US20090272060A1 - Cladding System for Roofs and Facades - Google Patents

Cladding System for Roofs and Facades Download PDF

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Publication number
US20090272060A1
US20090272060A1 US12/112,232 US11223208A US2009272060A1 US 20090272060 A1 US20090272060 A1 US 20090272060A1 US 11223208 A US11223208 A US 11223208A US 2009272060 A1 US2009272060 A1 US 2009272060A1
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Prior art keywords
track
fin
lengthwise
panels
panel
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US12/112,232
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David Lucchesi
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David Lucchesi
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings 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
    • E04F13/0889Coverings 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
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/24Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like
    • E04D3/30Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like of metal
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/36Connecting; Fastening
    • E04D3/361Connecting; Fastening by specially-profiled marginal portions of the slabs or sheets
    • E04D3/362Connecting; Fastening by specially-profiled marginal portions of the slabs or sheets by locking the edge of one slab or sheet within the profiled marginal portion of the adjacent slab or sheet, e.g. using separate connecting elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings 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
    • E04F13/0801Separate fastening elements
    • E04F13/0803Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings 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
    • E04F13/0801Separate fastening elements
    • E04F13/0803Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
    • E04F13/081Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements
    • E04F13/0821Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements located in-between two adjacent covering elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings 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
    • E04F13/12Coverings 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 of metal or with an outer layer of metal or enameled metal
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F17/00Vertical ducts; Channels, e.g. for drainage

Abstract

A system for cladding roofs and facades of buildings includes elongated tracks. Each track has opposed lengthwise edges curved inwardly over opposed portions of the track. Each of a plurality of elongated panels has opposed lengthwise edges curved inwardly over opposed portions of the panel. Each panel is adapted to be interlocked between two spaced, parallel tracks. The system also includes fin components. Each fin component has two lengthwise edge portions defining a base of the fin component. A fin depends from the base of the fin component, which is adapted to be interlocked within a track with the fin extending away from the track with lengthwise edges of two proximate panels interlocked between the base of the fin component and the lengthwise edges of the track. Similar systems are provided for corners, overhangs, and jambs as may be encountered in a building.

Description

    BACKGROUND OF THE INVENTION
  • 1. Field of the Invention
  • The present invention relates to systems and methods for cladding buildings, and more particularly, to systems and methods for cladding roofs and facades of new or existing structures.
  • 2. Description of Related Art
  • A variety of systems and methods are known in the art for covering interior walls, ceilings, exterior walls, and roofs of buildings. Of such systems, many are directed to paneling or cladding systems for covering roofs and exterior walls.
  • The architectural properties and appearances of buildings are a matter of continual improvement and variation as architectural trends and technical improvements evolve over time. One popular method of treating facades and roofs involves use of cladding or paneling systems to cover exterior surfaces of buildings. Metallic panels are often used as cladding components; however, a wide variety of cladding systems use other diverse materials, including slate, marble and granite. Metallic cladding materials such as zinc and copper are easily workable, relatively light weight, and can provide architecturally sound coverings for buildings. Zinc and copper cladding panels also have the benefit of developing a decorative patina giving coloring, patterns, and textures that can improve over time.
  • Cladding systems not only provide for attractive appearance, they can contribute to weather proofing and insulation of a building. There is a need to anchor large areas of cladding to the underlying wall structures at regular intervals so as to provide good adherence to the underlying structure and to avoid bulging or warping. Many systems break up large areas of cladding with channels or ridges to create the appearance of planks.
  • An exemplary cladding system is described in U.S. Pat. No. 6,212,842 to Martinez, which describes a preformed roof cover having a quadrilateral shape, more specifically an isosceles trapezoid shape. The long edges of each panel have raised ridges. The first raised ridge has a free edge folded toward the opposite edge. The second raised edge has a circular hem opening along the outer lateral side thereof. The free edge of the first ridge can be fit into the circular hem of an adjacent panel to create a continuous cladding over a roof. After a panel element is placed on a roof, it is fastened to the underlying support structure of the roof.
  • Such conventional methods and systems generally have been considered satisfactory for their intended purpose. However, there is still a need for improved devices and methods for cladding and paneling buildings. There is also a continued need in the art for improved systems and methods that provide structurally sound, aesthetically pleasing cladding for roofs and facades while being easy to make and use.
  • SUMMARY OF THE INVENTION
  • The present invention is directed to a new and useful system for cladding roofs and facades of buildings. The system includes a plurality of elongated tracks, each track being configured and adapted to be affixed to a building and having opposed lengthwise edges curved inwardly over opposed sections of the track. A plurality of elongated panels are provided, each panel having opposed lengthwise edges curved inwardly over opposed sections of the panel. Each panel is adapted to be interlocked between two spaced, parallel tracks, with each lengthwise edge of each panel interlocked with a lengthwise edge of a track. The system also includes a plurality of fin components. Each fin component has two lengthwise edge portions defining a base of the fin component. A fin depends from the base of the fin component. Each fin component is adapted to be interlocked within a track with the fin extending away from the track with lengthwise edges of two proximate panels interlocked between the base of the fin component and the lengthwise edges of the track.
  • In one aspect of the cladding system, the tracks, panels, and fin components are configured and adapted to interlock together with each fin extending between and spaced apart from the panels interlocked with the respective fin component and track. At least one of the tracks, panels, and fin components can include a material selected from the group consisting of zinc, copper, aluminum, stainless steel, galvanized steel, terne, terne coated stainless steel, Freedom Grey (available from Englert Inc. of Perth Amboy, N.J.), Monel® (available from the Special Metals Corporation of Huntington, W. Va.), nickel, lead, and lead coated copper, or any other suitable material. The tracks, panels, and fin components can be configured and adapted to interlock together with portions of the lengthwise edges of the tracks, panels, and fin components parallel to the main section of each respective track.
  • In another aspect of the invention, a plurality of end mounting components are provided, each configured and adapted to be affixed to an underlying structure between two parallel, spaced tracks and to interlock with adjacent ends of a pair of panels that are adjacent lengthwise to one another and are interlocked with the two parallel tracks. Each panel can include a first end curved under a portion of the panel and a second end opposite the first end and curved over a portion of the panel, and the first end of each panel can be configured and adapted to interlock with the second end of a lengthwise adjacent panel and with the end mounting component. It is also contemplated that the panels can be configured and adapted to have main sections thereof substantially coplanar with one another when the panels are interlocked with respective track and fin components. Moreover, each fin component can be dimensioned and adapted to interlock with a track and pair of proximate panels with the fin depending from the respective track beyond a plane defined by the substantially coplanar main sections of the panels.
  • It is also contemplated that in various embodiments, a main section of each elongated track defines a central longitudinal axis, and each track is symmetrical across the central longitudinal axis thereof. A main section of each elongated panel can similarly define a central longitudinal axis, and each panel can be symmetrical across the central longitudinal axis thereof. The base of each fin component can also define a central longitudinal axis, and each fin component can be symmetrical across the central longitudinal axis thereof. The fin components, panels, and/or tracks can have a cross-sectional profile that includes a shape that is generally rectangular, semi-circular, T-shaped, or any other suitable shape and proportions.
  • The invention also provides a kit for making a cladding system for roofs and facades. The kit includes a plurality of elongated tracks, each track being configured and adapted to be affixed to a building and having opposed lengthwise edges curved inwardly over opposed sections of the track. The kit includes a plurality of elongated panels, each panel having opposed lengthwise edges curved inwardly over opposed sections of the panel. Each panel is configured and adapted to be interlocked between two spaced, parallel tracks with each lengthwise edge of each panel interlocked with a lengthwise edge of a track. The kit further includes a plurality of fin components. Each fin component has two lengthwise edge portions defining a base of the fin component. A fin depends from the base of the fin component. Each fin component is configured and adapted to be interlocked within a track with the fin extending away from the track so that lengthwise edges of two proximate panels are interlocked between the base of the fin component and the lengthwise edges of the track. Means are included to affix the tracks to a roof or building facade. It is envisioned that the means to affix the tracks can be configured and adapted to accommodate nails, screws, bolts, staples, rivets, or any other suitable type of fastener.
  • A method is provided in accordance with the invention for cladding roofs and facades of buildings. The method includes providing a plurality of elongated tracks, each track having opposed lengthwise edges curved inwardly over opposed portions of the track. The method further includes affixing the tracks to a building in a spaced, parallel relationship to each other. A step is included for providing a plurality of elongated panels, each panel having opposed lengthwise edges curved inwardly over opposed portions of the panel, wherein each panel is configured and adapted to be interlocked between two parallel tracks with each lengthwise edge of each panel interlocked with a lengthwise edge of a track. A further step of interlocking the panels to the tracks is provided. The method also includes providing a plurality of fin components, each fin component having two lengthwise edge portions defining a base of the fin component, and a fin depending from the base of the fin component, wherein each fin component is configured and adapted to be interlocked within a track with the fin extending away from the track so that the lengthwise edges of two proximate panels are interlocked between the base of the fin component and the lengthwise edges of the track. The method includes a still further step of interlocking the lengthwise edges of proximate panels between the base of a fin component and the lengthwise edges of each track to effect cladding of a portion of a building.
  • In accordance with one aspect of the method of cladding roofs and facades, the step of providing a plurality of fin components includes providing fin components configured and adapted so that when each fin component is interlocked with a track and associated panels, each fin is spaced apart from the lengthwise edges of the panels interlocked with the respective fin component and track. The step of interlocking the lengthwise edges of proximate panels can include interlocking the fin component with the lengthwise edges of proximate panels with the fin spaced apart from the lengthwise edges of the panels.
  • In various embodiments, the method further includes providing a plurality of end mounting components each configured and adapted to be affixed to an underlying structure between two parallel tracks and to interlock with adjacent ends of a pair of panels adjacent lengthwise to one another and both interlocked with the two parallel tracks, wherein each panel includes a first end curved over a section of the panel and a second end opposite the first end and curved over an opposed portion of the panel in a curve direction opposite that of the first end. The method can further include interlocking the first end of each panel with the second end of a lengthwise adjacent panel and with the end mounting component.
  • The step of interlocking the first end of each panel with the second end of a lengthwise adjacent panel can include interlocking lengthwise adjacent panels with main sections thereof being substantially coplanar with one another. It is also envisioned that the step of providing a plurality of elongated fin components can include providing fin components wherein each fin component is dimensioned and adapted to interlock with a track and pair of proximate panels with the fin extending perpendicularly away from the respective track beyond a plane defined by the substantially coplanar main sections of the panels.
  • A system is also provided for cladding roofs and facades at an inside corner of a building. This system includes an elongated track having opposed lengthwise edges curved inwardly over opposed portions of the track, wherein the opposed portions of the track are at a substantially right angle to one another with the lengthwise edges of the track inside the substantially right angle. A pair of elongated panels is included, each panel having opposed lengthwise edges curved inwardly over opposed sections of the panel, wherein one of the lengthwise edges of each panel is adapted to be interlocked with one of the lengthwise edges of the track. The system also includes a pair of elongated mounting components. Each mounting component has first and second lengthwise portions, wherein the first lengthwise portion is configured and adapted to be affixed to an underlying structure, and wherein the second lengthwise portion is configured and adapted to be interlocked between a lengthwise edge of the track and one of the panels.
  • In further accordance with the invention, a system is provided for cladding roofs and facades at an outside corner of a building. This system includes an elongated track having opposed lengthwise edges curved inwardly over opposed sections of the track, wherein the opposed portions of the track are at a substantially right angle to one another with the lengthwise edges of the track outside or extending from the substantially right angle. A pair of elongated panels is included, each panel having a pair of lengthwise edges curved inwardly over opposed portions of the panel, wherein a lengthwise edge of each panel is adapted to be interlocked with one of the lengthwise edges of the track. The system also includes a pair of elongated mounting components. Each mounting component has first and second lengthwise portions. The first lengthwise portion of the mounting component is configured and adapted to be affixed to an underlying structure. The second lengthwise portion of the mounting component is configured and adapted to be interlocked between a lengthwise edge of the track and a lengthwise edge of one of the panels.
  • The invention also provides a system for cladding roofs and facades at a jamb of a building. This system includes an elongated end closure component having opposed lengthwise edges at a substantially right angle to one another. An elongated panel has lengthwise edges curved inwardly over opposed sections of the panel. An elongated mounting component having first and second lengthwise portions is also included, wherein the first lengthwise portion is configured and adapted to be affixed to an underlying structure, and wherein the second lengthwise portion is configured and adapted to interlock the lengthwise edge of the elongated panel between a lengthwise edge of the end closure component and the second lengthwise portion of the mounting component.
  • These and other features of the systems and methods of the subject invention will become more readily apparent to those skilled in the art from the following detailed description of a preferred embodiment taken in conjunction with the drawings.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • So that those skilled in the art to which the subject invention appertains will readily understand how to make and use the systems and methods of the subject invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
  • FIG. 1 is a cross-sectional plan view of portion of a cladding system in accordance with the present invention, showing edges of two panels interlocked between a track and a fin component;
  • FIG. 2 is front view of a portion of the cladding system of FIG. 1, showing the spacing between the fin and two panels proximate therewith;
  • FIG. 3 is a perspective view of a portion of the cladding system of FIG. 1, showing the fin extending away from the track, between the panels and protruding beyond the outward faces of the panels;
  • FIG. 4 is a front view of the cladding system of FIG. 1 in place on an exterior wall of a building, showing the tiling pattern of the panels;
  • FIG. 5 is a cross-sectional elevation view of a lap joint of the cladding system of FIG. 1, showing ends of two adjacent panels interlocked together with an end mounting component affixed to a building;
  • FIG. 6 is a cross-sectional plan view of a cladding system for an inside corner in accordance with the present invention, showing a treatment at an inside corner of a building with edges of two panels interlocked with an angled track and two mounting components;
  • FIG. 7 is cross-sectional plan view of a cladding system for an outside corner or overhang in accordance with the present invention, showing a treatment at an outside corner of a building with edges of two panels interlocked with an angled track and two mounting components;
  • FIG. 8 is a cross-sectional plan view of a cladding system for use adjacent to a door or window jamb in accordance with the present invention, showing a panel interlocked with an end closure component and a mounting component;
  • FIG. 9 is a cross-sectional plan view of a portion of a cladding system in accordance with the present invention, showing a track accommodating a fin component with a generally semi-circular cross-sectional profile;
  • FIG. 10 is a cross-sectional plan view of a portion of a cladding system in accordance with the present invention, showing a track accommodating a fin component with a generally rectangular cross-sectional profile;
  • FIG. 11 is a cross-sectional plan view of a portion of a cladding system in accordance with the present invention, showing a track accommodating a fin component with a generally T-shaped cross-sectional profile;
  • FIG. 12 is a cross-sectional plan view of a portion of a cladding system in accordance with the present invention, showing a track accommodating a fin component with an elongate rectangular cross-sectional profile;
  • FIG. 13, is a cross-sectional plan view of a portion of a cladding system in accordance with the present invention, showing a track accommodating a fin component with a generally square cross-sectional profile, with two tandem fasteners anchoring the track; and
  • FIG. 14 is a cross-sectional plan view of a portion of a cladding system in accordance with a the present invention, showing a track accommodating a fin component with a generally paddle-shaped cross-sectional profile.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
  • Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject invention. In accordance with the invention, a system for cladding roofs and facades of buildings is provided, including a plurality of elongated tracks, each track being configured and adapted to be affixed to a building and having opposed lengthwise edges curved inwardly over opposed sections of the track. A plurality of elongated panels are provided, each panel having opposed lengthwise edges curved inwardly over opposed sections of the panel. Each panel is adapted to be interlocked between two spaced, parallel tracks, with each lengthwise edge of each panel interlocked with a lengthwise edge of a track. The system also includes a plurality of elongated fin components. Each fin component has two lengthwise edge portions defining a base of the fin component. A fin extends substantially perpendicularly from the base of the fin component. Each fin component is adapted to be interlocked within a track with the fin extending away from the track with lengthwise edges of two proximate panels interlocked between the base of the fin component and the lengthwise edges of the track.
  • For purpose of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of the system in accordance with the invention is shown in FIG. 1 and is designated generally by reference character 100. Other embodiments of a system in accordance with the invention, or aspects thereof are provided in FIGS. 2-8, as will be described. The system of the invention can be used for cladding roofs or facades of buildings, or in any other suitable application to provide an architecturally sound covering of underlying building structures.
  • In accordance with the invention, cladding system 100 includes a plurality of elongated tracks 102, one of which is shown in FIG. 1. Each track 102 is configured and adapted to be affixed to an underlying structure 122 that is part of a building or static structure. Opposed lengthwise edges 104 and 104′ of track 102 are curved inwardly over opposed sections 106 and 106′ of track 102, respectively.
  • The system also includes elongated panels 108. Each panel 108 has opposed lengthwise edges 110 and 110′ curved inwardly over opposed sections 112 and 112′ of the respective panels 108. Each panel 108 is adapted to be interlocked between two spaced, parallel tracks 102, with each lengthwise edge 110/110′ of each panel 108 interlocked with a lengthwise edge 104/104′ of a track 102.
  • With further reference to FIG. 1, the system also includes an elongated fin component 114 configured for interlocking with each track 102. Each fin component 114 has two lengthwise edge portions 116 and 116′ defining a base 118 of the fin component 114. A fin 120 extends substantially perpendicularly from base 118 of fin component 114. Each fin component 114 is adapted to be interlocked, as shown in FIG. 1, within a track 102 with fin 120 extending away from track 102 with lengthwise edges 110 and 110′ of two proximate panels 108 interlocked between base 118 of fin component 114 and lengthwise edges 104 and 104′ of track 102. While fin 120 is shown an described extending substantially perpendicularly from base 118 of fin component 114, those skilled in the art will appreciate that fin 120 can be angled with respect to base 118 at any suitable angle.
  • As indicated in FIGS. 1 and 2, tracks 102, panels 108, and fin components 114 are configured and adapted to interlock together so that each fin 120 extends between and is spaced apart from panels 108 interlocked with the respective fin component 114 and track 102. The gaps between fin 120 and neighboring panels 108 have a width “w” as shown in FIGS. 1 and 2. Moreover, tracks 102, panels 108, and fin components 114 can be configured and adapted to interlock together with portions of their lengthwise edges 104/110/116 and 104′/110′/116′ parallel to a main section 107 of tracks 102. Longitudinal edges 110 and 110′ of panels 108 are sandwiched between longitudinal edges 104 and 104′ of tracks 102 and bases 118 of fin components 114, as shown in FIG. 1. In this arrangement, panels 108 are securely affixed to cladding system 100, which is affixed to an underlying structure 122 or other static structure with any suitable fasteners 124. Fin component 114 also forms a covering to help shield track 102 and fasteners 124 from exposure to the elements.
  • Tracks 102, panels 108, and fin components 114 can include zinc, copper, aluminum, stainless steel, galvanized steel, terne, terne coated stainless steel, Freedom Grey (available from Englert Inc. of Perth Amboy, N.J.), Monel® (available from the Special Metals Corporation of Huntington, W. Va.), nickel, lead, and lead coated copper, or any other suitable materials. It is not necessary for tracks 102, panels 108, and fin components 114 to be of the same material, however, care should be exercised when using dissimilar metals in combinations that are easily compromised by galvanic corrosion. Copper and Zinc have various advantages for use in cladding system 100, including ease of forming the various components, malleability for the formation of relatively thin, light weight cladding components, and the decorative surface qualities produced as the cladding naturally weathers and patinates.
  • Sections 106 and 106′ of each track 102 define a central longitudinal axis A, and each track is symmetrical across axis A. Base 118 of each elongated fin component 114 can also define a central longitudinal axis, which in FIG. 2 is the same as axis A. Each fin component 114 is symmetrical across axis A. Similarly, main section 113 of each elongated panel 108 can similarly define a central longitudinal axis B, and each panel 108 can be symmetrical across the axis B. Symmetrical parts facilitate interchangeability and simplicity in orienting the various components during assembly. However, those skilled in the art will readily appreciate that while tracks 102, panels 108, and fin components 114 are symmetrical, the symmetry is optional and any of these components can be asymmetrical without departing from the spirit and scope of the invention.
  • Referring now to FIG. 3, several panels 108 can be interlocked with each pair of parallel tracks 102 to form a substantially planar surface with main sections 113 of panels 108. Fin 120 extends essentially perpendicularly away from track 102 and protrudes beyond the substantially planar surface of main panel sections 113. When several parallel tracks 102 have panels 108 and fin components 114 interlocked therewith, tiling patterns can be formed. FIG. 4 shows an exemplary tiling pattern on an exterior wall of a building including windows 117. The pattern in FIG. 4 includes panels 108 joined end to end in the vertical direction and interlocked with tracks 102 (not shown in FIG. 4) and fin components 114 in the horizontal direction. Proximate columns of panels 108 are staggered so that end joints 126 thereof are located vertically at about the center of the length of proximate panels 108. However, those skilled in the art will readily appreciate that system 100 can be oriented with the lengths of tracks 102, panels 108, and fin components 114 running in the horizontal direction rather than the vertical, or on any other suitable angle. While end joints 126 are shown as being substantially perpendicular to tracks 102, it is also contemplated that end joints 126 can be oriented at any suitable angle with respect to tracks 102. Moreover, any staggering pattern can be used, including patterns where panels 108 are of different lengths from one another to provide a random staggering appearance, without departing from the spirit and scope of the invention. It is advantageous for tracks 102 to run the entire length of system 100 to provide a continuous anchor for panels 108 to underlying structure 122.
  • Each end joint 126 between panels 108 provides for panels 108 to be physically interlocked together and anchored to the underlying structure 122. As shown in FIG. 5, system 100 includes a plurality of end mounting components 128, each of which is configured and adapted to be affixed to underlying structure 122 between two parallel tracks 102 (not shown in FIG. 5) and to interlock with adjacent ends of a pair of panels 108 that are adjacent lengthwise to one another and are interlocked with the same two parallel tracks 102. Each panel 108 includes a first end 130 curved under portion of the panel and a second end 132 opposite first end 130 and curved over a portion of panel 108. Thus, first end 130 of a first panel 108 and second end 132 of an adjacent panel 108 can interlock together, as shown in FIG. 5, to form joint 126. End mounting component 128 is also interlocked with first and second ends 130/132 to affix panels 108 to underlying structure 122.
  • Second end 132 of each panel 108 is set inward from main portion 113 of panel 108 so that when interlocked end to end, main sections 113 of interlocked panels 108 are substantially coplanar with one another. This gives panels 108 a substantially sigmoid or S-shaped cross section in the longitudinal direction. It is also possible to have first end 130 protrude outward from main section 113 in lieu of or in addition to second end 132 being set inward. Moreover, those skilled in the art will readily appreciate that setting second end 132 inward is optional, since panels 108 can be configured to ramp or protrude slightly out of the plane of tracks 102 at their first or second end 130/132. These configurations are advantageous especially if panels 108 are oriented as shown in FIG. 5 with first ends 130 downward and second ends 132 upward, since precipitation and condensation water tend to be shed over joint 126 without entering system 100 or reaching underlying structure 122.
  • It is envisioned that the components of system 100 can be manufactured in various shapes, sizes, and configurations individually, can be provided as a prefabricated kit, can be custom formed on or off a building sight, or can be provided in any other suitable way. Nails, screws, bolts, staples, rivets, and/or any other suitable means can be used as fasteners to affix tracks 102 and end mounting components 128 to an underlying structure. Bores can be pre-formed through tracks 102 for accommodating fasteners to affix tracks 102 to an underlying structure. It is also possible to form bores in tracks 102, such as by drilling, prior to applying fasteners to tracks 102. The bores can be reinforced, for example with threaded reinforcement means configured to engage bolts or screws, if bolts or screws are used as fasteners. If tracks 102 are of a material and thickness that can be easily punctured by fasteners such as nails, bores through the tracks can be omitted.
  • A method is provided in accordance with the present invention for cladding roofs and facades of buildings. The method includes providing a plurality of elongated tracks (e.g. tracks 102). The method further includes affixing the tracks to a building in a spaced, parallel relationship to each other. As discussed above, any suitable means can be used for affixing the tracks to the underlying structure. A step is included for providing a plurality of elongated panels (e.g. panels 108). With the tracks in place, the panels can be interlocked to the tracks. It is possible to deform the panels and/or tracks slightly to interlock the panels. It is also possible to interlock an end of a panel with ends of two adjacent, parallel tracks and slide the panel along the tracks into place. An end mounting component (e.g. component 128) can be provided between each endwise adjacent pair of panels, as described above, and the panels can be interlocked therewith to provide further anchoring to the underlying structure in addition to the anchoring provided by the tracks.
  • The method also includes providing a plurality of elongated fin components (e.g. fin components 114). The lengthwise edges of proximate panels can be interlocked between the base of a fin component and the lengthwise edges of each track to provide a cladding over a portion of a building. As with the panels, the fin components can be snapped into place by slightly deforming the fin components and/or tracks, or the fin components can be slid down their respective tracks from an end thereof. It is also possible to interlock the fin component with the track prior to interlocking the panels. Interlocking fin component 114 before or after interlocking panels 108 can be made easier by squeezing fin 120 to make it easier to slide fin component 114 along track 102. With the components of system 100 interlocked in place, there can be some play into and out of the plane of panels 108 for the components interlocked in tracks 102. This play is desirable for ease of installation and appearance, however, the play is optional since system 100 can also be made without play.
  • System 100 has been described above in general for covering flat portions of buildings or other static structures. It is also contemplated that system 100 can be configured to clad portions of buildings that are non-flat, such as curved or angled surfaces. Additionally, system 100 can include components for treating inward corners, outward corners, door/window jambs, and other portions of buildings as needed. The following descriptions for special conditions are exemplary, and those skilled in the art will readily appreciate that system 100 can include other treatments as needed without departing from the sprit and scope of the invention.
  • With reference now to FIG. 6, for cladding roofs and facades at inside or inward corners, system 100 can include an elongated L-shaped track 134 having opposed lengthwise edges 136 and 136′ curved inwardly over portions 138 and 138′ of track 134. Portions 138 and 138′ of track 134 comprise two lengthwise portions at a substantially right angle α to one another with lengthwise edges 136 and 136′ of track 134 inside angle α. While the inward corner shown in FIG. 6 is a substantially right angle, those skilled in the art will readily appreciate that corners at any other angle can be treated in a similar fashion with the two lengthwise portions of track 134 angled to match.
  • A pair of elongated panels 108 can each be interlocked with one of lengthwise edges 136 and 136′ of track 134, much as described above with respect to track 102. A pair of elongated mounting components or cleats 140 are provided for affixing track 134 to underlying structure 122. Each cleat or mounting component 140 has a first lengthwise portion 142 and second lengthwise portion 144, giving cleat 140 a generally S- or Z-shaped cross-section as shown in FIG. 6. First lengthwise portion 142 is configured and adapted to be affixed to the underlying structure 122, by any suitable fasting means as described above. Second lengthwise portion 144 of cleat 140 is configured and adapted to be interlocked between a lengthwise edge 136/136′ of track 134 and one of the panels 108. Cleats 140 do not need to run the entire length of track 134, but can rather be spaced intermittently along the length of track 134. To construct the corner treatment shown in FIG. 6, track 134 can be affixed using cleats 140 with appropriate fasteners, and then panels 108 can be interlocked at an end of track 134 and then slid along track 134 into place. The ends of panels 108 can be interlocked with a lap joint 126, as described above. It may also be possible to snap panels 108 into place without sliding them along track 134, depending on the dimensions of the various components and the flexibility of the materials used.
  • Referring now to FIG. 7, for cladding roofs and facades at an outside or outward corners, system 100 can include an elongated track 146 having opposed lengthwise edges 148 and 148′ curved inwardly over portions 150 and 150′ of track 146. Portions 150 and 150′ of track 146 have two lengthwise sections at a substantially right angle β to one another with lengthwise edges 148 and 148′ of track 146 outside of angle β. As with the treatment of FIG. 6, while the outward corner shown in FIG. 7 is a substantially right angle, those skilled in the art will readily appreciate that corners at any other angle can be treated in a similar fashion with the two lengthwise sections of track 146 angled to match.
  • A pair of elongated panels 108 can each be interlocked with respective lengthwise edges 148 and 148′ of track 146, much as described above with respect to track 102. A pair of elongated mounting components or cleats 152 are provided for affixing track 146 to underlying structure 122. Each cleat or mounting component 152 has a first lengthwise portion 154 and second lengthwise portion 156. First lengthwise portion 154 is configured and adapted to be affixed to underlying structure 122, by any suitable fasting means as described above. Second lengthwise portion 156 of cleat 152 is configured and adapted to be interlocked between a lengthwise edge 148 or 148′ of track 146 and one of the panels 108. A portion of cleat 152 can optionally wrap around edge 148 or 148′ of track 146 to be between track 146 and a lengthwise edge 110 of panel 108, as shown in FIG. 7. Panels 108 have a special edge configuration that is slightly wider than the normal panels 108 to accommodate cleats 152. However, it is also possible to use the same panels 108 used generally with system 100. To construct the corner treatment shown in FIG. 7, the same techniques described above with respect to the inner corner treatment shown in FIG. 6 can be used.
  • As shown in FIG. 8, system 100 includes a treatment for jambs of windows, doors, or any other jamb treatment. An elongated end closure component 158 is provided having opposed lengthwise edges 160 and 160′ at a substantially right angle to one another. As described above, any suitable angle can be accommodated, with edges 160 and 160′ angled to match. End component 158 is affixed between a jamb 162 and underlying structure 122. An elongated panel 108 can be interlocked with the lengthwise edge 110 thereof proximate the exterior edge 160 of end component 158. An elongated cleat or mounting component 140, such as those described above with respect to FIG. 6, can be affixed to underlying structure 122 with its second lengthwise portion 144 interlocked with lengthwise edge 110 of panel 108 so that lengthwise edge 110 of panel 108 is located between the exterior portion of end closure component 158 and the second lengthwise portion 144 of cleat 140. End closure piece 158 can run the entire length of the jamb. The treatment shown in FIG. 8 can be constructed by affixing cleat 140 to underlying structure 122, sliding or snapping panel 108 into cleat 140, affixing end component 158 around the jamb corner to be interlocked between panel 108 and underlying structure 122, and then assembling the jamb.
  • While FIGS. 5-8 have shown exemplary treatments for lap joints, corners, and jamb conditions, those skilled in the art will readily appreciate that the treatments described above are optional and any suitable treatments can be used in conjunction with system 100 without departing from the spirit and scope of the invention. Moreover, the variations of the components of system 100 are also possible. FIG. 9 shows one such example, in which panels 108 are interlocked with a track having width X wide enough to accommodate a fin component 214 that is relatively wide compared to fin 120 described above. Fin 220 of fin component 214 has a cross-sectional profile that is generally semi-circular. Similarly, FIG. 10 shows another example in which a fin component 314 having a fin 320 with a generally rectangular cross-sectional profile is accommodated by track 202.
  • Further examples include fin component 414 having fin 420 with a generally T-shaped cross-section, as shown in FIG. 11, and component 514 having a fin 520 with an elongate rectangular cross-section shown in FIG. 12 having a tip that is flat as opposed to pointed. FIG. 13 shows a fin component 614 having a fin 620 with a generally square cross-sectional profile, and a track 602 accommodating two tandem fasteners 624. FIG. 14 shows an example in which a fin component 714 has a fin 720 with a generally paddle-shaped cross sectional profile. Those skilled in the art will readily appreciate that the fin components, tracks, panels, and other components of system 100 can have any suitable shapes, profiles, proportions, and sizes without departing from the spirit and scope of the invention.
  • The methods and systems of the present invention, as described above and shown in the drawings, provide for cladding of interior and exterior surfaces of buildings and other static structures with superior properties including improved ease of assembly while being structurally and architecturally sound. Moreover, the systems described above are modular and have assembly/installation that can go together rapidly, while providing flexibility for variations in shape and proportion to give different appearances as appropriate. While the apparatus and methods of subject invention have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and scope of the subject invention.

Claims (25)

1. A system for cladding roofs and facades of buildings comprising:
a) a plurality of elongated tracks, each track being configured and adapted to be affixed to a building and having opposed lengthwise edges curved inwardly over opposed sections of the track;
b) a plurality of elongated panels, each panel having opposed lengthwise edges curved inwardly over opposed sections of the panel, wherein each panel is adapted to be interlocked between two spaced, parallel tracks, with each lengthwise edge of each panel interlocked with a lengthwise edge of a track; and
c) a plurality of fin components, each fin component having two lengthwise edge portions defining a base of the fin component, and a fin depending from the base of the fin component, wherein each fin component is adapted to be interlocked within a track, the fin extending away from the track, with lengthwise edges of two proximate panels interlocked between the base of the fin component and the lengthwise edges of the track.
2. A system for cladding roofs and facades as recited in claim 1, wherein the tracks, panels, and fin components are configured and adapted to interlock together with each fin extending between and spaced apart from the panels interlocked with the respective fin component and track.
3. A system for cladding roofs and facades as recited in claim 1, wherein at least one of the tracks, panels, and fin components includes a material selected from the group consisting of zinc, copper, aluminum, stainless steel, galvanized steel, terne, terne coated stainless steel, Freedom Grey, Monel®, nickel, lead, and lead coated copper.
4. A system for cladding roofs and facades as recited in claim 1, further comprising a plurality of end mounting components each configured and adapted to be affixed to an underlying structure between two parallel, spaced tracks and to interlock with adjacent ends of a pair of panels adjacent lengthwise to one another and interlocked with said two parallel tracks, wherein each panel includes a first end curved under a portion of the panel and a second end opposite the first end and curved over a portion of the panel, and wherein the first end of each panel is configured and adapted to interlock with the second end of a lengthwise adjacent panel and with an end mounting component.
5. A system for cladding roofs and facades as recited in claim 4, wherein the panels are configured and adapted to have the main sections thereof substantially coplanar with one another when the panels are interlocked with respective tracks and fin components.
6. A system for cladding roofs and facades as recited in claim 5, wherein each fin component is dimensioned and adapted to interlock with a track and pair of proximate panels with the fin depending from the respective track beyond a plane defined by the substantially coplanar main sections of the panels.
7. A system for cladding roofs and facades as recited in claim 1, wherein a main section of each elongated track defines a central longitudinal axis, and wherein each track is symmetrical across the central longitudinal axis thereof.
8. A system for cladding roofs and facades as recited in claim 1, wherein a main section of each elongated panel defines a central longitudinal axis, and wherein each panel is symmetrical across the central longitudinal axis thereof.
9. A system for cladding roofs and facades as recited in claim 1, wherein the base of each fin component defines a central longitudinal axis, and wherein each fin component is symmetrical across the central longitudinal axis thereof.
10. A system for cladding roofs and facades as recited in claim 1, wherein the tracks, panels, and fin components are configured and adapted to interlock together with portions of the lengthwise edges of the tracks, panels, and fin components parallel to the main section of each respective track.
11. A kit for making a cladding system for roofs and facades, the kit comprising:
a) a plurality of elongated tracks, each track being configured and adapted to be affixed to a building and having opposed lengthwise edges curved inwardly over opposed portions of the track;
b) a plurality of elongated panels, each panel having opposed lengthwise edges curved inwardly over opposed portions of the panel, wherein each panel is configured and adapted to be interlocked between two spaced, parallel tracks with each lengthwise edge of each panel interlocked with a lengthwise edge of a track;
c) a plurality of fin components, each fin component having two lengthwise edge portions defining a base of the fin component, and a fin depending from the base of the fin component, wherein each fin component is configured and adapted to be interlocked within a track with the fin extending away from the track so that lengthwise edges of two proximate panels are interlocked between the base of the fin component and the lengthwise edges of the track; and
d) means to affix the tracks to a roof or building facade.
12. A kit for making a cladding system for roofs and facades as recited in claim 11, wherein the means to affix the tracks are configured and adapted to accommodate fasteners of a type selected from the group consisting of: nails, screws, bolts, staples, and rivets.
13. A kit for making a cladding system for roofs and facades as recited in claim 11, wherein the tracks, panels, and fin components are configured and adapted to interlock together with each fin extending between and spaced apart from the panels interlocked with the respective fin component and track.
14. A kit for making a cladding system for roofs and facades as recited in claim 11, further comprising a plurality of end mounting components each configured and adapted to be affixed to an underlying structure between two parallel tracks and to interlock with adjacent ends of a pair of panels adjacent lengthwise to one another and interlocked with the two parallel tracks, wherein each panel includes a first end curved under a portion of the panel and a second end opposite the first end and curved over a portion of the panel, and wherein the first end of each panel is configured and adapted to interlock with the second end of a lengthwise adjacent panel and with the end mounting component.
15. A kit for making a cladding system for roofs and facades as recited in claim 14, wherein the panels are configured and adapted to have the main sections thereof be substantially coplanar with one another when the panels are interlocked with respective tracks and fin components, and wherein each fin component is dimensioned and adapted to interlock with a track and pair of proximate panels with the fin extending perpendicularly away from the respective track beyond a plane defined by the substantially coplanar main sections of the panels.
16. A kit for making a cladding system for roofs and facades as recited in claim 11, wherein a fin component has a cross-sectional profile that is generally rectangular.
17. A kit for making a cladding system for roofs and facades as recited in claim 11, wherein a fin component has a cross-sectional profile that is generally semi-circular.
18. A method of cladding roofs and facades of buildings comprising:
a) providing a plurality of elongated tracks, each track having opposed lengthwise edges curved inwardly over opposed portions of the track;
b) affixing the tracks to a building in a spaced, parallel relationship to each other;
c) providing a plurality of elongated panels, each panel having opposed lengthwise edges curved inwardly over opposed portions of the panel, wherein each panel is configured and adapted to be interlocked between two parallel tracks with each lengthwise edge of each panel interlocked with a lengthwise edge of a track;
d) interlocking the panels to the tracks;
e) providing a plurality of fin components, each fin component having two lengthwise edge portions together defining a base of the fin component, and a fin depending from the base of the fin component, wherein each fin component is configured and adapted to be interlocked within a track with the fin extending away from the track so that the lengthwise edges of two proximate panels are interlocked between the base of the fin component and the lengthwise edges of the track; and
f) interlocking the lengthwise edges of proximate panels between the base of a fin component and the lengthwise edges of each track to effect cladding of a portion of a building.
19. A method of cladding roofs and facades as recited in claim 18, wherein the step of providing a plurality of fin components includes providing fin components configured and adapted so that when each fin component is interlocked with a track and panels, each fin is spaced apart from the lengthwise edges of panels interlocked with the respective fin component and track, and wherein the step of interlocking the lengthwise edges of proximate panels includes interlocking the fin component with the lengthwise edges of proximate panels with the fin spaced apart from the lengthwise edges of the panels.
20. A method of cladding roofs and facades as recited in claim 18, further comprising:
a) providing a plurality of end mounting components each configured and adapted to be affixed to an underlying structure between two parallel tracks and to interlock with adjacent ends of a pair of panels adjacent lengthwise to one another and both interlocked with the two parallel tracks, wherein each panel includes a first end curved over a portion of the panel and a second end opposite the first end and curved over the an opposed portion of the panel in a curve direction opposite that of the first end; and
b) interlocking the first end of each panel with the second end of a lengthwise adjacent panel and with the end mounting component.
21. A method of cladding roofs and facades as recited in claim 20, wherein the step of interlocking the first end of each panel with the second end of a lengthwise adjacent panel includes interlocking lengthwise adjacent panels with main sections thereof being substantially coplanar with one another.
22. A method of cladding roofs and facades as recited in claim 21, wherein the step of providing a plurality of elongated fin components includes providing fin components wherein each fin component is dimensioned and adapted to interlock with a track and pair of proximate panels with the fin extending perpendicularly away from the respective track beyond a plane defined by the substantially coplanar main sections of the panels.
23. A system for cladding roofs and facades at an inside corner of a building comprising:
a) an elongated track having opposed lengthwise edges curved inwardly over opposed portions of the track, wherein the opposed portions of the track are at a substantially right angle to one another with the lengthwise edges of the track inside the substantially right angle;
b) a pair of elongated panels, each panel having opposed lengthwise edges curved inwardly over opposed portions of the panel, wherein one of the lengthwise edges of each panel is adapted to be interlocked with one of the lengthwise edges of the track; and
c) a pair of elongated mounting components, each mounting component including first and second lengthwise portions, wherein the first lengthwise portion is configured and adapted to be affixed to an underlying structure, and wherein the second lengthwise portion is configured and adapted to be interlocked between a lengthwise edge of the track and one of the panels.
24. A system for cladding roofs and facades at an outside corner of a building comprising:
a) an elongated track having opposed lengthwise edges curved inwardly over opposed portions of the track, wherein the opposed portions of the track are at a substantially right angle to one another with the lengthwise edges of the track outside the substantially right angle;
b) a pair of elongated panels, each panel having a pair of lengthwise edges curved inwardly over opposed portions of the panel, wherein a lengthwise edge of each panel is adapted to be interlocked with one of the lengthwise edges of the track; and
c) a pair of elongated mounting components, each mounting component having first and second lengthwise portions, wherein the first lengthwise portion is configured and adapted to be affixed to an underlying structure, and wherein the second lengthwise portion is configured and adapted to be interlocked between a lengthwise edge of the track and a lengthwise edge of one of the panels.
25. A system for cladding roofs and facades at a jamb of a building comprising:
a) an elongated end closure component having opposed lengthwise edges at a substantially right angle to one another;
b) an elongated panel having a lengthwise edge curved inwardly over opposed portions of the panel; and
c) an elongated mounting component having first and second lengthwise portions, wherein the first lengthwise portion is configured and adapted to be affixed to an underlying structure, and wherein the second lengthwise portion is configured and adapted to interlock the lengthwise edge of the panel between a lengthwise edge of the end closure component and the second lengthwise portion of the mounting component.
US12/112,232 2008-04-30 2008-04-30 Cladding System for Roofs and Facades Abandoned US20090272060A1 (en)

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