U.S. patent application number 11/080325 was filed with the patent office on 2006-09-21 for decorative modular tile cladding system and method.
Invention is credited to Jaime C. JR. Salles.
Application Number | 20060207194 11/080325 |
Document ID | / |
Family ID | 37008841 |
Filed Date | 2006-09-21 |
United States Patent
Application |
20060207194 |
Kind Code |
A1 |
Salles; Jaime C. JR. |
September 21, 2006 |
Decorative modular tile cladding system and method
Abstract
A decorative modular tile cladding system comprising a plurality
of rectilinear or curvilinear polygonal tiles that include means
for interlocking with each other to create a continuous "skin" that
is used as cladding for exterior or interior surfaces of a
structure. At least three separate means for interconnecting the
tiles are contemplated: (1) folded tabs on each of the tiles that
engage tabs on adjacent tiles to create a secure connection between
tiles; (2) clips that are designed to engage the edges of adjacent
tiles; (3) punched tabs or punched pockets to receive and engage a
complementary tab. The tiles are attached to a standard sheathing
substructure or substrate, and incorporate details for water, gas,
and/or vapor exchange or expansion. In the preferred embodiment,
the tiles are composed of metal, vinyl or plastic, although other
materials are contemplated.
Inventors: |
Salles; Jaime C. JR.;
(Croton on Hudson, NY) |
Correspondence
Address: |
James G. Coplit, Esq.;Grimes & Battersby, LLP
Third Floor
488 Main Avenue
Norwalk
CT
06851
US
|
Family ID: |
37008841 |
Appl. No.: |
11/080325 |
Filed: |
March 15, 2005 |
Current U.S.
Class: |
52/81.4 |
Current CPC
Class: |
E04F 13/0889
20130101 |
Class at
Publication: |
052/081.4 |
International
Class: |
E04B 7/08 20060101
E04B007/08 |
Claims
1. A decorative modular tile cladding system for covering a surface
and for conforming to any contours on said surface, said system
comprising a plurality of polygonal tiles each including means for
interlocking with each other so as to create a continuous and
uninterrupted covering that may easily be modified to accomodate
architectural elements on said surface, wherein said tiles are
designed in a first and second complementary configuration such
that a tile of said first configuration is interlocked with a tile
of said second configuration.
2. The decorative modular tile cladding system of claim 1, wherein
said tiles include outer edges and said means for interlocking
comprises two or more folded tabs disposed along said outer
edges.
3. The decorative modular tile cladding system of claim 2, wherein
said tiles include top edges and bottom edges, and wherein said
folded tabs include top folded tabs disposed along said top edges
and bottom folded tabs disposed along said bottom edges.
4. The decorative modular tile cladding system of claim 3, wherein
said tiles include an upper surface and a lower surface, and
wherein said top folded tabs are folded over said upper surface and
said bottom folded tabs are folded back against said lower surface
such that said upper folded tab engages said lower folded tabs on
adjacent tiles.
5. The decorative modular tile cladding system of claim 4, wherein
said top folded tab includes a notch therein.
6. The decorative modular tile cladding system of claim 5, wherein
said tiles include a top leading edge and further wherein at least
one hole is disposed along said top leading edge, said hole being
adapted to receive a fastener, wherein said hole corresponds to
said notch when said top folded tab is folded against said upper
surface.
7. The decorative modular tile cladding system of claim 3, further
including weep holes provided along said bottom folded tabs to
allow fluids and vapors to pass through said system.
8. The decorative modular tile cladding system of claim 2, wherein
said tabs do not meet in flush alignment, thereby allowing fluids
and vapors to pass through said system.
9. The decorative modular tile cladding system of claim 1, wherein
said tiles are composed of a material that may easily be cut and
shaped.
10. The decorative modular tile cladding system of claim 9, wherein
material is selected from the group consisting of metal, vinyl and
plastic.
11. The decorative modular tile cladding system of claim 1, wherein
said tiles may be cut, and further including edge detailing strips
for providing an aesthetically pleasing and architecturally sound
cover for cut portions of said tiles.
12. The decorative modular tile cladding system of claim 1, further
including drip edges and boundary trims.
13. The decorative modular tile cladding system of claim 1, wherein
said surface includes corners, and wherein said tiles are adapted
to be bent around said corners to thereby provide a continuous and
uninterrupted cover.
14. The decorative modular tile cladding system of claim 1, wherein
said surface includes corners and architectural elements, and
wherein said tiles are adapted to be cut to fit around said corners
and said architectural elements to thereby provide a continuous and
uninterrupted cover, and wherein said system further includes
detailing elements to cover and dress said cut tiles.
15. The decorative modular tile cladding system of claim 1, wherein
said first configuration and said second configuration are
identical.
16. The decorative modular tile cladding system of claim 1, wherein
said tiles include an extended upper surface and bottom edges
having a bottom pattern, and wherein bottom folded tabs are
disposed along said bottom edges and wherein at least one punched
tab is provided in said extended upper surface such that said
punched tabs conform to receive said bottom pattern.
17. The decorative modular tile cladding system of claim 1, wherein
said tiles include an extended upper surface and bottom edges
having a bottom pattern, and wherein bottom folded tabs are
disposed along said bottom edges and wherein at least one punched
pocket is provided in said extended upper surface such that said
punched tabs conform to said bottom pattern and further wherein the
shape of said punched pocket conforms to receive said bottom folded
tabs.
18. The decorative modular tile cladding system of claim 16 or 17,
wherein said first configuration and said second configuration are
identical.
19. A decorative modular tile cladding system for covering a
surface and for conforming to any contours on said surface, said
system comprising a plurality of polygonal, metal tiles each
including top edges, bottom edges, an upper surface, a lower
surface, and means for interlocking with each other so as to create
a continuous and uninterrupted covering that may easily be modified
to accomodate architectural elements on said surface, wherein said
tiles are designed in a first and second complementary
configuration such that a tile of said first configuration is
interlocked with a tile of said second configuration, wherein said
means for interlocking comprises two or more folded tabs disposed
along said outer edges, and wherein said top folded tabs are folded
over said upper surface and said bottom folded tabs are folded back
against said lower surface such that said upper folded tab engages
said lower folded tabs on adjacent tiles.
20. The decorative modular tile cladding system of claim 19,
wherein said first configuration and said second configuration are
identical.
21. A method for installing a decorative modular tile cladding
system for covering a surface and for conforming to any contours on
said surface, said method comprising the steps of: providing a
plurality of polygonal tiles each including means for interlocking
with each other so as to create a continuous and uninterrupted
covering that may easily be modified to accomodate architectural
elements on said surface, wherein said tiles are designed in a
first and second complementary configuration such that a tile of
said first configuration is interlocked with a tile of said second
configuration attaching a tile of said first configuration to said
surface using a fastener; interlocking a tile of said second
configuration to said attached tile of said first configuration;
attaching said tile of said second configuration to said surface;
and repeatedly interlocking and attaching tiles of said first
configuration and said second configuration to thereby cover said
surface.
22. The method of claim 21, further including the step of first
attaching a fold strip to said surface, wherein said fold strip
includes means for interlocking with said tiles and wherein a first
row of tiles is installed along said fold strip.
23. The method of claim 22, wherein said tiles include an extended
surface and bottom edges having a bottom pattern, and wherein
bottom folded tabs are disposed along said bottom edges and wherein
at least one punched tab is provided in said extended surface such
that said punched tabs conform to receive said bottom pattern,
further including the step of repairing said covering by removing a
damaged tile and seamlessly replacing said damaged tile with a
repair tile.
24. The method of claim 22, wherein said tiles include an extended
upper surface and bottom edges having a bottom pattern, and wherein
bottom folded tabs are disposed along said bottom edges and wherein
at least one punched pocket is provided in said extended upper
surface such that said punched tabs conform to said bottom pattern
and further wherein the shape of said punched pocket conforms to
receive said bottom folded tabs, further including the step of
repairing said covering by removing a damaged tile and seamlessly
replacing said damaged tile with a repair tile.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a decorative
modular tile cladding system, and more particularly, to a
decorative modular tile cladding system and method ideally suited
for the exterior surfaces of buildings, and more particularly to a
decorative modular tile cladding system comprising a plurality of
tiles that include means for interlocking with each other to create
a continuous "skin" that is used as cladding for the outside or
inside surfaces of a residential or commercial structure or similar
structure.
[0003] 2. Description of the Prior Art
[0004] Systems for decorating and protecting the outer surfaces of
buildings, particularly residential buildings, have long been known
in the art. Examples of such systems include shingles, stucco,
stone, brick and siding. The most common example of the latter
method for covering and protecting the exterior surface of the
structure are long extruded panels or elements of material such as
vinyl or aluminum, which are installed in either a horizontal or
vertical configuration on the sides of the structure. The benefit
of such systems is that they are relatively easy to install and
maintain, although they are not necessarily the most aesthetically
pleasing solutions. An example of a sheet metal siding system
wherein the individual elements interlock with each other is
disclosed in U.S. Pat. No. 754,541, which issued to Charlebois on
Mar. 15, 1904 for "Sheet Metal Siding."
[0005] Another method that is somewhat similar to that of siding is
cladding, wherein sheets of various textures and/or colors are
applied directly to the exterior of the structure. In addition to
plastics and vinyl, various other materials are available for
cladding, including metal, cement and even glass, which afford a
highly weather resistant substrate or skin. Unfortunately, the
design choices for such materials, particularly metal, are quite
limited, and provide an aesthetically inappropriate installation to
design. Such systems are also not generally available for "off the
shelf" applications, and require special equipment, tooling or
training for installation.
[0006] While there exist systems in the prior art that utilize
metal detailing and exterior cladding, such prior art references
are quite limited. The current metal siding/cladding market breaks
up into to several categories: (1) the industrial utilitarian
approach, using corrugated sheet metal for roofs and metal walls;
(2) the architectural, commercial, residential approaches where
metal is used to replicate another siding form (such as aluminum
clapboard siding or metal plate type installations on commercial
sites), which approach incorporates proprietary fabrication and
support structures to enable installation, thereby necessitating
the purchase of particular substructure/substrate to install; and
(3) the pressed metal market that usually addresses interior
ceiling and decorative wall motifs (e.g., turn of the century
pressed tin ceiling). Other than some cast iron decorative metal
elements, however, examples of the turn-of-the-century work are
normally limited to interior installations.
[0007] There are various references in the prior art for cladding
systems or similar systems for the creation of an external or
internal "skin," wherein individual panels interlock with each
other to create a single unit. For example, U.S. Pat. No.
2,454,307, which issued to Cooley on Nov. 23, 1948 for an
"Interlocking Mosaic" discloses a structure composed of a plurality
of interlocking members.
[0008] Systems for aligning or otherwise orienting tiles or other
elements used in covering surfaces such as walls or floors have
also been disclosed in the prior art. For example, U.S. Pat. No.
2,490,577, which issued to Brown on Dec. 6, 1949 for "Interlocking
Wall Tile" teaches interlocking wall tiles having flanges for
interconnecting adjacent tiles wherein a tab allows for spacing and
alignment for the installation of plastic wall tile.
[0009] It should be appreciated that the tiles used in such
cladding or tiling systems need not be rectangular. For example,
hexagonal tiles are disclosed in U.S. Pat. No. 358,175, which
issued to Thomas on Feb. 22, 1887 for "Metallic Plate for Facing
Walls." In fact, a wide variety of non-traditional patterns,
geometries or designs may be contemplated for the individual panels
or tiles of a cladding system, as suggested by U.S. Pat. No.
4,133,152, which issued to Penrose on Jan. 9, 1979 for "Set of
Tiles for Covering a Surface."
[0010] The tiles in such systems need not be limited to
installation on walls or exterior vertical surfaces. For example,
U.S. Pat. No. 5,584,592, which issued to Martin on Feb. 3, 2004 for
"Interlocking Floor Panels" discloses a tiling system having
interlocking tiles for use as a portable floor for dancing or
shows. Alternatively, the tiles or panels need not be attached to a
pre-existing surface such as a wall or floor, but may in fact be
used to create a free-standing structure or unit, as is disclosed
in U.S. Pat. No. 2,918,151, which issued to Kennedy on Dec. 22,
1959 for "Self-Sustaining Building Unit and Wall."
[0011] It should also be appreciated that the cladding, tiling or
siding system need not be two-dimensional in design or appearance.
A variety of three-dimensional systems have also been developed,
many of them for use in connection with roofs as well as on walls
or floors. Examples include U.S. Pat. No. 4,295,316, which issued
to Carlson on Oct. 20, 1981 for "Nestable Building Wall Panel";
U.S. Pat. No. 4,930,282, which issued to Meadows on Jun. 5, 1990
for "Architectural Tile"; and U.S. Pat. No. 5,074,093, which issued
to Meadows on Dec. 24, 1991 for "Overlapping Architectural
Tiles."
[0012] As shall be appreciated, the prior art fails to specifically
address either the problem or the solution arrived upon by
applicant.
SUMMARY OF THE INVENTION
[0013] Against the foregoing background, it is a primary object of
the present invention to provide a decorative modular tile cladding
system and method for installing same.
[0014] It is another object of the present invention to provide
such a decorative modular tile cladding system that is manufactured
of metal.
[0015] It is yet another object of the present invention to provide
such a decorative modular tile cladding system that may be
purchased off the shelf and easily installed with currently
available installation tooling.
[0016] It is another object of the present invention to provide
such a decorative modular tile cladding system that may be easily
adapted to any installation.
[0017] It is but another object of the present invention to provide
such a decorative module that is customizable to any
application.
[0018] It is still another object of the present invention to
provide such a decorative modular tile cladding system that is
aesthetic as well as functional.
[0019] It is but another object of the present invention to provide
such a decorative modular tile cladding system that allows for
water run off.
[0020] It is yet another object of the present invention to provide
such a decorative modular tile cladding system that utilizes an
installation methodology that is invisible from the exterior.
[0021] It is but another object of the present invention to provide
such a decorative modular tile cladding system that may include
perforations to allow it to be mechanically attached to a standard
sheathing substructure or other substrate with ease.
[0022] It is yet another object of the present invention to provide
such a decorative modular tile cladding system that includes weep
holes to permit the exchange of water, gas and vapor from behind
the tile to the exterior.
[0023] It is still another object of the present invention to
provide such a decorative modular tile cladding system that allows
application on, and once applied lies flat on, any type of surface,
including flat, convex and concave surfaces.
[0024] It is another object of the present invention to provide
such a decorative modular tile cladding system that achieves a
secure full perimeter for each modular tile.
[0025] It is yet another object of the present invention to provide
such a decorative modular tile cladding system that allows for
installation on a surface with a negative angle off vertical.
[0026] It is another object of the present invention to provide
such a decorative modular tile cladding system that includes
detailing for architectural perforations.
[0027] It is still another object of the present invention to
provide such a decorative modular tile cladding system that can
wrap around corners and other architectural features (without
breaking pattern), such as windows, doors, inside and outside
corners, overhangs and other siding types where mixed siding use is
contemplated.
[0028] It is another object of the present invention to provide
such a decorative modular tile cladding system that requires no
special structural underlayment.
[0029] It is yet another object of the present invention to provide
such a decorative modular tile cladding system that may be applied
to any type of structural underlayment, including special
engineered substructures.
[0030] It is but another object of the present invention to provide
such a decorative modular tile cladding system that uses
off-the-shelf materials such as copper, brass, bronze, aluminum
and/or steel sheet metal, and is adaptive to other materials, such
as plastics, vinyls and composites.
[0031] It is another object of the present invention to provide
such a decorative modular tile cladding system that allows for
various expansion coefficients of different metals.
[0032] It is yet another object of the present invention to provide
such a decorative modular tile cladding system that includes full
perimeter interlocking and captured joints with true water
management detailing.
[0033] It is still another object of the present invention to
provide such a decorative modular tile cladding system that allows
for intermixing colors and materials.
[0034] It is another object of the present invention to provide
such a decorative modular tile cladding system that is
affordable.
[0035] It is yet another object of the present invention to provide
such a decorative modular tile cladding system that features off
the shelf availability and opens the installation to semi-custom
applications.
[0036] It is another object of the present invention to provide
such a decorative modular tile cladding system that allows for many
modularized tile designs and integration of different modular
styles/designs.
[0037] It is but another object of the present invention to provide
such a decorative modular tile cladding system that is truly
decorative and functional in a new way and does not merely emulate
and mimic traditional materials and methodologies like brick,
stone, clapboard or vinyl siding.
[0038] It is still another object of the present invention to
provide such a decorative modular tile cladding system that creates
a whole new look from a design perspective with enhanced functional
qualities as well.
[0039] It is another object of the present invention to provide
such a decorative modular tile cladding system that features
enhanced breathability over other siding systems.
[0040] It is but another object of the present invention to provide
such a decorative modular tile cladding system that is easy to
repair.
[0041] To the accomplishments of the foregoing objects and
advantages, the present invention, in brief summary, is a
decorative modular tile cladding system polygonal tiles that
include means for interlocking with each other to create a
continuous "skin" that is used as cladding for the side of a
structure. The tiles may be rectilinear or curvilinear as desired.
At least three separate means for interconnecting the tiles are
contemplated, including: (1) folded tabs on each of the tiles that
engage tabs on adjacent tiles to create a secure connection between
tiles; (2) clips that are designed to engage the edges of adjacent
tiles; and (3) punched pockets and punched tabs to receive and
engage a complementary tab. The tiles may be attached to a standard
sheathing substructure or substrate, regardless of the shape or
size of the structure to which the tiles are being attached,
including curved surfaces, and incorporate details for
water/gas/vapor exchange, as well as expansion. In the preferred
embodiment, the tiles are composed of metal or plastic, although
other materials are contemplated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The foregoing and still other objects and advantages of the
present invention will be more apparent from the detailed
explanation of the preferred embodiments of the invention in
connection with the accompanying drawings, wherein:
[0043] FIG. 1 is a top plan view of the decorative modular tile
cladding system of the present invention;
[0044] FIG. 2 is a top plan view of the left handed and right
handed tiles of the decorative modular tile cladding system of FIG.
1;
[0045] FIG. 3 is a top plan view of the decorative modular tile
cladding system of the present invention showing various elements
thereof in closer detail;
[0046] FIGS. 4A-4C are top plan views of the decorative modular
tile cladding system of the present invention using clips for
attachment of adjacent tiles;
[0047] FIGS. 5A-5C are top plan views of the decorative modular
tile cladding system of the present invention using folded fingers
in place of folded tabs for attachment of adjacent tiles;
[0048] FIG. 6A-6C are cutaway side views showing the installation
of the decorative modular tile cladding system of the present
invention;
[0049] FIG. 7A-7C are cutaway side views showing the water
management system of the decorative modular tile cladding system of
the present invention and comparing said installation to the
installation of an another siding system;
[0050] FIGS. 8-8B are perspective illustrations showing the
installation of the decorative modular tile cladding system of the
present invention and the various solutions used for addressing
architectural elements such as corners and windows;
[0051] FIGS. 9-13 are top plan views of various tile fields of the
decorative modular tile cladding system of the present
invention;
[0052] FIG. 14 is an illustration of the rules governing
orientation and placement of the pockets, tabs, clips and weep
holes of the decorative modular tile cladding system of the present
invention.
[0053] FIGS. 15A-15C are top plan views of the decorative modular
tile cladding system of the present invention using Punched Tabs
with an extended tile shape.
[0054] FIGS. 16A-16C are top plan views of the decorative modular
tile cladding system of the present invention using Punched Pockets
with an extended tile shape.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] Referring to the drawings and, in particular, to FIGS. 1-3
thereof, the decorative modular tile cladding system of the present
invention is provided and is referred to generally by reference
numeral 10. The decorative modular tile cladding system 10
comprises a plurality of rectilinear polygonal tiles 12 which in
the preferred embodiment are manufactured from metal, such as
copper, brass, bronze, aluminum and/or steel sheet metal.
[0056] Alternatively, other materials may be used, such as vinyl or
plastic, or composites, which materials will have a different
aesthetic than the metal tiles 12, but may be far less expensive to
manufacture and may be easier to install. It should also be
appreciated that although in the preferred embodiment the tiles 12
are rectilinear, there are an unlimited number of shapes and
configurations that would be just as effective, including
curvilinear shapes.
[0057] The tiles 12 include interlocking means 14, which allow
adjacent tiles 12 to be interconnected to thereby create a
continuous "skin" that may be used as cladding for the side of a
structure, either externally or internally. Alternatively, the
cladding may be used on a floor or even a ceiling of the structure,
although the water management feature of the system would not be
implemented in such use. In the preferred embodiment, the
interlocking means 14 comprise at least one folded tab 16 on at
least one edge 18 of the tile 12, which folded tabs 16 engage the
folded tabs 16 on adjacent tiles 12 to create a secure connection,
wherein the entire surface created thereby becomes an
interconnected breathable "skin." The folded tabs 16 allow the full
perimeter 20 of the tiles 12 to be self sealing, with the design
features of interlocking means 14 allows for both edges to be
captured and anchored yet free to move, thereby giving the
individual tiles 12 room for thermal expansion and contraction
while being completely attached to the substructure 21, whether
such substructure be sheathing, substrate, specially engineered
substructure such as concrete or steel, or other materials or
systems.
[0058] In the preferred embodiment, each tile 12 is of the same
shape and size, and includes weep holes 22 that facilitate the
management of water 23 by the tiles 12. In such embodiment, two
types of folded tabs 16 are provided on each tile 12--a top folded
tab 24 and a bottom folded tab 26. The top folded tab 24 is
characterized by a tab 16 that is folded down and over the upper
surface 28 of the tile 12. The top folded tabs 24 include a notch
30, which notch corresponds to one or more holes 32 that may be
disposed along the top leading edge 34 of the tile face 28, which
holes 32 are provided to allow for fasteners such as screws to be
installed along the top leading edge 34 of the tiles 12. It should
be appreciated that the holes 32 are not necessary to the
installation of the cladding system 10 inasmuch as nails or
self-tapping screws may be used to pierce the tiles 12 if no holes
32 are provided. However, the notches are spaced appropriately for
the attachment of these types of fasteners. It should also be
appreciated that the unique interlocking structure of the
decorative modular tile cladding system 10 ensures that the
fasteners will not be visible when the tiles 12 are installed due
to the overlapping tabs 24, 26.
[0059] The bottom folded tabs 26 are provided along the bottom edge
36 of the tiles 12, said bottom folded tabs 26 being characterized
by a tab 16 that is folded under the tiles 12 such that they would
be facing the substrate when the tile 12 is applied to the wall.
Adjacent tiles 12 are attached by sliding the edge of tab 26 of one
tile 12 under and into the top edge 34 of the adjacent tile such
that the bottom folded tab 26 engages the top folded tab 24 or
pocket of the tile 12 or tiles 12 beneath it. As illustrated in the
various Figures showing the different configurations of the tiles
12, each tile 12 is thereby secured and fastened on all edges 18
thereof. A detailed illustration of the interlocking means is shown
in FIGS. 6A-6B-6C. In such illustrations, the interaction of the
top folded tab 24 and the bottom folded tab 26 is highlighted, as
is the fact that the tiles 12 also serve to hide the fastener when
installed.
[0060] It should be appreciated that in the preferred embodiment,
the tabs 16 are designed so they do not exactly meet at the corners
38, allowing for vapor and water respiration and escape. Another
aspect of the water management of the decorative modular tile
cladding system 10 of the present invention are the weep holes 22,
which features prevent the collection or pooling of water 23 or
other fluids in the folds 16 of the tiles 12. As illustrated in
FIGS. 7A-7C, the weep holes 22 located along the bottom folded tabs
26 allow for rain water, condensation and other fluids and gases to
pass through and not collect in the wells 39 created by the folded
tabs 24, 26. In fact, these weep holes 22 allow for water that
condenses along the back surface 29 of the tiles 12 to escape,
thereby preventing any damage to the tiles 12 or to the
substructure 21 upon which the tiles 12 are installed. A comparison
of the water management feature of the present invention is
illustrated in FIGS. 7A and 7B, with FIG. 7A detailing the water
management of the siding system of Thomas (U.S. Pat. No. 358,175)
wherein the water 23 is allowed to pool, and the water and vapor
management of the cladding system 10 of the present invention being
shown in FIG. 7B.
[0061] It has been observed that, depending on the modular design
of the tiles 12, two or more types of tiles 12 may be required to
make up the decorative modular tile cladding system 10 of the
present invention, although certain designs may only require one
type of tile 12. As illustrated in FIG. 2, one of the embodiments
of the present invention requiring two types of tiles 12 is shown,
wherein these two types can generally be described as a "right
handed" tile 40 and a "left handed" tile 42, with each having a
design that mirrors the other for use at different ends of the
surface. In addition to being mirror images, the tiles 40, 42 may
also be different rotations or flipped versions of the same design.
Alternatively, the two tiles 40, 42 may be entirely different in
size or orientation.
[0062] Termination elements 44 and edge detailing strips 46 may
also be provided, which objects are designed to allow attachment of
cut ends 48 of the tile field 50 defined by the interconnected
tiles 12 as it is terminated or otherwise impacted by the
architectural elements, corners or edges of the structure. Other
folded elements may also be provided for the system 10, including
drip edges 52 and boundary/edge trim 54. It should be appreciated
that these elements are merely for illustrative purposes only, as a
number of additional design features are anticipated.
[0063] The installation of the decorative modular tile cladding
system 10 of the present invention is as easy as the installation
of current off-the-shelf siding systems, and uses similar tools,
although the technique and process of coverage is fundamentally
different, particularly with respect to dealing with edges and
wrapping around corners. As has already been discussed, the system
10 is designed to be installed directly onto any type of
substructure 21, including standard sheathing such as a normal
1/2'' plywood sheathing substrate covered with an appropriate water
and vapor barrier such as tarpaper. Each tile 12 is captured using
a fastening device such as a screw or appropriately rated nail,
such as a 6 flat-headed pan screw, on the top edge 34 in the
appropriate holes 32 or alternatively without the need for holes
32, provided that the fasteners pierce the tiles 12 at the provided
notch 30 or fastening protocol, and will be covered by the folded
tab 16 so as to hide them from view when the cladding system is
completely installed, and follow specific layout pattern to be
provided depending on tile specs. As tiles 12 are laid into each
other, the bottom folded tab 26 captures half of the top folded
tabs 24 of the two tiles 12 directly below it. Special beginning
and termination tiles can also be provided (or created on site)
depending on site needs. Tiles 12 are laid from the bottom up in
the opposite direction of water flow.
[0064] In an alternative embodiment, clips 56 may be provided to
engage the edges 18 of adjacent tiles 12. In yet another
alternative embodiment, fingers 58 may be used instead of tabs 16,
which fingers 58 may be cut so as to create the notch 30 for
example, and which may also be folded in much the same was as tabs
16. In the embodiment wherein fingers 58 are used in place of tabs
16, the need to notch out tabs when tile 12 installation is
conforming to a corner or other architectural feature is
eliminated, thereby facilitating the preparation of the tiles 12
for installation on site. The tile 12 can also be bent without
notching the bottom folded tab 26 or top folded tab 24. It should
be appreciated that in this embodiment, it is preferable to orient
the finger 58 parallel to the vertical axis, or alternatively to
the plumb of the design of the tile field 50. The corresponding
finger 58 may be pre-notched for access to hole 32 or in
determining fastening pattern/protocol. Finally, in such
embodiment, if the tile 12 is folded around a corner, only the
finger tabs 58 in the area of the fold will deform, precluding the
need to notch the tabs 58 when making a bend during
installation.
[0065] Illustrated in FIGS. 9 through 13 are some of the variations
of tile fields 50 that may be created using the decorative modular
tile cladding system 10 of the present invention. These variations
are provided for illustrative purposes only, and should not be
construed as limiting the potential designs or configurations of
the tiles 12. It should be appreciated that in some of these
configurations, more than a right tile 40 and left tile 42 are
utilized, as shown in FIGS. 12 and 13.
[0066] FIG. 14 illustrates a protocol by which the folded tabs 16
are oriented and placed on the tile 12. The joint protocol
establishes the determination of an over edge 60 and under edge 62
to the geometric pattern of the tile 12, allowing the tiles 12 to
be overlapped and secured. The overlap and layout of the two folds
64 that comprise one segment 66 connection is determined by the
orientation of each segment 66 of the geometric pattern to the
vertical axis. By drawing a bounding box 70 around the anchor
points 72 to each segment 66, one can readily determine which area
is above and below the segment 66. The tile 12 comprising the area
above the segment 66 receives a backward fold 74 and the tile that
comprises the lower area of the segment receives a forward fold 76
to create the leading edge 34, a punched pocket or punched tab.
[0067] The backward fold 74 has a length equal to the segment 66
with edges 18A tapered inward and a depth slightly shorter than the
corresponding forward facing fold 76, a weep hole 22 detail at the
meeting points of the segments 66 where two folds 74 meet, not to
extend into to the forward face 28 to allow for the release of
surface water and migration of condensate water 23 that may form in
the boundary layer between the cladding and the substructure 21. In
the embodiment having fingers 58, the backwards fold 74 is
similarly formed from extension 78 and subdivided into fingers
58.
[0068] The forward fold 76 is formed from forward fold extension
78A which is approximately twice the tab depth which is folded over
itself in half to meet tile face 28. Notches 30 and hole 32 are
punched into the fold 76 corresponding to fastener placement in one
embodiment. In still another embodiment, wherein the fingers 58
subdivide the tab 16 allowing for vertical bending of the tile 12
without cutting the fold 64 on corner bends during installation,
forward folds 76 is similarly formed from extension 78A, wherein
said extension 78A is subdivided to form fingers 58.
[0069] In the embodiment using clips 58 (Embodiment 2), the area
below segment 66 does not receive a fold 64, but merely includes
extension 78, and clips 58 slide over this extension 78 and are
captured with fasteners through the tile 12. In yet another
embodiment, a punched pocket or punched tab is forged on the blank
and aligned to the pattern of tiles 12 and of the same depth as the
slightly smaller of the corresponding backwards tab 74.
[0070] In the preferred embodiment, installation of the cladding
system 10 is commenced by attaching a fold strip 80 to the
substructure 21 to capture the starting tile 12 course, and a drip
edge 52 detail finish, and subsequent tiles 12 are fastened in
series in an upward direction. A tile 12 is slid up such that its
bottom folded tab 26 engages the top folded tab 24 of the fastened
bottom course of tiles 12. The tile 12 is thereafter fastened to
the substructure 21 along the top edge 34, with or without clips
58. As the tile field 50 reaches a corner, the tile 12 is marked to
the corner and bent and the installation proceeds. It should be
realized that the tile field 50 need not bend on the tile pattern's
50 geometric axis. On any edges 18 that terminate the pattern, a
fold strip 44 is nailed and the tile 12 is captured thereby.
[0071] In yet another embodiment of the present invention, as
illustrated in FIGS. 15A-16C, punched tabs 82 or punched pockets 84
are used in place of some of the folded tabs 16. In the creation of
a punched tab 82 or punched pocket 84, the blank tile 12 may take
an extended shape 86 incorporating the uppermost horizontal level
encompassed by the geometric shape of the tile 12.
[0072] The extended shape 86 derives its outline on the left by
taking on the left most edge of the left-most bounding box 70 used
in determining left most edge 60. The outline on the right is
similarly determined by taking on the right most edge of the right
most bounding box 70 used in determining the right most edge 60.
Finally, the extended shape 86 derives its uppermost boundary by
taking on the top most edge of the top most bounding box 70 used in
determining the top most edge 60.
[0073] In this embodiment when creating a bottom fold 26 under the
edge 62, the folds are determined by the shape of the tile 12 of
the intended system 10 as bottom edge 36 conforms to the geometric
pattern. The punched tab 82 or punched pockets 84 are machined
slightly away and in a pattern that follows the tile 12 position of
the upper edge formed by the pattern 12.
[0074] In the preferred embodiment, the overall outline of the
extended shape 86 will remain true to the top most outline and thus
form a dependable registration outline for the installation
procedure and facilitate the alignment of the pattern and its
feature set correctly on the structure during installation. It
should be appreciated, however, that certain tile patterns may make
it advantageous to strictly adhere to the right, left, top or any
combination in determining the tile's 12 outline in setting up the
coordinate system. This will allow a vertical or horizontal
registration protocol to be established. By transferring the
corresponding registration protocol on the intended structure, a
correct alignment and spacing of the installation of the tile field
50 may be facilitated.
[0075] In the case of a repair where a damage tile is removed, this
embodiment provides the anchoring for the repair tile 12 to capture
the installed punched pockets 84. The repair tile 12 that will take
a slightly new form or protocol therefore has access to the
established hidden anchoring mechanism and can readily engage the
tile 12 above it.
[0076] Finally, an added feature of this embodiment is that the
resulting opening in the extended shape 86 tile face 28 results in
openings that are situated directly behind and above the
overlapping tile 12 above it allowing protection from the
environment but increasing the vapor exchange and heat transfer
exchange from behind the tile field 50.
[0077] Of course, it should be appreciated that any combination of
the systems and methods taught herein may be utilized in one
tile.
[0078] Having thus described the invention with particular
reference to the preferred forms thereof, it will be obvious that
various changes and modifications can be made therein without
departing from the spirit and scope of the present invention as
defined by the appended claims.
* * * * *