WO2005090033A1 - Materiau a effet brique - Google Patents

Materiau a effet brique Download PDF

Info

Publication number
WO2005090033A1
WO2005090033A1 PCT/GB2005/001075 GB2005001075W WO2005090033A1 WO 2005090033 A1 WO2005090033 A1 WO 2005090033A1 GB 2005001075 W GB2005001075 W GB 2005001075W WO 2005090033 A1 WO2005090033 A1 WO 2005090033A1
Authority
WO
WIPO (PCT)
Prior art keywords
brick
effect
mixture
substrate
regions
Prior art date
Application number
PCT/GB2005/001075
Other languages
English (en)
Inventor
Tony De Marco
Alan Craigie
Original Assignee
Tony De Marco
Alan Craigie
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 Tony De Marco, Alan Craigie filed Critical Tony De Marco
Publication of WO2005090033A1 publication Critical patent/WO2005090033A1/fr

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
    • B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0453—Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F11/00—Designs imitating artistic work
    • B44F11/06—Imitation of ceramic patterns
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings 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
    • E04F13/14—Coverings 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
    • E04F13/147—Coverings 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
    • B28B7/0073—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with moulding surfaces simulating assembled bricks or blocks with mortar joints
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2002/005—Appearance of panels
    • E04C2002/007—Panels with the appearance of a brick wall

Definitions

  • the present invention relates to a material for providing a surface having the appearance of brickwork.
  • the invention also extends to a method for producing the material and a method of providing a surface using the material .
  • Building walls from bricks and mortar is also expensive and time-consuming. Therefore it may be desirable to build a wall using a less expensive method and then provide a surface decoration that gives the impression of a brick wall. It is known to decorate walls with brick slips or tiles that are manufactured from fired clay.
  • the present invention provides a method of forming a brick-effect material comprising: providing a substrate; forming at least one brick-effect region on the substrate from a mixture comprising brick particles and adhesive; and allowing the mixture to harden.
  • the present invention provides a relatively inexpensive way to produce a material with the appearance of brick.
  • the present invention provides a decorative material comprising a substrate and at least one brick-effect region on the substrate, wherein the brick-effect region is formed from a mixture comprising brick particles and adhesive.
  • the present invention provides a relatively inexpensive material with the appearance of brick.
  • the brick-effect region is substantially rectangular in order to give the appearance of the visible surface of a standard brick.
  • the brick-effect region typically has a length and height corresponding to that of a standard brick, i.e. 225 mm by 75 mm.
  • the thickness of the brick-effect region is preferably less than 25 mm, and in the preferred embodiment is approximately 12 mm.
  • the material comprises a plurality of brick-effect regions each having the appearance of a discrete brick.
  • the brick-effect regions may be arranged in a brickwork pattern on the substrate.
  • the brick-effect regions are spaced and the spaces between the brick-effect regions are pointed.
  • a panel may be formed which can be mounted on a surface, such as a wall, and instantly provides the surface with the appearance of brickwork.
  • Such panels are relatively inexpensive and simple to produce and are quick and easy to fix to existing structures or frames.
  • a brick-effect surface can be installed in a building in a greatly reduced time and at greatly reduced cost.
  • the invention provides a brick-effect panel formed according to the above method or from the above material .
  • the invention provides a method of providing a surface having the appearance of brickwork, the method comprising fixing a plurality of the above panels to a support.
  • the support may be an existing wall or floor or may be a support structure, such as a timber framework.
  • the panels of the invention may be used as building materials mounted to a framework to create walls with the appearance of brickwork.
  • the arrangement of brick-effect regions may include at least one gap devoid of a brick-effect region proximate the periphery of the panel.
  • the gap may be dimensioned to be approximately half the length of the brick-effect regions.
  • the brick-effect regions are arranged in a traditional brickwork pattern with each row of bricks offset from the neighbouring rows by one half brick length, a gap corresponding to a half-brick length is defined at the end of alternate rows on the panel .
  • a gap corresponding to a half-brick length is defined at the end of alternate rows on the panel .
  • the invention provides a method of providing a surface having the appearance of brickwork, the method comprising: fixing a plurality of the panels to a support such that the gaps on adjacent panels form a space for at least one additional brick-effect region; and fixing, for example with adhesive, at least one additional brick-effect region in the space.
  • the method may further comprise pointing around the additional brick-effect region.
  • the periphery of the panel may be substantially coterminous with the edge of the brickwork pattern of the brick-effect regions. In this way, the panels may interlock to form a continuous brickwork pattern.
  • the interface between adjacent panels may be pointed when the panels have been mounted to the surface to be decorated.
  • the substrate may be flexible.
  • the substrate is substantially rigid.
  • the substrate may be a sheet or board of any suitable material.
  • a wooden board is preferred and in the particular embodiments described, the substrate is a plywood board.
  • the substrate may be formed of a fireproof material .
  • the substrate may have a textured or roughened surface to ensure satisfactory adhesion of the brick-effect regions.
  • the substrate may be textured with a saw.
  • the brick particles may be of any suitable size.
  • the brick particles may have a maximum diameter of 5 mm or less, preferably 3 mm or less. Crushed brick, brick powder or any other particulate brick material may be used.
  • the brick particles need not be formed from brick clay, but -may be formed from another material, such as crushed limestone, coloured as necessary to provide a brick effect in the resultant material.
  • Any suitable adhesive may be used in the mixture.
  • a particularly preferred adhesive is polyvinyl acetate (PVA) .
  • the presently preferred adhesive is Evo-Stik 9517 multi- purpose PVA.
  • a cross-linker may be added.
  • the mixture may comprise additional components, for example water.
  • the preferred mixture comprises one part adhesive, one part water and sufficient crushed brick to make a flowing mixture .
  • the mixture further comprises glass fibres.
  • the mixture may be applied to the substrate or the substrate may be applied to the mixture.
  • An adhesive layer may be provided between the substrate and the mixture.
  • the adhesive in the adhesive layer may be the same adhesive as that in the mixture or a different adhesive. Conveniently, the same adhesive is used.
  • the mixture may be formed on the substrate in a continuous layer and the discrete brick-effect regions may be defined by removing or displacing portions of the mixture, for example by stamping a brickwork pattern onto the layer of mixture.
  • the brick-effect region is defined by a mould for the mixture, which preferably defines a plurality of brick- effect regions. The mould may be positioned on the substrate (and adhesive layer, if required) and the mixture may be poured into the mould. Alternatively, the components of the mixture may be mixed in the mould.
  • the mould may be vibrated, or otherwise mechanically agitated, with the mixture in the mould, to allow the mixture to slump and fill the voids in the mould. Compression forces may further be applied to the upper surface of the mould to further compress the mixture .
  • the mould may be formed from a sheet of material with cut-outs to define the brick-effect regions.
  • a suitable material is medium density fibreboard (MDF) , fibre glass, rubber or other elastomer.
  • MDF medium density fibreboard
  • the edges of the mould which define the brick-effect regions may be tapered to allow easy separation of the mould from the material .
  • the mixture may be allowed to harden naturally. However, for rapid manufacture, the mixture is preferably hardened by heating or a similar hardening process.
  • a decorative panel comprising a plurality of brick-effect regions mounted on a substrate to give the appearance of brickwork.
  • the brick-effect regions may be mutually spaced and pointed in the spaces between adjacent brick-effect regions.
  • Figure 1 illustrates the formation of a brick- effect panel according to the invention
  • Figure 2 is a perspective view of a panel made as shown in Figure 1
  • Figure 3 is a view of a wall formed from the panels of Figure 2.
  • an 8 ft x 4 ft x 1/2 in (2.4 mx 1.2 mx 12 mm) plywood board 1 is laid on a flat table.
  • the plywood board 1 is coated with PVA adhesive (not shown) and a cut-out mould 2 defining a brickwork pattern is positioned on the board 1.
  • the depth of the mould 2 is typically 12 mm, which represents the desired thickness of the brick pattern on the panel .
  • a mixture 3 of crushed brick, PVA adhesive and water is made up. Brick particles having a diameter from 3 mm down to small dust particles can be used.
  • the components of the mixture are typically combined with sufficient crushed brick and one part adhesive to one part water in order to form a flowing mixture 3.
  • the mixture also includes glass fibres. The fibres are typically 6 mm long and are mixed into the mixture at a ratio of approximately 0.9 kg of glass fibres per m 3 of crushed brick.
  • the mixture 3 is then poured into each compartment of the mould 2 by travelling.
  • the table upon which the board 1 is placed has a vibratory action, which allows the mixture 3 to slump and fill the voids of the mould 2.
  • the mixture can be further compressed within the mould using a roller applied to the upper surface of the mould. Alteratively, the compression could be piston driven or a roller press could be used.
  • heat is applied to the surface of the mixture 3 by blowing warm air over it to set the mixture 3.
  • the mould 2 is released leaving a panel 4 with the appearance of a brick wall, as shown in Figure 2.
  • the panel is placed in an oven for about 20 minutes at 250°C. As shown in Figure 2, the panel 4 has every half brick on the sides left blank.
  • the half brick spaces 5 line up to make full brick spaces. These spaces 5 can then be filled . with a full-size brick slip 6 made from the mixture of crushed brick, water and adhesive.
  • a full-size brick slip 6 made from the mixture of crushed brick, water and adhesive.
  • the panels 4 are lined up so that these half brick spaces 5 align and leave full brick spaces at every other row along the join. These spaces are filled in by adhering pre-made brick dust brick slips 6 into these voids and further pointing with the mortar paste.
  • the panels 4 can be used for turning corners to reproduce a brick corner effect. In the case of window reveals, the overall effect does not differ from a traditional brick building except that the brick-effect panel 4 is perfect.
  • the weight of one panel 4 is easily managed by two persons. However, if weight is an issue, the thickness of the board 1 and/or the thickness of the brick-effect layer may be reduced, which would also reduce cost.
  • the major application of the panels 4 is in prefabricated or timber-framed buildings.
  • the advantages over the traditional system of bricklaying are speed, a relatively lightweight structure and the cost of the finished structure.
  • the panels 4 may also be used in other applications, such as mobile home cladding, sectional site offices, showroom display, exhibition work or DIY home improvement .
  • the present invention has been described in the context of brick-effect panels, the invention could be applied to panels providing other effects.
  • a brick-effect panel is formed on a substrate by pouring a mixture of brick particles and adhesive into a mould and allowing the mixture to harden.
  • the brick-effect panels are relatively inexpensive and can be used to quickly construct a wall with the appearance of brickwork.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Finishing Walls (AREA)

Abstract

La présente invention concerne un panneau à effet brique formé sur un substrat (1) par coulage d'un mélange (3) de particules de briques et d'un adhésif dans un moule (2), puis durcissement dudit mélange (3). Les panneaux à effet brique obtenus selon le mode de réalisation décrit dans cette invention sont relativement bon marché et ils peuvent être utilisés pour construire rapidement un mur ayant l'apparence d'un mur en briques.
PCT/GB2005/001075 2004-03-19 2005-03-21 Materiau a effet brique WO2005090033A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0406295A GB2412125A (en) 2004-03-19 2004-03-19 Panel simulating brickwork
GB0406295.6 2004-03-19

Publications (1)

Publication Number Publication Date
WO2005090033A1 true WO2005090033A1 (fr) 2005-09-29

Family

ID=32118076

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2005/001075 WO2005090033A1 (fr) 2004-03-19 2005-03-21 Materiau a effet brique

Country Status (2)

Country Link
GB (1) GB2412125A (fr)
WO (1) WO2005090033A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014077576A1 (fr) * 2012-11-15 2014-05-22 Tak Seung Ho Module cadre de corps mural permettant à un mur en briques d'être construit sans briques

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1792883B1 (fr) * 2005-12-01 2014-04-16 Newstone s.r.l. Panneau de parement et methode de production

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2819495A (en) * 1951-10-03 1958-01-14 Krausz Isidor Method of making building blocks
US3177279A (en) * 1961-10-19 1965-04-06 Cavrok Mfg Company Method of molding a decorative building panel
WO1983002472A1 (fr) * 1982-01-18 1983-07-21 LARSEN, Hans, Sondergaard Element isolant en forme de plaque avec un parement en coquille dans un motif de pierre pour une construction et son procede de production
US4647000A (en) * 1984-05-02 1987-03-03 Hideharu Osada Flexible mold for forming simulated tile or brick surfaces

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB345617A (en) * 1929-12-18 1931-03-18 Arthur Ernest Everard Cuckow Improvements in or relating to fibro cement building sheets and the like
DK104393C (da) * 1963-07-10 1966-05-09 Ejlert Engen Væg- og facadebeklædningsmateriale bestående af et bøjeligt underlag forsynet med af fuger adskilte felter af med elastisk formstof sammenbundet pulvermasse.
GB1376895A (en) * 1970-12-10 1974-12-11 Banbury Buildings Holdings Ltd Simulated brick article of concrete or like material
GB1463311A (en) * 1973-05-08 1977-02-02 Feb Ltd Simulation of brickwork etc
GB1581355A (en) * 1978-03-10 1980-12-10 Bamford V C Building panels
US4644719A (en) * 1983-06-10 1987-02-24 Salazar Edward J Decorative wall panel
GB2328627A (en) * 1997-08-19 1999-03-03 Dean James Clowes Building elements

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2819495A (en) * 1951-10-03 1958-01-14 Krausz Isidor Method of making building blocks
US3177279A (en) * 1961-10-19 1965-04-06 Cavrok Mfg Company Method of molding a decorative building panel
WO1983002472A1 (fr) * 1982-01-18 1983-07-21 LARSEN, Hans, Sondergaard Element isolant en forme de plaque avec un parement en coquille dans un motif de pierre pour une construction et son procede de production
US4647000A (en) * 1984-05-02 1987-03-03 Hideharu Osada Flexible mold for forming simulated tile or brick surfaces

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014077576A1 (fr) * 2012-11-15 2014-05-22 Tak Seung Ho Module cadre de corps mural permettant à un mur en briques d'être construit sans briques

Also Published As

Publication number Publication date
GB2412125A (en) 2005-09-21
GB0406295D0 (en) 2004-04-21

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