GB2611791A

GB2611791A - Facade

Info

Publication number: GB2611791A
Application number: GB2114700.4A
Authority: GB
Inventors: Adam Jay Daniel
Original assignee: Tophat Industries Ltd
Current assignee: Tophat Industries Ltd
Priority date: 2021-10-14
Filing date: 2021-10-14
Publication date: 2023-04-19
Also published as: WO2023062387A1; EP4416346A1; CN118382739A; AU2022366259A1; GB202114700D0; CA3235260A1

Abstract

A flexible prefabricated facade surface covering for installation on a surface of a structure, comprises a supporting layer; a plurality of surface elements connected to the supporting layer; and a filler provided between adjacent surface elements and connected to the supporting layer. The surface elements and filler may be of the same material but of different colours and may be of a flexible polymer. The supporting layer may be a flexible mesh which may be embedded within the surface elements.

Description

Facade The present disclosure relates to facades for buildings.

Traditional methods of preparing facades have involved attaching surface elements such as thin brick or other masonry elements, known as slips, to a structure, for example by adhesively bonding individual slips to a substrate, and then pointing the entire facade, or using supporting rails bolted directly to the structure surface and then pointing the gaps between each of the slips. Such methods of forming a facade have been implemented in order to provide a relatively cost effective and quick method of forming a facade for a structure, removing the need for skilled masonry labour, but keeping the appearance of a traditional masonry construction. However, such methods are still time and labour intensive.

The present invention seeks to provide an improved system for providing a facade for a stnicture.

According to an aspect of the invention, a flexible prefabricated facade surface covering for installation on a surface of a structure comprises a supporting layer, a plurality of surface elements connected to the supporting layer, and a filler provided between adjacent surface elements and connected to the supporting layer.

According to an aspect of the invention a method of forming a flexible prefabricated facade surface covering for installation on a surface of a structure comprises providing a supporting layer, providing a plurality of surface elements connected to the supporting layer, and providing a filler between adjacent surface elements and connected to the supporting layer.

The present disclosure will now be described by way of non-limiting examples with reference to the drawings, in which: Figure 1 shows an arrangement of a prefabricated facade surface covering; Figure 2 shows a cross-section of a prefabricated facade surface covering; Figure 3 shows a cross-section of a surface element; Figure 4 shows a plurality of prefabricated facade surface coverings attached adjacent to one another; Figure 5A shows a surface element stencil; Figure 5B shows a cross-section of an arrangement including the surface element stencil, a supporting layer, and a manufacturing board.

Figure 6A shows a filler stencil; Figure 6B shows a cross-section of an arrangement including the filler stencil, surface elements, the supporting layer, and the manufacturing board, Figure 7 shows an apparatus for forming surface elements and filler on a supporting layer; Figure 8 shows another view of an apparatus for forming surface elements and filler on a supporting layer; Figure 9 shows a filler material shaping tool.

As shown in Figure I, an arrangement of a prefabricated, or pre-engineered, facade surface covering 10 comprises a supporting layer 100, surface elements 200, and filler 300.

A plurality of surface elements 200 are connected to the supporting layer 100. Filler 300 is provided between adjacent surface elements. The filler 300 is also connected to the supporting layer.

In an arrangement, 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 surface elements 200, and/or flexible filler 300. The prefabricated facade surface covering may be flexible such that during handling or transport, distortions or deformations of the prefabricated facade surface covering does not result in cracking occurring. Alternatively or additionally, the prefabricated facade surface covering may be flexible such that it may be elastically deformed without cracking. In some arrangements, unlike traditional materials used in construction, e.g. ceramics and bricks, which are brittle and will readily crack when deformed, the supporting layer, surface elements, and filler may not crack when force is exerted on them but instead will flex to some extent.

In an arrangement, cracking or other permanent damage to the flexible prefabricated flexible facade panel may be prevented when the panel is subject to handling or installation stresses by providing a flexible supporting layer 100, and flexible filler 300. In such an arrangement, even if the surface elements are not flexible, cracks at the joint or joints between the surface elements 200 and filler 300 may be mitigated. In an arrangement, all of the components provided on the prefabricated facade surface covering are flexible. This may mean that there are no rigid elements at which a crack may form when the prefabricated facade surface covering is handled or otherwise distorted.

In some arrangements, providing flexible surface elements, and filler may improve the resistance of the prefabricated facade surface covering to hydrodynamic forces, such as freeze-thaw.

In some arrangements, providing a flexible supporting layer 100 results in the overall prefabricated facade surface covering 10 being thinner and lighter than if the supporting layer 100 were stiff. In some arrangements, providing a flexible supporting layer 100 can enable the prefabricated facade surface covering 10 to be rolled into a roll of surface covering 10 during transportation.

In an arrangement, the prefabricated facade surface covering is flexible such that a prefabricated facade surface covering 10 having dimensions of 600mm x 600mm can bend without cracking at a deflection angle of up to 100, optionally up to 150, optionally up to 20°, optionally up to 25°, optionally up to 30° in all directions. The deflection angle may be calculated based on the difference in angle between a tangent of one edge of the prefabricated facade surface covering and a tangent of an opposite edge. Such deflection angles are not possible to obtain using traditional masonry or using facade panels provided with brick slips and mortar, without cracking or otherwise permanently deforming or damaging the facade panel.

In an arrangement, the surface elements 200 are formed directly onto the supporting layer 100. Additionally, or alternatively, the filler 300 is formed directly onto the supporting layer 100. In these arrangements, the surface elements and/or filler may be formed by providing a viscous liquid or slurry surface element material and/or a viscous liquid or slurry filler material onto the supporting layer 100, which are then hardened to form the surface elements and/or filler onto the supporting layer. Further details of these arrangements will be described below.

In an alternative arrangement, surface elements 200 are formed separately from the supporting layer, and are subsequently connected to the supporting layer 100. In this arrangement, the filler 300 can also be formed separately from the supporting layer 100 and be connected to the supporting layer in a similar manner to the surface elements 200, or be formed directly onto the surface layer as will be discussed below. In arrangements in which the surface elements and/or the filler, are formed separately from the supporting layer, the surface elements 200 and/or filler 300 can be connected to the supporting layer 100 using adhesive and/or mechanical fixings. In some arrangements, the adhesive is provided between a rear surface of the surface elements, which is a face of the surface elements facing the supporting layer 100, and a front surface of the supporting layer. In some arrangements, the adhesive is provided between a rear surface of the filler 300, which is the face of the filler provided facing the supporting layer 100. In an arrangement, adhesive is provided between the surface elements 200 and the filler 300. Providing adhesive between the surface elements 200 and the filler 300, may improve the water resistance of the prefabricated facade surface covering by providing a water-tight connection between adjacent surface elements arid the filler provided between them.

In an arrangement, the supporting layer 100 may extend beyond the edges of the surface elements 200 of the prefabricated facade surface covering 10. The supporting layer may extend beyond the surface elements on an edge of the prefabricated facade surface covering, but not on an opposing edge, such that the supporting layer 100 of a first prefabricated facade surface covering 10 may overlap with the supporting layer 100 of a second, adjacent, prefabricated facade surface covering. As a result, this may increase the overall strength of the facade.

In an arrangement, the supporting layer 100 is 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 for installation on a structure. In arrangements, the mesh may be a plastic mesh made from an extruded, oriented, expanded, woven, or tubular plastic material. In other arrangements, the mesh may be a metal mesh made from woven, knitted, welded, expanded, or sintered, metal, or any other suitable technique. In arrangements in which the supporting layer 100 is a mesh, the surface elements 200 and/or filler 300 can be formed directly onto the mesh supporting layer, or can be separately formed and then connected to the mesh as described above. In an arrangements in which the supporting layer 100 is a flexible mesh, and the surface elements 200 and/or filler 300 are formed onto the mesh supporting layer such that the mesh is embedded within a portion of the surface elements 200 and/or filler 300, the prefabricated facade surface covering can be made strong. As a result, each surface element can resist an impact with a reduced risk of falling debris. Additionally, should a portion of the connection between the prefabricated facade surface covering 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.

In alternative arrangements, the supporting layer 100 is a flexible panel The flexible panel may be made from polymer, or metal, or any other suitable material used in 30 construction.

In the arrangement shown in Figure 2, the supporting layer 100 is a flexible mesh. The surface elements 200 and filler 300 are formed on the mesh supporting layer 100. During the formation of the surface elements and filler on the mesh supporting layer, the surface element material, and the filler material, before being hardened, will spread to surround the mesh supporting layer material. Once hardened, this will result in the mesh becoming embedded within each of the surface elements This will also result in the mesh becoming embedded within the filler 300.

Embedding the mesh supporting layer 100 into the surface elements 200 and the filler 300 can enable a secure mechanical connection to be formed between the surface elements 200 and filler 300 and the supporting layer 100.

In alternative arrangements, in which the supporting layer 100 is not a mesh, but is a solid panel with no openings, directly forming the surface elements 200 and filler 300 onto the surface of the supporting layer by hardening the surface element material and filler material may still enable a strong connection to be formed can be formed with or without the use of an additional adhesive.

Surface elements 200 may be any form of decorative and/or functional element found on a building. The surface elements may imitate the appearance of bricks, stone, wood, metal, ceramics and polymers. It will be understood that the present invention is not Is limited to any specific surface elements. Surface elements may have a common shape that may tessellate to cover the supporting layer 100, for example rectangles or squares In an arrangement, surface elements 200 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 may be used in place of a traditional masonry wall.

In an arrangement, the surface elements 200 are made from 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. For example, the polymer material may be an acrylate polymer or a polyacrylate polymer. The flexible 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.

In an arrangement, the surface elements are made from an adhesive polymer material, which can be hardened in order to form the solid flexible polymer material For example, the surface elements are made from an acrylate polymer or a polyacrylate polymer. In an arrangement, 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.

In an arrangement, the material from which the surface elements 200 are made may additionally comprise colourings so that the surface elements 200 take on a specific colour.

For example, in arrangements in which the surface elements 200 are intended to replicate the appearance of conventional bricks, the surface element material may be provided with a terracotta or brown colouring, but in other arrangements an off-white or grey colouring may be used. Of course it will be understood that any colouring may be used, depending on the specific application In an arrangement, a surface element 200 may have a width that is greater than its height Alternatively, a surface element 200 may have a height that is greater than its width. Alternatively, a surface element 200 may have a height that is equal to its width. A prefabricated facade surface covering 10 may be provided with multiple different sizes of surface elements 200 and/or surface elements with different ratios of width to height.

The filler 300 is provided between the surface elements 200 on the supporting layer 100. In an arrangement, the filler 300 is provided between all of the gaps between surface elements 200. In an arrangement, the filler 300 completely seals the gaps between adjacent surface elements, and may result in a water-tight and leak-proof seal. In an arrangement, the filler 300 may also be provided around the periphery of the surface elements around the periphery of the prefabricated facade surface covering 10.

The filler may be a decorative material to fill in the gaps between the surface elements 200. In an arrangement, the filler performs both a decorative and functional role, in order to provide a sealant around the surface elements, and/or securing the surface elements to one another and fixing them in place.

In an arrangement, the filler is deposited to conceal the supporting layer 100. In an arrangement, the filler is chosen in dependence on the surface elements used in the prefabricated facade surface coverings. For example, when the surface elements are intended to replicate traditional masonry, the filler may be mortar, or may have the appearance of mortar.

In an arrangement, the filler is made from a flexible polymer material. In an arrangement, the filler 300 is made from the same flexible material as the surface elements 200, except for the provision of a different colouring. For example, when the surface elements are intended to replicate traditional masonry, the filler may be provided with a grey colouring to have the appearance of mortar.

In an arrangement, for example in which the prefabricated facade surface covering 10 is intended to replicate the appearance of traditional masonry on the exterior of a building, it is desirable that the surface elements 200 do not all appear identical. Providing a variation of colours for the plurality of surface elements 200 on the prefabricated facade surface covering 10 is desirable to achieve a more natural appearance. In an arrangement, this variation in surface element 200 colour may be achieved by forming the surface elements 200 from differently coloured materials.

In an alternative arrangement, as shown in Figure 3, the surface elements 200 include a main surface element portion 210. The main surface element 210 forms the majority of surface element 200, and is coloured to match the main desired colour for the surface elements 200. For example, the main surface element portion 210 may have a terracotta or brown colouring when the surface elements are intended to replicate traditional bricks. To achieve the desired natural variation in colour, surface elements 200 may be provided with a colouring layer material 220.

The colouring layer material 220 may be applied to a subset of, or to one or more of the surface elements 200 on the prefabricated facade surface covering 10. The colouring layer material 220 may have a colour similar to, but different from, the colour of the main surface element portion 210. The colouring layer material 220 may otherwise have an identical material composition to the main surface element portion 210. Providing the same material, e.g. the same adhesive flexible polymer material, can provide a good bond between the main surface element portion 210 and the colouring layer material 220. In an arrangement, a plurality of different colouring layer materials, each having a different shade of the main colour, are provided so that the surface elements 200 have a variety of shades of the main desired surface element colour.

In an arrangement, the amount of colouring layer material 220 applied to the surface elements is small, enough to only change the colour of the surface of the surface element 200 such that the thickness of the surface elements formed from only the main surface element portion 210, and those additional comprising colouring layer material 220, are substantially similar.

In an arrangement, the surface elements 200 to which the colouring layer material 220 is applied are randomly selected by an operator at the time of preparing the prefabricated facade surface covering 10. The random distribution of colouring layer material 220 can be varied between prefabricated facade surface coverings 10 so that a pattern of differently shaded surface elements 200 does not appear on the surface of the structure. The operator may apply the colouring layer material 220 to a predetermined number of surface elements 200 in each prefabricated surface covering 10.

In an arrangement, as shown in Figure 3, the surface elements 200 additionally include a coating of a surface finish powder 230. 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.

In an arrangement, the surface finish powder 230 is 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. In an arrangement, the surface finish powder 230 is distributed, or dusted, using a shaker or other dispenser suitable for dispensing a powder, across the surface elements. 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 finish powder 230 may be made from a powdered form of the material which the surface elements are intended to replicate. The surface finish powder may have any appropriate grain size, depending on the desired finish of the prefabricated facade surface covering. In an arrangement, the surface finish powder is UV stable and/or noncombustible. For example, in an arrangement in which the surface elements are intended to replicate traditional bricks, the surface finish powder may be made from a brick powder.

In other examples, the surface finish powder 230 may be concrete dust or stone dust in order to replicate other forms of construction materials. In some arrangements, 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.

As shown in Figure 4, a surface of a structure may include a plurality of prefabricated facade surface coverings 10a and 10b. Each prefabricated facade surface covering 10a, 10b may have a common, tessellating shape. For example, when replicating traditional masonry, rows of surface elements 200 may be provided which are offset from one another, such the edges of each prefabricated facade surface covering 10 has surface element protrusions and recesses. In this arrangement, the protruding surface elements of one prefabricated facade surface covering 10a may interface with the recessed portions of another prefabricated facade surface covering 10. This results in surface elements from a first of the prefabricated facade surface coverings interlocking with the surface elements from the second of the prefabricated facade surface coverings. By forming the prefabricated facade surface covering 10 in this manner, it is possible to seamlessly place prefabricated facade surface coverings 10 adjacent to one another to form a continuous facade from a single design of a prefabricated facade surface covering 10.

As shown in Figure 4, filler 300 may be provided on the periphery of the surface elements on an edge of the prefabricated facade surface covering 10, but may be omitted from the periphery of the surface elements on an opposite edge of the prefabricated facade surface covering 10. For example, as can be seen in Figure 4, for each of the prefabricated facade surface coverings 10a and 10b, filler is provided along the right and bottom peripheries, but is omitted from the left and upper peripheries. As a result of the tessellating shape with filler provided and omitted from the same locations on each prefabricated facade surface covering 10a and 10b, filler is provided between adjacent surface elements 200 of adjacent prefabricated facade surface coverings 10a and 10b. In other words, additional filler 300 is not required at the joint between adjacent prefabricated facade surface coverings such that there is no further work required to the outer surface finish of the surface of a structure. This reduces the amount of work to be done on site when installing the prefabricated surface covering 10 to a building.

The prefabricated facade surface covering 10 may be manufactured in a factory or an off-site location. In an arrangement, the prefabricated facade surface coverings may be transported to a construction site for installation on a building. In an arrangement, the prefabricated facade surface coverings 10 may be installed on the exterior of a building, to form an external facade of the building. Alternatively or additionally, 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.

In an arrangement, 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.

In an arrangement, 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. In an arrangement, the adhesive is made from the same material and/or colour as the filler 300. 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 filler 300, 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. By providing a prefabricated facade surface covering 10 according to the present invention, the application of filler 300 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 filler 300 between each of the surface elements.

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 applying the filler 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.

In an arrangement, methods of forming the prefabricated facade surface covering as described above include providing the supporting layer 100, providing the surface elements 200 onto the supporting layer, and providing the filler 300 between adjacent surface elements. Although the above arrangements of the present invention have been described in the case where the prefabricated facade surface covering is flexible, the methods described below may be used to produce a prefabricated facade surface covering which is not flexible, whilst retaining the advantages described below.

In an arrangement, the surface elements 200 are formed on the supporting layer by using a surface element stencil, and providing the surface element material onto the supporting layer through the openings of the surface element stencil. An example of a surface element stencil 400 is shown in Figure 5A. As shown in Figure 5A, the surface element stencil 400 comprises openings 410 defining the plurality of surface elements 200 to be formed on the supporting layer in their respective locations. The surface element material can flow into the openings of the surface element stencil 400 in order to fill the openings to take on the desired shape of the surface elements 200.

In an arrangement, the surface element stencil 400 is provided onto the supporting layer 100. Then, the surface element material is passed onto the supporting layer 100 through the openings of the surface element stencil. The surface element stencil 400 masks the remainder of the supporting layer 100. This results in surface element material contacting the supporting layer 100 only at the locations where the openings 410 are provided.

In an arrangement, the surface element stencil 400 is aligned with the supporting layer 100 using one or more datum points provided on the surface element stencil and/or the supporting layer. In an arrangement, a datum point can be provided along an edge of the surface element stencil 400 as shown in Figure 5B. As shown in Figure 5B, a surface element stencil datum point 450 is provided along an edge of the surface element stencil 400. The surface element stencil datum point 450 may contact the edge of a manufacturing board 50 upon which the surface element stencil 400 and supporting layer 100 are provided. This interaction may enable the surface element stencil 400 to be held in its designated location, with the other components between the surface element stencil 400 and the manufacturing board, such as the supporting layer 100 and any other components, being held or clamped in place, restricting slipping or movement of those components. Once the surface element material has been provided, the surface element material may be hardened with the surface element stencil 400 remaining in place. Once the surface elements have been formed, the surface element stencil 400 may be removed. In an alternative arrangement, the surface element material may first be allowed to partially harden so that it may hold its shape without the assistance of the surface element stencil 400, and the surface element stencil 400 may be removed before the surface element material has fully hardened.

In an arrangement, after providing the surface element material onto the supporting layer 100, whilst the surface element stencil 400 is still in place and before hardening the surface element material, the colouring layer material 220 can be provided through one or more of the openings 410 of the surface element stencil 400. The colouring layer material 220 can be provided using any suitable means such as a screen printing system described in detail below, or by painting or pouring the colouring layer material from a container containing the prepared colouring layer material to the selected openings 410. This can have the advantage of accurately providing the colouring layer material 220 to a subset, or one or more of the surface elements 200 using the surface element stencil 400.

In arrangements, the surface element stencil 400 is removed after providing the surface element material and the colouring layer material 220, and the step of hardening includes hardening both the surface element material and the colouring layer material 220 together.

In arrangements, the surface finish powder 230 can be provided, as described above, onto the surface element material (and the colouring layer material 220 if present) before hardening, which can enable a good bond to be achieved between the surface finish powder 230 and the surface elements. 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 material. In an arrangement, the surface finish powder 230 is pressed into the surface of the surface element material to further ensure that the surface finish powder is embedded within the surface element material. This may be performed using a flat pressing tool, or a roller which is passed over the surface of the surface element material. This may have the advantage that, after the surface elements are formed, the surface finish powder 230 is less likely to be removed from the surface elements 200 during handling, transit, and once installed to the structure. In an arrangement, after the surface finish powder 230 has been distributed across the surface element material, the surface finish powder 230 may be spread or smudged using a sponge. This can be used to avoid creating high density regions of surface finish powder that extend across adjacent surface elements, which would be indicative of forming those surface elements together, so that a more natural appearance of the prefabricated facade surface covering is achieved.

In an arrangement, the surface finishing powder 230 is applied before removing the surface element stencil 400, which can ensure that surface finish powder is only applied to 25 the surface of the surface elements 200. This may be advantageous in arrangements where the supporting layer 100 is a panel without openings.

In an arrangement, before hardening the surface elements 200 and before providing the surface finish powder 230, the surface of the surface element material is provided with a surface texture. In an arrangement, this is achieved by contacting or touching the surface of the surface elements by a tool or object. In an arrangement, the tool may be a flat sheet which is pressed or slapped against the surface of the surface element material. The surface element material may briefly adhere to the flat sheet, and as the sheet is removed from the surface, an uneven and natural texture will be imparted to the surface of the surface elements. In alternative arrangements, the tool may have a specific texture intended to impart a desired texture to the surface of the surface elements.

In an arrangement, after hardening the surface element material to form the surface elements 200, a filler stencil 500 is provided onto the supporting layer 100. As shown in Figure 6A, the filler stencil 500 comprises openings 510, corresponding to gaps between the surface elements 200 at which the filler 300 is to be formed on the supporting layer 100.

In an arrangement, the filler stencil 500 is aligned with the supporting layer 100 and/or the surface element stencil using one or more datum points provided on the filler stencil, the surface element stencil and/or the supporting layer. As shown in Figure 6B, a filler stencil datum 550 may be provided in a similar manner to the surface element material datum point 450 provided on the surface element stencil 400.

After providing the filler stencil 500, the filler material is provided onto the supporting layer 100 through the openings 510 of the filler stencil 500. The filler material may flow into the openings of the filler stencil 500 in order to fill the openings to take on the desired shape of the filler 300. The filler stencil 500 is laid on top of the supporting layer 100 and the surface elements 200. In an arrangement, because the surface elements 200 have been hardened, there is a low risk of damaging or otherwise affecting the surface elements 200 by providing the filler stencil 500 onto the surface of the surface elements.

However, in other arrangements, the filler stencil 500 may be provided onto the surface element material and the filler material be provided before the surface elements are hardened.

In an arrangement as shown in Figure 6, the filler stencil 500 comprises connecting portions 520 in order to provide masking portions of the filler stencil at locations not directly connected to the periphery of the filler stencil 500. The connecting portions may be made sufficiently small such that the filler material may flow underneath the connecting portions 520 to fill the gap underneath the connecting portions.

In an arrangement, the openings 510 of the filler stencil 500 have the same width as the gaps between adjacent surface elements 200. In other arrangements, the openings 510 of the filler stencil 500 are narrower than the gaps between the surface elements 200. This can provide the advantage that the filler material does not contact the tops or the sides of the surface elements 200 as the filler material is provided into the gaps between adjacent surface elements.

In an arrangement, the filler stencil 500 comprises edge projections formed underneath the filler stencil. The edge projections may have a height equal to the thickness of the surface elements 200. The edge projections provide a boundary wall, defining the boundary to which the filler material is allowed to spread to. In arrangements in which the filler stencil 500 is placed on top of the already formed surface elements 200, the edge projections are necessary to contain the spread of the filler material, so as to provide a neat edge to the filler 300 at locations where the filler material is not completely contained by the already formed surface elements 200.

In a variation, filler 300 may be provided between the surface elements 200 in two steps using a different filler stencil for each step. In a first step, all lines of filler oriented in a first direction, for example corresponding to vertical lines when the prefabricated facade panel is installed. In the second step, the remaining lines of filler, oriented in a second direction orthogonal to the first direction are formed. In each step in such a process, the filler material is provided through openings of the stencil into the gaps between the surface elements 200. While the stencil is in place, the surface of the filler material is wiped along the opening in the stencil using a resilient object such as a sponge. This removes the excess filler material and the use of a resilient object may enable it to slightly pass through the openings in the stencil and shape the filler material within the space between the surface elements 200. In such a process, a relatively thin stencil may be used, for example one that is approximately 0.4mm thick.

After providing the filler material in the gaps between adjacent surface elements 200, the filler material is then hardened.

In an arrangement in which the supporting layer 100 is a mesh, a flat surface, such as a plastic sheet, may be provided underneath the supporting layer 100 during production to prevent the surface element material and filler material from falling out underneath the supporting layer 100 during formation. The flat surface may be selected so that the surface elements and filler do not strongly adhere, in order to enable the prefabricated facade surface covering 10 to be easily removed from it.

In an arrangement, the surface element material and filler material are provided onto the supporting layer 100 using a screen printing system as shown in Figures 7 and 8.

As shown in Figures 7 and 8, the screen printing system includes an applicator 600 and a blade 610. The applicator is provided with a supply of the material which is to be supplied to the supporting layer. The blade 610 is provided adjacent to the applicator and is arranged to press material into the stencil, and also restricts excess material being applied from the applicator 600. In an arrangement, the blade 610 may have a straight edge.

In an arrangement, the applicator 600 is provided with the surface element material, and the surface element stencil 400 is provided onto the supporting layer 100. Then the surface element stencil 400 and the supporting layer 100 are together moved relative to the applicator 600 and blade 610. In an arrangement, moving the surface element stencil 400 and the supporting layer 100 relative to the applicator 600 and blade 610 involves the surface element stencil 400 and the supporting layer 100 being held in place, and the applicator and blade being moved across the surface of the surface element stencil 400 and the supporting layer 100. In an alternative arrangement, moving the surface element stencil 400 and the supporting layer 100 relative to the applicator 600 and blade 610 involves the applicator and blade being fixed in place and the surface element stencil 400 and the supporting layer 100 being moved underneath the applicator and blade. In an alternative arrangement, both the surface element stencil 400 and the supporting layer 100, and the applicator 600 and blade 610 may be moved.

After forming the surface elements 200, the process can be repeated with the filler material and the filler stencil 500. In an arrangement, the applicator can be purged of remaining surface element material, and the applicator can be loaded with the filler material for the application of the filler material. In an alternative arrangement, a separate applicator can be provided with a supply of the filler material for the application of the filler material.

In an arrangement, before hardening the filler material to form the filler 300, a shape is applied to the exposed surface of the filler material. As shown in Figure 2, the surface of the filler 300 has a concave shape, which can be achieved through shaping the surface of the filler material. However, other shapes of the surface of the filler material can be achieved. Applying a shape to the surface of the filler material can assist in replicating the desired aesthetic of the prefabricated facade surface covering 10. For example, in arrangements in which the prefabricated facade surface covering is intended to replicate traditional masonry, the shape of the surface may be any shape that is applied to mortar in traditional masonry. Whilst in the arrangement shown in Figure 2 the filler 300 has a concave shape, in other arrangements surface shape may be a V-joint, weathered joint, beaded joint, struck joint, rake joint, or flush joint, for example. Applying a shape to the surface of the filler material can also compact the filler material and ensure that there is a good connection between the edges of the filler material and the adjacent surface elements.

In an arrangement, applying a shape, or shaping the surface of the filler material is performed using a manual shaping tool. The manual shaping tool may be run, dragged, or scraped along the surface of each line of filler material between adjacent surface elements.

In an arrangement, the manual shaping tool is a traditional masonry pointing tool, selected in dependence on the desired shape of the filler 300.

In an alternative arrangement, the shaping of the filler material can be performed using a filler material shaping tool 700, as shown in Figure 9. As shown in Figure 9, the filler material shaping tool 700 has a configuration corresponding to the plurality of gaps between a plurality of the surface elements. The filler material shaping tool 700 also has a shape corresponding to the desired surface shape of the filler 300. For example, the filler material shaping tool 700 may have a convex shape to achieve a concave shape on the filler material.

In an arrangement, the configuration of the filler material shaping tool 700 corresponds to the locations of all of the gaps in between the surface elements 200 formed on the prefabricated facade surface covering 10. In this arrangement, the filler material shaping tool 700 can shape all of the filler material provided between the surface elements 200 at the same time. In other arrangements, the filler material shaping tool 700 has a configuration that corresponds to a portion of the gaps between adjacent surface elements.

In an arrangement, the filler material shaping tool 700 may be a skeleton structure corresponding only the plurality of gaps between the plurality of surface elements. In such an arrangement the only contact between the prefabricated facade panel and the filler material shaping tool is at the locations of the filler material. In another arrangement, the filler material shaping tool may be a planar structure comprising protrusions located at the locations of the plurality of gaps. The filler material shaping tool 700 may function as a stamp which can be pressed into the gaps between all, or a plurality of, the surface elements in order to shape the filler material.

Alternatively, the filler material shaping tool 700 may be in the form of a roller, having a pattern formed on the roller corresponding to the locations of the gaps between adjacent surface elements. The roller form of the filler material shaping tool may be of a suitable size so as to be provided on the production line of the screen printing process, and be calibrated to the one or more datum points provided on the filler stencil, the surface element stencil and/or the supporting layer.

The filler material shaping tool may have a filler material shaping tool datum point 750, which may be provided in a similar manner to the filler stencil datum point 550, or the surface element stencil datum point 450.

Using the filler material shaping tool 700 can allow for a much faster processing time for shaping the filler material on the prefabricated facade surface covering 10, compared to manually shaping each section of filler material individually and may reduce the requirement for manual labour.

In an arrangement, a release material 710 can be provided between the filler material shaping tool 700 and the filler material in order to prevent the filler material shaping tool 700 from sticking to the filler material. The release layer may be made from any material which does not easily stick to the filler material upon being pressed into it by the filler material shaping tool, does not leave, or leaves a minimal imprint mark, in the filler material of its own structure, and/or can be easily washed or reused. In an arrangement, the release material 710 is a woven fibrous material such as nylon and/or cotton.

In an arrangement, the prefabricated facade surface covering may be rotated into a vertical plane before the filler material is shaped. This can allow for any excess filler material which is displaced by the manual shaping tool or filler material shaping tool to fall away from the prefabricated facade surface covering, and minimise the risk of it becoming adhered to the prefabricated facade surface covering.

Claims

Claims 1. A flexible prefabricated facade surface covering for installation on a surface of a structure, comprising: a supporting layer; a plurality of surface elements connected to the supporting layer and a filler provided between adjacent surface elements and connected to the supporting layer.
2 The prefabricated facade surface covering according to claim 1, wherein the surface elements and the filler are made from the same material, subject to the surface elements and/or the filler optionally comprising different colouring additives.
3. The prefabricated facade surface covering according to any preceding claim wherein the surface elements and/or the filler is made from a flexible polymer material.
4. The prefabricated facade surface covering according to any preceding claim, wherein the supporting layer is a flexible mesh
5. The prefabricated facade surface covering according to claim 4, wherein the mesh is embedded within each of the surface elements
6. The prefabricated facade surface covering according to claim 4 or claim 5, wherein the mesh is embedded within the filler.
7. The prefabricated facade surface covering according to any preceding claim, wherein the surface elements comprise a coating of surface finish powder.
8. The prefabricated facade surface covering according to any preceding claim, wherein the plurality of surface elements are formed with at least two different colours.
9 The prefabricated facade surface covering according to any preceding claim, wherein the prefabricated facade surface covering comprises a tessellating shape, such that when a plurality of the prefabricated facade surface coverings are installed adjacent to one another, the surface elements from a first of the prefabricated facade surface coverings interlock with the surface elements from a second of the prefabricated facade surface coverings,
10. The prefabricated facade surface covering according to claim 9, wherein the finer is provided adjacent surface elements on an edge of the prefabricated facade surface covering, and omitted from surface elements on an opposing edge of the prefabricated facade surface covering, such that when the plurality of prefabricated facade surface coverings are installed adjacent to one another, filler is provided adjacent surface elements of adjacent prefabricated facade surface coverings
11. The prefabricated facade surface covering according to any preceding claim, wherein the prefabricated facade surface covering is flexible such that the prefabricated facade panel may be elastically deformed under handling or installation without cracking or permanent damage occurring.
12. A building, a modular building unit or any component thereof comprising a prefabricated facade surface covering according to any preceding claim
13. The building, a modular building unit or any component thereof of claim 12, wherein the prefabricated facade surface covering is attached to a surface of the building, a modular building unit or any component thereof using adhesive.
14. The building, a modular building unit or any component thereof of claim 13, wherein the adhesive is formed from the same material as the filler.
15. A method of forming a flexible prefabricated facade surface covering for installation on a surface of a structure, the method comprising: providing a supporting layer; providing a plurality of surface elements connected to the supporting layer; and providing a filler between adjacent surface elements and connected to the supporting layer.
16. The method of claim 15, wherein the step of providing the plurality of surface elements connected to the supporting layer comprises: providing a surface element stencil onto the supporting layer, the surface element stencil comprising openings defining the plurality of surface elements to be formed on the supporting layer; and providing a surface element material onto the supporting layer through the openings of the surface element stencil.
17. The method of claim 16, wherein the step of providing the surface element material onto the supporting layer through the openings of the surface element stencil comprises: providing an applicator arranged to supply the surface element material across a width of the surface element stencil, moving the supporting layer and the surface element stencil together relative to the applicator, while supplying the surface element material; and providing a blade adjacent to the applicator arranged to remove excess surface element material.
18 The method of any one of claims 16 to 17, further comprising: providing a colouring layer material onto one or more of the surface elements, the colouring layer material being made from the same material as the surface elements material but having a different colour from the surface element material.
19. The method of any one of claims 16 to 18, further comprising contacting the surface element material with a tool or object to impart a surface texture to the surface elements.
20. The method of any one of claims 16 to 19, further comprising: distributing a surface finish powder across the surface element material, or colouring layer material where provided, of one or more of the surface elements.
21. The method of claim 20, further comprising pressing the surface finish powder into the surface element material or colouring layer material where provided, to embed the surface finish powder into the surface element material or colouring layer material.
22. The method of any one of claims 16 to 21, further comprising: before providing the filler between adjacent surface elements, hardening the surface element material, and the colouring layer material where provided, to form the plurality of surface elements connected to the supporting layer.
23 The method of any one of claims 15 to 22, wherein the step of providing the filler between adjacent surface elements and connected to the supporting layer comprises: providing a filler stencil onto the supporting layer, the filler stencil comprising openings corresponding to gaps between the surface elements at which the filler is to be formed between adjacent surface elements on the supporting layer; and providing a filler material onto the supporting layer through the openings of the filler stencil
24. The method of claim 23, wherein the openings of the filler stencil are narrower than the gaps between the surface elements
25. The method of any one of claims 23 to 24, wherein the step of providing the filler material onto the supporting layer through the openings of the filler stencil comprises: providing an applicator arranged to supply the filler material across a width of the filler stencil; moving the supporting panel and the filler stencil together relative to the applicator, while supplying the filler material; and providing a blade adjacent to the applicator arranged to remove excess filler material.
26. The method of any one of claims 23 to 25, further comprising: after providing the tiller material onto the supporting panel, applying a shape to the exposed surface of the filler material.
27. The method of claim 26, wherein applying a shape to the exposed surface of the filler material is performed by moving a manual shaping tool along the surface of each line of the filler material between adjacent surface elements.
28 The method of claim 26, wherein applying a shape to the exposed surface of the finer material is performed by pressing a filler material shaping tool into the filler material, the filler material shaping tool having a configuration corresponding to a plurality of gaps between a plurality of adjacent surface elements, and a desired finished shape of the surface of the filler material.
29. The method of claim 28, wherein before the step of pressing the filler material shaping tool into the filler material further a release layer is provided between the filler material and the filler material shaping tool.
The method of any one of claims 15 to 29, wherein the steps of providing the surface elements and the filler comprise providing surface elements and filler made from the same material, subject to the surface elements and/or the filler optionally comprising different colouring additives.
31. The method of any one of claims 16 to 30, wherein the surface elements and/or the filler is made from a flexible polymer material.
32. The method of any one of claims 15 to 31, wherein the supporting layer is a flexible mesh.
33. The method of any one of claims 15 to 32, wherein the prefabricated facade surface covering is flexible such that the prefabricated facade panel may be elastically deformed under handling or installation without cracking or permanent damage occurring.
34. A method of constructing or overcladding a building or a modular building unit, or any component thereof, comprising providing one or more prefabricated facade surface coverings according to claims 1 to 14 or preparing one or more prefabricated facade surface coverings according to the method of any one of claims 15 to 33, and connecting the prefabricated facade surface covering to the building or modular building unit or any component thereof
35. The method of constructing or overcladding a building or modular building unit or any component thereof, according to claim 34, wherein the step of connecting the one or more prefabricated facade surface coverings comprises using adhesive
36. The method of constructing or overcladding a building or modular building unit or any component thereof, according to claim 35, wherein the adhesive is formed from the same material as the filler.