AU2020203997A1

AU2020203997A1 - Panel mounting

Info

Publication number: AU2020203997A1
Application number: AU2020203997A
Authority: AU
Inventors: Giuseppe Boscaino
Original assignee: CSR Building Products Ltd
Current assignee: CSR Building Products Ltd
Priority date: 2019-06-13
Filing date: 2020-06-15
Publication date: 2021-01-07

Abstract

A system and method for mounting an elongate profile to an underlying substrate is disclosed. The system comprises a mounting strip having a base configured for location with respect to the underlying substrate. The base is 5 further configured to be secured with respect to the underlying substrate. The mounting strip further comprises opposing walls, each wall projecting out from and along the base. Each wall comprises a laterally outwards projection for interacting with the profile in a manner such that the profile is retained at the mounting strip. The system also comprises an elongate profile. The profile 10 comprises an opening at its underside to receive therein the projecting walls of the mounting strip. The profile comprises at least one external wall and at least one internal wall. The at least one internal wall comprises flanges that extend along and inwardly of the profile. Each internal flange is located at an intermediate location along the at least one internal wall. Each internal flange 15 engages a respective lateral projection of the mounting strip. When the elongate profile is mounted to the mounting strip, each internal flange is located to be retained under its respective lateral projection, and the at least one external wall of the elongate profile is able to extend down to the underlying substrate in use. 11616811_1 (GHMatters) P111105.AU *-l LL) C5 0'I

Description

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PANEL MOUNTING TECHNICAL FIELD

This disclosure relates to a system and an associated profile which can be mounted to one or more underlying substrates (e.g. at a joint between adjacent substrates). The system and profile can be used with AAC substrates (e.g. panels) as well as other wall substrates, panels and cladding types including rendered brick walls, fibre cement sheeted walls, concrete panels and walls, etc.). A range of different profiles can be employed with the system to provide a range of different aesthetic effects.

BACKGROUND ART

Cladding for structures such as buildings can be profiled. In this regard, the profiling of the cladding can visually and aesthetically break up what may otherwise be a generally flat and/or planar surface.

It is relatively straight-forward to impart a profile to metal cladding. In this regard, a continuous strip of coated metal (e.g. steel, aluminium, etc.) cladding can be roll-formed or extruded to impart a desired profile to the metal strip. The profiling can also be such that, when affixing the cladding to a facade of a building, adjacent profiled strips can be overlapped to give the appearance of a generally continuous surface.

It is less straight-forward to impart a profile to non-metal cladding, such as AAC (autoclaved aerated concrete) substrates, rendered brick walls, fibre cement sheets, concrete panels, etc. Whilst a profile can be moulded or machined into such non-metal substrates, adjacent panels/sheets still have a joint therebetween, which must be covered in some way (typically be some type or filling or rendering step on site).

Arrangements are known for covering a joint between wall and ceiling panels. For example, GB 2075079 discloses a capping strip used for covering joints between adjacent edges of panels in the walls and ceilings of caravans and similar. The capping strip comprises an elongate base strip and an elongate cover strip, each having co-operating longitudinal projection formations for snap engagement of the strips together. The base strip and cover strip are each made of a plastic material, and each strip deliberately has a low profile (i.e. so as not to highlight the joint). The base strip is secured to adjacent hardboard wall or ceiling panels by nailing, stapling or screwing the base strip over a joint between the panels.

WO 2017/113007 discloses a cleanroom panel system in which adjacent plastic panels are thermo-plastically welded together at a joint. WO 2017/113007 also discloses elongated snap-in panel anchoring units to be attached to the outboard major surface of the plastic panels using thermoplastic welded junctions, although not to the joint. Each unit includes complementary first and second elongate members arranged to be latched together through an interfering engagement. The anchoring units are for anchoring an external supporting structure (e.g. structural element, framework, armature, etc.) to the panels. The anchoring units are not designed for providing a profile to the panels.

US 2018/0038096 discloses a vertical batten that forms part of a water management system for an outer surface of exterior siding panels. The vertical batten comprises a bracket for mounting to the exterior siding panels and an outer cover for securing to the bracket. The outer cover of the vertical batten has a complex profile on its underside, requiring it to be slid into position on the underlying bracket. Again, each of the bracket and outer cover deliberately have a low profile (i.e. so as not to highlight the joint).

It is to be understood that the reference herein to prior art does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country.

SUMMARY

Disclosed herein is a system for mounting an elongate profile to an underlying substrate. For example, the system can enable a profile to be mounted at a single substrate, or at and along a joint between adjacent substrates (in which latter case the system can mount the profile with respect to two or more substrates). As set forth above, the system may be deployed with AAC substrates (e.g. AAC panels), as well as other: substrates, panels and cladding types, including rendered brick walls, fibre cement sheeted walls, concrete panels and walls, metal sheeted walls, timber sheeted and panel walls, etc. In addition, the system can be deployed with a range of different profiles to thereby provide a range of different aesthetic (i.e. profiled) effects to the underlying substrate(s).

The system as disclosed herein comprises a mounting strip for securing with respect to the underlying substrate (e.g. to be secured to adjacent substrates at a joint). The system also discloses an elongate profile for mounting to the mounting strip. The mounting strip can first be secured to the substrate(s). When mounting along a joint, the mounting strip can be aligned with respect to the joint. Once the mounting strip is mounted to/aligned with the underlying substrate(s), the elongate profile can be mounted thereto. When the profile is mounted, the mounting strip may be concealed (e.g. hidden), and the profile may appear to be contiguous with (i.e. a part of) the underlying substrate(s). Thus, the system can be employed to give the appearance of a continuous profiled wall at a structure (e.g. building).

The mounting strip as disclosed herein can comprise a base. The base can be configured for location with respect to the underlying substrate. The base can be configured to be secured with respect to the underlying substrate. For example, an underside of the mounting strip base may be configured for location at the underlying substrate in a flat- or flush-mounted manner. Further, the mounting strip base may be located on an outer face of an underlying substrate, or along and over a joint, or adjacent to a joint, or across a joint, etc. Typically, the base can have a sufficient width such that it is able to span the joint (i.e. respective sides of the base can lap over respective underlying substrates).

The mounting strip can further comprise opposing walls. Each wall can project out from and along the base. Each wall may be integrally formed with (e.g. machined out of or integrally moulded/extruded with) the base. Each wall can comprise a laterally outwards projection for interacting with the profile in a manner such that the profile is able to be retained at the mounting strip. In some embodiments of the mounting strip, each lateral projection may be provided along a distal edge of its respective projecting wall.

The elongate profile as disclosed herein can comprise an opening at its underside. The opening can receive therein the projecting walls of the mounting strip. The profile can further comprise at least one external wall and at least one internal wall. The at least one internal wall can comprise flanges that extend along and inwardly of the profile. Each internal flange can be located at an intermediate location along the at least one internal wall. In use, each internal flange can engage a respective lateral projection of the mounting strip.

The system is further configured such that, when the elongate profile is mounted to the mounting strip, each internal flange is located to be retained under its respective lateral projection. This mounts the profile to the mounting strip. Further, the system is configured such that the at least one external wall of the elongate profile is able to extend down to the underlying substrate(s) in use. This can both conceal the mounting strip and give the appearance that the profile is contiguous with (i.e. a part of) the underlying substrate(s) - e.g. to give the appearance of a continuous profiled wall at a building. This appearance of contiguity and continuity can be further enhanced when the profile has the same colour as the underlying substrates.

The present system contrasts with each of the prior art systems as set forth in the Background herein. For example, in GB 2075079 the plastic capping strip is used to cover (i.e. conceal) joints between adjacent panels in the walls and ceilings of caravans, and thus it is undesirable for it to have a prominent profile (i.e. otherwise the capping strip protrudes into the caravan room). For this reason, the base and cover strips and the resulting capping strip each deliberately have a low profile. Due to this low profile, each of the strips must be made of a plastic material to provide enough material flexibility for the snap-engagement to occur. Further, in GB 2075079, the co-operating lips that snap engage the strips together must all be disposed at the distal ends of the inter-engaging limbs, otherwise a capping strip with such a low profile could not be achieved. Conversely, in the elongate profile as disclosed herein, each internal flange is to be located at an intermediate location along the internal wall(s). This is because the present system teaches the converse to GB 2075079, namely, a system in which an elongate profile is selected to impart a prominent (i.e. noticeable) profile to the exterior of a structure (e.g. building).

Again, in WO 2017/113007, the snap-in panel anchoring units are attached to the outboard major surface of the plastic panels and not to a joint. Each anchoring unit comprises first and second elongate members. Unlike the elongate profile as disclosed herein, the second member of the unit has spaced walls, with inward projections arranged at a distal end of the walls to latch to intermediate outward projections of the first member. Further, because the anchoring units are for anchoring an external supporting structure to the panels, the spaced walls of the second member locate adjacent to and do not conceal a base of thefirst member (i.e. unlike the elongate profile as disclosed herein, the spaced walls do not extend to the panels in use and thus do not seek to conceal or hide the first unit).

Likewise, in a similar manner to each of GB 2075079 and WO 2017/113007, US 2018/0038096 discloses that the inward projections of the receivers of the outer cover are each located along a distal end of a respective receiver. This enables opposing receivers to receive therein the latches, with the inward projections of the receivers then latching with the latches. Conversely, in the elongate profile as disclosed herein, each internal flange is located at an intermediate location along the internal wall(s), because the elongate profile as disclosed herein is intended to have a prominent profile and to impart a profiled appearance to the exterior of a structure (e.g. building).

The system as disclosed herein can find particular application in covering (e.g. hiding) a joint between adjacent substrates (e.g. the retained profile can overlay and thus mask or obscure a joint that is defined between adjacent panels, sheets or cladding). The system can thus eliminate a rendering or filling step at the joint. The system can improve the aesthetics at such a joint (e.g. an aesthetically designed profile can be retained at the joint) to give a profiled effect to the resultant surface (e.g. to a clad surface).

When retained at the mounting strip, the profile may give an appearance to the underlying substrate(s) (e.g. panels, sheets) that suggests that they are formed from a different type of (e.g. a metal cladding-type) material. For example, when the profile overlies a joint so that it cannot be seen, the profile may appear to be contiguous with and to form a part of and/or be integrated with the adjacent underlying substrate(s).

In some embodiments, the base of the mounting strip may be elongate. For example, the base may have a length such that it can be located over and along a panel or along a joint (e.g. for a part or full length of the panel or the joint). When the mounting strip extends along the panel joint only for a part length thereof, a number of mounting strips can be secured along and over the panel or joint, end to-end, the strips optionally abutting at their adjacent ends. The mounting strip(s) may also be cut to length to suit a given panel or joint length.

In some embodiments, a flexible jointing material may be arranged between adjacent underlying substrates (e.g. prior to securing the mounting strip, a bead of a sealant material may be arranged between adjacent panels). The flexible jointing material can allow for movement at the joint (e.g. due to thermal expansion, settling of a construction, etc.). Thus, after applying the bead of a sealant and after securing the mounting strip over the joint, the flexible jointing material can continue to flex and accommodate movement at the joint, without this being visually detectable or discernible. Further, even if there is minor movement in the jointing material (e.g. over time), such movement can be accommodated by the present system. Also, the system can act as additional weather-proofing.

Further, because the system may be employed to cover a joint between adjacent underlying substrates, the system can hide a control joint when the latter is employed between the adjacent substrates.

As set forth above, because the system may be employed to cover a joint between adjacent underlying substrates, the system can eliminate the need for rendering or other types of surface-finishing at the joint, such surface-finishes typically being employed to hide or mask the joint. Further, because the system can eliminate render or other surface-finish at a joint, the system can in turn eliminate the need to render the entire wall. Additionally, instead of render, a textured paint may be employed for the substrates. This can save considerable cost and time.

In some embodiments, the at least one external wall of the elongate profile may be defined by opposing external sidewalls. Each external sidewall may extend down to the underlying substrate (e.g. each sidewall may extend to a respective one of the adjacent underlying substrates at a joint). In other embodiments, the at least one external wall of the elongate profile may be defined by a single curved external sidewall (i.e. the exterior of the profile can have a curved, semi cylindrical appearance). In this case, the single curved external wall can comprise flanges that extend along and inwardly from opposite internal sides of the profile.

In some embodiments, the at least one internal wall of the elongate profile may be defined by:

(i) an inwardly facing surface of each of the opposing external sidewalls in this case, each internal flange may project laterally inwards of a respective inwardly facing surface; or

(ii) opposing inner walls that are each inwardly spaced from the opposing external sidewalls - in this case, each internal flange may project laterally inwards of a respective inner wall.

The elongate profile (i) can be used for example on the outer surface of an underlying substrate (e.g. panel), along joints between adjacent substrates, etc. Further, the inwardly facing surfaces of profile (i) may converge - moving from the opening at the underside of the elongate profile towards a top side of the elongate profile.

Typically, the elongate profile (ii) is used at a perimeter of a structure (e.g. building) that comprises a number of underlying panels. Further, the inner walls of profile (ii) - i.e. that are inwardly spaced from the external sidewalls - may converge - moving from the opening at the underside of the elongate profile towards a top side of the elongate profile.

This convergence of the inwardly facing surfaces/inner walls of the profile can allow the mounting strip base to locate in the opening (as set forth below) whilst enabling the profile internal flanges to still engage with the lateral projections of the mounting strip.

In some embodiments of the mounting strip, each projecting wall may extend along the base adjacent to but spaced inwardly from a respective side edge of the base. Thus, the mounting strip base can be wider than the projecting walls and can locate in the opening (e.g. in a snug or flush-mounted manner), and yet each lateral projection of the mounting strip can still engage with and retain thereunder its respective internal flange.

In some embodiments, a hollow may be defined in the underside of the elongate profile. The entrance to the hollow can be via the opening. The hollow may be configured to receive (e.g. fully) therein the projecting walls of the mounting strip.

In the case of the elongate profile (i), the hollow may be at least in part defined by the inwardly facing surfaces of the external sidewalls.

In the case of the elongate profile (ii), the hollow may be at least in part defined by the inner walls that are inwardly spaced from the external sidewalls. In the case of the elongate profile (ii), the hollow may form a smaller hollow within a larger hollow of the profile.

In some embodiments, the hollow may be further configured to receive therein the base of the mounting strip. Thus, when the elongate profile is mounted to the mounting strip, the base can locate in the opening and the mounting strip can be thereby concealed (e.g. hidden) by the elongate profile. As above, the location of the mounting strip base in the opening may be a snug fit or a flush-mount.

In the case of the elongate profile (i), a web may extend between and join the external sidewalls at a location above the internal flanges. The web can serve to stiffen the profile. The web may define a side of the hollow.

In the case of the elongate profile (ii), a web may extend between and join the inner walls at a location above the internal flanges. Again, the web can serve to stiffen the profile and may define a side of the hollow.

In some embodiments of the mounting strip, each projecting wall may project sufficiently out from the base such that, when the elongate profile is mounted to the mounting strip, each projecting wall is able to deflect inwardly. This configuration of the projecting walls can enable the profile to be snap-, press-, push- or interference-fit onto, to thereby be retained in use at, the mounting strip.

In some embodiments of the mounting strip, each lateral projection may comprise a bevelled outer surface. The bevelled outer surface may be configured such that, when the elongate profile is mounted to the mounting strip, the internal flanges of the at least one internal wall are able to travel across respective bevelled outer surfaces to thereby cause the projecting walls to be deflected inwardly. Such inward deflection can continue until each internal flange moves past its respective lateral projection, whereupon each projecting wall can deflect back outwardly. The internal flanges can thereby move relatively inwards to locate under and behind their respective lateral projections, thereby retaining the elongate profile to the mounting strip. As above, this may be a type of snap-fit mounting.

In some embodiments, each of the mounting strip and elongate profile may be of metal, such as an extrusion of aluminium. By employing a metal or metallic material for the profile, the 'illusion' of the entire facade of a structure (e.g. building) being of a metal or metallic material can be enhanced. In other embodiments, the mounting strip may be of plastic.

In some embodiments of a metal or metallic mounting strip, when each lateral projection is provided along a distal edge of its respective projecting wall, the projecting wall may be provided with a width and a length that is sufficient to enable the metal or metallic material of the wall to deflect when the elongate profile is secured thereto. In other words, whilst metals and metallic materials generally have limited flex, an appropriate configuration of the mounting strip can ensure that sufficient flex is provided to enable the profile to be snap-, press-, push- or interference-fit onto the mounting strip.

In some embodiments, the mounting strip may further comprise an elongate strip of two-sided adhesive backing tape arranged at an in-use underside of the base thereof. The backing tape may have a removable cover strip applied thereto which in use is removed when securing the mounting strip to the underlying substrate (e.g. to adjacent substrates at a joint). For example, the mounting strip may be supplied with the adhesive backing tape already secured to the underside of the base, and also with the removable cover strip secured thereto. In use, a user may then remove the cover strip to enable the mounting strip to be secured to the underlying substrate.

In some embodiments, the system may further comprise at least one end cap. Each end cap may be configured for fitting into and closing in use a respective open end of a given elongate profile (e.g. where such an open end remains exposed after having attached one or more profiles to a structure). Depending on the shape of the elongate profile, the end cap can be reconfigured accordingly. Further, the end cap may be configured to be snap-, press-, push- or interference-fit into the open end of the profile.

In some embodiments, the system may further comprise at least one joiner. Each joiner may be configured forjoining adjacent elongate profiles. For example, the joiner may be configured to enable it to join:

- two adjacent profiles that are arranged end-to-end in a line;

- two profiles that are arranged so as to meet at a corner on a planar face of a single substrate or a planar face defined by multiple such substrates;

- two profiles that are arranged so as to meet around a corner of a structure (e.g. one profile is located on a front wall, and one profile is located on a sidewall of the structure).

In practice, the system may take the form of a kit of components. For example, for each joint between adjacent underlying substrates, a sufficiently long profile may be supplied along with one or more of the mounting strips. In the kit, a suitable tool or tools may be supplied for mounting each profile to respective mounting strip(s).

Also disclosed herein is an elongate profile for use with the system as set forth above. The profile can be configured in the various ways as outlined above. The profile may be of metal or a metallic material (e.g. a metal alloy or composite). The profile may be an extrusion (e.g. of aluminium). Alternatively, the profile may be cast or 3D printed (e.g. from metal or a metallic material). The profile may be fabricated to have a length that corresponds to the length of a panel or a joint between the adjacent substrates.

Also disclosed herein is a method for mounting an elongate profile to an underlying substrate. The method can enable the profile to be mounted at a single substrate, or at and along a joint between adjacent substrates (in which latter case the method can mount the profile with respect to two or more substrates).

The method can comprise securing a base of a mounting strip with respect to the underlying substrate. The mounting strip can be as defined in the system set forth above.

The method can also comprise mounting an elongate profile at the mounting strip. The profile can be as defined in the system set forth above.

In the method as disclosed herein, the base of the mounting strip may be located over and along ajoint between adjacent substrates. As set forth above, the mounting strip may extend for a part or full length of the joint. The mounting strip may contribute to weatherproofing at the joint.

In the method as disclosed herein, the mounting strip may comprise adhesive backing tape secured to the underside of the base, along with a removable cover strip secured thereto. The method may then comprise:

- peeling off a short length of the removable cover strip from each end of the backing tape,

- adhering one end of the backing tape to the underlying substrate;

- aligning the mounting strip on the underlying substrate, such as by using a suitable levelling tool (e.g. a spirit level, laser level, measuring tape, ruler, etc.);

- adhering the other end of the backing tape to the underlying substrate, and removing a remainder of the cover strip from the backing tape;

- pressuring the mounting strip to adhere to the underlying substrate (a suitable pressuring tool, such as that described below) may be used.

In the method as disclosed herein, once the mounting strip has been secured to the underlying substrate, the elongate profile may be mounted thereto by force, such as by using a tool such as a mallet (e.g. a rubber mallet), force spreader bar, etc.

In the method as disclosed herein, once the mounting strip has been secured to the underlying substrate, and once each elongate profile has been mounted to a mounting strip:

-exposed profile open ends can be closed with a suitable end cap as set forth above;

adjacent elongate profiles can be joined with a suitable joiner as set forth above.

BRIEF DESCRIPTION OF THE DRAWINGS

A number of embodiments of the system will now be described, by way of example only, with reference to the accompanying drawings in which:

Figs. 1A & 1B are end and perspective views of an embodiment of a mounting strip that forms part of the system as disclosed herein.

Figs. 2A & 2B are end and perspective views of an embodiment of a bullnose profile that forms part of the system as disclosed herein.

Figs. 3A & 3B schematically illustrate the bullnose profile of Fig. 2 when mounted to the mounting strip of Fig. 1.

Figs. 4A & 4B are end and perspective views of an embodiment of a trapezoidal profile that forms part of the system as disclosed herein.

Fig. 5 is an end view that schematically illustrates the mounting strip of Fig. 1 and the trapezoidal profile of Fig. 4 when assembled.

Fig. 6 shows perspective views to schematically illustrate the bullnose profile of Fig. 2 being mounted to the mounting strip of Fig. 1.

Fig. 7 shows perspective views to schematically illustrate the trapezoidal profile of Fig. 4 being mounted to the mounting strip of Fig. 1.

Fig. 8A is an end view of another embodiment of a trapezoidal profile that comprises an internal stiffening web and that forms part of the system as disclosed herein, and Fig. 8B schematically illustrates the trapezoidal profile of Fig. 8A when mounted to the mounting strip of Fig. 1.

Figs. 9A & 9B are end and perspective views of an embodiment of a square (perimeter) profile that form part of the system as disclosed herein, and Fig. 9C schematically illustrates the square profile of Figs. 9A & 9B when mounted to the mounting strip of Fig. 1.

Figs. 10A to 10E respectively show perspective, side, rear, assembled/disassembled and end-mounted views of an embodiment of an end cap for the bullnose profile of Fig. 2, forming a part of the system as disclosed herein.

Figs. 11A to 11E respectively show perspective, side, rear, assembled/disassembled and end-mounted views of an embodiment of an end cap for the trapezoidal profile of Fig. 4, forming a part of the system as disclosed herein.

Figs. 12A to 12D & 12F respectively show perspective, side, rear, disassembled and end-mounted views of an embodiment of an end cap for the square (perimeter) profile of Fig. 9, forming a part of the system as disclosed herein.

Figs. 12E & 12G respectively show perspective disassembled and end-mounted views of the square profile end cap when mounted to a parapet profile (see Fig. 20), forming a part of the system as disclosed herein.

Figs. 13A to 13C respectively show, rear, end-mounted and disassembled views of an embodiment of an end cap for the web-stiffened trapezoidal profile of Fig. 8, forming a part of the system as disclosed herein.

Figs. 14A & 14B respectively show top perspective, bottom perspective, and assembled views of a cornerjoiner forjoining two square (perimeter) profiles of Fig. 9 at a comer on a face of a structure (see Fig. 28), forming a part of the system as disclosed herein.

Figs. 15A & 15B respectively show top perspective, bottom perspective, and assembled views of another cornerjoiner forjoining two square (perimeter) profiles of Fig. 9 at (i.e. around) a corner on adjacent faces of a structure (see Fig. 27), forming a part of the system as disclosed herein.

Figs. 16A to 16C respectively show top perspective, bottom perspective, assembled, and exploded views of a straight (end-to-end) joiner for joining two square (perimeter) profiles of Fig. 9 in a straight line on a face of a structure (i.e. see Figs. 16C and 27), forming a part of the system as disclosed herein.

Figs. 17A to 17C respectively show rear perspective, front assembled perspective, and exploded schematic views of an external comer joiner for joining two parapet profiles of Fig. 20 at a structure, forming a part of the system as disclosed herein.

Fig. 18 shows a front perspective view of an internal corner joiner for joining two parapet profiles of Fig. 20 at a structure, forming a part of the system as disclosed herein.

Figs. 19A to 19C respectively show front perspective, rear perspective, side schematic, and exploded schematic views of a straight (end-to-end) joiner for joining two parapet profiles of Fig. 20 at a structure, forming a part of the system as disclosed herein.

Figs. 20A to 20D respectively show top perspective, side, and structure assembled views, and assembled detail views of a parapet profile, forming a part of the system as disclosed herein.

Figs. 21A to 21C respectively show side, top perspective, and structure assembled views of a cantilevered (panel base) angle, forming a part of the system as disclosed herein.

Fig. 22 schematically depicts the steps for readying and then mounting a profile at a structure, forming a part of the system and method as disclosed herein.

Fig. 23 is a perspective view of adjacent panels that define a joint therebetween, the joint ready to receive thereat a mounting strip according to Fig. 1, with Fig. 23A showing a detail of the joint.

Figs. 24A to 24D respectively show: a mounting strip being prepared for mounting to the joint; the strip being levelled/aligned; the strip being adhesively affixed to the adjacent panels using a pressure-tool; the pressure tool used to press-adhere the strip to the joint.

Fig. 25 is a perspective view of the adjacent panels of Figs. 23 & 24, with a trapezoidal profile according to Fig. 4 having been snap-fitted and retained to the joint and mounting strip at the two panels.

Fig. 26 is a schematic sectional view of a framework at a facade of a building, with two panels shown mounted to the framework.

Fig. 27 is a schematic perspective view of a near-complete facade of a building, the perimeter profile of the window being shown part-complete, the building being clad with the system as disclosed herein.

Figs. 28A to 28F respectively show: a window detail at facade of a building; the mounting strips being arranged around the window opening; a square (perimeter) profile being mounted to the mounting strip using a rubber mallet and spreader member; the resultant square profiles having been secured around the window opening; a detail of one such corner; corner joiners secured to the perimeter profiles to complete the window opening.

Fig. 29 is a schematic perspective view of a completed facade of a building, the building being clad with the system as disclosed herein.

DETAILED DESCRIPTION

In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. The illustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised and other changes may be made without departing from the spirit or scope of the subject matter presented. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

A number of embodiments of a system for mounting an elongate profile (e.g. 40, 50, 60 or 70) to an underlying substrate (e.g. panel P) will now be described with reference to the accompanying drawings. The system can enable the profile to be mounted at a single substrate or to multiple substrates. The system can enable the profile to be mounted at and along a joint between adjacent substrates. Typically, the system is deployed with AAC substrates (e.g. AAC panels). However, the system can also be engineered for use with rendered brick walls, fibre cement sheeted walls, concrete panels/walls, metal sheeted walls, timber sheeted and panelled walls, etc. The system can be readily adapted to the various joints that exist with and between each such different substrate.

As set forth below, the system can employ a range of different profiles to thereby provide a range of different aesthetic (i.e. profiled) effects to the underlying substrate(s). The ability of the system to accommodate a range of profiles can provide a range of different aesthetic (i.e. various profiling) effects. In this regard, a combination of different profiles can be employed when cladding a face of a structure (e.g. building).

Backing Clip (Fig. 1)

To mount a profile to an underlying substrate, the system makes use of a mounting strip in the form of a backing clip 20. The backing clip 20 can enable the mounting of a range of different profiles (e.g. profiles 40, 50, 60, 70) to one or more panels P, as set forth hereafter.

Figs. 1 A & 1B show an embodiment of the backing clip 20. As explained below, the backing clip 20 is secured with respect to (e.g. adhered to) the underlying substrate(s). For example, the backing clip 20 can be secured to adjacent substrates (i.e. to adjacent panels P) along panels (see Fig. 28B) or at and along a joint J (see Fig. 22, Step 9). Whilst the backing clip 20 can be formed (e.g. moulded or extruded) from plastic, typically the backing clip 20 is extruded from a metal or metal alloy such as aluminium. Aluminium is light, strong and corrosion resistant.

As explained below, the backing clip 20 can be secured to prepared panel(s). When mounting the backing clip 20 along a joint J between adjacent panels P, the clip 20 is typically aligned with respect to the joint (e.g. using a spirit level, laser level, measuring tape, ruler, etc.). Once the backing clip 20 has been mounted to and aligned with the underlying panel(s) P, a profile (e.g. 40, 50, 60 or 70) can be mounted thereto, such as by snap-mounting. Once the profile has been mounted, typically the backing clip 20 becomes concealed (e.g. hidden), so that the profile can then appear to be contiguous with (i.e. a part of) the underlying panel(s). As explained in greater detail below, the system can be employed to give the appearance of a continuous profiled wall at a structure (e.g. building).

In a typical application, the backing clip 20 can be mounted to cover (e.g. hide) a joint J that is defined between adjacent panels P (see Figs. 22 - 25). Thus, once a profile (e.g. 40, 50, 60, 70) is secured to clip 20, the system is able to provide an overlay that masks or obscures the joint J (see Figs. 22, 25, 27, 29). This can eliminate the need for a rendering step, a filling step or other type of surface finishing at the joint, and indeed can eliminate such steps for an entire wall (i.e. such surface-finishes are normally employed/required to hide or mask the joint(s) in a wall and consume time and expense).

The backing clip 20 comprises a generally planar elongate base 22 that is configured for location over and along, and for securing to the panel(s) P or joint J in a flat- or flush-mounted manner (see e.g. Figs. 22 & 25). In this regard, the underside 24 of the base 22 is planar. As explained in greater detail below, an elongate strip of two-sided adhesive backing tape 26 can be secured (i.e. adhered) to the underside 24 of the base 22. The backing tape 26 has a removable cover strip 27 (Figs. 22 & 24A) applied thereto which in use is removed prior to securing the backing clip 20 to the panel(s) P or joint J (e.g. with a suitable pressure tool as described below).

The backing clip 20 can be supplied (e.g. in a kit) with the backing tape 26 already secured to underside 24 of the base 22 (i.e. with the removable cover strip still attached). In use, a user may then progressively remove the cover strip to enable the backing clip 20 to be secured to the panel(s) P or joint J.

The backing clip 20 is fabricated so that the base 22 has a sufficient width to fully span a joint J (i.e. respective sides of the base 22 lap over the edges of the adjacent panels P to completely cover the joint J - see Figs. 22 & 25).

Typically, the backing clip 20 is fabricated (e.g. extruded) to have a length that enables it to locate over and along a full length of joint J. However, for a long length profile, and if necessary, two or more backing clips may be secured in an end-to-end relationship along and over the joint J defined between panels P, with the clips abutting at their adjacent ends. The backing clip 20 can also be cut to length to suit a given length of panel or joint (e.g. on site, with a drop saw fitted with a suitable cutting disc/blade).

As above, the backing clip 20 is configured to interact with and retain a profile thereat in use (e.g. profile 40, 50, 60, 70). As above, when the profile is retained at the backing clip 20 it hides the backing clip 20 thereunder in use (see e.g. Fig. 22, Step 10).

In this regard, the backing clip 20 comprises two opposing walls 28 that extend up from and for a length of the base 22. Typically, each wall 28 is integrally formed with the base 22 (e.g. each wall is integrally moulded/extruded with or is machined out of the base 22). When the backing clip 20 comprises a metal or metallic material, each wall 28 is provided with a sufficient width and length that enables the metal or metallic material of the wall to flex/deflect when the profile is being secured thereto. Whilst metals and metallic materials generally have limited flex, each wall 28 is nevertheless configured to ensure that sufficient flex is provided to enable the profile to be snap-, press-, push- or interference-fit onto the backing clip 20. As explained below, a suitable tool (e.g. rubber mallet and spreader member) may be required to force-fit the profile onto the backing clip 20.

To facilitate securement of the profile to the backing clip 20, each wall 28 comprises a laterally outwards projection in the form of a respective lip 30 that extends for a length of the wall 28, typically along its distal edge. As explained below, each lip 30 can interact with a corresponding internal flange of a given profile to mount and retain the profile at the backing clip 20 in use.

In this regard, each lip 30 comprises a downwardly angled bevel 32 that also extends for a length of the wall 28. Each bevel 32 slopes down to and terminates at a shoulder 34 of each lip 30. As explained below with reference to Figs. 3A and 3B, the bevel 32 facilitates snap-, press-, push- or interference-fit of the profile onto the backing clip 20 (i.e. in the direction of arrow D shown in Fig. 1B) because the internal flange of the profile can travel down and across the bevel during mounting of the profile to the backing clip. Further, the shoulder 34 can retain thereunder the profile internal flange, thereby capturing the profile on the backing clip 20, as is also explained below with reference to Figs. 3A and 3B.

The walls 28 extend along and are parallel to, but inset from, respective opposite long side walls 36 of the base 22. Thus, the width of the base is 22 is greater than the outermost distance between the opposing lips 30. This enables the base 22 to locate closely (e.g. snugly) within an opening of a profile (see e.g. Fig. 3A), but nevertheless, it also allows a desired tapering profile to be employed, which profile can still engage with the lips 30.

An outwardly facing surface of the base 22 also has an elongate groove in the form of a V-channel 38 that extends centrally along a length of the base 22. The V-channel 38 provides a 'visual-clue' centreline for a user during alignment of the backing clip. The V-channel 38 also provides an option to use spaced additional fasteners (e.g. self-tapping screws) that can be driven through the V-channel 38 and into one or more of the panels P, or into the joint J (e.g. into a jointing material). The V-channel 38 thus provides an extra degree of freedom in the securing of clip 20 with respect to panels P or joint J.

Bullnose Profile (Figs. 2 & 3)

Referring now to Figs. 2A and 2B, afirst elongate profile embodiment takes the form of an elongate bullnose profile 40. Typically, the profile 40 is an extrusion (e.g. it is extruded from a metal or metal alloy), although in some cases it may be formed (e.g. extruded, 3D printed, moulded) from a plastic such as a polymeric resin. As explained in greater detail hereafter, the profile 40 can be mounted and retained on the backing clip 20 by pushing/guiding/urging it in the direction of arrow D (Fig. 1B).

Typically, the profile 40 is fabricated (e.g. extruded) in a factory and is then cut to length on site - e.g. to have a length that corresponds to the length of the joint J located between adjacent panels P. In this regard, the profile can be fabricated to be unbroken along the entire length of a panel or joint.

The profile 40 comprises an opening 0 defined at its underside. The opening 0 opens into a hollow interior H of the profile 40. The opening 0 receives therethrough the projecting walls 28 of the backing clip 20. The opening 0 can receive therein (e.g. snugly - see Fig. 3A) the base 22 of backing clip 20. The profile walls 42 can thus surround and 'flush-mount' to the base 22 of backing clip 20 when the profile has been secured to the backing clip 20.

Whilst the profile can be formed to comprise just one external wall (e.g. a single semi-cylindrical wall), in the embodiment of Figs. 2A and 2B, the profile 40 comprises two external walls 42 which generally taper inwards, i.e. from opening 0 towards a curved profile apex 44. A stiffening web 45 is provided within the profile 40 and extends along and between to join the walls 42. In use, the web 45 restricts outward deflection of the walls 42 and, along with the walls 42, defines a hollow H with the profile 40.

Further, whilst the profile can be formed to comprise just one internal wall (e.g. an inward facing surface of a single semi-cylindrical wall), the internal surfaces 47 of each wall 42 are formed to have internal flanges in the form of ridges 46 extending along and inwardly of the hollow H of profile 40. It will be seen that each internal ridge 46 is located at an intermediate location along the internal surface 47. This is so that each ridge 46 can, in use, engage a respective laterally projecting lip 30 of the backing clip 20 (see Fig. 3A).

The profile 40 also comprises inwardly turned feet 48 that extend along and inwardly of a lower distal edge of each wall 42 and into the opening 0 of profile 40. As shown in Fig. 3A, the feet 48 can locate against the sidewalls 36 of backing clip base 22 in use.

System - Backing Clip & Profile (Figs. 3 & 6-7)

Figs. 3A, 3B & 6 show the profile 40 mounted to the backing clip 20. Fig. 3B shows the backing clip 20 having been partially slid-out from the profile 40 (i.e. for illustrative purposes only). Once the profile 40 is mounted to backing clip 20, each internal ridge 46 is located to be retained under its respective laterally projecting lip 30 (i.e. adjacent to shoulder 34). This securely mounts the profile 40 to the backing clip 20.

The system is also configured such that each wall 42 of the profile 40 is able to extend down to an underlying substrate S in use (see Figs. 3A & 3b). This conceals the backing clip 20 and gives the appearance that the profile is contiguous with (i.e. a part of) the underlying substrate. For example, when the profile has the same colour as the underlying substrate (e.g. walls of a building) this arrangement can give the appearance of a continuous profiled wall at the building.

When mounting the profile 40 to a backing clip 20 that has been secured to a substrate, the backing clip walls 28 pass via opening 0 defined between the profile walls 42 and into the hollow H defined within the profile 40. Eventually, the bevels 32 of lips 30 that are defined along the distal end edge of each wall 28 come into engagement with the internal ridges 46 of the profile 40. The internal ridges 46 travel down the bevels 32, with this action mainly causing the backing clip walls 28 to each deflect inwardly towards each other (i.e. there is much less outward deflection of the profile walls 42 due to the proximity of each internal ridge 46 to the stiffening web 45). Once the ridges 46 have moved passed the lips 30, the backing clip walls 28 each deflect back outwardly, away from each other, so that the ridges 46 locate under the lips 30, adjacent to the shoulders 34. The profile 40 thereby becomes secured to the backing clip 20.

Usually this action is rapid and, when the backing clip 20 and profile 40 are each of a metal material, usually this action requires the use of a tool/tools. Usually this action is a snap-fit of the profile 40 onto the backing clip 20. Typically, the resultant fit is a relatively tight fit, such that the profile 40 does not slide along the backing clip 20 once secured thereto.

As set forth above, the system finds particular application with substrates in the form of AAC panels (see e.g. Figs. 17 and 19 - 27). The system can improve the aesthetics at a joint between adjacent AAC panels (i.e. an aesthetically designed profile 40 can be retained at each joint J). The system can impart to the resultant clad surface a profiled cladding appearance (see especially Fig. 29). In this regard, the profiled appearance can suggest to an observer that the substrates (e.g. the underlying panels or sheets) are formed from a different type of material. For example, the resulting clad surface can be akin in appearance to a metal-clad surface. Further, because the joint cannot be seen, the profile appears to an observer to form part of and/or be integrated with the underlying panels or sheets.

Typically, prior to securing the backing clip 20 along a joint, a flexible jointing material is arranged in the joint. A suitable material can be selected that allows for the movement at the joint (e.g. due to thermal expansion/contraction, settling of a building foundation, etc.). Even after securing the backing clip 20 over the joint, the flexible jointing material can continue to flex and accommodate movement at the joint, without this being visually detectable or discernible due to the overlying backing clip 20 and profile. Further, even if there is cracking or fracture within the jointing material (e.g. over time), this cracking or fracture is obscured, covered over and allowed for with the present system.

The system as set forth herein can be supplied as a kit, along with a suitable number of panels P. In the kit, an 'internal' profile 40, 50 or 60, along with a respective number of backing clips 20, can be supplied for an external wall of a structure (e.g. building). Further, the kit can comprise a suitable number of 'external' perimeter/border profiles 70, each being supplied with a respective number of backing clips 20.

Trapezoidal Profile (Figs. 4 & 5)

Referring now to Figs. 4A, 4B and 5, where like reference numbers/letters denote similar or like parts, a second elongate profile embodiment takes the form of a trapezoidal profile 50, the profile being internally configured to interact with and be secured to the backing clip 20. Again, the profile 50 is an extrusion (e.g. of metal/alloy), although it may be formed from plastic. Again, the profile 50 can be mounted and retained on the backing clip 20 by pushing/guiding/urging it in the direction of arrow D (Fig. IB). Again, the profile 50 can be fabricated in a factory and cut to length on site.

The profile 50 again comprises an opening 0 defined at its underside that opens into a hollow interior H of the profile. The opening 0 receives therethrough the projecting walls 28 of the backing clip 20 and the base 22 of backing clip 20 (i.e. profile walls 52 surround and 'flush-mount' to the base 22 once the profile 50 has been secured to the backing clip 20).

The two external walls 52 again generally taper inwards, i.e. from opening 0 towards a flat profile apex 54. Profile 50 does not comprise an additional stiffening web.

The internal surfaces 55 of each wall 52 are formed to have internal flanges in the form of ridges 56 that extend along and inwardly of the hollow H of profile 50. Again, each internal ridge 56 is located at an intermediate location along the internal surface 55 so that, in use, it can engage a respective laterally projecting lip 30 of the backing clip 20 (see Fig. 5). Again, the profile 50 comprises inwardly turned feet 58 that extend along and inwardly of a lower distal edge of each wall 52 and into the opening 0 of profile 50. As shown in Fig. 5, the feet 58 can locate against the sidewalls 36 of backing clip base 22 in use.

Fig. 7 shows the profile 50 mounted to the backing clip 20.

Trapezoidal Profile (Stiffening Web - Fig. 8)

Referring now to Figs. 8A and 8B, where like reference numbers/letters denote similar or like parts to Figs. 4 & 5, a third elongate profile embodiment takes the form of a stiffened trapezoidal profile 60. Again, the profile 60 is internally configured to interact with and be secured to the backing clip 20. Again, the profile 60 is an extrusion (e.g. of metal/alloy), although it may be formed from plastic. Again, the profile 60 can be mounted and retained on the backing clip 20 by pushing/guiding/urging it in the direction of arrow D (Fig. IB). Again, the profile 60 can be fabricated in a factory and cut to length on site.

However, in distinction to the trapezoidal profile 50, the walls 62 of profile 60 are lengthened and are also connected to each other by a stiffening web 67. Web 67 serves to stiffen and strengthen the profile 60, helping the side walls 62 to resist outward deflection in use. This stiffening of the profile 60 against outwards deflection can further enhance retention of the profile at the backing clip 20.

Perimeter Profile (Fig. 9)

Referring now to Figs. 9A to 9C, a fourth elongate profile embodiment takes the form of a box-type perimeter profile 70, the profile again being internally configured to be secured to the backing clip 20. Again, the profile 70 is an extrusion (e.g. of metal/alloy), although it may be formed from plastic. Again, the profile 70 can be mounted and retained on the backing clip 20 by pushing/guiding/urging it in the direction of arrow D (Fig. 1B). Again, the profile 70 can be fabricated in a factory and cut to length on site.

The profile 70 is 'bulkier' in appearance and volume in comparison to the more 'slimline' profiles 40, 50, 60. In this regard, the profile 70 is designed to be used at a cladding perimeter or border (e.g. window opening), as shown in Figs. 27 to 29, whereas the profiles 40, 50, 60 are used on and between panels P (e.g. along joints, around windows, etc.).

The box-section of profile 70 comprises opposing external walls 72 that extend to a box top wall 74. The profile 70 also comprises opposing and inwardly tapering inner walls 76. The inner walls 76 are respectively spaced from the external walls 72 and taper from the opening 0 to an inner web 78. The inner walls 76 are connected to the external walls 72 by base walls 80. An extension of each base wall 80 defines a respective foot 82 at the opening 0.

Each inner wall 76 comprises an internal ridge 84 for locating under to be retained at a respective laterally projecting lip 30 of the backing clip 20 (i.e. adjacent to shoulder 34 when the profile 70 has been mounted to backing clip 20 (see Fig. 7C).

End Caps (Figs. 10-13)

Referring now to Figs. 10A to 10E, an end cap 90 for mounting into an open end of a bullnose profile 40 is shown (see also Fig. 6). The end cap 90 comprises three fingers 92 that protrude from an upper end of an inside face 94 of the end cap. Each finger 92 has a generally triangular profile that facilitates its snug/interference/push-fit into the opening OE at the end of the bullnose profile 40 (see Fig. 1OD). The end cap 90 provides a neat finish to an open bullnose profile 40.

Figs. 11A to 11E show an end cap 100 for mounting into an open end of a trapezoidal profile 50 (see also Fig. 7). Again, the end cap 100 comprises three fingers 102 that protrude from an inside face 104 of the end cap. Again, each finger 102 has a generally triangular profile that facilitates its snug/interference/push-fit into the opening OE at the end of the trapezoidal profile 50 (see Fig. 1ID). Again, the end cap 100 provides a neat finish to an open trapezoidal profile 50.

Referring firstly to Figs. 12A to 12C, 12D & 12F, an end cap 110 for mounting into an open end of a square (perimeter) profile 70 is shown. In this case, the end cap 110 comprises four fingers 112 that protrude from an inside face 114 of the end cap. Again, each finger 112 has a generally triangular profile that facilitates its snug/interference/push-fit into the opening OE at the end of the trapezoidal profile 50 (see Fig. 12D).

However, the end cap 110 also has two alignment tabs 116 that protrude from the cap inside face 114 adjacent to a respective side of the cap 110. Whilst each tab 116 further facilitates the snug/interference/push-fit of cap 110 into the opening

OE of profile 70, the tabs 116 are particularly provided for and suited to enable the mounting of cap 110 to a parapet profile 200 (see Figs. 12E & 12G and see also Fig. 20). In this regard, the tabs 116 interfere with webs 202 and 204 of the parapet profile 200. Thus, end cap 110 is suitable for providing a neat finish to both the square (perimeter) profile 70 and a parapet profile 200.

Referring now to Figs. 13A to 13E, an end cap 120 for mounting into an open end of a web-stiffened (67) trapezoidal profile 60 is shown. Again, the end cap comprises four fingers; two larger fingers 122 that protrude from an upper end of inside face 124 and two smaller fingers 126 that protrude from a middle of inside face 124 of the end cap. Again, each finger 122, 124 has a generally triangular profile that facilitates its snug/interference/push-fit into the opening OE at the end of the trapezoidal profile 60 (see Fig. 13C). Again, the end cap 120 provides a neat finish to an open web-stiffened trapezoidal profile 60.

Perimeter Profile - Joiners (Figs. 14 - 16)

Various joiners will now be described. The joiners can cover deliberate spacing gaps between various of the components of the system. These gaps can allow for thermal expansion/contraction and foundation settling to be accommodated in use.

Referring firstly to Figs. 14A & 14B, a comerjoiner 130 is shown forjoining two adjacent square (perimeter) profiles 70 at a corner (e.g. around an opening such as a window - see Fig. 28F). The cornerjoiner 130 comprises an external face 132, side walls 134 that project from the external face 132, and an inner corner element 136 that projects from the external face 132. The comer joiner 130 can sit snugly over the two adjacent profiles 70 at the corner. The corner joiner 130 can be adhesively affixed to the two adjacent profiles 70 at the corner. The corner joiner 130 can have the same colour as the profiles 70 as well as the panels P. This can provide a neat and aesthetic finish to each such comer.

Referring now to Figs. 15A & 15B, a comer joiner 140 is shown for joining two adjacent square (perimeter) profiles 70 at a corner that is defined between a front wall (F) and a side wall (S) (see Fig. 27) - e.g. around the end of a building. The cornerjoiner 140 comprises external faces 142,144 and side walls 146,148 that project from and extend between the external faces 142,144. The cornerjoiner 140 can sit snugly over the ends of two adjacent profiles 70 at the corner. Again, the comer joiner 140 can be adhesively affixed to the two adjacent profiles 70 at the corner. Again, the comer joiner 140 can have the same colour as the profiles 70 as well as the panels P. This can provide a neat and aesthetic finish to each such corner.

Referring now to Figs. 16A to 16C, a straight joiner 150 is shown for joining two adjacent square (perimeter) profiles 70 aligned end-to-end (see Figs. 16C and 27). The straightjoiner 150 comprises an external face 152, and side walls 154 and 156 that project from the external face 152. The joiner 150 can sit snugly over the two adjacent profiles 70 (see Fig. 16C). The joiner 150 can be adhesively affixed (i.e. see line of adhesive A in Fig. 16C) to the two adjacent profiles 70. The straight joiner 150 can have the same colour as the profiles 70 as well as the panels P. This can provide a neat and aesthetic finish to a facade.

Parapet Profile - Joiners (Figs. 17 - 19)

Referring now to Figs. 17A to 17C, an external parapet corner joiner 160 is shown for externally joining two adjacent parapet profiles 200 at a comer that is defined between a front wall (F) and a side wall (S) - see Fig. 17C (e.g. around the top end edge of a building). The comer joiner 160 comprises a corner body defined by an upper surface 162, side walls 164 that project down from the upper surface 162, and an upper corner element 166 that projects up from the upper surface 162. The comerjoiner 160 can sit snugly over the two adjacent parapet profiles 200 at the comer (see Fig. 17B). The comer joiner 160 can be adhesively affixed to the two adjacent parapet profiles 200 at the comer. Again, the corner joiner 160 can have the same colour as the profiles 200 as well as the panels P. This can provide a neat and aesthetic finish to each such comer.

Referring now to Fig. 18, an internal parapet corner joiner 170 is shown for internally joining two adjacent parapet profiles 200 at an internal corner that is defined between adjacent walls. The internal comer joiner 170 comprises a corner body defined by an upper surface 172, side walls 174 that project down from the upper surface 172, and upper side walls 176,178 that project up from the upper surface 172. As shown in Fig. 18, the corner joiner 170 can again sit snugly over the two adjacent parapet profiles 200 at the internal corner. The corner joiner 170 can be adhesively affixed to the two adjacent parapet profiles 200 at the internal corner. Again, the comer joiner 170 can have the same colour as the profiles 200 as well as the panels P. This can provide a neat and aesthetic finish to each such corner.

Referring now to Figs. 19A to 19C, a straight parapet joiner 180 is shown for joining two adjacent parapet profiles 200 end-to-end (i.e. in a straight line - see Fig. 19C). The straight joiner 180 comprises an upper surface 182, a lower front wall 184 that projects down from a front edge of the upper surface 182, and an upper front wall 186 that projects up from a back edge of the upper surface 182. Each front wall comprises a lip 188 along its distal edge for lapping over a corresponding edge of the adjacent parapet profiles 200 - i.e. for a secure mounting thereto and joining thereof. In this regard, the straight joiner 180 can sit snugly over the two end-to-end adjacent parapet profiles 200 (see Fig. 19B). The straight joiner 180 can be adhesively affixed to the two adjacent parapet profiles 200 - see adhesive lines A on Fig. 19C. Again, the straight joiner 180 can have the same colour as the profiles 200 as well as the panels P. This can provide a neat and aesthetic finish to each such corner.

Parapet Profile - (Fig. 20)

Referring now to Figs. 20A to 20D, a parapet profile 200 is shown. The parapet profile 200 is typically installed after all other profiles are in place. The parapet profile 200 is designed to also provide a fall and a fixing point for roof capping.

The parapet profile comprises an upstanding central wall 201 from which the forward web 202 projects. A downwardly projecting web 204 defines an in-use front 'skirt of the parapet profile 200 under which a profile 40,50 can locate (see Fig. 20D). A rearward web 206 extends rearwardly in use of the parapet profile 200 and enables the profile 200 to be secured to the top of a panel P (see Figs. 20C & 20D). The central wall 201 continues on below the forward web 202 and rearward web 206 to define an inner rim 208, which can abut against the outside face of a panel P (see Figs. 20C & 20D).

As best shown in Figs. 20C & 20D, the parapet profile 200 is mounted to the panel P by a suitable fastener FA (e.g. e.g. a self-tapping screw). The panel P is mounted to framework FW (e.g. a timber or steel frame) via a number of spaced, horizontal top hat sections TH, and via suitable fasteners FA (e.g. self-tapping screws).

A continuous bead of sealant A is typically applied to the top outside edge of the panel P to weather seal the underside junction. Once parapet profile 200 is secured in place, a parapet flashing PF can be installed over the top of the assembly (Fig. 20C).

Cantilevered Angle (for panel base - Fig. 21)

Referring now to Figs. 21A to 21C, where similar reference numbers to Fig. 20 are employed, a cantilevered angle 220 is shown. The cantilevered angle 220 is designed to provide a framework fixing point for a lower end of a panel P.

The cantilevered angle 220 comprises a base wall 222 and an upstanding rear wall 224. The upstanding rear wall can be secured to the rear of a panel P via a respective fastener FA (see Fig. 21C). A forward, downwardly angled water drainage lip 226 projects and extends forwardly along the front edge of the base wall 222. The lip 226 projects beyond the panel P in use (see Fig. 21C) to direct water away from the facade.

As best shown in Fig. 21C, the cantilevered angle 220 is secured to extend along and under the length of multiple adjacent panels at a wall of a facade. The rear wall 224 of angle 220 is connected via a connector piece CP and fastener FA to a soffit lining SL. Again, a continuous bead of sealant A is typically applied to the internal junction of base wall 222 with rear wall 224 so as to adhere to a rear edge of the panel P to weather seal the junction.

Examples

Non-limiting examples of the system and method as disclosed herein will now be provided. Reference is made especially to Figs. 22 to 27.

Example 1

The system employed smooth, 75mm thick, steel-reinforced AAC panels, which were vertically secured to a structural frame via horizontal perforated top hat sections TH (see e.g. Fig. 26). A weatherproofing wall membrane M was provided between the top hat sections TH and the timber or steel framework FW.

As shown in Fig. 23A, a sealant (SE) was typically applied between adjacent panels (P) along a joint (J).

The system was able to create a defined look of a traditional standing seam and metal cladding system (see e.g. Figs. 27 & 29), but with all of the performance benefits of AAC panels and their associated mounting systems.

The AAC panels were provided with a new surface finish technology that was able to be painted, rather than rendered. This saved considerable time during construction of a facade.

It can be seen from the drawings that the system allowed for various of the components to be spaced from each other and then the resultant gaps to be covered with the various joiners and covering members. This allowed for thermal expansion/contraction and foundation settling to be accommodated in use.

For example, Fig. 28 shows the spacings between the backing clips 20 and the perimeter profiles 70 located around a window WI. The corner joiner 130 was able to cover the spacings in a visually appealing and unnoticeable manner. The profiles 40,50 were also able to run up close to the perimeter profiles 70 (see double-headed arrow of Fig. 28A).

The backing clip (20) was universal and was easily fixed along the vertical AAC panel joint. Typically, pre-coated aluminium profiles (40, 50, 60, 70) were simply and easily snap-fitted onto the backing clip (20) to achieve any required look. Initially, the aluminium profile was supplied in two different profiles shapes: bullnose (40) or trapezoidal (50), which were designed to suit varying project requirements and to provide design versatility. Other profile shapes could be designed as required.

The profiles were powder-coated and were initially available in three popular colours: Dune®, BasaltTM and Monument. The profiles were also available in a raw milled aluminium, allowing the profile to be simply painted onsite and colour matched to any project.

The system was able to provide a fire rating of up to 180/180/180 when subjected to an external fire source. The system was able to provide an acoustic performance of Rw + Ctr 35 to 39 based on a 210mm wall system thickness. The system was able to provide a thermal performance of RI.61 to R3.57.

System wall thicknesses that were initially supplied comprised: 199mm, based on 90mm stud + 10mm plasterboard + 24mm top hat + 75mm AAC panel. With variations in stud thickness and top hats, wall widths were able to be varied between 179mm to 210mm (excluding profile depth).

The system was initially supplied with standard panel sizes: (2400mm length x 600mm width x 75mm thickness); (2550mm x 600mm x 75mm); (2700mm x 600mm x 75mm); (2800mm x 600mm x 75mm); (2850mm x 600mm x 75mm); (3000mm x 600mm x 75mm); (3300mm x 600mm x 75mm).

Example 2

Referring now to Fig. 22, the following steps were generally followed when preparing a facade of a structure (e.g. building) using the present system.

Step 1

Perforated top hats (TH) were affixed to timber or steel frame (FW), ensuring they were plumb and level. Usually a moisture barrier membrane (M) was installed between the tops hats and frame.

Step 2

Any exposed steel reinforcing, as a result of cutting of the AAC panels, was coated (C) with an anti-corrosion paint,

Step 3

Before commencement of installation of the AAC panels, an assessment was made of the module layout (ML), taking into account (e.g. window) opening sizes and locations to minimise 'notching' of the AAC panels.

Step 4

The AAC panels were vertically affixed by applying either a fire sealant or an AAC panel adhesive. The AAC panels were then screwed off (SO) to the perforated top hats.

Step 5

Any minor panel imperfections were patched (P), and screw holes were in-filled, using either a patching paint (e.g. Dulux Acratex PowerPatch@) or a filler (e.g. Selleys Spakfilla Rapid®).

Step 6

A coating system (CS) was applied comprising a suitable primer and two coats of an elastomeric top coat. Suitable coatings were Dulux AcraTex@. This coating system was allowed to fully dry prior to installation of the backing clips (20) and panel profiles (40,50).

Step 7

An adhesion promoter (AP - e.g. 3M API11@) was applied to the wall at the backing clip (20) location prior to backing clip installation.

Step 8

The removable cover strip (27) was peeled away from the backing tape (26) that had been pre-affixed to backing clip (20). A suitable backing tape was a 3M VHB@ GPH Tape.

Step 9

The backing clip (20) was affixed to the panel wall. The methodology typically employed is also shown in Figs. 24A to 24D and was as follows:

- peel off a short length of the cover strip (27) from each end of the backing tape (26).

- manually adhere one end of the exposed backing tape (26) to the

underlying AAC panels at the joint (J).

- align the backing clip (20) along the joint (J) using a suitable levelling tool such as a spirit level (SL) (or laser level, measuring tape, ruler, etc.).

- manually adhere the other end of the backing tape (26) to the underlying

AAC panels at the joint (J) and remove a remainder of the cover strip (27) from the backing tape (26).

- pressure the backing clip (20) to adhere to the underlying AAC panels at the joint (J) using a suitable pressuring tool, such as the hand-held pressure tool (PT) shown in Figs. 24C & 24D.

The hand-held pressure tool (PT) shown in Figs. 24C & 24D comprised parallel grooves G is a major (pressure) face thereof for receiving therein the two opposing walls 28 of the backing clip 20 therein (see Fig. 24C). This enabled a user to apply considerable force to the backing clip 20 to secure it to the panels P.

Step 10

Each profile (40,50) was snap-mounted to the now-affixed backing clip (20). A rubber mallet (RM) such as shown in Fig. 28C, was typically used for attaching each profile, and for square profile (70) a force spreader bar (SB) was additionally used to prevent profile damage.

System & Method - Features and Benefits:

• The system and method offered a reduced installed cost compared to that of standing seam (and similar) metal cladding systems.

• The system and method eliminated the issues associated with a generally flat metal cladding system in terms of considerably reduced morning and afternoon glancing (reflected) light and glare.

• The system and method offered a choice of prefinished aluminium profiles, simplifying the construction process.

• The system and method offered used non-combustible AAC panels to achieve a fire rating performance of FRL 180/180/180.

• The system and method offered superior thermal performance compared to standing seam (and similar) metal cladding systems.

Variations and modifications may be made to the system as previously described without departing from the spirit or ambit of the disclosure.

For example, the backing clip 20 can be formed of (e.g. extruded, printed or machined from) a relatively inflexible material such as metal or resin. Then, each profile can comprise (either internally, or in totality) a deflectable (e.g. resilient plastics) material. In another variation, the backing clip 20 and profile can each be formed of a relatively flexible (e.g. resilient plastics) material. In this case, the profile may require separate adhesion to the backing clip 20. In a further variation, the backing clip 20 and profile may each be formed of a relatively inflexible material, in which case the profile can be slide-mounted onto the backing clip 20 at an end thereof, before or after the backing clip 20 has been secured to the substrates.

In another variation, the base 22 of backing clip 20 may be provided with a number of discrete apertures spaced out along its length, each for a respective fastener. This can be in addition to or in place of the two-sided backing tape 26.

Other profile shapes are also contemplated, such as a triangular profile, inverted U-type profile, square profile, etc.

Different securing formations of the backing clip 20 are also contemplated. For example, the walls 28 can each be replaced with formations that are configured to be 'squeezed' to interact and secure with corresponding internal formations defined within the profile - e.g. in a press-, friction- or interference- type fit.

In the claims which follow and in the preceding description of the system and method, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the system and method.

Claims

1. A system for mounting an elongate profile to an underlying substrate, the system comprising:

• a mounting strip comprising a base configured for location with respect to the underlying substrate, the base being further configured to be secured with respect to the underlying substrate, the mounting strip further comprising opposing walls, each wall projecting out from and along the base, each wall comprising a laterally outwards projection for interacting with the profile in a manner such that the profile is retained at the mounting strip;

• an elongate profile that comprises an opening at its underside to receive therein the projecting walls of the mounting strip, the profile comprising at least one external wall and at least one internal wall, the at least one internal wall comprising flanges that extend along and inwardly of the profile, each internal flange located at an intermediate location along the at least one internal wall, each internal flange for engaging a respective lateral projection of the mounting strip;

the system being further configured such that, when the elongate profile is mounted to the mounting strip, each internal flange is located to be retained under its respective lateral projection, and the at least one external wall of the elongate profile is able to extend down to the underlying substrate in use.

2. A system according to claim 1, wherein the elongate profile comprises opposing external sidewalls which extend down to the underlying substrate, and wherein the at least one internal wall is defined by:

(i) an inwardly facing surface of each of the opposing external sidewalls, wherein each internal flange projects laterally inwards of a respective inwardly facing surface; or

116168111 (GHMatters)P111105.AU

(ii) opposing inner walls that are each inwardly spaced from the opposing external sidewalls, wherein each internal flange projects laterally inwards of a respective inner wall.

3. A system according to claim 2 wherein a hollow is defined in the underside of the elongate profile, the entrance to the hollow being via the opening, and the hollow being configured to receive therein the projecting walls of the mounting strip, the hollow being at least in part defined by:

(i) the inwardly facing surfaces of the external sidewalls;

(ii) the inner walls that are inwardly spaced from the external sidewalls.

4. A system according to claim 3 wherein the hollow is further configured to receive therein the base of the mounting strip whereby, when the elongate profile is mounted to the mounting strip, the base locates in the opening and the mounting strip is concealed by the elongate profile.

5. A system according to any one of claims 2 to 4 wherein a web extends between and joins:

(i) the external sidewalls at a location above the internal flanges;

(ii) the inner walls at a location above the internal flanges.

6. A system according to any one of claims 2 to 5 wherein (i) the inwardly facing surfaces of the external sidewalls; or (ii) the inner walls that are inwardly spaced from the external sidewalls, converge - moving from the opening at the underside of the elongate profile towards a top side of the elongate profile.

7. A system according to claim 6 wherein, in the mounting strip, each projecting wall extends along the base adjacent to but spaced inwardly from a respective side edge of the base, such that the mounting strip base can locate in the opening and such that each lateral projection of the mounting strip can engage with and retain thereunder its respective internal flange.

116168111 (GHMatters)P111105.AU

8. A system according to any one of the preceding claims wherein, in the mounting strip, each projecting wall projects sufficiently out from the base such that, when the elongate profile is mounted to the mounting strip, each projecting wall can deflect inwardly to enable the profile to be snap-, press-, push- or interference-fit onto, and thereby to be retained in use at, the mounting strip.

9. A system according to any one of the preceding claims wherein, in the mounting strip, each lateral projection is provided along a distal edge of its respective projecting wall.

10. A system according to any one of the preceding claims wherein each lateral projection of the mounting strip comprises a bevelled outer surface configured such that, when the elongate profile is mounted to the mounting strip, the internal flanges of the at least one internal wall are able to travel across the bevelled outer surfaces to thereby cause the projecting walls to be deflected inwardly, until each internal flange moves past its respective lateral projection, whereupon each projecting wall can deflect back outwardly, and the internal flanges can locate under and behind their respective lateral projections, thereby retaining the elongate profile to the mounting strip.

11. A system according to any one of the preceding claims wherein each of the mounting strip and elongate profile are of metal, such as an extrusion of aluminium.

12. A system according to claim 11 wherein, in the mounting strip, when each lateral projection is provided along a distal edge of its respective projecting wall, the projecting wall has a width and a length that is sufficient to enable the metal of the wall to deflect when the elongate profile is secured thereto.

13. A system according to any one of the preceding claims wherein the mounting strip further comprises an elongate strip of two-sided adhesive backing tape arranged at an in-use underside of the base thereof, the backing tape having

116168111 (GHMatters)P111105.AU a removable cover strip applied thereto which in use is removed when securing to the underlying substrate.

14. A system according to any one of the preceding claims, the system further comprising one or more of:

(a) an end cap, the end cap for fitting into and closing in use a respective open end of a given elongate profile;

(b) a joiner, each joiner being configured for joining adjacent elongate profiles at each of: end-to-end in a line; at a corner on a planar face of a substrate; around a corner of a structure.

15. A profile for use with the system as set forth in any one of claims I to 14.

16. A method for mounting an elongate profile to an underlying substrate, the method comprising:

- securing a base of a mounting strip with respect to the underlying substrate, the mounting strip being as defined in any one of claims 1 to 14.

- mounting an elongate profile at the mounting strip, the profile being as defined in any one of claims 1 to 14.

17. A method according to claim 16 wherein the base of the mounting strip is located over and along a joint between adjacent substrates.

18. A method according to claim 16 or 17 wherein the mounting strip is as defined in claim 13, and wherein the method further comprises:

- peeling off a short length of the removable cover strip from each end of the backing tape, and adhering one end of the backing tape to the underlying substrate;

116168111 (GHMatters)P111105.AU

- aligning the mounting strip on the underlying substrate, such as by using a suitable levelling tool;

- pressuring the mounting strip to adhere to the underlying substrate.

19. A method according to claim 18 wherein the mounting strip is pressured to adhere to the underlying substrate by a preconfigured pressure-applicator tool, the tool adapted to receive therein the opposing projecting walls of the mounting strip so as to apply pressure directly to the base to cause it to adhere to the underlying substrate.

20. A method according to any one of claims 16 to 19 wherein, once the mounting strip has been secured to the underlying substrate, the elongate profile is mounted thereto by force, such as by using a tool such as a mallet.

21. A method according to any one of claims 16 to 20 wherein, once the mounting strip has been secured to the underlying substrate, and once each elongate profile has been mounted to a mounting strip:

- exposed profile open ends can be closed with a suitable end cap as defined in claim 14;

- adjacent elongate profiles can be joined with a suitable joiner as defined in claim 14.

116168111 (GHMatters)P111105.AU

Fig. 1A 20 Fig. 1B 28

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Fig. 2A Fig. 2B 44 40 40 44 45

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