PANEL STRUCTURE AND PANEL FOR USE IN FORMING SUCH STRUCTURE

Abstract: A panel structure comprises building panels (10) arranged in an edge-to-edge abutting relationship, each comprising a panel (12) of polymer concrete having a repeating relief pattern (18) in the exposed face thereof. The relief pattern imitates the appearance of brickwork and repeats itself substantially without interruption across the joints between the panels. Each panel (10) further comprises a supporting framework (14) of timber affixed to the rear face of the polymer concrete panel, and a heat insulating material (16) in voids formed by the framework.

Description: TITLE : PANEL STRUCTURE AND PANEL FOR USE IN FORMING SUCH STRUCTURE THIS INVENTION relates to a panel structure and to a panel for use in forming such a structure. According to the invention there is provided a panel structure 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 face thereof, which relief pattern repeats itself substantially without interruption across the joint. The first panel may have recesses therein, the panel structure further comprising panel elements which extend from the second panel into the recesses, the panel elements forming part of the relief pattern. The recesses may be in the exposed face of the first panel, the arrangement being such that the panel elements overlie the first panel. There may be recesses in the exposed face of the second panel as well, the arrangement being such that the panel elements extend into the recesses of the second panel and overlie the second panel. The panel elements may be secured in position by means of. an adhesive. In an alternative arrangement the panel elements may be integral with the second panel. In a further alternative arrangement the recesses may be in the edge of the first panel so as to give the edge a toothed configuration. BSTITUTE SHEET 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. The panels may be of polymer concrete. Each panel may have a supporting framework secured thereto on that face thereof which is opposite the exposed face, and a sheet of fabric attached to and spanning the supporting framework, the fabric being embedded in a resin which is bonded to the polymer concrete. The panel structure may further comprise a heat insulating material in voids formed by the supporting framework. The panels may 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 the grooves into the other. Further according to the invention there is provided a building panel for use in a panel structure as defined above, the panel having a repeating relief pattern in an exposed face thereof, and recesses therein for receiving said panel elements. The relief pattern may comprise rows of raised rectangular portions so as to imitate the appearance of brickwork, the recesses being formed in the exposed face of the panel by the absence at either one or both ends of alternate of said rows of those raised portions which would otherwise have been there to represent half a brick. The invention will now be described in more detail, by way of example, with reference to the accompanying drawings. In the drawings: Figure 1 is a front elevation of a building panel 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; 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, after the panel elements have been installed; Figure 7 is a section on VII-VII in Figure 5; Figure 8 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 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 16 of, for example, expanded polystyrene or a mineral heat insulation material filling the voids formed by the framework. The polymer concrete panel 12 has a repeating relief pattern in a face thereof which will, in use, be 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 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 edges of the polymer concrete panel 12 there are recesses 20 in the exposed face of the panel. The recesses 20 are 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 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 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 condition, in a silicone rubber mould (not shown) which has ridges therein to form the relief pattern. The 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 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 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 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 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 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 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 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 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 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 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 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 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 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 as wide 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.

Claims: CLAIMS : 1. A panel structure comprising first and second panels which are arranged in an edge-to-edge abutting relationship to form a joint between the panels, characterised therein that each panel (10) has a repeating relief pattern (18) in an exposed face thereof, which relief pattern repeats itself substantially without interruption across the joint. 2. A panel structure as claimed in claim 1, characterised therein that the first panel (10) has recesses (20, 42) therein, and that it further comprises panel elements (36, 40, 44) which extend from the second panel (10) into the recesses, the panel elements forming part of the relief pattern. 3. A panel structure as claimed in claim 2, characterised therein that the recesses (20) are in the exposed face of the first panel, and wherein the panel elements (36, 40) overlie the first panel. 4. A panel structure as claimed in claim 3, characterised therein that there are recesses (20) in the exposed face of the second panel, and that the panel elements (36) extend into the recesses of the second panel and overlie the second panel. 5. A panel structure as claimed in claim 4, characterised therein that the panel elements (36) are secured in position by means of an adhesive. 6. A panel structure as claimed in claim 3, characterised therein that the panel elements (40) are integral with the second panel. 7. A panel structure as claimed in claim 2, characterised therein that the recesses (42) are in the edge of the first panel so- as to give the edge a toothed configuration. 8. A panel structure as claimed in any one of claims 2 to 7, characterised therein that the relief pattern (18) is such as to imitate the appearance of brickwork, and wherein the panel elements (36, 40, 44) are each rectangular to imitate the appearance of a brick. 9. A panel structure as claimed in any one of. the preceding claims, characterised therein that the panels (12) are of polymer concrete. 10. A panel structure as claimed in claim 9, characterised therein that each panel (12) has a supporting framework (14) secured thereto on that face thereof which is opposite the exposed face, and a sheet of fabric (22) attached to and spanning the supporting framework, the fabric being embedded in a resin which is bonded to the polymer concrete. 11. A panel structure as claimed in claim 10, characterised therein that it further comprises a heat insulating material (16) in voids formed by the supporting framework (14). 12. A panel structure as claimed in any one of the preceding claims, characterised therein that the panels (10) each have a groove (26) along the abutting edges thereof, the grooves being in register with one another and there being a sealing strip (34) which extends from one of the grooves into the other. 13. A building panel for use in a panel structure as claimed in claim 2 or any claim depending therefrom. characterised therein that it has a repeating relief pattern (18) in an exposed face thereof, and recesses (20, 42) therein for receiving said panel elements. 14. A building panel as claimed in claim 13, characterised therein that the relief pattern comprises rows of raised rectangular portions (18) so as to imitate the appearance of brickwork, and wherein the recesses (20) are formed in the exposed face of the panel by the absence at either one or both ends of alternate of said rows of those raised portions which would otherwise have been there to represent half a . brick.

Inventors: BAGUS EBRAHIM, ROBERTSON ADRIAAN JOHANNES, BAGUS, EBRAHIM, ROBERTSON, ADRIAAN, JOHANNES
Applicants: WORLDWIDE BUILDING SYSTEMS NV, WORLDWIDE BUILDING SYSTEMS N.V.
Application year: 1992
Main classification: B44F9
IPC codes: B44F9, E04F13