U.S. patent application number 09/872516 was filed with the patent office on 2002-04-18 for fastening system for an expandable building panel.
Invention is credited to Bodine, Darryl C., Dorsey, William C., Patel, Kartik A..
Application Number | 20020043037 09/872516 |
Document ID | / |
Family ID | 26932912 |
Filed Date | 2002-04-18 |
United States Patent
Application |
20020043037 |
Kind Code |
A1 |
Dorsey, William C. ; et
al. |
April 18, 2002 |
Fastening system for an expandable building panel
Abstract
A fastening system for attaching an expandable building panel or
surface covering system to a substrate is provided. The fastening
system includes at least one slip clip which, when utilized, allows
for longitudinal movement of the building panel, while
substantially preventing transverse movement. Typically, a spring
clip will be used in combination with the slip clip to apply
pressure to the panel, thereby allowing expansion and contraction
of the panel in a longitudinal direction while eliminating gaps
between the adjacent end-to-end panels. A method of installing
building panels using the described fastening system is also
provided.
Inventors: |
Dorsey, William C.;
(Conestoga, PA) ; Patel, Kartik A.; (Landisville,
PA) ; Bodine, Darryl C.; (St. Joseph, MI) |
Correspondence
Address: |
WOMBLE CARLYLE SANDRIDGE & RICE, PLLC
P.O. Box 7037
Atlanta
GA
30357-0037
US
|
Family ID: |
26932912 |
Appl. No.: |
09/872516 |
Filed: |
June 2, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60239822 |
Oct 12, 2000 |
|
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|
Current U.S.
Class: |
52/506.05 ;
52/127.6; 52/285.3; 52/489.1; 52/506.08 |
Current CPC
Class: |
F16B 5/0628 20130101;
E04F 19/02 20130101; E04F 13/0864 20130101 |
Class at
Publication: |
52/506.05 ;
52/506.08; 52/489.1; 52/127.6; 52/285.3 |
International
Class: |
E04B 001/38 |
Claims
What is claimed is:
1. A fastening system for an expandable panel comprising: at least
one slip clip.
2. The fastening system of claim 1 further comprising at least one
spring clip used in combination with the slip clip to fasten the
panel yet allow expansion and contraction of the panel in a
longitudinal direction.
3. A surface covering system comprising a panel having a fastening
flange and a slip clip.
4. The surface covering system of claim 3 further comprising a
spring clip used in combination with the slip clip to fasten the
panel yet allow expansion and contraction of the panel in a
longitudinal direction.
5. A fastening system for an expandable panel comprising: at least
one slip clip attached to a substrate and cooperating with a
longitudinal edge of the expandable panel.
6. The fastening system of claim 5, wherein the slip clip includes
a lower tab attached to the substrate and an upper tab engaging a
flange on the expandable panel.
7. The fastening system of claim 5, further comprising at least one
spring clip cooperating with a lateral edge of the expandable
panel.
8. The fastening system of claim 7, wherein the spring clip applies
compressive force to the expandable panel.
9. A fastening system for an expandable panel comprising: an
expandable panel having a longitudinal edge and a transverse edge;
attachment means, attaching the longitudinal edge of the panel
directly to a substrate and permitting relative movement between
the panel and the substrate in the longitudinal direction; and at
least one spring clip adjacent the transverse edge of the
panel.
10. The fastening system of claim 9, wherein the spring clip
includes a body and an arm attached to the body at an angle to the
body.
11. The fastening system of claim 10, wherein the ends of the
spring clip are curved.
12. A fastening system for an expandable panel comprising: at least
one spring clip.
13. The fastening system of claim 12, wherein the spring clip
includes a body and an arm attached to the body at an angle to the
body.
14. The fastening system of claim 13, wherein the ends of the
spring clip are curved.
15. A method of attaching expandable panels including one or more
flanges to a surface, the method comprising: attaching one or more
slip clips to a substrate, whereby a portion of the slip clip
covers a portion of the flange and permits longitudinal movement
but not lateral movement of the expandable panel to which the
flange is attached.
16. The method of claim 15, further comprising the step of:
disposing one or more spring clips along a lateral side of the
expandable panel, whereby the spring clip applies compressive force
to the panel.
17. The method of claim 15, wherein the expandable panel is formed
of polyvinyl chloride.
18. The method of claim 15, wherein the expandable panel includes a
design element.
19. The method of claim 18, wherein the design element is selected
from a wood finish, a marble finish and a stone finish.
Description
BACKGROUND
[0001] I. Field of the Invention
[0002] The present invention generally relates to fastening systems
for building panels. More specifically, the present invention
relates to a fastening system that accommodates the relative
expansion and/or contraction between a building panel and the
substrate to which the panel is attached.
[0003] II. Background of the Invention
[0004] Wooden ceilings, walls, wainscoting and flooring made of
interlocking planks or panels of wood are common in the building
industry. So-called "tongue and groove" paneling systems are widely
utilized in porches, sunrooms, decks, kitchens, flooring and in
other living spaces. These products have traditionally and
overwhelmingly been wood-based. A typical wooden tongue and groove
wood panel system is represented in FIG. 1 (not to scale). FIG. 1
depicts a typical end view of a known wooden plank or panel system
showing how the edge details of the plank may be designed so that
the planks can be installed side-by-side. Once joined, the planks
may exhibit a V-shaped groove at the junction of the panels.
[0005] Wood products dominate the paneling market, because wood
products typically appear more aesthetically pleasing to the
consumer. Panels made from plastic materials such as thermoplastic
polymers, on the other hand, typically offer higher resistance to
moisture, potentially lower cost, lighter weight, and better fire
resistance. To gain acceptance and approval from the general
public, however, such plastic panels must exhibit a high quality
finish. Thus, there is a need to create a high-quality panel with a
visual finish that exhibits a level of quality and fit capable of
challenging wood paneling. In other words, consumers expect a
certain smoothness of finish and quality "look" for the finished
product.
[0006] Additionally, materials used for ceilings and other interior
finishes must be tested for fire resistance. Since untreated wooden
materials are known to support combustion, certain plastic
compounds typically perform better in fire resistance testing.
[0007] When paneling systems are employed, for instance, outdoors,
the paneling systems are typically exposed to higher humidity and
broader ranges of temperature than most indoor applications. There
remains a need for ceiling, flooring and wall materials that target
such demanding environments. Most commercially available ceiling
products are not intended for outdoor or high-humidity
applications. It is, however, desirable to provide products that
can withstand such extreme environmental conditions, since people
are spending less time in basements and more time in sunrooms and
on porches, decks and similar spaces, as evidenced by an increase
in the construction of such spaces.
[0008] Such demanding environments require that consideration in
designing and installing a paneling system take into account the
impact of varying temperature and humidity on the choice of
construction materials. In a given installation, the substrate to
which the panels are attached will expand and contract
insignificantly, but the panels will expand and contract
significantly along their length as the ambient temperature varies.
The temperature coefficient of linear expansion .alpha. is defined
by equation (1), where L is the length of the specimen in inches,
(.delta.L/.delta.T).sub.p is the change in length in inches with
respect to the change in temperature in .degree. C. at a specified
constant pressure p,
.alpha.=(1/L)*(.delta.L/.delta.T).sub.p (1)
[0009] For most solids the linear expansion approximates equation
(2), where L2 is the expanded length in inches, L1 is the initial
length in inches, T2 is the final temperature in .degree. C. and T1
is the initial temperature in .degree. C.,
L2=(L1)*(1+.alpha.(T2-T1)) (2)
[0010] For rigid PVC based materials, the .alpha. value is
10.sup.-5 in/in .degree. C. The calculations utilizing the
equations stated above showed that the expansion/contraction of a
40 foot span of building panel would be approximately 1.5
inches.
[0011] If the panels are simply nailed to a surface, warping or
sagging can develop. Thus, a system is needed that will provide for
the relative thermal expansion and contraction between the
substrate and the panels.
[0012] Although plastic panels are known to be less susceptible to
these environmental conditions, one characteristic of extruded
general purpose polyvinyl chloride (PVC) is its high thermal
coefficient of expansion in the axis of the extrusion. In an
extruded PVC plank of 12 feet in length, for instance, seasonal
temperature variations may cause a length change of up to 1/2 inch.
Known means of fastening of such panels to the surface of a
building are not, however, much more advanced than those known for
typical wooden systems. In fact, plastic panels are typically
attached by nailing or stapling, a flange generally being provided
along an edge of the panel for the purpose of attaching the panel
to a surface.
[0013] Traditional installation methods for plastic panels
generally require nailing or stapling planks or panels side-by-side
to cover a desired surface. A known method for installing a typical
plank is shown in FIG. 2. A plank 206 is fastened to a surface 200
(e.g. a wall or ceiling) using a fastening flange 204. The flange
204, which is part of the plank 206, is fabricated with a series of
fastening slots 202. The plank 206 is held in place temporarily by
partially driving nails 201 at two or more points along its length.
Alternatively, some plank systems provide elements that allow
succeeding rows to be held by fitting to a previously attached run,
where it is held by friction (not shown). The plank 206 is
subsequently fastened by driving additional nails 203, 205, and 207
through the slots 202 in the flange 204, then completely driving
the nails 201.
[0014] In geographical areas subject to wide temperature
variations, there are two important installation considerations.
First, the fasteners, such as nails 201, 203, 205, and 207 cannot
be driven tightly into the mounting surface 200 onto which the
plank 206 is being mounted. Fasteners that hold the plank too
tightly to the mounting surface 200 will prevent movement necessary
to accommodate dimensional changes due to variations in seasonal
temperature. Second, the fasteners also must be driven into the
center of the nailing slots, as shown, for instance, by nails 203.
Fasteners driven into the slots 202 in the manner of nails 205
and/or 207, or in some combination thereof, may also prevent
movement of the plank necessary to compensate for thermal expansion
and contraction. In addition, if the installation is improper, not
allowing the planks freedom to expand and contract along their
length, the planks may bow, warp and/or buckle as the plank expands
and contracts.
[0015] Further, in some situations, fixed length planks may be too
short to fully span the desired space, requiring the installation
of planks end to end. If more than one plank is needed to span the
length of a ceiling or wall to be covered, it is likely that
thermal effects may cause gaps to appear between abutting planks.
This is sometimes addressed by using moldings, decorative elements,
or other coverings, to hide the butt joints. Consumers, however,
prefer the more natural look of unbroken runs of siding and plank
materials. Thus, there is a need for installation techniques that
eliminate gaps between planks.
[0016] Since plastic building panels, (particularly PVC materials),
have high thermal coefficients of expansion, it is important to
allow for movement of planks during installation. Thus, there is a
need for a fastening system that accommodates thermal effects. As
seen above, even when a means of permitting plank movement is
supplied, in the form of slotted nailing slots, improper
installation practices will mitigate its effectiveness. Thus, there
is a need for installation hardware and methods that provide for
the movement of the planks.
SUMMARY OF THE INVENTION
[0017] The present invention is directed to a system for fastening
expandable planks to a surface wherein the planks are allowed to
expand and contract without warping, buckling or dislodging of the
planks from the mounting surface. The fastening system may include
one or more slip clips fastened to the mounting surface and aligned
to hold an expandable panel in place, while allowing the panel to
expand or contract. The slip clip may include a lower tab which
anchors the slip clip to the mounting surface and an upper tab
which engages the plank.
[0018] The fastening system may also include one or more spring
clips positioned at the end of at least one plank in order to
maintain compressive force on the planks as they expand or
contract. The spring clip may include at least one arm formed at an
angle to the body thereof. One or more spring clips may be used in
conjunction with one or more slip clips slotted flanges, netted
flanges or other attachment means that allow for movement of a
plank.
[0019] These and other aspects of the present invention are set
forth in greater detail in the brief description of the drawings
and the detailed description of the invention below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A full and enabling disclosure of the present invention,
including the best mode thereof, to one of ordinary skill in the
art, is set forth more particularly in the remainder of the
specification, including reference to the accompanying figures
wherein:
[0021] FIG. 1 is an end view of a typical tongue and groove
planking system according to the prior art.
[0022] FIG. 2 is a top view of a fastening system for a building
panel according to the prior art.
[0023] FIG. 3a is a top view of an embodiment of a slip clip of the
fastening system of the present invention.
[0024] FIG. 3b is a cross-sectional view of the slip clip of FIG.
3a.
[0025] FIG. 4 is a perspective view of a section of a slip clip of
the present invention engaging a building panel.
[0026] FIG. 5 is a top view of an embodiment of the fastening
system of the present invention.
[0027] FIG. 6a is a side view of an embodiment of a spring clip of
the present invention.
[0028] FIG. 6b is a top view of the spring clip of FIG. 6a.
[0029] FIG. 7 is a perspective view of an embodiment of the
fastening system according to the present invention showing
fastening of a building panel to a mounting surface using the slip
clip and the spring clip in combination to fasten the panel.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Reference will now be made in detail to some embodiments of
the invention, one or more examples of which are illustrated in the
drawings. Each example is provided by way of explanation of the
invention, and is not meant as a limitation of the invention. For
example, features illustrated or described as part of one
embodiment can be used on or in conjunction with other embodiments
to yield yet a further embodiment. It is intended that the present
invention includes such modifications and variations.
[0031] Building panels are provided with a fastening system or
mechanism according to the present invention that allow for thermal
expansion. The expandable panels may be formed of polyvinyl
chloride, or similar polymer or polymeric blend, and have a design
element, such as a wood, marble, stone or similar finish. When
properly installed, the fastening mechanism accommodates for
thermally induced dimensional changes in the building panel. This
reduces the chances for buckling, bowing, or warping of the
building panel when exposed to a broad range of temperatures.
[0032] The present invention has the advantage of allowing a
building panel to move as it expands and contracts. When properly
installed, the slip clips firmly hold the building panel in order
to inhibit and/or prevent movement thereof both in a direction
perpendicular to the long dimension of the panel and a direction
perpendicular to the surface of the substrate to which the panel is
attached, while allowing longitudinal movement of the panel due to
thermal expansion.
[0033] The fastening system of the present invention may use one or
more slip clips to hold the fastening flange of a building panel
against a mounting surface, while also providing for lateral or
longitudinal movement due to expansion or contraction.
[0034] Another feature of the present invention is the added
advantage of easy installation. The slip clips are designed so that
even when they are firmly attached to the mounting surface, the
force applied to the fastening flange is small enough to permit
longitudinal movement while being sufficient to prevent transverse
movement.
[0035] The present invention also has the advantage of providing
flexibility in installation such that less skilled installers may
achieve a proper installation. Because the slip clips do not
constrain the longitudinal movement of the building panel, it is
not necessary for the installer to properly utilize the fastening
slots in the fastening flange of the panel. The slip clips need
only be aligned along the length of the building panel to line it
up with an adjacent panel. Further, a slip clip may be slightly out
of line with other slip clips, in at least one direction, without
substantially affecting the uniformity of the installed
paneling.
[0036] The present invention has yet another advantage of
permitting end-to-end installation of building panels without gaps
developing between panels and without the use of moldings over the
butt joint between the panels.
[0037] The fastening system of the present invention represents an
improvement over existing installation methods, since the fasteners
that hold the slip clips to the mounting surface can be
significantly more firmly fastened without pinching the building
panel, and positioning of the slip clip will not constrain
longitudinal movement of the building panel. The slip clip of the
present invention can be attached to the mounting surface in a
variety of ways including, but not limited to, nailing, stapling,
riveting, and gluing.
[0038] The present invention includes an apparatus and method of
installation directed to solving the problems mentioned above. The
fastening system for installing expandable building panels may
include two components, a "slip clip" and a "spring clip," which
combine to create a system that enables expandable building panels
to accommodate changes in dimension due to thermal effects. As used
herein, to suggest that a building panel is "expandable" means that
the panel will expand and/or contract with changes in ambient
temperature.
[0039] The components of the fastening system according to the
present invention are typically made of any of, but are not limited
to, the following materials: polymers, copolymers, homopolymers
and/or combinations thereof, wood, and metal. Typically, exemplary
polymers useful in the present invention include: polyvinylchloride
(PVC), polycarbonate, polyacetal, polyamide, and polyethylene. PVC
is highly resistant to humidity and has a high temperature
coefficient of expansion.
[0040] A slip clip 304 according to the present invention is shown
in FIGS. 3a and 3b. The slip clip 304 may include a lower tab 301,
which is fastened to the substrate or mounting surface, and an
upper tab 300, which engages the adjacent panel. The upper tab 300
may be displaced from the lower tab 301 by a distance "h" of
nominally 0.05 inches. This is slightly more than the nominal
thickness of a typical fastening flange 204 (as discussed above).
Alternatively, the upper tab 300 may be a spring tab, not shown,
which may be attached directly to lower tab 301. Such a spring tab
may be curved so as to engage a panel in a similar fashion as upper
tab 300, while also directing compressive force to the panel to
hold it in place. Additionally, a fastening hole 302 is provided in
the lower tab 301. Typically, the hole is nominally 0.063 inches in
diameter to accept commonly used mounting nails. It is possible to
fabricate slip clips in varying lengths and thicknesses. However,
the design disclosed provides a good balance of strength and
material use.
[0041] In one embodiment, the slip clip includes a horizontal flat
portion that is adapted to abut a surface on which it is to be
mounted, a means for attaching the clip to the surface, a vertical
portion that extends roughly to the level of a flange on a panel to
be adhered to the surface, and a horizontal portion attached to the
vertical portion that extends along the surface of a flange to be
adjacent to the surface of the surface.
[0042] FIG. 4 depicts a perspective view of a section of a building
panel 206 showing how the slip clip 304 engages the fastening
flange 204 of the building panel. Rather than using the fastening
slot 202, the slip clip 304 fits over the edge of the flange 204,
retaining the building panel 206 against the mounting surface 200
(not shown), but permitting movement in the longitudinal dimension,
(as shown by the arrows in FIG. 5), of the building panel. The slip
clip 304 is secured with a fastener 503 using the fastening hole
302. Alternately, the slip clip 304 can be stapled or fastened in
whatever manner is appropriate for the mounting surface to be
covered.
[0043] Turning to FIG. 5, a fastening flange 204 extends from one
edge of the building panel 206 for the purpose of providing a
device for attaching the building panel to a mounting surface 200.
The fastening flange 204 typically includes at least one slot 202
along its length, and may optionally have a series of slots 202,
that have typically provided locations for fastening by a fastener
503, which includes, but is not limited to nails, screws, staples
and the like. The slots 202 are nominally about 0.975 inches long
and about 0.125 inches wide, on about 1.75 inch centers. The
fastening flange 204 typically has the following dimensions:
nominally about 0.026 inches thick, while extending from the
building panel 206 about 0.53 inches.
[0044] When installing the building panel system, thermal expansion
typically is accommodated when the center of each slot 202 is used
for fastening the building panel 206 in place. The fastening system
of the present invention thus provides for a simpler installation
process than previously known.
[0045] FIG. 5 depicts an installation scenario similar to that of
FIG. 2, with slip clips 304 nailed into the mounting surface 200
instead of using the fastening slots 202 in the fastening flange
204 of the panel. In this case, the tacking nails 201 may still be
used to hold the building panel 206 in place until the slip clips
304 are installed. The nails 201 can then be either removed or
driven further into the panel, if done in a way that does not
prevent the panel from moving longitudinally.
[0046] In addition to the slip clip mounting method of the present
invention, a spring clip 704 shown, for instance, in FIG. 6, may be
used in combination with the slip clip. Alternatively, the slip
clip may be used with slotted flanges, netted flanges or other
fastening mechanisms that allow for movement of a building panel
relative to the substrate to which it is fastened. In mounting an
expandable panel having a longitudinal edge and a transverse edge,
attachment means, such as, for example, slip clips, nails flanges
or other related means, may be used to attach the longitudinal edge
of the panel directly to a substrate, while permitting relative
movement between the panel and the substrate in the longitudinal
direction. At least one slip clip may be adjacent the transverse
edge of the panel. The spring clip is typically a hot dipped
galvanized steel spring. Other suitable materials may be used as
long as they can provide a spring-type effect and preferably not
rust, such as stainless steel and plastic. Typically, the spring
clip 704 will be formed with at least one arm 706 formed at an
angle to the body 708 of the spring clip. Depending on the choice
of materials, as well as the dimensions for construction, the
spring clip 704 will be flexible when force is applied to the clip,
as shown for instance in FIG. 7. The spring clip 704 is utilized in
applications requiring that a building panel 206 or a series of
end-to-end panels be pushed in one direction to close one or more
gaps, either to secure a single panel or to form a long run of
series of panels. When inserted, the spring clip 704 applies end
compression or compressive force to the panel, thereby allowing for
expansion and contraction of the panel. In one embodiment, a trim
piece is used to cover the spring clip. The trim piece can extend
beyond the spring clip and cover a portion of the panel, with the
proviso that the trim piece permits the panel to expand and
compress the spring clip.
[0047] It may be possible to utilize a coil-type spring instead of
the angled spring clip 704 depicted herein. However, the angled
spring clip is easier and less expensive to fabricate, while still
providing the necessary force to prevent gaps from appearing
between panels and/or perimeter elements.
[0048] FIG. 7 depicts a typical spring clip and slip clip
installation. A series of slip clips 304 secure the fastening
flange 204 of a building panel 206 to a ceiling, wall or other
mounting surface 200 between two perimeter elements 701 and 705
which are perpendicular to the mounting surface and at least as
thick as the panel 206. As shown herein, the building panel 206 is
butted against perimeter element 705, while the spring clip 704 is
installed between the perimeter element 701 and the edge of the
building panel 206. As shown in FIG. 6, the end of the arms 706
should be curved to permit the arms to move or slide rather than
gouge the perimeter element 701. The ends of the arms 706 may be in
the shape of a ball or sphere 707 or have a general curved
cross-sectional shape such as shown at 709.
[0049] Having thus described the invention in detail, it should be
apparent that various modifications can be made in the present
invention without departing from the spirit and scope of the
following claims.
* * * * *