GB2613104A

GB2613104A - Cavity tray system with jointing structures

Info

Publication number: GB2613104A
Application number: GB2302748.5A
Authority: GB
Inventors: Pulcini Stefano
Original assignee: ACS Stainless Steel Fixings Ltd
Current assignee: ACS Stainless Steel Fixings Ltd
Priority date: 2019-10-30
Filing date: 2020-10-29
Publication date: 2023-05-24
Anticipated expiration: 2040-10-29
Also published as: GB2588649B; GB2589989A; GB202205538D0; GB202313793D0; GB2620691B; WO2021084047A1; GB2589989B; GB202020187D0; GB202017213D0; GB2590783A; GB2620691A; GB2602439B; GB202302748D0; GB2613104B; GB2590783B; GB2588649A; GB201915784D0; GB2602439A; GB202012808D0

Abstract

The present disclosure provides a wall cavity tray system (1, 1a) for positioning within the cavity (2) of a cavity wall (3) in order to direct water towards the exterior of a building structure, the system comprising first (10) and second (20) trays, each comprising a first surface, that, in use, are adapted to be located at an angle to one another within the cavity (2), the first surface of the first tray (10) being adapted to be angled downwardly across the cavity (2) in a direction from an inner leaf of the cavity wall (3) towards an outer leaf of the cavity wall (3), and the first surface of the second tray (20) adjoining a lower portion of the first tray (10) and being adapted to extend into the outer leaf of the cavity wall (3). The first and second trays (10, 20) may be constructed as separate trays or in other embodiments may be integrally formed.

Description

CAVITY TRAY SYSTEM WITH JOINTING STRUCTURES

The present application relates to a system of inserts which are to be placed within a cavity wall region of a building. In particular, the system presents a number of trays which are to be appropriately connected to the interior walls within a cavity wall, in order to direct water away from a main structure and lead to this properly draining to the outside of the building. Further, a number of different mechanisms for joining adjacent trays together into the complete system are described.

A common building construction is that of a main structure which is produced using the latest building technology and materials, surrounded on the outside by a cladding, perhaps made of more traditional materials like bricks. The benefits of this structure are that the main building can be built from any number of new materials and therefore fulfil all building regulations as these develop, while the cladding forms an outer wall that can be made more aesthetically pleasing. Such a structure typically includes a cavity between the main building and the cladding, wherein this cavity not only increases insulation of the building from the external elements and environment, but also allows greater flexibility when constructing the main building structure.

As will be appreciated, it is possible that water, vapour and any other liquids, may permeate into the cavity structure, and form droplets which will, under the act of gravity, drop down the interior of the cavity. Additionally, the interior sides of the walls making up the cavity wall also provide a condensation point for water, or other liquids, which will also mean that droplets and moisture will run down the sides of the interior of the cavity wall. It will be appreciated that water gathering at the bottom of the cavity wall can lead to damage to both walls making up the cavity wall, and in particular to the wall making up the main structure. It is further noted that many building materials, especially bricks, are permeable and will soak up and store water if this is not satisfactorily removed. Such issues are undesirable, as they shorten the lifetime of the structure or lead to undesirable and unwanted repairs falling due.

Systems are known for attracting and guiding the moisture which arises in the cavity wall. However increased safety in building regulations and the like, requires that all building materials conform to high standards in fire prevention and that they minimise the possible spread of any fire. The present disclosure presents a system of water guidance for collecting and channelling water existing within the cavity wall, whilst also ensuring appropriate conformity with building regulations, in particular the requirement of low flammability to the structure.

According to a first aspect of the present invention there is provided a wall cavity tray system as defined.

According to a second aspect of the present invention there is provided a building structure comprising a cavity wall wherein a wall tray system according to the first aspect of the present invention is located.

Examples of the present invention will now be described with reference to the accompanying drawings.

DESCRIPTION OF THE FIGURES

Fig. 1: Cross-sectional view of a cavity wall showing a wall cavity tray system in accordance with the present invention.

Fig. 2: Perspective view of the outer wall of a cavity wall showing the cavity tray system according to Fig. 1.

Fig. 3: Fig. 4: Fig. 5a: Fig. 5b: Perspective view of one example of the cavity tray system.

Perspective view of another example of the cavity tray system without a fixing structure to the wall.

Perspective view of a different, single piece, cavity tray system. Perspective view of a single piece cavity tray system which has no fixings with the inner leaf of the cavity wall.

Fig 6a: View of a two-piece cavity tray system in which the angled tray is positioned within, or attached to an element of, the inner leaf of the cavity wall.

Fig 6b: View of a one-piece cavity tray system in which the angled tray is positioned within, or attached to an element of, the inner leaf of the cavity wall.

Fig. 7a: Corner structure of a cavity wall showing elements of the present tray system for an exterior corner.

Fig. 7b: Exploded view of corner structure seen in Fig. 7a.

Fig. 8: Corner structure of a cavity wall showing elements of the present tray system for an interior corner.

Fig. 9a: Exploded view of two-piece external corner cavity wall tray system.

Fig. 9b: Exploded view of two-piece interior corner cavity wall tray system.

Fig. 10: Modified cavity tray structure in perspective view.

Fig. ha: Cavity tray system integrated with a masonry support system for a cavity wall.

Fig. lib: Cross-sectional view of Fig. 11a.

Fig. 12: Cross-sectional view of a modified version of the cavity tray system shown in Fig. 11b.

Fig. 13: Cavity tray system showing a lintel tray and water guiding ends.

Fig. 14a: Cavity trays system showing removable guides.

Fig. 14b: Removable guide structure of Fig. 14a.

Fig. 15: Cavity tray system showing a lip in horizontal section for liquid guidance and jointing.

Fig. 16: Drainage holes through a brick wall.

Fig. 17a: Cavity tray with jointing structure on one lateral edge.

Fig. 17b: View of a first planar section of the cavity tray shown in Fig. 17a.

Fig. 17c: View of two overlapping planar sections of cavity trays as shown in Figs. 17a and 17b.

Fig. 18a: Cavity tray with jointing structures on both lateral edges.

Fig. 18b: View of a first planar section of the cavity tray shown in Fig. 18a.

Fig. 18c: View of first planar sections of two overlapping cavity trays, one as shown in Fig. 18a and one without a jointing structure.

Fig. 19a: Cavity tray system with upwardly and downwardly extending flanges for jointing structure.

Fig. 19b: View of two overlapping planar sections of the cavity trays shown in Fig. 19a.

Fig. 20: Cavity tray showing ribbed jointing structure.

Fig. 21a: View of two cavity trays with overlap for a bolted joint there-between.

Fig. 21b: View of the two cavity trays in Fig. 21a in alignment with fixation means.

Fig. 21c: Complete bolted joint between adjacent cavity trays.

Fig. 22a: Tray showing hemmed joint.

Fig. 22b: Close-up of an underlap of the hemmed joint.

Fig. 22c: Close-up of an overlap of the hemmed joint.

Fig. 23a: Two cavity trays with hemmed joint prior to engagement.

Fig. 23b: Two cavity trays with hemmed joint in engagement.

Fig. 23c: Engaged cavity trays of Fig. 23b showing cap.

Fig. 23d: Final structure of hemmed cavity trays and cap.

Fig. 24a: Single hemmed joint for cavity trays.

Fig. 24b: Close-up of single hemmed joint.

Fig. 25: View showing welded joint.

Fig. 26: View showing an induction heated joint.

Fig. 27a: Adjacent cavity trays for mechanical fixing joint.

Fig. 27b: Adjacent cavity trays showing clasp to hold trays together.

Fig. 27c: Close-up of joint of Fig. 27b with clasp in place.

Fig. 27d: Close-up of clasp shown in Fig. 27b.

Fig. 28a: Mechanical joint with jointing lip of variable height.

Fig. 28b: Joint of Fig. 28a with clasp holding trays in alignment.

Fig. 29a: Joint with clasp having drainage holes.

Fig. 29b: Cross-section of clasp in Fig. 29a.

Fig. 29c: Joint of Fig. 29a including a cover protecting the drainage holes.

Fig. 30a: Mechanical joint with further drainage channels at joint.

Fig. 30b: Cross-section of tray showing drainage channels at joint.

Fig. 30c: Mechanical joint of Fig. 30a with cap holding trays in alignment.

Fig. 31a: Mechanical joint employing a rolled jointing lip, non-engaged.

Fig. 31b: Mechanical joint employing a rolled jointing lip, engaged.

Fig. 32a: Joint between adjacent trays employing a jointing patch, non-engaged.

Fig. 32b: Joint between adjacent trays employing a jointing patch, engaged.

DESCRIPTION

In the following, similar reference numerals will be attributed to items of the different structures which fulfil the same function or purpose.

As can be seen in the Figures the present disclosure relates to a one la or two-piece wall cavity tray system 1 which is to be positioned within the cavity 2 of a cavity wall 3. The cavity wall 3 comprises an inner leaf, or interior building wall, and an outer leaf, or external wall or cladding, which will typically form the exterior of the building, with a cavity 2 there-between. As shown in Figs. 1, 2 and 3, a first, two-piece cavity tray system 1 according to the present disclosure comprises two separate elements, a first cavity tray 10 which is for connecting to the inner wall of the cavity wall 3; a second cavity tray 20 which is for integrating with the outer, exterior wall of the cavity wall 3. This two-piece system allows for flexible and easy integration of the cavity tray system 1 within a building, whilst also ensuring that appropriate directing of water, or any other liquids, which exist within the cavity 2 of the cavity wall 3 are directed appropriately and guided out of the cavity 2, as indicated by the arrows in the Figures.

The first cavity tray 10 is seen in Fig. 3 as comprising an angled planar structure which is to be, or is, attached to the inner wall of the cavity wall 3. It will be noted in the following that each of the planar sections is shown to be flat, and without surface decoration or further shapes; this is by way of example only. Indeed, each tray comprises a respective first surface which is used and adapted for guiding liquids out of the cavity 2; in the following these first surfaces are defined as planar sections. The present disclosure also covers not-flat surfaces, or "planar sections", perhaps exhibiting a slight curve, if beneficial. Additionally, the present disclosure covers "planar sections" which are ridged, or corrugated or have other, non-linear cross-sections. The primary requirement of the planar sections and portions is to ensure that water or other liquid droplets are properly directed from the cavity 2 to the outside of the cavity wall 3. To this end, the term "planar" is not be construed in a literal and restrictive sense, rather it is to be understood functionally as providing an appropriate surface for guiding droplets out of the cavity 2.

The first cavity tray 10 has a surface providing a first planar section 11, for attachment to the interior wall of the cavity wall 3. The first planar section 11 is preferably provided with a series of holes 12 there-through which allow easy fitting of the first cavity tray 10 to the inner wall of the cavity wall 3. Fig. 3 show generally round holes 12, however it will be appreciated that other fixing structures are appropriate; these may include elongate slots through which a fixing element, for example a screw of bolt, can be threaded for attachment to the interior wall of the cavity wall 3. Additionally, it is understood that the mechanism of fixation could be one of providing hook-like slots in the first planar section 11, wherein the hook-like slots (not shown in the Figures) could be used to hang the first cavity tray 10 to the interior surface or wall of the cavity wall 3.

If the interior wall were to be made from a brick-like construction, such that a mortar course were provided between bricks, the first planar section 11 could be provided as an upper lip 19 which can be inserted into the mortar course or any other element of the inner leaf, in order to fix the first cavity tray 10 within the cavity 2 of the cavity wall 3. An example of a two-piece cavity tray showing the upper lip 19 for attaching the first cavity tray 10 into the inner leaf is shown in Fig. 6a. It will be appreciated that a number of different mechanisms for attaching the first cavity tray 10 are available, and will be chosen appropriately with the nature of the building.

The first cavity tray 10 also comprises another surface providing a second planar section 13, which is shown angled away from the interior wall of the cavity wall 3. The first cavity tray 10 is preferably an integral structure made of a single sheet of material which is bent or cranked to form the first planar section 11 and the second planar section 13 angled with respect to the first planar section 11. It will be appreciated from Fig. 3, that when the first planar section 11 is appropriately affixed to the interior surface of one of the walls in the cavity wall 3, the second planar section 13 is angled away from this interior surface and provides a skirt-like structure which extends into, and generally across, the cavity 2 of the cavity wall 3. As can be seen from the arrows in the Figures, especially in Fig. 3, liquid which drops down through the cavity 2 will come into contact with the second planar section 13 and be appropriately guided along the surface of the second planar section 13 and away from the wall to which the first cavity tray 10 is affixed. In this manner, moisture and water droplets which are within the cavity 2 of the cavity wall 3 will be guided away from the walls by the first cavity tray 10.

As is also seen in Fig. 3, the cavity tray system 1 comprises a second cavity tray 20. As shown in Fig. 3, the second cavity tray 20 is intended to be positioned below the first cavity tray 10 when the cavity tray system 1 is in use. The second cavity tray 20 comprises an elongate section 21 which, preferably, is so sized and structured that it will allow embedding within the mortar course of the exterior wall making up the cavity wall 3. Of course, it is also possible to reverse the positioning of the first cavity tray 10 and second cavity tray 20, such that the brick structure as shown in the Figures comprises the inner leaf, inner wall, or building wall, of the cavity wall 3. As is clear from Fig. 3, the elongate section 21 will be firmly held within the mortar of the brick construction wall, thus holding the second cavity tray 20 within the cavity wall 3. It is possible to provide the elongate section 21 with a number of holes or elongate slots 23 therein. The provision of such elongate slots 23 allows for the mortar within the mortar course of the outer wall to pass from the lower to upper side of the elongate section 21 and thus ensures reliable and solid fitting of the elongate section 21 within the mortar course in the wall.

As can be seen in Fig. 3, the second cavity tray 20 also comprises an upturned lip 22 extending out of the plane of the elongate section 21. The upturned lip 22 is intended to facilitate the flow of water from the cavity 2 out of the cavity 2. Provision of the second cavity tray 20 with merely the elongate section 21, would allow for water droplets to move in both directions, as seen in Fig. 3 from left to right, and thus drop within the cavity 2 of the cavity wall 3 and not be guided out of said cavity 2. The upturned lip 22 will ensure that water which lands on the elongate section 21 cannot spread and fall off the tray 20 into the cavity 2 but will be guided through and out of the cavity 2.

In order to facilitate the drainage of the water out of the cavity 2, the brick course in a brick construction wall is provided with a series of weep holes 30, as can be seen in Fig. 16. These weep holes 30 pass from the interior of the cavity 2 to the outside of the cavity wall 3, and thus ensure that any liquid or moisture which has been captured by the cavity tray system 1, in the manner described above, will drain out of the cavity 2. The weep holes 30 are shown in Fig. 16 between bricks in the wall, however may also be possible to position such weep holes 30 within a mortar course of the wall as needed.

It will be appreciated that the two-piece construction to the wall cavity tray system 1 is particularly advantageous as this allows a great deal of flexibility and ease in attaching the cavity tray system 1 within a cavity wall 3. Providing a single piece construction which is intended to bridge from the interior side of the interior wall of the cavity wall 3 across the cavity 2 and then through the exterior wall of the cavity wall 3, puts undue strain on the accuracy of building the cavity wall 3. Furthermore, it is not uncommon for buildings to settle with time, thus meaning that the interior and exterior wall of the cavity wall 3 may move with respect to each other during time, or during different seasons where temperature changes will affect the structures and elements thereof differently. The two-piece construction is, therefore, desirable for ensuring appropriate handling of moisture within the cavity 2, whilst also improving the ease of construction. It will be seen from the Figures that the lengths of the first cavity tray 10 and second cavity tray 20 are preferably the same, such that easy overlap of the two trays will arise.

That said, in certain situations the two-piece cavity tray system 1 described above may not be desired or useable. In such circumstances, the one-piece cavity tray system la as shown in Fig. 5a and 6b can be used. Fig. 5a has all of the above described features: including a second planar section 13 forming a skirt-like structure that is integrated with a first planar section 11 which is to be fitted within the mortar course of a masonry wall, but the second cavity tray 20 is provided by a further section or extension 50, of the second planar section 13.

This further extension 50 is, as seen in Fig. 5a, provided at the lower edge of the angled second planar section 13 and is integral therewith. This angled structure allows for the lower extension 50 to act as the above described second cavity tray 20 and guide the water out of the cavity 2, however this extension 50 does not require that an upturned lip 22 is provided as there is no gap between the skirt-like structure and the extension, as there is in the two-piece cavity tray 1.

In Fig. 6b, a one-piece cavity tray is provided which has the upper lip 19 for attachment within the mortar course, or to another element, of the inner leaf.

When looking at the cross-section in Fig. 1 and with reference to Fig. 3, it is clear that the upturned lip 22 of the second cavity tray 20 makes an angle with the elongate section 21 which is approximately the same as the angle between the first 11 and second 13 planar sections of the first cavity tray 10. This similarity in the angles will allow for good overlapping of the individual tray sections, and should also assist in guiding the lower edge of the first cavity tray 10 and with the second cavity tray 20. Of course, different angles may be provided, however as required.

It will further be clear that the size of the first and second cavity trays 10, 20 (or skirt-like projection and extension 50 as seen in the one-piece cavity tray la in Fig. 5a) can be selected to appropriately bridge the cavity 2 of the cavity wall 3. Depending upon the width between the two walls making up the cavity wall 3, the first cavity tray 10 and second cavity tray 20 will have different sizes.

Preferably, the second planar section 13 is provided with an appropriate angle and length such that it will completely, or almost completely, bridge the cavity 2 of the cavity wall 3. The upturned lip 22 of the second cavity tray 20 is thus preferably also positioned so that it will lie behind the lower end of the second planar section 13, thus catching any water dropping through the cavity 2 of the cavity wall 3. This thus means that the size of the elongate section 21 and upturned lip 22 are appropriately chosen to properly integrate with the first cavity tray 10. In particular, the width of the elongate section 21 should be enough to ensure that it can be securely held within the mortar course of the brick construction wall, whilst also ensuring that the elongate section 21 extends far enough into the cavity 2 such that the upturned lip 22 will be positioned behind the lower distal end of the second planar section 13. In the one-piece cavity tray la of Fig. 5a, the extension 50 is so structured that it will fit within the mortar course and be securely held therein and will protrude within the cavity 2; the skirt-like structure 13 will then extend at an appropriate angle and for an appropriate length that the cavity 2 is then properly bridged and the upper edge of the skirt-like structure rests on the interior wall of the other wall. When the first planar section 11 is present in the one-piece cavity tray la, this would then rest on the interior wall for fixing of the one-piece cavity tray la to the wall.

As shown in Fig. 4, the provision of the first planar section 11 is optional. A two-piece wall cavity tray 1 system can be provided with a single, angled plate 13 acting as the first cavity tray 10 without the first planar section 11 formed therewith. In this manner, construction of the first cavity tray 10 is simplified and the system still works to guide liquid from the cavity 2 to the outside. The single sheet first cavity tray 10 can be employed with the one-piece cavity tray la construction of Fig. 5a as required within the same cavity wall. It is further of note that the first cavity tray 10 has a length which is wider than the cavity 2 of the cavity wall 3, such that it will only fit into the cavity 2 when making a sloping angle from one wall of the cavity wall 3 to the other wall. In this manner, any liquid dropping onto the first cavity tray 10 will slide down the first cavity tray 10 toward the second cavity tray 20 and out of the cavity 2. Fig. 5b shows another example of a first cavity tray 10 without the first planar section 11; in this example, a one-piece cavity tray la is provided in a similar manner to that described above with respect to Fig. 5a.

The cavity wall 3 according to Figs. 7a, 7b and 8 is also shown with a corner therein: an external corner is shown in Figs. 7a and 7b and an interior corner is shown in Fig. 8, wherein each corner section comprises an appropriate corner cavity tray system according to the present invention. Here the wall cavity tray system 40 is fabricated so as to fit around an exterior corner, or into an interior corner, of the cavity wall 3, thus making a corner cavity tray. It will be appreciated that the system shown in Figs. 7a and 7b represents an external or outward corner for the cavity wall 3, that is the corner is a convex corner. The principles of the corner cavity tray system 40 work equally well for a convex corner in the cavity wall 3, as shown in Fig. 8; the principles of the corner cavity tray design 40 are so constructed to appropriately guide moisture from the cavity 2 as above.

As seen in Fig. 7a, the corner cavity tray design 40 has a first cavity tray providing a corner cavity tray 41 which is appropriately shaped such that it will fit around an external corner of one of the walls in the cavity wall 3. The cavity tray 41 therefore has two sections at an angle with respect to each other which progress around the corner in the cavity wall 3 and provide an outward facing skirt-like structure 42 away from each of the inner leaves making up the cavity wall 3, thus ensuring that water will be appropriately guided away from the interior surface of the inner leaves of the cavity wall 3. The corner cavity tray 41 is provided with one or more upstanding first planar portions 43, two are shown, which are provided at an angle with respect to each other. The first planar portions 43 fulfil the role of the first planar sections 11 of the cavity tray system 1 described above. These first planar portions 43 are intended to be affixed to the inner leaves of the cavity wall 3 and are thus provided with an angle there-between which matches the angle of the corner making up the cavity wall 3. In the example shown in Fig. 7a, the corner is approximately 900, thus meaning that the angle between the first planar portions 43 is also approximately 90°. In the same manner as above, the first planar portions 43 may be provided with a series of holes or slots or hooks for attaching the corner cavity tray 41 to the inner leaves of the cavity wall 3. The disclosure above relating to the fixation is equally applicable to the corner cavity tray 41. It is also conceivable that the first planar portion 43 comprise a single, angled element which fits around the corner. In the same manner as shown in Fig. 6a and 6b, the first planar portion 43 may also be an upper lip which fits within a mortar course or another element of the inner leaf.

As will be seen in Fig. 7a, the skirt-like structure 42 extends diagonally away from the first planar portions 43 outwardly around the convex bend in the cavity wall 3, thus appropriately bridging the entire gap of the cavity 2 around this convex corner. In Fig. 8, where the corner in the cavity wall 3 is a concave corner, the skirt-like structure 42 generally progresses inwardly to make an inward facing skirt-like structure 42, which equally bridges across the entirety of the cavity 2 within the cavity wall 3.

In order to make up the full corner cavity tray system 40, it will be appreciated that the second cavity tray 20 as described above could be integrated in the region of the outer leaf of making up the cavity wall 3. By positioning the second cavity trays 20 in each of the outer leaves on either side of the corner of the cavity wall 3, these can be so positioned such that the lips 22 pass behind the lower portions of the skirt sections of the corner cavity tray 41, thus ensuring the flow of moisture as described above with regard to Figs. 1 and 2.

Instead of utilising two cavity trays 20 it is also possible to provide a single construction second tray element which is comprised of a planar L-shaped part 90 and an angled lip 91. Such a structure can be seen in Fig. 9a for an external corner and in Fig. 9b for an interior corner. The second tray element is a single L-shaped construction which will pass around the corner of the cavity wall 3. The angle of the second tray element will be tailored to match the angle of the corner in the cavity wall 3, so as to properly integrate with the corner cavity tray 41. In the same manner as the second cavity tray 20, the second tray element is intended to fit within a mortar course of the outer leaves of the wall. The L-shaped part 90 will thus be held firmly in the outer leaf and the angled lip 91 will extend into the cavity 2 of the cavity wall 3. The angled lip 91 is, in the same manner as above with regard to the upturned lip 22 and second planar section 13, positioned such that it will lie behind the lower portion of the skirt-like structure 42 of the corner cavity tray. Again, the angle of the angled lip 91 with respect to the plane of the L-shaped part 90 is the same as the angle between the portion making the skirt-like structure 42 and each of the first planar portions 43.

It is also possible to make the corner cavity tray 41 of an integral structure which also comprises the extension 48 from the lower distal end of the skirt-like structure 42 -this is shown in Figs. 7a, 7b and 8. In this manner, the entire corner cavity tray 41 is intended to be a single integral item which will appropriately bridge the cavity 2 of the cavity wall 3. The extension 48 will fit within a mortar course of the outer leaf in the same manner as the second cavity tray 20 or the L-shaped part 90. With the extension 48 being an integral part of the skirt-like structure 42, the appropriate guidance of liquid through to the brick construction wall is ensured. Again, the wall is preferably provided with drainage holes 30 to allow the water to escape to the exterior.

As shown in Fig. 7b, the extensions 48 will not meet each other within the brick wall when they extend directly outward from the skirt-like structure 42. To ensure a complete solution, either the extensions 48 are angled at the corner point so that they follow the line of the bend and do meet, or a separate plate 49 is provided which fits between the two extension 48 and completes the lower water protection in the corner. It will be clear that in an interior corner, as seen in Fig. 8, the extensions 48 will either overlap, or they have an inwardly angled taper toward the corner, such that they provide a complete coverage in the mortar course.

As can be seen in Fig. 7a, the skirt-like structure 42 is an unbroken angled structure extending from the inner leaf of the cavity wall 3 across to the outer leaf of the wall on either side of the corner in the cavity wall 3. This structure provides a complete watertight structure which ensures all water will be removed appropriately from the cavity 2. In the case of the concave corner of the cavity wall 3, the two surfaces making up the skirt-like structure 42 extend into the corner of the corner region, and again will meet at a line which extends from the interior corner of the inner leaf of the cavity wall 3 outward to the exterior leaf making up the cavity wall 3. This is shown in Fig. 8. In the first, convex corner, case, the upper side of the skirt-like structure 42 is not as wide as the lower side of the skirt-like structure 42 for each of the two elements either side of the corner. In the second, concave corner structure, the upper edge of the skirt-like structure 42 has a greater width than the lower edge of the skirt-like structure 42 either side of the corner.

If the corner cavity system is provided with the L-shaped second tray element, the width of the L-shaped part 90 is sufficient that it will be held firmly within a mortar course making up the outer leaf of the wall, and ensure that the angled lip 91 extends appropriately within the cavity 2 such that the angled lip 91 is positioned behind the lower portion of the skirt-like structure 42. This will ensure that water is appropriately channelled away from the cavity 2 in the same manner as described above for the cavity tray system 1. In the same manner as above for the second cavity tray 20, the second tray element can comprise a series of holes or slots therein such that the mortar of the mortar course will provide a bridge from the upper to lower side of the second tray element thus firmly fixing this within the mortar course.

When fixing the corner cavity tray 41 into the cavity wall 3, a choice of whether to use the second cavity trays 20 on either side of the corner, an L-shaped second tray element or the cavity tray 41 with the integral extensions 48 will be made. In the same manner as above, the second cavity tray 20, second tray element or extensions 48 will be positioned within a mortar course of the outer leaf of the wall, and then the corner cavity tray 41 is either attached to the inner leaf on either side of the corner region, such that the lower portion of the skirt-like structure 42 is above and in front of the upturned lip 22 or angled lip, when the two-part construction is used. If the one-part corner cavity tray 41 with integral extension 48 is used, as shown in Figs. 7a, 7b and 8, then the corner cavity tray 41 is then appropriately located around a corner and the first planar portions 43 or the single angled first planar portion, if provided, need only be attached to the inner leaf of the wall on either side of the corner.

A further aspect of the tray systems of the present disclosure is shown in Fig. 10. As can be seen in Fig. 10, this provides a modification to the two-piece cavity tray 1 as described above in relation to Fig. 3; this is by way of example only, and it will be realised that the modification shown in Fig. 10 can also apply to any of the systems and concepts defined herein, as required. Looking at Fig. 10, a third planar section 60 is provided attached to the lower edge of the second planar section 13, that is along the edge which is opposite that adjacent the first planar section 11. This third planar section 60 extends at an angle to the second planar section 13. That is, the skirt-like structure of the first cavity tray 10 is cranked to form an upper planar section 13 and a lower planar section 60 when in use. As will be appreciated, the third planar section 60 is angled downward from the edge of the second planar section 13, in order that it will guide liquids which land on the second planar section 13 toward the second cavity tray 20. Of course, if the cavity system is a one-piece cavity tray la, then the third planar section 60 will be positioned between the second planar section 13 and the extension 50, as seen in Fig. 5a. The third planar section 60 can also be integrated within the lower sides of the skirt-like sections 42 seen in the corner cavity tray system 40 of Figs. 7a, 7b and 8. The use of this third planar section is useful when there are obstacles within the cavity 2 which would physically conflict with the one-piece la or two-piece 2 cavity trays or the corner cavity tray system 40 described above.

Another beneficial use of the third planar section 60, is to allow integration of the cavity tray system with a masonry support system for the building. As seen in Fig. 11a, a masonry support system comprises a series of brackets 70 which are located within the cavity 2 in the cavity wall 3. The use of a masonry support system is known in the art and the addition of the third planar section 60 allows for the cavity trays systems 1, 40 to be positioned around the same; this is best seen in the cross-sectional view of Fig. 11b. It is also possible for the second cavity tray 20 to be an integral part of the masonry support system 70 itself. In this case the function of the second cavity tray 20 and an angle section support member of the masonry support system are combined. This integration can improve the manufacture and integrity of the cavity tray systems 1, 40. It is also possible to utilise the brackets 70 of the masonry support system as support brackets for holding the one-piece cavity tray la in place. The embodiment shown in Figs. ha and llb show the first cavity tray 10 affixed to an inner leaf by means of the first planar section 11. Alternatively, as shown in Fig. 12, the first cavity tray 10 can be attached directly to the brackets 70 of a masonry support system by means of a flap 71 which is angled downward and is attached directly to the brackets 70 of the masonry support system or attached between the brackets 70 of the masonry support system and the inner leaf.

In order to ensure that the liquid which is collected by the cavity tray system 1, la, 40 is properly guided out of the cavity 2, the second cavity tray 20 or the extensions 50 in the one-piece cavity tray la system may be provided with one or more upwardly extending flaps 80. These upwardly extending flaps 80 extend out of the plane of the second cavity tray 20 or the extensions 50 and will stop liquid movement over the surface in a lateral direction, instead ensuring that the liquid flows only in the direction of leaving the cavity 2. The upwardly extending flaps 80 may form an integral part of the second cavity tray 20. In Fig. 13, the second cavity tray 20 forms part of a lintel for the outer leaf with two upwardly extending flaps 80 positioned at the ends thereof to guide liquid; of course, only one upwardly extending flap 80 may be needed.

Figs. 14a and 14b show upwardly extending flaps 80 that are separate items that form part of a cavity tray system 1, la as required. As shown in Fig. 14b, each upwardly extending flap 80 is formed from two generally planar pieces which are angled with respect to each other. The planar pieces are angled such that when a first of the planar pieces 81 is positioned on the second cavity tray 20, the second planar piece 82 will extend out of the plane of the second cavity tray 20 thus defining a guide which ensures liquid flow across the second cavity tray 20 and out of the cavity 2. As seen in Fig. 14b, the second planar piece 82, which is intended to extend out of the plane of the second cavity tray 20, is provided with a cut-out corner 83 which allows this to fit against the angled first cavity tray 10 and improve the liquid-tight seal. The second planar piece 82 is also wider than the first planar piece 81, thus ensuring that the edges of the separate upwardly extending flap 80 abuts the first cavity tray 10. Fig. 15 shows another embodiment of upwardly extending flap 80, in which the upwardly extending flap SO is in the form of an integral lip 84 at the end of the second cavity tray 20. This lip 84, further highlighted in Fig. 15 at **, extends upwards in use, out of the plane of the second cavity tray 20 and will also guide liquid out of the cavity 2 to the exterior of the cavity wall 3.

In order to improve the join adjacent first 10 and second 20 cavity trays in use, these are typically positioned with a lateral overlap to ensure complete coverage of the cavity 2 in the cavity wall 3. In addition, one or more of the lateral edges of the cavity trays can be provided with a jointing structure. Figs. 17a to 17c show one example of the jointing structure which is a lip, or flange 100, at one of the lateral edges of the first cavity tray 10. In the example of Figs. 17a to 17c, one of the lateral edges of the first cavity tray 10 is provided with the flange 100 and this is highlighted at **. Fig. 17b shows the view along the direction of the second planar section 13 toward the first planar section 11 and thus the flange 100 can be seen extending upward from the lateral edge of the second planar section 13. Fig 17c shows two adjacent first cavity trays 10 in use, where one overlaps the other and the flange 100 provides a single line contact on the underside of the upper first cavity tray 10, thus improving liquid-tightness. This structure also helps to ensure that there is a gap between the overlapping first cavity trays 10, thus preventing any retention of liquid in this region that may otherwise occur if the two cavity trays 10 were in full contact. Whilst Figs. 17a to 17c show the jointing structure for the first cavity tray 10, the same concept can be applied to the second cavity tray 20 to ensure improved liquid drainage.

Figs. 18a to 18c show a similar jointing structure to that shown in Figs. 17a to 17c, however the jointing structure is provided at both lateral edges of the first cavity tray 10 by the dual flanges 101. Again, the location of the dual flanges 101 is highlighted in Figs. 18a to 18c at **. The dual flanges 101 provide the same effect as the flange 100 of Figs. 17a to 17c, however as seen in Fig. 18c, the jointing structure is such that every other first cavity tray 10 will be provided with the dual flanges 101. As the dual flanges 101 provide appropriate jointing on both lateral edges of the respective first cavity trays 10, the remaining first cavity trays 10 do not need a jointing structure to still gain all of the advantages of improved liquid drainage discussed above. Again, whilst Figs. 18a to 18c show the dual flange 101 jointing structure for the first cavity tray 10, the same concept can be applied to the second cavity tray 20 to ensure improved liquid drainage.

Figs. 19a and 19b show a further jointing structure which combines the dual flanges 101 as seen in Figs. 18a to 18c with a downward flange 102. In the system shown in Fig. 19b, every other first cavity tray 10 is provided with the jointing structure of the dual flanges 101 from Figs. 18a to 18c and the remaining first cavity trays 10 are provided with downward flanges 102 from each lateral edge thereof. The downward flanges 102 extend from the lower side of the lateral edges of the first cavity tray 10 and, in use, will make contact with the upper surface of the adjacent first cavity tray 10 over which is overlaps. Rather than providing jointing structures on only half of the first cavity trays 10, as in Figs. 18a to 18c, the example in Figs. 19a and 19b ensures that the overlap region has two line contact points at either lateral edge of the overlap. This provides even greater separation of the first cavity trays 10 in the overlap region and improves liquid drainage from the cavity 2. Again, whilst Figs. 19a and 19b show the jointing structure for the first cavity tray 10, the same dual flange 101 and downward flange 102 concept can be applied to the second cavity tray 20 to ensure improved liquid drainage.

A further jointing structure is shown in Fig. 20 which includes one or more ribs 103 at or near the lateral edges of the respective first 10 and second 20 cavity trays. Fig. 20 shows the ribs 103 at/near both lateral edges of the first 10 and second 20 cavity trays, however the jointing structure will also function if only one lateral edge is provided with the one or more ribs 103. Whilst three, equally spaced apart ribs 103 are shown at and near the lateral edge of the respective first 10 and second 20 cavity trays in Fig. 20, this is by way of example only. The number, spacing and precise location of the ribs 103 can vary as required.

Additionally, the ribs 103 can be upwardly or downwardly extending, as judged with the first 10 and second 20 cavity trays are in use, or a mixture of both directions for extension can be accommodated. In particular, the ribs 103 on every other first 10 and second 20 cavity tray may extend upward, the ribs 103 on the remaining first 10 and second 20 cavity trays may extend downward to appropriately interlock with the upwardly extending ribs 103. In the same manner as for the flanges 100, dual flanges 101 and downward flanges 102 these interact in the overlapping regions between adjacent first 10 and second 20 cavity trays to ensure improved liquid drainage from the cavity 2.

Whilst the jointing systems of Figs. 17a to 20 are each shown for the two-piece cavity tray system 1, the same jointing structures may be employed on the lateral edges of the trays forming one-piece cavity tray system la. The same improved liquid drainage at the overlapping regions of adjacent trays in the one-piece cavity tray system la as discussed above for the two-piece cavity tray system 1, will thus arise. Furthermore, in each of the jointing systems the liquid tightness can be further improved by providing a sealant between all overlapping parts or the respective lateral edges of overlapping parts. The use of the jointing structures above further provides overlapping regions of vertically separated first 10 and second 20 cavity trays, such regions may also provide appropriate locations for providing sealant such that this is generally protected and the lifetime thereof is improved.

Further jointing systems and techniques for holding together the individual adjacent elements of the two-piece cavity trace system 1 or the one-piece cavity tray system la are shown in Figs. 21 to 32. Each of Figs. 21 to 32 shows a series of different jointing structures applied between adjacent second cavity trays 20.

The principle of the jointing structures shown in each of Figs. 21 to 32 is to provide a properly watertight gap between adjacent second cavity trays 20 in the two-piece cavity tray system 1. The entire system of cavity trays is improved by avoiding the use of sealant materials between adjacent cavity trays, whether that be first cavity trays 10 or second cavity trays 20, as the sealant can deteriorate with time and ay add additional materials or steps when integrating the cavity tray systems with cavity walls 3.

It will be appreciated that the solutions given in Figs. 21 to 32 are shown for the second cavity tray 20 only. This is purely by way of example: it will be clear to the reader that the jointing solutions being presented are, typically, equally applicable to the first cavity trays 10 of the two-piece cavity tray system 1.

Furthermore, the one-piece cavity tray system la having the structure shown in Figs. 5a and 6b for example, can also be jointed together at adjacent sections by any of the techniques described below and in Figs. 21 to 32. The use of the second cavity trays 20 in the following is therefore exemplary. It will also be noted that the second cavity trays 20 shown in many of the figures have the elongate section 21 and an option for the upturned lip 22 being at an approximate right angle to the plane of the elongate section 21. This approximately 90° bend between the elongate section 21 and upturned lip 22 is also not limiting, the upturned lip 22 may have any angle with respect to the elongate section 21. A 90° angle is particularly useful in manufacturing the second cavity trays 20, but is not necessarily limiting on the following disclosure.

Figs. 21a to 21c show a series of images relating to a bolted joint between adjacent second cavity trays 20. In Fig. 21a, an overlap 110 is shown between the upper second cavity tray 20 and the lower second cavity tray 20. The bolted joint between adjacent cavity trays is constructed by overlapping adjacent cavity trays to give a sufficient overlap 110, thereby securing the adjacent cavity trays together whilst also ensuring that the connection between the adjacent cavity trays can be made watertight. In Fig. 21b, one or more fasteners 111 is/are applied to the overlap 110, the one or more fasteners 111 ideally passing through the elongate sections 21 of each of the second cavity trays 20, thus holding the two cavity trays together. One or more further fasteners 111 can also be provided into the overlapping upturned lips 22, as can be in Fig. 21b, thus also fixing the upturned lips 22 together at the overlap 110. As shown in Fig. 21c, the adjacent cavity trays are consequently held together by means of the one or more fasteners 111. The one or more fasteners 111 can be used to hold the two cavity trays in close physical alignment at the overlap 110, thus making the overlap 110 watertight and avoiding that moisture can pass through the gap between the overlapping cavity trays. The number of fasteners 111 is chosen depending upon the physical dimensions of the cavity trays, or the second cavity trays 20 as shown in Figs. 21a to 21c. The number of fasteners 111 is ideally sufficient to ensure a close proximity overlap between the adjacent cavity trays which can then be put under enough pressure in order to ensure that the overlap 111 is watertight. Evidently, increasing the number of fasteners 111 will increase the possible fixing force between the adjacent cavity trays and will improve the water-tightness. The nature of the fasteners 111 is not especially limited; it is conceived that screws, bolts or rivets could be utilised in order to hold the adjacent cavity trays together and provide the watertight overlap 110.

Figs. 22a to 22c show a hemmed joint between adjacent cavity trays. Fig. 22a shows a complete second cavity tray 20 comprising a first hemmed joint overlap 112 at the left hand side of the image as well as a second hemmed joint overlap 113 at the right hand side of the image. Fig. 22b shows a close-up of the first hemmed joint overlap 112 and Fig. 22c shows a close-up of the second hemmed joint overlap 113. It will be appreciated from the close-up images of Figs. 22b and 22c that the first and second hemmed joint overlaps 112, 113 an be formed by rolling the respective ends of the cavity tray back over itself, in order to create a gap between the cavity tray and the hemmed joint overlaps. The first hemmed joint overlap 112 as shown in Fig. 22b is rolled in such a way that the rolled section lies next to the exterior side of the cavity tray; this being known as an underlap 115. By contrast, the second hemmed joint overlap 113 shown in Fig. 22c is an overlap 114, wherein this end of the cavity tray is rolled over such that it lies adjacent to the interior section of the cavity tray. In both the overlap 114 and underlap 115, an extended air gap or slot extends between the two sections of the cavity tray which have been rolled over and the cavity tray itself, thus allowing for adjacent cavity trays to be engaged with each other by slotting the underlap 115 within the gap formed by the overlap 114. The underlap 115 can slide within the air gap or slot between the overlap 114 and the remainder of the cavity tray, thus filling the air gap in both the overlap 114 and underlap 115 and creating a reliable connection between the adjacent trays which is also watertight. The rolling process will, of course, be so tailored to ensure that the air gap or slot between the overlap 114 and underlap 115 with the cavity tray provides a gap thickness which approximates the thickness of the material making up the cavity tray and allows the interlocking described above and provides the watertight joint.

In Fig. 23a, adjacent cavity trays are shown in perspective view, and the interaction between the two cavity trays when forming the hemmed joint can be clearly seen. As shown by the two arrows in Fig. 23a, the upper cavity tray which presents the overlap 114 will be positioned on top of the lower cavity tray with the underlap 115 positioned beyond the extent of the overlap 114. By pulling the trays longitudinally away from each other, the underlap 115 will be engaged with the overlap 114. This engagement between two adjacent trays can be seen in the image of Fig. 23b. As shown in Fig. 23b, the two adjacent cavity trays are properly linked and have interlocking and interlaced overlap 114 and underlap 115.

Once the adjacent cavity trays have been connected by means of the hemmed joint, as shown in Fig. 23b, it is also possible to provide a cap 116 overlapping sections of the hemmed joint. The cap 116 is shown as a separate element above the cavity trays in Fig. 23c, and is located above the hemmed joint in the upturned lip 22 of the two adjacent cavity trays, in this case the second cavity trays 20. The cap 116 is a folded clip-like member, preferably formed from metal but any resilient material which will hold its shape is appropriate, wherein the cap 116 will slot over the upturned lips 22 in the region of the hemmed joint and hold the adjacent second cavity trays 20 together. The cap 116 is ideally of a V-shape cross-section, such that when applying the cap 116 to the hemmed joint the gap between the two sides of the cap 116 narrows and the force and friction between the cap 116 and the upturned lips 22 increases. By pressing the cap 116 into engagement with the upturned lips 22, the hemmed joint can be provided with a further security measure to hold the adjacent cavity trays together. The cap 116 may also be formed in a U-shape cross-section, wherein the gap between the two sides of the cap 116 is a little narrower than the hemmed joint at the upturned lips 22 of the cavity trays 20, thus ensuring a frictional engagement between the cap 116 and the upturned lips 22. Once the cap 116 is in place, it can then be crimped or seamed into engagement with the upturned lips 22 at the hemmed joint.

Looking at the joint in Figs. 24a and 24b, this represents a one-sided hemmed joint. In a similar manner to the hemmed joint shown in Figs. 22 and 23, the one-sided hemmed joint has only one end of the respective cavity tray rolled over on itself. The solution shown in Figs. 22a to 22c has each end of the cavity tray rolled in different directions to provide the overlap 114 and underlap 115. The concept shown in Figs. 24a and 24b of the one-sided hemmed joint, is that the double hem 117 provides a slot into which the end of an adjacent cavity tray may be slidably engaged. The double hem 117 is formed by rolling the end of the cavity tray first underneath the cavity tray in order to provide an underlap 115, as shown in Fig. 24b, and then rolling the underlap 115 back over itself to create the double hem 117. The rolled first section forming the underlap 115 is long enough such that it can be rolled in the opposite direction to create a rolled extension 118 which lies parallel to the underlap 115 but creates an air gap or slot there-between. The air gap or slot between the underlap 115 and the rolled extension 118 provides the gap into which the adjacent cavity tray can be slidably engaged. The double hem 117 is shown in cross-section in Fig. 24b, wherein the rolled extension 118 extends beyond the edge of the cavity tray and provides the gap between the rolled extension 118 and the underlap 115. This one-sided hemmed joint means that only one end of the cavity tray need be rolled in formation of the completed cavity tray, which improves the workability of the tray production. In the same manner as shown in Figs. 23c and 23d, a cap 116 can be added to the one-sided hemmed joint in the region of the overlap between the upturned lips 22 on the adjacent trays. This cap 116 is not shown in the figures.

Fig. 25 represents a welded joint between adjacent cavity trays. The provision of a weld 119 lying between the ends of the adjacent cavity trays, which can then be heated in the known manner to weld the adjacent cavity trays together, will provide a proper connection between the adjacent cavity trays which will also be watertight. The solution given in Fig. 25 is one in which the two cavity trays are located such that their ends appropriately align, and the weld 119 is placed there-between and properly heated to weld the two cavity trays together. Of course, the weld 119 could be placed between an overlap 110 between the adjacent cavity trays, as shown generally in Fig. 21b, where instead of applying the fasteners 111 in Fig. 21b a weld is formed along the edge of said overlap. Welding is a well-known technique and can be appropriately performed such that the adjacent cavity trays are essentially formed into a single unit and no gap exists there-between, thus ensuring a watertight connection.

Fig. 26 shows an example of an induction heating joint. In the example described above for the welded joint in which the two ends of the adjacent cavity trays are overlapped and welded together, induction heating allows for the two adjacent cavity trays to be overlapped with each other and a filler material 120 positioned between the two overlapping cavity trays. The filler material 120 is well-known in the art, and for example solder could be used as the filler material. The inductive heating technique then applies an RF field either side of the overlapping sections of cavity tray filled with the filler material 120, the RF field heating the materials within the field, in particular the filler material 120, causing the filler material 120 to melt and create a satisfactory bond between the adjacent cavity trays. Using sufficient filler material 120 will ensure that the overlap region between the two adjacent cavity trays will be completely filled and formed to be watertight, thus ensuring that the adjacent cavity trays are both firmly connected to each other and a watertight seal is provided there-between. Induction soldering is a particularly advantageous solution in this case: whilst it may provide a slightly weaker joint than induction braising or welding, it avoids the melting of any section of the cavity trays and provides a proper watertight seal without adding thermal stress to the cavity tray itself. Induction heating may be a well-known technique, however application of induction heating to the connection between adjacent cavity trays is not well-known.

Figs. 27a to 27d show a first mechanical fixing joint employing a clasp 122 to hold together jointing lips 121 on adjacent cavity trays. The cavity trays shown in Figs. 27a to 27c are the second cavity trays with associated upturned lips 22. The clasp 122 is thus appropriately formed to interact and hold the adjacent cavity trays together whilst accommodating the upturned lip 22. With regard to using this first mechanical fixing with the first cavity trays 10, the structure of the clasp 122 will be appropriate for bridging the gap between adjacent first cavity trays 10. This is not shown in the figures, however it will be evident from the discussion below of the clasp 122 and the interaction with the jointing lip 121 how this would be extended to the first cavity tray 10.

As shown in Fig. 27a, each end of the second cavity tray 20 is provided with a jointing lip 121. The jointing lip 121 extends upwards and inward from the elongate section 21 and upturned lip 22, respectively. The ends of the adjacent cavity trays thus have jointing lips 121 which extend slightly into the channel region of the second cavity tray 20. When positioning the adjacent second cavity trays 20 in longitudinal alignment as shown in Fig. 27b, by following the arrow shown in the enlarged section of 27a, the two jointing lips 121 will be in alignment as shown in the enlarged portion of Fig. 27b. This alignment between the adjacent jointing lips 121 can then be used with the clasp 122 to hold the adjacent second cavity trays 20 together. The clasp 122 is of a generally L-shaped form with an extending overlap 124 which extends away from the shorter side of the L-shaped clasp 122 in the same, or same general, direction as the longer side of the L-shaped clasp 122. The structure of the clasp 122 can best be seen in Fig. 27d, wherein the clasp 122 is shown overlapping the adjacent jointing lips 121 of the adjacent second cavity trays 20, thus holding the adjacent second cavity trays 20 together in a watertight manner. The clasp 122 extends over the entirety of the overlapping jointing lips 121 and has either a V-shaped or U-shaped cross-section. In the same manner as for the cap 116 described above, the clasp 122 is intended to frictionally engage and hold together the adjacent second cavity trays 20. The decreasing gap width of the V-shaped cross-section or the narrow gap in the U-shaped cross-section of the clasp 122 will appropriately engage the two jointing lips 121 together, forming the combined adjacent second cavity trays 20. In the case of the first cavity tray 10 the form of the jointing lip 121 and clasp 122 will be different, however the principle of connecting the adjacent first cavity trays 10 together will be the same. Once the clasp 122 is in place, it can be crimped or seamed to improve the mechanical connection. As can be seen in the enlarged section of Fig. 27b, a clasp gap 123 is preferably provided at the top side of the upturned lip 22 of the second cavity tray 20 between the top edge of the upturned lip 22 and the jointing lip 121. This clasp gap 123 allows for the overlap 124 of the clasp 122 to slot there-between, thus improving the connection between the upper edges of the upturned lips 22 of adjacent second cavity trays 20. Fig. 27c shows the adjacent second cavity trays 20 in alignment with the clasp 122 engaged with the adjacent upturned jointing lips 121. The jointing lip 121 engaged with the clasp 122 as shown in Fig. 27c thus provides an appropriate watertight seal. The jointing lip 121 passes through the exterior leaf of the cavity wall 3, to this end it preferably has a height when combined with the clasp 122 which matches the thickness of the mortar in the exterior leaf of the cavity wall 3. This not only ensures that the jointing lip 121 and clasp 122 will fit within the exterior leaf, but it also separates the individual second cavity trays 20 and directs the moisture out of the cavity wall 3 by minimising sideways seepage of such moisture.

Figs. 28a and 28b show a modified mechanical fixing from that shown in Figs. 27a to 27d. Most of the principles are the same, however it will be noted that the jointing lip 121c in Figs. 28a and 28b has a different form. The connection in Figs. 28a and 28b is by means of a jointing lip 121c comprising a taller lip section 121a and a shorter lip section 121b. The taller lip section 121a extends from the upturned lip 22 of the second cavity tray 20 into the tray region towards the front of the second cavity tray 20. At a point along the upturned lip 121c, the taller lip section 121a gives way to the shorter lip section 121b which extends all the way to the front edge of the second cavity tray 20. The form of the transition between the taller lip section 121a and shorter lip section 121b is not particularly limited, and a curved profile is shown in Fig. 28a. Likewise, a straight edged transition to form a step could also be provided. The modified clasp 122a has the same form as the taller lip section 121a and shorter lip section 121b, such that it will also make a good frictional connection between the adjacent second cavity trays 20. Again, in a similar manner to the clasp 122 shown in Fig. 27d, the cross-section of the modified clasp 122a could either be V form or U form, such that when sliding the modified clasp 122a over the taller lip section 121a and shorter lip section 121b, a tight frictional fit is ensured holding the adjacent second cavity tray sections 20 together. In the same manner as shown in the enlarged section of 27b and in 27d, a clasp gap 123 and overlap 124 are provided therefore ensuring that the modified clasp 122a properly engages the jointing lip 121c and holds the adjacent second cavity trays 20 together.

The specific position of the transition between the taller lip section 121a and shorter lip section 121b is chosen to engage with the amount of the second cavity tray 20 which extends out of the exterior leaf of the cavity wall 3 into the cavity. In use, the second cavity tray 20 shown in Figs. 28a and 28b will be positioned within the mortar course of the exterior wall of the cavity wall 3, up to the point that the transition aligns with the inner side of the bricks making the exterior wall. The second cavity tray 20 will then extend into the cavity of the cavity wall 3 to the extent defined by the taller lip section 121a. This means that there will be the taller lip section 121a within the cavity of the cavity wall 3, thus providing a section within the second cavity tray stopping motion of moisture or water along the length of the second cavity trays when in alignment and in the exterior leaf of the cavity wall 3, thus ensuring proper handling of the moisture and promoting that this be directed out of the cavity wall 3. In the same manner as described above for the clasp 122 in Figs. 27c and 27d, once the modified clasp 122a is frictionally engaged with the taller lip section 121a and shorter lip section 121b, it can be crimped or seamed with the jointing lips 121 in order to properly hold the adjacent second cavity trays 20 together.

A further modified weep hole clasp 125 is shown in Figs. 29a to 29c. In the same manner as shown in Figs. 27a and 27b, the second cavity tray 20 is provided with a jointing lip 121 at either end thereof. When the two cavity trays 20 are in alignment, the jointing lips 121 appropriately align and the weep hole clasp 125 can be positioned over the jointing lips 121, in particular along the jointing lip 121 in the elongate section 21 of the second cavity tray 20. The cross-section of the weep hole clasp 125 is shown in Fig. 29b, wherein this has a central region formed as either a V cross-section or U cross-section, in the same manner as the clasp 122 shown in relation to Figs. 27a to 27d. Either side of the central section, the weep hole clasp 125 is rolled over to create elongate channels along the longitudinal length of the weep hole clasp 125, these channels providing the function of weep holes 126. A small gap 127 exists between the end of the rolled section of the weep hole clasp 125 forming the weep holes 126, thus meaning that any moisture which lands on the weep hole clasp 125 can pass through the gap 127 into the weep holes 126. The central V-shaped or U-shaped cross-section of the weep hole clasp will engage, ideally frictionally, with the jointing lips 121 on the adjacent second cavity trays 20, and then can be crimped or seamed to the jointing lips 121 to hold the weep hole clasp 125 in firm engagement with the jointing lips 121, holding the two adjacent second cavity trays 20 together and in alignment. The weep hole clasp 125 will extend along the entirety of the jointing lip 121 and will therefore bridge the exterior wall of the cavity wall 3, thus providing the weep holes 126 from the interior of the cavity wall 3 to the exterior. This weep hole clasp 125 thus provides a further set of weep holes 126 allowing moisture to escape from the cavity in the cavity wall 3. As shown in Fig. 29c, an L-plate 140 can be positioned over the top of the inner end of the weep hole clasp 125, providing a cover over a section of the weep hole clasp 125 with the second part of the L-plate 140 positioned behind the upturned lip 22. The L-plate 140 is useful in protecting the weep holes 126 from any mortar dropping in the cavity of the cavity wall 3, in particular as further construction of the cavity wall 3 proceeds. Evidently, providing the weep hole clasp 125 only to have the weep holes 126 blocked by mortar, rather destroys the purpose of the weep hole clasp 125. In addition to the U-shape or V-shape central portion of the weep hole clasp 125, this can be provided by a squared U-shape as shown in Fig. 29b.

Figs. 30a to 30c show a modification of the jointing lip 121 in Figs. 27a and 27b. In the same manner as shown in Fig. 28a, the drainage jointing lip 128 has a first taller section 128a towards the upturned lip 22 of the second cavity tray 20. A shorter section 128b is then provided extending from the taller section 128a to the front of the second cavity tray 20 which will be held within the outer leaf of the cavity tray 3. The shorter section 128b of the drainage jointing lip 128 is formed by folding over the top of the short section 128b of the drainage jointing lip 128 back into general contact with the elongate section 21 of the second cavity tray 20. As can be seen in the face-on view in Fig. 30b, the folded over section of the drainage jointing lip 128 creates a lip weep hole 129. This lip weep hole 129 functions in the same way as the weep holes 126 in the weep hole clasp 125, and extends through the mortar of the external leaf of the cavity wall 3. This lip weep hole 129 therefore provides a drainage channel from the interior of the cavity wall 3 to the exterior, in the same way as the weep holes 126 shown in Fig. 29b. The taller section 128b of the drainage jointing lip 128 can be used in combination with a lip cap 130, as shown in Fig. 30c. The lip cap 130 has the same general form as the cap 116, and is utilised to grip together the two taller sections 128b of the drainage jointing lip 128 in order to hold together the adjacent second cavity trays 20. The lip clasp 130 can have either a V-shaped profile or U-shaped profile, in the same manner as cap 116, and after positioning over the taller sections 128b of the drainage jointing lip 128 can be crimped or seamed to the taller section 128b of the drainage jointing lip 128 thus holding together the two portions of adjacent cavity tray 20.

Figs. 31a and 31b provide another mechanical fixing for adjacent cavity trays, wherein the joint is formed by complimentary rolled jointing lips 131. Each rolled jointing lip 131 extends upward from the elongate section 21 of the second cavity tray 20, and then is rolled over to form a rolled section 132. As can be seen in Fig. 31a: in the left hand second cavity tray 20, the rolled jointing lip 131 extends vertically and then the rolled section 132 extends outwardly away from the tray region of the second cavity tray 20. On the right hand second cavity tray 20, the rolled jointing lip 131 extends upward and is rolled such that the rolled section 132 extends over the elongate section 21 of the second cavity tray 20. The two rolled jointing lips 131 therefore have complimentary form and the upper cavity tray can be positioned over the lower cavity tray 20 and the upper rolled jointing lip 131 which extends outward from the second cavity tray 20 will overlap the lower rolled jointing lip 131 and hold the adjacent second cavity trays 20 together. It will be clear from Fig. 31b that the rolled sections 132 of each of the rolled jointing lips 131 extend generally downward toward the upper surface of the elongate section 21. This downward angle to the rolled section 132 ensures that the adjacent second cavity trays 20 will be pushed into appropriate alignment with each other and the adjacent second cavity trays 20 will thus form a joined unit and extended tray. The upper rolled section 131 obviously appropriately overlaps with the lower rolled section 132, and is ideally positioned slightly further above the elongate section 21 in order to ensure that the lower side of the adjacent cavity trays is at the same point and forms a generally flat surface. The upper rolled section 132 obviously overlaps the seal between the two rolled jointing lips 131, thus ensuring that the connection is also watertight. Any moisture dropping from above onto the rolled jointing lip 131 will be directed onto the elongate section 21 of the appropriate second cavity tray 20; in Fig. 31b this would be the right hand second cavity tray 20. Once the two cavity trays are appropriately aligned and the two rolled jointing lips 131 are in complimentary engagement, the two rolled jointing lips 131 can be crimped or seamed together in order to hold the adjacent cavity trays 20 in appropriate alignment.

Figs. 32a and 32b provide a flexible joint between adjacent cavity trays. The adjacent cavity trays are structured in the same manner as shown in Fig. 27a, and each has the same jointing lip 121. Instead of using the clasp 122 shown in Fig. 27b, a joint patch 133 is provided. The joint patch 133 allows for the adjacent cavity trays to not make physical contact, but will integrate with each of the jointing lips 121 on each of the cavity trays in order to ensure that the cavity trays can be both joined together and provide a watertight seal there-between.

This may be particularly useful if cavity trays, in particular the second cavity trays 20 as shown in figures, are provided from either end of a construction, and may not exactly match when the two extended tracks of the cavity trays meet. Alternatively, this can simply provide a section of more flexibility between adjacent cavity trays. As shown in Fig. 32a, the joint patch 133 is provided with the same L-shaped form as the second cavity tray 20 either side of the joint to be made. The joint patch 133 has a patch elongate section 134 which matches the size of the elongate section 21 of the second cavity trays 20, and a patch upturned lip 135 which again matches the size of the upturned lip 22 of the second cavity trays 20. To this end, when the joint patch 133 overlaps the jointing lips 121 the patch elongate section 134 and patch upturned lip 135 will complete the channel and the second cavity tray 20 system will be fully complete and watertight. The joint patch 133 is provided at each side with patch clasps 136, these patch clasps generally having the same form as the clasp 122 shown in Fig. 27b. The patch claps 136 are integrally formed, or appropriately attached, to the patch elongate section 134 and patch upturned lip 135. The joint patch 133 therefore has two patch clasps 136 which are so positioned to align with the jointing lips 121 on each of the adjacent second cavity trays 20. As shown in Fig. 32b, when the jointing patch 133 is positioned over the up jointing lips 121 on each of the second cavity trays 20, the patch clasps 136 will engage each of the jointing lips 121 and after crimping or seaming together, will create an appropriate watertight joint between the adjacent cavity trays.

It will be appreciated that the discussion relating to Figs. 28, 29 and 30 are generally most appropriate for the second cavity tray 20 alone. Given that each of these solutions generally provides a structure which is intended to either integrate with the position of the second cavity tray 20 within the outer leaf of the cavity wall 3, or even provide a drainage channel through the exterior wall of the cavity wall 3, these structures are less beneficial when applied to the first cavity trays 10. This does not mean that they cannot be used with the first cavity trays 10, it just means that their additional functionality is of limited benefit.

In each of the above concepts, the material making up the elements is of a non-flammable nature. This appropriately reduces any fire concerns in modern buildings. Most preferably, the material for each of these elements is stainless steel, as this does not rust and has a very high melting point and is considered to be a safe material choice. Furthermore, it will be clear that the individual elements of each of the options can be appropriately combined with other elements to make a complete modular system of water handling -as seen in Fig. 7a, for example, the elongate structures of Figs. 3 to 6b can be positioned along the straight walls of the cavity wall 3, and then they abut or overlap with the corner structures shown in Figs. 7a to 9b. In order to provide even further watertightness, each of the elements, once fitted, can be provided with an appropriate sealant at the edges with other elements of the cavity tray systems of with the walls of the cavity wall 3. In order to facilitate this, it will further be appreciated that the angle which the second planar section 13 of the first cavity tray 10 makes with the interior wall of the cavity wall 3 would preferentially match the angle which the skirt-like structure 42 makes with the interior wall. In this manner, when the corner sections shown in Figs. 7a to 9b abut the cavity trays shown in any of Figs. 3 to 6b, the planar sections will match up and overlap to provide a complete skirt-like coverage around the building -this can be understood from Fig. 7a.

CLAUSES

1. A wall cavity tray system for positioning within the cavity of a cavity wall in order to direct water towards the exterior of a building structure, the system comprising first and second trays, each comprising a first surface, that, in use, are adapted to be located at an angle to one another within the cavity, the first surface of the first tray being adapted to be angled downwardly across the cavity in a direction from an inner leaf of the cavity wall towards an outer leaf of the cavity wall, and the first surface of the second tray adjoining a lower portion of the first tray and being adapted to extend into the outer leaf of the cavity wall. 2. 3. 4. 5. 6. 7.

The wall cavity tray system of clause 1, wherein the first tray further comprises a second surface, the first and second surfaces of the first tray being integrally formed and angled with respect to each other.

The wall cavity tray system of clause 2, wherein the second surface of the first tray comprises holes, slots or other fixation means to allow the first tray to be attached to the inner leaf of the cavity wall.

The wall cavity tray system of clause 2, wherein the second surface is adapted to be fixed within, or to an element of, the inner leaf of the cavity wall.

The wall cavity tray system of any of the previous clauses, wherein the first surface of the second tray is sized to ensure that it can be securely held in a mortar course of the outer leaf of the cavity.

The wall cavity tray system of any of the previous clauses, wherein the first and second trays are integrally formed.

The wall cavity tray system of any clauses 1 to 5, wherein the first and second trays are separate trays and the second tray comprises an upturned lip extending at an angle from an edge of its first surface.

8. The wall cavity tray system of clause 7, wherein the upturned lip is positioned behind a lower edge of the first surface of the first tray, and the lower edge of the first tray rests on or is positioned above the first surface of the second tray.

9. The wall cavity tray system of any of the previous clauses, wherein the first surface of the first tray is cranked to define two angled planar sections comprising, in use, an upper planar section and a lower planar section that comprises said lower portion that adjoins the first surface of the second tray.

10. The wall cavity tray system of any of the previous clauses, wherein the first and second trays are fabricated to fit around or into a corner defined by the cavity wall.

11. The wall cavity tray system of clause 10, wherein the first tray is fabricated to fit around an external corner defined by the cavity wall, wherein the first surface of the first tray comprises two sections at an angle to each other such that, in use, they form an outwardly extending skirt-like structure bridging the cavity between the inner leaf and outer leaf of the cavity wall either side of the corner.

12. The wall cavity tray system of clause 10, wherein the first tray is fabricated to fit into an internal corner defined by the cavity wall, wherein the first surface of the first tray comprises two sections at an angle to each other such that, in use, they form an inwardly extending skirt-like structure bridging the cavity between the inner leaf and outer leaf of the cavity wall either side of the corner.

13. The wall cavity tray system of either of clauses 11 or 12, wherein the second tray is integrally formed with the first tray and extends from the lower edge of the skirt-like structure, which forms the lower portion of the first tray, into the outer leaf of the cavity wall.

14. The wall cavity tray system of any of clauses 11 or 12, wherein the first and second trays are separate trays and the second tray is angled so as to fit within the outer leaf of the cavity wall and around the corner defined therein.

15. The wall cavity tray system of any of the previous clauses, wherein the first surface of the second tray comprises holes or slots therein.

16. The wall cavity tray system of any of the previous clauses, wherein the second tray comprises at least a part of a support member of a masonry support system adapted to be secured to the inner leaf of the cavity wall.

17. The wall cavity tray system of clause 16 when dependent on clause 9, wherein the first tray is configured such that the upper planar section and lower planar section will fit over and in front of one or more brackets of the masonry support system, respectively, when in use.

18. The wall cavity tray system of any of the previous clauses, wherein the second tray comprises at least a part of a lintel adapted to form part of the outer leaf of the cavity wall.

19. The wall cavity tray system of any of the previous clauses, wherein the second tray comprises one or more upwardly extending flaps to direct liquid flow toward the exterior of the cavity wall and not over the ends of the second tray into the cavity.

20. The wall cavity tray system of any of the previous clauses, wherein the first surface of the second tray is adapted to bridge the outer leaf when in use.

21. The wall cavity tray system of any of the previous clauses, wherein either one, or both, of the first and second trays is provided with a jointing structure along at least one of its lateral edges, that being the edge which will lie over or under an adjacent respective tray when in use, the jointing structure being adapted to reduce liquid retention in regions of adjacent and overlapping cavity trays when in use.

22. A building structure comprising a cavity wall wherein a wall cavity tray system of any of the preceding clauses is located, the second tray of the wall tray system being positioned within a mortar course of an outer leaf of the cavity wall and extending into the cavity and the first tray extending from the second tray upward and across the cavity into contact with an inner leaf of the cavity wall.

23. The building structure according to clause 22, wherein a plurality of first and second trays are provided and respective, adjacent first and second trays overlap with each other.

24. The building structure cavity wall according to clause 22 or clause 23, wherein the outer leaf of the cavity wall comprises weep holes in a course of masonry or a mortar course adjacent the first surface of the second tray to allow water to drain from the cavity.

25. The building structure according to any of clauses 22 to 24, wherein gaps between separate elements of the wall cavity tray system and/or gaps between elements of the wall cavity tray system and the inner and outer leaves of the cavity wall adjacent to said elements are closed by a sealant.

Claims

CLAIMS1. A wall cavity tray system for positioning within the cavity of a cavity wall, between a main building structure and an outer wall, in order to direct water towards the outer wall, and for the reduction of fire concerns in buildings of modern construction, the system comprising a first tray and a second tray, each comprising a first surface, which first surfaces, in use, are located at an angle to one another within the cavity, the first surface of the first tray being sized so that it can, in use, be angled downwardly across the cavity in a direction from an inner leaf of the cavity wall of the main structure towards an outer leaf of the cavity wall of the outer wall, and the first surface of the second tray adjoining or being located below a lower portion of the first tray and being sized to extend into the outer leaf of the cavity wall of the outer wall; wherein both of the first and second trays are provided with a jointing structure in the form of one or more ribs along at least one of the lateral edges of each tray, the lateral edge being the edge which will lie over or under an adjacent respective tray when in use, wherein the rib on the first tray and the rib on the second tray are configured to act as a jointing structure with an adjacent respective tray when in use; wherein the wall cavity tray system is formed from stainless steel.
2. The wall cavity tray system of claim 1, wherein the ribs extend out of the plane of the first surfaces of the respective first and second trays, when said ribs are present.
3. The wall cavity tray system of any of the previous claim, wherein the first tray further comprises a second surface, the first and second surfaces of the first tray being integrally formed and angled with respect to each other.
4. The wall cavity tray system of claim 3, wherein the second surface of the first tray comprises holes, slots or other fixation means to allow the first tray to be attached to the inner leaf of the cavity wall.
S. The wall cavity tray system of any of the previous claims, wherein the first and second trays are a one-piece construction.
6. The wall cavity tray system of any claims 1 to 4, wherein the first and second trays are separate trays and the second tray comprises an upturned lip extending at an angle from an edge of its first surface. 7. 8. 9. 10. 11. 12. 13. 14.
The wall cavity tray system of claim 6, wherein the upturned lip is positioned behind a lower edge of the first surface of the first tray, and the lower edge of the first tray rests on or is positioned above the first surface of the second tray.
The wall cavity tray system of any of the previous claims, wherein the first surface of the first tray is cranked to define two angled planar sections comprising, in use, an upper planar section and a lower planar section that comprises said lower portion that adjoins or is located above the first surface of the second tray.
The wall cavity tray system of any of the previous claims, wherein each jointing structure comprises three ribs.
The wall cavity tray system of any of the previous claims, wherein the first tray is fabricated to fit around an external corner defined by the cavity wall, wherein the first surface of the first tray comprises two sections at an angle to each other such that, in use, they form an outwardly extending skirt-like structure bridging the cavity between the inner leaf and outer leaf of the cavity wall either side of the corner.
The wall cavity tray system of any of claims 1 to 9, wherein the first tray is fabricated to fit into an internal corner defined by the cavity wall, wherein the first surface of the first tray comprises two sections at an angle to each other such that, in use, they form an inwardly extending skirt-like structure bridging the cavity between the inner leaf and outer leaf of the cavity wall either side of the corner.
The wall cavity tray system of either of claims 10 or 11, when not dependent upon claims 7 and 8, wherein the second tray is integrally formed with the first tray and extends from the lower edge of the skirt-like structure, which forms the lower portion of the first tray, into the outer leaf of the cavity wall.
The wall cavity tray system of any of claims 10 or 11, when not dependent upon claim 6, wherein the first and second trays are separate trays and the second tray is angled so as to fit within the outer leaf of the cavity wall and around the corner defined therein.
The wall cavity tray system of any of the previous claims, wherein the first surface of the second tray comprises holes or slots therein.
15. The wall cavity tray system of any of the previous claims, wherein the second tray comprises at least a part of a support member of a masonry support system adapted to be secured to the inner leaf of the cavity wall.
16. The wall cavity tray system of claim 15 when dependent on claim 8, wherein the first tray is configured such that the upper planar section and lower planar section will fit over and in front of one or more brackets of the masonry support system, respectively, when in use.
17. The wall cavity tray system of any of the previous claims, wherein the second tray comprises at least a part of a lintel adapted to form part of the outer leaf of the cavity wall.
18. The wall cavity tray system of any of the previous claims, wherein the second tray comprises one or more upwardly extending flaps to direct liquid flow toward the exterior of the cavity wall and not over the ends of the second tray into the cavity.
19. The wall cavity tray system of any of the previous claims, wherein the first surface of the second tray is sized to bridge the outer leaf when in use.
20. The wall cavity tray system of any preceding claim, wherein the outer wall is a cladding surround.
21. The wall cavity tray system of claim 20, wherein the cladding surround is comprised of bricks.
22. A masonry support system for positioning within the cavity of a cavity wall, between a main building structure and an outer wall, in order to direct water towards the outer wall, and for the reduction of fire concerns in buildings of modern construction, the masonry support system comprising: a masonry support element formed from a series of brackets, and the wall cavity tray system of any preceding claim.
23. A building structure comprising a cavity wall wherein a wall cavity tray system of any of the preceding claims is located, the second tray of the wall tray system being positioned within a mortar course of an outer leaf of the cavity wall and extending into the cavity and the first tray extending from the second tray upward and across the cavity into contact with an inner leaf of the cavity wall.
24. The building structure according to claim 24, wherein a plurality of first and second trays are provided and respective, adjacent first and second trays overlap with each other.
25. The building structure cavity wall according to claim 23 or claim 24, wherein the outer leaf of the cavity wall comprises weep holes in a course of masonry or a mortar course adjacent the first surface of the second tray to allow water to drain from the cavity.
26. The building structure according to any of claims 23 to 25, wherein gaps between separate elements of the wall cavity tray system and/or gaps between elements of the wall cavity tray system and the inner and outer leaves of the cavity wall adjacent to said elements are closed by a sealant.