GB2551478A - An artificial wall panel and method of formation thereof - Google Patents

An artificial wall panel and method of formation thereof Download PDF

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Publication number
GB2551478A
GB2551478A GB1608417.0A GB201608417A GB2551478A GB 2551478 A GB2551478 A GB 2551478A GB 201608417 A GB201608417 A GB 201608417A GB 2551478 A GB2551478 A GB 2551478A
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GB
United Kingdom
Prior art keywords
artificial
panel
facing
filler
compositions
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1608417.0A
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GB201608417D0 (en
Inventor
Anthony Michael Parrish John
Frederick Smith Thomas
John Smith Robert
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tarmac Building Products Ltd
Original Assignee
Tarmac Building Products Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tarmac Building Products Ltd filed Critical Tarmac Building Products Ltd
Priority to GB1608417.0A priority Critical patent/GB2551478A/en
Publication of GB201608417D0 publication Critical patent/GB201608417D0/en
Publication of GB2551478A publication Critical patent/GB2551478A/en
Withdrawn legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E04F13/147Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer imitating natural stone, brick work or the like
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/041Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres composed of a number of smaller elements, e.g. bricks, also combined with a slab of hardenable material

Abstract

The method includes using two facing compositions each comprising by volume a major proportion of powdered stone and a minor proportion of particulate mica a first colouring agent and a binder. The compositions are distinguished by having different colouring agents. A mould 1 is coated with the compositions so that the surface of the mould is covered with both compositions. A filler is introduced allowing the compositions to cure. Insulation may be attached to the wall panel and may be attached via mechanical or adhesive. A reinforcing member may be inserted into the filler and be partially exposed and be connected to the insulation.

Description

Title: An artificial wall panel and method of formation thereof.
Description of Invention
This invention relates to an artificial wall panel and, more particularly, to an artificial wall panel which includes at least two facing compositions having different colours to each other. The invention also resides in a method of forming such an artificial wall panel.
In recent times property developers have been struggling to meet increasing demands to build new homes and buildings. Reasons for this include a growing shortage of building resources, such as bricks, and also the diminishing supply of skilled labourers, particularly bricklayers. Moreover, the skilled labourers that are available command higher real wages than in previous years, meaning that it is not as cost effective as it used to be for property developers to build in the conventional way.
To address this problem efforts have been made to provide artificial wall panels to be used in place of walls assembled by conventional bricklaying methods. Such artificial wall panels can be factory created and transported to a building site in a state ready to be assembled into a building - for instance by connecting the artificial wall panel to a pre-assembled foundation wall. It is to be appreciated that buildings can be assembled on site very quickly using this technique, in contrast to conventional bricklaying methods.
One type of artificial wall panel involves utilising brick slips that are fixed to a backing member in a manner to simulate the appearance of a brick wall. Brick slips are tiles that are either cut from an existing brick or tiles that are manufactured using similar techniques to the way in which bricks are manufactured. This type of artificial wall panel has a realistic appearance because, when installed, the outward facing part of the wall panel is formed of slips of real bricks. However, these wall panels suffer from the same drawbacks as described above, in that they are heavily reliant on building resources (which are in short supply) and/or they are costly to manufacture because, for example, they require the services of skilled labourers to fix the brick slips to the backing member. It is to be appreciated that this can be laborious.
Thus, efforts within the industry have been directed towards the development of an artificial wall panel which utilises facing materials intended to imitate a real brick wall. However, to date, it has not been possible to provide such a wall panel having a “real-life” brick effect.
It is to be appreciated that the surfaces of real bricks are mottled by discolorations and burn spots, typically caused by coke or other organic inclusions in the clay. The challenge has been to imitate these mottled discolorations to the extent that a person in the trade would have great difficulty in establishing whether an artificial wall panel is indeed artificial or whether it has been formed by using brick slips.
The applicant is currently unaware of any artificial wall panels utilising imitation facing materials that have been commercialised successfully due to the fact that it is unmistakable that such artificial wall panels are imitation.
Embodiments of the invention provide an artificial wall panel (and method of formation thereof) that seeks to overcome, or at least substantially reduce, the disadvantages discussed above.
In one aspect of the invention, we provide a method of forming an artificial wall panel, the method including the steps of: providing a first facing composition containing, by volume, a major proportion of powdered stone, a minor proportion of particulate mica, a first colouring agent and a binder therefor; providing a second facing composition containing, by volume, a major proportion of powdered stone, a minor proportion of particulate mica, a second colouring agent and a binder therefor, the second colouring agent having a different colour to the first colouring agent; coating the interior surface of a mould with a quantity of the first facing composition and a quantity of the second facing composition such that parts of the interior surface of the mould are covered by the first and second facing compositions; and introducing to the mould a filler and allowing the first and second facing compositions and the filler to cure.
The applicant has surprisingly discovered that by providing two or more facing compositions containing a major proportion of powdered stone, a minor proportion of mica, whereby each facing composition has a different colour, it can be possible to create an artificial wall panel having the mottled effect of a brick wall formed from real bricks.
In some embodiments, the first and second facing compositions may be allowed to at least partially cure prior to the introduction of the filler. For instance, the first and second facing compositions may be allowed to partially cure for at least 30 minutes (e.g. 30 minutes to 4 hours) prior to the introduction of the filler. In some embodiments, the first and second facing compositions may be allowed to cure fully prior to the introduction of the filler. For instance, the first and second compositions may be allowed to cure for over 12 hours.
In some embodiments, insulation (such as polyurethane) may be attached to the artificial wall panel to provide an insulated artificial wall panel. For instance, the insulation may be attached to the filler once the filler has cured.
In some embodiments, the insulation may be provided in the form of a board or from a roll.
In some embodiments, the insulation may be attached to the artificial wall panel using adhesive or by mechanical means, such as rivets or screws.
In some embodiments, a part of the insulation may be brought into contact with the filler as the filler is curing so that the filler itself bonds the insulation to the artificial wall panel.
In some embodiments, at least one longitudinal reinforcing member (such as a rigid, e.g. metal, rod) may be at least partially inserted into the filler as the filler is curing so as to provide the artificial wall panel with reinforcement. For instance, the or each longitudinal reinforcing member may be at least partially inserted into the filler so that the length thereof is substantially parallel to the plane of the artificial wall panel. Alternatively, the or each longitudinal reinforcing member may be at least partially inserted into the filler so that the length thereof is substantially orthogonal to the plane of the artificial wall panel.
In some embodiments, the insulation may be directly or indirectly connected to an exposed (or at least partially exposed) part of the or each longitudinal reinforcing member.
In a second aspect, we provide an artificial wall panel formed by: providing a first facing composition containing, by volume, a major proportion of powdered stone, a minor proportion of particulate mica, a first colouring agent and a binder therefor; providing a second facing composition containing, by volume, a major proportion of powdered stone, a minor proportion of particulate mica, a second colouring agent and a binder therefor, the second colouring agent having a different colour to the first colouring agent; coating the interior surface of a mould with a quantity of the first facing composition and a quantity of the second facing composition such that parts of the interior surface of the mould are covered by the first and second facing compositions; and introducing to the mould a filler and allowing the first and second facing compositions and the filler to cure.
In some embodiments, one or more further facing compositions may be provided, the or each facing composition including a respective colouring agent having a different colour to the first and second colouring agents.
In some embodiments, the first and/or second and/or further (if present) colouring agents may include one or more respective organic or inorganic pigments, such as ferric oxides.
In some embodiments, the respective first and/or second and/or further (if present) facing compositions may include, by volume, 1.5 to 8 parts of powdered stone and one part of mica.
In some embodiments, the respective first and/or second and/or further (if present) facing compositions may include, by volume, 2 to 6 parts of powdered stone and one part of mica.
In some embodiments, the respective first and/or second and/or further (if present) facing compositions may include, by volume, 2.5 to 4 parts of powdered stone and one part of mica.
In some embodiments, the stone may be in the form of dust or flour grade.
In some embodiments, the binder may be hydraulic cement, such as Portland cement.
In some embodiments, the mica may be of 20-100 mesh particle size.
In some embodiments, the filler may be concrete or screed, e.g. self-levelling screed.
Further features of the invention are set out in the dependent claims thereto which are appended hereto.
Embodiments of the various aspects of the invention will now be described by way of example only and with reference to the accompanying drawings, of which:
Figure 1 shows a step during a mould forming process;
Figure 2 is a plan view of the interior surface of the mould of Figure 1 ready for coating;
Figure 3 is a plan view of the mould that has been filled in accordance with the invention;
Figure 4 shows an artificial wall panel in accordance with a first embodiment; and
Figure 5 shows an artificial wall panel in accordance with a second embodiment.
Referring first to figure 1, and prior to carrying out the invention, a mould, indicated generally at 1, may be created. The mould 1 may be created by arranging an array of real bricks 2 within a frame 3, the frame 3 having the dimensions of the mould 1 that is to be created with the real bricks 2 being arranged in a desired pattern.
The real bricks 2 may be fixed relative to the frame 3. A material (e.g. expanding foam filler) may be introduced into the gaps 4 between the real bricks 2 to a depth of approximately 6 to 12 mm, e.g. 8 mm, short of the upper surface of the real bricks 2. A mould-forming solution is poured over the real bricks 2 and into the gaps 4 before being allowed to cure. Non-limiting examples of a mould-forming solution include silicone rubber solution and urethane rubber solution. The mould-forming solution is allowed to cure to form the mould 1, which mould 1 can then be removed from the frame 3 (as shown in figure 1). It is to be appreciated, therefore, that the mould 1 is a negative of the array of real bricks 2 and also a negative of the to-be formed artificial wall panel.
Figure 2 is a plan view of the mould 1 of figure 1 with its interior surface 10 facing upwards. The interior surface 10 is demarcated by series of first 10a and second ridges 10b, the first ridges 10a being perpendicular to the second ridges 10b. The height of the ridges 10a, 10b is determined by the quantity of material that has been introduced into the gaps 4 between the real bricks 2 when creating the mould 1. Thus, the heights of the ridges 10a, 10b are typically 6 to 12 mm, e.g. 8 mm. The ridges 10a, 10b demarcate parts 5 of the mould 1 whereby each part 5 defines one brick of the to-be-formed artificial wall panel.
Methods of forming an artificial wall panel according to the invention will now be described. A first facing composition containing, by volume, a major proportion of powdered stone, a minor proportion of particulate mica, a first colouring agent and a binder therefor is provided. A second facing composition containing, by volume, a major proportion of powdered stone, a minor proportion of particulate mica, a second colouring agent and a binder therefor is also provided.
Optional further facing compositions may be provided having the same or similar constituents as the first and second facing compositions.
The first, second and further (if present) facing compositions each include a colouring agent having a unique colour such that the colour of the facing compositions differ from one another.
The colouring agents may include inorganic pigments, such as ferric oxides.
The colouring agents may have yellow, orange, red, brown, black, white, purple, blue or green colours. Examples of inorganic pigments that display these colours are known in the art and can be sourced from distributors such as LANXESS (www.lanxess.com).
Parts 5 of the interior surface of the mould 1 are at least partially covered by the first facing composition and parts 5 are at least partially covered by the second and any optional further facing compositions. For reasons that will become apparent further below it is desirable to avoid coating the ridges 10a, 10b with any of the facing compositions. In other words, it is desirable to only coat the interior surfaces of the parts 5 with the facing compositions. In at least one part 5 of the mould 1, it is essential that the first, second and further (if present) facing compositions make contact with the interior surface itself, so that each of the facing compositions can be visible once the artificial wall panel has been removed from the mould 1.
The first, second and further (if present) facing compositions may be introduced by spraying, painting or pouring. The ratio of first, second and further (if present) facing compositions may vary in one part 5 when compared to another part 5. This is so that different visual effects can be achieved at various locations across the surface of the artificial wall panel. For instance, at least one part 5 may be covered only by the first facing composition, at least one part 5 may be covered only by the second facing composition, and at least one part 5 may be covered by first and second facing compositions. The or each part 5 covered by first and second facing compositions may be covered by an equal quantity of each or by a major quantity of the first facing composition and a minor quantity of the second facing composition, or vice versa.
Referring now to figure 3, filler (e.g. concrete) 6 is then introduced to the mould 1 over the first, second and further (if present) facing compositions. The facing compositions and the filler 6 are allowed to cure. Once cured, the resultant artificial wall panel can be removed from the mould 1.
Artificial wall panels formed using this method display a mottled effect that would otherwise only be displayed on a wall formed of real bricks or an artificial wall formed using brick slips. Without being bound by any strict theory, it is considered that the presence of mica, which has a characteristic shimmer, in the facing compositions and the fact that there are at least two facing compositions of differing colour results in the desired effect.
In some embodiments it may be desirable to form an insulated artificial wall panel. Therefore, insulation (such as polyurethane board) may be attached to the rear surface of the artificial wall panel. It is to be appreciated that there are numerous ways in which the insulation could be attached to the artificial wall panel. For instance, insulation may be adhered or mechanically attached to the artificial wall panel. The insulation could be attached to the artificial wall panel prior to assembling the combined artificial wall panel and insulation into a building. Alternatively, the insulation may be attached to a pre-assembled foundation wall prior to mounting the artificial wall panel thereto.
In some embodiments the insulation may be attached to the artificial wall panel during manufacture thereof. For instance, the insulation could be brought into contact with the filler as the filler is curing so that the filler itself bonds the insulation to the artificial wall panel.
In some embodiments it may be desirable to form a reinforced artificial wall panel (which could be insulated or not). In such embodiments a rigid rod may be at least partially inserted into the filler as the filler is curing. The rigid rod could be inserted into the filler such that its length is substantially parallel to the plane of the artificial wall panel. Alternatively, the rigid rod could be inserted into the filler such that its length is substantially orthogonal to the plane of the artificial wall panel.
In embodiments having both insulation and reinforcement, the insulation could be directly or indirectly connected to an exposed part of the rigid rod.
Example 1
First and second facing compositions were made up from 4 parts by volume of powdered limestone to one part of mica and one part of Portland cement binder, with sufficient water to produce sprayable mortars. The first facing composition was coloured by an orange pigment and the second facing composition was coloured by a red pigment. The first and second facing compositions were then sprayed into the mould 1 as described above before being allowed to at least partially cure for approximately 1 hour. Filler 6 was then introduced to the mould 1 over the first and second facing compositions and the facing compositions and filler 6 were allowed to fully cure. The artificial wall panel 7 depicted by figure 4 was removed from the mould 1.
As can be appreciated, certain parts 5a of the artificial wall panel 7 exhibit a mottled effect which gives the wall panel 7 the appearance of a wall formed from real bricks or an artificial wall formed using brick slips. It is clear that there are parts 5b that display only the first (orange) facing composition. Thus, not all parts 5a, 5b need display a mottled effect.
The filler 6 is also visible from the facing side of the artificial wall panel 7. It is to be appreciated that the filler 6 is intended to represent mortar between the individual bricks. This effect is achieved by ensuring that the ridges 10a, 10b are not covered by any of the facing compositions, as described above.
Example 2
First and second facing compositions were made up from 1.5 parts by volume of powdered limestone to one part of mica and one part of Portland cement binder, with sufficient water to produce sprayable mortars. The first facing composition was coloured by a yellow pigment and the second facing composition was coloured by a red pigment. The first and second facing compositions were then sprayed into the mould 1 as described above before being allowed to at least partially cure for approximately 1 hour. Filler 6’ was then introduced to the mould 1 over the first and second facing compositions and the facing compositions and filler 6’ were allowed to fully cure. The artificial wall panel 7’ depicted by figure 5 was removed from the mould 1.
As can be appreciated, certain parts 5a’ of the artificial wall panel 7’ exhibit a mottled effect which gives the wall panel 7’ the appearance of a wall formed from real bricks or an artificial wall formed using brick slips. It is clear that there are parts 5b’ that display only the first (yellow) facing composition. Thus, not all parts 5a’, 5b’ need display a mottled effect.
The filler 6’ is also visible from the facing side of the wall panel 7’ as in the first example.
It has been found that the method of the present invention results in an artificial wall panel characterised by a mottled effect that very closely resembles the discolorations and burn spots of real bricks. It is considered by the applicant that those in the trade would have great difficulty in establishing (by appearance) whether an artificial wall panel of the invention is indeed artificial or not.
Thus, embodiments of the invention are considered to provide a quick and cost effective method of forming an artificial wall panel having the appearance of a brick wall formed using real bricks or an artificial wall panel formed using brick slips.
When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.
The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims (19)

Claims
1. A method of forming an artificial wall panel, the method including the steps of: providing a first facing composition containing, by volume, a major proportion of powdered stone, a minor proportion of particulate mica, a first colouring agent and a binder therefor; providing a second facing composition containing, by volume, a major proportion of powdered stone, a minor proportion of particulate mica, a second colouring agent and a binder therefor, the second colouring agent having a different colour to the first colouring agent; coating the interior surface of a mould with a quantity of the first facing composition and a quantity of the second facing composition such that parts of the interior surface of the mould are covered by the first and second facing compositions; and introducing to the mould a filler and allowing the first and second facing compositions and the filler to cure.
2. A method according to claim 1, wherein the first and second facing compositions are allowed to at least partially cure prior to the introduction of the filler.
3. A method according to claim 1 or claim 2, wherein insulation is attached to the artificial wall panel to provide an insulated artificial wall panel.
4. A method according to claim 3, wherein the insulation is provided in the form of a board or from a roll.
5. A method according to claim 3 or claim 4, wherein the insulation is attached to the artificial wall panel using adhesive or mechanical means.
6. A method according to any one of claims 3 to 5, wherein a part of the insulation is brought into contact with the filler as the filler is curing so that the filler itself bonds the insulation to the artificial wall panel.
7. A method according to any preceding claim, wherein at least one longitudinal reinforcing member is at least partially inserted into the filler as the filler is curing so as to provide the artificial wall panel with reinforcement.
8. A method according to claim 7, when dependent on any one of claims 3 to 6, wherein the insulation is directly or indirectly connected to an exposed or at least partially exposed part of the or each longitudinal reinforcing member.
9. An artificial wall panel formed by the method of any one of claims 1 to 8.
10. An artificial wall panel according to claim 9, wherein the first and/or second colouring agents include one or more respective organic or inorganic pigments.
11. An artificial wall panel according to claim 9 or claim 10, wherein the respective first and/or second facing compositions include, by volume, 1.5 to 8 parts of powdered stone and one part of mica.
12. An artificial wall panel according to claim 9 or claim 10, wherein the respective first and/or second facing compositions include, by volume, 2 to 6 parts of powdered stone and one part of mica.
13. An artificial wall panel according to claim 9 or claim 10, wherein the respective first and/or second facing compositions include, by volume, 2.5 to 4 parts of powdered stone and one part of mica.
14. An artificial wall panel according to any one of claims 9 to 13, wherein the stone is in the form of dust or flour grade.
15. An artificial wall panel according to any one of claims 9 to 14, wherein the binder is a hydraulic cement.
16. An artificial wall panel according to any one of claims 9 to 15, wherein the mica is of 20-100 mesh particle size.
17. A method of forming an artificial wall panel substantially as hereinbefore described.
18. An artificial wall panel substantially as hereinbefore described with reference to and as shown in the accompanying drawings.
19. Any novel feature or novel combination of features described herein and/or shown in the accompanying drawings.
GB1608417.0A 2016-05-13 2016-05-13 An artificial wall panel and method of formation thereof Withdrawn GB2551478A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1608417.0A GB2551478A (en) 2016-05-13 2016-05-13 An artificial wall panel and method of formation thereof

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1608417.0A GB2551478A (en) 2016-05-13 2016-05-13 An artificial wall panel and method of formation thereof

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GB201608417D0 GB201608417D0 (en) 2016-06-29
GB2551478A true GB2551478A (en) 2017-12-27

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050087908A1 (en) * 2003-10-24 2005-04-28 Moe Nasr Simulated stone and masonry and brick textured siding panels
US20070227087A1 (en) * 2003-10-24 2007-10-04 Crane Plastics Company Llc Method of manufacturing simulated stone, brick, and masonry panels and wall structures
US20090056257A1 (en) * 2003-10-24 2009-03-05 Crane Building Products Llc Foaming of simulated stone structures

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050087908A1 (en) * 2003-10-24 2005-04-28 Moe Nasr Simulated stone and masonry and brick textured siding panels
US20070227087A1 (en) * 2003-10-24 2007-10-04 Crane Plastics Company Llc Method of manufacturing simulated stone, brick, and masonry panels and wall structures
US20090056257A1 (en) * 2003-10-24 2009-03-05 Crane Building Products Llc Foaming of simulated stone structures

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