NZ530895A - Polystyrene weatherboards - Google Patents

Abstract

A polystyrene weatherboard includes interlocking means and a pre-installation coating. The weatherboard has sufficient structural integrity to enable it to be fixed directly to wall framing and function as an effective exterior building cladding without the need for supportive backing over and above the wall framing.

Description

Patents Form No. 5 1 53 08 95 THE PATENTS ACT 1953 COMPLETE SPECIFICATION No.530895 WEATHERBOARDS We, OUR BRANDS LTD, a New Zealand company of 14 Ormiston Road, Flatbush, Auckland, New Zealand, hereby declare this invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: INTELLECTUAL PROPERTY OFFICE OF N.Z. 1 3 APR 2005 RECEIVED 2 TITLE Weatherboards.

FIELD OF THE INVENTION This invention relates to weatherboards for building applications.

BACKGROUND In the context of construction it is known to use weatherboards to clad a building. These are traditionally milled from a wooden material and can account for a significant proportion of the costs in constructing a building such as a house. It accordingly is an object of at least one form of the invention to provide an alternative to the wooden weatherboard, or at least to provide the public with a useful choice.

The term "comprising", "comprises", or derivatives thereof, if and when used herein, should be interpreted non-exclusively — ie to convey "consisting of or including".

SUMMARY OF THE INVENTION According to one aspect of the invention there is provided a polystyrene weatherboard, the weatherboard having interlocking means and a pre-instaliation coating, the weatherboard having sufficient structural integrity to enable it to be fixed directly to wall framing and function as an effective exterior building cladding without the need for supportive backing over and above the wall framing, the interlocking means formed to enable the weatherboard to interlock with another identical or substantially similar board in a substantially weatherproof fashion when the first mentioned weatherboard is in use.

Optionally the weatherboard is substantially long running — ie its long ways dimension greatly exceeds its cross ways dimension. 3 Optionally the pre-installation coating comprises plaster, or a spray of a polyurethane, an epoxy, or an acrylic formulation.

Optionally the interlocking means is formed to enable tongue and groove engagement between weatherboards.

Optionally the interlocking means comprises a male portion at one part of the weatherboard and a female portion at another part of the weatherboard to enable the weatherboard to engage identical or substantially similar weatherboards in a tongue and groove manner.

Optionally the interlocking means involves a step adapted to engage a stepped or non-stepped portion of another identical or substantially similar weatherboard.

Optionally a face of the weatherboard has grooves to facilitate drainage when the weatherboard is installed with said face immediately adjacent wall framing.

Optionally the weatherboard has a central cavity.

Optionally the weatherboard is formed to simulate a plurality of smaller weatherboards.

Optionally the weatherboard is formed to simulate a line of bricks. In this case the weatherboard may or may not have the thickness of a standard brick.

Optionally the weatherboard is formed with a corrugated exterior surface — eg to simulate corrugated iron.

According to another aspect of the invention there is provided a method of construction involving using a weatherboard as described above, driving a fixing member through 4 the weatherboard to secure the weatherboard to wall framing, and engaging a second identical or substantially similar weatherboard with the first mentioned weatherboard and fixing the second mentioned weatherboard to wall framing such that a portion of the second mentioned weatherboard overlaps and thus hides the fixing member mentioned in relation to the first mentioned weatherboard.

DESCRIPTION OF THE DRAWINGS Some preferred embodiments of the invention will now be described by way of example and with reference to the accompanying drawings of which: Figure 1 is a transverse cross section view of a polystyrene weatherboard, Figure 2 provides transverse cross section views of alternative polystyrene weatherboards demonstrating the manner of engagement for each alternative, Figure 3 provides transverse cross section views of two polystyrene weatherboards of similar shape to that of figure 1 but demonstrating the option for alternative thicknesses, Figure 4 provides transverse cross section views of polystyrene weatherboards formed in various sizes, Figure 5 illustrates various optional leading face shapes and forms for polystyrene weatherboards, Figure 6 provides transverse cross section views of polystyrene weatherboards demonstrating alternative leading edge profiles, Figure 7 provides transverse cross section views of polystyrene weatherboards corresponding to that figure 1 when fastened to wall framing, Figure 8 provides transverse cross section views demonstrating the manner of engagement of particular polystyrene weatherboard profiles, Figures 9A and 9B illustrate combinations of polystyrene weatherboards with other building components, Figure 10 is a perspective view of a weatherboard corresponding to that of figure 1, Figure 11 is a perspective view of weatherboards adapted for vertical rather than horizontal engagement, Figure 12 illustrates a polystyrene weatherboard made with substantial thickness and formed to simulate a line of bricks, Figure 13 illustrates the weatherboard of figure 12 when in use with other such weatherboards, and Figure 14 is a transverse cross section view illustrating a polystyrene weatherboard formed to simulate corrugated iron.

DETAILED DESCRIPTION Referring to figure 1, an embodiment of the invention involves a polystyrene 6 weatherboard 1 for cladding a building, for example a domestic dwelling such as a house. The weatherboard 1 comprises an exterior face 2 intended for facing outwards of the building when in use. The exterior face 2 may have a suitable pre-installation coating, for example plaster or a spray of polyurethane, epoxy, or an acrylic formulation. The term "pre-installation" in relation to the coating means that the coating has been applied as part of the manufacturing process of the weatherboard. The coating may or may not involve fiberglass reinforcing mesh or the like. The weatherboard 1 may involve a finish coating such as a suitable paint or the like applied as part of the manufacturing process. As shown in figure 1, the weatherboard 1 has a lower groove 3 and an upper tongue 4. The weatherboard I can thus interlock with other such weatherboards, or similar weatherboards, in overlapping tongue and groove fashion.

Figure 2 shows parts of various other polystyrene weatherboard pairs 5, 6, 7 and 8 demonstrating the manner in which they engage one another. The engagement is in each case intended to prevent ingress of wind and rain to the wall cavity of a building. As shown at item 6 the engagement may be between two stepped portions of different weatherboards, or as shown at item 8 between a stepped and a non-stepped portion of different weatherboards.

Referring to figure 3, items 9 and 10 illustrate the use of polystyrene weatherboards of alternative thickness depending on the desired level of thermal insulation for a building. Weatherboard thickness may also be determined by other factors, for example aesthetic considerations.

With reference to figure 4, polystyrene weatherboards according to the invention may be formed in double width 11, triple width 12, or other multiple widths 13. 7 The lines 14 — 19 in figure 5 convey various building exterior wall surface shapes possible by way of the invention. The lines shown in figure 5 should be taken as made up of the exterior faces of polystyrene weatherboards when combined as the exterior cladding of a building. Item 20 indicates that a myriad of other wall surface shapes are possible depending on architectural requirements.

Referring to figure 6, the exterior faces of polystyrene weatherboards in accordance with the invention may have sharp edges 21 and/or rounded edges 22. These can be formed in the weatherboards before or after they are attached to wall framing, for example in the case of renovations so as to match the profile of adjacent traditional weatherboards.

Figure 7 illustrates a mode of fastening weatherboards corresponding to the figure 1 embodiment to wall framing by way of fixing members (eg nails or screws, etc) 24. As shown, a fixing member 24 is applied to the upper part of the weatherboard which is then covered over by the lower part of the next weatherboard. As also shown at figure 7, a further fixing member 26 (eg a nail or screw, etc) may be applied to a lower part of each weatherboard. The lower fixing member 26 may not be covered by another weatherboard but can be plastered over or otherwise stopped, etc. In some cases the fixing member may be left visible as an aesthetic feature.

Figure 8 shows alternative weatherboard profiles with alternative engagement portions 27 and 28.

Figures 9A and 9B illustrate the way in which polystyrene weatherboards I can combine with other building components which may or may not be of polystyrene, depending on the application concerned. The weatherboards 1 may be combined at comers of the building with exterior corner banding 29, with interior banding 30, with end caps 31 in association with surrounding brick 32 or other types of cladding. The weatherboards 1 may engage with 8 window jambs 33 attaching substantially behind windows 34, and with window sills 35 attached behind windows 34 where the sills overlap the weatherboard 1. The weatherboards may also be used in association with flashings in a similar way to the engagement configuration shown at figure 8. The weatherboards may also be used in association with other connections used with traditional weatherboards. In some embodiments of the invention a batten may be fixed to framing to facilitate drainage.

Figure 10 shows a polystyrene weatherboard 36 similar to that of figure 1 where the board is sufficiently thick to provide a good measure thermal insulation. In some embodiments the polystyrene weatherboard may include additional insulation. The rear surface of the weatherboard has a network of diamond shaped drainage groves 37 to deal with possible moisture.

Figure 11 illustrates an optional mode of joining polystyrene weatherboards 38 in the vertical dimension rather than the horizontal. The weatherboards 38 may have rusticated facings.

Figure 12 illustrates a polystyrene weatherboard 39 formed to simulate a line of bricks. Figure 13 illustrates the weatherboard 39 when fixed to wall framing 40 by way of a fixing member 41 and interlocked with other such boards to provide an exterior cladding for a building. The weatherboard 39 is the thickness of a standard brick but in other embodiments the thickness could be substantially reduced.

Figure 14 illustrates a polystyrene weatherboard with an exterior face formed to simulate corrugated iron.

Those skilled in the art will appreciate that at least some embodiments of the invention provide light weight, easily handled and fixed, thermally insulating weatherboards. 9 It should be appreciated that the weatherboards of certain embodiments of the invention may be suitable for interlocking with weatherboards of different embodiments. To achieving this the weatherboards may have complimentary interlocking means even if they differ in general appearance, etc.

While some preferred forms of the invention have been described by way of example it should be appreciated that modifications and improvements can occur without departing from the scope of the appended claims.

Claims (13)

WHAT WE CLAIM IS:

1. A polystyrene weatherboard, the weatherboard having interlocking means and a pre-installation coating, the weatherboard having sufficient structural integrity to enable it to be fixed directly to wall framing and function as an effective exterior building cladding without the need for supportive backing over and above the wall framing, the interlocking means formed to enable the weatherboard to interlock with another identical or substantially similar board in a substantially weatherproof fashion when the first mentioned weatherboard is in use.

2. A weatherboard according to claim 1, formed so that is substantially long running.

3. A weatherboard according to claim 1 or 2, wherein the pre-installation coating comprises plaster, or a spray of a polyurethane, an epoxy, or an acrylic formulation.

4. A weatherboard according to claim 1, 2 or 3, wherein the interlocking means is formed to enable tongue and groove engagement between weatherboards.

5. A weatherboard according to any one of the preceding claims, wherein the interlocking means comprises a male portion at one part of the weatherboard and a female portion at another part of the weatherboard to enable the weatherboard to engage identical or substantially similar weatherboards in a tongue and groove manner.

6. A weatherboard according to claim 1, 2 or 3, wherein the interlocking means involves a step adapted to engage a stepped or non-stepped portion of another identical or substantially similar weatherboard. 11

7. A weatherboard according to any one of the preceding claims, wherein a face of the weatherboard has grooves to facilitate drainage when the weatherboard is installed with said face immediately adjacent wall framing.

8. A weatherboard according to any one of the preceding claims, wherein the weatherboard has a central cavity.

9. A weatherboard according to any one of the preceding claims, wherein the weatherboard is formed to simulate a plurality of smaller weatherboards.

10. A weatherboard according to any one claims 1-8, wherein the weatherboard is formed to simulate a line of bricks.

11. A weatherboard according to any one claims 1-8, wherein the weatherboard is formed with a corrugated exterior surface.

12. A weatherboard substantially as described herein with reference to any of the weatherboard images of figures 1, 2, 4, 6, 8,10, 11,12 and 14.

13. A method of construction involving using a weatherboard according to any one of the preceding claims, driving a fixing member through the weatherboard to secure the weatherboard to wall framing, and engaging a second identical or substantially similar weatherboard with the first mentioned weatherboard and fixing the second mentioned weatherboard to wall framing such that a portion of the second mentioned weatherboard overlaps and thus hides the fixing member mentioned in relation to the first mentioned weatherboard. OUR BRANDS LTD By Their Attorney "INTELLECTUAL PHijVtRTY OFFICE] f-.iZ 1 3 APR 2005 RECEIVED