AU2018219979A1

AU2018219979A1 - A cladding for application to a structure and an assembly of the cladding with the structure

Info

Publication number: AU2018219979A1
Application number: AU2018219979A
Authority: AU
Inventors: Andrew Gillies
Original assignee: Fairview Architectural Pty Ltd
Current assignee: Fairview Architectural Pty Ltd
Priority date: 2018-02-26
Filing date: 2018-08-20
Publication date: 2019-09-12
Also published as: AU2018102156A4; GB2571396A; GB201816592D0

Abstract

A CLADDING FOR APPLICATION TO A STRUCTURE AND AN ASSEMBLY OF THE CLADDING WITH THE STRUCTURE Abstract A cladding for application to a structure, the cladding comprising: a core layer having a first core side and a second core side, the first core side being opposite to the second core side; an outer layer bonded with the core layer on the first core side, through a first adhesive layer; and an inner layer bonded with the core layer on the second core side, through a second adhesive layer. Preferably the outer layer and the inner layer are made up of steel and the respective thicknesses of the outer layer and the inner layer range between 0.2 to 0.5 mm (0.008 - 0.02 inch) and the melting point of the steel varies between 1425 - 1540 °C. FIGURE 3C to accompany the abstract.

Description

Abstract

A cladding for application to a structure, the cladding comprising: a core layer having a first core side and a second core side, the first core side being opposite to the second core side; an outer layer bonded with the core layer on the first core side, through a first adhesive layer; and an inner layer bonded with the core layer on the second core side, through a second adhesive layer. Preferably the outer layer and the inner layer are made up of steel and the respective thicknesses of the outer layer and the inner layer range between 0.2 to 0.5 mm (0.008 - 0.02 inch) and the melting point of the steel varies between 1425 - 1540 °C.

FIGURE 3C to accompany the abstract.

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Fig. 3C

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A CLADDING FOR APPLICATION TO A STRUCTURE AND AN ASSEMBLY OF THE CLADDING WITH THE STRUCTURE

Technical Field [001] The present invention generally relates to claddings used in construction industry and in particular to a cladding for application to a structure and an assembly of the cladding with the structure.

Background [002] Claddings are generally used in construction industry for application on an exterior of a building structure for a variety of reasons. Some of the intended functions of a cladding include thermal insulation, weather resistance, aesthetics and sound proofing. However, in a past decade or two, claddings have attracted a lot of negative attention owing to them being a fire hazard. During installation of the cladding, there is a gap that is maintained between walls of the building structure and the cladding to allow water, that would otherwise be collected, to run down to the ground. However, in the event of fire, those gaps make the cladding act as a chimney by drawing in air, thereby resulting in even larger flames.

[003] It is imperative therefore, that the cladding be made up of fire resistant materials, to ensure that the fire is not initiated in the first place or at least is not spread to the cladding. Even though historically materials such as wood, wheat/rice straw fibres and concrete have been used for claddings, the present day claddings are increasingly being made up of aluminium composites and offer better reliability as compared to wood or straw fibres in the event of fire. However, even aluminium is known for its relatively lower melting point (roughly 660 °C), causing the cladding to disintegrate, when temperatures involved exceed a certain threshold. Unfortunately, even the present day cladding fixing systems include extensive use of aluminium. As a consequence, even though the cladding is able to resist the fire, the fixing system might give in causing severe damage to the building structure.

[004] It is therefore desirable to have a cladding for application to a structure and an assembly of the cladding with the structure that provides a simple and efficient solution to the deficiencies of the prior art or at least provides a useful alternative.

[005] Throughout this specification, unless the context requires otherwise, the words “comprise”, “comprises” and “comprising” will be understood to imply the inclusion of a stated step or element or group of steps or elements but not the exclusion of any other step or element or group of steps or elements.

2018219979 20 Aug 2018 [006] Any one of the terms: “including” or “which includes” or “that includes” as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others.

[007] Any discussion of the background art throughout the specification should in no way be considered as an admission that such background art is prior art nor that such background art is widely known or forms part of the common general knowledge in the field in Australia or worldwide.

Summary [008] There is provided a cladding for application to a structure, the cladding comprising a core layer having a first core side and a second core side, the first core side being opposite to the second core side, an outer layer bonded with the core layer on the first core side, through a first adhesive layer and an inner layer bonded with the core layer on the second core side, through a second adhesive layer.

[009] It is an advantage of the present invention that the use of layered structure in the cladding allows exposed layers to be made up of fire resistant and relatively higher melting point materials such as steel, while internal layers may be made up of fire resistant and relatively lighter materials such as minerals, metal composites and polymers etc. In this manner, the cladding would be able to withstand fires and resulting high temperatures, while not excessively loading fixing systems used to install the cladding to the structure.

[010] The cladding may further comprise an outer coating on an exposed surface of the outer layer.

[Oil] The outer coating may include one or more of Polyethylene (PE), FEVE, Polyvinylidine Fluoride (PVDF) and fluoropolymers.

[012] The cladding may further comprise an inner coating on an exposed surface of the inner layer.

[013] The inner coating may include one or more of Polyethylene (PE), FEVE, Polyvinylidine Fluoride (PVDF) and fluoropolymers.

[014] Material of the core layer may be selected from group comprising minerals, metals, metal alloys, composites, concrete and polymers.

[015] The core layer may be provided with a predetermined profile.

[016] The core layer may be in form of a honeycomb structure.

[017] The honeycomb structure may be normal to the outer layer and/or the inner layer.

[018] The honeycomb structure may be parallel to the outer layer and/or the inner layer.

2018219979 20 Aug 2018 [019] A polygonal cross-section of the honeycomb structure may be parallel to the outer layer and/or the inner layer.

[020] The outer layer and the inner layer may be made up of steel.

[021] Respective thicknesses of the outer layer and the inner layer may range between 0.2 to 0.5 mm (0.008 - 0.02 inch).

[022] Melting point of the steel may vary between 1425 - 1540 °C.

[023] Respective thicknesses of the first adhesive layer and the second adhesive layer may vary up to 1 mm (0.004 inch).

[024] There is provided an assembly of a cladding with a structure, wherein the cladding comprises a core layer having a first core side and a second core side, the first core side being opposite to the second core side, an outer layer bonded with the core layer on the first core side, through a first adhesive layer and an inner layer bonded with the core layer on the second core side, through a second adhesive layer, the assembly comprising an intermediate member having at least a first arm, a second arm and a third arm, such that, the second arm and the third arm are extending in mutually opposite directions from the first arm. Further, the first arm is attached with the cladding through a first attachment means and the second arm is attached with the structure through a second attachment means.

[025] The intermediate member may be made up of steel.

[026] The first attachment means may include rivets.

[027] The second attachment means may include screws.

[028] The assembly may further comprise a backer rod and a sealant provided between the cladding and another cladding and/or between the cladding and the structure.

Brief Description of Drawings [029] At least one example of the invention will be described with reference to the accompanying drawings, in which:

[030] Figure 1 illustrates a sectional view of a cladding for application to a structure, in accordance with an embodiment of the present invention;

[031] Figure 2 illustrates a sectional view of a cladding with a profiled core layer, in accordance with another embodiment of the present invention;

[032] Figure 3A illustrates a sectional view of a cladding with a core layer having a honeycomb structure, in accordance with yet another embodiment of the present invention; [033] Figure 3B illustrates a sectional view of the cladding with the core layer having a honeycomb structure, in accordance with yet another embodiment of the present invention;

2018219979 20 Aug 2018 [034] Figure 3C illustrates a broken-out sectional view of the cladding with the core layer having a honeycomb structure, in accordance with yet another embodiment of the present invention;

[035] Figure 4 illustrates a sectional view of an assembly of a cladding with a structure in accordance with an embodiment of the present invention;

[036] Figure 5 illustrates a sectional view of an assembly of a cladding with a structure in accordance with another embodiment of the present invention; and [037] Figure 6 illustrates a sectional view of an assembly of a cladding with a structure in accordance with yet another embodiment of the present invention.

[038] It should be noted in the accompanying drawings and description below that like or the same reference numerals in different drawings denote the same or similar elements.

Description of Embodiments [039] A cladding for application to a structure, that is fire resistant, is envisaged to be made up of several fire resistant materials and/or their composites. It is further envisaged that sufficient amount of metal, that has a relatively higher melting point, be used in order to ensure that the cladding does not disintegrate in an event of fire. Since extensive use of metal may lead to increase in weight of the cladding causing additional stress on the fixing systems, the cladding may be designed to have multiple layers. In that manner, the layers that are prone to direct exposure to the fire may be made of the metal with the higher melting point, while internal sandwiched layers may be made from lightweight materials. It is further envisaged that even the fixing systems used to assemble the cladding with the structure include use of the metals with relatively higher melting points.

[040] Figure 1 illustrates a sectional view of a cladding 100 for application to a structure, in accordance with an embodiment of the present invention. The cladding 100 is envisaged to include a core layer 108 having a first core side and a second core side, the first core side being opposite to the second core side. In that manner, the first core side in considered to be oriented towards the ambient and the second core side in considered to be oriented towards the ambient. In several embodiments, a material of the core layer 108 is selected from group comprising minerals, metals, metal alloys, composites, concrete and polymers. Typical examples of minerals include limestone, dolomite, sandstone, granite, marble and basalt etc.

[041] Further, an outer layer 104 is bonded with the core layer 108 on the first core side, through a first adhesive layer 106. The outer layer 104 is envisaged to be made up of steel with a typical thickness ranging between 0.2 to 0.5 mm (0.008 - 0.02 inch). In the context of this specification, “steel” is envisaged to be an alloy of carbon and iron having up to 2.5% of carbon

2018219979 20 Aug 2018 by weight, and is envisaged to encapsulate carbon steels, alloy steels, stainless steels, tool steels and other known types in the art.

[042] Steels offer advantage of relatively higher melting points (roughly 1425 - 1540 °C). The first adhesive layer 106 may use any known adhesive in the art having a typical thickness of up to 1 mm (0.004 inch). Additionally, an inner layer 112 bonded with the core layer 108 on the second core side, through a second adhesive layer 110. The inner layer 112 too is envisaged to be made up of steel with a typical thickness ranging between 0.2 to 0.5 mm (0.008 - 0.02 inch). Moreover, the second adhesive layer 110 too may use any known adhesive in the art having a typical thickness of up to 1 mm (0.004 inch). It is further envisaged that all exposed surfaces of the outer layer 104 and the inner layer 112 may be provided with outer coating 102 and inner coating 114, respectively. The outer coating 102 and the inner coating 114 maybe made from Polyethylene (PE), FEVE, Polyvinylidine Fluoride (PVDF) or other fluoropolymers. Further, the outer coating 102 and the inner coating 114 may be sprayed, baked, or roller-coated on to the outer layer 104 and the inner layer 112, respectively.

[043] The core layer 108 need not always be a solid layer, there may be other alternatives to structure of the core layer 108 for achieving different objectives, such as greater rigidity, better thermal insulation, weather resistance and the like.

[044] Figure 2 illustrates a sectional view of the cladding 100 with a profiled core layer 108, in accordance with another embodiment of the present invention. The core layer 108 has been provided with a predetermined profile for greater rigidity.

[045] Figure 3A illustrates a sectional view of the cladding 100 with the core layer 108 having a honeycomb structure, in accordance with yet another embodiment of the present invention. The honeycomb structure as illustrated in Figure 3A runs normal to the outer layer 104 and/or the inner layer 112. Figure 3B illustrates a sectional view of the cladding 100 with the core layer 108 having the honeycomb structure, in accordance with yet another embodiment of the present invention. The honeycomb structure as illustrated in Figure 3B runs parallel to the outer layer 104 and/or inner layer 112. The honeycomb structure allows for relatively greater strength for the same weight of the core layer 108. Figure 3C illustrates a broken-out sectional view of the cladding 100 with the core layer 108 having a honeycomb structure, in accordance with yet another embodiment of the present invention. As illustrated in Figure 3C, polygonal crosssections of the honeycomb structure, at any depth, run parallel to the outer layer 104 and/or the inner layer 102. In that manner, orientations of the honeycomb structure may vary as per anisotropic strength requirements specific to different applications.

2018219979 20 Aug 2018 [046] When it comes to assembling the cladding 100 with a structure, such as a portion of a building, there may be various arrangements of a fixing system that may be possible. The cladding 100 in itself may be available in a number of shapes (such as rectangular/triangular panels and open box type) and sizes. The fixing systems may be designed to suit the shapes and sizes of the cladding 100 and other considerations such as location of the cladding 100, types of load (wind, rain and snow etc.) and strength of each load etc. The fixing systems in that manner will include steel support structures, brackets and top-hats etc. Typical locations for installing the cladding 100 include, but are not limited to, attachments to masonry walls, concrete slab junctions, soffit junctions, external comers, internal comers and window sills etc. [047] Figure 4 illustrates a sectional view of an assembly 400 of the cladding 100 with a stmcture 410 in accordance with an embodiment of the present invention. An external surface of the stmcture 410 has been provided with a vapour barrier 414 designed to prevent, or at least impede diffusion of moisture into the building stmcture. Further, connected at the stmcture 410 is a top-hat 412 for aiding assembly of the cladding 100 with the stmcture 410. The vapour barrier 414 and the top-hat 412 are envisaged to be a part of the stmcture 410. Additionally, one or more intermediate members 420 have been provided for assembly of the cladding 100 with the stmcture 410. The intermediate member 420 is envisaged to include a first arm 422, a second arm 424 and a third arm 426. The second arm 424 and the third arm 426 are extending in mutually opposite directions from the first arm 422. This gives the intermediate member 420 a “Z” like stmcture. In several embodiments, the first arm 422 is normal to both the second arm 424 and the third arm 426. Additionally, in several embodiments, the intermediate member 420 is envisaged to be made up of steel owing to relatively higher melting point of steel.

[048] Further can be seen from Figure 4 that the first arm 422 is attached with the cladding 100 through a first attachment means 432 and the second arm 424 is attached with the stmcture 410 (or the top-hat 412) through a second attachment means 434. The first attachment means 432 may include rivets. The second attachment means 434 may include screws. Additionally, a backer rod 442 and a sealant 444 have provided between the cladding 100 and another cladding 100. The arrangement of the assembly 400 shown in Figure 4 is one of many alternate arrangements possible while assembling the cladding 100 with the stmcture 410, without departing from the scope of the invention.

[049] Figure 5 illustrates a sectional view of an assembly of the cladding 100 with the stmcture 410 in accordance with another embodiment 500 of the present invention. Here, the backer rod 442 and the sealant 444 have been provided between the cladding 100 and a masonry wall 510 of the stmcture 410.

2018219979 20 Aug 2018 [050] Figure 6 illustrates a sectional view of an assembly of the cladding 100 with the structure 410 in accordance with yet another embodiment 600 of the present invention. Here, the backer rod 442 and the sealant 444 have been provided between the cladding 100 and a slab junction 610 of the structure 410.

[051] The present invention elucidated through various embodiments, offers a number of advantages. First the use of metals, minerals and composites makes the cladding fire resistant, while layered structure keeps weight of the cladding to relatively minimal. Additionally, use of steel in the cladding and the assembly of the cladding with the structure prevents the cladding and the fixing systems from failing prematurely during event of fire.

[052] The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. Examples and limitations disclosed herein are intended to be not limiting in any manner, and modifications may be made without departing from the spirit of the present disclosure. Those skilled in the art will recognize that many variations are possible within the spirit and scope of the disclosure, and their equivalents, in which all terms are to be understood in their broadest possible sense unless otherwise indicated.

Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the disclosure is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present disclosure and appended claims.

Claims

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CLAIMS:

1. A cladding for application to a structure, the cladding comprising:

a core layer having a first core side and a second core side, the first core side being opposite to the second core side;

an outer layer bonded with the core layer on the first core side, through a first adhesive layer; and an inner layer bonded with the core layer on the second core side, through a second adhesive layer.
2. The cladding as claimed in claim 1, further comprising an outer coating on an exposed surface of the outer layer.
3. The cladding as claimed in claim 2, wherein the outer coating includes one or more of Polyethylene (PE), FEVE, Polyvinylidine Fluoride (PVDF) and fluoropolymers.
4. The cladding as claimed in claim 1, further comprising an inner coating on an exposed surface of the inner layer.
5. The cladding as claimed in claim 4, wherein the inner coating includes one or more of Polyethylene (PE), FEVE, Polyvinylidine Fluoride (PVDF) and fluoropolymers.
6. The cladding as claimed in claim 1, wherein material of the core layer is selected from group comprising minerals, metals, metal alloys, composites, concrete and polymers.
7. The cladding as claimed in claim 1, wherein the core layer has been provided with a predetermined profile.
8. The cladding as claimed in claim 1, wherein the core layer is in form of a honeycomb structure.
9. The cladding as claimed in claim 8, wherein the honeycomb structure is normal to the outer layer and/or the inner layer.
10. The cladding as claimed in claim 8, wherein the honeycomb structure is parallel to the outer layer and/or the inner layer.
11. The cladding as claimed in claim 8, wherein a polygonal cross-section of the honeycomb structure is parallel to the outer layer and/or the inner layer.
12. The cladding as claimed in claim 1, wherein the outer layer and the inner layer are made up of steel.
13. The cladding as claimed in claim 12, wherein respective thicknesses of the outer layer and the inner layer range between 0.2 to 0.5 mm (0.008 - 0.02 inch).

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14. The cladding as claimed in claim 12, wherein melting point of the steel varies between 1425 - 1540 °C.
15. The cladding as claimed in claim 1, wherein respective thicknesses of the first adhesive layer and the second adhesive layer vary up to 1 mm (0.004 inch).
16. An assembly of a cladding with a structure, wherein the cladding comprises a core layer having a first core side and a second core side, the first core side being opposite to the second core side, an outer layer bonded with the core layer on the first core side, through a first adhesive layer and an inner layer bonded with the core layer on the second core side, through a second adhesive layer, the assembly comprising:

an intermediate member having at least a first arm, a second arm and a third arm, such that, the second arm and the third arm are extending in mutually opposite directions from the first arm; wherein the first arm is attached with the cladding through a first attachment means and the second arm is attached with the structure through a second attachment means.
17. The assembly as claimed in claim 16, wherein the intermediate member is made up of steel.
18. The assembly as claimed in claim 16, wherein the first attachment means includes rivets.
19. The assembly as claimed in claim 16, wherein the second attachment means includes screws.
20. The assembly as claimed in claim 16, further comprising a backer rod and a sealant provided between the cladding and another cladding and/or between the cladding and the structure.
21. A cladding for application to a structure, the cladding comprising:

a core layer having a first core side and a second core side, the first core side being opposite to the second core side;

an outer layer bonded with the core layer on the first core side, through a first adhesive layer; and an inner layer bonded with the core layer on the second core side, through a second adhesive layer, wherein the outer layer and the inner layer are made up of steel and wherein the respective thicknesses of the outer layer and the inner layer range between 0.2 to 0.5 mm (0.008 - 0.02 inch) and wherein melting point of the steel varies between 1425 - 1540 °C.