Technical Field

This invention broadly relates to a claddin assembly or wall. Background he.Inyentio-H

It is desirable in the building industty to provide cladding adjacent to a building substrate such as a stud frame or a masonry wall Existing cladding systems have one or more of the following disadvantages:

1) lack integrity and strength'

2) lack flexibility, particularly if disassembly is required;

3) unsatisfactory noise insulation;

4) susceptible to conducting heat into the interior of the building; and

5) heavy in weight and hence cumbersome and difficult to handle

Apart from the above, many concrete and brick retaining wall absorb moisture which subsequently seeps through resulting in degradation of external stone appearance. This is common even with expensive waterproofing facility in conventional masonry retaining walls.

It is an object of the present invention to provide a cladding assembly which is capable of overcoming or ameliorating the above disadvantages or which will at least provide a useful alternative.

Summary of the Invention

According to a first aspect of the present invention there is provided a cladding assembly including:

a pluralit of connecting means; each connecting means having a first member adapted to be affixed to a frame or an exterior of a building, and a second member configured to engage one or more cladding means; and

one or more interlocking means, the or each interlocking means having a anchoring portion and an engaging portion adapted in use to interlock with the or each cladding means.

Preferably, each connecting means is in the form of an elongate rail. Optionally, each connecting means is in the form of a discrete bracket.

The first and second members are preferred t be orthogonal to each other, in a preferred embodiment the first member is the form of a back plate adapted to be affixed to the frame or exterior of the building. Typically, the frame includes studs to which the back plate is affixed by fastening means. Alternatively, the exterior of the building may ^¬ be a masonry wall In this case, the cladding assembly are preferred to include uprights adapted to be affixed to the masonr wall Each upright is preferred to be in the form of an H-shaped batten with a pair side plates. Each side plate has a plurality of L-shaped indents. The L-shaped indents are spaced apart and adapted to engage the back plate so as to support the elongate rail it is preferred that the second member is in the form of a base plate with one or more slots. When there are multiple slots, the slots are equally spaced apart. More preferably, the base plate includes one or more apertures so configured as to allow moisture to escape. The apertures are preferred to be in the form of weep/holes.

In a preferred embodiment, each cladding means takes the form of a block having a groove which runs along at least its top and bottom surfaces, Each block is preferably made of insulating material combined with a natural stone facade.

The interlocking means is preferred to be in the form of a comb having an elongate body and a plurality of prongs extending from the body in one direction. Preferably, each prong is capable of passing through the slot provided in the base p!ate and subsequently being received in the groove provided in either the top or bottom surface of the block. Optionally _. , the binding comb includes a flange from the bod extending in another direction. The flange is preferred t have a thickness substantially identical to that of the base plate of the connecting means .

According to a second aspect of the present invention there is provided an interlocking means for use in a cladding assembly, the interlocking means including:

an elongate body configured in use to engage a groove of one or more cladding means; and

plurality of prongs extending from the body in one direction, each prong being adapted in use to pass through a slot provided in a member of a connecting mean and subsequentl being received in a groove provided in another element. The other element may be another claddin means, a concrete footing or building slab.

Preferably, the interlocking means has a pair of flanges extending from the body in another direction, each of the flanges having a thickness substantially identical to that of the member of the connecting means.

According to a third aspect of the present invention there is provided a connecting means for use in a cladding system, the connecting means including:

a first member adapted to be affixed to a frame or an exterior of a building; and a second member configured to engage one or more cladding means;

wherein the second member includes one or more slots, each or the slot being configured to receive a prong of an interlocking means adapted to secure the connecting means to the one or more cladding means.

According to a fourth aspect of the present invention there is provided a cladding or wall assembly including:

a first cladding means having a first groove and a second cladding means having a second groove, the first and second cladding means being spaced apart;

a spacer having first and second engaging means which are adapted to correspond to the first and second grooves respectively; wherein the space includes an element adapted to facilitate filling of the space between the first and second cladding means.

Preferably, the assembly includes a pair of rails adapted t secure the first and second cladding means to a surface, respectively. Each rail is preferred to be T-shaped with a base member adapted to be affixed to a suiface and a vertical member adapted to engage a groove provided on an underside of the first or second cladding means.

Preferably, the element is flanked by the first and second engaging means. The first and second engaging means are in the form of flanges orientated perpendicularly to the element. In use, the flanges are received in the first and second grooves, respectively.

Optionally, each of the first and second engaging means is in the form of a series of slots running along the edge of the element. In this embodiment, the assembly includes one or more interlocking means adapted to secure the spacer to the cladding means. Each interlocking means is preferred to be in the form of a comb having an elongate body and a plurality of prongs extending from the body in one direction. Preferably, each pron is capable of passing through one of the slots provided i the element and subsequently received in the groove provided in the cladding means.

In a preferred embodiment, the element includes one or more orifices adapted to facilitate filling of the space between the first and second cladding means.

According to fifth aspect of the present invention there is provi ded a method of building a cladding, the method including the steps of:

(i) providing a connecting means which has a first member and a second member;

(ii) providing an interlocking means which has an anchoring portion and an engaging portion;

(iii) affixing the first member to a frame or exterior of a building; (iv) engaging the anchoring portion of the interlocking means with the second member of the connectin means and subsequently a surface on which the cladding is to be built;

(v) placing a cladding means on top of the second member of the connecting means such that the engaging portion of the interlocking means interlocks with a cladding means;

(vi) providing a further connecting means on top of the previous cladding means;

(vii) affixing the first member of the further connecting means to the frame or exterior of the building;

(viii) engaging the anchoring portion of a further interlocking means with the second member of the further connecting means and subsequently the top of previous cladding means;

(ix) placing a further cladding means on top of the second member of the further connecting means such that the engaging portion of the further interlocking means interlocks with the further cladding means;

(x) repeating steps (vi) to (ix) until the cladding reaches a desired height.

Accordin to a sixth aspect of the present invention there is provided a method of constructing a cladding or wall, the method including the steps of;

(i) providing a first cladding means having a first groove and a second cladding means having a second groove in a spaced apart manner;

(ii) placing a spacer having first and second engaging means on top of the cladding means, the first and second engaging means corresponding to the first and second grooves respectively;

(iii) filling of the space between the first and second cladding means through an element provided in the spacer. Preferably the method includes a further step of providing a pair of rails adapted to secure the first and second cladding means to a surface on which the cladding or wall is to be constructed, respectively.

If: should be noted that the steps in the above described methods need not be carried out in any specific order.

Brief Description of the Dra wings

The invention may be better understood from the following non-limiting description of preferred embodiment, in which:

Figure 1 is a perspective view of an elongate rail being a component of the cladding assembly in accordance with the present invention;

Figure 2A is a side view of a comb being a component of the -cladding assembly; Figure 2B is an end view of the comb of Figure 2A;

Figure 3 is a perspective view of an insulation block being a component of the claddin assembly;

Figure 4 is a perspective view of a bracket being a component of the claddmg assembly;

Figure 5A is a perspective view another embodiment of a comb being a component of the cladding assembly;

Figure 5B is an end view of the comb of Figure 5A;

Figures 6A to H illustrates the steps and procedure involved in constructing the claddmg assembly of the present invention onto a stud frame using an elongate rail and multiple brackets;

Figures 7A to H illustrates the steps and procedure involved in constructing the cladding assembl of the present invention onto a stud frame using only elongate rails; .Figures 8 A to H illustrates the steps and procedure involved in constructing the cladding assembly of the present invention onto a masonry wall using elongate rails;

Figure 9 is a perspective view of a batten being a component of the cladding assembly;

Figure 1 OA to H illustrates the steps and procedure involved in constructing a cladding or wall assembly in accordance with the present invention having the insulation blocks and combs as components;

Figure 1 1 is a perspective view of one embodiment of a spacer as a component of the cladding or wall assembly of Figures I OA to H;

Figure 12 is a perspective view of anotlier embodiment of a spacer as a component of the cladding or wall assembly of Figures 1 OA to H.

Detailed Description of the Drawings

Referring to Figure 1. a cladding assembly 10 (see Figure 10) has a plurality of connecting means in the form of an elongate rail 12. The elongate rail 12 has a first member in the form of a back plate 14 and a second member in the form of a base plate 16. The back and base plates 14 <& 16 are orthogonal to each ther. The back plate 14 has holes 18 & 20 which are provided to receive fastening means such as bolts or rivets (not shown) for affixing the rail 12 to a frame or an exterior of a building (not shown).

As shown in Figure 1 , the base plate 16 is provided to engage and support one or more cladding means. The base plate 16 has a plurality of slots 22 which are equally spaced apart. The base plate 16 also has a plurality of apertures 24 located along its rear end. The apertures 24 are in the form of weepholcs so as to allow moisture to escape.

Referring to Figures 2A & 2B, the cladding assembly also consists of a plurality of interlocking means in the form of a comb 26 which has an engaging portion in the form of an elongate body 28 and an anchoring portion in the form of multiple prongs 30 extending from the body 28 downwardly, in use, each prong 30 passes through one of the slots 22 provided in the base plate 16 and is subsequently received in a groove (see Figure 3) provided in either the top of bottom surface of a cladding means which takes the form of a block 46, whereas the elongate body 28 interlocks with one or more cladding means placed thereupon.

Referring to Figure 3, each groove 36 runs along the top surface 38. bottom surface 40 and vertical end surfaces 42 & 44. Each block 46 is made of insulating material 48 combined with a natural stone facade 50.

Turning to Figure 4, in another embodiment, the connecting means is in the form of a discrete bracket 52. The discrete bracket 52 also has a first member in the form of a hack plate 54 and a second member in the form of a base plate 56. The back and base plates 54 & 56 are orthogonal to each other. The back plate 54 has holes 58 which are provided to receive fastening means such as bolts or rivets (hot shown) for affixing the bracket 52 to a frame or an exterior of a building (not shown).

As shown in Figure 4, the base plate 56 is provided to engage and support one cladding means. In contrast to the elongate rail 12, the base plate 56 of the bracket 52 has one slot. 22.

Turning to Figures 5A & 5B, another embodiment of the comb 32 may be used in combination with the bracket 52. The comb 32 includes a pair of flanges 34 which extend sideway from the body 28. Each flange 34 has a thickness substantially identical to that of the base plate 56 of the bracket 52. As such, the comb 32 may be used to take up the space between the underside of a block tha sits on top of another providing further support for the blocks in between brackets.

Referring to Figures 6A to H, the cladding assembly 10A is to be built onto a frame 60 including studs 62 to which the back plate 1.4 is affixed by fastening means, The method starts with the step of securing a first elongate rail 12 to the studs 62. The prongs 30 of the comb 26 is then, provided to pass through the slots 22 provided in the base plate 16 of the elongate rail 12 and subsequently received in a groove (not shown) provided in a concrete substrate on which the cladding is to be built, A. block 46 of insulating material is then placed on top of the base plate 16 of the elongate rail 12 such that the elongate body 28 which stands proud is received within a groove 36 provided on the undersid of the block 46 thereby securing the block 46 in position with respect to the stud frame. Brackets 52 are then placed on top of the block 46 and secured to the stud 62. The base plate of each bracket 52 is rested on the top surface of the block 46 such that one or more combs 32 (each with flanges 34) can be installed to secure the brackets 52 with the block 46. A further block 64 with a groove in the underside is then landed on top of the first block 46 such that the elongate bod 28 is received in the groove thereby achieving interlocking of the block 64 to the first block 46. Further brackets 52, blocks 64 and comb 32 are provided to facilitate building of a claddin of desired dimension,

Turning to .Figures 7A to H, similar steps to those described above may be earned out to build a cladding, except that continuous elongate rails 66 are used instead of discrete brackets 52,

Referring to Figures 8 A to H, the cladding assembly 10 is to be built onto a masonry wall. Generally, the steps involved are identical to those shown in Figures 7A to FT. However, by nature, masonry walls quite typically have an uneven surface, in this case, uprights in the form of fixing battens may be affixed to masonry walls so as to provide a level surface framework on for example a large multi-storey building. The elongate rails 3 are then mounted onto these battens. Referring to in Figure 9, each upright is in the form of an Fshaped batten 70 with a pair side plates 72, Each side plate 72 has a number of pairs of L-shaped indents 74. The L-shaped indents 74 equally are spaced apart. As shown in Figure 9, the back plate 14 of elongate rail 12 is tucked into the indents 74 having returns 76 preventing the elongate rail 12 from detaching.

The blocks 64 described above can also be used as components to form a stand-alone claddin or wall assembly 78. Referring to Figures 10A to H, such a cladding or wall assembly 78 consists of two spaced apart blocks 46, each of which has groove 36 which runs along its top, bottom and side surfaces. As best shown in Figures 10A and B, the assembly 78 has a pair of rails 80 configured to secure the blocks 46 to a concrete slab 82, respectively. Each rail 80 is T-shaped with a base member 84 which is affixed to the concrete slab 82 and a vertical member 86 which engages a groove 88 provided o an underside of each of the blocks 46. As shown in Figures IOC to H _s a spacer 90 A is provided with first and second engaging means which are configured to correspond to the grooves 94, respectively.

Referring to Figure 1 1, the spacer 90 A is shown having an. element 96 flanked by the first and second engaging means in the form of flanges 92 being orientated perpendicularly to the element 96. In use, the flanges 92 are received in the two grooves 94, respectively, thereby binding the blocks 46 together. As shown in Figure 11 , the element 96 has four orifices 98 which facilitate filling of cement core into the space between the blocks 46. Once cured, the cement locks everything together creating the strength required for a structural cavity wall or fence or retaining wall

Turning back to Figures 10A to H, the steps involved in building the cladding or wall assembly 78 are shown. It should be noted that further blocks 100 are installed adjacent to blocks 46 in a similar manner. Furthemiore, additional blocks 102 are placed on top of both blocks 4 and 100 using combs 26 for alignment and interlocking purposes,

Referrin to Figure 12, another embodiment of the spacer 90B is shown. The spacer 90B is provided in a roll 104 which can be fragmented to suit blocks of different lengths. In this embodiment, the first and second engaging means are in the form of a series of slots 106 running along the edges 108 & 1 10 of the element 1 12. Interlocking means in the form of combs 26 are used to secure the spacer 90B to blocks 46 by way of engagement of the prongs 30 and grooves 94.

Referring to Figure I OH, it is contemplated that the assembly 78 could be completed with insulation board on the inside facing thereby reducing the building costs, as external aesthetic materials would not be required. This also provides a completely waterproof seal . It should also be noted that the wall assembly 78 may be utilised to form a load bearing wall or a fence. As a load bearing wall for home and building constructions, the insulation board can be used on internal walls with common render/plaster or dr wall fixed directly after the power and water services have been installed and connected. The completed assembly would be core fi lled with concrete creating a load bearing structure. Whereas when used to form a non-structural fence, the assembl 78 may be accomplished without core filling with concrete which makes construction very quick, easy and clean. The simplicity of a fence with such a construction would be well within the capabilities of most DIY people.

Industrial Applicability

Now that preferred embodiments of the present invention has been described in some detail, it will be apparent to a skilled person in the art that the cladding or wall assembly of the present invention has industrial applicability in that it may offer at least the following advantages;

1. it provides insulation in the outside on the building substrate resulting in much better heat and noise insulation, performance;

2. it is versatile in relation to assembly and disassembly if required;

3. it facilitates alignment in a simple fashion;

4. it is simple and easy to install; and

5. it is applicable to buildings with a stud frame or masonry walls.

Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. All such variations and modifications are to be considered within the scope and spirit of the present invention the nature of which is to be determined from the foregoing description.