Arrangement for a facade

Abstract

 The invention relates to an arrangement for a facade. The arrangement includes
- brackets (20) to be attached to the wall (10),
- wall elements (12) to be placed between each two brackets (20) holding each wall element (12) at a distance from the wall.
The wall element (12) is a casing structure made of aluminium surrounded by an outer envelope (54), the casing structure having at least one intermediate web (56). The wall element (12) has a basic shape of an elongated panel.

Description

[0001] The invention relates to an arrangement for a facade, which arrangement includes

• brackets to be attached to the wall
• wall elements to be placed between each two brackets, these holding each wall element at a distance from the wall, and in which
• the wall element is a casing structure made of aluminium surrounded by an outer envelope, with the basic shape of an elongated panel, relative to the length of which the second visible dimension is essentially smaller.

[0002] Many different wall elements, as well as arrangements formed from them to form a facade, are known. The arrangements include wall elements, as well as attachments for attaching them. Wall elements are traditionally made from masonry and sheet metal. A problem with masonry wall elements is their considerable weight, which can be, for example,60 kg/m². This great weight leads to problems in attaching the wall elements, especially in connection with renovation projects. The heavy wall elements place considerable demands on the frame to which the wall elements are attached. In new buildings too, light wall elements are advantageous.

[0003] The weight of wall elements has been successfully reduced by manufacturing them from aluminium. The square weight of wall elements manufactured from aluminium can be, for example, 15 kg/m². Wall elements of this kind are cassettes, in which the internal and external jackets are welded to, or folded over each other. Such elements will not withstand a high point load without damage, i.e. their surface hardness is low. The cassette solution according to JP publication 2006112110, in which a thin-shell cassette is filled with an insulating substance, provides surface hardness only to a limited extent. Life-cycle philosophy sees such a composite product as inexpedient, because it is difficult to recycle.

[0004] Up until now, wall elements manufactured from aluminium have been mainly of a shell construction, in which folds stiffen the wall element. Thermal expansion causes buckling in an aluminium wall element. The problems of external appearance caused by buckling are a drawback to the use of wall elements of folded aluminium.

[0005] Utility models DK9500342U3 and DE20307725U1 disclose the use of relatively massive profiles as facade elements, as well as a suitable attachment system for them. The upper edge of the profile must be lifted above its final position, so that the lower edge can be lifted into its own groove.

[0006] A wall-element system utilizing extruded profiles is disclosed in publication US3100556. However, the construction is extremely complicated, comprising several open profiles to be locked to each other.

[0007] Facade panels often need to be of a considerable size, so that the surface will be uniform. Thus, in this case, the minimum panel height to be aimed at is set as 150 mm and preferably 180 mm while a height of at least 300 mm is often necessary. In addition, the panel should be quite thin, because it is wished to limit the thickness of the structure. Thus, the preferred cross-section of the panels is mainly shaped as a narrow rectangle. This is also an advantageous shape in terms of transport technology.

[0008] The invention is intended to create a new type of arrangement for a facade, in which a light, stiff, easily recycled, rugged, and easily installed wall-panel and attachment combination is achieved.

[0009] In a preferred embodiment, the attachment belonging to the arrangement permits thermal expansion of the aluminium wall element. The arrangement according to the invention is characterized by the fact that the wall element is a cellular structure of a uniform material, in which there is at least one intermediate web inside the casing, dividing the space formed by the outer envelope into at least two separate, closed parts. The stiffness and durability of the wall element relative to point forces are achieved with a wall thickness of 1,5 - 4 mm, preferably 1,8 - 3,2 mm. One or more intermediate webs inside the envelope, together with a sufficient material thickness, will provide the necessary stiffness, if the total thickness of the element is kept reasonable (20 - 30 mm). The larger dimension of the space closed with the aid of the intermediate webs is at most 3 - 6-times the smaller dimension.

[0010] It is surprising, that considerably large enclosed panel profiles can be manufactured by extrusion, in other words from extruded aluminium. This provides a very homogeneous structure and outstandingly good facade surface. The problem has been regarded as being the spreading of the billet in the extruder to become an enclosed, relatively thin profile with a width that is as much as twice the diameter of the billet, in which profile there are, in addition, one or more webs dividing the space delimited by the envelope into separate enclosed spaces. By extrusion, it is possible to manufacture a wall element, which fulfils all of the wishes referred to above concerning the wall element's appearance, homogeneity, sufficient size, stiffness, surface strength, and ecological quality.

[0011] The flexible attachment arrangement permits the elements to move in the attachments, when the elements expand due to heat. The term thermal expansion refers broadly to changes in dimension, both expansion and contraction, arising from variations in temperature. In addition, the flexible attachment arrangement permits the elements to be attached more easily than before and also permits movement due to thermal expansion. In the longitudinal direction, 3 - 5-mm joints are left, at which a vertical base sheet can also be used to protect the base structure. The base sheet can also protrude from the joint, thus forming its own visual element in the joint. The base sheet extends on both sides of the joint and collects rainwater entering the joint and leads it downwards.

[0012] The arrangement according to the invention provides the following advantages:

• Durable solution
• Ventilated structure
• Fully recyclable
• Can be re-surfaced
• Easy to maintain
• Possibility to replace a single panel, i.e. element
• Creative solution
• Good technical properties
• Hidden attachment
• Attachment system holds the facade surface straight in all conditions

[0013] Other preferred embodiments of the invention are described in connection with the later examples of applications.

[0014] In the following, the invention is described in detail with reference to the accompanying drawings depicting one application of the invention, in which

Figure 1a

shows a cross-section of a wall surface formed with the wall elements according to the invention,

Figure 1b

shows the flexible connection, according to the invention, between the wall elements and the attachments,

Figure 2

shows a wall element according to the invention,

Figure 3a

shows the body of the attachment according to the invention,

Figure 3b

shows the lower spring element of the attachment according to the invention,

Figure 3c

shows the upper spring element of the attachment according to the invention,

Figure 4a

shows the formation of the arrangement according to the invention, and

Figure 4b

shows the formation of the arrangement according to the invention.

[0015] Figure 1a shows a cross-section of the wall surface 10 formed by wall elements 12 according to the invention. More specifically, the wall surface 10 is formed by an element arrangement 11 for forming a wall surface 10 from wall elements 12 and attachments 20. The wall elements 12 include a body component 14 and a bracket 16. The attachment 20 includes a wall-frame 18 bracket 22 and wall-element 12 brackets 24 and 24'. In addition, between the brackets 24, 24' and the brackets 16, 16' in the wall element 12, there are flexible elements 47, 49 for creating a flexible attachment 38, 38'. The flexible attachment created by the flexible element permits the wall elements to move relative to the attachments and, in turn, relative to the wall frame. As the wall elements are free to move relative to the attachments, the thermal expansion of the wall elements will not cause deformations in the wall elements. The flexible attachment also makes it easier than before to attach and detach the wall elements.

[0016] In the cross-section shown in Figure 1a, the upper bracket 24 in the attachment 20 includes a flexible element 49 for forming a flexible attachment 38 with the lower edge of the wall element 12. As the flexible elements 47, 49 are part of the attachment 20, there is no need for flexible elements in the wall element 12 itself. When the attachments are secured in the wall frame, the flexible elements take up directly their final locations. Correspondingly, the lower bracket 24' includes a second flexible element 47, in order to form the lower flexible attachment 38'.

[0017] Figure 1b shows a cross-section of the wall element 12 at its top and bottom, i.e. in connection with the attachment 20. The attachment 20 includes the attachment point 23 of the lower wall element 12' and the attachment point 25 of the upper wall element 12". The bracket 16 belonging to the wall element 12 includes a lower attaching shape 26 (toothed lower edge) and an upper attaching shape 28 (edge flange). The lower attaching shape 26 of the wall element 12 is located in the attachment 20 at the attachment point 25 of the upper wall element 12". The upper attaching shape 28 of the wall element 12, which comprises an edge flange extending over the plane of the rear surface, is placed at the attachment point 23 of the lower wall element 12'. In addition, the attachment point 25 of the upper wall element 12" includes a two-sided, U-shaped flexible element 49 receiving the downwardly extending lower flange on the plane of the rear surface, in which there is toothing. The two-side flexible element 49 secures the toothed lower end of the wall element firmly to the attachment.

[0018] A space is formed downwards and behind the wall element 12 of otherwise even thickness, for the upwards opening U attachment point 25. The lower enclosed space C of the wall element is therefore narrowed downwards and covers the attachment 20.

[0019] The cross-section shown in Figure 1b shows that the attachment 20 includes the attachment point 23 of the lower wall element 12' and the attachment point 25 of the upper wall element 12". The attachment point 23 of the lower wall element 12' includes a one-sided flexible element 47, which is located in its own groove slightly below the point of the support flange 20' of the attachment 20. The one-sided flexible element permits easily installation, as the upper flange (attaching shape 28) of the element can be pushed at an angle between the support flange 20' and the flexible element 47 and rotated into place. The flexible element 47 then remains to press the upper edge against the support flange 20'. In addition, the one-sided flexible element permits the movement of the wall element as a result of thermal expansion.

[0020] Figure 2 shows the wall element 12 according to the invention, in which there is a body component 14 and brackets 16, 16'. The body component 14 is of a cellular construction 34 comprising enclosed spaces A, B, and C formed by intermediate webs 56, surrounded by an outer shell 54, i.e. an envelope. The wall element formed of a cellular structure is stiff and transmits its deformations to the brackets and, in turn, to the flexible attachment.

[0021] The flexible attachment permits movement, of as much as a few millimetres longitudinally, between the wall element and the attachment. The wall element will then not buckle.

[0022] The wall element 12 shown in Figure 2 is of extruded aluminium. A corrosion-resistant wall element, which can be surface treated in very many different ways, is obtained form the aluminium.

[0023] The wall element is preferably manufactured by extrusion. A closed profile, in which there is additionally one or more webs, the width of which profile is as much as double the billet's diameter (200 mm), is spread from a round billet.

[0024] If the wall element is manufactured by extrusion, both the outer shell and the necessary intermediate webs can be manufactured in the wall element simultaneously in a single process. Though the dies required by the extruder form a considerable cost, the advantages offered by the cellular structure favour extrusion.

[0025] Some of the dimensions of the wall element are marked by letters in Figure 2. Dimension a, i.e. the full height of the wall element, can be, for example, 298 mm. The full height can also be, for example, about 200 mm (one intermediate web) or 400 mm (three webs), the thickness dimension remaining the same. Higher wall elements are used in high and large surfaces, when the appearance of then a high wall surface will be pleasant. The length of the wall element, i.e. its horizontal dimension, is typically in metres, for example, 6 metres. Because the length of the wall elements can be as great as this, a large uniform wall surface can be made from them. Next, some example values are given for the other dimensions of the figure: dimension a is 298 mm. Dimension b is 275 mm. Dimension c is 47,1 mm. Dimensions d and e are 100 mm. Dimension f is 11,6 mm. Dimension g is 22,5 mm. The extrusion thickness of the envelope 34' is 2,2 mm.

[0026] Typical technical data for a facade:

material: Extruded aluminium EN-AW

weight: 12,5 kg/m2 (including attachment skeleton)

panel size: 200 / 285 x 200...6000 mm

thermal expansion: 24 µm/m°C

[0027] Figure 3a shows the attachment body 21 of the attachment according to the invention. In order to attach the wall element to the attachment, more specifically to the body 21 of the attachment, the wall frame 18 (Figure 1) includes a bracket 22 and the wall element 12 (Figures 1a, 1b) the upper and lower brackets 24 and 24'. A flexible attachment 38 (Figure 1b) is arranged in the upper part of the attachment in the lower bracket.

[0028] Thermal expansion and deformations are often a problem with aluminium wall elements. The arrangement according to the invention, together with the attachment is suitable for attaching such thermally expanding wall elements.

[0029] The attachment body 21 shown in Figure 3a includes the bracket of the lower edge of the wall element 12 and the bracket 24' of the upper flange 24'. Here, the attachment body 21 is shown separately, without the flexible elements 47 and 49. The attachment body 21 is formed as its own profile. The width of the attachment, i.e. the length of the profile, is about 30 mm.

[0030] Figure 3b shows the attachment's 21 flexible element 49, which is formed of a U-shaped rubber profile, which locks into the groove in the bracket 24. The two-sided flexible element permits movement arising from the thermal expansion of the element to take place between the element and the flexible element, in the horizontal direction of the element. In the vertical direction, in turn, the movement due to the thermal expansion of the element takes place mainly in the upper edge of the wall element. Because there is little vertical movement in connection with the two-sided flexible element, the lower edges of the wall elements remain in place in the vertical direction. As the wall elements remain in place in the vertical direction, the alignment of the wall elements remains as desired.

[0031] Figure 3c shows the lower flexible element 47 of the attachment 21 for the upper flange of the wall element. The flexible element 47 is installed in the lower attachment groove of the attachment 21. The flexible element 47 is one-sided and permits movement in both the vertical and horizontal directions.

[0032] Figure 4a shows the formation of the arrangement according to the invention. The wall surface 10 is formed from wall elements 12. These are attached to the wall 18 by means of attachments 20, which are first of all attached to the wall 18. After this, the wall element 12 is attached to the attachments 20, first at its upper end 30 by lifting the upper end 30 of the wall element 12 into the upper attachment 40, in order to form a flexible attachment 46 of the upper end and, after this, by pressing the lower end 32 of the wall element 12 into the lower attachment 42, in order to form a flexible attachment 38 of the lower end. The arrangement is quite precise dimensionally, in that the wall element has just enough space to rise sufficiently to allow the lower end to be installed. Thus, no tools are required when installing the wall elements in the attachments. As no tools are used when attaching the wall elements to the attachments, the wall elements cannot be damaged by tools.

[0033] Figure 4b shows the formation of the arrangement according to the invention, once the wall element being installed in Figure 4a is in place and the next wall element is being installed above the previous wall element.

[0034] Figures 4a and 4b can also be interpreted as showing the removal of wall elements. In that case, Figure 4b will be before Figure 4a in time. The wall elements 12 can be taken off the wall 18 by lifting the wall element 12 from the lower attachment 25 and then lowering the wall element 12 out of the upper attachment 23.

[0035] Figure 4b shows that, by dimensioning the brackets 16, 16' of the wall element 12, and especially the lower end 36 of the cellular structure 34 belonging to the body component as desired, it is possible to influence the detaching and attaching sequence. If the lower end of the cellular structure extends sufficiently downwards, the lower wall element cannot be removed while the upper wall element is in place. On the other hand, if the lower end of the cellular structure is short, the lower wall element can be removed, even if the upper wall element is in place. A long lower part of the cellular structure, which prevents the wall elements from detaching from the wall, is preferably used in the lower parts of the wall. Vandals cannot then easily remove wall elements. In turn, a shorter lower part of the cellular structure can be used higher up in the wall, when the wall elements can be detached in any order whatever. As any wall element whatever can be removed from the wall surface, a small area of the wall surface can be repaired simply, without extensive dismantling.

Claims

1. Arrangement for a facade, which arrangement includes

- brackets (16) to be attached to the wall (18),

- relatively thin wall elements (12) with an elongated basic shape, in which the two larger dimensions form the visible wall surface (10), and in which each wall element (12) is arranged to be attached at a distance from the wall (18) by means of the said brackets (16), in such a way that, seen from the direction of the largest dimension, the brackets (16) lock the wall element (12) between them in the direction of the smaller visible dimension, and, in which

- the wall element (12) is a casing structure surrounded by an outer envelope (34') and manufactured from aluminium,

characterized in that the wall element (12) is a cellular structure (34) of a uniform material, in which there is at least one intermediate web (56) inside the casing, dividing the space formed by the outer shell (54) into at least two separate closed parts (A, B, C).

2. Arrangement according to Claim 1, characterized in that the said smaller visible dimension is 150 - 500 mm, preferably 180 - 320 mm.

3. Arrangement according to Claim 1 or 2, characterized in that the thickness of the envelope (34') is 1,5 - 4 mm, preferably 1,8 - 3,2 mm.

4. Wall element according to any of Claims 1 - 3, characterized in that the wall element (12) is formed as a uniform profile by extrusion.

5. Wall element according to any of Claims 1 - 4, characterized in that the depth dimension, i.e. thickness, of the wall element (12) is 15 - 40 mm, preferably 20 - 30 mm.

6. Arrangement according to any of Claims 1 - 5, characterized in that thin edges (26, 28) are formed in the wall element (12) as attachment lugs located essentially at the ends of the said smaller visible dimension and on a uniform place with the rear part of the wall element (12), and in the brackets (20) there are spaces corresponding to each said edge (26, 28), in such a way that one edge (28) of the wall element(12) and the corresponding space in the bracket (20) permit the opposite edge (26) to be lifted from the outside when installing a wall element (12) in the bracket (20).

7. Arrangement according to Claim 6, characterized in that on at least one side of the smaller dimension the bracket (20) includes a flexible element (47) holding the wall element (12) in place.

8. Arrangement according to Claim 6 or 7, characterized in that the first edge (28) to be set in place is arranged to be pushed at an angle in the bracket (20), between the outer support flange (20') and the flexible element (47) remaining inside, so that, when the wall element (12) is turned into place, the edge (28) of the element remains pressed by the flexible element (47) against the said outer flange (20').

9. Wall element according to any of Claims 1 - 8, characterized in that the wall element (12) has an essentially narrow cross-sectional profile of even thickness, in which attachment edges (26, 28) for attachment are formed on the rear plane.

10. Arrangement according to Claim 6 or 7, characterized in that a U-shaped flexible element (49) is fitted in the bracket (20) to receive the edge (26) of the wall element (12), which is equipped with toothing to increase the retaining force.

Drawing