EP4644109A2 - Façade de façade - Google Patents

Façade de façade

Info

Publication number: EP4644109A2
Authority: EP; European Patent Office
Prior art keywords: layer; stencil; surface elements; material layer; forming
Prior art date: 2023-12-21
Legal status (The legal status 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 status listed.): Pending

Application number

EP25203726.2A

Other languages

German (de)

English (en)

Other versions

EP4644109A3 (fr

Inventor

Daniel Adam JAY

Edward Oliver Allen

Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)

Mauer Ltd

Original Assignee

Mauer Ltd

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.)

2023-12-21

Filing date

2024-12-19

Publication date

2025-11-05

2024-12-19 Application filed by Mauer Ltd filed Critical Mauer Ltd

2025-11-05 Publication of EP4644109A2 publication Critical patent/EP4644109A2/fr

2025-12-31 Publication of EP4644109A3 publication Critical patent/EP4644109A3/fr

Status Pending legal-status Critical Current

Links

Classifications

- 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
- 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
- B44C5/0461—Ornamental plaques, e.g. decorative panels, decorative veneers used as wall coverings
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44D—PAINTING OR ARTISTIC DRAWING, NOT OTHERWISE PROVIDED FOR; PRESERVING PAINTINGS; SURFACE TREATMENT TO OBTAIN SPECIAL ARTISTIC SURFACE EFFECTS OR FINISHES
- B44D2/00—Special techniques in artistic painting or drawing, e.g. oil painting, water painting, pastel painting, relief painting
- B44D2/007—Special techniques in artistic painting or drawing, e.g. oil painting, water painting, pastel painting, relief painting using stencils in artistic drawing or painting operations
- 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
- E04F13/0862—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 composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F9/00—Designs imitating natural patterns

Definitions

the present disclosure relates to a façade for a building or structure, methods for forming a façade, an apparatus for forming a façade, a stencil for use in forming a façade, and a building or modular building unit, or any component thereof, comprising a façade.
Alternative methods include screen printing surface elements, such as bricks, onto a board, allowing the surface elements to dry, and then screen print the pointing adhesive and then drying again.
Such methods include two drying cycles, two sets of labour, human error quality control issues with aesthetic, and difficulty in controlling output volume.
Alternative methods include using a layered material, for example with a grey material layer (for pointing) overlayed with a red material layer (for red brick adhesive), then once adhesive starts to dry, a tool is used to cut the pointing channels to create the brick shapes in the red material layer.
a layered material for example with a grey material layer (for pointing) overlayed with a red material layer (for red brick adhesive)
a tool is used to cut the pointing channels to create the brick shapes in the red material layer.
Such methods require thick layers of the grey and red materials, the cutting tools make the edges of the surface elements look artificial (because they are too straight) and the pointing/brick interface does not look authentic.
Alternative methods include manually applying brick textures/tones and finishing, or using rudimentary automated processes for finishing. These processes either create repetition in the aesthetic or, when manually applied results in variance between façade surface coverings (e.g. of bricks) which soon become apparent when the façade surface coverings are placed next to each other.
façade surface coverings e.g. of bricks
the known methods are too expensive (in terms of time and/or labour and/or materials), or the aesthetics look too artificial to satisfy planning and location requirements.
the present invention seeks to provide an improved method, stencil and apparatus for forming a prefabricated façade surface covering and an improved prefabricated façade surface covering.
a method of forming a prefabricated façade surface covering for installation on a surface of a structure comprising: forming a first material layer on a supporting layer; providing a stencil on the first material layer, the stencil defining a plurality of openings; forming a second material layer through the openings of the stencil, the second material layer comprising a plurality of surface elements and being disposed on the first layer; shaping the first material to position part of the first material layer between adjacent surface elements; and adapting at least one of the surface elements to have a different colour, surface texture and/or surface finish from other surface elements.
a stencil for use in forming a prefabricated façade surface covering having a first layer and a second layer comprising a plurality of surface elements disposed on the first layer, the stencil defining a plurality of openings for the formation of the plurality of surface elements and defining a masking region between adjacent openings, wherein the stencil comprises a protrusion on the masking region, the protrusion being configured to shape the first layer positioned between adjacent surface elements.
a prefabricated façade surface covering for installation on a surface of a structure comprising: a supporting layer; a first layer connected to the supporting layer; and a second layer comprising a plurality of surface elements disposed on the first layer, wherein part of the first layer is positioned between adjacent surface elements.
a building a modular building unit or any component thereof comprising a prefabricated facade surface covering.
an apparatus for forming a prefabricated façade surface covering comprising a first material layer on a supporting layer and a second material layer comprising a plurality of surface elements disposed on the first layer
the apparatus comprising a main body, a first blade and a second blade, wherein: the main body is configured to move at least part of a supporting layer from a first processing location to a second processing location to a third processing location; the first blade is configured to form, at the first processing location, the first material layer disposed on the supporting layer; the second location is provided between the first blade and the second blade and is configured to receive a stencil on the first material layer; and the second blade is configured to form, at the third processing location, a second material layer disposed on the first material.
the invention is the creation of an aesthetic façade surface covering which may be cost effective, eco-friendly, durable, non-combustible layered, authentic, and which may replicate the look of many external building wall aesthetics.
the invention may be produced in a linear fashion that reduces or minimizes human inputs. It may utilize a variable yet repeatable production system to maintain quality and unique output.
a prefabricated, or pre-engineered, facade surface covering 10 is provided, for example as shown in figure 1 .
the covering comprises a supporting layer 100, a first layer 300 and a second layer comprising a plurality of surface elements 200.
the first layer 300 is connected to the supporting layer 100.
the second layer is disposed on the first layer 300.
each of the plurality of surface elements 200 is connected to the first layer 300.
the plurality of surface elements 200 can be formed on the first layer 300, i.e. after the first layer is formed.
the plurality of surface elements 200 are not in direct contact with the supporting layer.
the plurality of surface elements may only be in contact with the first layer 300.
the first layer 300 may be exposed between adjacent surface elements 200, as shown in figure 1 .
Surface elements 200 may be any form of decorative and/or functional element found on a building.
the surface elements 200 may imitate the appearance of bricks, stone, wood, metal, ceramics and polymers.
the surface elements 200 may imitate the appearance of external roof tiles, patio or flooring slabs, interior wall (e.g. kitchen/bathroom) tiling, etc.. It will be understood that the present invention is not limited to any specific surface elements 200.
Surface elements 200 may have a common shape, for example rectangles or squares, that may tessellate with gaps between through which the first material layer 300 can be seen.
the surface elements 200 may have the appearance of thin brick elements, which may be referred to as brick slips or stone slips.
Brick slips or stone slips replicate the appearance of conventional bricks or stones. However, because they do not perform a load bearing function, they are able to be thinner and therefore lighter than traditional bricks or stones.
a prefabricated facade surface covering with brick slip or stone slip surface elements 200 may be used in place of a traditional masonry wall.
the first material may be mortar, or may have the appearance of mortar.
the first material may be intended to have the appearance of pointing.
the first material layer 300 visible between adjacent surface elements 200 may perform both a decorative and functional role, in order to provide a sealant around the edges of the surface elements 200, and securing the surface elements 200 to the supporting layer 100.
a cross-section of the prefabricated surface covering 10 is shown in figure 2 .
the first layer 300 is provided between the second layer and the supporting layer 100, due to the first layer 300 being disposed on the supporting layer 100. Additionally, part of the first layer 300 is positioned between adjacent surface elements 200. In other words, as shown in the cross-section in figure 2 , a portion of the first layer 300 is provided between adjacent surface elements 200 in cross section.
first material extends into a gap in the second material layer between adjacent surface elements 200, i.e. the space that separates two adjacent surface elements. This means that part of the first layer 300 is adjacent to, and between, facing sides of adjacent surface elements. Preferably, some of the material of the first layer 300 is positioned inbetween each two adjacent surface elements 200.
the part of the first layer 300 positioned between adjacent surface elements 200 is connected to at least one, and preferably both, facing sides 201 of the adjacent surface elements 200.
the part of the first layer between adjacent surface elements 200 is preferably connected to the surface elements on either side of that part of the first layer. This is shown in figure 2 in that the first material is pushed up the edge of the adjacent surface elements 200 and is touching the facing sides 201 of the respective surface elements 200.
Facing sides 201 are the side surfaces of surface elements which would face each other, were it not for the first material being positioned inbetween. In other word, for each surface element, there will be a side surface which, when formed on the prefabricated façade surface, is substantially parallel to a side surface of another adjacent surface element. These facing side surfaces are generally substantially perpendicular to the main surface (although this is not a necessity). Facing sides 201 of two adjacent surface elements 200 are labelled in figures 1 and 2 .
the part of the first layer 300 positioned between adjacent surface elements 200 is preferably shaped, for example, is substantially U-shaped or V-shaped.
the part of the first layer 300 positioned between adjacent surface elements 200 is substantially U-shaped in figure 2 .
the part of the first layer 300 positioned between adjacent surface elements 200 may have a greater thickness at the edges, where in contact with the adjacent surface elements 200. Portions of the first layer 300 between the surface elements 200 and the supporting layer 100, i.e. beneath the surface elements 200, may differ in that the thickness may be substantially uniform.
the first layer 300 may be provided with uniform thickness in the areas on which the surface elements 200 are disposed and having a varying thickness in the regions between the surface elements 200. This is shown in figure 2 .
the portion of the first layer 300 may have a thickness, e.g. in the middle between adjacent surface elements 200, which is less than the areas of uniform thickness.
the portion of the first layer 300 may have a thickness, e.g. at the edge next to the surface element, which is greater than the areas of uniform thickness.
the first layer 300 may substantially cover the supporting layer 100. In other words, the first layer 300 may form a layer over most of the supporting layer 100. Additionally or alternatively, the first layer 300 may form an uninterrupted layer (i.e. without any gaps or holes) over a substantial part of the supporting layer 100. Some of the supporting layer 100 may be exposed around at least one edge of the covering to allow for easier connection between adjacent coverings during installation.
the prefabricated facade surface covering 10 is flexible. Providing a flexible prefabricated facade surface covering 10 may be achieved by providing a flexible supporting layer 100, flexible second layer 200, and/or flexible first layer 300.
the prefabricated facade surface covering 10 may be flexible as described in WO 2023/062387 , which is hereby incorporated by reference in its entirety.
the supporting layer 100 may be a flexible mesh.
the mesh may be made from connected strands of metal, fibre, polymer, or other material suitable for use in construction of a prefabricated facade surface covering 10 for installation on a structure.
the mesh may be a plastic mesh made from an extruded, oriented, expanded, woven, or tubular plastic material. Additionally or alternatively, the mesh may be a metal mesh made from woven, knitted, welded, expanded, or sintered, metal, or any other suitable technique.
the first material layer 300 can be formed directly onto the mesh supporting layer.
the prefabricated facade surface covering 10 can be made strong. Additionally, should a portion of the connection between the prefabricated facade surface covering 10 and the structure fail, the surrounding area can support the failed area, for example, until the necessary repair can be made, improving the safety of the system.
the supporting layer 100 is a flexible mesh.
the first layer 300 is formed on the mesh supporting layer 100.
the first material before being hardened, may spread to surround the mesh supporting layer material. Once hardened, this will result in the mesh becoming embedded within the first layer 300. Embedding the mesh supporting layer 100 into the first layer 300 can enable a secure mechanical connection to be formed between the first layer 300 and the supporting layer 100.
a flat surface such as a plastic sheet or a solid board, may be provided underneath the supporting layer 100 during fabrication (i.e. production) to prevent the first material from falling out underneath the supporting layer 100 during formation.
the flat surface may be selected so that the first material does not strongly adhere, in order to enable the prefabricated facade surface covering 10 to be easily removed from it.
a solid board such as a manufacturing board 50 as shown in figure 4 , may be used to more easily move the supporting layer 100 during fabrication.
the first material and/or the second material may be a polymer material, preferably a flexible polymer material.
the polymer material may be any suitable polymer material which is suitable for use in construction and use on a prefabricated facade surface covering 10.
the surface elements 200 may be made from an adhesive polymer material, which can be hardened in order to form the solid polymer material, or more preferably, the solid flexible polymer material.
the surface elements 200 may be made from acrylate polymer or a polyacrylate polymer.
the adhesive polymer material may harden by drying, pressure, contact, heat, cross-linking (i.e. in the case of multicomponent adhesives), UV radiation, heat, or moisture.
the polymer material may be selected based on its weather resistance properties, fire resistance, breathability, ability to withstand UV radiation, and ability to function at a broad range of different temperatures.
Use of an acrylate polymer or a polyacrylate polymer may be advantageous to provide breathability, because as the acrylate polymer or a polyacrylate polymer dries, it may create a porous structure.
the first layer 300 and the second layer may be the same material, i.e. the first material and the second material may be the same, except for the optional provision of different colouring.
the first material and the second material may be the same except for the use of different colour additives.
Using the same material for the first and second layer may be particularly useful because it allows for easy adhesion between the layers.
the first layer 300 (which can be seen between the surface elements 200) may be provided with a grey colouring to have the appearance of mortar.
the second material may additionally comprise colourings so that the surface elements 200 take on a specific colour.
the second material may be provided with a terracotta or brown colouring.
alternatives, such as an off-white or grey colouring may be used. It will be understood that any colouring may be used, depending on the specific application.
the colour of the surface elements 200 may be determined by a colouring layer material 220.
the colour layer material may be a thin layer which can be provided on a main body 210 of at least one of the surface elements 200, as shown in figure 5A .
the colour layer material may be applied to all of the surface elements 200 on the prefabricated facade surface covering 10, or may be applied to a subset or one or more of the surface elements 200.
the colour layer material may be a thin layer of pigment/acrylic/water formulation on the surface of the surface elements 200.
At least one surface element 200 may include a coating of a surface finish powder 230, for example, as shown in figures 5A and 5B .
the surface finish powder 230 may be applied to all of the surface elements 200 on the prefabricated facade surface covering 10, or may be applied to a subset or one or more of the surface elements 200.
the surface finish powder 230 may be distributed across the entire prefabricated facade panel 10, so that all of the surface elements 200 are covered in a layer of the surface finish powder. If the colouring layer material 220 is provided, the surface finish powder is provided on the colouring layer material, as shown in figure 5A .
the surface finish powder 230 may be made from a powdered form of the material which the surface elements 200 are intended to replicate.
the surface finish powder may be made from a brick powder.
the surface finish powder 230 may be concrete dust or stone dust in order to replicate other forms of construction materials.
the surface finish powder may have any appropriate grain size, depending on the desired finish of the prefabricated facade surface covering 10.
the surface finish powder may be UV stable and/or non-combustible.
a different colour of surface finish powder 230 may be provided to different surface elements 200, in order to further replicate the natural variance of colourings found in traditional masonry construction.
the surface of the main body 210 may be textured to improve the aesthetic and variation of the surface elements 200.
additional peaks and troughs can be added to the surface of the surface elements 200 to increase variation and further replicate the natural variance of surfaces, for example, such as those found in traditional masonry construction.
the covering described herein may be formed by the method and/or apparatus in any of the variations or alternatives described herein. Although it will be understood that the covering could also be formed using an adapted or alternative method and/or apparatus.
a method is provided of forming a prefabricated façade surface covering 10 for installation on a surface of a structure.
the method comprises: forming a first material layer 300 on a supporting layer 100; positioning a stencil 400 on the first material layer 300, the stencil 400 defining a plurality of openings 410; forming a second material layer through the openings 410 of the stencil 400, the second material layer comprising a plurality of surface elements 200 and being disposed on the first layer 300; shaping the first material to position part of the first material layer between adjacent surface elements; and adapting at least one of the surface elements to have a different colour, surface texture and/or surface finish from other surface elements.
the method may be used to form the façade surface covering 10 as described herein, including any of the variations or alternatives described herein.
the method may include providing the supporting layer 100.
the supporting layer 100 may optionally be provided on a surface, for example the manufacturing board 50.
the manufacturing board 50 may be loaded onto an apparatus 500, for example only, and the supporting layer 100 may be applied and fixed to a surface of the manufacturing board 50.
the supporting layer 100 may be placed over the manufacturing board 50 and the supporting layer 100 may be cut to length, preferably with a small leading edge to feed through a gap below a blade (described further below).
the first material layer 300 may be formed by providing the first material on the supporting layer 100.
the method may include supplying the first material across a width of the supporting layer 100, or at least across a width on which the surface covering 10 is to be formed.
the first material may be supplied by an applicator 504 configured to supply the first material, although alternatively, the first material could be supplied manually.
the method may comprise moving the supporting layer 100 relative to a first applicator, while the applicator supplies the first material (preferably across a width of the supporting layer 100).
the first material may a viscous liquid or slurry surface element material which is provided onto the supporting layer 100. Forming the first material layer 300 directly on the supporting layer 100 may avoid the requirement for a separate adhesive. This may be beneficial because it may make it easier to provide a prefabricated facade surface covering 10 and may have improved fire resistance given that no separate adhesive is needed.
Forming the first material layer 300 may comprise levelling the first material provided on the supporting layer 100.
the first material may be levelled by a blade configured to redistribute first material on the supporting layer 100 and/or remove excess first material on the supporting layer 100.
Forming the first material layer 300 may comprise moving the supporting layer 100 and first material relative to a first blade 502.
the first blade 502 may have a straight edge.
the first blade 502 may be a rigid blade.
the first blade 502 may be positioned adjacent to the first applicator.
the supporting layer 100 and first material are moved whilst the first blade 502 is held in place.
the supporting layer 100 and first material may be moved through an apparatus 500, e.g. as described herein.
the supporting layer 100 and the first material may be moved by a conveyor belt 540 or another type of moving means for example.
the supporting layer 100 and the first material may be moved together relative to the first blade 502, although at least some of the first material in contact with the blade may be redistributed or removed as the supporting layer 100 and first material moves relative to the blade.
the first material layer 300 is substantially flat.
the first material layer 300 preferably has a substantially uniform thickness (before further steps are taken).
the supporting layer 100 may be cut to size based on the overall intended size of the façade and the manufacturing board 50. In particular, excess supporting layer 100 can be cut away to make an edge of the supporting layer 100 flush with an edge of the manufacturing board 50 (if used) and to remove excess first material.
Providing a stencil 400 on the first material layer 300 comprises placing a stencil 400 on the surface of the first material layer 300 formed on the supporting layer 100.
the stencil 400 is positioned on the first material layer 300, i.e. after the first material is provided and before the second material is provided.
the stencil 400 may be provided after the first material is levelled by the first blade 502 and before the second material is provided as described further below.
the stencil 400 defines a plurality of openings 410 for the formation of the plurality of surface elements 200, as shown in figures 3A and 3B .
the openings 410 correspond to the surface elements 200 to be formed on the first material layer 300.
the stencil 400 defines a masking region around the outside of each opening and between adjacent openings 410. The masking region is configured to substantially prevent the second material from being redistributed beneath the stencil 400 on the first material layer 300.
the stencil 400 is configured to form the plurality of surface elements 200 of the second layer which are substantially the same shape as the openings 410.
the stencil 400 comprises a protrusion 420 on a side of the stencil 400 for contact with the first material layer 300.
the stencil 400 may comprise a protrusion 420 on the masking region.
the protrusion 420 being configured to shape the first layer 300 positioned between adjacent surface elements 200.
the protrusion 420 may be designed, for example, to form the first material between the adjacent surface elements 200 into a curved, pointing shape when the stencil 400 is under pressure from a second blade (used for pushing the second material into the stencil 400 to make the surface elements 200 as described further below).
This shaped protrusion 420 can result in the first material flowing up the edge of the surface elements 200 so that there is an authentic aesthetic seal. This is particularly beneficial for avoiding formation of surface elements with 90 degree edges which makes the facade look artificial.
the protrusion 420 may be beneficial not only because it can be used to shape the first layer 300, but also because the shape may reduce the likelihood of the first material layer 300 sticking to the stencil 400 (compared with a flat stencil).
the stencil 400 may be positioned in a specific location on the first material layer 300.
the stencil 400 may be aligned using a reference point on the stencil 400 and/or on the first material layer 300 and/or on the supporting layer 100.
the method described herein may be carried out using the stencil 400 described in any of the variations or alternatives described herein. Although it will be understood that the method could also be carried out using an adapted or alternative stencil.
the stencil 400 may be as shown in figures 3A and 3B , which is described in further detail below.
the method includes shaping the first material to position part of the first material layer between adjacent surface elements 200.
first material extends into a gap in the second material layer between adjacent surface elements 200 i.e. the space that separates two adjacent surface elements.
part of the first layer 300 is adjacent to, and between, facing sides of adjacent surface elements.
some of the material of the first layer 300 is positioned in between each two adjacent surface elements 200.
shaping the first material comprises shaping the part of the first layer 300 positioned between adjacent surface elements 200 to connect to at least one, and preferably both, facing sides 201 of the adjacent surface elements 200.
the part of the first layer between adjacent surface elements 200 is preferably connected to the surface elements on either side of that part of the first layer. This is shown in figure 2 in that the first material is pushed up the edge of the adjacent surface elements 200 and is touching the sides of the respective surface elements 200.
the shaping of the first material between the surface elements 200 can be performed using the stencil 400.
the shaping of the first material may comprise pushing the stencil 400 into a surface of the first material layer 300 to shape regions of the first material positioned between adjacent surface elements 200.
the protrusion 420 of the stencil 400 has a configuration corresponding to the plurality of gaps between the surface elements 200.
the protrusion 420 of the stencil 400 also has a shape corresponding to the desired surface shape of the first material between the surface elements 200, and around the outer edges of outer surface elements 200.
the protrusion 420 may have a convex shape to achieve a concave shape on the first material in the regions between the surface elements 200.
the protrusion 420 may be a shaped foam.
the stencil 400 may comprise a base 430 which is preferably substantially uniform in thickness.
the shaped foam may be attached to the base 430, e.g. using an adhesive.
the use of the shaped foam may be beneficial in reducing sticking between the stencil 400 and the first material compared to prior known systems in which material was removed from the façade when (alternative, previously known) stencils were used.
the shaped foam may be any appropriate material.
the shaped foam may be sponge, rubber (for example any synthetic rubber, e.g. EPDM, although natural rubber could be used), or latex. Other materials may be used.
the stencil 400 may comprise an anti-sticking solution (which may be otherwise referred to as an adhesive barrier) to further reduce or even avoid the stencil 400 sticking to the façade, and particularly to the first material.
the anti-sticking solution may assist in removal of the stencil 400 from the first material layer 300.
the anti-sticking solution may provide a barrier.
the anti-sticking solution may comprise water and cleaning agent, for example, washing up liquid.
the anti-sticking solution may comprise water with any appropriate cleaning agent, e.g. detergent or soap.
the method may comprise a step of providing anti-sticking solution on the stencil 400, and particularly on the surface of the stencil 400 which is to come into contact with the first material and/or second material.
the anti-sticking solution may be applied to the stencil 400 prior to the stencil 400 being positioned on the first material layer 300. It is preferable for the anti-sticking solution to be applied to the stencil 400 rather than across the entire first material layer 300, because this may otherwise affect the bonding of the second material layer to the first material layer 300.
the stencil 400 is provided on the first material layer 300 before the first material layer 300 has dried and/or cured (i.e. hardened).
the stencil 400 is preferably provided on the first layer 300 when the first material layer 300 is still wet.
the stencil 400 can be used to shape the first material layer 300 between the plurality of surface elements 200. This allows the regions of the first material layer 300 which are to be seen between adjacent surface elements 200 to be shaped.
the surface of the first material between adjacent surface elements 200 has a concave shape, which can be achieved through shaping the surface of the first material using the stencil 400 (and particularly, using the protrusion 420).
other shapes of the surface of the first material layer 300 between adjacent surface elements 200 can be achieved.
Applying a shape to the surface of the first material can assist in replicating the desired aesthetic of the prefabricated facade surface covering 10.
the shape of the surface may be any shape that is applied to mortar in traditional masonry.
figure 2 shows the first material layer 300 having a concave shape between the surface elements 200, other surface shapes include a V-joint, weathered joint, struck joint, or rake joint, for example. Applying a shape to the surface of the first material between the surface elements 200 can also compact the first material and ensure that there is a good connection between the edges of the first material and the adjacent surface elements 200.
the method may comprise pushing the stencil 400 into a surface of the first material layer 300 to shape regions of the first material positioned between adjacent surface elements 200.
the stencil 400 is pushed into the surface of the first material layer 300 when the second material layer is levelled.
second material can be pushed through the openings 410 of the stencil 400, and the stencil 400 can be pushed into the surface of the first material layer 300. This simultaneously forms the surface elements 200 of the second layer, whilst also shaping the regions of the first material between the surface elements 200.
the surface of the protrusion 420 is shaped so that when pressed into the first layer, the material of the first layer is redistributed, preferably so that at least part of the first layer is pushed up and between adjacent surface elements, and more preferably still, so that the part of the first later between adjacent surface elements connects to at least one facing side of an adjacent surface element.
An example of a stencil 400 when pushed into the first material layer 300 and when the second material layer is provided through the openings 410 of the stencil 400 is shown in figure 4 .
the configuration of the protrusion 420 corresponds to all the locations of all of the gaps in between the surface elements 200 to be formed on the covering 10.
the stencil 400 can shape all of the first material provided between the surface elements 200 at the same time.
the stencil 400 may comprise a planar structure or base 430 comprising a protrusion 420 located at the locations of the plurality of gaps between the surface elements 200.
the planar structure or based may be made from PVC.
the stencil 400 can be pressed into the gaps between all, or a plurality of, the surface elements 200 in order to shape the filler material.
Having a stencil 400 with the protrusion 420 and openings 410 can allow for a much faster processing time for shaping the first material and forming the second material on the prefabricated facade surface covering 10, compared to other known methods and may reduce the requirement for manual labour.
such a stencil 400 allows for the first material to be shaped at the same time as the second material is formed, which means that the stencil 400 is used for two functions at the same time.
Forming the second material layer through the openings 410 of the stencil 400 generally comprises providing the second material onto the first material layer 300 through the openings 410 of the stencil 400.
the second material is provided on the first material layer 300 before the first material layer 300 has dried and/or cured (i.e. hardened).
the second material is preferably provided on the first layer 300 when the first material layer 300 is still wet.
the second material can flow into the openings 410 of the stencil 400 in order to fill the openings 410 to take on the desired shape of the surface elements 200.
the stencil 400 masks the remainder of the first material layer 300. This results in second material contacting the first material layer 300 only at the locations where the openings 410 are provided.
the second material layer may be formed of a single layer, or alternatively, may be formed of multiple sub-layers.
the second material layer may comprise multiple parallel layers of second material.
the multiple sub-layers may be formed by building up sub-layers of second material on top of each other.
Forming the second material layer may comprise supplying the second material across a width of the first material layer 300 and/or stencil 400, or at least across a width on which the plurality of surface elements 200 are to be formed.
the second material may be supplied by an applicator 508 configured to supply the second material, described in further detail below, although alternatively, the second material could be supplied manually.
the method may comprise moving the first material layer 300 (already disposed on the supporting layer 100) and the stencil 400 relative to a second applicator 508, while the second applicator 508 supplies the second material (preferably across a width of the stencil 400).
the first material layer 300 and the stencil 400 may be moved together relative to the second applicator whilst the second material is supplied.
the second material may a viscous liquid or slurry surface element material which is provided onto the first material layer 300, and which is then hardened to form the surface elements 200. Forming the second layer directly on the first layer 300, particularly when the first layer 300 is still wet, may avoid the requirement for a separate adhesive. This may be beneficial because it may make it easier to provide a prefabricated facade surface covering 10 with improved fire resistance.
Forming the second material layer may comprise levelling the second material provided on the first material layer 300.
the second material may be levelled by a blade configured to redistribute second material on the first material layer 300 and/or remove excess second material on the first material layer 300. This may be similar to a screen printing process.
Forming the second material layer may comprise moving the first material layer 300 (disposed on the supporting layer 100), the stencil 400 and the second material relative to a second blade 503.
the second blade 503 may have a straight edge.
the second blade 503 may be a rigid blade.
the second blade 503 may be positioned adjacent to the second applicator.
the first material layer 300, the stencil 400 and the second material are moved whilst the second blade 503 is held in place.
the first material layer 300, the stencil 400 and the second material may be moved through an apparatus, e.g. as described herein.
the first material layer 300, the stencil 400 and the second material may be moved by a conveyor belt 540 for example, or another type of moving means.
the first material layer 300 (disposed on the supporting layer 100), the stencil 400 and the second material may be moved together relative to the second blade 503, although at least some of the second material in contact with the blade may be redistributed or removed as the first material layer 300, the stencil 400 and the second material moves relative to the blade.
the first material layer 300, the stencil 400 and the second material are moved relative to the blade, the second material is pushed through the openings 410 of the stencil 400 and is disposed on the first material layer 300.
the plurality of surface elements 200 are formed which correspond to the openings 410 defined in the stencil 400.
the plurality of surface elements 200 of the second layer are substantially flat.
the plurality of surface elements 200 forming the second layer preferably have a substantially uniform thickness.
a trowel can be passed over the stencil 400 (e.g. in the same direction as the conveyor), to redistribute second material. This can push the first material back towards a facing side 201 of the surface element 200. This is beneficial in improving the reliability of a connection between the part of the first material layer between the surface elements and the facing side of adjacent surface elements. This process can be implemented to improve quality as and when desired.
the second material layer may be formed by carrying out the steps described above repeatedly, e.g. using the same applicator and blade (e.g. second applicator 508 and second blade 503) and moving the partially formed prefabricated façade back to the second or third processing location so that additional second material can be added on top of the sub-layer of second material already formed.
the second material layer may be formed by carrying out the steps described successively, e.g. using a different applicator and blade (e.g. a further applicator providing second material and further blade) and moving the partially formed prefabricated façade through successive locations after the third processing location to add an additional sub-layer of second material at each further applicator and blade combination.
first and second applicators and blades are referred to above, it would be understood that the first applicator and the second applicator may be the same and/or the first blade 502 and the second blade 503 may be the same.
the applicator can be purged of remaining first material, and the applicator can be loaded with the second material for the application of the second material.
the first applicator and second applicator are individual applicators which are used in succession, for example, as in the apparatus 500 described below (which also includes two individual blades which are used in succession).
the method may further comprise removing the stencil 400.
the first material layer 300 and second material layer may be dried and/or cured (i.e. hardened) with the stencil 400 remaining in place.
the stencil 400 may be removed.
the first material layer 300 and/or the second material layer may first be allowed to partially harden so that it may hold its shape without the assistance of the stencil 400, and the stencil 400 may be removed before the first material layer 300 and/or the second material layer has fully dried and/or cured.
the method may comprise a drying step after the second material layer is formed, wherein the first and second material layers are dried and/or cured.
the method may carry out at least some of the above described steps in the given order.
the method may comprise forming the first material layer 300, providing the stencil 400, and forming the second material layer in sequential order.
the method may comprise moving the supporting layer 100 through various processing locations of an apparatus to sequentially perform the steps of forming the first material layer 300, providing the stencil 400, and forming the second material layer.
the method includes adapting at least one of the surface elements to have a different colour, surface texture and/or surface finish from other surface elements.
additional steps after formation of the second layer may include applying a colour layer material and/or a surface texture and/or surface finish powder to a surface of at least one surface element.
the method includes adapting the plurality of surface elements so that each surface element is unique, i.e. has a unique combination of colour, texture and surface finish compared to any of the other surface elements on that prefabricated façade surface covering, and preferably is unique compared to other surface elements on other prefabricated façade surface coverings. This may include adapting a colour, surface texture and/or surface finish of a subset of the plurality of surface elements, or all of the plurality of surface elements.
Adapting at least one of the surface elements may comprise applying the colour layer material to a surface of at least one of the surface elements 200.
the colouring layer material is applied to a subset, or one or more of the surface elements 200.
the colouring layer material is preferably applied before the second layer has dried and/or cured.
the colour layer material may be imparted by a tone roller 521.
Adapting at least one of the surface elements may comprise contacting a surface of the second material layer to impart a surface texture to a surface of at least one of the surface elements 200. This may be achieved by contacting or touching the surface of the surface elements 200 by a tool or object, preferably wherein the surface texture is imparted by a texture roller 511. As the roller (or other tool or object) is applied to at least one surface element, an uneven and natural texture will be imparted to the surface of the surface element. Alternatively, the roller may have a specific texture intended to impart a desired texture to the surface of the surface element. Optionally, a pigmented water solution is applied to the texture roller 511.
Adapting at least one of the surface elements may comprise distributing a surface finish powder to a surface of at least one of the surface elements 200, preferably wherein the surface finish powder is distributed with a powder roller (i.e. a surface finish powder roller).
the surface finish powder 230 is provided onto at least one surface element material before hardening of the second material (and/or before hardening of the colouring layer material 220 if present), as this can enable a good bond to be achieved between the surface finish powder 230 and the surface elements 200. This may be because the surface element material (and the colouring layer material 220 if present) will still be wet or tacky, allowing the surface finish powder 230 to be slightly embedded within the surface element.
the roller when a roller is used to distribute the surface finish powder, the roller may also press the surface finish powder 230 into the surface of the surface element which can further ensure that the surface finish powder is embedded within the surface element. Pressing the surface finish powder into the surface may have the advantage that, after the surface elements 200 are formed, the surface finish powder 230 is less likely to be removed during handling, transit, and once installed to the structure.
a different type of pressing tool such as a flat pressing tool could be used.
the steps of applying a colour layer material and/or a surface texture and/or surface finish powder may be done in any order (after formation of the second layer). However, it may be preferred to apply the texture first, then the colour, then the finish powder (or variations thereof if only some of these steps are provided). In particular, providing the surface finish powder after the other steps means that the final product will have loose finish powder, which improves the overall look of the surface covering 10. Carrying out the texture step before the colouring step reduces the likelihood of removing the colour layer during the step of adding the texture.
the steps of applying a colour layer material and/or a surface texture and/or surface finish powder are done before removing the stencil 400 so that the applications are to the surface of the surface elements 200 only (and not the first layer 300 between the surface elements).
any combination of the above steps may be carried out in an apparatus.
the method described herein may be carried out by the apparatus 500 described in further detail below. Although it will be understood that the method could also be formed using an adapted or alternative apparatus.
an apparatus 500 is provided, for example, as shown in figures 6, 7 , and 8 .
the apparatus 500 is suitable for forming a prefabricated façade surface covering comprising a first material layer 300 and a second material layer, the second material layer comprising a plurality of surface elements 200 disposed on the first layer 300.
the apparatus 500 may be beneficial in reducing material wastage and cleaning requirements of the apparatus 500 and component parts.
the apparatus 500 comprises a 501, the first blade 502 and the second blade 503.
the main body 501 may be configured to support other components of the apparatus 500.
the main body 501 is configured to move at least part of the supporting layer 100 through the apparatus 500, and preferably through sequential processing stations.
the main body 501 is configured to move the supporting layer 100 from a first processing location A to a second processing location B to a third processing location C.
the main body 501 may be configured to move the supporting layer 100 to or from additional processing locations. It will be understood that the layers described above may be formed on the supporting layer 100 during fabrication of the façade.
the apparatus 500 may provide a production line for fabricating the façade.
the apparatus 500 may be a continuous production line, in which at least part of the supporting layer 100 is moved through the apparatus 500.
a continual and measurable output may be produced, creating the option for improved adaptability of the line, to suit customer requirements, i.e. the line can be sped up to meet high demand and slowed for standard production.
the main body 501 may comprise a conveyor belt 540.
a conveyor belt is particularly useful as it allows the speed of movement of the supporting layer 100 through the apparatus 500 to be controlled, e.g. to control the time at which the supporting layer 100 is positioned at any given processing location.
the conveyor belt 540 may be provided to move the supporting layer 100 between multiple locations of the apparatus 500.
the conveyor belt 540 can be controlled manually and/or automatically, for example, by having a control unit (not shown).
the apparatus 500 may comprise a roller table 550 configured to receive the prefabricated façade surface covering 10 downstream of the third processing location C. It may be beneficial to provide an alternate form of moving means, in addition to the conveyor below.
the prefabricated façade surface covering 10 may move from the conveyor belt 540 to the rolling table when mostly formed, and may be positioned on the roller table 550 whilst drying and/or curing or whilst being inspected before being moved to another location for drying and/or curing.
the roller table 550 may be configured to hold multiple formed façade surface coverings after they have been processed.
the supporting layer 100 is provided on a manufacturing board 50, e.g. a calcium silicate board.
the manufacturing board may otherwise be referred to as base boards.
the manufacturing board 50 may be precut to shape, or could be post cut (once the prefabricated façade is dry). Having a manufacturing board 50 pre-cut means that when placing a specific stencil shape over the pre-cut manufacturing board 50, the layer of first material will only be covering the area which is intended to form the facade, as opposed to coating a larger manufacturing board that includes areas around the facade. Additionally, pre-cutting the manufacturing board 50 means that unused smaller parts of the "waste" manufacturing board will be able to be used for other elements, such as smaller window reveal sections. This is beneficial in that it offers efficient nesting and material waste minimisation.
Multiple facades can be processed by the apparatus 500 at any one time, with different parts of the process being carried out in different processing locations.
a part of the supporting layer 100 may be attached to each of the manufacturing boards 50, which are then transported through the apparatus 500.
the manufacturing boards 50 can be run butted up to one another, with infill boards to correctly space them (if needed or desired). This is beneficial in that excess adhesive is not spread over the conveyor belt 540 and can be either reused on the following board or removed and reused. This in turn means less time is spent on maintenance of the line and both the quality and efficiency of the line can be improved.
the first blade 502 is configured to form, at the first processing location A, the first material layer 300 disposed on the supporting layer 100. More specifically, first material is provided on the supporting layer 100. The volume of first material applied is controlled by the first blade 502 that is calibrated to create a controlled gap for the first material to flow through. The position of the first blade 502 may be selected to calibrate the gap based on the relative position of the first blade 502 and the conveyor belt 540 (or other moving means), and considering the thickness of the supporting layer 100 (and any other board or layer on which the supporting layer 100 is provided).
the apparatus 500 may comprise the first applicator configured to provide the first material, as described above.
the first applicator may be adjacent to the first blade 502.
the first applicator may provide the first material to the first processing location A.
the first applicator may also be provided at the first location.
the second location is provided between the first blade 502 and the second blade 503 and is configured to receive a stencil 400 on the first material layer 300.
the apparatus 500 comprises a location (i.e. the second processing location B) for receiving the stencil 400.
the stencil 400 may be as in any of the variations or alternatives described herein. (although an alternative stencil could be provided)
the second location may be configured to receive the stencil 400 due to the position of at least the first blade 502 and the second blade 503.
the first blade 502 and the second blade 503 can be spaced apart from each other to allow for the positioning of a stencil 400 on the first material layer 300 at the second processing location B (i.e. between the first processing location A and the second processing location B).
the apparatus 500 may comprise the stencil 400 for positioning on the first material layer 300 at the second processing location B.
the apparatus 500 may comprise a means for holding the stencil 400.
the apparatus 500 may comprise a mechanism for placing the stencil 400 on the first material layer 300 at the second processing location B, i.e. to automatically place the stencil 400.
the apparatus 500 may comprise an actuated robotic arm or another actuated mechanism (not shown in the figures). Alternatively, this could be done manually.
the apparatus may comprise a vessel (not shown in the figures) which can be filled with anti-sticking solution.
the vessel may be shaped so that the stencil can be submerged in the anti-sticking solution, so that, for example, the protrusion 420 can be covered and/or filled with anti-sticking solution.
the vessel is a tray shape such that the stencil 400 can be submerged when flat.
the vessel may be provided adjacent to, and/or upstream of, the second processing location B.
the vessel is provided close to the second processing location B so that the stencil can be placed in the anti-sticking solution in the vessel, and the moved to the second processing location B.
the stencil 400 may be placed in the vessel manually.
the apparatus 500 may comprise a mechanism for placing the stencil 400 in the vessel.
the apparatus 500 may comprise an actuated robotic arm or another actuated mechanism (not shown in the figures).
the second blade 503 is configured to form, at the third processing location C, the second material layer disposed on the supporting layer 100. More specifically, second material is provided on the first material layer 300 and/or the stencil 400 and the second blade 503 is configured to form the second material layer on the first material layer 300.
the apparatus 500 may comprise the second applicator configured to provide the second material, as described above.
the second applicator may be adjacent to the second blade 503.
the second applicator may provide the second material to the third processing location C.
the second applicator may also be provided at the third processing location C.
the second blade 503 may be configured to press the stencil 400 into the first material layer 300 as the supporting layer 100 is moved by the main body 501 relative to the second blade 503.
the second blade 503 may be positioned relative to the main body 501 to form a gap between the blade and the main body 501.
the gap between the blade and the main body 501 may be selected to allow for the supporting layer 100, first material layer 300, second material and stencil 400 to pass beneath the blade.
the gap may mean that the blade presses on the stencil 400 as the supporting layer 100 is moved.
the second blade 503 also pushes the second material into the openings 410 of the stencil 400 to form the second layer.
the second blade 503 is thus configured to simultaneously press the stencil 400 into the first material layer 300 and to level the plurality of surface elements 200 forming the second layer.
the stencil 400 may be calibrated to be a total thickness (including the protrusion 420), so that when the stencil 400 passes under the second blade 503, the stencil 400 is under a controlled pressure (as the gap provided by the second blade 503 is also calibrated).
the gap between the surface on which the manufacturing board is supported (e.g. the conveyor belt) and the second blade 503 may be approximately 11 mm, but the partially formed façade on the manufacturing board 50 may be approximately 12 mm (e.g. comprising 9 mm of manufacturing board, 1.5 mm first material layer, and the stencil 400 having a thickness of approximately 1.5 mm), so that when the partially formed façade is pushed under the blade, the stencil is pushed down by approximately 1 mm into the first material layer.
the stencil 400 and second blade 503 are used to shape the first material positioned between the surface elements 200 whilst maintaining material usage control.
the values provided above are for example only, and different dimensions of gap and/or thickness of layers and/or manufacturing board 50 and/or stencil 400 may be provided. This means that the first material can be shaped whilst using the second blade 503 to wipe away excess second material. The removed second material can be recycled, thus reduces wastage.
the apparatus 500 may comprise a holder 505 configured to hold a roll of supporting layer 100, for example, as shown in figure 9 .
the main body 501 may be configured to move at least part of the supporting layer 100 from the holder 505 to the first processing location A.
the holder 505 may comprise a support layer rail 506, preferably held on a support.
the holder 505 may comprise a further support layer rail 507, which is positioned below the support layer rail 506.
the further support layer rail 507 may be positioned such that a roll of supporting layer 100 is pulled from the roll of supporting layer 100, and is pulled past the further support layer rail 507. This may be useful in controlling the angle of the supporting layer 100 as it is pulled from the holder 505 to the first processing location A, e.g. to keep the supporting layer 100 relatively flat.
the apparatus 500 may comprise a texture roller unit 510 configured to apply texture to a surface of at least one of the surface elements 200.
the apparatus 500 may comprise a tone roller unit 520 configured to apply colour to a surface of at least one of the surface elements 200.
the apparatus 500 may comprise a powder roller unit 530 configured to apply powder to at least one of the surface elements 200.
These roller units may provide for the automated application of aesthetic patina/character to the façade. These roller units are shown in further detail in figures 10 and 11 .
the texture roller unit 510 may comprise a texture roller 511.
a surface of the texture roller 511 may be designed to have 'peeks' and 'troughs' either continuously around the circumference of the texture roller 511 or split by the dimensions of the opening of the stencil 400 (i.e. the match at least one of surface of the surface elements 200).
the texture roller 511 may be coated with a latex type material.
a pigmented water solution can be applied to the texture roller 511, so that as the roller touches the surface of at least one surface element (which is preferably still wet).
the texture can be applied, but the water pigment stops the second material 'sticking' to the roller.
the texture roller 511 will repeat the same texture by rotation. However, at least one additional texture roller 511 could be provided. The at least one additional texture roller 511 may have a different radius and/or texture to the first texture roller 511. This would result in significant reduction in the repetition of texture occurring. By varying the circumference ratios of rollers, a unique texture can be produced on every surface element, with a similar aesthetic. In order to suit different styles and finishes, the rollers may be quickly interchanged to meet certain design needs, as described further below.
the tone roller unit 520 may comprise a tone roller 521.
the tone roller 521 may comprise pads of compressible open-cell sponge/foam. The pads may be positioned on the roller to correspond to the plurality of surface elements 200, and/or to the openings 410 in the stencil 400.
the tone roller 521 may have pads which correspond to at least one, or a subset of the surface elements 200, or even all the surface elements 200. There may be gaps between the pads which correspond to the masking regions of the stencil /regions of the first material between the surface elements 200. These pads may hold a pigment/acrylic/water formulation and gently press down onto the surface of the surface elements 200.
the use of these pads can be beneficial so as to not remove the texture applied through compressing the wet second material, but applying just enough pressure to transfer an amount of the pigmented water/acrylic solution from the sponge pad onto the surface of at least one surface element (which is preferably still wet).
the amount of pressure applied by the tone roller may depend on the position of the tone roller 521 above the surface on which the manufacturing board is provided. If too much pressure is applied by the tone roller, i.e. if the tone roller is too close to the partially fabricated facade, the roller may release too much pigment and may remove (e.g. squash) the texture already imparted on the surface. If too little pressure is applied by the tone roller 521, i.e. if the tone roller is too far from the partially fabricated facade, the roller may not release enough pigment.
the position of the tone roller may be selected by trial and error.
the tone roller 521 can be used to provide the colouring layer material 220.
At least one additional tone roller 521 could be provided.
the at least one additional tone roller 521 may have a different radius and/or pigment/acrylic/water formulation and/or different pad location to the first tone roller 521. This would result in significant reduction in the repetition of colouring occurring.
a unique tone/colouring can be produced on every surface element, with a similar aesthetic. This can reduce frequency of repetition to provide authenticity.
the surface finish powder roller unit 530 may comprise a surface finish powder roller 531 (otherwise known as a dust roller).
the surface finish powder roller 531 may comprise pads of compressible open-cell sponge/foam. The pads may be positioned on the roller to correspond to the plurality of surface elements 200, and/or to the openings 410 in the stencil 400.
the surface finish powder roller 531 may have pads which correspond to at least one, or a subset of the surface elements 200, or even all the surface elements 200. There may be gaps between the pads which correspond to the masking regions of the stencil/regions of the first material between the surface elements 200. These pads may hold surface finish powder and gently press down onto the surface of the surface elements 200.
the pads are compressed, and the surface finish powder applied to the at least one surface element.
the sponge/foam pads may be sprayed with a mist of water to allow a thin layer of surface finish powder to be dosed and stick to the surface of the pad. This process of dosing the surface of the pads can be repeated with every rotation of the surface finish powder roller 531.
the use of these pads can be beneficial so as to not remove the texture and/or tone applied, but applying just enough pressure to transfer an amount of the surface finish powder from the sponge pad onto the surface of at least one surface element (which is preferably still wet).
At least one additional surface finish powder roller 531 could be provided.
the at least one additional surface finish powder roller 531 may have a different radius and/or surface finish powder and/or different pad location to the first surface finish powder roller 531. This would result in significant reduction in the repetition occurring.
By varying the circumference ratios of rollers a unique distribution of surface finish powder can be produced on every surface element, with a similar aesthetic. This can reduce frequency of repetition to provide authenticity.
the manufacturing boards 50 may be set at dimensions to allow boards run 'butted-up' and the line to operate continuously, preferably with the infills calibrated to the relative dimensions of the rollers. This means that when one board has passed through the roller pads, the next board can arrive at the rollers with the stencil 400 positioned exactly to fit the location of the pads on the roller, reducing the need for resetting or recalibration between boards.
At least one of the roller units may comprise a support structure configured to hold at least one roller of the respective roller unit such that the roller can rotate about its longitudinal axis relative to the support structure.
Each roller unit may comprise multiple rollers, each with their own support structure.
the roller may be rotated about the axis by the supporting layer 100 (and first and second material and stencil 400) as the supporting layer 100 is moved relative to the roller.
the support structure may comprise a rail 525 and a pair of rail support boards 522, with one rail support board at either end of the rail 525.
the rail 525 may be fixed to the support board 522.
the rail 525 may rotate around its longitudinal axis when fixed to the support board 522, or it could be fixed in place. Either way, the roller (e.g. roller 521) can rotate around the rail 525.
Each rail support board 522 may have a plurality of holes 523 defined therein for attachment of the rail 525.
the position of the rail 525 relative to the surface elements 200 may be selected depending on the desired interaction between the roller and the surface elements 200.
the pressure applied by a roller on a surface of the façade may be selected by altering the height of the roller depending on how much colour and/or texture and/or finishing powder is to be applied on the surface.
At least one of the rail support boards 522 may be removably attached to the main body 501 such that the roller on the rail 525 can be quickly interchanged.
the rail support board 522 may be attached to the main body 501 by a screws connected to the main body 501 which pass through holes of the support board and have a fastening device 524, such as a nut which can be threaded onto the screw to keep the rail support board 522 in place.
the apparatus 500 shown in the figures includes all three roller units, any number of roller units may be provided. Thus, only one of the roller units may be provided, or two of the roller units may be provided. Alternatively, the apparatus 500 may not include any of these roller units.
Alternatives could be used instead, e.g. using manual tools and/or stamps to apply texture, and/or tone, and/or finishing powder.
Other alternatives include using 'stamps', for example, mounted on robotic arms or an overhead machine, to apply texture, tone and surface finishing powder to pre-determined points across the board.
Another alternative is to use a second conveyor with pads which acts in a similar way to the rollers, by applying the 3 aesthetic components across the board.
the apparatus is shown with a single manufacturing line (i.e. with one processing line of façade surfaces at different stages of fabrication), it will be understood that multiple manufacturing lines may be provided simultaneously.
multiple prefabricated façade surface coverings may be fabricated simultaneously, for example, by having the façade surfaces next to each other across the width of the apparatus.
the façade surfaces may be produced separately, i.e. by having separate façade surfaces which are processed individually.
the apparatus may be configured to move multiple supporting layers through the relevant processing locations, e.g. by having multiple rolls of supporting layer positioned on the support layer roller 506 and/or by having multiple manufacturing boards 50 adjacent to each other in the width direction.
the façade surfaces may be produced jointly, i.e.
the apparatus may be configured to move a single supporting layer (which is wider than the supporting layer 100 shown in the figures) through the relevant processing locations, wherein several facades are processed across the width of the supporting layer. Either way, each stage of the process can be carried out on multiple (e.g. 2, 3, 4 or more) façade surfaces simultaneously.
Multiple stencils may be provided in the second processing location, so that one stencil is provided for each façade surface covering.
one stencil may be provided which has a plurality of sets of openings, with each set of openings corresponding to a single façade surface covering.
the apparatus 500 described above may provide an automated, or semi-automated way to fabricate façade surface coverings. This may be particularly beneficial in reducing, or even avoiding, manual input.
the automated application of the texture, tone and/or dust may be particularly beneficial in reducing, or avoiding manual input, which previously required human input using hand tools.
the apparatus 500 may be particularly beneficial in that it can be used to imitate various different types of tiling, materials, etc.. It may also be easy to alter the type of façade that is produced, e.g. to imitate an alternate product, by some straightforward alterations, for example, including changing the first and/or second material (or changing a colour additive of at least one of the layers), changing the stencil used (e.g. to provide one with different openings and or shaped protrusions), and/or changing the roller configurations.
the prefabricated facade surface covering 10 may be manufactured in a factory or an off-site location.
the prefabricated facade surface coverings may be transported to a construction site for installation on a building.
the prefabricated facade surface coverings 10 may be installed on the exterior of a building, to form an external facade of the building.
the prefabricated facade surface coverings may installed on the interior of a building to form an interior facade.
the prefabricated facade surface coverings may be used to provide over cladding to a building.
the prefabricated facade surface coverings 10 may be installed, externally or internally, as part of a modular building unit.
Modular building units may be prefabricated sections of buildings assembled in a factory, which are then combined together on site to form a building.
the prefabricated facade surface coverings 10 are installed onto a surface of a structure by applying an adhesive between the surface of the structure and each prefabricated facade surface covering 10.
the adhesive is made from the same material and/or colour as the first material. This can have the advantage that if the adhesive squeezes out between adjacent prefabricated surface coverings 10, the adhesive will have the same appearance as the first material, and thus will not disturb the appearance of the surface of the structure.
the prefabricated facade surface covering 10 as described above may be prepared before installation on the surface of a structure.
the application of first material may not be required at the installation site or may be considerably reduced. This can save a considerable amount of time because the prefabricated facade surface coverings can be installed one after the other without spending time providing first material between each of the surface elements 200.
the prefabricated facade surface covering 10 according to the present invention may be advantageous over other prefabricated facade systems, because traditional prefabricated systems involve additional steps which must be performed by construction workers at the construction site, such as the application of filler, e.g. mortar. Such steps are avoided in the present invention by forming the surface elements 200 on the first material at the factory or off site location at which the prefabricated facade surface coverings are prepared. Preparing the prefabricated facade surface coverings 10 at the factory or off site location may be advantageous because the production steps can be performed indoors in a controlled environment, which may lead to a higher quality finished product prepared to higher quality control standards than when the facade is prepared on-site.
the supporting layer 100 is a flexible mesh
the supporting layer 100 may be a flexible panel.
the flexible panel may be made from polymer, or metal, or any other suitable material used in construction.
the supporting layer 100 may be a rigid mesh or a rigid panel. These may be provided in solid sections rather than from a roll as described above.
the supporting layer 100 is not a mesh, but is a solid panel (e.g. with no openings)
directly forming the first layer 300 onto the surface of the supporting layer 100 by hardening the first material may still enable a strong connection to be formed can be formed with or without the use of an additional adhesive.
first blade 502 and/or the second blade 503 is held in place whilst the supporting layer 100 and at least one of the first material, second material and/or stencil 400 are moved.
first blade 502 and/or the second blade 503 could be moved and the supporting layer 100 and at least one of the first material, second material and/or stencil 400 may be held in place.
the relevant blade could be moved across a surface of the covering during formation of the first material layer 300 and/or the second material layer.
both the relevant blade and the supporting layer 100 (and any of the relevant first and/or second materials and the stencil 400 if relevant) could be moved simultaneously.
the colouring layer material 220 is provided above by using rollers, it would be understood that the colouring layer material of the covering may be provided in any appropriate way.
the colouring layer material 220 can be provided using any suitable means such as a screen printing system, or by painting, or by pouring the colouring layer material from a container containing the prepared colouring layer material to the openings 410 of the stencil 400 when still in place (or through openings of an alternative stencil, e.g. one which provides openings for some surface elements 200 whilst masking other surface elements 200).
the colour of some of the surface elements 200 could be adapted manually, using a stamp.
the method and/or apparatus 500 could provide an additional step of forming colouring layer material on top of the second layer.
the colouring layer material could be provided by an additional applicator and blade as described above and may provide a thin layer on top of the second layer which allows for more colour variation of the plurality of surface elements 200. Such a colouring layer material could be provided before any additional or alternative steps are taken to colour, add texture and/or dust the second layer.
the surface finishing powder is provided above using a roller, it would be understood that the powder can be provided in any appropriate way.
the surface finish powder 230 may be distributed, or dusted, using a shaker or other dispenser suitable for dispensing a powder, across the surface elements 200. Using a shaker or other dispenser may create a natural variation in the surface finish powder density/distribution across the surface elements 200.
the surface texture is provided above using a roller, it would be understood that the texture can be imparted in any appropriate way.
a tool e.g. a stamp or other device can be used to impart a texture or pattern on the surface of the surface elements 200.

Landscapes

Engineering & Computer Science (AREA)
Architecture (AREA)
Civil Engineering (AREA)
Structural Engineering (AREA)
Chemical & Material Sciences (AREA)
Ceramic Engineering (AREA)
Finishing Walls (AREA)
Load-Bearing And Curtain Walls (AREA)
Panels For Use In Building Construction (AREA)

EP25203726.2A 2023-12-21 2024-12-19 Façade de façade Pending EP4644109A3 (fr)

Applications Claiming Priority (3)

Application Number	Priority Date	Filing Date	Title
GB2319788.2A GB2636791A (en)	2023-12-21	2023-12-21	Facade
EP24837586.7A EP4623169A1 (fr)	2023-12-21	2024-12-19	Façade
PCT/EP2024/087573 WO2025132902A1 (fr)	2023-12-21	2024-12-19	Façade

Related Parent Applications (1)

Application Number	Title	Priority Date	Filing Date
EP24837586.7A Division EP4623169A1 (fr)	2023-12-21	2024-12-19	Façade

Publications (2)

Publication Number	Publication Date
EP4644109A2 true EP4644109A2 (fr)	2025-11-05
EP4644109A3 EP4644109A3 (fr)	2025-12-31

Family

ID=89768107

Family Applications (3)

Application Number	Title	Priority Date	Filing Date
EP25203732.0A Pending EP4644110A3 (fr)	2023-12-21	2024-12-19	Façade de façade
EP25203726.2A Pending EP4644109A3 (fr)	2023-12-21	2024-12-19	Façade de façade
EP24837586.7A Pending EP4623169A1 (fr)	2023-12-21	2024-12-19	Façade

Family Applications Before (1)

Application Number	Title	Priority Date	Filing Date
EP25203732.0A Pending EP4644110A3 (fr)	2023-12-21	2024-12-19	Façade de façade

Family Applications After (1)

Application Number	Title	Priority Date	Filing Date
EP24837586.7A Pending EP4623169A1 (fr)	2023-12-21	2024-12-19	Façade

Country Status (3)

Country	Link
EP (3)	EP4644110A3 (fr)
GB (1)	GB2636791A (fr)
WO (1)	WO2025132902A1 (fr)

Citations (1)

* Cited by examiner, † Cited by third party
Publication number	Priority date	Publication date	Assignee	Title
WO2023062387A1 (fr)	2021-10-14	2023-04-20	TopHat Industries Limited	Façade

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number	Priority date	Publication date	Assignee	Title
US3435577A (en) *	1966-06-20	1969-04-01	James D O Leary	Wall construction
US5373676A (en) *	1992-09-28	1994-12-20	Francis; Steven R.	Thin brick panel assembly
GB2548156A (en) *	2016-03-11	2017-09-13	Paul James Bishop Ip Holdings Ltd	Improvements in or relating to a visible flexible facing layer
GB2575307B (en) *	2018-07-05	2022-11-23	Paul James Bishop Ip Holdings Ltd	Building-wall flexible cladding
EP3816364A1 (fr) *	2019-10-29	2021-05-05	Isosystems AG	Panneau de revêtement préfabriqué modulaire résistant au feu

2023
- 2023-12-21 GB GB2319788.2A patent/GB2636791A/en active Pending
2024
- 2024-12-19 EP EP25203732.0A patent/EP4644110A3/fr active Pending
- 2024-12-19 EP EP25203726.2A patent/EP4644109A3/fr active Pending
- 2024-12-19 WO PCT/EP2024/087573 patent/WO2025132902A1/fr active Pending
- 2024-12-19 EP EP24837586.7A patent/EP4623169A1/fr active Pending

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number	Priority date	Publication date	Assignee	Title
WO2023062387A1 (fr)	2021-10-14	2023-04-20	TopHat Industries Limited	Façade

Also Published As

Publication number	Publication date
EP4644109A3 (fr)	2025-12-31
EP4644110A2 (fr)	2025-11-05
WO2025132902A1 (fr)	2025-06-26
EP4623169A1 (fr)	2025-10-01
GB2636791A (en)	2025-07-02
GB202319788D0 (en)	2024-02-07
EP4644110A3 (fr)	2025-12-24

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