AU2013260743A1

AU2013260743A1 - Cladding systems

Info

Publication number: AU2013260743A1
Application number: AU2013260743A
Authority: AU
Inventors: Curt Van Zwol
Original assignee: Van Zwol Curt Mr
Current assignee: Van Zwol Curt Mr
Priority date: 2012-10-14
Filing date: 2013-11-22
Publication date: 2014-05-01

Abstract

In one preferred form there is provided a cladding system 10. A first channel 16 comprises a single U channel extrusion 19. A second channel 18 comprises a double U extrusion 24. A panel 40 is provided by a folded sheet 41. 28 26[ - j ____ ____ ____ ___ ____ ____ ___19

Description

1/12 Field of the Invention The present invention relates to cladding systems. In one preferred form there is provided a clip-in cladding system. Background to the Invention 5 To remove the unattractive look of a recently built structure such as an office building, shopping centre, retaining wall or industrial factory the external surfaces can be treated in a variety of ways such as painting, decorating or cladding. Many different cladding materials such as steel, glass and ceramic tiles can be fixed to these surfaces to produce a pleasant finish. One cladding material of choice in today's market is a product commonly known as .0 Aluminium Composite Material (ACM). ACM is a sheet product which consists of a polyethylene plastic core with an aluminium skin (generally about 0.5mm thick) either side. Sheets of this product range in thickness from around 2mm up to 10mm, however sheets of 3-4mm are preferred for cladding purposes. There are multiple fabrication and installation techniques to take ACM from a simple sheet .5 product to a cladding panel fixed to any number of typical construction substrates, the majority of which include cutting grooves into one side of the sheet which allow it to bend at the edges and form tabs, followed by fixing a pressed steel or extruded aluminium section to the tabs using screws or rivets, this process forms the cladding panel. If necessary (and it generally is, depending on the substrate) another pressed or extruded .0 section is then mounted using a mechanical fastener on the surface that requires cladding. The prefabricated panel is then physically held up in position and fixed to the pre-installed extrusion using another mechanical fastener. The last step of cladding the surface is to fill the gap between panels with a polyurethane flexible sealant. It would be advantageous to provide an improved cladding system, or at least provide the 15 public with a useful choice. It is against this background that the present invention has been developed. It is to be recognised that any discussion in the present specification is intended to explain the context of the present invention. It is not to be taken as an admission that the material discussed formed part of the prior art base or relevant general knowledge in any particular country or region. 30 Summary of the Invention According to a first aspect of preferred embodiments herein described there is provided a cladding system comprising: sheets fabricated with grooves with a specific layout and profile that allow each sheet to be folded in such a way that tabs are formed in a panel; where the tabs can be pushed into channel to lock the panel in position leaving the panel unable to come 35 out due to physical forces applied. Preferably each tab, when pushed into the channel, passes contours of a channel flange of the channel, and due to the contours of the channel flange being effectively locked in, due to the tab trying to re-open.

2/12 Preferably each tab is provided as a folded tab, the fold of the tab trying to return the tab to the state it was in previously before insertion. Preferably each tab is bent at an angle of over 90 degrees which can then be pushed into the channel. 5 Preferably each tab is bent at an angle of around 100 to 105 degrees which can then be pushed into the channel. Preferably each sheet includes a first groove allowing a tab to be bent at an angle of over 90 degrees; and a second groove a required distance from a first groove to give each panel a desired depth. .0 Preferably there are four tabs, a first groove for providing each of the four tabs, and a second groove spaced from each first groove for providing a panel depth. Preferably each first groove is a 135 degree V groove and each second groove is a 90 degree V groove. Preferably the sheets comprise aluminium composite material and the channel comprises .5 aluminium extruded channel. According to another aspect of preferred embodiments herein described there is provided a cladding system comprising: panels; and tabs formed in each panel; where the tabs can be pushed into channel to lock the panel in position leaving the panel unable to come out due to physical forces applied. .0 Preferably each tab, when pushed into the channel, passes contours of a channel flange of the channel, and due to the contours of the channel flange is effectively locked in, due to the tab trying to re-open. Preferably the panels have grooves with a specific layout and profile Preferably each tab is provided as a folded tab, the fold of the tab trying to return the tab to 25 the state it was in previously before insertion. According to another aspect of preferred embodiments herein described there is provided a cladding channel comprising: a u-shaped channel having a contour applied to an internal surface of the channel to provide a contoured flange for locking a tab of a panel in position. Preferably the contoured flange provides an angular contour as shown in Figure 1. 30 Preferably the angular contour is applied to one channel internal surface. In another embodiment the flange includes a rubber section for locking the panel in position, the rubber section allowing the panel to be firmly retained inside the channel with the ability to be removed when needed by compressing the rubber section allowing the tab to pass by.

3/12 Preferably the cladding channel includes resilient material located in the u-shaped channel to assist with securing the tab of the panel in position. Preferably the resilient material is provided to bias the panel outwardly Preferably the resilient material comprises a layer of foam material. 5 According to another aspect of preferred embodiments herein described there is provided cladding channel comprising: two u-shaped channels, each channel having a contour applied to an internal surface of the channel to provide a contoured flange for locking a tab of a panel in position. Preferably each flange provides an angular contour as shown in Figure 1. .0 Preferably the angular contour is applied to two channel internal surfaces. According to another aspect of preferred embodiments herein described there is provided a cladding system comprising: channel and panels; the channel for receiving the panels; the panels having tabs; where the channel has contoured surfaces allowing the tabs to be pushed into the channel; the contoured surfaces for preventing the panels from coming out of the .5 channel by the tabs of the panels being pressed against the contoured surfaces. According to another aspect of preferred embodiments herein described there is provided a cladding system comprising: a panel having a tab that is able to be pushed into a channel of an extrusion wherein when the panel is pushed into the channel, a fold in the tab continuously tries to return the tab to the state it was in previously to keep the end of the tab pressed .0 against a contoured surface of the extrusion, therefore restricting the panel from coming out of the extrusion. According to another aspect of preferred embodiments herein described there is provided a cladding panel having a tab that is able to be pushed into channel having a contoured flange to provide a folded tab pressed against the contoured flange of the channel that locks the 25 panel in position. Preferably the tension in the fold of the folded tab is provided to continuously try to return the tab to the state it was in previously, keeping the end of the tab pressed against the contoured surface of the channel therefore restricting the panel from coming out of the channel. 30 According to another aspect of preferred embodiments herein described there is provided a cladding system comprising: a mechanical locking system formed by the interaction of a grooved panels with contoured extruded channels. According to another aspect of preferred embodiments herein described there is provided a cladding panel having a folded tab for being pressed against the contoured surface of a 35 channel.

4/12 Preferably the tab is provided as a folded tab, the fold of the tab trying to return the tab to the state it was in previously before insertion. Preferably the cladding panel includes a plurality of a folded tabs, each tab for being pressed against the contoured surface of a channel. 5 Preferably the cladding panel is of rectangular form including four tabs. Preferably each tab is bent at an angle of over 90 degrees which can then be pushed into the channel. In a further aspect of the preferred embodiments herein described there is provided a clip-in cladding system that uses the same ACM sheets as described above with panels fabricated by .0 cutting grooves with a specific layout and profile that allows the sheet to be folded in such a way that the tabs formed can be pushed into a proprietary aluminium extruded channel, locking the panel into position leaving it unable to come out due to physical forces being applied between the panel and the extrusion, by the panel itself Preferably, the extrusions used to secure the clip-in cladding system panel, in embodiments, .5 to the surface requiring treatment generally have the following attributes: (i) they have cross section views similar to a single or double U; (ii) they have a web section with a void to allow a fastener to pass through and not interfere with the insertion depth of the panel; (iii) they have an angular contour applied to either one or two of the channels internal surfaces depending on whether it is the U or double U shaped section. In one embodiment the 0 approximate cross section size of the U shaped extrusion is 32x32mm with the double U section measuring 32x64mm. The channel wall thickness is preferably approximately 3.5mm including the textured internal wall. Various extrusions according to embodiments can be modified to various sizes. The contoured flange, in embodiments, allows the clip-in cladding system to work safely and .5 securely. The system would also be able to be installed using a selection of glazing extrusions or any channel. Preferably a textured surface is present. Preferably a small section of foam is placed at the bottom of the channel. Preferably the foam thickness of about 3-5mm thick to assist with ensuring that it does not impede the clips ability to engage with the channels flange and therefore not lock in place. Whilst the foam 30 could be placed along the full length of the extrusion, in preferred embodiment it could be located only in the area that the clip would be located. In embodiments, the profile and layout of the grooves that are cut into the ACM are chosen for the clip-in cladding system. Square and other shaped panels could be provided. It is envisaged that panels of any possible size (limited by the size of the ACM sheet) will be 35 provided. In an embodiment a square panel is mounted onto the extruded channel. In the embodiment there is preferably a groove with a 1350 V shaped profile, cut into one side of the sheet centred approximately 27.5mm in from the edge of the ACM panel leaving 0.8mm of 5/12 material thickness under the groove allowing a tab to be bent at an angle of over 900, preferably around 100-105' which can then be pushed into the channel. As the edge of the tab passes the contours on the channel flange it is effectively locked in due to the constant forces acting on the tab to try to re-open. If foam has been placed in the 5 bottom of the channel it is considered that there would be more forces trying to push the panel out therefore further engaging the panel with the extrusion. This would remove the chance of the panel becoming lose and also remove any unwanted noise due to the panel vibrating in the wind or a third source of motion e.g. a generator in a maritime application. If the panel is pulled on to attempt to remove it or even due to gravity under its own weight .0 the tab will be again stopped from coming out by the contours on the channel flange. While not required to lock the panel in place but may be necessary depending on the application, a second groove with a profile of 90' may be cut onto the ACM panel at the required distance from the first groove to give the panel the desired depth. Finally the cladding can be finished off with a flexible polyurethane sealant. .5 The mechanical locking system formed by the interaction of the grooved ACM with the contoured extruded channel, forms the basis of several preferred clip-in cladding systems. Embodiments preferably reduce the requirement of a four piece assembly type systems which in addition needs at least three separate fasteners and seven stages of fabrication / installation down to a two piece system requiring only one fastener and 5 stages of fabrication to safely 0 and effectively clad unsightly surfaces in our developing urban and more highly populated areas. It is to be recognised that other aspects, preferred forms and advantages of the present invention will be apparent from the present specification including the detailed description, drawings and claims. '5 BRIEF DESCRIPTION OF DRAWINGS In order to facilitate a better understanding of the present invention, several preferred embodiments will now be described with reference to the accompanying drawings, in which: Figure 1 is a cross-sectional view of an extrusion used in a clip-in cladding system according to a first preferred embodiment of the present invention; 30 Figure 2 is a cross-sectional view of another extrusion used in the clip-in cladding system; Figures 3a to 3e show a number of further extrusions used in the clip-in cladding system; Figures 4 and 5 shows a panel of the clip-in cladding system; Figures 6a and 6b shows a number of items including a V-groove of the panel shown in Figures 4 and 5; 6/12 Figure 7 shows a process of the panel shown in Figures 4 and 5 being pushed into the extrusion shown in Figure 2; Figure 8 shown a typical layout of the clip-in cladding system shown in Figure 1. DETAILED DESCRIPTION OF THE EMBODIMENTS 5 As would be apparent, each of the embodiments is specifically described and that the present invention is not to be construed as being limited to any specific feature or element of any one of the embodiments. Neither is the present invention to be construed as being limited to any feature of a number of the embodiments or variations described in relation to the embodiments. .0 Figures 1 to 8 illustrate a clip-in cladding system 10 according to a first preferred embodiment of the present invention. The Figures are considered to give a greater understanding of the development in hardware and practices for the safe and efficient production and installation of cladding onto built surfaces. The clip-in cladding system 10 is considered to be advantageous for several reasons as would be apparent from the description .5 as a whole. Figures 1 and 2 provides respective cross sectional views of two channels 16, 18 providing standard extrusions used in the clip-in cladding system 10. The first channel 16 comprises a single U channel extrusion _19. The channel 16 provides a primary section of the clip-in cladding system 10 sub frame 20 (See Figure 8). The sub frame 20 is the frame onto which 0 the panels 22 of the clip-in cladding system 10 are fastened. The channel 16 is considered to be sufficient to complete the sub frame for an entire structure requiring cladding. The channel 18 is a secondary section that is considered to increase the efficiency of the installation and the quality of the finish. The channelL8 is provided as a double U extrusion 15 24 as shown in Figure 2. Item A in Figure 1 shows the void in the web of the channel 16 to pass through especially when the channel 16 shown in Figure 1, is mounted in its side. Item B shows the angled contour on the inside face 26 of the extrusion flange 28 where the ACM cladding panels tab 30 will lock in stopping the panel from coming back out. Item Q shows a foam portion 30 placed at the bottom of the channel 16. The foam portion 30 is considered to assist with keeping the tab engaged with the channel 3. Figures 3a to 3e shows five other fasteners which can be used in the assembly of the sub 35 frame 20 for specific variations of the typical installation. Extrusions C, D, F, and G all retain the contoured surface described above. Each recess 36 includes an inwardly facing contoured surface 34. Extrusion E replaces the contoured surface of the other extrusions C, D, F and G with an extruded rubber section 38, this allows the panel to be firmly retained inside the channel with the ability to be removed when needed by compressing the rubber 7/12 section 38 and allowing the tab to pass by. The extruded rubber section 38 provides a contoured surface that retains the tab in position. Figures 4 to 6b show a typical clip-in cladding system panel 40 formed from ACM sheet 41. 5 that can be used with the previously described fasteners 16, 18. Item H shows a 1350 V groove which is in this embodiment, cut 27.5mm (See distance 42 of Figure 6b) away from the panel edge 44 to form the tab M bent to approximately 1050 illustrated by angle 46. A shown in Figure 6b, angle 47 is 90 degrees and angle 48 is 135 degrees. Two grooves are .0 provided on each side of the sheet 41 which provides four tabs 56. Each of the tabs 56 is provided by a first groove H. A second groove K is spaced inwardly of each groove H providing a tab to allow the panel 4-0 to have a desired depth. Figure 7 shows the process of the panel 40 being pushed into the extrusion. N shows the tab .5 still at the approximate angle of 105'. When the panel is pushed into the channel the tension in the fold continuously tries to return the tab to the state it was in previously. This tension is provided by the width of the channel 52 keeping the end of the tab pressed against the contoured surface of the extrusion P, therefore restricting the panel from coming out of the extrusion. 0 When the panel compresses the foam 54 the tab is kept engaged with the contoured channel flange giving further resistance to the dislocation of the panel 40 from the extrusion P. This is considered to be advantageous. The foam provides resilient material that biases the tab of the panel outwardly away from the channel to press against the contoured surface of the contoured flange. This would remove the chance of the panel becoming lose and also remove .5 any unwanted noise due to the panel vibrating in the wind or a third source of motion e.g. a generator in a maritime application. As would be appreciated there is provided a clip-in cladding system comprising sheets fabricated with grooves with a specific layout and profile that allow each sheet to be folded in such a way that tabs are formed in a panel. The tabs can be pushed into channel to lock the 30 panel in position leaving the panel unable to come out due to physical forces applied. Upon pushing into the channel, tension is provided in the tab. Each tab, when pushed into the channel, passes contours of a channel flange of the channel, and due to the contours of the channel flange is effectively locked in, due to the tab trying to re-open. Each tab is provided as a folded tab, the fold of the tab trying to return the tab to the 35 state it was in previously before insertion. The panels are formed by folding the grooves to provided folded tabs. The tabs extend into the panel, upwardly towards the cladding panel body. The tabs are folded in an inward direction into the panel. In the embodiments a V shape is formed between the cladding panel sides and tab. The fold is provided by the lower portion of the V-shape. 40 In embodiments a series of contoured portions provide the contoured surfaces. As shown in a number of Figures the series of contoured portion provides a sawtooth type configuration to 8/12 bear against the tab, and lock the tab in position. The series of contoured portions is considered to be advantageous. The end of the tabs engage with the sawtooth portions facing downwardly into each channel. Other contours, such those described, and undulating contours are of course possible. 5 A cladding channel (fastener) is provided locking the panel into position leaving it unable to come out due to physical forces being applied between the panel and the extrusion, by the panel itself. In one embodiment there is provided a u-shaped channel having a contour applied to a single internal surface of the channel to provide a contoured flange for locking a tab of a panel in position. In another embodiment two u-shaped channels are arranged side .0 by side in a single fastener, each channel of the cladding channel having a contour applied to an internal surface of the channel to provide a contoured flange for locking a tab of a corresponding panel in position. The two u shaped portions have a central portion and two flanges. The contoured surfaces are provided on the inner surface of the two flanges extending from the base of the u-shaped portions to face inwardly. .5 The channel is provided for receiving the panels. As described the channel has contoured surfaces allowing tabs of the panels to be pushed into the channel; the contoured surfaces for preventing the panels from coming out of the channel by the tabs of the panels being pressed against the contoured surfaces. A fold in each the tab continuously tries to return the tab to the state it was in previously to keep the end of the tab pressed against a contoured surface of .0 the extrusion, therefore restricting the panel from coming out of the extrusion. Figure 8 shows a typical layout of the clip-in cladding system and the various types of applications including: external and internal corners, flush end stops, negative details. The variations and panel types and assemblies are not limited to those mentioned in this document. Various alterations and equivalent forms may be provided without departing from 15 the spirit and scope of the present invention. This includes modifications within the scope of the appended claims along with all modifications, alternative constructions and equivalents. The locking effect of the folded tab pressed against the contoured surface of the extrusion, all associated items, processes and practices associated with the clip-in cladding system 10 are considered by the applicant to be developments in decorative cladding. 30 There is no intention to limit the present invention to the specific embodiments shown in the drawings. The present invention is to be construed beneficially to the applicant and the invention given its full scope. In the present specification, the presence of particular features does not preclude the existence of further features. The words 'comprising', 'including' and 'having' are to be construed in an inclusive rather than an exclusive sense. 35 It is to be recognised that any discussion in the present specification is intended to explain the context of the present invention. It is not to be taken as an admission that the material discussed formed part of the prior art base or relevant general knowledge in any particular country or region.

Claims

1. A cladding system comprising: sheets fabricated with grooves with a specific layout and profile that allow each sheet to be folded in such a way that tabs are formed in a panel; where the tabs can be pushed into channel to lock the panel in position leaving 5 the panel unable to come out due to physical forces applied.

2. A cladding system as claimed in claim 1 wherein each tab, when pushed into the channel, passes contours of a channel flange of the channel, and due to the contours of the channel flange is effectively locked in, due to the tab trying to re-open. .0

3. A cladding system as claimed in claim 2 wherein each tab is provided as a folded tab, the fold of the tab trying to return the tab to the state it was in previously before insertion. .5

4. A cladding system as claimed in claim 1, 2 or 3 wherein each tab is bent at an angle of over 90 degrees which can then be pushed into the channel.

5. A cladding system as claimed in any one of claims I to 4 wherein each tab is bent at an angle of around 100 to 105 degrees which can then be pushed into the channel. -O

6. A cladding system as claimed in any one of claims I to 5 wherein each sheet includes a first groove allowing a tab to be bent at an angle; and a second groove a required distance from a first groove to give each panel a desired depth. .5

7. A cladding system as claimed in any one of claims I to 6 wherein each sheet includes a 135 degree V groove allowing a tab to be bent at an angle.

8. A cladding system as claimed in any one of claims I to 7 where the sheets comprise aluminium composite material and the channel comprises aluminium extruded 30 channel.

9. A cladding system comprising: panels; and tabs are formed in each panel; where the tabs can be pushed into channel to lock the panel in position leaving the panel unable to come out due to physical forces applied. 35

10. A cladding system as claimed in claim 9 wherein each tab, when pushed into the channel, passes contours of a channel flange of the channel, and due to the contours of the channel flange is effectively locked in, due to the tab trying to re-open. 40

11. A cladding system as claimed in claim 9 or 10 wherein each tab is provided as a folded tab, the fold of the tab trying to return the tab to the state it was in previously before insertion. 10/12

12. Cladding channel comprising: a u-shaped channel having a contour applied to an internal surface of the channel to provide a contoured flange for locking a tab of a panel in position. 5

13. Cladding channel as claimed in claim 12 wherein the contoured flange provides angular contour as shown in Figure 1.

14. Cladding channel as claimed in claim 13 wherein the angular contour is applied to one channel internal surface. .0

15. Cladding channel as claimed in claim 12 wherein the flange includes a rubber section for locking the panel in position, the rubber section allowing the panel to be firmly retained inside the channel with the ability to be removed when needed by compressing the rubber section allowing the tab to pass by. .5

16. Cladding channel as claimed in any one of claims 12 to 15 including resilient material located in the u-shaped channel to assist with securing the tab of the panel in position.

17. Cladding channel as claimed in claim 16 wherein the resilient material is provided to O0 bias the panel outwardly.

18. Cladding channel as claimed in claim 16 to 17 wherein the resilient material comprises a layer of foam material. .5

19. Cladding channel comprising: two u-shaped channels, each channel having a contour applied to an internal surface of the channel to provide a contoured flange for locking a tab of a panel in position.

20. Cladding channel as claimed in claim 19 wherein the contoured flange provides 30 angular contour as shown in Figure 1.

21. Cladding channel as claimed in claim 19 or 20 wherein an angular contour is applied to two channel internal surfaces. 35

22. A cladding system comprising: channel and panels; the channel for receiving the panels; the panels having tabs; where the channel has contoured surfaces allowing the tabs to be pushed into the channel; the contoured surfaces for preventing the panels from coming out of the channel by the tabs of the panels being pressed against the contoured surfaces. 40

23. A cladding system comprising: a panel having a tab that is able to be pushed into a channel of an extrusion wherein when the panel is pushed into the channel, a fold in the tab continuously tries to return the tab to the state it was in previously to keep the 11/12 end of the tab pressed against a contoured surface of the extrusion, therefore restricting the panel from coming out of the extrusion.

24. A cladding panel having a tab that is able to be pushed into channel having a 5 contoured flange to provide a folded tab pressed against the contoured flange of the channel that locks the panel in position.

25. A cladding system as claimed in claim 24 wherein tension in the fold of the folded tab is provided to continuously try to return the tab to the state it was in previously, .0 keeping the end of the tab pressed against the contoured surface of the channel therefore restricting the panel from coming out of the channel.

26. A cladding system comprising: a mechanical locking system formed by the interaction of a grooved panels with contoured extruded channels. .5

27. A cladding panel having a folded tab for being pressed against the contoured surface of a channel.

28. A cladding panel as claimed in claim 26 wherein the tab is provided as a folded tab, o0 the fold of the tab trying to return the tab to the state it was in previously before insertion.

29. A cladding panel as claimed in claim 27 including a plurality of a folded tabs, each tab for being pressed against the contoured surface of a channel. -5

30. A cladding panel as claimed in claim 29 of rectangular form including four tabs.

31. A cladding system as claimed in any one of claims 26 to 30 wherein each tab is bent at an angle of over 90 degrees which can then be pushed into the channel. 30

32. A cladding system as claimed in any one of claims 26 to 31 wherein each tab is bent at an angle of around 100 to 105 degrees which can then be pushed into the channel.