Composite Constructional Element And Method Of Manufacturing A Composite Constructional Element

Abstract

A composite constructional element 1 comprises a plank profile 2 defining a rear face 6 and two opposed edge sections 4 and 5 of the constructional element. Each edge section includes an edge face 4 a, 5 a. A cladding material 3 is moulded into the plank profile to extend continuously between the opposed edge faces such that it is retained by the rear face and the opposed edge faces. The plank profile may further comprise retaining formations 4 b, 5 d shaped to retain the moulded cladding material attached to the plank profile. A method of manufacturing the composite constructional element is also disclosed.

1 . A composite constructional element comprising: 
 a plank profile defining a rear face and two opposed edge sections of the constructional element, each edge section including an edge face; and    a cladding material moulded into the plank profile to extend continuously between the opposed edge faces such that it is retained by the rear face and the opposed edge faces.    
   
   
       2 . A composite constructional element comprising: 
 a plank profile defining a rear face and two opposed edge sections of the constructional element, each edge section including an edge face; and    material moulded into the plank profile such that it is retained by the rear face and the opposed edge faces;    wherein the plank profile further comprises at least one retaining formation shaped to retain the moulded cladding material attached to the plank profile.    
   
   
       3 . The composite constructional element according to  claim 2 , wherein the retaining formations are formed adjacent to or as part of the edge sections.  
   
   
       4 . The composite constructional element according to  claim 3 , wherein the retaining formations comprise longitudinal channels of substantially uniform cross section and filled with cladding material, and being shaped in cross section to retain the moulded cladding material attached to the plank profile.  
   
   
       5 . The composite constructional element according to  claim 1 , wherein the cladding material forms substantially an entire front face of the constructional element.  
   
   
       6 . The composite constructional element according to  claim 1 , wherein each edge section comprises an attachment formation for attachment to a mating attachment formation on an adjacent constructional element.  
   
   
       7 . The composite constructional element according to  claim 6 , wherein the attachment formations comprise a frontwardly facing channel formed on one edge section and a rearwardly projecting lip formed on the opposed edge section, wherein the lip is capable of clipping into or being retained at a channel of an adjacent constructional element.  
   
   
       8 . The composite constructional element according to  claim 7 , wherein the lip includes a recess such that, when clipped into or retained at a mating channel of an adjacent constructional element, a recess is defined between a base of the mating channel and the lip.  
   
   
       9 . The composite constructional element according to  claim 8 , wherein the channel projects outwards beyond one edge face, and the lip is formed inwards from the opposed edge face.  
   
   
       10 . The composite constructional element according to  claim 9 , wherein the channel is formed as a separate piece and includes a depending portion which extends over the adjacent edge face and is embedded in the cladding material once the constructional element is formed.  
   
   
       11 . The composite constructional element according to  claim 7 , wherein, when the plank profile comprises at least one retaining formation shaped to retain the moulded cladding material attached to the plank profile, the lip comprises one of the retaining formations.  
   
   
       12 . The composite constructional element according to  claim 6 , wherein the plank profile, including the rear face, the edge sections and the attachment formations, is integrally formed from a sheet material.  
   
   
       13 . The composite constructional element according to  claim 1 , wherein the plank profile is formed from sheet steel.  
   
   
       14 . The A composite constructional element according to  claim 13 , wherein the plank profile is roll formed.  
   
   
       15 . The composite constructional element according to  claim 1 , wherein the plank profile includes at least one longitudinal stiffening formation comprising a ridge.  
   
   
       16 . The composite constructional element according to  claim 1 , wherein the cladding material comprises cement, concrete, fibre cement, fibreglass, cellulose, foamed polymeric material, ceramics or polystyrene.  
   
   
       17 . The composite constructional element according to  claim 1 , wherein the cladding material is glass reinforced cement.  
   
   
       18 . A method of manufacturing a composite constructional element comprising the steps of: 
 providing a plank profile comprising a rear face and two opposed edge sections, each edge section including an edge face; and    moulding a cladding material into the plank profile such that it extends continuously between the opposed edge faces and is retained by the rear face and the opposed edge faces.    
   
   
       19 . A method of manufacturing a composite constructional element comprising the steps of: 
 providing a plank profile comprising a rear face and two opposed edge sections, each edge section including an edge face, the plank profile further comprising at least one retaining formation; and    moulding a cladding material into the plank profile such that it moulds into the retaining formation to attach to the plank profile and is retained by the rear face and the opposed edge faces.    
   
   
       20 . The method according to  claim 18 , wherein the plank profile is roll formed from sheet steel.  
   
   
       21 . The method according to  claim 18 , wherein the plank profile comprises the only mould for moulding the cladding material.  
   
   
       22 . (canceled)