US20230340789A1

US20230340789A1 - Systems and methods for building panels with patterned edge for moisture drainage and air ventilation

Info

Publication number: US20230340789A1
Application number: US18/017,017
Authority: US
Inventors: Steven Norwood
Original assignee: Norwood Architecture Inc
Current assignee: Norwood Architecture Inc
Priority date: 2020-07-20
Filing date: 2021-07-20
Publication date: 2023-10-26
Also published as: CA3185837A1; WO2022020390A1

Abstract

A building panel for ventilation and drainage includes a rear surface, a front surface, and a patterned edge spanning from the rear surface towards the front surface that, when the building panel is mounted at a substrate, creates a ventilation and drainage path between the building panel and the substrate. The front surface may have a drainage element thereon such that, when an additional building panel is installed and overlaps the building panel, the drainage element creates a ventilation and drainage path between the building panel and the additional building panel. The front surface may be a front surface of a first panel portion and the rear surface may be a rear surface of a second panel portion.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application benefits from and claims priority to U.S. provisional patent application Ser. No. 63/054,098, filed on Jul. 20, 2020. This application also benefits from and claims priority to U.S. provisional patent application Ser. No. 63/055,133, filed on Jul. 22, 2020. The disclosures of each of the aforementioned applications are incorporated herein by reference in their entireties.

BACKGROUND

The exterior roof and wall elements of buildings are comprised of multiple elements. The exterior walls include wall coverings that provide weather protection for the building. These coverings include but are not limited to veneers, siding, exterior insulation and finish systems, architectural trim, flashing, cladding, panels, wall shingles, wall shakes, wall tiles, and similar elements. The exterior walls also typically include a weather-resistant barrier or water-resistive barrier (WRB) beneath the cladding or siding as an example.
The roof similarly includes roof coverings that provide weather protection for the building. The roof covering, or roof assembly, may include flashing, roof shingles, roof shakes, roof tiles, roof panels, roll roofing, built-up roofing, thermoset roofing, liquid-applied roof coatings, sprayed polyurethane foam roofing, and thermoplastic roofing as examples. Roof underlayment may include roofing felt, and a variety of roll membrane products.
Wall and roof shingles, shakes, and tiles have historically been fabricated and installed as single units individually placed and secured with one or two fasteners. Shingles shakes, and tiles are often secured only to the underlying sheathing or to furring strips installed perpendicular to the roof or wall framing. They are often not secured to the framing members such as rafters, or wall framing such as studs.
Roof panels and wall cladding or siding often span over multiple framing members in the roof or wall and are attached to the frame of the structure typically through the sheathing. In cases, roof and wall panels are attached to furring strips. The furring strips are attached to the underlying framing through the sheathing.

SUMMARY OF THE EMBODIMENTS

The above-discussed wall coverings, roof coverings, and the assemblies on which they are mounted sometimes suffer from damage due to moisture and lack of ventilation and drainage behind the wall coverings or roof coverings. To reduce the potential for damage due to moisture and to improve the ventilation and drainage in roof and wall systems, embodiments of a geometric building panel system include at least one geometric building panel fabricated with a patterned edge(s) that, through the geometry of the edge of the geometric building panels, creates a ventilation and drainage path when the geometric building panels are installed at an angle to an underlying substrate. The geometric building panel systems and methods discussed herein may serve as a roof or wall covering. The geometric building panels of the systems discussed herein may be roof panels, roof shingles, roof shakes, roof tiles, wall shingles, walls siding, wall shakes, wall tiles, wall panels, or wall cladding. The geometric building panel(s) may be of one-piece construction, or may include multiple layers of the same or different material, wherein one of the layers includes the patterned edge to create the ventilation and drainage path. As used herein, the terms “geometric building panel,” “building panel,” “panel,” and the like are interchangeable unless otherwise specified or understood by those with ordinary skill in the art.
In a first aspect, a building panel for ventilation and drainage includes: a rear surface and a front surface having a drainage element thereon such that, when an additional building panel is installed and overlaps the building panel, the drainage element creates a ventilation and drainage path between the building panel and the additional building panel. The building panel may include a patterned edge spanning from the rear surface towards the front surface that, when the building panel is mounted at a substrate, creates a second ventilation and drainage path between the building panel and the substrate.
In a second aspect, a building panel for ventilation and drainage includes: a front surface and a rear surface aligned with respect to the front surface such that, when the building panel is mounted adjacent an additional building panel, the front surface and an additional front surface of the additional building panel are substantially parallel. The building panel may include a patterned edge spanning from the rear surface towards the front surface that, when the building panel is mounted at a substrate, creates a ventilation and drainage path between the building panel and the substrate or the building panel and an adjacent building panel.
In a third aspect, a building panel for ventilation and drainage includes a first panel portion defining a front surface of the building panel and a second panel portion defining a rear surface of the building panel. The building panel may include a patterned edge spanning from the rear surface towards the front surface that, when the building panel is mounted at a substrate, creates a ventilation and drainage path between the building panel and the substrate.

BRIEF DESCRIPTION OF THE FIGURES

FIGS. 1A-B illustrate an embodiment of the geometric building panel system where a plurality of geometric building panels are mounted on the exterior wall substrate of a structure in the form of siding or cladding, in embodiments.

FIG. 2 is a diagram of a geometric building panel, which is an example of one of the geometric building panels of FIG. 1 , in embodiments.

FIG. 3 illustrates examples of geometric building panels with various patterned edges, in embodiments.

FIG. 4A-B illustrates an embodiment of a geometric building panel system where the geometric building panels are mounted on the exterior wall of a structure in the form of siding or cladding, in embodiments.

FIG. 5 illustrates an embodiment of a geometric building panel, which is an embodiment of the geometric building panels discussed above, and patterned edge where a portion of the geometric building panel is reinforced with a mesh, lath, or fabric, in embodiments.

FIG. 6 illustrates a geometric building panel, which is an embodiment of the geometric building panels discussed above, that may be of standard fabrication and a separate patterned edge piece with a patterned edge that is fabricated separately from the body of the geometric building panel.

FIG. 7 is a cross section view of a geometric building panel system of lapped geometric building panels with patterned upper edges, in embodiments.

FIG. 8 depicts a perspective view of the first geometric building panel of FIG. 7 , showing protrusions extending from an exterior (or front) face of the geometric building panel, in embodiments.

FIG. 9 illustrates an embodiment of a geometric building panel, which is an embodiment of the geometric building panels discussed above, and patterned edge where a portion of the geometric building panel includes channels, in embodiments.

FIG. 10 illustrates an embodiment of a layered geometric building panel, which is an embodiment of the geometric building panels discussed above.

FIG. 11 depicts a geometric building panel of one-piece construction that includes a front panel portion, and a rear panel portion, in embodiments.

FIG. 12 shows a front perspective view of the geometric building panel of FIG. 10 or 11 .

FIG. 13 is a cross section view of a geometric building panel system of lapped geometric building panels with patterned upper edges and a front panel portion and a rear panel portion, in embodiments.

FIGS. 14A-B depict a patterned edge that allows for vertical mounting of the geometric building panels, in embodiments.

FIG. 15 is a cross section view of geometric building panels installed as roof panels such as roof shingles or shakes or tiles, in embodiments.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIGS. 1A-B illustrates an embodiment of the geometric building panel system (100) where a plurality of geometric building panels (102) are mounted on the exterior wall substrate (110) of a structure in the form of siding or cladding, in embodiments. FIG. 1 illustrates three rows (106(1))-106(3)) of siding with each row (106) of siding lapped over an adjacent, lower row of siding. The figure shows in the lowest or first row (106(1)) of siding a geometric building panel (102(1)). The first row 106(1) of siding is shown mounted on a starter strip (108) provided to establish the correct angle for the geometric building panel (102(1)) relative to the substrate (110) on which the geometric building panel (102(1)) is mounted to. Spacing between the substrate (110) and first row (106(1)) (or other rows of siding) may be created/set by means other than a starter strip, such as washers, or double-headed washer fasteners (e.g., fastener (720) shown in FIG. 7 and discussed below). In this embodiment, the substrate (110) is a wood based sheathing with a covering of weather or water resistive barrier, or WRB (not shown). In all the figures herein, weather or water resistive barrier may be applied over the sheathing or substrate. However, the substrate (110) may be other material or another component, such as insulation board, backing board, etc. The geometric building panel (102) may have a length such that the geometric building panel (102), when installed on a structure, spans multiple framing bays of the structure. Although not shown, additional furring strips beyond the starter strip (or roof battens when the geometric building panels (102) are used as roof shingles or tiles) may be installed over the substrate (110) which may include sheathing, and/or weather resistive barrier or roofing membrane).
When each geometric building panel (102) is mounted at an angle (α) to the substrate (110) as shown, the geometric building panel system (100) creates a capillary break, drainage, and/or ventilation space, path or plane (112) where a top-portion of each geometric building panel (102) has a patterned edge (120) that, at least a part of, does not touch the substrate (110). The patterned edge (120) may have any shape of patterned edges discussed herein, including those shown in FIG. 3 and discussed below. In an embodiment, the patterned edge (120) is cut into a geometric building panel of one-piece construction. In an embodiment, the patterned edge (120) is embossed into a geometric building panel of one-piece construction. The patterned edge (120) may be formed during manufacturing of the geometric building panel, or during a secondary manufacturing process. In at least some embodiments, patterned edge (120) is applied during a secondary manufacturing process. In an embodiment, the patterned edge may be fabricated separately and bonded or fused to a standard non-geometric building panel.
As used herein, the term “patterned edge”, including the patterned edge (120), may indicate an uninterrupted and continuous outline, contour, and/or patterned perimeter along the edge of the geometric building panel to provide said capillary break, drainage and/or ventilation plane or path along the entire length of the geometric building panel. In at least some embodiments, the term “patterned edge” as used herein, including the patterned edge (120), means an interrupted contour along the edge of the geometric building panel. For example, the patterned edge may be interrupted at regular or irregular intervals to allow for stronger sections of edge or for fastener locations. The term “patterned edge” may refer to an edge of the geometric building panel, or a portion thereof, that spans from a rear surface of the geometric building panel towards a front surface of the geometric building panel. Thus, the term “patterned edge” indicates different structure than protrusions or channels/grooves that protrude from or recess into the rear surface of the geometric building panel. Accordingly, in at least some embodiments, a “patterned edge” as used herein may only provide said capillary break, drainage and/or ventilation plane or path when the geometric building panel is mounted at an angle with respect to a substrate at which the geometric building panel is mounted to.
In an embodiment, the angle (α) of the geometric building panel (102) to the substrate (110) may be approximately five to ten degrees from vertical (plumb). Angles outside of five to ten degrees may be utilized without departing form the scope hereof. In at least one embodiment, the patterned edge (120) spans from a rear surface to a front surface of the geometric building panel (102).
The geometric building panel (102) lap over each other at the overlap region, the bottom of which is indicated by dashed line (114). Proximate areas of geometric building panel contact with the substrate, an optional fastening hole (116) may be provided through the geometric building panel (102) (e.g., defined by the geometric building panel (102)). The fastening hole (116) may be located within a region of the geometric building panel (102) where a longitudinal cross-section of the geometric building panel (102) crosses the fastening hole (116) also crosses the patterned edge (120). The geometric building panels (102) contact the substrate at discrete points or areas (118) and due to the angle at which the geometric building panels are mounted, the patterned edge (120) creates space or gap between the back of the geometric building panel and the substrate (110) along portions of the edge. In embodiments, spacing (119) between the points or areas (118) of contact may be less than or equal to three inches to allow for horizontal structural support of the siding. In embodiments, spacing (119) between the points or areas (118) of contact may be less than or equal to two inches to allow for horizontal structural support of the siding. In embodiments, the vertical height (121) e.g., height of the serrations, undulations, and/or crenellations, of the points or areas (118) may be less than or equal to three inches such that the patterned edge is less susceptible to breaking. In embodiments, the vertical height e.g., height of the serrations, undulations, and/or crenellations, of the points or areas (118) may be less than or equal to two inches such that the patterned edge is less susceptible to breaking. The geometric building panel or individual layers or portions may be of any thickness, including 1/32 inch, 1/16 inch, ⅛ inch, ¼ inch, ⅜ inch, ½ inch, and ⅝ inch.
FIG. 2 is a diagram view 200 of a geometric building panel (202), which is an example of one of the geometric building panels (102) of FIG. 1 , in embodiments. FIG. 2 illustrates a geometric building panel (202) mounted at an angle (204) to a substrate (206). Angle (204) is an example of angle (α) and substrate (206) is an example of substrate (110) discussed above with respect to FIG. 1 . The geometric building panel (202) includes a patterned edge (208) (which is an example of patterned edge (120) of FIG. 1 ) which in the embodiment of FIG. 2 includes serrations with points (210(1)—(3)). As can be seen in the shadow (213) cast by the patterned edge (208), the angle at which the geometric building panel is mounted to the substrate creates a capillary break, drainage, and/or ventilation space, path or plane (212) between each of the contact points (210) of the patterned edge (208) and the substrate (206). The geometric building panel (202) may include an optional fastening zone (215) along which the geometric building panel, indicated by a hatched pattern in the figure, may be fastened to the substrate or structure. In an embodiment the fastening zone (215) may occur adjacent the patterned edge in a portion that is reinforced or thicker than the balance of the geometric building panel (e.g., portion (510) discussed below). The geometric building panel (202) may include an optional pre-drilled or manufactured hole (214) for fastening the geometric building panel that may be located anywhere on the geometric building panel. In one embodiment, the optional pre-drilled or manufactured hole (214) is located at or above the fastening zone (215). In an embodiment the pre-drilled or manufactured holes (214) may serve as an additional ventilation and drainage feature. The pre-drilled or manufactured holes (214) may exceed in number the minimum required for fastening of the geometric building panel.
FIG. 3 illustrates examples of geometric building panels (302) with various patterned edges, in embodiments. The patterned edge of any of the geometric building panels may have a shape selected from the group of shapes including serrated, saw-tooth pattern, notched pattern, toothed pattern, serrated pattern, zigzag pattern, undulation pattern, scalloped pattern, stepped pattern, curved pattern, pattern of tabs, pattern of points, and crenulated pattern. The geometric building panels 302 shown in FIG. 3 are examples of geometric building panels (102) of FIG. 1 . Geometric building panel (302(1)) includes a serrated edge (304). Thus, geometric building panel (302(1)) is also an example of geometric building panel (202) of FIG. 2. Geometric building panel (302(2)) includes an undulated edge (306). Geometric building panel (302(3)) includes a zigzag edge (308). FIG. 3 also includes examples of Geometric Panels used as shakes, shingles, or tiles for walls or roofs that may not extend over multiple framing bays. These examples include edges that may be used on any geometric building panel discussed herein. Geometric building panel (302(4)) includes a ‘toothed’ or crenulated edge (310). Geometric building panel (302(5)) includes a scalloped edge (312). Geometric building panel (302(6)) includes a shallow patterned edge (314) sufficient to create a capillary break when mounted at an angle to a substrate. The geometric building panels (302(1)-(6)) may include an optional fastening zone (316) along which the geometric building panels, indicated by a dashed line, may be fastened to the substrate or structure. The zone provides a defined zone to allow fastening without positioning the geometric building panel to align with underlying framing or structure. The zone may occur at any area of the geometric building panels and may follow the patterned edge, as shown by non-linear fastening zone edge (318).
In any of the above-described shapes of the patterned edges, spacing between the points or areas of contact (e.g., the upper-most edges of the shapes in any configuration shown in FIG. 3 , such as between the crenellations, serrations, or undulations shown in FIG. 3 ) may be less than or equal to three inches to allow for horizontal structural support of the siding. In any of the above-described shapes of the patterned edges, spacing between the points or areas of contact (e.g., the upper-most edges of the shapes in any configuration shown in FIG. 3 , such as between the crenellations, serrations, or undulations shown in FIG. 3 ) may be less than or equal to two inches to allow for horizontal structural support of the siding.
FIG. 4 illustrates an embodiment of a geometric building panel system (400) where the geometric building panels (402) are mounted on the exterior wall of a structure in the form of siding or cladding, in embodiments. Geometric building panels (402) are examples of geometric building panels (102), and thus the discussion of geometric building panels (102) applies to geometric building panels (402), and vice versa, and is incorporated here by reference, unless otherwise stated or contradictory to the following. FIG. 4 illustrates three rows (404(1)— (3)) of siding or cladding. The figure shows in the lowest or first row (404(1)) of siding geometric building panels (402(1)-(2)). The first row (404(1)) of siding is mounted on starter strip (108) provided to establish the correct angle for the geometric building panels (402) relative to the substrate (110). The angle between the back of the geometric building panel is indicated as Alpha similar to FIG. 1B. Spacing between the substrate (110) and first row (404(1)) (or other rows of siding) may be created/set by means other than a starter strip, such as washers, or double-headed washer fasteners (e.g., fastener (720) shown in FIG. 7 and discussed below). The exterior face (406) of the geometric building panels (402) in this embodiment is plumb or vertical) when mounted and the cross section of the geometric building panels (402) is a polygonal and is not rectilinear. The interior face (408) of the geometric building panels (402) that faces the substrate (110) is mounted at an angle to the substrate (130). Thus, because the interior face (e.g., the rear surface) (408) is angled with respect to the exterior face (e.g., the front surface) (406), when the geometric building panel (402) is mounted adjacent an additional building geometric building panel, the front surface and an additional front surface of the additional geometric building panel are substantially parallel. When mounted the geometric building panels system (400) creates a drainage and ventilation path, or capillary break (413) where the interior face (408) of the geometric building panels (402) only touch the substrate (110) at limited contact points as defined by the patterned edge (410) of each geometric building panels (402). The patterned edge (410) may have any shape of patterned edges discussed herein, including those shown in FIG. 3 and discussed above. The patterned edge (410) spans from a rear surface towards, but not all the way to, a front surface of the geometric building panel (402). At the areas of geometric building panel contact with the substrate, an optional fastening hole (412) may be provided. The fastening hole may occur at any location on the geometric building panel. In an embodiment the fastening hole may be pre drilled or manufactured. In an embodiment the fastening holes may serve as an additional ventilation and drainage feature and may exceed in number the minimum required for fastening of the geometric building panel. The geometric building panels (402) contact the substrate (110) at discrete points or areas (414) and due to the angle at which the back of geometric building panels are mounted, create a capillary break, drainage, and/or ventilation space, path or plane (413) between the geometric building panel and the substrate.
FIG. 5 illustrates an embodiment of a geometric building panel (502), which is an embodiment of the geometric building panels (102) discussed above, and patterned edge (520) where a portion (510) of the geometric building panel is reinforced with a mesh, lath, or fabric, in embodiments. Instead of, or alternatively to, being reinforced, the portion (510) may be thicker than the remaining portion of the geometric building panel. Thus, any of the embodiments of geometric building panels discussed herein may further include a portion thereof that is reinforced with a mesh, lath, fabric, or other material. The portion thereof (e.g., portion (510)) may be located at an overlap region where an upper geometric building panel, when the given geometric building panel is installed, overlaps and covers the overlap portion that is reinforced such that the overlap region is not visible when installed. In embodiments, the portion (510) is the entire geometric building panel (502). In other words, the reinforcement is throughout, or on, the entire geometric building panel (502).
FIG. 6 illustrates a geometric building panel (602), which is an embodiment of the geometric building panels (102) discussed above, that may be of standard fabrication and a separate patterned edge piece (610) with a patterned edge (620) that is fabricated separately from the body of the geometric building panel. In an embodiment, the patterned edge of (602) does not extend to the horizontal leg of (610) creating freeboard between the lowest elements of the patterned edge and the horizontal leg of (610). In this embodiment, the separate patterned edge piece (610) also serves as a flashing element between siding, or cladding panels.
FIG. 7 is a cross section view of a geometric building panel system (700) of lapped geometric building panels (702) with patterned upper edges, in embodiments. Although shown a having a specific geometric shape, the lapped geometric building panels (702) may be any of the geometric building panels discussed above. The lowest geometric building panel (702(1)) includes an optional protrusion (770) that forms a capillary break, drainage, and/or ventilation space, path or plane (780(1)) between the geometric building panel and the geometric building panel (702(2)) mounted over it. The protrusion (770) may be located in an overlap region of the geometric building panel (702) (e.g., a region of the lower geometric building panel ((702(1)) that is overlapped by the adjacent upper geometric building panel (702(2)). Although a single protrusion (770) is shown in the cross-section view, there may be more protrusions, aligned or not aligned without departing from the scope hereof. For example, said protrusions (770) may include any of the omnidirectional ventilation and drainage patterns described in US patent application publication number 2020/0087928A1, filed Nov. 25, 2019 and which is incorporated by reference herein in its entirety). In embodiments, the protrusions (770) may not be protrusions, but instead be cutout draining channels or other ventilation and drainage element.
Protrusion (770) may be embossed on the front face during manufacturing of the geometric building panel (702). This configuration provides a unique advantage in ventilation and drainage systems of siding panels. Particularly, fiber-cement siding panels are difficult to create patterns (e.g., the protrusion pattern) on both sides thereof. However, via embossing, stamping, or otherwise forming the pattern during buildup of the fiber cement panel (e.g., by putting a pattern on one of the rollers during a Hatcheck process) one can put a pattern on one side of the panel. The protrusion (770) may be the same material (e.g., integral to or added onto a main panel portion as a separate component but of the same material) as the body of the geometric building panel (702). The protrusion (770) may be different material than (e.g., added onto as a separate component) as the body of the geometric building panel (702).
The present application allows for a method of manufacture where the geometric building panel includes a patterned edge and also protrusions or channels on one face of the geometric building panel. This method of manufacture allows geometric building panels to be cut from larger panels in the manufacturing process. In the fiber cement Hatschek process, the individual geometric building panels may be cut using standard equipment but with the modification that the individual geometric building panels are cut from the large panel along a zig-zag or serrated line as an example. One face of the geometric building panel may include protrusions, easily manufactured using standard drum roller and patterning processes. A single serrated cut in the larger panel (e.g., to create the shape of geometric building panel (302(1)) creates patterned edges for two geometric building panels (one for adjacent geometric building panels during the manufacturing of the fiber cement siding). This greatly simplifies manufacturing while at the same time providing a product that has two planes of ventilation and drainage—one between the geometric building panel and the substrate, and one between the geometric building panel and an adjacent geometric building panel in lapped siding.
Although not shown, any other of the geometric building panels (702) in the geometric building panel system (700) may include said optional protrusion (770). The geometric building panels (702) are mounted at an angle to substrate or structure (740) (which may be substrate (110) discussed above) and are fastened with a standard fastener (750). The patterned edge (715) creates a capillary break, drainage, and/or ventilation space, path or plane (725) between the geometric building panels (702) and the substrate or structure (740). FIG. 7 also shows an alternate or additional embodiment where the geometric building panel (702(2)) with a Patterned edge (715(2)) is mounted at an angle to the substrate or structure (740) and fastened with a double headed fastener, a fastener with a washer, or any fastener with a head (720) that creates a capillary break, drainage, and/or ventilation space, path or plane (780(2)) between the geometric building panel (702(2)) and the geometric building panel lapped over it (702(3)). In an embodiment the fastener (720) includes a washer with edges that match the mounted angle of the geometric building panels. In an embodiment, the fastener (702) washer or head creates a thermal break between the geometric building panels and the substrate and/or the geometric building panels and other panels. In an embodiment, one or more double-headed fasteners are placed into the substrate prior to the mounting of the siding or cladding. The double headed fastener placed under the siding or cladding between the siding or cladding and the substrate creates a capillary break, drainage, and/or ventilation space, path or plane between the back of the siding or cladding and the substrate.
FIG. 8 depicts a perspective view of the first geometric building panel (702(1)) of FIG. 7 , showing protrusions (770) extending from an exterior (or front) face (802) of the geometric building panel.
FIG. 9 illustrates an embodiment of a geometric building panel (902), which is an embodiment of the geometric building panels (102) discussed above, and patterned edge (904) where a portion (910) of the geometric building panel includes channels (906). Channels (906) are additional or alternative to the protrusions (770) discussed above with respect to FIG. 7 . Channels (906) are shown as straight channels, but may also include bumps, protrusions, cutaways, ridges, meandering channels, squiggles, or valleys. The channels (906) may be random or follow a regular pattern and may be of any shape or dimension. Portion (910) may be included in any of the embodiments of geometric building panels discussed herein. Portion (910) may be the same location as portion (510) discussed above with reference to FIG. 5 . Thus, portion (910) may be located at an overlap region where an upper geometric building panel, when the given geometric building panel is installed, overlaps and covers the overlap portion that is reinforced such that the overlap region is not visible, or a portion thereof is not visible, when installed. In an embodiment, the channels or protrusions may be on either or both the front or back face of any of the geometric building panels.
FIG. 10 illustrates an embodiment of a layered geometric building panel (1000), which is an embodiment of the geometric building panels (102) discussed above. FIGS. 1-9 illustrate geometric building panels that are of one-piece construction. The term “one-piece construction” as used herein refers to geometric building panels that are made of a single material, or a composite of multiple materials that are intermixed together (e.g., fiber cement), but generally are a consistent composition of said multiple materials. This “one-piece construction” may also be referred to as “solid” and/or “monolithic.” The term “layered” as used herein refers to geometric building panels having a first layer of a first material, and a distinguishable second, or more, layers of a separate material. The second or more layers of separate material may be of the same as the first material, but two or more layers joined together. “Joined” includes gluing, adhering, bonding, heat bonding, fusing, welding, laminating, mechanically fastening, pressing, or otherwise attaching or joining two or more layers together. Referring to FIGS. 1-9 , although shown as a one-piece construction, those geometric building panels may also be layered construction. For example, the geometric building panels may be layered, or multi-layered, laminate materials. As another example, the geometric building panel shown in FIGS. 7 and 8 may include a first layer that forms the patterned edge, and a second layer that includes the protrusions (770) or channels (906).
In FIG. 10 , the geometric building panel (1000) may include a front panel portion (1002) that is joined to a rear panel portion (1004). Thus, of the interior (or rear) surface (1006) of the geometric building panel (1000) is a rear surface of the rear panel portion (1004) and the exposed (or front) surface (1008) of the geometric building panel (1000) is the front surface of the front panel portion (1002). The rear panel portion (1004) includes patterned edge (1010), which may be the shape and have any of the characteristic of any patterned edge discussed herein. The patterned edge (1010) spans from the rear surface of the rear panel portion (1004) to the rear surface of the front panel portion (1002) of the geometric building panel (1000). In an embodiment the layers are manufactured separately, are physically distinct, and are installed individually, sequentially, or together.
In embodiments, the front panel portion (1002) and the rear panel portion (1004) may be of one-piece construction as defined above or may be separate pieces of the same or different materials. In embodiments, the front panel portion (1002) and the rear panel portion (1004) are different materials. In embodiments, the front panel portion (1002) is made of any one or more of fiber cement, clay, cement, cement based materials, concrete, asphalt, wood, wood based materials, wood fiber, oriented strand board, hardboard, high pressure laminate, PVC, plastic, rubber, foam, foam insulation, extruded polystyrene, expanded polystyrene, polyisocyanurate, fly-ash, waste materials, glass, glass fiber reinforced concrete and cement, glass fiber reinforced plastic, carbon fiber reinforced plastic, cellulose, insulation, and metal or any other material used in the fabrication of roof and wall cladding and coverings, and any combination thereof. In embodiments, the rear panel portion (1004) is made of any one or more of fiber cement, clay, cement, cement based materials, concrete, asphalt, wood, wood based materials, wood fiber, oriented strand board, hardboard, high pressure laminate, PVC, plastic, rubber, foam, foam insulation, extruded polystyrene, expanded polystyrene, polyisocyanurate, fly-ash, waste materials, glass, glass fiber reinforced concrete and cement, glass fiber reinforced plastic, carbon fiber reinforced plastic, cellulose, insulation, and metal or any other material used in the fabrication of roof and wall cladding and coverings, and any combination thereof. Any combination of the above-discussed materials for the front panel portion (1002) and the rear panel portion (1004) are contemplated by this disclosure. In a specific embodiment the front panel portion (1002) is fiber cement, and the rear panel portion (1004) is insulation. In a specific embodiment the front panel portion (1002) is wood, and the rear panel portion (1004) is insulation. In a specific embodiment the front panel portion (1002) is fiber cement, and the rear panel portion (1004) is foam. In a specific embodiment the front panel portion (1002) is wood, and the rear panel portion (1004) is foam. In a specific embodiment the front panel portion (1002) and the rear panel portion (1004) are of wood based hardboard.
In FIG. 11 , the geometric building panel (1100) is of one-piece construction and may include a front panel portion (1102) and a rear panel portion (1104), similar to front panel portion (1002) and rear panel portion (1004), but the front panel portion (1102) and a rear panel portion (1104) are integral with one another. This configuration (and the configuration of FIG. 10 ) provides the advantage that the overlap of one geometric building panel to another does not need to cover the entire area of the patterned edge because the front panel portion (1102) covers the patterned edge. In addition, the front panel portion (1102) reinforces and protects the patterned edge of the rear panel portion (1104). The patterned edge (1110) spans from the rear surface of the rear panel portion (1104) towards, but not all the way to, the front surface of the front panel portion (1106) of the geometric building panel (1100). In an embodiment the edges of the front panel portion shown in FIG. 11 , or the front panel layer shown in FIG. 10 , extend beyond the rear panel portion and rear panel layer respectively.
FIG. 12 shows a front perspective view of the geometric building panel (1000) or (1100), where dashed line (1202) indicates whether the front panel portion or layer and the rear panel portions or layer of the geometric building panel are layered (e.g., geometric building panel (1000)), or integral within the geometric building panel (e.g., geometric building panel 1100). In such embodiment, the patterned edge may be cut, routed, or otherwise embossed into a geometric building panel of one-piece construction, or established via layered construction where one or more of the layers includes a patterned edge.
FIG. 13 is a cross section view of a geometric building panel system (1301) of lapped geometric building panels (1300) with patterned upper edges and a front panel portion or layer (1302) and a rear panel portion or layer (1304), in embodiments. Geometric building panels (1300) may be either geometric building panel (1000) or (1100) discussed above. Although not shown, any of the geometric building panels (1300) may include protrusions similar to protrusions (770) and/or channels similar to channels (906) as discussed above. In an embodiment the protrusions (770) or channels (906) may occur on any surface of either the front or rear panel layer or portion. The lowest geometric building panel in system (1301) may be mounted on a starter strip (not shown in FIG. 13 , e.g., starter strip (108) discussed above) provided to establish the correct angle for the geometric building panel relative to the substrate on which the geometric building panel is mounted to. A capillary break, drainage and/or ventilation plane (1320) between the substrate and first row (or other rows of siding) may be created/set by means other than a starter strip, such as washers, or double-headed washer fasteners (e.g., fastener (720) shown in FIG. 7 and discussed above).
The patterned edge (1305) of geometric building panels (1300) creates a capillary break, drainage, and/or ventilation space, path or plane (1320) between the geometric building panels (1300) and the substrate or structure (1306). FIG. 13 also shows an alternate or additional embodiment where the geometric building panels (1300) include a drip edge (1308). Drip edges (1308) are created by a first edge (1310) of the front panel portion (1302) extending beyond a second edge (1312) of the second panel portion (1304). The first edge (1310) and the second edge (1312) are on opposite sides of the geometric building panel (1300) than the patterned edge (1305). Drip edges (1308) reduce the risk of capillary action at the drip edge and promote drainage from the front face of the geometric building panel.
FIGS. 14A-B depict an additional embodiment of the patterned edge (1404) that allows for vertical mounting of the geometric building panels (1402). Geometric building panels (1402) are shown having a first panel portion or layer (1406) and a second panel portion or layer (1408). Although shown as layered configuration, geometric building panels (1402) may alternatively be of one-piece construction. The first layer (1406) is shown as a front (exterior) layer, and the second layer (1408) is shown as a rear (interior layer). The second panel layer (1408) includes the patterned edge (1404). When water or air gets behind the second layer (1408), between the geometric building panel and the substrate (110) the geometric building panel is mounted thereon, it may escape via a ventilation and drainage path or plane (1410) created by the patterned edge. The ventilation and drainage path or plane (1410) is defined between peaks (1412) of the patterned edge (1404). In the embodiment of FIG. 14 , a first dimension (e.g., height) (1414) of the patterned edge (1404) is greater than a second dimension (e.g., height) (1416) of the overlap portion (1418) of the first panel portion. This ratio of first height (1414) to second height (1416) creates a gap, or capillary break (1417) between adjacent geometric building panels (1402) where water or air can escape. The valleys (1420) of the patterned edge (1404) may be sloped or tapered from the rear to front to aid in water drainage downward and outward when mounted.
In FIGS. 10-14B, although two layers are shown, there may be more layers without departing from the scope hereof. Moreover, in any embodiment of the geometric building panels herein, there may be additional coatings, such as paint, glazing, film, or other protective and/or nonstructural coatings covering the front surface, rear surface, any surface, or all surfaces of the geometric building panel.
FIG. 15 is a cross section view of geometric building panels (1502) installed as roof panels such as roof shingles or shakes. Geometric building panels (1502) may include any of the above-discussed features of geometric building panels herein. Specifically, the geometric building panels (1502) include at least a patterned edge (1504), which may be any of the patterned edges discussed herein, and are shown installed with each upper-adjacent geometric building panels lapped over the lower-adjacent geometric building panels. Like the siding or cladding panels, the roof panels (1502) may begin with a starter strip (1508) (or other spacer, washer, spaced fastener, etc.) to establish the proper slope of the panels relative to the substrate (1506) (which, in this embodiment is a roof substrate or sheathing), and optional roof membrane or underlayment (1510). In an embodiment, the starter strip (1508) of the wall and roof panels includes drainage and ventilation features.
Combinations of Features and Advantages
Features described above as well as those claimed below may be combined in various ways without departing from the scope hereof. The following enumerated examples illustrate some possible, non-limiting combinations and additional features/advantages of any of the above-described embodiments shown and described with respect to the figures. In the following discussion, the terms “geometric building panels,” “geometric building panel system,” “patterned edge,” “protrusion,” refer to any of the corresponding features discussed above in any of the above-discussed embodiments unless otherwise stated.
In any embodiment discussed herein, the geometric building panels described herein can be used as a wall covering.
In any embodiment discussed herein, the geometric building panels described herein can be used as a roof covering.
In embodiments, the angle of the geometric building panels to a substrate to which they are mounted on may be approximately five to ten degrees from vertical (plumb). When installed as a system of overlapping geometric building panels, mounted at an angle to a substrate, the upper patterned edge of any one of the geometric building panels therein said installed system provide a continuous capillary break, drainage and/or ventilation plane or path between the substrate and the respective geometric building panel. In at least some embodiments, the patterned edge is uninterrupted and continuous along the edge of the geometric building panel to provide said capillary break, drainage and/or ventilation plane or path along the entire length of the geometric building panel. This approach advantageously eliminates ‘pinch-points’ in the system that can block or trap water and cause degradation of and damage to the wall panel/cladding/siding and/or the underlying substrate. The free movement of air and water around the limited contact points the patterned edge of the geometric building panel system allows moisture and humidity to disperse, reducing the risk of damage and degradation to moisture sensitive substrates and panels. The increased capacity of the geometric building panel system to disperse moisture and to dry provides durability benefits over the common wall and roofing coverings currently used, and further expands the materials that can be used for wall and roof coverings to a broader range of recycled, lower density, and non-traditional materials. As an example, some hardboard wall covering products with a history of moisture problems will benefit from the increased air flow, as will some siding and cladding products that tend to absorb and hold water in the wall or roof covering.
In at least some embodiments, the patterned edge is formed in the geometric building panel in a secondary manufacturing process. In at least some embodiments, the patterned edge is applied in a secondary manufacturing process.
Embodiments herein may enable the geometric building panel to be directly mounted to the underlying substrate (e.g., a sheathing panel with or without a WRB) and the patterned edge alone creates a drainage plane or path, a ventilation plane or path, or a capillary break between the geometric building panel and the substrate on which it is mounted without the use of separate channels, ridges, bumps, or cut-aways in the body of the geometric building panel.
Fastening of the geometric building panels may occur anywhere on or within the geometric building panels. Pre-manufactured fastening holes or notations may occur anywhere on or within the geometric building panels. To reduce the risk of panel breakage and to provide support, the general area of the patterned edge that is closest to touching, or touches, the underlying substrate, structure, sheathing, or WRB is the likely fastening point, and may include a fastening hole or notation indicating where to fasten the geometric building panels to the substrate. The fastening points may be any one or more of predetermined, pre-marked, pre-drilled, reinforced, or any combination thereof. The fastening point, hole, or notation, may be located within a region of the geometric building panel where a longitudinal cross-section of the geometric building panel crosses the fastening hole also crosses the patterned edge.
The geometric building panel system provides unique advantages to other cladding and roofing systems currently produced. When mounted at an angle, the patterned edge of the geometric building panel(s) creates portions of the geometric building panel that contact the underlying substrate or structure at discrete locations, with surrounding open spaces, or gaps that do not contact the underlying substrate or structure. The open spaces or gaps create a capillary break, a drainage path or plane, and a ventilation path or plane that improves the drainage and ventilation of the system. The open spaces or gaps created by the patterned edge are illustrated in the above-discussed figures, including, but not limited to, FIG. 2 .
The geometric building panels can either span over multiple framing bays similar to exterior siding or roof panels, or can be limited to smaller units that are not large enough to span over multiple framing bays or rafters similar to shingles, shakes, and tiles. Thus, in at least some embodiments, any of the above-discussed geometric building panels may be in the form of a patterned edge on individual roofing tiles or shakes that do not span across multiple rafters.
When the geometric building panels span over multiple framing members they provide an efficiency of installation advantage over individual shingles, shakes, and tiles as the speed of installation is greater per square foot for larger panel products. The drainage and ventilation feature is maintained in geometric building panels that extend over multiple framing bays. For each piece, the geometric building panels that span multiple framing bays provide multiple fastening locations to the frame of the building. Individual shingles, shakes, and tiles are fastened to the sheathing, or require additional furring systems to provide the same fastening strength that multi-framing bay cladding panels such as the larger geometric building panels may provide.
When the geometric building panels are used in a system of single shingles, shakes, or tiles, the geometric building panels also provide a capillary break, drainage and/or ventilation path or plane through the limited contact points of the shingles, shakes, or tiles. The capillary break, drainage and/or ventilation feature of the patterned edge is provided at the edge of the shingle, shake, or tile and the panel can be manufactured, flat, and planar, with a rectangular shape. The smaller sizes provide greater design pattern flexibility and ease of installation in irregular areas.
In both the smaller single shingles, shake or tiles and the larger multi-framing bay geometric building panels in the form of siding or cladding, the use of drainage and ventilation surface features on the exterior or interior face of the geometric building panel are not necessary to provide the drainage and ventilation feature of the patterned edge. The ‘exterior face’ is the face of the geometric building panel exposed to the exterior or atmosphere (e.g., visible or exposed when installed). The ‘interior face’ of the geometric building panel is the face of the geometric building panel exposed to the substrate, panel, or structure on which the geometric building panel is mounted. Similarly, the inner or rear face or surface of a geometric building panel faces the substrate, and the outer or front face or surface of a geometric building panel faces the exterior.
The geometric building panels provide a manufacturing and fabrication advantage over other drainage and ventilation panel designs that solely utilize bumps, ridges, indentations, cutaways or other features located on, or in the interior or exterior face of the geometric building panel as defined above. The geometric building panels can be manufactured as ‘flat’ panels without protrusions or cut outs on the exterior or interior face. Alternatively, the geometric building panels may include protrusions or cutouts on only the exterior face (e.g., one face of the geometric building panel) at an overlap location (e.g., as discussed above regarding protrusion (770)). The patterned edge of the flat geometric building panels can be subsequently cut or formed into or from the edge of the geometric building panels. The majority of siding and cladding panel manufacturing in wood based, fiber cement, plastic, fly-ash, metal, and composite panels are fabricated in industrial processes that produce ‘flat’ panels that are rectilinear in cross section. These industrial processes create board and panel products that are ‘flat’, particularly on the interior and exterior face similar to sawn boards, plywood panels, extruded boards, and Oriented Strand Board (OSB) panels. Currently the edges of the individual siding or cladding panels are cut through water jet, mechanical saws, or other means. To produce the patterned edge, the geometric building panel edges can be cut in an undulated, zigzag, scalloped, or other pattern as described herein.
The geometric building panels can be manufactured in the currently available industrial processes as the interior and exterior faces of the geometric building panels are flat similar to currently produced fiber cement, OSB, plywood, and hardboard products. In cross section, the geometric building panels may be rectilinear. The interior face of the geometric building panels that is mounted against the substrate or structure can be ‘flat’ or formed in one plane, and the drainage and ventilation feature provided only by the patterned edge. The geometric building panels and the patterned edge provide a ventilation, drainage, and/or capillary break mechanism without, necessarily, the use of raised or lowered elements in the interior or exterior faces of the geometric building panel.
Another benefit and advantage of the invention as described is that the geometric building panels can be easily stacked. As the geometric building panels do not necessarily require protrusions on their interior or exterior faces, the risk of damage to the geometric building panels in transport is reduced. In addition, the packaging of the geometric building panels is simplified and more efficient over panels that include raised drainage features in the interior or exterior face of the geometric building panels. The stacking efficiency is also a benefit is certain manufacturing processes that require curing, drying or autoclaving of the geometric building panels as the geometric building panels can be stacked efficiently.
The geometric building panels can be fabricated in one material and do not necessarily require laminates, reinforcements, or multiple layers. Alternately, the geometric building panels can be fabricated as a laminate of the same, similar, or different materials. The geometric building panels can be fabricated of composite materials in a single or multiple layers. The geometric building panels may have mesh, lath, and/or fabric reinforcement throughout the entire length and width of the geometric building panel, or may have said mesh, lath, and/or fabric reinforcement at just the patterned edge location.
The geometric building panels may include a portion adjacent the patterned edge that includes channels, bumps, squiggles, ridges, or other patterns. The channels, bumps, squiggles, ridges, or other patterns may follow a regular pattern, or may be random. Said channels, bumps, squiggles, ridges, or other patterns may be located at an overlap region between a first geometric building panel, and an adjacent geometric building panel lapped thereover. Thus, the channels, bumps, squiggles, ridges, or other patterns provide the advantage of providing a second ventilation and drainage path between an exterior or front surface of a first geometric building panel and a rear or interior surface of an adjacent overlapping geometric building panel.
The geometric building panel system has the advantage of providing a capillary break, ventilation and drainage in a system without necessarily introducing separate drainage mats or furring strips. This advantage simplifies the installation and reduces costs. The capillary break, ventilation and drainage mechanism is provided by the geometric building panels and patterned edge system without the labor and material costs of additional furring or drainage mats.
The geometric building panels may be of rigid or flexible materials. When fabricated of rigid materials, the geometric building panels eliminate the concerns of soft or flexible drainage mats which have reportedly lead to ‘blow-outs’ at the back side of conventional cladding panels when fastened over soft of flexible drainage mats.
The geometric building panels discussed herein may reduce energy costs by providing for the flow of air and subsequent cooling advantages for the walls and roofs of buildings. In addition, energy use and cost may be reduced by insulating geometric building panels, or insulating portions and/or layers of the geometric building panels, such as the layered panels shown in FIGS. 10-13 discussed above.
In any of the above embodiments, the geometric building panels system may include multiple geometric building panels with patterned edge(s) mounted to a wall or roof. Where mounted on a wall, the installation may begin with a drainage and ventilation furring starter strip (as described in Norwood Architecture, Inc. patent application publication number 2020/0087928A1, filed Nov. 25, 2019 and which is incorporated by reference herein in its entirety) or with an alternate design to provide a capillary break, drainage and/or ventilation at the base of the wall assembly. Spacing between the substrate and first row (or other rows of siding) may be created/set by means other than a starter strip, such as washers, or double-headed washer fasteners (e.g., fastener (720) shown in FIG. 7 and discussed above). The geometric building panels are installed shingle-lapped with each geometric building panel overlapping the lower geometric building panel as shown in FIG. 1 . The initial starter strip provides the support for the angle of the initial, first geometric building panel installed.
In an embodiment the geometric building panel system is incorporated into a system of wall or roof flashing and membranes to provide a capillary break, drainage, and/or ventilation and weather protection to the substrate and structure on which the geometric building panels are mounted.
The geometric building panels may be installed over a WRB and sheathing. The geometric building panels may be fastened to the metal, wood, concrete or other framing and sheathing system.
In an embodiment, the geometric building panels are lapped over each other. As the geometric building panels lap over each other, the thickness of the lower geometric building panel causes the upper geometric building panel to be installed at a slight angle to vertical. The thickness of the geometric building panels may vary and will include, but is not limited to, a thickness of one quarter of an inch, to one inch in thickness. The geometric building panels include a patterned edge or edges. In a lapped system, an upper geometric building panel may lap a lower geometric building panel such that the lower edge of the upper geometric building panel entirely covers the patterned edge of the lower geometric building panel. The uppermost points or edges of the patterned edge on the lower geometric building panel contacts the underlying substrate at discrete locations and does not contact the substrate at others as shown if FIG. 2 . The geometry of the angle combined with the patterned edge of the geometric building panels creates a capillary break, drainage, and/or ventilation space, plane or path between the substrate or structure and the geometric building panel. The capillary break, drainage and/or ventilation space, plane or path can be drained and vented at the base of the wall, within the wall at selected locations by the incorporation of through wall flashing, and/or at the top of the wall. In certain building types, where required, fire-stopping of the capillary break, drainage and/or ventilation space, path or plane can be achieved with through wall flashing, intumescent tape or material, or other method.
In an embodiment, any of the geometric building panels described herein can be extruded or fabricated with a rectilinear cross section. The interior face of the rectilinear section, facing the substrate or structure, and the exterior face of the geometric building panel, facing the exterior, may be parallel to each other. The exterior face may include additional architectural features such as grain patterns, moldings, decorative patterns, or simulations of brick, stone, or other traditional materials or roof and wall coverings.
In an embodiment the patterned edge of the any of the geometric building panels discussed herein may include any of multiple shapes or patterns described herein. Examples of these edges are shown in FIG. 3 . The geometric building panel system may be comprised of a series of geometric building panel sidings, claddings, panels, shingles, shakes, or tiles as shown in FIG. 3 .
In an embodiment, any of the geometric building panels described herein are not rectilinear in cross section. In this embodiment the cross section of the geometric building panel is an irregular polygon. In an embodiment the irregular polygon includes, when mounted on a structure an exterior face that is vertical (plumb) or horizontal (level). As shown in FIG. 4 , the exposed face of the geometric building panel is plumb or vertical. The face that is exposed to the sheathing is at angle. In this embodiment, the geometric building panel do not necessarily lap over each other.
Although the geometric building panels do not require reinforcement, any of the geometric building panels discussed herein may include metal, fiberglass, carbon, or other reinforcement including but not limited to mesh, lath, or mats of these materials. The reinforcement may be surface applied or may be embedded in the geometric building panel. The reinforcement may cover all or a portion of the geometric building panel. The reinforcement may be located proximate only the expected fastening locations of the geometric building panel as shown in FIG. 5 .
In an embodiment, the patterned edge of any of a geometric building panel may be manufactured as a stand-alone product as shown in FIG. 6 . The separate edge may include independent capillary break, drainage and/or ventilation features and may be adhered or mechanically attached to the body of the geometric building panels. In an embodiment, the patterned edge of the geometric building panels may be fabricated of the same or of a different material than the body of the geometric building panel. The two materials may be joined in a separate process.
In an embodiment, any of the geometric building panels discussed herein may be fabricated from any one or more of fiber cement, clay, cement, cement based materials, concrete, asphalt, wood, wood based materials, wood fiber, oriented strand board, hardboard, high pressure laminate, PVC, plastic, rubber, foam, foam insulation, extruded polystyrene, expanded polystyrene, polyisocyanurate, fly-ash, waste materials, glass, glass fiber reinforced concrete and cement, glass fiber reinforced plastic, carbon fiber reinforced plastic, cellulose, insulation, and metal or any other material used in the fabrication of roof and wall cladding and coverings, and any combination thereof. In an embodiment, any of the geometric building panels discussed herein may be any one or more of extruded, molded, milled, stamped, pressed, embossed, sawn, laminated, machined, layered, glued, fused, autoclaved, mechanically joined, formed, or any combination thereof.
In an embodiment, any of the geometric building panels discussed herein may include a fastening hole. Any of the geometric building panels discussed herein may include an optional fastening zone along which the geometric building panels may be fastened to the substrate or structure. The zone provides a defined area to allow fastening without positioning or cutting the geometric building panels to align with underlying framing or structure. The zone may occur at any area or portion of the geometric building panel may follow the Patterned Edge.
In an embodiment any of the geometric building panels discussed herein may include surface features such as bumps, protrusions, cutaways, ridges, valleys, and other elements on either the interior or exterior face of the geometric building panel that when combined with the patterned edge(s) provide additional capillary break, drainage and/or ventilation spaces, paths or planes. The surface features may be located between the geometric building panel and the substrate or structure on which the geometric building panels are mounted. The surface features may be located between two geometric building panels as shown in FIG. 7 . The surface features such as may be applied in a separate manufacturing process, may be composed of a different material, and may be located on any surface of the geometric building panels.
In an embodiment, any of the geometric building panels discussed herein may be hung in a manner as to create a gap between the faces of the panels.
In an embodiment, any of the geometric building panels discussed herein may be laminated with a drainage mat, drainage screen, or drainage material.
In an embodiment any of the geometric building panels discussed herein may be fastened with double headed fasteners, screws with washers, or fasteners with an offset feature as shown in FIG. 7 . The double headed fasteners, screws with washers, or fasteners with an offset feature, when combined with the undulating, serrated, or zigzagged edge(s) of the geometric building panel provide additional capillary break, drainage and/or ventilation spaces, paths or planes between the geometric building panels and the substrate, between two geometric building panels, or between the geometric building panels and another surface.
In an embodiment, the any of the geometric building panels discussed herein may be of varying shapes, and sizes.
In an embodiment, any of the geometric building panels discussed herein do not span between framing members.
In an embodiment, to further increase the capillary break, ventilation and/or drainage spaces, paths or planes the geometric building panels discussed herein may be mounted on furring, batten(s), blocking, strapping, purlins, or sub-framing.
In an embodiment the patterned edge(s) of any of the geometric building panels discussed herein may be out of plane with the main body of the geometric building panel.
In an embodiment the patterned edge(s) of any of the geometric building panels discussed herein may be on one or more edges of the geometric building panel.
In an embodiment any of the geometric building panels discussed herein may be fabricated through an extrusion process. In the extrusion process the geometric building panels may vary in thickness at portions of the cross section of the geometric building panel. An extrusion process typically utilizes a die, through which material is pressed to create a shape. The cross section of opening in the die may vary to create a geometric building panel with a cross section that is irregular in shape.
In an embodiment, the patterned edge of the geometric building panels is of increased thickness as compared to the balance, or rest of the geometric building panel at the fastening location to provide additional support for fastening.
In an embodiment any of the geometric building panels discussed herein are mounted as a roof panel system. When mounted as roof panels, the geometric building panels may be installed at an angle of approximately five to ten degrees from the surface of the underlayment of the roof. The geometric building panel system comprised of geometric building panels provides improved capillary break, ventilation and/or drainage spaces, paths or planes between the roof covering and the roof substrate or structure.
Changes may be made in the above methods and systems without departing from the scope hereof. It should thus be noted that the matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. The following claims are intended to cover all generic and specific features described herein, as well as all statements of the scope of the present method and system, which, as a matter of language, might be said to fall therebetween.

Claims

What is claimed is:

1. A building panel for ventilation and drainage comprising:

a rear surface;

a front surface having a drainage element thereon such that, when an additional building panel is installed and overlaps the building panel, the drainage element creates a ventilation and drainage path between the building panel and the additional building panel; and

a patterned edge spanning from the rear surface towards the front surface that, when the building panel is mounted at a substrate, creates a second ventilation and drainage path between the building panel and the substrate.

2. The building panel of claim 1, the drainage element being a drainage element selected from the group of drainage elements composed of bumps, protrusions, cutaways, ridges, channels, squiggles, or valleys.

3. The building panel of claim 1, the patterned edge spanning from the rear surface all the way to the front surface.

4. The building panel of claim 1, the patterned edge having a shape selected from the group of shapes including serrated, saw-tooth pattern, notched pattern, toothed pattern, serrated pattern, zigzag pattern, undulation pattern, scalloped pattern, stepped pattern, curved pattern, pattern of tabs, pattern of points, and crenulated pattern.

5. The building panel of claim 1, the building panel being of one-piece construction.

6. The building panel of claim 1, the building panel being of layered construction.

7. The building panel of claim 1, the building panel composed of a material selected from the group of materials including one or more of fiber cement, clay, cement, cement based materials, concrete, asphalt, wood, wood based materials, wood fiber, oriented strand board, hardboard, high pressure laminate, PVC, plastic, rubber, foam, foam insulation, extruded polystyrene, expanded polystyrene, polyisocyanurate, fly-ash, waste materials, glass, glass fiber reinforced concrete and cement, glass fiber reinforced plastic, carbon fiber reinforced plastic, cellulose, insulation, metal, and any combination thereof.

8. The building panel of claim 1, the building panel including a first panel portion and a second panel portion.

9. The building panel of claim 8, the first panel portion being made of a first material, the second panel portion being made of a second material.

10. The building panel of claim 9, the first material being different than the second material.

11. The building panel of claim 9, the first material being the same as the second material.

12. The building panel of claim 8, wherein:

the first panel portion includes the front surface;

the second panel portion includes the patterned edge; and

the first panel portion conceals the patterned edge.

13. The building panel of claim 1, the building panel defining a fastening hole or fastening notation.

14. The building panel of claim 13, the fastening hole or notation being located within a region of the building panel where a longitudinal cross-section of the geometric building panel crosses the fastening hole or the fastening notation also crosses the patterned edge.

15. The building panel of claim 1, the building panel being a roof panel.

16. The building panel of claim 1, the building panel being a siding panel.

17. The building panel of claim 1, the building panel having a length such that the building panel, when installed on a structure, spans multiple framing bays of the structure.

18. The building panel of claim 1, the building panel mounted at a substrate, an angle of the building panel being set via a starter strip.

19. The building panel of claim 1, the building panel mounted at a substrate, an angle of the building panel being set via one or more of a fastener, a double headed fastener, and a single-headed fastener and one or more washers.

20. A building panel for ventilation and drainage comprising:

a front surface;

a rear surface aligned with respect to the front surface such that, when the building panel is mounted adjacent an additional building panel, the front surface and an additional front surface of the additional building panel are substantially parallel;

patterned edge spanning from the rear surface towards the front surface that, when the building panel is mounted at a substrate, creates a ventilation and drainage path between the building panel and the substrate or the building panel and an adjacent building panel.

21. The building panel of claim 20, the rear surface angled with respect to the front surface.

22. The building panel of claim 20, the rear surface being parallel with respect to the front surface.

23. The panel of claim 20, the front surface defining an overlap portion that covers an adjacent patterned edge of the adjacent panel when mounted to a structure.

24. The panel of claim 23, a first height of the patterned edge being greater than a second height of the overlap portion.

25. The building panel of claim 20, the patterned edge spanning from the rear surface all the way to the front surface.

26. The building panel of claim 20, the patterned edge having a shape selected from the group of shapes including serrated, saw-tooth pattern, notched pattern, toothed pattern, serrated pattern, zigzag pattern, undulation pattern, scalloped pattern, stepped pattern, curved pattern, pattern of tabs, pattern of points, and crenulated pattern.

27. The building panel of claim 20, the building panel being of one-piece construction.

28. The building panel of claim 20, the building panel being of layered construction.

29. The building panel of claim 20, the building panel composed of a material selected from the group of materials including one or more of fiber cement, clay, cement, cement based materials, concrete, asphalt, wood, wood based materials, wood fiber, oriented strand board, hardboard, high pressure laminate, PVC, plastic, rubber, foam, foam insulation, extruded polystyrene, expanded polystyrene, polyisocyanurate, fly-ash, waste materials, glass, glass fiber reinforced concrete and cement, glass fiber reinforced plastic, carbon fiber reinforced plastic, cellulose, insulation, metal, and any combination thereof.

30. The building panel of claim 20, the building panel including a first panel portion and a second panel portion.

31. The building panel of claim 30, the first panel portion being made of a first material, the second panel portion being made of a second material.

32. The building panel of claim 31, the first material being different than the second material.

33. The building panel of claim 31, the first material being the same as the second material.

34. The building panel of claim 30, wherein:

the first panel portion includes the front surface;

the second panel portion includes the patterned edge; and

the first panel portion conceals the patterned edge.

35. The building panel of claim 20, the building panel defining a fastening hole or fastening notation.

36. The building panel of claim 35, the fastening hole or notation being located within a region of the building panel where a longitudinal cross-section of the geometric building panel crosses the fastening hole or the fastening notation also crosses the patterned edge.

37. The building panel of claim 20, the building panel being a roof panel.

38. The building panel of claim 20, the building panel being a siding panel.

39. The building panel of claim 20, the building panel having a length such that the building panel, when installed on a structure, spans multiple framing bays of the structure.

40. The building panel of claim 20, the building panel mounted at a substrate, an angle of the building panel being set via a starter strip.

41. The building panel of claim 20, the building panel mounted at a substrate, an angle of the building panel being set via one or more of a fastener, a double headed fastener, and a single-headed fastener and one or more washers.

42. A building panel for ventilation and drainage comprising:

a first panel portion defining a front surface of the building panel;

a second panel portion defining a rear surface of the building panel;

patterned edge spanning from the rear surface towards the front surface that, when the building panel is mounted at a substrate, creates a ventilation and drainage path between the building panel and the substrate.

43. The building panel of claim 42, the rear surface angled with respect to the front surface.

44. The building panel of claim 42, the rear surface being parallel with respect to the front surface.

45. The panel of claim 42, the front surface defining an overlap portion that covers an adjacent patterned edge of the adjacent panel when mounted to a structure.

46. The panel of claim 45, a first height of the patterned edge being greater than a second height of the overlap portion.

47. The building panel of claim 42, the patterned edge spanning from the rear surface all the way to the front surface.

48. The building panel of claim 42, the patterned edge having a shape selected from the group of shapes including serrated, saw-tooth pattern, notched pattern, toothed pattern, serrated pattern, zigzag pattern, undulation pattern, scalloped pattern, stepped pattern, curved pattern, pattern of tabs, pattern of points, and crenulated pattern.

49. The building panel of claim 42, the building panel being of one-piece construction.

50. The building panel of claim 42, the building panel being of layered construction.

51. The building panel of claim 42, the building panel composed of a material selected from the group of materials including one or more of fiber cement, clay, cement, cement based materials, concrete, asphalt, wood, wood based materials, wood fiber, oriented strand board, hardboard, high pressure laminate, PVC, plastic, rubber, foam, foam insulation, extruded polystyrene, expanded polystyrene, polyisocyanurate, fly-ash, waste materials, glass, glass fiber reinforced concrete and cement, glass fiber reinforced plastic, carbon fiber reinforced plastic, cellulose, insulation, metal, and any combination thereof.

52. The building panel of claim 42, the first panel portion being made of a first material, the second panel portion being made of a second material.

53. The building panel of claim 52, the first material being different than the second material.

54. The building panel of claim 52, the first material being the same as the second material.

55. The building panel of claim 42, wherein:

the first panel portion includes the front surface;

the second panel portion includes the patterned edge; and

the first panel portion conceals the patterned edge.

56. The building panel of claim 42, the building panel defining a fastening hole or fastening notation.

57. The building panel of claim 56, the fastening hole or notation being located within a region of the building panel where a longitudinal cross-section of the geometric building panel crosses the fastening hole or the fastening notation also crosses the patterned edge.

58. The building panel of claim 42, the building panel being a roof panel.

59. The building panel of claim 42, the building panel being a siding panel.

60. The building panel of claim 42, the building panel having a length such that the building panel, when installed on a structure, spans multiple framing bays of the structure.

61. The building panel of claim 42, the building panel mounted at a substrate, an angle of the building panel being set via a starter strip.

62. The building panel of claim 42, the building panel mounted at a substrate, an angle of the building panel being set via one or more of a fastener, a double headed fastener, and a single-headed fastener and one or more washers.