GB2589958A

GB2589958A - Applicator and method for forming an adhesive layer

Info

Publication number: GB2589958A
Application number: GB2014288.1A
Authority: GB
Inventors: Coyle Sean
Original assignee: Keystone Lintels Ltd
Current assignee: Keystone Lintels Ltd
Priority date: 2019-09-10
Filing date: 2020-09-10
Publication date: 2021-06-16
Also published as: GB202014288D0; GB201913018D0

Abstract

Provided is an applicator 1 suitable for creating a profile in a layer of adhesive such as mortar or cement. The applicator 1 comprises a profile-forming means 2 including a means 3 for forming a pointing region and a means 4 for forming an attachment region, where an item such as a tile or a brick slip can be attached. The profile-forming means can include notches 6 in the pointing region 3 and notches 7 in the attachment region 4. The applicator 1 can be formed of a resilient/flexible material such as plastic; and be controlled mechanically, electrically, hydraulically, pneumatically. Also provided is a method of forming an adhesive layer on a substrate, the method comprising: introducing adhesive to the surface of the substrate; and then forming a profiled layer of the adhesive, wherein the profile includes a pointing region and a region where a covering element, such as a tile or brick slip, can be attached.

Description

APPLICATOR AND METHOD FOR FORMING AN ADHESIVE LAYER

The present invention relates to an applicator for spreading adhesive such as mortar on a substrate prior to affixing covering elements such as brick slips to the substrate.

Applicators are used to spread layers of adhesive such as mortar on a fixing surface prior to affixing covering elements, such as brick slips or tiles, thereto. Applicators which have notches in their edges allow an installer to form patterned layers of adhesive, providing several advantages over flat and uniform layers. Firstly, use of a notched applicator allows the installer to control the volume of adhesive used per unit area of the fixing surface, making sure that an appropriate amount of adhesive is used for each covering element. Furthermore, gaps between the elongate spans of adhesive allow the adhesive to spread out under pressure, allowing the height of each covering element to be adjusted and made level with its neighbours. Spreading out of the adhesive also compensates for any unevenness of the substrate.

When installing a plurality of covering elements on a substrate using an adhesive, each covering element must be carefully placed relative to the adjacent covering elements in order to create the desired pattern. This is time consuming since the covering elements must be correctly spaced with appropriate gaps between them. Current applicators provide no way of guiding the placement of covering elements on the patterned layer of adhesive and zo considerable skill is required on the part of the installer. Furthermore, after the covering elements have been attached to the substrate with the adhesive it is necessary to 'fill in' gaps between adjacent covering elements by 'pointing' or 'grouting'. This is a time-consuming process and requires the use of e.g. a finger pointing trowel to smooth over the adhesive in the gaps.

It is an object of the invention to obviate or mitigate the problems outlined above. In particular, it is an object of the invention to reduce the amount of time required to adhere covering elements to a substrate.

It is a further object of the invention to provide an applicator for adhesive which can 30 provide guidance for the spacing between covering elements.

It is a yet further object of the invention to provide an applicator for adhesive which removes the need for separate adhesive spreading and pointing/grouting operations.

According to a first aspect of the invention there is provided a method of forming an adhesive layer on a substrate for the attachment of covering elements thereto, the method comprising: introducing a quantity of adhesive to a surface of the substrate; and forming a profiled layer of adhesive on the substrate, wherein the profiled layer of adhesive includes at least one pointing region and at least one covering element attachment region.

Advantageously, the inclusion of a pointing region in the profiled layer of adhesive provides guidance for the placement of covering elements on the layer of adhesive. This reduces the skill and judgement required by the installer to place covering elements in the correct position on the substrate.

Preferably the method comprises introducing a quantity of tile or brick adhesive to the surface Ideally the method comprises introducing a quantity of mortar to the surface.

Preferably the method comprises introducing a quantity of epoxy-based adhesive to the surface Preferably the method comprises laying a bed or dollops of adhesive on the surface of the substrate.

Ideally the method comprises introducing a quantity of adhesive to a surface of a masonry substrate such as a concrete wall, a metal substrate such as a lintel or panel, a wooden 15 substrate such as a chipboard backing panel or a magnesium oxide particle board.

Ideally the method comprises using an applicator to form the profiled layer of adhesive on the surface of the substrate.

Optionally, the method comprises using a non-manual applicator.

Ideally, the method comprising using a machine operated applicator.

Preferably, the method comprising using mechanical, electrical, electronic, electromechanical, hydraulic or pneumatic control means or any combination of these for controlling the operation of the applicator.

Optionally the method comprises using a robot-mounted applicator to form the profiled layer of adhesive on the surface of the substrate.

Preferably the method comprises spreading the quantity of adhesive on the surface of the substrate.

Ideally the method comprises applying a shear force to the layer of adhesive.

Preferably a shear force is applied to the layer of adhesive using the applicator. Preferably the method comprises using a feeder to introduce adhesive to the surface in 30 front of, through or beside the applicator.

Ideally, the method comprises using a hopper to introduce adhesive to the surface in front of, through or beside the applicator.

Ideally the method comprises forming one or more elongate spans of adhesive on the substrate.

Ideally the method comprises forming on the substrate one or more elongate spans of adhesive having a uniform cross section.

Preferably the method comprises forming on the substrate one or more elongate spans of adhesive having a constant volume per unit length.

Preferably the method comprises forming on the substrate one or more elongate spans of adhesive each having a triangular, trapezoidal, rectangular, square or semicircular cross section.

Ideally the method comprises forming on the substrate one or more regions with 5 substantially no adhesive.

Ideally the method comprises forming on the substrate, between elongate spans of adhesive, one or more regions with substantially no adhesive, said regions having a width of 0-10 mm.

Preferably the method comprises forming a single elongate span of adhesive in the 10 pointing region.

Preferably the method comprises forming an elongate span of adhesive having a rectangular cross section in the pointing region.

Preferably the method comprises forming an elongate span of adhesive having a height of 5-25 mm in the pointing region. The height is measured in a direction normal to the planar 15 surface of the substrate.

Ideally the method comprises forming an elongate span of adhesive having a height of between 6 mm and 8 mm and most preferably 7 mm in the pointing region.

Preferably the method comprises forming an elongate span of adhesive having a width of 5-25 mm in the pointing region. The width is measured in the direction between adjacent 20 covering elements.

Ideally the method comprises forming an elongate span of adhesive having a width of between 8 mm and 12 mm and most preferably 10 mm in the pointing region.

Preferably the method comprises covering the entire width of the pointing region with a single elongate span of adhesive.

Preferably the method comprises covering a 10 mm-wide pointing region with a single elongate span of adhesive.

Ideally the method comprises forming a plurality of elongate spans of adhesive in the covering element attachment region.

Ideally the method comprises forming, in the covering element attachment region, one 30 or more elongate spans of adhesive having a triangular cross section.

Optionally the method comprises forming, in the covering element attachment region, one or more elongate spans of adhesive having a rectangular cross section.

Preferably the method comprises forming, in the covering element attachment region, one or more elongate spans of adhesive having a height of 2-10 mm.

Ideally the method comprises forming, in the covering element attachment region, one or more elongate spans of adhesive having a height of 4 mm.

Preferably the method comprises forming, in the covering element attachment region, one or more elongate spans of adhesive having a width of 2-15 mm.

Ideally the method comprises forming, in the covering element attachment region, one or more elongate spans of adhesive having a width of 6 mm.

Preferably the method comprises forming one or more elongate spans of adhesive in the covering element attachment region having a height which is less than the height of the or each 5 elongate span of adhesive in the pointing region.

Preferably the method comprises forming a covering element attachment region having a width of between 10 mm and 500 mm.

Preferably the method comprises forming a covering element attachment region having a width of between 60 to 70 mm and most preferably at least 65 mm, having a width of between 10 95 to 110 mm and most preferably at least 102 mm or having a width of between 210 to 220 mm and most preferably at least 215 mm.

Preferably the method comprises forming a covering element attachment region having a width that is equal to or greater than the width of a brick slip.

Preferably the method comprises placing one or more covering elements on the profiled 15 layer of adhesive.

Preferably the method comprises placing one or more masonry slips, brick slips, composite slips, glass reinforced plastic (GRP) slips or tiles on the profiled layer of adhesive.

Preferably the method comprises placing a covering element on the profiled layer of adhesive in the covering element attachment region.

Preferably the method comprises placing a covering element on the profiled layer of adhesive in a position that is adjacent to and/or abuts the pointing region.

Preferably the method comprises pressing the covering element into the profiled layer of adhesive. Advantageously, pressing the covering element into the profiled layer of adhesive causes the elongate spans of adhesive to spread out, allowing adjustment of the height of the covering element and increasing the surface area of adhesive which is in contact with the covering element to ensure that the covering element makes good contact with the adhesive.

Preferably the method comprises repeating the steps of placing and pressing covering elements on the layer of adhesive. Advantageously, this creates a course of covering elements which are aligned along one edge of each covering element and a pointing region.

Preferably the method comprises introducing a further quantity of adhesive to the surface of the substrate adjacent to a quantity of adhesive and/or course of covering elements on the substrate and forming a further profiled layer of adhesive adjacent to a quantity of adhesive and/or course of covering elements on the substrate.

Preferably the method comprises forming a pointing region in a region which is adjacent 35 to a previously-placed covering element.

Preferably the method comprises placing multiple covering elements such that adjacent covering elements or courses of covering elements are separated by a pointing region.

Preferably the method comprises repeating one or more of the method steps until the entire surface or a portion of the surface of the substrate is covered with profiled layers of adhesive and/or covering elements.

According to a second aspect of the invention there is provided an applicator for forming a profiled layer of adhesive, the applicator comprising a profile forming means wherein the profile forming means includes at least one pointing region forming means and at least one attachment region forming means.

Advantageously, the applicator allows an installer to create both an attachment surface 10 for covering elements to be attached to as well as a pointing region using a single tool. This reduces the amount of time taken to install covering elements on the surface.

Ideally the applicator is formed of a rigid material.

Preferably the applicator is formed of a resilient and/or flexible material.

Preferably the applicator is formed of a plastic, composite or metal.

Ideally the applicator comprises a body.

Preferably the applicator body is planar.

Preferably the applicator body comprises a base having an edge. Preferably the base has a virtual edge which is linear or straight.

Preferably the applicator comprises a top edge opposite the base and two lateral side edges which connect the base and the top.

Optionally the applicator comprises a plurality of pointing region forming means. Optionally the applicator comprises a plurality of attachment region forming means. Preferably the applicator comprises a handle integrally formed with or attached to the body. Advantageously, the handle improves the ease with which the applicator can be manipulated in order to spread adhesive over the surface of a substrate.

Optionally, the applicator is a non-manual applicator.

Ideally, the applicator is a machine operated applicator.

Preferably, the applicator comprises a mechanical, electrical, electronic, electromechanical, hydraulic or pneumatic control means or any combination of these for controlling the operation of the applicator.

Optionally the applicator is a robot-mounted applicator which is mechanically manipulated by a robotic arm.

Preferably the profile forming means is located at the base edge of the applicator.

Preferably the applicator includes multiple profile forming means on separate edges of the applicator.

Preferably the multiple profile forming means located on separate edges of the applicator have pointing region forming means and/or attachment region forming means of different dimensions.

Preferably the profile forming means is formed across the full width of base edge.

Ideally the profile forming means comprises one or more notches.

Preferably the or each notch is formed by removing a portion of material from an edge of the applicator.

Preferably the attachment region forming means is located adjacent to the pointing region forming means.

Preferably the pointing region forming means and the attachment region forming means are located on a single edge of the applicator.

Ideally the pointing region forming means comprises a pointing region notch.

Preferably the pointing region notch has a rectangular or square cross section. Preferably the pointing region notch has at least one straight edge.

Preferably the pointing region notch has at least one curved edge.

Preferably the pointing region notch has a width dimension and a height dimension.

Preferably the width of the pointing region notch is 5-25 mm.

Ideally the width of the pointing region notch is 10 mm.

Ideally the height of the pointing region notch is 5-25 mm.

Ideally the height of the pointing region notch is 7 mm.

Preferably the pointing region forming means is located at a peripheral edge of the profile forming means.

Ideally the attachment region forming means has a regularly patterned profile.

Ideally the attachment region forming means has a saw-tooth profile.

Optionally the attachment region forming means has a crenellated profile.

Ideally the attachment region forming means comprises one or more attachment region notches.

Preferably the or each attachment region notch has a triangular, trapezoidal, rectangular, square or semicircular cross section.

Preferably the or each attachment region notch has a width dimension and a height dimension.

Preferably the width of the or each attachment region notch is 2-15 mm.

Ideally the width of the or each attachment region notch is 6 mm.

Preferably the height of the or each attachment region notch is 2-10 mm.

Ideally the height of the or each attachment region notch is 4 mm.

Ideally the height of the or each attachment region notch is less than the height of the pointing region notch.

Preferably the attachment region forming means has a width of between 10 mm and 500 MM.

Preferably the attachment region forming means has a width of between 60 to 70 mm and most preferably at least 65 mm, having a width of between 95 to 110 mm and most preferably 5 at least 102 mm or having a width of between 210 to 220 mm and most preferably at least 215 mm.

Ideally the attachment region forming means comprises a regular arrangement of attachment region notches.

Ideally the attachment region forming means comprises three or more equally spaced 10 attachment region notches.

Optionally each attachment region notch is separated from a neighboring notch by a portion of the base edge of the applicator.

Optionally each attachment region notch is separated from a neighboring notch by a distance of 10 mm.

It will be appreciated that optional features applicable to one aspect of the invention can be used in any combination, and in any number. Moreover, they can also be used with any of the other aspects of the invention in any combination and in any number. This includes, but is not limited to, the dependent claims from any claim being used as dependent claims for any other claim in the claims of this application.

The invention will now be described with reference to the accompanying drawings which show, by way of example only, two embodiments of an apparatus in accordance with the invention.

Figure 1 is a plan view of first embodiment of an applicator in accordance with an aspect 25 of the invention.

Figure 2 is a cross sectional view of a substrate to which an adhesive has been applied. Figure 3 is a cross sectional view of the applicator of figure 1 and a substrate to which an adhesive has been applied.

Figure 4 is a cross sectional view of a substrate and a profiled layer of adhesive.

Figure 5 is a cross sectional view of a substrate having a layer of adhesive and a plurality of covering elements.

Figure 6 is a plan view of an second embodiment of an applicator in accordance with an aspect of the invention.

In Figure 1 there is shown an embodiment of an applicator indicated generally by the numeral 1. The applicator comprises a profile forming arrangement 2 which includes a pointing region forming arrangement 3 and an attachment region forming arrangement 4. The applicator 1 is formed of a rigid material and comprises a planar body 5 with a base edge 5a, a top edge 5b, and two lateral side edges Sc, 5d which connect the base and the top edges 5a, 5b. The attachment region forming arrangement 4 is located adjacent to the pointing region forming arrangement 3 on the base edge 5a of the applicator 1. The profile forming arrangement 2 is formed across the full width of base edge 5a. The profile forming arrangement 2 comprises a pointing region notch 6 and a plurality of attachment region notches 7. Each notch is formed by removing a portion of material from the base edge 5a of the applicator 1.

The pointing region notch 6 has a rectangular cross section with a straight face edge 6a and a straight side edge 6b. The pointing region notch 6 has a width of 10 mm and a height of 7 mm, these being the lengths of the face edge 6a and the side edge 6b of the notch, respectively.

The pointing region notch 6 is located at a peripheral edge of the profile forming arrangement 2 i.e. adjacent to a lateral side edge 5c.

The attachment region forming arrangement 4 has a saw-tooth profile and includes a plurality of triangular attachment region notches 7 in a regular arrangement. Each attachment region notch 7 has a width of 6 mm and a height of 4 mm with a first edge 7a and a second edge 7b. The height 40 of each attachment region notch 7 is less than the height 30 of the pointing region notch 6. The attachment region forming arrangement has a full width of greater than 65 mm, 102 mm or 215 mm i.e. greater than the width of a standard brick slip.

The applicator 1 is used to form a profiled layer of adhesive 8 on the surface 9a of a substrate 9 for the subsequent attachment of covering elements 10 to the substrate 9. In the zo preferred embodiment the covering elements 10 are masonry slips, brick slips, composite slips, glass reinforced plastic (GRP) slips or files and the adhesive is a file or brick adhesive such as mortar. The substrate 9 is a masonry substrate such as a concrete wall, a metal substrate such as a steel panel or lintel, a wooden substrate such as a chipboard backing panel or a magnesium oxide particle board or similar particle board.

In the first step of the method, a quantity of adhesive 8 is introduced to a surface of the substrate that will be covered by covering elements 10. The adhesive 8 is introduced to the surface by laying a bed of adhesive or placing dollops of adhesive onto the surface 9a of the substrate 9. Figure 2 shows a layer of mortar 8 which has been introduced to the surface 9a of substrate 9 at a location that is adjacent to a covering element 10 which has already been fixed to the substrate.

In the second step of the method the adhesive 8 is formed into a profiled layer using the applicator 1 (figure 3). The profiled layer is formed by the profile forming arrangement 2 which applies a shear force to the adhesive 8 when the applicator 1 is dragged across said adhesive 8 in a direction substantially perpendicular to the main body 5 of the applicator 1 and across the substrate 9. The act of dragging the applicator 1 spreads the adhesive 8 and may be repeated several times in order to properly form the profiled layer of adhesive 8. During the dragging operation, the extremity of the attachment region forming arrangement 4 (i.e. the extremity of the base edge of the applicator 1 which can be thought of as lying along a virtual straight edge) contacts the surface 9a of substrate 9, and the peripheral edge 5c of the applicator 1 on the side of the pointing region notch 6 makes contact with the exposed edge of a previously laid covering element 10. The edge of the previously laid covering element 10 is used as a guide to allow a substantially straight dragging action across the surface 9a.

The result of forming the adhesive 8 into a profiled layer is shown in figure 4. The profiled layer includes a pointing region 11 and a covering element attachment region 13. After the forming step, the profiled layer of adhesive 8 comprises a plurality elongate spans of adhesive, each elongate span having a uniform cross section with a constant volume per unit length. The entire width of the pointing region is covered by a single span of adhesive and the width of the attachment region is covered by a plurality of elongate spans of adhesive. All of the elongate spans of adhesive are parallel. Each elongate span of adhesive is separated from neighbouring spans of adhesive by a region with substantially no adhesive. In the example of figure 4 the region with substantially no adhesive is very thin but in alternative embodiments the region with substantially no adhesive may be wider up to 10 mm.

In the pointing region the single span of adhesive 11 has a rectangular cross section corresponding to the shape of the pointing region notch 6 in applicator 1 with a face edge ha and a side edge 11 b, as shown in figure 4. The elongate span of adhesive 11 has a height of 7 mm and a width of 10 mm, the width of the span of adhesive 11 being equal to the total width of the pointing region. As can be seen in figures 3 and 4, the pointing region is located adjacent to the previously placed covering element 10.

In the covering element attachment region 12 there is formed a plurality of parallel elongate spans of mortar 13 each having a triangular cross section having faces 13a and 13b, as shown in figure 4. The cross section of the mortar in the covering element attachment region 12 corresponds to the shape of the covering element attachment region notches in applicator 1. Each elongate span of adhesive 13 in the covering element attachment region 12 has a height of 4 mm and a width of 6 mm. The height of each elongate span of adhesive 13 in the covering element attachment region 12 is less than the height of the elongate span of adhesive 11 in the pointing region. The full width of the covering element attachment region is larger than 65 mm, 102 mm or 215 mm i.e. greater than the width of a covering element 10. It will of course be appreciated that the dimensions are exemplary only and any dimensions to suit the requirements can be readily achieved.

After the layer of adhesive 8 has been formed into a profiled layer using the applicator 1, a covering element 10 is placed on the profiled layer of adhesive in the covering element attachment region 12. The covering element 10 is placed in a position such that an edge of the covering element 10 is adjacent to the pointing region and abuts the side edge 11 b of the adhesive 11 in the pointing region. During installation, the side edge 11 b of the elongate span of adhesive 11 is used as a guide for the placement of further covering elements 10 in the course.

The covering element 10 is pressed into the profiled layer of adhesive 8 so that the elongate spans of adhesive 13 in the attachment region 12 spread out and are compressed to a height of approximately 3 mm. The height of the covering element 10 above the surface 9a can therefore be set/adjusted and the surface area of the adhesive 8 that is in contact with the covering element 10 is increased to ensure good bonding.

The steps of introducing adhesive to the substrate 9, forming the profiled layer of adhesive and placing and pressing covering elements 10 on the layer of adhesive 8 are repeated as many times as is necessary to create the desired coverage of the surface with covering elements and adhesive/mortar. Covering elements 10 in each course are aligned along an edge 11b of adhesive in a pointing region and covering elements 10 in successive courses are separated by a pointing region. Once all of the covering elements have been placed in position the adhesive is allowed to cure, typically for 24 hours.

Figure 6 shows a second embodiment of an applicator indicated generally by the numeral 101. This second applicator 100 is similar to the first applicator except that the second applicator 15 101 comprises two pointing region forming arrangements 103 and two attachment region forming arrangements 104.

As will be understood by the skilled person, a number of potential modifications to the above embodiment of the invention are possible without departing from the scope of the invention. For example, the applicator may be formed from any suitable resilient and/or flexible, plastic, zo composite or metal material such as PVC or steel. The applicator 1,101 may comprise a handle that is integrally formed with or attached to the body 5. Incorporation of a handle with the applicator improves the ease with which the applicator can be manipulated in order to spread adhesive over the surface of a substrate. Alternatively or additionally the applicator 1,101 may be mounted on a robotic arm for example to allow adhesive to be applied to the substrate in an automated manner.

Any suitable adhesive 8 may be used to attach covering elements 10 to the substrate 9 including epoxy-based adhesives. The adhesive 8 may be introduced to the surface of substrate 9 using a feeder which introduces adhesive to the surface 9 in front of, through or beside the applicator.

The applicator 1,101 may be used to form pointing regions/elongate spans of mortar along multiple directions by running the applicator 1,101 in a number of e.g. perpendicular directions or along perpendicular edges of multiple covering elements 10. The pointing region notch 6 may include one straight edge and one concave or convex curved edge, or two curved edges. The width of the pointing region notch 6 may be between 1 mm and 40 mm or between 5 mm and 25 mm. The height of the pointing region notch 6 may be between 1 mm and 40 mm or between 5 mm and 25 mm.

The attachment region forming arrangement 4,104 may have a crenellated profile and the or each attachment region notch 7 may have a trapezoidal, rectangular, square or semicircular cross section. The width of the or each attachment region notch 7 may be between 1 mm and 40 mm or between 2 mm and 10 mm and the height of the or each attachment region notch 7 may be between 1 mm and 40 mm or between 5 mm and 25 mm. The attachment region forming arrangement 12 can have any suitable width such as between 10 mm and 500 mm or between 50 mm and 250 mm. The attachment region forming arrangement 12 may comprise three or more equally spaced attachment region notches 7 and each of these may be separated from a neighboring notch 6,7 by a portion of the base edge 5a of the applicator 1,101 e.g. by a distance of 10 mm.

The method of forming an adhesive layer on a substrate may include forming any number of pointing regions/attachment regions simultaneously and the applicator 1,101 may include any 10 number of pointing region forming arrangements 3,103 and any number of attachment region forming means 4,104.

The or each elongate span of adhesive 11,13 may have a triangular, trapezoidal, rectangular, square or semicircular cross section. Each region with substantially no adhesive may have a width in the range 0-10 mm. The elongate span of adhesive 11 in the pointing region may have a height of between 1 and 40 mm or between 5 mm and 25 mm and a width of between 1 and 40 mm or between 5 mm and 25 mm. The adhesive height in the pointing region can vary depending on the covering element thickness and may match the thickness of a covering element, the thickness of the covering element being e.g. 7 mm or any thickness in the range of 5-25 mm or in the range of 1-40 mm. Alternatively, the adhesive height in the pointing region may be less than the thickness of the covering element e.g. a 7mm thick covering element with a 5mm high adhesive in the pointing region. The width of the pointing region itself may be between 1 mm and 40 mm or between 5 mm and 25 mm. The or each elongate span of adhesive in the covering element attachment region 13 may have a rectangular or square cross section, a height of between 1 and 40 mm or between 2 mm and 10 mm, and a width of between 1 and 40 mm or between 2 mm and 15 mm. The width of the covering element attachment region 13 may be between 10 mm and 500 mm or between 50 mm and 250 mm. It will of course be appreciated that the dimensions are exemplary only and any dimensions to suit the requirements can be readily achieved.

In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of the values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of the parameter, lying between the more preferred and the less preferred of the alternatives, is itself preferred to the less preferred value and also to each value lying between the less preferred value and the intermediate value.

The features disclosed in the foregoing description or the following drawings, expressed in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of 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 as defined in the appended claims.

Claims

CLAIMS1. A method of forming an adhesive layer on a substrate for the attachment of covering elements thereto, the method comprising: introducing a quantity of adhesive to a surface of the substrate; and forming a profiled layer of adhesive on the substrate, wherein the profiled layer of adhesive includes at least one pointing region and at least one covering element attachment region.
2. The method as claimed in claim 1, further comprising introducing a quantity of tile or brick adhesive or mortar or epoxy-based adhesive to the surface.
3. The method as claimed in claim 1, further comprising laying a bed or dollops of adhesive on the surface of the substrate.
4. The method as claimed in any preceding claim, wherein the method comprises introducing a quantity of adhesive to a surface of a masonry substrate such as a concrete wall, a metal substrate such as a lintel or panel, a wooden substrate such as a chipboard backing panel or a particle board such as a magnesium oxide particle board.
5. The method as claimed in any preceding claim, wherein the method comprises using an applicator to form the profiled layer of adhesive on the surface of the substrate.
6. The method as claimed in any preceding claim, wherein the method comprises using a machine operated applicator.
7. The method as claimed in claim 5, wherein the method comprises applying a shear force to the layer of adhesive using the applicator.
8. The method as claimed in any claim 5 or 7, wherein the method comprises using a feeder to introduce adhesive to the surface in front of, through or beside the applicator.
9. The method as claimed in any preceding claim, wherein the method comprises forming one or more elongate spans of adhesive on the substrate.
The method as claimed in any preceding claim, wherein the method comprises forming on the substrate one or more regions with substantially no adhesive.
11 The method as claimed in any preceding claim, wherein the method comprises forming a single elongate span of adhesive in the pointing region.
12 The method as claimed in any preceding claim, wherein the method comprises forming a covering element attachment region having a width of between 60 to 70 mm and most preferably at least 65 mm, or having a width of between 95 to 110 mm and most preferably at least 102 mm or having a width of between 210 to 220 mm and most preferably at least 215 mm.
13 The method as claimed in any preceding claim, wherein the method comprises forming a covering element attachment region having a width that is equal to or greater than the width of a brick slip.
14 The method as claimed in any preceding claim, wherein the method comprises placing one or more covering elements on the profiled layer of adhesive.
The method as claimed in any preceding claim, wherein the method comprises placing multiple covering elements such that adjacent covering elements or courses of covering elements are separated by a pointing region.
16 An applicator for forming a profiled layer of adhesive, the applicator comprising a profile forming means wherein the profile forming means includes at least one pointing region forming means and at least one attachment region forming means.
17 An applicator as claimed in claim 16, wherein the applicator is formed of a resilient and/or flexible material.
18 An applicator as claimed in claim 16 or claim 17, wherein the applicator body is a planar body comprising a base having an edge.
19 An applicator as claimed in any one of claims 16 to 18, wherein the applicator is a machine operated applicator.
20 An applicator as claimed in any one of claims 16 to 19, wherein the applicator comprises a mechanical, electrical, electronic, electromechanical, hydraulic or pneumatic control means or any combination of these for controlling the operation of the applicator.
21 An applicator as claimed in claim 18, wherein the profile forming means is located at the base edge of the applicator.
22 An applicator as claimed in claim 16, wherein the applicator includes multiple profile forming means on separate edges of the applicator, the multiple profile forming means located on separate edges of the applicator have pointing region forming means and/or attachment region forming means of different dimensions.
23 An applicator as claimed in any one of claims 16 to 22, wherein the profile forming means is formed across the full width of base edge.
24 An applicator as claimed in any one of claims 16 to 23, wherein the profile forming means comprises one or more notches.An applicator as claimed in any one of claims 16 to 24, wherein the pointing region forming means is located at a peripheral edge of the profile forming means.