AU2020100448A4

AU2020100448A4 - Cladding panel arrangement

Info

Publication number: AU2020100448A4
Application number: AU2020100448A
Authority: AU
Inventors: Puneet Chaphalker; Sami Immonen
Original assignee: Stratco Australia Pty Ltd
Current assignee: Stratco Australia Pty Ltd
Priority date: 2019-03-29
Filing date: 2020-03-24
Publication date: 2020-04-30
Anticipated expiration: 2028-03-24
Also published as: AU2020100447A4

Abstract

The invention relates to an interlocking cladding panel arrangement. The cladding panel arrangement includes a pair of first and second interlockable cladding panels mounted in a side-by-side configuration on a support structure. The first cladding panel includes a first interlocking formation. The second cladding panel includes a second interlocking formation in interlocked engagement with the first interlocking formation. The cladding panel arrangement further includes an abutment in fixed relation to the first interlocking formation and located adjacent to the second interlocking formation for retaining the second interlocking formation against movement out of said interlocked engagement with the first interlocking formation. The abutment is integrally formed with the first interlocking formation. Page 1ofI1 CD - co CD m m co ItCD 0-L (CD co 00 m m)

Description

CLADDING PANEL ARRANGEMENT

Priority Cross Reference [0001] The present invention claims priority to Australian provisional patent application 2019901072 filed 29 March 2019, the entire disclosure of which is hereby incorporated by reference.

Technical Field [0002] The present invention relates to the field of building cladding such as roof or wall cladding. In particular, the invention relates to a cladding panel arrangement for fastening to a structure.

Background of Invention [0003] The following discussion of the background to the invention is intended to facilitate an understanding of the invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of the application.

[0004] In building applications, roofing or walling cladding involves the fastening of a series of cladding panels to an underlying support structure such as a row of battens or joists. Cladding panels formed of sheet metal are particularly popular due to their relatively low cost, quick installation and high-durability. Furthermore, metallic cladding panels are available in a large range of colours allowing a building fagade or roof to be conveniently coloured according to aesthetic preference.

[0005] Cladding panels are normally installed in an overlapping configuration and anchored to the support structure using screws or similar fasteners. The visual presence of fasteners is less of a concern in roofing applications because the fasteners are often obscured from street level view or are sufficiently far away from the observer so as not to create a detrimental aesthetic impact. In contrast, the

2020100448 24 Mar 2020 fasteners used in wall cladding applications are typically more observable and are therefore less desirable in terms of building aesthetics.

[0006] In response to this problem, wall cladding has been developed which uses an interlocking configuration designed to reduce or eliminate the visual appearance of fasteners. Interlocking panel systems involve panels formed with a male-type tongue on one side and a corresponding female-type folded recess on the opposing side. In use, only the female side of each panel is anchored to the support structure. The tongue of each subsequent panel is inserted into the folded recess of the previous panel in a manner which overlaps and conceals the fastener of the previous panel. In this manner, the fasteners are concealed from view to create the desired fastener-free aesthetic appearance.

[0007] However, one drawback to this configuration is that the male side of each panel is not anchored to the structure and is retained in position only via its engagement with the recess of the adjacent panel. Depending on the stiffness of the sheet metal used to form the panel, it is possible for wind to induce sufficient flex in a panel so as to lift and disengage the male side of a panel from the corresponding female side of the adjacent panel. This can result in the male side of a panel disconnecting from the structure. Wind-induced panel disconnection is increased with the increased use of lighter gauge (and less stiff) steel panels designed for reducing transportation cost and material consumption.

[0008] As well as exposing the underlying structure to damage from wind and rain, the male side of a disconnected panel can flap uncontrollably in the wind, still anchored by its female side. This can deform or damage the panel and can also cause the next male side to become disengaged, creating a knock-on effect of sequential panel disconnection.

[0009] It is therefore desirable to provide a novel device or system to improve the wind-resistance of cladding panels.

[0010] Before turning to a summary of the invention, it is useful to provide an explanation of some of the terms that will be used to define the spatial relation of various parts thereof. Spatial references throughout this specification will generally be based upon a wall or roof cladding installation in which cladding is mounted to an

2020100448 24 Mar 2020 underlying structure, for example a wall joist, roof batten or ply board base structure. With this environment as the basis, some parts may then be defined with reference to the cladding. For example, an object which is “underneath’ or “beneath” the cladding will be understood as being on an internal side of the cladding and not necessarily ‘below’ in terms of vertical elevation, although the object may also be vertically lower in the instance of a roof installation.

[0011] Further, it will be understood that a cladding panels always have an interior and an exterior and thus some parts may be defined with directional reference to “inner”, “inwardly”, “outer”, “outwardly”, “upstanding” with respect to the interior of the cladding panel. It should be appreciated that cladding panels can also be installed within a building interior and therefore references to “exterior” relate to the exterior side of the panel and not necessarily to the outside of a building or structure.

[0012] Additionally, it will be understood that a cladding panel typically comprises a generally planar fascia portion extending between a pair of sides. In this regard, references herein to a ‘side’ of a panel will be understood as referring to the opposing side edges of the panel as opposed to the inner and outer surfaces of the fascia panel. Where a cladding panel is generally rectangular in profile, the ‘sides’ of the panel may comprise the opposing longitudinal side edges which are located adjacent to the side edges of an adjacent cladding panel, in the side-by-side installation configuration.

Summary of Invention [0013] According to a first aspect of the present invention, there is provided an interlocking cladding panel arrangement, including: a pair of first and second interlockable cladding panels mounted in a side-by-side configuration on a support structure, the first cladding panel including a first interlocking formation and the second cladding panel including a second interlocking formation in interlocked engagement with the first interlocking formation; and an abutment in fixed relation to the first interlocking formation and located adjacent to the second interlocking formation for retaining the second interlocking formation against movement out of said interlocked engagement with the first interlocking formation wherein the abutment is integrally formed with the first interlocking formation.

2020100448 24 Mar 2020 [0014] The present invention advantageously provides an abutment to retain a cladding panel in the desirable interlocked position. It will be appreciated that interlocked engagement between cladding panels is a removable engagement which is capable of being disengaged by sufficient movement away from the interlocked position. During high-wind conditions, significant flexion can be induced in the panel. This movement can urge a side of the panel which is interlocked with an adjacent panel (but otherwise unfastened to the support structure) to become disengaged. The provision of the abutment adjacent to the second interlocking formation an interference to retain the second interlocking formation against excessive movement. The abutment therefore operates to reduce or eliminate the possibility of the panel side being disengaged due to high-wind or other external factors such as earthquakes or vandalism.

[0015] The present invention may therefore enable the use of desirably thinner and lighter cladding panels without the reduction in wind-resistance which is typical of previous systems. Furthermore, the abutment may be located beneath the cladding panels and are therefore concealed. In this manner, the present invention also provides a cladding panel arrangement which can be free from visible fasteners and visible clips.

[0016] Furthermore, the abutment is advantageously integrally formed with the first interlocking formation. In contrast to previous systems which have involved the use of separate clips or fasteners, the present invention provides a cladding panel with an abutment that is integrally formed. The abutment may be contemporaneously formed during manufacture of the first interlocking formation. The abutment may be roll formed.

[0017] The abutment can comprise a distal end of a sheet material from which the cladding panel is produced. For example, a distal end of the sheet material which is folded or bent to produce an upstanding abutment portion.

[0018] The provision of an abutment that is integrally formed with the fist interlocking formation is advantageous insofar as the abutment can be formed at the same time and via the same process as the first interlocking formation. The abutment can therefore be produced at low-cost and in a time-efficient manner. This is in

2020100448 24 Mar 2020 contrast to alternative systems which involve a separate panel clip or fasteners or other systems which involve an abutment that has been stamped or pressed into the cladding panel. The stamping or pressing or an abutment necessarily involves a separate manufacturing technique from production of the first interlocking formation and is therefore not integrally formed with the first interlocking formation. This introduces additional complexity and cost into the manufacturing process.

[0019] The first interlocking formation and the abutment may be roll formed contemporaneously. For example, the cladding panel may be produced by roll forming (or via a similar process) sheet material such as sheet metal. The abutment which is integrally formed with the first interlocking formation can be formed via the same manufacturing technique. The abutment may comprise a folded portion of the cladding panel. For example, the abutment may comprise a flange folded during manufacture of the first interlocking formation. The flange may be folded via roll forming or via a similar process.

[0020] It will be appreciated that types of interlocking panel arrangements can vary. It is therefore envisaged that the invention may be used with a variety of different interlocking formations capable of interlocking engagement with one another. However, in a particular embodiment of the invention, the first interlocking formation comprises a female formation having a recess and the second interlocking formation comprises a male formation having a tongue configured for insertion into the recess during interlocking engagement.

[0021] The tongue may comprise a flange, member, shank, boss, web or other similar projection. The recess may comprise a cavity, opening, channel or any other suitable void for receiving the tongue.

[0022] In a particular embodiment of the invention, each cladding panel includes a pair of opposing sides comprising a male side which includes the male formation and a female side which includes the female formation. According to this embodiment, a series of identical cladding panels may be connected together in interlocked engagement.

[0023] In alternative forms of the invention, the cladding panels of the present invention may each include just one female side and one male side with an opposing

2020100448 24 Mar 2020 side of the panels comprising no formation whatsoever. Alternatively, cladding panels may include a pair of opposing female sides or a pair of opposing male sides.

[0024] In a particular embodiment of the invention, during interlocked engagement, the abutment is positioned to retain movement of the tongue out of receipt within the recess. In one form of the invention, the tongue includes a distal end for insertion into the recess and a proximal end from which the tongue extends and the abutment is, in use, positioned adjacent to the proximal end for obstructing withdrawal of the tongue from the recess.

[0025] In some forms of the invention, the abutment may normally contact a side of the cladding panel. For example, the abutment may be positioned such that an inside surface of the unfastened panel is butted up against the abutment. This arrangement may be desirable in certain installations where minimal movement of the unfastened panel side is required.

[0026] In an alternative embodiment of the invention, the tongue may extend from a sidewall of the male side and in the interlocked position the abutment is normally spaced apart from the sidewall. In this configuration, an unfastened side (for example the male side) is normally spaced apart from the abutment but may nonetheless move into contact with the abutment. For example, in the normal position (i.e. without windinduced flexion) the unfastened side may be spaced from the abutments. This configuration may allow for some partial movement of the unfastened side away from the interlocked position until contacting the abutment at which point further movement is prevented. This configuration may desirably provide a larger space between the abutment and the recess of a pre-fastened female side. During installation of a cladding panel arrangement, the larger spacing may facilitate the positioning of a male side into interlocking engagement with a pre-fastened female side.

[0027] According to particular embodiment of the invention, the female sides of the cladding panels are, in use, secured to the support structure for example, via screws or similar fasteners. The female sides of the cladding panels may be screwed through in situ using, for example, self-tapping screws. Alternatively, the female sides could include pre-drilled fastener openings for receiving a fastener.

2020100448 24 Mar 2020 [0028] According to a particular embodiment of the invention, the male side is, in use, located between the female side and the abutment. The abutment may therefore block the withdrawal path of the tongue by obstructing removal from the recess of the female side. The recess can define a depth direction extending inwardly from the female side. The abutment may be orientated so as to intersect the depth direction of the recess i.e. the abutment may cross an axis defined by the recess. In this manner, the abutment may interfere or obstruct withdrawal of the tongue along the depth direction thereby preventing withdrawal.

[0029] The support structure onto which the cladding panel arrangement of the invention is mounted may comprise any structure intended to be cladded and may include an internal or external wall, floor, roof or ceiling. For example, the support structure could comprise wall studs, floor joists, roof battens or other similar structure.

[0030] The specific mode of installation cladding panel may vary. For example, a female side of a first cladding panel may be fastened to the support structure, for example via screws, and then a male side of an adjacent second cladding panel is positioned into interlocked engagement with the pre-fastened female side. In this example, the unfastened male side can be positioned adjacent to the abutment so as to be retained from movement away from interlocked engagement with the fastened female side of the adjacent panel.

[0031] In a particular form of the invention, the first interlocking formation is, in use, pre-fastened to the support structure and the second interlocking formation is manually locatable into interlocked engagement with the pre-fastened first interlocking formation.

[0032] In this context, it will be appreciated that a ‘fastened side’ refers to a side which is directly connected to the support structure for example via a fastener such as a bolt, nail or screw. Similarly, an ‘unfastened side’ is a side which is not directly connected to the support structure via a fastener but may nonetheless be secured or mounted to the support structure via interlocking engagement with another component that is directly connected to the support structure for example via engagement with a fastened panel.

2020100448 24 Mar 2020 [0033] The abutment of the present invention may be formed in a variety of configurations suitable for maintaining interlocked engagement between the pair of cladding panels.

[0034] According to a particular embodiment of the invention, the abutment is integrally formed in the female side of the first cladding panel. For example, the abutment may comprise a part of the female side and therefore also a part of the cladding panel. This form of the invention advantageously minimises the number of components required in the cladding installation process by integrating the abutment into the cladding panel.

[0035] The abutment may be spaced from the recess to define an opening for receiving the male side of the second cladding panel and for facilitating insertion of the tongue into the recess. The abutment may extend generally perpendicularly from an axis of the recess. The abutment may comprise any suitable formation that can act as a suitable barrier against movement for example the abutment may comprise a lip, fold, profile, wave, rise or rib. In a particular form of the invention, the female side includes an underlap portion extending between the abutment and the recess and the abutment comprises an upstanding wall extending from the underlap portion.

[0036] According to this embodiment of the invention, the abutment may be formed simultaneously with the cladding panel. For example, the cladding panel may be roll formed from sheet metal to include the features of the male and female sides including the sidewalls of the male and female sides, the tongue, the recess, the underlap portion and the abutment. It will be appreciated that other manufacturing methods may be utilised such as stamping, hot rolling, welding, punching or other suitable methods.

[0037] The cladding panel may be preferably formed from metal but may alternatively be formed from polymer in which case additive manufacturing methods or methods such as injection moulding may be used to produce the cladding panels of the present invention.

[0038] In an alternative form of the invention, the abutment may be another portion of the cladding panel. For example, the abutment may be integrally formed at the male side of a cladding panel.

2020100448 24 Mar 2020 [0039] In use, the male side of an adjacent cladding panel may be positioned into the opening between the recess and the abutment and the tongue then inserted into the recess and the tongue seated upon the underlap portion. The underlap portion may include a kink providing fastener clearance for a fastener head located beneath the tongue. For example, a screw may be used to fasten the underlap portion to the support structure and the screw head may locate into the fastener clearance beneath the tongue when inserted into the recess.

[0040] The present invention may also relate to a cladding panel for use in abovedescribed interlocking panel arrangement.

[0041] According to a second aspect of the present invention, there is provided an interlocking cladding panel for use in an interlocking cladding panel arrangement, the cladding panel including a pair of opposite sides comprising a female side and a male side configured for interlocking engagement with the female side of an adjacent cladding panel in a side-by-side cladding panel configuration; and the female side further including an abutment for retaining the male side against movement out of interlocked engagement with the female side, the abutment being integrally formed with the female side of the cladding panel.

[0042] It will be appreciated that the various features, alternatives and procedures discussed above with reference to the first aspect of the invention may also be applied to the second aspect of the invention.

[0043] According to the second aspect of the invention, the male side can include a tongue and the female side can include a recess for receiving the tongue of the adjacent panel during interlocking engagement. The female side can include an underlapping portion extending between the recess and the abutment and the abutment extending from the underlapping portion. The abutment may be generally perpendicular with a longitudinal axis of the tongue. For example, the abutment may comprise a folded portion extending perpendicularly from the underlapping portion. The abutment may be produced simultaneously with the female side via the same manufacturing process such as roll forming or similar processes.

[0044] According to a third aspect of the invention, there is provided an interlocking cladding panel for use in an interlocking cladding panel arrangement, the

2020100448 24 Mar 2020 cladding panel including a first interlocking formation for interlocking engagement with a second interlocking formation of a second cladding panel, the first interlocking formation comprising a female formation having a recess for receiving a male formation having a tongue configured for insertion into the recess during interlocking engagement, the cladding panel further including an abutment in fixed relation to the recess and being located adjacent to the tongue during interlocking engagement, for retaining the tongue against movement out of said interlocked engagement with the recess, the abutment being integrally formed with the female formation.

[0045] As discussed with reference to the first and second aspects of the invention, the abutment in the third aspect of the invention can be produced contemporaneously with the female formation and therefore at lower cost and with less production complexity.

Brief Description of Drawings [0046] In order that the invention may be more fully understood, an embodiment of the present invention will now be described with reference to the figures in which:

[0047] Figure 1 is a side view of a pair of interlocking cladding panels according to an aspect of the present invention; and [0048] Figure 2 is a closer perspective of section A in Figure 12, illustrating interlocking ends of the pair of cladding panels.

Detailed Description [0049] Turning to Figures 1 and 2, there is illustrated an alternative embodiment of the present invention in which a retention abutment is integrally formed with the female side of the cladding panel.

[0050] Figure 1 illustrates a pair of identical first and second interlocking cladding panels 132, 134 mounted in a side-by-side configuration. Each cladding panel includes a pair of opposing male and female sides 136, 140. The female sides 140 comprise a first interlocking formation comprising a recess 142 and the male sides 136 comprise a second interlocking formation comprising a tongue 138 extending from a sidewall 150. A planar fascia portion 170 extends between the opposing male

2020100448 24 Mar 2020 and female sides 136, 140. The female side 140 further includes a sidewall 151 which is parallel to the sidewall 150 of the male side 136.

[0051] As best illustrated in Figure 1, the first and second cladding panels 132, 134 are in interlocking engagement wherein the tongue 138 of the second cladding panel 134 is received and within the recess 140 of the first cladding panel 132. In this manner, the cladding panels are partially connected such that upward movement of the second cladding panel 170 (as per the perspective in Figure 2) would be prevented by contact between the tongue 138 of the second cladding panel and the recess 142 of the first cladding panel.

[0052] The female sides 140 of the cladding panels 132, 134 further include an abutment comprising an upstanding wall 180 extending perpendicularly from an underlapping portion 144 of the female side. Recess 142 has a depth which extends along a depth direction labelled Y which is intersected by upstanding wall 180. In this manner, a withdrawal movement of the tongue 138 to the right of Figure 2 along the depth direction Y would result in contact between sidewall 150 and the upstanding wall 180 thereby preventing further withdrawal movement of the tongue 138 and retaining the male side 136 against disengagement with the female side 140. Underlapping portion 140 includes a kink 116 which provides a fastener clearance 182 beneath the tongue 138.

[0053] The cladding panels 132, 134 are formed from a sheet material which is folded at each end to produce the second interlocking formation comprising the male side 136 and the first interlocking formation comprising the female side 140. The upstanding wall 180 comprises a distal edge of the sheet material from which the female side 140 is formed which is integrally formed with the female side 140 by folding the upstanding wall 180 perpendicularly to the underlapping portion 144. The upstanding all 180 extends generally parallel to the sidewall 151 on the female side 151.

[0054] The upstanding wall 180 is integrally formed in the cladding panels 132, 134. In particular, the upstanding wall 180 is roll formed. The upstanding wall is thereby formed contemporaneously during manufacture of the female side 140 of the cladding panels 132, 134. The upstanding wall 180 is thereby formed via the same

2020100448 24 Mar 2020 manufacturing process as the rest of the female interlocking formation. Production of the upstanding wall 180 is therefore cost and time effective insofar as a separate clip is not required and a separate manufacturing stage or manufacturing technique is not required.

[0055] The present invention therefore provides a concealed abutment which blocks movement of the interlocking wall cladding, relative to the support structure and which is concealed from view. The present invention therefore facilitates the use of desirable thinner and lighter cladding panels which are more susceptible to windinduced flexion, and without requiring visible screws through the cladding which diminish aesthetic appearance. Furthermore, the provision of an abutment which is integrally and contemporaneously formed with the female interlocking formation of the cladding panel reduces cost insofar as a separate manufacturing step is not required to produce the abutment.

[0056] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit and scope of the present invention.

[0057] Where the terms comprise, comprises, comprised or comprising are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other feature, integer, step, component or group thereof.

Claims

The claims defining the invention are as follows

1. An interlocking cladding panel arrangement, including:

a pair of first and second interlockable cladding panels mounted in a side-by-side configuration on a support structure, the first cladding panel including a first interlocking formation and the second cladding panel including a second interlocking formation in interlocked engagement with the first interlocking formation; and an abutment in fixed relation to the first interlocking formation and located adjacent to the second interlocking formation for retaining the second interlocking formation against movement out of said interlocked engagement with the first interlocking formation, wherein the abutment is integrally formed with the first interlocking formation.
2. An interlocking cladding panel arrangement according to claim 1, the abutment being roll formed.
3. An interlocking cladding panel arrangement according to claims 1 or 2, the first interlocking formation comprising a female formation having a recess and the second interlocking formation comprising a male formation having a tongue configured for insertion into the recess during interlocking engagement.
4. An interlocking cladding panel arrangement according to any one of claims 3 wherein, during interlocked engagement, the abutment retains movement of the tongue out of receipt within the recess.
5. An interlocking cladding panel arrangement according to claim 3 or 4, each cladding panel including a pair of opposing sides comprising a male side which includes the male formation and a female side which includes the female formation.
6. An interlocking cladding panel arrangement according to any one of claims 3 to 5 , the tongue including a distal end for insertion into the recess and a proximal end from which the tongue extends and the abutment being, in use, positioned

2020100448 24 Mar 2020 adjacent to the proximal end for obstructing withdrawal of the tongue from the recess.
7. An interlocking cladding panel arrangement according to any one of claims 3 to 6, the tongue extending from a sidewall of the male side and wherein, in the interlocked position, the abutment being normally spaced apart from the sidewall.
8. An interlocking cladding panel arrangement according to any one of claims 5 to 7 the male side being, in use, located between the female side and the abutment.
9. An interlocking cladding panel arrangement according to claim 9, the abutment being spaced from the recess to define an opening for receiving the male side of the second cladding panel and facilitating insertion of the tongue into the recess.
10. An interlocking cladding panel arrangement according to claims 9 or 10, the first cladding panel, the abutment extending generally perpendicularly from an axis of the recess.
11. An interlocking cladding panel arrangement according to any one of claims 5 to 10, the female side including an underlap portion extending between the abutment and the recess and the abutment comprising an upstanding wall extending from the underlap portion.
12. An interlocking cladding panel arrangement according to claim 11, the upstanding wall comprising a flange folded approximately perpendicularly to the underlap portion.
13. An interlocking cladding panel arrangement according to claim 11, the underlap portion including a kink providing fastener clearance for a fastener head located beneath the tongue.
14. An interlocking cladding panel arrangement according to any one of the preceding claims, the first interlocking formation being, in use, pre-fastened to the support structure and the second interlocking formation being manually locatable into interlocked engagement with the pre-fastened first interlocking formation.
15. A cladding panel for use in the interlocking cladding panel arrangement according to any one of the preceding claims.

2020100448 24 Mar 2020
16. An interlocking cladding panel for use in an interlocking cladding panel arrangement, the cladding panel including:

• a pair of opposite sides comprising a female side and a male side configured for interlocking engagement with the female side of an adjacent cladding panel in a side-by-side cladding panel configuration;

• the female side further including an abutment for retaining the male side against movement out of interlocked engagement with the female side, the abutment being integrally formed with the female side of the cladding panel.
17. An interlocking cladding panel according to claim 16, the male side including a tongue and the female side including a recess for receiving the tongue of the adjacent panel during interlocking engagement
18. An interlocking cladding panel according to claim 17, the female side including an underlapping portion extending between the recess and the abutment and the abutment extending from the underlapping portion.
19. An interlocking cladding panel according to claim 18, the abutment being generally perpendicular with a longitudinal axis of the tongue.
20. An interlocking cladding panel for use in an interlocking cladding panel arrangement, the cladding panel including a first interlocking formation for interlocking engagement with a second interlocking formation of a second cladding panel, the first interlocking formation comprising a female formation having a recess for receiving a male formation having a tongue configured for insertion into the recess during interlocking engagement, the cladding panel further including an abutment in fixed relation to the recess and being located adjacent to the tongue during interlocking engagement, for retaining the tongue against movement out of said interlocked engagement with the recess, the abutment being integrally formed with the female formation.