GB2634546A

GB2634546A - Mounting rail

Info

Publication number: GB2634546A
Application number: GB2315634.2A
Authority: GB
Inventors: Jarmoozi Fowad
Original assignee: Ibstock Brick Ltd
Current assignee: Ibstock Brick Ltd
Priority date: 2023-10-12
Filing date: 2023-10-12
Publication date: 2025-04-16
Also published as: GB202315634D0

Abstract

Mounting rail 10 for mounting a building element to a building structure and including an elongate body 12 comprising a support plate 18 extending between front 16 and back 14 plates, and a reinforcing arrangement comprising a region of increased thickness of the body. The back plate and front plate define a groove 20 therebetween for receiving a part of a building element thereon. The building elements may be brick slips in an array. The building structure may be an internal or external wall. The reinforcement may comprise a rib 22 at an uppermost end of the back plate, or a curved edge 24, 30 of enlarged thickness between the intersection of either the back and support plates or front and support plates. The front and back plates be parallel, and be perpendicular to the support plate. The front plate may comprise a lower region 16b having a greater length than an upper region 16a, the reinforcement being a rib on the upper or lower regions. The back plate may comprise mounting apertures for receiving attachment members to secure the rail to a bracket or wall. The body may be formed from extruded metal like aluminium.

Description

Mounting Rail

FIELD

The present teachings relate to a mounting rail, a frame assembly, and a cladding assembly for mounting a building element to a building structure. The present teachings also relate to a method of prefabricating a cladding assembly.

BACKGROUND

Brick slips are thin sections of brick that are provided on external (or internal) surfaces of a building structure (i.e. a wall). An array of brick slips is typically mounted onto a wall surface, so as to provide a traditional 'brick' wall finish. One method of covering a wall surface with brick slips is to mount them directly onto the wall surface, e.g. using an adhesive. Whilst this method of mounting is relatively simple, the bond between the brick slips and the wall structure may not be sufficient, or may deteriorate over time, due to poor application of the adhesive.

These traditional means of mounting a building element to a building structure can be complex and time-consuming.

An alternative method of covering a wall surface with brick slips, cladding tiles, or brick tiles is to mount them to a mounting rail. Mounting rails, or cladding rails, are widely used in construction and architecture to mount cladding tiles, brick tiles, or brick slips to a building structure. Building elements such as these may be used for enhancing the appearance and durability of the building structures. These mounting rails are required to be strong, durable, and rigid in order to support the weight of building elements, as well as other forces that may act on the building structure.

The present teachings seek to provide an improved mounting rail. 25 SUMMARY According to a first aspect, there is provided a mounting rail for mounting a building element to a building structure, the mounting rail comprising an elongate body comprising: a back plate; a front plate; a support plate extending between the back plate and the front plate, said back plate and front plate defining a groove therebetween for receiving a part of a building element thereon; and a reinforcing arrangement, wherein the reinforcing arrangement comprises a region of increased thickness of the body.

Advantageously, the reinforcement arrangement has been found to improve the strength and rigidity of the mounting rail, thereby improving structural performance of the mounting rail.

The reinforcing arrangement may comprise a reinforcing rib on the back plate. Advantageously, the provision of a reinforcing rib on the back plate has been found to improve the strength and load-bearing capacity of the mounting rail.

The reinforcing rib may be located towards an uppermost end, for example at the uppermost end, of the back plate. Advantageously, positioning the reinforcing rib toward or at an uppermost end of the back plate facilitates the use of a wide range of attachment members for fixing the back plate to a building structure. Specifically, there is adequate space on the back plate for receiving an attachment member, e.g. a screw, bolt or rivet. The configuration of the back plate does not necessitate for the use of a smaller attachment only, and a screw or rivet with a larger head could be utilised.

The reinforcing arrangement may comprise a region of enlarged thickness at an intersection between the back plate and the support plate. Advantageously, the positioning of a region of increased thickness at the intersection between the support plate and the back plate has been found to improve the structural integrity of the rail, thereby improving the structural performance of any resulting assembly.

The support plate and the back plate may be configured so as to define a first curved edge at the intersection between the back plate and the support plate. Advantageously, implementing a curved edge has been found to increase the ease and thus the cost of manufacture of the mounting rail.

The reinforcing arrangement may comprise a region of enlarged thickness at an intersection between the front plate and the support plate. Advantageously, including a region of increased thickness in such a position provides improved support to a building element engaged in the rail, improving the rigidity of the rail and the structural performance of a resulting assembly.

The support plate and the front plate may be configured so as to define a second curved edge at the intersection between the front plate and the support plate.

Advantageously, implementing a curved edge has been found to increase the ease and thus the cost of manufacture of the mounting rail.

The second curved edge may be provided at the intersection between the support plate and a lower region of the front plate.

The support plate may extend substantially perpendicularly from the back plate.

Advantageously, the configuration of the support plate relative to the back plate has been found to improve the structural performance of the mounting rail, while also reducing the build-up of heat around the back plate in the case of a fire.

The support plate may extend from a lowermost end of the back plate.

Advantageously, the configuration of the support plate relative to the back plate has been found to improve the structural performance of the mounting rail, while also reducing the build-up of heat around the back plate in the case of a thermal event. This is in contrast to mounting rails of the prior art in which the support plate extends at an angle (obtuse or acute) relative to the back plate. Reducing heat build-up in the mounting rail set forth improves the structural integrity of the rail and reduces the risk of deformation of the rail in response to heat.

The front plate may be arranged substantially perpendicularly to the support plate. Advantageously, the configuration of the support plate relative to the front plate has been found to improve the rigidity of the support plate, increasing its ability to robustly support a building element, in use.

In exemplary embodiments, the support plate extends so as to define a generally perpendicular angle between both the support plate and the front plate and the support plate and the back plate. In this case, the build-up of heat in the case of a thermal event is reduced in contrast to conventional mounting rails. In this way, the structural integrity of the rail is increased.

The front plate and back plate may be substantially parallel. Advantageously, the arrangement set forth has been found to improve the robustness of the mounting rail, particularly when supporting building elements.

An intersection between the front plate and the support plate may be at a location between an uppermost end and a lowermost end of the front plate, so as to define upper and lower regions of the front plate. Advantageously, configuring the mounting rail in such a way has been found to facilitate the mounting rail supporting multiple building elements. For example, a first element can be positioned on the support plate and engage with the upper region of the front plate. A second mounting rail and second element can be positioned vertically below the first mounting rail and building element such that the second element can engage with the lower region of the front plate. In this way, the mounting rails provide support for numerous building elements, facilitating an assembly of elements that is structurally sound.

The lower region of the front plate may have a greater length than the upper region of the front plate. Advantageously, the increased length of the lower region facilitates additional support for a building element positioned vertically beneath the mounting rail (i.e. on a separate mounting rail vertically spaced apart from the first).

The reinforcing arrangement may comprise a reinforcing rib on the front plate.

The reinforcing arrangement may comprise a reinforcing rib at the lower region and/or upper region of the front plate.

The back plate may comprise a mounting surface on a side of the back plate distal to the support plate, and wherein said surface is substantially planar. Advantageously, the planar back plate has been found to result in a reduction in the build-up of heat behind the outermost surface of the plate in the case of a thermal event. This is particularly important once the rail is utilised in a full assembly, since the build-up of heat can reduce the structural integrity of an assembly. Moreover, the planar back plate can be simply and robustly mounted to a bracket or other surface when assembled, further increasing the structural integrity of an assembly.

The back plate may comprise a plurality of mounting apertures extending therethrough, said mounting apertures configured for receiving an attachment member to secure the mounting rail to a bracket or building structure.

The body may be formed from extruded metal. Utilising an extruded body has been found to improve the ease of manufacture of the rail, particularly for forming the reinforcement arrangement, whilst also resulting in a rail that exhibits improved strength and structural integrity.

The body may be formed from extruded aluminium. Advantageously, aluminium is a lightweight but strong material, thereby reducing the weight load on an assembly while still maintaining the integrity and stability of a cladding assembly.

According to a second aspect, there is provided a frame assembly for mounting a building element to a building structure, the frame assembly comprising: first and second spaced apart brackets; and first and second mounting rails according to the first aspect mounted to the first and second brackets to define a spacing therebetween for receiving building elements, wherein the first and second mounting rails are moveably mounted to the first and second brackets such that the mounting rail can move relative to the brackets between a collapsed state and an expanded state, and wherein the spacing between the first and second mounting rails is greater in the expanded state than in the collapsed state.

Advantageously, the frame assembly can be effectively collapsed so as to form a more compact assembly that is easily transportable to a final destination. The collapsed assembly can then be simply returned to its expanded state for use.

The first and second mounting rails may be pivotably mounted to the first and second brackets such that the mounting rail can pivot relative to the bracket between the collapsed state and the expanded state. Advantageously, the pivotable mounting of the mounting rail provides an intuitive and simple means of moving the assembly between its collapsed and expanded states, thereby increasing the ease at which the prefabricated frame assembly can be transported and prepared for use.

According to a third aspect, there is provided a cladding assembly for mounting a building element to a building structure, the cladding assembly comprising: a frame assembly according to the second aspect; and a plurality of building elements mounted to the first and second mounting rails.

The building elements may be brick slips.

The cladding assembly may comprise a spacer positioned between adjacent building elements. Advantageously, the spacer can be used to maintain a consistent horizontal distance between adjacent cladding panels. Ensuring precise spacing can facilitate balanced weight distribution across the assembly, while also improving the appearance of the assembly.

The spacer may define a generally T-shaped body, and wherein the spacer is arranged such that a first arm or shoulder of the spacer is received in a slot or groove in a first building element and a second arm or shoulder of the spacer is received in a slot or groove in an adjacent building element. Advantageously, the T-shaped spacer has been found to provide structural support to the assembly, while also providing effective spacing.

According to a fourth aspect, there is provided a method of prefabricating a cladding assembly, comprising the steps of: providing a frame assembly according to the second aspect; and mounting a plurality of building elements to the first and second mounting rails.

The building elements may be brick slips.

The step of mounting a plurality of building elements to the first and second mounting rails may be carried out offsite in a factory environment.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described with reference to the accompanying drawings, in which: Figure 1 is a perspective view of an end of a mounting rail; Figure 2 is a front view of a frame assembly in an expanded state; Figure 3 is a cross-sectional view of the frame assembly of Figure 2; Figure 4 is the frame assembly of Figure 2 in the collapsed state; Figure 5 is a cross-sectional view of the frame assembly of Figure 4; Figure 6 is a front view of a cladding assembly; and Figure 7 is a cross-sectional view of the cladding assembly of Figure 6.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Referring firstly to Figure 1, a mounting rail 10 for mounting a building element to a building structure is illustrated. The building element is an element utilised in a building structure, e.g. a cladding panel. In some embodiments, the cladding panel is a metal panel, a wood panel, a composite panel, a stone panel, or a brick slip. It should be appreciated that any combination of cladding panels could be mounted on the mounting rail.

The mounting rail 10 has an elongate body 12, of which only an end portion is shown in Figure 1. It should be understood that the elongate body 12 continues to extend longitudinally to define a length. The length of the elongate body 12 is any length suitable for mounting the desired building element or elements. For example, if only one building element is intended to be mounted on the mounting rail 10, the elongate body 12 may only have a length equivalent to a length of the one building element. Put another way, the elongate body 12 can have any length suitable for receiving the desired type and number of building elements. In exemplary embodiments, the cross sectional profile of the elongate body 12 is uniform across the entire of or substantially all of the length.

As can be seen in Figure 1, the elongate body 12 has a back plate 14, a front plate 16 and a support plate 18. The back plate 14 is spaced apart from the front plate 16. The support plate 18 extends between the back plate 14 and the front plate 16. The back plate 14 and the front plate 16 define a groove 20 therebetween. The groove 20 is defined by the space between the back plate 14 and the front plate 16. In exemplary embodiments, the groove 20 is defined as the space between the back plate 14, the front plate 16 and the support plate 18. The elongate body 12 is configured such that a part of a building element can be received in the groove 20. The support plate 18 is positioned such that a building element can be received in the groove 20 and on the support plate 18, i.e. such that the support plate 18 supports a building element within the groove 20.

In the illustrated embodiment, the support plate 18 extends from the back plate 14 so as to define an intersection between the back plate 14 and the support plate 18. In exemplary embodiments, the support plate 18 extends from a location towards a lowermost end of the back plate 14. In this way, the intersection between the back plate 14 and the support plate 18 can be seen as being toward the lowermost end of the back plate.

It should be understood that the terms "uppermost" and "lowermost" used herein are in relation to the intended orientation of the component relative to the ground, i.e. the uppermost end is the end distal to the ground, the lowermost end is the end closest to the ground when the respective component (e.g. the mounting rail 10 in this case) is oriented and installed as intended (i.e. as shown in the figures). The term "toward the lowermost end" can be seen as referring to a location on the back plate 14 (or any plate) that is closer to the lowermost end than to an uppermost end. Similarly, as used herein, the term "toward the uppermost end" can be seen as referring to a location on the back plate 14 (or any plate) that is closer to the uppermost end than the lowermost end.

In Figure 1, the support plate 18 extends from a lowermost end of the back plate 14. In this way, the intersection between the back plate 14 and the support plate 18 is at the lowermost end of the back plate 14. This arrangement improves the mechanical strength of the mounting rail 10. It should be understood that the support plate 18 may extend from a different position of the back plate 14 in alternative embodiments, i.e. between an uppermost and lowermost end of the back plate 14.

The support plate 18 extends substantially perpendicularly from the back plate 14 in exemplary embodiments. It should be understood that the term "substantially perpendicularly" accounts for slight deviations in the angle between the plates (e.g. as a result of manufacturing or assembly error, or by the surfaces at the point of intersection of the two plates being curved). The configuration of the support plate 18 relative to the back plate has been found to improve the structural performance of the mounting rail 10, while also reducing the build-up of heat around the back plate 14 in the case of a fire. The substantially perpendicular angle between the back plate 14 and the support plate 18 therefore increases the structural integrity of the rail 10 and reduces the risk of deformation of the rail 10 in response to heat.

The support plate 18 includes an uppermost surface 18a that is intended to receive a building element (e.g. a cladding panel, or a brick slip). It is generally preferable for the support plate 18 to be substantially parallel with the ground of an environment in which the mounting rail 10 is intended to be installed, such that the building element or elements mounted therein are substantially parallel with the ground. This is preferable for both aesthetics and for structural integrity.

The front plate 16 is arranged substantially perpendicularly to the support plate 18. The configuration of the support plate 18 relative to the front plate 16 has been found to improve the rigidity of the support plate 18 and the front plate 16, increasing the ability of the mounting rail 10 to robustly support a building element, in use.

In exemplary embodiments, the support plate 18 extends so as to define a generally perpendicular angle between both the support plate 18 and the front plate 16, and the support plate 18 and the back plate 14. In this case, the build-up of heat in the case of a fire is reduced in contrast to mounting rails with plates that are angled relative to each other (i.e. arranged to define obtuse or acute angles). In this way, the structural integrity of the rail 10 is increased compared with conventional mounting rails.

In some embodiments, one or more of the back plate 14, the front plate 16, and the support plate 18 may be provided as a substantially planar plate. In the illustrated embodiment, the back plate 14, the front plate 16 and the support plate 18 are each provided as substantially planar plates.

As can be seen in Figure 1, the front plate 16 and the back plate 14 are substantially parallel. Such an arrangement improves the robustness of the mounting rail 10 when supporting building elements. The parallel front and back plates 14, 16 alongside the perpendicularly arranged support plate 18 results in a mounting rail 10 that is robust, simple to manufacture and simple to assemble.

The support plate 18 extends from the front plate 16 so as to define an intersection between the front plate 16 and the support plate 18. In the illustrated embodiment, the intersection between the front plate 16 and the support plate 18 is at a location between an uppermost end and a lowermost end of the front plate. In this way, an upper region 16a of the front plate 16 is defined as a region between the intersection of the front plate 16 and support plate 18 and the uppermost end of the front plate 16. A lower region 16b of the front plate 16 is defined as a region between the intersection of the front plate 16 and support plate 18 and the lowermost end of the front plate 16.

As will be discussed in more detail below, configuring the mounting rail 10 in such a way has been found to facilitate the mounting rail 10 supporting multiple building elements. For example, a first building element can be positioned on the support plate 18 and engage with the upper region 16a of the front plate. A second mounting rail and second building element can be positioned vertically below the first mounting rail 10 and building element such that the second building element can engage with the lower region 16b of the front plate 16. In this way, the mounting rails 10, and specifically the front plate 16, can provide support for numerous building elements, facilitating an assembly defined by an array of building elements that is structurally sound.

In the illustrated embodiment, the lower region 16b of the front plate 16 has a greater length than the upper region 16a of the front plate 16. More specifically, the support plate 18 extends from the front plate 16 so as to define the point of intersection between the support plate 18 and the front plate 16 toward the uppermost end of the front plate 16, i.e. at a position closer to the uppermost end than to the lowermost end of the front plate 16. The increased length of the lower region 16b facilitates additional support for a building element positioned vertically beneath the mounting rail (i.e. on a separate mounting rail vertically spaced apart beneath the first).

In exemplary embodiments, and as will be discussed in more detail in relation to Figure 6 and 7, the arrangement of the back plate 14, the front plate 16 and the support plate 18 relative to one another facilitates the secure mounting of a building element in the groove 20.

The front plate 16 has an outermost surface that faces away from the back plate 14 and an innermost surface that faces towards the back plate 14. In exemplary embodiments, the outermost surface of the front plate 16 is substantially planar. The innermost surface of the front plate 16 may be substantially planar.

The back plate 14 includes a mounting surface (not shown) on a side of the back plate 14 distal to the support plate. In exemplary embodiments, the mounting surface is substantially planar. The planar back plate 14 has been found to result in a reduction in the build-up of heat behind the outermost surface of the plate, in the event of a fire. This is particularly important once the rail 10 is utilised in a full assembly, since the build-up of heat can reduce the structural integrity of an assembly. Moreover, the planar back plate 14 can be simply and robustly mounted to a bracket or other surface when assembled, further increasing the structural integrity of an assembly.

In exemplary embodiments, the elongate body 12 of the mounting rail 10 includes a reinforcing arrangement. The reinforcement arrangement includes or is defined by one or more regions of increased thickness in the elongate body 12. The reinforcement arrangement (i.e. the region or regions of increased thickness) improves the strength and rigidity of the mounting rail 10. In this way, the structural performance of the mounting rail 10 is improved. In exemplary embodiments, the elongate body 12 has a generally uniform thickness, with the reinforcing arrangement being defined by areas in which the uniform thickness is interrupted, i.e. in which the elongate body 12 is thicker.

In Figure 1, the reinforcement arrangement includes an area of increased thickness on the back plate 14. Specifically, the reinforcement arrangement includes a reinforcing rib 22 on the back plate 14. The reinforcing rib 22 is in the form of a projection that extends from the back plate 14 in a direction toward the front plate 16. In exemplary embodiments, the projection defines an angle relative to the back plate 14. In some embodiments, the angle is between 90° and 180°, preferably between 90° and 135°. In exemplary embodiments, the reinforcing rib 22 tapers into a pointed end that is pointed in a direction away from the back plate 14 towards the front plate 16. The tapered or pointed end of the reinforcing rib 22 defines a region of maximum thickness of the back plate 14. The reinforcement rib 22 has been found to improve the strength and load-bearing capacity of the mounting rail 10. The reinforcing rib 22 may be located toward an uppermost end of the back plate 14 in exemplary embodiments, or may be arranged at any other suitable location on the back plate 14.

As can be seen in Figure 1, the reinforcing rib is located at the uppermost end of the back plate 14. Positioning the reinforcing rib 22 toward or at an uppermost end of the back plate 14 facilitates the use of a wide range of attachment members for fixing elements to the back plate 14 or fixing the back plate 14 to a building structure. Specifically, there is adequate space on the back plate 14 for receiving an attachment member, e.g. a screw, bolt or rivet. In this way, a larger attachment member could be utilised (e.g. a screw with a larger head). In exemplary embodiments, the reinforcing rib 22 is positioned towards an uppermost end of the back plate 14 and the back plate 14 is configured to receive an attachment member at a central region of the back plate 14. This arrangement improves distribution of weight across the back plate 14 in use, improving the flexural strength of the mounting rail 10, as well as facilitating improved resistance to lateral restraint forces acting on the rail 10.

In some embodiments, the reinforcement arrangement includes an area of increased thickness on the front plate 16, for example on the upper region 16a and/or the lower region 16b of the front plate 16. Although not shown, in one embodiment, the reinforcing arrangement includes a reinforcing rib on the front plate 16, for example on the upper region 16a and/or the lower region 16b of the front plate 16. The reinforcing rib on the front plate 16 may have any of the abovementioned features of the reinforcing rib 22 on the back plate 18.

In the illustrated embodiment, the reinforcing arrangement includes a region of enlarged thickness 24 at the intersection between the back plate 14 and the support plate 18. Put another way, the intersection between the back plate 14 and the support plate 18 defines a corner, said corner being of increased thickness. The positioning of the region of enlarged 24 thickness at the intersection between the support plate 18 and the back plate 14 has been found to improve the structural integrity of the rail 10, thereby improving the structural performance of any resulting assembly.

As can be seen in Figure 1, the support plate 18 and the back plate 14 are configured so as to define a first curved edge at the intersection between the back plate 14 and the support plate 14. In this way, the corner between the back plate 14 and the support plate 18 is curved. Implementing the curved edge 26 has been found to increase the ease and thus the cost of manufacture of the mounting rail 10. In exemplary embodiments, the curved edge 26 defines an edge of the region of enlarged thickness 24. The combination of the curved edge 26 and increased thickness 24 at the intersection between the support plate 18 and the back plate 14 improves the load-bearing capability of the rail 10.

The back plate 14 includes an outermost surface that faces toward the front plate 16 (i.e. the surface from which the reinforcing rib 22 and/or the support plate 18 extend). The outermost surface of the back plate 14 includes a planar region that is positioned between the reinforcing rib 22 at or toward an uppermost end and the region of enlarged thickness 24 at or toward a lowermost end. The support plate 18 includes a planar region that is intended to support a building element.

As discussed above, the support plate 18 is arranged so as to be substantially perpendicular to the back plate 14. The curved edge 26 provides a curved transition between the support plate 18 and the back plate 14. In this way, it should be understood that in exemplary embodiments, it is the planar region of the back plate 14 that is substantially perpendicular to the planar region of the support plate 18. The curved edge 26 therefore provides a curved transition between the two perpendicular surfaces.

In exemplary embodiments of the kind illustrated, the reinforcing arrangement includes a second region of enlarged thickness 28 at the intersection between the front plate 16 and the support plate 18. Including the second region of increased thickness 28 in such a position provides improved support to a building element engaged in the groove 20, improving the rigidity of the rail 10 and the structural performance of a resulting assembly. As shown in Figure 1, the support plate 18 and the front plate 16 are configured so as to define a second curved edge 30 at the intersection between the front plate 16 and the support plate 18. In exemplary embodiments, the curved edge 30 defines an edge of the second region of enlarged thickness 28. Implementing the curved edge 30 has been found to increase the ease and thus the cost of manufacture of the mounting rail 10.

In the illustrated embodiment, the support plate 18 and the lower region 16b of the front plate 16 are configured to define the second curved edge 30. Put another way, a curved junction is provided between the support plate 18 and the lower region 16b of the front plate 16. In an alternative embodiment, a third curved edge is provided at the intersection between the support plate 18 and the upper region 16a of the front plate 16. The third curved edge may be provided in addition to, or instead of, the second curved edge 30.

In the illustrated embodiment, the intersection between the upper region 16a of the front plate 16 and the support plate 18 defines a substantially perpendicular angle. The upper region 16a and the lower region 16b of the front plate 16 both define a generally planar surface in the illustrated embodiments. The planar surface of the upper and lower regions 16a, 16b is substantially perpendicular to the planar region of the support plate 18. In this way, the curved edge 30 can be seen as providing a curved transition between the perpendicular surfaces of the lower region 16b of the front plate 16 and the support plate 18.

It should be appreciated that any combination of the regions of increased or enlarged thickness described herein could be included to define the reinforcing arrangement of the mounting rail 10. In some embodiments, the mounting rail 10 only includes one region of increased thickness.

Although not shown in Figure 1, the back plate 18 includes at least one mounting aperture extending therethrough. In a preferred embodiment, the back plate 18 includes a plurality of mounting apertures extending therethrough. The plurality of mounting apertures are distributed across the length of the back plate 18 in exemplary embodiments. The or each mounting aperture is defined by an opening through the back plate 18 for receiving an attachment member (e.g. a screw or a bolt) to secure the mounting rail 10 to a bracket or building structure. It should be appreciated that any suitable means may be applied to secure the mounting rail 10 to a bracket or building structure, and so in some embodiments, the mounting apertures may not be present. For example, the mounting rail 10 may be adhesively bounded, welded or clamped to a bracket or a building structure.

In exemplary embodiments, the elongate body 12 is formed from extruded metal. Forming the body 12 from extruded metal has been found to improve the ease of manufacture of the rail 10, particularly for forming the reinforcing arrangement, whilst also resulting in a rail 10 that exhibits strength and structural integrity. In an exemplary embodiment, the elongate body 12 is formed from extruded aluminium. Aluminium is a lightweight but strong material. As such, forming the body from aluminium reduces the weight load of the rail 10 while still maintaining the integrity and stability of a resulting assembly. It should be appreciated that the body 12 may be formed from alternative means in some embodiments. For example, the body 12 may be formed from other extruded metals. Alternatively, the body 12 can be formed from roll forming, stamping, bending of sheet metal, or welding and fabrication of metal components.

In some embodiments, the mounting rail 10 is secured directly to a building structure. However, as will be discussed in more detail below, the mounting rail 10 may be provided as part of a frame assembly which is then secured to a building structure.

Referring now to Figures 2 to 5, a frame assembly for mounting a building element to a building structure is indicated generally at 32. As will be discussed in more detail below, the assembly 32 is configured so as to move between an expanded state and a collapsed state. The assembly 32 of Figure 2 and Figure 3 is in the expanded state. The expanded state can be seen as the arrangement of the assembly intended for final use (e.g. to receive building elements and be fixed to a building structure). The assembly 32 of Figure 4 and 5 is in the collapsed state. The collapsed state can be seen as the arrangement of the assembly intended for effectively storing or transporting the assembly 32 to a location in which it is intended to be fixed (i.e. to a building structure).

Referring firstly to Figure 2, a front view of the frame assembly 32 can be seen.

The frame assembly 32 includes a first bracket and a second bracket 34. In the illustrated embodiment, the brackets 34 are identical, although the brackets 34 may be different in alternative embodiments. The brackets 34 are represented in a broken line in Figure 2, so as to indicate that the brackets 34 are positioned at the back of the assembly 32 when viewing the assembly 32 as intended when the assembly is installed.

As shown in Figure 2, the brackets 34 are spaced apart from each other. The brackets 34 are spaced apart in the horizontal direction (i.e. such that a horizontal spacing is formed between the adjacent brackets 34). Although only two brackets 34 are shown in the figures, it should be appreciated that any number of brackets 34 may be used in alternative embodiments.

The frame assembly 32 includes a first and a second mounting rail 10 in exemplary embodiments. The mounting rails 10 of the assembly 32 are the same as the mounting rail 10 described in relation to Figure 1. In the illustrated embodiment, eight mounting rails 10 are provided. It should be appreciated that the mounting rails are substantially identical. Identical components have not been individually labelled for purposes of clarity. It should also be appreciated that any number of mounting rails 10 may be used in the frame assembly 32. In some embodiments, only one mounting rail 10 is used.

As shown in Figure 2, each mounting rail 10 is arranged so as to be spaced apart from an immediately adjacent mounting rail 10. In the figure, the mounting rails 10 are evenly spaced apart in the vertical direction (i.e. relative to the ground). Each mounting rail 10 is mounted to the first and the second brackets so as to define a spacing S therebetween for receiving building elements. Specifically, the mounting rail 10 is mounted such that the mounting surface of the back plate 14 of the rail engages with the bracket 34.

An attachment member 36 is provided to secure each mounting rail 10 to the respective bracket 34. Specifically, in this embodiment, each mounting rail 10 includes at least two apertures extending through the respective back plate 18. The apertures are intended to align with the desired position of a respective bracket, such that an attachment member 36 can extend through the respective aperture and secure the mounting rail 10 to the respective bracket 34 at the desired position along the length of the mounting rail 10. In this way, two attachment members 36 are provided per rail 10, to secure the rail 10 to two brackets 34.

The means of mounting the mounting rail 10 to the bracket 34 will now be discussed in relation to Figure 3. Figure 3 provides a cross-sectional view of the assembly 32 of Figure 2 along the X-X line. From this view, only one bracket 34 is visible.

As can be seen most clearly in Figure 3, the spacing S is defined as the distance between the uppermost end of the backplate 14 of a first mounting rail 10 and a lowermost end of the backplate 14 of a second mounting rail 10 mounted adjacent to the first 10.

In Figure 3, the attachment member 36 extends through an aperture in the back plate 14 of a respective mounting rail 10 and through an opening in a respective bracket 34. In the illustrated embodiment, the attachment member 36 is a screw, a bolt or a rivet. However, as noted above, any suitable means of attachment can be provided.

In exemplary embodiments, the mounting rails 10 are moveably mounted to the first and second brackets 34. In this way, each mounting rail 10 can move relative to the brackets 34. More particularly, the mounting rails 10 are mounted to the first and second brackets 34 such that each rail can move between the collapsed state and the expanded state.

In exemplary embodiments, the mounting rails 10 are pivotably mounted to the first and second brackets 34. In this way, each mounting rail 10 can pivot relative to the brackets 34 between the expanded state and the collapsed state.

In the illustrated embodiment, the mounting rails 10 are moveably mounted to the brackets 34 via a respective attachment member 36. In exemplary embodiments, each attachment member 36 defines a pivot axis P about which a respective mounting rail 10 can pivot. In the illustrated embodiment, the pivot axis P extends in a direction that is generally perpendicular to the back plate 14 of a respective mounting rail 10 and to a respective bracket 34.

Figure 4 and Figure 5 indicate the assembly 32 in the collapsed state. Figure 5 is a cross sectional view of the assembly 32 of Figure 4 along the line X-X. Only the differences to the assembly 32 of Figures 2 and 3 will be discussed in detail.

In Figure 4 and Figure 5, the mounting rails 10 have been pivoted relative to the brackets 34 into the collapsed state. The mounting rails 10 have thus moved so as to reduce the spacing S. More specifically, it can be seen from Figures 2 to 5 (i.e. comparing Figure 2 with Figure 4 and comparing Figure 3 with Figure 5) that the spacing S between adjacent mounting rails 10 is greater when the assembly is in the expanded state compared with when the assembly is in the collapsed state.

The frame assembly 32 can thus be effectively collapsed so as to form a more compact assembly 32 (i.e. a vertical spacing between adjacent rails 10 is reduced). The assembly 32 is therefore more easily transportable to a final destination. The collapsed assembly can then be simply returned to its expanded state for use.

The moveable arrangement of the mounting rails 10 therefore allows the frame assembly to be premade in an offsite area (e.g. a factory) before being simply transported to a final destination for installing to a building structure. In this way, the efficiency of installing the frame assembly 10 in its final destination is improved, since the steps of securing the rails to the brackets has already been completed.

Such efficiencies are more difficult to obtain with conventional frame assemblies, since it is difficult to store and transport frame assemblies that are fully fabricated and in the expanded state. Reducing the spacing between adjacent mounting rails in the present assembly improves the ease of storage, handling and transporting the assembly 32 when in the collapsed state. Moreover, the pivotable mounting of the mounting rails 10 to the brackets 32 provides an intuitive and simple means of moving the assembly between its collapsed and expanded states, thereby increasing the ease at which the prefabricated frame assembly can be transported and prepared for use.

In an exemplary embodiment, the assembly 32 is configured such that the spacing S is reduced to approximately zero when in the collapsed state. This can be seen most clearly in Figure 5, in which the uppermost end of the back plate of a first mounting rail 10 is in contact with the lowermost end of the back plate of a second, adjacent mounting rail 10. The resulting collapsed assembly 32 is highly compact and easy to handle and transport.

A cladding assembly 38 will now be described with reference to Figure 6 and Figure 7.

Figure 6 is a front view of the cladding assembly 38, although some elements that are not typically visible from this view have been included for clarity. Figure 7 is a cross sectional view of the cladding assembly across line Y-Y in Figure 6.

The cladding assembly 38 includes the frame assembly 32 described in relation to Figures 2 to 5, i.e. includes mounting rails 10 as described in relation to Figure 1, and brackets 34. The cladding assembly 38 also includes a plurality of building elements 40 mounted to the mounting rails 10. For example, if two mounting rails 10 are provided, a plurality of building elements 40 are mounted to each of the first and second rails 10 in exemplary embodiments. Multiple building elements 40 are positioned adjacent one another across the length of each mounting rail 10 so as to define an array of building elements 40.

As can be seen in Figure 7, each building element 40 has been mounted in the groove 20 between the back plate 14 and front plate 16 of the mounting rail 10. The building element 40 is supported on an underside by the support plate 18. As can be seen, part of the building element 40 extends beyond the front plate 16.

The building element is an element utilised in a building structure, e.g. a cladding panel. In some embodiments, the cladding panel is a metal panel, a wood panel, a composite panel, a stone panel, or a brick slip. It should be appreciated that any combination of cladding panels could be used in the cladding assembly 38, e.g. different types of panels may be used in a single assembly.

In the illustrated embodiment, all of the building elements 40 in the assembly 38 have the same dimensions. It should be appreciated that differently sized elements 40 may be used in alternative embodiments, e.g. some of the cladding panels may be longer than others.

Referring to Figure 6, the cladding assembly 38 includes a spacer 42 positioned between adjacent building elements 40. In the figures, a plurality of spacers 42 are provided. The spacers 42 are positioned periodically along the length of the mounting rails 10 between each horizontally adjacent building element 40.

The spacers 42 act to maintain a consistent horizontal distance between adjacent building elements 40. Utilising the spacers 42 to provide such precise spacing can facilitate balanced weight distribution (i.e. of the building elements 40) across the assembly 38, while also improving the appearance of the assembly 38. In some embodiments, it may not be desirable to have a consistent spacing between adjacent building elements 40. For example, it may be preferred to have irregular spacing between building elements 40 for aesthetic reasons. In this case, different sized spacers 42 may be provided, with larger spacers providing a larger space between adjacent building elements 40, and smaller spacers providing a smaller separation between adjacent building elements 40. In the illustrated example, the plurality of spacers 42 are identical, so as to provide an even or regular spacing of the building elements 40 in the cladding assembly 38.

In exemplary embodiments, the spacers 42 define a generally T-shaped body. Put another way, the spacers 42 each have an elongate stem, a first arm or shoulder that projects from the stem in a first direction, and a second arm or shoulder that projects from the stem in a second direction opposite to the first. Preferably, the two arms or shoulders extend from the stem so as to define a substantially perpendicular angle therebetween. In exemplary embodiments, the T-shaped shaper 42 can be arranged such that the first arm or shoulder extends toward a first building element 40, and the second arm or shoulder extends toward a second, adjacent building element.

In some embodiments, the first arm or shoulder extends into a slot or groove in a first building element and the second arm or shoulder extends into a slot or groove in an adjacent building element. The T-shaped spacer 42 has been found to provide structural support to the assembly 38, while also providing effective spacing between adjacent building elements 40.

Although not shown in the figures, the spacers 42 are not positioned at the front of the assembly 32 (i.e. from the view in Figure 6) in exemplary embodiments.

Instead, it is preferred to position the spacers 42 in a region set back from the front of the assembly 32 so as to engage with a middle or rearward region of a respective building element 40. In this way, the spacer 42 provides effective spacing between adjacent building elements 40 without being visible at the front of the cladding assembly 38.

In some embodiments, mortar 44 can be provided between adjacent building elements 40. The provision of mortar 44 can increase the rigidity and integrity of the assembly 38. Mortar 44 can also improve the appearance of the assembly 38, since component parts of the assembly 38 that may be less aesthetically pleasing are essentially blocked from view by the mortar 44. Specifically, the mortar 44 can cover the mounting rail 10, any spacers 42, the brackets 34 and the attachment members 36 such that these components are not visible (or at least less visible) from a front view. In a preferred embodiment, the mortar is provided such that only the building elements 40 and mortar 44 are visible from the front view.

In this way, positioning the spacers 42 so as to be set back from the front of the assembly 32 provides an area to introduce mortar thereto so as to provide coverage in the space defined by the spacers 42, and thus coverage of the spacers 42 themselves (and other components of the assembly 38 as noted above).

As can be seen more clearly in Figure 7, each building element 40 includes first slot 40a and a second slot 40b. The slots may also be referred to as recesses or grooves in some embodiments.

The first slot 40a extends partially into an uppermost end of the building element 40 and the second slot extends partially into a lowermost end of the building element 40. In the illustrated embodiment, the first slot 40a is configured to receive the lower region 16b of the front plate 16 a mounting rail 10. The second slot 40b is configured to receive the upper region 16a of the front plate 16 of a second, adjacent mounting rail 10. Put another way, both slots 40a, 40b extend into the building element 40 to define a slot length. The slot length of each slot corresponds to the length of the upper and lower regions 16a, 16b of the front plate 16.

In the present embodiments, the slot length of the first slot 40a is greater than the slot length of the second slot 40b so as to correspond with the greater length of the lower region 16b compared with the upper region 16a of the mounting rail 10. The first and second slots 40a, 40b are generally aligned along the length of the building element 40. This arrangement facilitates the slots receiving the generally aligned adjacent mounting rails 10.

In exemplary embodiments, the slots 40a, 40b can be dimensioned so as to provide an interference fit between a respective mounting rail 10 and building element 40. In alternative embodiments, the first and second slots 40a, 40b may be replaced by a single slot that extends along the entire length of the of the building element (i.e. from an uppermost end to a lowermost end). In such an embodiment, the building element 40 can be arranged such that the lower region 16b of the front plate 16 of a first mounting rail 10 is received in the slot at an uppermost end of the building element 40, and the upper region 16a of the front plate 16 of a second, adjacent mounting rail 10 is received in the slot at a lowermost end of the building element 40.

The arrangement of the mounting rail 10 and the building elements 40 facilitates the obstruction from view of at least portions of the mounting rail 10 when the assembly 38 is viewed from a front view. This is due, in part, to the back plate 14 and support plate 18 of the rail 10 being covered by the building elements 40 received in the groove 20. The obstruction is also provided by the front plate 16 being substantially covered by the building elements 40 when received in the slots 40a, 40b. As such, the appearance of the assembly 38 is improved.

In a preferred embodiment, the slots 40a, 40b also extend in a generally longitudinal direction through the building element 40. In this way, the front plate 16 of the mounting rail is received across the entire longitudinal length of a building element 40. The longitudinal extension of the slots 40a, 40b provides a region for a spacer 42 to engage with a respective building element 40. Specifically, the first arm or shoulder of the spacer 42 can engage with at least one of the slots 40a, 40b of a first building element 40, and the second arm or shoulder of the spacer 42 can engage with at least one of the slots 40a, 40b of a second, adjacent building element 40. In alternative embodiments, a separate longitudinal slot may be provided in the building element 40 for receiving the spacer 40.

A method of prefabricating the cladding assembly 38 will now be discussed.

The frame assembly 32 described in relation to Figures 2 to 5 is first assembled. The frame assembly 32 is fabricated by providing at least two brackets 34, and at least two mounting rails 10. The mounting rails 10 are mounted to the brackets 34, e.g. via attachment members 36.

Next, a plurality of building elements 40 are mounted to the mounting rails 10. In some embodiments, this step includes the mounting of various spacers 42, and/or the introduction of mortar 44 between the spaced apart building elements 40.

The fabrication of the frame assembly 32 can occur offsite (i.e. not in the final location at which the cladding assembly 38 is intended for). In such an embodiment, once the frame assembly 32 has been fabricated, the frame assembly 32 can be moved into its collapsed state and be transported to a location at which the assembly 32 is intended to be installed.

Once the frame assembly 32 is at the location at which the assembly 32 is intended to be installed, the frame assembly 32 can be simply moved into its expanded state.

At this point, the building elements 40 are mounted to the mounting rails 10 and the brackets 34 can be secured to a building structure.

In some embodiments, the entire cladding assembly 38 can be prefabricated offsite (e.g. in a factory environment). In such an embodiment, the plurality of building elements 40 are mounted to the mounting rails 10 in a different location, before the entire cladding assembly 38 is transported to location at which the assembly 38 is intended to be installed.

In this way, the cladding assembly 38 can be simply received in the location it is to be installed, and simply positioned and secured in the desired location. This removes the need to install the building elements 40 at this location, thereby improving the efficiency of installing a cladding assembly 38.

Although the teachings have been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope as defined in the appended claims.

Claims

Claims 1. A mounting rail for mounting a building element to a building structure, the mounting rail comprising an elongate body comprising: a back plate; a front plate; a support plate extending between the back plate and the front plate, said back plate and front plate defining a groove therebetween for receiving a part of a building element thereon; and a reinforcing arrangement, wherein the reinforcing arrangement comprises a region of increased thickness of the body.
2. The mounting rail of claim 1, wherein the reinforcing arrangement comprises a reinforcing rib on the back plate.
3. The mounting rail of claim 2, wherein the reinforcing rib is located towards an uppermost end, for example at the uppermost end, of the back plate.
4. The mounting rail of any preceding claim, wherein the reinforcing arrangement comprises a region of enlarged thickness at an intersection between the back plate and the support plate.
5. The mounting rail of claim 4, wherein the support plate and the back plate are configured so as to define a first curved edge at the intersection between the back plate and the support plate.
6. The mounting rail of any of any preceding claim, wherein the reinforcing arrangement comprises a region of enlarged thickness at an intersection between the front plate and the support plate.
7. The mounting rail of claim 6, wherein the support plate and the front plate are configured so as to define a second curved edge at the intersection between the front plate and the support plate; optionally, wherein the second curved edge is provided at the intersection between the support plate and a lower region of the front plate.
8. The mounting rail of any preceding claim, wherein the support plate extends substantially perpendicularly from the back plate.
9. The mounting rail of any preceding claim, wherein the support plate extends from a lowermost end of the back plate.
10.The mounting rail of any preceding claim, wherein the front plate is arranged substantially perpendicularly to the support plate.
11.The mounting rail of any preceding claim, wherein the front plate and back plate are substantially parallel.
12.The mounting rail of any preceding claim, wherein an intersection between the front plate and the support plate is at a location between an uppermost end and a lowermost end of the front plate, so as to define upper and lower regions of the front plate.
13.The mounting rail of claim 12, wherein the lower region of the front plate has a greater length than the upper region of the front plate.
14.The mounting rail of claim 12 or claim 13, wherein the reinforcing arrangement comprises a reinforcing rib on the front plate, optionally comprising a reinforcing rib at the lower region and/or upper region of the front plate.
15.The mounting rail of any preceding claim, wherein the back plate comprises a mounting surface on a side of the back plate distal to the support plate, and wherein said surface is substantially planar.
16. The mounting rail of any preceding claim, wherein the back plate comprises a plurality of mounting apertures extending therethrough, said mounting apertures configured for receiving an attachment member to secure the mounting rail to a bracket or building structure.
17.The mounting rail of any preceding claim, wherein the body is formed from extruded metal, for example extruded aluminium.
18.A frame assembly for mounting a building element to a building structure, the frame assembly comprising: first and second spaced apart brackets; and first and second mounting rails according to any preceding claim mounted to the first and second brackets to define a spacing therebetween for receiving building elements, wherein the first and second mounting rails are moveably mounted to the first and second brackets such that the mounting rail can move relative to the brackets between a collapsed state and an expanded state, and wherein the spacing between the first and second mounting rails is greater in the expanded state than in the collapsed state.
19.The frame assembly of claim 18, wherein the first and second mounting rails are pivotably mounted to the first and second brackets such that the mounting rail can pivot relative to the bracket between the collapsed state and the expanded state.
20.A cladding assembly for mounting a building element to a building structure, the cladding assembly comprising: the frame assembly of claim 18 or claim 19; and a plurality of building elements mounted to the first and second mounting rails.
21.The cladding assembly of claim 20, comprising a spacer positioned between adjacent building elements.
22.The cladding assembly of claim 21, wherein the spacer defines a generally T-shaped body, and wherein the spacer is arranged such that a first arm or shoulder of the spacer is received in a slot or groove in a first building element and a second arm or shoulder of the spacer is received in a slot or groove in an adjacent building element.
23. A method of prefabricating a cladding assembly, comprising the steps of: providing a frame assembly according to claim 18 or 19; and mounting a plurality of building elements to the first and second mounting rails.
24. The method of claim 23, wherein the step of mounting a plurality of building elements to the first and second mounting rails is offsite in a factory environment.