Technical Field

[0001] The present application relates to a cladding system, in particular for use in building facade cladding or ceiling or wall lining. Other applications of the cladding system include boats and ships, caravans, motor homes and modular displays. The invention also relates to a method of installing a cladding system.

Background

[0002] Building cladding typically consists of a number of flat rectangular or square panels of material that are fitted to a supporting structure attached to a building facade in order to present an aesthetically pleasing appearance to the exterior of the building. Typically, the underlying support structure or framework is firstly attached to the building facade using screws or other fastening means. The cladding panels are then individually attached to the support structure using high bond double sided tape and/or mechanical fixings.

[0003] One of the most popular types of cladding panel available to the building industry is an aluminium composite cladding panel that consists of an aluminium skin sandwiching a core of non-aluminium material. Aluminium composite cladding panels come in various forms. One of the most popular types of aluminium composite cladding panel used in Australia and overseas has a 100% polyethylene (PE) core, which is extremely flammable. It is estimated that many thousands of buildings in Australia alone are clad with this type of panel. Many other buildings are clad with aluminium panels having a fire resistant (FR) core that still contains approximately 30% PE. However, the PE in the core is still combustible. High rise building fires at the Lacrosse residential building in Melbourne, 2012 and the Grenfell Tower residential building fire in London, 2017 have highlighted the dangers of using combustible cladding panels on medium and high rise buildings in particular. The investigations into those fires found that PE cladding on the exterior of the building was as a major factor in the speed at which the fires spread from one floor of the building to other floors of the building. PE cladding has been widely used as building cladding in Australia, in part because it is lightweight, durable and relatively economical, although labour intensive to install on site. However, in the wake of these and other fires, there is a renewed impetus to remove existing combustible cladding from buildings and to replace it with non-combustible cladding. In addition, there is a desire that new high and medium rise buildings should also be clad in a non- combustible cladding. As such, there is a need for a cladding system that is non- combustible, easy to assemble and install and which can produce an aesthetic surface finish.

[0004] It is an object of the invention to provide a cladding system and method of installation that meets one or more of these needs at least to an extent or which provides a useful alternative to existing cladding systems.

[0005] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each of the appended claims.

Summary

[0006] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0007] The cladding system disclosed herein includes a modular set of panels and profile carriers that can be quickly and easily connected together to provide both a supporting structure and interchangeable exterior appearance in a single cladding system. The panels and profile carriers are connectable together with a snap fit pivoting connection that allows the cladding system to be installed on both a flat surface or on a gently curved surface. Profiles of different aesthetic appearance can be connected to the profile carriers to create different exterior appearances. In some embodiments, the profiles can be later disconnected from the profile carriers and replaced with profiles of a different shape to alter the exterior appearance of the cladding.

[0008] According to a first aspect, there is provided a cladding system for use on a building facade, ceiling or the like, comprising: a first profile carrier and a second profile carrier, each of the first profile carrier and the second profile carrier having a first end, a second end and a central profile portion, and being adapted for attachment to a substrate, the central profile portion having a first end and a second end, wherein either the first end and the second end of the central profile portion of each of the first profile carrier and the second profile carrier or the first end and the second end of each of the first profile carrier and the second profile carrier includes a first part of a two- part pivoting connector; and an insert panel adapted at a first attachment portion thereof for removable attachment to the second end of the central profile portion of the first profile carrier or the second end of the profile carrier and adapted at a second attachment portion thereof for removable attachment to the first end of the central profile portion of the second profile carrier or the first end of the profile carrier, wherein each of the first attachment portion and the second attachment portion of the insert panel includes a second part of the two-part pivoting connector.

[0009] The cladding system is modular and as such is easily assembled together to create a cladding for a building facade or the ceiling or wall of a room, for example. The pivoting connection between the first and second profile carriers and the insert panel allows the cladding system to be installed on both a flat surface and a curved surface, presenting a substantially continuous curved appearance over a curved surface rather than a faceted appearance as would typically be the case where individual panels are used.

[0010] In embodiments, upon connection of the first part of the two-part pivoting connector to the second part of the two-part pivoting connector, the insert panel is permitted to pivotably move relative to the first profile carrier and the second profile carrier. In embodiments, the first profile carrier and the second profile carrier are each attachable to a single substrate that is adapted for attachment to a building facade. In embodiments, the central profile portion is a central profile carrying portion. The central profile carrying portion may be adapted for carrying a separate and/or integral cladding profile member thereon.

[0011] In an embodiment, the first part of the two-part pivoting connector comprises one of a bead and a socket and the second part of the two-part pivoting connector comprises the other of the bead and the socket. In embodiments, the first part of the two-part pivoting connector includes the socket and the second part of the two-part pivoting connector includes the bead, wherein the bead, which is some embodiments is a cylindrical bead, is securable within the socket with a snap-in connection.

[0012] In an embodiment, the bead is arranged to protrude from each of the first attachment portion and the second attachment portion of the insert panel, and the socket of each of the first profile carrier and the second profile carrier includes a cam surface for receiving the bead as it enters the socket during installation of the cladding system. In this manner, the bead can be guided over the cam surface into the socket where it snaps into a secured position.

[0013] In an embodiment, the first part of the two-part pivoting connector further comprises a stop portion for limiting pivoting movement of the insert panel relative thereto. The stop portion ensures that the insert panel cannot be pivoted beyond a certain angle relative to the first and second profile carriers when the cladding system is installed on a curved surface. In an embodiment, the second part of the pivoting connector includes an abutment portion adapted for abutting contact with the stop portion of the first part of the pivoting connector.

[0014] The first end and the second end of each of the first profile carrier and the second profile carrier may each include an outer supporting flange adapted for secure attachment to a corresponding supporting flange of the insert panel. In an embodiment, the first profile carrier and the second profile carrier each includes a substrate contacting portion and a bridging portion disposed between and connecting the substrate contacting portion and the central profile portion, wherein a junction between the bridging portion and the substrate contacting portion is flexible. The flexible junction between the bridging portion and the substrate contacting portion allows the substrate contacting portion to remain flat against the substrate whilst allowing the supporting flange members of the insert panel and the profile carriers to absorb slight movement due to e.g. wind loading of the cladding system once installed.

[0015] In an embodiment, the insert panel has an externally facing surface relative to the substrate and an internally facing surface relative to the substrate that is opposite the externally facing surface, wherein the respective corresponding flange of the insert panel is disposed on the internally facing surface thereof for secure attachment to the supporting flange of the respective one of the first profile carrier and the second profile carrier.

[0016] In embodiments, the externally facing surface of the insert panel is

substantially flat. In one embodiment, the central profile portion of each of the first profile carrier and the second profile carrier has a substantially flat externally facing surface. In another embodiment, the central profile portion of each of the first profile carrier and of the second profile carrier has a three-dimensional externally facing profile surface. In a further embodiment, the cladding system includes a profile member that is removably attachable to at least one of the first profile carrier and the second profile carrier, the profile member having an externally facing profile surface that may be either substantially flat or it may be three dimensional. In embodiments, the profile member is removably attachable to the first profile carrier and/or the second profile carrier with a snap fit. The modular system therefore allows for a profile of the externally facing surface of the cladding profile carriers to be integrally formed with the carrier, or it can be attached as a separate component that can be later removed and changed if so desired. In either case, a variety of different external surface appearances are envisaged that can provide significantly different external appearances of the cladding as desired or as appropriate for a particular application of the cladding. For example, a building facade cladding may require the externally facing surface to have a striking three dimensional appearance, whereas a ceiling cladding may require a more discrete, substantially flat externally facing surface to match that of the insert panel. The cladding can be easily disassembled if desired, for example to alter the appearance of the cladding, without dismantling the entire cladding system.

[0017] In embodiments, the first profile carrier, the second profile carrier, insert panel and, where used, the integral or separate profile member, are manufactured from aluminium, which may be anodized. Aluminium is a completely non-combustible material that meets Australian and other fire safety guidelines for use in buildings. Aluminium can present a refined appearance and when anodized is sufficiently weatherproof for use on the outer facade of a building in a coastal environment, which makes it ideal for use as a fire-safe cladding material in coastal buildings.

[0018] In embodiments, the cladding system includes a substrate that is adapted for attachment to a building structure, the substrate further being adapted for attachment to the substrate contacting portions of each of the first profile carrier and the second profile carrier.

[0019] According to a second aspect, a method of installing a cladding system according to the first aspect comprises: a) securing the substrate to a building structure; b) securing the first profile carrier and the second profile carrier to the substrate in spaced relation with one another; c) inserting the bead of a first attachment portion of the insert panel into a socket of the first profile carrier; and d) inserting the bead of a second attachment portion of the insert panel into a socket of the second profile carrier. [0020] The method may further comprise, after step d): e) attaching a profile member to an externally facing surface of at least one of the first profile carrier and the second profile carrier.

[0021] The method may further comprise, after any one of step b) or c) or d): f) connecting male and female portions of a two-part insert panel together.

[0022] According to a third aspect, a method of installing cladding comprises installing the cladding system in accordance with the fourth aspect, repeating steps a) to d) and, optionally, step e) and/or step f) such that at least one further cladding system is secured to the substrate in spaced relation with the first cladding system and further inserting a further insert panel between the cladding system and the at least one further cladding system.

Brief Description of Drawings

[0023] One or more embodiments of the invention will now be described by way of specific example(s) with reference to the accompanying drawings, in which:

[0024] Figure 1 shows a cross-sectional view of components of a first embodiment of a cladding system in accordance with the invention;

[0025] Figure 2a is a cross- sectional view of a first or second profile carrier of the cladding system;

[0026] Figure 2b is a perspective view of the first or second profile carrier of Figure 2a;

[0027] Figure 3a is a cross- sectional view of a first embodiment of an insert panel of the cladding system; [0028] Figure 3b is a perspective view of the insert panel of Figure 3a;

[0029] Figure 3c is a cross- sectional view of a second embodiment of an insert panel of the cladding system;

[0030] Figure 3d is a perspective view of the insert panel of Figure 3c;

[0031] Figure 4a is a cross-sectional view of a first embodiment of a profile member;

[0032] Figure 4b is a perspective view of the profile member of Figure 4a;

[0033] Figure. 5a is a cross-sectional view of a first embodiment of an integral profile carrier; having a 3-D profile;

[0034] Figure 5b is a perspective view of the integral profile carrier of Figure 5a;

[0035] Figure. 6a is a cross-sectional view of a second embodiment of an integral profile carrier; having a flat profile;

[0036] Figure 6b is a perspective view of the integral profile carrier of Figure 6a;

[0037] Fig. 7a is a cross-sectional view of a substrate or rail of the cladding system;

[0038] Figure 7b is a perspective view of a rail of the cladding system;

[0039] Figure 7c is a cross-sectional view of a part rail (a) used at the top of a cladding installation;

[0040] Figure 7d is a cross-sectional view of a part rail (b) used at the base of a cladding installation;

[0041] Figure 8a is a side view of a first embodiment of a fastener for use with the cladding system; [0042] Figure 8b is a front elevation view of the fastener of Figure 8 a;

[0043] Figure 8c is a rear elevation view of the fastener of Figure 8a;

[0044] Figure 8d is a perspective view of the fastener of Figure 8a;

[0045] Figure 9a is a side view of a second embodiment of a fastener for use with the cladding system;

[0046] Figure 9b is a front elevation view of the fastener of Figure 9a;

[0047] Figure 9c is a rear elevation view of the fastener of Figure 9a;

[0048] Figure 9d is a perspective view of the fastener of Figure 9a;

[0049] Figures 10a- lOh is an illustration of the installation of an embodiment of the cladding system;

[0050] Figure 1 la is a sectional view of a portion of two profile carriers attached to a rail;

[0051] Figure 1 lb is a sectional view of the profile carriers and rail of Figure 11a;

[0052] Figure 1 lc is an elevational view of the rail of Figure 11a;

[0053] Figure 12a is a cross-sectional view of profile members being aligned with first and second profile carriers;

[0054] Figure 12b is a cross-sectional view of an insert panel being installed between first and second profile carriers;

[0055] Figure 13a is a cross-sectional view of integral profile carriers being aligned with a rail; [0056] Figure 13b is a cross-sectional view of an insert panel being installed between first and second integral profile carriers;

[0057] Fig. 14a- 14d is an enlarged view of the connection of the two-part pivoting connector of the insert panel and profile carrier;

[0058] Fig. 15a-15c is an elevation view, side view and perspective view of a spring clip for use with the cladding system;

[0059] Figure 16 is an elevation view and perspective view of endplates for use with the cladding system;

[0060] Figure 17 is a cross- sectional view of the components of the first embodiment of a cladding system installed on a curved facade; and

[0061] Figure 18a is a sectional view of a plurality of profile members installed on a rail;

[0062] Figure 18b is an elevational view of the rail of Figure 18a;

[0063] Figure 19a is a cross-sectional view of a female portion of a third embodiment of an insert panel of the cladding system;

[0064] Figure 19b is a perspective view of the insert panel of Figure 19a;

[0065] Figure 19c is a cross-sectional view of a male portion of the third embodiment of an insert panel of the cladding system;

[0066] Figure 19d is a perspective view of the insert panel of Figure 19c;

[0067] Figure 19e is a cross-sectional view of a complete third embodiment of the insert panel according to the third embodiment; [0068] Figure 19f is a perspective view of the complete insert panel of Figure 19e;

[0069] Figure 20a is a cross-sectional view of an insert panel according to the third embodiment attached to first and second integral profile carriers according to a second embodiment thereof, installed on a flat facade;

[0070] Figure 20b is a cross sectional view of the insert panel and first and second integral profile carriers of Figure 20a, installed on a curved facade; and

[0071] Figure 21 is a cross-sectional view of the cladding system components of Figure 20a installed on a flat facade and illustrating a corner adaptation of the insert panel.

Description of Embodiments

[0072] Figure 1 shows a sectional view of a first embodiment of a cladding system 1. The cladding system includes a first profile carrier 10, a second profile carrier 30 and an insert panel 50. The cladding system also includes a profile member 70 attached to each of the first cladding profile member 10 and the second cladding profile member 30, and a substrate 90, for example a rail 90. The first profile carrier 10, second profile carrier 30, insert panel 50 and profile member 70 are extruded aluminium components having the same length dimension as one another.

First and second profile carriers

[0073] The first profile carrier 10 and the second profile carrier 30 each consist of a thin plate-like aluminium extrusion. The two components are identical and will be described herein primarily with reference to the first cladding profile member 10, best seen in Figures 2a and 2b. The first profile carrier 10 can be of any length appropriate to the cladding application, to a maximum length of about 3.2 metres and has a symmetrical cross-sectional profile, with a central profile portion 12 flanked either side by a generally flat substrate contacting portion 14, 16. The central profile portion 12 of this embodiment is slightly elevated above the substrate contacting portions 14, 16 when shown in the cross-sectional view of Figure 2(a) and is connected to the substrate contacting portions 14, 16 with an angled bridging portion 18, 20. An angle θ subtended between the flat substrate contacting portion 14, 16 and the bridging portion 18, 20 at junction 15 is about 45°. As the first profile carrier 10 is plate-like, the material at the junction 15 between the flat substrate contacting portions 14, 16 and the bridging portions 18, 20 is thin and imparts a degree of flexibility to the junction 15, which assists the use of the cladding system on a curved surface as will be explained later.

[0074] The first profile carrier 10 has a longitudinal axis of symmetry X-X as seen in Figure 2(b), and an externally facing side and an internally facing side relative to a substrate to which it is to be attached. The central profile portion 12 has a first end 21 and a second end 23, at each of which is an insert panel 'snap-in' portion that effectively forms one part of a two-part pivoting connector for connection to the insert panel 50. The insert panel 'snap-in' portion includes a pair of attachment flanges 21, 23 that extend externally away from each end of an external surface of the central profile portion 12 and each of which bears a rounded socket 32, 33 that faces a first end 28 and second end 26 respectively of the first profile carrier 10. Referring to Figure 2(a) and also to Figures 14a-14d, the sockets 32, 33 further extend into a lower cam surface 34, 35 that terminates in a slightly upturned lip 36, 37. The lip 36, 37 functions both as a guide for inserting a second part of the two-part pivoting connector (to be described later) into the socket 32,33 and also serves as a stop to limit pivoting movement of the second part of the pivoting connector relative to the socket 32,33 once the two-parts are assembled together. The socket 32, 33 also includes an upper retaining lip 39, 40 at an upper entrance thereof. The attachment flanges 21, 23 further include a profile member 'snap-in' portion facing inwardly towards the axis of symmetry X-X. The profile member 'snap-in' portion consists of a guide surface 25 and a return 27 that is adapted to receive a corresponding 'snap-in' portion of the profile member 70. [0075] As shown in Figure 2a, the lateral extremities of the substrate contacting portions 14, 16 of the first profile carrier 10 include a right-angled dog-legged portion having a vertical leg 22, 24 and a horizontal outer flange at the first end 28 and the second end 26 of the first profile carrier 10. The substrate contacting portions 14, 16 have a slightly thicker cross-section than the rest of the first profile carrier 10 to provide rigidity to the component. Upper and lower ends of the substrate contacting portions 14, 16 each include a pair of fastener receiving apertures 29 therein for attachment of the cladding profile carrier 10 to the substrate 90 and a v-groove 38 for ease of location of a fastener in the fastener receiving aperture 29. A lower end of each of the substrate contacting portions 14, 16 further includes a clip locating aperture 17, shown in Figure 8a, directly below and spaced from each of the fastener receiving apertures 29.

[0076] The second profile carrier 30 is identical to the first profile carrier 10 and its features will not be repeated here.

Insert panel

[0077] Figure 3(a) shows a cross-sectional view of a first embodiment of an insert panel 50 that is adapted for being removably snapped into place between the first profile carrier 10 and the second profile carrier 30. Figure 3(b) shows a perspective view of the insert panel 50. The insert panel 50 has a thin, generally flat cross-sectional profile that is symmetric about an axis of symmetry Y-Y. An externally facing surface 52 of the insert panel is flat and smooth. An internally facing surface 54 of the insert panel 50 includes attachment portions that enable it to be attached to the first profile carrier 10 and the second profile carrier 30.

[0078] When viewed in cross-section, either side of the axis of symmetry Y-Y is a downwardly depending inverse-T shaped flange 56, 58. A flat portion of the inverse-T- shaped flange has a surface area that is the same as a surface area of the horizontal outer flange 26, 28 of the first profile carrier 10 and the second profile carrier 30 so as to form abutting surfaces that provide support for the insert panel 50 once the cladding system 1 is installed. The clearance between the two abutting surfaces allows for temporary bonding of the snap-in insert panel 50 to facilitate efficiency of the installation. At the lateral extremities of the insert panel 50 are downwardly depending flanges 60, 62 that have at their ends an outwardly protruding attachment portion in the form of a bead, in this example a cylindrical bead 64, 66. In alternative embodiments, the bead may take other forms such as, but not limited to, spherical, part- spherical or part-cylindrical. The cylindrical beads 64, 66 form the second part of the two-part pivoting connector and are sized to snugly snap-fit into the respective socket 32, 33 of the first profile carrier 10 or the second profile carrier 30 as seen in Figure 1.

[0079] Figure 3(c) and Figure 3(d) show a second embodiment of the insert panel 250 that is half the width of the first embodiment of the insert panel 50. The insert panel 250 is used where a narrower link between profile carriers is required. It can also be used at a corner of the building or wall to which the cladding is to be applied to provide an aesthetically pleasing appearance. The insert panel 250 includes the same inverted T-shaped flange 256 for abutting the outer flange 26 or 28 of the first profile carrier 10. In some embodiments of the insert panel 250, one of the downwardly depending portions 60, 62 is removed to leave a flat edge to the insert panel without a pivoting connector. With this embodiment, corresponding flat edges of two of the insert panels 250 can abut one another at a corner of the building facade using an aluminium extruded angle.

Profile member

[0080] Figure 4(a) shows a cross-sectional view of a first embodiment of the profile member 70. Figure 4(b) shows a perspective view of the profile member. The profile member 70 snap fits into the first profile carrier 10 and the second profile carrier 30 to give a three-dimensional aspect to the exterior appearance of the cladding system 1. The profile member 70 generally consists of a carrier attachment portion 72 and a profile portion 74. The profile portion 74 is adapted to present an externally facing profile relative to the profile carriers 10, 30 and can take many different forms. In the present embodiment, the profile portion has a generally elongate protruding 'Eiffel Tower'™ shaped cross-section i.e. generally elongate triangular shape that tapers with a slight curve towards a upper end thereof, with a base of the protruding profile disposed adjacent the carrier attachment portion 72 and a rounded tip of the protruding shaped profile portion 74 extending away from the carrier attachment portion 72. The carrier attachment portion 72 includes a pair of downwardly extending legs 76, 78, that are joined together by a connecting flat bridge portion 80. As viewed in Figure 4(a), the downwardly extending legs 76, 78 each have a clip 82, 84 at an end thereof for snap-in attachment into the return 27 of the attachment flanges 21, 23 (seen in Figure 14(a)) of the first profile carrier 10 and second profile carrier 30 for securing the profile member 70 to the first profile carrier 10 and the second profile carrier 30.

[0081] In this first embodiment of the profile member 70, the interior of the profile member 70 is hollow to minimise the weight of the component. However, when viewed in cross-section as in Figure 4(a), the interior includes an upper fitting 86 and a lower fitting 88 that each include a recessed portion in which can be received a respective end of an elongate stiffener 89, shown in dotted lines in Figure 4(a), to provide extra rigidity to the profile member 70. The stiffener 89 is made of aluminium or other suitable rigid and non-combustible plate material.

[0082] In other embodiments of the profile member 70 that are not illustrated, other three dimensional profiles, for example rectangular, are envisaged for the profile member 70 that are suitable for use on a building facade. Alternatively, the profile of the profile member 70 may constitute a flat surface (not shown in the drawings). In this alternative embodiment, the profile member 70 produces a generally flat exterior appearance to the cladding and can be used to line a ceiling of a room or interior wall as well as to clad a building facade. Alternatively, the flat surface profile member 70 can be used as an intermediary fixing plate for alternative three-dimensional profiles using concealed fixings that are suitable for both the flat profile and alternative profile materials and for the nature of the cladding or lining installation. Integral profile carrier

[0083] In an alternative embodiment of the profile carriers shown in Figure 5a and Figure 5b, the central profile portion 12 of each of the first or second profile carriers 10, 30 has a profile member integrally formed with it. These integral profile carriers 170, 180 can be used in place of the separate profile carrier 10, 30 and profile member 70 components where there is a requirement for a more robust cladding system and is similarly formed from an aluminium extrusion. Figures 5(a) and 5(b) show a first integral profile carrier 170. A second integral profile carrier 180, shown in Figure 18(a), is identical to the first integral profile carrier 170. The following description refers to the first integral profile carrier 170 only for clarity. Each integral profile carrier 170 has a profile portion 174 having the same external profile shape as the profile portion 74 of the profile member 70. However, in this embodiment, the central profile portion consists of a flat bridge portion 182 that is integrally formed with attachment flanges 121, 123 that have the same form and function as the attachment flanges 21, 23. The integral profile carrier 170 otherwise includes the remaining features of the first profile carrier 10, including substrate contacting portions 114, 116, outer flanges 126, 128, the attachment flanges 121, 123 bearing the first part of the two-part pivoting connector, including sockets 132, 133. An interior of the profile portion 174 includes an upper fitting 186 and a lower fitting 188 that each include a recess in which can be received a respective end of an elongate stiffener plate 189, shown in dotted lines in Figure 5a. The stiffener plate 189 is made of aluminium or other suitably robust non-combustible plate material.

[0084] In a variation of the integral profile carrier 270 shown in Figure 6(a) and Figure (6b), the profile portion 274 of the integral profile carrier 270 is substantially flat, for use in a ceiling or wall lining/cladding application.

[0085] The integral profile carrier 170, 270 can be used together with the insert panels 50, 250 in cladding applications that require the cladding system to be particularly robust to withstand the environmental conditions in which it will be employed, for example as the exterior facade of a coastal building or high rise towers. [0086] Figures 19 to 21 show a further embodiment of the cladding system

comprising of a first integral profile carrier 370, a second integral profile carrier 380 and an insert panel 350. The insert panel 350 is a two-part insert panel having a female portion 351 and a male portion 353. The female portion 351 and the male portion 353 each have a substantially flat externally facing surface 352. The female portion 351 consists of a first flat panel that includes the externally facing surface 352 and which, when viewed in cross-section as in Figure 19a, has a short downwardly or internally depending arm approximately half way along a width thereof that terminates with a second flat panel that lies parallel to the first flat panel. A female channel 356 is formed between the first and second flat panels. The female portion 351 further includes a first attachment portion in the form of a bead, for example a cylindrical bead 364, protruding from an internal surface 354 of the first flat panel of the female portion 351 adjacent the channel 356, for attachment to the first integral profile carrier 370. The male portion 353 consists of a main flat panel 357 that includes the externally facing surface 352, and which, when viewed in cross-section as in Figure 19c, includes a short dog-leg to an extension panel 358 adapted for being received in the channel 356 of the female portion 351. The extension panel 358 has a cylindrical bead 359 extending along a longitudinal edge thereof that provides a snug fit in the channel 356. As such, the female portion 351 and the male portion 353 are adapted such that the male portion 353 is releasably and adjustably securable in the channel 356 of the female portion 351 of the insert panel 350. The adjustability allows for any variation in tolerance between the integral profile carriers 370, 380.

[0087] The male portion 353 further includes a second attachment portion, also in the form of a cylindrical bead 366; that protrudes from an internal surface 355 of the male portion 353 for attachment to the second integral profile carrier 380.

[0088] The integral profile carriers 370, 380 are similar to the integral profile carriers 170, 180. However, the location of the sockets 332, 333 is no longer at the first and second ends of the central profile. Instead, the sockets 332, 333 are included at the first end and the second end of each of the first integral profile carrier 370 and the second integral profile carrier 380 and are oriented to face externally so as to receive the internally facing cylindrical beads 364, 366 of the insert panel 350 therein. As such, the two-part pivoting connector parts are closer together than in the previous embodiments, such that additional support flanges are not required between the profile carrier s and the insert panel. In use, when the cylindrical bead 364 and the cylindrical bead 366 are connected into the sockets 332, 333 of the integral profile carriers 370, 380, the insert panel 350 substantially covers a substrate contacting portion 316 of the second end of the first integral profile carrier 370 and a substrate contacting portion 314 of the first end of the second integral profile carrier 380. As shown in Figure 20(b), this embodiment of the cladding system is adaptable for use on a curved building facade by virtue of the two-part pivoting connectors 332, 366 and 333, 364 and a flexible junction 315 of bridging portions 318, 320 and the substrate contacting portions 314, 316 of the first profile carrier 370 and of the second profile carrier 380.

[0089] In a variation of the two-part insert panel 350 shown in Figure 21, two of the female portions 351 can be utilised on adjacent integral profile carriers 370, 380 that are installed to abridge a corner portion of a facade. A corner insert 360 consists of two thin male flat panels 368 arranged at an angle to one another so as to accommodate the corner of the facade and such that each of the panels 368 can be received in the channel 356 of a respective female portion 351.

[0090] Whilst the insert panel 350 has been described and illustrated with integral profile carriers, it will be appreciated that the insert panel 350 can also be used with profile carriers having a detachable profile member, provided that the first part of the two-part pivoting connector is as described for the integral profile carriers 370, 380.

[0091] The insert panel 350, integral profile carriers 370, 380 and the carrier insert 360 are all manufactured from aluminium and as such are non-combustible.

Substrate

[0092] The substrate 90 of the cladding system 1 is an aluminium rail to which the first and second profile carriers 10, 30 or integral profile carriers 170, 180, 270, 370, 380 can be removably yet securely attached by completely non-combustible means as will be described below. The rail 90 is shown in cross-sectional view in Figure 7(a) and in perspective view in Figure 7(b). The rail 90 consists of a rectangular back plate 92, in front of which is formed hollow upper and lower rail sections 94, 96 and a middle hollow section 98, respectively. The upper rail section 94 includes an elongate front wall 91 spanning the width of the rail 90 and an upper wall 93 and a lower wall 95, each connecting the front wall 91 to the back plate 92. The lower rail section 96 includes an elongate front wall 101 spanning the length of the rail 90 and an upper wall 103 and a lower wall 105, each connecting the front wall 101 to the back plate 92. The front wall 101 of the lower rail section 96 extends below the lower wall 105 to provide a support surface for the substrate contacting portion 14, 16 of the profile carriers 10, 30 or the substrate contacting portions 114, 116 of the integral profile carriers 170, 180, once the cladding system 1 is installed.

[0093] The hollow middle section 98 is formed of a rear part of the lower wall 95 of the upper rail section 94, a rear part of the upper wall 103 of the lower rail section 96 and a front wall 107 that extends between the two, recessed back from the front wall 91 of the upper rail section 94 and the front wall 101 of the lower rail section 96. The front wall 107 provides a support surface for a flashing 109 (shown in Figure 11) that is optionally installed on the rail 90 to provide an element of weather proofing of the cladding system 1.

[0094] The upper rail section 94 and the lower rail section 96 each include a series of pairs of substantially equi-spaced fastener receiving apertures or keyhole apertures 112 that include an upper circular portion 114 and a lower tapered portion 116 that extends beneath the circular portion 114 and tapers in a direction extending away from the circular portion 114.

[0095] The keyhole apertures 112 of the upper rail section 94 are arranged in vertical alignment with the keyhole apertures 112 of the lower rail section 96. Beneath the keyhole apertures 112 of the upper rail section 94 and vertically spaced therefrom is a series of pairs of small circular clip receiving apertures 118 to secure the profile carriers 10, 30; 170 180 to the rail 90. Between two of the keyhole apertures 112 in each of the front wall 91 and the front wall 101 is a larger circular fixing aperture 120 for fixing the rail 90 to a building facade or ceiling structure or the like.

Fastener

[0096] The keyhole apertures 112 are sized to partially receive a fastener. A first embodiment of the fastener 140, shown in Figures 8(a) to 8(d), is made of stainless steel and has an axisymmetric body having a longitudinal axis L-L, a proximal end and a distal end. Figure 8(a) shows a side view of the fastener 140. The proximal end of the fastener body has a hexagonal head 142 disposed perpendicularly to the

longitudinal axis. A cylindrical flange 144 is disposed perpendicularly to the longitudinal axis adjacent the hexagonal head 142. Adjacent the cylindrical flange 144 is a cylindrical threaded portion 146 and a narrower shaft portion 148. The distal end of the fastener consists of a parabolic conical portion 150 adjacent the shaft, a tip 152 of the parabolic conical portion 150 defining the distal end of the fastener 140. As shown in Figure 8(a), a diameter of the cylindrical thread portion 146 is substantially the same as the diameter of a base of the parabolic conical portion 150. In the embodiment shown, a length dimension of each of the hexagonal head 142, the cylindrical flange 144, the cylindrical threaded portion 146 and the shaft 148 is approximately the same. The length dimension, in particular, of the shaft portion 148 is designed to be the same as a thickness of the front wall 91 of the upper rail section 94 of the rail 90 and of the front wall 101 of the lower rail section 96 of the rail 90.

Similarly, the cylindrical threaded portion 146 is designed to have a length dimension that is the same as a thickness of the substrate contacting portions 14, 16 of the first and second profile carriers 10, 30 or the substrate contacting portions 114, 116 of the integral profile carriers 170, 180, 270. It will be appreciated by the skilled person that the length of the shaft portion 148 and the cylindrical threaded portion 146 is adaptable to the thickness of the front walls 91, 101 and of the substrate contacting portions 14, 16; 114, 116 of the particular cladding application. Similarly, the shaft portion 148 is sized to sustain any natural forces to dislodge the profile carrier 10, 30; 170, 180, 270. [0097] A diameter of the shaft 148 is narrower than a diameter of the cylindrical threaded portion 146 and of a base of the parabolic conical portion 150 so as to form an annular recess between the parabolic conical portion 150 and the cylindrical threaded portion 146. The cylindrical flange 144 has a diameter that is greater than the diameter of the cylindrical threaded portion 146. The diameter of the cylindrical threaded portion 146 is very slightly larger than a diameter of the apertures 29 of the profile carriers 10, 30; 170, 180. This is so that the threaded portion 146 bites into the aluminium aperture 29 during installation of the fastener 140. The diameter of the cylindrical flange 144 is also greater than a diameter of the circular portion 114 of the keyway apertures 112 in the rail 90 so that it cannot pass through it.

[0098] A second embodiment of the fastener 240 is shown in Figures 9(a) to 9(d). In this embodiment, the cylindrical threaded portion 146 is replaced with a cylindrical tapered portion 246 that is adapted to pressure fit into the apertures 29 of the profile carriers 10, 30; 170; 180. Otherwise, the fastener 240 is identical to the fastener 140.

Installation of profile carriers to substrate

[0099] With reference to Figures 10 to 12, installation of the cladding system 1, comprising the first and second profile carriers 10, 30, insert panel 50 and a profile member 70, is now described. The first step is to secure the rail or other substrate 90 to a structure, in this example a building structure, to which the cladding is to be installed. The first profile carrier 10 and the second profile carrier 30 are then secured to the substrate 90 in spaced relation with one another. The cylindrical bead 64, 66 of a first end of the insert panel 50 is then inserted into the socket 32, 33 of the first profile carrier and the cylindrical bead 64, 66 of a second end of the insert panel 50 is inserted with a snap fit into the socket 32, 33 of the second profile carrier. If the profile carriers already have an integral profile portion 174, this completes the main component installation. Otherwise, a profile member 70 is then snapped into an externally facing surface of at least one of the first profile carrier 10 and the second profile carrier 30. [0100] The above installation method applies equally to the cladding system 1 comprising first and second integral profile carriers 370, 380 and insert panel 350. If the insert panel 350 is being installed onto the integral profile carriers 370, 380, then the male portion 353 is connected into the female portion 353, usually prior to inserting the cylindrical beads 364, 366 into the sockets 332, 333 of the first and second profile carriers 370, 380. In some circumstances, the cylindrical bead 364, 366 of one or other of the male or female portions 351, 353 may be attached to the respective socket 332, 333 prior to connecting the male and female portions 351, 353 together.

[0101] The installation process is described in more detail as follows. For the purpose of this embodiment, the structure is a building facade 155, shown in dotted lines in Figure 12a and Figure 12b. The rail 90 is secured to the building facade 155 with a commercially available anchor or such fixing inserted through the circular fixing apertures 120 of the rail 90 and through the building facade 155. A pair of the rails 90 is installed in this manner, vertically spaced from one another at a distance that corresponds to the length of the elongate first profile carrier 10 that is to be attached to it. In this embodiment, the first profile carrier 10 is up to about 3m long and is installed in a vertical orientation onto an upper rail 90a and a lower rail 90b as shown in Figure 10. Alternatively, the rails 90 could be spaced horizontally from one another such that the cladding panels and carrier members are also oriented horizontally. The fasteners 140, 240 can be pre-located in the apertures 29a, 29b in the factory or other site of manufacture. The fastener 140 is inserted into the aperture 29a or 29b such that the cylindrical threaded portion 146 bites into the circumference of the fixing aperture 29a, 29b and is held in place there. If the fastener 240 is used, it is inserted into the aperture 29a, 29b such that the cylindrical tapered portion 246 pressure fits into the

circumference of the fixing aperture 29a, 29b and is held in place there. The fastener 140, 240 may stay in this position until the profile carrier 10 reaches the installation site.

[0102] To install a profile carrier, for example the first profile carrier 10 to the rails 90 at the installation site, the fixing apertures 29 of the first profile carrier 10 are aligned with a set of the circular portions 114 of the key way apertures 112 of the rails 90 as shown in Figure 10. The upper fixing apertures 29a of the first profile carrier 10 are aligned with the key way apertures 112 in the lower rail section 96b of the upper rail 90a. The lower fixing apertures 29b are aligned with the key way apertures 112 in the upper rail section 94b of the lower rail 90b.

[0103] To secure the first profile carrier 10 to the rails 90, a fastener 140 or 240 is easily pushed through each of the fixing apertures 29a, 29b of the first profile carrier 10 and into the circular portions 114 of the key way apertures 112 of the rails 90a, 90b as shown in Figure 10(a) until the cylindrical flange 144 of the fastener 140, 240 abuts the substrate contacting portion 14, 16. As best seen in Figures 11 and 12, in this position the cylindrical threaded portion 146 of the fastener 140 is situated in the fixing aperture 29a, 29b of the first profile carrier 10, the shaft portion 148 is positioned inside the circular portion 114 of the key way aperture 112 and the parabolic conical portion 150 has passed through the keyway aperture 112 and is located inside the upper rail section 94 or lower rail section 96, depending on the particular keyway aperture 112 through which it is installed. In this position, the fastener 140 can be pushed downwards into the base of the tapered portion 116 of the keyway aperture 112 as shown in Figure 11. The tapered portion 116 receives the shaft 148 of the fastener 140, 240 with a pressure fit so as to clamp the substrate contacting portion 14, 16 and the front wall 91 or front wall 101 of the rails 90 together such that they are substantially immovable relative to one another.

[0104] It will be apparent to the skilled person that each of the profile carriers and integral profile carriers can be secured to the substrate in the same manner as described above. Accordingly, the components of all embodiments of the cladding system 1 can be assembled to the substrate rail 90 using non-combustible means without relying on any adhesive based tapes that would remain combustible even if the cladding panels or components themselves were not combustible.

[0105] As shown in Figure 11(a) and Figure 11(c), two or more profile carriers 10, 30 or, in this example, integral profile carriers 170, 180; 270 can be installed in a vertical arrangement on the rails 90 to create a longer profile appearance to the cladding system 1. For example, Figure 11(a) and Figure 11(c) show the lower end of a first integral profile carrier 170 installed on an upper rail section 94 and the upper end of another integral profile carrier 170 installed on a lower rail section 96 of the rail 90. The integral profile carriers 170 can be installed simultaneously on the rail 90 due to the pre-aligned fastener receiving apertures 29a, 29b and keyhole apertures 112, which enable a consistent and accurate installation of the profile carriers 170 on the rail 90. This in turn facilitates easy snap-in installation of the insert panels 50, 250.

[0106] As seen in Figure 10a, a spring clip 190 can also be located on a lower end of the first profile carrier 10 either during pre-installation at the factory or during installation on site. The spring clip 190, shown in more detail in Figure 15(a) to 15(c), is a narrow strip of bent spring steel that is adapted to wrap around a bottom edge 152 of the profile carrier 10. The spring clip 190 also includes a rounded upper edge 194 that curves away from the profile carrier 10 upon installation and a locating pin 196 that is sized to fit closely into one of the clip locating apertures 17 of the first profile carrier 10 and the clip receiving apertures 118 in the upper rail section 94 of the rail 90 upon installation. The locating pin 156 is located but not pushed through the clip locating aperture 17 during pre-installation. However, it cannot pass through the clip locating aperture 17 or the clip receiving aperture 118 until the fastener 140, 240 has been pushed down into the tapered portion 116 of the keyway aperture 112. Only then will the clip locating aperture 17 and the clip receiving aperture 118 line up so that this is possible. Accordingly, once the apertures are aligned, the locating pin 196 of the spring clip 190 is pushed through the clip locating aperture 17 and the clip receiving aperture 118 to secure the first profile carrier 10 to the upper rail section 94 of the rail 90b as shown in Figure 10b. The spring clip 190 therefore functions to ensure that the first profile carrier 10 cannot be easily displaced or removed from the rails 90 due to environmental forces or vandalism.

[0107] The above installation process is repeated for the second profile carrier 30 such that a horizontal gap is maintained between the first profile carrier 10 and the second profile carrier 30 as shown in Figure 12a and Figure 12b, for receiving the insert panel 50. Accordingly, the first profile carrier 10 and the second profile carrier 30 are thereby secured to the rails 90a, 90b in spaced relation with one another.

[0108] As shown in Figure 10(c) and Figure 12, if a separate profile member 70 is to be attached to the cladding system 1, the profile member 70 is then snap-fit onto each of the first profile carrier 10 and the second profile carrier 30. This is achieved by guiding the downwardly extending legs 76, 78 of the profile member 70 inside the attachment flanges 21, 23 of the first and second profile carriers 10, 30, such that the clips 82, 84 at an end thereof snap-in into the return 27 of the attachment flanges 21, 23 of the first and second profile carriers 10, 30 to secure the profile member 70 to first and second profile carriers 10, 30 as seen in Figure 10(d).

[0109] Alternatively, if the profile member is integrally formed with the first profile carrier and the second profile carrier as seen in Figures 13a and 13b, the above step is omitted.

[0110] As shown in the installation step of Figure lOe and in the cross-sectional view of Figure 12b, the insert panel 50 is then aligned with the first profile carrier 10 and the second profile carrier 30. The cylindrical bead 64 of the first end of the insert panel 50 is inserted into the socket 32 of the first profile carrier 10. Figure 11 shows this step in more detail.

[0111] The cylindrical bead 64 is guided towards the cam surface 34 in Figure 14(a). In Figure 14(b) the cylindrical bead 64 makes contact with the cam surface 34, and can be pushed sideways into the socket as shown in Figure 14(c). Finally, in Figure 14(d), the cylindrical bead 64 is snugly yet pivotably retained in the socket 33 by the upper retaining lip 40. As shown in Figure 10(f), the insert panel 50 is thus connected to the first profile carrier 10.

[0112] Meanwhile, as shown in Figure 12(b), the corresponding depending inverse-T shaped flanges 56, 58 of the insert panel 50 are then brought into contact with one another as the insert panel 50 is rotated towards the second profile carrier 30 and the cylindrical bead 66 snap fits into place in the socket 32. The main components of the cladding system 1 are now assembled, as shown in Figure 1. If desired, the joints between the attachment flanges 21, 23 and the profile member 70 and the insert panel 50 can be caulked with a coloured intumescent material to seal the joints against water and debris ingress. As seen in Figure 19(g), Figure 10(h) and Figure 16 (a) and (b), an end panel 160b is fitted to the ends of the profile member 70, or an end panel 160a is fitted to the ends of the integral profile carrier 170, via a screw or other suitable fixing means (not shown) that extends through one or more screw fixing apertures 164 in the end panel 160a, 160b and is supportably received in a screw flute 166 in the interior of the profile member 70 or integral profile carrier 170. An end panel 162, shown in Figure 16(c), is similarly fitted to the ends of the insert panel 50 via a screw or other suitable fixing means (not shown) that extends through one or more screw fixing apertures 163 in the end panel 162 and is supportably received in a screw flute 166 in the interior of the insert panel 50. A similar end panel, not shown, can be fitted to the ends of the narrower insert panel 250.

[0113] The insert panel 50 lies flat once it is snap-fit into place, supported by the two- part pivoting connectors 32, 66; 33, 64 at either end of the insert panel 50 and also by flanges 56, 58 and 26, 28 as shown in Figure 1. Referring to Figure 17, the cladding system is adaptable for use on a curved building facade by virtue of the two-part pivoting connectors 32, 66 and 33, 64 and the flexible junction 15 of the bridging portions 18, 20 and the substrate contacting portions 14, 16 of the first profile carrier 10 and of the second profile carrier 30. As shown in Figure 17, when utilised on a curved surface having a radius of e.g. 2 metres, the horizontal outer flanges 26, 28 of the second profile carrier and the first profile carrier respectively will be angled slightly upwardly rather than horizontally. The inverse T-shaped flanges 56, 58 can be removed to allow for installation of the cladding system 1 on a facade or other surface having a smaller radius, for example of under 2m. For this purpose, the inverse T- shaped flanges 56, 58 are extruded with a snap-off groove to enable ease of their removal. The flexible junction 15 allows the substrate contacting portions 14, 16 to lie flat on the rail 90 but to absorb the curvature in the facade 155. The pivoting connections between the insert panel 50 and the first profile carrier 10 and the second profile carrier 30 allows the components to pivot slightly relative to one another such that the cladding system 1 maintains a fluidity of appearance on such a curved surface, in contrast to individually installed panels that present a faceted appearance on a curved surface.

[0114] The components of the cladding system 1 described above are one element of a fully installed cladding. A fully installed cladding consists of a plurality of the cladding systems 1, interconnected with a further insert panel 50, as shown in Figure 18. The cladding can be used on the facade of a building, or for lining a ceiling or internal wall.

[0115] The cladding system provides a modular cladding that is adaptable for providing cladding or ceiling/wall lining of different two-dimensional or three- dimensional appearance. The snap-fit connection between the central profile portion 12 of the profile carriers 10, 30 or integral profile carriers 170, 180 and the insert panels 50, 250 or between the integral profile carriers 370, 380 and the insert panel 350 produces a clean external appearance to the cladding as the fixings 29, 17 of the profile carriers 10, 30 or the integral profile carriers 170, 180, 370, 380 are covered by the insert panel 50, 250, 350 once it is snapped into place. The cladding system 1 can be partially pre-assembled in the factory so as reduce the installation time on-site and the snap-in connections are quick to assemble. The pre-aligned keyhole apertures 112 and fastener receiving apertures 29a, 29b allow installation work to be commenced at multiple locations simultaneously, ensuring that the insert panels 50, 250, 350 can be easily snapped into place. The two-part pivoting connector between the insert panel 50, 250 and the profile carriers 10, 30 or the integral profile carriers 170, 180, 370, 380 allows the cladding system 1 to be adaptable for installation on to a curved surface of down to approximately 2m radius. The cladding system 1 can be retro-fitted to an existing building facade to provide a non-combustible exterior cladding or as a refurbishment of the building exterior.

[0116] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.