TECHNICAL FIELD
The present disclosure relates to a panel assembly, panel system and panelling method. In an example, the panels are exterior cladding panels fitted to substrate forming the outside of a building.
BACKGROUND ART
Panels are routinely used in construction, e.g. for exterior cladding, floors, roofs, and interior walls. In many cases, panels are required to be fitted to a substrate with a cavity provided between the panel and the substrate. To achieve this, framing or bracketing systems may be used, wherein a frame and/or brackets are fixed to the substrate before panels are fixed to the frame and/or brackets.
However, such systems tend to be complex and time consuming to install. They may require significant time to ensure correct alignment of components on the substrate and/or may require high numbers of manual fixings, such as screws, bolts and/or rivets. Often, fixings must be driven through the surface of a finished panel, which may be detrimental to the aesthetic of the panels.
It is an aim of the present disclosure to at least partially address some or all of the above problems.
SUMMARY OF THE INVENTION
According to a first aspect of the disclosure there is provided a panel assembly comprising: a panel comprising rear and front surfaces; a first rail connected to the rear surface of the panel; one or more brackets connected to the first rail and configured to travel along the first rail; wherein the one or more brackets are configured to be fixed to a substrate, while connected to the panel via the first rail.
Optionally, a fixing portion of each bracket extends beyond an edge of the panel, said fixing portion being configured to be fixed to the substrate. Optionally, the fixing portion comprises one or more openings configured to accept a mechanical fixing. Optionally, the fixing portion extends beyond the edge of the panel sufficiently to allow access to the fixing portion by a device configured to drive a mechanical fixing.
Optionally, the panel comprises a reference edge and the rail is arranged substantially at the reference edge.
Optionally, only one first rail is provided and only the brackets connected to the one first rail are configured to be fixed to a substrate while connected to the panel. Optionally, the panel is configured to be fixedly attached to the substrate only via the one first rail and the brackets connected thereto. Optionally, the fixed attachment is provided by one or more mechanical fixings.
Optionally, the first rail comprises one or more rail engaging parts, and each bracket comprises one or more bracket engaging parts respectively configured to engage with each other to connect each bracket to the rail. Optionally, the one or more rail engaging parts comprises a female part and the one or more bracket engaging parts comprise a male part. Optionally, the one or more rail engaging parts comprises a first wall substantially parallel to the rear surface of the panel, and a second wall substantially parallel to the rear surface of the panel, wherein a gap is provided between the first and second walls; and the one or more bracket engaging parts comprises a third wall configured to fit into the gap between the first and second walls of the one or more rail engaging parts.
Optionally, the panel assembly comprises two rail engaging parts and two respective bracket engaging parts. Optionally, the two rail engaging parts are arranged at opposing edges of the first rail.
Optionally, each bracket is configured to slide along the first rail. Optionally, each bracket is configured to slide onto the first rail to connect the bracket to the first rail.
Optionally, each bracket comprises a body portion extending substantially perpendicular to the rear surface of the panel and connected at a first end to the first rail, and a fixing portion extending substantially parallel to the rear surface of the panel at a second end of the body portion opposite the first end.
Optionally, each bracket comprises an abutment portion configured to provide a surface for abutment against further panel assembly positioned adjacent the panel assembly. Optionally, the abutment portion extends beyond an edge of the panel.
Optionally, each rail is fixed to the rear surface of the panel by one or more mechanical fixings.
Optionally, the one or more mechanical fixings passes completely through the panel.
Optionally, the panel assembly further comprises a finishing layer connected to the front surface of the panel. Optionally, the finishing layer is arranged to cover the one or more mechanical fixings.
Optionally, the panel assembly further comprises a second rail, wherein the further rail is configured to connect to one or more further brackets that are each fixed to the substrate. Optionally, the first rail and the second rail are arranged substantially at opposite edges of the panel to each other. Optionally, the further rail comprises a flange configured to abut the edge of the panel at which the further rail is arranged.
According to a second aspect of the disclosure there is provided a kit of parts for assembling the panel assembly of the first aspect, comprising at least one first rail and at least one bracket. Optionally, the kit of parts further comprises at least one panel.
According to a third aspect of the disclosure, there is provided panel assembly comprising: a panel comprising front and rear surfaces; a rail connected to the rear surface of the panel; one or more adjustment fixings, connected to the rail and configured to engage with a respective adjustment bracket fixed to a substrate, and the distance between the adjustment bracket and the rear surface of the panel is adjustable by actuating the adjustment fixing.
Optionally, the adjustment fixing comprises a head and a threaded shaft and is arranged to pass through an opening in the rail such that the head faces the rear surface of the panel and the threaded portion extends substantially perpendicular to the rear surface of the panel and is free to rotate within the opening in the rail; the threaded shaft of the mechanical fixing is configured to engage with a threaded opening in each adjustment bracket fixed to a substrate; and the distance between each adjustment bracket and the rear surface of the panel is adjustable by rotating the mechanical fixing.
Optionally, the panel comprises an opening for access to the adjustment fixing for actuating each adjustment fixing from the front side of the panel.
Optionally, the panel assembly further comprises one or more adjustment brackets.
Optionally, each adjustment bracket comprises a body portion extending substantially perpendicular to the rear surface of the panel and comprising the threaded opening at a first end, and a fixing portion extending substantially parallel to the rear surface of the panel at a second end of the body portion opposite the first end.
According to a fourth aspect of the invention, there is provided a kit of parts for assembling the panel assembly of the third aspect, comprising at least one rail and at least one adjustment fixing. Optionally, the kit of parts further comprises at least one bracket. Optionally, the kit of parts further comprises at least one panel.
According to a fifth aspect of the disclosure there is provided a panel system comprising a plurality of panel assemblies according to the first aspect and/or the third aspect, fixed to a substrate. Optionally, the panel system comprises a start-of-run panel assembly according to the first aspect when comprising the further rail, a mid-run panel assembly according to the first aspect, wherein the panel assemblies are fixed to the substrate in a run starting with the start-of-run panel assembly. Optionally, the panel system comprises an end-of-run panel assembly according to the third aspect, wherein the run ends with the end-of-run panel assembly.
According to a sixth aspect of the disclosure there is provided a method of panelling a substrate comprising fixing the panel system according to the fifth aspect to a substrate. Optionally, the method comprises assembling each panel assembly prior to fixing the panel assembly to the substrate.
According to a seventh aspect of the disclosure there is provided a method of manufacturing a panel assembly according to the first or third aspects, comprising forming openings configured to receive mechanical fixing for connecting the rail by computer controlled machining, prior to connecting the rail to the rear surface of the panel. Optionally, the panels are additionally cut to size during the computer controlled machining.
According to an eight aspect of the disclosure there is provided a building comprising the panel system of the fifth aspect. Optionally, the building comprises at least a ground floor building module and a first floor building module.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the disclosure are described below by way of non-limiting examples and with reference to the accompanying drawings, in which:
FIG. 1 shows an example panel assembly;
FIG. 2 shows a first example rail;
FIG. 3 shows a first example bracket;
FIG. 4 shows a first part of an example panel system;
FIG. 5 shows a second part of the example panel system;
FIG. 6 shows a second example rail; and
FIG. 7 shows an example adjustment mechanism.
DETAILED DESCRIPTION
An example panel assembly 1 is shown in FIG. 1. The panel assembly 1 forms part of a panel system, such as the panel system 10 shown in FIGS. 4 and 5. As shown in FIG. 1, the panel assembly 1 comprises a panel 2, having a rear surface 21 and a front surface 22. The rear surface is arranged closer to a substrate 6 to which the panel 2 is to be installed, to face inward, towards the substrate 6, in use, and may not be visible after installation of the panel 2. The front surface 23 is arranged further from the substrate 6, to face outward, away from the substrate, in use, and may be visible after installation of the panel 2. The panel 2 may be formed from one or more of composite façade board, tiles, solar panel, glazed panel, render carrier board, metal profiled aesthetic sheet panel, and timber panelised board, for example.
The terms rear and front, rearward and frontward, and further derivations thereof, are used herein to denote relative positions respectively closer to or further from the substrate in a direction perpendicular to the rear surface of a panel 2, generally the horizontal direction in the Figures. The terms top and bottom, upper and lower, and further derivations thereof, are used herein to denote relative positions in a direction parallel to a panel 2, generally the vertical direction in the Figures. The terms left and right, and side, and further derivations thereof, are used herein to denote relative positions in a direction parallel to a panel 2, generally the into and out of the page in the Figures.
As shown in FIG. 1, a rail 3 is connected to the rear surface 21 of the panel 2. In this example, only one rail 3 is provided. FIG. 1 shows only a cross-section through the rail 3, but the rail 3 extends in a direction into and/or out of the page. The rail 3 may be a substantially straight, elongated rail. The rail 3 may extend the full width of the panel 2. Alternatively, the rail 3 may extend part of the width of the panel 2. The rail 3 may have a substantially uniform cross-section over its full length. The rail 3 may be constructed, for example, by extrusion. The rail 3 may be formed from metal, such as aluminium or steel.
As shown in FIG. 1, the rail 3 may be connected to the rear surface 21 of the panel 2 by one or more rail fixings 5. The rail fixings 5 may be a mechanical fixing such as a rivet, screw or bolt. The rail fixings 5 may pass completely through the panel 2. Alternatively, the fixings 5 may be rear-only fixings that do not pass through the front of the panel 2.
Although not shown, the panel 2 may comprise a finishing layer connected to the front surface 22 of the panel 2. The finishing layer may be a decorative layer, such as a layer imitating the appearance of brickwork. The finishing layer may be arranged on the panel 2 to cover the rail fixings 5.
As shown in FIG. 1, the panel assembly 1 further comprises at least one bracket 4, connected to the rail 3 and configured to travel along the rail 3, e.g. slide along the rail 3 side-to-side. FIG. 1 shows only a cross-section through the bracket 4, but the bracket 4 extends in a direction into and/or out of the page. The bracket 4 may have a substantially uniform cross-section over its full length. The bracket 4 may be constructed, for example, by extrusion. The bracket 4 may be formed from metal, such as aluminium or steel.
As shown in FIGS. 4 and 5, the bracket 4 may be configured to be fixed to the substrate 6 while connected to the panel 2, i.e. via the rail 3. In other words, the bracket 4 may be is connected to the panel before the panel assembly 1 is fixed to the substrate 6. The number of brackets provided per panel assembly 1 is generally determined by the size and/or weight of the panel 2. The longer the panel 2 in the left-to-right direction, and/or the heavier the panel 2, the more brackets 4 may be required. Preferably, at least two brackets 4 are provided for increased stability.
In the panel assembly 1, the rail 3 also ensures correct positioning of the brackets 4 relative to the panel 2 in the top-to-bottom direction. The rail 3 also provides a moveable connection between the bracket 4 and the panel 2 for preferable positioning of the brackets 4 in the left-to-right direction. When the panel assembly 1 is presented to the substrate 6 for installation thereto, an operative can slide the brackets 4 into the desired position left-to-right for preferable fixation. The position may correspond to the position of substrate support 6A, such as wooden stud. When assembling the panel assembly 1, the bracket 4 may slide onto the rail 3 to connect the bracket 4 to the rail 3.
FIG. 2 shows an example rail 3, in cross-section, when not connected to the panel 2 and the bracket 4. As shown in FIG. 2, the rail 3 comprises a rail body 31. In this example, the rail body 31 forms a central part of the rail 3, top-to-bottom. As shown, the rail body 31 may be substantially parallel to the rear surface 21 of the panel 2, when connected thereto. As shown, at opposing top and bottom edges of the rail body 31 there may be provided respective rail engaging portions 32. The rail engaging portions 32 are configured to engage with respective engaging portions 43 of the bracket 4 to connect thereto.
As shown in FIG. 2, the rail engaging portions 32 may comprise a first wall 33 and a second wall 34, separated by a gap. As shown, the first and second walls 33, 34 may respectively be on rearward and frontward sides of the gap. As shown, the first and second walls 33, 34 may be substantially parallel to the rear surface of the panel 2, when connected thereto. As shown in FIG. 2, where the first and second walls 33, 34 connect to the rail body 31, the first and second walls 33, 34 may be curved so as to respectively form two left-right halves of a U-shape or inverted U-shape.
As shown in FIG. 2, a plurality of openings 35 may be formed in the bracket body 31 for accommodating a mechanical fixing, such as the rail fixing 5. These openings 35 may be circular holes, or slots, for example. These maybe formed after an extrusion process forming the rail 3. As shown in FIG. 2, upper and lower ridges may be provided in the rail body 31 above and below the location of the openings 35. These ridges may extend the full length of the rail 3 and may provide strength to the rail 3.
The panel 2 may also comprise pre-formed openings, such as circular holes, or slots, for accommodating the rail fixings 5. The openings in the panel 2 and the openings in the rail 3 may be configured to align for correct positioning of the rail 3 on the panel 2.
As shown in FIG. 2, the frontward, second wall 34 of the engaging parts 32 may be offset from the rail body 31 in the direction perpendicular to the rear surface 21 of the panel 2, when the rail 3 is connected thereto. Accordingly, a recess space 36 is formed between the rail body 31 and the rear surface 21 of the panel 2, when the rail 3 is connected thereto.
As shown in FIG. 2, the second wall 34 of the upper engaging part 32 may extend substantially further than the first wall 33. As shown in FIG. 1, this part of the second wall 34 forms an abutment part 37 configured to extend substantially beyond a top edge of the panel 2, when the rail 3 is connected thereto. As shown in FIG. 4, the abutment part 37 may be configured to provide a surface for abutment against another panel 2 positioned above the panel assembly 1 to ensure alignment between adjacent panel assemblies.
As shown in FIG. 1, the panel 2 may comprise a reference edge, in the example the top edge of the panel 2. The reference edge may be straight edge, an in this example, but in other examples the reference edge may be curved. As shown in FIG. 1, the rail 3 may be connected to the panel 2 substantially at the reference edge. In the case of a straight reference edge, the rail 3 may be arranged substantially parallel to the reference edge. As shown, a portion of the rail 3, i.e. the abutment part 37 may extend substantiality beyond the reference edge of the panel 2.
FIG. 3 shows an example bracket 4, in cross-section, when not connected to the rail 3. As shown in FIG. 3, the bracket 4 may comprise a bracket body 41. As shown, the bracket body 41 may extend substantially perpendicular to the rear surface 21 of the panel 2, when the bracket 4 is connected thereto. The bracket body 41 may be connected at a first end to the rail 3. As shown in FIG. 3, the bracket 4 may also comprise a fixing portion 42 that extends substantially parallel to the rear surface of the panel 2 at a second end of the body portion 41, opposite the first end. The first and second ends of the body portion 41 are displaced in a direction perpendicular to the rear surface 21 of the panel 2, when the bracket 4 is connected thereto. The bracket body 41 ensures that a gap is provided between the substrate 6 and the panel 2. The depth of the gap is largely determined by the length of the bracket body in the direction perpendicular to the rear surface 21 of the panel 2.
As shown in FIG. 3, the bracket 4 may comprise bracket engaging parts 43 configured to engage with respective rail engaging parts 32. As shown in FIG. 3, two bracket engaging parts 43 are provided at upper and lower portions of the bracket body 41. As shown, the bracket engaging parts 43 may comprise male parts configured to engage with female parts of the bracket engaging parts 32. As shown, the bracket engaging parts 43 may extend inwards from respective top and bottom parts of the bracket body 41. The bracket engaging parts 43 may be formed from a wall, i.e. a third wall configured to fit into the gap between the first and second walls 33, 34 forming the rail engaging parts 32.
As shown in FIG. 1, the fixing portion 42 of the bracket 4 is configured to extend beyond the reference edge of the panel 2, when the bracket 4 is connected thereto. As shown, the fixing portion 42 may also be configured to extend beyond the abutment part 37 of the rail 3, when the bracket 4 is connected thereto. These features enable the fixing portion 42 to be fixed to a substrate easily by providing access above the reference edge of the panel 2. Preferably, the fixing portion 42 extends beyond the edge of the panel 2 sufficiently to allow excess to the fixing portion 42 by a device configured to drive a mechanical fixing, such as a drill driver.
As shown in FIGS. 4 and 5, the bracket fixing portion 42 may be connected to the substrate 6, and optionally the substrate support 6A, by one or more bracket fixings 7. The bracket fixings 7 may be a mechanical fixing such as a screw, bolt or rivet. The bracket fixing portion 42 may comprise one or more openings, such as holes or slots, configured to accept the bracket fixings 7. The bracket 4 may be fixedly attached (e.g. as opposed to detachably attached) to the substrate, e.g. in the manner described above. The brackets 4 connected to the rail 3 may provide the only means of fixed attachment to the substrate 6.
FIGS. 4 and 5 show an example panel system 10 comprising plural panel assemblies 1. The panel assemblies 1 are fixed to a substrate 6. In the example panel system 10 shown in FIGS. 4 and 5, the panels 2 are cladding panels for the side of a building. However, it should be understood that alternative example systems, e.g. pitched roof panels or roof mounter solar panels, may use the same or similar components.
In the example panel system 10, the substrate 6 may be oriented strand board (OSB), for example. Although not shown, the substrate 6 may comprise additional layers, such as membrane layers. As shown, the substrate 6 may be supported by substrate supports 6A. The substrate supports 6A may be wooden studs, for example. In other examples, the substrate may be concrete or brick, for example.
In the example panel system 10, panel assemblies 1 may be arranged adjacent each other, e.g. in a tessellated arrangement. In the example panel system 10 shown in FIGS. 4 and 5, panel assemblies may be arranged in runs, such as the vertical run shown in FIGS. 4 and 5. In such an arrangement, panel assemblies 1 are arranged in order, in a run direction, starting from a first end of the run.
As described, a panel assembly 1 in the panel system 10 may be fixed to the substrate only by brackets 4 connected to rails 3 that extend substantially horizontally and are arranged at a substantially horizontal reference edge of the panel 2. This removes the need for substantially vertical edges of panels 2 to be aligned with specific locations on the substrate in order to be fixed to the substrate. Such specific locations may correspond to positions of studs, for example.
In the example shown in FIGS. 4 and 5, the building is formed in two modules, namely a ground floor module GF and a first floor module FF. Reference below is made to the ground floor and the first floor, but it should be understood that these are merely convenient labels for differentiating parts or components, and may be used in examples that do not comprise ground and first floor modules.
FIG. 4 shows a section of a panel run on a ground floor module GF comprising a ground floor start-of-run panel assembly 1A and a mid-run panel assembly 1B. Although cut off in FIG. 4, the mid-run panel assembly 1B is identical to the panel assembly 1 shown in FIG. 1. As shown in FIG. 4, the ground floor start-of-run panel assembly 1A may be substantially the same as the mid-run panel assembly 1A, but comprising a further ground floor rail 3A, in addition to the rail 3 described above (hereinafter standard rail 3). As shown, ground floor start-of-run panel assembly 1A may further comprise corresponding panel fixings 5.
FIG. 6 shows an example ground floor rail 3A, in cross-section, when not connected to the panel 2. As shown in FIG. 2, the ground floor rail 3A comprises a rail body 31. In this example, the rail body 31 forms the length the rail 3A. As shown, the rail body 31 may be substantially parallel to the rear surface 21 of the panel 2, when connected thereto. As shown, the ground floor rail 3A may comprise a rail engaging portion 32. As shown in FIG. 4, the rail engaging portion 32 is configured to engage with an engaging portion 43 of a corresponding bracket 4. As shown in FIG. 4, the rail engaging portion 32 of the ground floor rail 2 may be configured to hook onto a bracket 4 (this may provide a detachable attachment to the bracket 4, for example).
As shown in FIG. 6, the rail engaging portion 32 may comprise a first wall 33 and a second wall 34, separated by a gap. As shown, the second wall 34 of the ground floor rail 3A may be part of the rail body 31. As shown, the first and second walls 33, 34 may respectively be on rearward and frontward sides of the gap. As shown, the first wall 33 may be substantially parallel to the rear surface of the panel 2, when connected thereto. As shown in FIG. 6, where the first wall 33 connects to the rail body 31, the first wall 33 may be curved so as to form an inverted U-shape with the rail body 31.
A plurality of openings 35 may be formed in the bracket body 31 for accommodating a mechanical fixing, such as the rail fixing 5. These openings 35 may be circular holes, or slots, for example. These maybe formed after an extrusion process forming the rail 3A.
As shown in FIG. 4, the panel 2 may comprise a second reference edge, opposite the (first) reference edge described above. In the example, the second reference edge is the bottom edge of the panel 2. The second reference edge may be straight edge, an in this example, but in other examples the reference edge may be curved. As shown in FIG. 4, the ground floor rail 3A may be connected to the panel 2 substantially at the second reference edge. In the case of a straight reference edge, the ground floor rail 3A may be arranged substantially parallel to the second reference edge.
As shown in FIG. 6, the ground floor rail 3A may comprise a flange 38 extending from the rail body 31 substantially in a direction perpendicular to the rear surface 21 of the panel 2, when the ground floor rail 3A is connected thereto. The flange 38 is configured to abut the second reference edge. As shown, the flange 38 may be arranged at a substantially central part of the rail body 31, as opposed to an end part. Accordingly, an end part of the rail body 31 may abut the rear face 21 of the panel. The flange 38 may help to support the panel 2.
As shown in FIG. 4, the ground floor rail 3A is configured to connect with a bracket 4. As shown, the bracket 4 may be the substantially the same as the bracket 4 described above that is connected to the standard rail 3. However, the bracket 4 may be arranged inverted, such that the fixing portion 42 extends downwards from the bracket body 41, instead of upwards.
As shown in FIG. 3, the bracket 4 may comprise a secondary bracket engaging part 43A, different from the bracket engaging parts 43 described above (hereinafter, primary bracket engaging parts 43). As shown, in FIG. 3, the secondary bracket engaging part 43A is provided at a lower portion of the bracket body 41 (which is an upper portion in the inverted arrangement shown in FIG. 4). As shown, the secondary bracket engaging part 43A may comprise a male part configured to engage with a female part of the ground floor bracket engaging parts 32A. As shown, the bracket engaging part 43A may extend outwards from the bracket body 41. The secondary bracket engaging part 43A may be formed from a wall, i.e. a third wall configured to fit into the gap between the first and second walls 33, 34 forming the ground floor rail engaging part 32.
As shown in FIG. 4, the ground floor rail engaging part 32 may be configured to fit onto the upward extending secondary bracket engaging part 43A of the inverted bracket 4. As shown the ground floor rail body 31 may be configured to abut the bracket 4, e.g. specifically, the bracket body 31.
The inverted bracket 4 may be fixed to the substrate 6, and optionally the substrate support 6A, prior to connecting the ground floor rail 3A thereto. When the ground floor start-of-run panel assembly 1A is positioned on the inverted bracket 4, the brackets 4 connected to the standard rail 3 at the top of the panel assembly may be fixed to the substrate 6, and optionally the substrate support 6A, by bracket fixings 7.
When the ground floor start-of-run panel assembly 1A is fixed, the mid-run panel assembly 1B may be positioned against the abutment part 37 of the bracket 3 arranged at the first reference edge of the ground floor start-of-run panel assembly 1A, and then the brackets 4 of the mid-run panel assembly may be fixed to the substrate 6, and optionally the substrate support 6A, by bracket fixings 7. Further mid-run panel assemblies 1B may be positioned and fixed to the to the substrate 6, and optionally the substrate support 6A, in the same way. As shown, adjacent panel assemblies (e.g. start-of-run panel assembly 1A and mid-run panel assemblies 1B, or two mid-run panel assemblies 1B) may abut each other at respective adjacent edges. As shown, this abutment be such such that brackets 4 fixing a first panel assembly to the substrate are covered by the panel of a second panel assembly.
FIG. 5 shows a section of a run on the ground floor module GF comprising a ground floor end-of-run panel assembly 1C. The ground floor end-of-run panel assembly 1C comprises a panel 2 comprising front and rear surfaces 21, 22 and a rail 3 connected to the rear surface of the panel 21. As shown, the rail 3 may be identical to the standard rail 3 described above. As shown, the ground floor end-of-run panel assembly 1C may also comprise an adjustment fixing 8. As shown, the adjustment fixing 8 connects to an adjustment bracket 4A configured to be fixed to the substrate, and optionally a substrate support 6A.
FIG. 7 shows an adjustment mechanism for adjusting the gap size between the panel 2 and the substrate. The adjustment mechanism comprises the rail 3, the adjustment fixing 8 of the ground floor end-of-run panel assembly 1C and the adjustment bracket 4A. The adjustment mechanism allows adjustment of the gap size between the panel 2 and the substrate 6. This adjustment may be particularly advantageous if a first floor module FF is arranged above the ground floor module GF because allows correction of any misalignment between adjacent panels 2 on the a first floor module FF the ground floor module GF.
In other examples, the adjustment mechanism may be used wherever adjustment is likely to be required, such as interfaces with window or door openings, chimney stacks, etc., as well as laterally adjacent building modules. The adjustment mechanism may be suitably arranged for adjustment in any desired plane.
As shown in FIG. 7, the adjustment fixing 8 may comprise a threaded shaft 81 and head 82. The adjustment fixing 8 may be arranged to pass through an opening 35 in the rail 3 such that the head 82 faces the rear surface 21 of the panel 2 and the threaded portion 81 extends substantially perpendicular to the rear surface 21 of the panel 2 and is free to rotate within the opening 35 in the rail 3. As shown, the head 82 may be configured to be located in the recess space 36 of the rail 3.
As shown in FIG. 7, the threaded shaft 41 of the adjustment fixing 8 may be configured to engage with a threaded opening 44 in the adjustment bracket 4A, fixed to the substrate 6. The distance between the adjustment bracket 4A and the rear surface 21 of the panel 2 may be adjustable by rotating the adjustment fixing 8.
As shown in FIG. 7, the adjustment bracket 4A may comprise a bracket body 41. As shown, the bracket body 41 may extend substantially perpendicular to the rear surface 21 of the panel 2, when the adjustment bracket 4A is connected thereto. The bracket body 41 may comprise the threaded opening 44 at a first end thereof, connectable to the adjustment fixing 8. The first and second ends of the body portion 41 are displaced in a direction perpendicular to the rear surface 21 of the panel 2, when the bracket 4 is connected thereto.
As shown in FIG. 7, the adjustment bracket 4A may comprise a fixing portion 42 that extends substantially parallel to the rear surface of the panel 2 at a second end of the body portion 41, opposite the first end. As shown in FIG. 5, the adjustment bracket 4A may be arranged such that, in use, the fixing portion 42 extends downwards, i.e. in the opposite direction to the fixing portion 42 of a standard bracket 4. However, in some examples, the opposite arrangement may be used.
The adjustment bracket 4A may be fixed to the substrate 6, and optionally the substrate support 6A, prior to connection to the adjustment fixing 8 of the ground floor end-of-run panel assembly 1C. Accordingly, the adjustment bracket may not be considered part of the ground floor end-of-run panel assembly 1C. The adjustment bracket 4A may be positioned by means of a jig (not shown) relative to a previous panel assembly, e.g. a mid-run panel assembly 1B, that is already fixed to the substrate 6. The jig may ensure correct positioning of the adjustment bracket 4A on the substrate 6. The panel assembly 1C may be positioned as described above, e.g. against an abutment part 37 of the previous panel assembly 1B. The threaded shaft 81 of the adjustment fixing 8 may then be engaged with the threaded opening 44 of the adjustment bracket 4A, by rotating the adjustment fixing 8.
The panel 2 of ground floor end-of-run panel assembly 1C may comprise an opening for access to the head 82 of the adjustment fixing for rotating the adjustment fixing 8 from the front side of the panel 2. The head 82 may comprise a tool engaging portion, such as a correspondingly shaped recess, for engagement with a torque imparting tool such as a screw driver or hex key.
FIG. 5 shows a section of a panel run on a first floor module FF arranged above the ground floor module GF, comprising a first floor start-of-run panel assembly 1D. The first floor start-of-run panel assembly 1D may be substantially the same as the mid-run panel assembly 1A, but comprising a further rail 3 arranged substantially at the second reference edge of the panel 2, in addition to the rail 3 arranged at the first reference edge described above and shown in FIG. 1. As shown, the first floor start-of-run panel assembly 1D may further comprise panel fixings 5 for the further rail 3.
As shown in FIG. 5, the further rail 3 may be a standard rail 3, as described above and shown in FIG. 2. However, as shown in FIG. 5, the further rail 3 may be inverted compared to the rail 3 arranged at the first reference edge of the panel 2, i.e. so that the abutment part 37 extends downward rather than upward. Further, the further rail 3 may be arranged such that no part of the rail 3, even the abutment part 37, extends beyond the second reference edge of the panel 2.
The first floor start-of-run panel assembly 1D may further comprise one or more further brackets 4. The further brackets 4 may be standard brackets 4 as described above and shown in FIG. 3. As shown in FIG. 5, the further brackets 4 may be arranged such that the fixing portion 4 extends upwards. The further brackets 4 may be connected to the further rail 3 largely as described above. However, in this example, the further rail 3 is inverted so the engaging parts 43 of the further bracket engaged with the opposite engaging parts of the rail 32 compared to the arrangement described above in relation to FIG. 1.
As shown in FIG. 5, the fixing portion 42 of the further bracket 4 is arranged to face the rear surface of the panel 2. Therefore, bracket fixings 7 may need to be driven through the panel 2 to fix the bracket 4 to the substrate 6. In some examples, openings may be provided in the panel 2, aligned with the position of the bracket fixings 7, to allow the bracket fixings 7 to pass through. The openings may be plugged after fixing.
The panel assemblies 1, 1A, 1B, 1C, 1D described above may be assembled from a kit of parts comprising, as required, a panel 2, at least one rail 3, 3A, at least one bracket 4, 4A and at least one adjustment fixing 8. As described above, an optional finishing layer may be connected to the front surface 22 of the panel 2, after connecting the rail 3, 3A to the panel 2.
The panels 2 may be machined, e.g. by computer numerical control (CNC) machining, to form the openings in the panels 2 for accommodating fixings, such as the panel fixings 5 or bracket fixings 7. As described above, this may ensure correct positioning of the rail 3 and/or bracket 4 with respect to the panel 2. The panels 2 may additionally be cut to size by the CNC machining process.
Any of the materials used for forming the above described components may be non-combustible materials. The materials are preferably durable and stable to weathering. Further the materials and design are preferably suitable for use in dynamic wind and impact environments.
The above described system, through the use of the brackets 4, 4A and rails 3, 3A, may provide a strong, interlocked array of panels that all work together to provide strength and stability. The above described system, through the use of the brackets 4, 4A and rails 3, 3A, may provide fast and accurate installation.
It should be understood that variations of the above described examples are possible in light of the above teachings, without departing from the spirit or scope of the disclose as defined by the claims. For example, features described with reference to one example may be combined with features described with reference to another example.
LIST OF REFERENCE SIGNS
1 panel assembly
1A ground floor start-of-run panel assembly
1B mid-run panel assembly
1C ground floor end-of-run panel assembly
1D first floor start of run assembly
10 panel system
- GF ground floor module
- FF first floor module
2 panel
21 rear surface
22 front surface
3 standard rail
3A ground floor rail
31 rail body
32 engaging part
33 first wall
34 second wall
35 through hole
36 recess space
37 abutment part
38 flange
4 standard bracket
4A adjustment bracket
41 bracket body
42 fixing portion
43 primary engaging part
43A secondary engaging part
44 threaded opening
5 rail fixing
6 substrate
6A substrate support
7 bracket fixing
8 adjustment fixing
81 threaded shaft
82 head
Patent Application
20250179808
