EP4630635A2 - Fascia panel system, a packing element for a fascia panel system & method of attaching a fascia panel to a wall - Google Patents

Fascia panel system, a packing element for a fascia panel system & method of attaching a fascia panel to a wall

Info

Publication number
EP4630635A2
EP4630635A2 EP23836906.0A EP23836906A EP4630635A2 EP 4630635 A2 EP4630635 A2 EP 4630635A2 EP 23836906 A EP23836906 A EP 23836906A EP 4630635 A2 EP4630635 A2 EP 4630635A2
Authority
EP
European Patent Office
Prior art keywords
packing element
fascia panel
prong
aperture
fascia
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23836906.0A
Other languages
German (de)
French (fr)
Inventor
Simon Christopher Braid
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Progroup Corp Ltd
Original Assignee
Progroup Corp Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Progroup Corp Ltd filed Critical Progroup Corp Ltd
Publication of EP4630635A2 publication Critical patent/EP4630635A2/en
Pending legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801—Separate fastening elements
    • E04F13/0832—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements
    • E04F13/0833—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable
    • E04F13/0846—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable the fastening elements engaging holes or grooves in the side faces of the covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801—Separate fastening elements
    • E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
    • E04F13/081—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements
    • E04F13/0816—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements extending into the back side of the covering elements
    • E04F13/0817—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements extending into the back side of the covering elements extending completely through the covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801—Separate fastening elements
    • E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
    • E04F13/081—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements
    • E04F13/0816—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements extending into the back side of the covering elements
    • E04F13/0819—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements extending into the back side of the covering elements inserted into grooves in the back side of the covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801—Separate fastening elements
    • E04F13/0832—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements
    • E04F13/0833—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable
    • E04F13/0835—Separate fastening elements without load-supporting elongated furring elements between wall and covering elements not adjustable the fastening elements extending into the back side of the covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
    • E04F13/0894—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with tongue and groove connections
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/12—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of metal or with an outer layer of metal or enameled metal
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/18—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles

Definitions

  • the invention relates to a fascia panel system, a packing element for a fascia panel system, and a method for attaching a fascia panel to a wall.
  • Fascia panels are applied to substrates, such as building walls to protect the walls and for decorative purposes. Fascia panels can be applied to external or internal walls. In some instances, it is desirable to space the fascia panels away from the wall on which they are mounted to allow air to circulate between the fascia panels and the wall. However, it can be a difficult and time-consuming process to mount fascia panels in this manner since fascia panel systems have not been designed with this mounting process in mind. In particular, it can be difficult for installers to hold the fascia panel, a packing element and simultaneously fix the fascia panel to the wall. An alternative method is to fix multiple batons to the wall, and then fix the fascia panel to the batons, however this solution doesn’t work particularly well when the wall is uneven.
  • the invention seeks to provide a fascia panel system, a packing element, and a method for attaching a fascia panel to a wall that addresses at least one of the above- mentioned problems, or at least provides an alternative arrangement to known fascia panel systems, packing elements and methods.
  • a fascia panel system according to claim 1 .
  • the invention provides an improved fascia panel system that can be more easily applied to a wall by attaching packing elements to the fascia panels to form a sub-assembly prior to fastening the panels to the walls.
  • a fascia panel system According to another aspect, there is provided a fascia panel system.
  • the fascia panel system can include at least one fascia panel having at least one first connector formation.
  • the fascia panel system can include a plurality of fascia panels, and typically includes many panels, sufficient to cover the wall being treated.
  • the fascia panel system can include at least one packing element.
  • the packing element can include a body.
  • the body can include a second connector formation.
  • the second connector formation can be arranged to engage the first connector formation.
  • the first connector formation can be arranged to receive at least part of the second connector formation.
  • At least part of the second connector formation can be arranged for insertion into the first connector formation.
  • the second connector formation can be arranged to engage the fascia panel, for example adjacent to the first connector formation.
  • the body can include an aperture formed in the body.
  • the fascia panel system includes a plurality of packing elements.
  • the fascia panel system can include a fastener.
  • the fastener can be arranged for insertion into the aperture formed in the packing element body.
  • the fastener can be arranged to fix the fascia panel and the packing element to a substrate.
  • the substrate can be a wall, such as a building wall.
  • the fascia panel system can include a plurality of fasteners.
  • the first connector formation can comprise an aperture and/or recess formed in the fascia panel.
  • the aperture can extend through the thickness of the fascia panel.
  • At least part of the second connector formation can be arranged for insertion into the aperture and/or recess.
  • the second connector formation can be sized and shaped such that the second connector formation engages the fascia panel adjacent the aperture and/or recess.
  • the second connector formation can be sized and shaped to enable the second connector formation to move within the aperture and/or recess while the second formation engages the fascia panel adjacent the aperture and/or recess.
  • the second formation moves in at least one direction within the plane of the fascia panel.
  • the second connector formation engages fascia panel at the aperture and/or recess in a manner that enables the fascia panel to move a little relative to the packing element.
  • the second connector formation can be arranged to move within the aperture and/or recess, when the packing element is fixed to the substrate by the fastener, to accommodate thermal expansion and contraction of the fascia panel.
  • the aperture can comprise a slot.
  • the slot is elongate and has a longitudinal axis.
  • the second connector formation can be arranged to move within the slot, for example in a direction of the longitudinal axis of the slot.
  • the aperture can comprise a hole, such as a circular hole.
  • the recess can comprise a channel.
  • the channel is elongate and has a longitudinal axis.
  • the second connector formation can be arranged to move within the channel, for example in a direction of the longitudinal axis of the channel.
  • the fascia panel can include a single first connector formation.
  • the single connector formation can be arranged to receive a plurality of second connector formations.
  • the first connector formation can comprise a single slot/hole/channel that is arranged to receive all of the second connector formations. That is, each packing element for the fascia panel engages with the single slot/hole/channel formed in the fascia panel.
  • the fascia panel can include a plurality of first connector formations.
  • the number of first connector formations provided can be at least in part determined by the size of the panel.
  • the fascia panel includes several first connector formations.
  • Each first connector formation is preferably arranged to receive a single second connector formation.
  • at least one of the first connector formations of the plurality of first connector formations can be arranged to receive a plurality of second connector formations. For example, at least two packing elements for the respective slot/hole/channel.
  • At least one of the apertures and/or recesses can be sized and shaped such that the respective second connector formation engages the fascia panel at the respective aperture and/or recess in a manner that fixes the position of the fascia panel with respect to the respective packing element. That is, there is no movement of the respective second connector formation within the respective aperture and/or recess.
  • the at least one first connector formation can be located adjacent a peripheral portion of the fascia panel. This enables the fascia panel to be fixed to the substrate adjacent an edge of the panel, for example a longitudinal edge of the panel.
  • the first connector formations can be distributed in rectilinear manner.
  • the first connector formations can be spaced apart from one another.
  • the first connector formations can be evenly distributed along the length and/or width of the fascia panel.
  • the fascia panel can include an arrangement of apertures and/or recesses located adjacent an edge of the fascia panel, for example a longitudinal edge of the panel.
  • the apertures and/or recesses can be distributed along the length of the fascia panel. This provides multiple positions for the packing elements to connect with and support the panel.
  • the apertures and/or recesses can be arranged in a line, for example a rectilinear line.
  • the apertures and/or recesses can be spaced apart from one another along the line.
  • the apertures comprise slots
  • the longitudinal axes of the slots can be aligned with one another.
  • the recesses comprise channels
  • the longitudinal axes of the channels can be aligned with one another.
  • the peripheral portion can be stepped relative to a maj or surface of the fascia panel.
  • the stepped portion is preferably stepped in a direction towards the rear side of the panel, such that an outwardly facing major surface of the panel is in advance of the stepped portion.
  • the stepped portion enables an adjacent fascia panel to overlap the peripheral portion.
  • the stepped arrangement improves the aesthetics of the fascia panel over an arrangement wherein two edges can be abutted against one another, since no gaps are visible. It also enables a more reliable seal to be provided between adjacent panels, when required, for example where a bead of sealant can be used to seal adjacent fascia panels.
  • the stepped arrangement also enables adjacent panels to support one another rather than having to independently support each longitudinal edge of the panel with packing elements.
  • the second connector formation can include a first prong.
  • the first prong can protrude outwards from a packing element body.
  • the first prong can be arranged for insertion into the first connector formation.
  • the first prong can be arranged for insertion into the aperture formed in the fascia panel, and to engage the fascia panel adjacent the aperture.
  • the second connector formation can include a second prong.
  • the second prong can protrude outwards from packing element body.
  • the second prong can be arranged for insertion into the first connector formation.
  • the second prong can be arranged for insertion into the aperture formed in the fascia panel, and to engage the fascia panel adjacent the aperture.
  • the second prong engages a part of the fascia panel that is located opposite to a part of the fascia panel engaged by the first prong.
  • the second connector formation can include a third prong.
  • the third prong can protrude outwards from packing element body.
  • the third prong can be arranged for insertion into the first connector formation.
  • the third prong can be arranged for insertion into the aperture formed in the fascia panel, and to engage the fascia panel adjacent the aperture.
  • the second connector formation can include a fourth prong.
  • the fourth prong can protrude outwards from packing element body.
  • the fourth prong can be arranged for insertion into the first connector formation.
  • the fourth prong can be arranged for insertion into the aperture formed in the fascia panel, and to engage the fascia panel adjacent the aperture.
  • the fourth prong engages a part of the fascia panel that is located opposite to a part of the fascia panel engaged by the third prong.
  • the first prong, second prong, third prong and fourth prong can be arranged for insertion into the same aperture or slot.
  • At least one of the first prong, second prong, third prong, and fourth prong has a tapered leading edge. This facilitates insertion of the prongs into the first connector formation.
  • the second connector formation can be resiliently deformable. This enables the packing element to be clipped on to the fascia panel.
  • at least one of the first prong, second prong, third prong and fourth prong can be resiliently deformable.
  • At least one of the first prong, second prong, third prong and fourth prong can protrude outwards from an end wall of the packing element body.
  • the end wall can be an outwardly facing wall when the packing element body is mounted on the substrate.
  • the packing element aperture can be located adjacent the second connector formation.
  • the first prong, second prong, third prong and fourth prong can be distributed about the aperture.
  • the packing element aperture can be located on the end wall of the packing element body.
  • the aperture can be located in a central portion of the end wall.
  • the packing element can be moulded.
  • the packing element can be injection moulded.
  • the packing element can comprise a plastics material, such as thermoplastic material.
  • the packing element can be made from polypropylene.
  • the packing element body can be hollow, or can include hollow portions.
  • the packing element body can include a tubular member arranged to receive the fastener.
  • the fastener can be inserted into the tubular member through the packing element aperture.
  • the tubular member can be arranged co-axially with the packing element aperture.
  • the tubular member can extend from the end wall into the body, that is, in a direction that is opposite to the direction in which the first prong, second prong, third prong and fourth prong protrude from the end wall.
  • a central longitudinal axis of the tubular member can be perpendicular to the end wall of the packing element body.
  • the packing element body can include side walls.
  • the end wall can be perpendicular to the side walls.
  • the packing element body can include internal webbing between the tubular member and the side walls.
  • the substrate can comprise a wall.
  • the wall can include plaster.
  • the wall can include wood.
  • the wall can include brick.
  • a hole may be formed in the substrate, for example to receive a wall plug, and the fastener can be screwed into the wall plug.
  • the fastener can comprise any suitable fastener, such as a screw nail, staple, or threaded fastener for fixing the fascia panels and packing elements to the substrate.
  • the packing element can include a body having a connector formation arranged to engage with a connector formation of a fascia panel.
  • the packing element body can include an aperture arranged to receive a fastener for fixing the fascia panel and the packing element to a substrate.
  • a packing element for a fascia panel system can include a body having a connector formation.
  • the connector formation can include a first resilient prong.
  • the first resilient prong can protrude outwards from an end wall of the body.
  • the first resilient prong can be arranged for insertion into a slot formed in a fascia panel.
  • the body can include an aperture arranged to receive a fastener for fixing the fascia panel and the packing element to a substrate.
  • the connector formation can include a second resilient prong.
  • the second resilient prong can protrude outwards from the end wall of the body.
  • the second resilient prong can be arranged for insertion into the slot formed in a fascia panel.
  • the connector formation can include a third resilient prong.
  • the third resilient prong can protrude outwards from the end wall of the packing element body.
  • the third resilient prong can be arranged for insertion into the slot formed in a fascia panel.
  • the connector formation can include a fourth resilient prong.
  • the fourth resilient prong can protrude outwards from the end wall of the packing element body.
  • the fourth resilient prong can be arranged for insertion into the slot formed in a fascia panel.
  • At least one of the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong can have a tapered leading edge. This facilitates insertion of the prongs into the first connector formation.
  • the aperture in the packing element body can be located adjacent at least one of the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong. In some embodiments, the aperture can be located between the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong. At least one of the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong can be in close proximity with the aperture, and can be distributed around the aperture.
  • the packing element can be moulded.
  • the packing element can be injection moulded.
  • the packing element can comprise a plastics material, such as thermoplastic material. In some embodiments the packing element can be made from polypropylene.
  • the packing element body can be substantially hollow, or can include hollow portions.
  • the packing element body can include a tubular member arranged to receive the fastener.
  • the fastener can be inserted into the tubular member through the packing element aperture.
  • the tubular member can be arranged co-axially with the packing element aperture.
  • the tubular member can extend from the end wall into the body, that is, in a direction that is opposite to the direction in which the first prong, second prong, third prong and fourth prong protrude from the end wall.
  • a central longitudinal axis of the tubular member can be perpendicular to the end wall of the packing element body.
  • the packing element body can include side walls.
  • the end wall can be perpendicular to the side walls.
  • the packing element body can include internal webbing between the tubular member and the side walls.
  • the packing element can be arranged according to any configuration described herein.
  • a method for attaching a fascia panel to a wall can include providing a fascia panel system, comprising a fascia panel having an aperture and/or recess formed therein, and at least one packing element including a body having a connector formation including a first resilient prong, wherein the first resilient prong protrudes outwards from an end wall of the body, and an aperture formed in the end wall of the body.
  • the method can include attaching the packing element to the fascia panel in a manner such that the first resilient prong is inserted into the aperture and/or recess.
  • the method can include fixing the fascia panel and packing element to the wall, for example by driving a fastener through the fascia panel aperture and/or recess into the aperture formed in the end wall of the packing element body, and into the wall.
  • the method can include providing a second packing element including a body having a connector formation including a first resilient prong, wherein the first resilient prong protrudes outwards from an end wall of the body, and an aperture formed in the end wall of the body.
  • the method can include attaching the second packing element to the fascia panel in a manner such that the first resilient prong of the second packing element is inserted into the aperture and/or recess, or another aperture and/or recess formed in the fascia panel.
  • the method can include mounting the fascia panel, with the packing elements attached thereto, onto the w r all.
  • the method can include fixing the fascia panel and second packing element to the wall by driving a second fastener through the fascia panel aperture and/or recess into the aperture formed in the end wall of the second packing element body, and into the wall.
  • the method can include providing a further packing element including a body having a connector formation including a first resilient prong, wherein the first resilient prong protrudes outwards from an end wall of the body, and an aperture formed in the end wall of the body.
  • the method can include attaching the further packing element to the fascia panel in a manner such that the first resilient prong of the further packing element is inserted into the aperture and/or recess, or another aperture and/or recess formed in the fascia panel.
  • the method can include fixing the fascia panel and further packing element to the wall, for example by driving a further fastener through the fascia panel aperture and/or recess into the aperture formed in the end wall of the further packing element body, and into the wall.
  • the fascia panel system can be arranged according to any configuration described herein.
  • the method can include providing a second fascia panel having at least one apertures and/or recess formed therein.
  • the method can include providing additional packing elements.
  • the method can include attaching packing elements to at least some of the apertures and/or recesses.
  • the method can include attaching the second fascia panel to the wall in a manner such that a part of the second fascia panel overlaps a part of the fascia panel, and preferably that part of the fascia panel to which the packing element, second packing element and further packing element are connected.
  • the method can include fixing the second fascia panel to the wall by driving fasteners through the second fascia panel apertures and/or recesses into the apertures formed in the additional packing elements, and into the wall.
  • the method can be repeated for subsequent fascia panels and packing elements until the wall is covered.
  • the fascia panel system comprises at least one fascia panel provided with at least one first connector formation comprising an aperture or recess; at least one packing element comprising a body with an aperture formed in the body, and a second connector formation.
  • the first and second connector formation are configured to connect the packing element to the fascia panel to form a sub-assembly.
  • the method comprises the steps of: connecting the packing element to the fascia panel to form a sub-assembly wherein the apertures in the fascia panel and the packing element are aligned and driving a fastener through the aligned apertures into the wall to fix the sub-assembly to the wall.
  • the method can include the step of connecting at least one more packing element to the subassembly and driving a fastener through each of the aligned apertures in the sub-assembly.
  • the method an include the steps of preparing a second sub-assembly, positioning the second sub-assembly on the wall so as to at least partially overlap with the first sub-assembly and driving a fastener through each of the aligned apertures in the second sub-assembly.
  • the method can include the step of overlapping the first sub-assembly with the second subassembly such that the second sub-assembly covers the fasteners of the first sub-assembly.
  • Figure 1 is an isometric view from the rear a part of fascia panel system according to the invention.
  • Figure 2 is a rear view of the part of the fascia panel system of Figure 1 ;
  • Figure 3 is an isometric view from the front of the part of the fascia panel system of Figure i;
  • Figure 4 is an isometric view from the rear of the part of the fascia panel shown in Figure 1;
  • Figure 5 is a rear view of the part of the fascia panel of Figure 4.
  • Figure 6 is an isometric view of a packing element used in the fascia panel system of Figure 1 ;
  • Figure 7 is an end view of the packing element of Figure 6;
  • Figure 8 is a plan view from above of the packing element of Figure 6;
  • FIG. 9 is a flow diagram of a method for installing fascia panels onto a building wall.
  • Figure 1 shows part of fascia panel system 1 according to the invention, which includes a fascia panel 3 (sometimes referred to as a “fascia wall panel”); a packing element 5; and a fastener 7.
  • the fascia panel system 1 includes multiple fascia panels 3, multiple packing elements 5, and multiple fasteners 7.
  • a sufficient number of the fascia panels 3, packing elements 5, and fasteners 7 are provided to cover a substrate, which is typically a building wall.
  • Each fascia panel 3 is generally rectangular in plan.
  • Each fascia panel 3 includes an arrangement of apertures formed through the thickness of the panel 3, from a front side 11 to a rear side 13.
  • the apertures 9 are in the form of slots and/or holes.
  • each aperture 9 is sized and/or shaped to enable there to be a small amount of relative movement between the panel 3 and the packing element 5, for example to allow the panel 3 to expand and contract due to thermal changes.
  • slots has the advantage of allowing a small amount of relative movement between the panel 3 and the packing element 5 along a longitudinal axis of the slot to allow the panel 3 to expand and contract due to thermal changes.
  • holes can have a different shape from a slot, for example the hole can have a circular shape.
  • the apertures 9 are located adjacent a first longitudinal edge 10 of the panel, and are preferably formed through a stepped portion 14 of the panel. This enables the fascia panel to be fixed to the substrate adjacent the longitudinal edge of the panel 10.
  • each slot 9 is rectilinear and has a central longitudinal axis.
  • the central longitudinal axes of the rectilinear slots 9 are aligned, such that the slots 9 are distributed, in a spaced apart fashion, along a line.
  • the line of rectilinear slots 9 is arranged parallel to the first longitudinal edge 10 of the panel.
  • the rear side 13 of the panel includes first and second reinforcement ribs 15,17.
  • the reinforcement ribs 15,17 stiffen the panel 3.
  • Each reinforcement rib 15,17 extends along the length of the panel.
  • the first reinforcement rib 15 has a generally rectangular transverse crosssection.
  • the first reinforcement rib 15 is arranged parallel a second longitudinal edge 19 of the panel, and is spaced apart from the second longitudinal edge 19.
  • the second reinforcement rib 17 has a generally triangular transverse cross-section.
  • the second reinforcement rib 17 is arranged parallel with the first reinforcement rib 17, and is located centrally on the rear side 13 of the panel.
  • a part 21 of the rear side of the panel that is located between the first reinforcement rib 15 and the second longitudinal edge 19 of a second panel 3B overlaps the stepped part 15 of a first panel 3A (see Figure 3).
  • the first reinforcement rib 15 butts up against the first longitudinal edge 10, and therefore the first reinforcement rib 15 helps to correctly position and orientate the second panel 3B relative to the first panel 3 A.
  • Each fascia panel 3 can be made from any suitable material, such as a plastics material, wood, and/or fibre board.
  • the packing element 5 comprises a moulded component, and preferably an injection moulded component.
  • the packing element 5 can be made from a thermoplastic such as polypropylene.
  • the packing element 5 includes a body 23.
  • the body 23 is generally cuboid in shape.
  • the body has an end wall 25.
  • the end wall 25 faces outwardly when the packing element 5 is installed.
  • the body 23 includes side walls 27.
  • the end wall 25 is perpendicular to the side walls 27.
  • the body 23 is substantially hollow, or includes hollow portions.
  • An aperture 29 is formed through the end wall 25, preferably in a central portion of the end wall 25.
  • a tubular member 31 extends inwardly into the body 23 from an internal side of the end wall 25.
  • the tubular member 31 is arranged co-axially with the aperture 29.
  • a central longitudinal axis of the tubular member 1 is arranged perpendicularly to the end wall 25 of the packing element body.
  • the tubular member 31 is arranged to receive the fastener 7, which is inserted into the tubular member 31 through the aperture 29.
  • the diameter of the tubular member 29 and/or the thread of the fastener 7 can be selected, such that the fastener 7 engages the tubular member 29 as the fastener 7 passes through the packing element 5, for example the fastener 7 can be arranged to bite into the tubular member 29.
  • the diameter of the tubular member 29 and/or the thread of the fastener 7 can be selected, such that the fastener 7 does not engage the tubular member 29 as the fastener 7 passes through the packing element 5.
  • the diameter of the tubular member 29 and/or the diameter of the screw thread can be selected such that there is a clearance between the thread and the tubular member 29.
  • the body 23 includes internal webbing 33 between the tubular member 31 and side walls 27 of the packing element body.
  • the webbing 33 supports the tubular member 31, and improves the rigidity of the body 23.
  • the packing element 5 is releasably attachable to the fascia panel 3 to from a sub-assembly.
  • the packing element 5 includes first, second, third and fourth resilient prongs 35,37,39,41 .
  • the prongs 35,37,39,41 are arranged for insertion into one of the slots 9 and to engage with the fascia panel 3 adjacent the slot 9 in order to clip the packing element 5 to the fascia panel 3.
  • each slot 9 acts as a connector formation for the fascia panel 3
  • the prongs 35,37,39,41 act as a connector formation for the packing element 5.
  • the first and second prongs 35,37 provide a first pair of prongs, wherein the first prong 35 is arranged to engage a first side of the slot 9 and the second prong 37 is arranged to engage a second side of the slot 9.
  • the third and fourth prongs 39,41 provide a second pair of prongs, wherein the third prong 39 is arranged to engage the first slide of the slot 9 and the fourth prong 41 is arranged to engage the second side of the slot 9.
  • the prongs 35,37,39,41 can include a tapered leading end 35a, 37a, 39a, 41 a to assist insertion of the prongs 35,37,39,41 into the slot 9.
  • the prongs 35,37,39,41 protrude outwardly from the end wall 25, and preferably protrude perpendicularly outwards from the end wall 25.
  • the prongs 35,37,39,41 are located on a central portion of the end wall 25. Having the prongs 35,37,39,41 located centrally enables there to be some play between the packing element 5 and the fascia panel 3.
  • the prongs 35,37,39,41 can be located adjacent to aperture 29.
  • the prongs 35,37,39,41 can be located immediately next to the aperture 29.
  • the first pair of prongs 35,39 can be arranged diametrically opposite to the second pair of prongs 39,41.
  • the fasteners 7 may be any type of suitable type such as a screw, nail, staple, or threaded fastener and are selected to be sufficiently long to penetrate through the fascia panel 3 and the packing element 5, and to bite into the substrate on which the panel 3 is mounted.
  • the type of fastener 7 used for a particular application will depend in part on the materials from which the panel 3, packing element 5 and substrate are made, and the dimensions of the panel 3 and the packing element. It may be desirable to drill holes into the substrate and insert wall plugs, prior to screwing the panel 3 to substrate.
  • a method for installing fascia panels onto a wall will be described with reference to Figure 9.
  • proving the materials required for the installation process which typically includes providing a plurality of fascia panels 3, a plurality of packing elements 5 and a plurality of fasteners 7.
  • several packing elements 5 are clipped to a first fascia panel 3 to form a sub-assembly prior to mounting the fascia panel 3 onto a building wall.
  • the packing elements 5 are distributed along the length of the panel 3.
  • packing elements 5 can be attached to two longitudinal edges of the first panel 3A.
  • a baton can be applied to the wall for the longitudinal side of the panel that does not include packing elements 5.
  • the longitudinal edge of the first panel 3 A that does not have packing elements 5 attached thereto can rest on the baton.
  • the first panel 3A is mounted onto the wall, with the packing elements 5 attached thereto whereby the apertures in the fascia panel 3 and the packing element 5 are aligned for a fastener 7 to extend through both of them.
  • the first panel 3A is fixed to the wall by driving respective fasteners 7 through the respective slots 9 and into the apertures 29 formed in the respective packing elements 5, until the fasteners 7 engage the wall and/or a wall plug previously inserted into the wall.
  • the second panel 3B is mounted onto the wall in a manner such that the longitudinal part 21 of the rear side of the panel that is located between the first reinforcement rib 15 and the second longitudinal edge 19 of a second panel 3B, overlaps the stepped part 15 of the first panel 3 A thereby covering the fasteners of the first panel 3A (see Figure 3).
  • the second panel 3B is fixed to the wall by driving respective fasteners 7 through the respective slots 9 and into the apertures 29 formed in the respective packing elements 5, until the fasteners 7 engage the wall and/or a wall plug previously inserted into the wall.
  • the further panel 3 is mounted onto the wall in a manner such that the longitudinal part 21 of the rear side of the panel that is located between the first reinforcement rib 15 and the second longitudinal edge 19 of the further panel 3, overlaps the stepped part 15 of the second panel 3B.
  • the further panel 3 is fixed to the wall by driving respective fasteners 7 through the respective slots 9 and into the apertures 29 formed in the respective packing elements 5, until the fasteners 7 engage the wall and/or a wall plug previously inserted into the wall.
  • the panels 3 can be applied to the wall in any suitable orientation. Typically, the longitudinal direction of the panels 3 is oriented in the horizontal direction or the vertical direction.
  • the packing element 5 can include a different number of prongs 35,37,39,41 to clip the packing element 5 to the fascia panel 3.
  • the packing element 5 can include at least one prong, and preferably includes a plurality of prongs, arranged to engage the fascia panel in the vicinity of the slot.
  • the number of apertures 9 can be different.
  • the apertures 9 can have a different arrangement.
  • the apertures 9 can have a different location with respect to the panel, for example, the apertures 9 can be formed adjacent a shorter edge.
  • Apertures can be formed adjacent a plurality of edges.
  • the fascia panel can comprise a single aperture, such as a single slot that extends along an edge of the fascia panel, and the prongs of each of the packing element can be arranged for insertion into the single slot, and to engage the fascia panel at spaced apart locations adjacent the single slot.
  • the panel can have a single second connector formation that is arranged to interact with the first connector formation of multiple packing elements.
  • the fascia panel can include at least one recess, such as at least one channel.
  • the fascia panel can comprise a single recess, such as a single channel that extends along an edge of the fascia panel, and the prongs of each of the packing element can be arranged for insertion into the single channel, and to engage the fascia panel at spaced apart locations adjacent the single channel.
  • the panel can have a single second connector formation that is arranged to interact with the first connector formation of multiple packing elements.
  • the fascia panel can include a plurality of recesses, such as a plurality of channels.
  • the plurality of channels can be arranged similarly to the plurality of slots shown in the figures.
  • each packing element can be arranged to engage with a single recess.
  • the fascia panel can include at least one aperture and at least one recess.
  • the fascia panel can include some second connector formations that comprise both a recessed part and an aperture part.
  • the term “at least one of the” is to be interpreted in the sense of “and/or”.
  • the term “at least one of the first prong and the second prong” is to be interpreted as meaning any one of the following: the first prong alone; the second prong alone; or the combination of the first and second prongs.
  • the term “at least one of the first prong, the second prong and the third prong” is to be interpreted as meaning any one of the following: the first prong alone; the second prong alone; the third prong alone; the combination of the first prong and the second prong; the combination of the first prong and the third prong; the combination of the second prong and the third prong; or the combination of the first prong, the second prong and the third prong.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Connection Of Plates (AREA)
  • Finishing Walls (AREA)
  • Gasket Seals (AREA)

Abstract

Disclosed is an a fascia panel system, comprising at least one fascia panel provided with at least one first connector formation comprising an aperture or recess and at least one packing element comprising a body with an aperture formed in the body, and a second connector formation. The first and second connector formations are configured to connect the packing element to the fascia panel to form a sub-assembly. The aperture/recess in the fascia panel and the aperture in the body of the packing element are configured to align, such that a fastener can extend through both the fascia panel and the packing element for fixing the sub-assembly to a substrate.

Description

FASCIA PANEL SYSTEM, A PACKING ELEMENT FOR A FASCIA PANEL SYSTEM & METHOD OF ATTACHING A FASCIA PANEL TO A WALL
The invention relates to a fascia panel system, a packing element for a fascia panel system, and a method for attaching a fascia panel to a wall.
Fascia panels are applied to substrates, such as building walls to protect the walls and for decorative purposes. Fascia panels can be applied to external or internal walls. In some instances, it is desirable to space the fascia panels away from the wall on which they are mounted to allow air to circulate between the fascia panels and the wall. However, it can be a difficult and time-consuming process to mount fascia panels in this manner since fascia panel systems have not been designed with this mounting process in mind. In particular, it can be difficult for installers to hold the fascia panel, a packing element and simultaneously fix the fascia panel to the wall. An alternative method is to fix multiple batons to the wall, and then fix the fascia panel to the batons, however this solution doesn’t work particularly well when the wall is uneven.
Accordingly, the invention seeks to provide a fascia panel system, a packing element, and a method for attaching a fascia panel to a wall that addresses at least one of the above- mentioned problems, or at least provides an alternative arrangement to known fascia panel systems, packing elements and methods.
According to one aspect, there is provided a fascia panel system according to claim 1 . The invention provides an improved fascia panel system that can be more easily applied to a wall by attaching packing elements to the fascia panels to form a sub-assembly prior to fastening the panels to the walls.
According to another aspect, there is provided a fascia panel system.
The fascia panel system can include at least one fascia panel having at least one first connector formation. The fascia panel system can include a plurality of fascia panels, and typically includes many panels, sufficient to cover the wall being treated.
The fascia panel system can include at least one packing element. The packing element can include a body. The body can include a second connector formation. The second connector formation can be arranged to engage the first connector formation. The first connector formation can be arranged to receive at least part of the second connector formation. At least part of the second connector formation can be arranged for insertion into the first connector formation. The second connector formation can be arranged to engage the fascia panel, for example adjacent to the first connector formation. The body can include an aperture formed in the body.
Typically, the fascia panel system includes a plurality of packing elements.
The fascia panel system can include a fastener. The fastener can be arranged for insertion into the aperture formed in the packing element body. The fastener can be arranged to fix the fascia panel and the packing element to a substrate. The substrate can be a wall, such as a building wall. The fascia panel system can include a plurality of fasteners.
The first connector formation can comprise an aperture and/or recess formed in the fascia panel. The aperture can extend through the thickness of the fascia panel.
At least part of the second connector formation can be arranged for insertion into the aperture and/or recess.
The second connector formation can be sized and shaped such that the second connector formation engages the fascia panel adjacent the aperture and/or recess. The second connector formation can be sized and shaped to enable the second connector formation to move within the aperture and/or recess while the second formation engages the fascia panel adjacent the aperture and/or recess. Typically, the second formation moves in at least one direction within the plane of the fascia panel. Thus, in some embodiments, the second connector formation engages fascia panel at the aperture and/or recess in a manner that enables the fascia panel to move a little relative to the packing element. For example, the second connector formation can be arranged to move within the aperture and/or recess, when the packing element is fixed to the substrate by the fastener, to accommodate thermal expansion and contraction of the fascia panel.
The aperture can comprise a slot. The slot is elongate and has a longitudinal axis. The second connector formation can be arranged to move within the slot, for example in a direction of the longitudinal axis of the slot.
The aperture can comprise a hole, such as a circular hole.
The recess can comprise a channel. The channel is elongate and has a longitudinal axis. The second connector formation can be arranged to move within the channel, for example in a direction of the longitudinal axis of the channel. The fascia panel can include a single first connector formation. The single connector formation can be arranged to receive a plurality of second connector formations. For example, the first connector formation can comprise a single slot/hole/channel that is arranged to receive all of the second connector formations. That is, each packing element for the fascia panel engages with the single slot/hole/channel formed in the fascia panel.
The fascia panel can include a plurality of first connector formations. The number of first connector formations provided can be at least in part determined by the size of the panel. In some embodiments, the fascia panel includes several first connector formations. Each first connector formation is preferably arranged to receive a single second connector formation. For example, one slot/hole/channel per packing element. In some embodiments, at least one of the first connector formations of the plurality of first connector formations can be arranged to receive a plurality of second connector formations. For example, at least two packing elements for the respective slot/hole/channel.
In some embodiments, at least one of the apertures and/or recesses can be sized and shaped such that the respective second connector formation engages the fascia panel at the respective aperture and/or recess in a manner that fixes the position of the fascia panel with respect to the respective packing element. That is, there is no movement of the respective second connector formation within the respective aperture and/or recess.
The at least one first connector formation can be located adjacent a peripheral portion of the fascia panel. This enables the fascia panel to be fixed to the substrate adjacent an edge of the panel, for example a longitudinal edge of the panel.
For embodiments including a plurality of first connector formations, the first connector formations can be distributed in rectilinear manner. The first connector formations can be spaced apart from one another. The first connector formations can be evenly distributed along the length and/or width of the fascia panel.
In some embodiments, the fascia panel can include an arrangement of apertures and/or recesses located adjacent an edge of the fascia panel, for example a longitudinal edge of the panel. The apertures and/or recesses can be distributed along the length of the fascia panel. This provides multiple positions for the packing elements to connect with and support the panel.
The apertures and/or recesses can be arranged in a line, for example a rectilinear line. The apertures and/or recesses can be spaced apart from one another along the line. For embodiments wherein the apertures comprise slots, the longitudinal axes of the slots can be aligned with one another. For embodiments wherein the recesses comprise channels, the longitudinal axes of the channels can be aligned with one another.
The peripheral portion can be stepped relative to a maj or surface of the fascia panel. The stepped portion is preferably stepped in a direction towards the rear side of the panel, such that an outwardly facing major surface of the panel is in advance of the stepped portion. The stepped portion enables an adjacent fascia panel to overlap the peripheral portion. The stepped arrangement improves the aesthetics of the fascia panel over an arrangement wherein two edges can be abutted against one another, since no gaps are visible. It also enables a more reliable seal to be provided between adjacent panels, when required, for example where a bead of sealant can be used to seal adjacent fascia panels. The stepped arrangement also enables adjacent panels to support one another rather than having to independently support each longitudinal edge of the panel with packing elements.
The second connector formation can include a first prong. The first prong can protrude outwards from a packing element body. The first prong can be arranged for insertion into the first connector formation. For example, the first prong can be arranged for insertion into the aperture formed in the fascia panel, and to engage the fascia panel adjacent the aperture.
The second connector formation can include a second prong. The second prong can protrude outwards from packing element body. The second prong can be arranged for insertion into the first connector formation. For example, the second prong can be arranged for insertion into the aperture formed in the fascia panel, and to engage the fascia panel adjacent the aperture. Typically, the second prong engages a part of the fascia panel that is located opposite to a part of the fascia panel engaged by the first prong.
The second connector formation can include a third prong. The third prong can protrude outwards from packing element body. The third prong can be arranged for insertion into the first connector formation. For example, the third prong can be arranged for insertion into the aperture formed in the fascia panel, and to engage the fascia panel adjacent the aperture.
The second connector formation can include a fourth prong. The fourth prong can protrude outwards from packing element body. The fourth prong can be arranged for insertion into the first connector formation. For example, the fourth prong can be arranged for insertion into the aperture formed in the fascia panel, and to engage the fascia panel adjacent the aperture. Typically, the fourth prong engages a part of the fascia panel that is located opposite to a part of the fascia panel engaged by the third prong. Thus the first prong, second prong, third prong and fourth prong can be arranged for insertion into the same aperture or slot.
At least one of the first prong, second prong, third prong, and fourth prong has a tapered leading edge. This facilitates insertion of the prongs into the first connector formation.
The second connector formation can be resiliently deformable. This enables the packing element to be clipped on to the fascia panel. For example, at least one of the first prong, second prong, third prong and fourth prong can be resiliently deformable.
At least one of the first prong, second prong, third prong and fourth prong can protrude outwards from an end wall of the packing element body. The end wall can be an outwardly facing wall when the packing element body is mounted on the substrate.
The packing element aperture can be located adjacent the second connector formation. The first prong, second prong, third prong and fourth prong can be distributed about the aperture.
The packing element aperture can be located on the end wall of the packing element body. For example, the aperture can be located in a central portion of the end wall.
The packing element can be moulded. For example, the packing element can be injection moulded.
The packing element can comprise a plastics material, such as thermoplastic material. In some embodiments the packing element can be made from polypropylene.
The packing element body can be hollow, or can include hollow portions.
The packing element body can include a tubular member arranged to receive the fastener.
The fastener can be inserted into the tubular member through the packing element aperture.
The tubular member can be arranged co-axially with the packing element aperture.
The tubular member can extend from the end wall into the body, that is, in a direction that is opposite to the direction in which the first prong, second prong, third prong and fourth prong protrude from the end wall. A central longitudinal axis of the tubular member can be perpendicular to the end wall of the packing element body.
The packing element body can include side walls. The end wall can be perpendicular to the side walls. The packing element body can include internal webbing between the tubular member and the side walls.
The substrate can comprise a wall. The wall can include plaster. The wall can include wood. The wall can include brick. A hole may be formed in the substrate, for example to receive a wall plug, and the fastener can be screwed into the wall plug. The fastener can comprise any suitable fastener, such as a screw nail, staple, or threaded fastener for fixing the fascia panels and packing elements to the substrate.
According to another aspect, there is provided a packing element for a fascia panel system. The packing element can include a body having a connector formation arranged to engage with a connector formation of a fascia panel.
The packing element body can include an aperture arranged to receive a fastener for fixing the fascia panel and the packing element to a substrate.
According to another aspect, there is provided a packing element for a fascia panel system. The packing element can include a body having a connector formation. The connector formation can include a first resilient prong. The first resilient prong can protrude outwards from an end wall of the body. The first resilient prong can be arranged for insertion into a slot formed in a fascia panel. The body can include an aperture arranged to receive a fastener for fixing the fascia panel and the packing element to a substrate. The invention enables the packing element to be clipped on to the fascia panel before the panel is attached to the wall, thereby improving the ease with which the panel can be applied to the wall.
The connector formation can include a second resilient prong. The second resilient prong can protrude outwards from the end wall of the body. The second resilient prong can be arranged for insertion into the slot formed in a fascia panel. The connector formation can include a third resilient prong. The third resilient prong can protrude outwards from the end wall of the packing element body. The third resilient prong can be arranged for insertion into the slot formed in a fascia panel. The connector formation can include a fourth resilient prong. The fourth resilient prong can protrude outwards from the end wall of the packing element body. The fourth resilient prong can be arranged for insertion into the slot formed in a fascia panel.
At least one of the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong can have a tapered leading edge. This facilitates insertion of the prongs into the first connector formation.
The aperture in the packing element body can be located adjacent at least one of the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong. In some embodiments, the aperture can be located between the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong. At least one of the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong can be in close proximity with the aperture, and can be distributed around the aperture. The packing element can be moulded. For example, the packing element can be injection moulded. The packing element can comprise a plastics material, such as thermoplastic material. In some embodiments the packing element can be made from polypropylene. The packing element body can be substantially hollow, or can include hollow portions.
The packing element body can include a tubular member arranged to receive the fastener. The fastener can be inserted into the tubular member through the packing element aperture.
The tubular member can be arranged co-axially with the packing element aperture. The tubular member can extend from the end wall into the body, that is, in a direction that is opposite to the direction in which the first prong, second prong, third prong and fourth prong protrude from the end wall. A central longitudinal axis of the tubular member can be perpendicular to the end wall of the packing element body.
The packing element body can include side walls. The end wall can be perpendicular to the side walls. The packing element body can include internal webbing between the tubular member and the side walls.
The packing element can be arranged according to any configuration described herein. According to another aspect, there is provided a method for attaching a fascia panel to a wall. The method can include providing a fascia panel system, comprising a fascia panel having an aperture and/or recess formed therein, and at least one packing element including a body having a connector formation including a first resilient prong, wherein the first resilient prong protrudes outwards from an end wall of the body, and an aperture formed in the end wall of the body. The method can include attaching the packing element to the fascia panel in a manner such that the first resilient prong is inserted into the aperture and/or recess. The method can include fixing the fascia panel and packing element to the wall, for example by driving a fastener through the fascia panel aperture and/or recess into the aperture formed in the end wall of the packing element body, and into the wall.
The method can include providing a second packing element including a body having a connector formation including a first resilient prong, wherein the first resilient prong protrudes outwards from an end wall of the body, and an aperture formed in the end wall of the body. The method can include attaching the second packing element to the fascia panel in a manner such that the first resilient prong of the second packing element is inserted into the aperture and/or recess, or another aperture and/or recess formed in the fascia panel. The method can include mounting the fascia panel, with the packing elements attached thereto, onto the wrall. The method can include fixing the fascia panel and second packing element to the wall by driving a second fastener through the fascia panel aperture and/or recess into the aperture formed in the end wall of the second packing element body, and into the wall.
The method can include providing a further packing element including a body having a connector formation including a first resilient prong, wherein the first resilient prong protrudes outwards from an end wall of the body, and an aperture formed in the end wall of the body. The method can include attaching the further packing element to the fascia panel in a manner such that the first resilient prong of the further packing element is inserted into the aperture and/or recess, or another aperture and/or recess formed in the fascia panel. The method can include fixing the fascia panel and further packing element to the wall, for example by driving a further fastener through the fascia panel aperture and/or recess into the aperture formed in the end wall of the further packing element body, and into the wall.
The fascia panel system can be arranged according to any configuration described herein.
The method can include providing a second fascia panel having at least one apertures and/or recess formed therein. The method can include providing additional packing elements. The method can include attaching packing elements to at least some of the apertures and/or recesses. The method can include attaching the second fascia panel to the wall in a manner such that a part of the second fascia panel overlaps a part of the fascia panel, and preferably that part of the fascia panel to which the packing element, second packing element and further packing element are connected. The method can include fixing the second fascia panel to the wall by driving fasteners through the second fascia panel apertures and/or recesses into the apertures formed in the additional packing elements, and into the wall.
The method can be repeated for subsequent fascia panels and packing elements until the wall is covered.
In another aspect there is provided a method of fastening a fascia panel to a wall using a fascia panel system. The fascia panel system comprises at least one fascia panel provided with at least one first connector formation comprising an aperture or recess; at least one packing element comprising a body with an aperture formed in the body, and a second connector formation. The first and second connector formation are configured to connect the packing element to the fascia panel to form a sub-assembly. The method comprises the steps of: connecting the packing element to the fascia panel to form a sub-assembly wherein the apertures in the fascia panel and the packing element are aligned and driving a fastener through the aligned apertures into the wall to fix the sub-assembly to the wall. The method can include the step of connecting at least one more packing element to the subassembly and driving a fastener through each of the aligned apertures in the sub-assembly.
The method an include the steps of preparing a second sub-assembly, positioning the second sub-assembly on the wall so as to at least partially overlap with the first sub-assembly and driving a fastener through each of the aligned apertures in the second sub-assembly.
The method can include the step of overlapping the first sub-assembly with the second subassembly such that the second sub-assembly covers the fasteners of the first sub-assembly.
The various aspects of the present invention can be practiced alone or in combination with one or more of the other aspects, as will be appreciated by those skilled in the relevant arts. The various aspects of the invention can optionally be provided in combination with one or more of the optional features of the other aspects of the invention. Also, optional features described in relation to one aspect can typically be combined alone or together with other features in different aspects of the invention. Any subject matter described in this specification can be combined with any other subject matter in the specification to form a novel combination.
Embodiments of the invention will now be described by way of example only with reference to the drawings, wherein:
Figure 1 is an isometric view from the rear a part of fascia panel system according to the invention;
Figure 2 is a rear view of the part of the fascia panel system of Figure 1 ;
Figure 3 is an isometric view from the front of the part of the fascia panel system of Figure i;
Figure 4 is an isometric view from the rear of the part of the fascia panel shown in Figure 1;
Figure 5 is a rear view of the part of the fascia panel of Figure 4;
Figure 6 is an isometric view of a packing element used in the fascia panel system of Figure 1 ;
Figure 7 is an end view of the packing element of Figure 6;
Figure 8 is a plan view from above of the packing element of Figure 6; and
Figure 9 is a flow diagram of a method for installing fascia panels onto a building wall. Figure 1 shows part of fascia panel system 1 according to the invention, which includes a fascia panel 3 (sometimes referred to as a “fascia wall panel”); a packing element 5; and a fastener 7. In practice, the fascia panel system 1 includes multiple fascia panels 3, multiple packing elements 5, and multiple fasteners 7. A sufficient number of the fascia panels 3, packing elements 5, and fasteners 7 are provided to cover a substrate, which is typically a building wall. Each fascia panel 3 is generally rectangular in plan. Each fascia panel 3 includes an arrangement of apertures formed through the thickness of the panel 3, from a front side 11 to a rear side 13. Typically, the apertures 9 are in the form of slots and/or holes. Typically, each aperture 9 is sized and/or shaped to enable there to be a small amount of relative movement between the panel 3 and the packing element 5, for example to allow the panel 3 to expand and contract due to thermal changes. For example, using slots has the advantage of allowing a small amount of relative movement between the panel 3 and the packing element 5 along a longitudinal axis of the slot to allow the panel 3 to expand and contract due to thermal changes. Where holes are used, they can have a different shape from a slot, for example the hole can have a circular shape. The apertures 9 are located adjacent a first longitudinal edge 10 of the panel, and are preferably formed through a stepped portion 14 of the panel. This enables the fascia panel to be fixed to the substrate adjacent the longitudinal edge of the panel 10.
In Figures 1 to 5, the apertures 9 are shown as slots. Typically, each slot 9 is rectilinear and has a central longitudinal axis. The central longitudinal axes of the rectilinear slots 9 are aligned, such that the slots 9 are distributed, in a spaced apart fashion, along a line. Typically, the line of rectilinear slots 9 is arranged parallel to the first longitudinal edge 10 of the panel.
The rear side 13 of the panel includes first and second reinforcement ribs 15,17. The reinforcement ribs 15,17 stiffen the panel 3. Each reinforcement rib 15,17 extends along the length of the panel. The first reinforcement rib 15 has a generally rectangular transverse crosssection. The first reinforcement rib 15 is arranged parallel a second longitudinal edge 19 of the panel, and is spaced apart from the second longitudinal edge 19. The second reinforcement rib 17 has a generally triangular transverse cross-section. The second reinforcement rib 17 is arranged parallel with the first reinforcement rib 17, and is located centrally on the rear side 13 of the panel.
When fascia panels 3 are mounted onto a wall, a part 21 of the rear side of the panel that is located between the first reinforcement rib 15 and the second longitudinal edge 19 of a second panel 3B, overlaps the stepped part 15 of a first panel 3A (see Figure 3). The first reinforcement rib 15 butts up against the first longitudinal edge 10, and therefore the first reinforcement rib 15 helps to correctly position and orientate the second panel 3B relative to the first panel 3 A.
Each fascia panel 3 can be made from any suitable material, such as a plastics material, wood, and/or fibre board.
The packing element 5 comprises a moulded component, and preferably an injection moulded component. The packing element 5 can be made from a thermoplastic such as polypropylene. The packing element 5 includes a body 23. The body 23 is generally cuboid in shape. The body has an end wall 25. The end wall 25 faces outwardly when the packing element 5 is installed. The body 23 includes side walls 27. The end wall 25 is perpendicular to the side walls 27. Preferably the body 23 is substantially hollow, or includes hollow portions.
An aperture 29 is formed through the end wall 25, preferably in a central portion of the end wall 25. A tubular member 31 extends inwardly into the body 23 from an internal side of the end wall 25. The tubular member 31 is arranged co-axially with the aperture 29. A central longitudinal axis of the tubular member 1 is arranged perpendicularly to the end wall 25 of the packing element body. The tubular member 31 is arranged to receive the fastener 7, which is inserted into the tubular member 31 through the aperture 29.
The diameter of the tubular member 29 and/or the thread of the fastener 7 can be selected, such that the fastener 7 engages the tubular member 29 as the fastener 7 passes through the packing element 5, for example the fastener 7 can be arranged to bite into the tubular member 29. Alternatively, the diameter of the tubular member 29 and/or the thread of the fastener 7 can be selected, such that the fastener 7 does not engage the tubular member 29 as the fastener 7 passes through the packing element 5. For example, the diameter of the tubular member 29 and/or the diameter of the screw thread, can be selected such that there is a clearance between the thread and the tubular member 29.
The body 23 includes internal webbing 33 between the tubular member 31 and side walls 27 of the packing element body. The webbing 33 supports the tubular member 31, and improves the rigidity of the body 23. The packing element 5 is releasably attachable to the fascia panel 3 to from a sub-assembly.
The packing element 5 includes first, second, third and fourth resilient prongs 35,37,39,41 . The prongs 35,37,39,41 are arranged for insertion into one of the slots 9 and to engage with the fascia panel 3 adjacent the slot 9 in order to clip the packing element 5 to the fascia panel 3. Thus each slot 9 acts as a connector formation for the fascia panel 3, and the prongs 35,37,39,41 act as a connector formation for the packing element 5. The first and second prongs 35,37 provide a first pair of prongs, wherein the first prong 35 is arranged to engage a first side of the slot 9 and the second prong 37 is arranged to engage a second side of the slot 9. The third and fourth prongs 39,41 provide a second pair of prongs, wherein the third prong 39 is arranged to engage the first slide of the slot 9 and the fourth prong 41 is arranged to engage the second side of the slot 9.
The prongs 35,37,39,41 can include a tapered leading end 35a, 37a, 39a, 41 a to assist insertion of the prongs 35,37,39,41 into the slot 9.
The prongs 35,37,39,41 protrude outwardly from the end wall 25, and preferably protrude perpendicularly outwards from the end wall 25. Preferably the prongs 35,37,39,41 are located on a central portion of the end wall 25. Having the prongs 35,37,39,41 located centrally enables there to be some play between the packing element 5 and the fascia panel 3. The prongs 35,37,39,41 can be located adjacent to aperture 29. For example, the prongs 35,37,39,41 can be located immediately next to the aperture 29. The first pair of prongs 35,39 can be arranged diametrically opposite to the second pair of prongs 39,41.
The fasteners 7 may be any type of suitable type such as a screw, nail, staple, or threaded fastener and are selected to be sufficiently long to penetrate through the fascia panel 3 and the packing element 5, and to bite into the substrate on which the panel 3 is mounted. The type of fastener 7 used for a particular application will depend in part on the materials from which the panel 3, packing element 5 and substrate are made, and the dimensions of the panel 3 and the packing element. It may be desirable to drill holes into the substrate and insert wall plugs, prior to screwing the panel 3 to substrate.
A method for installing fascia panels onto a wall will be described with reference to Figure 9. As an initial step, proving the materials required for the installation process, which typically includes providing a plurality of fascia panels 3, a plurality of packing elements 5 and a plurality of fasteners 7. During an installation process, several packing elements 5 are clipped to a first fascia panel 3 to form a sub-assembly prior to mounting the fascia panel 3 onto a building wall. The packing elements 5 are distributed along the length of the panel 3. For the first panel 3 A, it may be necessary to have a panel that has two sets of slots, one adjacent to each longitudinal edge of the panel. Thus for the first panel 3A, packing elements 5 can be attached to two longitudinal edges of the first panel 3A. Alternatively, if all panels 3 are arranged similarly to the panel 3 shown in the Figures, a baton can be applied to the wall for the longitudinal side of the panel that does not include packing elements 5. The longitudinal edge of the first panel 3 A that does not have packing elements 5 attached thereto can rest on the baton.
The first panel 3A is mounted onto the wall, with the packing elements 5 attached thereto whereby the apertures in the fascia panel 3 and the packing element 5 are aligned for a fastener 7 to extend through both of them.
The first panel 3A is fixed to the wall by driving respective fasteners 7 through the respective slots 9 and into the apertures 29 formed in the respective packing elements 5, until the fasteners 7 engage the wall and/or a wall plug previously inserted into the wall.
Several packing elements 5 are clipped to a second fascia panel 3B prior to mounting the second panel 3B onto the wall.
The second panel 3B is mounted onto the wall in a manner such that the longitudinal part 21 of the rear side of the panel that is located between the first reinforcement rib 15 and the second longitudinal edge 19 of a second panel 3B, overlaps the stepped part 15 of the first panel 3 A thereby covering the fasteners of the first panel 3A (see Figure 3).
The second panel 3B is fixed to the wall by driving respective fasteners 7 through the respective slots 9 and into the apertures 29 formed in the respective packing elements 5, until the fasteners 7 engage the wall and/or a wall plug previously inserted into the wall.
Several packing elements 5 are clipped to a further fascia panel 3 prior to mounting the further panel 3B onto the wall.
The further panel 3 is mounted onto the wall in a manner such that the longitudinal part 21 of the rear side of the panel that is located between the first reinforcement rib 15 and the second longitudinal edge 19 of the further panel 3, overlaps the stepped part 15 of the second panel 3B. The further panel 3 is fixed to the wall by driving respective fasteners 7 through the respective slots 9 and into the apertures 29 formed in the respective packing elements 5, until the fasteners 7 engage the wall and/or a wall plug previously inserted into the wall.
This process is repeated for further fascia panels and packing elements until the wall is covered. The panels 3 can be applied to the wall in any suitable orientation. Typically, the longitudinal direction of the panels 3 is oriented in the horizontal direction or the vertical direction.
It will be appreciated by the skilled person that modifications can be made to the above embodiments that fall within the scope of the invention, for example the packing element 5 can include a different number of prongs 35,37,39,41 to clip the packing element 5 to the fascia panel 3. The packing element 5 can include at least one prong, and preferably includes a plurality of prongs, arranged to engage the fascia panel in the vicinity of the slot.
The number of apertures 9 can be different. The apertures 9 can have a different arrangement. The apertures 9 can have a different location with respect to the panel, for example, the apertures 9 can be formed adjacent a shorter edge. Apertures can be formed adjacent a plurality of edges.
Instead of including a plurality of apertures 9, the fascia panel can comprise a single aperture, such as a single slot that extends along an edge of the fascia panel, and the prongs of each of the packing element can be arranged for insertion into the single slot, and to engage the fascia panel at spaced apart locations adjacent the single slot. Thus the panel can have a single second connector formation that is arranged to interact with the first connector formation of multiple packing elements.
In addition, or alternatively to, the at least one aperture 9, the fascia panel can include at least one recess, such as at least one channel. For example, the fascia panel can comprise a single recess, such as a single channel that extends along an edge of the fascia panel, and the prongs of each of the packing element can be arranged for insertion into the single channel, and to engage the fascia panel at spaced apart locations adjacent the single channel. Thus the panel can have a single second connector formation that is arranged to interact with the first connector formation of multiple packing elements.
The fascia panel can include a plurality of recesses, such as a plurality of channels. The plurality of channels can be arranged similarly to the plurality of slots shown in the figures. For example, each packing element can be arranged to engage with a single recess. The fascia panel can include at least one aperture and at least one recess.
The fascia panel can include some second connector formations that comprise both a recessed part and an aperture part.
The description presents exemplary embodiments and, together with the drawings, serves to explain principles of the invention. However, the scope of the invention is not intended to be limited to the precise details of the embodiments or exact adherence with all method installation steps, since variations will be apparent to a skilled person and are deemed also to be covered by the claims. Terms for components used herein should be given a broad interpretation that also encompasses equivalent functions and features. In some cases, several alternative terms (synonyms) for structural features have been provided but such terms are not intended to be exhaustive.
Descriptive terms should also be given the broadest possible interpretation; e.g. the term "comprising" as used in this specification means "including" such that interpreting each statement in this specification that includes the term "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner. Directional terms such as “vertical”, “horizontal”, “up”, “down”, “upper” and “lower” may be used for convenience of explanation usually with reference to the illustrations and are not intended to be ultimately limiting if an equivalent function can be achieved with an alternative dimension and/or direction.
The description herein refers to embodiments with particular combinations of configuration steps or features, however, it is envisaged that further combinations and cross-combinations of compatible steps or features between embodiments will be possible. Indeed, isolated features may function independently as an invention from other features and not necessarily require implementation as a complete combination. Any feature from an embodiment can be isolated from that embodiment and included in any other embodiment.
The term “at least one of the” is to be interpreted in the sense of “and/or”. For example, the term “at least one of the first prong and the second prong” is to be interpreted as meaning any one of the following: the first prong alone; the second prong alone; or the combination of the first and second prongs. As another example, the term “at least one of the first prong, the second prong and the third prong” is to be interpreted as meaning any one of the following: the first prong alone; the second prong alone; the third prong alone; the combination of the first prong and the second prong; the combination of the first prong and the third prong; the combination of the second prong and the third prong; or the combination of the first prong, the second prong and the third prong.

Claims

1 . A fascia panel system, comprising: at least one fascia panel provided with at least one first connector formation comprising an aperture or recess; at least one packing element comprising a body with an aperture formed in the body, and a second connector formation; the first and second connector formations being configured to connect the packing element to the fascia panel to form a sub- assembly; wherein the aperture/recess in the fascia panel and the aperture in the body of the packing element are configured to align, such that a fastener can extend through both the fascia panel and the packing element for fixing the sub-assembly to a substrate.
2. The fascia panel of claim 1, wherein the second connector formation is sized and shaped to enable the second connector portion to move within the aperture and/or recess, whilst the second connector portion engages the fascia board adjacent the aperture andzor recess.
3. The fascia panel of claim 1 or 2, wherein the aperture comprises at least one of: a slot and a hole; and/or the recess comprises a channel.
4. The fascia panel system of any one of the preceding claims, wherein the fascia panel includes a plurality of first connector formations.
5. The fascia panel system of claim 4, wherein the first connector formations are located adjacent a peripheral portion of the fascia panel.
6. The fascia panel system of claim 5, wherein the peripheral portion is stepped relative to a major surface of the fascia panel.
7. The fascia panel system of any one of the preceding claims, wherein the second connector formation includes a first prong that protrudes outwards from the packing element body, wherein the first prong is arranged for insertion into the first connector formation. The fascia panel system of claim 7, wherein the second connector formation includes a second prong that protrudes outwards from packing element body, wherein the second prong is arranged for insertion into the first connector formation. The fascia panel system of claim 8, wherein the second connector formation includes a third prong that protrudes outwards from packing element body, wherein the third prong is arranged for insertion into the first connector formation. The fascia panel system of claim 9, wherein the second connector formation includes a fourth prong that protrudes outwards from packing element body, wherein the fourth prong is arranged for insertion into the first connector formation. The fascia panel system of any one of claims 7 to 10, wherein at least one of the first prong, second prong, third prong, and fourth prong has a tapered leading edge. The fascia panel system of any one of claims 7 to 11, wherein at least one of the first prong, second prong, third prong and fourth prong protrudes outwards from an end wall of the packing element body. The fascia panel system of any one of the preceding claims, wherein the aperture in the packing element body is located adjacent the second connector formation. The fascia panel system of any one of the preceding claims, wherein the second connector formation is resiliently deformable. The fascia panel system of any one of the preceding claims, wherein the packing element is moulded. The fascia panel system of any one of the preceding claims, wherein the packing element comprises a plastics material, such as thermoplastic material. The fascia panel system of any one of the preceding claims, wherein the packing element body is substantially hollow, or includes hollow portions. The fascia panel system of any one of the preceding claims, wherein the packing element body includes a tubular member arranged to receive the fastener, which is inserted into the tubular member through the aperture. The fascia panel system of claim 18, wherein the tubular member extends into the packing element body from the aperture formed in the packing element body. The fascia panel system of claim 18 or 19, wherein the packing element body includes side walls and internal webbing between the tubular member and the side walls. The fascia panel system of any one of the preceding claims, comprising a plurality of packing elements. A packing element for a fascia panel system, comprising: a body having a connector formation arranged to engage with a connector formation of a fascia panel to form a sub-assembly, and an aperture formed in the body that is arranged to receive a fastener extending through the sub-assembly for fixing the sub-assembly to a substrate. A packing element according to claim 22 wherein the a connector formation of the body comprises a first resilient prong that is arranged for insertion into a slot formed in the fascia panel. The packing element of claim 22 or 23, wherein the connector formation includes at least one of: i) a second resilient prong; ii) a second and third resilient prong; and iii) a second, third and fourth resilient prong. The packing element of any one of claims 22 to 24, wherein at least one of the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong has a tapered leading edge. The packing element of any one of claims 22 to 25, wherein the aperture in the packing element body is located adjacent at least one of the first resilient prong, the second resilient prong, the third resilient prong and the fourth resilient prong. The packing element of any one of claims 22 to 26, wherein the packing element is moulded. The packing element of any one of claims 22 to 27, wherein the packing element comprises a plastics material, such as thermoplastic material. The packing element of any one of claims 22 to 28, wherein the packing element body is substantially hollow or includes hollow portions. The packing element of any one of claims 22 to 29, wherein the packing element body includes a tubular member that extends from the aperture formed in the packing element body. The packing element of claim 30, wherein a central longitudinal axis of the tubular member is arranged perpendicular to the end wall of the packing element body. The packing element of 30 or 31, wherein the packing element body includes side walls and internal webbing connecting the tubular member to the side walls. A method of fastening a fascia panel to a wall using a fascia panel system, the fascia panel system comprising: at least one fascia panel provided with at least one first connector formation comprising an aperture or recess; at least one packing element comprising a body with an aperture formed in the body, and a second connector formation, the first and second connector formation being configured to connect the packing element to the fascia panel to form a sub-assembly the method comprising the steps of: connecting the packing element to the fascia panel to form a sub-assembly wherein the apertures in the fascia panel and the packing element are aligned; driving a fastener through the aligned apertures into the wall to fix the sub-assembly to the wall. A method according to claim 33 comprising the step of connecting at least one more packing element to the sub-assembly and driving a fastener through each of the aligned apertures in the sub-assembly. A method according to any of claims 33 to 34 comprising the steps of: preparing a second sub-assembly; positioning the second sub-assembly on the wall so as to at least partially overlap with the first sub-assembly; driving a fastener through each of the aligned apertures in the second sub-assembly. 6. A method according to claim 35 further comprising the step of overlapping the first sub-assembly with the second sub-assembly such that the second sub-assembly covers the fasteners of the first sub-assembly.
EP23836906.0A 2022-12-02 2023-12-01 Fascia panel system, a packing element for a fascia panel system & method of attaching a fascia panel to a wall Pending EP4630635A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB2218158.0A GB2625074A (en) 2022-12-02 2022-12-02 Fascia panel system, a packaging element for a fascia panel system & method of attaching a fascia panel to a wall
PCT/GB2023/000056 WO2024115868A2 (en) 2022-12-02 2023-12-01 Fascia panel system, a packing element for a fascia panel system & method of attaching a fascia panel to a wall

Publications (1)

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EP4630635A2 true EP4630635A2 (en) 2025-10-15

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Application Number Title Priority Date Filing Date
EP23836906.0A Pending EP4630635A2 (en) 2022-12-02 2023-12-01 Fascia panel system, a packing element for a fascia panel system & method of attaching a fascia panel to a wall

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EP (1) EP4630635A2 (en)
GB (1) GB2625074A (en)
WO (1) WO2024115868A2 (en)

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITVR20070043A1 (en) * 2007-03-22 2008-09-23 Valeria Santolin LAMINATED LEATHER FLOOR WITH FLEXIBLE SELF-LOCKING SYSTEM
US8959748B2 (en) * 2011-04-13 2015-02-24 E I Du Pont De Nemours And Company Method for assembling panels of dissimilar materials
EP2927391A1 (en) * 2014-04-04 2015-10-07 Gaber S.R.L. Device for fixing to a wall functional and decorative elements such as paintings, panels and the like, and functional and decorative element comprising the fixing device
US10961719B2 (en) * 2017-02-21 2021-03-30 Klevaklip Systems Pty Ltd. Decking clip
JP2022055567A (en) * 2020-09-29 2022-04-08 アイジー工業株式会社 Weathering structure for laterally jointed part of dry wall material

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GB202218158D0 (en) 2023-01-18
GB2625074A (en) 2024-06-12
WO2024115868A2 (en) 2024-06-06
WO2024115868A3 (en) 2025-05-22

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