U.S. patent application number 10/797325 was filed with the patent office on 2004-09-02 for method and apparatus for cladding elongated structural members.
Invention is credited to Curtis, Gary N., Reynolds, Glenn A..
Application Number | 20040168383 10/797325 |
Document ID | / |
Family ID | 27803931 |
Filed Date | 2004-09-02 |
United States Patent
Application |
20040168383 |
Kind Code |
A1 |
Reynolds, Glenn A. ; et
al. |
September 2, 2004 |
Method and apparatus for cladding elongated structural members
Abstract
A method and apparatus for the attachment of sheet cladding and
other thin surfaces to structural frame members such as in space
frames and other lattice structures. A batten assembly may be
either partially integrated into an elongated structural member or
attached by fasteners. A batten receiver provides a pair of sheet
margin receiving channels and a fastener guide channel. The batten
receiver may be integrated into the surface of the elongated
structural member which for example, may be a tubular member or
I-beam. The mating batten comprises shoulders which are essentially
congruent to the receiving channels. Between the shoulders, an
elongated recess mates with a pair of guide walls in the receiver.
A fastener such as a metal screw having a cutting tip, may be
installed through the recess and the guide channel and into the
wall of the elongated structural member to provide secure
connection of the batten members to one another. The shoulder and
receiving channels receive the sheet margins in compressive
engagement. The invention herein permits the cladding of elongated
structural members in an aesthetically pleasing flush mounting
configuration which allows for water run-off from the cladding
sheet surfaces. The invention also provides an advantageous hidden
round seal configuration which while also being aesthetically more
pleasing, is also more protective of the seal integrity. This
invention also provides batten attachments of sheet cladding and
other thin surfaces to elongated members of a tubular
cross-section.
Inventors: |
Reynolds, Glenn A.; (Long
Beach, CA) ; Curtis, Gary N.; (Long Beach,
CA) |
Correspondence
Address: |
LEONARD TACHNER, A PROFESSIONAL LAW
CORPORATION
17961 SKY PARK CIRCLE, SUITE 38-E
IRVINE
CA
92614
|
Family ID: |
27803931 |
Appl. No.: |
10/797325 |
Filed: |
March 9, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10797325 |
Mar 9, 2004 |
|
|
|
10087639 |
Mar 1, 2002 |
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Current U.S.
Class: |
52/273 ; 52/222;
52/63 |
Current CPC
Class: |
E04H 15/646 20130101;
E04B 1/3211 20130101; E04F 13/0889 20130101; E04B 2001/3252
20130101; E04F 13/0814 20130101 |
Class at
Publication: |
052/273 ;
052/222; 052/063 |
International
Class: |
E04D 001/00; E04B
001/12 |
Claims
We claim:
1. An apparatus for affixing cladding sheets directly to elongated
structural members, the sheets having shapeable margin portions;
the apparatus comprising: a batten assembly having a receiver
affixed to said structural member for receiving said margin
portions and a mating batten for correspondingly engaging said
receiver for retaining said margin portions in a locked relation
with said structural member; said assembly being substantially
co-linear with said structural member; said mating batten being
substantially co-planar with said cladding sheets adjacent said
structural member; wherein said batten assembly is spaced from said
structural member by at least one standoff stud connected to both
said assembly and to said structural member.
2. The apparatus recited in claim 1 wherein said cladding sheets
and said structural members are made of dissimilar metals.
3. The apparatus recited in claim 1 wherein said dissimilar metals
are aluminum and steel.
4. The apparatus recited in claim 1 wherein said batten assembly
extends substantially the entire length of said structural
member.
5. The apparatus recited in claim 1 wherein said batten assembly is
made of a material which is substantially non-conductive to
electrical energy.
6. The apparatus recited in claim 1 wherein said batten assembly is
substantially non-conductive to thermal energy.
7. An apparatus for cladding elongated structural members having a
tubular cross-section; the apparatus comprising: a batten assembly
having a first portion affixed to a radial wall of at least one of
said tubular members and a second portion selectively engaging said
first portion in at least partial congruent relation to trap
cladding therebetween in compressive relation; said batten assembly
being configured to be substantially co-planar with said cladding
adjacent said at least one tubular member; wherein said batten
assembly is spaced from said structural member by at least one
standoff stud connected to both said assembly and to said
structural member.
8. The apparatus recited in claim 7 wherein said batten assembly is
made of a material which is substantially non-conductive to
electrical energy.
9. The apparatus recited in claim 7 wherein said batten assembly is
substantially non-conductive to thermal energy.
10. A method for cladding elongated structural members; the method
comprising the steps of: a) providing a batten assembly having a
batten receiver and a mating batten, the batten receiver having at
least one channel for receiving the margin of a cladding sheet, the
mating batten having a shoulder that is substantially congruent to
said channel; b) affixing said batten receiver to one said
structural member; c) bending said sheet margin to conform to said
channel; d) placing said sheet margin in said channel so that said
cladding sheet will be flush with said batten assembly; e) trapping
said margin in said channel by positioning said shoulder of said
mating batten in said channel; and f) fastening said mating batten
to said batten receiver; wherein step a) comprises the step of
making said batten assembly out of a material which is
substantially non-conductive to at least one of thermal and
electrical energy.
11. The method recited in claim 10 wherein step b) comprises the
step of connecting said receiver to said one structural member by
using a standoff stud to space said receiver from said structural
member.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No.
10/087,639 filed Mar. 1, 2002 and claims priority therefrom.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of
structural design and more specifically to attachment of cladding
surfaces to elongated structural members such as for creating large
volume enclosures.
BACKGROUND ART
[0003] An example of conventional dome construction is illustrated
in U.S. Pat. No. 3,909,994 to Richter. This construction employs
structural frame members arranged in a polygonal pattern forming
framed openings. These openings are covered with thin sheet
material to provide an enclosure without openings. The edge margins
of the sheet material are locked and retained by retainer members
which incorporate flanged gasket elements to seal the sheets to the
structural frame members. The flanged structural members and the
sheet margins are connected to hub members. The sheets are
connected to the structural members by bar portions which clamp
down on the sheet margins curved to form flanges. Because the bar
portions extend above the sheet surfaces, each sheet is surrounded
by an elevated perimeter and exposed gaskets. This configuration is
typical of prior art structures where a cladding sheet is affixed
to a system of frame members with flanges.
[0004] One significant disadvantage of such prior art is that the
elevated perimeter around respective sheet surfaces creates a
barrier to water drainage thereby promoting collection of rain
water and the like. This promotes corrosion, mildew, dirt
accumulation and other forms of deterioration which can be
detrimental to the function and appearance of the structure.
[0005] Another significant disadvantage is the limitation of the
use of the batten and receiver cladding system to flanged
structural members only. This limitation leaves out elongated
members with a tubular cross-section.
[0006] Another disadvantage is the exposure of the sealing gasket
to the ambient environment above the frame members. This often
means exposure to the outside elements such as extreme temperatures
and moisture including pooled rain water as noted above. Such
exposure can reduce gasket effectiveness, permit leakage and
require frequent and costly maintenance. Moreover, the prior art
sealing gasket is irregularly shaped and specifically
configured.
[0007] Based upon the foregoing, it can be readily observed that
there is a need for an improved way of affixing cladding surfaces
to tubular and flanged elongated structural members to overcome the
deficiencies of the prior art. More specifically, it would be a
significant improvement to provide a flush-mounted cladding
connection apparatus which would obviate elevated sheet perimeters
that would otherwise interfere with water drainage. It would be a
major improvement to provide a batten and receiver cladding
connection for elongated members with a tubular cross-section. It
would also be a welcome improvement to provide a design where the
elastomeric seal or gasket is a simple round or O-ring type
cross-section and is not exposed to the outside elements so that
the gasket life is greatly improved. These improvements would be
particularly useful in a frame structure which employs tubular
structural members such as those disclosed in U.S. Pat. No.
5,956,917 to Reynolds, a co-inventor hereof.
SUMMARY OF THE INVENTION
[0008] The present invention meets the aforementioned needs and
provides the desired improvements for the attachment of sheet
cladding and other non-load bearing thin surfaces to structural
frame members such as in space frames and other lattice structures.
The present invention may also be used advantageously to provide
ceilings, or inverted roofs where the structural members are
located above an underlying uninterrupted surface. The invention
may also be provided in certain embodiments for use in connecting
aluminum sheeting to steel structural members without substantial
contact between the dissimilar metals. Other embodiments find
utility where thermal or electrical isolation is needed between
structural members and cladding or other sheet material.
[0009] A principal feature of the preferred embodiments of the
invention comprises a unique batten configuration which may be
either partially integrated into an elongated structural member or
attached by fasteners. A batten receiver provides a pair of sheet
margin receiving channels and a fastener guide channel. The batten
receiver may be integrated into the surface of the elongated
structural member which for example, may be a tubular member or
I-beam. The mating batten comprises shoulders which are essentially
congruent to the receiving channels. Between the shoulders, an
elongated recess mates with a pair of guide walls in the receiver.
A fastener such as a metal screw having a cutting tip, may be
installed through the recess and the guide channel and into the
wall of the elongated structural member to provide secure
connection of the batten members to one another. The shoulder and
receiving channels receive the sheet margins in compressive
engagement. Retention strips commonly referred to as a "cat's paw"
may be optionally provided on the mating shoulder and channel
surfaces to provide added security in retaining the sheet
therebetween. The mating batten is uniquely configured to be flush
with the cladding sheet to obviate water run-off barriers and to
provide an aesthetically pleasing interface. Moreover, the mating
batten provides a seal receptacle for receiving an elongated
elastomeric O-ring seal that is isolated from the exposed surface
of the batten so that the seal is not exposed to the environment.
It will thus be seen hereinafter, that the present invention
provides a number of unique and highly advantageous features with
the principal object of overcoming the aforementioned deficiencies
of the prior art. More specifically, the invention herein permits
the cladding of elongated structural members in an aesthetically
pleasing flush mounting configuration which allows for water
run-off from the cladding sheet surfaces. The invention also
provides a batten and receiver cladding connection for elongated
members with a tubular cross-section. The invention also provides
an advantageous hidden round seal configuration which while also
being aesthetically more pleasing, is also more protective of the
seal integrity and does not need to be uniquely configured for this
particular apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The aforementioned objects and advantages of the present
invention, as well as additional objects and advantages thereof,
will be more fully understood hereinafter as a result of a detailed
description of a preferred embodiment when taken in conjunction
with the following drawings in which:
[0011] FIG. 1 is a three-dimensional view of an I-beam comprising a
partially integrated batten design in accordance with a preferred
embodiment of the invention;
[0012] FIG. 2 is a cross-sectional view of the improved I-beam of
FIG. 1;
[0013] FIG. 3 is a cross-sectional view of a tubular structural
member comprising a partially integrated batten design similar to
that of FIG. 1 but also illustrating the mating batten, cladding
and a fastener of a preferred embodiment;
[0014] FIG. 4 is similar to FIG. 3 but showing the batten fully
secured to the tubular member by the fastener and engaging the
cladding sheet margins;
[0015] FIG. 5 is a three-dimensional view of the tubular
member/cladding arrangement of FIG. 4 with the cladding and batten
partially removed;
[0016] FIG. 6 is a cross-sectional view of an alternative
embodiment of the invention employing a non-integrated or "split
batten" wherein both batten members are separated from the
underlying structural member and connected to the structural member
by a standoff device affixed to both the batten receiver and the
structural member;
[0017] FIG. 7 is a cross-sectional view of the split batten upper
portion;
[0018] FIG. 8 is a cross-sectional view of the split batten lower
portion;
[0019] FIG. 9 is a three dimensional view of the embodiment of FIG.
6 with the cladding, batten and tubular structural member partially
removed; and
[0020] FIG. 10 is a three-dimensional view of yet another
embodiment of the invention which is particularly usefully for
thermally or electrically isolating the cladding from the elongated
structural member.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] Referring initially to FIGS. 1 and 2, it will be seen that
in a first embodiment 10 of the invention, an I-beam 12 has
integrated therewith a cladding batten receiver 14. The receiver
comprises a pair of shoulders 16 and a pair of guide walls 18. A
receiving channel 20 is formed between each shoulder and an
adjacent guide wall. The channel 20 is preferably U-shaped having
an inclined planar side 17 leading into the curved or arched
channel. This shape facilitates receiving a gently bent and curved
cladding sheet margin as will become more evident hereinafter. The
pair of guide walls 18 form a fastener guide channel 22 between
them for receiving and guiding a fastener as will be also made more
clear below.
[0022] Referring to FIGS. 3,4 and 5, it will be seen that a first
alternative embodiment 25 is similar to the embodiment of FIGS. 1
and 2, but implemented in a tubular elongated member 26 instead of
flanged elongated members as found in the prior art. More
specifically, a batten receiver 28 is integral to the tube wall and
comprises shoulders 30 and guide walls 32 and has a pair of
receiving channels 34. Similarly, a batten 36 has a pair of rounded
ridges 38 which are substantially congruent to channels 34. Batten
36 also comprises a pair of seal receptacles 40 each designed to
retain an elongated O-ring elastomeric seal 42. A fastener 46 is
received in a guide channel 44 and extends through the wall of the
tubular structural member 26. When the batten 36 is compressed into
engagement with the batten receiver 28 by the fastener 46 as
depicted in FIG. 4, the margins of cladding sheets 45 are trapped
therebetween with the elastomeric seal 42 compressed against the
sheet. Moreover, as also seen in FIG. 4 as well as FIG. 5, the
upper surface of batten 36 lies substantially flush (i.e., in
co-planar relation) with cladding sheets 45 to permit unobstructed
water run-off without any elevated barriers such as found in
relevant prior art.
[0023] Another alternative embodiment 55 is shown in FIGS. 6
through 9. This embodiment is particularly useful where the
elongated member and the batten 3 components and cladding are made
of dissimilar metals.
[0024] For example, if the tubular structural member 56 were made
of steel, an aluminum batten assembly 58 can be affixed by means of
a standoff stud 66 having a shoulder 68. Moreover, the cladding 64
may be aluminum sheeting. Thus, this embodiment permits aluminum
cladding of steel structural members. The batten assembly 58 of
this embodiment is substantially similar to that of the FIG. 5
embodiment with one major distinction. Batten receiver 60 is an
independent component and is not an integral part of the tubular
member 56. In all other respects, the batten assembly 58 is
identical to that of the integral embodiments. Specifically, a
batten 62 has a pair of shoulders 63 which are substantially
congruent to channels 61 of batten receiver 60. A guide channel 67
is provided to direct a fastener into stud 66.
[0025] FIG. 9 also depicts a technique for splicing cladding
members to one another without attachment to a structural member.
For example, if it were required to join two cladding sheets to
fill a space between structural members, the non-integral batten
60/62 of FIGS. 6-9, would enable such joining.
[0026] Yet another embodiment 75 is illustrated in FIG. 10. This
embodiment is particularly useful where it is desired to either
thermally or electrically isolate the cladding 70 from the tubular
structural member 72. The lower batten member 74 may be made of a
selected insulating material such as a thermally and/or
electrically non-conductive composite. The upper batten member 76
is secured by means of fasteners 77 and the lower batten member 74
is secured by fasteners 78 through apertures 80 and into the
structural member 72.
[0027] Having the benefit of learning of a number of embodiments of
the invention, it will be understood that still other embodiments
as well as variations in those illustrated are contemplated. By way
of example, while structural members comprising I-beams and
circular tubes have been disclosed, it should be apparent that the
invention may be employed for direct cladding of other shaped
structural members, such as those having a triangular, square,
rectangular or irregular cross-section or combinations thereof.
Furthermore, while the disclosed embodiments illustrate generally
planar cladding, the invention does not require use with flat
sheets, but may be used with more complex surfaces such as convex,
concave or non-uniform variations in shapes and thicknesses.
[0028] Accordingly, those having skill in the relevant art will
perceive various modifications and additions which may be readily
made to the disclosed versions. However, such modifications and
additions may be within the scope of the invention which is limited
only by the appended claims and their equivalents.
* * * * *