflg a render to the insulating boards to provide a weather proof seal which can be suitably painted. 1$

It is found that traditional cementitious. renders comprising sand, cement and possibly time, do not form a suitable bond with the insulating bqards, and are too heavy to baspported by the boards.

Accordingly, a is necessary to use an acrylic reader with external insulation systems The acrylic renders form a chemical bond with the Insulation boards which improves the adhes;on of the render to the boards, and are lightweight compared with the traditional cementitous render. However, acrylic renders are expensive and have caustic properties which present a working hazard for plasterers and the like.

According to a first aspect of the present invention, there is provided a render suppott panel for a 2S wall, the panel comprising: a first phrallty of Interconnecting ribs defining a first mesh; a second plurality of interconnecting ribs defining a second mesh; the first and second mesh being arranged adjacent each other in spaced relation, the first mesh being coupled to the second mesh by a plurality of connecting memrs Advantageously, the panel provides a rigid, durable icey for render w that tradjtlonal mortar and lime renders for example, in addition to acrylic renders, may be used to cover insulation boards when eçternally lnsulatjng houses and the liKe. Howeyer, it Is also enyjsaged that the panel may be applied to relatively smooth watts and surfaces which require the application of a render, thereby.

obviating the requirement to first create a mechanical key mt the surface to whir.h the render can adhere.

In an embodiment of the invention,, the first mesh compstes a substantially planar arrangement of S the first plurality of InterconnectIng ribs,, and the second mesh comprises a substantially planar arrangement of the second plurality of Interconnecting ribs.

In an embqdiment, the first mesh comprises a contour which is substantially matched to a contour of the second mesh to provide for a substantially uniform spacing of the First and second mesh across the panel. In this manner the planar arrangements are arranged to extend in substantially pekrallel planes.

The connectIng members extend between the first and second mesh to rigidly couple the first iind second meshet. and may extend across the width and/or length of the panel. In an afternative ernbodtrnen(, the connecting members may comprise a first connecting portion disposed on the first mesh and a secqnd connecting portion or, the second mesh, which are detachabIi connectable with each other to permit the first and second mesh to detachably couple together. Ihe first amid second c9nnecting portions may comprLce respectively complimentary chapcl portions, to enable th first and second portions to snap-lock togethes for example.

In an embodiment, it is envisaged that the connecting members may comprise a different length, such that the separation of the first and second mesh may vary across the panel, to accommodate, any unduIation associated with the underlying wall for example, or a sloping wall for example. hi either situation, the different sized connecting members enable the outermost mesh to provide for a substantIally flat, vertical guide forthe render, The panel prefrabIy further comprises a plurality or elongate protruding ribs which extend along the panel at a sIde, of the first mesh which is opposite the side arranged. to extend adjacent the second mesh. In this manner, the elongate protruding ribs are arranged to extend, at. an outer sIde of the panel, above the first mesh and serve to assist a plasterer For example; when applying a layer of render to the panel.

Preferably, the' panel further' comprises a plurality of regions for' receivIng fasteners fr Fastening' the panel to a wall, for example. in an embodiment, the fasteners are arranged to pass through the first mesh and abut the second mesh to couple the panel to a wall qr simllr. Accordingly, the regions comprise a recessed portion of the panel to avotd the fastener extending outwardly from the flrst mesh and which otherwise may impede the application ot render to the paneL flit regions preferably comprise a plurality of first regions on the. first mesh' which comprise a suj,stantialiy'open S region of the first mesh, and a plurality of second regions on the second mesh which comprise a substantially solid, narn&y unmeshed region; In ati errtbodlrrtent, the panel urther comprises a plurality Qf mesh inserts which are arranged to couple within the first regions to cover the fasteners and close the open regions. Proferably, the inserts are arranged to snap-lock within the open regrons.

According to a second aspect of the present invention, there i, provided a render support: panel assembly for a wall the assembly comprising a render support panel according to the fitst aspect and' a plurality of fasteners for fastening the panel to the wall.

frreferabiç the fasteners comprise an exten4e4 head portion for abutting the second mesh, particularly, a second region of the second mesh, and an elongate coupling portion which extends from the hctd, and which' Is arranged to pass into a wall, for example. In an embodiment, the coupling potion may comprise' a plurality of external barbs, which may he indflted to an axis of the coupling portion to. facilitate the insertion of the portion Into the wail, but which serve to resist the removal of the portion from the wall. In aP alternative embodiment, the coupling portIon may comprise an external thread portion for screwing into the wall.

According to a third aspect'of the present invention, there Is provided thermal insulation hoard, for a waIl, the insulation board comprising a render support panel according to the first' aspect, the second mesh of the panel being rigidly coupled to the board, In an embodiment, the second mesh may. be coupled to the board by a chemical bond, through use of an, adhesiv or a physical bond, such as stapling.

An embodiment qF the present invention will now be described by way of example only and with reference to the accompanying drawings, in'which: Figure 1 is a plan view of a render support panel according to an embodiment of the present invention; Figure 2 is a side view oF the panel illustrated In figure 1; Figure 3 Is a magnified side view of a portion of the parti illustrated in figure 1; Figure 4 is a side view of a render support panel assembly according to an embodiment of the present inventltrn in use; and,.

Figure 5 i a side view of a thermal insulation board according to an embodiment of the present invention.

Referring to figures 1 end 2 of the drawings, there is IJlustrated a render support panel 10 according t an embodiment of th present invention, for facHitating the application of render to smooth surfaces, such as insulation boards and the like, when externally insulatin properties. The panel 10 comprises a fIrst svbftantially planar arrangement of a plurality of interconnecting ribs lie. which may be Formed of a plastics material, for example. The ribs ha' extend a ross' the width nd length of the panel and are coupled at their intersectich to Form a first mesh Ii comprising a generally rectangular arrangement of apertures llb. The panel 10 further comprises a second substantially planat arrangement of a plurality of interconnecting ribs lie, which may similarly he formed of a plastics material, for example. The ribs 12a similarly extend across the width and length of the panel and are coupled at their Intersection to form a second msh 12 comprising a generally xectanguiar arrangernentofapertures 12b.

In a first erqboclknent, the first and second mesh 11, 12 are coupled by a plurality of connecting members 13 which extend between the ribs. lie of the first mesh 11. and the ribs 12a of the second mesh 12, to hold the first and second mesh 11,12 in a substantially rigid configuration in which the apertures lib, iIb are substantially alignedA as illustrated In figure ef the drawings. In art 3(1 alternative embodiment however, which is not illustrated, the connecting members 13 may comprise a first connecting portion (not shown) rigidly coupled at a proximal end to the ribs lie of the first mesh 11 and a second connecting portion (not shown) rigidly coupled at a proximal end thereof to the ribs 12a of the second mesh 12. The first arid second portions (not showni are separately arranged on the respective mesh in an arrangement and with a spacing therebetween which Is common to both the first and second mesh U, 12, so, tMt the fIrst and second portions (not shown) can cooperate when aligned to couple the meshes 11, 12 of the panel 10 together..

In an embodiment, the first arid second connecting portions (not shown) may crnnprlse respective S complimentary' shaped formations (not shown), such as male and female type connecting portions respectiVely, at the distal end thereof which permit the Rrft and second portions (not shown) and thus the first and second mesh 11, 12, to detachably couple together. ft Is envisaged that these formations (not shown) may permit the first mesh it to be suitably. positioned over the secopd mesh 12 when the panel 10 is to he sited around a window (not shown) in a wall, for exampte. to

In an embodiment, the connecting members 13 may comprise substantially the same length, such that the spacing between the fint and second mesh 12 is substantially uniform across the panel 10. However, in an alternative embodiment, the connecting members 13 may comprise a variabk length, sgch that the spacing between the first and second mesh 11,12 can yaw acrxss the pane! 10.

It Is envisaged that this variable separation may be used to reduce the effect of any undulMlpns in the underlying waft or a stcpfng waft for examplc, so that the outermost mesh can be presented to the plasterer (not shown) as, a substantially flat and if necessary, vertical guide for the render.

Referring also to fIgure 3 of the drawings, the pahel 10 further comprises a plurality of open regions 14 1n the flrst'mesh 11 and a plurality otsolid regions 15 in the second mesh 12. The regIons 14,15 are rezularly arranged on each mesh 11, 12 so that the open reEions 14 on the first mesh ii can become aligned adjacent the solid regions 15 of the second mesh 12. The open regions 14 enable a Estener to pass through the first mesh ii and couple with the adjacent solid regions 15. In particular, the fasteners are arranged to pass through an aperture 16 In the solid regions 15, for fastening the panel 10 to a waft of a property, such as an external watt.

ReMrring to figure 4 of' the drawings; there is illustrated a render support panel assembly 20 according to an embodiment of the present, Invention. The assembly Illustrates the support panel described above and, so lIke festures have been referenced using the same numerals. In use, the panel 10 Is arranged to secure a thermal insulation layer, such as a rigid thermal insulation board 30 between the panel 10 and an underlying wall 40;, sch as an external walt'of a property (not shown) and also to provide a mechanical key for the application of a traditional cernentitious render (ndt shown) and/or' art acrylIc render.

The panel 10 and thus the Insulation layer 3Ois secured to the wall 40 usIng a plurality of fasteners 50. the fasteners 50 comprise a head portion or disc 51 which is sized to be smaller than the open regions 14 formed in the FIrst mesh 11, and an elongate coupling portion or shaft $2 which is rigidly coupled to a central portion of the disc 51. The elongate shaft $2 Is arranged to. pass through an aperture 16 in the soli4 region 15 at the second mesh 12 so that the disc S can abut the solid re$ion 15. In this respect, the diameter of the dIsc Slis sized to be larger than the diameter at the aperture 16. The elongate shaft 1 is arranged to piss Into an aperture (nut shown) formed within the Insulation layer 30 and the underlying wall 40 to secure the panel 10: to the wall 40. To resist the mayernent of the fastener 50 out from the aperture in the wait 40. the elongate shitft 52 may comprise a plurality of barbs 53 which are inclined relatIve to an axis of the shaft 52. Alternatively, the shaft 52 nwy comprise an externally threaded portion $4 for screwing the ftner 130 into the aperture (not shown) in the wall 40.

It Is envisaged that the open regions 14 on the lkst mesh 11 may present areas of the panel 10 .5 whereby the render may not adhere and so nce the panel 10 hn been suitably secured to the wall, one or more inserts 60 may then be placed within the open regions 14 of the First mesh U to cover the disc 51 of the fasteners SQ and provide for a uniform distribution of the first mesh 11 qver the wall 40. It is&nvisaged that the incerts60 may be sizedto lormasnap-fit within the open regions 14.

Once the panel 10 has been suitably coupled to the wall, a plasterer (not shown) raay then apply the render to the panel 10 to cover the wall 40 and the insulation boards 30. The panel 10 further comprises a plurality of protruding rIbs 17 which extend along the panel 10, outwardly from the plane of the first mesh 11. These protruding ilbs 17 are arranged to extmnd approximateLy 1-3mm from the first mesh 11 and serve tn assist the plasterer In achieving a smooth, even thickness of render across the panel 10.

The present invention extends in a further embodiment to a thermal insulation board 70, as illustrated Ip figure $ of the drawings. In this embodiment, It is envisaged that the above described support panel 10 and In particular the second mesh 12 may be chemically bonded to an insulation board 30 Or othetwlse n*cbarilcalty coupled thereto using staples tnot shown), for example4 This arrangement is thought to provide fora more readily achievabl coçzplg of the tnsulatlo 31) and panel 10 to an. external wall 40 for example, Since It obviates the requirement to drill en aperture in the insulation 30 and wall 40, while holding the panel 10 and!nsuation 30 suItably alIgned against, the watt 40 rorn the foregoing therefore, ft is evident that the support pane asst*mbiy and thermal Insulation board provide for the application o a traditional cementitlous render to srnçoth surfaces and ir! particular, facilitate the application of ttadl$*nai cementitious render to insulating boards used when external insulating properties.