Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F13/00—Coverings or linings, e.g. for walls or ceilings
  • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
  • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
  • E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections

Definitions

• the present invention relates generally to a decorative modular tile cladding system, and more particularly, to a decorative modular tile cladding system and method ideally suited for the exterior surfaces of buildings, and more particularly to a decorative modular tile cladding system comprising a plurality of tiles that include means for interlocking with each other to create a continuous "skin" that is used as cladding for the outside or inside surfaces of a residential or commercial structure or similar structure.
• cladding Another method that is somewhat similar to that of siding is cladding, wherein sheets of various textures and/or colors are applied directly to the exterior of the structure.
• various other materials are available for cladding, including metal, cement and even glass, which afford a highly weather resistant substrate or skin.
• metal the design choices for such materials, particularly metal, are quite limited, and provide an aesthetically inappropriate installation to design.
• Such systems are also not generally available for ⁇ "off the shelf” applications, and require special equipment, tooling or training for installation.
• the tiles used in such cladding or tiling systems need not be rectangular.
• hexagonal tiles are disclosed in U.S. Patent No. 358,175, which issued to Thomas on February 22, 1887 for "Metallic Plate for Facing Walls.”
• a wide variety of non-traditional patterns, geometries or designs may be contemplated for the individual panels or tiles of a cladding system, as suggested by U.S. Patent No. 4,133,152, which issued to Penrose on January 9, 1979 for "Set of Tiles for Covering a Surface.”
• It is yet another object of the present invention to provide such a decorative modular tile cladding system that allows for installation on a surface with a negative angle off vertical. It is another object of the present invention to provide such a decorative modular tile cladding system that includes detailing for architectural perforations.
• the present invention in brief summary, is a decorative modular tile cladding system polygonal tiles that include means for interlocking with each other to create a continuous "skin" that is used as cladding for the side of a structure.
• the tiles may be rectilinear or curvilinear as desired.
• At least three separate means for interconnecting the tiles are contemplated, including: (1) folded tabs on each of the tiles that engage tabs on adjacent tiles to create a secure connection between tiles; (2) clips that are designed to engage the edges of adjacent tiles; and (3) punched pockets and punched tabs to receive and engage a••complementary tab.
• The., tiles may be attached to a standard sheathing substructure or substrate, regardless of the shape or size of the structure to which the tiles are being attached, including curved surfaces, and incorporate details for water/gas/vapor exchange, as well as expansion.
• the tiles are composed of metal or plastic, although other materials are contemplated.
• PIG. 1 is a top plan view of the decorative modular tile cladding system of the present invention
• FIG. 2 is a top plan view of the left handed and right handed tiles of the decorative modular tile cladding system of FIG. 1;
• FIG. 3 is a top plan view of the decorative modular tile cladding system of the present invention showing various elements thereof in closer detail;
• FIGs. 4A-4C are top plan views of the decorative modular tile cladding system of the present invention using clips for attachment of adjacent- tiles;
• FIGs. 5A-5C are top plan views of the decorative modular tile cladding system of the present invention using folded fingers in place of folded tabs for attachment of adjacent tiles,-
• FIG. 6A-6C are cutaway side views showing the installation of the decorative modular tile cladding system of the present invention.
• FIG. 7A- 7C are cutaway side views showing the water management system of the decorative modular tile cladding system of the present invention and comparing said installation to the installation of an another siding system;
• FIGs. 8-8B are perspective illustrations showing the installation of the decorative modular tile cladding system of the present invention and the various solutions used for addressing architectural elements such as corners and windows;
• FIGs. 9-13 are top plan views of various tile fields of the decorative modular tile cladding system of the present invention.
• FIG. 14 is an illustration of the rules governing orientation and placement of the pockets, tabs, clips and weep holes of the decorative modular tile cladding system of the present invention.
• Figs. 15A-15C are top plan views of the decorative modular tile cladding system of the present invention using Punched Tabs with an extended tile shape.
• Figsv -16A-16C are- top plan views of the decorative modular tile cladding system of the present invention using Punched Pockets with an extended tile shape.
• the decorative modular tile cladding system 10 comprises a plurality of rectilinear polygonal tiles 12 which in the preferred embodiment are manufactured from metal, such as copper, brass, bronze, aluminum and/or steel sheet metal. Alternatively, other materials may be used, such as vinyl or plastic, or composites, which materials will have a different aesthetic than the metal tiles 12, but may be far less expensive to manufacture and may be easier to install. It should also be appreciated that although in the preferred embodiment the tiles 12 are rectilinear, there are an unlimited number of shapes and configurations that would be just as effective, including curvilinear shapes.
• the tiles 12 include interlocking means 14, which allow adjacent tiles 12 to be interconnected to thereby create a continuous "skin" that may be used as cladding for the side of a structure, either externally or internally.
• the cladding may be used on a floor or even a ceiling of the structure, although the water management feature of the system would not be implemented in such use.
• the interlocking means 14 comprise at least one folded tab 16 on at least one edge 18 of the tile 12, which folded tabs 16 engage the folded tabs 16 on adjacent tiles 12 to create a secure connection, wherein the entire surface created thereby becomes an interconnected breathable "skin.”
• the folded tabs 16 allow the full perimeter 20 of the tiles 12 to be self sealing, with the design features of interlocking means 14 allows for both edges to be captured and anchored yet free to move, thereby giving the individual tiles 12 room for thermal expansion and contraction while being completely attached to the substructure 21, whether such substructure be sheathing, substrate, specially engineered substructure such as concrete or steel, or other materials or systems.
• each tile 12 is of the same shape and size, and includes weep holes 22 that facilitate the management of water 23 by the tiles 12.
• two types of folded tabs 16 are provided on each tile 12 - a top folded tab 24 and a bottom folded tab 26.
• the top folded tab 24 is characterized by a tab 16 that is folded down and over the upper surface 28 of the tile 12.
• the top folded tabs 24 include a notch 30, which notch corresponds to one or more holes 32 that may be disposed along the top leading edge 34 of the tile face 28, which holes 32 are provided to allow for fasteners such as screws to be installed along the top leading edge 34 of the tiles 12.
• the holes 32 are not necessary to the installation of the cladding system 10 inasmuch as nails or self-tapping screws may be used to pierce the tiles 12 if no holes 32 are provided. However, the notches are spaced appropriately for the attachment of these types of fasteners. It should also be appreciated that the unique interlocking structure of the decorative modular tile cladding system 10 ensures that the fasteners will not be visible when the tiles 12 are installed due to the overlapping tabs 24, 26.
• the bottom folded tabs 26 are provided along the bottom edge 36 of the tiles 12, said bottom folded tabs 26 being characterized by a tab 16 that is folded under the tiles 12 such that they would be facing the substrate when the tile 12 is applied to the wall.
• Adjacent tiles 12 are attached by sliding the edge of tab- 26 of one tile 12 under and into the top edge 34 of the adjacent tile such that the' bottom folded tab 26 engages the top folded tab 24 or pocket of the tile 12 or tiles 12 beneath it .
• each tile 12 is thereby secured and fastened on all edges 18 thereof.
• a detailed illustration of the interlocking means is shown in FIGs. 6A-6B- 6C.
• top folded tab 24 and the bottom folded tab 26 are highlighted, as is the fact that the tiles 12 also serve to hide the fastener when installed.
• the tabs 16 are designed so they do not exactly meet at the corners 38, allowing for vapor and water respiration and escape.
• FIGs. 7A-7C Another aspect of the water management of the decorative modular tile cladding system 10 of the present invention are the weep holes 22, which features prevent the collection or pooling of water 23 or other fluids in the folds 16 of the tiles 12.
• the weep holes 22 located along the bottom folded tabs 26 allow for rain water, condensation and other fluids and gases to pass through and not collect in the wells 39 created by the folded tabs 24, 26.
• these weep holes 22 allow for water that condenses along the back surface 29 of the tiles 12 to escape, thereby preventing any damage to the tiles 12 or to the substructure 21 upon which the tiles 12 are installed.
• FIGs. 7A and 7B A comparison of the water management feature of the present Invention is illustrated in FIGs. 7A and 7B, with-FI-G. 7A detailing the water management of the siding system of Thomas (U.S. Patent No. 358,175) wherein the water 23 is allowed to pool, and the water and vapor management of the cladding system 10 of the present invention being shown in FIG
• two or more types of tiles 12 may be required to make up the decorative modular tile cladding system 10 of the present invention, although certain designs may only require one type of tile 12.
• one of the embodiments of the present invention requiring two types of tiles 12 is shown, wherein these two types can generally be described as a "right handed" tile 40 and a "left handed” tile 42, with each having a design that mirrors the other for use at different ends of the surface.
• the tiles 40, 42 may also be different rotations or flipped versions of the same design.
• the two tiles 40, 42 may be entirely different in size or orientation.
• Termination elements 44 and edge detailing strips 46 may also be provided, which objects are designed to allow attachment of cut ends 48 of the tile field 50 defined by the interconnected tiles 12 as it is terminated or otherwise impacted by the architectural elements, corners or edges of the structure.
• Other folded elements may also' be provided for the system 10., including drip edges 52 and boundary/edge trim 54. It should be appreciated that these elements are merely for illustrative purposes only, as a number of additional design features are anticipated.
• the installation of the decorative modular tile cladding system 10 of the present invention is as easy as the installation of current off-the-shelf siding systems, and uses similar tools, although the technique and process of coverage is fundamentally different, particularly with respect to dealing with edges and wrapping around corners.
• the system 10 is designed to be installed directly onto any type of substructure 21, including standard sheathing such as a normal %" plywood sheathing substrate covered with an appropriate water and vapor barrier such as tarpaper.
• Each tile 12 is captured using a fastening device such as a screw or appropriately rated nail, such as a 6 flat-headed pan screw, on the top edge 34 in the appropriate holes 32 or alternatively without the need for holes 32, provided that the fasteners pierce the tiles 12 at the provided notch 30 or fastening protocol, and will be covered by the folded tab 16 so as to hide them from view when the cladding system is completely installed, and follow specific layout pattern to be provided depending on tile specs.
• the bottom folded tab 26 captures half of the top folded tabs 24 of the two tiles 12 directly below it. Special beginning and termination tiles can also be provided (or created on site) depending on site needs.
• Tiles .12 are laid from the bottom up in the opposite direction of water flow.
• clips 56 may be provided to engage the edges 18 of adjacent tiles 12.
• fingers 58 may be used instead of tabs 16, which fingers 58 may be cut so as to create the notch 30 for example, and which may also be folded in much the same was as tabs 16.
• the need to notch out tabs when tile 12 installation is conforming to a corner or other architectural feature is eliminated, thereby facilitating the preparation of the tiles 12 for installation on site.
• the tile 12 can also be bent without notching the bottom folded tab 26 or top folded tab 24. It should be appreciated that in this embodiment, it is preferable to orient the finger 58 parallel to the vertical axis, or alternatively to the plumb of the design of the tile field 50.
• the corresponding finger 58 may be pre-notched for access to hole 32 or in determining fastening pattern/protocol.
• FIGs. 9 through 13 Illustrated in FIGs. 9 through 13 are some of the variations of tile fields 50 that may be created using the decorative modular tile cladding system 10 of the present invention. These variations are provided for illustrative purposes only, and should not be construed as limiting the potential designs or configurations of the tiles 12. It should be appreciated that in some of these configurations, more than a right tile 40 and left tile 42 are utilized, as shown in FIGs. 12 and 13.
• FIG. 14 illustrates a protocol by which the folded tabs 16 are oriented and placed on the tile 12. The joint protocol establishes the determination of an over edge 60 and under edge 62 to the geometric pattern of the tile 12, allowing the tiles 12 to be overlapped and secured.
• the overlap and layout of the two folds 64 that comprise one segment 66 connection is determined by the orientation of each segment 66 of the geometric pattern to the vertical axis.
• a bounding box 70 around the anchor points 72 to each segment 66 one can readily determine which area is above and below the segment 66.
• the tile 12 comprising the area above the segment 66 receives a backward fold 74 and the tile that comprises the lower area of the segment receives a forward fold 76 to create the leading edge 34, a punched pocket or punched tab.
• the backward fold 74 has a length equal to the segment 66 with edges 18A tapered inward and a depth slightly shorter than the corresponding forward facing fold 76, a weep hole 22 detail at the meeting points of the segments 66 where two folds 74 meet, not to extend into to the forward face 28 to allow for the release of surface water and migration of condensate water 23 that may form in the boundary layer between the cladding and the substructure 21.
• the backwards fold 74 is similarly formed from extension 78 and subdivided into fingers 58.
• the forward fold 76 is formed from forward fold extension 78A which is approximately twice the tab depth which is folded over itself in half to meet tile face 28.
• Notches 30 and hole 32 are punched into the fold 76 corresponding to fastener placement in one embodiment.
• forward folds 76 is similarly formed from extension 78A, wherein said extension 78A is subdivided to form fingers 58.
• the area below segment 66 does not receive a fold 64, but merely includes extension 78, and clips 58 slide over this extension 78 and are captured with fasteners through the tile 12.
• a punched pocket or ' punched tab is'forged "on the blank and aligned to the pattern of tiles 12 and of the same depth as the slightly smaller of the corresponding backwards tab 74.
• installation of the cladding system 10 is commenced by attaching a fold strip 80 to the substructure 21 to capture the starting tile 12 course, and a drip edge 52 detail finish, and subsequent tiles 12 are fastened in series in an upward direction.
• a tile 12 is slid up such that its bottom folded tab 26 engages the top folded tab 24 of the fastened bottom course of tiles 12.
• the tile 12 is thereafter fastened to the substructure 21 along the top edge 34, with or without clips 58.
• the tile field 50 As the tile field 50 reaches a corner, the tile 12 is marked to the corner and bent and the installation proceeds. It should be realized that the tile field 50 need not bend on the tile pattern's 50 geometric axis. On any edges 18 that terminate the pattern, a fold strip 44 is nailed and the tile 12 is captured thereby.
• punched tabs 82 or punched pockets 84 are used in place of some of the folded tabs 16.
• the blank tile 12 may take an extended shape 86 incorporating the uppermost horizontal level encompassed by the geometric shape of the tile 12.
• the extended shape 86 derives its outline on the left by taking on the left most edge of the left-most bounding box 70 used in determining left most edge 60.
• the outline on the right is similarly determined by taking on the right most edge of the right most bounding box 70 used in determining the right most edge 60.
• the extended shape 86 derives its uppermost boundary by taking on the top most edge of the top most bounding box 70 used in determining the top most edge 60.
• the folds are determined by the shape of the tile 12 of the intended system 10 as bottom edge 36 conforms to the geometric pattern.
• the punched tab 82 or punched pockets 84 are machined slightly away and in a pattern that follows the tile 12 position of the upper edge formed by the pattern 12.
• the overall outline of the extended shape 86 will remain true to the top most outline and thus form a dependable registration outline for the installation procedure and facilitate the alignment of the pattern and its feature set- correctly on the structure during installation. It s ' hould be appreciated, however, that certain tile patterns may make it advantageous to strictly adhere to the right, left, top or any combination in determining the tile's 12 outline in setting up the coordinate system. This will allow a vertical or horizontal registration protocol to be established. By transferring the corresponding registration protocol on the intended structure, a correct alignment and spacing of the installation of the tile field 50 may be facilitated. In the case of a repair where a damage tile is removed, this embodiment provides the anchoring for the repair tile 12 to capture the installed punched pockets 84. The repair tile 12 that will take a slightly new form or protocol therefore has access to the established hidden anchoring mechanism and can readily engage the tile 12 above it .
• an added feature of this embodiment is that the resulting opening in the extended shape 86 tile face 28 results in openings that are situated directly behind and above the overlapping tile 12 above it allowing protection from the environment but increasing the vapor exchange and heat transfer exchange from behind the tile field 50.

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Finishing Walls (AREA)

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• 2005
  • 2005-03-15 US US11/080,325 patent/US20060207194A1/en not_active Abandoned
• 2006
  • 2006-03-13 CA CA002573033A patent/CA2573033A1/en not_active Abandoned
  • 2006-03-13 EP EP06748363A patent/EP1866494A2/de not_active Withdrawn
  • 2006-03-13 WO PCT/US2006/008908 patent/WO2006101802A2/en not_active Ceased

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