IES960239A2 - Manufacture of cladding systems - Google Patents

Abstract

Extruded aluminium sections of a desired profile are prepared (5) and delivered to a taping station (10). At the taping station (10), protective adhesive tapes are led from tape rolls and aligned and applied to opposite sides of each aluminium section. Downstream of the taping section (10), each aluminium section is delivered to a cutting station (38) at which the aluminium section is cut into a plurality of frame members of a preset desirable size and configuration. Then the frame members are delivered as required through one or more machining and fitting stations (39). A plurality of the frame members are joined together to form a cladding frame for reception of one or more cladding panels. <Fig. 28>.

Description

Manufacture of Cladding Systems This invention relates to a method and apparatus for the manufacture of cladding systems.

The invention particularly relates to the manufacture of cladding systems comprising a plurality of pre-fabricated aluminium frames supporting cladding panels which are mounted on the aluminium frames. It is an object of the invention to manufacture high quality cladding systems of this type in an efficient and trouble-free manner.

According to the invention, there is provided a method for the manufacture of cladding systems, each cladding system comprising a plurality of aluminium frames supporting cladding panels mounted on the frames, the method comprising the steps: preparing an extruded aluminium section of a desired profile; delivering the aluminium section to a taping station; leading two adhesive tapes associated with the aluminium section from a pair spaced-apart tape rolls and joining the tapes together; engaging the tapes with an end of the aluminium section; aligning the aluminium section with the adhesive tapes , delivering the aluminium section between the rolls of tape in alignment with the tapes; pulling the tapes from the tape rolls and laying down the tapes on opposite side faces of the aluminium section; feeding the aluminium section between a pair of spaced-apart rollers downstream of the tape rolls engaging opposite taped sides of the aluminium section with the rollers; pressing and smoothing the tape onto opposite sides of the section by means of the rollers; cutting the tape; delivering the taped aluminium section from the taping station to a cutting station; cutting the aluminium section into a plurality of frame members of a pre-set desirable size and configuration at the cutting station; delivering the frame members as required through one or more machining and fitting stations for machining each frame member and mounting any desired fittings and attachments on the frame members; and joining a plurality of the frame members together, forming a cladding frame for reception of one or more cladding panels.

In one embodiment of the invention, the method includes aligning each aluminium section with the adhesive tapes by mounting each tape roll on a rotatable support shaft, aligning each tape roll with a pair of spaced-apart section guides, feeding the aluminium section between the tape rolls and between the guides to the rollers, the 8860239 guides engaging with opposite sides of the aluminium section as the aluminium section is passing between the guides .

In another embodiment of the invention, each tape roll is slidably mounted on the support shaft for aligning the tape roll with the guides, releasable locking means being provided to secure the tape roll in alignment with the guides. Preferably, each guide comprises a pair of spaced-apart rotatable guide rails.

In another embodiment of the invention, each pair of guide rails is mounted on a carrier, the carriers being slidably mounted on a support for adjusting the width between the guides .

In a further embodiment of the invention, the rollers comprise a fixed roller and a movable roller mounted on a support frame, the movable roller being slidable on the support frame for adjusting the width between the rollers.

In one embodiment of the invention, the method includes: cutting the aluminium section into a plurality of frame members forming tubular side frame members having mitred ends; drilling at least one nail hole adjacent each mitred end of each frame member; joining a plurality of the frame members together forming a cladding frame of a desired configuration; inserting an L-shaped cleat between adjacent frame members at mitred ends of the frame members; 239 - 4 inserting a nail through each nail hole into the cleat pinning the frame members to the cleat.

In another embodiment of the invention, the method includes injecting an adhesive filler into the mitred ends of the frame members after nailing the frame members together.

In a preferred embodiment of the invention, the extruded aluminium section has a re-entrant slot extending along a side face of the aluminium section for slidably receiving a mounting shoe having an outwardly extending fastener thereon for engaging with a support structure in use for mounting the cladding frame on the support structure.

The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings, in which:Fig. 1 is a perspective view of a taping device used in a method of manufacture of cladding systems according to the invention; Fig. 2 is a side elevational view of the device; taping Fig. 3 is a plan view of the taping device; Fig. 4 is a perspective view showing the device in use; taping Fig. 5 is a side sectional elevational view taping device in use; of the Fig. 6 is a plan view of the taping device, in use; 8960230 Fig. 7 is a plan view of a cladding frame manufactured according to the invention; Fig. 8 is a detail perspective view of a mitre joint assembly used in the frame; Fig. 9 is a perspective view showing interconnection of frame members; Fig. 10 is a perspective view of a nailing tool used in manufacture of the frame; Fig. 11 is an exploded perspective view of the nailing tool; Fig. 12 is a perspective view of the nailing tool and an associated nail; Fig. 13 is a detail perspective view illustrating insertion of a nail into a frame by means of the nail tool; Fig. 14 is a detail elevational view of a tip of the nailing tool; Fig. 15 is another detail elevational view of the tip of the nailing tool illustrating removal of the guide pin; Fig. 16 is a detail perspective view of portion of an aluminium section used for the manufacture of cladding systems according to the invention; Fig. 17 is a plan view of a mounting shoe for the aluminium section shown in Fig. 16; 5960239 Fig. 18 is a sectional elevational view of the mounting shoe; Fig. 19 is a plan view of the mounting shoe and an associated mounting bolt; Fig. 20 is an end elevational view of the shoe and mounting bolt; Fig. 21 is a detail elevational view of the aluminium section shown in Fig. 16, in use; Fig. 22 is a detail sectional view taken along the line A-A of Fig. 21; Fig. 23 is an enlarged detail elevational view showing portion of the aluminium section of Fig. 21; Fig. 24 is a detail sectional view showing another aluminium frame section; Fig. 25 is an elevational view of a cladding panel formed according to the method of the invention; Fig. 26 is a plan view illustrating mounting of the cladding panel in an ope in a building; Fig. 27 is a detail elevational view of portion of a building incorporating cladding panels according to the invention; and Fig. 28 is a schematic flow chart illustrating a method for the manufacture of aluminium cladding systems according to the invention. 8960230 A method and apparatus for the manufacture of aluminium cladding systems according to the invention will be described with reference to the accompanying drawings.

Extruded aluminium sections of a desired profile are prepared (5) and delivered to a taping device 10 at a taping station. Referring to Figs. 1 to 3, the taping device 10 has a base 11 with a pair of spaced-apart uprights 12 upstanding on the base 11. Adhesive tape supports 13, 14 are provided on the base 11 and at an upper end of one of the uprights 12. Each tape support 13, 14 comprises bearings 15 on which a rotatable shaft 16 is mounted. Plugs 17 are slidable along the shaft 16 to engage and hold a roll of tape 18 on the shaft 16. Locking screws 19 are operable to lock the plugs 17 on the shaft 16. The plugs allow positioning of the tape roll 18 at any desired location along the shaft 10 for alignment with guides 20 described later.

Mounted between the uprights 12 are a pair of guides 20. Each guide 20 comprises a carrier or slider 21 carrying a pair of spaced-apart rotatable upright guide rails 22. Each slider 21 is slidably mounted on a pair of spacedapart bars 24 extending between the uprights 12. Thus, the spacing between the sliders 21, and hence the guides 20, can be readily easily and quickly adjusted to accommodate aluminium sections of different widths. In use, the guides 20 engage opposite sides of an aluminium section as it is delivered through the taping device 10. Each tape roll 18 can be slid along its associated shaft 16 for aligning the tape roll with the guides 20 for correct alignment of tapes delivered from the tape rolls 18 with the aluminium section as it passes between the guides 20.

Also mounted on the uprights 12 are a pair of rollers, namely, a lower fixed roller 26 and an upper movable roller 27. The rollers 26, 27 extend horizontally between the uprights 12. The movable roller 27 is mounted at each end on a carriage 29 which is vertically slidable on an upright 12. A screw handle 30 at an upper end of each upright 12 is connected to the carriage 29 and is operable to raise and lower the movable roller 27 for adjustment of the spacing between the rollers 26, 27.

At the taping device 10, adhesive tapes 32 are lead from a pair spaced-apart tape rolls 18 and the ends of the tapes 32 are joined together. An end of an aluminium section 35 is then engaged with the tape and the section is delivered between the rolls 18 of the tape, engaging the tapes 32 with opposite side faces 36, 37 of the section 35. Guide rails 22 correctly align the section 35 with the tapes 32. Downstream of the rolls 18 of tape the section is delivered between the pair of spaced-apart rollers 26, 27 which press and smooth the tapes 32 onto opposite sides 36, 37 of the section 35. When the full section 35 has been delivered between the rollers 26, 27, the tapes are cut in preparation for reception of another aluminium section 35.

It will be appreciated that the taping device 10 can be readily easily adjusted to accommodate aluminium sections of different widths and configuration for readily, easily and quickly applying protective tapes onto opposite side faces of the aluminium section.

Downstream of the taping station taped aluminium sections 35 are delivered to a cutting station 38 at which each section 35 is cut into a plurality of frame members of a pre-set desirable size and configuration. For example, it may be desirable to bevel each end of the frame members 806023© for subsequent assembly as will be described later into rectangular cladding frames.

After cutting the frame members are delivered through one or more machining and fitting stations 39 for carrying out as required, various machining operations such as drilling and punching holes and slots in the frame members and at fitting stations, various fittings such as brackets, hinges and the like may be attached to the frame members as required.

Referring to Figs. 7 to 15, after the required machining and fitting operations have been carried out on the frame members a plurality of frame members 40, 41, 42 are joined together (43) to form a cladding frame 44 for reception of cladding panels. Typically the cladding frames 44 are of rectangular configuration comprising four outer side members 40, 41 interconnected at each end by bevelled joints 45. One or more cross frame members 42 may be mounted extending between side frame members 40 for subdividing the outer frame for reception of a number of cladding panels.

The mitred ends of the frame members may be joined in any suitable fashion.

In a preferred arrangement the mitred ends of the outer frame sections 40, 41 are joined by nailing and gluing. To join two outer frame members 40, 41 an L-shaped cleat 47 is inserted into the frame members 40, 41 at the join. A nail 48 is inserted through the frame members into each leg of the cleat 47 and hammered home. Then, optionally, an adhesive filler is injected at the corner from an adhesive gun 50 for bonding, filling and sealing each corner joint. §960239 - 10 The cladding frames 44 are subsequently transported to a site and when mounted in position on a wall or roof of a building 52 (Fig. 27) cladding panels of glass or indeed other material can then be mounted on the frames 44. Fig. 25 shows an alternative cladding frame 55 incorporating windows 56, glass cladding panels 57 and wooden cladding panels 58. Once in position, the protective tapes 32 are then stripped from the frames 44, 55.

Referring to Figs. 10 to 15, nailing of the frame sections 40, 41 will be described in more detail. Fig. 10 shows a nailing tool 60 having a shank with a lower striking end 612 for engaging and driving a nail 63 through a nail hole 64 in a frame member 40 and into the cleat 47. A guide pin 65 is mounted in an associated slot 62 at the lower striking end 61 of the shank, extending outwardly therefrom to engage within a complementary socket 66 at an upper end of the nail 63 for holding the tool 60 in position when nailing. The guide pins 65 tend to wear or break during use and need to be regularly replaced. To facilitate this, an inner end 67 of the guide pin 65 locates within an access opening 68 at the lower end 61 of the shank to allow for the insertion of a screwdriver 69 or the like tool to eject a broken guide pin 65 as shown in Fig. 15.

A mounting system for frames formed from one type of aluminium section is shown in Fig. 16 which comprises a re-entrant slot 70 which is formed along one face of the aluminium section profile 35 for slidably receiving a mounting shoe 71 having an outwardly extending bolt 72 for attachment of the frame member to a rail, purlin or the like structural frame of the building as shown in Figs. 21 to 23. Grooves 73 are provided in a surface of the shoe 71 for pick up by self tapping screws which can be inserted through lips 74 to secure the shoe 71 in any desired position along the section 35. It will be noted that an outer face 76 of the shoe 71 is stepped having an outwardly projecting central portion 77 which is a snug fit between free edges of the lips 74. In use, when mounting the cladding frames on, for example, a steel subframe, the shoe 71 can be moved along the slot 70 for location with complementary mounting holes in the steel frame.

Figs. 21 to 23 show portion of a cladding system comprising frames 90 carrying glazing panels 91. In this case, the frames 90 form portion of a roof, being mounted on steel roof support beams 92. The frames 90 are mounted on the beams 92 by sliding shoes 71 along each aluminium section 35 for alignment with mounting holes 93 in the beams 92. Spacing washers 94 may be used to accommodate any misalignment between adjacent beams 92.

Fig. 24 shows another aluminium section 35 shown in an arrangement for carrying glazing panels 80.

It will be appreciated that the invention provides a method and apparatus which facilitates the efficient manufacture of high quality cladding systems of the type described. Advantageously, the taping of the aluminium sections prior to delivering the aluminium sections through the various manufacturing steps ensures that the size of the aluminium sections which will be exposed in use are protected from marks and blemishes which can occur due to handling by personnel and machinery. Once the cladding frames are in position, the tapes can subsequently be removed to reveal clean and blemish-free surfaces. The taping device facilitates the rapid and accurate application of tapes onto the aluminium sections. Size adjustment of the taping device can be carried out quickly and easily to accommodate aluminium sections of 8960239 - 12 different size and configuration. Also, the positioning and alignment of the tapes with the side faces to which they are to be applied is readily easily achieved for accurate and efficient laying down of the protective tape on the aluminium section.

The nailing of the frame sections together facilitates rapid construction of frames of a desired configuration giving a high quality and secure joint between frame sections. The construction of the nailing tool facilitates rapid insertion of the nails and the arrangement of the nail guide allows the nail guide to be readily easily changed as required.

It will be appreciated that the arrangement of the aluminium sections which incorporate the sliding mounting shoe greatly facilitate alignment of cladding frames with support structures of steel or other material. This facilitates trouble-free mounting of the cladding frames on site accommodating inaccuracies in the pre-drilling and mounting of the support structures.

The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail.

Claims (5)

1. A method for the manufacture of cladding systems, each cladding system comprising a plurality of aluminium frames supporting cladding panels mounted on the frames, the method comprising the steps: preparing an extruded aluminium section of a desired profile; delivering the aluminium section to a taping station; leading two adhesive tapes associated with the aluminium section from a pair spaced-apart tape rolls and joining the tapes together; engaging the tapes with an end of the aluminium section; aligning the aluminium section with the adhesive tapes, delivering the aluminium section between the rolls of tape in alignment with the tapes; pulling the tapes from the tape roils and laying down the tapes on opposite side faces of the aluminium section; feeding the aluminium section between a pair of spaced-apart rollers downstream of the tape rolls engaging opposite taped sides of the aluminium section with the rollers; - 14 pressing and smoothing the tape onto opposite sides of the section by means of the rollers; cutting the tape; delivering the taped aluminium section from the taping station to a cutting station; cutting the aluminium section into a plurality of frame members of a pre-set desirable size and configuration at the cutting station; delivering the frame members as required through one or more machining and fitting stations for machining each frame member and mounting any desired fittings and attachments on the frame members; and joining a plurality of the frame members together, forming a cladding frame for reception of one or more cladding panels. A method as claimed in claim 1 wherein the method includes aligning each aluminium section with the adhesive tapes by mounting each tape roll on a rotatable support shaft, aligning each tape roll with a pair of spaced-apart section guides, feeding the aluminium section between the tape rolls and between the guides to the rollers, the guides engaging with opposite sides of the aluminium section as the aluminium section is passing between the guides, and preferably wherein each tape roll is slidably mounted on the support shaft for aligning the tape roll with the guides, releasable locking means being provided to secure the tape roll in alignment with the guides, and preferably each guide comprises a pair of spaced89 6 0

2. 3 0 - 15 apart rotatable guide rails, and preferably each pair of guide rails is mounted on a carrier, the carriers being slidably mounted on a support for adjusting the width between the guides, and preferably the rollers comprise a fixed roller and a movable roller mounted on a support frame, the movable roller being slidable on the support frame for adjusting the width between the rollers.

3. A method as claimed in any preceding claim, in which the method includes: cutting the aluminium section into a plurality of frame members forming tubular side frame members having mitred ends; drilling at least one nail hole adjacent each mitred end of each frame member; joining a plurality of the frame members together forming a cladding frame of a desired configuration; inserting an L-shaped cleat between adjacent frame members at mitred ends of the frame members; inserting a nail through each nail hole into the cleat pinning the frame members to the cleat.

4. A method for the manufacture of cladding systems substantially as hereinbefore described with reference to the accompanying drawings.

5. A cladding system whenever produced according to the method as claimed in any preceding claim.