Note: Descriptions are shown in the official language in which they were submitted.
21 73842
wo 9~ 74 - L C-l/i~4/00103
Impro~ements ~ or r~l~tin~ to r cf~l~ed s~ n~ M~teri~s
TECE~NICAL FFF 7~,n
This inventioIl relates to b~ in~ maten~ls, a~d to methods of impro~
their char~rt~7;$tics by applying a surface co~tin~. F~r co~l~,e~ipn~ e only,
the present i7-~ention will be descibed with ~eference to bnil7n~;n~
materials such a9 panels used in c~ i7 F stru~t7~res such EIS wall, and
roof panels, and in particul~r p~nel~ made ~om hydrocarbon l~ased
fo~m.~ for which the invention may be pa7ticularly aprli~-Rhle. ~owe~er,
it is to be ~nderstoot that it i9 not to be limited as such. Moreover,
becau~e the invention may have other appli~ati~ ~s it is to be unde,~Lood
that the p~ior art and pos~ible embotlim~n~s of t~e i~entio~ as discussed
beIow are giveIl hy way of e~ample only.
BAC~G~?.O~ ART
Convel~tionally panels used in bllildings for ~ ;ne ~t~uctures are
prot~ct~rl/f~ni~hed and/or reinforced by a surface layer of a Inaterial s~lch
as paint, fibreglass polyester or epox~ resL~, pl~Qt~.~, concrete/cement and
the like. P~int is the most ¢ommnn1y used material for finis~ine ~d
weather proofing wood based matenals, plaster is tlsed on sof~cer gib-
board type materials or with latb~ but is not ~e~erally ~uitable for
e~terior sur~aces, ~rhile concrete/cement is common1y l~.sed for ~ni~ine
extern~l surfaces of cladding materials $uch ~s ~ood, brick or
hydrocarbon based foa~ panels. With concrete/cement finishes a
~uitable mater~al ~uch as a mesh may be attac~ed to the s~ ace to
improve hQnf~in~ to the surface. Due to the ~eig~t and fragile n~ture of
the ce~ent coating this mu~t gener~lly be applied once the panel has
been irlstalled in position. The applic~tion ~pe~tion is thus ~ulnerable to
2 ~ 73~2
gS/10674 - PCI~NZ94100103
~eather coIlditions and there is a requirement for s~ e~ on site labour,
especially ~hen special finishes or curved s~rfaces such as at cor~ers or
around pillars are required. This adds to the ¢ost and co~ction ~ime.
Furthermore, since the coating is applied afte~ the panel has been
att~rhe.l to ~u~olL meInbers, the co~inE relies ~olely o~ ~hesirm tu the
substrate and is thus susceptible to debonding.
i'ibre~l~ss polyeste~ or epo2~y resin fi~iqh~s pro~ride a ve~y tough light
weight fle~ble fi~i~h and are ~ommonly ~ed vvith wood based matenals.
H-...ev~r due to the cost of the epo~y resi~ this n~etho~ is not generally
econl mical for large ~lrface ~eas. Fur1;he~more~ polyester res~ tend
to dissol~re l~lroc~r~on ba~ed fo ~m ms~eri~ kin~ them unsl~it~hle
for tbis aprliratjon,
Certain paints whic~ do not dissolve t~e foam, sucll as pla~ic (acrylic~
Paints maY be aDl~lied to the surface tn nrmn~lP s~ r~ ;n o~ AJ~
improvement in stre~gth and weather resi~tarlce to the foam panel,
however the ~nount of protectir~n proYided is generally not ~ffi~ient for
building panels. Although additional ~t~e~th may be p~ovided by
applying a thick laye~ of paint with ~ rei~forcing mesh such as a
f~bregla~s cloth e~he~e~ therein, if applied thickly such paints reqwre a
considerable time to harden. Furthe.more, the cost of the pai~t makes
the process expen~ive.
There is thu~ a need for a surface fin~sh for builbing materials/panels
~hic~ can be applied off site, ana ~ particular for a ~urface fini~h that is
su~tab~e for fini.~hine hydrocarbon based foam panel materials or
~t~F~r,hin~ in~ to foPm mateIials, ~vhi~h is flexible ~d tough and
~hich ca~ ~et in thick applications.
21 7~842
wo ~s110674 Pcr~ 03
Matenals such as mi~ctures of acryllc modif~er P~IMA~ F~-2727
supplied by Rohm & Haas Ltd mi2ced with a Portland cement are known
for their a~;lity to set in thick applicatio~s even u~der wate~, and are
used for app~ tion~ such ~s repairing and S~-AlinE~ around foundations
which may e~en be under water. These mixtures depend for thelr set~ng
ability on the complementa~ setting characteristics of cement ~d
acrylic, the ceme~t ta3~ing up moisture to set and the ac2ylic gi~ up
moisture. They are therefore not depende~t on the atmospheric
moisture/d~in~ for setting and can thus be applied thickly Since they
have a high percent~ge of cement and/or ~and they provide a rela~ively
low cost repair medium, and are tough and weatherproof. These
mater~ls huw~v~;:r have not h~r~vrore beeIl used or co~ci~red for l~rge
scale aprlir~inn as a surface tr~ t for b~ nF mateIials, o~ ~or use
as adhesi~es ~vith foam ~atenals.
It is an object of the present invention to provide a m.ethod of treating a
surface of a bl~ in~ material using a material such as all acrylic
modifier/f;ller mi~ such as that described abovel 90 as to address ~e
above problems or at least to provide the public with a usefill ~ni~e
Ftlrther aspects and advantage~ of the present inve~tio~ will beco~e
apparent f rom ~e ensuin~ description ~hich ~s given ~y way o~ example
ol~ly.
I~SCLOSUR~: OF' THE Il~ION
In t~le broadest sen~e the present inventio~ provides protective coating for
application to material comprismg cemen~, and/or sand ~r ~nother fi}ler
~nd ~n ac~rlic p~ly~e~
2 1 73~2
~vo gS/10674 ~ 03
- ~he invention provides a met~od of forming a preformed buiIdi~g
element characterised by applyin~ a protecti~e co~ting to a s~bst~te
comprising cement and/or sa~d or another filler and an acrylic polymer
in layers and progres~ively building up t~e co~tin~ until the desired
co~tine th~cknes~ has beeIl re~ e~.
The substr~te can be a ~dro-carboll based foam.
The protectr~e cos~;n~ ca~ be provided with a rei~forcin~ materi~l.
The rc~ fOs ~ g material ~ be a flexible lat~.
The acrylic pol~mer can in~lude polymethyl acrylate.
The aclylic polymer can be a polyIner co~sis~ng of Cl-18 ~1 ac~ylates.
The acrylic polymer can be a polymer consi8ting of Cl-18 alkyl
me~hac~lates.
The acrylic polymer can be of the structure;
Rz
~C - C~
,C-- -~ 1
R1 can consist of one or more of hydrogen, methyl, ethyl, butyl or other
suitable aliphatic hydrogen chains.
R2 can consist of hydrogen ~nd~or methyl.
:Rl c~n be mainly compnsed of Inethyl ~roups wit~ ~2 being hydro~en.
~ ~ 73342
wo gS/10~74 ~ ~4/00103
The substrate can be pro~nded wit~ a longitudinal c~vity to facilitate
bPn~;ne of the ~l~m~nt
The ca~ty ca~ be V-shaped.
The ca~ity can be dish shaped.
The method can include the step of appl~g a protective co~ E on o~e
surfiace alld a layer of building paper on the ~osi~ surface.
The filler material may iuclude glElS9 beadg, cel~amic bubble8, chalk,
quartz, pe~lite marble, silica F~n~-~, ~atural stone or synt~tic filling
ageIlt~.
The reinforcing mate~al may be poly~4~01ene, glas~, ~ylon~ meta
c~l~o~, Olelin, or ~ m~ltari5~1~; Of ~ 1 or specific fo~ms.
With a matenal sllch as the material descnbed above, si~ce the materi~lis relatively i~eYrensive compared to epo~y resin~, it caII pronae a low
cost alt~ ;ve tre~t~n~nt for b~ inE~ p~nels and the like. Furthe~nore,
since it is relatively light iD weight, i~ fle~ihlP~ and does not di~olve foam
t~ype materials, it can be ~ed for co~t;n.~ foam pa~el~ o~f site. The panels
can then be fitted to ~ b~ inE structure without the need for fi~t~e~
sllrface treatment once in~talled. The iIl~tallatioll opera~on is thus not
vulnerable to we~er condi~ons, a~d there is not the r~lu~re~ent for
~killed on site lab~ur. Also since ~ hment ~embers ~ h as n~ls
p~ss through the pa~els there is not the t~n~Pn~y for debo~ E ofthe
surfa~e coating. F~ermore, the p~n~l~ can ~e cut and shaped of~ site
as ~equired. Dlle to the f~e~ble nature of the co~tin~ (which can be
determined by mi~lre ratios) the panels c~n also be bent OIl inst~l~AtjQn
aIld if ~rp corner~ are required, the rear of the paneI ~ay be relief cut
2 1 73842
WO gS/10674 PCI/NZg4/00103
to enable a sharp bend to be made such as for a corner portion. The foam
~oated mate~ial ~ay also be formed in a vanety of shapes for dirrt~ -t
buildin~ applications. For example coated half cylindric~l shapes may be
made for fitting oYer posts to provide a pilla~, or corner piece~ may be
~nade for fitt~ng between panels at corners.
Imitation f;nishes such as of brick, wood, weather board, rou~h cast
concrete and the l;kP, may be fo~ed o~l the su~face of panel~ of a variet3r
of ma~ials by appl~ring the matrix mate~al to a flat or pre-~h~pe-l
surface, and theIl working the ~at~c matenal as required prior to
set~ng.
Reinforcil~.g ~imil5~r to t~le f~ont ~o?~t1n~ or of other materials 811Ch as
b~ ing paper ~ay also be adhered to the re~r su~face of the fo~
p~3n~lR. This would negate the require:~ent for on xite ins~llA~ion of
~uilding paper. The panels could al~o be used as an alternati~e to gi~
board lini~g ~nd could have ~he fiIlal p~t/w~llp~per applied in the
facto~. Wil;h s~ hle reinforci~g, rooftiles ~r,d tbe like inco,~olating a
fo~ type subtr~te may be pos~ible
Panel$ could also be ~ade with a~ e~in r f;nish on one ~ide and interior
finish on the ot~er side and f;tted to a b~ in~ stru~ure, for e~ample
wi~h a simple "I" type connector bet~reen the panels to provide a joint,
thus Pn~h~ c~ ine of a buildin~ to be done in a short time.
Panels suitable for complete sectioIl~ such ~s wall or fence panels may
also be po~.~ihle. For example a thick fo~nl panel may be made with
cavities to take roof support~ or fence supports, or to form moulds for
pouring concrete :iu~Gl~ pillars That may provide for roof support.
This m~y be prepared and coated with t~e mat~ m~terial off site, ~nd
2 1 73842
WO95/106?4 1 ~/r~94100103
t~en ql~ickly ~ bled at the site, ~vithout the need for skilled on site
la~our. Alte~nal;ively or in addition wit~ ~all panels, these may ~e made
with extra reinforcement band~ laid into the matnx over the panel$ to
give the reqwred strength for roof support. Suitable mate~ial clad with
the matrix cl~tltljn~ ~ay also be formed ~nth ca~nties for enc~sin~ objects
such as e~isting structural members (i.e. pillars), or fo~ settin~ in
positio~ and then p~u~ng a mate~al such as concrete into the cav~ty to
fo~n a st-ructural member.
FurtheL ."ore, a method of construction may be applied to the
co~struction of comrlete s~;ructures made up using a subslr~Le m~t~.ri~l
such as poly~ es,e ~rhich is then completely or p~rtially e~c~e l with
the mat~x . Due to the ~ ti~r praperties and ease of forming of the
~ubst~ate, and the ~reller~t water resistaDt ~ ulJe~ lie~ of tl~e co~ is
method of construction may be sllit~hle for tl~e m~n~7~ct~7re of articles
suc~ ~g letter bo~es, p~llars, he~mS~ posts, aIld cnnt~iners.
Since the m~t~Y mZIt4~ 3 flesible and totlgh and adheres stron~ly to
foam materi~ls, it may also be suitable as an alternative to metal
cl~-l;nf~ used part~cularly for cool xtore panéls. The matrix material
could be easily repaired if d~m~ged, a:nd moi~ture content of the fo~
substrate ~ould be easily ~hPl~k~ by simply inserting a probe through l;he
¢o~t.in~ rn~teria~ and subsequently repainn~ ~ith a ~uitable material.
The strong a~hesive properties of the matri~ material ~lso make it
suitable as an adhesi~e for at~hing foam p~nPl~ to objects such as a
supportin$ ~tructure. Panel~ could thus be boIlded in position rather
than u~ing pins and the like thereby avoiding the need to punctllre the
foaIn material and leave it vulnerable to moisture absorption and
cont~min~ti~n.
~ 1 73842
WOgSJ10674 ~ l~.n~ 00l03
The tough fle2nble ~ture of the co~tin~ may al~o make it suitable for
coating floor and ~leckinE mat~ri~ and for co~inE~ mate~ls for use in
fenci;qg and as fence pnn~.l.c.
T~e e~cellent water proofing prope~ties of t~e ~at~i~; may make it
lJrefe,~ble as a co~1;ne ~or extenor ~urfaces, comp~red to convelltional
plaster co~tin~-C aIld the lil~e.
varie~r of l~pes of the abo~e described matr~ material may be used
~epe~ inE on ,~ ulent~ pro~ided they enable a tough fle~nble co~
of relati~ely low cost suitable for aprl;~tin~ to buildi~g material~, For
e~a~nple the proportions and types of mat~ri~l.c u8ed in ~e flexible
modifier P~IMAL~ F~-2727 ~nay be varied a~ requir~d or desired, and
add~tives such as fire retarda~ts may be ~ e~l, or other filler~ u~ed.
In co~t~ne 1~e s~rface of the bnil~ matenal, ~ ional co~til~s of
differe~t mate~ e may also be applied as req~ired or des~red. For
example the ~urface may fi~st be coated ~;vith a thin p~ coat of a
~uitable material pnor to npplying t~e IT~a~ materi~l. Alternatively or
in addition, further coats of other material may be applied oYer or
~etween layers of the m~trt~ material. ~or exa~ple ~aterial such as
treated wood chip8, or spherical light weight ceramic or po~y~ly,el.e
bubbles may be u~ed ss a filler to liFht~n the c~a1in~ material, or may be
sprinkled o~ the surface between co~t~ne~ to provide ~lr~ onal bulk. The
matnx materi~l may be applied by any suit~ble mean~ 3~or eY~mple it
may be spre~d by hand, b~ush, or rolled ~ith a roller, sprayed ~Il, or
applied by dipping the pa~el in the matrix m~teriAl
2'J~ ~3~4~
WO gS~10674 PC~ 94100103
~ny suitable t~pe of. reinforcing m_te~ial may be applied to the surfa~e
pro~rided this is able to bond with the material aIld has sufficient
strength. For example a glass f;bre ~ater~al ~ay be most s1litable
bo~ever other ~i~rous materials such as KE~ o~ carbon fibres or
polyester fibres may be used. I'he rei~for :~ng nlnte~ iAl may be applied i~
any suitable fo~m such as a mat (unidirer~ h~l open weave ~esh) or as
chopped ~trand. Chopped stra~d may provide a ~reater impact
resistance for c~ applir~t;o~ due ~Q the abili~ of the fibre~ to align
wit~ t~e lo~in~ direclion in the fle~hle mat;ri~ m~t~ In the case of
~hopped strand applicatio~, the rei~orcirlg material may be applied
together with the matlix material. Worl~ing of the I~ei~ur~ ~to the
matrix may be b~ any suitable method such as presS~lg, rolLi~g,
br~ in~, surface pre~ure or vibration, or by the addition of farther
mal~c ms~tc~ ion or ~acuum ~.oce~e~
Additio~al matri~ matenal may be applied o~er the ~r~t co~t. This
material may be the same as that of the first coat or may be di~e ~.L.
V~ious ~pes of b~ mate~ial may ~e suitable for tre~ nt by the
~bove method. For example, pol~ e in~ nn in ~heet fo~n or
profiled, light weight concrete panels, timber T'~Plq. asbestos, ce~ent
fibre boards, co~posites of the above in~ludillg ~,ome ins~ tin~ or fire
reta~ding m.aterial~.
In treating th~ rface of the b~ inE material, a fi~ft coat of either
epo~y, polyurethane, or ac~lic, ~ixed ~nth a h~rdener may be applied.
In a ~er~ d embodiment an all ac~ylic rno~ifi~ of the type PRTl~
FP~2727 ~s supplied by ~ohm ~ Haas Ltd may be suitable. A possible
mi~tllre ratio for this may be 100 part~ of P~IlUAr~ FM2727 modifier
2~ 73842
V~'O !~5/10674 - PCTJNZ94~00103
and 100 parts of Portla~d ~ement confo~ming to AST~ C-150. If required
tr~ aid in pro~uction, additional ceme~t m~y be added along with other
ing~edients such as #70 grade mesh sand, strengthening ~lbres,
thickener, defoamer, coalescing agerlt, ~urfactants and dispersants,
plasticisers, water, colora~ts, mica a~d white c~nPrlt as required or
desired.
In t~e case of an alkali resistant glass mat ~el~ulce~ent for the abave
mo~ified cement m~, this may vary in weight and densi~. For PY~m~lP
llS~m/m2 gives a moderately light weight l~fo~ me~t, ~vhilst 2 layer~
of 115~m/m2 or a layer of 2~0g~2 or even two layer~ of 2~0gm/m2 gives
much stronger reinforce~ent. Fo~ general fn~n wall aprli
alkali re~istant libre glass mat of 130~/m2 m~ be most suitable.
If a ~ec~-n~ coat m~triY is applied ~i-~ can be either a ,51'mil~r 2~1iX to the
first coat mat~ ~lesr--ihed abo~e or can be made di~- e~tly to provide
di~erent ~urface characteristics. For PY~rrlrle, the ~ec~rl~l m ~t~iY may
comp~se 10~ parts of PR~MAT~) EM2727 fle~ble moAifip-r to 200 parts of
Portland cempnt confonning to ASI~I C-150. If desi~ed this could also
have co~bin~tion~ of the same additional ingredie~ts as the first coat
matrix rle~r~h~d ~bove.
Additional layers of the above matrix m~xes a~d re;~orcing may be
applied in association with a reinforcing ~aterial such as alkali
resistant glass of wo~ren mesh open constrll~tion fo~ (u~idirectio~al
alkall resista~t reinforcin~ mesh of open weave) having ~rying weights
from lOOgm/m2 to 600~ or mo~e dependin~ ~ reinforc~~ent
reql~irements.
2 i 738~2
~10674 ~ T~z94Jo0103
Surface finishes may be carried out in the factor~r or on ~ite. I~picalfinishes m~y include, te~ctures, drag tgpe scratcbing fir~ishes, trowel
smooth ~ni.~h~s, fo,~ed or profiled fini-c~e~ to obtai~ either ve~y smooth
or predetermi~led f;ni~hinE shapes and pattern~, coloured ~lnishes,
painted f~l~ishes, spoIlged or speci~l effect ~niS~eS. An e~ca~ple of a
spe~ial ef~ect f~ish may be achieved wil~h a mi~et~e of lO0 p~rts of saI-d
type ~50 ~nesh, 30 parts of Portland cement to ASIM C-1500, lO parts of
p~TMAT~ F~2727 mo~i~er, and water as required. To this could be
added a range of, or all of, t~e c~n ~inntions of additional i~gre~ient~ ~s
included in the m~trix coat ~i~re~ desc~ibed abo~e.
Vanou~ mefllo~c may be u6ed for j~n~n~e~ the panel~ o~ site once
installed, a~d for treatirlg the edges of t~e r~ To ensure again~t a~y
seepage into ~he panels up through the bottom ed~e6 additioslal b~clc
~rap~i~g of ~he panel~ may be carned otlt by ~ing a layer of the matn~
material with reinfor~ a~ req~ired.
The edges of the panels to be joined may be simply butt joirlted toge~her, or
jo~ed using edge 6trip~ with or ~ithout a h~ckinF rod and 9A~I~, and a
reinfo~cin~ fabric such a~ rips of alkr li ~istaIlt glags mat may be cut
to an ~}~pr~ iate width ~nd ~t~rhed ~oss the jo~t wi1 h a cos~tinf~ of the
~bove matr~x mat~rsl, or some other ~he-~jve or pla~ter. Alte~atively
the edges ~nay be ton~ue and groo~ed, slotted, ~hip-l~pped, or straight or
bevelled or tapered to take a jointinE strip suc~ as a plastic or aluInini~m
'rI" or "T" jointin~ st~ip. Joints may also be covered with h~ten~ such as
w~th Tudor ~rpe b~ in~2.
wo9S~10674 2 1 7 :~ 8 4 2 ~ iY4/OOI113
~RIE~ nESCRIPlIO~ OF l~IE n~AWINGS
Fu~ther aspects of the present invention will beco~e apFarent from the
ensuing descript~on ~hich is given by way of example only and with
reference to the drawings accompanying the provisional speci~ç-ation in
which:
Fi~nre 1: i~ a schematic plan ~iew of foam panel illu~trating a
b~ ine material accordi~g to the p~esent inveIltion and its
Tnet~o~ of tr~Pn~ ~nd
re 2: ic a ~chematlc plan view of corner piece for a ~wlding
illustrating another building matenal according to the
prese~t i~ ;nn, and
F`~ure 3: is a perspecti~e view of ~refor~ed coTner b~ elements
of the prese~ in~Pn~ d
F'igure 4: i~ a sectional vie~ of a corner construction ill accorda~ce
with the present invenh'on, and
Fig~-re 5: i~ a side perspective view of a t~pical wall con~t~uction usinlz
lhe building elements of the pre~ent iTlv~ntio2~ and
Fi~ure ~: is ~n end vie~v of a eyebrow b~ ing Pl~smer~t of the present
invention, and
Figllre 6a: illustrates a fixing detail in~ si~re of the eyebrow el~m~nt of
Fi~re 6, ~nd
F;~re 7: illustrates a number of alternative shapes for buildi~g
elemPnt~ of the present invention.
2 1 73842
WO g5/1067~1 PC:l'Jl`lZ94/00103
BEST ~IOD~, FO~ CA~YING OUT THE ~*T~ON
Ha.ving regard to ~igure 1, there LS shown a schematic section~l vie~ of a
p~nel generally indicated by arrow 1 comprising a polystyrene foam
substrate 2 coated with fibre glass rei~forced coa~nE gener~ indicate~l
by arrow 3. The co~t~ne 3 co~ ts of a first layer 4 of a rn~fAl ~1 a layer of
alkali resistant ~ s fibre mat 5, a ~ecoll~ layer 6 of a m~t~i~ material, a
spIinkl~n~ of ~a~d a~d nptionally a ~;ni-~hin~ coat of pai~t 7. The fil'fit
layer 4 matrix material ifi made u~ing a ~L~u~ of a~ tely 100
part~ by weight of ac~ c flP~7hle modifier p~lMAT~ F~ 727 2~d 180
parts by weight of cement. The second layer 6 m~tris m~t~ri~l is of
cirnil~r compo~ition to that of the Srst layer 4 m~ material with
~ddit~nal sand. A re~ surface 8 of the sub~trate ~ iB cGve~ad with a
layer of building paper 9 which is adhered to the substrate 2 with a
co~t. nE of t~e mat~x material of ~imil:~r co~posstion to that of the layer
4. l~he panel 1 i~ ~tt~heA to a suppo~ting structure 10 by mea~6 of nails
11. The head~ of the nails are covered over with a material ~;mi7~r to that
of t~e r.~ iY ~te~al of the ~e~on.l layer 6,
'rhe panel 1 showIl in th~ embodime~ is pro~ded with the fibre glass
reinforced co~in~ 3 off site. Since the reinforced coating 3 is li~ht in
weight a~d flexible, the pallel 1 can thell be easily tran~ e~ to the site
and fitted into position on the supporting ~t~ucture 10, ~vithout t~e
possihility of ~m~Ee to the su~face ~s ~vould be the case with a cement
coated foam panels.
In t~eatin~ the surface of the foam substrate 2, the m~ r mater~l 4 is
fi~t applied by ~olling, ~pray~ng or ot~erwise a mi~re of the ~atrix
onto the substrate ~. ~he fibre glass mat S is 'chen laid over the layer of
matrix 4 and pressed in with rollers ~o that t~e matrilc ~aterial
~3
~i 7S84~
Wo ssrlo~74 PcrA~4~ 0~
permeates bett1veen the fibres of the mat 5. A co~ting of a se~Qn~ mat~c
material 6 is then applied by sprayin~ and s~n~ ~ith #70 ~rade sand,
and the panel ~Ilowed to d~ and ~ubseque~tly painted as reqllired.
D~ing may be by air d~ying but other methods 8Ut:~ as -Qnap he~ Rith
i~a-red radiatio~ dehu~idif~i~g or ove~ cur~ng may be ~sed. A
~ini.chir~ coat of paint i~ then ~prayed on the pa~el rea~y for tral~Qport to
the site for inFt~ tion After n:3ilin~ the panel in pOQit~on on ~ite t~e nail
head~ are covt;~ed over with a thin layer of a c;mils~r ~ iY ms~t~
F~gure 2 _how~ another em~o~lima~lt of the ~r;Bent invention in ~e form
of a corner fitting 20 for a building. ~n this figure com~o~pn~ ~imil~r to
tho~e of the first embo~l;m~r~t ~re in~;c~t-~l witl~ t~e s~me numeral a~d
descriptio~ omitted. The cor~er ~tting 20 i~ u~ed at co~ers of
, ~.d differs fiom the panel of l~ re 1 i~ that a notch has been
cut in the rear of the panêl afl;er ~ ¢ture so that the panel ¢an be
bent tllough gO. Due to the flp~ible nature of t~e fibre glass reinforced
¢~ti~ 3, tbis does not crack on ben~ hlinE c,~ .~t:d corIIer sections
to be fo~med by simply not~i~g ~he foam and be~rlinE, ei~her on site or a~
p~e-formed f~ctory corIler piece~.
Wit~ respect to E'igures 3 and 4, the co~er el~m~t illu~trated is provided
with a lon~itt~d;tl~l V~h~rl cut~out 13 in the subst~ate m~tGrl~l 2 which
en~ble~ sections of the elPmP~t to be folded at r~ght ~ngles and f;xed to
corner st~ucture ~lPmpnt~ 14 as indicated. The cut-out 13 can be dish-
~haped ~hich is mo~e swtable for~~ to cu~ved st~uctures.
E`igure 5 of the dr~wings illustrates ti~Lurd of the co~ner el~merltc Of
Fig~re 3 to a corner st~ructure ~as show~ in Figure 4) alld adjoining pa~el
.elemP~ts 1 fi~ed ~o wall structure members ~ 5.
14
~ ~ 73842
WO 95/10674 PCr~NZ94100103
Fi4~ures 6 and 6a show ~n eyebrow element 1~ ~d its method of ~ture to
a ~ame s~cture 17.
Figure 7 shows alternative ~ros~-section of the building elements i~ the
farm of "mouldings", for trimming and fin;~h;n~ g the elements of
the present inventinn
Al~ of the elementq descnbed can be r~ile~, qtapled and/or glued in place.
I believe the advantages of my l~ention to be ag follo~, howe~er it
~hould be appreci~ that all such advantages may not be xp~ on all
e~bod;.ne~s af the i~v~t;on~ and the foll~ li~t is th~ u-~ given by
way of e2cample oIlly ~ being ~ ive of pot~n~l advant~ge~ of t;lle
pre~ent in~entiotn E'urthermore, it is not int~nde~l that tbe ad~ tage~ of
the present i~ventio~ be restnc~ed tu tbose of the list which follow~.
l 'rhe matr~x ~ate~ial treatment ~n~hle~ paIlel~ such a~ ~oam ~ype
panels for b~ es to be made llp of~ite and then ~talled withaut
~he need for further f;~i~hin~ or ~th 0~ m~n;n~l fini~hin~
Panels can thel~fGlé be made in a continuous productioll pr~ces$
with reduced ~1vastage. Problems relfl~;ne to delays due to ~eather
coT~;t;srl~ ~nd the like are thus ~voided, ~ le~ o~ site labour is not
required, and rapid co~struction is p~fi~ible ~n~hlin~ reductio~ in
construction co~ts.
2. ~i~her quality can al~o be en~ured ~rou~h facto~y quality control.
For example accuratel~.¢ur~ed surfaces and flat surface~ can be
easily produced. Also confo~rLity of production conditions can be
ensured ~o the products can be manll~Pçt~.red under optimum
condit1ons, with mate~ials mee~ing requ~ed ~ t~nrl~rdEi.
2 ~ 7 :S8~2
W0 !~5/10674 ~ r~4/00lw
3. Wastage of ~atenals c~ be avoided since :mate~ials can be ~ade to
the required size and shape in the facto~y 80 that minirn:~l cllttine
~nd ~ormin~ is required on site.
4. Lo~v cost light ~ei~ht poly~ly~el~e foam panels can be used in a wide
r~nge of applica~ions since the matrix ~aterial does not te~d to
dissolve pol~xLyrene foams.
A~pects of the y~ese~t i~vention have been ~PC~ihe~ by way of e~ample
only and it should be appre~ t~ ~at mo~i~c~1~olle and ~ m~ly be
made thereto without de~ L~ ~OI~l the scope t~ereof as ~efinP~ in the
~ppex~ded cl~ms.
16
