NZ246395A

NZ246395A - Edge joint of polymer concrete panels timber framed on their rear faces: panels have repeating surface relief-pattern eg brick-like or stone-like appearance

Info

Publication number: NZ246395A
Application number: NZ246395A
Authority: NZ
Inventors: Ebrahim Bagus; Adriaan Johannes Robertson
Original assignee: Worldwide Building Systems Nv
Priority date: 1991-12-11
Filing date: 1992-12-10
Publication date: 1996-08-27
Also published as: CZ142594A3; HU9401635D0; EP0618989B1; MY107848A; AU667207B2; SK70394A3; BR9206911A; WO1993012308A1; DE69210628D1; IL103947A; HUT71273A; CA2125501A1; IL103947A0; RU94030371A; AP9200460A0; OA09957A; AU3268393A; AP362A; ATE137834T1; BG98845A

Description

New Zealand No. International No. 246395 TO BE ENTERED AFTER ACCEPTANCE AND PUBUCAT10N Priority dates: 2.5-3-°IZ International filing date: /<?- /2.-^2.

Classification: to^ei/oo, 7*; ;•38; E04FI3ll(* Pubfication date: ^ g 1996 Journal No.: NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION Title of invention: Panel structure and panel for use in forming such structure Name, addrt^s and nationality of applicant(s) as in international application form: WORLDWIDE BUILDING SYSTEMS NV, 1-5 Plaza, Jojo Correa, WiHemstad, Curacao, Netherlands Antilles. 24 6 3 THIS INVENTION relates to a panel structure and to a panel for use In forming such a structure.

It is often desired to provide the exposed face of a building structure with a repeating pattern 5 which gives the structure the appearance of having been built from bricks and mortar or by some other traditional building method which results in a repeating surface pattern. The approach heretofore has been to provide such a building structure with a 10 structural part which alone is sufficient to give the structure its strength and then to clad this structural part with cladding panels which give the structure its desited appearance. The erection of such a structure is therefore essentially a two-part operation, the 15 first being to erect the strength-giving structural part and the second being the installation o£ the cladding panels.

An example of such a prior art structure can be found in US-A-4 299 069.

It is an object of the present invention to provide a structure whose erection, essentially is a one-part operation, consisting of the fastening together of panels to form the structure, the panels themselves giving the structure its structural strength 25 as well as the desired appearance, and where, with no or little additional work, the joint between adjacent panels is effectively concealed.

According to the invention there is provided a panel structure comprising first and second panels 30 which are arranged in an edge-to-edge abutting relationship to form a joint between the panels, each panel having a .jiepeailiig^juili^f pJattern in an exposed \ 10 m 1994 ! J -2a- 24 8 3 In a further alternative arrangement the recesses may be in the edge of the polymer concrete panel of the first panel, so as to give the edge a toothed configuration.

The relief pattern may be such as to imitate the appearance of brickwork, the panel elements each being rectangular to imitate the appearance of a brick.

Each panel may further comprise a sheet of fabric attached to and spanning the framework, the 10 fabric being embedded in a resin which is bonded to the polymer concrete of the polymer concrete panel.

Each panel may further comprise a heat insulating material in voids formed by the respective framework.

The panels may each have a groove along the abutting edges thereof -he grooves being in register with one another and tnere being a sealing strip which extends from one of the grooves into the other.

• The sealing strip may be embedded in a 20 sealing substance in each of the grooves. The sealing substance may, for example, be a polysulphide sealant.

Further according to the invention there is provided a building panel for use in a panel structure as defined above, the building panel comprising a 25 structural panel of polymer concrete having said relief pattern formed in the front face thereof, and a framework secured to and standing proud of the rear face of the polymer concrete panel.

The invention will now be described in more 24 6 3 9 front face thereof, which relief pattern repeats itself substantially without interruption across the joint, characterised therein that each panel comprises a structural panel of polymer concrete having said relief pattern formed in the front face thereof, and a framework secured to and standing proud of the rear face of the polymer concrete panel, and that the first and second panels are secured together by fasteners which engage with the respective frameworks.

The polymer concrete panel of the first panel may have recesses therein, and the panel structure may further comprise panel elements which extend from the polymer concrete panel of the second panel into the recesses, the panel elements forming part of the relief pattern.

The recesses may be in the front face of the polymer concrete panel of the first panel, the panel elements overlying the polymer concrete panel of the first panel.

There may be recesses in the front face of the polymer concrete panel of the second panel, the panel elements extending into the recesses of, and overlying, the polymer concrete panel of the second panel.

The panel elements may be secured in position by means of an adhesive.

The adhesive may be of a type that remains yieldable after it has set. For example, it may be a polysulphide adhesive.

In an alternative arrangement the panel elements may be integral with the second panel. 3- detail, by way of example, wi"th reference to the accompanying drawings.

In the drawings: Figure 1 is a front elevation of a building panel 5 in accordance with the invention; Figure 2 is a rear elevation of the building panel; Figure 3 is a section on III-III in Figure 1; Figure 4 is a detail of part of Figure 3; 10 Figure 5 is a detail front elevation of part of a panel structure made up of building panels of the type illustrated in Figures 1 to 4, before installation of panel elements; Figure 6 shows the panel structure of Figure 5, 15 after the panel elements have been Installed; Figure 7 is a section on VII-VII in Figure 6; Figure B is an exploded pictorial view of part of the panel structure of Figures 5 to 7; Figure 9 is an exploded pictorial view of part of 20 an alternative form of panel structure in accordance with the invention; and Figure 10 is an exploded pictorial view of part of a further alternative form of panel structure in accordance with the invention.

Referring first to Figures 1 to 4, reference numeral 10 generally indicates a building panel which comprises a panel 12 of polymer concrete, a supporting framework 14 of timber affixed to the rear face of the polymer concrete panel, and a heat insulating material 30 16 of, for example, expanded polystyrene or a mineral heat insulation material filling the voids formed by the framework. 2 4 6 5 9S N.Z. PATENT OFFICE 1 7 MAY 1996 RECEIVED The polymer concrete panel 12 has a repeating relief pattern in a face thereof which will, in use, be 246395 the exposed face, ie the face shown in Figure 1. In the example illustrated, the relief pattern is such as to imitate the appearance of stretcher bond brickwork. In other words, the panel has rows of raised 5 rectangular portions 18 which are spaced from each other, each raised portion representing a brick, and the spaces between the raised portions representing mortar joints. Along each of the vertical eiges of the polymer concrete panel 12 there are recesses 20 in the 10 exposed face o£ the panel. The recesses 20 an>. formed by the absence in alternate rows, of the raised portions which would otherwise have been at the ends of the rows to represent half a brick. One of the vertical edges of the panel (the right hand one in 15 Figure 1) is flush with the corresponding ends of the raised portions 18, whereas the other vertical edge (the left hand one in Figure 1) is spaced from the corresponding ends of the raised portions by a distance which is'equal to the spacing between adjacent raised 20 portions (ie the width of a mortar joint).

The building panels 10 may, if desired, incorporate window or door frames (not shown).

The polymer concrete panel 12 is formed by casting polymer concrete, while still in a fluid 25 condition, in a silicone rubber mould (not shown) which has ridges therein to form the relief pattern.

Polymer concrete is made of a mixture of crushed silicate or stone aggregate and a suitable plastics resin to which a hardener and an accelerator have been added.

The framework 14 has a sheet of fabric 22 (eg a glass fibre fabric) secured thereto by means of, for example, staples 24, the fabric sheet spanning the framework. The . framework 14 with the fabric sheet 22 attached thereto is placed on the polymer concrete in the mould, with the fabric sheet contacting the polymer iO 93/12308 PCT/N L92/00222 246 3 9 concrete, before the polymer concrete has fully hardened, and the fabric Impregnated with a coat of plastics resin to which a hardener and an accelerator have been added. This will have the effect of bonding 5 the fabric sheet 22, and thus the framework 14, to the polymer concrete panel 12. The resin impregnated fabric sheet 22 furthermore reinforces the polymer concrete panel 12 and renders it water-impermeable.

The framework 14 is rebated as shown, which 10 results in a groove 26 being formed peripherally of the building panel, immediately behind the polymer concrete panel 12.

Once the resin has hardened, the panel 10 is removed from the mould.

Referring now to Figures 5 to 8, reference numeral 30 generally Indicates a panel structure which comprises a number of building panels 10 of the type illustrated in Figures 1 to 4, joined together in an edge-to-edge abutting relationship. To secure the 20 building panels 10 together the frameworks 14 are drilled to receive fixing bolts 32. If necessary, part of the heat insulating material 16 Is cut away to enable the fixing bolts 32 to be inserted and fastened. Before fastening a pair of adjacent building panels 25 together, a suitable sealant such as, for example, a polysulphide sealant is> run along the opposed grooves 26 and a PVC sealing strip 34 inserted, the sealing strip extending from the one groove 26 into the other.

Once the panels 10 have been erected, panel 30 elements 36 of the same polymer concrete as the panels 12 are secured in position by means of an adhesive, The panel elements 36 are rectangular, each imitating [0 93/12308 L4 6 3 9 5 the appearance of a single brick, and are accommodated In the recesses 20. As furthermore shown in Figure 5, panel elements 36 may also be used where two of the panels 10 join one another along a horizontal joint.

The adhesive that Is used to secure the panel elements 36 in position Is preferably an adhesive that is able to yield somewhat even after it has set. A polysulphide may, for example, be used for this purpose. It will be seen that, once the panel elements 10 36 are in position, the relief pattern repeats itself substantially without interruption across the joints between the panels. The panel elements 36 thus effectively conceal the joints between adjacent panels 10. This is so even if there should be slight movement 15 between the panels subsequent to erection.

To finish off the construction, an inner panel 38 of, for example, gypsum board is nailed to the inside to the framework 14.

The panel construction shown in Figure 9 is 20 similar to that shown in Figures 5 to 8, the same reference numerals being used to indicate the same parts. It differs from the construction shown in Figures 5 to 8 in that, instead of separate panel elements 36 being employed, panel elements 40 are 25 provided which are integral with the polymer concrete panel 12. When erected, the panel elements 40 are accommodated in the recesses 20.

The panel construction shown in Figure 10 is also similar to that shown in Figures 5 to 8, the same 30 reference numerals being used to indicate the same parts. It differs from the construction shown in Figures 5 to 8 in that, instead of the panels having recesses 20 in the exposed face thereof, they have recesses 42 in one of the vertical edges thereof so as 24 6 39 5 -to give -the edge a toothed configuration. Likewise, they have panel elements 44 along the other vertical edge thereof, the panel elements being integral with the polymer concrete panel 12. The panel elements 44 are of the same thickness as the polymer concrete panel 12 and so give this edge of the panel also a toothed configuration. When erected, the panel elements 44 enter into the recesses 42. 8 24 6 3 f j

Claims

WHAT WE CLAIM IS:

1. A structural assembly comprising first and second panels which are arranged in an edge-to-edge abutting relationship to form a joint between the panels, each panel having a repeating relief pattern in an exposed front face thereof, which relief pattern repeats itself substantially without interruption across the joint, characterised therein that each panel comprises a structural panel of polymer concrete as hereinbefore defined having said relief pattern formed in the front face thereof, and a framework secured to and standing proud of the rear face of the polymer concrete panel, and that the first and second panels are secured together by fasteners which engage with the respective frameworks.

2. An assembly as claimed in claim 1, characterised therein that the polymer concrete panel of the first panel has recesses therein, and that the panel structure further comprises panel elements which extend from the polymer concrete panel of the second panel into the recesses, the panel elements forming^ part of the relief pattern. t|

3. An assembly as claimed in claim 2, ^ \ v> characterised therein that the recesses are xn the front face of the polymer concrete panel of the first panel, and that the panel elements overlie the polymer concrete panel of the first panel. 24639 9

4. An assembly as claimed in claim 3, characterised therein that there are recesses in the front face of the polymer concrete panel of the second panel, and that the panel elements extend into the 5 recesses of, and overlie, the polymer concrete panel of the second panel.

5. An assembly as claimed in claim 4, characterised therein that the panel elements are secured in position by adhesive. 10

6. An assembly as claimed in claim 5, characterised therein that the adhesive is of a type that remains yieldable after it has set.

7. An assembly as claimed in claim 6, characterised therein that the adhesive is a 15 polysulphide adhesive.

8. An assembly as claimed in claim 3, characterised therein that the panel elements are integral with the second panel.

9. An assembly as claimed in claim 2, 20 characterised therein that the recesses are in the edge of the polymer concrete panel of the first panel, so as to give the edge a toothed configuration.

10 . An assembly as claimed in any one of claims 2 to 9, characterised therein that the relief pattern is 25 such as to imitate the appearance of brickwork, and that the panel elements are each rectangular to imitate the appearance of a brick.

11. An assembly as claimed in any one of the N Z. PATENT OffK* 1 7 MAY 1996 L received 10 240 39 5 preceding claims, characterised therein that each panel further comprises a sheet of fabric attached to and spanning the respective framework, the fabric being embedded in a resin which is bonded to the polymer 5 concrete panel.

12. An assembly as claimed in claim 11, characterised therein that each panel further comprises a heat insulating material in voids formed by the respective framework. 10

13. An assembly as claimed in any one of the preceding claims, characterised therein that the panels each have a groove along the abutting edges thereof, the grooves being in register with one another and there being a sealing strip which extends from one of 15 the grooves into the other.

14. An assembly as claimed in claim 13, characterised therein that the sealing strip is embedded in a sealing substance in each of the grooves.

15. An assembly as claimed in claim 14, 20 characterised therein that the sealing substance is a polysulphide sealant.