GB2513464A - Bracket - Google Patents

Abstract

A bracket for supporting a façade wall panel having a base portion 3 and a protruding portion 5 comprises fibre-reinforced polymer material optionally with intumescent filler. The protruding portion has a slot 27 defined by a fixing member and a gripping member so that a facade panel mounting member can be temporarily supported prior to accurate positioning and fixing using apertures 17. Also claimed is a bracket with base and protruding portions, where at least a major portion of the protruding portion comprises a fibre-reinforced polymer with intumescent filler. The base is preferably fixed to a wall via apertures 15.

Description

Intellectual Property Office Application No. GB1403924.2 RT1\4 Date:t9 August 20t4 The following terms are registered trade marks and should be read as such wherever they occur in this document: Keviar Celazole Ultem Intellectual Property Office is an operating name of the Patent Office www.ipo.govuk Bracket

FIELD OF THE INVENTION

This invention pertains generally to the field of façade walls, façade wall systems and brackets for façade walls. More particularly, the invention r&ates to a bracket for a façade wall arid method of manufacturing the same, and to a façade wall system and construction method.

BACKGROUND OF THE INVENTION

Façade walls are increasingly utilised in building construction or retrofit projects to provide a moduhir external appearance to a building or in applying external insulation to a building.

Façade systems typically comprises a plurality of façade panels which may be supported by a support framework consisting of T-profiles affixed to protruding brackets mounted on the wall to which the façade is to be retained against. Optionally, within the cavity between the façade wall and the supporting wall there may be disposed insulation material.

There is a need for improved brackets for use with a variety of façade wall systems which have advantageous and desirable properties.

The present inventor has invented a new bracket for use with façade wall systems.

PROBLEM TO BE SOLVED BY THE INVENTION

There is a need for improvements in brackets for façade wall systems.

It is an object of this invention to provide a bracket for a façade wall system that demonstrates good thermal transfer performance, is relatively low cost to manufacture and is energy efficient to manufacture and is adaptable for use in a range of façade wall applications.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided a bracket comprising a base portion for abutting and affixing to a wall and a protruding portion protruding from the base portion which protruding portion is configured for engagement with a façade support member for supporting or mounting a façade wall element, wherein the base portion and the protruding portion comprise fibre-reinforced polymer material, and the protruding portion comprises an engagement portion comprising a fixing member to which a support member may be mounted and a gripping member which fixing element and gripping JO arm together form a slot dimensioned to receive the support member.

In a second aspect of the invention, there is provided a bracket comprising a base portion for abutting and affixing to a wall and a protruding portion protruding from the base portion which protruding portion is configured for engagement with a façade support member for supporting or mounting a façade wall element, wherein the bracket is formed of a material having a thermal conductivity as defined hereinafter.

In a third aspect of the invention, there is provided a bracket comprising a base portion for abutting and affixing to a wall and a protruding portion protruding from the base portion which protruding portion is configured for engagement with a façade support member for supporting or mounting a façade wall element, wherein the bracket is formed of a material having a fire performance as defined hereinafter.

In a fourth aspect of the invention there is provided a bracket comprising a base portion for abutting and affixing to a wall and a protruding portion protruding from the base portion which protruding portion is configured for engagement with a façade support member for supporting or mounting a façade wall element, wherein the bracket is formed of a basalt fibre reinforced polymer material.

In a fifth aspect of the invention, there is provided a bracket.

In a sixth aspect of the invention, there is provided a method of manufacturing a bracket as defined above.

In a seventh aspect, there is provided a façade wall system comprising a bracket as defined above.

ADVANTAGES OF THE INVENTION

The bracket of the present invention provides a façade bracket with excellent strength suitable for heavy load façade panels and excellent fire and low conductivity performance. Further, they are readily adaptable for wider cavity systems.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a diagrammatic representation in perspective view of a bracket according to one embodiment of the invention; Figure 2 is a diagrammatic representation in perspective view of a bracket according to another embodiment of the invention; and Figure 3 is a diagrammatic representation in perspective view of a bracket according to a yet further embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention provides for an improved bracket for affixing a façade wall system to a supporting wall in buildings or other stmctures.

The bracket of the present invention preferably comprises a fibre-reinforced polymer and/or is formed of a material so as to have a conductivity of from 0.3 to 0.5 W/mK and/or is formed of a material so as to have a desirable fire resistance, Preferably the bracket of the invention comprises a fibre-reinforced polymer.

The bracket of the invention comprises a base portion and a protruding portion.

The base portion is configured to be affixed to a supporting structure or wall for the façade wall (i.e. the supporting structure or wall to which the façade wall is to be attached), The base portion therefore has a support-contacting surface and a façade facing surface, the protruding portion protruding -j -outward from the façade facing surface of the base portion. The base portion is typically configured with a plurality of apertures for receiving fixings such as screws for affixing to the supporting wall. The base portion is preferably substantially planar and is preferably substantially oblong, i.e. rectangular, in shape.

The protruding portion protrudes in any suitable configuration and from any position or arrangement from the base portion and is configured for mounting a mounting member such as a T-profile for a façade support frame.

A part of the base portion associated with the protruding portion and a part of the protruding portion associated with the base where the protruding portion protrudes from the base may be referred to as the bracket junction.

Positions on the base portion or protruding portion may be defined herein with reference to the bracket junction (e.g. proximal or distal, local or peripheral to the bracket junction).

Preferably, at least a portion of the protruding portion comprises a fibre reinforced polymer (FRP) material and more preferahiy is formed of or consists essentially of a fibre reinforced polymer material and still more preferably a major extent. Most preferably substantially the whole of the protruding portion comprises, is formed from or consists essentially of a fibre reinforced polymer.

Alternatively, a portion of the protruding portion proximal to the bracket junction comprises fibre reinforced polymer, whilst a distal portion comprises a different material, such as a metal (e.g. aluminum or steel). The use of fibre reinforced polymer in the protruding portion has the ability to reduce thermal bridging across a cavity within a façade wall system (which often will contain a layer of insulation typically up against the support or wall on which the façade wall is mounted), Thus the fibre reinforced polymer from which the protruding portion is made is preferably a low thermal conductivity fibre reinforced polymer material by which it is meant having a thermal conductivity of 0.5 W/mK or less.

Accordingly, there are two alternative embodiments. In a first embodiment, the base portion may be made of a different material, other than low thermal conductivity fibre reinforced polymer. In this embodiment, the base portion may be made of any suitable material, which is typically characterised as having high material strength, good fire resistance, and is capable of being firmly secured to the support wall. For example, the base portion may be aluminium or steel or any other suitable material, typically in plate form, In this embodiment, where the material is different, the base portion and the protruding portion may be made separately and then joined and preferably the protruding portion and the base portion may have corresponding engaging and receiving means for securedly joining the two portions for use. This configuration may have the advantage that the base portions may be affixed to the supporting wall prior to connecting the protruding portions thereto, which may then be slotted arid/or glued into place in situ, In a second, and preferred, embodiment, at least a portion of both the base and the protruding portions comprise a fibre reinforced polymer material and more preferably are formed of or consist essentially of a fibre reinforced polymer material and still more preferably a maj or extent and most preferably substantially the whole of the base and protruding portions comprise, are formed from or consist essentially of a fibre reinforced polymer, The fibre reinforced polymer in the base and protruding portions may be the same or different.

Optionally, the fibre reinforced polymer in both the base and the protruding portions are low thermal conductivity fibre reinforced polymer materials, Preferably, the base and protruding portions may be made together (e.g. by pultrusion of a profile comprising the base and protruding portions or by a single injection moulding process), The base portion is preferably a panel element or plate or substantially planar element or plate with local variations, The base portion preferably conforms to two directions, an elongate direction (defined by the general orientation of a longer edge of the base portion) and a contracted direction (defined by the general orientation of a shorter edge of the base portion), which elongate and contracted directions are preferably substantially orthogonal to one another but in the plane of the substantially planar base portion. Preferably the base portion is rectangular, preferably having two longer edges (in an elongate direction) and two shorter edges (in a contracted direction), Preferably the protruding portion is generally a panel element or plate or substantially planar element or plate with local variations and preferably orientated in a plane that is substantially parallel with the elongate direction. The protruding portion may protrude at an angle to the base portion of from say 45 degrees to 90 degrees, preferably from 80 to 90 degrees and most preferably about 90 degrees. The plane of the protruding portion is preferably generally orthogonal to the plane of the base portion.

The point at where the protruding portion meets the base portion may be considered the bracket junction. The bracket junction may be positioned at any configuration on the base portion, but preferably so that the protruding portion is in a plane generally parallel to the elongate direction of the base portion.

Optionally the bracket] unction is configured so that the bracket has a T-profile, which may be a symmetrical T-proflle or an off-set T profile where one arm of the T (forming the base portion) is shorter than the other arm of the T forming the base portion. PreferaNy, the bracket defines an L-profile whereby the bracket junction is formed along one edge of the base portion, typically a long edge of a rectangular base portion.

Where the bracket defines an offset T-profile or an L-profile the long edge of the base portion farthest from the bracket junction may be referred to herein as the peripheral edge or distal edge, whilst the long edge of the base portion closest to the bracket junction may be referred to as the junction edge or proximal edge, lii such an embodiment, the short edges may be referred to as the short edges or orthogonal edges.

The protruding portion may extend from the base portion by an orthogonal extent, being the distance from the plane of the base portion orthogonally to the distal (free) end of the protruding portion. The orthogonal extent of the protruding portion may approximate to the depth of the bracket as used herein, The protruding portion has an elongate extent being the dimension of the protruding portion in the elongate direction. Preferably the elongate extent of the protruding portion is substantially the same as that of the base portion or within 94 thereof or within I 0% thereof Preferably, the base portion may be dimensioned to support the protruding portion and any façade support members and façade panels mounted thereon and in particular to prevent movement about the dimensions thereof and which thus depends on the orthogonal extent of the protruding portion. Preferably, the contracted dimension (the length of the base portion in the contracted direction) is at least 40 mm, preferably at least 50 mm. Preferably the elongate dimension (the length of the base portion in the elongate direction) of the base portion is at least 50 mm, preferably from 60 to 500 mm, more preferably in the range 75 to 400 mm depending upon the orthogonal extent (or depth) of the bracket.

The orthogonal extent of the protruding portion may be sized according to the size of the cavity intended to be defined by the façade wall. The greater the amount of insulation required, the greater the orthogonal extent of protruding portion (and depth of bracket) required. The greater the depth of the bracket the greater the chaflenge in achieving the required strength, thermal bridging and fire resistance. The protruding portion may be extended so as to provide a façade wall bracket for a cavity in the range 75 mm to 500 mm, for example, such as from 95 mm to 350 mm. The table below sets out a range of cavity depths and associated ranges of bracket elongate dimension and protruding portion orthogonal extents (or bracket depths) which the brackets as defined according to the invention and any embodiment herein may be adapted.

Bracket elon2ate dimension/mm Protrudin2 portion orthoonal Façade wall extent (or bracket depth)/mm cavity depth range Range Preferred Range Preferred 50-125 80 75-115 90 90-130 100-180 160 90-150 120 125-160 150-240 200 120-180 150 150-200 200-280 240 150-2 10 180 185-220 240-320 280 180-240 210 215-250 240-360 320 210-270 240 240-280 320-400 360 240-300 270 2'75-310 360-450 400 270-450 330 300-500 The maximum and average thickness of the bracket portions may be adapted according to the specific requirements. For example, for the greater bracket depth, thicker protruding portions and optionally base portions may be desirable. The bracket thickness may range across the above ranges of elongate and protruding portion orthogonal dimensions from about 5 mm to about 25 mm, preferably about 5 to about 15 mm.

Typically, in use, the bracket of the invention supports a façade wall which defines a cavity within at least a portion of which insulation may be disposed, typically in a portion adjacent the supporting structure or wall. Thereby, the insulation surrounds the bracket of the invention. It is a preferred feature of the present invention that the base portion tapers to reduced thickness toward its peripheral edge (in the case of an L-shaped profile) or its peripheral edges or peripheral and local edges (in the case of a symmetrical or offset T-shaped profile).

Preferably, the base portion tapers to an edge thickness of 5 mm or less, preferably 3 mm or less an optionally 2 mm or less and optionally incorporating an curved edge profile. By providing a tapered peripheral edge, the insulation may fit snugly against the bracket base portion (which is typically orientated so that the peripheral edge is substantially vertical), which has the advantage of reducing the ri sIc of air gaps forming (e.g. creating air channels) behind the insulation (i.e. between the insulation and the supporting structure or wall) as compared with a squared edge.

A squared edge may cause an air gap of between 10 and 15 mm at least, which if replicated may lead to thermal bypass which is known to substantially undermine insulative effect, Accordingly, the provision of tapered elongate edge or edges on the base portion is highly preferred.

The protruding portion preferably comprises an engagement portion for engaging with a mounting member, being a façade support or façade frame member or support strip, such as a T-profile, for supporting one or more façade elements. The engagement portion comprises a fixing member to which a mounting member may be mounted and preferably a gripping member. The fixing member and the gripping member together defining a slot dimensioned to receive (typically snugly) a mounting member (or façade support member). The fixing member and gripping member together define at least a distal portion (the free end) of the protruding portion of the bracket such that a slot formed by the fixing member and gripping member is substantially coplanar with the fixing member (and protruding portion) and preferably is substantially orthogonal and perpendicular to the plane of the base portion (and thus the supporting structure), Optionally, the fixing member and gripping member together define the entire or substantially all of the protruding portion (such that the protruding portion essentially defines two protrusions from the base portion, which are substantially parallel), which arrangement may be desirable where the cavity to be bridged by the bracket is narrow or where the support member is configured at such a dimension for engagement with the slot in the protruding portion that is comparable with the depth of the bracket. Preferably, the fixing member and gripping member together define a distal portion of the protruding portion, the remainder of the protruding portion between the base portion and the engagement portion being a trunk from which the fixing member and optionally the gripping member extend.

The fixing member is typically provided with a plurality of apertures, typically for alignment with corresponding apertures on the mounting member which may be screwed or otherwise secured together. The apertures are provided typically disposed along an elongate extent of a distal portion of the fixing member. The fixing member is a load bearing member. At least two apertures may be provided on the distal portion of the fixing member, preferably three and more preferably four apertures, There are two general embodiments of the bracket of the invention relating to the gripping member. According to one embodiment, the gripping member extends in a substantially parallel plane to the fixing member to substantially the same extent as the fixing member and is provided with an aligned set of apertures for receiving a fixing to secure in place the mounting member to the bracket via both the fixing member and the gripping member, According to this embodiment, both the fixing member and gripping member may be load bearing. According to a second and preferred embodiment, the gripping member extends in a substantially parallel plane to the fixing member to a lesser extent whereby the distal fixing portion of the fixing member in which the apertures are disposed is unencumbered by the gripping element. Preferably, the gripping member extends at least 2 mm short, more preferably at least 3 mm short and optionally up to 5mm short (or more) of the proximal edge of the apertures formed in the fixing member.

In a preferred embodiment in which the protruding portion comprises a trunk and an engagement portion distal thereto, the gripping member may extend in the orthogonal direction from the trunk or may branch from the fixing member. Either embodiment is suitable, but it is preferred that the gripping member extends from the trunk, Preferably, where the bracket is an offset T-profile or L-profile, the gripping member is positioned to the inward lateral direction of the fixing member (which is the direction toward the peripheral edge of the base element) rather than the outward lateral direction (which is the other direction).

The gripping member preferably defines a slot surface (the surface of the gripping member opposing the surface of fixing member) substantially opposes the fixing member surface and spaced therefrom so as to receive a support member in the slot and snugly support the support member so that it can be retained in position whilst the support members are being positioned and then affixed to each of a plurality of bracket mounted on a support structure.

Preferably, the slot surface is substantially planar and substantially equidistant along the majority of its orthogonal and elongate extent from the opposing fixing member surface.

Preferably the lateral dimension of the slot (the distance between the slot surface of the gripping member and the opposing surface of the fixing member) is such as to snugly receive the support member and more preferably is dimensioned to receive the support member on application of a force (by inserting the support member into the slot) to cause a minor degree of resilient displacement -10-of the gripping member from the fixing member. By being resiliently displaceable, e.g. by bending or pivoting of the gripping member away from the fixing member, the gripping member may apply a resilient force against the member within the slot and preferably hold it in place until it is affixed by pemianent means to the fixing member.

Optionally the resilient displacement may be effected by providing the gripping member with a bending moment to provide resilient displacement sufficient to enable insertion of the support member into the slot and to retain it in position otherwise unsupported, Preferably, the resilient displacement is effected by providing a resilient flex point or resilient hinge, preferably a resilient living hinge' on the gripping member (either part way along its orthogonal extent or at the gripper junction, being the junction of the gripping member with either the trunk or the fixing member).

Preferably, a resilient flex point or resilient living hinge and is provided by having a short extent (in the orthogonal direction) of at least 2mm and up to, for example 5 mm, of profile extending the full elongation of the gripping member having a thickness typically less than the gripping area of the gripping member and preferably of 5 mm or less, more preferably 3mm or less, Thus, the gripping member may resiliently pivot about the living hinge or flex point to provide a resiliently displaceable gripping member.

Preferably, the gripping member has a profile thickness that is substantially constant along the majority of its extent. The profile thickness of a gripping member (in the gripping portion thereof) is preferably in the region of 2 to 0 mm, preferably 3 to 6 mm and more preferably 4-5 mm. Since according to a preferred embodiment, the gripping member is not load bearing (i.e. not bearing the load of the façade panels) then regardless of the cavity size, the profile thickness of the gripping member need not differ from the above. Similarly, it is prefered that the slot defined by the fixing member and gripping member for receiving a supporting member may have a depth of from 20 to 100 mm, preferably 25 to 60 mm and more preferably 30 to 50mm (e.g. 3 5-45 mm) and most preferably about mm again need not differ from these dimensions even for larger cavities.

The slot lateral dimension is selected to meet the requirements of gripping the support member to be slotted and gripped therein, but is typically at rest about 1 to 3 mm, e.g. 1.5 to 2.5 mm, or 1.75 to 2.25 mm and more usually about 2 mm, The distal end of the gripping member may be tapered or curved to provide an opening to the slot.

The configuration of the slot arid in particular, according to the preferred embodiment, the resiliently displacable gripping member and its substantially planar slot-facing surface as against the rigid load bearing fixing member provides a gripping means (or helping hand) which provides a gripping force on the member on the entire surface of the support member (eg, T-profile) inserted into the slot (rather than along, for example a slot-ward protmding ridge from the gripping member in a slot that otherwise provides non-retentive clearance to the support member inserted therein), Thus more stable retention of a support member inserted into the slot may be achieved. In particular it is notahie that the most tightly held part of the support member inserted into the slot is always that part that is received furthest into the slot. Any risk of rotation within the plan of the slot is thereby reduced and the angle at which the supporting member is placed on insertion may be better retained.

Optionally the engagement portion comprises or consists of a metal (e.g. aluminium or steel) and optionally the fixing member comprises metal.

Optionally, no integral gripping member is provided, Alternatively, a separate clip of metal (eg, stainless steel) or plastic may be provided which is configured to clip over the engaging portion to provide a helping hand' to hold and engage a T-shaped profile in position on the bracket.

A characterizing feature of the bracket in a preferred embodiment of the present invention is that aside from reinforcement about fixing apertures, the thickness of load bearing portions of the protruding portion may decrease along the orthogonal extent of the protrusion, Accordingly, the trunk of protruding portion -12-may comprise a thicker profile than the fixing member. A particular feature of the invention is that since the depth of the slot need not vary for brackets suitable for increased cavity depths, then nor need the orthogonal extent of the fixing member.

Since increased cavity depths do not necessarily mean a greater load, the stress on the fixing member and on the junction between the fixing member and the trunk of a bracket for a fixed load at different cavity depths assuming the same orthogonal extent of fixing member and same depth of slot should remain substantially the same irrespective of the total length of the protruding portion. The additional length may therefore be accommodated in the trunk of the protruding portion and additional profile thickness accommodated in the trunk of the protruding portion.

Preferably, the fixing member has a profile thickness of 2.5 to 15 mm, more preferably 3 to 6 mm, still more preferably 3.5 to 5 mm and most preferably about 4mm.

The fixing member and the gripping member are each preferably rectangular-shaped plate members.

The contracted dimension of the base portion is preferably sized to be from 3/8 to 6/8 of the orthogonal extent of the protruding portion and most preferably 4.5/8 to 5.5/8 and most preferably about 5/8 thereof In one embodiment in which the depth (measured from the base surface of the bracket to the proximal edge of the mounting apertures on the fixing member) is about 74 mm, the contracted dimension is about 54 mm. Typically the contracted dimension will range from about 40 to 300 mm and for a conventional range of cavity depths (e.g. up to 160 mm) from about 50 to 100 mm.

The fixing apertures provided in the base portion are preferably disposed centred about the mid point between the inward lateral surface of the protruding portion and the peripheral edge of the base portion (especially for preferred L-shaped profiles). The base portion may be tapered toward the peripheral edge, typically over a distance along the contracted direction of about 5 to 15 mm and preferably along 20 to 25% of contracted dimension of the base portion.

-13 -Preferably, the portions of the bracket about the fixing and mounting apertures on either or preferably both of the base portion and the fixing member are reinforced. Reinforcement may be provided by metal inserts (e.g. which may be incorporated during formation of the base portion and/or protruding portion such as during injection moulding. Alternatively, the reinforcement may be provided with material and more particular fibrous material so that at least a portion of the base portion and/or fixing member about the fixing and mounting apertures has an increased profile thickness by comparison with the surrounding profile area. In the case of the fixing member, the additional material is preferably provided on the lateral outward surface thereof so as not to encumber the slot.

Reinforcement may also be provided about the bracket junction.

In one embodiment (e.g. an embodiment which is manufactured by injection moulding), the bracket is mechanically reinforced by the use of structural ribs. Preferably, the base portion and/or the protruding portion are planar panel elements having protruding structural ribs formed on the surface thereof The ribs may extend along the protruding portion from the base toward the distal end and optionally may decrease in depth (or taper) from base toward the distal end. The ribs may extend along the base portion from the bracket junction toward the distal edge. The depth of the ribs may be up to about 30mm, e.g. 10-25 mm. Preferably there are 3 to 7 ribs, e.g. 4 or 5 ribs, on one or each of the base portion and the protruding portion.

Preferably, the fibre-reinforced polymer (FRP) useful in the manufacture of at least a portion of and optionally the entirety of the protruding portion and preferably also the base portion is formed of a fibre dispersed in a cured polymer resin. Any suitable fibre or fibres may be used in the manufacture of the fibre-reinforced polymer. Examples of fibres that may be used in the FRP in accordance with the present invention may be synthetic and/or natural fibres and may include any one or a combination of: glass fibres; carbon fibres; boron fibres; KevlarTM fibres; mineral fibres; basalt fibre; polymer fibres such as polyester, polyethylene or aramids; or natural fibres such as cotton, jute, hemp or flax.

Preferably the fibres are selected from fibres having low thermal conductivity and -14-more preferably high strength. Thus, preferably, the fibres are selected from glass fibres (e.g. high modulus glass fibre) and basalt fibres and most preferably basalt fibres.

Optionally, more than one fibre material can be used in combination in the fibre-reinforced polymer in forming the bracket of the invention. Such constitution of combinations of fibre materials may vary across the profile (but will typically be consistent along the elongate direction of the bracket) so as to provide different properties at different parts of the profile (e.g. greater strength and rigidity about fixing holes in the base portion and lower conductivity along the protruding portion) or radially from core to surface, Suitable such combinations of fibre materials might be, for example, any two or more of glass fibres, polymer fibres, carbon fibres and basalt fibres in combination, such as glass and basalt fibres or basalt and carbon fibres in combination.

Particularly suitable fiber-reinforced polymers for the wall-tie of the invention include glass fiber-reinforced polymers or basalt fiber-reinforced polymer.

The fibres may be orientated and layed down in any suitable arrangement, e,g. random, partially aligned or aligned, continuous rovings, chopped roving mats or continuous woven roving mats.

The bracket profile may be fonned of a core of fibre-reinforced polymer, preferably basalt fibre. Optionally, the bracket profile may comprise more than one layer of fibre reinforced polymer material, For example, the bracket profile may comprise of an elongate core of fibre-reinforced polymer and one or more layers of fibre-reinforced polymer layed thereon, In one embodiment, the bracket profile comprises a core of FRP having randomly orientated or chopped roving fibres and an outer layer of FRP having continuous woven roving mat (or veil) and, optionally, further layers therebetween or thereon. In another embodiment, the body portion comprises a core of FRP having continuous rovings and at least one layer of FRP thereon which may comprise a layer of randomly orientated or chopped roving fibre-reinforced polymer, a layer of FRP having lateral fibres and a layer of FRP having -15 -longitudinal fibres. An outer layer may be provided by providing a mat of randomly orientated fibres or, preferably, a continuous woven roving fibre mat.

In these multi-layer embodiments, the fibre may be the same or different in each or any layer, but is preferably basalt fibre.

Tn another embodiment, the bracket comprises long or short glass fibre injection moulded content with a high percentage (e.g. at least 45, preferably at least 60) of glass fibre.

The fibre-reinforced body portion of an embodiment of the invention may be manufactured by any suitable means, such as pultrusion, injection moulding, resin transfer moulding, vacuum bag and press moulding, press moulding, compression moulding, or filament winding. In one preferred embodiment, the body portion is manufactured by pultrusion. In another preferred embodiment, the body portion is manufactured by injection moulding. According to this embodiment, polyamide resin is preferred. Optionally, in providing injection moulded portions, a basalt or glass fibre fabric pre-peg' or dry fibre may be laid into the mould and injected over with resin.

Preferably, the bracket profile comprises a surface veil of continuous woven fibre mat, an intermediate two mat at 300 gsm and a core two mats at 450 gsm, Any suitable resin may be used.

The resin, for example may be selected from one or a combination of epoxy resins, vinyl ester resins, polyester resins (such as isopthalic polyester resins), polyurethane resins, polyamide resins, polyamide-imide resins, polyimide resins, polyether ketones (e.g. polyether ether ketone, PEEK), polyphenyline sulphide, polyarvlsulfone, polyethersulfone, polyetherimide (e.g. UltemTM PET), polybenzamidazole (e.g. Celazoletm' PBI), pthalonitrire or phenolic resins, or acrylic or modified acrylic resin, urethane acrylate resin, or inorganic resin systems.

Preferably, the resin is one or a combination of polyurethane, phenolic resin, modified acrylic resin ad more preferably a polyurethane and/or acrylic or modified acrylic resin, In particular, the preferred resin for use with continuous fibres (e.g. -16-by pultrusion manufacturing process) is a thermoset resin such as phenolic resin.

The preferred resin for use in injection moulding manufacture (using short or long fibres) is a thermoplastic resin such as polyamide or PEEK.

Preferably the bracket has a fibre loading of at least 40%, more preferably at least 45%, more preferably at least 50% by weight, e.g. at least 60 % and preferably in the range 50-75 % more preferably 60-70%. This may be as defined in terms of the weight percent of fibre in the composite material used in the bracket and/or as the weight percent of fibre relative to the total weight of fibre and resin in the bracket.

Certain additives may optionally be included in the resin fonnulation to enhance performance, such as intumescent fillers (e.g. intumescent hydrate fillers) to improve fire resistance (which are preferbaly incorporated by dissolving or dispersing in the resin), such as alumina trihydrate and/or clay fillers, such as clay nano particles (to enhance fire resistance and increase strength) and/or alumina or silica fillers. Optionally ATH (or other filler) is included in the formulation, preferably in an amount of up to 25% by weight, preferably 1 0-20%, Preferably this is the combined filler weight.

Optional fibre and resin combinations may be selected from any combination of the above fibres and resins as required or desired, prefered examples of which include: -Basalt fibre and phenolic resin -High modulus glass fibre and phenolic resin -Basalt fibre and acrylic resin -High modulus glass fibre and acrylic resin -Basalt fibre and acrylic resin with 10-20% alumina trihydrate (ATIT) -High modulus glass fibre with acrylic resin and 10-20% ATH -Basalt fibre and polyurethane resin -High modulus glass fibre and polyurethane resin -Basalt fibre and urethane acrylate resin (e.g. that available under the trade name Crestapoltm1) optionally with ATH filler -17- -High modulus glass fibre and urethane acrylate resin (e.g. that available under the trade name Crestapoltm1) optionally with ATh filler -Basalt fibre and modified acrylic resin (e.g. that available under the trade name ModarTM) optionally with ATM filler -High modulus glass fibre and modified acrylic resin (e.g. that available under the trade name Modar') optionally with ATH filler Particularly preferred are basalt fibre and polyurethane or basalt fibre with modified acrylic resin with ATH filler (preferably 10-20% by weight).

A particular advantage of polyurethane resin is it makes the FRP more workable and in particular is useful in enabling fixings to be made to the FRP and screwthread fixings to be applied with reduced risk of failure, A particular advantage of the ATH filler is that it enhances the fire performance of the bracket itself and, in particular, increases the likelihood that the even in significant fire conditions, brackets will continue to support the load applied without failure.

Another particularly preferred composition is glass fibre and polyamide or PEEK resin, preferably with an ATH filler.

A selection of effective fibre reinforced polymer compositions in accordance with the present invention are set out in the table below. The table illustrates the proportion by weight of fibre, resin and filler. Optionally, further additives in minor amounts may also be included, Ref Fibre Wt% (no Vt % (with R Wt% (no Wt% (with Eider Wt% ar mkr fer A Basalt 40-70 4.6t) Phenolic 30-60 20-50 Myt 10-30 B Basalt 40-70 40-60 Aclylic 30-60 20-50 Mvt 10-50 C Basalt 40-70 40-60 Polyurethane 30-60 20-50 Anyt 10-30 D Basalt 40-70 40-60 Urethane aeivlatc 3O3O 20-50 Any 10-30 H Basalt 40-70 40-60 Modified actylie 30-60 20-50 Mvt 10-30 F Glass 40-70 40-60 Plienolie 30-60 20-50 Myt 10-30 G Glass 411-71) 40-60 Aeiylic 3lV,ll 21)-SI) Any 10-30 H Glass 40-70 40-60 Polyurethane 30-60 20-50 Anyt 10-30 I Glass 40-70 40-60 urethane aervlate 30-60 20-50 Anyt 10-30 Glass 40-70 40-60 Modified servile 30-60 20-50 Myt 10-30 -18-K Basalt 40-70 10-60 Polyamide-irnide 30-60 20-50 Anyt 10-50 L BasaIl 40-70 40-60 PEEK 30-60 20-50 Anyt 10-30 Ni Basalt 40-70 40-60 Poivethcñrnidc 300 20-50 Any 10-30 N Basalt 40-70 40-60 Poivbenzamidazole 30-60 20-50 Anyt 10-50 O Glass 40-70 40-60 Polyainide-iinide 30430 20-50 Ailyt 10-30 P Glass 40-70 40-60 PEEl' 30-60 20-50 Anyt 10-30 Q Glass 40-70 40-60 Polyethethnide 30-60 20-50 Anyt 10-30 k Glass 411-711 40-60 Polvbcnzarnidazolc 3114311 211-511 Any 10-30 * prelèrably an iniurnesceni, such as those mentioned above, preferably ATH The formulations A-J preferably comprise continuous fibres and are preferably manufactured by pultrusion, whilst formulations K-R preferably comprise long (e.g. 10 to 100mm, e.g. 20 to 30 mm) or short (e.g. up to 10 mm, or up to 5mm) fibres and are preferably manufactured by injection moulding.

Optionally an outer layer of FRP may be provided in the bracket profile which comprise continuous rovings and more preferably continuous woven veil of preferably basalt fibre whereby the outer portion, e.g. 5-10% of the thickness, of the profile comprises FRP with a high fibre loading, e.g. at least 60%, preferably at least 75%. Optionally, this outer portion is provided with a mixture of the fibre as mentioned along with resin (e.g. a preferred resin) and filler such as a hydrated intumescent filler e.g. ATH, the respective proportions being at least 60% fibre, 10-20% filler and up to 30% resin, more preferably a filler-fibre to resin ratio of at least 80:20, still more preferably at least 85:15 and still more preferably at least 90: tO, Optionally this may be further coated, In any case, a highly effective fire performance bracket may be achieved according to this optional embodiment.

Optionally, the bracket may be provided with an outer coat for enhancing the fire resistance of the bracket. The outer coat may be any suitable material, such as a Kevlartm'1 coating or other heat resistant material, Optionally, the outer coat comprises a granular, preferably of variable size grains, material such as a silica-based material, e.g. sand, preferaNy adhered to the outer surface with a suitable heat-resistant resin, Optionally an outer coated layer may be formed -19-which comprises a resin with good fire performance heavily loaded with an intumescent clay.

Optionally, the bracket may be provided with a fire resistant laminate or jacket as a secondary process, for example an external ceramic layer or rockwool layer.

Coatings or paints may be added as a secondary process after production.

The bracket of the invention may comprise any combination of features hereinbefore described. The combination of each preferred feature with the general disclosure of other features should be understood as having been specifically disclosed herein and in particular the combination of each preferred feature in combination should be understood as having been disclosed herein.

The bracket of the present invention and, in particular, the preferred embodiments of the invention using the preferred materials of the invention provide high strength, enhanced fire-resistance and low thermally conductive brackets for use in façade systems.

The fire performances of the preferred embodiments of the brackets are capable of meeting A2 flame retardant material standards, The brackets according to preferred embodiments described when using the EN 13501 standard, achieve 6 minutes 42s fire resistance (no change over this time in Bunsen burner fiam), retained mechanical strength for fifteen minutes in a 20-1200C fire curve bracket; no significant mechanical alteration after 5 minutes when subject to a heat of tOkW.

The brackets of the present invention and preferred embodiments preferably have a thermal conductivity of 0.3 W/mK to 0.4 W/mK, preferably 0.35 W/mK to 0,45 W/mK, preferably 0,38 \V/mK to 0,42K W/m and most preferably about 0,4 W/mK, A unique benefit of the brackets of the present invention is the thermal break effect of the acceptably low thermal conductivity material combined -20 -with impressive fire resistance and fire performance of the bracket along with the mechanical strength required for taking façade loads of up to 65 kg/rn2.

Preferably the brackets of the present invention are capable, in for example a preferred embodiment with 10mm trunk wall thickness and proffle (base) width of 54 mm and depth (distance from base to distal end of gripping member) of 74 mm, of mechanical performance of one or more of at least the following: -to resist loads on the cladding of o wind loading of 2400 pa of push / pull giving no big deflections (e.g. up to 1mm deflection is ok) and no residual displacement (e.g. 01mm is ok).

o With a wind load of 3600 Pa the whole system will hang on (safety test) with deflections and long term damage accepted in such a severe storm.

-Capable of receiving in combination with other brackets in the system a tile service load of up to 65kg/rn2 2-4 brackets are needed / m2 for the aforementioned loading (this may be advantageous over other less strong systems that need more brackets / m2 -Shear strength of the profile to withstand a minimum of 1050N of load on the bracket alone.

-Resistance to wind load for both tension and compression loads 31 80N In mechanical testing shear loads are 740 N, a displacement less than 2 mm, 780 N, a displacement of 0.5 mm -Tensile rupture of the bracket was a force not lower than 4000 N. -21 -In preferred embodiments of the invention, the brackets preferably withstand: * Allowable stress is at least 20 M/mm2, preferably 23N/mm2 and when subjected to the load could be 5.1 8N/rnrn2 which is excellent.

* Shear Strength at least 750, e.g. 780.72N * Shear due to the weight of the facade of up to 65 kg/rn2, bracket designed to allowable shear is 45N/mm2 and the when subjected to such high loads mentioned above is 25N/nun2 Preferably a bracket according to the present invention has a tensile strength of at least 4000 N and preferably also a shear strength consistent with the above.

In another embodiment, the bracket of the invention may comprise glass-ceramic matrix composites.

In another embodiment, a bracket of the invention and comprising any of the embodiments described herein in terms of the composite material may flirther comprise a high heat mechanical reinforcement embedded within the material, wherein in the event of heat affecting the structural integrity of the main body of a bracket the mechanical reinforcement prevents degradation. For example, the mechanical reinforcement may comprises a plurality of interlinked chain links (e.g. of metal). In normal use, these chain links would not form a thermal bridge as they would be arranged so that each link is separated from the next by an insulating material, but that in the event of the insulating material of the body of the bracket failin& they may come into contact to form a structural support, preventing movement of the bracket more than a few cms.

In one preferred embodiment, the bracket of the invention comprises a metal (e.g. aluminium or steel) base element and a metal (aluminium or steel) fixing member of the engaging portion and separated by a portion of the protruding portion of fibre reinforced polymer of any of the embodiments described. Thus, strength and fire resistance at key mechanical points (the fixings) could be obtained whilst the thermal bridging is minimised.

The relative fibre, resin and filler loadings may in another embodiment be expressed as volume fractions of the composition. According to this embodiment, the figures quoted hereinbefore as wt?/o may be considerd volume fractions of the material as an alternative embodiment.

In another aspect of the invention, there is provided a façade system comprising a plurality of brackets as hereinbefore described for affixing to a supporting structure or supporting wall; for mounting to a plurality of brackets a longitudinally extended profile, preferably a T-profile, forming a framework on which to mount a plurality of façade panel elements and provided with a means for receiving a façade panel element or mounting means therefore; and a plurality of façade panel elements configured for mounting onto the longitudinally extended profiles (typically each panel abridging at least two profiles) optionally via a mounting means adapted for engagement with the profiles and the panels.

According to this and any other aspect, the brackets may be mounted on a supporting structure or wall so that the elongate direction is configured vertically, Thereby the plurality of longitudinally extending profiles (or T profiles) which comprise mounting members may extend vertically and façade elements may be mounted so as to extend horizontally between two vertically extending T-profiles. Optionally, the longitudinally extending profiles are aluminium profiles (or of any other suitable material). Optionally the longitudinally extending profiles are of material having a thermal conductivity less than 0.5 W/mK, such as a fibre-reinforced polymer which may be any fibre-reinforced polymer as hereinbefore defined for the bracket. Optionally the panel elements may be ceramic, concrete, glass, fibre reinforced composite (such as that defined hereinbefore for the bracket), steel, etc. The invention will now be described in more detail, without limitation, with reference to the accompanying Figures, -23 -In Figure 1 an L-shaped bracket I comprises a base portion 3 and a protmding portion 5 protruding from the base portion 3 at a bracket junction 7 in a direction orthogonal to the plane of the base portion 3. The substantially planar base portion 3 is rectangular having an elongate direction (the direction of the long edges) and a contracted direction (the direction of the short edges) and the portruding portion 5 is substantially planar arid defines a plane parallel with the elongate direction. The base portion 3 tapers toward peripheral edge 9 from the reinforced portion t t which defines a thicker profile t3 to support fixing apertures 15. The tapered peripheral edge 9 allows insulation to fit more snugly against the bracket and supporting wall (not shown) to which the base portion 3 would be affixed whereby the risk of gaps and resultant thermal bypass may be reduced.

The bracket is formed preferably from fibre reinforced polymer comprising basalt or glass fibre (or any other suitable fibre or composite thereof) and a resin such as modified acrylate or polyurethane (or any other suitable resin).

An outer layer of material comprises a continous mat veil of fibre. Additional fibre mats may be used for reinforcement of the areas around the fixing and mounting apertures 15,17 and the bracket junction 7. Additives for strength and fire resistance may be used as may a fire resistant coating.

Protruding portion 5 comprises a thicker profiled trunk 19 and an engaging portion 21 distal to the trunk 19 relative to the bracketjunction 7. The engaging portion 21 has a fixing member 23 and a gripping member 25 which each project from the trunk 19 and together define a slot 27 for receiving a support member profile (not shown) which is for providing a frame or mounting for façade elements. The slot 27 has a width of about 2 mm arid is flanked by the gripping member 25 having a thickness of 4 mm and the fixing member 23 having a width of 4 mm. The gripping member 25 is of substantially constant profile thickness along its extent (outward in an orthogonal direction relative to the plane of the base portion 3) from resilient living hinge 29 about which the gripping member 25 may resiliently pivot or flex when a mounting member is inserted into the slot 27.

Thereby, the gripping member 25 may grip by way of a helping hand any mounting member inserted into the slot 27 and retain in position against the rigid load -24 -bearing fixing member 23 until the correctly positioned mounting member is mounted to the fixing member 23 via screw fixings through apertures 17. The fixing member 23 extends outward beyond the gripping member 25 so that only the fixing member 23 is physically secured to a mounting member and the apertures 17 may be accessed unencumbered by the gripping member 25. Mounting reinforcement 3 t is provided to enhance the strength around the apertures 17 without encumbering access to slot 27.

According to one embodiment having the appearance of bracket 1, the bracket 1 may be manufactured by pultrusion using, from inside to outside glass or basalt fibre chopped strand mat and/or continuous rovings on the inside and about the outside continuous woven roving mat veil with reinforced strips of matt, continuous rovings or woven rovings where reinforcement is required.

Preferably, from inside to outside two 450 gsm chopped strand mats are used at the core, then two 300 gsm chopped strand mats are used followed by a continuous woven roving surface veil. A polyurethane, phenolic or modified acrylic resin optionally with I 0-20?/o ATFT (alumina trihydrate) may be used, By using a continuous woven fibre roving mat, the resin loading may be reduced and a higher tensile strength and fire resistance can be achieved.

The bracket of this embodiment is designed to support façade of up to 65 kg/m2.

In Figure 2, an L-shaped bracket 1 in the form of profile formed by pultrusion is provided with a low density protruding portion 5 and base portion 3 whereby a framework is provided that achieves the necessary strength in the bracket but using considerably less material, In Figure 3, an L-shaped bracket I is illustrated which may be formed by inj ection moulding. This bracket 1 typically comprises glass fibre in polyamide or PEEK resin, The bracket comprises planar panel like protruding portion S and base portion 3, each configured with five ribs 29 running along at least a part of the extent of the protruding portion S and along the width of the base portion 3 to provide additional structural integrity, -25 -The invention has been described with reference to a preferred embodiment, However, it will be appreciated that variations and modifications can be effected by a person of ordinary skill in the art without departing from the scope of the invention.

-26 -

Claims (2)

1. C LA I NI S: 1. A bracket comprising a base portion for abutting and affixing to a wall and a protruding portion protruding from the base portion which protruding portion is configured for engagement with a façade support member for supporting or mounting a façade wall element, wherein the base portion and the protruding portion comprise fibre-reinforced polymer material, and the protruding portion comprises an engagement portion comprising a fixing member to which a support member may be mounted and a gripping member which fixing element and gripping arm together form a slot dimensioned to receive the support member.
2. 2. A bracket comprising a base portion for abutting and affixing to a wall and a protruding portion protruding from the base portion which protruding portion is configured for engagement with a façade support member for supporting or mounting a façade wall element, wherein at least a major portion of the protruding portion extending from the base portion comprises a fibre-reinforced polymer material containing an intumescent filler.

   3, A bracket substantially as hereinbefore described with reference to the drawings.-27 -