Field of the Invention

The present invention relates to an improved wall cladding system and particularly, although not exclusively, to wall cladding systems where brick slips are installed on a rail system.

Background

Wall cladding systems are well known and provide fast and efficient installations of wall claddings, typically to provide the exterior fagade of a building. Known wall cladding systems can use a rail system where the rail system is secured to an underlying wall structure of the building. Cladding components are hung on the rail system to cover the underlying wall structure, typically providing aesthetic appeal and weather protection (when installed externally). Brick tiles (also called brick slips or slips), having the appearance of standard bricks but with a thinner depth, can be used as a cladding component, to achieve an effective appearance of a traditional brick-built wall.

A known wall cladding system for installing brick cladding is provided by the applicant under the brand name CORIUM TM (herein the acknowledged art). Here, a rail system is installed by mechanically fixing the rail system to the substructure of a buildings envelope. Brick tiles are then clipped into the rail system and the vertical and horizontal joints are suitably pointed with mortar to give the final appearance of a traditional brick fagade. Figure 1 shows the acknowledged art rail system 10. As shown, vertical supports 20 are initially fixed to the substructure of the building by a suitable fixing method (e.g. mechanical fixing screws or bolts). The vertical supports 20 are suitably spaced, which to fit with other components of the building envelope may be around 600mm (e.g. if insulation is installed between the vertical supports). A plurality of horizontal rails 30 are then mechanically fixed to the vertical supports. In the acknowledged art rail system 10, adjacent horizontal rails 30 are configured to interlock and the horizontal rails are formed from steel. The exact design of the rail system 10 and fixing to the underlying substructure is configurable to suit the application.

The horizontal steel rails 30 of the related art rail system are profiled to suit the brickwork coursing height and the brick tile. Importantly, the profile (see figure 2) of the steel rail 30 includes opposed recesses 31 , 32 into which the brick tile can be clipped to become mechanically fixed to the rail 30. The opposed recesses are a first recess 31 and a second recess 32. The recesses are opposed across the rail 30. That is, the rail 30 has a longitudinal length corresponding to the direction of installation. So, when the rail is installed horizontally, the rail’s longitudinal length is horizontal, and the recesses are opposed across the rail in a vertical direction. Thus, the rail provides a slot into which the brick tile is inserted. The slot has a longitudinal length along the length of the rail and is bounded across the rail by the first and second recesses. In the orientation shown in Figures 1 and 2, the acknowledged art rail system provides an upper recess 31 (i.e. first recess) and a lower recess 32 (i.e. second recess). Referring to Figure 4, the upper recess 31 is formed by an overhung lip 33 that is shown as projecting downwardly from a sloped upper face 34. The sloped upper face 34 is connected to a planar rear face 35. The overhung lip 33 generates the upper recess 31 . That is, the upper recess 31 is defined as the longitudinal space generated between the overhung lip and the rear face and extends along the length of the rail at an upper portion of the rail 30. The overhung lip 33 acts like curled fingers around the brick tile to mechanically prevent a top portion of the brick from coming out of the recess. The lower recess 32 is formed by a projection 36 that extends upwards from a lower face 37. The lower face 37 is connected to the planar rear face 35. The lower face is, suitably, approximately orthogonal to the rear face. A front nose of the lower face 37 has a downward extension 38 with a hooked end 39 that hooks around an overhung lip of an adjacent rail to interlock said rails 30. The projection 36 in the lower face 37 extends along the length of the rail and provides the second (lower) recess 32 between the projection and the rear face 35. The brick tile includes a notch in which the projection locates. As explained below, the projection is located in the notch by causing the projection and I or the overhung lip to flex apart. The flexing opens the slot formed in the rail 30 to allow the projection to be located in the notch, before the resilient flexing closes the slot to mechanically secure the brick tile from being removed out of the slot.

The rail 30 of the related art rail system is bent into the profiled shape from a flat sheet. In particular, the projection 36 is formed by a folded ridge in the lower face. The flexing to open and close the slot suitably may comprise the profile flexing at one or more of the bends in the sheet. But the flexing may also occur along the various faces. Typically, the flexing to open and close the slot occurs at the bend joining the rear face 35 to the upper 34 and I or lower 37 faces. Here, the slope of the sloped upper face 34 provides a space between the lower surface of an interlocked adjacent rail into which the portions can flex to open and close the slots.

The brick tiles of the acknowledged art system, which may also be referred to as brick slips or brick slip tiles, are extruded in a manufacturing process or otherwise moulded as is known in the art and have a cross-section profile suitably configured for the rails 30. Because the brick tile is typically extruded, the cross-section is constant along the tile. As shown in Figure 3, the brick tile 40 has a front elevation 41 that provides the front aspect of the fagade and, from an aesthetic point of view, is the principal element of the cladding. As explained, a notch 43 is formed in a lower elevation of the brick tile. The notch forms a front lobe 44 and a rear lobe 45. It is the rear lobe that locates in the recess of the rail. As shown, the front lobe extends downwardly from the lower elevation of the brick further than the rear lobe. Thus, the front lobe extends the front elevation past the rear lobe, which covers a portion of the downward extension 38 when the brick tile is clipped into the rail. A top elevation 46 of the brick tile 40 includes a shoulder 47 that extends upwardly. It is the shoulder of the top elevation that locates in the recess of the rail. A rear elevation of the brick tile includes a cavity 48. The cavity 48 reduces the material necessary to manufacture the brick tile, as well as providing a space to accommodate the fixings that fix the rails 30 to the substructure (e.g. the fixings that connect the rail to the vertical supports).

The brick tiles 40 are clipped into the rail by offering up the brick tile at an angle to the rail and inserting the shoulder 47 into the first (e.g. upper) recess 31 . The brick tile is then pivoted downwardly so that the rear lobe begins to enter the slot of the rail. Typically, the brick tile 40 will enter the slot until the rear lobe 45 abuts the protrusion on the rail. At this point, the brick tile is forced over the projection 36 (for instance, by striking the front elevation of the brick tile with a rubber mallet). Here, as explained, the slot is opened by flexing of the rail and so that the rear lobe 45 rides over the projection 36 until the brick tile is fully installed with the projection inserted into the notch of the brick tile. The vertical spacing of the brick tiles installed in adjacent rails 30 is dictated by the design of the rails. The brick tiles can be slid along the longitudinal length of the rail’s slot to adjust the horizontal spacing and to ensure the aesthetic effect is achieved (i.e. mosaicking etc). Once the brick tiles 40 have been clipped into the rail system 10, the horizontal and vertical gaps can be filled with mortar 49 to lock the tiles together and to provide the finished aesthetic result of a traditional brick wall - see Figure 5 and mortar 49.

In Figure 1 and 2, the CORIUM rail system 10 is shown configured to install the brick tiles 40 in a horizontal configuration. But an advantage of the CORIUM rail system and brick tile is that the rail system 10 can also be installed in other orientations, for instance the rails can be installed vertically. Here the elements are all installed rotated through ninety degrees. Conceivably, the rail system is also not limited to being installed on a vertical fagade and other orientations are possible (i.e. slopes or horizontal facades). It will be appreciated that the various orientations (i.e. top I bottom and upper / lower) provided in relation to the horizontal orientation will also be rotated. However, herein references to orientation will be given relative to a horizontal orientation. That is, when the rail 30 is installed with the longitudinal length extending in a horizontal direction and the rear face of the rails installed vertically such that the first recess of the rail is an upper recess and the second recess of the rail is a lower recess and the brick has a front elevation that extends in a vertical plane when installed with an upwardly extending shoulder on the upper face and a notch in the lower face. Thus, as an example, even if the rail system is installed, for instance, vertically, the brick tile will still be said to have an upper elevation even though the upper elevation would actually be installed in a vertical plane.

The acknowledged art rail system provides a versatile cladding system using extruded brick tiles. Brick tiles are extruded to the profiled shape and cut to length whilst soft before being dried fired. Consequently, the extruded brick tiles are manufactured within a consistent tolerance. Thus, the wire cut bricks are produced with a manufacturing tolerance suitable for being fixed within the slots of the acknowledged art rail system 10. However, the acknowledged art rail system is not particularly suitable for use with brick tiles that are produced with a large dimensional tolerance. For instance, soft mud/stock bricks are produced with a larger dimensional tolerance than extruded bricks. It is also popular to manufacture brick slips (being brick tiles that are slimmer than traditional bricks) by face cutting existing bricks, which might have a larger range of sizes produced from the same batch I process. When installing a brick slip produced towards the large dimensional tolerance, the brick slip might be larger than intended and will not fit into the slot in the rail because the rail cannot expand wide enough to accommodate the larger size. Likewise, when installing a brick slip produced towards the smaller dimensional tolerance, the brick slip might be smaller than intended and will be a loose fit in the slot in the rail. If the fitting becomes loose, the mechanical connection between the rail and brick slip can be insufficient resulting in failure of the cladding (i.e. the brick slip becoming loose from the rail). Whilst it is possible to quality check the brick tiles and to reject under / oversized brick tiles from use, it would be advantageous to provide a rail system able to accommodate brick tiles with a wider size tolerance. The present invention has been devised in light of the above considerations. In particular, it is an aim of to provide a more versatile wall cladding system that can allow a wider range of brick slips to be clipped in place.

Summary of the Invention

According to the exemplary embodiments, there is therefore provided a rail having intermittent upper and lower fingers projecting from a rear face. The intermittent upper and lower fingers do not extend along the length of the rear face. That is, the intermittent fingers do not extend along the full length of the rail. Rather, the intermittent upper and lower fingers extend over a portion of the rail’s length. Suitably, the intermittent upper fingers are opposed to the intermittent lower fingers. That is, an extent of an upper finger along a length of the rail is mirrored by a corresponding extent of a lower finger along the length of the rail. In the exemplary embodiments, the intermittent upper fingers comprise a plurality of upper fingers. And suitably, the intermittent lower fingers comprise a plurality of lower fingers. Suitably, the number of the plurality of upper and lower fingers is configured to provide a first upper / lower finger and a second upper I lower finger per brick. Here, suitably, the first upper I lower finger is spaced from the second upper I lower finger so as to contact end regions of an installed brick tile. The end regions of the brick tiles may be a region within 25% of the length of the brick tile. That is, the central 50% of the brick tile is not contacted by a respective upper / lower finger of the plurality of fingers. However, in some embodiments a third or more fingers are envisaged per brick tile. For instance, a third upper I lower finger can be provided between the first and second upper / lower fingers. For instance, for securing an end region of a % brick. Advantageously, the intermittent upper and lower fingers provide a rail that is able to accommodate a brick tile manufactured within a large tolerance of sizes.

In the exemplary embodiments, the extent of the length of the rear face along which the intermittent upper fingers extend is suitably less than 50% of the length of the rail. In some embodiments, the extent is less than 40% or less than 35% or around 30%. The extent of the length of the rear face along which the intermittent upper fingers extend is suitably more than 10% of the length of the rail. In some embodiments, the extent is more than 15%, or more than 20% of the length of the rail. Additionally, or alternatively, the extent of the intermittent upper fingers is suitably configured to cover between 20% and 30% of the length of each brick tile being installed. For instance, suitably, the extent of the intermittent upper fingers is configured to extend around 25% of the length of each brick tile, that is between 22 % and 27% of the length of each brick tile. In one exemplary embodiment, wherein the rail is configured so that two upper fingers of the plurality of the upper fingers in the intermittent upper fingers are in contact with each brick, the first upper finger and the second upper finger can have an extent of around 12% of the length of a brick tile. For instance, between 10% and 15% of the length of the brick.

In the exemplary embodiments, the extent of the length of the rear face along which the intermittent lower fingers extend is suitably less than 50% of the length of the rail. In some embodiments, the extent is less than 40% or less than 35% or around 30%. The extent of the length of the rear face along which the intermittent lower fingers extend is suitably more than 10% of the length of the rail. In some embodiments, the extent is more than 15%, or more than 20% of the length of the rail. Additionally, or alternatively, the extent of the intermittent lower fingers is suitably configured to cover between 20% and 30% of the length of each brick tile being installed. For instance, suitably, the extent of the intermittent lower fingers is configured to extend around 25% of the length of each brick tile, that is between 22% and 27% of the length of each brick tile. In one exemplary embodiment, wherein the rail is configured so that two lower fingers of the plurality of the lower fingers in the intermittent lower fingers are in contact with each brick, the first lower finger and the second lower finger can have an extent of around 12% of the length of a brick tile. For instance, between 10% and 15% of the length of the brick.

The intermittent upper fingers and the intermittent lower fingers suitably comprise a first type of finger. The first type of finger extends from the rear face. Here the first type of finger comprises a proximal portion and a distal portion connected at a knuckle. The knuckle is configured such that the distal portion extends towards a centre of the rail. For instance, the distal portion extends downwardly relative to the rear face, and suitably at an angle of around 52°. here, it is envisaged the angle formed between the distal portion and rear face is suitably between 45° and 60°. The proximal portion extends from the rear face at an angle of between 80° and 100° and preferably around 90°. Suitably, the first finger is bent from a flat sheet. Here, the proximal portion is bent at a first angle to extend away from the rear face and bent at a second angle to form the knuckle. The angle of the knuckle suitably slants the distal portion to the rear face. Here, the distal portion can be angled between 45° and 60°.

The intermittent upper fingers and the intermittent lower fingers suitably comprise a second type of finger. The second type of finger extends from the rear face. Here the second type of finger comprises a proximal portion and a distal portion. The distal portion is interconnected to the proximal portion by a medial portion. Here the medial portion extends towards the centre of the rail. The medial portion allows the distal portion to extend away from the centre of the rail, with a terminal end of the distal portion falling substantially in a plane with the proximal portion. That is, the terminal end of the finger lies in a plane that does not extend outwards past the plane of the proximal portion. The proximal portion extends from the rear face at an angle of between 80° and 100° and preferably around 90°. Suitably, the medial portion is joined at a first bend to the proximal portion. The first bend suitably causes the medial portion to be substantially parallel with the rear surface. Here, it is envisaged the first bend may cause the medial portion to extend +- 5° to the plane of the rear face. Suitably, the medial portion is joined at a second bend to the distal portion. The second bend suitably causes the distal portion to be slanted to the rear face. The distal portion may be substantially parallel to the distal portion of a first type of finger. For instance, the second bend might cause the distal portion to be angled to the rear face around 52°. Here, the distal portion can be angled between 45° and 60°. In exemplary embodiments, the medial portion has a dimension normal to the length of the rail of between 20% and 40% or between 25% and 30% or around 30% of the dimension of the proximal portion normal to the length of the rail.

In the exemplary embodiments, an upper finger of the intermittent upper fingers opposes a lower finger of the intermittent lower fingers. Here, one of said fingers is said first type of finger and the other finger is said second type of finger. Suitably, all the intermittent upper fingers are the same type of finger, and all the intermittent lower fingers are the same different type of finger.

In the exemplary embodiments, a brick tile for being mechanically held to the rail is substantially cuboid. Here, the brick tile has a front face, that provides the finished aesthetic face, and an opposed rear face, that typically lies adjacent the rear face of the rail when installed. End faces between the front and rear face are typically generally formed in a rectangular plane. Upper and lower faces of the brick tile each include a notch. Herein, the notch in the upper face will be referenced as the upper notch. And the notch in the lower face will be referenced as the lower notch. However, the upper/lower terminology is a largely superficial reference as typically the brick tile will be installable in either orientation. That is, advantageously, the upper notch and the lower notch are designed to be identical. Or put alternatively, the brick tile has a central line of symmetry in an orthogonal plane between the front, rear and end faces. Thus, the installer does not have to select a correct orientation of the brick tile during installation.

The upper and lower notches in the upper and lower faces respectively, are suitably spaced from the rear face a first distance. The first distance can suitably be substantially equal to the depth of the notch. That is, the depth of the notch from the major plane of the respective upper or lower face towards the other face. It will be appreciated that the first distance is configured to be operatively similar to a length of the proximal portion of a first type of finger or a second type of finger.

The upper and lower faces of the brick tile extend perpendicularly from the front face. The upper and lower faces are substantially planar from the front face to the start of the respective notch. Walls of the notch are substantially perpendicular to the upper and lower faces, wherein substantially perpendicular includes the walls and I or faces having a draw for demoulding. In exemplary embodiments, the respective upper or lower face between the notch and the rear face is stepped in towards the centre of the brick tile relative to the respective upper or lower face between the front face and the notch. That is, the respective upper or lower face includes a front portion (i.e. between the front face and the notch) and a rear portion (i.e. between the rear face and the notch) wherein the rear portion is closer to the centre of the brick tile than the front portion. The rear portion might be spaced closer to the centre by around half the depth of the notch. Here, the front face has a greater height than the rear face. The height being measured between the upper and lower faces. When the brick tile is installed on a rail, the intermittent upper fingers and the intermittent lower fingers are concealed by the front face. That is, the rear surface of the rail between the proximal portions of the respective upper and lower intermittent fingers has a height operatively configured to correspond to the height of the rear face of the brick tile, wherein the front face of the brick tile has a greater height such that when viewed in a perspective perpendicular to the front face, the upper and lower intermittent fingers lie behind the front face.

Suitably, the respective notches in the upper and lower faces extend the full length of the brick tile. Thus, the brick tiles are provided with some lateral movement to obtain even spacings between adjacent brick tiles.

The brick tile is clipped to the rail by inserting the upper and lower intermittent fingers into the upper and lower notches of the brick tile. Suitably, in the embodiments having first type of intermittent fingers and second type of intermittent fingers, the tile is offered up to the rail at an angle with the respective notch of the brick tile spaced closer to the first type of fingers than to the second type of fingers. The distal portion of the fist type of fingers can be inserted into the respective notch. Here, the rear face of the brick tile can be brought into abutment with the slanted distal portion of the second type of finger. The medial portion of the second type of finger is inserted into the respective notch of the brick tile by pivoting the brick tile to be parallel to the rail with the rear surface of the rail and the rear face of the brick tile substantially lying adjacent each other. The slanted distal portion can help the brick tile slide against the rail and cause a mouth formed between upper and lower fingers to open to clip the brick into the rail. The intermittent configuration of the upper and lower fingers allows the rail to be resiliently expandable about a greater size tolerance of the brick tile. Consequently, a greater tolerance of brick tile manufacturing can be accommodated and tightly secured.

There is therefore provided a rail for a wall cladding system, the rail comprising a rear face, a set of intermittent upper fingers that extend from an upper portion of the rear face and a set of intermittent lower fingers that extend from a lower portion of the rear face. There is also provided a brick slip having front face, a rear face an upper face, a lower face and two end faces, wherein the upper face has a notch and the lower face as a notch.

In some embodiments the rail is attached directly to the substructure or vertical supports as is known. Here, each rail is adapted for receiving multiple brick tiles. However, in some exemplary embodiments, the rail is provided as an adaptor rail, wherein the adaptor rail is clipped to a substructure rail. For instance, the substructure rail can be a known rail. Suitably, the adaptor rail is configured for receiving a single brick tile, but adaptor rails configured to clip a plurality of brick tiles is also envisaged. However, the adaptor rail is envisaged as having a reduced length to the substructure rail. Here, multiple assemblies of a brick tile and adaptor rail are assembled to the substructure rail. As well as the rear face and intermittent upper and lower fingers that act as forward-facing clips for clipping the adaptor rail to the brick tile, the adaptor rail includes rearward facing clips to engage opposed fixing recesses of the rail assembly. That is, the rearward facing clips can be configured to replicate the connection fit of a known brick tile with the substructure rail.

In the exemplary embodiments, the rearward facing clips extend from the rear face in a direction opposed to the intermittent fingers. The rearward facing clips comprise a shoulder portion and a lobe portion. Here, the shoulder portion is configured to fit into one of an upper or lower recess formed in the substructure rail, and the lobe portion is configured to fit into the other of the upper or lower recess. For instance, the upper and lower recesses may be formed continuously in the substructure rail wherein the adaptor rail provides an adaptor for installing brick tiles with a larger manufacturing tolerance that might cause the connection problems with the lower range of accommodated movement of the continuous recesses in the substructure rail.

In the exemplary embodiments, the shoulder portion has a tip that is angled relative to the rear face and configured, when the adaptor rail is installed in a substructure rail, to wedge between two opposed contacts within the respective recess. For instance, the tip in some embodiments extends generally perpendicularly to the rear face. Here, contact between the respective recess (for instance a sloped upper face of the substructure rail) and a distal termination of the tip provides one of the opposed contacts. In exemplary embodiments, the tip is connected to an offset face that is generally parallel to the rear face but offset rearwardly therefrom. It is contact between a portion of the offset face and the respective recess (for instance a planar rear face of the substructure rail). In the exemplary embodiments, the offset face is connected to the rear face by a transition portion. In the exemplary embodiments, the transition portion is connected to the rear face by a bend. The transition portion can be planar. And the bend between the rear face and transition portion is suitably between 90° and 130° and preferably around 106°. Suitably, the shoulder is formed by being bent from a blank sheet.

In the exemplary embodiment, the lobe is configured, when the adaptor rail is installed in a substructure rail, to wedge between two opposed contacts within the respective recess. Suitably, the lobe forms a ledge for receiving a projection of the substructure rail. Here, the ledge comprises a ledge face that extends from the rear face. For instance, perpendicularly from the rear face. The ledge further comprises an abutment face that extends away from a centre of the adaptor rail and from the ledge face. It is contact between the abutment face and the projection on the substructure rail that provides one of the opposed contacts. Suitably the lobe provides a lower abutment face configured to contact with a lower face of the substructure rail. Thus, it will be appreciated that the lower abutment face extends generally perpendicular to the rear face. Suitably, the lobe provides a rear abutment face configured to contact with a planar rear face of the substructure rail. Thus, it will be appreciated that the rear abutment face extends generally parallel with the rear face. In the exemplary embodiments, the lower abutment face and rear abutment face are connected by a sloped transition. Here, the sloped transition is angled to the rear face, and provides a ramp to urge the opening of the substructure rail to accommodate the lobe passing the projection. For instance, the sloped transition may be angled between 30° and 60° to the rear face. Suitably the lobe is formed by being bent from a blank sheet.

In the exemplary embodiments, the rearward facing clips and the intermittent upper and lower fingers are formed by bending a blank. Here, suitably, the rearward facing clips extend in a longitudinal direction between first and second sets of upper and lower fingers that form the intermittent upper and lower fingers. Thus, the adaptor rail is formed by pressing or stamping or cutting or otherwise forming a flat sheet forming the blank. The blank is formed so that portions of the sheet forming the intermittent fingers are separated from portions of the sheet forming the rearward facing clips. Subsequently, the intermittent upper and lower fingers are bend in a forward direction and the rearward facing clips are bent in a rearward direction.

The adaptor rail is assembled to the substructure rail by clipping the rearward facing clips of the adaptor rail into a slot formed in the substructure rail. Prior to or subsequently to clipping the adaptor rail to the substructure rail, a brick tile is assembled to the adaptor rail as herein described. Typically, multiple adaptor rails will be clipped to the substructure rail. The arrangement of the brick tile can be adapted by sliding the adaptor rail in the substructure rail and additionally or alternatively by any movement accommodated for by the intermittent fingers and between the brick tile and the adaptor rial. There is therefore provided a method of forming a wall cladding by fixing a substructure rail to a substructure being clad and clipping a rearward facing clip of the adaptor rail into opposed fixing recesses of the substructure rail to connect a brick tile having a large dimensional tolerance to the rail. Suitably, prior to clipping the adaptor rail to the substructure rail, an intermittent upper finger and an intermittent lower finger of the adaptor rail are inserted into a respective upper and lower notch of a brick tile. The method may comprise clipping multiple brick tiles to the adaptor rail and I or clipping multiple adaptor rails to a single substructure rail. Furthermore, the method may comprise sliding the adaptor rail along the substructure rail to adjust the position of the adaptor rail along the substructure rail.

There is therefore provided a wall cladding system comprising a substructure rail, a brick tile and an adaptor rail, wherein: the rail assembly provides opposed fixing recesses; the brick tile has opposed notches; and the adaptor comprising forward facing clips to engage the opposed notches of the brick tile and rearward facing clips to engage the opposed fixing recesses of the rail assembly.

It will be appreciated that the substructure rail is suitably an existing rail of a wall cladding system and the adaptor rail enables a wider selection of brick tiles (i.e. brick tiles that might otherwise have too larger manufacturing tolerance to be repeatedly secured in the existing rail) to be used in the wall cladding system. Thus, the substructure rail includes opposed upper and lower recesses into which known brick tiles are clipped or into which the rearward facing clips of the adaptor rail can alternatively be clipped. The opposed upper and lower recesses are continuously formed along the length of the substructure rail to define a slot. The slot is resiliently openable to clip a known brick tile or the rearward facing clips of the adaptor rail. Suitably, the upper recess is formed by an overhung lip. The overhung lip may project downwardly from a sloped upper face that is connected to a planar rear face. Suitably, the lower recess is formed by a projection. Here, the projection extends from a lower face that is connected to the planar rear face. Suitably a front nose of the lower face has a downward extension with a hooked end.

There is also provided an adaptor rail comprising a rear face, a set of intermittent upper fingers that extend from an upper portion of the rear face and a set of intermittent lower fingers that extend from a lower portion of the rear face. The adaptor rail further comprising rearward facing clips from the rear face.

There is also provided a brick tile having a front face, a rear face, and opposed side faces, wherein respective upper and lower faces each have a notch, wherein a rear portion of the brick slip between the notch and rear face does not extend past a front portion of the brick slip between the front face and the notch.

There is further provided a kit comprising an adaptor rail and a brick tile. Wherein the adaptor rail has a rear face, a set of intermittent upper fingers that extend from an upper portion of the rear face and a set of intermittent lower fingers that extend from a lower portion of the rear face. The adaptor rail further comprising rearward facing clips from the rear face. The set of intermittent upper fingers comprising a first upper finger and a second upper finger. The set of intermittent lower fingers comprising a first lower finger and a second lower finger. The first and second upper fingers and the first and second lower fingers are spaced apart to contact a respective end region of the brick tile. For instance, an end region being within 25% of the length of the brick tile. The brick tile having a front face, a rear face, and opposed side faces, wherein respective upper and lower faces each have a notch. And wherein the adaptor rail and brick tile are configured to be assembled by inserting the first and second upper fingers into the notch in the upper face of the brick tile, and by inserting the first and second lower fingers into the notch in the lower face of the brick tile.

The invention includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

Summary of the Figures

Embodiments and experiments illustrating the principles of the exemplary embodiments will now be discussed with reference to the accompanying figures in which:

Figure 1 is a schematic front view of a rail system for an acknowledged art wall cladding system;

Figure 2 is a side perspective view of the rail system of Figure 1 according to the acknowledged art wall cladding system;

Figure 3 is a front perspective view of a brick tile suitable for assembling to the rail system of Figures 1 and 2 and in accordance with the acknowledged art wall cladding system;

Figure 4 is a schematic end view of: a brick tile of figure 3; a rail of the rail system of Figures 1 and 2; and the brick tile assembled to the rail in accordance with the acknowledged art wall cladding system;

Figure 5 is a schematic cross-section through the acknowledged art wall cladding system;

Figure 6 is a front view of an adaptor rail in accordance with an exemplary embodiment along with cross- sectional detail views through sections AA and BB;

Figure 7a is an end view of a thick brick tile according to an exemplary embodiment and Figure 7b is an end view of a thin brick tile according to an exemplary embodiment;

Figure 8 is a perspective end view of a brick tile of Figure 7 being assembled to an adaptor rail of Figure 6;

Figure 9 is an end view of the assembled brick tile of Figure 7 and adaptor rail of Figure 6;

Figure 10 is a perspective view of the assembled brick tile of Figure 7 and adaptor rail of Figure 6 from one elevation;

Figure 11 is a perspective view of the assembled brick tile of Figure 7 and adaptor rail of Figure 6 from the other elevation;

Figure 12 is an end view of a wall cladding system according to the exemplary embodiments;

Figure 13 is afront perspective view of the wall cladding system; Figure 14 is a front and end view of an adaptor rail in accordance with an exemplary embodiment along with cross-sectional detail views through sections AA and BB; and

Figure 15 is an end view of a wall cladding system according to an exemplary embodiment using the adaptor rail of Figure 14 and the brick tile of Figure 7.

Detailed Description of the Invention

Aspects and embodiments of the exemplary embodiments will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art.

Figure 6 shows a rail 100 according to an exemplary embodiment. The rail 100 is adapted for receiving a single brick tile 200 (see figure 7 and as described below). Although termed a brick tile, the interchangeable terms brick slip or slip can and are used herein to refer to the same component. The rail 100 is adapted for receiving the brick tile by the provision of intermittent upper fingers 110 that project from a rear face 120 and by the provision of intermittent lower fingers 130 that also extend from the rear face 120. Suitably, the intermittent upper fingers comprises a plurality of upper fingers 111 that are spaced along a length of the rail. That is that are spaced along an upper region 121 of the rear face. Likewise, suitably the intermittent lower fingers comprise a plurality of lower fingers 131 that are spaced along a length of the rail. That is that are spaced along a lower region 122 of the rear face. In figure 6, the rail is shown with a first upper finger 111 and a first lower finger 131 at one end region of the rail (i.e. an end region of the rear face), and a second upper finger 111 and a second lower finger 131 at an opposed end region of the rail (i.e. an opposed end region of the rear face). The first upper finger and the first lower finger are suitably opposed about a mid-line of the rail. Whilst the rail being adapted for receiving a single brick is envisaged as being particularly suitable, it will be understood that the rail can be adapted for receiving a plurality of bricks by repeating further upper and lower fingers along a mid-portion of the rail 100. Additionally, or alternatively, the rail can be adapted for receiving long format tiles, for instance where a long format tile is around two or three times as long as a more standard format tile corresponding to a length of a traditional brick. Here, it is envisaged the rail might be configured to provide more than three or more than four individual fingers in each of the upper and lower intermittent fingers in contact with each brick. Or suitably five or six intermittent fingers in each of the upper and lower intermittent fingers in contact with each brick. Where three or more fingers in each of the upper and lower intermittent fingers are configured to be in coOntact with a brick tile, or where the rail is configured to receive a plurality of brick tiles each in contact with a plurality of fingers in each of the upper and lower intermittent fingers, it is envisaged the respective fingers will have a similar ratio to extent along the brick to the brick length. And in particular the extent of the intermittent upper and I or lower fingers may be between around 10% to 50% of the length of the rail.

As will be appreciated, the rail is configured to form a component in a rail system, wherein the rail system is suitable for use in a wall cladding system. Thus, the rail can be directly secured to a building’s envelope for receiving and securing the brick tiles there to, or the rail 100 can be secured to vertical supports, or otherwise secured to the building’s envelope as is known in the art. However, one particular exemplary application of the rail is as an adaptor rail, wherein the adaptor rail receives and secures a brick tile (or a plurality of brick tiles) and the adaptor rail is subsequently secured in a substructure rail of the rail system. For instance, the substructure rail is envisaged as being a known rail as described in the background section. The rail 100 will therefore be described herein in detail in relation to an adaptor rail 100, wherein the rail further includes a rearward facing clip 140 suitable for securing the adaptor rail in to opposed recesses providing a slot of a substructure rail. That is, the rearward facing clip is suitably adapted (e.g. sized and shaped) to clip into the first recess 31 and the second recess 32 as described in relation to Figures 1 to 5. However, it will be appreciated that the rearward facing clip can be adapted to suit alternative substructure rails by adapting the size and shape of the rearward facing clip accordingly. Due to the function of the adaptor rail, it is envisaged the adaptor rail may be referred to in marketing as a ‘clip’.

The rear face 120 is shown in figure 6 as including a series of holes 125. The series of holes reduce the material and weight of the adaptor rail, but may be primarily configured for use in the manufacturing process. Otherwise, the rear face 120 is shown as being substantially planar. That is, the rear face is formed from a substantially planar sheet. It is envisaged the rear face 120, whilst remaining substantially planar, may also be adapted to include ribs or the like for providing structural strength or rigidity to the rail 100. In accordance with materials used in existing rail systems, it is envisaged the adaptor rail 100 will be formed from metal, for instance steel, but other suitable materials are equally applicable. As will be described herein, in particularly suitable embodiments, the intermittent upper fingers 110, the intermittent lower fingers 130, and the reward facing clip 140 (where provided, e.g. when the rail is configured as an adaptor rail) are suitably formed by a bending operation. That is, the features are bent from the rear face 120. Thus, the rail adaptor is formed from a blank, comprising a sheet. Via punching or stamping or other cutting and forming operations, the intermittent upper fingers are bent from an upper region of the blank in a forward direction, the intermittent lower fingers are bent from a lower region of the blank in the forward direction, and the rearward facing clip is bent from the upper and lower regions in an opposed direction from the rear face to the intermittent fingers.

Referring to section AA of Figure 6, the rearward facing clip 140 is shown in more detail. Here, the rearward facing clip 140 is shown as comprising a shoulder portion 142. The shoulder portion is configured (i.e. sized and shaped) to locate in a recess of a substructure rail. That is, suitably, the shoulder portion 142 is sized and shaped to replicate the shoulder 47 (see figure 3) of the acknowledged art brick tile. The shoulder portion 142 is therefore shown as comprising a tip 143, where a distal termination of the tip provides an abutment between the adaptor rail and the substructure rail when the adaptor rail is clipped into the substructure rail. The tip 143 is angled to the rear face, and shown angled substantially perpendicularly to the rear face 120. As mentioned, the shoulder is suitably bent from the rear face and is shown as being connected thereto via an offset face 144 and a transition portion 145. The offset face 144 provides a second abutment with the substructure rail, where the second abutment is opposed to the abutment between the tip and the substructure rail so that the shoulder can be wedged into the upper recess of the substructure rail. The offset face is shown as being parallel to the rear face 120, but off set rearwardly thereto. The transition portion connects the rear face and the offset portion. The transition portion is bent at a first bend from the rear face, the offset face 144 is bent from the transition portion at a second bend and the tip is bent from the offset face at a further bend. The bends forming the shoulder portion are substantially parallel to each other. Moreover, the bends are substantially aligned to a length of the adaptor rail. Thus, resiliency in the bends enables the lobe to flex to assist is the clipping of the adaptor rail into the substructure rail.

The rearward facing clip 140 further comprises a lobe portion 146. The lobe portion is configured (i.e. sized and shaped) to locate in a recess of a substructure rail. That is, suitably, the lobe portion 146 is sized and shaped to replicate the lobe 45 (see figure 3) of the acknowledged art brick tile. The lobe portion 146 is therefore shown as comprising ledge 146a that extends (e.g. is bent from) the rear face 120. The ledge is configured to receive a projection (i.e. the projection 36 of the acknowledged art rail - see figure 4). Here, the ledge comprises a ledge face 146b and an abutment face 146c. the abutment face is bent from the ledge face and forms the stop against which the projection acts. That is, the ledge replicates the notch of the acknowledged art brick tile. A lower abutment face 147 extends from the abutment face. The lower abutment face 147 is arranged to lie adjacent a lower face 37 of the substructure rail. A rear abutment face 148 is arranged to lie adjacent a rear face 35 of the substructure rail. The rear abutment face and the lower abutment face are interconnected by a sloped transition 149. The ledge face 146a is bent from the rear face 120 at a first bend and suitably bent at a perpendicular angle. Likewise, the abutment face 146b is bent at a second bend from the ledge face 146a, and suitably bent at a perpendicular angle. The lower abutment face 147 is bent at a further bend from the abutment face 146b. The sloped transition and rear abutment face are likewise, respectively bent from the lower abutment face and the sloped transition at further bends. The bends forming the lobe portion are substantially parallel to each other. Moreover, the bends are substantially aligned to a length of the adaptor rail. Thus, resiliency in the bends enables the lobe to flex to assist is the clipping of the adaptor rail into the substructure rail.

Referring to section BB of Figure 6, the intermittent upper fingers 110 and the intermittent lower fingers 130 are shown in more detail. The intermittent upper fingers 120 are shown comprising a set of a first type of finger 150. As explained above, in the figures showing an adaptor rail configured to receive a single brick tile, the set of first type of fingers comprises two first type of fingers spaced apart along the rail. However, further first type of fingers in the set are envisaged as explained herein. The intermittent lower fingers 130 are shown comprising a set of a second type of finger 160. As explained above, in the figures showing an adaptor rail 100 configured to receive a single brick tile, the set of second type of fingers comprises two second type of fingers spaced apart along the rail. However, further second type of fingers in the set are envisaged as explained herein.

Each first type of finger 150 suitably comprises a proximal portion 152 and a distal portion 154 connected by a knuckle 156. The proximal portion extends from the rear face 120, and is suitably bent therefore at a first bend. The first bend suitably forms a perpendicular angle. The knuckle 156 comprises a second bend and slants the distal portion to extend into a notch in the brick tile (as herein described). Thus, the distal portion hooks over the brick tile to assist in mechanically securing the brick tile to the adaptor rail. The bends forming the first type of finger are substantially parallel to each other. Moreover, the bends are substantially aligned to a length of the adaptor rail. Thus, resiliency in the bends enables the first type of finger to flex to assist is the clipping of the brick tile into the adaptor rail 100.

Each second type of finger 160 suitably comprises a proximal portion 162 and a distal portion 164 interconnected by a medial portion 166. The proximal portion extends from the rear face 120, and is suitably bent therefore at a first bend. The first bend suitably forms a perpendicular angle. The medial portion 156 is bent from the proximal portion so as to extend into a notch in the brick tile (as herein described). The distal portion is bent from the medial portion to be slanted relative to the rear face. Thus, the medial portion hooks over the brick tile to assist in mechanically securing the brick tile to the adaptor rail. And the distal portion provides a slope to assist in clipping the brick into the intermittent fingers. The bends forming the second type of finger are substantially parallel to each other. Moreover, the bends are substantially aligned to a length of the adaptor rail. Thus, resiliency in the bends enables the second type of finger to flex to assist is the clipping of the brick tile into the adaptor rail 100.

Advantageously, because the intermittent upper and lower fingers do not extend the length of the adaptor rail, the intermittent fingers can be used to clip a brick tile manufactured within a broader tolerance range. That is, the intermittent fingers can be configured to accommodate a larger size range of brick tile than can be achieved with the acknowledged art rail wherein the recesses are formed by bends extending substantially the full length of the rail or brick. Furthermore, when provided as an adaptor rail, the spacing between the plurality of fingers in each respective set of upper and lower intermittent fingers provides a convenient location to arrange the rearward facing clip. That is, by separating the upper region and the lower region of the blank from which the adaptor rail is manufactured across the length direction, portions of the upper region and lower region can be bent in a forward direction to form the intermittent fingers, and an intermediate portion (between the portions bent forwardly) can be bent in a rearward direction to form the rearward facing clip. Thus, as shown, slits 124 are formed in the blank to separate the intermittent fingers and rearward facing clip, but otherwise, the rearward facing clip extends along a length of the rail substantially between a first finger and a second finger in the respective sets of first and second types of finger.

Referring now to Figure 7, there is shown a brick tile according to exemplary embodiments. The brick tile 200 is cuboid having a front face 202, a rear face 204, an upper face 206, and a lower face 208. As will be appreciated end faces 209 (see figure 8) complete the cuboid shape. The front face forms the finished face generating the facade of the wall cladding system. The upper and lower faces 206, 208 include notches 210 for receiving the intermittent fingers of the adaptor rail. The notches are formed as channels having a substantially square profile and running the entire length of the brick tile 200. The brick tile is substantially symmetrical about a central plane extending between the front, rear and end faces. Thus, the brick tile can be installed in either orientation into the adaptor rail. As shown, the rear face, that corresponds to the rear face of the adaptor rail, is shorter than the front face. In Figure 7a the depth of the brick tile between the front face and rear face is shown as being larger than the depth of the brick tile in Figure 7b. But otherwise, the notches are substantially similar so that thick and thin brick tiles can be arranged in the adaptor rails.

As shown in Figure 8, the brick tile 200 is clipped into the adaptor rail 100 by inserting one of the notches in to the upper intermittent fingers. For instance, the brick tile 200 is offered at an angle to the rear face of the adaptor rail, and the distal portion of the first type of fingers inserted into the notch. Here the sloped arrangement of the distal portion allows the distal portion to be aligned adjacent a face of the notch with the brick offered up at an angle. The brick tile 200 is then rotated to bring the rear face of the brick tile 200 to substantially lie against the rear face of the adaptor rail 100. During the rotations, the brick tile comes into contact with the distal end of the lower intermittent fingers. By urging (i.e. striking the brick tile with a rubber mallet or otherwise pushing the brick tile towards the adaptor rail) the brick tile towards the adaptor rail, the resilient flexing provided by the intermittent fingers allows the brick tile to slide along the sloped distal portion of the lower intermittent fingers until the medial portion snaps or otherwise enters the other notch. In this arrangement, the brick tile is mechanically held in the adaptor rail. Here, the rear face of the brick tile lies substantially against the rear face of the adaptor rail. The intermittent upper and lower fingers being spaced apart across the rear face a distance equivalent to the height of the rear face of the brick tile, bearing in mind the manufacturing tolerance. Moreover, the knuckle of the first type of intermittent finger is spaced from the rear face by the proximal portion substantially an equivalent distance as to the distance the notch is spaced from the rear face of the brick tile (again, bearing in mind the manufacturing tolerance). Likewise, the medial portion of the second type of intermittent fingers is spaced an equivalent distance. Once clipped into the adaptor rail 100, the brick tile is mechanically connected and prevented from being unclipped without substantial force.

Figures 10 and 11 show in closer detail, the respective intermittent fingers inserted into the notches. As shown, the adaptor rail is a shorter length than the brick tile. Thus, some lateral movement of the brick tile relative to the adaptor rail can be accommodated before the respective intermittent fingers slide out of the notch.

Suitably subsequent to the brick tile being clipped into the adaptor rail (though the order is not envisaged as being limiting), the adaptor rail is clipped into the substructure rail. It will be appreciated that the adaptor rail can be clipped into the substructure rail substantially as the acknowledged art brick tile is clipped into the acknowledged art rail. Indeed, an advantage of the exemplary embodiments is that the rearward facing clip of the adaptor rail substantially simulates the acknowledged art brick tile. The adaptor rail can be slid along the substructure rail to obtain a desired horizontal arrangement as is known in the art with the acknowledged art system.

Figures 12 and 13 show a part assembled wall cladding system wherein a plurality of exemplary adaptor rails are clipped into a series of substructure rails attached to a building fagade. As will be appreciated, the gaps between adjacent brick tiles are suitably pointed. For instance, a mortar can be injected into the gaps and pointed as is known in the art. The mortar or other pointing fixes the wall cladding system, with the brick tiles being mechanically secured to the substructure rail, via the adaptor rail, to prevent the brick tiles coming loose. Advantageously, the rail of the exemplary embedment’s having intermittent upper and lower fingers and in particular an adaptor rail further including a rearward facing clip enables brick tiles manufactured to a larger size tolerance to be utilised in wall cladding systems and in particular to adapt known rail systems thereto.

Figure 14 shows a further exemplary embodiment of an adaptor rail 100. The adaptor rail is substantially the same as the previous described adaptor rail in relation to Figures 6. The principal difference is the provision of ribs 170 that act to strengthen the rear face. Horizontal 172 and vertical 174 ribs are shown. The ribs are suitably pressed indentations in the rear face and act to provide stiffness to the rear face. More minor differences to the previous embodiment can be seen in the distal portion 154 of the first type of finger terminating in a downwardly extending stub. That is, the stub is a short portion that lies substantially parallel to the rear face. On the second type of finger, the distal portion 164 extends past the lowermost extent of the proximal portion 162. Finally, the shoulder and lobe of the rearward facing clip, is bent from the rear face in a substantially similar plane to the bend from which the first finger and second finger bend rather than being offset.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the word “comprise” and “include”, and variations such as “comprises”, “comprising”, and “including” 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.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means for example +/- 10%.