GB2072235A - Cladding and cladding components - Google Patents

Abstract

A cladding panel comprises a cold rolled sheet (12) provided with identical side edge portions comprising a rolled-back part (14) and a two-limbed lip (15) which serves to both reinforce the edges of the panel (12) and provide a securing element for a cover strip (30). The panel is one component of a cladding which can comprise other components such as a mullion/door assembly, the other components such as mullions being provided with identical side edge configurations to the panels so that all components of the cladding are interchangeable. <IMAGE>

Description

SPECIFICATION Cladding system and components This invention relates to a cladding system and more particularly to components for use in such a system especially cladding panels and mullions.

A cladding system comprises components such as panels, mullions with, doors or other components, windows and the like which are intended to be fixed to a framework, such as a steel framework to provide the roof, walls etc. of a building.

One object of the invention is to provide a new and improved cladding system.

According to one aspect of the invention, we provide a cladding system comprising a plurality of components adapted to be fixed to a framework and disposed in side-by-side relationship, each of said components being of such configuration that any one component can be disposed in side-byside relationship with at least any one of the other components.

The components may comprise at least two of the following: a cladding panel, a mullion and associated door or other component, a louvre window.

All the components may have at least one side edge of identical configuration.

Preferably all the components have both side eges of identical configuration.

The width of each component may be equal to or a multiple of a predetermined module width.

A cladding panel for use in such a cladding system has hitherto usually been in one of the following four forms.

The first form is a single metal sheet formed to a desired profile.

A second form is an insulated panel comprising an outer metal sheet formed to a desired profile and an inner metal sheet with an insulating material between the sheets. The insulating material may be in sheet form and may be bonded to the inner and outer sheets or the insulating material may be injection moulded between the sheets or may comprise a !oose material such as glass wool or granular material; in at least the latter two cases a suitable closure is provided to provide an enclosure for the insulating material.

The above described second form is preformed in a factory prior to delivery to site.

In a third form, the panel is essentially as described above in connection with the second form but is constructed on site from the above described separate components.

The fourth form is essentially similar to that of the second form except that the inner and outer sheets are provided with edge parts which totally enclose the insulating material and the edge parts of adjacent panels are adapted to be abutted and suitable sealing means are provided to seal the joint between the panels externally of the building.

In practice, a problem is encountered with the first form in that the side parts of the sheet are easily damaged during transport and particularly during handling on site since the side parts of the sheets are relatively thin and on site the usual practice is for the sheets to be handled by gripping the side parts which frequently cause buckling thereof. In the case of the second and third types at least one edge of the outer sheet projects beyond the insulating material to provide a portion adapted to overlap with an adjacent sheet to provide a weather seal between the sheets externally of the building and this projecting part is relatively weak and so can be damaged in a similar manner to the sheet of the first form.

The fourth form is not prone to such damage because the metal sheets have edge parts to form the above described enclosure and so the end parts of the sheets are strong. However, hitherto, panels of the fourth form have always been handed, generally to facilitate a male and female joint between adjacent sheets and the creation of a weather seal therebetween. This presents, however, the disadvantage that panels of the fourth form are not reversible, i.e. top to bottom and neither do they lend themselves to the simple fitting of doors and windows in the walls of the building.

Also, it has not been easy and the finish is not attractive, to insert windows, doors and the like into a building with existing cladding systems because the asymmetric sheets generally cause the window or the like to be off centre which requires unsightly trim and extra work.

It is accordingly a further object of the present invention to provide a panel for a cladding system whereby the above mentioned disadvantages are overcome.

According to a second aspect of the invention we provide a cladding panel for use in a cladding system according to the first aspect of the invention, said panel comprising a metal sheet formed to a symmetrical configuration and having a reinforcing and cover securing element at each of the two opposite sides of the sheet.

The metal sheet may be formed to a symmetrical ribbed profile and the profile may comprise ribs parallel to said sides and the ribs may be of trapezoidal configuration.

The reinforcing element may comprise a second thickness of the sheet and may be integral with the sheet and provided by bending a side part of the sheet back on itself or may be separate from the sheet and secured thereto by any suitable means.

The cover securing element may comprise a lip extending inwardly from the edge of the sheet and away from the surface of the side part of the sheet.

The cover securing element may comprise a side portion of said reinforcing element.

The panel may be of any of the above described four forms.

According to another aspect of the invention we provide a cladding system comprising two cladding panels according to the second aspect of the invention, said panels being located in side-byside relationship with a said side of one sheet extending parallel and adjacent to a said side of the other sheet, fastener means engaged with a portion of at least one of the sheets adjacent to said side thereof and a cover being engaged with the cover securing element of each panel and covering the adjacent sides of the sheets and said fastener means.

Where the panel is of a ribbed profile, said cover may be of a configuration identical to the configuration of an appropriate rib of said ribbed profile so as to continue the ribbed profile uniformly between the panels.

According to another aspect of the invention we provide a cladding system comprising at least one cladding panel according to the first aspect of the invention, and a mullion for a door, window or other component, the mullion being provided with a cover securing element, and means for connecting the mullion to the side part of said cladding panel, such that the cover securing elements of the panel and the mullion are at the desired modular spacing to be engaged by a cover which covers the adjacent side of the sheet and mullion and said connecting means.

Where the panel is of a ribbed configuration, said cover may be of a configuration identical to the configuration of an appropriate rib of said ribbed profile se as to continue the ribbed profile.

Where the panel is an insulated panel, the mullion is of a thickness equal to the thickness of the insulated panel.

A second panel according to the first aspect of the invention may be provided in side-by-side relationship with the side of the first panel but spaced therefrom and there being a second mullion connected to the second panel as described in connection with the first mullion and first panel and a space being provided between the mullions in which a desired component is mounted.

The components may comprise any door, window or the like, the combination of two mullions and component being of a combined width equal to the width of each of the said panels.

Cladding systems embodying the above described aspects of the invention or utilizing a cladding panel according to the second aspect of the invention overcome the above described advantages. It is to be noted that the panels embodying the invention are symmetrical and hence can be reversed top for bottom. Further, additional components such as doors, windows and the like may be conveniently and easily introduced into thp cladding system simply by connecting the mullions to the side of two panels embodying the invention which are spaced apart by a distance equal to their own modular width and mounting a component of the appropriate size between the mullions.

According to a yet further aspect of the invention, we provide a building comprising a framework having fixed thereto a cladding system according to the first aspect of the invention.

If it is desired to modify the building according to the yet further aspect of the invention during its life, this can be done by removing one or more components of the cladding system and, repiacing them by one or more new components or by interchanging one or more components of the cladding system at one location of the building for one or more components from a different location in the building.

The provision of the reinforcing element at the side of each outer sheet of the panel reinforces this edge and prevents it becoming damaged during transport or handling. Further, provision of the cover securing element, which is conveniently provided as an side part of the reinforcing element, ensures that there is always provided suitable securing means for a cover element which can continue a ribbed profile of the sheet and cover means for fixing the panels in position and also, where appropriate, connecting means between the mullion and panel.

A further problem encountered with cladding panels currently in use is that the overall width of the panel varies.

This is because the panels are formed with ribs and it will be appreciated that small variations in the angle of the sides of the ribs will lead to a variation in the overall width of the panel. In practice, the amount of spring back occurring after formation of the ribs is unpredictable, within the limits, and hence the final width of the panel is unpredictable, within limits. Whilst the variation in width occurring is relatively small it is sufficient, particular in a building having a large number of panels arranged side-to-side to give rise to a considerable cumulative error.

It is accordingly a further object of the invention to provide a method of making a cladding panel whereby the above mentioned problem is overcome or reduced.

Thus, according to a stiil further aspect of the invention we provide a method of making a cladding panel comprising the steps of taking a sheet of metal, forming a desired profile thereon, said profile comprising at least one rib extending longitudinally of the panel, thereafter acting on opposed side portions of the panel and bending the material of the panel back on itself to form a double thickness portion and ensuring that the overall width of the panel after said bending operation is of a predetermined width. There may be a plurality of parallel ribs spaced apart transverse of the panel.

Preferably, during the bending back of the side portions an upturned lip is formed on that free end of the bent back portion.

Said lip may have a first limb extending away from the edge of the panel and from the adjacent surface of the panel and from the inner end of said first limb a second limb extending towards the edge of the panel and away from said surface of the panel so as to provide a lip or generally V-section.

The method may include the further step of connecting a second sheet to the first sheet with insulating material therebetween.

The invention will now be described in more detail by way of example with reference to the accompanying drawings wherein: FIGURE 1 is a diagrammatic transverse crosssectional view through a sheet for use in a panel embodying the invention, shown during a first stage of manufacture; FIGURE 2 is a view similar to that of Figure 1 but showing the sheet at a second stage during manufacture; FIGURE 3 is a diagrammatic cross-sectional view through a panel embodying the invention; FIGURE 4 is a diagrammatic fragmentary crosssectional view of a cladding system embodying the invention; FIGURE 5 is a diagrammatic fragmentary crosssectional view through another embodiment of the invention; FIGURE 6 is a diagrammatic fragmentary crosssectional view through a further embodiment of the invention;; FIGURE 7 is a diagrammatic fragmentary crosssectional view through a yet further embodiment of the invention; and FIGURE 8 is a diagrammatic cross-sectional fragmentary view through a still further embodiment of the invent;on.

Referring now to the Figures and in particular to Figures 1 and 3, a sheet which may be of steel, aluminium, aluminium alloy or any other desired material is formed in the present example by cold rolling, to a desired shape. (In the example illustrated a ribbed profile comprising three pairs of smaller ribs 10 separated by two larger ribs 11.) The ribs 10 and 11 are of trapezoidal configuration. If desired, the ribs may be of other configuration that trapezoidal and also any other desired pattern of ribs or any other profile may be applied.

It will be seen that the thus formed sheet 12 is of a width W greater than the desired final width of the panel We which final width is slightly smaller than the basic module width M of the cladding systems with which the panel is intended to be used.

After forming the sheet 1 2 to the configuration shown in Figure 1, the side portions 13 extending beyond the desired module width M are rolled back upon themselves as shown at 14 and in addition a two-limbed lip 1 5 is formed at the end of the rolled-back part 1 4. The rolled-back part 14 provides a reinforcing element for the edges of the sheet whilst the lip 1 5 provides a cover securing element as hereinafter to be described.

It will be noted that the final width of the sheet 1 2 after the roll forming of the edge portion, Wf is slightly smaller than the module width M by a predetermined amount sufficient to accommodate, between adjacent panels, a desired fastening means within the module width M.

The thus formed sheet 12 may be utilized in a panel of any of the four forms described hereinbefore. That is to say it may be used alone to provide a cladding panel or it may be provided with suitable insulation material I, together with an inner sheet, which may be planar or ribbed as desired and, if desired, the inner sheet may be provided with an upstanding edge flange to form an enclosure with the sheet 12, this being the arrangement shown in Figure 3 wherein the inner sheet is shown at 16, has edge flanges 1 7 which have inturned lips 18 welded to the inwardly facing side of the sheet 12. Suitable insulation material I, is provided within the panel between the sheets such as an injection moulded material, fibreglass wool or granular material.

It will be noted that the centre of the larger ribs 11 are spaced apart by a distance D and that this distance D is equal to the distance from the centre of each rib 11 to the end of the module width M.

By forming the sheet 1 2 in a two-stage process variation of the final width Wf of the sheet is avoided.

In existing cladding sheets, the final width is variable due to variations in the hardness of the material used, in the thickness of the material used, in dependance upon the nature of any coating applied to the sheet and variations in the manufacturing process or variation in any other manufacturing process which is used. By the method of the present invention any variations which arise during the first stage of forming due to the hereinbefore mentioned causes can be allowed for in the second stage wherein the edge is rolled. It will be appreciated that the position of the bend Wf and of the position of join between the two limbs of the lip 1 5, in relation to the final width Wf if fixed and that variation in the overall width of the sheet W arising at the end of the first stage is compensated for by variation in the length of the "free" limb of the lip 1 5.

Referring now to Figure 4. Where it is desired to secure two of the panels described hereinbefore, as shown in Figure 3, in position to a framework the two panels, indicated at P, and P2 in Figure 4 are arranged in parallel side-to-side relationship with the sides of the sheets 1 2 located spaced apart by the desired predetermined amount from the module line L. A suitable fastener 1 9 having a securing plate 20 beneath its head is then driven into a part F such as a panel or the like, of the framework of a building to which the panels are to be secured with the securing plate 20 engaging the bent-over parts 14 of the panels 12.

A cover strip 30 having a trapezoidai configuration identical to that of the larger ribs 11 is provided and has side lips 31 adapted to engage a lower limb 32 of the lips 1 5 whilst the side parts 33 of the cover strip lie in face-to-face engagement with side limbs 34 of the lips 1 5. The position of the line of join J between the limbs 32 and 34 is accurately positioned so that on the one hand the length of the inturned lip 31 is such that the lower extremity 35 of the cover strip 30 engages the upper surface of the sheet 1 2 when the end of the inturned lip 31 engages the limb 32 of the lip 15 and, on the other hand, so that the predetermined trapezoidal shape of the cover strip 30 is not distorted as a result of engagement with the limb 34 and to ensure that the sides 33 lie in engagement with the limb 34.

Thus, the present invention provides a side portion of the panels which is strengthened and hence not distortable in use, provides a strengthened part for fixing and conveniently provides an anchor means for a cover strip to mask the means of connection between the panels and the fixing means. At the same time, the cover strip repeats the pattern of ribbing.

In an alternative embodiment shown in Figure 5, the panels are arranged essentially as described hereinbefore except that in this case the insulation I and rear sheet 1 6 and associated edge flange 1 7 and lip 1 8 extend further than in the embodiment described with reference to Figure 4 so as to provide a relatively small space centred on the line L of the module suitable to yieldingly accommodate the stem 36 of the T-shaped trim strip 37.

In this embodiment, two separate fasteners 19 are provided, in this case without any securing plate 20, the fasteners 1 9 extending through the bent-back parts 14 of the associated sheet 12 of the panels P1 and P2. In the other respects the arrangement is as described in connection with Figure 4 and same reference numerals have been used to refer to corresponding parts.

Referring now to Figure 6, there is shown a cladding system incorporating a component 47 such as a door. In this case, two panels P1, P2 in the same form as described hereinbefore are located so that their sides are spaced in the above described predetermined distance from the module line L and a mullion 40 is connected to each panel by means of securing plates 41 by suitable fasteners such as 'pop' rivets passing through the double thickness parts 14 of the sheets 12, of the panels P, and P2 and through a double thickness part 42 of the associated mullion 40.

Each mullion 40 has a double thickness part 42 with an end lip 43 which parts are of identical configuration to the parts 14 and 1 5 of the panels P1 and P2. The remainder of the mullion comprises a transversely extending part 44 and a rear part 45 so that the mullion is of generally channel configuration and of a thickness equal to that of the panels P1 and P2. In the example illustrated the mullions are reinforced by a box section tube 46.

The mullions are provided with a suitable means (not shown), to mount the component 47 thereon. For example, one mullion 4Q may be provided with hinges to hinge a door, window or the like thereto and the other mullion with a catch to secure the windows o door in a closed position.

Cover strips 30 are again provided in an exactly similar manner to that described hereinbefore in connection with the previous embodiments. It is particularly to be noted that the combination of the two mullions 40 and the component 47 is of a width equal to the final width Wot of the panels P and P2.

If desired, the box section tubular members 46 can be omitted from the mullions depending upon the load to be carried by the mullions in which case the arrangement as shown in Figure 7 is achieved.

Referring now to Figure 8, the manner in which a corner of a building is trimmed is illustrated. At the corner of the building, two panels P1 and P2 identical to those described hereinbefore in connection with Figure 4 are provided and a corner trim strip 50 having side portions 51 and 52 of its limbs provided with inturned lips identical to the inturned lips 31 so the cover strips 30 is fitted in position in engagement with the lips 1 5 of the sheet 12 of the panels P1 and P2 in an exactly similar manner as the cover strip 30 of the fixing position.

If desired, the part providing the reinforced element and cover securing element may be formed separately from the remainder of the panels or mullions and fixed thereto by a suitable fixing means such as 'pop' rivets.

The panel 12 may be of any desired configuration and may, for example, simulate masonry as described in our co-pending application No. 8009367.

The cladding system according to the present invention comprising a plurality of panels as described hereinbefore, and other components such as a mullion/door assembly 40, 47 illustrated in Figure 6 or a mullion/window assembly described with reference to Figure 6, louvred panels, fixed windows, curtain glazing and the like are all made so that both sides of each component are identical, that is to say, in the case of a mullion/other component assembly, the mullions are formed so that both mullions are of identical configuration and of the same configuration to the panels, or in the case of other components such as windows or curtain glazing, the frames thereof are similarly of the same edge configuration as the panels. Consequently, each component is not handed and all the components are therefore completely interchangeable with each other.This therefore facilitates erection of a building from standard components of either identical width or a width which is a multiple of a standard module width, so that two or more components of, for example the basic module width, can be replaced by a single component having a width equal to the appropriate multiple of the module width.

In addition, if during the life of a building it is desired to change the facilities offered by the building, for example to introduce a door at a particular location, it is merely necessary to replace the component or components present at that location by the newly desired component such as a door or doors. Alternatively, it may be desired to keep the same facilities in the building but to provide them at different locations, in which case it is merely a case of interchanging the component or components at one location for that or those at the other location.

Not only are the configurations of the sides of the component identical, but in addition selfflashing heads and cills of a component are also identical and it is therefore possible to fit any unit quickly into any desired position by the fitting of blind rivets, all of which are concealed in a cover strip which joins the panels or other components together. Further, the frames of all the components other than panels are identical, giving a superior finish to the wall of the building and every component matches an adjacent component.

The height of the components may vary. For example, a window one metre high may be provided with panels of appropriate height above and below, and on the adjacent component an adjustable louvre may be provided, say two metres deep, with walls of appropriate height above and below.

For aesthetic reasons, the tops of the windows, louvres and the like would be arranged to be level preferably with the top of the access doors.

The frames of the components, such as doors in which case the frames are mullions, or fixed windows, are contained within the width of the cladding panels and therefore do not intrude into the interior of the building.

Claims (33)

1. A cladding system comprising a plurality of components adapted to be fixed to a framework and disposed in side-by-side relationship, each of said components being of such configuration that any one component can be disposed in side-byside relationship with at least one of the other components.

2. A cladding system according to Claim 1 wherein the components comprise at least two selected from the following: a cladding panel, a mullion and associated component, a window, a louvre.

3. A cladding system according to Claim 1 or Claim 2 wherein all the components have at least one side edge of identical configuration.

4. A cladding system according to Claim 3 wherein all the components have both side edges of identical configuration.

5. A cladding system according to any one of the preceding claims wherein the width of each component is equal to or a multiple of a basic module width.

6. A cladding panel for use in a cladding system according to any one of the preceding claims, said panel comprising a metal sheet formed to a symmetrical configuration and having a reinforcing and cover securing element at each of the two opposite sides of the sheet.

7. A cladding panel according to Claim 6 wherein the metal sheet is formed to a symmetrical ribbed profile and the profile comprises ribs parallel to said sides.

8. A cladding panel according to Claim 7 wherein the ribs are of trapezoidal configuration.

9. A cladding panel according to any one of Claims 6 to 8 wherein the reinforcing element comprises a second thickness of the sheet and is integral with the sheet and provided by bending a side part of the sheet back on itself.

10. A cladding panel according to any one of Claims 6 to 8 wherein the reinforcing element is separate from the sheet and secured thereto.

11. A cladding panel according to any one of Claims 6 to 10 wherein the cover securing element comprises a lip extending inwardly from the edge of the sheet and away from the surface of the side part of the sheet.

12. A cladding panel according to Claim 11 wherein the cover securing element comprises a side portion of said reinforcing element.

13. A cladding panel according to any one of Claims 6 to 12 wherein the panel is a single metal sheet formed to a desired profile.

14. A cladding panel according to any one Claims 6 to 12 wherein the panel is an insulated panel preformed in a factory prior to delivery to site, comprising an outer metal sheet formed to a desired profile and an inner metal sheet with insulating material between the sheets.

1 5. A cladding panel according to any one of Claims 6 to 12 wherein the panel is an insulated panel formed on site and comprising an outer metal sheet formed to a desired profile and an inner metal sheet with insulating material between the sheets.

1 6. A cladding panel according to any one of Claims 6 to 1 2 wherein the panel is an insulated panel comprising an outer metal sheet formed to a desired profile and an inner metal sheet with insulating material between the sheets, the inner and outer sheets being provided with edge parts which totally enclose the insulating material and the edge parts of adjacent panels being adapted to be abutted.

1 7. A cladding system according to any one of Claim 1 to 5 comprising two cladding panels according to any one of Claims 6 to 16, said panels being located in side-by-side relationship with a said side of one sheet extending parallel and adjacent to a said side of the other sheet, fastener means engaged with a portion of at least one of the sheets adjacent to said side thereof and a cover being engaged with the cover securing element of each panel and covering the adjacent sides of the sheets and said fastener means.

1 8. A cladding system according to Claim 1 7 wherein the panel is of ribbed profile and said cover is of a configuration identical to the configuration of an appropriate rib of said ribbed profile so as to continue the ribbed profile uniformly between the panels.

1 9. A cladding system according to any one of Claims 1 to 5 and comprising at least one cladding panel according to any one of Claims 6 to 16, and a mullion for a door, window or other component, the mullion being provided with a cover securing element, and means for connecting the mullion to the side part of said cladding panel, such that the cover securing elements of the panel and the mullion are at the desired modular spacing to be engaged by a cover which covers the adjacent side of the sheet and mullion and said connecting means.

20. A cladding system according to Claim 19 wherein the panel is of a ribbed configuration, said cover is of a configuration identical to the configuration of an appropriate rib of said ribbed profile so as to continue the ribbed profile.

21. A cladding system according to Claim 20 wherein the panel is an insulated panel and the mullion is of a thickness equal to the thickness of the insulated panel.

22. A cladding system according to any one of Claims 19 to 21 wherein a second panel according to any one of Claims 6 to 16 is provided in side-by-side relationship with the side of the first panel but spaced therefrom and there being a second mullion connected to the second panel similar to the first mullion and first panel and a space being provided between the mullions in which a desired component is mounted.

23. A cladding system according to Claim 22 wherein the components comprises a door, window or the like, the combination of two mullions and components being of a combined width equal to the width of each of the said panels.

24. A building comprising a framework to which is fixed a cladding system according to any one of Claims 1 to 5 or 17 to 23.

25. A method of making a cladding panel comprising the steps of taking a sheet of metal, forming a desired profile thereon, said profile comprising at least one rib extending longitudinally of the panel, thereafter acting on opposed side portions of the panel and bending the material of the panel back on itself to form a double thickness portion and ensuring that the overall width of the panel after said bending operation is of a predetermined width.

26. A method according to Claim 25 wherein a plurality of parallel ribs are spaced apart transversely of the panel.

27. A method according to Claim 25 or Claim 26 wherein during the bending back of the side portions an upturned lip is formed on the free end of the bent back portion.

28. A method according to Claim 27 wherein said lip has a first limb extending away from the edge of the panel and from the adjacent surface of the panel and from the inner end of said first limb, a second limb extending towards the edge of the panel and away from said surface of the panel so as to provide a lip or generally V-section.

29. A method according to any one of Claims 25 to 28 wherein the method includes the further step of connecting a second sheet to the first sheet with insulating material therebetween.

30. A cladding system substantially as herein before described with reference to and as shown in the accompanying drawings.

31. A cladding panel substantially as hereinbefore described with reference to and as shown in the accompanying drawings.

32. A building clad with a cladding system substantially as hereinbefore described with reference to and as shown in the accompanying drawings.

33. A method of making a cladding panel substantially as hereinbefore described with reference to the accompanying drawings.