CA2589263A1

CA2589263A1 - A weatherboard system and related means of/or providing a weatherboard assembly

Info

Publication number: CA2589263A1
Application number: CA002589263A
Authority: CA
Inventors: Jeffery Kenneth Tanner
Original assignee: Individual
Current assignee: PUREPINE MOULDINGS Ltd
Priority date: 2004-12-02
Filing date: 2005-11-30
Publication date: 2006-06-08
Also published as: WO2006059912A1; KR20070105309A; EP1831479A1; EP1831479A4; JP2008522063A

Abstract

Weatherboard system for fixing overlapping sidings, comprises a first weatherboard (7) having a slot (4) into which a fixing block (5) is provided that receives a nail (45) that passes through the inner most board at the overlap, wherein the block clips to the outermost weatherboard at the overlap in a groove (12).

Description

A WEATHERBOARD SYSTEM AND RELATED MEANS OF/OR
PROVIDING A WEATHERBOARD ASSEMBLY
FIELD OF THE INVENTION
The present invention relates to a weatherboard system and related means of/or providing a weatherboard assembly.
In particular, although not solely, the invention relates to a weatherboard system for use on an external surface of a building structure, the system may be provided for installation in kitset form.

BACKGROUND OF THE INVENTION
Different configurations of weatherboard systems are known within the art. Generally, weatherboards are used to line or clad the externals of a house or building for the purposes of protection against natural elements and for providing a means of insulating warmth for occupants inside.
A typical weatherboard system in New Zealand, secures weatherboards to the framing structure of a house or building where individual panels are fastened to the frame studs in a horizontal, complimentary and overlapping formation, such that the panels angle outward and downwards. Use of such weatherboards has proven popular as a result of the system providing for low cost construction.
Over time, variations on the weatherboard system have been able to provide aesthetically pleasing house cladding while still taking advantage of the low cost construction method.
Patent specifications US3866378 and US2276170 represent typical weatherboard fastening systems within the art. US3866378 provides an architectural siding or panel system for buildings and the like. The system described incorporates thin film or flexible plastic material covering a panel board. Flexible panels are secured to each other at unexposed edges or areas using a dual groove and complimentary locking strip. Securing of each of the panel boards within the unexposed regions is performed utilising dual grooves and a fixing block means so that the overlapping edge is located to the overlapped edge. Direct fastening to the wall stud is formed by the use of a nail at the top edge of the overlapped panel.
US22761710 further provides for a weatherboard system utilising a similar overlapping configuration where the innermost edge of a panel is nailed into a frame stud as is done traditionally. Engaging panel surfaces (at the overlap regions of the panel edges) exhibit grooves on complimentary sides and are used to house fabricated cleats, positioned and located so that both form an engageable securing means to locate the panels proximal to each other. The upper edge of the panel is nailed into the housing structure thus hidden by the overlapping region.
In both instances above, the weatherboard systems described still introduce a degree of complexity which can detract from the economic and assembly advantages of the system in general. For example, US3866378 requires two independent yet coinplimentary grooves to be manufactured into the panel boards. Further, each panel board is subsequently wrapped with a thin film and/or flexible plastic material which envelops each panel board. This may offer other advantages depending upon customer needs, however, the added complexity in both component fabrication and preparation increases the overall cost to the consumer.
This similarly applies with the weatherboard system described in US2276170. This invention utilises a complimentary cleat system where both overlapping and complimentary weatherboard panels require grooves and cleats both being complimentary and engaging for securing purposes. This entails further processing and preparation of the individual panels resulting in extra cost to the end user.
Accordingly, it is an object of the present invention to provide a cost effective weatllerboard assembly and/or system for installation external of a house, dwelling or building structure which addresses the above disadvantages of current weatherboard systems and/or which at least provides the public with a useful choice.

BRIEF DESCRIPTION OF THE INVENTION

In a first aspect the present invention consists in a weatherboard system, for fixing a plurality of horizontally extending weatherboards in partial overlapping relationship, against a structure to be clad, said weatherboard system including;

a first weather board (herein after "upper more weatherboard") that presents a longitudinally extending first face that in use faces said structure to be clad, and a longitudinally extending second face that in use faces away from said structure to be clad, and a longitudinally extending third face that in use projects away from said structure to be clad, yet faces said structure to be clad, a slot provided in, and extending longitudinally along said third face of said upper weather board, a second weatherboard ( herein after "lower more weather board") that presents, a longitudinally extending first face that in use faces the structure to be clad, a longitudinally extending second face that in use faces away from said structure to be clad and partially overlaps with said third face of said first board, a longitudinally extending third face that in use projects away from said structure to be clad, yet faces, said structure to be clad, a fixing block adapted to receive a penetrative fastener, said fixing block to be engaged at or proximate the upper edge of said second face of said lower more weather board and by said fastener to become secured to said structure to be clad, said fixing block to be inserted into said first slot for fastening said upper more weatherboard to said structure to be clad.

Preferably said fastener can pass through said lower more weatherboard to fasten said lower more weatherboard to said structure to be clad.

Preferably a surface relief is provided in and extending longitudinally along the second face of said like weatherboard, said fixing block to locate with said lower more weather board at said surface relief.

Preferably a plurality of fixing blocks are provided at discrete locations along each said weatherboard.

Preferably a single fixing block extends a substantial part of the slot.
Preferably said fixing block includes an aperture through which said fastener can extend.

Preferably said fastener is a nail.

Preferably said nail when in use, sits flush with a surface of said fixing block and passes through said lower more weatherboard.

Preferably said first face of said lower more weatherboard sits flush against said structure to be clad.

Preferably said second face of said lower more weatherboard sits flush against the third face of said upper more weatherboard.

Preferably said surface relief of said lower more weatherboard is provided at or towards the upward most longitudinal edge of said lower more weatherboard.

Preferably said slot of said upper more weatherboard is provided towards the lower most longitudinally extending edge of said upper more weatherboard.

Preferably in location, no substantial gap exists at the region of overlap of said upper and lower more weatherboards.

Preferably said fixing block is a plastic fixing block.
Preferably said fixing block is a wooden fixing block.

Preferably said fixing block has been separated from a continuous cross section elongate member of a cross section identical to that of the fixing block.
Preferably said slot includes an undercut upper longitudinally extending slot wall and said fixing block includes an upper surface to sit contiguous said longitudinally extending slot wall.

Preferably said fixing block in a vertical cross section perpendicular to said longitudinal direction includes a surface to engage said slot in a manner to prevent said slot moving in a horizontal direction.

Preferably said surface is an upwardly facing and structure facing surface of said fixing block.

In a further aspect the present invention consists in a building that has as cladding, the weatherboard system as hereinbefore described.

In a further aspect the present invention consists in a weatherboard system as hereinbefore described and with reference to the accompanying drawings.

In a further aspect the present invention consists in a building which is cladded by a weatherboard system as hereinbefore described with reference to the accoinpanying drawings.

Preferably said fixing block is engaged to the second weatherboard when the weatherboard is in-situ.

Preferably said fixing block is inserted with the slot of said first weatherboard in a manner to prevent the movement of said first weatherboard once engaged with said fixing block in a direction outwardly from said structure.

In a further aspect the present invention consists in a method of cladding a structure by engaging an upper more weatherboard that presents a longitudinally extending first face that in use faces said structure to be clad, and a longitudinally extending second face that in use faces away from said structure to be clad, and a longitudinally extending third face that in use projects away from said structure to be clad, yet faces said structure to be clad, a slot provided in, and extending longitudinally along said third face of said upper weather board, to a a lower more weather board that presents, a longitudinally extending first face that in use faces the structure to be clad, a longitudinally extending second face that in use faces away from said structure to be clad and partially overlaps with said third face of said first board, a longitudinally extending third face that in use projects away from said structure to be clad, yet faces, said structure to be clad, where a fixing block is engaged at or proximate the upper edge of said second face of said lower more weather board by a penetrative fastener passing though said lower most weatherboard, holding said lower more weather board to said fixed stucture, by inserting fixing block into the slot of said upper more weatherboard.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention will now be described with reference to the accompanying drawings wherein, Figure 1A shows a schematic perspective view of a single weatherboard panel when viewed from an angle internal to the panelling, Figure 1B shows a perspective schematic view of a single weatherboard panel illustrating the engaging relationship with a fixing block, Figure 2 shows a schematic perspective view of multiple weatherboard panels assembled with a cutaway portion showing the internal assembly configuration, Figure 3A shows a close up schematic view of the fixing block secured in accordance with the present invention as identified in Figure 3B, and Figure 3B shows a schematic view of an assembly of panels to a framework providing a cutaway and sectional view of assembly points in accordance with the present invention and cutaway assembly of the panels as applied and assembled to a housing structure, and Figure 4 shows a sectional view of multiple weatherboard panels assembled with a cutaway portion showing the internal assembly configuration.
DETAILED DESCRIPTION OF THE INVENTION
The most preferred embodiment of the present invention can be seen as illustrated in Figures 1 through 3.

Figure 1A shows a perspective view of a portion of a weatherboard or weatherboard panel 7 in accordance with the present invention. The weatherboards 7 are normally a moulded timber component of a constant cross section over its entire length. Such weatherboards 7 will include an external face 27 which is predominantly exposed to the exterior of the building. This exterior face will be primed and painted to provide a weather surface to exclude rain, wind and cold air to a certain extent from entering the building. The weatherboards 7 are engaged to a frame work structure 9 of a building in an overlapping condition to each other. As such the exterior face 27, although substantially planar, is not oriented in a vertical condition. It is slightly angled to the vertical and as such a particular profile of the weatherboard 7 is often incorporated so that the weatherboard 7 can assume such an angled condition yet still be securely affixed to the structure 9 of the building. The weatherboard will include a bevelled surface 28 being at an angle to the exterior surface 27.
The bevelled surface 28 will sit flush against parts of the structure 9 of the building.
A lower weatherboard 6, as for example shown in Figure 3B, will include an upper edge 30 and a lower edge 40. The upper edge 30 is juxtaposed the lower edge 40 of the upper weatherboard 7. Likewise the upper weatherboard 7 has an upper edge 30 which will be juxtaposed the lower edge of the upper weatherboard 8. An overlap occurs between weatherboards to an extent sufficient to allow for components within the overlap to be provided for securing both the upper edge 30 of a weatherboard to the structure 9 and for securing the lower edge 40 of a weatherboard to the upper edge of a weatherboard immediately below. Such affixing of weatherboards together occurs by the use of a fixing block 1.
Each of the weatherboards is modified by including a slot or groove at both its upper edge 30 and at its lower edge 40 for the purposes of locating the fixing block 1. At the upper edge of a weatherboard panel 7, a first groove surface 12 is manufactured along the length of the weatherboard into the exterior surface. Figure lA and 1B illustrate this as being a cut-away portion but it may equally be a distinct groove embedded close to the uppermost edge of the weatherboard. Alternatively, the grooves may be fmite length recesses or cut-away portions centred at periodic distances along the length of each panel 7 corresponding to the wall studs of the building structure and able to receive the fixing block 1 units.
A further modification to the weatherboard 7 is a second groove 4 manufactured into the interior facing surface of the weatherboard 7 at the lower edge and extending along the entire length of the weatherboard 7. Similarly, the recess may be a groove or a cut-away as is achieved for the first groove. The grooves may also be fmite length recesses or cut-away portions centred at periodic distances along the length of each weatherboard 7 corresponding to the same as is used for the first grooves.
Figure 1A shows also a schematic view of a fixing block 1 used to fasten the top edge of the weatherboard 7 at the surface 12 to the building structure 9.
The fixing block 1 is also the fundamental component used to locate and secure the interior lower edge of an upper weatherboard panel 7 or 8. Figure 1A
indicates the direction required for it to be engageable to the coinplimentary second groove 4 associated with the interior lower edge of the weatherboard 7.
Insertion of the fixing block 1 is shown in Figure 1B where the weatherboard 7 is located and thus assembled to the fixing block 1 as indicated. It must be noted that Figure lA and 1B both present a perspective view looking toward the internal face of a weatherboard of the present invention. This is to better visualise the way and means with which the fixing block engages the second groove provided within the lower interior edge of the weatherboard 7.
In accordance with the most preferred embodiment of the present invention, the fixing block 1 is a block of finite longitudinal length (aligned with the elongate direction of a weatherboard) and of constant cross section throughout. The block comprises a first elongate surface 12A which juxtaposes the inner surface of the first groove 12 when assembling a weatherboard system of the present invention. It may be appreciated that the fixing block 1 may be equal in length to that of the weatherboard 7 thus extending the entire length of the weatherboard. In this instance, the holes 5 for receiving a fastening means 45 (nail, screw, or the like) may be at periodic or independent distances along the length of the fixing block 1. This alternative embodiment establishes further utility as a more secure seal provides for additional weather resistance in that the resistance to encroaching water is increased when moisture attempts to enter the cladding system from underneath an upper weatherboard.

The cross section of the fixing block 1, from the first elongate surface, presents an outward projection to defining the surface 10 to locate within the second groove 4 of the lower edge of the weatherboard 7 when assembled.
Preferably, the projection is of an upward and outward nature to secure within the second groove 4. The fixing block 1 may also be of any cross section which provides for an appropriate abutment with the inner surface within the first groove 12 of the upper exterior edge of the weatherboard 7 and allows for a cross sectional projection to be appropriately engageable by the second groove 4. It will be appreciated that the cross section of the projection of the fixing block 1 will be complimentary to the cross section of the second groove 4 within the lower edge of the weatherboard 7. The complimentary nature of the projection of the fixing block 1 and the second groove 4 provides for the appropriate location and securement of the overlapping panel edge to be achieved.

Figure 2 presents. a perspective view of a plurality of weatherboards fastened as preferred by the present invention. As shown, a cross sectional slice through the assembly points has been made at the locations of which the boards are secured. Shown in Figure 2 is the way and means to which a weatherboard is aligned aild secured in relation to a stud frame. Preferably, this is done using a nail 45 (as shown in Figure 4) or similar fastening device through the hole 5 as indicated in Figure lA. From Figure 2 it is easily appreciated as to how the fixing block 1 provides a singular fastening of the lower overlapped edge weatherboard to the upper edge of the lower panel while securing the -ZZ-overlapping edge weatherboard and providing for a simple bottom to top assembly of such.
A further schematic of that shown in Figure 2 is illustrated in Figure 3.
Figure 3B presents a schematic view of two weatherboards 6, 7 assembled in accordance with the present invention as fastened to framing studs 9 of a standard house frame structure. The weatherboard 7 has been cut at a location in which a fixing block 1 has been used to further visualise the internal assembly arrangement. The lower inost weatherboard 6 exhibits a fixing block 1 which is further presented in Figure 3A. The order of assembly of the panel boards in accordance with the present invention is also illustrated in Figure 3B where the uppermost weatherboard 8 is shown prior to assembly with the lower weatherboard 7 in accordance with the directions as identified by the accompanying arrows.
By the use of Figures 2 and 3 it may be appreciated as to the ease of assembly of a weatherboard in accordance with the present invention. Assembly would begin with a lower most weatherboard being installed at the base of the house frame to establish a reference from which to begin assembling and forming the overlapping formation. Once the lowermost weatherboard has been levelled appropriately, the fixing block 1 is secured to each fraine stud 9 using a nai145 or similar fastening means through the hole 5 provided (shown in Figure 45). In each case, the fixing block 1 is placed on the surface 12 and nailed into the stud 9 securing both the upper edge of the panel and fastening to the frame stud 9.
Once achieved across the length of the weatherboard at all stud 9 locations, the subsequent overlapping panel may be inserted in place so that the internal face 28 is juxtaposed against the frame stud 9 above the lower weatherboard. It may be appreciated that the angle at this surface is directly consequential to the outward projection (angle of) at which the surface 2 makes with the vertical side of the house.
Further manoeuvring of the weatherboard may be required to vertically lower the panel such that the uppermost surface of the fixing block 1 rests comfortably against the uppermost face down surface of the internal groove 4 of the interior side of the weatherboard. Once in position, the process continues where further fixing blocks 1 are then fastened at the appropriate stud 9 positions for engagement with the subsequent (upper) weatherboard.
The fastener or penetrative.fastener as herein described may be a nail, but may instead by a screw.
Where the term "facing" is used herein with reference to surfaces, it is to be understood to not be limited to being parallel surfaces. It is to be understood that the normal to such a surface projects to another surface or a plane of said other surface, yet may also project in a direction non parallel to the other surface.

Claims

1. A weatherboard system, for fixing a plurality of horizontally extending weatherboards in partial overlapping relationship, against a structure to be clad, said weatherboard system including;

a first weather board (herein after "upper more weatherboard") that presents a longitudinally extending first face that in use faces said structure to be clad, and a longitudinally extending second face that in use faces away from said structure to be clad, and a longitudinally extending third face that in use projects away from said structure to be clad, yet faces said structure to be clad, a slot provided in, and extending longitudinally along said third face of said upper weather board, a second weatherboard ( herein after "lower more weather board") that presents, a longitudinally extending first face that in use faces the structure to be clad, a longitudinally extending second face that in use faces away from said structure to be clad and partially overlaps with said third face of said first board, a longitudinally extending third face that in use projects away from said structure to be clad, yet faces, said structure to be clad, a fixing block adapted to receive a penetrative fastener, said fixing block to be engaged at or proximate the upper edge of said second face of said lower more weather board and by said fastener to become secured to said structure to be clad, said fixing block to be inserted into said first slot for fastening said upper more weatherboard to said structure to be clad.

2. A system as claimed in claim 1 wherein said fastener can pass through said lower more weatherboard to fasten said lower more weatherboard to said structure to be clad.

3. A system as claimed in claims 1 or 2 wherein a surface relief is provided in and extending longitudinally along the second face of said like weatherboard, said fixing block to locate with said lower more weather board at said surface relief.

4. A weatherboard system as claimed in any one of claims 1 to 3 wherein a plurality of fixing blocks are provided at discrete locations along each said weatherboard.

5. A weatherboard system as claimed in any one of claims 1 or 4 wherein a single fixing block extends a substantial part of the slot.

6. A weatherboard system as claimed in any one of claims 1 to 5 wherein said fixing block includes an aperture through which said fastener can extend.

7. A weatherboard system as claimed in any one of claims 1 to 6 wherein said fastener is a nail.

8. A weatherboard system as claimed in claim 7 wherein said nail when in use, sits flush with a surface of said fixing block and passes through said lower more weatherboard.

9. A weatherboard system as claimed in any one of claims 1 to 8 wherein said first face of said lower more weatherboard sits flush against said structure to be clad.

10. A weatherboard system as claimed in any one of claims 1 to 9 wherein said second face of said lower more weatherboard sits flush against the third face of said upper more weatherboard.

11. A weatherboard system as claimed in any one of claims 1 to 10 wherein said surface relief of said lower more weatherboard is provided at or towards the upward most longitudinal edge of said lower more weatherboard.

12. A weatherboard system as claimed in any one of claims 1 to 11 wherein said slot of said upper more weatherboard is provided towards the lower most longitudinally extending edge of said upper more weatherboard.

13. A weatherboard system as claimed in any one of claims 1 to 12 wherein in location, no substantial gap exists at the region of overlap of said upper and lower more weatherboards.

14. A weatherboard system as claimed in any one of claims 1 to 13 wherein said fixing block is a plastic fixing block.

15. A weatherboard system as claimed in any one of claims 1 to 13 wherein said fixing block is a wooden fixing block.

16. A weatherboard system as claimed in any one of claims 1 to 15 wherein said fixing block has been separated from a continuous cross section elongate member of a cross section identical to that of the fixing block.

17. A weather board system as claimed in any one of claims 1 to 16 wherein said slot includes an undercut upper longitudinally extending slot wall and said fixing block includes an upper surface to sit contiguous said longitudinally extending slot wall.

18. A weather board system as claimed in any one of claims 1 to 17 wherein said fixing block in a vertical cross section perpendicular to said longitudinal direction includes a surface to engage said slot in a manner to prevent said slot moving in a horizontal direction.

19. A weather board system as claimed in claim 18 wherein said surface is an upwardly facing and structure facing surface of said fixing block.

20. A building that has as cladding, the weatherboard system as claimed in any one of claims 1 to 19.

21. A weatherboard system as claimed in any one of claims 1 to 19 and with reference to the accompanying drawings.

22. A building which is cladded by a weatherboard system as claimed in any one of claims 1 to 16 with reference to the accompanying drawings.

23. A weatherboard system as claimed in any one of claims 1 to 19 wherein said fixing block is engaged to the second weatherboard when the weatherboard is in-situ.

24. A weatherboard system as claimed in any one of claims 1 to 19 wherein said fixing block is inserted with the slot of said first weatherboard in a manner to prevent the movement of said first weatherboard once engaged with said fixing block in a direction outwardly from said structure.

25. A method of cladding a structure by engaging an upper more weatherboard that presents a longitudinally extending first face that in use faces said structure to be clad, and a longitudinally extending second face that in use faces away from said structure to be clad, and a longitudinally extending third face that in use projects away from said structure to be clad, yet faces said structure to be clad, a slot provided in, and extending longitudinally along said third face of said upper weather board, to a a lower more weather board that presents, a longitudinally extending first face that in use faces the structure to be clad, a longitudinally extending second face that in use faces away from said structure to be clad and partially overlaps with said third face of said first board, a longitudinally extending third face that in use projects away from said structure to be clad, yet faces, said structure to be clad, where a fixing block is engaged at or proximate the upper edge of said second face of said lower more weather board by a penetrative fastener passing though said lower most weatherboard, holding said lower more weather board to said fixed stucture, by inserting fixing block into the slot of said upper more weatherboard.