The present invention relates to components for the assembly of brick tile façades and to methods of using such components. More specifically the present invention relates to a spacer element for brick tiles configured to retain brick tiles more reliably in an intended position.
Brick tiles, or slip bricks, are used in modern façade construction to provide an appearance of solid brickwork. Such brick tiles are mounted onto a rail arrangement of multiple horizontally extending and vertically spaced apart brick-carrying rails. Joints between the individual brick tiles can be filled with mortar to provide the appearance of a solid brick wall.
Brick tiles typically comprise one or more grooves to engage a brick-carrying rail on which they are mounted. The grooves are located at the rear face or at one or more side faces of a brick tile, such that the brick tile front face provides the appearance of a conventional brick without grooves, in a manner allowing the brick-carrying rails to remain concealed behind the brick tile. I.e., the grooves may extend along the rear of a brick tile or along its top and base faces. As a brick tile is usually considerably shorter than a brick-carrying rail, in order to position a brick tile along the brick-carrying rail, it is usually intended to be slipped onto and along the brick-carrying rail during construction of a wall.
Some systems comprise brick tiles with a tapered insertion edge that allows a brick to be pushed frontally onto the rail arrangement, and to clip into place. This avoids having to slide a brick laterally for a long distance. However, considerable force can be required to push a brick onto a rail, which complicates assembly.
Great British patent application GB1709829.4 by the present applicant, published as GB2565266, discloses a brick-carrying rail design with sound-damping properties.
The present invention is concerned with improving certain aspects of the construction of brick tile walls.
In accordance with a first aspect of the invention, there is provided a slip brick arrangement as defined in claim 1. The slip brick arrangement is of the type for use in a façade cladding system and comprises a slip brick and a spacer element.
The slip brick comprises at least one rail-engaging groove to engage with a brick-retaining rail to be provided. The spacer element comprises a main spacer body at least part of which is to be positioned inside the rail-engaging groove. The main spacer body comprises a protrusion to hinder sliding of the spacer element towards the brick-retaining rail.
In some embodiments, the spacer element comprises an arm extending from said main spacer body, the arm constituting a part to be positioned inside the rail-engaging groove to hold the main spacer body laterally on the slip brick thereby to maintain a distance between the slip brick and another slip brick to be provided.
The arm allows the main spacer body to hook onto the rail-engaging groove. The protrusion may be on the arm. The protrusion may be on a portion of the main spacer body that is not part of the arm. In that case, the protrusion may be outside the rail-engaging groove, on a portion of the main spacer body positioned laterally of the slip brick.
In some embodiments, the spacer element comprises a generally planar surface portion and the protrusion extends away from the planar surface portion.
The protrusion extends away from the general plane of the surface portion or surface. The protrusion may be located within the outline silhouette of the surface portion, i.e. more centrally than an outermost edge of the surface portion.
In some embodiments, the spacer element is made from sheet metal.
In some embodiments, the protrusion is provided by a tab.
The tab may be provided by lancing a sheet metal portion. The protrusion may be provided by an edge of a sheet metal portion, e.g. by a bent edge. The protrusion may protrude at least as far from the plane of the sheet metal portion as the thickness of the sheet metal portion.
In some embodiments, the protrusion is integral with the main spacer body.
Conveniently, if the spacer element is made from sheet metal, the protrusion may be formed by lancing or otherwise suitably forming the sheet, to produce one or more corners or tabs that protrude away from the planar extension of the metal sheet. In other embodiments the protrusion may be a separate component mounted on the main spacer body.
In some embodiments, the main spacer body is made from spring steel.
By manufacturing the spacer element from sprung steel it provides resilient properties, helping to bias the brick into a safe position.
In some embodiments, the main spacer body is arched.
The biasing properties of the spacer element can be further improved by arching the main spacer body. For spacer elements made from otherwise planar shapes, an arched spacer body provides profile thickness perpendicular to the planar extension without requiring a thicker cross-section of the body. An arched spacer body can be considered to have a concave side and a convex side.
In some embodiments, the protrusion is located on a concave side of the main spacer body.
In such embodiments the protrusion is located on the concave side of the arch. Thereby, temporary compression of the arch to flatten it urges the protrusion out of the concave portion, or further outward, against the brick-retaining rail against which it is intended to abut. If forces act in the removal direction of the slip brick then such forces push the protrusion against a brick-retaining rail, preventing its removal. To contrast this with a situation otherwise expected in the absence of a spacer with protrusion, in that case pushing the brick against the brick-retaining rail would cause the slip brick to sit looser.
In some embodiments, at least a portion of the protrusion protrudes outside the concave side of the main spacer body, i.e. beyond the volume defined by the concavity of the arch.
Thereby it can be ensured that the protrusion engages a brick-retaining rail whether or not the arched body is temporarily flattened, i.e. particularly in a rest condition of the arched body.
In some embodiments, the protrusion is located near an end of the main spacer body.
The protrusion may be located on the arm or on the main spacer body. The protrusion may be located, in the longitudinal extension of the spacer element, opposite the groove-engaging side of the arm.
In some embodiments, the protrusion provides an abutment surface opposite the rail-engaging groove whereby the arm is urged into the rail-engaging groove when the protrusion abuts against the brick-retaining rail.
In accordance with a second aspect of the invention, there is provided a spacer element as defined in claim 13. The spacer element is for use with a slip brick to be provided, the slip brick being of the type comprising a rail-engaging groove, wherein the spacer element is made from an unitary sheet providing a main spacer body and an arm extending from the main spacer body to engage in the rail-engaging groove, wherein the main spacer body comprises a lanced portion providing a protrusion.
The protrusion may be positioned on or near the arm-carrying end of the main spacer body. The protrusion may be positioned opposite the arm. The protrusion may be positioned on the arm.
Any one or more features described in relation to the first aspect may also be present in embodiments of the second aspect. In some embodiments, the main spacer body is made from spring steel. In some embodiments, the main spacer body is arched. In some embodiments, the spacer body is arched in the opposite direction of the protrusion such that the protrusion is located on a concave side of the main spacer body. In embodiments, at least a portion of the protrusion protrudes outside the concave side of the main spacer body particularly in a rest condition of the main spacer body.
The slip brick arrangement of the first aspect, and/or the spacer element of the second aspect, may be comprised in a façade cladding system. In embodiments, the spacer element of the first aspect is provided without a slip brick.
In accordance with a third aspect of the invention, there is disclosed a façade cladding system. The façade cladding system comprises a slip brick arrangement according to any one of the embodiments of the first aspect and/or a spacer element according to any one of the embodiments of the second aspect.
It will be understood that a façade cladding system is typically installed on an underlying support or backing structure.
The slip brick arrangement of the first aspect, using the spacer element of the second aspect, allows slip bricks with grooves along their elongate dimension to be installed vertically, i.e. such that the brick-retaining rails are oriented vertically and such that the rail-engaging grooves are oriented vertically. The secure retention of the slip bricks no longer relies only on the mass of the slip brick to prevent a slip brick from falling out of the rail.
Surprisingly, the retention provided by the spacer element of the invention also allows slip bricks to be installed horizontally, e.g. to the underside of ceilings or overhangs, to provide a horizontally extending façade.
Exemplary embodiments of the invention will now be described with reference to the Figures, in which:
A plurality of slip bricks 10 (only two bricks 10a and 10b being annotated in
To maintain a practically homogenous spacing between joints, brick spacers 8 are located in the interstitial space between two slip bricks 10 (
The longer lateral sides 13, 14 are provided with a rail-engaging groove 16, a first groove 16a in one of the longer lateral sides 13 (in
The grooves 16a, 16b have a generally rectangular, thin profile providing a thin straight trench extending uniformly along the width of the slip brick 10, and are shaped to slidingly engage a lip constituting a retaining profile of brick-carrying rail (see e.g. rails 2, 4a, 4b, 4c, 4d or 6 in
The grooves 16a, 16b may be located centrally within the thickness of the slip brick 10, providing a bi-symmetric cross-section (symmetric along the plane between front and back faces and symmetric along the horizontal plane between the grooves 16a and 16b). The grooves 16a, 16b may be located off-centre, closer to the rear face 12 or closer to the front face 11. By providing a groove 16a, 16b off-centre, closer to the rear face 12, more brick material protrudes outward, providing a deeper brick-to-brick joint space for receiving mortar material. The grooves 16a, 16b are slightly deeper than the retaining profile of the brick-retaining rails 2, 4, 6, to be able to work with wider tolerances and to allow a slip brick 10 to be levered onto a brick-carrying rail from the front as follows: First, the slip brick 10 is slotted from below onto, and pushed upward against, a rail above such that the first (top) groove 16a engages the rail above, then the slip brick 10 is held vertically and allowed to drop, such that the second (bottom) groove 16b slots onto the rail beneath. At this stage, before mortar is added, a slip brick 10 could be unseated by pushing it up. In practice this is not an issue as the slip brick 10 has sufficient mass to sit securely in place, however in practice this allows individual slip bricks to be easily unseated if necessary for lateral alignment along the length of the brick-carrying rail.
Turning to the brick spacer 8, this is a generally flat piece of sheet metal comprising a main spacer body 17 with a hook 18 extending laterally, in the plane of the sheet metal, from the main spacer body 17. The spacer element has a general shape of a letter “L” formed from a rectangular main spacer body 17 and a rectangular arm extending a portion of the main spacer body 17 to provide the hook 18. The L-shape is convenient to manufacture from sheet metal, e.g. by stamping. For instance, the L-shape may facilitate manufacturing with little waste.
The hook 18 comprises an inner edge 19 by which the brick spacer 8 can be engaged in a groove 16 of the slip brick 10 (see also
The spacer element 20c of
Part-way along the length of the spacer element 20c, the sheet material has been lanced to provide a cut 28. The cut 28 is located within the height of the arm 24, i.e. along the longitudinal extent of the main spacer body 22c the cut 28 is located between the groove-engaging edge 25 and the arm-carrying end 26. The cut 28 comprises a straighter edge 30 nearer the arm-carrying end 26 and a bent edge 32c distal to the arm-carrying end 26. The bent edge 32c constitutes a protrusion extending from the plane of the main spacer body 22c (see
The overall length of the spacer element 20c corresponds closely to, or exceeds, the height of the slip brick 10, such that the spacer element 20c spans the distance between two adjacent brick-retaining rails (e.g., the brick-retaining rails immediately above and below) when it is located on a slip brick 10.
By using a spacer element 20c with a protrusion, it is possible to create vertically extending brick arrangements of the type shown in
Surprisingly, when using a spacer element 20c of the invention, the slip bricks 10 remain horizontally secure between two rails, without a risk of a slip brick 10 sliding or falling from the rails. This is because, once a slip brick 10 is inserted together with a spacer element 20c, the bent edge 32c reduces and practically eliminates horizontal leeway, as it protrudes from the plane of the spacer element 20c and abuts against the retaining profile of the brick-retaining rail 40. Although the retaining profile and the spacer element 20c may be made from relatively thin material, as the bent edge 32c is curved away from the retaining profile against which it abuts (see
The distance-maintaining function of the spacer element 20c is improved by providing an arched main spacer body 22c, because the arched main spacer body 22c provides a wider-profiled seating surface compared to a straight planar brick spacer.
The arrangement shown in
It will be understood that mortar material is to be applied in the joints to conceal the spacers and rails, and to provide a solid brick wall appearance. As the only materials used are metal (rails and spacer elements), brick and mortar, this facilitates the manufacture of these components from materials with high fire rating.
Surprisingly, the retention properties achieved with the spacer element 20a, 20b or 20c allow a slip brick to be installed on the underside of a ceiling or overhang. This provides the opportunity to incorporate slip bricks in horizontally extending façades.
The spacer element 20c is inserted laterally, in the extension of a groove 16a, by locating its arm 24 in the groove 16 of the slip brick 10. In this orientation, the bent edge 32c of the arm 24 abuts one of the brick-retaining rails. Thereby, the slip brick 10 has no longer enough leeway to slide in the insertion direction. As such the slip brick 10 is prevented from sliding perpendicular to the extension of the brick-retaining rails. This practically prevents the slip brick from falling out of the rail arrangement. Although only one slip brick 10 is illustrated in
The arrangements described herein allow slip brick grooves with larger tolerances to be used while maintaining slip bricks safely in their rails. Furthermore, the same slip brick type, with grooves along the elongate side, can be used for both horizontally and vertically extending brick arrangements.
The spacer elements 20a, 20b, 20c may be provided with a texture to improve its mortar binding behaviour.
The bent edges 32a and 32b, illustrated in
The arm 24, illustrated in
It will be understood that the protrusions may be provided in any suitable form and/or material, also within the main spacer body.
The present invention allows bricks with generally rectangular profile to be used, avoiding a need for tapered insertion edges as is known from other systems. By avoiding tapered insertion edges, the groove walls are thicker and therefore less susceptible for damage.
Number | Date | Country | Kind |
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1912747.1 | Sep 2019 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/GB2020/052113 | 9/4/2020 | WO |