GB2296515A - Panel resembling tiling - Google Patents

Abstract

A panel duplicating the appearance of a ceramic tiled, and grouted surface, using gel coat 2 as a primary external surface, such surface being supported by a glass 1 resin composite skin, bonded under vacuum, to a rigid substrate of, preferably medium density fibre board 4, the internal face 3 of the structure being a glass/resin composite skin, bonded under vacuum, to the substrate, and having an irregular surface to promote the adhesion of the finished structure to the host material. Such method provides for total encapsulation of the substrate 4 and may be produced in sheet form of pre-determined sizes. <IMAGE>

Description

IMPROVEMENTS RELATING TO SURFACE COVERINGS The invention relates to apparatus and particularly but not exclusively to panels having a preselected and typically traditional appearance and also to a method for cladding, covering or forming walls, floors, ceilings, roofs and the like.

Tiles have been widely used for many years primarily to protect and also to decorate walls, floors, ceilings, roofs and the like. Typically, ceramic tiles mounted and connected theretogether by grout are used indoors, whilst outdoors typically overlapping tiles are mounted on roofs or outside walls. In both cases, the object is to provide a sealed layer which is impermeable to water.

There are however a number of problems associated with the use of tiles both on the inside and on the outside of buildings. For example, and significantly in circumstances where efficiency and cost effectiveness are paramount, making and installing tiles is often labour intensive, time-consuming and expensive.

Furthermore, in order for the fixed tiles to be effective, they must be precision mounted so that there are no gaps through which small objects or fluids such as water can penetrate.

In addition, installing tiles in awkward places for example around installations such as toilets, sinks or baths can be fraught with problems for the workman. It is often necessary for example to cut tiles to the required size and shape in order to fit them. Tiles are typically very fragile and can shatter when not cut in the correct manner, or may be ineffective when mounted or wasted if not cut to the correct size.

Once installed, tiles can be difficult to remove for example, for replacement or repair, so that as a style of tile decoration goes out of fashion, it can be problematical and very expensive to change. Furthermore, indoors where typically grout is used to fix individual tiles, the tiles and grout can be difficult to keep clean. Tiles are often used in kitchens and bathrooms, environments which are predominantly warm and humid so encouraging the growth of bacteria and mould. Grout filled crevices between tiles are particularly susceptible to such growths. Mould and bacteria etc as well as the rigorous cleaning, either mechanically or chemically, necessary to eradicate these organisms may damage the grout and possibly the tiles. As a result, grout may be displaced and tiles may become loose and even dislodged which in itself represents a safety hazard.At the very least the grout and possibly the tiles can be become discoloured and so unattractive in an environment where hygiene is important. This is particularly undesirable in a health care environment.

When one considers the above disadvantages and the expense of producing individual tiles, it is surprising that an acceptable alternative has not been developed. Indeed, vinyl wall paper embossed with a tiled shaped relief though popular has still not attained widespread use in shower cabinets or around the top of sinks and baths or in the kitchen or healthcare environments. This would seem to be because the paper is relatively fragile and so amongst other things, susceptible to impregnation by water following repeated exposure to same. It will be apparent the end result is rotting of the paper a situation inconsistent with the desired objective of coverings for walls, ceilings etc.

Fixing ceramic tiles to a substrate and then mounting the substrate to a wall has also been suggested as an alternative, however the problems of cost and cutting such panels to a preselected size and shape and the problems associated with hygiene still remain.

It is therefore a first object of the invention to provide an apparatus, and a method for making said apparatus, for covering, cladding or forming walls, floors etc.

It is a further object of the invention that such an apparatus is easy, simple and quick to install.

It is a further object of the invention, that such an apparatus is relatively simple and so cheap to manufacture.

It is a further object of the invention that such an apparatus is easy to keep clean and therefore it is hygienic.

It is a further object of the invention that such apparatus is designed with safety in mind and is therefore able to resist fire.

According to the invention there is therefore provided a structure comprising: first and second outer layers having a support means attached therebetween and wherein at least one of said layers is provided, over at least a part of its surface, with an image of preselected design and appearance.

It will be understood that where the image is an impression or a relief representing a preselected pattern of tiles then at least a part of at least one of said layers will be provided with a decorative surface.

Ideally, said impression or relief incorporates the shape and appearance of grout between said tiles.

It will be understood from the above that a structure according to the invention can be manufactured to any preselected specification thus determining its size, shape and appearance and so that problems associated with installation and prolonged use are overcome.

In a further preferred embodiment, one of the outer layers of said structure is provided with a substantially smooth outer surface so as to facilitate the mounting of said structure. Typically this surface is defined as the rear. Alternatively, both of said first and second layers are provided with an impression or relief.

Preferably the impression or relief of said first layer is different from that of said second layer.

In a further preferred embodiment at least one of said layers comprises an external skin for example a gel coat, and at least one bonding support layer for attaching same to said external skin and said support means.

Ideally, at least the outermost surface of said external skin is adapted to be waterproof and preferably hygienic. Preferably at least the outermost surface of the external skin and ideally at least the outermost surface of the bonding support layer complies with BS6920 (suitability of products for use in contact with water intended for human consumption). Moreover ideally, at least the outermost surface of at least said external skin or said bonding support layer is adapted to be fire retardant. Preferably said external skin and ideally said bonding support layer are adapted to comply with BS476 Class 1 part 7 (fire retardant regulations).

In a further preferred embodiment the outermost surface of said external skin or said bonding support layer is adapted to have a Barcol hardness of not less than 50.

In a yet further preferred embodiment one of said layers and/or said bonding support layer comprises at least one resinous substance such as general purpose resin, casting resin, fire retardant resin, glass/resin composite and the like.

Preferably said support means comprises at least one substrate, ideally made from dense fibre board such as ply board, plasterboard, glassfibre or the like.

Alternatively or in addition said support means comprises wood, plastic, metal etc.

In a preferred embodiment said structure is adapted to be load bearing. Ideally said structure is adapted to be free standing by for example the provision of a base foot or the like.

According to the invention there is also provided a method for making a structure comprising.

a) introducing solidifiable material for forming a first layer into a mould of preselected size, shape and design; b) positioning a support means of preselected size and shape on said solidifiable material; c) introducing solidifiable material for forming a second layer on to the said substrate; and d) exposing the contents of the mould to solidifying conditions whereby said layers solidify so as to entrap said support means therebetween and said solidifiable material positioned adjacent said mould design is provided with an outermost impression corresponding to said mould design.

In a preferred embodiment, step (d) of said method is replaced by the following procedure: e) enclosing said layers and said support means within a mould prior to f) exposing the contents of the mould to solidifying conditions.

Preferably said solidifying conditions include a vacuum and/or external pressure and/or heat and/or a chemical change.

In a preferred embodiment, at least one of said steps (a) and (c) includes i) applying a coating to at least a part of the inner surface of the mould, and if necessary, curing said coating; ii) repeating step (i) as required; and then iii) introducing a solidifiable bonding support material; and iv) repeating step (iii) as required.

In a further preferred embodiment, said method includes spraying the inner surface of at least a first section of the mould with a gel coating; introducing at least one solidifiable resinous substance into said first section of the mould; positioning at least one substrate, preferably of glass fibre, on the surface of said resinous substance; introducing at least one solidifiable resinous substance onto said substrate; applying a further gel coating to the remaining parts of the mould, if desired; enclosing the contents of the mould within the mould; exposing the contents of the mould to a vacuum until the contents have set.

According to the invention there is also provided a structure as hereindescribed made according to any of the methods of the invention.

Preferred embodiments of the invention will now be described, by way of example only, with reference to and as illustrated in the accompanying drawings.

Figure 1 shows a perspective cut-away view of a structure in accordance with the invention.

Figure 2 shows a perspective cut-away view of an alternative structure in accordance with the invention.

Figure 3 shows a perspective view of an alternative structure in accordance with the invention.

Referring firstly to Figure 1, a panel 1, having a first outer layer 2, an inner substrate 4 and a second layer 3, is shown. In this embodiment. Panel 1 is shown to be rectangular. It will be understood by those skilled in the art, that, panel 1 can be constructed in any suitable size and shape as desired and in particular panel 1 may be made so as to be fitted into a particular location. Alternatively or in addition, panel 1 can be cut to the required size and/or shape or even deformed for example by bending slightly in order to fit into a particular location.

Substrate 4 is relatively rigid and is sandwiched between and ideally bonded to outer layers 2 and 3. The provision of outer layers on both sides of substrate 4 is preferred because it prevents warping of substrate 4 and hence of panel 1.

In this particular embodiment, outer layers 2 and 3 effectively encase substrate 4 so that the edge 7 of substrate 4 is sealed within the material of outer layers 2 and 3 at panel edge 8. It can be envisaged by those skilled in the art that substrate 4 need not be completely enclosed at the edges in this way. This is particularly true if substrate 4 comprises material impervious to water.

Outer layer 2 is moulded and textured on its outermost surface to provide a relief here in the form imitation ceramic tiles 5 separated by imitation grout lines 6.

Though relief 5 is here shown as ceramic tiles, it is envisaged that alternative impressions can be used and are intended to be covered by this application.

Outer layer 3 has a substantial planar outermost surface for locating panel 1 onto, for example, a walls, ceiling or floor. In addition outer layer 3 can be provided with ridges, protrusions, recesses, holes and the like in order facilitate this.

Outer layers 2 and 3 are made from a glass/resin composite and substrate 4 here is a glass fibre board. Other materials such as composite materials, plastics, resinous substances such as general purpose resin, casting resin and/or fire retardant resin, and the like may be used for layers 2 and 3. Substrate 4 can be formed from ply board, plasterboard, wood, metal etc and may comprise a number of separate sections.

Referring now to Figure 2, like reference numerals refer to like afore referenced features.

Outer layer 2 here comprises an exposed outermost skin 2A and an innermost layer 2B. Innermost layer 2B provides a backing to outermost skin 2A and bonds skin 2A to substrate 4. Outermost skin 2A comprises a cured gel material which is impermeable to water and is hygienic. In particular the material of skin 2A and preferably the material of innermost layer 2B complies with BS6920 the British Standard with regard to products for use in contact with water intended for human consumption. This ensures that panel 1 is particularly suitable for use in a domestic or healthcare environment. Furthermore panel 1 and in particular outer layers 2 and 3 of panel 1 are fire retardant, again. increasing the suitability of panel 1 for use in the home and more especially, the kitchen or as a surround for a fireplace.

Innermost layer 2B is typically a resin and it bonds skin 2A to substrate 4. Skin 2A and ideally layer 2B are decorated and coloured so as to resemble ceramic tiles and so accentuate the relief 5 including imitation grout lines 6.

Outer layer 2 is provided in Figure 2 with 12 imitation tile shapes SA. Outer layer 3 is also provided with relief 5 in this embodiment comprising smaller imitation tile shapes SB. Indeed, 35 imitation tiles SB (not all shown) are provided in outer layer 3. Tiles SA and SB may be different. not only in number but also in colour, shape, pattern, impression and design and it will be understood by those skilled in the art that these alternatives are intended to be covered by this application. Panel 1 of Figure 2 is ideally suited to use as a side wall for a shower cubicle, particular for shower cubicles adjacent or forming part of a bath, since water resistant surfaces are needed on both sides of such a wall. Panel 1 may be provided with pivots or base mountings as required.Panels according to the invention can be mounted directly if desired, onto walls, ceilings, roofs etc using screws, nails, cement, adhesives and the like.

Referring now to Figure 3, a cylindrical structure 9 is shown. Structure 9 here comprises a semi-cylindrical section 10 and two quarter cylindrical sections 1 1A and 11 B, located adjacent each other at seams 12.

Each of these sections comprise inner and outer layers 14 and 16, which are typically made from casting resin, and a substrate 15. Substrate 15 and also layers 14 and 16 are shaped so as to form cylindrical structure 9. The innermost surface of layer 14 is predominantly smooth so that structure 9 or any of the individual sections can be mounted on, for example, a pillar or column or even a curved wall, floor or ceiling. The innermost surface of layer 16 can also be provided with ridges and/or recesses and the like in order to facilitate the mounting and/or positioning of sections 10, 1 lA and 11B.

The outermost surface of layer 16 of sections 10, 1 IA and 1 IB is provided with an impression representing differently sized ceramic tiles 13A separated by imitation grout lines 13B. Tiles 13A are shown here to be rectangular but may indeed be octagonal, for example, or any other desired shape. Indeed, relief 13 can be of any desired shape or design.

In order to make panels according to the invention, it is first necessary to prepare a suitable mould. Known technology has been used to produce a mould of suitable size and shape.

Firstly, the required number and style of tiles are positioned and mirror waxed clean. Plasticine is placed in between the tiles to give the impression of grout.

A first coat of tooling gel is applied and left to dry for 20 minutes. This is then repeated. A layer of paper tissue is placed over this in order to prevent air going in. This is then repeated. Next liquid matt glass, for a typically sized panel of 2'6" x 4', around 450g will be needed. Further layers of matt glass are added in order to build up the mould. Since ducts will be necessary to form a vacuum within the mould, small indentations are formed in the mould, or tubes are inserted into the mould. The mould is left to cure for 3 days at 60-70 F. A corresponding second half to the mould can be similarly made. Alternatively a blank can be used.

Once the mould of suitable shape and size has been made, the next stage is the preparation of the panel. The first step is usually the introduction of a gel coating which will form the outermost surface of the panel in the mould. Ideally this can be sprayed onto part or all of the inner surfaces of the mould, though it is possible to prepare a panel without it, this outer layer is one of the most convenient and cost effective ways of providing a robust and hygienic surface. Suitable materials may of course be found which will eliminate the need for this layer. Once the coating layer has cured. usually about 20 minutes the next step is the introduction of liquified glass resin layer or other suitable material into the mould.

The substrate typically is made from glass fibre, plywood etc, and is laid over the top of the liquified glass resin. A second layer of liquified glass resin is introduced on top of the substrate. If required a further gel coating may also be provided either on top of the glass resin or preferably on the inner surface of the remaining part of the mould.

The mould is then closed and using the ducts provided in the mould for this purpose, the mould is evacuated typically to a vacuum of 221b/in2 in order to precipitate solidification of the glass resin. Once the resin has solidified the mould can be removed and the edges of the panel trimmed off or shaped as desired.

As will be appreciated by those skilled in the art, solidification of the resin layer may alternatively or in addition be precipitated by heat or pressure or indeed chemically. These alternatives are intended to be covered by this application.

From the above it will be understood that the above apparatus and method of forming the apparatus presents considerable advantages over the prior art. In particular, the time taken and the cost and skill involved in installing cladding or 'tiling' walls, floors, ceilings and roofs etc can be considerably reduced. Indeed 'tiling' for example a room goes from being one of the more complex DIY activities to one of the simplest. Furthermore. the provision of panels, the surfaces of which are as robust and as versatile as tiles and which are adapted to be easily kept hygienically clean whilst involving a fraction of the cost in terms of production and installation, makes these panels highly suitable for such environments such as hospitals, prisons, swimming pools etc.

Claims (7)

CLAIMS.

1. An apparatus and particularly but not exclusively to panels having a preselected and typically traditional appearance and also to a method for cladding covering or forming watts, floors ceilings roofs and the likc.

2, An apparatus as claimed in Claim 1 wherein the image over at kast part of its external or facing surface is that ofa preselected pattern of tiles.

3. An apparatus as Claimed in Claim 1 and Claim 2 wherein the image incorporates the shape and appearance of grout between said tiles.

4. An apparatus as Claimed in Claim 1 Claim 2 and Claim 3 wherein the external or facing surface is easy to clean and is hygienic to conform to B.S. 6920 (suitability of products for use in contact with water intended for human consumption.)

5. An apparatus as Claimed in Claim 7 that may be manufactured to any preselected specification thus determining its size.

6. An apparatus as Claimed in Claims 123 45 as Claimed above, that has nt least one substrate support structure, ideally made from dense fibre board, such as ply board, plastcrboard glassfibre or die like. Alternatively or in addition said substrate support structure may comprise wood, metal or plastic.

7. An apparatus as Claimed in Claim 1 and Claim 6 where the said selected substrate is encapsulated by layers, to the preferred thickness, of solidifiable material cured within the confines ofthe apparatus. Sucl curing bring effected as a chemical reaction aiid being preformed under a controllable vacuum.

S. An apparatus as Claimed in Claim 7 where the solidifiable material ingredients forming the bonding support layer are adapted to comply with B.S. 476 Class 1 part 7 (fire retardant regulations.) 9. An apparatus as claimed in Claiins 7 to S as detailed above whereby a preferred decoration may be interposed between the bonding support layer as described in Claim 8 and external or facing surface as Claimed in Claim 4.