Cladding Assembly and Components Thereof

16:33 FAX +61 7 3229 3384 CULLENS 005/019 CLADDING ASSEMBLY AND COMPONENTS THEREOF The present invention relates generally to a cladding assembly, and also to various components of the cladding assembly. The present invention also relates to a method of securing a panel to a support structure. Although the present invention will be described with particular reference to securing a roof panel to a support structure, it will be appreciated that this is by way of example only and that the invention may be used to secure a variety of other panels to various support structures. Panels used as claddings for roofs are typically formed from a rolled steel sheet having a series of parallel ribs extending longitudinally along the panels. These roofing panels are typically fastened to an underlying support structure in an overlapping manner to provide the desired weather resistance. The roofing panels may be secured to the support structure of the roof in a variety of ways. One way of securing the roofing panels to the support structure is with fasteners which extend through the panels and are fixed into the support structure. The use of fasteners that are fixed through the panel results in a structure that is more susceptible to leakage due to the holes in the roofing panels that must be adequately sealed. In order to overcome the potential for leakage through the roofing panels, it is known to use clips that are secured to the support structure and which clips are adapted to extend into the ribs of the roofing panel and retain the roofing panel in position by engaging with the ribs. Advantageously, the absence of any fasteners that extend through the roofing panel also results in a more aesthetically pleasing cladding due to the use of the concealed fixing. Generally, the clips used to engage with the ribs of the roofing panel are rigid and do not undergo substantial deformation during the installation of the roofing panels. Typically, it is the ribs of the roofing panel that splay in order to be received over the clips. As such, the clips are typically designed to be manufactured to undergo minimal deformation during the installation process. Published Australian Patent Application No. 2007211921 discloses another method of securing a roofing panel to a support structure. The method employs a COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:33 FAX +61 7 3229 3384 CULLENS 006/019 plurality of retaining members which are secured to the channels of the roofing panel and to the support structure. Each retaining member comprises a body and a pair of wings. The body is adapted to be affixed to the support structure, and the wings are resiliently deformable. In a disengaged condition, the wings extend substantially perpendicularly to the body. In an engaged condition, the wings are pressed into a swept configuration wherein the wings lockingly engage lands disposed on side walls of a channel of the panel. When fasteners in the form of individual clips or retaining members such as those described above are used to secure ribbed roof panels to a support structure, the fasteners are usually secured to the support structure before the panels are secured to the fasteners. Consequently, care needs to be taken when securing the fasteners to the support structure to ensure that the fasteners align with the ribs of the roof panels. This can be difficult and tedious to accomplish. Before the panels are suitably secured to the support structure, which typically comprises a plurality of purlins which extend across the top of, and which are secured to, a plurality of rafters, a layer of insulation is often placed on top of the purlins. The panels are then placed on top of the insulation and secured to the purlins so that areas of the insulation which are located between the panels and the purlins are compressed between the panels and the purlins. Compressing the insulation can be problematic in that the compressed areas of the insulation usually do not perform at an optimum level. In other words, compressing the insulation can compromise the heat insulating properties of the insulation. If the performance of the roof insulation is compromised, the energy efficiency of the rest of the building structure can be impaired so that more energy is required to cool or heat the interior of the building structure. In order to improve the energy efficiency of building structures, Section J of the Building Code of Australia ("BCA") requires the presence of an air gap between the roof panels of a building structure and its roof support structure so that the roof insulation is not compressed between the roof panels and the support structure. It would be desirable to employ existing methods of securing roofing panels to a support structure, such as the method disclosed in Published Australian Patent COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:33 FAX +61 7 3229 3384 CULLENS 007/019 Application No. 2007211921, whilst at the same time complying with Section J of the BCA, It is an object of the present invention to overcome, or at least ameliorate, one or more of the deficiencies of the prior art mentioned above, or to provide the consumer with a useful or commercial choice. Other objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, a preferred embodiment of the present invention is disclosed. According to a first broad aspect of the present invention there is provided a cladding assembly comprising a panel, a retaining member secured to the panel, and a spacer member secured to the retaining member, the spacer member being securable to a support structure such that the panel and the retaining member are spaced from the support structure by the spacer member. According to a second broad aspect of the present invention there is provided a spacer member for spacing a panel and a retaining member which is secured to the panel from a support structure, the spacer member being adapted to be secured to the retaining member and the support structure. According to a third broad aspect of the present invention there is provided a retaining device for securing a panel to a support structure, the retaining device comprising a plurality of retaining members which are securable to the panel, and a positioning base secured to the retaining members. According to a fourth broad aspect of the present invention there is provided a method of securing a panel to a support structure, the method comprising the steps of: (i) securing a spacer member to a retaining member; and (ii) securing the retaining member to the panel. By spacing the panel and the retaining member from the support structure by a suitable distance, the spacer member allows a layer of insulation to be accommodated between the panel and the support structure without the insulation being compressed between the panel and the support structure so that the building COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:34 FAX +61 7 3229 3384 CULLENS 008/019 structure which includes the panel is able to comply with Section J of the Building Code of Australia. Securing a positioning base to the retaining members of the retaining device allows the retaining members to be spaced apart from each other at appropriate intervals. For example, in the case where the retaining members are received by a plurality of channels of the panel, the retaining members may be spaced apart from each other at intervals which match the intervals at which the channels are spaced apart from each other, thus making it easier to align the retaining members with the channels when securing the panel to the retaining device. The panel may be any suitable type of panel. For example, the panel may be a roof panel or a wall panel. Preferably, the panel includes a channel for receiving the retaining member. In a particular preferred form, the panel is a ribbed panel which includes a rib which includes the channel. The ribbed panel may be of any convenient configuration. A ribbed panel formed from a sheet of rolled steel is particularly suited for use in the present invention. It is envisaged that a panel formed from other materials and combinations of materials may also be used to effect with the present invention. In particular, a panel having an insulated foam disposed between a lower ribbed sheet and an outer skin is also envisaged as being useful in the present invention in a manner whereby the retaining member extends into and engages a channel in the lower ribbed sheet of the panel. The channel of the panel preferably has opposed side wails, each side wall having a land for engaging with the retaining member. The lands located on the side walls may be formed by a simple step in the side wall. It will be appreciated however that the land may be provided by other suitable means. In a particular preferred form, the side walls of the channel taper so that they form a generally tnmcated V-shaped cross section. Tapered side walls are preferred as the tapered side walls advantageously assist in the location and insertion of the retaining member within the channel. The channel preferably extends the length of the panel. The retaining member may be any suitable type of retaining member. Preferably, the retaining member is in the form of a clip. In a particular preferred form, the retaining member includes a body which is adapted to be secured relative to COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:34 FAX +61 7 3229 3384 CULLENS 009/019 the support structure. The body of the retaining member is preferably adapted to be secured to the spacer member. An opening may extend through the body of the retaining member. The opening may be used to receive a screw, rivet or nail, for example, which may be used to secure the retaining member relative to the spacer member or the support structure. It is preferred that the body of the retaining member be shaped to correspond to the shape of a channel in the panel in order to be closely received therein to provide additional structural support to the panel. The body of the retaining member preferably includes a catch for engaging with a latch of the spacer member such that the retaining member and the spacer member are thereby able to be secured together. The retaining member preferably also includes a pair of wings, wherein the wings are resiliently deformable and in a disengaged condition extend substantially perpendicularly to the body, and in an engaged condition are pressed into a swept configuration wherein the wings engage with lands of a channel of the panel. Upon engagement of the panel, the wings are pressed into a swept configuration and "clip" into position against lands formed on the side walls of the channel. The deformation of the wings to be received within the channel allows the wings to follow the profile of the channel and thereby provide additional support to the panel and also an additional locking strength whereby the removal of the panel from the retaining member is resisted. The retaining member is preferably made from plastics material and is preferably injection moulded. It will be appreciated however that the retaining member may be made from other materials which may be suitable to provide wings which are resiliently deformabIe upon being pressed into a channel of the panel. For example, the retaining member may be fabricated from nylon material or engineered nylon materials. The spacer member may be any suitable type of spacer member. Preferably, the spacer member includes a body which is adapted to be secured to the retaining member and the support structure. Although in a preferred form, the body is hollow, in other preferred embodiments, the body may be substantially solid. The body may have any suitable shape. For example, the body may have a substantially rectangular COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:34 FAX +61 7 3229 3384 CULLENS 010/019 bottom, a substantially rectangular top, and a plurality of substantially rectangular side walls extending between the bottom and the top. The body of the spacer member may be tapered. An opening may extend through the body of the spacer member. The opening may be used to receive a screw, rivet or nail, for example, which may be used to secure the spacer member relative to the retaining member or the support structure. The spacer member preferably also includes a latch which extends from the body of the spacer member, the latch being engagable with a catch of the retaining member such that the spacer member and the retaining member are thereby able to be secured together. The spacer member may be securable to any suitable support structure. For example, the spacer member may be securable to a rafter or a puffin of a roof. it will be appreciated that the spacer member may be secured to other types of support structure and that it is not necessarily limited to be secured to a roof. The spacer member may space the panel and the retaining member from the support structure by any suitable distance. Preferably, the spacer member is able to space the panel and the retaining member from the support structure so that a layer of insulation is able to be accommodated between the panel and the support structure without being compressed or excessively compressed between the panel and the support structure. For example, the spacer member is preferably able to space the panel and the retaining member from the support structure so that a roofing blanket, such as for example, a Bradford Anticon TM Roofing Blanket, is able to be accommodated between the panel and the rafters or purlins of a building roof without being excessively compressed between the panel and the rafters or purlins. The spacer member is preferably made from plastics material and is preferably injection moulded. It wilI be appreciated however that the spacer member may be made from other suitable materials. For example, the spacer member may be fabricated from nylon material or engineered nylon materials. Preferably, there is a layer of insulation located between the panel and the support structure. The retaining device may have any suitable number of retaining members. For example, the retaining device may have 2 to 10 retaining members. In a particular COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:34 FAX +61 7 3229 3384 CULLENS 011/019 preferred form, the retaining device includes three retaining members. Each of the retaining members may be receivable by a respective one of a plurality of spaced apart channels of the panel. The retaining members may be equidistantly spaced apart from each other. The retaining members are preferably spaced apart from each other along the positioning base at intervals which are substantially the same as the intervals at which the channels of the panel are spaced apart from each other. The retaining members of the retaining device are preferably identical to each other. It is also preferred that the retaining members are aligned with each other. The positioning base of the retaining device may be of any suitable type. Preferably, the positioning base includes one or more elongate members which extend between the retaining members. Preferably, the positioning base is substantially straight. In a preferred form, the positioning base includes a respective opening adjacent to each of the retaining members, wherein each opening is able to receive a latch of a respective spacer member which is secured to each of the retaining members. The positioning base of the retaining device is preferably adapted so that a plurality of the retaining devices are able to be secured together. Preferably, the positioning base includes a first end, and a second end, the first end and the second end being adapted so that the first end of the positioning base of a first retaining device is able to engage with the second end of a second retaining device such that the first and second retaining devices are thereby secured together. For example, in a particular preferred form, the positioning base includes a stud located adjacent to the first end, and a recess and an opening are located adjacent to the second end, wherein the recess of a first retaining device positioning base is able to receive the first end of a second retaining device positioning base such that the stud of the first retaining device positioning base is received by the opening of the second retaining device positioning base. The positioning base is preferably made from plastics material and is preferably injection moulded. It will be appreciated however that the positioning base may be made from other materials. For example, the positioning base may be COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:35 FAX +61 7 3229 3384 CULLENS 012/019 fabricated from nylon material or engineered nylon materials. Preferably, the positioning base of the retaining device is integrally formed with the retaining members of the retaining device. For example, the positioning base and the retaining members may be integrally moulded together. In order that the invention may be more fully understood and put into practice, a preferred embodiment thereof will now be described with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a spacer member according to a preferred embodiment of one aspect of the present invention; Figure 2 is a top view of the spacer member; Figure 3 is a front view of the spacer member; Figure 4 is a side view of the spacer member; Figure 5 is a perspective view of a retaining device according to a preferred embodiment of another aspect of the present invention; Figure 6 is a bottom view of the retaining device; Figure 7 is a front view of a partially assembled cladding assembly according to a preferred embodiment of another aspect of the present invention; Figure 8 is a perspective view which depicts a first retaining device secured to a second retaining device. Referring to figures 1 to 4, a spacer member 20 is manufactured from nylon, and includes a hollow body 21. Body 21 includes a substantially flat and rectangular bottom 22, a substantially flat and rectangular top 23, and a plurality of substantially rectangular sides 24 extending between the bottom 22 and the top 23. A pair of substantially rectangular openings 25 extend through the body 21, as does a circular opening 26 which is located between the two rectangular openings Spacer member 20 also includes a pair of opposing latches 27 which extend from the top 23 of the body 21. Referring to figures 5 and 6, a retaining device 30 is also manufactured from nylon. Retaining device 30 includes a plurality of retaining members 31 which are securable to a panel which includes a plurality of spaced apart channels, and a positioning base 32 which is integrally formed with the retaining members 31. The COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:35 FAX +61 7 3229 3384 CULLENS 013/019 retaining members 31 are spaced apart from each other along the positioning base 32 at intervals which are substantially the same as the intervals at which the channels of the panel are spaced apart from each other. Each retaining member 31 is similar to the retaining member disclosed in published Australian Patent Application No. 2007211921 which is hereby incorporated by reference in its entirety. Each retaining member 31 has a pair of substantially horizontal wings 33 and 34. A recess 35 extends through the wings 33 and 34 and extends part way through the retaining member 31. A bore 36 extends completely through the retaining member 31. Recess 35 is contained within a body 37 of the retaining member 31. The body 37 of the retaining member 31 has a triangular frame 38 to which the wings 33 and 34 are attached. The body 37 also includes a central column 39 within which the recess 35 is disposed. The central column 39 extends from a base of the body 37 to the wings 33 and 34. A pair of catches 41 (only one of which is visible in the figures) are located on opposite sides of the body 37. Flanges 42 and 43 (see figure 7) of the retaining member 31 extend from the triangular frame 38. The bore 36 extends through the wings 33 and 34 and also through the base Base 40 is adapted to rest on a structural support such as, for example, a rafter or purlin of a roof. The positioning base 32 includes an elongate member 50 which extends between the retaining members 31. Elongate member 50 includes a respective opening 51 located adjacent to each of the retaining members 31. Member 50 also includes a first end 52 and a second end 53. A stud 54 which includes an enlarged head is located adjacent to the first end 52 of the elongate member 50. A recess and an opening 56 are located adjacent to the second end 53. Referring to figure 7, a partially assembled cladding assembly 60 for a roof includes a ribbed panel 61 positioned above the retaining device 30 for engagement with the retaining members 31 thereof. Ribbed panel 61 includes a plurality of channels 62. Each channel 62 is positioned above a respective retaining member 31. Each channel 62 has a pair of opposed side walls 63 and 64, and a substantially flat top 65. The flat top 65 provides a channel 62 that is in the shape of a truncated V. COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:35 FAX +61 7 3229 3384 CULLENS 014/019 Each side wall 63 includes a land 66, and each side wall 64 includes a land 67. Also, each side wall 63 includes an upper side wall 68, and each side wall 64 includes an upper side wail 69. A respective spacer member 20 is secured to each of the retaining members 31 of the retaining device 30. In particular, for each of the retaining members 31, the base 40 of the retaining member 31 is placed on the top 23 of the spacer member so that each latch 27 of the spacer member 20 engages with a respective catch 41 of the retaining member 31 so that the retaining member 31 is thereby secured to the spacer member 20. One of the latches 27 of each spacer member 20 extends through a respective one of the openings 51 in the positioning base 32. Each spacer member 20 rests on a support structure 70. Support structure may, for example, be a rafter or purlin of a roof. Cladding assembly 60 is secured to the support structure 70 with a suitable fastener. For example, cladding assembly 60 may be secured to the support structure with screws, bolts, nails, rivets or the like which extend through the bore 36 of the retaining members 31, the circular opening 26 in the spacer members 20, and the support structure To complete the assembly of the cladding assembly 60, the ribbed panel 61 is pressed down on to and in locking engagement with the retaining members 31. Upon pressing the ribbed panel 61 down on to the retaining members 31, the side walls 63 and 64 of the channels 62 sweep the wings 33 and 34 of the retaining members 31 into a swept condition (not depicted). The wings 33 and 34 are pressed against the lands 66 and 67, and resiliently spring out into engagement with the upper side walls 68 and 69 of the ribbed panel 61. In this way, the retaining members 31 are secured to the ribbed panel 61. The flanges 42 and 43 of each retaining member 31 extend from the triangular frame 38 of the retaining member 31 into engagement with the side walls 63, 64 of the channel 62. The spacer members 20 spaces the retaining device 30 and the ribbed panel 61 from the support structure 70 so that a layer 71 of insulation or the like is able to be accommodated between the retaining device 30 and the support structure 70 without COMS ID No: ARCS-255001 Received IP Australia: Time 16:35 FAX +61 7 3229 3384 CULLENS 015/019 being compressed between the retaining device 30, panel 61 and the support structure so as to comply with Section J of the Building Code of Australia. A plurality of the retaining devices 30 are able to be secured together end to end. Referring to figure 8, a first retaining device 30a is shown secured to a second retaining device 30b. The recess 55a which is located adjacent the second end 53a of the first retaining device's positioning base 32a receives the first end 52b of the second retaining device's positioning base 32b such that the stud 54b of the second retaining device's positioning base 32b is received by the opening 56a of the second retaining device's positioning base 32b. The enlarged head of the stud 54b inhibits the stud 54b from being withdrawn from the opening 56a so that the first retaining device 30a is thereby secured to the second retaining device 30b. The first end 52a of the first retaining device's positioning base 32a is able to be secured to the second end of a third retaining device's positioning base in a similar manner to which the first end of the second retaining device's positioning base 32b is secured to the second end 53a of the first retaining device's positioning base 32a. Throughout the specification and the claims, unless the context requires otherwise, the term "comprise", or variations such as "comprises" or "comprising", will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers. Throughout the specification and claims, unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms. It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof. The variations and modifications as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth. It will be clearly understood that, if a prior art publication is referred to herein, that reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country. COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02 16:35 FAX +61 7 3229 3384 CULLENS 016/019 CLAIM S: 1. A cladding assembly comprising a panel, a retaining member secured to the panel, and a spacer member secured to the retaining member, the spacer member being securable to a support structure such that the panel and the retaining member are spaced from the support structure by the spacer member. 2. A spacer member for spacing a panel and a retaining member which is secured to the panel from a support structure, the spacer member being adapted to be secured to the retaining member and the support structure. 3. A retaining device for securing a panel to a support structure, the retaining device comprising a plurality of retaining members which are securable to the panel, and a positioning base secured to the retaining members. 4. A method of securing a panel to a support structure, the method comprising the steps of: (i) securing a spacer member to a retaining member; and (ii) securing the retaining member to the panel. COMS ID No: ARCS-255001 Received by IP Australia: Time (H:m) 17:40 Date (Y-M-d) 2009-11-02