Patent Description:
A common building construction is that of a main structure which is produced using the latest building technology and materials, surrounded on the outside by a cladding, perhaps made of more traditional materials like bricks. The benefits of this structure are that the main building can be built from any number of new materials and therefore fulfil all building regulations as these develop, while the cladding forms an outer wall that can be made more aesthetically pleasing. Such a structure typically includes a cavity between the main building and the cladding, wherein this cavity not only increases insulation of the building from the external elements and environment, but also allows greater flexibility when constructing the main building structure. Previous disclosures related to this field include <CIT>, <CIT>, <CIT> and <CIT>.

<CIT> discloses a tile block veneer wall structure comprising a supporting wall with an integral tile block holding frame unit. The holding frame unit defining horizontally extending channels stacked above one another that are used to accommodate tile blocks.

<CIT> discloses a masonry panel for a building structure comprising a plurality of elongate members that each define a bed for accommodating a single course of masonry slips. Legs or flanges that engage in two slots in two sides of the slips retain the slips.

<CIT> discloses a building component assembly having a covering arrangement attached to a building component by an attachment arrangement. The attachment arrangement utilises mechanical fixing means to fix the covering arrangement to a building component.

<CIT> discloses a structural building component comprising a rigid elongate beam and at least one facing element for facing a portion of said beam. Whereby, the facing element is fixed to said beam.

There is a particular difficulty however with certain building designs being constructed in this manner. Namely one such design is that of an arch construction. Arches are used in buildings to enlarge entrances, allow more light into enclosed spaces, or to mimic older style building design such as large arches used as entrances at coaching inns. There is therefore a need to be able to create such building designs through the use of the cladding based construction. The present invention seeks to address these problems and provides both an apparatus for construction of the arch as well as a method of assembly.

According to a first aspect of the invention there is provided a frame for retaining one or more masonry slips, the one or more masonry slips each having at least two slots formed on at least two sides thereof, respectively, the frame comprising a supporting structure comprising a back plate, wherein the supporting structure is configured to house two or more masonry slips, two or more face rails positioned on the back plate of the supporting structure wherein each face rail is configured to house at least one masonry slip, each face rail comprising a projection directed away from the back plate of the supporting structure, and further comprising a retaining element positioned at the end of the projection and such that the retaining element is approximately parallel to the back plate of the supporting structure, wherein the retaining element is configured to be positioned within one of the two slots formed on the sides of the masonry slip, wherein the supporting structure is a curved supporting structure.

This has the advantage of enabling an archway to be formed using a cladding type construction.

A further optional feature comprises a spacer element configured to be positioned within a slot of a first masonry slip housed by the first face rail, and within a slot of a second masonry slip housed by the second face rail, such that the spacer element maintains a set gap between the first masonry slip and the second masonry slip. This is particularly advantageous as the spacer element mechanically holds the masonry slip and stops it from rotating in situ and therefore moving from its intended position. Such movements may be hazardous so this greatly improves the design.

According to a further aspect of the invention there is provided method of assembling the frame of the first aspect, the method of assembly comprising fabricating a frame according to the first aspect comprising a back plate and at least two face rails wherein the supporting structure is curved;
installing a first masonry slip into a first face rail by rotating the first masonry slip such that the first masonry slip passes via the projection of the first face rail, installing a second masonry slip into the second face rail by rotating the second masonry slip such that it passes via the projection of the second face rail, wherein the slot on the side of each masonry slip is positioned level with the retaining element of the corresponding face rail parallel to the back plate, positioning the retaining elements within the corresponding slot on the side of the corresponding masonry slip.

Optionally, the method of assembly further comprising the steps of inserting a first spacer element into the side of the masonry slip, whilst allowing enough room for the adjacent masonry slip to subsequently be installed, and once the adjacent masonry slip is installed rotating the spacer element such that the spacer element is in contact with both the first and the second masonry slips, preventing the masonry slips form being rotated in the opposite direction to which they were installed. Advantageously this may hold the masonry slips effectively.

Optionally, wherein the spacer elements are washers, and the method of assembly further comprising the steps of fixing the spacer elements to the back plate, wherein the backing plate comprises pre-cut holts in locations aligned with centres of joints between adjacent masonry slips. Advantageously this may offer a low cost solution.

There is described herein a frame for retaining one or more masonry slips, the one or more masonry slips each having at least two slots formed on at least two sides thereof, respectively, the frame comprising a supporting structure comprising a back plate, wherein the supporting structure is configured to house two or more masonry slips, two or more face rails positioned on the back plate of the supporting structure wherein each face rail is configured to house at least one masonry slip, each face rail comprising a projection directed away from the back plate of the supporting structure, and further comprising a retaining element positioned at the end of the projection and such that the retaining element is approximately parallel to the back plate of the supporting structure, wherein the retaining element is configured to be positioned within one of the two slots formed on the sides of the masonry slip, wherein the supporting structure is a curved supporting structure. This has the advantage of enabling an archway to be formed using a cladding type construction.

<FIG> shows an archway <NUM> spanning a gap between a proximal and distal end portions. The archway shown holds its own weight - moreover arches may have to hold both their own weight as well as the weight of some or all of an auxiliary structure positioned above the arch.

<FIG> shows a cross section of the arch <NUM> of <FIG>. This shows that the arch <NUM> may be formed by a supporting structure such as a fabricated section, or steel girder or the like functioning as a lintel. The cross section may be hollow, or may comprise a fabricated section, or steel girder that is not hollow. As can be seen in the cross section whilst the cross section is broadly rectangular there is a lip <NUM> at the top extending from the frontal surface (referred to as the back plate)<NUM>. When installed masonry slips may be substantially flush with the edge of this lip. Alternatively, they may extend beyond the lip. The lip is perpendicular with the back plate <NUM> of the supporting structure. The back plate <NUM> is the face of the arch facing outward from the building. The underside plate <NUM> is also shown.

<FIG> shows a frame <NUM> comprising face rails <NUM> and soffit rails <NUM> attached to the supporting structure of <FIG>. <FIG> shows a frontal view. The face rails <NUM> each comprise at least one projection <NUM> directed away from the back plate <NUM> of the supporting structure. The projection <NUM> comprises a retaining element <NUM> positioned at the end of the projection <NUM> and such that the retaining element <NUM> is approximately parallel to the back plate <NUM> of the supporting structure. In <FIG> the retaining elements <NUM> can be seen as hemispherical shapes on the face rails <NUM>. The retaining elements <NUM> may be any shape. The projection <NUM> themselves are hidden by the retaining elements <NUM>. The projection is perpendicular to the plan of the page in <FIG> and would point directly out of the page. The projection <NUM> provides a separation distance between the face rail <NUM> and the retaining element <NUM> in which a masonry slip <NUM> can be positioned. It is noted that in <FIG> each face rail <NUM> comprises two projections <NUM> and retaining elements <NUM>. It is noted however than any number of projections <NUM> and retaining elements <NUM> may be used. It is also noted that multiple retaining elements <NUM> may emanate from a single projection <NUM>.

<FIG> also shows the soffit rails <NUM>. The soffit rails <NUM> are attached to the underside plate <NUM>. The underside plate <NUM> is shown as being the underside of the arch <NUM>. Each soffit rail <NUM> comprises two projections <NUM> extending away from the underside plate <NUM> of the supporting structure <NUM>. The projections <NUM> in each pair are spaced apart from each other. Each soffit rail <NUM> further comprises a retaining element <NUM> extending from the end of each projection <NUM> such that the retaining elements <NUM> are substantially parallel to the underside plate <NUM> of the supporting structure <NUM>. The retaining elements <NUM> are attached to the projections <NUM>. In each pair there is a first projection <NUM> with an associated retaining element <NUM>, and a second projection <NUM> with an associated retaining element <NUM>. The first and second retaining element <NUM> extend towards each other such that each soffit rail <NUM> and pair of projections <NUM> can form a slot for a masonry slip <NUM> such that in use the masonry slip <NUM> may be held by the soffit rail <NUM>.

<FIG> shows a side view of the frame of <FIG> in a side view. The face rail <NUM> on the back plate <NUM> of the supporting frame <NUM> is seen in <FIG>. The projections <NUM> are perpendicular to the back plate <NUM>. The projection <NUM> of the soffit rail <NUM> is also seen. The projection <NUM> of the soffit rail <NUM> is perpendicular to the underside plate <NUM> of the supporting structure <NUM>.

<FIG> shows an enlarged perspective view of a portion of the frame of <FIG>, wherein that portion is in the centre of the frame <NUM> in <FIG>. This shows the face rails <NUM>, projections <NUM> and retaining elements 24as described above. It also shows the soffit rails <NUM>, projections <NUM> and retaining elements <NUM> as described above. It is noted that in this example each face rail <NUM> comprises projections <NUM> on just one side, whereas soffit rails <NUM> comprise projections <NUM> on both the left and right hand sides.

<FIG> shows a masonry slip <NUM>. The masonry slip shown is in an L-shape - however many other shapes may be use. The greater length <NUM> of the masonry slip <NUM> may fit within a face rail <NUM>, whilst the shorter length <NUM> may fit within the soffit rail <NUM>. Alternatively the opposite configuration may be used with the greater length <NUM> fitting within the soffit rail <NUM>. Alternatively, both lengths of the masonry slip <NUM> may be the same length and merely referred to as first and second lengths. They may then be used interchangeably between the face <NUM> and soffit <NUM> rails. Indentations <NUM> are shown on both sides of the masonry slip <NUM>. The retaining elements <NUM>, <NUM> may fit within the indentations. It is noted that the indentations on the greater length <NUM> of the masonry slip <NUM> may be on only one side, however for flexibility of use it may be advantageous for indentations <NUM> to be positioned on both sides as shown.

<FIG> shows the masonry slips <NUM> being rotated <NUM> so that they pass via the projections <NUM> of the Face Rails <NUM>. The masonry slip <NUM> is therefore positioned as shown such that when the indentation <NUM> in the side of the masonry slip <NUM> is level with the retaining element <NUM> of the face rail <NUM> parallel to the backing plate <NUM> this is rotated the opposite way <NUM> (shown in <FIG>) so that the retaining element <NUM> sits within the indentation <NUM>. It is noted that indentation and slot may be used interchangeably.

<FIG> shows the masonry slips <NUM> in situ after being positioned within the face rails <NUM>. This shows that the retaining elements <NUM> are positioned within the indentation <NUM> of the masonry slip <NUM>.

<FIG> shows the spacer element <NUM> being inserted into the side of a masonry slip. It is essential that the masonry slips <NUM> are securely fastened to the supporting structure <NUM>. In some instances, the use of the face rails <NUM> will be enough. In other instances, the optional soffit rails <NUM> may also be used. In the embodiment shown in <FIG> additional spacer elements <NUM> are being installed such that the masonry slips <NUM> are even more secure. Various forms of masonry slip <NUM> may be used. For example, those in <FIG> are shown as being rectangular in profile (which includes an L-shape as shown above). In this example the spacer element <NUM> may comprise a clip like structure comprising a central body portion and two arms <NUM> extending from either side of the body portion, the arms <NUM> extending towards the centre of the body portion and towards each other, optionally wherein central body portion of the spacer element is substantially flat. In <FIG> these are positioned between a first masonry slip and a second masonry slip.

<FIG> shows an alternate form of spacer element <NUM> being inserted in the side of the masonry slip <NUM>. The spacer element of <FIG> comprises a washer like structure, optionally wherein the spacer element comprises a central body with two projections. The first projection <NUM> emanates from a proximal end of the central body upwards, and the second projection <NUM> emanates from a distal end of the central body downwards, further optionally wherein the projections are rounded and atraumatic. In this embodiment the washer is predominantly flat.

In both <FIG> and <FIG> the spacer elements are inserted into the indentation <NUM> of the masonry slip <NUM> to be installed. During installation enough space is kept for the adjacent masonry slip <NUM> to subsequently be installed.

<FIG> shows a frame with the face rail <NUM>, soffit rails <NUM>, masonry slips <NUM> and spacer elements <NUM> all attached. This shows the angled spacer elements, and the retaining elements, retaining the masonry slip. The process shown in <FIG> and <FIG> has been repeated such that all masonry slips in the arch are installed.

After all of the masonry slips were installed the spacers <NUM> were then rotated to contact the adjacent masonry slip <NUM> so that the spacer elements <NUM> prevent the masonry slips from rotating in the opposite direction to the direction in which they were installed. This effectively freezes the masonry slips <NUM> in place. Optional further adhesive may be used to cement the location of the masonry slips further.

<FIG> shows a frame with the face rails <NUM>, soffit rails <NUM>, masonry slips <NUM>, and spacer elements <NUM> all attached, with a different form of spacer element shown. The washer like spacer element in shown in <FIG>.

<FIG> and <FIG> show the frames of <FIG> and <FIG> in cross section. <FIG> shows that both the retaining element <NUM>, <NUM> and the spacer element <NUM> are positioned in the indentation <NUM> of the masonry slip <NUM>. <FIG> additionally shows that for elements were washer like spacer elements <NUM> are used some type of further adhesive may be used to anchor the spacer element. In <FIG> a self-tapping screw <NUM> is used to anchor the spacer element through a pre-cut hole in the face rail (shown as a circle on the face of the face rail in many of the previous Figures). However other types of anchoring may be used as would be well known to the person skilled in the art.

An archway may therefore be manufactured using the frame described above. A building incorporating such an archway and/or frame may also be manufactured.

As is shown in the preceding Figures the arch <NUM> may be assembled fabricating a supporting structure comprising a back plate <NUM> and at least two face rails <NUM>. The supporting structure <NUM> may also comprise at least one soffit rail <NUM>, but this is an optional feature. A first masonry slip <NUM> may be installed into a first face rail <NUM> by rotating the first masonry slip <NUM> such that the first masonry slip passes via the projection <NUM> of the first face rail <NUM> (as is shown in <FIG>). A second masonry slip <NUM> may then be installed by rotating the second masonry slip <NUM> such that it passes via the projection <NUM> of the second face rail <NUM>. The indentation <NUM> on the side of each masonry slip is positioned level with the retaining element <NUM> of the corresponding face rail <NUM> parallel to the back plate <NUM>. The retaining elements <NUM> may then be positioned within the corresponding indentation <NUM> on the side of the corresponding masonry slip.

It is noted that use of the spacer elements <NUM>, <NUM> is entirely optional. If spacer elements are used they may be installed by inserting a first spacer element <NUM>, <NUM> into the side of the masonry slip, whilst allowing enough room for the adjacent masonry slip <NUM> to subsequently be installed. Once the adjacent masonry slip <NUM> is installed the spacer element may be rotated such that the spacer element <NUM>, <NUM> is in contact with both the first and the second masonry slips, preventing the masonry slips from being rotated in the opposite direction to which they were installed.

As noted above in relation to <FIG> when the spacer elements are washers <NUM>, a further step of assembly may include fixing the spacer elements <NUM> to the back plate <NUM>, wherein the backing plate comprises pre-cut holes in locations aligned with centres of joints between adjacent masonry slips. The holes may alternatively be cut on the face rails <NUM>.

As previously noted one additional optional step in fabricating the supporting structure may comprise soffit rails <NUM> to the underside plate <NUM> of the supporting structure <NUM>.

Claim 1:
A frame (<NUM>) for retaining one or more masonry slips, the one or more masonry slips (<NUM>) each having at least two slots formed on at least two sides thereof, respectively, the frame comprising:
a supporting structure comprising a back plate (<NUM>), wherein the supporting structure is configured to house two or more masonry slips (<NUM>);
two or more face rails (<NUM>) positioned on the back plate (<NUM>) of the supporting structure wherein each face rail (<NUM>) is configured to house at least one masonry slip (<NUM>), each face rail comprising a projection (<NUM>) directed away from the back plate (<NUM>) of the supporting structure, and further comprising a retaining element (<NUM>) positioned at the end of the projection (<NUM>) and such that the retaining element (<NUM>) is approximately parallel to the back plate (<NUM>) of the supporting structure, wherein the retaining element (<NUM>) is configured to be positioned within one of the two slots formed on the sides of the masonry slip (<NUM>);
characterized in that
the supporting structure is a curved supporting structure.