WO2001014659A1

WO2001014659A1 - Sheathing elements

Info

Publication number: WO2001014659A1
Application number: PCT/NZ2000/000158
Authority: WO
Inventors: James Cameron Ross
Original assignee: Metro Shingles (Intl) Limited
Priority date: 1999-08-19
Filing date: 2000-08-17
Publication date: 2001-03-01
Also published as: AU6742400A

Abstract

A planar sheathing element (1) manufactured from sheet metal to replicate two or three courses of tiles (4). At appropriate 'tile length' intervals an inward step is formed across the width of the element (1) to replicate an upper tile (4) course overlapping a next lower tile (4) course. The tiles (4) are replicated by alternate planar lands (3) and planar depressions (2) repeated across a course with the tiles (4) of one course being offset to those of an adjacent course. At an underlay side (7) of each element (1) longitudinally extending weather channels (12) are provided these being set in from the adjacent edge (11) of the element (1). A pair of indents (15) are provided in a step (6), one indent (15) being within the underlay portion (7). The other indent (15) is set in from the opposing overlap side (11) of the element. When the sides of two elements (1) are overlapped the indent (15) of the overlapping element clips into the indent (15) of the underlap element. Interlocking elements (16) and tongues (18, 19) are provided along the upper and lower edges (9, 10) enabling longitudinal interlocked overlapping of elements (1). A mounting tab (17) is provided along the upper edge (9) enabling attachment, such as by nailing, to a supporting structure to be sheathed.

Description

TITLE: IMPROVEMENTS IN AND RELATING TO SHEATHING ELEMENTS

TECHNICAL FIELD OF THE INVENTION

This invention relates to an exterior sheathing element in particular a sheet metal sheathing element useful for roofing.

BACKGROUND ART OF THE INVENTION

Various sheet metal exterior sheathing elements are known. Typically they are fabricated to replicate a series of tiles, shingles, shakes or similar elements (hereinafter collectively called "tiles") disposed side by side as a single course of tiles in the one element. A problem with such tiles is providing for the hidden fixing thereof in situ and also providing an appropriate weather resistant overlap between laterally adjacent sheathing elements.

An intention of this invention is to provide a sheet metal sheathing element which will replicate a plurality, such as two or three, courses of tiles in a single sheathing element. It has been found that with providing such a multi-course sheathing element the weather resistant difficulties mentioned above are compounded. An intention of this invention is to provide a multi-course sheathing element having side portions which provide appropriate weather resisting co-operative overlaps and underlaps in situ. A further intention is to provide the public with a useful choice.

DISCLOSURE OF THE INVENTION According to a first embodiment of this invention there is provided a substantially planar exterior sheathing element having an upper edge and a lower edge adapted to, in situ, be attached to a supporting structure in overlap with an adjacent upper and lower sheathing element, the sheathing element being configured to replicate a plurality of both laterally and longitudinally overlapping tiles, the replication including an inward step formed partway down the sheathing element and extending the full width thereof as to replicate an overlap between an upper and a lower course of tiles, the replication also providing that the tiles of one course appear laterally off-set to the tiles of the other course, the sheathing element including, an underlap side portion at one side thereof incorporating at least one downwardly directed weathering channel extending the full length thereof and set-in from the adjacent side edge of the element, a pair of indents formed in the step, one indent being within the underlap side portion and the other indent in a co-operative position adjacently inward of the opposite and overlap side edge of the element whereby with two such elements in side by side overlap the overlapping indent will clip within the underlap indent.

According to a second embodiment of this invention there is provided an exterior sheathing element as described in the preceding paragraph wherein the underlap side portion includes a plurality of weathering channels spaced inward of the adjacent edge of the element by a border zone with the associated indent being formed in the border zone.

According to a third embodiment of this invention there is provided an exterior sheathing element as described in the immediately preceding paragraph wherein the indent in the underlap side portion is set in from the associated side edge of the element.

According to a fourth embodiment of this invention there is provided an exterior sheathing element as described in any one of the three immediately preceding paragraphs wherein the tile replication of each course of tiles includes a series of planar lands laterally separated by intervening planar depressions, at least some of the downturns defining and common to adjacent lands and depressions being disposed at an angle marginally off-set to the longitudinal axis of the element and the overlap side edge of the element is correspondingly off-set as will match with the downturns bordering an underlap side portion when two elements are disposed in side by side overlap.

According to a fifth embodiment of this invention there is provided a substantially planar exterior sheathing element as described in any one of the four preceding paragraphs wherein a lower edge portion thereof forms a channel on an inner face of the element and an upper and opposite parallel edge portion forms a channel on an outer face of the element with a mounting tab projecting clear of the upper channel forming edge portion in a substantially co-planar relationship to the main body of the element, in situ, the structure enabling an underlap side portion of a first sheathing element to be overlapped by an overlap side portion of a second sheathing element with their corresponding folded edge portions and their indents engaged and both elements attached to a supporting structure by attachment means extending through their mounting tabs and a lower folded edge of a third sheathing element to be engaged over and about the upper folded edge of at least one of the first and second sheathing elements, the sequence being repeatable sheath the supporting structure..

BRIEF DESCRIPTION OF DRAWINGS

In further describing the invention reference is made to the accompanying drawings wherein:

Fig 1 is a plan view of a preferred embodiment, and

Fig 2 is an enlarged end view (but without some detail) in the direction of arrow "A" on Fig 1, the details missing being depicted in the following drawings wherein.

Fig 3 is a longitudinal view on line 3-3 on Fig 1.

Fig 4 is a longitudinal view on line 4-4 on Fig 1.

Fig 5 is a longitudinal view on line 5-5 on Fig 1.

Fig 6 is a longitudinal view on line 6-6 on Fig 1.

Fig 7 is a cross-sectional view on line 7-7 on Fig 1.

BEST MODE OF CARRYING OUT THE INVENTION

A sheathing element 1 is preferably pressed from sheet metal to have an irregular pattern configuration of spaced apart lands 3 and shallow depressions 2. As described in more detail below with particular reference to Fig. 8, in situ, an element 1 is mounted in conjunction with other such elements in the orientation depicted in Fig 1 with an upper edge 9 and a lower edge 10. Thus the longitudinal axis herein is considered as being between the upper edge 9 and the lower edge 10. A characteristic of the sheathing element 1 is the replication provides for two or three courses of tiles 4, three courses being depicted in the drawings. The tiles 4 of each course are preferably formed by pressing a series of planar lands 3 laterally separated by intervening planar shallow, for example about 5mm deep, depressions 2. Preferably at least some of the downturns 5 defining and common to adjacent lands 3 and depressions 2 are disposed at an angle marginally off-set to the longitudinal axis of the element. Preferably the depressions 2 and lands 3 in one course are replicated to be laterally off-set to those in a next adjacent course to enhance the replication feature whereby an appearance of randomly positioned individual tiles 4 results. Preferably the element 1 is coated with small stone chips (not depicted) to further enhance the elements appearance and improve its weathering qualities.

The replication includes, at an appropriate position to delineate one or two courses of tiles as required, an inward step 6 extending the full width of the sheathing element 1. The inward step(s) 6 are provided to replicate an overlap between an upper tile 4 course and an adjacent lower course of tiles 4. Thus, as depicted, two inward steps 6 are provided to delineate a three tile 4 course sheathing element 1. Preferably the rise or depth of the steps 6 is substantially larger than the depth of the depressions 2, being for example about 12mm in depth.

At one side (referring to Fig 1, the left side) the sheathing element 1 is provided with an underlap side portion 7. Preferably the replication provides that the underlap side portion 7 corresponds with what would otherwise be a depression 2 of each tile 4 course. The underlay side portion 7 is formed with at least one downwardly extending weathering channel 12. Preferably a plurality of weathering channels 12 disposed in adjacent spaced apart parallel relationship are provided preferably in the nature of a corrugated configuration. Preferably the weathering channels 12 are formed prior to forming the step(s) 6 and thus they continue through each step 6. Preferably the underlap side portion 7 includes a border zone 14 between the weathering channels 12 and the associated edge 11 of the element 1.

Referring in particular to Figs. l and 7, the border zone 14 continues the replication configuration, that is, the border zone 14 is formed in the depression 2 containing the channels 12. Thus, in situ, the border zone 14 and the channels 12 will nest under a corresponding land 3 of an overlapping element 1. Preferably the line of the side edge 11 associated with the overlap end of the element 1 is off-set to correspond to the off-set of the downturns 5 bordering an underlap portion 7. Thus, as depicted in Fig 8, with elements 1 in lateral overlap, the edge 11 of an overlap side will blend with the line of the downturns 5 of the bordering tiles 4 of an underlying element 1. Additional attachment, to that described below, to a supporting structure may be provided through the border zone 14. To that end apertures (not depicted) may be formed in the border zone 14.

With reference to Figs.l, 3 and 4 in particular, a pair of indents 15 are provided in at least one step 6, and preferably both steps 6 where formed, whereby with side by side overlapping of elements 1 the indent(s) 15 of the overlapping element can be clipped within the indent(s) 15 of the underlap element 1. To that end, preferably one indent 15 is formed in a section of a step 6 within the underlap side portion 7 and in particular in the border zone 14. Typically the indents 15 are in the form of dimples pressed into the material of a step 5. As depicted, in situ the underlap side portion 7 is overlapped the indent 15 therein may pierce the material and thus form an aperture. It is envisaged this may ensure a more positive snap-fitting of a indent 15 of an overlap element 1 therein. The indent 15 of an underlap side portion 7 may otherwise be formed as an aperture however it is envisaged that this will not be cost effective. Preferably the underlap indent 15 is set in form the adjacent edge 11 of the element 1 as not to intersect with that edge.

Referring in particular to Figs. 5, 6 and 8 the upper edge 9 and lower edge 10 of the sheathing element are disposed parallel to one another and are preferably formed with interlocking channels 16 and associated tongues 18 and 19. Preferably lower edge 10 portion is turned back on itself to form tongue 18 and a channel 16 on an inner face of the element 1. Upper and opposite edge 9 portion is turned back on itself twice to form tongue 19 and a channel 16 on an outer face of the element 1. The second folding back forms a mounting tab 17 projecting clear of the upper channel 16 forming edge 9 in a substantially co-planar relationship to the main body of tiles 4 of the element 1. At the overlap side 11 of an element 1 a tab 17 free portion 20 is preferably provided to facilitate the lateral overlapping of two elements 1.

In situ, an underlap side portion 7 of a first sheathing element 1 can be overlapped by an opposite or overlap side portion of a second sheathing element 1 with their corresponding folded edge portions 9 and 10 engaged with one another and also their indents 15 engaged as aforesaid. Both elements 1 can be attached to a supporting structure by attachment means extending through their mounting tabs 17. A lower folded edge 10 of a third sheathing element 1 can them be engaged over and about the upper folded edge 9 of at least one of the first and second sheathing elements 1 and preferably over part of both including their overlapping edges 11. This sequence is undertaken in a repeating manner to sheath the supporting structure. A more detailed description of the interlocking and mounting of the elements 1 is given in our earlier PCT Patent Application No. PCT/NZ99/00018.

Claims

1. A substantially planar exterior sheathing element having an upper edge and a lower edge adapted to, in situ, be attached to a supporting structure in overlap with an adjacent upper and lower sheathing element, the sheathing element being configured to replicate a plurality of both laterally and longitudinally overlapping tiles, the replication including an inward step formed partway down the sheathing element and extending the full width thereof as to replicate an overlap between an upper and a lower course of tiles, the replication also providing that the tiles of one course appear laterally off-set to the tiles of the other course, the sheathing element including, an underlap side portion at one side thereof incorporating at least one downwardly directed weathering channel extending the full length thereof and set-in from the adjacent side edge of the element, a pair of indents formed in the step, one indent being within the underlap side portion and the other indent in a co-operative position adjacently inward of the opposite and overlap side edge of the element whereby with two such elements in side by side overlap the overlapping indent will clip within the underlap indent.

2. An exterior sheathing element as claimed in claim 1 wherein the underlap side portion includes a plurality of weathering channels spaced inward of the adjacent edge of the element by a border zone with the associated indent being formed in the border zone.

3. An exterior sheathing element as claimed in either claim 1 or claim 2 wherein the indent in the underlap side portion is set in from the associated side edge of the element.

4. An exterior sheathing element as claimed in any one of the preceding paragraphs wherein the tile replication of each course of tiles includes a series of planar lands laterally separated by intervening planar depressions, at least some of the downturns defining and common to adjacent lands and depressions being disposed at an angle marginally off-set to the longitudinal axis of the element and the overlap side edge of the element is correspondingly off- set as will match with the downturns bordering an underlap side portion when two elements are disposed in side by side overlap.

5. An exterior sheathing element as claimed in claim 4 wherein two steps are provided to replicate three courses of tiles and the tiles in each course are laterally off-set to those of an adjacent course.

6. An exterior sheathing element as claimed in either claim 4 or claim 5 wherein the weather channels and the bordering zone of each tile course are formed in what would otherwise be a planar depression.

7. A substantially planar exterior sheathing element as claimed in any one of the preceding claims wherein a lower edge portion thereof forms a channel on an inner face of the element and an upper and opposite parallel edge portion forms a channel on an outer face of the element with a mounting tab projecting clear of the upper channel forming edge portion in a substantially co-planar relationship to the main body of the element, in situ, the structure enabling an underlap side portion of a first sheathing element to be overlapped by an overlap side portion of a second sheathing element with their corresponding folded edge portions and their indents engaged and both elements attached to a supporting structure by attachment means extending through their mounting tabs and a lower folded edge of a third sheathing element to be engaged over and about the upper folded edge of at least one of the first and second sheathing elements, the sequence being repeatable sheath the supporting structure..

8. A sheathing element substantially as herein described with reference to the accompanying drawings.