WO2009059392A1 - Apparatus and method for installing cladding to structures - Google Patents

Apparatus and method for installing cladding to structures Download PDF

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Publication number
WO2009059392A1
WO2009059392A1 PCT/CA2007/002003 CA2007002003W WO2009059392A1 WO 2009059392 A1 WO2009059392 A1 WO 2009059392A1 CA 2007002003 W CA2007002003 W CA 2007002003W WO 2009059392 A1 WO2009059392 A1 WO 2009059392A1
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WO
WIPO (PCT)
Prior art keywords
mounting surface
panel
flange
supporting
panels
Prior art date
Application number
PCT/CA2007/002003
Other languages
French (fr)
Original Assignee
Lysyuk, Dmytro
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lysyuk, Dmytro filed Critical Lysyuk, Dmytro
Priority to PCT/CA2007/002003 priority Critical patent/WO2009059392A1/en
Publication of WO2009059392A1 publication Critical patent/WO2009059392A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801—Separate fastening elements
    • E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
    • E04F13/0805—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and the wall
    • E04F13/0808—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and the wall adjustable in several directions one of which is perpendicular to the wall
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801—Separate fastening elements
    • E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
    • E04F13/081—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements
    • E04F13/0816—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements the additional fastening elements extending into the back side of the covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0801—Separate fastening elements
    • E04F13/0803—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements
    • E04F13/081—Separate fastening elements with load-supporting elongated furring elements between wall and covering elements with additional fastening elements between furring elements and covering elements
    • E04F13/083—Hooking means on the back side of the covering elements

Definitions

  • TITLE APPARATUS AND METHOD FOR INSTALLING CLADDING TO
  • Applicant's teachings relate to apparatuses and methods for installing cladding to structures, such as, for example, a building.
  • a cladding system comprising: a panel of selected cladding comprising an interior side and first and second generally opposing edges; a first supporting profile comprising: (i) a first panel mounting surface secured to the interior side of the panel toward the first edge; (ii) a first structure mounting surface connected to and offset from the first panel mounting surface in a first direction extending from the second edge to the first edge and in a second direction orthogonal to the first direction; and (iii) a first flange connected to and offset from the first structure mounting surface in the first direction and in a direction generally opposite the second lateral direction, the first flange projecting generally in the first direction; a second supporting profile comprising: (i) a second panel mounting surface secured to the interior side of the panel toward the second edge; and (ii) a second flange connected to and offset from the second panel mounting surface in a direction opposite the first direction and in the second direction, the second flange projecting generally in the direction;
  • an apparatus for installing panels of selected cladding to a structure for panels having an interior side and first and second generally opposing edges
  • the apparatus comprising: apparatus for installing panels of selected cladding to a structure, each of the panels having an interior side and first and second generally opposing edges, the apparatus comprising: a first supporting profile for attachment to the interior side of the panels toward the first edge, the first supporting profile comprising: (i) a first panel mounting surface extending generally in a first direction; (ii) a first structure mounting surface connected to and offset from the first panel mounting surface in the first direction and in a second direction generally orthogonal to the first lateral direction; and (iii) a first flange connected to and offset from the first structure mounting surface in the first direction and in a direction generally opposite the second direction, the first flange projecting generally in the first direction; a second supporting profile for attachment to the interior side of the panels toward the second edge, the second supporting
  • a structure comprising a plurality of panels of selected cladding, each of the panels comprising an interior side having first and second supporting profiles secured thereto, the first and second supporting profiles spaced apart toward generally opposing edges, the first and second supporting profiles each comprising first and second flanges, respectively, the first and second flanges of a given panel projecting in generally opposing directions away from one another, the first flange of a given panel configured to be retained in a slot defined by the second flange and the interior surface of a subsequent panel, the first supporting profile of each panel connected to a surface of the structure defining a series of spaced courses of panels.
  • a method of installing cladding to a structure comprising: providing a structure, the structure comprising a surface to be cladded; providing a plurality of panels of selected cladding, the panels comprising interior and exterior sides; securing a first supporting profile and a second supporting profile on the interior sides of each of the panels, the first and second supporting profiles spaced apart toward generally opposing edges of each of the panels; connecting the first supporting profile of at least one of the panels to the surface of the structure to the at least one panel as a base course; fixing the second supporting profile of at least another one of the panels to the first supporting profile of the at least one panel of the base course to install the at least another one panel as a subsequent course; and connecting the first supporting profile of the at least another one panel of the subsequent course to the surface of the structure.
  • FIG. 1 shows sectional, side and perspective views of a first supporting profile according to various embodiments of applicant's teachings
  • FIG. 2 shows sectional, side and perspective views of a second supporting profile according to various embodiments of applicant's teachings
  • FIG. 4 shows side views of a second supporting profile being secured to a panel of selected cladding
  • FIG. 5 shows perspective views of a panel of selected cladding including first and second supporting profiles secured thereto;
  • FIG. 6 shows side views of a panel of selected cladding having first and second supporting profiles secured thereto being connected and fixed to a surface;
  • FIG. 7 shows a perspective view of base profiles secured to floor slabs;
  • FIG. 8 shows a perspective view of anchor bolts and a thermal break on a floor slab
  • FIG. 9 shows a perspective view of a first base profile secured to a floor slab
  • FIG. 10 shows a perspective view of a plurality of first base profiles secured to two successive floor slabs
  • FIG. 11 shows a perspective view of a second base profile secured to first base profile secured to a floor slab
  • FIG. 12 shows perspective view of two second base profiles secured to first base profile secured to a floor slab
  • FIG. 13 shows a perspective view of a plurality of second base profiles extending vertically between successive floor slabs
  • FIG. 14 shows a perspective view of panels of selected cladding installed on an exterior of a structure.
  • Applicant's teachings relate to apparatuses and methods to install cladding to structures, such as, for example, a building.
  • applicant provides supporting profiles that are secured to panels of selected cladding that allow the panels to be fixed to exteriors of structures.
  • the profiles are generally of two categories, namely first and second supporting profiles, which are fixed to interior sides of the panels and which support the cladding. It can be appreciated, however, that applicant's teachings are not intended to be limited to only these two particular profiles, and that other supporting profiles are possible within applicant's teachings.
  • a first supporting profile 100 is shown featuring a first panel mounting surface 102, a first structure mounting surface 104, and first flange 106 projecting generally away from the first panel mounting surface 102.
  • the first structure mounting surface 104 is disposed between the first panel mounting surface 102 and the first flange 106.
  • the first structure mounting surface 104, the first panel mounting surface 102 and the first flange 106 may be provided generally parallel in the same first direction, the first direction generally corresponding to a direction along an interior surface of a panel (not shown) between second and first edges when secured to the first supporting profile 100, as discussed below.
  • the first panel mounting surface 102 is connected to and offset from the first structure mounting surface 104 by first transverse web 107, and the first structure mounting surface 104 is connected to and offset from the first flange 106 by second transverse web 109.
  • the first and second transverse webs may be provided generally parallel in a second direction corresponding to a direction orthogonal to an interior surface of a panel when secured to the first supporting profile 100.
  • the first panel mounting surface 102 of each first supporting profile 100 may be predrilled with at least two attachment points 108 for securing the first supporting profile to a panel (not shown), and the first structure mounting surface 104 of each first supporting profile 100 may be predrilled with at least two connection points 111 for connecting the first supporting profile 100 to the surface of a structure to be cladded.
  • first and second flanges 106, 118 of the first and second supporting profiles 100, 114 may have flared distal edges 124, 126, respectively, enabling a snap fit, as will hereinafter become apparent.
  • the second supporting profiles 114 are also configured for attachment to the interior side 130 of each of the panels 128.
  • the second supporting profiles 114 are configured for attachment toward the second edge 136 of the panel, which can be a lower edge, for example, when oriented in an installed position.
  • FIGS. 5A and 5B show the panel 128' complete with supporting profiles 100, 114 secured thereto. As illustrated, the supporting profiles 100, 114 have lengths that generally match lengths of the opposing edges 134,
  • the supporting profiles 100, 114 are shown secured to each of the panels 128 at the two spaced apart attachment points 108, 122, respectively, which may be predilled in the supporting profiles or drilled at the time the supporting profiles 100, 114 are secured to the panel 128.
  • attachment holes need not be provided.
  • the panels 128 can be prepared with the supporting profiles 100, 114 as a separate step at a location remote from the structure to be cladded.
  • FIGS. 6A to 6F illustrate an example of the general method of affixing the panels 128' to a surface 140 of a structure, for example, an exterior surface of a building.
  • the surface 140 need not be a continuous flat surface, and can be a skeletal building structure comprising a series of vertically spaced floor slabs, for example, in which case the supporting profiles 100, 114 can be secured to the outer surfaces of the floor slabs.
  • the panels 128', featuring the supporting profiles 100, 114 are secured to the surface 140 either directly (e.g., screws, bolts or adhesive) or indirectly (e.g., via a plurality of base profiles, as discussed below).
  • the distal edges 124, 126 may be flared so that the first flange 106 is received by the second flange 118 according to a snap fit sliding arrangement, with the distal edge 126 of the second flange 118 deflecting away from the interior side 130 of the panel to accept the first flange 106.
  • the tolerance between the first flange 106 and the slot 138 can vary, for example, from a loose sliding fit to a friction fit. A tighter fit between the first flange 106 and the slot 138 will restrict the movement of the panel 128' once installed onto the surface 140), but may make installation more difficult. If a tighter fit is desired, the interaction between the first flange 106 and the slot 138 will generally depend on the surface characteristics of the selected cladding.
  • Another method of establishing a base course of cladding is to secure the first supporting profile 100 of a panel 128' to the surface 140 without first securing a first supporting profile 100 absent a panel 128.
  • the second edge 136 of the panel 128' would not be secured to the surface 140.
  • a yet another method of establishing a base course of cladding is to secure the first supporting profile 100 to a panel 128 along the second edge 136 of the panel 128, so as to mirror the first supporting profile 100 along the first edge 134.
  • both first supporting profiles 100 could be secured to the surface 140 to establish a base course.
  • the second edge 136 of a subsequent course may conceal the fastening hardware 142 present on the first structure mounting surface 104 of a given course once installed.
  • the first and second supporting profiles 100, 114 may be configured to maintain adjacent panels 128' spaced apart to provide a desired gap 144 to allow for expansion
  • the base profiles 200 comprise a first base profile 208 that is secured to the floor slab 204, and a second base profile 210 that is secured to the first base profile 208.
  • the second base profile 210 presents the outwardly facing flanges 206.
  • anchor bolts 212 are secured within matching holes in floor slabs 204.
  • Applicant is not intended to be limited to anchor bolts 212 however, and other suitable mechanical fixings are contemplated by applicant's teachings.
  • a thermal break 214 can be positioned.
  • the thermal break 214 can be of, for example, but not limited to, an insulating polyester material in sheet form.
  • the first base profile 208 is fixed to the anchor bolts 212 (by nuts 216 for the various embodiments illustrated, but not limited to this structure) so that the thermal break 214 is provided between the first base profile 208 and the floor slab 204.
  • the first base profile 208 is provided with openings 218 in a first member 220 that are arranged to generally align with the anchor bolts 212.
  • the second base profile 210 slides between the generally opposed panels 224 and 226 of the first base profile 208, and, more particularly for some embodiments of applicant's teachings where the cartridge 222 is provided, the second base profile 210 presents a web 228 that can be fitted in sliding fit within a slot 230 within the cartridge 222.
  • the second profile 210 can be fixed in place by suitable fastening means (e.g., nuts and bolts) so that the flanges 206 face outwardly from floor slabs 204 (and consequently structure 202).
  • the cartridge 222 can first be slid onto web 228 of the second profile 210, and then the cartridge 222/second base profile 210 combination slid between the generally opposed panels 224 and 226 of the first base profile 208.
  • supporting profiles such as, for example, but not limited to, the first supporting profiles 100 illustrated in FIG. 1
  • the first supporting profiles 100 may be secured to the flanges 206 by, for example, but not limited to, rivets, bolts, or screws.
  • a plurality of panels can be installed until a desired number of courses of selected cladding has been installed on the building structure (FIG. 14). Additional steps may be taken in order to install insulation or to construct a desired internal wall, for example.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)

Abstract

Apparatuses and methods for installing panels of selected cladding to a structure, such as a building, are disclosed. First and second support profiles are secured on an interior side of each panel towards opposing edges. The first supporting profile of a panel can be connected to a structure to establish a base course. The first supporting profile presents a first flange projecting outwardly to engage a slot presented by the second supporting profile of a subsequent course. The slot can be defined by space between a second flange in the second supporting profile and the interior side of the panel of the subsequent course. The first supporting profile of the subsequent course can then be connected to the structure. The panels can be installed in courses in this manner until a desired area on the structure is cladded.

Description

TITLE: APPARATUS AND METHOD FOR INSTALLING CLADDING TO
STRUCTURES
FIELD
[0001] Applicant's teachings relate to apparatuses and methods for installing cladding to structures, such as, for example, a building.
INTRODUCTION [0002] Known methods exist for creating aluminum, stone, tile or other panel facades for buildings. The known methods typically employ techniques in which the existing wall of the building is decorated, i.e. finished, with insulation and covered by different exterior finishes like aluminum, ceramic, granite, brick or glass etc. However, in some cases, known methods for creating a panel facade involve relatively complicated support structures. In some cases, known methods for creating a panel facade are relatively time consuming. In some cases, known methods for creating a panel facade rely on relatively expensive materials. In some of these known methods, the building substructure, such as joists, railings, anchors, insulation and other wall components, such as insulation and external panels, are installed from the outside of the building. In some cases, known methods require the use of swing stages, scaffolding, safety lines and belts, hoists or jeylifts.
SUMMARY
[0003] In various embodiments of applicant's teachings, a cladding system is disclosed comprising: a panel of selected cladding comprising an interior side and first and second generally opposing edges; a first supporting profile comprising: (i) a first panel mounting surface secured to the interior side of the panel toward the first edge; (ii) a first structure mounting surface connected to and offset from the first panel mounting surface in a first direction extending from the second edge to the first edge and in a second direction orthogonal to the first direction; and (iii) a first flange connected to and offset from the first structure mounting surface in the first direction and in a direction generally opposite the second lateral direction, the first flange projecting generally in the first direction; a second supporting profile comprising: (i) a second panel mounting surface secured to the interior side of the panel toward the second edge; and (ii) a second flange connected to and offset from the second panel mounting surface in a direction opposite the first direction and in the second direction, the second flange projecting generally in the direction opposite the first direction, the second flange configured to engage the first flange of an adjacent panel.
[0004] In various embodiments of applicant's teachings, an apparatus for installing panels of selected cladding to a structure, such as, for example, a building, is disclosed for panels having an interior side and first and second generally opposing edges, the apparatus comprising: apparatus for installing panels of selected cladding to a structure, each of the panels having an interior side and first and second generally opposing edges, the apparatus comprising: a first supporting profile for attachment to the interior side of the panels toward the first edge, the first supporting profile comprising: (i) a first panel mounting surface extending generally in a first direction; (ii) a first structure mounting surface connected to and offset from the first panel mounting surface in the first direction and in a second direction generally orthogonal to the first lateral direction; and (iii) a first flange connected to and offset from the first structure mounting surface in the first direction and in a direction generally opposite the second direction, the first flange projecting generally in the first direction; a second supporting profile for attachment to the interior side of the panels toward the second edge, the second supporting profiles comprising: (i) a second panel mounting surface; and (ii) a second flange connected to and offset from the second panel mounting surface, the second flange configured to engage the first flange.
[0005] In various embodiments of applicant's teachings, a structure is disclosed comprising a plurality of panels of selected cladding, each of the panels comprising an interior side having first and second supporting profiles secured thereto, the first and second supporting profiles spaced apart toward generally opposing edges, the first and second supporting profiles each comprising first and second flanges, respectively, the first and second flanges of a given panel projecting in generally opposing directions away from one another, the first flange of a given panel configured to be retained in a slot defined by the second flange and the interior surface of a subsequent panel, the first supporting profile of each panel connected to a surface of the structure defining a series of spaced courses of panels.
[0006] In various embodiments of applicant's teachings, a method of installing cladding to a structure, such as, for example, a building, is disclosed comprising: providing a structure, the structure comprising a surface to be cladded; providing a plurality of panels of selected cladding, the panels comprising interior and exterior sides; securing a first supporting profile and a second supporting profile on the interior sides of each of the panels, the first and second supporting profiles spaced apart toward generally opposing edges of each of the panels; connecting the first supporting profile of at least one of the panels to the surface of the structure to the at least one panel as a base course; fixing the second supporting profile of at least another one of the panels to the first supporting profile of the at least one panel of the base course to install the at least another one panel as a subsequent course; and connecting the first supporting profile of the at least another one panel of the subsequent course to the surface of the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The skilled person in the art will understand that the drawings, described below, are for illustration purposes only. The drawings are not intended to limit the scope of the applicant's teachings in any way.
[0008] FIG. 1 shows sectional, side and perspective views of a first supporting profile according to various embodiments of applicant's teachings;
[0009] FIG. 2 shows sectional, side and perspective views of a second supporting profile according to various embodiments of applicant's teachings; - A -
[0010] FIG. 3 shows side views of a first supporting profile being secured to a panel of selected cladding;
[0011] FIG. 4 shows side views of a second supporting profile being secured to a panel of selected cladding; [0012] FIG. 5 shows perspective views of a panel of selected cladding including first and second supporting profiles secured thereto;
[0013] FIG. 6 shows side views of a panel of selected cladding having first and second supporting profiles secured thereto being connected and fixed to a surface; [0014] FIG. 7 shows a perspective view of base profiles secured to floor slabs;
[0015] FIG. 8 shows a perspective view of anchor bolts and a thermal break on a floor slab;
[0016] FIG. 9 shows a perspective view of a first base profile secured to a floor slab;
[0017] FIG. 10 shows a perspective view of a plurality of first base profiles secured to two successive floor slabs;
[0018] FIG. 11 shows a perspective view of a second base profile secured to first base profile secured to a floor slab; [0019] FIG. 12 shows perspective view of two second base profiles secured to first base profile secured to a floor slab;
[0020] FIG. 13 shows a perspective view of a plurality of second base profiles extending vertically between successive floor slabs; and
[0021] FIG. 14 shows a perspective view of panels of selected cladding installed on an exterior of a structure. DETAILED DESCRIPTION
[0022] Various apparatuses or methods will be described below to provide an example of embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover apparatuses or methods that are not described below. The claimed inventions are not limited to apparatuses or methods having all of the features of any one apparatus or method described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or method described below is not an embodiment of any claimed invention. The applicant(s), inventor(s) and/or owner(s) reserve all rights in any invention disclosed in an apparatus or method described below that is not claimed in this document and do not abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.
[0023] Applicant's teachings relate to apparatuses and methods to install cladding to structures, such as, for example, a building. In particular, applicant provides supporting profiles that are secured to panels of selected cladding that allow the panels to be fixed to exteriors of structures. In accordance with various embodiments of applicant's teachings, the profiles are generally of two categories, namely first and second supporting profiles, which are fixed to interior sides of the panels and which support the cladding. It can be appreciated, however, that applicant's teachings are not intended to be limited to only these two particular profiles, and that other supporting profiles are possible within applicant's teachings.
[0024] Referring to FIGS. 1A to 1C, a first supporting profile 100 is shown featuring a first panel mounting surface 102, a first structure mounting surface 104, and first flange 106 projecting generally away from the first panel mounting surface 102. The first structure mounting surface 104 is disposed between the first panel mounting surface 102 and the first flange 106. As shown best in FIG. 1A, the first structure mounting surface 104, the first panel mounting surface 102 and the first flange 106 may be provided generally parallel in the same first direction, the first direction generally corresponding to a direction along an interior surface of a panel (not shown) between second and first edges when secured to the first supporting profile 100, as discussed below. The first panel mounting surface 102 is connected to and offset from the first structure mounting surface 104 by first transverse web 107, and the first structure mounting surface 104 is connected to and offset from the first flange 106 by second transverse web 109. The first and second transverse webs may be provided generally parallel in a second direction corresponding to a direction orthogonal to an interior surface of a panel when secured to the first supporting profile 100. [0025] The first panel mounting surface 102 of each first supporting profile 100 may be predrilled with at least two attachment points 108 for securing the first supporting profile to a panel (not shown), and the first structure mounting surface 104 of each first supporting profile 100 may be predrilled with at least two connection points 111 for connecting the first supporting profile 100 to the surface of a structure to be cladded.
[0026] An optional second structure mounting surface 110 may also be provided, disposed on an opposite side of the first panel mounting surface 102 from the first structure mounting surface 104. The second structure mounting surface 110 is generally parallel with the first structure mounting surface 104. The second structure mounting surface 110 is connected to the first panel mounting surface 102 by a third transverse web 113. The first, second, and third transverse webs 107, 109, 113 each may be parallel (in the second direction) and be equally sized in terms of widths so as to space the cladding apart from the structure in a consistent manner. The first supporting profiles 100 may also include a groove 112 adapted to receive in snap fit a flange of an insulation supporting profiles (not shown) that may be included to support courses of insulation provided along the interior of the cladding once the cladding has been installed.
[0027] Referring to FIGS. 2A to 2C, a second supporting profile 114 is provided complementary with the first supporting profile 100, as will hereinafter become apparent. The second supporting profile 114 includes a second panel mounting surface 116, and a second flange 118 configured to be spaced apart from the interior side of the panel (not shown) when the second supporting profile 114 is secured to the panel. The second flange 118 is separated from the second panel mounting surface 116 by a jog 119. The second flange 118 projects generally away from the second panel mounting surface 116. The second supporting profile 114 may further comprise a third structure mounting surface 120. The third structure mounting surface 120 is connected to and offset from the second panel mounting surface 116 by a fourth transverse web 121. The second panel mounting surface 116, the second flange 118 and the third structure mounting surface 120 can be provided generally parallel. The second panel mounting surfaces 116 of the second supporting profiles 114 may also be predrilled with at least two attachment points 122.
[0028] Referring to FIGS. 1A and 2A, the first and second flanges 106, 118 of the first and second supporting profiles 100, 114 may have flared distal edges 124, 126, respectively, enabling a snap fit, as will hereinafter become apparent.
[0029] Referring to FIGS. 3A to 3D, a panel 128 of selected cladding is shown having interior and exterior sides 130, 132 and first and second edges 134, 136. The first and second edges 134, 136 are generally opposing. The panels 128 of selected cladding can be formed from a variety of suitable materials, such as ceramic, natural granite, epoxy fiber, cement fiber, metal, composite, natural stone, artificial stone, and laminate materials, for example. The first supporting profiles 100 are configured for attachment to the interior side 130 of each of the panels 128 towards the first edge 134. The first edge 134 can be an upper edge of the panel when oriented in an installed position, for example. The first supporting profile 100 can be provided with the distal edge 124 of the first flange 106 extending beyond the first edge 134, so that the first transverse web 107 is presented generally flush with the first edge 134. This allows access to the first structure mounting surface 104 for fastening. The first supporting profiles 100 can be secured to the panels 128 by a fastening means, such as screws (e.g., self-tapping screws), bolts, adhesive, etc. In this case, a screw 138 is used to secure the first supporting profile 100 to the panel 128.
[0030] It should be appreciated that the terms upper, lower, top, bottom, etc., are used in this disclosure for the sake of clarity and relate to the position of the first and second supporting profiles and the panels when in an installed orientation in accordance with the specific examples illustrated. In particular, the term exterior refers to a direction generally away from the surface of the structure being cladded, while the term interior refers to a direction generally toward the surface of the structure being cladded. Applicant's teachings are not intended to be limited to particular orientations of the supporting profiles 100, 114 and/or the panels 128, and that various orientations are possible within applicant's teachings.
[0031] Referring to FIGS. 4A to 4D, the second supporting profiles 114 are also configured for attachment to the interior side 130 of each of the panels 128. The second supporting profiles 114 are configured for attachment toward the second edge 136 of the panel, which can be a lower edge, for example, when oriented in an installed position. The second flange
118 is configured to be spaced apart from the interior side 130 of the panel 128 when the second supporting profile 114 is secured to the panel 128, defining a slot 138 sized to receive the first flange 106 of the first supporting profile 100 in sliding fit, as described below. As shown in FIG. 4, the first, second and third structure engagement surfaces 104, 110, 120, according to the illustrated embodiment of applicant's teachings, are spaced away from the first and second panel mounting surfaces 102, 116 to maintain the panels 128 generally parallel with the surface of the structure once installed. As well, the distal edge 126 is inset from the second edge 136 of the panel 128.
[0032] FIGS. 5A and 5B show the panel 128' complete with supporting profiles 100, 114 secured thereto. As illustrated, the supporting profiles 100, 114 have lengths that generally match lengths of the opposing edges 134,
136 of the panels 128. Furthermore, the supporting profiles 100, 114 are shown secured to each of the panels 128 at the two spaced apart attachment points 108, 122, respectively, which may be predilled in the supporting profiles or drilled at the time the supporting profiles 100, 114 are secured to the panel 128. Alternatively, if adhesive is used to secure the supporting profiles 100, 114 to the panel, for example, attachment holes need not be provided. It should be appreciated that, advantageously, the panels 128 can be prepared with the supporting profiles 100, 114 as a separate step at a location remote from the structure to be cladded.
[0033] In accordance with applicant's teachings, FIGS. 6A to 6F illustrate an example of the general method of affixing the panels 128' to a surface 140 of a structure, for example, an exterior surface of a building. It should be understood that the surface 140 need not be a continuous flat surface, and can be a skeletal building structure comprising a series of vertically spaced floor slabs, for example, in which case the supporting profiles 100, 114 can be secured to the outer surfaces of the floor slabs. The panels 128', featuring the supporting profiles 100, 114, are secured to the surface 140 either directly (e.g., screws, bolts or adhesive) or indirectly (e.g., via a plurality of base profiles, as discussed below).
[0034] As shown in FIGS. 6A to 6F, to establish a base course of cladding, a first supporting profile 100 may optionally be first secured to the surface 140, absent a panel. A panel 128' with first and second supporting profiles 100, 114 is then provided above the first supporting profile. The first flange 106 of the first supporting profile 100 secured to the surface 140 is received with sliding fit in the slot 138 formed between the second flange 118 of the second supporting profile 114 secured to the panel 128 and the interior side 130 of the panel 128. As shown in FIG. 6D, the distal edges 124, 126 may be flared so that the first flange 106 is received by the second flange 118 according to a snap fit sliding arrangement, with the distal edge 126 of the second flange 118 deflecting away from the interior side 130 of the panel to accept the first flange 106. It should be appreciated that the tolerance between the first flange 106 and the slot 138 can vary, for example, from a loose sliding fit to a friction fit. A tighter fit between the first flange 106 and the slot 138 will restrict the movement of the panel 128' once installed onto the surface 140), but may make installation more difficult. If a tighter fit is desired, the interaction between the first flange 106 and the slot 138 will generally depend on the surface characteristics of the selected cladding.
[0035] Referring to FIG. 6F, the first structure mounting surface 104 of the first supporting profile 100 of the panel 128' can then be secured to the surface 140 using self-tapping screws, anchor screws, adhesive or bolts, for example. In this case, a screw 142 is used. As mentioned previously, the first supporting profiles 100 may include two or more spaced apart connection points (not shown), which may be predilled in the first supporting profiles 100 similar to the attachment points 108, or drilled at the time the first supporting profiles 100 are secured to the panel 128.
[0036] It should be understood that, alternative to what is illustrated in FIG. 6, another method of establishing a base course of cladding is to secure the first supporting profile 100 of a panel 128' to the surface 140 without first securing a first supporting profile 100 absent a panel 128. In this case, the second edge 136 of the panel 128' would not be secured to the surface 140. A yet another method of establishing a base course of cladding is to secure the first supporting profile 100 to a panel 128 along the second edge 136 of the panel 128, so as to mirror the first supporting profile 100 along the first edge 134. In this case, both first supporting profiles 100 could be secured to the surface 140 to establish a base course.
[0037] Advantageously, the second edge 136 of a subsequent course may conceal the fastening hardware 142 present on the first structure mounting surface 104 of a given course once installed. However, the first and second supporting profiles 100, 114 may be configured to maintain adjacent panels 128' spaced apart to provide a desired gap 144 to allow for expansion
(FIG. 6H). Otherwise, the first and second supporting profiles 100, 114 may be configured to maintain first edge 134 of a panel 128' and second edge 136 of an adjacent panel 128' touching or close to it, which may be aesthetically desirable. Furthermore, some room may be left between the distal edge 124 of the first flange 106 and the jog 119 of the second supporting profile 114 (FIG. 6H) to allow for thermal expansion, in which case the first profile 100 is the weight-bearing support for panel. [0038] Therefore, the method of installing cladding to a structure in accordance with various embodiments of applicant's teachings include the following general steps: providing a structure, the structure comprising a surface to be cladded; providing a plurality of panels of selected cladding, the panels comprising interior and exterior sides; securing a first supporting profile and a second supporting profile on the interior sides of each of the panels, the first and second supporting profiles spaced apart toward generally opposing edges of each of the panels; connecting the first supporting profile of at least one of the panels to the surface of the structure to the at least one panel as a base course; fixing the second supporting profile of at least another one of the panels to the first supporting profile of the at least one panel of the base course to install the at least another one panel as a subsequent course; and connecting the first supporting profile of the at least another one panel of the subsequent course to the surface of the structure.
[0039] In accordance with applicant's teachings, these steps can be repeating so as to install a desired number of panels on the surface of the structure to define a base course of cladding, i.e. in this case horizontally, and install a desired number of panels on the surface to define until a desired number of successive courses of the panels has been installed on the surface of the structure. In addition to having successive courses with the cladding aligned horizontally, persons of skill would recognize that the cladding according to the applicant's teachings can be applied to the structure in an angled orientation, and/or in a staggered arrangement.
[0040] It should be understood that a particular advantage for the various embodiments of applicant's teachings is that, once a first course of panels have been installed, ensuring that base course is properly leveled, subsequent courses of the panels can be installed without having to level each course. It should also be appreciated that panels comprising first and second supporting profiles secured thereto can be installed relatively quickly, and with few tools required. Another advantage relates to the fact that the supporting profiles have a generally uniform cross-section and therefore can be manufactured by an extrusion technique. Other aspects of the applicant's teachings may be further understood in light of the following, which should not be construed as limiting the scope of the present teachings in any way.
[0041] Referring to FIG. 7, an example is provided for a means of affixing the supporting profiles 100, 114 to the exterior of a structure. A base profile 200 is disclosed fixed to a skeletal structure 202, such as, for example, but not limited to, a building. The skeletal building structure generally comprises a plurality of vertically spaced floor slabs 204, or at least a floor slab and a similar structure to form the ceiling/roof of the building. For the various embodiments of applicant's teachings, the base profiles 200 are secured to the floor slabs 204, as illustrated in FIG. 7. As can be seen in FIG. 7, the base profiles 200 may extend vertically to span at least two of the vertically spaced floor slabs 204.
[0042] Further, for various embodiments of applicant's teachings, the base profiles 200 present flanges 206 facing outwardly from the floor slabs 204 and the building structure 202. The flanges 206 are adapted to retain the supporting profiles 102. For instance, the supporting profiles 102 can be fixed to the flanges 206 of the base profiles 200 by, for example, but not limited to, rivets, bolts, screws or adhesive.
[0043] Moreover, in accordance with applicant's teachings, the base profiles 200 comprise a first base profile 208 that is secured to the floor slab 204, and a second base profile 210 that is secured to the first base profile 208. For various embodiments of applicant's teachings, the second base profile 210 presents the outwardly facing flanges 206.
[0044] In accordance with various embodiments of applicant's teachings, the base profiles 200 are secured to structure 202 as follows.
First, referring to FIG. 8, anchor bolts 212 are secured within matching holes in floor slabs 204. Applicant is not intended to be limited to anchor bolts 212 however, and other suitable mechanical fixings are contemplated by applicant's teachings. Once the anchor bolts 212 are in place, and in accordance with some embodiments of applicant's teachings, a thermal break 214 can be positioned. The thermal break 214 can be of, for example, but not limited to, an insulating polyester material in sheet form. As shown in FIG. 9, the first base profile 208 is fixed to the anchor bolts 212 (by nuts 216 for the various embodiments illustrated, but not limited to this structure) so that the thermal break 214 is provided between the first base profile 208 and the floor slab 204. The first base profile 208 is provided with openings 218 in a first member 220 that are arranged to generally align with the anchor bolts 212.
[0045] The above process can be repeated so that the first base profiles 208 are secured to the floor slabs 204 to create a vertical line between respective first base profiles 208 on successive floor slabs 204, as illustrated in FIG. 10.
[0046] After first base profiles 208 have been fixed to the floor slabs
204, for some embodiments of applicant's teachings, a second thermal break in the form of a cartridge 222 may be inserted into a slot provided between generally opposed panels 224 and 226 of the first base profile 208, as best illustrated having regard to FIG. 11. The second thermal break 222 can be, for example, but not limited to, of a plastic or polyester construction.
[0047] As illustrated in FIG. 11 , the second base profile 210 slides between the generally opposed panels 224 and 226 of the first base profile 208, and, more particularly for some embodiments of applicant's teachings where the cartridge 222 is provided, the second base profile 210 presents a web 228 that can be fitted in sliding fit within a slot 230 within the cartridge 222. The second profile 210 can be fixed in place by suitable fastening means (e.g., nuts and bolts) so that the flanges 206 face outwardly from floor slabs 204 (and consequently structure 202). It can be appreciated that for some embodiments of applicant's teachings, the cartridge 222 can first be slid onto web 228 of the second profile 210, and then the cartridge 222/second base profile 210 combination slid between the generally opposed panels 224 and 226 of the first base profile 208.
[0048] With reference to FIGS. 12 and 13, for various embodiments of applicant's teachings, the second base profiles 210 can be secured to the first base profiles 208 to extend vertically along aligned first base profiles 208 to span at least two of the vertically spaced floor slabs 204. Moreover, for some embodiments of applicant's teachings, the first base profiles 208 can receive two of the second base profiles 210: one extending upwardly from the first base profile 208 to the floor slabs above, and a second extending downwardly from the first base profile 208 to the floor slabs 204 therebelow. The steps of fixing the first and second base profiles 208, 210 as described may be repeated until a skeletal building structure that requires cladding is covered: this process basically creates the vertical structure that the supporting profiles 100, 114 are fixed to. [0049] In accordance with various embodiments of applicant's teachings, supporting profiles, such as, for example, but not limited to, the first supporting profiles 100 illustrated in FIG. 1 , can be fixed to the base profiles 200, and, for the embodiments illustrated, the flanges 206 of the second base profiles 210. The first supporting profiles 100 may be secured to the flanges 206 by, for example, but not limited to, rivets, bolts, or screws. As was previously explained having regard to the various examples of applicant's teachings, a plurality of panels can be installed until a desired number of courses of selected cladding has been installed on the building structure (FIG. 14). Additional steps may be taken in order to install insulation or to construct a desired internal wall, for example.
[0050] While the applicant's teachings are described in conjunction with various embodiments, it is not intended that the applicant's teachings be limited to such embodiments. On the contrary, the applicant's teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art.

Claims

I CLAIM:
1. A cladding system comprising: a) a panel of selected cladding comprising an interior side and first and second generally opposing edges; b) a first supporting profile comprising: i) a first panel mounting surface secured to the interior side of the panel toward the first edge; ii) a first structure mounting surface connected to and offset from the first panel mounting surface in a first direction extending from the second edge to the first edge and in a second direction orthogonal to the first direction; and iii) a first flange connected to and offset from the first structure mounting surface in the first direction and in a direction generally opposite the second lateral direction, the first flange projecting generally in the first direction; c) a second supporting profile comprising: i) a second panel mounting surface secured to the interior side of the panel toward the second edge; and ii) a second flange connected to and offset from the second panel mounting surface in a direction opposite the first direction and in the second direction, the second flange projecting generally in the direction opposite the first direction, the second flange configured to engage the first flange of an adjacent panel.
2. The system of claim 1 , wherein the first panel mounting surface, the first structure mounting surface and the first flange are generally parallel with the first direction.
3. The system of claim 2, wherein the second panel mounting surface and the second flange are generally parallel with the first direction.
4. The system of claim 3, wherein the first panel mounting surface is connected to the first structure mounting surface by a first transverse web.
5. The system of claim 4, wherein the first transverse web is generally flush with the first edge of the panel.
6. The system of claim 5, wherein the first structure mounting surface is connected to the first flange by a second transverse web.
7. The system of claim 6, wherein the first and second transverse webs are generally parallel with the second direction.
8. The system of claim 7, wherein the first and second transverse webs extend away from the interior side in the second direction generally equal widths.
9. The system of claim 8, wherein the second flange is spaced apart from the interior side of the panel defining a slot.
10. The system of claim 9, wherein the slot is sized to receive the first flange of the first supporting profile of an adjacent panel in sliding fit.
11. The system of claim 10, wherein a distal edge of the first flange extends in the first direction beyond the first edge.
12. The system of claim 11 , wherein a distal edge of the second flange is inset in the first direction from the second edge.
13. The system of claim 12, wherein the distal edges of the first and second flanges are flared enabling a snap fit.
14. The system of claim 13, wherein the first supporting profile further comprises a second structure mounting surface connected to and offset from the first panel mounting surface in the direction generally opposite the first direction and in the second direction.
15. The system of claim 14, wherein the second structure mounting surface is connected to the first panel mounting surface by a third transverse web.
16. The system of claim 15, wherein the third transverse web is generally parallel with the second direction and extends away from the interior side in the second direction a width generally equal to the widths of the first and second transverse webs.
17. The system of claim 16, wherein the second supporting profile further comprises a third structure mounting surface connected to and offset from the second panel mounting surface in the first direction and in the second direction.
18. The system of claim 17, wherein the third structure mounting surface is connected to the second panel mounting surface by a fourth transverse web.
19. The system of claim 18, wherein the fourth transverse web is generally parallel with the second direction and extends away from the interior side in the second direction a width generally equal to widths of the first, second and third transverse webs.
20. The system of any one of claims 1-19, wherein the first and second supporting profiles are configured to maintain adjacent panels spaced apart to allow a desired gap.
21. The system of any one of claims 1-20, wherein the panel mounting surfaces of each of the first and second supporting profiles are predrilled with at least two attachment points.
22. The system of any one of claims 1-21 , wherein the first structure mounting surfaces of each of the first supporting profiles are predrilled with at least two connection points.
23. An apparatus for installing panels of selected cladding to a structure, each of the panels having an interior side and first and second generally opposing edges, the apparatus comprising: a) a first supporting profile for attachment to the interior side of the panels toward the first edge, the first supporting profile comprising: i) a first panel mounting surface extending generally in a first direction; ii) a first structure mounting surface connected to and offset from the first panel mounting surface in the first direction and in a second direction generally orthogonal to the first lateral direction; and iii) a first flange connected to and offset from the first structure mounting surface in the first direction and in a direction generally opposite the second direction, the first flange projecting generally in the first direction; b) a second supporting profile for attachment to the interior side of the panels toward the second edge, the second supporting profiles comprising: i) a second panel mounting surface; and ii) a second flange connected to and offset from the second panel mounting surface, the second flange configured to engage the first flange.
24. The apparatus of claim 23, wherein the first panel mounting surface, the first structure mounting surface and the first flange are generally parallel with the first direction.
25. The apparatus of claim 24, wherein the second panel mounting surface and the second flange are generally parallel with the first direction.
26. The apparatus of claim 25, wherein the first panel mounting surface is connected to the first structure mounting surface by a first transverse web.
27. The apparatus of claim 26, wherein the first structure mounting surface is connected to the first flange by a second transverse web.
28. The apparatus of claim 27, wherein the first and second transverse webs are generally parallel with the second direction.
29. The apparatus of claim 28, wherein the second flange is configured to provide a slot sized to receive the first flange in sliding fit.
30. The apparatus of claim 29, wherein distal edges of the first and second flanges are flared enabling a snap fit.
31. The apparatus of claim 30, wherein the first supporting profile further comprises a second structure mounting surface connected to and offset from the first panel mounting surface in the direction generally opposite the first direction and in the second direction.
32. The apparatus of claim 31 , wherein the second structure mounting surface is connected to the first panel mounting surface by a third transverse web.
33. The apparatus of claim 32, wherein the third transverse web is generally parallel with the second direction.
34. The apparatus of claim 33, wherein the second supporting profile further comprises a third structure mounting surface connected to and offset from the second panel mounting surface in the first direction and in the second direction.
35. The apparatus of claim 34, wherein the third structure mounting surface is connected to the second panel mounting surface by a fourth transverse web.
36. The apparatus of claim 35, wherein the fourth transverse web is generally parallel with the second direction.
37. The apparatus of any one of claims 23-36, wherein the panel mounting surfaces of each of the first and second supporting profiles are predrilled with at least two attachment points.
38. The apparatus of any one of claims 23-37, wherein the first structure mounting surfaces of each of the first supporting profiles are predrilled with at least two connection points.
39. A structure comprising a plurality of panels of selected cladding, each of the panels comprising an interior side having first and second supporting profiles secured thereto, the first and second supporting profiles spaced apart toward generally opposing edges, the first and second supporting profiles each comprising first and second flanges, respectively, the first and second flanges of a given panel projecting in generally opposing directions away from one another, the first flange of a given panel configured to be retained in a slot defined by the second flange and the interior surface of a subsequent panel, the first supporting profile of each panel connected to a surface of the structure defining a series of spaced courses of panels.
40. A method of installing cladding to a structure, the method comprising: providing a structure, the structure comprising a surface to be cladded; providing a plurality of panels of selected cladding, the panels comprising interior and exterior sides; securing a first supporting profile and a second supporting profile on the interior sides of each of the panels, the first and second supporting profiles spaced apart toward generally opposing edges of each of the panels; connecting the first supporting profile of at least one of the panels to the surface of the structure to the at least one panel as a base course; fixing the second supporting profile of at least another one of the panels to the first supporting profile of the at least one panel of the base course to install the at least another one panel as a subsequent course; and connecting the first supporting profile of the at least another one panel of the subsequent course to the surface of the structure.
41. The method of claim 40, wherein the first supporting profile of the base course and the second supporting profile of the subsequent course are fixed to one another through a sliding fit.
42. The method of claim 41 , wherein the first supporting profile comprises a first flange that is retained within a slot presented by the second supporting profile.
43. The method of claim 42, wherein the slot is defined by a second flange spaced apart from the interior side of the panel.
44. The method of claim 43, wherein the first and second flanges are configured so that the first flange is retained in the slot by snap fit.
45. The method of any one of claims 40-44, wherein the opposing edges of the panels are generally parallel to one another.
46. The method of any one of claims 40-45, wherein lengths of the first and second supporting profiles generally match lengths of the opposing edges of the panels.
47. The method of any one of claims 40-46, wherein the first and second supporting profiles maintain the panels generally parallel with the surface of the structure when installed.
48. The method of any one of claims 40-47, wherein the panels of the base course are spaced apart from the panels of the subsequent course to allow a desired gap.
49. The method of any one of claims 40-48, wherein each of the first and second supporting profiles are secured to each of the panels at at least two spaced apart attachment points.
50. The method of claim 49, wherein the at least two attachment points are predilled in the first and second supporting profiles.
51. The method of any one of claims 40-50, wherein the first and second supporting profiles are secured to the panels by means of self-tapping screws, anchor screws, glue or bolts, or any combination thereof.
52. The method of any one of claims 40-51 , wherein the first supporting profiles of each course are connected to the surface of the structure at at least two spaced apart connection points.
53. The method of claim 52, wherein the at least two connection points are predilled in the first supporting profiles.
54. The method of any one of claims 40-53, further comprising connecting a first supporting profile to the structure to be fixed with the second supporting profile of the at least one panel of the base course.
55. The method of any one of claims 40-54, further comprising repeating steps (d) to (f) until a desired number of successive courses of the panels has been installed on the surface of the structure.
56. The method of any one of claims 40-55, wherein the structure is a skeletal building structure.
57. The method of claim 56, wherein the skeletal building structure comprises a plurality of vertically spaced floor slabs.
58. The method of claim 57, wherein the surface of the structure comprises surfaces of the plurality of floor slabs.
59. The method of claim 58, further comprising securing base profiles to the surfaces of the plurality of floor slabs, and then securing the first and second supporting profiles to the base profiles.
60. The method of claim 59, wherein the base profiles comprise first base profiles and second base profiles.
61. The method of claim 60, wherein the first base profiles are secured to the surfaces of the plurality of floor slabs second base profiles are secured to the first base profiles.
62. The method of claim 61 , wherein the second base profiles present flanges facing outwardly from the floor slabs, and the first and second supporting profiles are secured to the flanges.
63. The method of claim 62, wherein the second base profiles extend vertically to span at least two of the vertically spaced floor slabs.
64. The method of any one of claims 59-63, further comprising providing a thermal break between the base profiles and the floor slabs.
65. The method of any one of claims 40-64, wherein the panels of selected cladding are formed of a material selected from the group consisting of ceramic, natural granite, epoxy fiber, cement fiber, metal, composite, natural stone, artificial stone, and laminate.
PCT/CA2007/002003 2007-11-08 2007-11-08 Apparatus and method for installing cladding to structures WO2009059392A1 (en)

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