(19)
(11) EP 3 276 103 A1

(12) EUROPEAN PATENT APPLICATION

(43) Date of publication:
31.01.2018 Bulletin 2018/05

(21) Application number: 17183892.3

(22) Date of filing: 28.07.2017
(51) International Patent Classification (IPC): 
E04C 2/04(2006.01)
B28B 19/00(2006.01)
E04C 2/32(2006.01)
E04F 13/08(2006.01)
(84) Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR
Designated Extension States:
BA ME
Designated Validation States:
MA MD

(30) Priority: 28.07.2016 GB 201613086

(71) Applicant: Keystone Lintels Limited
Cookstown Tyrone BT80 9DG (GB)

(72) Inventor:
  • COYLE, Sean
    Cookstown, BT80 9DG (GB)

(74) Representative: Hanna, John Philip 
Hanna IP 4th Floor 58 Howard Street
Belfast BT1 6PJ
Belfast BT1 6PJ (GB)

   


(54) A METHOD OF CONSTRUCTING A PANEL


(57) A panel and a method of constructing a panel, the method comprising: providing a plurality of covering elements; arranging the covering elements on a surface; providing a supporting member; and affixing the supporting member to the covering elements to form the panel.




Description


[0001] The present invention is directed towards panels and methods of constructing panels, and in particular panels comprising a plurality of covering elements affixed to a supporting member.

[0002] Modern construction techniques have allowed for commercial and residential buildings to be rapidly assembled from pre-manufactured components, thereby allowing for faster and quicker construction as compared to traditional methods of gradually laying rows of bricks or masonry. The appearance of brick/masonry is still desired for aesthetic reasons, however, and this has led to a demand for attaching brick/masonry slips to the exterior surface of buildings to create a brick/masonry effect. This is typically performed by a skilled craftsman first applying a layer of mortar onto the building and then individually applying brick/masonry slips onto the building to form the desired brick/masonry effect. Such existing methods are laborious and negate some of the benefits of modern construction in reducing the speed and cost of assembly.

[0003] It is an object of the present invention to obviate and/or mitigate the problems of creating a brick/masonry effect or other desired aesthetic effect when constructing buildings.

[0004] Accordingly, the present invention provides a method of constructing a panel, the method comprising: providing a plurality of covering elements; arranging the covering elements on a surface; providing a supporting member; and affixing the supporting member to the covering elements to form the panel.

[0005] Advantageously, the present invention forms a panel with a plurality of covering elements attached thereto. Once formed, the panel can be affixed to a structure as desired so that the covering elements can provide their desired aesthetic effect. Ideally, the panel is a building panel suitable to be attached to a building structure to form an exterior surface of the building structure. Advantageously, the panel can be affixed or otherwise attached to a building structure such that the covering elements can provide their desired aesthetic effect.

[0006] Preferably, the surface is angled with respect to the vertical axis.

[0007] In one arrangement, the surface is angled in the range of between 30 degrees and 60 degrees with respect to the vertical axis, and most preferably is angled at about 45 degrees with respect to the vertical axis. In another arrangement, the surface is a horizontal support surface. By "horizontal support surface" we mean that the support surface is angled at about 90 degrees with respect to the vertical axis, and is therefore generally aligned with the horizontal axis. "Vertical axis" and "horizontal axis" have their common meanings. For example, the upstanding walls of a building will be generally aligned with the vertical axis while the floors and ceiling will generally be aligned with the horizontal axis.

[0008] Preferably, affixing the supporting member to the covering elements comprises lowering the supporting member onto the covering elements. The supporting member is preferably lowered onto the covering elements in a generally vertical direction. Further, as the supporting member is lowered it is ideally lowered at an angle which substantially corresponds to the angle with which the surface is arranged with respect to the vertical axis.

[0009] Ideally, the supporting member comprises an adhesive laden surface.

[0010] Preferably, the method step of affixing the supporting member to the covering elements comprises placing the adhesive laden surface onto the covering elements.

[0011] Preferably, the method step of providing the supporting member comprises applying an adhesive to a surface of the supporting member to form an adhesive laden surface.

[0012] Preferably, the method comprising applying the adhesive as a layer or in a pattern.

[0013] Ideally, the method step of affixing the supporting member to the covering elements further comprises pressing the adhesive laden surface of the supporting member onto the covering elements.

[0014] Preferably, the method step of pressing the adhesive laden surface of the supporting member onto the covering elements comprises pressing the adhesive laden surface of the supporting member onto the covering elements for a period of time that is sufficient to ensure a bond is formed between the supporting member and the covering elements.

[0015] Ideally, the method comprising using a polymer adhesive mortar.

[0016] Preferably, the method step of arranging the plurality of covering elements comprises arranging the plurality of covering elements in a selected pattern.

[0017] Ideally, the method comprising using a bond pattern.

[0018] Preferably, the method further comprises separating the panel from the surface.

[0019] In one arrangement, separating the panel from the surface comprises lifting the panel away from the surface, the lifting being ideally in the vertical direction.

[0020] In another arrangement, separating the panel from the surface comprises rotating the panel and surface generally around the horizontal axis until the surface is vertically above the panel, and further comprise lifting the surface away from the panel, the lifting being ideally in the vertical direction.

[0021] Preferably, the method further comprises applying a compressing force between the panel and the surface. Advantageously, this would encourage an improved bond between the covering elements and the panel.

[0022] Ideally in this alternative arrangement, the method further comprises applying a compressing force between the panel and the surface as they are being rotated to help maintain the covering elements in their desired arrangement.

[0023] Preferably in this alternative arrangement, rotating the panel and surface generally around the horizontal axis comprises rotating the panel and surface until the surface is vertically above the panel and the surface and panel are generally aligned with the horizontal plane.

[0024] Ideally, once the panel and surface are separated, the method further comprises allowing the adhesive to set. Advantageously, this allows a permanent bond to be formed between the supporting member and the covering elements.

[0025] Ideally, the method further comprising providing a template having a selected pattern, the template forming the surface on which the plurality of covering elements are arranged.

[0026] Preferably, the template comprises a plurality of recessed sections which are shaped to match the shape of the covering elements. Advantageously, in this way the covering elements can be placed in the recessed sections to form the selected pattern.

[0027] Preferably, the method comprises constructing a corner panel.

[0028] Ideally, the method step of providing a template comprises providing a corner template.

[0029] Advantageously, a corner panel can be attached to a corner section of a building.

[0030] Ideally, the method step of providing the corner template comprises providing a first template member, providing a second template member, and arranging the first and second template members together to form a corner shape.

[0031] Preferably, the method step of providing a supporting member comprises providing a corner supporting member.

[0032] Ideally, the method step of providing a corner supporting member comprises providing a first supporting member, providing a second supporting member, and arranging the first and second supporting members together to form a corner shape.

[0033] Preferably, the first and second supporting members have a width in the range of between 300 and 600 mm. More preferably, the first and second supporting members have a width in the range of between 327 and 552 mm.

[0034] Ideally, the first and second supporting members have a height in the range of between 300 and 700 mm. More preferably, the first and second supporting members have a height in the range of between 450 and 600 mm.

[0035] Preferably, the method step of arranging the first and second supporting members together comprises connecting the first supporting member to the second supporting member.

[0036] Ideally, the method step of connecting the first supporting member to the second supporting member comprises using at least one bracket to connect the first supporting member to the second supporting member.

[0037] Preferably, the method comprising providing at least one bracket which is an angle bracket.

[0038] Ideally, the method comprising at least temporarily affixing a template supporting member to the corner template.

[0039] Preferably, the method further comprises affixing the template supporting member to the corner template.

[0040] Ideally, the method further comprises mounting the corner template on a frame.

[0041] Preferably, the method further comprises providing the frame, and mounting the template on the frame.

[0042] Ideally, the method further comprises hingedly connecting side portions of the corner template to the frame.

[0043] Alternatively, the method comprises constructing a planar panel, and wherein providing the template comprises providing a planar template. In this alternative arrangement, the method step of providing a supporting member preferably comprises providing a planar supporting member.

[0044] Ideally, the planar supporting member has a width in the range of between 1800 and 2500 mm, and more preferably in the range of between 2000 and 2300 mm.

[0045] Preferably, the planar supporting member has a height in the range of between 300 and 700 mm, and more preferably in the range of between 450 and 600 mm.

[0046] Preferably, the method further comprises removing air pockets from the panel.

[0047] Ideally, the method step of removing air pockets comprises using a jointer to smooth and/or seal the adhesive joints between some or all of the covering elements.

[0048] Preferably, the method step of removing air pockets comprises using a jointer to form a shaped, external facing joint profile between some or all of the covering elements.

[0049] Ideally, the shaped, external facing joint profile is a curved, recessed shape.

[0050] Preferably, the covering elements have outer facing surfaces and internal facing surfaces, the outer facing surfaces being aesthetically designed, and wherein the method step of affixing the supporting member to the covering elements comprises affixing the supporting member to the internal facing surfaces of the covering elements.

[0051] Ideally, the method step of arranging the covering elements on the surface comprises placing the outer facing surfaces of the covering elements onto the surface.

[0052] Preferably, the covering elements are masonry covering elements.

[0053] Ideally, the covering elements are composite, acrylic, or synthetic covering elements.

[0054] Preferably, the covering elements are brick portions.

[0055] Ideally, the covering elements are brick, block or stone slips. The slips could be cut or fired slips.

[0056] Preferably, the supporting member is a rigid supporting member.

[0057] Ideally, the supporting member is suitable to be attached to a building structure to form an exterior surface of the building structure.

[0058] Preferably, the supporting member is weather resistant.

[0059] Preferably, the supporting member is a backing board.

[0060] Ideally, the backing board is one of a composite board, wood based board, cement particle board, magnesium oxide board, render carrying board, or calcium silicate board.

[0061] Alternatively, the supporting member is metal or metal alloy supporting member, and preferably a metal or metal alloy lintel.

[0062] In another alternative arrangement, the panel is a SIP panel being a structurally insulated panel. In this arrangement, the method allows a structural panel with a brick, block or stone facade to be constructed with a few simple steps.

[0063] Preferably, the method comprising providing the covering elements as masonry covering elements.

[0064] Ideally, the method comprising providing covering elements as composite, acrylic, or synthetic covering elements.

[0065] Preferably, the method comprising providing covering elements as brick portions.

[0066] Ideally, the method comprising providing covering elements as brick, block or stone slips.

[0067] Preferably, the method comprising providing the supporting member as a backing board.

[0068] Ideally, the method comprising providing the backing board as a cement particle board.

[0069] Ideally, the method comprising providing the backing board as a composite board, wood based board, cement particle board, magnesium oxide board, render carrying board, or calcium silicate board.

[0070] In one arrangement, the panel comprises opposed vertical edges, the opposed vertical edges having crenellations.

[0071] Ideally, the crenellations are shaped to interlock with the crenellations of an adjacent panel.

[0072] Preferably, the covering elements are arranged on the supporting member in a stretcher bond pattern, the crenellations correspond to the stretcher bond pattern.

[0073] Ideally, the surface is designed so that the exposed surfaces of the covering elements resting on the surface define an imaginary plane which is parallel to the surface of the supporting member engageable with the exposed surfaces of the covering elements at the point of engagement.

[0074] Accordingly, the present invention further comprises a panel constructed according to the method of: providing a plurality of covering elements; arranging the covering elements on a surface; providing a supporting member; and affixing the supporting member to the covering elements to form the panel.

[0075] The skilled man will appreciate that the above panel can be constructed according to any, some, or all of the additional method steps referred to above.

[0076] Accordingly, the present invention further comprises a panel, the panel comprising a supporting member and a plurality of covering elements affixed to the supporting member.

[0077] Ideally, the panel is a building panel suitable to be attached to a building structure to form an exterior surface of the building structure.

[0078] Ideally, the plurality of covering elements are affixed to the supporting member with an adhesive. The adhesive is preferably a polymer adhesive mortar.

[0079] Preferably, the plurality of covering elements are affixed to the supporting member in a selected pattern. The selected pattern being preferably a bond pattern.

[0080] In one arrangement, the panel is a planar panel.

[0081] In another arrangement, the panel is a corner panel. Preferably, the corner panel comprises a corner supporting member. The corner supporting member preferably comprises a first supporting member and a second supporting member angled with respect to one another and connected to each other to form a corner shape. The two supporting members are preferably angled at about 90 degrees with respect to one another. The panel preferably comprises at least one bracket to connect the first supporting member to the second supporting member. The bracket is ideally an angle bracket.

[0082] Ideally, the panel comprises smooth and/or sealed adhesive joints between some or all of the covering elements.

[0083] Preferably, the adhesive joints between some or all of the covering elements have a shaped, external facing joint profile. The shaped, external facing joint profile is preferably a curved, recessed shape.

[0084] Ideally, the covering elements comprises aesthetically designed outer facing surfaces.

[0085] Preferably, the covering elements are masonry covering elements.

[0086] Ideally, the covering elements are composite, acrylic, or synthetic covering elements.

[0087] Preferably, the covering elements are brick portions.

[0088] Ideally, the covering elements are brick, block or stone slips.

[0089] Preferably, the supporting member is a rigid supporting member.

[0090] Ideally, the supporting member is suitable to be attached to a building structure to form an exterior surface of the building structure.

[0091] Preferably, the supporting member is weather resistant.

[0092] Ideally, the supporting member is a backing board.

[0093] Preferably, the backing board is one of a composite board, wood based board a cement particle board, magnesium oxide board, render carrying board, or calcium silicate board.

[0094] Alternatively, the supporting member is metal or metal alloy supporting member, and preferably a metal or metal alloy lintel.

[0095] In one arrangement, the panel comprises opposed vertical edges, the opposed vertical edges having crenellations.

[0096] Ideally, the crenellations are shaped to interlock with the crenellations of an adjacent panel.

[0097] Preferably, the covering elements are arranged on the supporting member in a stretcher bond pattern, the crenellations correspond to the stretcher bond pattern.

[0098] The skilled man will also appreciate that all preferred or optional features of the invention described with reference to only some aspects or embodiments of the invention may be applied to all aspects of the invention.

[0099] 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.

[0100] The invention will now be described with reference to the accompanying drawings which shows by way of example specific illustrative implementations in accordance with the invention.

[0101] In the drawings:

Figure 1 is a perspective view of a panel according to a first illustrative implementation of the present invention;

Figure 2 is a perspective view of a template used in the construction of the panel in Figure 1;

Figure 3 is a perspective of a frame used in the construction of the panel of Figure 1;

Figure 4 is a sectional view of a frame and template being used in the process of constructing the panel in Figure 1.

Figure 5 is a perspective view of a template used in the construction of a panel according to a second illustrative implementation of the present invention;

Figure 6a is a plan view of the template in Figure 5;

Figure 6b is a side view of the template in Figure 5;

Figure 6c is a detailed plan view of the template in Figure 5; and

Figure 7 is a perspective view of a panel according to the second illustrative implementation of the present invention.



[0102] In Figures 1, 4 and 7 there is shown a panel indicated generally by the reference numerals 10 and 50. The panel 10, 50 comprises a supporting member 11 a, 11 b, 51 onto which a plurality of covering elements 13, 53 are affixed. The supporting member 11 a, 11b, 51 is a backing board, and in the particular arrangement shown in Figure 4, the supporting member 11 a, 11 b is a cement particle board although the invention is no way limited by the type of backing board. Other examples of the supporting member 11 a, 11 b, 51 include magnesium oxide board, render carrying board, and calcium silicate board. The covering elements 13, 53 have an aesthetically designed outer facing surface. This means that the panels 10, 50 can be used as building panels 10, 50 and be affixed to building structures to form an aesthetically pleasing outer surface. The covering elements 13, 53 can be masonry covering elements; composite, acrylic, or synthetic covering elements; brick portions; and brick, block or stone slips, cut or fired. In the particular arrangement shown in Figures 1, 4 and 7, the covering elements 13, 53 are brick slips. The covering elements 13, 53 are affixed to the supporting member 11 a, 11 b, 51 with an adhesive 17 (Figure 4) such as a polymer adhesive mortar. The supporting member 11 a, 11 b, 51, covering elements 13, 53 and method of affixing the covering elements 13, 53 to the supporting member 11 a, 11 b, 51 are not limited to any of the specific examples listed above. The panel 10, 50 is particularly suited for use as an aesthetically pleasing exterior surface for building structures. The panel 10, 50 can be assembled off-site/at the factory and later shipped to the construction site. This means that the laborious process of individually affixing covering elements to a section of the building is avoided.

[0103] The covering elements 13, 53 are affixed to the supporting member in a selected pattern. The selected pattern shown in Figures 1 and 7 is a stretcher bond pattern that mimics the traditional appearance of brickwork. The present invention is not limited to any specific type of pattern/bond pattern. Other examples of bond pattern within the scope of the present invention comprise stack bond, running bond, Flemish bond, English bond, Dutch bond/English cross, and common bond. The panels 10, 50 are able to additionally have other features to mimic the traditional appearance of brickwork, such as by having smooth and/or sealed adhesive joints between some or all of the covering elements 13, 53. The adhesive joints can have a shaped, external facing joint profile which in some particular arrangements is a curved, recessed shape. Other types of joints such as "V" shaped and weathered are also within the scope of the present invention.

[0104] Referring to Figures 1 and 4, there is shown a panel 10 according to a first illustrative implementation of the invention. The panel 10 is a corner panel 10 which means that is shaped so as to be attachable to a corner section of a building. The corner panel 10 comprises a corner supporting member 11 a, 11 b which includes a first supporting member 11 a and a second supporting member 11 b angled with respect to one another and connected to each other to form a corner shape. The particular arrangement shown in Figures 1 and 4 has the two supporting members 11 a, 11 b angled at about 90 degrees with respect to one another, but other angles are within the scope of the present invention. The panel 10 comprises at least one bracket 15 as shown in particular in Figure 4 for connecting the first supporting member 11 a to the second supporting member 11 b. The bracket 15 is an angle bracket 15, but other types of bracket are within the scope of the present invention.

[0105] The present invention is not limited to corner panels 10. Referring to Figure 7, there is shown a panel 50 according to a second illustrative implementation of the present invention. The panel 50 is a planar panel 50 and comprises a planar supporting member 51 and a plurality of covering elements 53 affixed to the planar supporting member 51.

[0106] Particular advantages of the panels 10, 50 of the present invention lie in their method of manufacture, which will now be described.

[0107] A plurality of the covering elements 13, 53 are provided and arranged on a surface. The surface is formed by a template 20, 30 which has a selected pattern by which the covering elements 13, 53 are to be arranged. Examples of the template 20, 30 are shown in Figures 2 and 5 to 6c. The template 20, 30 has, in particular, a number of recessed sections 23, 33 which are shaped to match the covering elements 13, 53 which are to be inserted into the recessed sections. In this way, by arranging the covering elements 13, 53 on to the surface formed by the template 20, 30, the covering elements can be easily arranged to form their desired pattern.

[0108] A supporting member 11 a, 11 b, 51 is provided and affixed to the covering elements 13, 53 to form the panel 10, 50. Affixing the supporting member 11 a, 11 b, 51 to the covering elements comprises lowering the supporting member 11 a, 11 b, 51 onto the covering elements 13, 53 such as in a generally vertical direction. As the supporting member 11 a, 11 b, 51 is lowered, it is arranged at an angle which substantially corresponds to the angle with which the surface is arranged with respect to the vertical axis. The surface 11 a, 11 b, 51 is designed so that the exposed surfaces of the covering elements 13, 53 resting on the surface define an imaginary plane which is parallel to the surface of the supporting member 11 a, 11 b, 51 engageable with the exposed surfaces of the covering elements 13, 53 at the point of engagement. As previously described, the supporting member 11 a, 11 b, 51 can be affixed to the covering elements 13, 53 using an adhesive 17 and to this end comprises an adhesive laden surface. Alternatively, the adhesive could be applied to the covering elements 13, 53. In these arrangements, affixing the supporting member 11 a, 11 b, 51 comprises placing the adhesive laden surface onto the covering elements 13, 53. In some arrangements, the adhesive laden surface is formed by applying an adhesive 17 to a surface of the supporting member 11 a, 11 b, 51. The adhesive laden surface is pressed down onto the covering elements 13, 53 for a period of time sufficient to ensure that a bond is formed between the supporting member 11 a, 11 b, 51 and the covering elements 13, 53. Once the bond is formed, the panel 10, 50 is separated from the surface. In one arrangement, the panel 10, 50 is separated by lifting the panel away from the surface such as by vertically lifting the panel 10, 50 away from the surface. In other arrangements, the panel 10, 50 is separated from the surface by rotating the panel 10, 50 and template 20, 30 generally around the horizontal axis unit the template 20, 30 is vertically above the panel 10, 50. In other words, the panel 10, 50 and template 20, 30 are rotated together until their relative vertical locations are reversed. That is, the panel 10, 50 and template 20, 30 are flipped over. The rotation is performed until the panel 10, 50 and template 20, 30 is generally aligned with the horizontal plane. The template 20, 30 is then lifted away from the panel 10, 50 such as by vertically lifting the template 20, 30 away from the panel 10, 50. To help ensure that the covering elements 13, 53 are held to the supporting member 11 a, 11 b, 51 as they are rotated so that they are held in their desired arrangement, a compressing force is applied between the panel 10, 50 and the template 20, 30 as they are being rotated. As the supporting member 11 a, 11b, 51 is compressed together with the covering members 13, 53, the adhesive flows into the joints between the covering members 13, 53. An adhesive 17 having a sufficient viscosity to allow the adhesive 17 to flow under the compressive force is required. Excess adhesive in the joints can be smoothed/removed using a jointing tool. Air pockets from the panel 10, 50 are removed. Removing air pockets comprises using a jointer (not shown) to smooth and/or seal the adhesive joints between some or all of the covering elements 13, 53. In some arrangements, removing air pockets comprises using the jointer to form a shaped, external facing joint profile, such as a curved, recessed shape, between some or all of the covering elements 13, 53. The adhesive 17 can then be allowed to set. This allows a permanent bond to be formed between the supporting member 11 a, 11 b, 51 and the covering elements 13, 53. The time required to allow the adhesive 17 to be set will be dependent on the curing time for the type of adhesive 17 used.

[0109] A particular method for constructing the corner panel 10 as shown in Figure 1 will now be described with reference to Figures 2 to 4.

[0110] The corner template 20 as shown in Figure 2 is assembled by angling two template components 20a, 20b with respect to one another to form a corner shape and attaching the two template components 20a, 20b together such as by using a corner bracket. Alternatively, the corner template 20 may be provided as an integral structure. The corner template 20 therefore forms a surface having two components which are both angled with respect to the vertical axis by at about 45 degrees to thereby form the corner section.

[0111] A frame 40 is provided to hold the corner template 20 in position. An example of the frame 40 is shown in Figures 3 and 4. The corner template 20 is mounted to the frame 40 which involves hingedly connecting, using hinge 45, the side portions of the corner template 20 to the frame 40. A template supporting member 41 is temporarily/non-permanently affixed to the corner template 20 to act as an additional support for the corner template 20.

[0112] The corner supporting member 11 a, 11 b as shown in Figure 1 is assembled by cutting a supporting member 11 a, 11 b to form a first supporting member 11 a and a second supporting member 11 b of a predetermined size. The first and second supporting members 11 a, 11 b are connected together via a corner bracket to form a corner shape. A corner support member 43 is provided and temporarily attached to the internal surface of the supporting member 11 a, 11 b to support the corner supporting member 11 a, 11 b and hold it in its corner shape.

[0113] Covering elements 13, which in this example are brick slips 13, are laid with their outer facing surface down into the recessed portions 23 of the corner template 20 such that the desired brick bond pattern is formed. The adhesive is then mixed/prepared and applied to the exterior surface of the supporting member 11 a, 11 b. The supporting member 11 a, 11 b is then lowered in a generally vertical direction downwards onto the covering elements 13 such that the adhesive laden surface of the supporting member 11 a, 11b contacts with the covering elements. Alternatively, the surface/template is moved towards the one or more support members for angled or planar panels. Pressure is applied to the supporting member 11 a, 11 b and/or the template 20, 30 to ensure that the covering elements 13 and the supporting member 11 a, 11 b are bonded together. After this, the panel 10 (i.e the supporting member 11 a, 11 b with covering elements 13 attached thereto) is carefully separated from the template 20 and placed on a surface with the covering elements 13 facing upwards. A jointer (not shown) is then used to remove air pockets form the adhesive joints between the covering elements 13 and form the desired external facing joint profile.

[0114] A particular method for constructing the planar panel 50 as shown in Figure 7 will now be described with reference to Figures 5 to 6c.

[0115] The planar template 30 as shown in Figures 5 to 6c is provided and laid on a flat, preferably generally horizontal surface.

[0116] The supporting member 51 is assembled by cutting a supporting member 51 to a predetermined size.

[0117] Covering elements 53, which in this example are brick slips 53, are laid with their outer facing surface down into the recessed portions 33 of the planar template 30 such that the desired brick bond pattern is formed. The adhesive is then mixed/prepared and applied to the exterior surface of the supporting member 51. The supporting member 51 is then lowered, preferably in a generally vertical direction downwards onto the covering elements 53 such that the adhesive laden surface of the supporting member 51 contacts with the covering elements 53. The surface formed by the planar template 30 is designed so that the exposed surfaces of the covering elements 53 resting on the surface define an imaginary plane which is parallel to the surface of the supporting member 51 engageable with the exposed surfaces of the covering elements 53 at the point of engagement. Pressure is applied to the supporting member 51 and/or the template to ensure that the covering elements 53 and the supporting member 51 are bonded together. After this, the planar panel (i.e the supporting member 51 with covering elements 53 attached thereto) is carefully separated from the template 30 and placed on a surface with the covering elements 53 facing upwards. A jointer (not shown) is then used to remove excess adhesive/air pockets form the adhesive joints between the covering elements 53 and form the desired external facing joint profile. The adhesive between the covering elements 53 and the supporting member 51 may be allowed to set in the positon where the supporting member 51 comes into contact with the covering members 53 or alternatively adhesive between the covering elements 53 and the supporting member 51 may be allowed to set in the positon where the supporting member 51 and the template 30 are flipped over ideally, through 180 degrees.

[0118] The above methods can be performed on a construction site, or in more advantageous embodiments performed off-site at a factory and shipped preassembled to a construction site. The panels 10, 50 are therefore provided at the construction site pre-assembled and can be quickly and attached to the exterior surface of the building to provide the desired aesthetic appearance.

[0119] 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 said values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.

[0120] 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

1. A method of constructing a panel, the method comprising: providing a plurality of covering elements; arranging the covering elements on a surface; providing a supporting member; and affixing the supporting member to the covering elements to form the panel.
 
2. A method as claimed in claim 1, wherein the method comprises affixing the supporting member to the covering elements comprising lowering the supporting member onto the covering elements.
 
3. A method as claimed in claim 1 or claim 2, wherein the method step of providing the supporting member comprises applying an adhesive to a surface of the supporting member to form an adhesive laden surface, the method step of affixing the supporting member to the covering elements comprises placing the adhesive laden surface onto the covering elements.
 
4. A method as claimed in claim 3, wherein the method step of affixing the supporting member to the covering elements further comprises pressing the adhesive laden surface of the supporting member onto the covering elements for a period of time that is sufficient to ensure a bond is formed between the supporting member and the covering elements.
 
5. A method as claimed in any one of the preceding claims, wherein the method step of arranging the plurality of covering elements comprises arranging the plurality of covering elements in a selected pattern.
 
6. A method as claimed in any one of the preceding claims, wherein the method further comprises separating the panel from the surface by comprising lifting the panel away from the surface or comprising rotating the panel and surface generally around the horizontal axis until the surface is vertically above the panel, and wherein the method further comprises lifting the surface away from the panel.
 
7. A method as claimed in any one of the preceding claims, wherein the method further comprises applying a compressing force between the panel and the surface.
 
8. A method as claimed in any one of the preceding claims, wherein the method further comprising providing a template having a selected pattern, the template forming the surface on which the plurality of covering elements are arranged.
 
9. A method as claimed in any one of the preceding claims, wherein the surface is designed so that exposed surfaces of the covering elements resting on the surface define an imaginary plane which is parallel to the surface of the supporting member engageable with the exposed surfaces of the covering elements at the point of engagement.
 
10. A method as claimed in any one of the preceding claims, wherein the method comprises constructing a corner panel.
 
11. A method as claimed in claim 10, wherein the method comprises providing a corner template and further where the method comprises providing a first template member, providing a second template member, and arranging the first and second template members together to form a corner shape.
 
12. A method as claimed in claim 10 or 11, wherein the method comprises the step of providing a corner supporting member comprising providing a first supporting member, providing a second supporting member, and arranging the first and second supporting members together to form a corner shape.
 
13. A method as claimed in any one of claims 10 to 12, wherein the method comprises arranging the first and second supporting members together comprising connecting the first supporting member to the second supporting member, the method further comprising at least temporarily affixing a template supporting member to the corner template.
 
14. A method as claimed in any one of the preceding claims, wherein the method further comprises removing air pockets from the panel.
 
15. A panel constructed according to the method of any one of claims 1 to 14.
 




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Search report