Cladding system

Abstract

A cladding system is disclosed. The cladding system includes: a plurality of natural stone panels, each of the panels having one or more cavities formed therein; a cured material within the cavities of the panels, the cured material being bonded to the panels; and at least one brace for securing the panels together and to a substrate. Each brace has an embedded portion that is embedded in the cured material to fix the brace to one or more of the panels. Each brace is one or more of the following types, such that each type is provided at least once: an interconnecting type, in which the embedded portion is embedded in and extends between the cured material in the cavities of two or more of the panels, and an anchoring type, which has an anchoring portion for securing to the substrate, the anchoring portion being exposed from the cured material.

Description

CLADDING SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONSThis application claims the benefit of U.S. Provisional Patent Application No. 63 / 568,633 filed on March 22, 2024, and titled EMBEDDED ANCHOR FOR NATURAL STONE, the entirety of which is incorporated herein by reference. This application further claims the benefit of U.S.Provisional Patent Application No. 63 / 686,245 filed on August 23, 2024, and titled CLADDING SYSTEM AND BRACE FOR NATURAL STONE, the entirety of which is incorporated herein by reference.FIELD

[0001] The present disclosure generally relates to cladding systems, and more particularly to cladding systems with natural stone panels and braces, such as anchors or brackets.BACKGROUND

[0002] Various types of cladding materials are commonly used on the exterior surface of buildings or on other structures, including for instance bricks, wood, stone, and plastic. Installed cladding may protect buildings or structure from wind and rain, increase the aesthetic appearance of a building or structure, serve as an additional insulation layer, and may increase the safety and durability of a building or structure.

[0003] Natural stone is one of the most aesthetically beautiful forms of cladding. However given the weight of natural stone, it is generally very labour intensive to install natural stonecladding. One method of installing natural stone is by the use of mortar. However, such masonry installations require skilled labour and are time intensive.

[0004] Another method of installing natural stone is the use of stone anchors that are placed on grooves typically at the bottom and top edges the stone. However, the installation of such anchored systems is also labour and time intensive. Additionally, many natural stones available on the market are constrained in thickness due to limitations in the weight of stones that can be supported by existing stone anchors.

[0005] As an alternative to natural stone, some manufacturers produce prefabricated panels with integrated flanges or anchors for fixing the panels to a substrate. However, unlike natural stone which comes in a wide range of shapes, sizes, colours, and thicknesses, the range of options for prefabricated panels are limited. Additionally, since a line of prefabricated panels from a given manufacturer usually come in only one or a small number of shapes and sizes, an installed wall using such prefabricated panels can appear repetitive and uninteresting.

[0006] This background serves only to set a scene to allow a person skilled in the art to better appreciate the following description. None of the above discussion should necessarily be taken as an acknowledgment that this discussion is part of the state of the art or is common general knowledge.SUMMARY

[0007] It should be appreciated that this summary is provided to introduce a selection of concepts that are further described below in the detailed description of embodiments. This summary is not intended to be used to limit the scope of the claimed subject matter.

[0008] While the contributions of known prefabricated panels are laudable, improvements and alternatives are generally desired. It is therefore an object of the present disclosure to at least provide a new and useful cladding system. Another object of the present disclosure is to provide a ready-to-install system for natural stone coming in a wide range of shapes, sizes, and thicknesses. Yet another object is to provide ready-to-install stone panels that can be quick and simple for regular homeowners to install with minimal tools and for a wide range of weather conditions. Other objects of the present disclosure may be apparent to a person of ordinary skill in the art in view of the below detailed description of embodiments.

[0009] Accordingly, in an aspect, there is provided a cladding system comprising: a plurality of natural stone panels, each of the panels having one or more cavities formed therein; a cured material within the cavities of the panels, the cured material being bonded to the panels; and at least one brace for securing the panels together and to a substrate, each brace having an embedded portion that is embedded in the cured material to fix the brace to one or more of the panels, and each brace being one or more of the following types, such that each type is provided at least once: an interconnecting type, in which the embedded portion is embedded in and extends between the cured material in the cavities of two or more of the panels, and an anchoring type, which has an anchoring portion for securing to the substrate, the anchoring portion being exposed from the cured material.

[0010] In one or more embodiments, the at least one brace may include one or more braces that are both the interconnecting type and the anchoring type. The at least one brace may include at least two braces, at least one of which is only the anchoring type and at least one of which is only the interconnecting type. All of the braces may be identical, without regard to their lengths and orientations.

[0011] In one or more embodiments, the plurality of panels may include at least three panels, two of which are stacked and positioned to a single side of the third.

[0012] In one or more embodiments, the anchoring portion may extend beyond a periphery of the plurality of panels and may include an anchoring aperture for receiving a fastener to secure the brace that is the anchoring type to the substrate.

[0013] In one or more embodiments, at least one of the cavities may have a plurality of groves formed in an innermost surface. Each of the cavities may be formed in a rear surface of the respective panel.

[0014] In one or more embodiments, for one or more braces that are the anchoring type, a gap of at least 1 mm may be provided between the anchoring portion and the one or more panels to which the braces are fixed via the cured material.

[0015] In one or more embodiments, the anchoring portion may extend from a surface of the cured material by a distance of at least 8 mm.

[0016] In another aspect, there is provided a cladding system comprising: a natural stone panel having one or more cavities formed therein; a cured material within the cavities of the panel, the cured material being bonded to the panel; and at least one brace for securing the panel to a substrate, the brace having an embedded portion and an exposed portion, the embedded portion being embedded in the cured material, the exposed portion being exposed from the cured material and including an anchoring portion for securing to the substrate, and the embedded portion having: a plunging part that increases in depth within the cured material as it extends away from the exposed portion; and a rising portion that decreases in depth within the cured material as it extends away from the plunging part.

[0017] In one or more embodiments, the plunging part may increase in depth as it extends away from the anchoring portion.

[0018] In one or more embodiments, the plunging part and the rising part may cooperate to partially surround a plug of the cured material. One or more sides of the plug may be directly connected to the cured material that is adjacent to the plug. The plug may extend across an entire width of the brace.

[0019] In one or more embodiments, the plunging part and the rising part may define an angle of direction change therebetween that is in the range of 90 to 180 degrees. The embedded portion may completely reverse direction within the cured material.

[0020] In one or more embodiments, the rising part may be directly connected to the plunging part, and the plunging part may be directly connected to the exposed portion.

[0021] In one or more embodiments, the anchoring portion may extend beyond a periphery of the panel and may include an anchoring aperture for receiving a fastener to secure the brace to the substrate.

[0022] In one or more embodiments, at least one of the cavities may have a plurality of groves formed in an innermost surface. Each of the cavities may be formed in a rear surface of the panel.

[0023] In one or more embodiments, a gap of at least 1 mm may be provided between the anchoring portion and the panel.

[0024] In one or more embodiments, the exposed portion may extend from a surface of the cured material by a distance of at least 8 mm.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The above summary and the below detailed description set out aspects and embodiment of the present disclosure that may be best understood in conjunction with the accompanying drawings, in which:

[0026] FIG. 1 is an isometric view of an embodiment of a cladding system, taken from a rear thereof;

[0027] FIG. 2 is an exploded view of the cladding system of FIG. 1;

[0028] FIG. 3 is a section view of the cladding system of FIG. 1, taken along line A-A inFIG. 1;

[0029] FIG. 4 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0030] FIG. 5 is an exploded view of the cladding system of FIG. 4;

[0031] FIG. 6 is a section view of the cladding system of FIG. 4, taken along line A-A in FIG. 4;

[0032] FIG. 7 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0033] FIG. 8 is an exploded view of the cladding system of FIG. 7;

[0034] FIG. 9 is a section view of the cladding system of FIG. 7, taken along line A-A inFIG. 7;

[0035] FIG. 10 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0036] FIG. 11 is an exploded view of the cladding system of FIG. 10;

[0037] FIG. 12 is a section view of the cladding system of FIG. 10, taken along line A-A in FIG. 10;

[0038] FIG. 13 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0039] FIG. 14 is an exploded view of the cladding system of FIG. 13;

[0040] FIG. 15 is a section view of the cladding system of FIG. 13, taken along line A-A in FIG. 13;

[0041] FIG. 16 is a section view of the cladding system of FIG. 13, taken along line B-B in FIG. 13;

[0042] FIG. 17 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0043] FIG. 18 is an exploded view of the cladding system of FIG. 17;

[0044] FIG. 19 is a section view of the cladding system of FIG. 17, taken along line A-A inFIG. 17;

[0045] FIG. 20 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0046] FIG. 21 is an exploded view of the cladding system of FIG. 20;

[0047] FIG. 22 is a section view of the cladding system of FIG. 20, taken along line A-A inFIG. 20;

[0048] FIG. 23 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0049] FIG. 24 is an exploded view of the cladding system of FIG. 23;

[0050] FIG. 25 is a section view of the cladding system of FIG. 23, taken along line A-A in FIG. 23;

[0051] FIG. 26 is a right side view of the cladding system of FIG. 23;

[0052] FIG. 27 is an isometric view of a plurality of the cladding systems of FIG. 23, showing the cladding systems secured to a substrate;

[0053] FIG. 28 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0054] FIG. 29 is an exploded view of the cladding system of FIG. 28;

[0055] FIG. 30 is a section view of the cladding system of FIG. 28, taken along line A-A inFIG. 28;

[0056] FIG. 31 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0057] FIG. 32 is an exploded view of the cladding system of FIG. 31;

[0058] FIG. 33 is a section view of the cladding system of FIG. 31, taken along line A-A inFIG. 31;

[0059] FIG. 34 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0060] FIG. 35 is an exploded view of the cladding system of FIG. 34;

[0061] FIG. 36 is a section view of the cladding system of FIG. 34, taken along line A-A inFIG. 34;

[0062] FIG. 37 is a top view of the cladding system of FIG. 34;

[0063] FIG. 38 is an isometric view of another embodiment of a cladding system, taken from a rear thereof;

[0064] FIG. 39 is an exploded view of the cladding system of FIG. 38;

[0065] FIG. 40 is a left side view of the cladding system of FIG. 38;

[0066] FIG. 41 is a top view of the cladding system of FIG. 38;

[0067] FIG. 42 is an isometric view of another embodiment of a cladding system, taken from a front thereof;

[0068] FIG. 43 is an isometric view of the cladding system of FIG. 42, taken from a rear thereof;

[0069] FIG. 44 is an exploded view of the cladding system of FIG. 42;

[0070] FIG. 45 is a section view of the cladding system of FIG. 42, taken along line A- A inFIG. 43;

[0071] FIG. 46 is an isometric view of another embodiment of a cladding system, taken from a front thereof;

[0072] FIG. 47 is an isometric view of the cladding system of FIG. 46, taken from a rear thereof;

[0073] FIG. 48 is an exploded view of the cladding system of FIG. 46;

[0074] FIG. 49 is a section view of the cladding system of FIG. 46, taken along line A-A inFIG. 47;

[0075] FIG. 50 is a section view of the cladding system of FIG. 46, taken along line B-B in FIG. 47;

[0076] FIG. 51 A is a top view of a pair of the cladding systems of FIG. 46, showing the pair in a close side-by-side arrangement;

[0077] FIG. 5 IB is an enlarged partial view of the cladding systems of FIG. 51 A, showing detail B of FIG. 51 A;

[0078] FIG. 52 is an isometric view of a brace of the cladding system of FIG. 10, taken from a rear of the brace;

[0079] FIG. 53 is a rear view of the brace of FIG. 52;

[0080] FIG. 54 is a right side view of the brace of FIG. 52;

[0081] FIG. 55 is an isometric view of another embodiment of a brace for a cladding system, taken from a rear of the brace;

[0082] FIG. 56 is a rear view of the brace of FIG. 55;

[0083] FIG. 57 is a right side view of the brace of FIG. 55;

[0084] FIG. 58 is an isometric view of another embodiment of a brace for a cladding system, taken from a rear of the brace; and

[0085] FIG. 59 is a right side view of the brace of FIG. 58.DETAILED DESCRIPTION OF EMBODIMENTS

[0086] Illustrative embodiments of the present disclosure will now be described in greater detail with reference to the accompanying drawings. The following explanation provides specific details for a thorough understanding of and enabling description for these embodiments. In some instances, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the illustrative embodiments. A person of ordinary skill in the art will understand that other embodiments may be practiced without departing from the scope of the present disclosure and what is claimed, and without necessarily including all of the specific details of the illustrative embodiments described herein.

[0087] As used herein, an element or feature described in the singular and preceded by the word “a” or “an” should be understood as not necessarily excluding a plural of the elements orfeatures. Further, references to “one example” or “one embodiment” are not intended to be interpreted as excluding the existence of additional examples or embodiments that also incorporate the described elements or features of that one example or one embodiment. As used herein, the term “and / or” can include any and all combinations of one or more of the associated listed elements or features. Moreover, it will be appreciated that the terms “comprising”, “having”, “including”, their conjugations and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive senses, that is to say these terms mean “including but not limited to”.

[0088] Reference herein to the phrases “an example”, “another example”, and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Additionally, the words "herein", "above", "below" and the like, when used in reference to what is described in the present disclosure, shall refer to this disclosure as a whole and not to any particular portions thereof.

[0089] Unless otherwise indicated, the terms “first”, “second”, etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to a “second” item does not require or preclude the existence of a lower-numbered item (e.g., a “first” item) and / or a higher-numbered item (e.g., a “third” item). Additionally, when the word "each" is used to refer to an element that was previously introduced as being at least one in number, the word "each" does not necessarily imply a plurality of the elements, but can also mean a singular element.

[0090] It will be understood that spatially relative terms, such as “under”, “below”, “lower” “over”, “above”, “upper”, “front”, “back”, and the like, may be used herein for ease of describing the relationship of an element or feature to another element or feature as depicted inthe figures. The spatially relative terms can, however, encompass different orientations in use or operation in addition to the orientation depicted in the figure.

[0091] As used herein, the terms “approximately”, “substantially”, “generally”, and “about” represent an amount or condition close to the stated amount or condition that results in the desired function being performed or the desired result being achieved. For example, the terms “approximately”, “substantially”, “generally”, and “about” may refer to an amount that is within engineering tolerances to the precise value specified, as would be appreciated by a person skilled in the art.

[0092] The present disclosure is intended to provide a new and useful cladding system. The embodiments disclosed herein may provide a ready-to-install system for natural stone coming in a wide range of shapes, sizes, and thicknesses. These ready-to-install systems can be quick and simple for regular homeowners to install with minimal tools and for a wide range of weather conditions. As will be appreciated, a plurality of the cladding systems disclosed herein may be secured to a substrate, such as a vertical wall, to create a stone wall look for example. It is also contemplated that the cladding systems disclosed herein may be placed on a horizontal surface, to create a stone floor look for example. The spaces around and between the cladding systems once installed can be filled, such as with mortar or grout, which may improve aesthetic appeal. The cladding systems disclosed herein may also be resistant to various failure modes, as discussed in greater detail below.

[0093] FIGS. 1 to 3 shown an embodiment of a cladding system that is generally identified by reference character 100. The cladding system 100 comprises a panel 102, a brace 104, and a cured material 106. The panel 102 is entirely formed of natural stone (i.e., a natural stone panel).The brace 104 is configured to be secured to a substrate, to thereby secure the cladding system100 to the substrate. The cured material 106 fixes the brace 104 to the panel 102.

[0094] Suitable substrates will be appreciated by those skilled in the art and may include the wall of a building or structure, such as a concrete wall, or a composite wall. Suitable substrates may also include masonry or a timber frame construction, for example. Some substrates may comprise studs or other reinforcements therein, which may provide a preferred location for securing the cladding system to the substrate.

[0095] The panel 102 can provide a decorative appeal when the cladding system 100 is installed. The panel 102 has a front surface 110 and a rear surface 112. The distance between the front surface 110 and the rear surface 112 defines a thickness (TPI) of the panel 102. The panel 102 also has a width (Wpi) in a generally horizontal direction, and a height (Hpi) in a generally vertical direction. As shown in FIG. 1, the width (Wpi) of the panel 102 is greater than the height (Hpi), and the thickness (TPI) of the panel 102 is less than both the width (Wpi) and the height (Hpi). In other embodiments, the relative dimensions of the width, the height, and the thickness of the panel may be different. As will be appreciated, the cladding systems described herein are intended to be used with stone panels having a wide range of different shapes and sizes.

[0096] A cavity 114 is formed in the rear surface 112 of the panel 102 (see FIG. 2). The cavity 114 may be formed for instance by running a blade multiple times across the rear surface 112, or for instance by running a wider blade across the rear surface 112 a single time (such as a blade that is 30 mm wide). However, it will be appreciated that a same or similar cavity may be formed in other ways. The cavity 114 extends in a longitudinal direction (LoDci) thereof. The longitudinal direction (LoDci) of the cavity 114 may, for instance, be the direction a blade is runto form the cavity 114. In the subject embodiment, the longitudinal direction (LoDci) of the cavity 114 extends in the same direction as the width (Wpi) of the panel 102. The cavity 114 has a length (Lei) defined in the longitudinal direction (LoDci). The cavity 114 also has a width (Wei) and a depth (Dei). The depth (Dei) of the cavity 114 is defined in the same direction as the thickness (Tpi) of the panel 102. The width (Wei) of the cavity 114 is defined in a lateral direction (LaDci) of the cavity 114, which is perpendicular to the longitudinal direction (LoDci). In the subject embodiment, the lateral direction (LaDci) of the cavity 114 extends in the same direction as the height (Hpi) of the panel 102. Accordingly, in the subject embodiment, the width (Wei) of the cavity 114 is defined in the same direction as the height (Hpi) of the panel 102 (i.e., the width (Wei) of the cavity 114 is defined in a direction that is perpendicular to the width (Wpi) of the panel 102).

[0097] The brace 104 (alternatively referred to herein as an anchor) is positioned partially within the cavity 114 on the rear surface 112 of the panel 102. While FIGS. 1 to 3 shows a single brace 104 for the panel 102, it will be appreciated that the number of braces used may vary depending on the dimensions and weight of the panel. The brace 104 is preferably made of metal. Although, alternate materials are possible. Suitable alternative materials would be sufficiently strong to support the weight of the stone panel 102 and sufficiently durable and weather resistant.

[0098] As shown in FIG. 2, the brace 104 includes a top portion 120, a middle portion 124, and a bottom portion 128. The top portion 120 may be connected to the middle portion 124 by a top connecting portion 122. Similarly, the bottom portion 128 may be connected to the middle portion 124 by a bottom connecting portion 126.

[0099] The top portion 120 and the bottom portion 128 of the brace 104 each include an anchoring aperture 130 for receiving a fastener therethrough, such as a screw or an anchor bolt, to secure the cladding system 100 to the substrate. Accordingly, the top portion 120 and the bottom portion 128 may each be referred to as an anchoring portion 132 of the brace 104. As shown in FIG. 3, the anchoring apertures 130 are located in parts of the top portion 120 and the bottom portion 128 that extend beyond the rear surface 112 of the panel 102 (i.e., beyond the top edge and the bottom edge of the rear surface 112, respectively). Accordingly, when the cladding system 100 is being installed, fasteners can be received through the anchoring apertures 130 and driven into the substrate without the panel 102 getting in the way. The parts of the top portion 120 and the bottom portion 128 that extend beyond the rear surface 112 of the panel 102, which include the anchoring apertures 130 therein, may each be referred to as an anchor receiving part 134.

[0100] When the cladding system 100 is fully assembled, a portion of the brace 104 is embedded in the cured material 106 and a portion of the brace 104 extends out of the cured material 106. The portion of the brace 104 that is embedded in the cured material 106 is defined as the embedded portion 140. The portion of the brace 104 that extends out of the cured material 106 is defined as the exposed portion 142. As shown in FIG. 3, in the subject embodiment, the embedded portion 140 comprises the top connecting portion 122, the middle portion 124, and the bottom connecting portion 126. As also shown in FIG. 3, in the subject embodiment, the exposed portion 142 comprises the top portion 120 and the bottom portion 128. In some embodiments, the embedded portion of the brace may comprise a plunging part and a rising part; these parts are described in greater detail below (see the description of FIGS. 28 to 30 and thecladding system 900, at least). The plunging part and the rising part can help to fix the brace to the panel.

[0101] The cured material 106 at least partially fills the cavity 114. Preferably, the cured material 106 fills the cavity 114 to be flush with the rear surface 112. The cured material 106 may include epoxy, adhesive, concrete, plaster, clay, or a combination thereof. During assembly of the cladding system 100, the part of the brace 104 that will become the embedded portion 140 is positioned within the cured material 106 in the cavity 114, before the cured material 106 hardens. Once the cured material 106 hardens, it bonds to the walls of the cavity 114 and secures the now embedded portion 140 in place, thereby fixing the brace 104 to the panel 102. As will be appreciated, both chemical bonds and mechanical bonds are within the meaning of “bonds”, “bonded”, and “bonding” as used herein.

[0102] FIGS. 4 to 6 show another embodiment of a cladding system that is generally identified by reference character 200. The cladding system 200 is similar to the cladding system 100, and like elements are denoted by like reference characters incremented by 100. Elements of the cladding system 200 that are identical to those of the cladding system 100 may not be further described herein, for brevity. As will be appreciated, the cladding system 200 is identical to the cladding system 100, except for the dimensions of the panel, the number of cavities in the panel, and the braces.

[0103] The cladding system 200 comprises a panel 202, a plurality of braces 204, and cured material 206. The panel 202 is entirely formed of natural stone. The braces 204 are configured to be secured to a substrate, to thereby to secure the cladding system 200 to the substrate. The cured material 206 fixes the braces 204 to the panel 202. The cured material 206 is identical to the cured material 106.

[0104] The panel 202 is identical to the panel 102, except for the dimensions of the panel and for the number and positioning of the cavities. That is, the panel 202 is greater in height and width than the panel 102, and the panel 202 has two cavities 214 that are positioned near a top and a bottom of the panel 202. Additionally, as will be appreciated, each of the cavities 214 is longer than the cavity 114, due to the greater width of the panel 202. The panel 202 has a front surface 210 and a rear surface 212. The rear surface 212 is shown in FIG. 4 and faces in an opposite direction to the front surface 210.

[0105] The two cavities 214 are formed in the rear surface 212 of the panel 202 (as shown in FIG. 5). Each of the cavities 214 is the same as the cavity 114, except for the length (as discussed above). One of the cavities 214a is formed near a top of the panel 202. The other one of the cavities 214b is formed near a bottom of the panel 202. Each of the cavities 214 extend in a respective longitudinal direction (LoDc?), along the rear surface 212 of the panel 202. Each of the cavities 214 may be formed in the same ways as the cavity 114 described above. The number, size, and shape of the cavities may vary depending for instance on the shape and weight of a given panel. Generally, larger and / or heavier panels will require a greater number of cavities compared to smaller and / or lighter panel.

[0106] When the panel 202 is installed on a substrate, the front surface 210 would face outward and away from the substrate. As will be appreciated, the front surface 210 may be relatively flat and smooth; although, alternate panels having various textures, shapes, and profiles are possible. For instance, a natural stone panel with a rounded or curved surface may be used. The ability to use the cladding system disclosed herein with a wide range of different shapes and sizes of stone may give a user the ability to create beautiful walls that are complex and aesthetically pleasing.

[0107] The plurality of braces 204 includes two braces 204, which are identical to each other (as shown in FIG. 5). Accordingly, only one of the braces 204 is further described herein, for brevity. The brace 204 includes a top portion 220a, a middle portion 224a, and a bottom portion 228a. The top portion 220a may be connected to the middle portion 224a by a top connecting portion 222a. The bottom portion 228a may be connected to the middle portion 224a by a bottom connecting portion 226a.

[0108] During assembly of the cladding system 200, the brace 204 is positioned on the rear surface 212 of the panel 202. The brace 204 is preferably positioned on the rear surface 212 such that the middle portion 224a is adjacent or close to an innermost surface 218 of the cavity 214a, and such that the top portion 220a and bottom portion 228a are adjacent or close to the rear surface 212 of the panel 202. As will be appreciated, the innermost surface 218 of the cavity 214a is the surface that defines the depth of the cavity 214a. The close arrangement or tight fit of the brace 204 with the innermost surface 218 of the cavity 214a and the rear surface 212 of the panel 202 may be achieved for instance by having the portions of the brace 204 connected by bends that are at or around 90 degrees, the middle portion 224a being equal to or around the width of the cavity 214, and the top connecting portion 222a and the bottom connecting portion 226a being equal to or around the depth of the cavity 214a.

[0109] The brace 204 also contains a second top portion 220b, a second middle portion 224b, and a second bottom portion 224b. The second middle portion 224b is positioned within the cavity 214b. The second top portion 220b may be connected to the second middle portion 224b by a second top connecting portion 222b. The second bottom portion 224b may be connected to the second middle portion 224b by a second bottom connecting portion 226b.

[0110] As will be appreciated, the second top portion may be connected to, or be the same part, as the bottom portion of the brace in some embodiments. For instance, as show for the brace 204 in FIG. 5, the second top portion 220b is connected to the bottom portion 228a of the brace 204. Alternatively, rather than being connected, there may be a space between the second top portion 220b and the bottom portion 228a, such that rather than a single continuous brace that spans from a top to a bottom of the panel 202, two separate braces are used (i.e., one brace for cavity 214a and another brace for cavity 214b). It will be appreciated that if there are N number of cavities, there may be 1 to N number of braces on a given vertical segment on the rear surface of the panel.[oni] In addition to bringing the middle portions 224a, 224b of the brace 204 into the cavities 214a, 214b, the top connecting portions 222a, 222b also provide a surface for bearing some of the weight of the panel 202, when the cladding system 200 is installed.

[0112] Similar to the brace 104, when the cladding system 200 is assembled, a portion of each of the braces 204 is embedded in the cured material 206 and a portion of each of the braces 204 extends out of the cured material 206 (see FIG. 6). The portion of the brace 204 that is embedded in the cured material 206 is defined as the embedded portion 240. The portion of the brace 204 that extends out of the cured material 206 is defined as the exposed portion 242. In the subject embodiment, the exposed portion 242 of each brace 204 comprises the top portion 220a, the bottom portion 228a, the second top portion 220b, and the second bottom portion 224b. In the subject embodiment, the embedded portion 240 of each brace 204 comprises the top connecting portion 222a, the middle portion 224a, the bottom connecting portion 226a, the second top connecting portion 222b, the second middle portion 224b, and the second bottom connecting portion 226b.

[0113] As shown in FIG. 4, an upper anchor receiving part 234a of the exposed portion 242 of each of the braces 204 extends above a top surface 236 of the panel 202 to receive a fastener, such as a screw or anchor bolt (not shown), to secure the cladding system 200 to a substrate. Similarly, a lower anchor receiving part 234b of the exposed portion 242 of each of the braces 204 extends below a bottom surface 238 of the panel 202 to receive a fastener, such as a screw or anchor bolt (not show), to secure the cladding system 200 to the substrate.

[0114] In addition to the generally rectangularly shaped panels described above, the cladding systems disclosed herein may also be employed with irregularly shaped panels, such as natural stone panels with rounded or curved edges.

[0115] FIGS. 7 to 9 show another embodiment of a cladding system that is generally identified by reference character 300. The cladding system 300 is similar to the cladding system 200, and like elements are denoted by like referenced characters incremented by 100. Elements of the cladding system 300 that are identical to those of the cladding system 200 may not be further described herein, for brevity. As will be appreciated, the cladding system 300 is identical to the cladding system 200, except for the irregular shape of the panel and one of the braces is truncated.

[0116] The cladding system 300 comprises a panel 302, a plurality of braces 304 and cured material 306. The panel 302 is entirely formed of natural stone. The braces 304 are configured to be secured to a substrate, to thereby to secure the cladding system 300 to the substrate. The cured material 306 fixes the braces 304 to the panel 302. The cured material 306 is identical to the cured material 206

[0117] The panel 302 is identical to the panel 202, except for the shape. As mentioned above, the panel 302 is irregularly shaped. The panel 302 has a front surface 310 and a rearsurface 312. Two cavities 314 are formed in the rear surface 312 of the panel 302 (similar to the panel 202). However, as a result of the irregular shape of the panel 302, the cavities 314 in the rear surface are not identical to each other. More specifically, the cavities 314 are not the same length. That is, one of the cavities 314a is greater in length than the other of the cavities 314b. It will be appreciated that in other embodiments, a single cavity or more than two cavities may also be possible depending on the dimensions and weight of the panel. In such cases, different sizes or lengths of braces may be used depending on how many cavities the braces will extend into.

[0118] The plurality of braces 304 includes two braces 304, which are not identical to each other. One of the braces 304a is the same as the brace 204 described above. The other of the braces 304b is shortened or truncated. The brace 304b is truncated to accommodate the irregular shape of the panel 302, and the shortened length of the cavity 314b. That is, the brace 304a is longer than the brace 304b such that the brace 304a extends into both cavities 314a, 314b (similar to the brace 204 described above), whereas the brace 304b only extends into cavity 314b. The brace 304b is truncated such that it does not include the second top portion, the second middle portion, the second bottom portion, or the second connecting portions described above for the brace 204.

[0119] While, in the above embodiments, the cavities have been shown as extending horizontally across the panels and the braces have been shown extending vertically against the rear surface of the panels, it will be appreciated that in other embodiments the orientation of the cavities and braces could vary. For instance, all of some of the cavities may extend vertically across the panels and receive horizontally placed braces. Such braces would then be secure to a substrate on the left and / or right sides of a panel rather than on the top and / or bottom of the panel. Diagonally orientated cavities and braces is also possible. Some alternative embodimentswith non-horizontal cavities and non-vertical braces are described here and shown in the accompanying drawings (such as FIGS. 17 to 19). However, other embodiments will be understood by those skilled in the art in view of the cladding systems described herein. The cladding systems described herein can be used with a wide range of different shapes and sizes of stone panels.

[0120] FIGS. 10 to 12 show another embodiment of a cladding system that is generally identified by reference character 400. The cladding system 400 is similar to the cladding system 200, and like elements are denoted by like reference characters incremented by 200. Elements of the cladding system 400 that are identical to those of the cladding system 200 may not be further described herein, for brevity. As will be appreciated, the cladding system 400 is identical to the cladding system 200, except for the braces and the addition of a bridge.

[0121] The cladding system comprises a panel 402, a plurality of braces 404, cured material 406, and a bridge 407. The panel 402 is entirely formed of natural stone. The braces 404 are configured to be secured to a substrate, to thereby to secure the cladding system 400 to the substrate. The cured material 406 fixes the braces 404 to the panel 402. The bridge 407 extends between two of the braces 404. The cured material 406 is identical to the cured material 206.

[0122] The panel 402 is identical to the panel 202. Accordingly, the panel 402 has a front surface 410 and a rear surface 412. Two elongate cavities 414 are formed in the rear surface 412 of the panel 402. Each of the cavities 414 is the same as the cavity 200 described above. In the cladding system 400, each of the cavities 414 extends across the entire width of the panel 402. However, in other embodiments of the cladding system, at least one of the cavities may extend partially across the panel, such that the cavity terminates within the panel.

[0123] The plurality of braces 404 includes three braces 404. A portion of each of the braces 404 is embedded in the cured material 406 within a respective one of the cavities 414, to fix the braces 404 to the panel 402. In the subject embodiment, two of the braces 404 are embedded within the cured material 406 in a topmost one of the cavities 414, and one of the braces 404 is embedded within the cured material 406 in a bottommost one of the cavities 414. In other embodiments, the cladding system may comprise one or more braces embedded within the cured material in one or more cavities. The number, size, and shape of the cavities and the number of braces may vary depending for instance on the shape and weight of a given panel. In this manner, the cladding system disclosed herein is adaptable to be used with a wide variety of natural stone panels.

[0124] As mentioned above, the cured material 406 is identical to the cured material 206. Accordingly, the cured material 406 at least partially fills the cavities 414. Preferably, the cured material 406 fills the cavities 414 to be flush with the rear surface 412. The cured material 406 may include epoxy, adhesive, concrete, plaster, clay, or a combination thereof. During assembly of the cladding system 400, the part of each brace 404 that will become the embedded portion 440 (described below) is positioned within the cured material 406 in a respective one of the cavities 414, before the cured material 406 hardens. Once the cured material 406 hardens, it bonds to the walls of the respective cavity 414 and secures the now embedded portion 440 in place. In this way, each of the braces 404 is fixed to the panel 402.

[0125] Each of the braces 404 extends beyond the rear surface 412 in a direction of orientation (ODB4) for the respective brace 404. As shown in FIG. 10, two of the braces 404 are oriented in a first direction (e.g., upward direction) and one of the braces 404 is oriented in a generally opposite, second direction (e.g., downward direction). Orienting the braces 404 indifferent directions can help to resist uplift on the cladding system 400 when it is secured to a substrate, such as uplift caused by wind. As will be appreciated, the direction of orientation for each brace in the cladding systems described herein can depend for instance on the shape of the panel and / or on the preferred mounting locations for the intended substrate.

[0126] Each of the braces 404 are identical in the subject embodiment. Accordingly, only one brace 404 is described below, for brevity. Enlarged views of the brace 404 are provided in FIGS. 52 to 54, which are described below. In other embodiments, the cladding system may comprise one or more of the braces shown in FIGS. 55 to 59, which are also described below. In some embodiments, the braces may comprise a combination of different designs which may not be identical, such as a combination of the braces shown in FIGS. 52 to 59. The brace 404 is preferably made of metal, though alternate materials are possible. Suitable alternative materials would be sufficiently strong to support the weight of panel 402 and sufficiently durable and weather resistant.

[0127] As shown in FIG. 11 and FIGS. 52 to 54, the brace 404 comprises a top portion 420, a connecting portion 422, a middle portion 424, and a bottom portion 428. The top portion 420 is connected to the middle portion 424 by the connecting portion 422. The bottom portion 428 is connected to the middle portion 424, opposite the connecting portion 422.

[0128] The top portion 420 includes an anchoring aperture 430 for receiving a fastener therethrough. Accordingly, the top portion 420 may be referred to as an anchoring portion 432 of the brace 404. The fastener may be a rivet to couple the brace 404 to the bridge 407 (as discussed below). Alternatively, the fastener may be a screw or an anchor bolt to directly secure the brace 404 to the substrate. The anchoring aperture 430 is located in an anchor receiving part 434 of the anchoring portion 432. The anchor receiving part 434 extends beyond the rear surface412 of the panel, such as beyond a top edge or a bottom edge of the rear surface 412 of the panel 402. Accordingly, when the cladding system 400 is being installed, a fastener can be received through the anchoring aperture 430, or through the bridge 407 (as described below), without the panel 402 getting in the way. In the subject embodiment, the anchoring aperture 430 is a slot. In other embodiments, the anchoring aperture may comprise a circular hole or other suitable shape depending for instance on the intended fastener to be used.

[0129] Similar to the brace 104 described above, when the cladding system 400 is fully assembled, a portion of each of the braces 404 is embedded in the cured material 406 and a portion of each of the braces 404 extends out of the cured material 406. The portion of the brace 404 that is embedded in the cured material 406 is defined as the embedded portion 440. The portion of the brace 404 that extends out of the cured material 406 is defined as the exposed portion 440. In the subject embodiment, the embedded portion 440 comprises the connecting portion 422, the middle portion 424, and the majority of the bottom portion 428 of the brace 404. In the subject embodiment, the exposed portion 440 comprises the top portion 420, and a small part (the spacer portion) of the bottom portion 428 of the brace 404. In other embodiments, the embedded portion 440 may comprise the entire bottom portion 428. The embedded portion of the brace further comprise a plunging part and a rising part, which can help to fix the brace to the panel. The spacer portion, the plunging part, and the rising part are all described in greater detail below (see the description of FIGS. 28 to 30 and the cladding system 900, at least). The brace 404 also includes an embedding feature 460, which is described in greater detail with reference to FIGS. 52 to 54, below. The embedding feature may also help to fix the brace to the panel.

[0130] The connecting portion 422, the middle portion 424, and the bottom portion 428 of each brace 404 are sized to fit at least partially within a respective one of the cavities 414.Preferably, these portions are sized such that the middle portion 424 is adjacent or close to an innermost surface 418 of the cavity 414, when the brace 404 is fully inserted into the cavity 414. Accordingly, a depth (DB4) of the connecting and bottom portions 422,428 is approximately equal to or greater than a depth of the cavity 414. In the embodiment shown in FIGS. 10 to 12 and 52 to 54, the depth (DB4) of connecting and bottom portions 422, 428 is approximately 12 mm. Similarly, the depth of the cavity 412 in the rear surface 412 of the panel 402 is approximately 12 mm.

[0131] To facilitate installing the cladding system 400 on a substrate, the cladding system 400 includes the bridge 407. The bridge 407 allows the cladding system 400 to be secured to the substrate at positions between the braces 404. The bridge 407 is coupled to and extends between a plurality of the braces 404. In the embodiment shown in FIGS. 10 to 12, the bridge 407 is coupled to and extends between the two braces 420 in the topmost one of the cavities 414. In other embodiments, the bridge may be coupled between more than two braces, or may be coupled to and extend from a single brace. The size, shape, and position of the bridge may vary depending for instance on the shape and weight of a given panel and / or on the construction of the substrate.

[0132] The bridge 407 comprises an elongate body (such as a bar) with a plurality of apertures 409 formed therein. During installation of the cladding system 400, one or more fasteners (such as anchor bolts or screws) are received through the apertures 409 and driven into the substrate, to secure the cladding system 400 to the substrate. The apertures 409 in the bridge 407 enable the cladding system 400 to be secured to the substate at positions between the braces 404. This can be advantageous when the braces 404 are not positioned at the preferred mounting locations for the substrate, such as when the braces 420 are not aligned with studs in a wall. Thebridge 407 can include apertures 409 with a plurality of different sizes and shapes to further facilitate installation. In some embodiments, the apertures 409 can comprise slots (as shown in FIGS. 10 and 11), circular holes, or a combination thereof (as shown in FIGS. 13 and 14). The size and shape of the apertures in the bridge can depend for instance on the construction of the substrate to which the cladding system will be secured. It may be advantageous to provide at least one aperture in the shape of an elongate slot to provide flexibility when positioning a fastener to secure the cladding system to the substrate.

[0133] The bridge 407 is coupled to the braces 404 by fasteners such as rivets (as shown in FIGS. 10 to 12), as discussed above. As will be appreciated, by securing the braces 404 to the bridge 407 using rivets through slot-shaped apertures as shown in FIGS. 10 and 11, it may be possible to slide the braces 420 relative to the bridge 407 during manufacturing of the cladding system 400 to optimize placement of the braces 404 relative to the panel 402. Though, in other embodiments, the bridge 407 may be secured to the braces 404 by other suitable means such as by welding, by adhesives, or by being integrally formed therewith.

[0134] FIGS. 13 to 16 show another embodiment of a cladding system that is generally identified by reference character 500. The cladding system 500 is similar to the cladding system 400, and like elements are denoted with like reference characters incremented by 100. Elements of the cladding system 500 that are identical to those of the cladding system 400 may not be further described herein, for brevity. As will be appreciated, the cladding system 500 is identical to the cladding system 400, except for the number of cavities (there is only one), the dimensions of the panel and the cavity, the apertures in the bridge, and the orientation of one of the braces.

[0135] The cladding system 500 comprises a panel 502, a plurality of braces 504, a cured material 506, and a bridge 507. The panel 502 is formed entirely of natural stone. The braces504 are configured to be secured to a substrate or to the bridge 507. The cured material 506 fixes the braces 504 to the panel 502. The bridge 507 extends between two of the braces 504. The cured material 506 is identical to the cured material 406. Similarly, the design of each of the braces 504 is identical to that of the braces 404.

[0136] The panel 502 is identical to the panel 402, except for the dimensions of the panel and for the cavity. That is, the height of the panel 502 is less than that of the panel 402, and the panel 502 has a single cavity that is wider than those of the panel 402. The panel 502 has a front surface 510 and a rear surface 512. The cavity 514 is formed in the rear surface 512 of the panel 502. As mentioned, the cavity 514 is wider than each of the cavities 414. However, the cavity 514 is otherwise identical to the cavities 414 and can be formed in the same ways.

[0137] Each of the braces 504 is identical to the brace 404, described above. However, one of the braces 504 in the cladding system 500 is oriented in a different direction than those of the cladding system 400. As shown in Fig. 13, one of the braces 504 is oriented in a generally perpendicular direction to the other two braces 504. That is, one of the braces 504 is oriented in a generally horizontal direction and the other braces 504 are oriented in generally vertical directions. As will be appreciated, the direction of orientation for each brace in the cladding systems described herein can depend for instance on the shape of the panel and / or on the preferred mounting locations for the intended substrate. Additionally, orienting at least one of the braces in a different direction to the other braces can help to resist uplift on the cladding system when it is secured to a substrate, such as uplift caused by wind.

[0138] The bridge 507 is identical to the bridge 407, except for the shape and number of the apertures 509. In the subject embodiment, the apertures 509 are a combination of slots andcircular holes. As can be seen in FIG. 14, there are more apertures 509 in the bridge 507 of the subject embodiment than there are in the bridge 407 of the previous embodiment.

[0139] FIGS. 17 to 19 show another embodiment of a cladding system that is generally identified by reference character 600. The cladding system 600 is similar to the cladding system 100, and like elements are denoted with like reference characters incremented by 500. Elements of the cladding system 600 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the cladding system 600 is identical to the cladding system 100, except for the irregular shape of the panel and for the design of the brace.

[0140] The cladding system 600 comprises a panel 602, a brace 604, and a cured material 606. The panel 602 is formed entirely of natural stone. The brace 604 is configured to be secured to a substrate, to thereby to secure the cladding system 600 to the substrate. The cured material 606 fixes the brace 604 to the panel 602. The cured material 606 is identical to the cured material 106. The design of the brace 604 is identical to the design of the brace 404.

[0141] The panel 602 is identical to the panel 102, except for the shape. As mentioned above, the panel 602 is irregularly shaped. The panel 602 has a front surface 610 and a rear surface 612. A single cavity 614 is formed in the rear surface 612. The cavity 614 is identical to the cavity 114, except the cavity 614 has slightly different dimensions than the cavity 114, due to the irregular shape of the panel 102. The cavity 614 can be formed in the same ways as the cavity 114.

[0142] The brace 604 is identical to one of the braces 404, described above. Accordingly, the brace 604 will not be further described herein, for brevity. Although the cladding system 600 is shown with a single brace 604 in FIGS. 17 to 19, in other embodiments the cladding system may comprise at least one brace 604, such as two or more braces 614. For instance, the claddingsystem 600 may include multiple braces when used in external application where additional forces (such as wind forces) will act on the panel 602, or when the panel 602 is irregularly shaped and requires additional braces 614 to be sufficiently secured to a substrate.

[0143] FIGS. 20 to 22 show another embodiment of a cladding system that is generally identified by reference character 700. The cladding system 700 is similar to the cladding system 600, and like elements are denoted with like reference characters incremented by 100. Elements of the cladding system 700 that are identical to those of the cladding system 600 may not be further described herein, for brevity. As will be appreciated, the cladding system 700 is identical to the cladding system 100, except the panel is a slightly different irregular shape, there are two cavities formed in the panel, there are two braces (one in each cavity), and each brace is oriented in the direction of a respective cavity.

[0144] The cladding system 700 comprises a panel 702, a plurality of braces 704, and cured material 706. The panel 702 is formed entirely of natural stone. The braces 704 are configured to be secured to a substrate, to thereby to secure the cladding system 700 to the substrate. The cured material 706 fixes the braces 704 to the panel 702. The cured material 706 is identical to the cured material 606.

[0145] The panel 702 is identical to the panel 602, except the irregular shape is slightly different and the panel 702 has two cavities formed therein (similar to the panel 402). The panel 702 has a front surface 710 and a rear surface 712. Two cavities 714 are formed in the rear surface 712 of the panel 702.

[0146] Each of the cavities 714 is identical to the cavity 614 (or the cavities 414), except for the cavities 714 have slightly different dimensions due to the irregular shape of the panel 702, and each of the cavities 714 is slightly askew from horizontal. That is, each of the cavities 714extends in a respective longitudinal direction (LoDc?) that is angled with regard to a generally horizontal direction (i.e., the longitudinal directions (LoDc?) are not aligned or parallel with the horizontal direction). The cavities 714 can be formed in the same ways as the cavity 614.

[0147] The plurality of braces 704 includes two braces 704. Each of the braces 704 is identical to the brace 604 described above, except for the orientation of the braces 704. That is, as shown in FIG. 20., a direction of orientation (ODB?) for each of the braces 704 is aligned with the longitudinal direction (LoDc?) of the respective cavity 714 that the brace 704 is positioned in.

[0148] FIGS. 23 to 27 show another embodiment of a cladding system that is generally identified by reference character 800. The cladding system 800 is similar to the cladding system 700, and like elements are denoted with like reference characters incremented by 100. Elements of the cladding system 800 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the cladding system 800 is identical to the cladding system 700, except for the shape of the panel and the orientation of the cavities.

[0149] The cladding system 800 comprise a panel 802, a plurality of braces 804, and a cured material 806. The panel 802 is formed entirely of natural stone. The braces 804 are configured to be secured to a substrate 801, to thereby to secure the cladding system 800 to the substrate to the substrate 801 (shown in FIG. 27). The cured material 806 fixes the braces 804 to the panel 802. The cured material 806 is identical to the cured material 706. The design of each of the braces 804 is identical to that of the braces 704.

[0150] The panel 802 is identical to the panel 702, except for the shape of the panel. That is, the panel 802 is less irregular than the panel 702, and the panel 802 includes a comer portion, described below. The panel 802 has a front surface 810 and a rear surface 812. Two cavities814 are formed in the rear surface 812 of the panel 802. The cavities 814 can be formed in the same way as the cavities 714.

[0151] Each of the cavities 814 is identical to the cavity 714 described above, except the cavities 814 are oriented generally vertically. That is, each of the cavities 814 has a longitudinal direction (LoDcs) that extends in a generally vertical direction of the cladding system 800. Accordingly, in contrast to the cladding system 100, in the subject embodiment a width of each of the cavities 814 is defined in a direction that is generally parallel to a width of the panel 802.

[0152] The panel 802 comprises a corner portion 856. The comer portion 856 extends from the rear surface 812 of the panel 802. When the cladding system 800 is secured to a substrate 801, the corner portion 856 wraps around a corner of the substrate 801 (as shown in FIG. 27). Accordingly, the comer portion 856 extends from the rear surface 812 of the panel 802 at an angle p. In the subject embodiment, the angle P is about 90 degrees. In other embodiment, the angle P can be in the range of 45 to 90 degrees. As will be appreciated, the angle P of the corner portion 856 will depend for instance on the shape of the substrate to which the cladding system 800 is intended to be secured.

[0153] The plurality of braces 804 includes two braces 804. Each of the braces 804 is identical to the brace 704 described above, except for the directions that the braces 804 point in, as described below. A single brace 804 is positioned in each of the cavities 814. Similar to the cladding system 700, a direction of orientation for each of the braces 804 is aligned with the longitudinal direction of the respective cavity 814 that the brace 804 is positioned in. Accordingly, due to the orientation of the cavities 814, each of the braces 804 points in a generally vertical direction (i.e., generally up, or generally down).

[0154] FIG. 27 shows a plurality of the cladding systems 800 installed on a substrate 801. The cladding systems 800 are secured to the substrate 801 by fasteners 852, such as screws or anchor bolts. As can be seen, the corner portions 856 of the cladding systems 800 wrap around a comer of the substrate 801, once installed. The substrate 801 comprises a wall, such as a timber frame construction. During subsequent installation, additional instances of the cladding systems disclosed herein can be secured to the substrate 801 to substantially cover the surface thereof. The spaces between and around the cladding systems can thereafter be filled, such as with mortar. Filling the spaces between and around the cladding systems may improve the overall appearance, such as by hiding the fasteners, and may increase stability.

[0155] FIGS. 28 to 30 show another embodiment of a cladding system that is generally identified by reference character 900. The cladding system 900 is similar to the cladding system 100, and like elements are denoted with like reference characters incremented by 800. Elements of the cladding system 900 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the cladding system is identical to the cladding system 100, except for the dimensions of the panel, except for the braces, and except for grooves that are included in the cavity.

[0156] The cladding system 900 comprises a panel 902, a plurality of braces 904, and a cured material 906. The panel 902 is formed entirely of natural stone. The braces 904 are configured to be secured to a substrate, to thereby secure the cladding system 900 to a substrate. The design of each of the braces 904 is identical to that of the braces 404. The cured material 906 fixes the braces 904 to the panel 902. The cured material 906 is identical to the cured material 106.

[0157] The panel 902 is identical to the panel 102, except for the width. That is, the panel902 has a width that is greater than the width of the panel 102. The panel 902 has a front surface910 and a rear surface 912. One elongate cavity 914 is formed in the rear surface 912 of the panel 902 (see FIG. 29).

[0158] The cavity 914 is identical to the cavity 114, except for the grooves described below. The cavity 914 extends in a longitudinal direction across the entire width of the panel 902. In the subject embodiment, a plurality of grooves 916 are formed in an innermost surface 918 of the cavity 914. The grooves 916 extends in the longitudinal direction of the cavity 914. During assembly of the cladding system 900, the grooves 916 can allow the cured material 906 to flow around and behind the braces 904 before the cured material 906 hardens, to help fix the braces 904 to the panel 902 once the cured material 906 hardens. As shown in FIG. 30, the grooves 916 have a rectangular- wave profile in the subject embodiments. In other embodiments, the grooves may have a saw-tooth profile, a sinusoidal profile, or another suitably shaped profile. In some embodiments, the grooves may comprise an array of grooves that extends in both the longitudinal direction and the lateral direction of the cavity, such as a rectangular pattern or a diamond pattern of grooves. The cavity 914 may be formed in generally the same way as the cavity 114. That is, the cavity 914 may be formed for instance by running a blade multiple times across the rear surface 912. To form the grooves 916, each time the blade is run across the rear surface 912, the blade can be alternated between two different depths of cut (one depth corresponding to the depth of the cavity 914, and the other depth corresponding to the depth of the cavity 914 plus the additional depth of the grooves). However, it will be appreciated that a same or similar cavity and grooves may be formed in other ways.

[0159] The plurality of braces 904 includes four braces 904. Each of the braces 904 is identical to the brace 404, described above and further described below with reference to FIGS.52 to 54. All of the braces 904 have the same design. Accordingly, for brevity, only one of the braces 904 is described below and identical features to those of the brace 404 may not be repeated. In other embodiments, the cladding system may comprise one or more of the braces shown in FIGS. 55 to 59, which are also described below. In some embodiments, the braces may comprise a combination of different designs which may not be identical, such as a combination of the braces shown in FIGS. 52 to 59. The brace 904 is preferably made of metal, though alternate materials are possible. Suitable alternative materials would be sufficiently strong to support the weight of panel 902 and sufficiently durable and weather resistant.

[0160] As shown in FIG. 30, the brace 904 comprises a top portion 920, a connecting portion 922, a middle portion 924, and a bottom portion 928. The top portion 920 is connected to the middle portion 924 by the connecting portion 922. The bottom portion 928 is connected to the middle portion 924.

[0161] The top portion 920 includes an anchoring aperture 930 for receiving a fastener therethrough, to secure the panel 902 to a substrate. Accordingly, the top portion 920 may be referred to as an anchoring portion 932 of the brace 904. Suitable fasteners may comprise an anchor bolt or a screw that extends through the anchoring aperture 930 into the substrate. The anchoring aperture 930 is located in an anchor receiving part 934 of the anchoring portion 932. The anchor receiving part 934 extends beyond a periphery of the rear surface 912 of the panel 902, such as beyond a top edge of the rear surface 912 of the panel 902 (as shown in FIG. 30). Accordingly, when the cladding system 900 is being installed, a fastener can be received through the anchoring aperture 930, without the panel 902 getting in the way. The anchoring aperture930 is a slot in the subject embodiment. In other embodiments, the anchoring aperture may be a circular hole or other suitable shape, depending for instance on the intended fastener to be used with the cladding system.

[0162] Similar to the brace 104 and the brace 404 described above, when the cladding system 900 is fully assembly, a portion of each of the braces 904 is embedded in the cured material 906 and a portion of each of the braces 904 extends out of the cured material 906. The portion of the brace 9X that is embedded in the cured material 906 is defined as the embedded portion 940. The portion of the brace 904 that extends out of the cured material 906 is defined as the exposed portion 942. In the subject embodiment, the embedded portion 940 comprises the connecting portion 922, the middle portion 924, and the majority of the bottom portion 928 of the brace 904. In the subject embodiment, the exposed portion 942 comprises the top portion 920, and a small part (the spacer portion 950, described below) of the bottom portion 928 of the brace 904.

[0163] The embedded portion 940 of each brace 904 is sized to fit within the cavity 914. Preferably, the embedded portion 940 is sized such that it contacts one or more peaks 954 of the grooves 916 in the cavity 914, when the brace 904 is fully inserted into the cavity 914. Accordingly, the depth (DB$>) of the embedded portion 940 is generally equal to a depth (Dc$>) of the cavity 914, when measured to the innermost surface 918 (i.e., the depth of the cavity 914 to the peaks 954 of the grooves 916). In the embodiment shown in FIGS. 28 to 30, the depth (DB$>) of the embedded portion 940 is approximately 12 mm. Similarly, the depth of the cavity 914 in the rear surface 912 of the panel 902 is approximately 12 mm. Preferably, the grooves provide an additional depth that is in the range of about 2 to 3 mm, but deeper or shallower grooves arepossible in other embodiments. The brace 904 further comprises an embedding feature 960, which is identical to the embedding feature 460 described below and shown in FIGS. 52 to 54.

[0164] The cladding system 900 includes multiple features to help fix each of the braces 904 to the panel 902 using the cured material 906. These features include the grooves 916 described above, the embedding feature described below, and the shape of the embedded portion 940 of the braces 904. In other, less preferred, embodiments, the cladding system may omit one or more of these features.

[0165] For each brace 904, the shape of the embedded portion 940 is configured to help fix the brace 904 to the panel 902 in multiple ways. The embedded portion 940 includes a plunging part 944 and a rising part 946 (as shown in FIG. 30). The plunging part 944 is the part of the embedded portion 940 that increases in depth within the cured material 906 as it extends away from the exposed portion 942, and preferably as it extends away from the anchoring portion 932 of the exposed portion 942. The rising part 946 is the part of the embedded portion 940 that decreases in depth within the cured material 906 as it extends away from the plunging part 944.

[0166] The plunging part 944 and the rising part 946 cooperate to partially surround a plug 970 of the cured material 906. As denoted by dashed lines in FIG. 28, the longitudinal sides 972 of the plug 970 are not surrounded by the plunging part 944 or the rising part 946. Accordingly, the longitudinal sides 972 of the plug 970 are directly connected, or bonded, to the rest of the cured material 906. Resultantly, in a first mode of failure, the sides of the plug 970 must be sheared from the rest of the cured material 906 in order for the plug and the brace 904 to break away from the panel 902. When a suitable cured material is used, such as those described herein, the cladding system 900 can be resilient to this first mode of failure due to the difficulty in shearing the cured material 906. In this way, the shape of the embedded portion 940, andparticularly how the plunging part 944 and the rising part 946 partially surround the plug 970, can help to fix the brace 904 to the panel 902.

[0167] The shape of the embedded portion 940 can also help to fix the brace 904 to the panel 902 in other ways, such as by helping to reduce the likelihood of a second mode of failure. In the second mode of failure, the brace 904 may become separated from the panel 902 without the plug 970 shearing from the rest of the cured material 906. This second mode of failure can occur when the brace 904 is pulled hard enough to “back out” of the cured material 906, along a path defined by the profile of the brace 904. To help reduce the likelihood of this second mode of failure, the embedded portion 940 includes the plunging part 944 and the rising part 946 described above. As will be appreciated, the embedded portion 940 changes direction within the cured material 906 as a result of the plunging part 944 and the rising part 946. That is, the embedded portion 940 goes from a part that increases in depth within the cured material 906, to a part that decreases in depth within the cured material 906.

[0168] Due to the change in direction within the cured material 906 caused by the plunging part 944 and the rising part 946, the embedded portion 940 must be physically deformed as the brace 904 is pulled out during the second mode of failure. This physical deformation of the embedded portion 940 may increase the energy required for the second mode of failure (i.e., may increase the pulling force required to cause the brace 904 to back out). In contrast, if the embedded portion was a flat plate embedded in the cured material without any change in direction, the brace could be pulled out along the profile of the plate (i.e., along the plane defined by the plate) without deforming the embedded portion.

[0169] Preferably, the embedded portion 940 completely reverses direction within the cured material 906, as shown in the subject embodiment, to help increase the added energy required tophysically deform the embedded portion 940 during the second mode of failure. That said, in other embodiments, the embedded portion may not completely reverse direction. In some embodiments, the plunging part and the rising part may define an angle of directional change that is the range of 90 to 180 degrees (i.e., between a 90 degree change in direction, and a complete reversal of direction). For example, in some embodiments, the plunging part may increase in depth within the cured material at an angle of about 45 degrees to the surface of the cured material, and the angle of directional change between the plunging part and the rising part may be about 90 degrees, such that the rising part decreases in depth within the cured material at a similar angle of about 45 degrees to the surface.

[0170] In the subject embodiment, the rising part 946 decreases in depth within the cured material 906 until it reaches a surface 908 of the cured material 906. The brace 904 then extends beyond the surface 908 of the cured material 906 to provide a further part of the exposed portion 942 of the brace 904. This further part is referred to herein as a spacer portion 950 of the brace 904. When the cladding system 900 is secured to a substrate, the spacer portion 950 abuts the substrate and helps to keep the rear surface 912 of the panel 902 spaced away from the substrate. Spacing the rear surface 912 away from the substrate can help to provide drainage behind the panel 902, such as for rain or other precipitation.

[0171] In the subject embodiment, the spacer portion 950 extends beyond the surface 908 of the cured material 906 by a length that is about equal to a thickness of the anchoring portion 932 (as shown in FIG. 30). In this way, the spacer portion 950 can help to keep the rear surface 912 evenly spaced from the substrate, when the cladding system 900 is installed. Keeping the cladding system 900 evenly spaced from the substrate when installed can improve the appearance of the cladding system 900. For instance, if multiple cladding systems 900 withsimilar thickness are installed on a wall, keeping the rear surfaces 912 of the cladding systems 900 evenly spaced from the wall can help to ensure that the front surfaces 910 will be generally aligned or flush with each other, thereby providing an aesthetically pleasing appearance for the clad wall.

[0172] FIGS. 31 to 33 show another embodiment of a cladding system that is generally identified by reference character 1000. The cladding system 1000 is similar to the cladding system 900, and like elements are denoted with like reference characters incremented by 100. Elements of the cladding system 1000 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the cladding system 1000 is identical to the cladding system 900, except for the brace.

[0173] The cladding system 1000 comprises a panel 1002, a brace 1004, and a cured material 1006. The panel 1002 is formed entirely of natural stone. The brace 1004 is configured to be secured to a substrate, to thereby to secure the cladding system 1000 to the substrate. The cured material 1006 fixes the brace 1004 to the panel 1002. The cured material 1006 is identical to the cured material 906.

[0174] The panel 1002 is identical to the panel 920. Accordingly, the panel 1002 comprises a front surface 1010, a rear surface 1012, a cavity 1014, and a plurality of grooves 1016, which are all identical to those of panel 902 and are not further described herein, for brevity.

[0175] The brace 1004 is similar to a plurality of the braces 904 fused together, side-by-side. Accordingly, the brace 1004 is identical to the brace 904, except the brace 1004 is wider and includes a plurality of anchoring apertures 1030 and embedding features 1060. The anchoring apertures 1030 and the embedding features 1060 are identical to the anchoring aperture 930 and the embedding feature 940, respectively, except as follows. The anchoring apertures 1030 arecircular holes in the subject embodiment, instead of slots. In the brace 1004, the anchoring apertures 1030 are approximately equally spaced across the width of the brace 1004, and are closely spaced (such as spaced every 1 inch). Accordingly, the brace 1004 can provide additional flexibility with respect to mounting locations for the fasteners, when securing the cladding system 1000 to a substrate. As will be appreciated, in the subject embodiment, the brace 1004 is approximately equal in width to the panel 1002. Preferably, the brace 1004 has a width in the range of about 36 to 39 inches, which can be the distance between studs in a typical timber frame construction, but longer or shorter braces are possible in other embodiments. In a preferred embodiment, the width of the brace may be at least 98 percent of the width of the panel(s), see FIG. 43 for example.

[0176] Similar to the brace 904, the brace 1004 is preferably made of metal, though alternate materials are possible. Suitable alternative materials would be sufficiently strong to support the weight of panel 1002 and sufficiently durable and weather resistant.

[0177] Similar to the brace 904, the brace 1004 comprises a top portion 1020, a connecting portion 1022, a middle portion 1024, and a bottom portion 1028. The brace 1004 also comprises an exposed portion 1042 and an embedded portion 1040, which includes a plunging part 1044 and a rising part 1046. Except for the width and the number of apertures and embedding features (as mentioned), all of the above listed portions and parts of the brace 1004 are identical to those of brace 904. Accordingly, the above description of these portions and parts for the brace 904 applies, mutatis mutandis, to the portions and parts for the brace 1004, and this description is not repeated herein, for brevity.

[0178] FIGS. 34 to 37 show another embodiment of a cladding system that is generally identified by reference character 1100. The cladding system 1100 is similar to the claddingsystem 1000, and like elements are denoted with like reference characters incremented by 100. Elements of the cladding system 1100 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the cladding system 1100 is identical to the cladding system 1000, except the brace includes a plurality of drainage apertures and a plurality of embedding apertures, and the brace has a greater depth.

[0179] The cladding system 1100 comprises a panel 1102, a brace 1104, and a cured material 1106. The panel 1102 is formed entirely of natural stone. The brace 1104 is configured to be secured to a substrate, to thereby to secure the cladding system 1100 to the substrate. The cured material 1106 fixes the brace 1104 to the panel 1102. The cured material 1106 is identical to the cured material 1006, except the depth of the cured material 1106 is less than that the cured material 1006. The panel 1102 is identical to the panel 1002.

[0180] The brace 1104 is identical to the brace 1004, except the brace 1104 includes a plurality of drainage apertures 1176 and a plurality of embedding apertures 1180, and the brace 1104 has a greater depth than the brace 1004. Accordingly, the brace 1104 comprises a top portion 1120, a connecting portion 1122, a middle portion 1124, and a bottom portion 1128.

[0181] The plurality of drainage apertures 1176 are configured to facilitate drainage behind the cladding system 1100. The drainage apertures 1176 are formed in the connecting portion 1122 and the bottom portion 1128 of the brace 1104. More particularly, the drainage apertures 1176 are formed in the parts of the connecting portion 1122 and the bottom portion 1128 that extends beyond a surface 1108 of the cured material 1106. Thus, the drainage apertures 1176 in the bottom portion 1128 are formed in a spacer portion 1150 of the brace 1104. When the cladding system 1100 is installed on a substrate, liquid (such as rain or other precipitation) that is flowing behind the cladding system 1100 can pass through the drainage apertures 1176 tofacilitate drainage. The drainage apertures 1176 in the connecting portion 1122 are a plurality of circular holes (see FIG. 37). The drainage apertures 1176 in the bottom portion 1128 are a plurality of notches (see FIGS. 34 and 35). In other embodiments, the drainage apertures may comprise holes, notches, slots, other suitable shaped openings, or a combination thereof. In some embodiment, the drainage apertures may be formed in one or more of the top portion, the connecting portion, and the bottom portion of the brace, depending on which portions would obstruct the path of liquid flowing behind the cladding system when installed.

[0182] The plurality of embedding apertures 1180 are configured to help embed the brace 1104 in the cured material 1106. The embedding apertures 1180 are formed in the connecting portion 1122 and the bottom portion 1128 of the brace 1104. More particularly, the embedding apertures 1180 are formed in the parts of the connecting portion 1122 and the bottom portion 1128 that are embedded in the cured material 1106. That is, the embedding apertures 1180 are formed in the embedded portion 1140 of the brace 1104. During assembly of the cladding system 1100, the embedding apertures 1180 can allow the cured material 1106 to flow through and behind the brace 1104 before the cured material 1106 hardens, to help fix the brace 1104 to the panel 1102 once the cured material 1106 hardens. The embedding apertures 1180 are a plurality of circular holes. In other embodiments, the embedding apertures may comprise holes, notches, slots, other suitable shaped openings, or a combination thereof.

[0183] As mentioned above, the brace 1104 has a greater depth than the brace 1004. Accordingly, both the bottom portion 1128 and the connecting portion 1122 of the brace 1104 extend further beyond the surface 1108 of the cured material 1106 than those of the brace 1004. As a result, when the cladding system 1100 is installed on the substrate, the rear surface 1112 of the panel 1102 is spaced apart from the substrate by a greater distance than for the claddingsystem 1000. Increasing the separation between the substrate and the rear surface 1112 of the panel 1102 can facilitate drainage behind the cladding system 1100.

[0184] In the subject embodiment, the bottom portion 1128 and the connecting portion 1122 extend approximately the same distance beyond the surface 1108 of the cured material 1106. That is, in the subject embodiment, both the bottom portion 1128 and the connecting portion 1122 extend about 8 mm beyond the surface 1108 of the cured material 1106 (as shown in FIG. 36). Accordingly, in the subject embodiment, the spacer portion 1150 extends about 8 mm beyond the surface 1108 of the cured material 1106. As a result, when the cladding system 1100 is installed on a substrate, the rear surface 1112 of the panel 1102 may be generally evenly spaced from the substrate, such that the panel 1102 is approximately parallel to the substrate. This generally even spacing can be desirable, as described above. However, it will be appreciated that in other embodiments, the bottom portion, the connecting portion, and / or the spacer portion of the brace may extend beyond the surface of the cured material by another distance, such as a distance in the range of about 8 to 12 mm. In some embodiments, the distances that the connecting portion and the bottom portion extend beyond the surface of the cured material may not be the same, such that the panel may be sloped or tilted when installed on a substrate. This sloped or tilted appearance may be aesthetically desirable in some instances.

[0185] FIGS. 38 to 41 show another embodiment of a cladding system that is generally identified by reference character 1200. The cladding system 1200 is similar to the cladding system 1100, and like elements are denoted with like reference characters incremented by 100. Elements of the cladding system 1200 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the cladding system 1200 isidentical to the cladding system 1100, except the cladding system 1200 includes a plurality of braces and one of those braces is oriented horizontally.

[0186] The cladding system 1200 comprises a panel 1202, a plurality of braces 1204, and a cured material 1206. The panel 1202 is formed entirely of natural stone. The braces 1204 are configured to be secured to a substrate, to thereby to secure the cladding system 1200 to the substrate. The cured material 1206 fixes the braces 1204 to the panel 1202. The cured material 1206 is identical to the cured material 1106.

[0187] The panel 1202 is identical to the panel 1102. Accordingly, the panel 1202 includes a front surface 1210 and a rear surface 1212. A single cavity 1214 is formed in the rear surface 1212 of the panel 1202. The cavity 1214 is identical to the cavity 1014.

[0188] The plurality of braces 1204 includes two braces 1204, which are not identical. Each of the braces 1204 is preferably made of metal, though alternate materials are possible. Suitable alternative materials materials would be sufficiently strong to support the weight of panel 1202 and sufficiently durable and weather resistant.

[0189] The plurality of braces 1204 comprises a brace 1204a that is vertically oriented and a brace 1204b that is horizontally oriented. The brace 1204a is identical to the brace 1104, described above. The brace 1204b is identical to the brace 904 described above, except the anchoring aperture 1230 is a circular hole, the direction of orientation of the brace 1204b is aligned with the longitudinal direction (LoDcn) of the cavity 1214, and the brace 1204b has a plurality of drainage and embedding apertures 1276, 1278. Accordingly, in the subject embodiment, the connecting portion 1222 and the bottom portion 1228 of the brace 1204b extends further beyond a surface 1218 of the cured material 1206 than those of the brace 904, in the same manner as was described above for the brace 1104 with regard to the brace 1004. Thus,the brace 1204b can facilitate drainage behind the cladding system 1200, in the same manner as described above for the brace 1104.

[0190] FIGS. 42 to 45 show another embodiment of a cladding system that is generally identified by reference character 1300. The cladding system 1300 is similar to the cladding system 1000, and like elements are denoted with like reference characters incremented by 300. Elements of the cladding system 1300 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the cladding system 1300 is identical to the cladding system 1000, except it includes a plurality of panels with different dimensions and no grooves in their cavities, and the brace is longer and has a plurality of embedding apertures.

[0191] The cladding system 1300 comprises a plurality of panels 1302, a brace 1304, and a cured material 1306. The panels 1302 are each formed entirely of natural stone. The brace 1304 is configured to secure the panels 1302 together and is configured to be secured to a substrate, to thereby to secure the cladding system 1300 to the substrate. The cured material 1306 fixes the brace 1304 to the panels 1302. The cured material 1306 is identical to the cured material 1006.

[0192] The plurality of panels 1302 includes two panels, which are identical except for their width. More particularly, the plurality of panels 1302 includes a first panel 1302a and a second panel 1302b. The first panel 1302a is wider than the second panel 1302b, but is otherwise identical. Accordingly, only the first panel 1302a is further described herein, for brevity.

[0193] The panel 1302a is similar to the panel 102, but is wider and has a cavity 1314 that is closer to a top of the panel. The panel 1302a has a front surface 1310 and a rear surface 1312. The distance between the front surface 1310 and the rear surface 1312 defines a thickness of the panel 1302a. The panel 1302a also has a width in a generally horizontal direction, and a heightin a generally vertical direction. The width of the panel 1302a is greater than the height, and the thickness of the panel 1302a is less than both the width and the height. In other embodiments, the relative dimensions of the width, the height, and the thickness of the panel may be different. As will be appreciated, the cladding systems described herein are intended to be used with stone panels having a wide range of different shapes and sizes.

[0194] The cavity 1314 is formed in the rear surface 1312 of the panel 1302a. The cavity 1314 is identical to the cavity 114. Optionally, the cavity 1314 may include grooves, which may be identical to the grooves 916 described above.

[0195] The brace 1304 is identical to the brace 1004, except the brace 1304 is longer and includes a plurality of embedding apertures 1378. Accordingly, the brace 1304 comprises an exposed portion 1342 and embedded portion 1340, and the embedded portion 1340 includes a plunging part and a rising part (as described above). The embedding apertures 1378 are formed in the embedded portion 1340, and are identical to the embedding apertures 1180. The brace 1304 comprises a top portion 1320, a connecting portion 1322, a middle portion 1324, and a bottom portion 1326, which are all identical to those of the brace 1004, except they are longer and the connecting portion 1322 and the bottom portion 1328 include the embedding apertures 1378.

[0196] As mentioned above, the brace 1304 is configured to secure the panels 1302 together. The brace 1304 is also configured to be secured to a substrate. Accordingly, the brace 1304 can be described as being both an interconnecting type of brace and an anchoring type of brace. As used herein, an interconnecting type of brace is a brace that extends between two or more of the panels and secures them together. For example, the interconnecting type of brace can be one in which the embedded portion is embedded in and extends between the cured material in thecavities of two or more of the panels, to secure the two or more of the panels together. As used herein, an anchoring type of brace is one which has an anchoring portion for securing to the substrate, the anchoring portion being exposed from the cured material. Accordingly, in the subject embodiment, the embedded portion 1340 of the brace 1304 is embedded in and extends between the cured material 1306 in the cavities 1314 of the panel 1302a and the panel 1302b, to secure the panels 1302a, 1302b together. In the subject embodiment, the brace 1304 includes an anchoring portion 1332 that is exposed from the cured material 1306 and extends beyond the rear surfaces 1312 of the panels 1302a, 1302b to be secured to a substrate.

[0197] While the subject embodiment has been described as comprising a single brace 1304 that is both the interconnecting type and the anchoring type, it will be appreciated that in other embodiments the cladding system may comprise one or more braces, each of which is the interconnecting type, the anchoring type, or both types. In embodiments with multiple panels, each type may be provided at least once. For example, in some embodiments with multiple panels, the cladding system may include a plurality of braces, at least one of which is only the interconnecting type and at least one of which is only the anchoring type. In such embodiments, the design of the interconnecting type of brace can be different from the design of the anchoring type of brace. However, it will be appreciated that having a single design of brace that can be used as either the interconnecting type, the anchoring type, or both may facilitate ease of manufacturing of the cladding system.

[0198] As will be appreciated, the design of the brace 1304 is very adaptable and allows this brace to be used with stone panels in a variety of arrangements and having a wide range of shapes. That is, the design of the brace 1304 allows for it to be used as either the interconnecting type only, the anchoring type only, or both types. Employing a brace with a design that can beused as the interconnecting type and / or the anchoring type may facilitate assembly of cladding systems. That is, a plurality of identical braces can be manufactured and then assembled with panels, as needed, as either the interconnecting type, the anchoring type, or both types to create a variety of different arrangements for the panels, and thus different looking cladding systems. Moreover, due to the repeating structure of the brace 1304, braces of this design can be cut to whatever length are needed during assembly of the cladding system to accommodate the shape and size of the panels, thereby further increasing adaptability. Preferably, the brace 1304 is at least 36 inches in length. Having a length of at least 36 inches can allow the brace 1304 to span between adjacent studs in a typical timber frame construction. In some embodiments, the brace can have a length in the range of 36 to 40 inches.

[0199] As will be appreciated, the number and types of braces in a cladding system will depend on the arrangement and shape of the panels. However, it is generally preferably to have anchoring braces near the top and side edges of the cladding system, to facilitate installation and to resist gravity and other forces on the cladding system once installed.

[0200] FIGS. 46 to 51 show another embodiment of a cladding system that is generally identified by reference character 1400. The cladding system 1400 is similar to the cladding system 1300, and like elements are denoted with like reference characters incremented by 100. Elements of the cladding system 1400 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the cladding system 1400 is identical to the cladding system 1300, except for the number, dimensions, and arrangement of the panels, and except for at least some of the braces.

[0201] The cladding system 1400 comprises a plurality of panels 1402, a plurality of braces1404, and a cured material 1406. The panels 1402 are each formed entirely of natural stone (i.e.,are natural stone panels). The plurality of braces 1404 is configured to secure the panels 1402 together and is configured to secure the cladding system 1400 to a substrate. The cured material 1406 fixes the braces 1404 to the panels 1402. The cured material 1406 is identical to the cured material 1306.

[0202] The plurality of panels 1402 includes three panels. More particularly, the plurality of panels 1402 includes a first panel 1402a, a second panel 1402b, and a third panel 1402c. As shown in FIG. 46, the arrangement of the panels 1402 provides a generally rectangular shape for the cladding system 1400, which may facilitate installation of multiple cladding systems 1400 on the substrate in close proximity to one another. In the subject embodiment, two of the panels 1402a, 1402b are stacked and position to a single side of the third panel 1402c. Accordingly, the widths of the two panels 1402a, 1402b are approximately equal to each other, and the combined heights of the two panels 1402a, 1402b are approximately equal to the height of the third panel 1402c. Although, in other embodiments, the widths and the heights of the panels may be differed. As will be appreciated, the cladding systems described herein are intended to be used with stone panels having a wide range of different shapes and sizes.

[0203] Each of the panels 1402 is similar to the panel 1302a described above, but has a different number of cavities formed therein, and some have different dimensions (as shown in the figures). Accordingly, each of the panels 1402 has a front surface 1410 and a rear surface 1412.

[0204] A plurality of cavities 1414 are formed in the rear surface 1412 of each of the panels1402. The first panel 1402a and the second panel 1402b each have two cavities 1414 formed in the rear surface 1412 thereof, and those two cavities 1414 are aligned generally perpendicular to each other. The third panel 1402c has three cavities 1414 formed in the rear surface 1412thereof, with two of the cavities 1414 being arranged parallel to each other and perpendicular to the third of the cavities 1414. Each of the cavities 1414 is identical to the cavity 114, and may be formed in the same ways described above. Optionally, one or more of the cavities 1414 may include grooves, which may be identical to the grooves 916 described above.

[0205] The plurality of braces 1404 comprises four braces 1404a, 1404b, 1404c, 1404d. The brace 1404a is identical to the brace 1304. The braces 1404b, 1404c are identical to the brace 1304, except they are each shorter in length and are oriented in generally horizontal directions. Accordingly, each of the braces 1404a, 1404b, 1404c comprises a top portion 1420, a connecting portion 1422, a middle portion 1424, and a bottom portion 1428, and each of the braces 1404a, 1404b, 1404c include an embedding portion 1440 and an exposed portion 1442. As will be appreciated, all of the braces 1404a, 1404b, 1404c are identical to each other, without regard to their lengths and orientations (that is, these braces are identical if you do not take into account their lengths or their orientations). Providing multiple braces that are all identical can facilitate manufacturing. That is, the identical braces can be manufactured in bulk and then cut to size and assembled as needed based on the size and shape of the panels in the cladding system. The brace 1404d is identical to the brace 1304, except the top portion is omitted. Accordingly, the brace 1404d comprises a connecting portion 1422, a middle portion 1424, and a bottom portion 1428 but not a top portion, and includes an embedding portion 1440 but not an exposed portion. Each of the braces 1404 comprise a plurality of embedding apertures 1478 and a plurality of embedding features 1460, which are identical to the embedding apertures 1378 and the embedding features 1060 described above, respectively.

[0206] Each of the braces 1404a, 1404b, 1404c includes an anchoring portion 1432 that is exposed from the cured material 1406 and extends beyond the rear surface 1412 of at least one ofthe panels 1402. Each of the anchoring portions 1432 includes a plurality of anchoring apertures 1430, which are identical to the anchoring apertures 1030 described above. When installing the cladding system 1400 on a substrate, a plurality of suitable fasteners are received through the anchoring apertures 1430 and extend into the substrate to secure the cladding system 1400 thereto.

[0207] When multiple instances of the cladding system 1400 are installed on a substrate, it may be generally desirable to locate the cladding systems 1400 in close proximity to each other. For example, it may be aesthetically desirable to have adjacent cladding systems 1400 touching, or nearly touching, each other. To facilitate close installation of the cladding systems disclosed herein without interference between the anchoring portions of adjacent braces, the cladding systems may include a peripheral gap as described below.

[0208] FIGS. 51 A and 5 IB show two instances of the cladding system 1400 in close proximity to each other. As will be appreciated, the left side of one of the cladding systems 1400 is touching, or nearly touch, the right side of the other one of the cladding system 1400. To facilitate this close proximity, a gap 14801 is provide between the braces 1404 and the rear surfaces 1412 of the panels 1402 to which they are fixed, near a periphery of the cladding systems 1400. When the cladding systems 1400 are positioned side-by-side, the anchoring portion 1432 of one of the braces 1404 of one of the cladding systems 1400 is at least partially received in the gap 1480 of the other one of the cladding system 1400 (as shown in FIG. 5 IB). By receiving the anchoring portion 1432 in the gap 1480, the cladding systems 1400 can be positioned with sides that are touching, or nearly touching, without the braces 1404 at the adjacent sides interfering with each other or interfering with the sides of the stone panels 1402. As will be appreciated, when the anchoring portion 1432 is received in the gap 1480, it may notbe possible to receive a fastener through that anchoring portion 1432 to secure the cladding system 1400 to a substrate. However, fasteners can be received through the other anchoring portions 1432 in the cladding system 1400, to allow the cladding system 1400 to be sufficiently secured to the substrate. In the subject embodiment, the gap 1480 is at least 1 mm. In some embodiments, the gap is preferably in the range of about 1 to 25 mm.

[0209] FIGS. 52 to 54 are enlarged views of one of the braces 404. As described above, the brace 404 comprises a top portion 420, a connecting portion 422, a middle portion 424, and a bottom portion 428. The top portion 420 is connected to the middle portion 424 by the connecting portion 422, and the bottom portion 428 is connected to an opposite end of the middle portion 424 from the connecting portion 422. The top portion 420 includes an anchoring aperture 430 for receiving a fastener therethrough.

[0210] The brace 404 further comprises an embedding feature 460. The embedding feature 460 is located in the embedded portion 440 of the brace 404. In the subject embodiment, the embedding feature 460 is located in the middle portion 424 of the brace 404. The embedding feature 460 comprises a plurality of holes 462 that are formed through the middle portion 424 of the brace 404. The holes 462 are triangular in shape and define a cross 464 therebetween. The embedding feature 460 can help to secure the embedded portion 440 in the cured material 406. For example, the cured material 406 may flow around the cross 464 and through the holes 462 before the cured material 406 hardens, such that the embedding feature 460 is fully encased in the cured material 406 once hardened. Additionally, the holes 462 of the embedding feature 460 can help to reduce the amount of material used to manufacture the brace 404, thereby reducing cost and weight.

[0211] FIGS. 55 to 57 show another embodiment of a brace that is generally identified by reference character 1504. The brace 1504 is similar to the brace 404, and like elements are denoted with like reference characters incremented by 1100. Elements of the brace 1504 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the brace 1504 is identical to the brace 404, except for the embedding feature in the middle portion. Accordingly, the brace 1504 comprises a top portion 1520, a connecting portion 1522, a middle portion 1524, and a bottom portion 1528, which are all identical to those of the brace 404, except for the embedding feature 1560 described below.

[0212] The embedding feature 1560 comprises a pair of legs 1562 (or tabs). The legs 1562 are formed in the middle portion 1524 of the brace 1504. The legs 1562 can help to create space for the cured material to flow under and around the brace 1504 before the cured material hardens, which can help to embed the middle portion 1524 of the brace in the cured material once it hardens. This can result in a stronger bond between the cured material and the embedded portion of the brace.

[0213] As shown in FIG. 57, each of the legs 1562 extends at an angle from a body 1564 of the middle portion 1524. Accordingly, each of the legs 1562 defines a respective leg angle 9 between the body 1564 and a longitudinal axis 1566 of the leg 1562. The leg angle 9 may be less than 90 degrees. In a preferred embodiment, the leg angle 9 is in the range of 35 to 45 degrees, and more preferably the leg angle 9 is approximate 45 degrees. In some embodiments, the legs 1562 may be oriented in different directions, for example as shown in FIG. 55. In other embodiments, the legs 1562 may be oriented in the same direction.

[0214] FIGS. 58 am 59 show another embodiment of a brace that is generally identified by reference character 1604. The brace 1604 is similar to the brace 404, and like elements aredenoted with like reference characters incremented by 1200. Elements of the brace 1604 that are identical to those described above may not be further described herein, for brevity. As will be appreciated, the brace 1604 is identical to the brace 404, except the middle portion does not include an embedding feature. Accordingly, the brace 1604 comprises a top portion 1620, a connecting portion 1622, a middle portion 1624, and a bottom portion 1628, which are all identical to those of the brace 404, except for the omitted embedding feature. Omitting the embedding feature can help to simplify the construction of the brace 1604, which may be desirable in some instances.

[0215] Although the panels are described herein as being formed entirely of natural stone, in other embodiments one or more panels may be formed substantially of natural stone, or may be formed with a majority of natural stone.

[0216] Although the embedding feature 460 has been shown and described herein as comprising a plurality of triangular holes in the middle portion of the brace and defining a cross therebetween, it will be appreciated that in other embodiments the embedding feature may comprise a plurality of circular holes, or other shapes of holes in a suitable pattern.

[0217] Although the embedding feature 1560 has been shown and described herein as a plurality of legs (or tabs), it will be appreciated that in other embodiments the embedding feature may comprise a plurality of another type of projecting element. In some embodiments, the embedding feature may be a single projecting element, such as a single leg (or tab).

[0218] Although embodiments of the cladding system have been described herein that include a spacer portion, such as the spacer portion 950, it will be appreciated that in other embodiments the spacer portion may be omitted. For example, in such embodiments, the risingpart may terminate before or at the surface of the cured material, such that the spacer portion is omitted.

[0219] Although embodiments have been described above and are shown in the accompanying drawings, it will be appreciated by those skilled in the art that variations and modifications may be made without departing from the scope as defined by the appended claims, and the scope of the claims should be given the broadest interpretation consistent with the specification as a whole.

[0220] The above detailed description of the embodiments is not intended to be exhaustive or to limit the invention to the precise form disclosed above or to the particular field of usage mentioned in this disclosure. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. Also, the teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.

[0221] All of the above patents and applications and other references, including any that may be listed in accompanying filing papers, are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions, and concepts of the various references described above to provide yet further embodiments of the invention.

[0222] Changes can be made to the invention in light of the above "Detailed Description of Embodiments". While the above description details certain embodiments of the invention and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Therefore, implementation details may varyconsiderably while still being encompassed by the invention disclosed herein. Particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated, unless specifically stated otherwise.

[0223] While certain aspects of the invention are presented below in certain claim forms, the inventors contemplate the various aspects of the invention in any number of claim forms. Accordingly, the inventors reserve the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the invention.

[0224] The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous changes and modifications will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all such suitable changes or modifications in structure or operation which may be resorted to are intended to fall within the scope of the claimed invention.

[0225] Although specific embodiments have been described above and are shown in the accompanying drawings, various embodiments of the disclosure will be further understood and are described in the following clauses:Clause 1. A cladding system comprising: a plurality of natural stone panels, each of the panels having one or more cavities formed therein; a cured material within the cavities of the panels, the cured material being bonded to the panels; andat least one brace for securing the panels together and to a substrate, each brace having an embedded portion that is embedded in the cured material to fix the brace to one or more of the panels, and each brace being one or more of the following types, such that each type is provided at least once: an interconnecting type, in which the embedded portion is embedded in and extends between the cured material in the cavities of two or more of the panels, and an anchoring type, which has an anchoring portion for securing to the substrate, the anchoring portion being exposed from the cured material.Clause 2. The cladding system of clause 1, wherein the at least one brace includes one or more braces that are both the interconnecting type and the anchoring type.Clause 3. The cladding system of clause 1 or 2, wherein the at least one brace includes at least two braces, at least one of which is only the anchoring type and at least one of which is only the interconnecting type.Clause 4. The cladding system of any one of clauses 1 to 3, wherein all of the braces are identical, without regard to their lengths and orientations.Clause 5. The cladding system of any one of clauses 1 to 4, wherein the plurality of panels includes at least three panels, two of which are stacked and positioned to a single side of the third.Clause 6. The cladding system of any one of clauses 1 to 5, wherein the anchoring portion extends beyond a periphery of the plurality of panels and includes an anchoring aperture for receiving a fastener to secure the brace that is the anchoring type to the substrate.Clause 7. The cladding system of any one of clauses 1 to 6, wherein at least one of the cavities has a plurality of groves formed in an innermost surface.Clause 8. The cladding system of any one of clauses 1 to 7, wherein each of the cavities is formed in a rear surface of the respective panel.Clause 9. The cladding system of any one of clauses 1 to 8, wherein, for one or more braces that are the anchoring type, a gap is provided between the anchoring portion and the one or more panels to which the braces are fixed via the cured material.Clause 10. The cladding system of clause 9, wherein the gap is at least 1 mm.Clause 11. The cladding system of any one of clauses 1 to 10, wherein the embedded portion includes at least one embedding feature.Clause 12. The cladding system of clause 11, wherein the embedding feature includes a plurality of holes that define a cross therebetween.Clause 13. The cladding system of clause 11, wherein the embedding feature includes at least one projecting element.Clause 14. The cladding system of any one of clauses 1 to 13, wherein the cured material is at least one of epoxy, adhesive, concrete, plaster, and clay.Clause 15. The cladding system of any one of clauses 1 to 14, wherein the anchoring portion extends from a surface of the cured material by a distance of at least 8 mm.Clause 16. A cladding system comprising: a natural stone panel having one or more cavities formed therein; a cured material within the cavities of the panel, the cured material being bonded to the panel; and at least one brace for securing the panel to a substrate, the brace having an embedded portion and an exposed portion, the embedded portion being embedded in the cured material, the exposed portion being exposed from the cured material and including an anchoring portion for securing to the substrate, and the embedded portion having: a plunging part that increases in depth within the cured material as it extends away from the exposed portion; and a rising portion that decreases in depth within the cured material as it extends away from the plunging part.Clause 17. The cladding system of clause 16, wherein the plunging part increases in depth as it extends away from the anchoring portion.Clause 18. The cladding system of clause 16 or 17, wherein the plunging part and the rising part cooperate to partially surround a plug of the cured material.Clause 19. The cladding system of clause 18, wherein one or more sides of the plug are directly connected to the cured material that is adjacent to the plug.Clause 20. The cladding system of clause 18 or 19, wherein the plug extends across an entire width of the brace.Clause 21. The cladding system of any one of clauses 16 to 20, wherein the plunging part and the rising part define an angle of direction change therebetween that is in the range of 90 to 180 degrees.Clause 22. The cladding system of any one of clauses 16 to 21, wherein the embedded portion completely reverses direction within the cured material.Clause 23. The cladding system of any one of clauses 16 to 22, wherein the rising part is directly connected to the plunging part, and the plunging part is directly connected to the exposed portion.Clause 24. The cladding system of any one of clauses 16 to 23, wherein the anchoring portion extends beyond a periphery of the panel and includes an anchoring aperture for receiving a fastener to secure the brace to the substrate.Clause 25. The cladding system of any one of clauses 16 to 24, wherein at least one of the cavities has a plurality of groves formed in an innermost surface.Clause 26. The cladding system of any one of clauses 16 to 25, wherein each of the cavities is formed in a rear surface of the panel.Clause 27. The cladding system of any one of clauses 16 to 26, wherein a gap is provided between the anchoring portion and the panel.Clause 28. The cladding system of clause 27, wherein the gap is at least 1 mm.Clause 29. The cladding system of any one of clauses 16 to 28, wherein the embedded portion includes at least one embedding feature.Clause 30. The cladding system of clause 29, wherein the embedding feature includes a plurality of holes that define a cross therebetween.Clause 31. The cladding system of clause 29, wherein the embedding feature includes at least one projecting element.Clause 32. The cladding system of any one of clauses 16 to 31, wherein the cured material is at least one of epoxy, adhesive, concrete, plaster, and clay. Clause 33. The cladding system of any one of clauses 16 to 32, wherein the exposed portion extends from a surface of the cured material by a distance of at least 8 mm.

Claims

CLAIMSWhat is claimed is:

1. A cladding system comprising: a plurality of natural stone panels, each of the panels having one or more cavities formed therein; a cured material within the cavities of the panels, the cured material being bonded to the panels; and at least one brace for securing the panels together and to a substrate, each brace having an embedded portion that is embedded in the cured material to fix the brace to one or more of the panels, and each brace being one or more of the following types, such that each type is provided at least once: an interconnecting type, in which the embedded portion is embedded in and extends between the cured material in the cavities of two or more of the panels, and an anchoring type, which has an anchoring portion for securing to the substrate, the anchoring portion being exposed from the cured material.

2. The cladding system of claim 1, wherein the at least one brace includes one or more braces that are both the interconnecting type and the anchoring type.

3. The cladding system of claim 1 or 2, wherein the at least one brace includes at least two braces, at least one of which is only the anchoring type and at least one of which is only the interconnecting type.

4. The cladding system of any one of claims 1 to 3, wherein all of the braces are identical, without regard to their lengths and orientations.

5. The cladding system of any one of claims 1 to 4, wherein the plurality of panels includes at least three panels, two of which are stacked and positioned to a single side of the third.

6. The cladding system of any one of claims 1 to 5, wherein the anchoring portion extends beyond a periphery of the plurality of panels and includes an anchoring aperture for receiving a fastener to secure the brace that is the anchoring type to the substrate.

7. The cladding system of any one of claims 1 to 6, wherein at least one of the cavities has a plurality of groves formed in an innermost surface.

8. The cladding system of any one of claims 1 to 7, wherein each of the cavities is formed in a rear surface of the respective panel.

9. The cladding system of any one of claims 1 to 8, wherein, for one or more braces that are the anchoring type, a gap of at least 1 mm is provided between the anchoring portion and the one or more panels to which the braces are fixed via the cured material.

10. The cladding system of any one of claims 1 to 9, wherein the anchoring portion extends from a surface of the cured material by a distance of at least 8 mm.

11. A cladding system comprising: a natural stone panel having one or more cavities formed therein; a cured material within the cavities of the panel, the cured material being bonded to the panel; and at least one brace for securing the panel to a substrate, the brace having an embedded portion and an exposed portion, the embedded portion being embedded in the cured material, the exposed portion being exposed from the cured material and including an anchoring portion for securing to the substrate, and the embedded portion having: a plunging part that increases in depth within the cured material as it extends away from the exposed portion; and a rising portion that decreases in depth within the cured material as it extends away from the plunging part.

12. The cladding system of claim 11, wherein the plunging part increases in depth as it extends away from the anchoring portion.

13. The cladding system of claim 11 or 12, wherein the plunging part and the rising part cooperate to partially surround a plug of the cured material.

14. The cladding system of claim 13, wherein one or more sides of the plug are directly connected to the cured material that is adjacent to the plug.

15. The cladding system of claim 13 or 14, wherein the plug extends across an entire width of the brace.

16. The cladding system of any one of claims 11 to 15, wherein the plunging part and the rising part define an angle of direction change therebetween that is in the range of 90 to 180 degrees.

17. The cladding system of any one of claims 11 to 16, wherein the embedded portion completely reverses direction within the cured material.

18. The cladding system of any one of claims 11 to 17, wherein the rising part is directly connected to the plunging part, and the plunging part is directly connected to the exposed portion.

19. The cladding system of any one of claims 11 to 18, wherein the anchoring portion extends beyond a periphery of the panel and includes an anchoring aperture for receiving a fastener to secure the brace to the substrate.

20. The cladding system of any one of claims 11 to 19, wherein at least one of the cavities has a plurality of groves formed in an innermost surface.

21. The cladding system of any one of claims 11 to 20, wherein each of the cavities is formed in a rear surface of the panel.

22. The cladding system of any one of claims 11 to 21, wherein a gap of at least 1 mm is provided between the anchoring portion and the panel.

23. The cladding system of any one of claims 11 to 22, wherein the exposed portion extends from a surface of the cured material by a distance of at least 8 mm.

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