EP3330449A1

EP3330449A1 - A building component

Info

Publication number: EP3330449A1
Application number: EP17205575.8A
Authority: EP
Inventors: Sean Plunkett Coyle
Original assignee: Masonry Support Systems Ltd
Current assignee: Masonry Support Systems Ltd
Priority date: 2016-12-05
Filing date: 2017-12-05
Publication date: 2018-06-06
Also published as: GB201620613D0

Abstract

A building component indicated generally by the reference numeral 1 having an elongate support structure 2. The elongate support structure 2 shaped to receive a covering element 3. The elongate support structure 2 has a mechanical fixing component 4. The covering element 3 has a corresponding mechanical retaining component 5 for cooperating with the mechanical fixing component 4 of the elongate support structure 2 for mechanically fixing the covering element 3 and the elongate support structure 2 together.

Description

The present invention is directed towards building components, and in particular to building components comprising an elongate support structure shaped to receive a plurality of covering elements. The building component can be a lintel for a doorway, archway or window opening.
The covering elements are designed to give an attractive outer appearance to the building component and can help the building component conform the building to the architectural style of those around it. Most commonly, the covering elements come in the form of masonry or synthetic slips which are relatively thin components fitted to the building component to provide the required shape and aesthetic. One of the most common types of masonry slips are brick slips which can be adhesively bonded to the lintel via a suitable adhesive and current solutions also provide cut-outs in the lintel. This allows a portion of the adhesive to pass there through and form a mechanical gripping formation on the backside of the lintel, further enhancing the grip the adhesive has on the lintel. In addition, the brick slips themselves can be provided with channels which permit the adhesive to travel or expand into the channels to further enhance the adhesive and mechanical attachment between the brick slips and the building component.
While these prior systems have been successful in enhancing the bond between the covering elements and the building components it is still desirable to further enhance the attachment of the covering elements and the building components in the event that the adhesive fails.
It is an objective of the present invention to enhance the attachment of covering elements to building components comprising an elongate support structure.
Accordingly, the present invention provides a building component comprising an elongate support structure shaped to receive at least one covering element, the elongate support structure comprising a mechanical fixing means for mechanically fixing the covering element and the elongate support structure together.
Preferably, the at least one covering element has a corresponding mechanical retaining means for cooperating with the mechanical fixing means of the elongate support structure for mechanically fixing the covering element and the elongate support structure together.
Ideally, the mechanical retaining means for cooperating with the mechanical fixing means and the mechanical fixing means are male and female means.
Preferably, the mechanical fixing means of the elongate support structure is a male fixing means for mechanically fixing the covering element and the elongate support structure together.
Ideally, the mechanical retaining means of the covering element is a female retaining means for mechanically fixing the covering element and the elongate support structure together.
Preferably, the female retaining means for mechanically fixing the covering element and the elongate support structure together comprises one or more recesses formed in the covering element.
Ideally, the mechanical fixing means of the elongate support structure is a flange-like projecting means for mechanically fixing the covering elements and the elongate support structure together. Forming a mechanical fixing between the elongate support structure and the covering element means that the flange-like projecting means forms an interlock with the covering elements. More preferably still, the flange-like projecting means are adapted to engage with one or more recesses provided in the covering element.
Preferably, the elongate support structure is adapted to receive an adhesive for adhesively bonding the one or more covering elements to the elongate support structure.
Ideally, the mechanical fixing means are adapted to enhance the adhesive bond between the covering elements and the elongate support structure. The mechanical fixing means preferably enhance the adhesive bond between the covering elements and the elongate support structure by forming an interlock with the covering elements. The interlock can limit or prevent the lateral and/or longitudinal and/or vertical displacement of the covering elements with respect to the elongate support structure.
Preferably, the mechanical fixing means are adapted to hold the covering elements in-place on the elongate support structure in the event that the adhesive bond between the covering elements and the elongate support structure weakens or fails.
Advantageously, the mechanical fixing means act as a back-up or fail safe device to prevent the covering elements from being separated from the elongate support structure even if the adhesive bond is weakened or fails entirely.
The present invention is particularly advantageous in situations where the building component is installed in a building above a walkway or other area which is frequently populated. In these installations, having covering elements drop downwards would be understandably problematic.
Ideally, the elongate support structure comprises a fascia wall, the fascia wall being adapted to receive the covering elements. The fascia wall is preferably adapted to receive an adhesive for adhesively bonding the covering elements to the elongate support structure.
Ideally, the fascia wall comprises one or more imperfections for enhancing the adhesive bonding between the fascia wall and the covering elements. The one or more imperfections preferably act as a keying surface.
Preferably, the imperfections in the fascia wall are perforations. The perforations may be round, square, diamond-shaped or slotted holes.
Ideally, the flange-like projecting means comprises a fascia flange-like projection, the fascia flange-like projection being adapted to extend from the fascia wall.
Preferably, the fascia flange-like projection being adapted to extend from a lower edge section of the fascia wall.
Ideally, the fascia flange-like projection being adapted to extend along some or all of the length of the lower edge section of the fascia wall.
In one arrangement, the fascia flange-like projection comprises a plurality of discrete projection components, the projection components being spaced apart along some or all of the length of the lower edge section of the fascia wall.
More preferably, the fascia flange-like projection extends continuously along some or all of the length of the lower edge section of the fascia wall.
Preferably, the fascia flange-like projection being attached to the fascia wall.
Being attached to the fascia wall preferably means that the fascia flange-like projection is mechanically fastened to the lower edge section of the fascia wall. Mechanically fastening includes welding, adhesively bonding, riveting, screwing, and/or nailing the fascia-flange like projection to the fascia wall.
Alternatively, the fascia flange-like projection being integrally formed with the fascia wall. By "integrally formed" we mean that the fascia flange-like projection is designed as an integral component of the fascia wall.
Alternatively still, the fascia flange-like projection being a unitary component of the fascia wall.
Preferably, the elongate support structure comprises a soffit wall, the soffit wall being adapted to receive the covering elements. The soffit wall is preferably adapted to receive an adhesive for adhesively bonding the covering elements to the elongate support structure.
Ideally, the soffit wall comprises one or more imperfections for enhancing the adhesive bonding between the fascia wall and the covering elements. The one or more imperfections preferably act as a keying surface.
Preferably, the imperfections in the soffit wall are perforations. The perforations may be round, square diamond-shaped or slotted holes.
Ideally, the flange-like projecting means comprises a soffit flange-like projection, the soffit flange-like projection being adapted to extend from the soffit wall.
Preferably, the soffit flange-like projection being adapted to extend from an edge section of the soffit wall. More preferably, the soffit flange-like projection being adapted to extend from an edge section of the soffit wall that is spaced apart from a fascia wall of the elongate support structure.
Ideally, the soffit flange-like projection being adapted to extend along some or all of the length of the edge section of the soffit wall.
In one arrangement, the soffit flange-like projection comprises a plurality of discrete projection components, the projection components being spaced apart along some or all of the length of the edge section of the soffit wall.
More preferably, the soffit flange-like projection extends continuously along some or all of the length of the edge section of the soffit wall.
Preferably, the soffit flange-like projection being adapted to extend away from the soffit wall and towards the fascia wall.
Ideally, the soffit flange-like projection comprises a flange portion extending generally downwardly form the soffit wall, and a lip or ridge extending generally perpendicular to the soffit wall and towards the fascia wall.
Preferably, the soffit flange-like projection being attached to the soffit wall.
Being attached to the soffit wall preferably means that the soffit flange-like projection is mechanically fastened to the soffit wall. Mechanically fastening includes welding, adhesively bonding, riveting, screwing, and/or nailing the soffit-flange like projection to the soffit wall.
Alternatively, the soffit flange-like projection being integrally formed with the soffit wall. By "integrally formed" we mean that the soffit flange-like projection is designed as an integral component of the soffit wall.
Alternatively still, the soffit flange-like projection being a unitary component of the soffit wall.
Preferably, the flange-like projecting means comprises a fascia flange-like projection extending from the fascia wall and a soffit flange-like projection extending from the soffit wall.
Ideally, the elongate support structure further comprises an inwardly facing wall, the inwardly facing wall being opposed to the fascia wall.
Preferably, the soffit wall connects the inwardly facing wall to the fascia wall.
Preferably still, the soffit wall, inwardly facing wall and fascia wall are connected together to form a generally U-shaped profile.
In one arrangement, the fascia wall, soffit wall, and inwardly facing wall form an integral or unitary structure.
In another preferred arrangement, fascia wall, soffit wall, and inwardly facing wall are separate components which are mechanically fastened together. Mechanically fastening includes welding, adhesively bonding, riveting, screwing, and/or nailing the fascia wall, soffit wall, and internally facing wall together.
The soffit flange-like projection is in one arrangement attached to or integrally formed with a lower edge section of the inwardly facing wall.
Ideally, the elongate support component is a metal or metal alloy elongate support component.
Preferably, the building component is attachable to a building to form an exterior section of the building.
Ideally, the building component is adaptable to span a doorway, archway or window opening in the building.
Preferably, the building component comprises a lintel. Most preferably, the lintel is a metal or metal alloy lintel.
Preferably, the lintel comprises the elongate support structure. The lintel has a support means which spans a width wider than the elongate support structure comprising protruding side members. The side members of the lintel extending beyond the elongate support structure can bear against the structure defining the doorway, archway or window opening to therefore support the elongate support structure over the doorway, archway or window opening.
The lintel support means preferably has a foot member and a leg member. The foot member is preferably substantially horizontal and/or the leg member is preferably substantially vertical.
Ideally, the foot member is attachable to the elongate support structure. This ideally means that a fascia wall of the elongate support structure is attached to foot member of the lintel support means.
Most preferably, the lintel support means is an L-shaped lintel although the lintel can be of a different shape such as a box-shaped or a top-hat shaped. Top-hat shaped lintels are also known as cavity wall lintels. The leg member can have an end section which is shaped for increased resistance to buckling and can further comprise reinforcing material.
Ideally, the building component further comprises a gusset extending between the lintel support means and the elongate support structure.
Preferably, the gusset extends from the rear of the leg member of the lintel support means and an inwardly facing wall of the elongate support member.
Preferably, the lintel support means is mechanically fastened to the elongate support component. Mechanically fastening includes welding, adhesively bonding, riveting, screwing, and/or nailing the lintel to the elongate support component.
Alternatively, the lintel support means and the elongate support component form an integral or unitary structure.
Alternatively still, the elongate support component itself can be a lintel. This means that there is no separate lintel support means which is attached or otherwise formed with the elongate support component.
In another optional arrangement, the building component is attachable to a wall of the building. In this optional arrangement, the building component preferably comprises one or more brackets, the brackets being attachable to the wall of the building, and being further adaptable to hold the elongate support component.
Preferably, the covering elements are L-shaped or pistol-shaped covering elements, the L-shaped or pistol-shaped covering elements comprising a first planar section and a second planar section generally perpendicular to the first planar-section.
Ideally, the first planar section is attachable to a fascia wall of the elongate support structure. The second planar section is preferably attachable to a soffit wall of the elongate support structure.
Preferably, the covering elements are masonry covering elements.
Ideally, the covering elements are composite, acrylic, or synthetic covering elements.
Preferably, the covering elements are brick portions.
Ideally, the covering elements are brick, block or stone slips. The slips could be cut or fired slips.
Preferably, the covering elements comprise one or more recesses for receiving the flange-like projection means. The one or more recesses are channels formed in the covering elements.
Ideally, the covering elements comprise two recesses formed in the first planar section of the covering elements, one or both of the recesses being sized to receive adhesive and/or a mechanical fixing means/fascia flange-like projection.
Preferably, the covering elements comprise a recess formed in the tail of the second planar section, the recess being sized to receive adhesive and/or the soffit flange-like projection.
Accordingly, the present invention provides a building component comprising: a plurality of covering elements; adhesive; and an elongate support structure shaped to receive the plurality of covering elements, the plurality of covering elements being adhesively bonded to the elongate support structure by the adhesive, the elongate support structure comprising a mechanical fixing means for breaching the integrity of the covering elements, the mechanical fixing means being adapted to enhance the adhesive bond between the covering elements and the elongate support structure.
The skilled man will appreciate that all preferred or optional features of the invention described with reference to only some aspects or embodiments of the invention may be applied to all aspects of the invention.
It will be appreciated that optional features applicable to one aspect of the invention can be used in any combination, and in any number. Moreover, they can also be used with any of the other aspects of the invention in any combination and in any number. This includes, but is not limited to, the dependent claims from any claim being used as dependent claims for any other claim in the claims of this application.
The invention will now be described with reference to the accompanying drawing which shows by way of example only one embodiment of an apparatus in accordance with the invention.

Figure 1 is a perspective view of the present invention.
Figure 2 is a cross-sectional view of the present invention.
Figure 3 is a plan view of the present invention.
Figure 4 is a front view of the present invention.
Figure 5 is a rear view of the present invention.
Figure 6 is a perspective view of the present invention engaged within the covering element.
Figure 7 is a cross-sectional view of the present invention engaged within the cover element.
Figure 8 is a plan view of the present invention engaged within the cover element.
Figure 9 is a front view of the present invention engaged within the cover element.
Figure 10 is a rear view of the present invention engaged within the cover element.

In the drawing, there is shown a building component indicated generally by the reference numeral 1 having an elongate support structure 2. The elongate support structure 2 shaped to receive a covering element 3, see figures 6 and 7. The elongate support structure 2 has a mechanical fixing component 4. The covering element 3 has a corresponding mechanical retaining component 5 for cooperating with the mechanical fixing component 4 of the elongate support structure 2 for mechanically fixing the covering element 3 and the elongate support structure 2 together.
The mechanical fixing component 4 of the elongate support structure 2 is a male fixing component 6 and the mechanical retaining component 5 of the covering element 3 is a female retaining component 7. The female retaining component 7 for mechanically fixing the covering element 3 and the elongate support structure 2 together has one or more recesses 8 formed in the covering element 3.
The mechanical fixing component 4 of the elongate support structure 2 is a flange-like projecting member 9 for mechanically fixing the covering elements 3 and the elongate support structure 2 together. Forming a mechanical fixing between the elongate support structure 2 and the covering element 3 means that the flange-like projecting member 9 forms an interlock with the covering elements 3. More specifically, the flange-like projecting member 9 is adapted to engage with the recesses 8 provided in the covering element 3.
The elongate support structure 2 is adapted to receive an adhesive (not shown) for adhesively bonding the covering element 3 to the elongate support structure 2. The mechanical fixing component 4 is adapted to enhance the adhesive bond between the covering element 3 and the elongate support structure 2. The mechanical fixing component 4 enhances the adhesive bond between the covering element 3 and the elongate support structure 2 by forming an interlock with the covering element 3. The interlock can limit or prevent the lateral and/or longitudinal and/or vertical displacement of the covering element 3 with respect to the elongate support structure 2.
The mechanical fixing components 4 are adapted to hold the covering elements 3 in-place on the elongate support structure 2 in the event that the adhesive bond between the covering elements 3 and the elongate support structure 2 weakens or fails. The mechanical fixing components 4 act as a "back-up" or fail safe device to prevent the covering elements 3 from being separated from the elongate support structure 2 even if the adhesive bond is weakened or fails entirely. The present invention is particularly advantageous in situations where the building component 1 is installed in a building (not shown) above a walkway or other area (not shown) which is frequently populated. In these installations, having covering elements 3 drop downwards would be understandably problematic.
The elongate support structure 2 comprises a fascia wall 11. The fascia wall 11 being adapted to receive the covering elements 3. The fascia wall 11 is adapted to receive an adhesive (not shown) for adhesively bonding the covering elements 3 to the elongate support structure 2. The fascia wall 11 comprises imperfections/perforations 12, see figures 4 and 5 for enhancing the adhesive bonding between the fascia wall 11 and the covering elements 3. The imperfections/perforations 12 act as a keying surface. The perforations 12 as shown in the drawings are diamond-shaped. However it must be appreciated the perforations 12 could also be round, square or slotted holes.
The flange-like projecting member 9 comprises a fascia flange-like projection 13. The fascia flange-like projection 13 being adapted to extend from a lower edge section 10 of the fascia wall 11.
In one arrangement not shown in the drawings, the fascia flange-like projection 13 comprises a plurality of discrete projection components (not shown), the projection components (not shown) being spaced apart along some or all of the length of the lower edge section 10 of the fascia wall 11.
The fascia flange-like projection 13 are mechanically fastened to the lower edge section 10 of the fascia wall 11 by the use of any type of fastening such as welding, adhesively bonding, riveting, screwing, and/or nailing the fascia flange-like projection 13 to the fascia wall 11.
The elongate support structure 2 has a soffit wall 14. The soffit wall 14 is adapted to receive the covering elements 3. The soffit wall 14 is adapted to receive an adhesive (not shown) for adhesively bonding the covering elements 3 to the elongate support structure 2. The soffit wall 14 has one or more imperfections/perforations 12 for enhancing the adhesive bonding between the fascia wall 11 and the covering elements 3. The imperfections/perforations 12 act as a keying surface and the perforations 12 may be round, square diamond-shaped or slotted holes.
The flange-like projecting member 9 comprises a soffit flange-like projection 15. The soffit flange-like projection 15 is adapted to extend from an edge section 16 of the soffit wall 14 that is spaced apart from a fascia wall 11 of the elongate support structure 2.
In one arrangement not shown in the drawings, the soffit flange-like projection 15 has a plurality of discrete projection components (not shown). The discrete projection components (not shown) being spaced apart along some or all of the length of the edge section 16 of the soffit wall 14.
The soffit flange-like projection 15 extends continuously along some or all of the length of the edge section 16 of the soffit wall 14 and extends away from the soffit wall 14 and towards the fascia wall 11. The soffit flange-like projection 15 has a flange portion 28 extending generally downwardly from the soffit wall 14, and a lip (or ridge) 18 which extends generally perpendicular to the soffit wall 14 and towards the fascia wall 11. The soffit flange-like projection 15 is attached to the soffit wall 14 by fastenings such as but not limited to welding, adhesively bonding, riveting, screwing, and/or nailing the soffit flange-like projection 15 to the soffit wall 14.
The flange-like projecting member 9 comprises a fascia flange-like projection 13 extending from the fascia wall 11 and a soffit flange-like projection 15 extending from the soffit wall 14. The elongate support structure 2 further has an inwardly facing wall 17. The inwardly facing wall 17 is opposed to the fascia wall 11. The soffit wall 14 connects the inwardly facing wall 17 to the fascia wall 11 to form a generally U-shaped profile. As shown in the drawings the fascia wall 11, soffit wall 14, and inwardly facing wall 17 are separate components which are mechanically fastened together. Mechanically fastening includes welding, adhesively bonding, riveting, screwing, and/or nailing the fascia wall 11, soffit wall 14, and internally facing wall 17 together.
The building component 1 is a lintel. The lintel 1 comprises the elongate support structure 2. The lintel has a support member 18 which spans a width wider than the elongate support structure comprising protruding side members 19. The side members 19 of the lintel 1 extends beyond the elongate support structure 2 and can bear against the structure defining the doorway, archway or window opening to therefore support the elongate support structure over the doorway, archway or window opening (not shown). The lintel support member 18 has a foot member 29 and a leg member 20. The foot member 29 is substantially horizontal and the leg member 20 is substantially vertical. The foot member 29 is attached to the elongate support structure 2. This means that a fascia wall 11 of the elongate support structure 2 is attached to foot member 19 of the lintel support member 18. The leg member 20 can although not shown in the drawings have an end section which is shaped for increased resistance to buckling and can further comprise reinforcing material.
The lintel 1 further has a gusset 21 extending between the lintel support member 18 and the elongate support structure 2. The gusset 21 extends from the rear of the leg member 20 of the lintel support member 18 and an inwardly facing wall 22 of the elongate support member 2.
The lintel support member 18 is mechanically fastened to the elongate support component 2. Mechanically fastening includes welding, adhesively bonding, riveting, screwing, and/or nailing the lintel to the elongate support component.
The covering elements 3 are L-shaped or pistol-shaped covering elements. The L-shaped or pistol-shaped covering elements 3 have a first planar section 23 and a second planar section 24 perpendicular to the first planar-section 23. The first planar section 23 is attached to a fascia wall 11 of the elongate support structure 2. The second planar section 24 is attached to a soffit wall 14 of the elongate support structure 2.
The covering elements 3 are brick, block or stone slips. The covering elements 3 have two recesses 25 formed in the first planar section 23 of the covering elements 3 and one or both of the recesses 25 are sized to receive adhesive (not shown) and/or a mechanical fixing component 4 / fascia flange-like projection 13. The covering elements 3 have a recess 26 formed in the tail 27 of the second planar section 24, the recess 26 being sized to receive adhesive (not shown) and/or the soffit flange-like projection 15.
In relation to the detailed description of the different embodiments of the invention, it will be understood that one or more technical features of one embodiment can be used in combination with one or more technical features of any other embodiment where the transferred use of the one or more technical features would be immediately apparent to a person of ordinary skill in the art to carry out a similar function in a similar way on the other embodiment.
In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled with an indication that one of the said values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of said parameter, lying between the more preferred and the less preferred of said alternatives, is itself preferred to said less preferred value and also to each value lying between said less preferred value and said intermediate value.
The features disclosed in the foregoing description or the following drawings, expressed in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of attaining the disclosed result, as appropriate, may separately, or in any combination of such features be utilised for realising the invention in diverse forms thereof.

Claims

A building component comprising an elongate support structure shaped to receive at least one covering element, the elongate support structure comprising a mechanical fixing means for mechanically fixing the covering element and the elongate support structure together.
A building component as claimed in claim 1, wherein the at least one covering element has a corresponding mechanical retaining means for cooperating with the mechanical fixing means of the elongate support structure for mechanically fixing the covering element and the elongate support structure together.
A building component as claimed in claim 1 or claim 2, wherein the mechanical retaining means for cooperating with the mechanical fixing means and the mechanical fixing means are male and female means.
A building component as claimed in claim 3, wherein the mechanical fixing means of the elongate support structure is a male fixing means for mechanically fixing the covering element and the elongate support structure together.
A building component as claimed in claim 3 or claim 4, wherein the mechanical retaining means of the covering element is a female retaining means for mechanically fixing the covering element and the elongate support structure together.
A building component as claimed in claim 5, wherein the female retaining means for mechanically fixing the covering element and the elongate support structure together comprises one or more recesses formed in the covering element.
A building component as claimed in any one of the preceding claims, wherein the mechanical fixing means of the elongate support structure is a flange-like projecting means for mechanically fixing the covering elements and the elongate support structure together.
A building component as claimed in any one of the preceding claims, wherein the elongate support structure is adapted to receive an adhesive for adhesively bonding the one or more covering elements to the elongate support structure.
A building component as claimed in claim 8, wherein the mechanical fixing means are adapted to enhance the adhesive bond between the covering elements and the elongate support structure.
A building component as claimed in claim 8 or claim 9, wherein the mechanical fixing means are adapted to enhance the adhesive bond between the covering elements and the elongate support structure by forming an interlock with the covering elements.
A building component as claimed in any one of claims 8 to 10, wherein the mechanical fixing means are adapted to hold the covering elements in-place on the elongate support structure in the event that the adhesive bond between the covering elements and the elongate support structure weakens or fails.
A building component as claimed in any one of the preceding claims, wherein the elongate support structure comprises a fascia wall.
A building component as claimed in claim 12, wherein the fascia wall is adapted to receive the covering elements.
A building component as claimed in claim 12 or claim 13, wherein the fascia wall is preferably adapted to receive an adhesive for adhesively bonding the covering elements to the elongate support structure.
A building component as claimed in any one of claims 12 to 14 when dependent on claim 7, wherein the flange-like projecting means comprises a fascia flange-like projection, the fascia flange-like projection being adapted to extend from the fascia wall.
A building component comprising: a plurality of covering elements; adhesive; and an elongate support structure shaped to receive the plurality of covering elements, the plurality of covering elements being adhesively bonded to the elongate support structure by the adhesive, the elongate support structure comprising a mechanical fixing means for breaching the integrity of the covering elements, the mechanical fixing means being adapted to enhance the adhesive bond between the covering elements and the elongate support structure.