GB2482355A

GB2482355A - Cladding panel with adjustable connector

Info

Publication number: GB2482355A
Application number: GB1015004.3A
Authority: GB
Inventors: Ken Hodge
Original assignee: ARCHITECTURAL FACADES AND SOFFIT SYSTEMS Ltd
Current assignee: ARCHITECTURAL FACADES AND SOFFIT SYSTEMS Ltd
Priority date: 2010-07-28
Filing date: 2010-09-09
Publication date: 2012-02-01
Anticipated expiration: 2030-09-09
Also published as: GB2482355B; GB201012581D0; GB2477587A; GB201015004D0

Abstract

A cladding panel (10, fig 1) comprising a first side region having a first engager 48 and a second, opposed side region having a plurality of spaced second engagers 50, 52, wherein in use, the first engager of the panel is able to engage with a second engager of an adjacent panel and relative movement of the panels in at least one direction is resisted. In use the first engager can be located in different second engager positions to alter the distance spanned by the two panels. The first engager may be a male engager and preferable has an arcuate portion and may extend across the whole panel. The second engager may comprise female engagers which may preferable be spaced, parallel engagers. The panel may comprise an extruded panel. A method of connecting two panels is also claimed.

Description

PANELS

The present invention relates to a method of forming a panel suitable for use in cladding a building, panels made according to that method, a plurality of adjacent panels made according to that method and a building incorporating panels made according to the method.

Buildings are often clad with ceramic tiles. There is often a space between adjacent tiles which is filled with a different colour of material from that of the tiles in order to create a pleasing grid pattern. However, such ceramic tiles are expensive to manufacture and are time consuming to apply.

Further, buildings are often clad with metal plates. In some instances these interlock to assist in shielding a structure that supports those plates. However, the walls to be clad vary in height and width. Accordingly, some plates will have to be cut to cover that area. In addition the pattern formed from such plates cannot be varied.

It is an aim of the present invention to attempt to overcome at least one of the above or other problems.

The present invention is defined in the claims and elsewhere in this specification.

The present invention includes any combination of the herein referred to features or limitations.

According to one aspect of the present invention, a method of forming a panel suitable for use in cladding a building comprising masking a first surface of the panel on a first side of the panel and coating a second surface of the panel on the first side.

The method may comprise heating the coating such as to more that 150°C or more than 200 °C.

The method may comprise removing the masking when the temperature of the panel is above 40°C or more than 50°C or less than 100°C or less than 80°C or when the temperature of the panel is 60°C.

The method may comprise masking the first surface which is a minor part of the panel and coating the second surface which is a major part of the panel.

The method may comprise applying a coating to the first surface and masking that coating wherein the masked coating is different to the coating subsequently applied to the second surface and may comprise applying a coating to the first surface, heating the panel and subsequently cooling the panel and then masking the first surface and then coating the second surface, heating the panel and then cooling the panel before removing the masking such as removing the masking when the temperature is more than 40°C.

The method may comprise making the first and second surfaces of different colour or of different texture.

At least one coating maybe polyester coating.

The method may comprise forming the panel with inter-engaging members on each side whereby a plurality of adjacent panels can engage each other.

The present invention also includes cladding a building when the panel has been made as herein referred to.

The panel comprises an extruded panel.

At least part of the first surface of the panels is arranged to be visible when the panels clad a building.

Part of a surface of one panel may be obscured by part of a second surface of an adjacent panel and part of the first surface of one panel may obscured by part of the second surface of an adjacent panel.

In a plurality of adjacent panels the ends may be separated by a divider and the divider may have the same surface as that of the previously masked surface and the width of the dividers may be the same as the exposed part of the previously masked surface.

Adjacent panels engage each other.

According to a further aspect of the present invention a method of cladding a building using a plurality of panels comprises locating panels adjacent to each other on the wall of a building to thereby clad the building such that at least a part of the panel that has been masked is visible.

The panels may be located adjacent to each other such that an end edge of the panel that has been masked is obscured by an adjacent panel.

The present invention can be carried into practice in various ways and one example will now be described with reference to and as shown in the accompanying drawings in which: Figure lisa perspective view of a panel 10; Figure 2 is a side view showing panels 10A and lOB engaged with each other; Figure 3 is a detailed view of a side region of a panel during the manufacturing process; and Figure 4 is a perspective view of part of a wall using the panels; Figure 5 is a side view of a modified panel according to the present invention; Figure 6 and 7 are detailed side views of the panels according to Figure 5 in alternative 1 5 interengaging positions, and Figure 8 is a view of a wall including a plurality of panels as shown in Figure 5.

Figure 1 shows an extruded aluminium panel 10.

The panel comprises a main planar surface 12 and a male 14 and female 16 inter-engaging portions at opposite side regions.

The male portion 14 is formed by a minor planar flange 18 connected to the edge of the main surface 12 by a rib 20. The plane of the minor flange 18 is parallel to the plane of the main surface 12 and coincident with the underside of the main surface.

The female portion 16 is formed by a channel 22 having an upwardly facing opening 24. The channel is formed by a first wall 26 extending downwardly from the main surface 12 at a distance spaced from the edge 28 of the main surface. A second wall 30 extends from the end of the wall 26 spaced from the main surface 12, and beyond the edge 28 before a third wall 32 extends upwardly, ending in the plane defined by the under surface of the main surface 12.

The first wall 26 is perpendicular to the main surface 12 and the second wall 30 extends perpendicular to the first wall 26 and the third wall 32 is perpendicular to the second wall.

In use a first panel 1OA will be secured to a building and a second panel lOB will then be tilted relative to the first panel to allow the male flange 18 to enter the channel 22 before the second panel is tilted in the opposite direction such that the upwardly facing surface of the flange 18 abuts the downwardly facing surface of the main surface 12 and the downwardly facing surface of the main surface 12 of the panel lOB abuts the top of the third wall 32. The second panel is then secured to the building.

It can be seen that about half the width of the flange 18 is exposed to define a section 34 that is approximately 10mm wide.

Figure 4 shows the vertical support flanges 40 to which the panels 10 are secured. Also secured to the flanges 40 are dividers 42 that include an outwardly facing wall 44 separating the horizontally aligned panels. The wall 44 may project to the same distance as the main surface 12 of the panels may have the same coating as that of the minor flange 18 and may have the same width as that extended by the minor flange 18. This provides a simulation of a tile effect.

In an alternative embodiment (not shown) the view of Figure 4 could be rotated through 90° to have the flanges 40 extending horizontally together with the waIls 44. In this arrangement the ends of the panels also extend horizontally.

An optional method of manufacture of the panels will now be described.

Step 1 The aluminium panel is first cleaned by spraying or passing the panel through an alkaline or acid solution.

Step 2 The panel is rinsed with water.

Step 3 The panel is sprayed or dipped in an acid based solution to de-smut the panel.

Step 4 The panel is then rinsed with water again.

Step 5 The panel is then passed through a tank containing chromate ions or chromate and phosphate ions as the active component having a weight of 2.25g/m2.

Step 6 The panel is then subjected to two further rinses with demineralised water.

Step 7 The minor flange 18 and the adjacent portion of the main surface 12 are then powder coated with a first polyester. Step8

The panel is heated to 200°C or more for at least 10 minutes.

Step 9 The panel cools to room temperature.

Step 10 Masking tape 36 is applied over the minor flange 18. The masking tape is a 50p thick polyester film having a silicone adhesive giving a total thickness of 83p. The tape can withstand 200°C.

Step 11 The complete panel is then powder coated with a second polyester, Step 12 The panel is then heated to 200°C for at least 10 minutes.

Step 13 The panel is then cooled but not to room temperature. Instead the panel is cooled to a temperature of 60°C or more and the masking tape is removed. It is important that the masking tape is removed at a temperature of 60°C or more as tests have shown that if the tape is left on until the panel has cooled to room temperature a residue from the tape is deposited on the flange.

The first and second polyesters may be of different colours or of different textures or both.

Whilst the invention has been described with first and second polyesters different materials could be used to provide the different colours or textures. Further it is possible that only one coating is polyester. Further, it is possible that only the major portion of the panel is coated with the masked part remaining uncoated.

With the section 34 of the flange 18 being exposed it can be seen that a plurality of panels that are connected together can give a similar visual effect to that of ceramic tiles with the section 36 giving a visual distinction between that part and the remainder of the visible panel. Many panels can be connected in this way to cover a major surface of at least one wall of a building.

Figures 5 to 7 show a modification that can be made to the panel described in Figures 1 to 4.

The panels 46, in Figures 5 to 7 is made as previously described and adjacent panels engage each other as previously described.

The panel 46 though includes a rounded end 48 at the top of the third wall 32. This end 48 can lie in one of two spaced parallel recesses 50, 52 formed in the underside of the main surface 12 of an adjacent panel.

The extent of the minor flange 18 is less than that shown in Figures ito 4. Accordingly, when the end 48 lies in the recess 52 the minor flange 18 is spaced from the first wall of the adjacent panel and the panels interengage each other to resist relative movement towards and away from each other in the plane of the panels.

When the end 48 engages the other recess 50, as shown in Figure 7, the minor flange 18 is adjacent to or abuts the first wall 26, In Figure 6 the adjacent panels may have the same tile effect as that shown in Figure 4 as the minor flange is visible. In Figure 7 though the edges of the main surfaces 12 of adjacent panels abut each other or are close to each other thereby obscuring or largely obscuring the minor flange 18 from view. Consequently, in Figure 7 the border between adjacent panels does not exhibit a tile effect.

It will be appreciated that there may be more than two spaced parallel recesses with the rib co-operating with one recess to obscure the minor flange, for instance, with another to expose part of the minor flange and a further recess to expose more of the minor flange. In this way, different tile effects may be given between panels having the same cross-section.

Whilst a panel having only one main surface width has been described different panel having different widths could be interengaged. Thus panels of 250mm width could engage with others of 200mm width or 100mm for example.

As shown in Figure 8, two adjacent panels 46A and 46B may obscure the minor flange 18.

The adjacent panels 46B and 46C have the minor flange 18 exposed and the panels 460 and 46D obscure the minor flange 18. In this way the tile effect is to have a double width tile.

An alternative or additional advantage of the panel 46 is that adjacent panels can interengage each other with the overall length of a set number of panels being able to be altered depending on which of the recesses 50 or 52 are engaged. Consequently a wall can be clad with the top and bottom being reached by the end of a full panel without the need to cut a panel to make the fit.

The panels may clad the inside or outside of a building.

It will be appreciated that the panels could be of any formation or width. Further it is possible that in some embodiments the panels may not engage with each other or may engage with a different formation.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

1 5 All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

C'aims 1. A cladding panel arranged, in use, to engage with a panel on each side, the panel including a first side region including a first engager and a second, opposed side region including a plurality of spaced second engagers and in which, in use, when the first engager of the panel engages one of a plurality of second engagers with an adjacent panel relative movement of the panels in at least one direction is resisted and in which, in use, the first engager of the panel is able to engage with a different second engager to alter the distance spanned by the two panels and in which, in use, one of the plurality of second engagers at the second side region of the panel is arranged to engage with a first engager of an adjacent panel, with relative movement of the panels in at least one direction being resisted by such engagement and in which a different one of the second engagers can be engaged by the first engager of an adjacent panel to alter the distance spanned by the two panels.
2. A panel as claimed in claim 1 in which, in use, when two panels engage each other, the relative movement they are arranged to resist is in a direction towards and away from each in the direction of the distance spanned by the two panels.
3. A panel as claimed in claim 1 or 2 in which the first engager is a male engager.
4. A panel as claimed in claim 3 in which the first engager includes an arcuate engaging surface.
5. A panel as claimed in claim 3 or 4 in which the first engager extends across the complete width of the panel.
6. A panel as claimed in any of claims 3 to 5 in which the male engager is arranged to extend outwardly with respect to the direction that the panel is arranged to be seen when a surface is clad.
7. A panel as claimed in any preceding claim in which the second engagers comprise female engagers.
8. A panel as claimed in claim 7 in which the female engagers comprise recesses.
9. A panel as claimed in any preceding claim in which the second engagers comprise spaced parallel engagers.
10. A panel as claimed in any preceding claim in which the second engagers extend across the complete length of the panel.
11. A panel as claimed in any preceding claim in which the second engagers face away from the surface of the panel that is arranged to be seen when a surface is to be clad.
12. A panel as claimed in any preceding claim comprising an extruded panel.
13. A panel as claimed in any preceding claim in which one side region includes an outwardly facing minor surface that, in use, is arranged to be at least partly obscured by the other side region of an adjacent panel when the first engager is engaged with at least one of the second engagers.
14. A panel a claimed in claim 13 in which the minor surface is arranged to be totally obscured when the first engager is engaged with one of the second engagers.
15. A panel as in claimed in claim 13 or 14 in which the area of the minor surface which that is visible is arranged to change when the first engager engages with different second engagers.
16. A method as claimed in any of claims 13 to 15 in which the panel includes a major surface of greater area than the minor surface.
17. A panel as claimed in claim 16 in which, in use, when the first engager engages a selected one of the second engagers the major surfaces of the adjacent panels are arranged to be substantially continuous across the panels.
18. A panel as claimed in any of claims 13 to 17 in which the minor surface has a different visual effect from the major surface.
19. A method of connecting at least two cladding panels comprising engaging a first engager located at a first side region of one panel with a selected one of spaced second engagers at a second opposed side region of another adjacent panel whereby the relative movement of the panels in at least one direction is arranged to be resisted by the engagement of the first and the selected second engagers and whereby the selection of the second engager that is engaged by the first engager alters the distance spanned by the two panels.
20. A method of connecting a least two cladding panels as claimed in claim 19 when the cladding panels are as claimed in any of claims ito 18.
21. A cladding comprising a plurality of cladding panels that have been connected by a method as claimed in claim 19 or 20.
22. Cladding comprising a plurality of cladding panels as claimed in any of claims ito 18.
23. Cladding as claimed in claim 22 in which at least two panels are identical.
24. Cladding as claimed in claim 22 or 23 in which at least two panels are non-identical.
25. Cladding as claimed in claim 24 in which at least two panels are of different width.AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWSUClaims 1. A system of cladding panels in which a first cladding panel is adapted, to engage with second and third cladding panels on each side, each panel including a first side region including a first engager and a second, opposed side region including a plurality of spaced second engagers and in which, the first engager of the first panel is adapted to engage one of a plurality of second engagers of an adjacent second panel the panels are inter-engaged and relative movement of the panels in at least one direction is resisted and in which, when connected, the first engager of the first panel s able to engage with a dfterent second engager of the second panel to alter the distance spanned by the first and second panels and in which, when engaged, one of the plurality of second engagers at the second side region of the first panel engages with a first engager of the adjacent third panel such that the panels are inter-engaged, with relative movement of the first and third panels in at least one direction (\J being resisted by such engagement and in which a different one of the second engagers of the first panel can be engaged by the first engager of the adjacent third panel to alter the distance spanned by the first and third panels, the first engager and second engagers comprising male and female engagers.2. Cladding panels as claimed in claim 1 in which, in use, when the first and second engagers of two panels engage each other, the relative movement they are arranged to resist is in a direction towards and away from each in the direction of the distance spanned by the two panels.3. Cladding panels as claimed in claim 1 or 2 in which the first engager is a male engager.4. Cladding panels as claimed in claim 3 in which the first engager includes an arcuate engaging surface.5. Cladding panels as claimed in claim 3 or 4 in which the first engager extends across the complete side of the panel.6. Cladding panels as claimed in any of claims 3 to 5 in which the male engager is arranged to extend outwardly towards the direction that the panel is arranged to be seen when a surface is clad.7. Cladding panels as claimed in any preceding claim in which the second engagers comprise female engagers.8. Cladding panels as claimed in claim 7 in which the female engagers comprise recesses.9. Cladding panels as claimed in any precethng claim in which the second engagers comprise spaced parallel engagers.10. Cladding panels as claimed in any preceding claim in which the second (\J engagers face in the opposed direction away from the surface of the panel that is arranged to be seen when a surface is to be clad.11. Cladding panels as claimed in any preceding claim comprising extruded panels.12. Cladding panels as claimed in any preceding claim in which one side region of each panel includes an outwardly acing minor surface that, in use, is arranged to be at least partly obscured by the other side region of an adjacent panel when the first engager is engaged with at least one of the second engagers.13. Cladding panels a claimed in claim 12 in which the minor surface is arranged to be totally obscured when the first engager is engaged with a selected one of the second engagers.14. Cladding panels as in claimed in claim 12 or 13 in which the area of the minor surface which that is visible is arranged to change when the first engager engages with different second engagers.15. Cladding panels as claimed in any of claims 13 to 15 in which the panel includes a major surface of greater area than the minor surface.16. Cladding panels as claimed in claim 16 in which, in use, when the first engager engages a selected one of the second engagers the major surfaces of the adjacent panels are arranged to be substantially continuous across the panels.17. Cladding panels as claimed in any of claims 13 to 17 in which the minor surface has a different visual effect from the major surface.18. A method of connecting at least three cladding pane's each including first and second opposed side regions comprising engaging a first engager located at a first side region of a first panel with a selected one of spaced second engagers at a second side region of an adjacent second pane' on one side of the first panel such that the panels are inter-engaged and whereby the relative movement of the panels in at least one direction is resisted by the engagement of the first and the selected second engagers and whereby the selection of the second engager that is engaged by the first engager alters the distance spanned by the first and second panels and with the first engager and second engagers cooperating by means of male and female engagers and a first engager of a third cladding pane' engaging a selected one of spaced second engagers of the first panel at the second side region of the first panel such that the first and third panels are interengaged and whereby the relative movement of the first and third panels is resisted by the engagement of the first and second engagers of the first and third panels and whereby the selection of the second engager that is engaged by the first engager alters the distance spanned by the first and third panels and with each of the first and second engagers cooperating by means of male and fema'e engagers, the third panel being located on the opposite side of the first panel to the second panel.19. A method of connecting a least two cladding panels as claimed in claim 18 when the cladding panels are as claimed in any of claims 2 to 17.20. A cladding comprising a plurality of cladding panels that have been connected by a method as claimed in claim 18 or 19.21. Cladding comprising a system of cladding panels as claimed in any of claims 1 to 17.22. Cladding as claimed in claim 21 in which at least two panels are identical.23. Cladding as claimed in claim 21 or 22 in which at least two panels are non-identical.24. Cladding as claimed in claim 23 in which at least two panels are of different width from one side from the first engager at a first side region to the second engagers on the other side region.