EP2189588A1

EP2189588A1 - Cladding piece and method for mounting same

Info

Publication number: EP2189588A1
Application number: EP07803677A
Authority: EP
Inventors: Enrique Zamora Loureiro; Juan Antonio Garcia Prades
Original assignee: Ceramica Saloni SA; Uralita Iberia SL
Current assignee: Ceramica Saloni SA; Coemac Iberia SL
Priority date: 2007-08-10
Filing date: 2007-08-10
Publication date: 2010-05-26
Also published as: WO2009022032A1

Abstract

The object of the present invention is a cladding piece used principally to cover walls and the method for mounting said piece to cover both the wall area and to resolve corners. The present solution permits the use of large pieces in which the outside face of said piece is composed of stone of very little thickness, and resolves the problems raised by lack of resistance and fragility which a single thin stone layer would demonstrate, as well as flatness and adequate meeting of adjacent pieces when these cover a large area.

Description

OBJECT OF THE INVENTION

The object of the present invention is a cladding piece used to cover walls and the method of mounting said piece in order to cover the area of the wall and to resolve coverage of corners.
The present solution permits the use of large pieces in which the external face of the piece consists of a thin ceramic or stone layer, which resolves any problems of lack of resistance and fragility which a single thin plate would normally raise; in addition to the flatness and correct meeting of adjacently arranged plates when a large area is covered.

BACKGROUND TO THE INVENTION

Wall cladding using ceramic or stone plates has traditionally made use of plates with dimensions which can be handled manually and which have sufficient thickness for the plate to be resistant, enabling handling during cladding work on site.
These relatively small plates can be adjusted on site so that the edges of one plate correctly meet with its adjacent plate. All that is required is use of a cement such as plaster or similar to ensure that the newly laid material permits deformation thus adjusting to its final position.
The high cost of some stone and interest in making better use of quarries has led to the development of plates with reinforced back faces.
In these pieces the front face comprises a small sized stone plate and the reinforcement may be set cement which maintains resistance.
In this type of piece, the thickness of the plate is not always maintained constant and the correct placement is achieved by adjusting the cement used in fixation so that the open face is able to conserve its flatness.
The need for reducing installation costs has led to the use of larger plates and the use of plates as high as one storey has been considered.
As the dimensions of these extremely high plates mean that they require a thinner plate, they tend to be difficult to handle and are fragile. In addition, the connection using mortar makes small positional deviations during fitting so that the edges are unacceptable as they give rise to uneven stepping in respect of the adjacent plates.
For example, patent GGB2374881 make use of plates with ceramic elements on their external face which should ensure the flatness of the external face in support of the internal face. In this case it is possible if the plate is not large.
In addition, in this patent the connections between the cladding plates give rise to passage through or direct accesses which communicate with the support and which should be covered, for example, by cement.
It is important to ensure that thermal or acoustic bridges are not established in order to achieve overall good performance of the cladding.
German utility model DE3804311 is known in which the backing of a plate incorporates an insulator which permits an increase in the resistance of the front plate. This front plate, which may be made of stone, is considered to be thin and large. However it does not resolve the mode of fitting, but rather that of ensuring its resistance by means of a support in the form of a back plate.
This invention resolves the disadvantages of fitting large plates, both in structural and positional terms, in meeting up other pieces in the final position of the cladding.

DESCRIPTION OF THE INVENTION

An initial aspect of the invention comprises a cladding piece, the final result of which is a plate with fragile material such as a stone or ceramic layer covering large areas on the external face.
The large size fitted covers of the invention means that each piece fitted covers a large area thus reducing installation costs; and the thinness implies lower cost of the piece in terms of the more expensive material when manufacturing.
The piece according to this first aspect of the invention comprises:

A first external plate,
A second internal structural reinforcement plate, where the first external plate is solid through its internal face with the second internal structural reinforcement plate where the piece is provided with one or more separators for attachment of the piece to the resistant structure on which it is fixed and where the separator(s) are joined on the internal face of the first plate.

The first plate is one which in the examples described shall be considered to be ceramic or stone and which, when fitted, will present the external face of the piece which is the subject of the invention. For example, if made of marble this plate should be as thin as possible.
The second structural reinforcement plate provides the whole item with its resistance and provides the first plate with its strength. If the external plate cracks, the presence of a second internal plate solid to the first will prevent the crack from extending; and in the case of breakage, it will prevent the plate from becoming detached.
The solid attachment of the external and internal plates may be achieved by application of a binding layer. In some cases this may be a simple adhesive and in others a layer with both acoustic and heat insulating properties. Similarly, fire resistance may be increased, the value of which shall depend not only on the properties of the insulated piece but also on the solutions for connection which will be described in detail below and included in the dependent claims.
A relevant differential element in terms of the state of the art is deemed to be the presence of separators comprising pieces joined on the internal face of the first plate. These separators are those which are linked directly to the resistant structure required to support the piece which is the subject of the invention and which determine the flatness of the final fitting of the cladding.
Given that the second internal structural reinforcement layer according to the invention comprises a less valuable material, perfect flatness of the whole piece is not necessarily achieved. The flatness of the piece with respect to other pieces (all of which should be coplanar) is achieved if in the joints of the piece according to the invention with the resistant structure, the distance to the external plate (which is flat except for distortion due to inflection) is properly calibrated. This is achieved by distributing the separators throughout the area of the piece which is the subject of the invention, and these establish a distance, according to the direction perpendicular to the first externally arranged, predetermined and well calibrated plate.
Given that the separators link the first plate with the structure and not the second internal plate, the first external plate is distanced from the structure by a distance determined by the attachment points established by the dimensions of the separators. According to the position of the separators, it may be necessary for the second plate to be provided with grooves which permit the passage of the separators so that they may be linked directly to the first plate.
Since the piece is manufactured providing the first plate with a second resistant plate at the time of manufacture, construction on site does not require setting and therefore there is no waiting time for final attachment.
A second aspect of the invention is the method of mounting the piece. Given that use is made of various construction details of the piece, the description of the stages of mounting of the piece will be made at the end of the detailed description of the invention.

DESCRIPTION OF THE DRAWINGS

The present descriptive report is supplemented by a series of drawings illustrative of a preferred embodiment but not, however, restricting the invention in any way.

Figure 1 shows a diagram of a piece according to an example of carrying out the invention. This same figure shows a section A-A of the cladding piece. The piece shown permits consecutive connection of various units in order to cover a specific area. The elevation of the piece is seen from a back view in order to show the separators which are concealed during operation following installation.
Figure 2 shows a diagram of the piece similar to figure 1 however, without the step linking it to the adjacent piece. The piece thus configured illustrates readiness for commencing the cladding work.
Figure 3 shows an example of installation with upper and lower guides supporting the vertical uprights to which the pieces of this example of the invention are attached.
Figures 4 and 5 show another example of an embodiment with fewer separators per piece. These figures show two pieces prior to connection and subsequent connection obtained by lateral displacement of the piece to be fitted, taking the piece already fitted as a reference. The views shown indicate the upper profile and also the elevation of the back piece in order to observe the separators.
Figure 6 shows how a corner section is resolved by using cladding pieces according to the invention.

DETAILED EXPLANATION OF THE INVENTION

Figures 1 and 2 show cladding pieces according to a first example of implementation of the invention. The piece shown in figure 2 permits the cladding to be initiated and the piece in figure 1 permits fitting of the second and subsequent pieces linked to each other.
The structure of the piece in the example of this invention represented in figure 1 consists of:

a first (1) plate preferably made from ceramic or stone, and with reduced thickness as it is the most valuable material and is used for the external face of the cladding.
a second(2) plate linked to the first and made from a cheaper material, used to provide the first (1) plate with resistance and strength. This second plate may be made from a composite material such as cardboard-plaster, laminated paper board, plaster, plaster reinforced with resins and others. The link with the first (1) plate may be made due to the fact that the second (2) plate material has adhesive capacity such as plaster or plaster with resins; or due to the fact that it has an intermediate connection layer (4). This intermediate connection layer (4) may be an adhesive which joins a first (1) and second (2) plate: or it may be a layer of insulating material which in turn is joined for example by adhesive to the first (1) and second (2) layer.
One or more separators (3). The separators (3) are pieces which are situated on the internal face of the first (1) plate. These pieces in this embodiment have a height (measured in a direction perpendicular to the main plane of the first (1) plate) greater than the thickness of the second (2) plate so that they emerge on top of this second plate (2). If necessary, the second plate (2) is provided with grooves (2.1) which enable the separators (3) to be situated directly on the first (1) plate. The piece of the example according to the invention is arranged vertical to its principal plane parallel to the wall, establishing connection to the resistant structure which keeps it in its final position.
The separators (3) are the components that are provided with means which will enable the plate to be correctly positioned in the three directions of the space.

Depth direction

This example makes use of a lower (7) and upper guide (6) arranged on the floor and on the ceiling respectively on which vertical uprights (5) are mounted. The upper and lower guides (6, 7) are profiles which permit fitting of the uprights. The guides (6, 7) establish a reference (R) which ensures flatness of the face, that is, of the plane (P) defined by the face of the first (1) plate.
Another option is that of attaching the uprights (5) directly to the fixed structure of the work. In this case, the uprights (5) should continue to ensure the flatness reference (R).
Prior to carrying out the installation of the pieces according to the example of this invention, the uprights (5) are fixed to the separators (3).
This attachment may be made by clipping or by insertion of the separator (3) in grooves. This second connection consists of the presence of a neck in the separator (3) which enters a groove of the upright (5). Entry is usually defined in a cavity which is sufficiently wide and, according to relative displacement of the upright (5) with respect to the separator ( 3), the neck enters up to the end of the groove making a definitive connection.
The type of connection used in this example permits rapid installation which does not affect the depth of the positioning. The depth in this case shall be defined by the height, not of the complete separator (3), but by the height measured from the base of the separator (3) up to the neck.
Figure 3 shows only 2 uprights (5) per piece as the third upright (5) is provided by the adjacent piece. Only the piece corresponding to figure 2 incorporates the three uprights.
Once the cladding piece according to the example of the invention incorporates uprights (5), fitting is then carried out either on the guides (6, 7) with the connection means provided; or directly on the work.
Optionally there may be other guides coinciding with the upper edge of the cladding piece and another guide with the lower edge of the cladding piece. In this case the upper and lower edges of the cladding piece shall be provided with an adapted form in order to receive the guides and which serve as additional means for ensuring flatness.
This flatness is ensured, although as occurs in this example, it is provided with sufficiently large pieces so as to over the total height from the floor to the ceiling; where, in the event of angular deviations in a plate of this size the adjacent edges could present unacceptable ridges.

Direction according to lateral and vertical displacements.

Figures 4 and 5 show another example of an embodiment with fewer separators (3) per piece. The figures show connection through lateral displacement. Lateral displacement permits a flap (1.1) (present due to the extension of the first (1) plate with respect to the second (2) plate) to enter a recess which forms a tongue and grooved connection.
Wide arrows indicate the direction of the displacement of a piece with respect to the adjacent piece for the tongue and grooved connection.
In this example, the separators (3) show a configuration which permits a shape connection. The configuration used combines "C" shaped sections and separators with an antagonistic form so that it adapts to the "C" shaped cavity.
Even if the forms are not antagonistic the support or the fact of at least two separators (3) of different pieces situated adjacently entering into contact permits restriction of lateral displacement.
The presence of separators (3), with configurations which permit connection of form restricts vertical displacement when both separators (3) fit into each other.
A mode of configuration is considered for the separators (3) which permits adjacent separators (3) to be clipped together. This particular means of configuration prevents the recently placed piece from slipping out or becoming disconnected. Clipping may give rise to a retention which may be overcome with a certain degree of force designed to separate the clipped separators (3); or it may be carried out by means of a setting without it being possible to separate them again.
The pieces represented in figures 4 and 5 are such that the first piece permits mounting to be commenced (as shown on the right) and the second through repetition enables the necessary area to be covered. In the elevation views the uprights are not shown in the interest of clarity in order to depict the connection between separators (3) in greater detail.

Resolving corners

Figure 6 shows a solution for corners. Having progressed with laying the pieces, the final piece incorporates a strip (8) which permits attachment and provides a reference for the pieces which are set in a perpendicular manner from the corner.
This means of resolving corners may be extrapolated to meetings with windows, doors and in general any cavity in the work.
In the case of windows the pieces may be designed to provide for recesses or cavities encountered on site permitting the presence of windows or other similar cavities.

Other construction details

Plates (1, 2) which make up the cladding piece may also be provided with other insulating plates on the back of the piece. That is, the insulating plate may be placed on the back face of the second (2) internal structural reinforcement plate.
In addition, in the joints there is no direct communication between the outside face and the back structure. However, it is possible to incorporate sealing cement.
In order to ensure connection to the uprights (5) they may also be screwed, riveted or by any similar means fixed onto the second (2) plate against the upright (5) or the back resistant structure onto the edge of the piece, coinciding with the staggered recess (1.2) which makes the first (1) and second (2) plate out of step. The entrance (1.2) where the connection is made, for example, the bolting is covered by the flap (1.1) of the adjacently placed piece and thus the tongue and grooving conceals the connection means.
Having considered various means of embodiment for the cladding piece, the following essential mounting stages are described

layout of the work,
placing of the grooves or profiles of floor and ceiling,
preparation of the pieces
fitting of the uprights
fitting of the first piece in the grooves or profiles of the floor and ceiling and in the uprights if necessary,
preparation and placing of the second and subsequent pieces until the length has been completed.

Preparation of the pieces consists mainly of cutting the pieces to size for covering the area using the cladding pieces. The first piece fitted is that which has no recess (1.2) as it is not required to receive another piece. Starting with this piece, other pieces provided with a recess (1.2) are incorporated since the entrance (1.2) will be covered by the flap (1.1) of the tongue and grooving.
Fitting of the uprights or the pieces is made on the guides or profiles of roof and floor and the piece is then moved laterally in order to permit entry of the tongue and grooving. According to figure 6, the order of placement of the pieces is from right to left until the corner is reached.
Having reached the corner installation, a strip (8) is fitted, arranged on the external face of the last piece fitted in order to begin mounting of the next corner piece taking the strip as a support and reference.
From this first piece following the corner, the order of growth will be downwards (as represented in figure 6). A wide arrow is used to indicate the direction and displacement of the final piece so that it enters the strip (8) thus ensuring the positional reference.

Claims

- Cladding piece which comprises:
• a first (1) external plate,

• a second (2) internal structural reinforcement plate, where the first (1) external plate is solid through its internal face to the second (2) internal structural reinforcement plate characterised in that it is provided with one or more separators on which it is fixed and where the separator(s) (3) are joined on the internal face of the first plate (1).
.- Cladding piece according to claim 1 characterised in that the second (2) internal structural reinforcement plate extends laterally from the first (1) external plate giving rise to a flap (1.1).
.- Cladding piece according to claim 2 characterised in that the second (2) internal structural reinforcement plate is provided on the side opposite to the flap (1.1) with a recess (1.2) which permits consecutive connection through tongue and grooving.
.- Cladding piece according to claim 1 characterised in that there is a binding layer between the first (1) plate and the second (2) plate.
.- Cladding piece according to claim 4 characterised in that the connecting layer (4) between the first (1) external plate and the second (2) internal structural reinforcement plate is a layer of adhesive.
.- Cladding piece according to claim 4 characterised in that the connecting layer (4) between the first (1) external plate and the second (2) internal structural reinforcement plate is an insulating layer joined to both.
. - Cladding piece according to claim 6 characterised in that the connection of the connecting the layer (4) with the first (1) external plate and the second (2) internal structural reinforcement plate is by means of adhesive.
. - Cladding piece according to claim 1 characterised in that the separator(s) (3) are situated on the internal face of the first (1) external plate coinciding with a groove (2.1) of the second (2) internal structural reinforcement plate.
. Cladding piece according to claim 1 characterised in that the separators (3) are provided with means which will enable the plate to be correctly positioned in the three directions of the space.
.- Cladding piece according to claims 1 or 9 characterised in that the separator(s) (3) are situated in such a way that in operating position following mounting, at least two separators (3) from different pieces arranged adjacently enter into contact.
.- Cladding piece according to claims 9 or 10 characterised in that the separator(s) (3) present a configuration which permits coupling of form between two separators (3) of different pieces arranged adjacently in such a way that in operating position following mounting, they prevent relative displacement of the adjacent edges of the pieces.
.- Cladding piece according to claims 1 or 11 characterised in that the connection between the separators (3) is made by clipping.
.- Cladding piece according to claim 12 characterised in that the clipping establishes a retention means which can be disconnected by the application of force.
.- Cladding piece according to claim 12 characterised in that the clipping is carried out by means of a setting.
.- Cladding piece according to claim 1 and either of claims 2 or 3 characterised in that at least one separator (3) coincides with the lateral recess (1.2) in order to permit reinforcement of the connection preferably by bolting, riveting or a similar process, between the second (2) internal plate and the upright (5) or the back resistant structure with the connection in operating position, following mounting, concealed by the flap (1.1) of the adjacent piece.
.- Cladding piece according to claim 1 characterised in that the separator elements (3) are provided with means of attachment with upright profiles (5).
.- Cladding piece according to claim 1 characterised in that an insulating layer is arranged on the back face of the second (2) internal structural reinforcement plate.
.- Cladding piece according to claim 1 characterised in that on the frontal face of the first (1) external plate there is a strip for meeting the next piece on a corner piece.
.- Cladding piece according to claim 1 characterised in that the edge of the piece to be placed above has a configuration able to receive a profile or groove.
.- Cladding piece according to claim 1 characterised in that the edge of the piece to be placed below has a configuration able to receive a profile or groove.
.- Cladding piece according to claim 1 characterised in that the material in the first (1) external plate is ceramic or stone.
. - Method for mounting the piece configured according to any of the previous claims characterised in that it includes the following stages:
• layout of the work

• fitting of grooves or profiles (6, 7) of the floor and the roof,

• preparation of the pieces,

• fitting of the uprights (5),

• fitting of the first piece in the grooves or profiles (6, 7) of the floor and ceiling and in the uprights (5) if necessary,

• Preparation and placing of the second (2) and subsequent pieces until the length has been completed.
.- Method for mounting the piece configured according to claim 22 characterised in that preparation of the pieces consists of cutting to size.
.- Method for mounting the piece configured according to claim 22 characterised in that prior to placing the first piece the initial upright (5) is fitted.
. - Method for mounting the piece configured according to claim 22 characterised in that the uprights (5) are placed on grooves or profiles (6, 7) of the floor and ceiling in order to admit the pieces.
.- Method for mounting the piece configured according to claim 22 characterised in that the uprights (5) are placed on the pieces for subsequent installation of the arrangement in the grooves or profiles (6, 7) of the floor and ceiling.
.- Method for mounting the piece configured according to claim 22 characterised in that an additional attachment of the piece to the upright (5) or rigid back structure is carried out, preferably by bolting, riveting or similar, applying the connection between the second (2) plate in the lateral recess (1. 2) of the piece and the upright (5) or rigid back structure.
.- Method for mounting the piece configured according to claim 22 characterised in that having reached the corner installation, a strip (8) is fitted arranged on the external face of the last piece fitted in order to begin mounting of the next corner piece taking the strip (8) as a support and reference.