WO2002095162A1

WO2002095162A1 - Brick slip fixture system

Info

Publication number: WO2002095162A1
Application number: PCT/GB2002/002383
Authority: WO
Inventors: David King
Original assignee: Knaufalcopor Limited
Priority date: 2001-05-22
Filing date: 2002-05-22
Publication date: 2002-11-28
Also published as: GB0328763D0; GB2391878A; GB2391878B

Abstract

A brick slip cladding panel is provided for fastening a support structure such as a wall, to provide the appearance of a brick wall. The panel comprises brick slips (6) fixed to a backing layer, wherein the backing layer comprises a foam layer (1) having a front face and a back face and a metal frame (2) disposed adjacent the fort face of the foam layer(1). The metal frame (2) comprises spaced, parallel, horizontal wires (2a) for supporting a row of brick slips (6), and non-horizontal wires (2b) fixed to the horizontal wires (2a) for supporting the horizontal wires (2a) and maintaining the horizontal wires (2a) in spaced, parallel orientation. The foam layer (1) comprises non-horizontal channels (1e) in the front face of the foam layer(1) for accommodating the non-horizontal wires (2b) therein. The horizontal wires (2a) protrude at least partially from the front face of the foam layer (1), and the non-horizontal wires (2b) are accommodated in the channels (1e) so as not to protrude from the front face of the foam layer (1). The metal frame (2) is fastenable to the support structure through the foam layer, for example with fasteners (3). Pointing mortar (5) may be applied in the grooves between adjacent brick slips (6).

Description

BRICK SLIP FIXTURE SYSTEM

TECHNICAL FIELD

This invention relates to cladding panels for fixing brick slips to a support structure, such as a wall, that provide the appearance of a brick wall and impart additional functionality to the support structure. More specifically, the invention relates to cladding panels that comprise brick slips fixed to a backing layer which, in turn, is fastened to the support structure.

BACKGROUND ART

Various cladding systems are known for creating the appearance and feel of a brick wall, i.e. a wall constructed from bricks and mortar, generally by covering a support structure, such as a breeze-block wall or a series of spaced support beams, columns or pillars, with a backing layer that serves to fasten brick slips. Brick slips are thin (for example, 15 mm thick), usually oblong, tiles of brick material that, when viewed face on, have the shape and appearance of bricks built into a wall. The brick slips are generally fixed to the backing layer with a suitable adhesive. In addition, the backing layer is generally provided with horizontal slots or protrusions into or onto which the slips can be fitted, or with horizontal ledges onto which the slips can be placed, to ensure correct alignment and adhesion of the slips in parallel, horizontal rows. Generally, the brick slips, when fixed in position to the backing layer, protrude from the backing layer such that a groove remains between adjacent slips. Mortar is applied into the groove as pointing material, thus completing the appearance of a brick wall.

The backing layer, with fixed brick slips and pointing mortar, is conveniently fastened to the support structure, which usually is vertical, in a number of adjacent panels, each panel generally comprising several rows of several brick slips. The brick slips and mortar may be pre-fixed to the backing layer before the panels are fastened to the support structure, or may be fixed to the backing layer once the backing layer has been fastened to the support structure. Depending on the particular system, the backing layer may consist of one or more layered subcomponents.

For example, in one known system, the backing layer consists of a relatively thick (e.g. 3-10 cm thick), flat surfaced layer of extruded polystyrene (XPS) foam layer, covered and adhered by a relatively thin (e.g. 1-5 mm thick) sheet of high impact polystyrene (HIPS) that has been vacuum formed to provide a contoured surface defining a series of spaced, parallel, horizontal ridges that are continuous across the width of each panel. The space between adjacent ridges defines a slot that can accommodate a row of brick slips. Thus, the upper and lower surfaces of each ridge act to support and align the brick slips for adhesion to the vertical surfaces of the sheet between ridges. The backing layer is fastened to a support structure using screws or nails driven through the sheet and foam layer to the support structure. Pointing mortar is applied in the grooves surrounding each fixed brick slip.

In a similar system, the backing layer again consists of a relatively thick, flat surfaced foam layer of extruded polystyrene (XPS) sheet, covered and adhered by a relatively thin sheet of HIPS that has been moulded to provide a contoured surface, but defining a series of spaced, parallel, horizontal ridges that are discontinuous across the width of each panel. The gaps between horizontally adjacent portions of each ridge are stated to permit water drainage down the panel wall.

In another system, the backing layer consists of a layer (e.g. 1-5 cm thick) of glass reinforced concrete (GRC), optionally over a layer of phenolic foam layer (e.g. 3-5 cm thick). The GRC layer is formed face down in a mould to provide a contoured surface defining a series of spaced, parallel, horizontal ridges that are continuous across the width of each panel. The upper surface of each ridge defines a ledge to support and align the brick slips for adhesion to the vertical surfaces of the GRC layer between the ridges. The vertical surfaces of the GRC layer may additionally be countersunk to provide indentations to accommodate the heads of fasteners driven through the layer to fix the GRC layer to a support structure. This ensures that the fasteners are flush with the surface to which the brick slips will be adhered, and will not protrude and thus obstruct an overlying brick slip. Alternatively, angled steel carrying hooks are mould into the reverse face of the GRC layer and fitted into complementary slots on the support structure to fasten the panels. Again, pointing mortar is applied in the grooves surrounding each fixed brick slip. An advantage of this system is that the GRC layer is fireproof. However, the GRC material is heavy and inflexible, thus necessitating strong fasteners. Also, because of the rigidity of the GRC material, the GRC panel must be castellated at the side edges to correspond to the brick slips, in order to prevent the brick slips from snapping at the joints between adjacent panels.

In another system, the backing layer consists of horizontal, parallel, interlocking strips of plastics coated metal, each strip so formed as to hold a row of brick slips. The interlocking edges of adjacent strips define protruding ridges that support the upper and lower surfaces of the slips. The slips are fixed to the vertical surfaces between the interlocking ridges with an adhesive, and pointing mortar is applied in the grooves surrounding each slip. The backing layer is fastened by nails or screws driven through the plastics coated strips into a support structure.

In yet another system, brick slips are laid face down on a level surface with temporary fillers or spacers positioned between adjacent slips, and polyurethane (PU) foam is directly moulded onto and thereby bonded to the reverse faces of the slips to provide a backing layer for the panel. The fillers or spacers are then removed to provide grooves on the front face of the panel, and pointing mortar is applied into the grooves. The backing layer is fastened to a support structure usually by bonding with adhesive.

In still another system, a row of brick slips each formed with an undercut horizontal groove is slid onto and over a complementary protruding horizontal ridge formed in a GRC backing layer. No adhesive is necessary since the interlocking groove and ridge hold the slips to the GRC backing layer. Pointing mortar is applied into the grooves between adjacent slips.

In another system, the backing layer consists of a steel sheet from which rows of spaced tabs have been punched and bent outwards so to protrude outwards from the sheet. The upper surfaces of the spaced tabs in a row support a row of brick slips for alignment and fixing with adhesive to the backing sheet. Alternatively, in another system, metal tabs protruding from a steel sheet are oriented vertically for adhesion to the sides of the brick slips. Pointing mortar is applied in the grooves between the brick slips. Optionally, the backing layer consists of a tabbed steel sheet as described, adhered to a foam layer. The backing layer is fastened by screws or nails driven through the steel sheet, and through the foam layer if present, into a support structure.

In another system, the backing layer consists of a layer (e.g. 3-10 cm thick) of polyurethane (PU) foam layer provided with horizontal rows of spaced steel cleats that function as supports for the brick slips. The slips are fixed to the foam layer with an adhesive, and pointing mortar is applied in the grooves between adjacent slips.

In another system, the backing layer is a meshed sheet of expanded metal which has been so formed as to provide spaced, parallel, horizontal rows of protruding ridges for aligning and supporting rows of brick slips. The supported slips are fixed to the expanded metal meshed sheet with an adhesive. The meshed sheet is fastened to a support structure using nails or screws.

In another system, the backing layer consists of a foam layer (e.g. 3-10 cm thick) which has been routed to remove horizontal, parallel strips of material, thereby leaving horizontal, parallel channels into which rows of brick slips can be fitted. The slips are fixed to the backing layer with an adhesive. If desired, pointing mortar is applied into the spaces between adjacent slips.

SUMMARY OF THE INVENTION

The present invention provides a further system for cladding a support structure with brick slip panels, which system is convenient to apply to support structures of steel, timber or masonry, can be produced at low cost, and which has fire advantages over other foam based systems.

Accordingly, the present invention provides a brick slip cladding panel for fastening to a support structure, comprising brick slips fixed to a backing layer, wherein the backing layer comprises a foam layer having a front face and a back face and a metal frame disposed adjacent the front face of the foam layer, the metal frame comprising a plurality of spaced, parallel, horizontal wires for supporting a row of brick slips, and a plurality of non-horizontal wires fixed to the horizontal wires for supporting the horizontal wires and maintaining the horizontal wires in spaced, parallel orientation, the foam layer comprising a plurality of non-horizontal channels in the front face of the foam layer for accommodating the plurality of non-horizontal wires therein, the horizontal wires protruding at least partially from the front face of the foam layer, and the non-horizontal wires being accommodated in the channels so as not to protrude from the front face of the foam layer, the metal frame being fastenable to the support structure through the foam layer.

Advantageously, the metal frame may afford a fire advantage to the cladding, by allowing heat to be conducted away. Another advantage is that the configuration of the metal frame can easily be adapted to a particular application. For example, the orientation, spacing, and cross sectional shape and dimensions of the wires can be altered to suit different brick slip shapes and sizes. It will be appreciated these alterations of the frame are relatively inexpensive to make compared with, for example, changes to a moulded part. Accordingly, the panels of the present invention have good flexibility in terms of their production for different brick slip cladding applications.

DISCLOSURE OF THE INVENTION

The panel components are described herein by reference to a panel stood upright, i.e. a vertically oriented panel such as for a wall, but it will be appreciated that the panels can be fastened to any vertical, slanted or horizontal support surface.

As used herein, by "non-horizontal wires" is meant wires angled at from 10 to 90 degrees, preferably from 30 to 90 degrees, with respect to the horizontal wires, in the plane of the frame. As used herein, the term "foam layer" means a layer formed of any dimensionally stable material, such as a uniform solid, foamed solid or porous solid material, that is weatherproof and to which the brick slips can be bonded using an appropriate adhesive. It will be appreciated that the foam layer should be substantially rigid, but may exhibit a degree of flexibility. Moreover, the foam layer should be lightweight and preferably heat insulating. Suitable materials include extruded polystyrene, polyurethane foam, polyisocyanate foam, phenolic foam, foamglass, and rock fibre with cement bound particle board. Other materials suitable for the purpose may be chosen by those skilled in the art. Preferably, the foam layer is formed of extruded polystyrene (XPS) sheet.

The panel dimensions may be chosen as convenient, for example using a foam layer from 50 to 500 cm in length and/or height, and from 2 to 7 cm in thickness. In a preferred embodiment, the panels have a length of about 200 cm, a height of about 100 cm and a thickness of about 4 cm. The panels can be produced in any desired industry standard or non-standard shapes and sizes, for example corresponding to standard door and window dimensions so as to facilitate cladding around doors or windows, or in curved or bent configurations so as to provide a curved or corner panel or module.

The foam layer of the panel may be provided with a surface finish to improve adhesion to the slips, for example using a waffle roller as is known in the art. If desired, the back face of the panel may be provided with a surface finish or contoured surface to provide improved contact or complementary engagement with the support structure.

The panel edges may be formed as straight, flat edges to allow adjacent panels to be aligned or contacted together in adjacent positions. Preferably, however, the top and bottom edges are formed as complementary, interengaging surfaces to allow adjacent panels to be fitted together one above another. Alternatively or additionally, the side edges may be formed as complementary surfaces to allow adjacent panels to be fitted together side by side.

In particular, the side edges, or the top and bottom edges, or both, of the foam layer may be formed as tongue and groove joints, or as half housed lap joints. Alternatively or in addition, the edges of adjacent panels may be formed as complementary crenellations, teeth or similar interlocking formations. Thus, the complementary surfaces ensure a partial overlap between adjacent foam layers of adjacent panels, providing an excellent moisture barrier for the cladding, or facilitate alignment of adjacent panels, or both. If desired, however, a moisture control layer, for example a waterproof, breathable membrane or film may be applied to the back face of the foam layer.

The front face of the foam layer, i.e. the face adjacent the brick slips, is provided with channels to accommodate the non-horizontal wires of the metal frame. The channels can be provided in the foam layer by any suitable method, preferably by routing. The width and thickness of the channels will be so selected as to correspond to the dimensions of the non-horizontal wires of the metal frame to ensure that those wires are flush with, or at least do not protrude from, the front surface of the foam layer. Thus, brick slips may be fixed to the front face of the foam layer without obstruction, so as to overlie the non-horizontal wires. Suitably, the channels are routed to a depth of 4-10 mm, preferably about 6 mm, and to a width of 4- 10 mm, preferably about 6 mm.

It will be appreciated that the channels will be non-horizontal,' and will further be spaced and parallel when the non-horizontal wires of the metal frame are spaced and parallel, and will further be vertical when the non-horizontal wires are vertical. When the panel is assembled and fastened to a support structure, the foam layer is securely supported between the metal frame on the front face of the foam layer and the support structure on the back face of the foam layer.

The non-horizontal channels provide easy alignment for correct orientation of the metal frame with respect to the foam layer when assembling the panel. A further advantage of the provision of the non-horizontal channels is that they can permit drainage of moisture down the panels. Moreover, as further explained below, the channels accommodate the non-horizontal wires to enable the brick slips to overlie the non-horizontal wires and be fixed to the foam layer, without being obstructed by the non-horizontal wires.

In a preferred embodiment, the front face of the foam layer is further provided with horizontal channels that are spaced so as to align with the horizontal wires of the frame. These horizontal channels provide a recess for a portion of the mortar that may be subsequently applied in the grooves between the slips, as explained further below. The provision of the horizontal grooves behind the horizontal wires allows the mortar to be retained around the horizontal wires, thus providing a secure anchorage for the mortar.

The metal frame is formed of horizontal wires to align and preferably support the brick slips, and non-horizontal wires to support the horizontal wires. Preferably, the non- horizontal wires will be spaced and parallel, and more preferably will be vertical. The spacing between the non-horizontal wires within a given panel frame may be vary, but the spacing preferably is regular across the whole frame, or is regular across the frame apart from the outermost wires at the edges of the frame. The spacings between the horizontal wires will be selected to correspond to the height of the brick slips to be aligned or supported on or between the horizontal wires, and allowing for mortar gaps between the rows of brick slips. Although different spacings could be used within a particular panel frame, for example if rows of brick slips of different heights are to be fixed to the panel, we prefer that the spacing is regular within a given panel frame. Most preferably, the non-horizontal wires are regularly spaced, vertical wires and the horizontal wires are also regularly spaced, so that the metal frame is configured as a regular grid of rectangles (except at the edge regions if the end non-horizontal wires are not regularly spaced).

The wires used for the metal frame are preferably of steel, for example stainless steel, uncoated steel, galvanised steel or zinc coated steel, or of aluminium. The horizontal and non-horizontal wires may be welded to one another, bonded with a suitable adhesive, bound with wire, or otherwise fastened together to provide the frame. If desired, the wires may be held together by mutual friction, for example by providing the wires with complementary notches, slots or apertures such that the wires can be held together by mechanical interaction. Preferably, the wires are welded or adhered together.

It will be appreciated that the wires can have any shape in cross-section, for example round, oval, oblong or irregular. From a technical perspective, preferably the horizontal wires have a flat top surface for supporting or adhering to the brick slips. Moreover, the back surface of the horizontal wires and front surface of the non-horizontal wires are preferably flat to provide a large contact surface for adhesion or welding between the horizontal and non-horizontal wires, so as to maximise the strength and integrity of the metal frame. Accordingly, viewed from a technical perspective, the horizontal wires, and preferably also the non-horizontal wires, are preferably of a substantially oblong cross-section, for example square or rectangular. In particular, we prefer that the wires are of a rectangular cross-section, with the long sides of the rectangle lying substantially horizontal to provide a large support or adhesion surface for the brick slips. Alternatively, the long sides may lie vertically, to afford sheet^' strength to the frame. Preferably, the wires are rectangular steel rods of cross section height and width dimensions in the range from 1 to 10 mm, preferably 5-8 mm x 2-4 mm, for example 6 mm x 3 mm. From a cost viewpoint, however, preferably the horizontal wires and non- horizontal wires are round in cross-section, with a cross-section diameter preferably in the range from 2 to 8 mm, more preferably from 3 to 6 mm, for example 3 or 4 mm. If desired, the horizontal wires may be of different cross-section from the non-horizontal wires, for example in a frame of 4 mm diameter, round horizontal wires and 3 mm diameter, round non-horizontal wires. Preferably, the cross section dimensions of the wires are such as to permit the frame to be cut using wire snips, to allow the frame to be easily trimmed or tailored to size, for example in situ, whilst at the same time affording adequate support for the brick slips and/or panel as a whole.

Since the horizontal wires provide alignment and preferably also support for the brick slips, the horizontal wires must protrude forwardly from the front face of the foam layer. At the same time, the brick slips are to be fixed to the front face of the foam layer, and at least some of the brick slips will overlie the non-horizontal wires. Accordingly, the non-horizontal wires lie within a first plane and the horizontal wires lie within a second plane that is disposed substantially, or preferably completely, in front of the first plane. Thus, the non-horizontal wires can be accommodated in the corresponding channels in the foam layer, so as not to protrude from the front face of the foam layer (which might otherwise cause obstruction to brick slips to be fixed to the foam layer), whilst at the same time the horizontal wires protrude from the front face of the foam layer to be able to support the brick slips. If desired, although more costly to produce, the foam layer of each panel can further comprise a stepped front top edge or a horizontal groove in the front face proximate the front top edge, and the metal frame further comprises a horizontal surface at or proximate the top of the metal frame for engaging the stepped top edge or horizontal groove of the foam layer. In this case, the horizontal surface is preferably provided by a horizontal wire disposed at or proximate the top of the metal frame and within, or substantially or completely behind, the plane of the non-horizontal wires. The stepped top edge or horizontal groove facilitates correct alignment and assembly of the metal frame to the foam layer.

It will be appreciated that the assembly of some or all of the major component parts of the panel, i.e. the metal frame, foam layer and brick slips, may be carried out in situ at the location of the support structure, or at the factory or manufacturing or assembly plant before being transported to the location of the support structure.

The panels may be fastened to any appropriate support structure, for example one or more support beams, columns or pillars, by fastening the metal frame to the support structure through the foam layer. Any suitable fastening means may be used for this purpose, for example a screw, nail, bolt, hook or clip means having a head portion for engaging the frame and a foot portion for engaging the support means.

In one embodiment, the metal frame is fastened through the foam layer using a plurality of elongate clips, each clip comprising a hooked end for engaging a non- horizontal wire and an eyed end for screw or nail fixing to the. support structure. The hooked and eyed ends of the clip are linked by an elongate portion of a length corresponding to the thickness of the foam layer. When the hooked end is engaged with a non-horizontal wire and a screw or nail fastener is inserted through the hole in the eyed end and driven into the support structure to fasten the eyed end against the support structure, the metal frame is thus fastened to the support structure.

The precise configuration of the hooked and eyed ends may be varied according to the dimensions of the wires and type of fastener to be used to fix the clip to the support structure. For example, to afford easy fixing we prefer that the hooked end is offset with respect to the eyed end, i.e. if the elongate portion of the clip is regarded as defining an axis, the hooked end and the eyed end extend radially outwards from the axis, and the hooked end is angularly or radially offset with respect to the eyed end. By providing offset hooked and eyed ends, access to the eyed end is not impeded by the hooked end when the clip is being fastened to the support structure, thereby advantageously facilitating fixing of the metal frame, and the panel as a whole, to the support structure. The clip is preferably hooked over a non-horizontal wire at a point immediately below a joint with a horizontal wire. This ensures that the hooked end overlying the non-horizontal wire does not interfere with any brick slips in so far as the hooked end might protrude into the plane of the brick slips, as the hooked end would protrude only into the mortar groove between adjacent slips.

In another and most preferred embodiment, one or more parts of the metal frame are so formed as to be recessed deep into or through the foam layer, so that the metal frame can contact the support structure either directly or, if desired, through a thin intervening separator or washer. Preferably, a portion of the frame above the uppermost slip- supporting horizontal wire is angled towards the back of the foam layer so that the top of the frame can make contact with the support structure to which it is to be fastened. In this preferred embodiment, the top portion of the foam layer is provided with a correspondingly angled surface, which surface may optionally be grooved, to accommodate the angled portion of the frame, or the top portion or is provided with slots, grooves or cut-outs to accommodate the angled portion of the frame. The angled frame portion is recessed (relative to the main frame portion supporting the slips) over the angled surface or in the corresponding slots, grooves or cut-outs in the foam layer, and the top of the frame can contact the support structure. Thus, the frame adjacent the front face of the foam layer is fastenable through the foam layer by the angled, recessed portion of the frame and suitable fastening means. For example a screw, nail, hook or clip means having a head portion for engaging the frame and a foot portion for engaging the support means can be used to fasten the frame.

Preferably, the angled frame portion terminates in an end portion bent back relative to the angled portion so as to lie flush against the support structure. Thus, the top ends of the non-horizontal wires of the frame can lie flat against the support structure for secure fastening thereto. Preferably, the top ends of the non-horizontal wires of the frame are fixed to one or more horizontal support wires, in the same manner as the slip-supporting horizontal wires, and preferably over the front of the non-horizontal wires. Thus, the headed portions of appropriate headed fasteners, for example screws, clips, bolts, nails, or hooks, can retain the support wire or wires relative to the support structure, so as to fasten the frame. More preferably, two horizontal support wires are provided at the top ends of the non-horizontal wires of the frame, spaced apart so that the appropriate headed fasteners can be inserted between the support wires and driven into the support structure. Suitably, the two horizontal support wires are spaced apart by a gap of 3 to 10 mm, for example about 5 mm, according to dimensions of the headed fasteners to be used, taking into account such factors as the overall frame size, panel weight and wire thickness.

Alternatively, but less preferred, the frame is fastened by angled frame portions along the sides of the panel instead of along the top of the panel. In this case, angled frame portions at the sides of the horizontal wires and corresponding recesses at the sides of the foam layer are provided, with non-horizontal support wires fixed to bent-back side ends of the horizontal wires, in analogous manner to that described above.

Preferably, the angled portions of the frame are angled by at least 30 degrees from the plane of the main portion of the frame, more preferably at least 45 degrees, still more preferably at least 60 degrees, and preferably less than 85 degrees, more preferably less than 75 degrees. Particularly preferred is an angle of about 67.5 degrees. By the 'main portion' of the frame is meant that portion which functions to support the brick slips over the front face of the panel, and does not refer to portions of the frame that are used primarily to fasten the frame to the support structure through the foam layer.

As mentioned, the ends of the angled wire portions are preferably bent back so as to lie flat against the intended support structure. Therefore, for panels intended to be fastened to a support surface extending parallel to or in the same plane as the panel, the angled wire portions are preferably bent back so as to lie parallel to the main portion of the frame. However, it will be appreciated that for panels intended to be fastened to support surfaces not extending in the same general plane as the panel, the angled and bent-back wire portions can be angled accordingly, in order to ensure a flush fit to the intended support surface.

Where the panels are fastened to the support structure through the foam layer by angled frame portions along the top portion of each panel, the bottom- portion of each panel is preferably so configured as to overlap at least the upper part of the angled frame portion of the panel below. More specifically, in such panels the bottom portion of the frame, and optionally also the lowest part of the front of the foam layer, extends below the lowest part of the back of the foam layer. Thus, any rainwater or moisture which might seep into the joint between panels fastened one above the other will tend to drain out towards the front exterior of the panel, instead of in towards the support structure where it might create dampness.

In the embodiments where the panels are fastenable through the foam layer by an angled, recessed top portion of the frame and suitable headed fastening means, preferably at least one of the sides of the frame, more preferably both sides, in particular at a lower portion of the side or sides, comprises an angled frame portion fastenable to the support structure, in order to secure the lower portion of the panel. More specifically, the angled side portion is constituted by an extended end portion of a horizontal slip-supporting wire, which extended end portion has been angled towards the support structure. The end is bent back to lie flush against the support structure surface, and preferably is configured in the shape of an eyelet for fastening to the support structure using a suitable headed fastener driven through the eyelet. The angled side portion is preferably angled by at least 45 degrees from the plane of the main portion of the frame, more preferably at least 60 degrees, and preferably less than 85 degrees. Particularly preferred is an angle of about 67.5 degrees. In order to facilitate access when fastening, the eyelet preferably extends into the space provided by a cutout portion of a crenellated side edge of the foam layer. The fastened eyelet is preferably covered when an adjacent panel having a complementary protruding crenellation is fitted aside the panel. Alternatively, or additionally, the bottom end of one or more non-horizontal wires of the frame may be formed as a hooked end to engage behind the uppermost horizontal slip-supporting wire of the panel below, for example around an angled wire of the top portion of the panel below, and thus secure the lower portion of the panel against the support structure indirectly via the frame of the panel below it.

As previously mentioned, the top and bottom edges of the foam layer are preferably formed as complementary, interengaging surfaces to allow adjacent panels to be fitted together one above another. In the embodiments where the panels are fastenable through the foam layer by an angled, recessed top portion of the frame and suitable fastening means, preferably the top and bottom edges of the foam layer allow fitting together of one panel above another so as to ensure that the desired spacing between horizontal wires is achieved between the lowest slip-supporting horizontal wire of an upper panel and the highest slip-supporting horizontal wire of an adjacent lower panel.

If desired, the bottom part of the frame of a panel can comprises an additional horizontal wire, fixed closely below the lowest slip-supporting horizontal wire, for alignment with the top surface of the uppermost row of brick slips fixed to the panel below. By 'closely' here is meant such that the distance between the bottom surface of the additional horizontal wire and the top surface of the lowest slip-supporting horizontal wire define the desired spacing for mortar between adjacent rows of brick slips. For example, if it is desired to fit a second panel above a first panel already fastened to the support structure and already having an upper row of brick slips fixed thereto, the additional horizontal wire of the second panel may be rested on the top surface of the upper row of brick slips of the first panel, and thus ensure the correct spacing between the slip-supporting wires of the first and second panels, and thereby the correct spacing between the adjacent rows of slips on the first and second panels. Having fastened the metal frame to the support structure, the brick slips, or any brick slips not already fixed, may then be adhered to the foam layer, and pointing mortar applied in the gaps between adjacent slips if desired, to complete the fixing and assembly of the panel in situ. In a preferred embodiment in which the foam layer comprises horizontal channels aligned behind the horizontal wires, the mortar is applied into the gaps between rows of slips and into the horizontal channels, so as to extend both in front and behind the horizontal wires. By extending at least partially around the wires, the mortar is securely retained by the wires. BRIEF DESCRIPTION OF DRAWINGS

The present invention will be further illustrated by reference to the following drawings, in which: Figure 1 represents an expanded view of a cladding panel in accordance with an embodiment of the invention (top edge detail not shown);

Figure 2 represents a top edge (detail shown) of the panel shown in Figure 1, in relation to the bottom edge of an adjacent panel;

Figure 3 represents a side edge of the panel shown in Figure 1, in relation to a side edge of an adj acent panel;

Figure 4 represents a detail view of a metal frame of the panel as shown in Figure 1, showing joints between horizontal and vertical wires;

Figure 5 represents an expanded partial view of a metal frame and foam layer for a cladding panel in accordance with an embodiment of the invention (left side and top edge detail shown);

Figure 6 represents a sectional side view of top and bottom portions of cladding panels as shown in Figure 5 (unexpanded section through uninterrupted vertical groove, with top and bottom shown separated);

Figure 7 represents an expanded partial view of a metal frame and foam layer for a cladding panel in accordance with an embodiment of the invention (left side and top edge detail shown);

Figure 8 represents a sectional side view of top and bottom portions of cladding panels as shown in Figure 7 (unexpanded section through uninterrupted vertical groove, with top and bottom portions shown separated); and Figure 9 represents a sectional side view of part of a cladding panel having a horizontally grooved foam layer, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

As shown in Figure 1, a rectangular foam layer 1 has a top edge la (top edge surface detail not shown), bottom edge lb and side edges lc, Id. Vertical channels le are formed in the front face of foam layer 1. A metal frame 2 comprises horizontal wires 2a welded to vertical wires 2b in grid of rectangles. Vertical wires 2b are behind horizontal wires 2a, and therefore can be accommodated in vertical channels le whilst horizontal wires 2a overlie foam layer 1 so as to protrude forwards from the front face of foam layer 1. Clip fixings 3 are used to fasten vertical wires 2b through foam layer 1 to a support structure (not shown). Brick slips 6 are fixed to the front face of foam layer 1 with beads of adhesive 4, supported on the upper surface of horizontal wires 2a.

Brick slips 6 overlie vertical wires 2b accommodated in channels le. Pointing mortar 5 is applied in the grooves between adjacent brick slips 6 so as to cover clips fixings 3.

As shown in Figure 2, top edge la is formed as a complementary surface with bottom edge 7b of foam layer 7 of an adjacent panel, in a half housed lap joint.

As shown in Figure 3, side edge lc is formed as a complementary surface with side edge 8d of foam layer 8 of an adjacent panel, in a tongue and groove joint.

As shown in Figure 4, vertical wire 2b having a rectangular cross section is welded to horizontal wire 2a having a rectangular cross section. The joint contact is provided by flat surfaces of wires 2a, 2b.

As shown in Figures 5 and 6, a rectangular foam layer 1 has a top edge la and left side edge lc. Top edge la, and the bottom edge lb of an adjacent panel above, are stepped so as to provide a half housed lap joint (shown open in Figure 6). Similarly, side edge lc is stepped for forming a half housed lap joint with a complementary right side edge of an adjacent panel (not shown). Left side edge lc of foam layer 1 has cut-outs 14a and teeth 14b for interlocking with corresponding teeth and cut-outs in the right side of an adjacent panel (not shown). Vertical channels le are formed in the front face of foam layer 1. A metal frame 2 comprises horizontal wires 2a welded to vertical wires 2b in a grid of rectangles. Vertical wires 2b are behind horizontal wires 2a, and therefore can be accommodated in vertical channels le whilst horizontal wires 2a overlie foam layer 1 so as to protrude forwards from the front face of foam layer 1. Angled top portion 11 is formed from the vertical wire portions extending above the uppermost horizontal wire overlying foam layer 1. Slots through the top portion of foam layer 1, having an angled channel surface 15 as shown in Figure 6, provide recesses through foam layer 1 for angled portion 11. Horizontal support wires 12 at the bent-back top ends 11a of angled portion 11 are narrowly spaced apart to provide a channel aperture for insertion of headed fasteners 13, e.g. nails. When driven into the support structure (not shown), fasteners 13 retain wires 12 with respect to the support surface so as to fasten frame 2 by angled portion 11 through foam layer 1 to the support structure. Brick slips 6 are fixed to the front face of foam layer 1 with adhesive 4, supported on horizontal wires 2a. Pointing mortar 5 is applied in the grooves between adjacent brick slips 6.

In Figures 7 and 8, representing a best mode of the present invention, a rectangular foam layer 1 has a top edge la and left side edge lc. Top edge la, and the bottom edge lb of an adjacent panel provide, are angled (joint shown open in Figure 8). Side edge lc is stepped for forming a half housed lap joint, and has cut-outs 14a and teeth 14b for interlocking with an adjacent panel (not shown). Angled top portion 11 is formed from the vertical wire portions extending above the uppermost horizontal wire overlying foam layer 1. Grooves in angled top edge la having an angled channel surface 15 as shown in Figure 8, provide recesses through foam layer 1 for angled portion 11. Additional horizontal wires 12 at the bent-back top ends 1 la of angled portion 11 are narrowly spaced apart to provide a channel aperture for insertion of headed fasteners 13. When driven into the support structure (not shown), fasteners 13 retain wires 12 with respect to the support surface so as to fasten frame 2 by angled portion 11 through foam layer 1 to the support structure. Additional guide wire 16 at the bottom of frame 2 rests on the top surface of the uppermost row of slips of the panel below, and the rear portion of bottom edge lb rests on upper wire 12, when the panels are fitted together one above the other. Eyelets 17 are secured to the support structure with appropriate fasteners (not shown), in order to fasten the lower portion of frame 2 to the support structure.

As shown in Figure 9, a horizontal groove 18 is provided in foam layer 1, so as to lie behind each horizontal wire 2a, whereby pointing mortar 5 applied into the gap between adjacent rows of brick slips 6 can extend into groove 18. Accordingly, mortar 5 can be applied behind or around wire 2a, and thus be anchored securely in the gap. EXAMPLES

The present invention is further illustrated by the following non-limiting examples:

Example 1:

A cladding panel as shown in Figure 1 is prepared:

The foam layer is of Polyfoam Plus (extruded polystyrene sheet, HFC blown) of dimensions 180 cm x 90 cm x 4 cm and exhibits the following characteristics: Thermal performance: 0.028 W/mK

Density: 27 kg/m³

Compressive strength: 220 kPa

Moisture absorption: 0.2% by volume.

The panels are surface finished on back and front faces using a waffle roller and routed to provide channels 6 mm wide and 6 mm deep on the front face, centred at 112.5 mm intervals on the length dimension.

The metal frame (180 cm x 90 cm) is formed of rectangular cross section steel rods (6 mm x 3 mm) that are hot dip galvanised or finished with High Zinc 'Bezinal' coating. The wire rods are welded together (180 cm rods overlaying 90 cm rods) to form a grid of rectangles centred at 75 mm intervals on the height dimension and at 112.5 mm intervals on the length dimension.

A moisture curing polyurethane adhesive (Apollo™ A9310) is applied in a single bead to fix a row of brick slips.

Polymer mix mortar is applied by compressed air gun, "icing bag" or cartridge (factory installation) or Standard 1.1.6 mortar is applied by pressure pointing gun (on site installation). Example 2:

A cladding panel as shown in Figure 7 is prepared:

The foam layer is of Polyfoam Plus (extruded polystyrene sheet, HFC blown) of dimensions 950 cm x 440 cm x 5 cm

The foam panels are surface finished on back and front faces using a waffle roller and routed to provide vertically and horizontally oriented channels 3 mm wide and 3 mm deep on the front face, centred at 112.5 mm intervals on the length dimension and at 75 mm intervals on the width dimension.

The top, bottom, and side edges are rebated to provide complementary half housed lap joint surfaces. Each vertical channel is further cut at the top edge of the foam panel to provide slots through the thickness of the foam, the slots each having an angled layer bottom surface, as recesses for an angled top portion of the frame. The channel bottom surface is cut to an angle of 22.5 degrees to the horizontal.

The side edges of the foam panels are further cut to provide interlocking cut-out and tooth portions.

The metal frame (950 cm x 440 cm) is formed of round cross section stainless steel rods (4 mm diameter) for the horizontal slip-supporting wires and round cross section stainless steel rods (3 mm diameter) for the vertical wires. The wire rods are welded together (950 cm rods overlaying 440 cm rods) to form a grid of rectangles centred at 75 mm intervals on the height dimension and at 112.5 mm intervals on the length dimension. Additional support and guide wires are welded at the top and bottom of the frame. The top portion of the frame is bent to an angle of 22.5 degrees to the vertical plane so as to complement the angled channels in the foam layer. The end portion of the thus angled top portion is bent back by 22.5 degrees so as to regain the vertical plane. Two hooked eyelets are formed at the ends of two lower horizontal support wire extensions, and the wire extensions are bent in a horizontal plane by an angle of 75 degrees, the eyelet ends then bent back by 75 degrees.

The frame is applied to the foam panel, with the vertical wires accommodated in the vertical channels, the horizontal wires lying over the horizontal channels, the angled top portion of the frame recessed in the slots, and the eyelets disposed inside the side edge cut-out portions of the foam panel.

The frame and foam panel is fastened to a support wall by headed 'EWF nails to fix the additional horizontal wire at the bent-back end portion of the angled top portion of the frame to the support wall. The lower part of the frame is secured by driving 'EWT nails through the eyelets into the support wall.

Polymer mix mortar is applied into the gaps between the brick slips by compressed air gun, "icing bag" or cartridge (factory installation) or Standard 1.1.6 mortar is applied by pressure pointing gun (on site installation). At least some mortar enters the horizontal channels behind the horizontal wires, so as to provide a secure anchorage for the mortar.

Claims

CLAIMS:

1. A brick slip cladding panel for fastening to a support structure, comprising brick slips fixed to a backing layer, wherein the backing layer comprises a foam layer having a front face and a back face and a metal frame disposed adjacent the front face of the foam layer, the metal frame comprising a plurality of spaced, parallel, horizontal wires for supporting a row of brick slips, and a plurality of non-horizontal wires fixed to the horizontal wires for supporting the horizontal wires and maintaining the horizontal wires in spaced, parallel orientation, the foam layer comprising a plurality of non-horizontal channels in the front face of the foam layer for accommodating the plurality of non-horizontal wires therein, the horizontal wires protruding at least partially from the front face of the foam layer, and the non-horizontal wires being accommodated in the channels so as not to protrude from the front face of the foam layer, the metal frame being fastenable to the support structure through the foam layer.

2. A cladding panel according to claim 1, wherein the non-horizontal wires are spaced, vertical wires.

3. A cladding panel according to claim 1 or claim 2, wherein the non-horizontal wires lie within a first plane and the horizontal wires lie within a second plane that is disposed substantially or completely in front of the first plane.

4. A cladding panel according to any of claims 1 to 3, wherein the non-horizontal wires are welded to the horizontal wires.

5. A cladding panel according to any of claims 1 to 3, wherein the non-horizontal wires are bonded to the horizontal wires with an adhesive.

6. A cladding panel according to any of claims 1 to 5, wherein the non-horizontal wires or the horizontal wires, or both, are of a substantially round cross-section.

7. A cladding panel according to any of claims 1 to 5, wherein the non-horizontal wires or the horizontal wires, or both, are of a substantially oblong cross-section.

8. A cladding panel according to claim 7, wherein the non-horizontal wires or the horizontal wires, or both, are of a rectangular cross-section.

9. A cladding panel according to any preceding claim, wherein the foam layer is formed of extruded polystyrene (XPS) material.

10. A cladding panel according to any preceding claim, wherein the wires are of steel.

11. A cladding panel according to any preceding claim, wherein the brick slips are fixed to the backing layer with an adhesive.

12. A cladding panel according to any preceding claim, wherein the top and bottom edges or the two side edges, or both, of the foam layer are shaped as engageable complementary surfaces, whereby adjacent panels may be engaged one above another or side by side, or both, at the complementary surfaces.

13. A cladding panel according to claim 12, wherein the complementary surfaces are in the form of crenellations.

14. A cladding panel according to any of claims 1 to 13, wherein the foam layer further comprises a stepped front top edge or a horizontal groove in the front face proximate the front top edge, and the metal frame further comprises a horizontal surface at or proximate the top of the metal frame for engaging the stepped top edge or horizontal groove of the foam layer.

15. A cladding panel according to claim 14, wherein the horizontal surface is provided by a horizontal wire disposed at or proximate the top of the metal frame and within, or substantially or completely behind, the plane of the non-horizontal wires.

16. A cladding panel according to any of claims 1 to 13, wherein a portion of the frame above the uppermost slip-supporting horizontal wire is angled towards the back of the foam layer so that the top of the frame can make contact with the support structure to which it is to be fastened.

17. A cladding panel according to claim 16, wherein the top portion of the foam layer comprises an angled, optionally grooved surface, or slots, grooves or cut-outs, to accommodate the angled portion of the frame.

18. A cladding panel according to claim 16 or claim 17, wherein the angled portion of the frame is angled by at least 45 degrees and less than 75 degrees from the plane of the main portion of the frame.

19. A cladding panel according to claim 18, wherein the angled portion of the frame is angled by about 67.5 degrees from the plane of the main portion of the frame.

20. A cladding panel according to any of claims 16 to 19, wherein the angled portion of the frame terminates in an end portion bent back relative to the angled portion so as to lie parallel to the plane of the main portion of the frame.

21. A cladding panel according to any of claims 16 to 20, further comprising two horizontal wires at the top ends of the non-horizontal wires of the frame, spaced apart for insertion of a headed fastener.

22. A cladding panel according to any of claims 16 to 21, wherein the bottom portion of the frame extends below the lowest part of the back of the foam layer.

23. A cladding panel according to any of claims 16 to 22, wherein the bottom portion of the frame comprises an additional horizontal wire fixed below the lowest slip-supporting horizontal wire.

24. A cladding panel according to any of claims 16 to 23, wherein an extended end of a horizontal slip-supporting wire is angled towards the support structure, and at its end is bent back and configured as an eyelet for fastening to the support structure.

25. A cladding panel according to any preceding claim, wherein the foam layer further comprises a plurality of horizontal channels in the front face of the foam layer and behind the horizontal wires, for accommodating mortar behind the horizontal wires.