NZ764186A - Cladding sheet, system and method - Google Patents

Abstract

The present invention provides a cladding sheet comprising a profile defining at least one groove extending along a length of the cladding sheet. In an eave lining system, a first plurality of these cladding sheets can be joined together widthwise to line a width of an eave; and a second plurality of these cladding sheets can be joined together lengthwise to line a length of the eave. The present invention reduces the number of components required, and thereby reduces cost, time and effort required for installation of eave liners. Also, the profile of the sheets facilitate accurate trimming of the sheet to size and easy aligning of overlapping sheets with each other. By overlapping one of more grooves of each sheet, the sheets may be securely and easily installed to provide a clean finish. f these cladding sheets can be joined together lengthwise to line a length of the eave. The present invention reduces the number of components required, and thereby reduces cost, time and effort required for installation of eave liners. Also, the profile of the sheets facilitate accurate trimming of the sheet to size and easy aligning of overlapping sheets with each other. By overlapping one of more grooves of each sheet, the sheets may be securely and easily installed to provide a clean finish.

Description

Cladding sheet, system and method The invention relates to cladding sheets, particularly but not exclusively, cladding sheets used as eave lining sheets and in associated systems and methods for lining eaves of a building.

Existing eave lining sheets are substantially smooth, flat sheets, typically manufactured of fibre cement blends. The sheets are nailed onto a support structure of a building, and "joining strips" or "joining trims" are installed along the edges of abutting sheets to cover the abutting edges.

In this context, there is a need for improved eave lining sheets, systems and methods, which reduce installation costs, time and effort.

According to one aspect of the present invention, there is provided a cladding sheet comprising: a profile defining at least one groove extending along a length of the cladding sheet.

The cladding sheet may be configured to be fastened to a supporting structure of a building at a base portion of the least one groove.

The cladding sheet may comprise: a first edge extending along the length of the cladding sheet; and a second edge opposite said first edge and extending along the length of the cladding sheet, wherein the at least one groove extends parallel to and adjacent the first edge.

The cladding sheet may be configured to be joined with a like cladding sheet, wherein the joint between the cladding sheets is adjacent said at least one groove of said cladding sheet.

The cladding sheet may be used to line an eave, a wall or a ceiling of the building. The cladding sheet may also be used to line a roof.

In a further aspect of the present invention, there is provided an eave lining system comprising: a plurality of cladding sheets described above, joined together widthwise to line a width of an eave; and a plurality of cladding sheets described above, joined together lengthwise to line a length of the eave.

In a further aspect of the present invention, there is provided a method of lining along a width of an eave using a plurality of cladding sheets described above, comprising: a) fastening a first cladding sheet to a supporting structure of the eave at a base portion of the at least one groove; b) joining a second/further cladding sheet to the first cladding sheet along the width of the eave, such that the second/further cladding sheet overlaps the first edge of the first/underlying cladding sheet, with the second edge of the second/further cladding sheet at or adjacent the at least one groove of the first/underlying cladding sheet; and c) repeating step (b) as necessary to line the entire width of the eave.

The joint between the second/further cladding sheet and the first/underlying cladding sheet may be such that the second edge of the second/further cladding sheet is: a) between the groove and the first edge of the first/underlying cladding sheet, b) between the groove and the second edge of the first/underlying cladding sheet, or c) along the groove of the first/underlying cladding sheet.

In a further aspect, there is provided the cladding sheet described above, further comprising: a plurality of grooves, each groove extending along the length of the cladding sheet, wherein the cladding sheet is configured to be fastened to a supporting structure of a building at a base portion of at least one groove.

The base portion of the at least one groove may be provided with an aperture for receiving a fastener.

The fastener may be a screw.

The cladding sheet may be manufactured of a metallic alloy.

At least one surface of the sheet may be finished with a protective paint or coating.

The profile may be corrugated.

In a further aspect, there is provided an eave lining system comprising: a plurality of cladding sheets described above, wherein adjacent cladding sheets are joined together by overlapping a portion of the adjacent cladding sheets.

The eave lining system may further comprise a flashing.

In a further aspect, there is provided a method of lining an eave of a building comprising: providing at least two cladding sheets, each sheet as described above, attaching the first/underlying cladding sheet to a supporting structure of the eave by fastening via the base portion of the at least one groove of the first/underlying eave lining sheet, positioning the second/further cladding sheet adjacent the first/underlying cladding sheet such that a portion of the second/further cladding sheet overlaps with a portion of the first/underlying cladding sheet, and attaching the second/further cladding sheet to the supporting structure by fastening via the base portion of the at least one groove of the second cladding sheet.

The width of each of the first and second/further cladding sheets may be sufficient to line the entire width of the eave, and the first and second/further cladding sheets may be positioned adjacent each other to line the entire length of the eave.

The grooves of the adjacent cladding sheets may be aligned with each other.

The method may further comprise attaching a flashing at an intersection between a cladding sheet and a wall of the building.

According to another aspect of the present invention, there is provided an eave lining sheet comprising a profile defined by a series of parallel grooves provided along a length of the eave lining sheet, wherein the eave lining sheet is configured to be fastened to a supporting structure of a building at a base portion of at least one groove.

The base portion of the at least one groove may be provided with an aperture for receiving a fastener.

The fastener may be a screw.

The eave lining sheet may be manufactured of a metallic alloy.

At least one surface of the sheet may be finished with a protective paint or coating.

The profile of the eave lining sheet may be corrugated.

According to a further aspect of the present invention, there is provided an eave lining system comprising a plurality of eave lining sheets described above.

Adjacent eave lining sheets may be joined together by overlapping a portion of each eave lining sheet.

The eave lining system may further comprise a flashing.

According to a further aspect of the present invention, there is provided a method of lining an eave of a building comprising: providing at least two eave lining sheets, each sheet as described above, attaching the first eave lining sheet to a supporting structure of the eave by fastening via the base portion of the at least one groove of the first eave lining sheet, positioning the second eave lining sheet such that a portion thereof overlaps with a portion of the first eave lining sheet, and attaching the second eave lining sheet to the supporting structure by fastening via the base portion of the at least one groove of the second eave lining sheet.

The method may further comprise attaching a flashing at an intersection between the first and/or second eave lining sheet and a wall of the building.

The invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which: Figure 1 illustrates the cross-sectional profile of a cladding/eave lining sheet according to one embodiment; Figure 2 illustrates the cladding/eave lining sheet as installed according to one embodiment; Figure 3 shows another view of the cladding/eave lining sheet as installed; Figure 4 shows a further view of the cladding/eave lining sheet as installed; Figure 5 illustrates the cross-sectional profile of a flashing which may be used in combination with the cladding/eave lining sheet; Figure 6 illustrates the flashing as installed according to one embodiment; Figure 7 illustrates multiple cladding/eave lining sheets installed according to one embodiment; Figure 8 is a close-up view of Figure 7; Figure 9 illustrates a cross-sectional profile of a cladding sheet according to another embodiment; Figures 10A and 10B illustrate two locations at which the cladding sheet of Figure 9 may be fastened to a support surface of a building and/or to join another cladding sheet; Figure 11 is a cross-sectional illustration of two cladding sheets joined together according to a first embodiment; Figure 12 is a cross-sectional illustration of two cladding sheets joined together according to a second embodiment; Figure 13 is a cross-sectional illustration of two cladding sheets joined together according to a third embodiment; Figure 14 illustrates two cladding sheets joined together to line a width of an eave according to one embodiment; Figure 15 is a plan view of two cladding sheets of Figure 9; and Figure 16 illustrates how the cladding sheets of Figure 15 may be joined to each other in accordance with the embodiment illustrated in Figure 11.

Figure 1 illustrates the cross-sectional profile of a cladding/eave lining sheet (hereinafter "eave lining sheet") according to one preferred embodiment. The eave lining sheet 10 comprises a profile defined by a series of substantially parallel grooves 2, 2a, 2b, 2c, 2d provided along a length of the eave lining sheet. As illustrated in Figures 3 and 4, the eave lining sheet 10 is configured to be fastened to a supporting structure 12 of a building at a base portion 3 of at least one groove 2. Preferably, the eave lining sheet is fastened to the supporting structure via a plurality (or all) of the grooves 2 of the sheet 10.

For succinctness, the following examples describe the cladding/eave lining sheet 10 used to line an eave of a building. However, it should be appreciated that the sheet 10 could be used to line other surfaces of the building, eg a wall or a ceiling of the building. In further embodiments, the cladding sheet 10 could be used to line a roof of the building.

The base portion 3 of the at least one groove 2 may be provided with an aperture (not shown) for receiving a fastener 8. In preferred embodiments, the fastener is a screw; however, alternative fastening means such as nails, staples, adhesive, etc may be used. The term "base portion" is used to define the region 3 of the groove 2 via which the eave lining sheet 10 is fastened to the building; however, it will be understood that this "base portion" will in fact be inverted so as to be positioned at the top of the sheet when installed (eg as shown in Figures 3 and 4).

The eave lining sheet 10 is preferably manufactured of a metallic alloy. In one example, the alloy is a steel, such as sold under the trade name COLORBOND®.

Alternative metallic alloys, such as zinc aluminum, may be used.

At least one surface 6 of the sheet may be finished with a protective paint or coating for improved aesthetics and weather resistance. Preferably, at least the surface of the sheet 10 that will be exposed once installed comprises the protective finish.

In one embodiment, each groove 2 of the eave lining sheet 10 is trapezoidal in profile. The base of each groove 2 is about 20mm wide and the opening of each groove 2 is about 30mm wide. The eave lining sheet 10 is substantially planar between grooves 2 and the distance between grooves 2 may be about 120mm. In alternative embodiments, the corrugated profile and dimensions of the eave lining sheet 10 may vary, but the sheet preferably comprises a plurality of grooves via which the sheet is fastened to the support structure of the building. At one end of the eave lining sheet, there may be provided a fold 4 for attaching to a fascia of the building. Each groove has a depth of about 3mm. In other embodiments, the groove may have a depth of between about 2mm and 5mm inclusive.

An eave lining system according to one preferred embodiment comprises a plurality of the eave lining sheets 10. The eave lining sheets 10 are joined together to cover a length and/or width of the eave of the building by overlapping a portion of the adjacent sheets. As illustrated in Figures 7 and 8, the overlapping portion may comprise one or more grooves 2 from each eave lining sheet, which grooves are superimposed or nested in one another where they overlap.

The eave lining system may further comprising a flashing 14 such as illustrated in Figure 5 to line the building where the eave 20 intersects with the wall of the building. The flashing 14 may be manufactured of the same material as the eave lining sheet 10. At least one surface 18 of the flashing may be finished with a protective paint or coating for improved aesthetics and weather resistance. The opposite surface or both surfaces may be finished with a protective paint or coating.

Edge fold 16 of flashing 14 has been found to increase the strength of the flashing 14, and to reduce scratching or damage to the eave lining sheet 10 that may be caused by repositioning of the flashing during installation. That is, when the flashing 14 is positioned on the eave sheet 10, there is only a small contact area between the flashing (being the internal surface of the edge fold 16) and the eave sheet 10, such that if flashing 14 is slid along the edge of the eave 20 when repositioning it during installation, there will be minimal (if any) cosmetic damage to the underlying eave sheet.

Transverse fold 22 of flashing 14 is positioned flush against the wall of the building and provides a neater finish for mitre joints around corners of the building.

Figure 6 illustrates the flashing 14 installed over the eave lining sheet 10 according to one embodiment. The flashing 14 may be attached using any suitable fasteners 19, such as screws. Apertures may be provided in the flashing 14 for receiving such fasteners. The flashing 14 may be trimmed to size as required during installation. As illustrated in Figure 6, for corner installations, edge portions of two pieces of flashing 14 may be overlapped for simpler and quicker installation, and a neat, weather-tight finish.

A method of lining an eave 20 of a building according to a preferred embodiment comprises providing at least two like eave lining sheets as described above and attaching the first eave lining sheet 10a to a supporting structure 12 of the eave 20 of the building by fastening via the base portion 3 of the at least one groove 2 of the first eave lining sheet 10a. The second eave lining sheet 10b is then positioned such that a portion of the second eave lining sheet 10b overlaps with a portion of the first eave lining sheet 10a. The second eave lining sheet 10b is attached to the supporting structure 12 by fastening via the base portion 3 of the at least one groove 2 of the second eave lining sheet 10b. As illustrated more clearly in Figure 8, the overlapping portions 11 of the sheets 10a, 10b may each comprise one or more grooves 2, which are aligned with each other/nest within each other when installed. Further eave lining sheets 10 may be provided and installed as necessary to line the entire width and/or length of the eave. The sheets 10 may be trimmed to size prior to installation, if required.

Embodiments of the present system and method eliminate the need for separate "joining strips" or "joining trims", which are a necessary component of prior art systems (in order to join prior art eave sheets together). Accordingly, the present system and method reduces the number of components required, and thereby reduces cost, time and effort required for installation of eave liners. Instead, by overlapping one of more grooves of each sheet, the sheets may be securely and easily installed to provide a clean finish. The corrugated profile of the present eave lining sheets 10 according to preferred embodiments also facilitates accurate trimming of the sheet to size (if required) and easy aligning of overlapping sheets with each other. Additionally, the corrugated profile improves the strength of the sheet 10, so that larger lengths and widths of the sheets may be provided, further reducing cost, time and effort during installation, manufacture, storage and transport of the sheets.

Another embodiment of the cladding sheet 100 is illustrated in Figures 9 to 16. The cladding sheet 100 comprises a profile defining at least one groove 102 extending along a length 104 of the cladding sheet. While the drawings illustrate that the cladding sheet 100 comprises a single groove 102, it should be appreciated that a plurality of grooves may be provided, spaced apart from each other along the width of the sheet, each groove extending the length 104 of the sheet.

The cladding sheet 100 comprises a first edge 106 extending along the length 104 of the cladding sheet, and a second edge 108 opposite the first edge and extending along the length of the cladding sheet. The groove 102 extends parallel to and adjacent the first edge 106. The first edge 106 may be defined by a flange 107 bent at an angle (eg 90 degrees) relative to the plane of the rest of the sheet, for convenient positioning of that edge against a wall of a building (particularly where the cladding sheet 100 is used to line an eave of the building). The second edge 108 may comprise a fold 105 for attaching to a fascia of the building.

As illustrated in Figure 10A, the cladding sheet 100 may be fastened to a supporting structure of a building at a base portion 103 of the least one groove 102.

Additionally or alternatively, as illustrated in Figure 10B, the cladding sheet 100 may be fastened to a supporting structure 112 of a building or to another cladding sheet adjacent the groove 102. The fastening means may comprise a screw and the cladding sheet 100 may be provided with one or more apertures for receiving the fastening means.

As illustrated in Figures 11 to 14, the cladding sheet 100 is configured to be joined with a like cladding sheet 100', wherein the joint 110 between the cladding sheets is adjacent the at least one groove 102 of cladding sheet 100. In preferred embodiments, the joint 110 is formed via pop riveting, although other suitable means of fastening the two sheets 100, 100' together may additionally or alternatively be utilized.

It will be appreciated that where a plurality of cladding sheets 100 are joined to each other, the resulting structure will comprise a plurality of grooves 102 running parallel to each other. That is, the resulting combination will be similar in structure, and may be similar in appearance, to the cladding sheet/eave liner embodiment of Figures 1 to 8. The provision, in this embodiment, of a plurality of cladding sheets to make up the final structure allows for more flexibility when combining the sheets to allow for variation in length and appearance of the final structure.

Specifically, the joint 110 between the cladding sheets 100, 100' may be such that the second edge 108' of the second/further cladding sheet 100' is between the groove 102 and the first edge 106 of the first/underlying cladding sheet 100, as illustrated in Figure 12. Multiple grooves 102, 102' will therefore be visible in the resulting structure, similar to the embodiment of Figures 1 to 8.

In another embodiment, the joint 110 between the cladding sheets 100, 100' is such that the second edge 108' of the second/further cladding sheet 100' is between the groove 102 and the second edge 108 of the first/underlying cladding sheet 100, as illustrated in Figure 13. This results in an overlapped finish, and a shorter overall length.

The cladding sheets may be joined at one or both sides adjacent the groove 102 of the underlying cladding sheet 100.

In a third embodiment, the joint 110 between the cladding sheets 100, 100' is such that the second edge 108' of the second/further cladding sheet 100' lies along the groove 102 of the first/underlying cladding sheet. In the example where the second edge 108' abuts the edge 114 of the 102, a flush finish is provided, as illustrated in Figures 11 and 16.

The cladding sheet 100 is manufactured of a suitably durable, weather resistant material such as a metallic alloy or a plastics material. In one example, the alloy is a steel, such as sold under the trade name COLORBOND®. Alternative metallic alloys, such as zinc aluminum, may be used. In addition to lining eaves, it is envisaged that the cladding sheet 100 could also be used to line other building structures, such as walls and ceilings. The cladding sheet 100 could also be used to line a roof of the building.

In one example, the cladding sheets 100 are used in an eave lining system.

The system comprises a plurality of cladding sheets joined together widthwise to line the width 118 of the eave and a plurality of cladding sheets joined together lengthwise to line the length of the eave.

The present disclosure also relates to a method of lining along a width 118 of an eave using a plurality of cladding sheets, the method comprising: a) fastening a first/underlying cladding sheet 100 to a supporting structure 112 of the eave at a base portion 103 of the at least one groove 102; b) joining a second/further cladding sheet 100' to the first cladding sheet 100 along the width 118 of the eave, such that the second/further cladding sheet overlaps the first edge 106 of the first/underlying cladding sheet, with the second edge 108' of the second/further cladding sheet at or adjacent the at least one groove 102 of the first/underlying cladding sheet; and c) repeating step (b) with further cladding sheets as necessary to line the entire width 118 of the eave. The method may further comprise installing a flashing at the intersection between the cladding sheet and the wall of the building.

In addition to lining the width of the eave, a plurality of cladding sheets may be joined lengthwise to line the length of the eave. Similarly to the embodiment described above in relation Figure 8, the grooves 102 of the adjacent cladding sheets may be aligned with each other/nest within each other when installed, with at least the underlying cladding sheets fastened to the supporting structure of the building at the base of the groove 102. Accordingly, embodiments of this system and method likewise eliminate the need for separate "joining strips" or "joining trims". By overlapping the grooves 102 of the underlying sheets when joining them lengthwise, the sheets may be securely and easily installed to provide a clean finish.

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above described exemplary embodiments.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavor to which this specification relates.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims (31)

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A cladding sheet comprising: a profile defining at least one groove extending along a length of the cladding sheet.

2. The cladding sheet of claim 1, wherein the cladding sheet is configured to be fastened to a supporting structure of a building at a base portion of the least one groove.

3. The cladding sheet of claim 1 or 2, comprising: a first edge extending along the length of the cladding sheet; and a second edge opposite said first edge and extending along the length of the cladding sheet, wherein the at least one groove extends parallel to and adjacent the first edge.

4. The cladding sheet of any one of the preceding claims, configured to be joined with a like cladding sheet, wherein the joint between the cladding sheets is adjacent said at least one groove of said cladding sheet.

5. The cladding sheet of any one of the preceding claims, used to line an eave, a wall, a ceiling, or roof of the building.

6. An eave lining system comprising: a plurality of cladding sheets according to any one of the preceding claims joined together widthwise to line a width of an eave; and a plurality of cladding sheets according to any one of the preceding claims, joined together lengthwise to line a length of the eave.

7. A method of lining along a width of an eave using a plurality of cladding sheets according to any one of claims 1 to 5, comprising: a) fastening a first/underlying cladding sheet to a supporting structure of the eave at a base portion of the at least one groove; b) joining a second/further cladding sheet to the first cladding sheet along the width of the eave, such that the second/further cladding sheet overlaps the first edge of the first/underlying cladding sheet, with the second edge of the second/further cladding sheet at or adjacent the at least one groove of the first/underlying cladding sheet; and c) repeating step (b) as necessary to line the entire width of the eave.

8. The method of claim 7, wherein the joint between the second/further cladding sheet and the first/underlying cladding sheet is such that the second edge of the second/further cladding sheet is: a) between the groove and the first edge of the first/underlying cladding sheet, b) between the groove and the second edge of the first/underlying cladding sheet, or c) along the groove of the first/underlying cladding sheet.

9. The cladding sheet of any one of claims 1 to 5 comprising: a plurality of grooves, each groove extending along the length of the cladding sheet, wherein the cladding sheet is configured to be fastened to a supporting structure of a building at a base portion of at least one groove.

10. The cladding sheet of claim 9, wherein the base portion of the at least one groove is provided with an aperture for receiving a fastener.

11. The cladding sheet of claim 10, wherein the fastener is a screw.

12. The cladding sheet of any one of claims 1 to 5 and 9 to 11, manufactured of a metallic alloy.

13. The cladding sheet of any one of claims 1 to 5 and 9 to 12, wherein at least one surface of the sheet is finished with a protective paint or coating.

14. The cladding sheet of claim 9 or any one of claims 10 to 13 where appended to claim 9, wherein the profile is corrugated.

15. An eave lining system comprising: a plurality of cladding sheets according to claim 9 or any one of claims 10 to 14 where appended to claim 9, wherein adjacent cladding sheets are joined together by overlapping a portion of the adjacent cladding sheets.

16. The eave lining system of claim 6 or 15, further comprising a flashing.

17. A method of lining an eave of a building comprising: providing at least two cladding sheets, each sheet in accordance with claim 9 or any one of claims 10 to 14 where appended to claim 9, attaching the first/underlying cladding sheet to a supporting structure of the eave by fastening via the base portion of the at least one groove of the first/underlying eave lining sheet, positioning the second/further cladding sheet adjacent the first/underlying cladding sheet such that a portion of the second/further cladding sheet overlaps with a portion of the first/underlying cladding sheet, and attaching the second/further cladding sheet to the supporting structure by fastening via the base portion of the at least one groove of the second cladding sheet.

18. The method of claim 17, wherein the width of each of the first and second/further cladding sheets is sufficient to line the entire width of the eave, and wherein the first and second/further cladding sheets are positioned adjacent each other to line the entire length of the eave.

19. The method of claim 17 or 18, wherein the grooves of the adjacent cladding sheets are aligned with each other.

20. The method of any one of claims 7, 8, 17, 18 or 19, further comprising attaching a flashing at an intersection between a cladding sheet and a wall of the building.

21. An eave lining sheet comprising: a profile defined by a series of parallel grooves provided along a length of the eave lining sheet, wherein the eave lining sheet is configured to be fastened to a supporting structure of a building at a base portion of at least one groove.

22. The eave lining sheet of claim 21, wherein the base portion of the at least one groove is provided with an aperture for receiving a fastener.

23. The eave lining sheet of claim 22, wherein the fastener is a screw.

24. The eave lining sheet of any one of claims 21 to 23, manufactured of a metallic alloy.

25. The eave lining sheet of any one of claims 21 to 24, wherein at least one surface of the sheet is finished with a protective paint or coating.

26. The eave lining sheet of any one of claims 21 to 25, wherein the profile is corrugated.

27. An eave lining system comprising: a plurality of eave lining sheets according to any one of claims 21 to 26.

28. The eave lining system of claim 27, wherein adjacent eave lining sheets are joined together by overlapping a portion of each eave lining sheet.

29. The eave lining system of claim 27 or 28, further comprising a flashing.

30. A method of lining an eave of a building comprising: providing at least two eave lining sheets, each sheet in accordance with any one of claims 21 to 26, attaching the first eave lining sheet to a supporting structure of the eave by fastening via the base portion of the at least one groove of the first eave lining sheet, positioning the second eave lining sheet such that a portion thereof overlaps with a portion of the first eave lining sheet, and attaching the second eave lining sheet to the supporting structure by fastening via the base portion of the at least one groove of the second eave lining sheet.

31. The method of claim 30, further comprising attaching a flashing at an intersection between the first and/or second eave lining sheet and a wall of the building.