GB2227553A

GB2227553A - Prefabricated modular chimney facade

Info

Publication number: GB2227553A
Application number: GB8901716A
Authority: GB
Inventors: Robert Wayne Newsome
Original assignee: Individual
Current assignee: Individual
Priority date: 1984-10-31
Filing date: 1989-01-26
Publication date: 1990-08-01
Anticipated expiration: 2009-01-26
Also published as: GB2206681B; GB2227553B; AU5737886A; GB2206681A; GB8901716D0; FR2617526B1; FR2617526A1; AU573086B2; GB8715683D0

Abstract

A prefabricated modular chimney facade 10 comprises a plurality of prefabricated moulded plastics modules 18, 20, 22, superimposable one on top of the other on the roof of a building, or against an external wall, to enclose a chimney stack or flue pipe which passes centrally up the facade. According to the particular structure described the individual units nest in mating engagement one with the other by means of the laterally off-set upper rims (60, 80) which nest in sliding engagement inside the base of the superimposed unit. <IMAGE>

Description

1 1 1 1 PREFABRICATED MODULAR CHIMNEY FACADE This invention relates to

prefabricated, modular chimney facades which may be mounted externally on a building to enclose a chimney stack or flue projecting therefrom.

Prefabricated, modular chimney facades are known in the art, two particular constructions, for example, being disclosed in Applicant's own EPA-0 246 372 and GB-A-2,206,681. Such prior art chimney facades have been successfully used and are commercially applicable to a number of operations. However, neither of the previously described structures is directly concerned with the minimization of the number of elements required for the chimney facade to provide a less costly structure.

The present invention seeks to improve upon the construction of chimney facades of the type described in those two patents.

In accordance with this invention, there is provided a prefabricated, modular chimney facade mountable externally on the roof, or against an external wall of a buliding, to enclose a chimney stack projecting upwardly from the roof, or extending vertically up said external wall, as the case may be, the facade comprising a prefabricated base unit mountable on said roof, or against said wall, to enclose the lower external portion of the chimney stack, the said base unit having an internal cross-sectional area substantially greater than that of the chimney stack thereby to leave a substantial air gap between the stack and the facade, and at least one other prefabricated unit surmountable the base unit to enclose the upper portion of the chimney stack, said other unit or units likewise having a cross-sectional area that is substantially greater than that of the chimney stack, and substantially equal to that of the base unit, and being of a matching external configuration so as to be surmountable one an top of the other, or on the base unit as the case may be, to provide a complete matching facade enclosing the chimney stack externally of the building, wherein the base unit and the or each of the said other units are defined by a prefabricated wall structure, the abutting upper and lower marginal regions of which are off-set laterally one from the other, whereby, when the units are mounted one on top of the other, the said marginal regions of the superimposed units nest in sliding engagement one inside the other. By providing modular units which nest one inside the other a generally improved, simpler and cheaper chimney facade is obtained.

1 i 2 The invention is further described with reference to the accompanying drawings, in which:

Figure 1 is a perspective, exploded view of a chimney facade according to the present invention; Figure 2 is an ele, vational view of the chimney facade of Figure 1 in a partially cut-away form; Figure 3 is a sectional view of the chimney facade taken along the section line 3-3 of Figure 2; Figure 4 is a sectional view of a join between orthogonally directed panels of the chimney facade; Figure 5 is an exploded perspective view of an alternative embodiment of a base unit for the facade; Figure 6 is a sectional view of a join between two superimposed units of the facade; Figure 7 is an elevational view of an embodiment of the chimney facade showing a chimney covering in phantom lines; and Figure 8 is a sectional view through part of the chimney facade of Figure 7.

Referring now to Figures 1 to 8, there is shown a prefabricated and modular chimney facade 10 according to this invention for enclosing chimney stack 12 passing at least partially therethrough. As is shown in Figures 1 and 2, the chimney facade 10 is secured to the roof 14 of a building (not shown) to enclose a projecting chimney stack or flue 12 (see Figures 2 and 3).

In accordance with the present invention, chimney facade 10 is used to provide a pleasing aesthetic enclosure, e.g. a simulated brick facade, for the flue pipe 12. As will be shown in the following paragraphs, the chimney facade 10 is composed of a plurality of elements which allow for a prefabricated and modular design requiring a minimum of construction time to be utilized as well as affording a simplicity of construction. Further, chimney facade 10 is constructed of materials which are substantially less -costly than brick facades while simultaneously allowing for low cost of maintenance. Further, the chimney facade 10 is formed from a plurality of constructional elements which in their knockdown state provide for a substantially high weight to volume ratio and thereby minimize shipping costs, which may be considerable. Generally, the chimney facade 10 of the W 3 - present invention may be used in connection with internal fireplaces or other heating mechanisms used in commercial andlor domestic environments.

In contrast to several prior art chinmey facades which have used structural materials such as brick, wood and other like constructional compositions, the facade 10 of the present invention provides for a modular system, preferably prefabricated plastics mouldings, which are fabricated off-site. Additionally, the lightweight characteristics of the facade allow for on-site placement and structural construction by a single person.

Facade 10 is formed of a small number of interchangeable sectional housings or units. Such sectional units are easily nested one within the other and thus, the volume is minimized for shipping purposes and provides for easy transportability to the site of construction. Entire units may be carried by one person and installed in a minimum amount of time to c fe crease labour costs. Furthermore, the units of facade 10 provide a minimum number of individual mountings with consequential minimisation of cost.

The chimney stack or flue pipe 12 itself may be formed from a conventional metallic composition, e.g. stainless steel or some like material, and is surrounded by an insulating air space, as is shown in Figure 2. Air is a well-known high thermal insulator and temperatures on the internal surfaces of the facade 10 have been found to be minimal and well within any temprature criteria for such systems.

In particular, temperatures have been found to rise only a few degrees an the exterior surfaces of the facade 10, even when the fireplace is being used giving rise to extremely high temperatures on the exterior surfaces of chinmey stack 12.

Further referring to Figures 1 to 3, it is seen that facade 10 includes a substantially vertically directed chimney stack 12 passing from within the building structure and through the roof 14. Chimney stack 12 is substan tially enclosed by chimney facade 10, as is seen in Figures 2 and 3.

Although the invention is described with reference to a roof mounted structure, it is to be understood that the principles described herein can be applied with a minimum of modifications to a prefabricated wall-mounted chimney facade.

It is to be understood that cap unit 22 as herein described may be directly coupled to the base unit 18, dependent upon the vertical length of 1 ---1 4 the chimney stack 12 and other considerations not important to the concept as herein described.

Second unit 20 includes a pair of sidewall members 24, 26 which are L-shaped in cross-sectional contour when taken in a plane normal to vertical direction 16. L-shaped sidewall members 24 and 26 are generally formed in one-piece construction and include interfacing end portions for mating engagement of respective L-shaped sidewall members 24 and 26. As can be seen in Figure 4, each of the L-shaped sidewall members 24 and 26 include a substantially horizontally directed flange member 28 and 30 respectively.

When the sidewall members 24 and 26 are in mated engagement, the flange members 28 and 30 engage at an interface 36. Each of the horizontally directed flange members 28 and 30 include respective end sections 32 and 34 with each of the end sections 32 and 34 terminating in a step shaped contour 36 for mating interface of flange members 28 and 30, each to the other.

Horizontal flange member end sections 32 and 34 may be bonded to each other through adhesive bonding or some like technique. Step contour 36 provides for an increased surface bonding area between flange members 28 and 30, and still further, gives the advantage of providing a zig-zag interface which minimizes passage of liquid therethrough, providing an operational advantage over an extended time, since facade structure 10 is exposed to atmospheric conditions.

In this manner, second unit L-shaped sidewall members 24 and 26 may be mounted each to the other and adhesively secured to provide an enclosure for chimney stack 12. Additionally, second unit L-shaped sidewall member 26 may include a lower horizontally directed flange member 38 having similar configuration to horizontal flange member 28 but being dis placed therefrom in vertical direction 16 as shown in Figure 1. The second unit horizontal flange member 38 would interface with and be bonded to a similar horizontal flange member formed on L-shaped sidewall member 24.

The base unit 18, as clearly seen in Figure 1, includes L-shaped sidewall members 40 and 42. As is seen in Figure 1, L-shaped side wall member 42 includes upper horizontally directed flange member 44 having step-shaped end sections 36 identical to end section contours provided for horizontal flange members 28 and 30 of the unit 20 previously described.

Further, the base unit 18 includes lower horizontally directed flange member 46 passing around the internal periphery of an internal wall of L-shaped sidewall member 42 for securement to an upper surface of the roof 14. Lower horizontally directed flange member 46 may be secured to the roof 14 by bonded securement or through nails or bolts inserted through bolt holes 48, as is shown. Lower horizontally directed flange member 46 of the L-shaped sidewall member 42 is adapted to be insertable and in nested interface with a similar lower horizontally directed flange member formed in the sidewall member 40, as was previously described for second base housing unit 20.

L-shaped sidewall members 40 and 42 are each formed in one-piece formation and comprise a substantially orthogonally directed respective frontal wall member 50, a sidewall member 52, a rear wall member 54, and a sidewall member 56. When roof inclination angle 58 is greater than zero, as is shown in Figure 2, opposing sidewall members 52 and 56 are contoured in the shape of a truncated rectangle. Front wall member 50 and rear wall member 54 are of similar rectangular contourg however, such are of differ ing heights to allow for vertical constrution of facade system 10 in a ver tical direction 16. In this inclined case, lower horizontally directed flange member 46 passes normal to a vertical plane defined by wall members 50, 529 56 and 54, but as can be seen in Figure 1, are angled at the inclination angle of the roof 14 in order to allow interfacing and securement of lower horizontally directed flange member 46 with the roof or external wall 14.

As can be seen, lower horizontally directed flange member 46 as well as horizontally directed flange member 44 of base unit 18 are directed inwardly of the base unit 18. In this. manner, attachments may be made to a roof 14, as well as between the L-shaped sidewall members 40 and 42, in a manner such that connections are not seen when observed external to the facade 10. This is an important concept in that chimney facade 10 as constructed should simulate a natural brick facing.

Referring now to Figures 1 and 6, there is shown the manner and mode of vertical interfacing of the base unit 18 to second unit 20. As can be seen, base unit 18 includes a substantially vertically directed upper flange member 60. Second unit 20 includes a substantially vertically directed lower flange member 62 such that when the first and second units 18 and 20 are in mated engagement, the flange members 60 and 62 are in interfacing relation each with respect to the other. When second unit 20 is mounted on the base unit 18, vertically directed flange members 60 and 62 ( t 6 are offset each from the other and provide for nested interface of upper and lower flange members 60 and 62.

Horizontally directed flange member 38 provides an interface shoulder 64 which provides a base for upper flange member 60 of unit 18. Similarly, interface shoulder 66 is formed on the base unit 18, as shown, to provide a base for vertically directed lower flange 62. Overlapping interface section 68 provides for contact area between vertically directed flange members 60 and 62 and provides for an adhesive bonding section. Alternatively, vertical flange members 60 and 62 may be bolted each to the other within interface area 68 to provide a secure mounting between the units 18 and 20. The overlapping relationship between vertically directed flange members 60 and 62 provides an increased adhesive bonding area to reduce transverse stresses applied to first and second units 18 and 20 in combina tion. Flange members 60 and 62 pass substantially throughout the peripheral contour of each section of first and second units 18 and 20 to reduce the horizontal stresses which may be applied to the facade 10. Additionally, it has been found that the horizonally directed flange members 38 and 40 extending at least partially around the inside of the units 18 and 20 provides for increased structural integrity of facade 10 when transverse forces are applied through extreme environmental conditions.

The nesting offset interface of vertical flange members 60 and 62 further provides for increased structural integrity of the superimposed first and second units 18 and 20 while maintaining an aesthetic appearance which does not detract from the external facade visual effect. Thus, if the external indicia is to be that of a brick facing as is depicted in the drawings, the particular overlapping and nested relationship of flange members 60 and 62 maintains the external appearance while providing a stable base for units 18 and 20 and incresing the combined structural integrity of the facade 10.

Additionally, horizontal flange members 38 and 40 in combined relation decrease the transverse stresses applied to the combined housing units 18 and 20 and provide for mounting of particular components within each of units 18 and 20, as has been previously described.

Further, as has been shown, first and second units 18 and 20 are mounted completely externally of the building structure and as depicted are mounted on top of the roof 14. Thus, there is no necessity to destroy the roof 14 when fixing the facade 10, as is herein provided.

j 7 Referring now to Figure 10, cap unit 22 likewise includes two L-shaped sidewall members 70 and 72. Each of the sidewall members 70 and 72 are formed in one-piece formation as was described for first and second units 18 and 20. L-shaped sidewall members 70 and 72 each include a vertically directed flange 74 which may be mounted in nested and inter facing relation with vertically directed flange 80 of the unit 20 in exactly the same manner as shown for the interface between first and second units 18 and 20 as depicted in Figure 6. The upper horizontal flange 78 on the cap unit extends partially internal the closed contour opening formed by the cross-section of cap unit 22 when in the constructed form, and further includes step contours 36 formed on the edges of horizontal flanges 76 and 78 to provide interface and bonded securement between L-shaped sidewall members 70 and 72, as has previously been described for first and second units 18 and 20.

It is to be understood that cap unit 22 may be mounted directly to the base unit 18 or in the alternative, there may be a plurality of intermediate units similar in construction to the unit 20 between the cap unit and the base unit. Openings 82 may be formed in the horizontal flanges 78 of the cap unit to provide a securement base for a partial closure or other mounting thereon.

Referring now to Figure 5, there is shown an alternative embodiment of the present invention wherein the individual units such as units 18 and 20 may be formed of a plurality of substantially planar wall members. In the embodiment shown in Figure 5, base unit 201 is formed of housi ng front and rear walls 84 and 86, as well as transversely displaced sidewalls 88 and 90.

Each of substantially planar wall members 84, 869 88 and 90 include lower horizontally directed flange members 94 which interface each with respect to the other through step contour 36, as has been previously discussed.

Additionally, each of wall members 84, 86, 88 and 90 include upper horizon tally directed flange members 96 interfacing each with respect to the other in a similar manner to that previously described. Additionally, lower verti cal flange members 94 associated with each of the wall members as shown in Figure 5 interface with the next lower unit, and upper vertical flange members 98 interface and are in nested relation with the next superimposed unit.

Referring now to Figure 7, there is shown a prefabricated chimney 8 ' facade 100 including a single base unit 102. Base unit 102 may be fabricated in the manner shown and described for chimney facade 10 of Figures 1 to 6.

Chimney facade 100 is designed to be secured to the pitched roof of a building having a predetermined pitch angle 58. As was the case for facade of Figures 1 to 7, there is provided a substantially vertically directed chimney stack 12 passing through the roof structure and being substantially enclosd by chimney facade 100. Base unit 102 includes lower surface 104 which is cut to the predetermined pitch angle 58 of the roof when taken with respect to base line 106.

The important consideration as shown in Figure 7 is that facade 100 may be brought on-site and may be cut to the correct roof pitch angle prior to securement. As has been described, base unit 102 subsequent to the cutting thereof may be secured to the roof by adhesive banding, mechanical bolting, or some like technique, not important to the invention as herein described.

Base unit 102 may be formed in one-piece formation and may be formed of a plastic composition material which allows lower surface 104 to be cut and contoured to roof pitch angle 58 with a minimum of effort.

Referring to Figure 8, there is seen an upper portion of facade em bodiment 100 including channel 108 formed in the upper section of the base unit 102 and extending substantially throughout a peripheral contour of base unit 102 to provide a flash channel for facade 100. Additionally, inclined upper surface 110 is formed adjacent channel 108 of the base unit 102 for directing liquid thereto. In this manner, channel 108 may provide a run- off channel for rain water or other liquid impinging on the covering shown in phantom line drawings of Figure 7.

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Claims

1. A prefabricated, modular chimney facade mountable externally on the roof, or against an external wall of a building, to enclose a chimney stack projecting upwardly from the roof, or extending vertically up said external wall, as the case may be, the facade comprising a prefabricated base unit mountable on said roof, or against said wall, to enclose the lower external portion of the chimney stack, the said base unit having an internal cross-sectional area substantially greater than that of the chimney stack thereby to leave a substantial air gap between the stack and the facade, and at least one other prefabricated unit surmountable the base unit to enclose the upper portion of the chimney stack, said other unit or units likewise having a cross-sectional area that is substantially greater than that of the chimney stack, and substantially equal to that of the base unit, and being of a matching external configuration so as to be surmountable one on top of the other, or on the base unit as the case may be, to provide a complete matching facade enclosing the chimney stack externally of the building, wherein the base unit and the or each of the said other units are defined by a prefabricated wall structure, the abutting upper and lower marginal regions of which are off -set _laterally one from the other, whereby, when the units are mounted one on top of the other, the said marginal regions of the superimposed units nest in sliding engagement one inside the other.

2. A chimney facade according to claim 1, wherein the upper marginal region of the base unit, and of each other unit if more than one, is or are inset laterally from the lower marginal region or regions of the superimpos able unit or units, if more than one, whereby when the units are mounted one on top of the other, the said upper marginal region of the base unit, or each unit if more than one, nest in sliding engagement inside the lower marginal region of the unit superimposed thereon.

3. A chimney facade according to claim 2, wherein the or each superim posable unit of the facade has an internal, inwardly directed flange exten ding therearound adjacent said lower marginal region(s) and which, when the unit or units are superimposed one on top of the other, form an abutment shoulder against which abuts the inset upper rim of the unit immediately therebelow and which nests therewith.

4. A chimney facade according to claim 3, wherein the or each superimposable unit of the facade has a second internal, inwardly directed flange extending therearound spaced from the first flange and located towards the upper rim of each unit.

5. A chimney facade according to any one of claims 1 to 4, wherein the said base unit has an inwardly directed internal flange extending around its bottom edge and providing means by which the base unit may be secured to the roof of the building around the lower portion of the projecting chimney stack.

6. A chimney facade according to any one of claims 1 to 5, wherein the unit has an inwardly directed internal flange extending therearound and located towards the upper rim of the base unit.

7. A chimney facade according to any one of claims 1 to 6, in which the units are of a rectangular configuration.

8. A chimney facade according to claim 7, in which one or more of the units are constructed of two or more separate wall sections provided with means along their vertical edges whereby the separate wall sections may be asesmbled to form the complete rectangular unit.

9. A chimney facade according to claim 8, wherein one or more of the units are constructed of two separate L-shaped wall sections provided with means along their vertical edges whereby the two L-shaped sections may be assembled to form the complete rectangular unit.

10. A chimney facade according to claim 8 or 9, as dependent upon any one of claims 2 to 6, wherein the internal flanges on each wall section are provided with abutting ends having a stepped configurationg which when the wall sections are assembled abut one another to form a stepped butt joint between the separate flange sections.

11. A chimney facade according to claim 10, wherein, when assembled, the stepped butt joints between adjoining flanges are secured by means of an adhesive.

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12. A chimney facade according to any one of claims 1 to 11, for mounting on a pitched roof, wherein the first prefabricated unit mountable on the roof around the lower portion of the projecting stack has a bottom end face lying in a plane inclined with respect to the axis of the facade at an angle equal to the pitch angle of the roof on which the facade is to be mounted.

13. A chimney facade according to any one of claims 1 to 12 p consisting of two prefabricated modular units, the one constituting said first unit and the other constituting a capping unit for the facade surmountable directly onto said first unit.

14. A chimney facade according to any one of claims 1 to 12, consisting 1 of three or more prefabricated modular units, one constituting said 'first unit, a second constituting a capping unit for the facade and at least one other unit positionable between the first unit and the capping unit.

15. A chimney facade according to any one of claims 1 to 12, wherein the individual prefabricated units of the facade are of a moulded plastics construction.

16. A chimney facade according to claim 1 substantially as hereinbefore described with reference to the accompanying drawings.

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