AU643573B2 - Siding butt jointing system and method - Google Patents

Description

643573 p00011 Regulation 3.2

AUSTRALIA

Patents Act, 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Original NAME OF APPLICANT: S'ACTUAL INVENTOR: 'ADDRESS FOR SERVICE: INVENTION TITLE: TERRANS ENTERPRISES PTY. LIMITED LESLIE TERRANS Peter Maxwell Associates Blaxland House, Suite 10, 5 Ross Street, NORTH PARRAMATTA NSW 2151 SIDING BUTT JOINTING SYSTEM AND

METHOD

The following statement is a full description of this invention, including the best method of performing it know to me:- -2- The present invention relates to improvements in cladding and, more particularly, to improvements in jointing systems for cladding for use on the exterior of houses and the like.

In the context of this specification "cladding" refers to a covering which is applied to the exterior wall surfaces of housing and like building structures. The cladding is composed of a plurality of elongate panels which are usually (although not necessarily) laid so that their longitudinal 0i9 axes lie horizontally, the panels applied in parallel and 0 usually engaged or interlocked vertically to provide continuous coverage of the surfaces.

Usually the elongate panels are manufactured in standard lengths. Where the standard lengths do not cover 0* the entire width of surface to be covered then it is necessary to place panels in horizontally adjacent relationship (usually aligned along a common longitudinal axis) in order to cover the entire width of the surface.

Furthermore, in the majority of cases, rather than being

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merely "adjacent", the horizontally adjacent panels will be in an adjoining relationship whereby an effort is made to ensure that there is no gap in the longitudinal continuity of coverage provided by the panels along the entire width of surface to be covered.

-3- The preferred form of joining horizontally adjoining cladding panels has been an overlap joint. Although not visually appealing, this joint has been utilised to avoid long term problems particularly those relating to differential expansion which might arise if other forms of jointing are used. The overlap joint has also been regarded as having the advantage of providing a solid joint.

The overlap joint suffers from a number of disadvantages. For example, the joint is not visually appealing and so installers must choose the location and facing direction of che joint with care. Primarily, the installer is urged to ensure that the joint faces away from the front of the buildlng and that preferably there be no 0o 00: joints of this type at all on the front of the building.

0 Wastage frequently results from the installer not being able to use the offcuts from the standard lengths of cladding panel supplied to site.

The overlap joint is difficult to fit as the cladding panels commonly used are not specifically manufactured to allow for this kind of joint. As the internal and external cross sections of the overlapped panels are identical, the panel which is forced to fit within an adjacent panel to form an overlap joint necessarily deforms the panel which lies on the outside of the joint.

-4- In addition, overlap joints cannot be nailed at the end to keep the joint in place. As a result distortion in the joint area can take place over time. Furthermore, an overlap joint is not properly sealed against the elements.

When forming the overlap joint, the installing tradesman has to cut out parts of the panel in an intricate pattern which is time consuming and relies for satisfactory execution on the individual skills of the tradesman. Hence tne quality of such joints is by no means uniform.

Another form of joining of horizontally adjoining cladding panels is a covered, abutted joint wherein the ends of the cladding panels are placed as close together as practicably possible (aligned along a common longitudinal axis) and some form of mechanical cover is placed over the S region of the joint whereby the joint is both held together and the line of the joint is covered. A major draw back to this form of joint is that it is visually quite ugly and tends to draw the attention of even the most casual observer thereby detracting significantly from the visual appeal that is one of the primary aims of the application of cladding to the exterior of houses and the 11i j.

Both the overlap joint and the covered joint do not necessarily lend themselves readily to utilisation in conjunction with all forms of cladding panel. In this regard, cladding panels can be divided broadly into two categories. The first category is panelling which is not adapted to include insulation within or as part of the panel.

This type of panel is either applied directly to a surface to be clad whereby there is effectively no insulation at all provided between that surface and the cladding panel shell.

Alternatively large flat sheets of insulating material (for example styrofoam) can be applied to the surface with the uninsulated cladding panels being applied over the top of the large flat insulation sheets.

The second category of panel includes a shell structure which, one way or another, accommodates insulation material within or against its underside surface.

The insulated type of panel presents particular problems in relation to differential expansion of the shell Sas compared with the insulation and the surface to which the panel is affixed. Certain jointing arrangements can exacerbate these differential expansion problems in certain instances.

It is an object of the present invention to overcome or ameliorate one or more of the abovementioned disadvantages.

Throughout this specification the term "mechanically connected to" with reference to the relationship between the joint support means and the joined ends of the cladding panels is intended to indicate a fixed connection between the components in all dimensions. The term does not include, for example, a realtionship between the joint support means and the cladding panel ends whereby the joint support means remains slidable within the cladding panel ends once the joint is completed. As will be indicated below, particular methods of forming the mechanical connection can include gluing of mating surfaces and/or fasteners passing through both mating surfaces.

Accordingly in one broad form of the invention there is provided a cladding panel butt joint assembly for butt joining adjacent end edges of first and second cladding panels when said cladding panels are affixed to a mounting surface; said assembly including joint support means adapted for location beneath a predetermined portion of adjacent ends of both of said first and second cladding panels whereby said ends are supported by and are mechanically connected to said joint support means; and wherein underside surfaces of said ends are caused to be aligned in a manner whereby it will S* follow that upper outer surfaces of said ends will be aligned flush with each other; and wherein said joint support means iS profiled so as to slidingly reside in a recessed portion o 9 of sai, panels defined within and by said underside surface of said ends.

Preferably said joint support means comprises a unitary, generally planar device.

In an alternative preferred form said joint support so means comprises a plurality of unitary, generally planar devices.

In yet another preferred form said joint support means comprises a generally planar device constructed from a first component and a second component; said first component adapted to reside within one of said ends and said second component adapted to reside in the other of said ends; said first and second components adapted to be jointed along a join line which is substantially aligned with the join line of said end edges of said first and second cladding panels.

Preferably abutting, mating edges of said first and second components which meet at said join line are profiled, 9 9 9 9 99 9 9 .9 9 9 9 9* 9 9 9 9 to meet in a plane inclined at an acute angle to the plane of said upper, outer surfaces of said ends.

Preferably said joint support means extends in depth below said ends of said first and second cladding panels and is supported within a cavity defined in said surface immediately below said butt joint assembly; said cavity allowing for movement of said joint support means both along the longitudinal axis of said cladding panels and generally at right angles thereto.

Preferably the cross section of said ends is constant and substantially identical.

w S* 44 4 4,o 4 4 e4 44 e 4* Preferably said top surface of said joint support is contoured to conform to said underside surface of said ends.

Preferably the depth of said joint support matches the depth of said ends of said first and second cladding panels whereby said joint support provides mechanical support for said joint assembly by virtue of being in contact with a mounting surface to which said first and second cladding

S

panels are affixed.

*e Preferably an adhesive is applied between said top S. surface of said joint support and said underside surface of

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S said ends whereby said top surface becomes permanently mechanically attached to said underside of said surface.

Preferably said adhesive is applied in the form of an adhesive tape having contact adhesive applied to both sides thereof.

tests In a particular preferred form mechanical fasteners are utilised either in conjunction with or as an alternative to said adhesive to attach mechanically said ends of said first and second cladding panels to said joint support whereby said top surface is urged against said underside surface.

In an alternative preferred form a temporary clamp assembly is utilised to urge said top surface against said underside surface unt1 said adhesive has set whereupon said clamp can be removed leaving a set, permanent butt joint.

Preferably said clamp comprises a clamp plate which extends over said first and second cladding panels in the region of said adjacent end edges and is clamped to top and bottom edge I J I portions of said first and second cladding panels in a manner whereby said clamp plate is urged downwardly against a top surface of said cladding panels whilst said edges together with said joint support are urged upwardly whereby said top surface of said joint support is urged against said underside surface of said predetermined portion of said first and second cladding panels.

In a particular preferred form each of said first and second cladding panels comprises an elongate shell portion of generally constant cross section in a plane at right angles to a longitudinal axis thereof; said elongate shell portion comprising an elongate profiled panel having a first flange running the length of a first longitudinal edge and a second flange running the length of a second longitudinal edge; said edges of said panel defining therebetween a front panel face .and a rear panel face; said flanges each comprising at least a first portion directed inwardly towards said rear panel face, said first portions of said first and second flanges 0 and said rear panel face together defining a slot region of constant cross section in a plane at right angles to said longitudinal axis; said slot region dimensioned so as to retain and longitudinally slidably receive said joint support therewithin.

Preferably said first flange includes a second portion extending from said first portion, a shell receiving slot of said first flange defined between said second portion and said first portion of said first flange, said shell receiving -11slot vertically and slidably receiving at least a portion of said second flange of a like cladding panel.

Preferably said first and second cladding panels additionally longitudinally slidably receive within said slot region an insulation backing panel which extends the length of both of said first and second cladding panels except for S that portion occupied by said joint support and a gap region of predetermined width on either side of said joint support.

Preferably said gap region is of the order of 2 cm on either side of said joint support.

0* Preferably said joint support is of the order of 8 to cm wide.

In order that the invention may be more readily understood and put into practical effect reference will now o*o* be made to the accompanying drawings wherein:- Fig. 1 is a perspective view of a butt cladding panel butt joint assembly according to one embodiment of the invention, Fig. 2 is a perspective and side section view of a cladding panel butt joint assembly according to a second embodiment of the invention, Fig. 3 is a perspective view and a side section view of a modified form of the second embodiment of the invention, Fig. 4 is a perspective view of the manner of -12making a cladding panel butt joint of the second embodiment.

Fig. 5 is a top plan and section views of a first embodiment of a butt joint clamp assembly which can be used to aid the manufacture of a cladding panel butt joint in accordance with the invention, Fig. 6 is a perspective view of a third embodiment 0 t',t of a cladding panel butt joint assembly according to the invention, Fig. 7 is a perspective view of an alternative form of a third embodiment of a cladding panel butt joint assembly according to the invention, Fig. 8 is a perspective view of a fourth embodiment of the cladding panel butt joint assembly according to the invention, Fig. 9 is a perspective view of a second 4 69 embodiment of a butt joint clamp assembly which can be used to aid the manufacture of a cladding panel butt joint in accordance with any one of the embodiments of the invention described, Fig. 10 is a perspective view of a fifth embodiment of a cladding butt joint assembly, and Fig. 11 is a perspective view of a sixth embodiment of a cladding butt joint assembly.

-13- With particular reference to Fig. 1 a first embodiment of the cladding panel butt joint assembly 10 comprises a joint support 11 shaped so as to be slidable within both end region 12 of first cladding panel 13 and end region 14 of cladding panel 15 as and when end region 12 is caused to abut end region 14 when first cladding panel 13 and second cladding panel 15 are longitudinally, horizontally aligned.

d 7 r* Cladding panels 13 and 15 are adapted to lie against S*i and be secured to a mounting surface 16 which, in the Majority of cases, will be the exterior surface of a dwelling O* or other building structure.

The cladding panels 13, 15 comprise elongate structures having generally planar face members 17, 18 respectively from which depend at top and bottom edges thereof flanges 19, 21, 22 which extend generally in the direction of mounting surface 16. The flanges 19, 20 and 21, 22 define respective S slot regions 23, 24 therebetween. The slot region 23 is bounded by planar face members 17 of first panel 13, flange S. portions 19, 20 thereof and the mounting surface 16 when cladding panel 13 is attached thereto. In similar manner slot 24 of second panel 15 is defined and bounded by generally plaiar face member 18, flanges 21, 22 and the mounting surface 16 when cladding panel 15 is attached thereto.

-14- The cross sectional, longitudinal profile of cladding panel 13 and cladding panel 15 is identical one to the other and along the entire longitudinal lengths thereof. The corresponding cross section of the joint support 11 is shaped to match at least thb nhape of the planar face member 17 and preferably also that of the flanges 19, 20 whereby even backing support is provided by the joint support 11 to panel -end region 12 of first cladding panel 13 and panel end region 14 of second cladding panel 15 when the joint support 11 is slid within respective slot regions 23, 24 thereof.

The manner of assembly of the cladding panel butt joint assembly of the first embodiment is a follows.

Cladding panels 13, 15 which are to be assembled in line with adjacent end regions 17, 18 are placed closely beside each other. This is facilitated by cutting the end of each end region to form a straight end which is perpendicular to the longitudinal axis of the respective cladding panels 13, 15. The panels are fixed according to fixing procedures *J known in the trade except that rather than overlapping the end regions 12, 14 the joint support 11 is slid into slot region 23 of first cladding panel 13 and thence second cladding panel 15 is placed in abutting relation thereto with the joint support 11 protruding into the slot region 24 thereof to approximately the same extent that It protrudes into the slot region 23 of first panel 13.

An adhesive is applied to the top face 25 of joint support 11 whereby when the butt joint is assembled the adhesive will cause the top face 25 of the joint support 11 to adhere to the underside of the panel end regions 17, 18 thereby forming a solid, permanent joint with first cladding panel 13 appearing continuous with second cladding panel save for the line of the join between the two panels.

The small indentation which occurs at the join line can DO"S: be filled with a suitable filler if desired of the same colour as the panels 13, 15 whereby an almost imperceptible 4* joint will result.

It will be appropriate to hold the butt joint assembly in position with the upper face 25 of joint support 11 being urged against the underside of the panel end regions 12, 14 whilst the adhesive is drying. This can be accomplished by utilising a tool of the type shown in Fig. 6.

The tool will be described in detail later in this specification.

"An alternative means of ensuring that the top face of joint support 11 is adhered to the underside of the panel end regions 12, 14 is by the use of strips of adhesive tape which have contact adhesive applied to both sides of the tape. In a particular form, as shown in Fig. 1, three strips of the adhesive tape 26, 27 and 28 are applied as illustrated running from a top edge to a bottom edge of the top face of the joint support 11. Once the butt joint assembly is assembled the upper faces of the adhesive tape strips will adhere to the underside of the panel end regions 12, 14.

Ideally first strip 26 adheres to the underside of end region -16- 12 whilst third strip 28 adheres to the underside of end region 14. Second strip 27 is placed so as to run down the midline of the joint support 11 so as to be placed immediately under the joint line of the butt joint whereby the second strip 27 performs two functions. Firstly the strip 27 acts to bind the top face of the joint support 11 to the underside of both of panel end regions 12 and 14.

Secondly the strip 27 acts as a barrier to prevent any filler Swhich is applied to the joint line from making contact with the joint support 11 itself. This is particularly important where the joint support 11 is made from polystyrene or the like as this material tends to be attacked by many forms of filler compound.

o...eo With reference to Figs. 2 and 3 a second embodiment of the invention is shown.

SFigs. 2 and 3 illustrate a form of panel which includes two longitudinally extending indentations 29, 30. Fig. 4 follows the same principles of construction as Figs. 2 and 3 save that there is only a single midline indentation 127 extending longitudinally therealong.

In both forms of the second embodiment the cladding panel assembly 110 comprises a cladding panel shell 111 which is adapted to longitudinally slidably receive an insulation sheet 112. The insulation sheet 112 is longitudinally, slidably retained within the shell 111 by means of the profiling of the top and bottom edge portions of the cladding -t -17panel shell 111 whereby opposed inner faces 130, 131 are created to slidably receive and retain corresponding top and bottom edge portions of the insulation sheet 112. The structures which create these faces additionally form a groove 128 in the lower edge of the shell 111 and a tongue 129 in the top edge of the shell 111 whereby like cladding panel shells can be stacked vertically one on top of the other to cover an entire mounting surface 16 in a solidly, 9 9 S* self supporting manner utilising fasteners attaching only the 0 top edges of each shell to the surface 16 by means of elongate, equally spaced slots 126 located in the top loop 125 of each shell 111.

The variations on the second embodiment shown in Figs.

2, 3, 4 and 5 of the present application may or may not 9 incorporate the longitudinally slidable insulation sheet 112 therein. However all versions will include a portion of an S insulation sheet which performs the function of a joint support 11. The manner of insertion and utilisation of joint support 11 is as described in the first embodiment with reference to Fig. 1 of this specification.

In the case where longitudinally slidable insulation sheets 112 are utilised then a gap 31 and 32 is left on each side of the butt joint to allow for differential expansion between the insulation sheet 112 and the abutting cladding panel shell pairs 111 and 124. Typically the width of the joint support 11 is of the order of 8 to 10 cm whilst the width of the gaps 31, 32 is approximately 1 to 2 cm.

-18- As described in respect of the first embodiment, an alternative to coating the top face of the joint support 11 entirely with adhesive is to utilise adhesive tape strips 26, 27, 28 as illustrated in Fig. 4 and as described with respect to the first embodiment.

With particular reference to Fig. 3, one form of the second embodiment utilises fasteners 32 secured through the panel end regions 12, 14 to the underlying joint support 11.

It is envisaged that the fasteners 32 can be utilised as a substitute for use of the butt joint clamp 33 illustrated in Fig. 6. The fasteners 32 can be P.V.C. self locking studs which require that a hole of appropriate diameter be drilled through the panel end regions 12, 14 and on into the joint support 11. The studs are then pressed into place and retained there by virtue of the one way nature of the flanges "of the studs.

With reference to Fig. 5 the butt joint clamp 33 S..comprises a clamp plate 34 adapted to overlie substantially e all of the butt joint assembly 10 and having claws 35, 36 protruding therefrom at top and bottom edges thereof attached to screwed rods 37, 38. The claws 35, 36 engage respectively top and bottom edge portions of cladding panel shell 111.

The claws 35, 36 are pivoted on screwed rods 37, 38. The screwed rods are retained within threaded holes 39, 40 in the clamp plate 34 whereby rotation of the screwed rods 37, 38 causes the claws 35, 36 to be moved either towards or away -19from clamp plate 34. Preferably a profile match member 41 is interposed between the clamp plate 34 and top surface of shell 111. The face of the matched member 41 which contacts the face of the shell 111 is shaped to match the profile of the shell at the points of contact whereby forces transmitted by the clamp 33 to the shell 111 are evenly distributed to prevent damage to the shell and to ensure even pressure is applied over the whole of the butt joint assembly whilst adhesive is setting.

In use the clamp 33 is placed over a butt joint

S**

assembly after all components as previously described are in position. Claws 35, 36 are caused to engage with top and S bottom edge portions of the shell 111 and screwed rods 37, 38 are screwed in the appropriate direction to cause clamp plate 34 to move downwardly along the screwed rods whereby match member 41 is urged against shell 111 whilst claws 35, 36 correspondingly cause the shell to be urged towards the match member 41. The end result is that the joint support 11 is urged against the underside of the face of shell 111 to ensure that adequate bonding of the interposed adhesive takes place.

Once the adhesive has set the clamp 33 can be removed and a filler applied as necessary to the joint line between shells 111 and 124.

Referring to Fig. 6 a third embodiment of the butt joint assembly is shown wherein a pair of joint supports is utili&ed to perform the function of the joint support 11 of previous embodiments.

This embodiment is suitable for use with cladding panels which are not designed to incorporate an insulating medium as part of the panel structure. This form of cladding panel can be applied either directly to a surface to be clad or to flat insulation sheets which have been applied over the surface to be clad.

This form of cladding will usually have one or more longitudinally extending cavities defined between the a underside of the panel shell and the surface to which the shell is attached. In the case of the embodiment illustrated in Fig. 7 the panel shall 301 defines a first longitudinal

U

cavity 302 anrd a second longitudinal cavity 303 which are parallel to each other and extend the full length of the 4 shell 301.

too* The shell 301 is applied to a relatively flat surface 304, This surface can be the exterior surface of a dwelling to be clad. Alternatively the surface can be a flat insulation sheeting which has been applied over the exterior surface to be clad for the purpose of providing insulation.

The shells 301 are applied in a manner as generally known in the art and as generally described in respect of the first and second embodiments.

In this case butt joints according to the invention are effected between adjacent ends of panel shells 301 by use of joint supports 305, 306 which are adapted to be slidingly, supportingly inserted within respective first and second longitudinal cavities 302, 303.

The manner of insertion and attachment of the joint supports 305, 306 to form a butt joint is the same as previously described in respect of the first and second embodiments save that two joint supports are applied as against only one.

With reference to Fig. 7 a variation of the third embodiment is illustrated wherein vertically adjacent panel f shells 307 and 308 are shaped so as to interlock when the upper panel 307 is lifted and applied to surface 304 whereby channel 309 defined on the inside lower edge of panel shell S 307 is caused to engage with downwardly extending protrusion 310 which stands proud from an upper edge of lower panel shell 308.

Each panel shell 307, 308 is affixed by fasteners applied through elongate, equally spaced slots 126 located along an upper edge of each of the panels. In this manner, once interlocked vertically, each panel shell is held against surface 304 by means of fasteners along its upper edge and is engaged along its lower edge by means of engagement of channel 309 with protrusion 310 of the upper edge of the next lowest shell.

As was described with reference to Fig. 6 joint supports 305, 306 are slotted individually within first longitudinal cavity 302 and second longitudinal cavity 303 of each panel shell 307, 308. The manner of placement and the I P -22manner of attachment of the joint suports 305, 306 is as was described in respect of Fig. 6 whereby longitudinally adjacent panel shells are caused to be butt jointed along a joint line defined by abutting end edges of longitudinally adjacent panels.

Fig. 8 illustrates a fourth embodiment of the butt joint assembly of the invention suitable for use where the S* cladding panels are laid upon pre-layed insulation sheets.

This arrangement can be used with both single and S' multiple joint supports and relies upon the creation of a cavity in insulation sheeting 401. The cavity 403 is adapted to receive a relatively thick joint support 402.

Furthermore, the cavity 403 is dimensioned to leave room for both vertical and horizontal movement of the joint support C. S 402 within the cavity 403 for the purpose both of initial *Ge ease of installation and for the purpose of allowing for differential expansion between the cladding components, the 0* joint support and the sheeting.

The depth of the joint support 402 in relation to the depth of cavity 403 is such that the top surface 404 of the joint support 402, when installed, will be urged against the underside of end portions of both of cladding panel shells 405, 406 whereby, in conjunction with the butt joint clamp (described elsewhere in this specification) the outer surfaces of the cladding panel shells 405, 406 are caused to be aligned flush and maintained in that condition once the joint is assembled and set.

-23- The installation procedure for this fourth embodiment is the same as for previous embodiments save that the installer must create cavity 403 at a location on sheeting 401 on site and after the insulation sheeting 401 is installed. The cavity 403 can be created by utilisation of gouging and/or cutting tools such as a chisel.

•Fig. 9 illustrates a second embodiment of the clamp assembly suitable for use to install any one of the butt S joint assemblies of the described embodiments.

The action of clamp assembly 42 on the adjacent ends of panels which are to be joined is as for the first embodiment of the clamp assembly to the extent that top and bottom edges of the panel shells are urged in the direction of a plate which is profiled to cover both of the end regions of the shells to be joined and thereby causes the top surfaces of the shells of the panels to be aligned in a flush manner.

In this embodiment of the clamp assembly 42 the assembly comprises a clamp plate 43 with apertures 44, 45 at opposed ends. At least one of the apertures 45 is in the form of a slot. Both apertures are adapted to slidingly receive screwed rods 46, 47 respectively.

At the lower end of both rods is attached a claw 48, 49 adapted (as with the first embodiment of the clamp) to engage top and bottom edge portions of the end regions of two panel shells to be joined.

-24- On the other ends of both screwed rods 46, 47 are applied wingnuts 50, 51 which, when rotated down the screwed rods, 46, 47 ~ill act against plate 43 so ao to cause claws 48, 49 to be pulled upwardly towards the plate 43.

In this manner when claws 48, 49 are engged with the top and bottom edges of the end regions of two panels to be joined, those end regions are urged upwardly against the underside of plate 43 thereby causing the top surfaces of the shells comprising the adjacent panels to be aligned in a flush manner.

*0 In its simplest form the plate 43 can be flat whereby it will engage with only the highest portions of the profile of the panel shells. Alternatively, and preferably, the 9 underside of the plate 43 is profiled to match the external profile of the panel shells which are to be joined.

With reference to Fig. 10, two ends 52, 53 are 9 supported by a joint support comprising respective first component 54 and second component 55 which reside in 9 9 respective first and second ends 52, 53 and are adapted to be joined generally along the join line of said first and second edges 53.

When joined, end faces 56, 57 of respective first component 54 an second component 55 meet in a plane which can be at an acute angle to the plane of the upper, outer surfaces 58, 59 of the cladding panels to be joined.

Specifically the angle between the planes may be 450 as shown in Fig. 10 or may be 90° as shown in Fig. 11.

The end faces 56, 57 can be permanently, sealingly joined by use of an adhesive compound. Alternatively, a double sided adhesive strip can be utilised.

In use the panels to be joined are caused to be joined by causing both the end faces 56, 57 of the respective components of joint support to be mated whereby the ends 52, 53 of the panels will also be closely mated about the join line. The entire assembly can be held in position by use of the clamp as previously described with respect to either Fig.

99 5 or Fig. 9. A sealant can be used to fill any minor indentations left at the join line after joining.

The first and second components 54, 55 comprising the oint support are best slid into position on site prior to joining of the ends 52, 53. The end faces 56, 57 can be joined first and then adhesive or double sided tape (as Goes&: described with reference to Fig. 4 or Fig. 8) can be utilised to connect the top surface of the completed joint support to the underside of the panel shells by sliding the panel shells together about the join line and holding them in position utilising the clamp assembly 33, 42.

The above describes only some embodiments of the present invention and modifications obvious to those skilled in the art can be made thereto without departing from the scope and spirit of the present invention.

For example the butt joint system and method of the present invention is adapted to be utilised in conjunction with most cladding panel shell profiles including, but not to -26be limited to, the specific profiles described in this specification.

Furthermore, the system andL method will work with shells constructed f,~om most commonly used cladding panel shell materials including aluminium, plastic, vinyl and the like.

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Claims (16)

1. A cladding panel butt joint assembly for butt joining adjacent end edges of first and second cladding panels when said cladding panels are affixed to a mounting surface; said assembly including joint support means adapted for location beneath a predetermined portion of adjacent ends of both of said first and second cladding panels whereby said ends are supported by and are mechanically connected to said joint support means; and wherein underside surfaces of said ends are caused to be aligned in a manner whereby it will follow that upper outer surfaces of said ends will be aligned flush with each other; and wherein said joint support means is profiled so as to slidingly reside in a recessed portion of said panels defined within and by said underside surfaces of said ends.

2. The assembly of Claim 1 wherein said joint support means comprises a unitary, generally planar device.

3. The assembly of Claim 1 wherein said joint support means comprises a plurality of unitary, generally planar devices.

4. The assembly of Claim 1 wherein said joint support means comprises a generally planar device constructed from a first component and a second component; said first component adapted to reside within one of said ends and said second component adapted to reside in the other of said ends; said first and second components adapted to be jointed along a join line which is substantially aligned with the join line of said end edges of said first and second cladding panels. *4*44* 4 4* 4 44 4 4 4 4 .4 4 4 4 4. 44 4 4 4 4\( 4.4 -28- The assembly of Claim 4 wherein abutting, mating edges of said first and second components which meet at said join line are profiled to meet in a plane inclined at an acute angle to the plane of said upper, outer surfaces of said ends.

6. The assembly of Claim 1 wherein said joint support means extends in depth below said ends of said first and second cladding panels and is supported within a cavity defined in said surface immediately below said butt joint assembly; said cavity allowing for movement of said joint support means both along the longitudinal axis of said cladding panels and generally at right angles thereto.

7. The assembly of claim 1 wherein the cross section of said ends is constant and substantially identical.

8. The assembly of claim 1 wherein an upper surface of said joint support means is contoured to conform to said underside surfaces of said ends.

9. The assembly of claim 1 wherein an adhesive is applied between said upper surface of said joint support means and said underside surfaces of said ends whereby said upper surface becomes attached to said undersides of said ends. The assembly of claim 9 wherein said adhesive is applied in the form of an adhesive tape having contact adhesive affixed to both sides thereof.

11. The assembly of claim 1 wherein mechanical fasteners are utilised to attach said ends of said first and second cladding panels to said joint support means whereby said upper surface of said joint support means is urged against 0 00 0 *r 0 C 00 *I 0? n 0 0 0 9.9. 00000 iii: -29- said underside surfaces of said ends.

12. The assembly of claim 9 wherein a temporary clamp assembly is utilised to urge said upper surface against said underside surface until said adhesive has set whereupon said clamp can be removed leaving a set, permanent butt joint.

13. The assembly of claim 12 wherein said clamp comprises a clamp plate which extends over said first and second cladding panels in the region of said adjacent end edges and is clamped to top and bottom edge portions of said first and second cladding panels in a manner whereby said clamp plate is urged downwardly against said upper, outer surfaces of said ends of said cladding panels whilst said edges together with said joint support means are urged upwardly whereby said upper surface of said joint support means is urged against said underside surfaces of said ends of said first and second cladding panels.

14. The assembly of claim 1 wherein each of said first and second cladding panels comprises an elongate shell portion of generally constant cross section in a plane at right angles to a longitudinal axis thereof; said elongate shell portion comprising an elongate profiled panel having a first flange running the length of a first longitudinal edge and a second flange running the length of a second longitudinal edge; said edges of said panel defining therebetween a front panel face and a rear panel face; said flanges each comprising at least a first portion directed inwardly towards said rear panel face, said first portions of said first and second flanges and said rear panel face togcther defining a slot region of 4*4444 9 4 9 .9 9* 9 9 4 9 4 9 9. 4 4 N constant cross section in a plane at right angles to said longitudinal axis; said slot region dimensioned so as to retain and longitudinally slidably receive said joint support therewithin. The assembly of claim 14 wherein said first flange includes a second portion extending from said first portion, a shell receiving slot of said first flange defined between said second portion and said first portion of said first flange, said shell receiving slat vertically and slidably receiving at least a portion of a said second flange of a like cladding panel.

16. The assembly of claim 15 wherein said first and second cladding panels additionally longitudinally slidably receive within said slot region an insulation backing panel which extends the length of both of said first and second cladding panels except for that portion occupied by said joint support and a gap region of predetermined width on either side of S. said joint support.

17. The assembly of claim 16 wherein said gap region is of e4 the order of 2 cm on either side of said joint support.

18. The assembly of claim 16 wherein said joint support 9 means is of the order of 8 to 10 cm wide. S *ot 9.. -31-

19. A cladding panel butt joint assembly as herei.nbefore particularly described with reference to what is shown in the accompanying drawings. Dated this 6th day of September, 1993. TERRANS ENTERPRISES PTY. LIMITED, Patent Attorneys for the Applicant: PETER MAXWELL ASSOCIATES U U U U .U U U U U U U U U U. U. *U C U U U U U U. U. U 0 U U OU U U U 0 S ABSTRACT A butt joint assembly (10) for joining evenly adjacent end edges (12, 14) of longitudinally adjacent first and second cladding panels (13, 15) wherein a joint support (11) is located symmetrically and supportingly beneath the joint line of the butt joint (10) and extends a predetermined distance on either side thereof. *040** At least the top face (25) of the joint support (11) is connected to the underside of the panel ends (12, 14). In a particular form the joint support (11) is adhered by use of double sided adhesive tape. Fasteners (32) can be 4 utilised to aid mechanical connection between the joint support 11 and the panel ends (12, 14). A butt joint clamp (33) is utilised to support the butt joint assembly (10) during assembly and/or whilst the adhesive is setting. In a further particular form the joint support is 6 comprised of a plurality of individual support members (305, S* 306) adapted to lie within end slots (302, 303) defined within the cladding panel shells. In yet a further particular form the joint supports are themselves joinable at the join line of the cladding panel ends (52, 53).