U.S. patent application number 11/251410 was filed with the patent office on 2006-04-20 for facing unit construction.
Invention is credited to Kevin M. O'Neill.
Application Number | 20060080942 11/251410 |
Document ID | / |
Family ID | 36179283 |
Filed Date | 2006-04-20 |
United States Patent
Application |
20060080942 |
Kind Code |
A1 |
O'Neill; Kevin M. |
April 20, 2006 |
Facing unit construction
Abstract
A facing unit construction is adapted for mounting facing units
on a structure, such as a roof or a wall. The facing units can
comprise various suitable materials, including slate, wood, tile,
metal, concrete, ceramic and plastic. Center channel spacers are
mounted on the structure and provide outwardly-projecting ribs for
positioning the facing units and inwardly-open channels for
draining water from underneath the facing units. Clip assemblies
are also mounted on the structure and include flanges for capturing
the facing unit upper edges and hooks for receiving the facing unit
lower edges. The hooks can also extend through receivers in the
facing units and can be provided with snow guards. The clip
assembly base clips can be configured for automatically aligning
nailing equipment. The facing units, spacers and clips form courses
on the structure, which overlap for gravity discharge of water.
Inventors: |
O'Neill; Kevin M.; (Overland
Park, KS) |
Correspondence
Address: |
CHASE LAW FIRM L.C
4400 COLLEGE BOULEVARD, SUITE 130
OVERLAND PARK
KS
66211
US
|
Family ID: |
36179283 |
Appl. No.: |
11/251410 |
Filed: |
October 14, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60619482 |
Oct 15, 2004 |
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Current U.S.
Class: |
52/790.1 |
Current CPC
Class: |
E04D 1/365 20130101;
E04D 2001/3432 20130101; E04D 12/002 20130101; E04D 2001/3411
20130101; E04D 2001/3458 20130101; E04D 2001/3438 20130101; E04D
1/16 20130101; E04D 1/34 20130101 |
Class at
Publication: |
052/790.1 |
International
Class: |
E04C 2/34 20060101
E04C002/34 |
Claims
1. A facing unit construction for a structure, which includes: a
plurality of spacers each having inner and outer faces, opposite
side edges and opposite ends; said spacers being adapted for
mounting on said structure; and each said spacer being adapted for
positioning a pair of facing units on said structure.
2. The construction according to claim 1, which includes: each said
spacer having a medial rib protruding from said outer face and
extending between said opposite ends in spaced relation inwardly
from said side edges; each said spacer being adapted for
positioning a pair of facing units on opposite sides of and
adjacent to the medial rib thereof; a plurality of clip assemblies
each including a base clip and a hook connected to the base clip
and extending therefrom; and said clip assemblies being adapted for
mounting said facing units on said structure by engaging said
facing units with said hooks.
3. The construction according to claim 2 wherein: each said spacer
includes a drain channel open at its inner face and extending
between said spacer ends.
4. The construction according to claim 3 wherein each said spacer
includes: a pair of side ribs projecting outwardly from its outer
face on each side of its medial rib and extending between said
spacer ends; and a receiver adapted for receiving a mechanical
fastener for attaching said spacer to the structure.
5. The construction according to claim 2, which includes: a
plurality of courses extending in generally parallel, overlapping
relation along said structure; each said course including a
plurality of said spacers, clip assemblies and facing units; each
said underlayment strip having alignment marking thereon for
positioning said spacers and clip assemblies on said structure; and
each said course overlapping the course below and/or being
overlapped by the course above.
6. The construction according to claim 1 wherein: each said base
clip includes a receiver adapted for receiving a fastener for
mounting said base clip on said structure; each said base clip
includes top and side flanges with respective notches for alignment
with a nailing device; each said base clip further includes a
bottom flange adapted for overlying a respective facing unit upper
edge.
7. The construction according to claim 6 wherein each said clip
assembly includes: said hook having a proximate end; said base clip
having a retainer engaging said hook proximate end and mounting
same on said base clip; said hook having a hook-shaped distal end
forming a receiver adapted to receive a facing unit lower edge; and
said hook having a shaft extending over said base clip bottom
flange.
8. The construction according to claim 1 wherein said facing units
comprise a material chosen from among the group consisting of:
slate; stone; saturated felt composition; wood; tile; concrete;
ceramic; plastic; and metal.
9. The construction according to claim 2 wherein each said facing
unit includes a receiver adapted for receiving a respective hook
distal end.
10. The construction according to claim 2 wherein each said hook
includes a snow guard mounted on its distal end.
11. A facing unit construction for a structure, which includes:
multiple facing unit courses extending in generally parallel
relation on said structure; each said course including a plurality
of facing units each having inner and outer faces, opposite side
edges and upper and lower ends; each said course including a
plurality of spacers each having inner and outer faces, opposite
side edges, opposite ends and a medial rib protruding from said
outer face and extending between said opposite ends in spaced
relation inwardly from said side edges; each said spacer being
adapted for mounting on said structure and for positioning a pair
of facing units on either side of and adjacent to said medial rib
thereof; each said course including a plurality of clip assemblies
each including a base clip and a hook connected to the base clip
and extending therefrom; and said clip assemblies being adapted for
mounting facing units on said structure by engaging same with said
hooks; and said courses overlapping on said structure with said
facing units being overlapped by the facing units of the course
above and/or overlapping the facing units of the course below.
12. The construction according to claim 11, which includes:
water-repellent underlayment strips positioned between overlapping
courses.
13. The construction according to claim 12 wherein each said
underlayment strip includes alignment markings corresponding to the
locations of respective facing units and indicia for identifying
the facing units to be installed thereat.
14. The construction according to claim 13, which includes: said
construction comprising a predetermined pattern of different-sized
facing units configured to cover a portion of said structure.
15. The construction according to claim 11, which includes: each
said base clip having a top flange and opposite side flanges; each
said flange having a notch; and said flanges and notches being
adapted for aligning a power nailing tool head.
16. The construction according to claim 15, which includes: each
said base clip having a bottom flange adapted for overlying a
respective facing tile upper end; and each said clip assembly
having a pair of said hooks extending over said bottom flange and
having outwardly-convex prebent configurations adapted for
deflecting inwardly upon installation of the next course above.
17. The construction according to claim 11, which includes: each
said facing tile including a hook receiver extending between its
inner and outer faces; and each said hook extending inside a
respective facing tile inner face below a respective facing tile
upper edge and through a respective hook receiver.
18. A facing unit construction for a structure, which includes:
multiple, overlapping facing unit courses extending in generally
parallel relation on said structure; water-repellent underlayment
strips positioned between overlapping courses and including
alignment markings corresponding to the locations of respective
facing units and indicia for identifying the facing units to be
installed thereat; each said course including a plurality of facing
units each having inner and outer faces, opposite side edges and
upper and lower ends; each said course including a plurality of
spacers each having inner and outer faces, opposite side edges,
opposite ends and a medial rib protruding from said outer face and
extending between said opposite ends in spaced relation inwardly
from said side edges; each said spacer having a drain channel open
at its inner face and extending between. said spacer ends below
said medial rib; each said spacer having two pairs of side ribs
extending between said spacer ends, each pair being located to a
respective side of said medial rib and protruding from said spacer
outer face; each said spacer being adapted for mounting on said
structure and for positioning a pair of facing units on either side
of and adjacent to said medial rib thereof; each said course
including a plurality of clip assemblies each including a base clip
and a hook connected to the base clip and extending therefrom; and
said clip assemblies being adapted for mounting facing units on
said structure by engaging same with said hooks; each said base
clip having a top flange and opposite side flanges; each said
flange having a notch; said flanges and notches being adapted for
aligning an automatic nailing tool head; said courses overlapping
on said structure with said facing units being overlapped by the
facing units of the course above and/or overlapping the facing
units of the course below; each said base clip having a bottom
flange adapted for overlying a respective facing tile upper end;
each said clip assembly having a pair of said hooks extending over
said bottom flange and having outwardly-convex prebent
configurations adapted for deflecting inwardly upon installation of
the next course above; and said construction comprising a
predetermined pattern of different-sized facing units configured to
cover a portion of said structure.
19. The construction according to claim 18 wherein each said hook
distal end includes a snow guard comprising a bent-wire loop
adapted for engaging a respective facing unit lower end for
retaining said facing unit in position, said loop lying in a plane
generally perpendicular to said hook and extending above said
facing unit upper surface and adapted for restraining snow
thereon.
20. The construction according to claim 18 wherein each said hook
distal end includes: a facing unit hook receiving a respective
facing tile lower end; and a snow guard positioned distally from
said facing unit hook and comprising a bent-wire loop lying in a
plane generally perpendicular to said hook and extending above said
facing unit upper surface and adapted for restraining snow thereon.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional
application Ser. No. 60/619,482, filed Oct. 15, 2004, which is
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to construction, and
in particular to a system for constructing an exterior surface,
such as a roof or siding, with individually-mounted facing
units.
[0004] 2. Description of the Related Art
[0005] A wide variety of construction materials are available for
accommodating the requirements of particular structures and
building sites. The considerations involved in selecting, designing
and specifying such materials include aesthetics, material cost,
installation cost, weather resistance, maintenance, thermal
resistance and availability. Surfaces of structures are often
covered with decorative and protective facing units, which
typically provide weather protection on exterior walls and roofs.
For example, facing units used for roofing materials include
composition shingles, wood shingles, wood shakes, cement tiles,
clay tiles, metal panels and slate. A well-known technique for
achieving positive, gravity drainage on sloping roof and vertical
wall surfaces is to overlap the facing units. For example, each
course of facing units can overlap the course directly below it. In
this manner the upper facing unit edges are covered. Facing unit
installation patterns are commonly laid out to achieve sufficient
overlaps to provide adequate moisture protection. Moreover, the
weight of the facing units can be used to advantage for holding
down the courses that they overlap, whereby uplifting wind forces
are resisted.
[0006] In addition to roof constructions, the same or similar
facing units are commonly used for vertical wall surfaces. Exterior
walls can be finished with materials having similar characteristics
to roofing materials. Such dual-purpose construction materials can
be used for achieving desired aesthetic effects, such as matching
roof and exterior wall surface appearances.
[0007] A facing unit construction should facilitate installation,
minimize the dead load of the resulting faced structure, be
cost-effective, provide weather protection and utilize the facing
unit materials efficiently. Heretofore there has not been available
a facing unit construction with the advantages and features of the
present invention.
SUMMARY OF THE INVENTION
[0008] In the practice of the present invention, a facing unit
construction is provided, which includes an underlayment subsystem,
spacers mounted on top of the underlayment subsystem and clip
assemblies for securing the facing units in an overlapping
configuration. The spacers include longitudinally-extending ribs
for aligning the adjacent facing units. The clip assemblies
comprise base clips for engaging the facing unit upper edges and
wire hooks for retaining the facing units. The construction is
adapted for facing roofs and walls with various facing units, which
can comprise different materials, shapes and sizes. The
construction can be preconfigured for desired aesthetic results,
including random and other layouts with different sizes of facing
units. Different configurations for the spacers and clip assemblies
can be utilized as needed to accommodate particular constructions
with various facing unit materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a facing unit construction
embodying the present invention.
[0010] FIG. 2 is a cross-sectional view thereof, showing a roof
construction application.
[0011] FIG. 3 is an enlarged, perspective view of a center channel
spacer.
[0012] FIG. 4 is an enlarged, perspective view of a clip
assembly.
[0013] FIG. 5 is a perspective view of a facing unit construction
comprising an alternative embodiment of the present invention
[0014] FIG. 6 is a perspective view thereof, showing a roof
construction application.
[0015] FIG. 7 is a cross-sectional view thereof, showing a roof
construction application.
[0016] FIG. 8 is an enlarged, perspective view of a hook
thereof.
[0017] FIG. 9 is an enlarged, perspective view of a spacer
thereof.
[0018] FIG. 10 is a perspective view of a facing unit roof
construction comprising an alternative embodiment of the present
invention.
[0019] FIG. 11 is a perspective view of a facing unit roof
construction comprising and alternative embodiment of the present
invention.
[0020] FIG. 12 is a perspective view of a facing unit roof
construction comprising an alternative embodiment of the present
invention.
[0021] FIG. 13 is an enlarged, perspective view of an alternative
embodiment clip assembly with a snow guard.
[0022] FIG. 14 is an enlarged, perspective view of an alternative
embodiment clip assembly with a snow guard extending from a facing
unit hook thereof.
[0023] FIG. 15 is an enlarged, perspective view of an alternative
clip assembly with double hooks.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Introduction and Environment
[0024] As required, detailed embodiments of the present invention
are disclosed herein; however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention, which
may be embodied in various forms. Therefore, specific structural
and functional details disclosed herein are not to be interpreted
as limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present invention in virtually any
appropriately detailed structure.
[0025] Certain terminology will be used in the following
description for convenience in reference only and will not be
limiting. Said terminology will include the words specifically
mentioned, derivatives thereof and words of similar meaning.
[0026] Referring to the drawings in more detail, the reference
numeral 2 generally designates a facing unit construction embodying
the present invention. Without limitation on the generality of
useful applications of the invention, the construction 2 shown in
FIG. 1 would be useful for constructing a roof or a wall. Suitable
underlayment strips 4 can be provided as appropriate for the
particular construction, taking into account environmental and
building code considerations. For example, building paper
comprising felt saturated with asphalt or a similar waterproofing
material is commonly utilized as a secondary moisture barrier, with
the external facing units comprising the primary moisture barrier.
Various materials can be used for underlayment, including
elastomers, PVC, HDPE, rubber, etc. The underlayment strips 4 can
optionally be printed with suitable alignment marking 6, which can
assist in properly aligning the adjacent underlayment strips 4.
Indicia 8 can be printed thereon to indicate, for example, the
sizes of facing units to be installed at particular locations. For
example, slate facing units are commonly available with approximate
widths of 8, 10 and 12 inches. The entire roof or wall can be
preconfigured, e.g. with a suitable CADD (Computer Aided Drafting
and Design) system, from which the underlayment can be printed with
the appropriate alignment markings 6 and indicia 8. Various
aesthetic effects can thus be preplanned and achieved.
[0027] Center channel spacers 12 (FIG. 3) are mounted with suitable
fasteners, such as nails 14, staples or other mechanical fasteners
at predetermined positions, which can be located by the alignment
markings 6 and the indicia 8. The spacers 12 are generally
perpendicular to the underlayment strips 4 whereby the finished
construction 2 will repel water with gravity. Each spacer 12
includes: inner and outer faces 16, 18; upper and lower ends 20,
22; opposite side edges 24; and fastener receivers 26. A medial or
center rib 28 extends between the ends 20, 22 approximately midway
between the side edges 24, projects outwardly from the outer face
18 and forms a drain channel 30 at the inner face 16 for directing
water out from the facing unit construction 2. Each spacer 12
includes side ribs 32 at the outer face 18, which space respective
facing units 10 slightly above the spacer outer face 18 and further
provide longitudinal rigidity for the spacer 12 in conjunction with
the medial rib 28. The ribbed configuration of the spacers 12 thus
minimizes moisture retention and facilitates air circulation for
drying the facing unit construction 2.
[0028] Each facing unit 10 can be secured by one or more clip
assemblies 34 (FIG. 4), which can be generally located on the
alignment markings 6 between respective spacers 12. Each clip
assembly 34 includes a base clip 36 with top and side flanges 38,
40 having notches 42, and a bottom flange 44. The base clip 36 can
be fabricated, for example, by sheet metal stamping or by another
suitable fabrication technique and includes retainers 46 and
locating bosses 48 for attaching a wire hook 50 at a proximate end
52 thereof. The hook 50 includes a shaft 54, which can be pre-bent
outwardly for compression by the facing units 10 upon installation
thereof. Each hook 50 terminates at a distal end 56 forming a
hook-shaped receiver. Suitable fasteners, such as nails 14, can be
utilized for fastening the base clips 36 in place. The base clip
top and side flanges 38, 40 and notches 42 are adapted for aligning
the head of nail coil gun with the base clip 36. For example, the
base clip 36 can be configured to engage the nail gun head whereby
a mounting nails 14 can be quickly and accurately driven through a
base clip receiver 60 and into the underlying structure in order to
expedite rapid installation of the clip assemblies 34. The base
clips 36 can also be preprinted with suitable alignment marks for
use in visually locating a nail gun head in proper position on the
base clip 36.
[0029] The construction 2 can comprise multiple courses 58, which
is typical of facing unit construction techniques. Each course 58
can comprise, for example, an underlayment strip 4, center channel
spacers 12, clip assemblies 34 and facing units 10. The
construction 2 of the present invention facilitates installation
course-by-course, starting with the lowermost whereby each
successive upper course overlaps the one below it in order to
facilitate gravity drainage. FIG. 2 shows a facing unit roof
construction 2 constructed according to this technique. The roof 62
includes sheathing 64, which receives the underlayment strips 4. A
starter board 66 can be provided adjacent to an eave 68 for
properly positioning the first (lowermost) course 58. The
underlayment strips 4 can be installed course-by-course, or the
entire surface of a roof or wall can be laid out in advance. The
spacers 12 and the clip assemblies 34 can then be installed and the
facing units 10 placed thereover by inserting lower edges 70
thereof in respective hook distal ends 56. Side edges 72 of the
facing units 10 can be placed against the spacer center ribs 28 for
proper spacing and alignment. The next course 58 retains the
immediately preceding course 58. Specifically, the base clip top
flanges 38 overlie upper and edges of the facing units 10,
capturing same in conjunction with the hooks 50.
[0030] The finished construction provides a uniform, finished
appearance with the clip assemblies being concealed except for the
hook distal ends 56 and the center channel spacers 12 being
concealed except for the center ribs 28. The exposed parts of the
facing unit construction 2 can be suitably finished for aesthetics
and compatibility with the facing units 10, which normally dominate
the finished appearance of the construction 2. For example, the
spacers 12 and the clip assemblies 34 can comprise various plastics
and metals, which can be tinted, painted, anodized and otherwise
finished in order to achieve the desired visual effect.
[0031] FIGS. 5-9 show a facing unit construction 102 comprising an
alternative embodiment of the present invention, which is likewise
adaptable for roof covering, wall siding and other structures.
Alignment markings 106 with indicia 108 are provided for guiding
the installation of hooks 110. Spacers 112 can be installed over
the hooks 110, for example with mechanical fasteners such as
staples 114. The facing units 10 are captured by the hooks 110 and
by the overlaps of the next-higher courses 116.
[0032] FIG. 10 shows another alternative embodiment facing unit
construction 122 with spacers 124 overlying hooks 126, which are
fastened to the underlying structure along alignment marking strips
128.
[0033] FIG. 11 shows another alternative embodiment facing unit
construction 132 with modified clip assemblies 134 including
modified hooks 136 including hook-shaped distal ends 138, which are
received in hook receivers 140 formed in modified facing units 142.
FIG. 12 shows another alternative embodiment facing unit
construction 152 with mechanical fasteners, such as nails 14,
placed within fastener receivers 156 and attaching the facing units
142 to the underlying structure. The fasteners, i.e. nails 14, are
substantially concealed whereby this construction is particularly
advantageous for siding and roofs wherein concealed fasteners are
preferred. The faster receivers 156 can be prefilled with a
suitable caulk or sealant 158, such as an elastomeric or
silicone-based compound.
[0034] FIG. 13 shows an alternative embodiment clip assembly 162
with a combination hook and snow guard 164, which functions to
minimize snow and ice masses sliding along the finished roof.
[0035] FIG. 14 shows another alternative embodiment clip assembly
172 with a snow guard 174 mounted on the end of a hook 150, such as
that described above.
[0036] FIG. 15 shows another alternative embodiment clip assembly
182 with a pair of hooks 184. A base clip 185 includes top and
bottom flanges 186, 188 and side flanges 190. The top and side
flanges 186, 190 included notches 192. The clip assembly 182 is
adapted for placement approximately midway along a respective
facing unit upper end 74. The modified clip assembly 182
accommodates installation of the facing units 10 with a single clip
assembly 182 on each.
[0037] One or more layers of underlayment can be provided for
protection from the elements. For example, the underlayment strips
4 can form a continuous layer and between-course underlayment
strips 76 can be provided in addition for overlapping placement
between respective courses 58 (FIG. 2).
[0038] It is to be understood that the invention can be embodied in
various forms, and is not to be limited to the examples discussed
above. Other components and configurations can be utilized in the
practice of the present invention. For example, although the
constructions described above are particularly suitable for
constructing slate roofs, wall siding and other constructions
utilizing various facing unit materials can be constructed
according to the present invention. Alternative facing units
include shingles, shakes, tiles and panels, which can comprise
wood, concrete, ceramic, plastic, metal, etc. Still further,
various fasteners including nails, staples, screws and adhesives
can be used for mounting, securing and attaching the various
components of the facing unit constructions. Suitable sealants,
caulks and adhesives can be utilized in the receivers, around
fasteners and between the different components as necessary for
achieving a weatherproof construction.
* * * * *