U.S. patent application number 12/112232 was filed with the patent office on 2009-11-05 for cladding system for roofs and facades.
Invention is credited to David Lucchesi.
Application Number | 20090272060 12/112232 |
Document ID | / |
Family ID | 41256188 |
Filed Date | 2009-11-05 |
United States Patent
Application |
20090272060 |
Kind Code |
A1 |
Lucchesi; David |
November 5, 2009 |
Cladding System for Roofs and Facades
Abstract
A system for cladding roofs and facades of buildings includes
elongated tracks. Each track has opposed lengthwise edges curved
inwardly over opposed portions of the track. Each of a plurality of
elongated panels has opposed lengthwise edges curved inwardly over
opposed portions of the panel. Each panel is adapted to be
interlocked between two spaced, parallel tracks. The system also
includes fin components. Each fin component has two lengthwise edge
portions defining a base of the fin component. A fin depends from
the base of the fin component, which is adapted to be interlocked
within a track with the fin extending away from the track with
lengthwise edges of two proximate panels interlocked between the
base of the fin component and the lengthwise edges of the track.
Similar systems are provided for corners, overhangs, and jambs as
may be encountered in a building.
Inventors: |
Lucchesi; David; (Danbury,
CT) |
Correspondence
Address: |
EDWARDS ANGELL PALMER & DODGE LLP
P.O. BOX 55874
BOSTON
MA
02205
US
|
Family ID: |
41256188 |
Appl. No.: |
12/112232 |
Filed: |
April 30, 2008 |
Current U.S.
Class: |
52/489.1 ;
52/586.1; 52/747.1 |
Current CPC
Class: |
E04D 3/362 20130101;
E04F 17/00 20130101; E04D 3/30 20130101; E04F 13/0821 20130101;
E04F 13/0889 20130101; E04F 13/12 20130101; E04F 13/0803
20130101 |
Class at
Publication: |
52/489.1 ;
52/586.1; 52/747.1 |
International
Class: |
E04G 11/48 20060101
E04G011/48; E04D 3/24 20060101 E04D003/24; E04F 13/08 20060101
E04F013/08 |
Claims
1. A system for cladding roofs and facades of buildings comprising:
a) a plurality of elongated tracks, each track being configured and
adapted to be affixed to a building and having opposed lengthwise
edges curved inwardly over opposed sections of the track; b) a
plurality of elongated panels, each panel having opposed lengthwise
edges curved inwardly over opposed sections of the panel, wherein
each panel is adapted to be interlocked between two spaced,
parallel tracks, with each lengthwise edge of each panel
interlocked with a lengthwise edge of a track; and c) a plurality
of fin components, each fin component having two lengthwise edge
portions defining a base of the fin component, and a fin depending
from the base of the fin component, wherein each fin component is
adapted to be interlocked within a track, the fin extending away
from the track, with lengthwise edges of two proximate panels
interlocked between the base of the fin component and the
lengthwise edges of the track.
2. A system for cladding roofs and facades as recited in claim 1,
wherein the tracks, panels, and fin components are configured and
adapted to interlock together with each fin extending between and
spaced apart from the panels interlocked with the respective fin
component and track.
3. A system for cladding roofs and facades as recited in claim 1,
wherein at least one of the tracks, panels, and fin components
includes a material selected from the group consisting of zinc,
copper, aluminum, stainless steel, galvanized steel, terne, terne
coated stainless steel, Freedom Grey, Monel.RTM., nickel, lead, and
lead coated copper.
4. A system for cladding roofs and facades as recited in claim 1,
further comprising a plurality of end mounting components each
configured and adapted to be affixed to an underlying structure
between two parallel, spaced tracks and to interlock with adjacent
ends of a pair of panels adjacent lengthwise to one another and
interlocked with said two parallel tracks, wherein each panel
includes a first end curved under a portion of the panel and a
second end opposite the first end and curved over a portion of the
panel, and wherein the first end of each panel is configured and
adapted to interlock with the second end of a lengthwise adjacent
panel and with an end mounting component.
5. A system for cladding roofs and facades as recited in claim 4,
wherein the panels are configured and adapted to have the main
sections thereof substantially coplanar with one another when the
panels are interlocked with respective tracks and fin
components.
6. A system for cladding roofs and facades as recited in claim 5,
wherein each fin component is dimensioned and adapted to interlock
with a track and pair of proximate panels with the fin depending
from the respective track beyond a plane defined by the
substantially coplanar main sections of the panels.
7. A system for cladding roofs and facades as recited in claim 1,
wherein a main section of each elongated track defines a central
longitudinal axis, and wherein each track is symmetrical across the
central longitudinal axis thereof.
8. A system for cladding roofs and facades as recited in claim 1,
wherein a main section of each elongated panel defines a central
longitudinal axis, and wherein each panel is symmetrical across the
central longitudinal axis thereof.
9. A system for cladding roofs and facades as recited in claim 1,
wherein the base of each fin component defines a central
longitudinal axis, and wherein each fin component is symmetrical
across the central longitudinal axis thereof.
10. A system for cladding roofs and facades as recited in claim 1,
wherein the tracks, panels, and fin components are configured and
adapted to interlock together with portions of the lengthwise edges
of the tracks, panels, and fin components parallel to the main
section of each respective track.
11. A kit for making a cladding system for roofs and facades, the
kit comprising: a) a plurality of elongated tracks, each track
being configured and adapted to be affixed to a building and having
opposed lengthwise edges curved inwardly over opposed portions of
the track; b) a plurality of elongated panels, each panel having
opposed lengthwise edges curved inwardly over opposed portions of
the panel, wherein each panel is configured and adapted to be
interlocked between two spaced, parallel tracks with each
lengthwise edge of each panel interlocked with a lengthwise edge of
a track; c) a plurality of fin components, each fin component
having two lengthwise edge portions defining a base of the fin
component, and a fin depending from the base of the fin component,
wherein each fin component is configured and adapted to be
interlocked within a track with the fin extending away from the
track so that lengthwise edges of two proximate panels are
interlocked between the base of the fin component and the
lengthwise edges of the track; and d) means to affix the tracks to
a roof or building facade.
12. A kit for making a cladding system for roofs and facades as
recited in claim 11, wherein the means to affix the tracks are
configured and adapted to accommodate fasteners of a type selected
from the group consisting of: nails, screws, bolts, staples, and
rivets.
13. A kit for making a cladding system for roofs and facades as
recited in claim 11, wherein the tracks, panels, and fin components
are configured and adapted to interlock together with each fin
extending between and spaced apart from the panels interlocked with
the respective fin component and track.
14. A kit for making a cladding system for roofs and facades as
recited in claim 11, further comprising a plurality of end mounting
components each configured and adapted to be affixed to an
underlying structure between two parallel tracks and to interlock
with adjacent ends of a pair of panels adjacent lengthwise to one
another and interlocked with the two parallel tracks, wherein each
panel includes a first end curved under a portion of the panel and
a second end opposite the first end and curved over a portion of
the panel, and wherein the first end of each panel is configured
and adapted to interlock with the second end of a lengthwise
adjacent panel and with the end mounting component.
15. A kit for making a cladding system for roofs and facades as
recited in claim 14, wherein the panels are configured and adapted
to have the main sections thereof be substantially coplanar with
one another when the panels are interlocked with respective tracks
and fin components, and wherein each fin component is dimensioned
and adapted to interlock with a track and pair of proximate panels
with the fin extending perpendicularly away from the respective
track beyond a plane defined by the substantially coplanar main
sections of the panels.
16. A kit for making a cladding system for roofs and facades as
recited in claim 11, wherein a fin component has a cross-sectional
profile that is generally rectangular.
17. A kit for making a cladding system for roofs and facades as
recited in claim 11, wherein a fin component has a cross-sectional
profile that is generally semi-circular.
18. A method of cladding roofs and facades of buildings comprising:
a) providing a plurality of elongated tracks, each track having
opposed lengthwise edges curved inwardly over opposed portions of
the track; b) affixing the tracks to a building in a spaced,
parallel relationship to each other; c) providing a plurality of
elongated panels, each panel having opposed lengthwise edges curved
inwardly over opposed portions of the panel, wherein each panel is
configured and adapted to be interlocked between two parallel
tracks with each lengthwise edge of each panel interlocked with a
lengthwise edge of a track; d) interlocking the panels to the
tracks; e) providing a plurality of fin components, each fin
component having two lengthwise edge portions together defining a
base of the fin component, and a fin depending from the base of the
fin component, wherein each fin component is configured and adapted
to be interlocked within a track with the fin extending away from
the track so that the lengthwise edges of two proximate panels are
interlocked between the base of the fin component and the
lengthwise edges of the track; and f) interlocking the lengthwise
edges of proximate panels between the base of a fin component and
the lengthwise edges of each track to effect cladding of a portion
of a building.
19. A method of cladding roofs and facades as recited in claim 18,
wherein the step of providing a plurality of fin components
includes providing fin components configured and adapted so that
when each fin component is interlocked with a track and panels,
each fin is spaced apart from the lengthwise edges of panels
interlocked with the respective fin component and track, and
wherein the step of interlocking the lengthwise edges of proximate
panels includes interlocking the fin component with the lengthwise
edges of proximate panels with the fin spaced apart from the
lengthwise edges of the panels.
20. A method of cladding roofs and facades as recited in claim 18,
further comprising: a) providing a plurality of end mounting
components each configured and adapted to be affixed to an
underlying structure between two parallel tracks and to interlock
with adjacent ends of a pair of panels adjacent lengthwise to one
another and both interlocked with the two parallel tracks, wherein
each panel includes a first end curved over a portion of the panel
and a second end opposite the first end and curved over the an
opposed portion of the panel in a curve direction opposite that of
the first end; and b) interlocking the first end of each panel with
the second end of a lengthwise adjacent panel and with the end
mounting component.
21. A method of cladding roofs and facades as recited in claim 20,
wherein the step of interlocking the first end of each panel with
the second end of a lengthwise adjacent panel includes interlocking
lengthwise adjacent panels with main sections thereof being
substantially coplanar with one another.
22. A method of cladding roofs and facades as recited in claim 21,
wherein the step of providing a plurality of elongated fin
components includes providing fin components wherein each fin
component is dimensioned and adapted to interlock with a track and
pair of proximate panels with the fin extending perpendicularly
away from the respective track beyond a plane defined by the
substantially coplanar main sections of the panels.
23. A system for cladding roofs and facades at an inside corner of
a building comprising: a) an elongated track having opposed
lengthwise edges curved inwardly over opposed portions of the
track, wherein the opposed portions of the track are at a
substantially right angle to one another with the lengthwise edges
of the track inside the substantially right angle; b) a pair of
elongated panels, each panel having opposed lengthwise edges curved
inwardly over opposed portions of the panel, wherein one of the
lengthwise edges of each panel is adapted to be interlocked with
one of the lengthwise edges of the track; and c) a pair of
elongated mounting components, each mounting component including
first and second lengthwise portions, wherein the first lengthwise
portion is configured and adapted to be affixed to an underlying
structure, and wherein the second lengthwise portion is configured
and adapted to be interlocked between a lengthwise edge of the
track and one of the panels.
24. A system for cladding roofs and facades at an outside corner of
a building comprising: a) an elongated track having opposed
lengthwise edges curved inwardly over opposed portions of the
track, wherein the opposed portions of the track are at a
substantially right angle to one another with the lengthwise edges
of the track outside the substantially right angle; b) a pair of
elongated panels, each panel having a pair of lengthwise edges
curved inwardly over opposed portions of the panel, wherein a
lengthwise edge of each panel is adapted to be interlocked with one
of the lengthwise edges of the track; and c) a pair of elongated
mounting components, each mounting component having first and
second lengthwise portions, wherein the first lengthwise portion is
configured and adapted to be affixed to an underlying structure,
and wherein the second lengthwise portion is configured and adapted
to be interlocked between a lengthwise edge of the track and a
lengthwise edge of one of the panels.
25. A system for cladding roofs and facades at a jamb of a building
comprising: a) an elongated end closure component having opposed
lengthwise edges at a substantially right angle to one another; b)
an elongated panel having a lengthwise edge curved inwardly over
opposed portions of the panel; and c) an elongated mounting
component having first and second lengthwise portions, wherein the
first lengthwise portion is configured and adapted to be affixed to
an underlying structure, and wherein the second lengthwise portion
is configured and adapted to interlock the lengthwise edge of the
panel between a lengthwise edge of the end closure component and
the second lengthwise portion of the mounting component.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to systems and methods for
cladding buildings, and more particularly, to systems and methods
for cladding roofs and facades of new or existing structures.
[0003] 2. Description of Related Art
[0004] A variety of systems and methods are known in the art for
covering interior walls, ceilings, exterior walls, and roofs of
buildings. Of such systems, many are directed to paneling or
cladding systems for covering roofs and exterior walls.
[0005] The architectural properties and appearances of buildings
are a matter of continual improvement and variation as
architectural trends and technical improvements evolve over time.
One popular method of treating facades and roofs involves use of
cladding or paneling systems to cover exterior surfaces of
buildings. Metallic panels are often used as cladding components;
however, a wide variety of cladding systems use other diverse
materials, including slate, marble and granite. Metallic cladding
materials such as zinc and copper are easily workable, relatively
light weight, and can provide architecturally sound coverings for
buildings. Zinc and copper cladding panels also have the benefit of
developing a decorative patina giving coloring, patterns, and
textures that can improve over time.
[0006] Cladding systems not only provide for attractive appearance,
they can contribute to weather proofing and insulation of a
building. There is a need to anchor large areas of cladding to the
underlying wall structures at regular intervals so as to provide
good adherence to the underlying structure and to avoid bulging or
warping. Many systems break up large areas of cladding with
channels or ridges to create the appearance of planks.
[0007] An exemplary cladding system is described in U.S. Pat. No.
6,212,842 to Martinez, which describes a preformed roof cover
having a quadrilateral shape, more specifically an isosceles
trapezoid shape. The long edges of each panel have raised ridges.
The first raised ridge has a free edge folded toward the opposite
edge. The second raised edge has a circular hem opening along the
outer lateral side thereof. The free edge of the first ridge can be
fit into the circular hem of an adjacent panel to create a
continuous cladding over a roof. After a panel element is placed on
a roof, it is fastened to the underlying support structure of the
roof.
[0008] Such conventional methods and systems generally have been
considered satisfactory for their intended purpose. However, there
is still a need for improved devices and methods for cladding and
paneling buildings. There is also a continued need in the art for
improved systems and methods that provide structurally sound,
aesthetically pleasing cladding for roofs and facades while being
easy to make and use.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a new and useful system
for cladding roofs and facades of buildings. The system includes a
plurality of elongated tracks, each track being configured and
adapted to be affixed to a building and having opposed lengthwise
edges curved inwardly over opposed sections of the track. A
plurality of elongated panels are provided, each panel having
opposed lengthwise edges curved inwardly over opposed sections of
the panel. Each panel is adapted to be interlocked between two
spaced, parallel tracks, with each lengthwise edge of each panel
interlocked with a lengthwise edge of a track. The system also
includes a plurality of fin components. Each fin component has two
lengthwise edge portions defining a base of the fin component. A
fin depends from the base of the fin component. Each fin component
is adapted to be interlocked within a track with the fin extending
away from the track with lengthwise edges of two proximate panels
interlocked between the base of the fin component and the
lengthwise edges of the track.
[0010] In one aspect of the cladding system, the tracks, panels,
and fin components are configured and adapted to interlock together
with each fin extending between and spaced apart from the panels
interlocked with the respective fin component and track. At least
one of the tracks, panels, and fin components can include a
material selected from the group consisting of zinc, copper,
aluminum, stainless steel, galvanized steel, terne, terne coated
stainless steel, Freedom Grey (available from Englert Inc. of Perth
Amboy, N.J.), Monel.RTM. (available from the Special Metals
Corporation of Huntington, W. Va.), nickel, lead, and lead coated
copper, or any other suitable material. The tracks, panels, and fin
components can be configured and adapted to interlock together with
portions of the lengthwise edges of the tracks, panels, and fin
components parallel to the main section of each respective
track.
[0011] In another aspect of the invention, a plurality of end
mounting components are provided, each configured and adapted to be
affixed to an underlying structure between two parallel, spaced
tracks and to interlock with adjacent ends of a pair of panels that
are adjacent lengthwise to one another and are interlocked with the
two parallel tracks. Each panel can include a first end curved
under a portion of the panel and a second end opposite the first
end and curved over a portion of the panel, and the first end of
each panel can be configured and adapted to interlock with the
second end of a lengthwise adjacent panel and with the end mounting
component. It is also contemplated that the panels can be
configured and adapted to have main sections thereof substantially
coplanar with one another when the panels are interlocked with
respective track and fin components. Moreover, each fin component
can be dimensioned and adapted to interlock with a track and pair
of proximate panels with the fin depending from the respective
track beyond a plane defined by the substantially coplanar main
sections of the panels.
[0012] It is also contemplated that in various embodiments, a main
section of each elongated track defines a central longitudinal
axis, and each track is symmetrical across the central longitudinal
axis thereof. A main section of each elongated panel can similarly
define a central longitudinal axis, and each panel can be
symmetrical across the central longitudinal axis thereof. The base
of each fin component can also define a central longitudinal axis,
and each fin component can be symmetrical across the central
longitudinal axis thereof. The fin components, panels, and/or
tracks can have a cross-sectional profile that includes a shape
that is generally rectangular, semi-circular, T-shaped, or any
other suitable shape and proportions.
[0013] The invention also provides a kit for making a cladding
system for roofs and facades. The kit includes a plurality of
elongated tracks, each track being configured and adapted to be
affixed to a building and having opposed lengthwise edges curved
inwardly over opposed sections of the track. The kit includes a
plurality of elongated panels, each panel having opposed lengthwise
edges curved inwardly over opposed sections of the panel. Each
panel is configured and adapted to be interlocked between two
spaced, parallel tracks with each lengthwise edge of each panel
interlocked with a lengthwise edge of a track. The kit further
includes a plurality of fin components. Each fin component has two
lengthwise edge portions defining a base of the fin component. A
fin depends from the base of the fin component. Each fin component
is configured and adapted to be interlocked within a track with the
fin extending away from the track so that lengthwise edges of two
proximate panels are interlocked between the base of the fin
component and the lengthwise edges of the track. Means are included
to affix the tracks to a roof or building facade. It is envisioned
that the means to affix the tracks can be configured and adapted to
accommodate nails, screws, bolts, staples, rivets, or any other
suitable type of fastener.
[0014] A method is provided in accordance with the invention for
cladding roofs and facades of buildings. The method includes
providing a plurality of elongated tracks, each track having
opposed lengthwise edges curved inwardly over opposed portions of
the track. The method further includes affixing the tracks to a
building in a spaced, parallel relationship to each other. A step
is included for providing a plurality of elongated panels, each
panel having opposed lengthwise edges curved inwardly over opposed
portions of the panel, wherein each panel is configured and adapted
to be interlocked between two parallel tracks with each lengthwise
edge of each panel interlocked with a lengthwise edge of a track. A
further step of interlocking the panels to the tracks is provided.
The method also includes providing a plurality of fin components,
each fin component having two lengthwise edge portions defining a
base of the fin component, and a fin depending from the base of the
fin component, wherein each fin component is configured and adapted
to be interlocked within a track with the fin extending away from
the track so that the lengthwise edges of two proximate panels are
interlocked between the base of the fin component and the
lengthwise edges of the track. The method includes a still further
step of interlocking the lengthwise edges of proximate panels
between the base of a fin component and the lengthwise edges of
each track to effect cladding of a portion of a building.
[0015] In accordance with one aspect of the method of cladding
roofs and facades, the step of providing a plurality of fin
components includes providing fin components configured and adapted
so that when each fin component is interlocked with a track and
associated panels, each fin is spaced apart from the lengthwise
edges of the panels interlocked with the respective fin component
and track. The step of interlocking the lengthwise edges of
proximate panels can include interlocking the fin component with
the lengthwise edges of proximate panels with the fin spaced apart
from the lengthwise edges of the panels.
[0016] In various embodiments, the method further includes
providing a plurality of end mounting components each configured
and adapted to be affixed to an underlying structure between two
parallel tracks and to interlock with adjacent ends of a pair of
panels adjacent lengthwise to one another and both interlocked with
the two parallel tracks, wherein each panel includes a first end
curved over a section of the panel and a second end opposite the
first end and curved over an opposed portion of the panel in a
curve direction opposite that of the first end. The method can
further include interlocking the first end of each panel with the
second end of a lengthwise adjacent panel and with the end mounting
component.
[0017] The step of interlocking the first end of each panel with
the second end of a lengthwise adjacent panel can include
interlocking lengthwise adjacent panels with main sections thereof
being substantially coplanar with one another. It is also
envisioned that the step of providing a plurality of elongated fin
components can include providing fin components wherein each fin
component is dimensioned and adapted to interlock with a track and
pair of proximate panels with the fin extending perpendicularly
away from the respective track beyond a plane defined by the
substantially coplanar main sections of the panels.
[0018] A system is also provided for cladding roofs and facades at
an inside corner of a building. This system includes an elongated
track having opposed lengthwise edges curved inwardly over opposed
portions of the track, wherein the opposed portions of the track
are at a substantially right angle to one another with the
lengthwise edges of the track inside the substantially right angle.
A pair of elongated panels is included, each panel having opposed
lengthwise edges curved inwardly over opposed sections of the
panel, wherein one of the lengthwise edges of each panel is adapted
to be interlocked with one of the lengthwise edges of the track.
The system also includes a pair of elongated mounting components.
Each mounting component has first and second lengthwise portions,
wherein the first lengthwise portion is configured and adapted to
be affixed to an underlying structure, and wherein the second
lengthwise portion is configured and adapted to be interlocked
between a lengthwise edge of the track and one of the panels.
[0019] In further accordance with the invention, a system is
provided for cladding roofs and facades at an outside corner of a
building. This system includes an elongated track having opposed
lengthwise edges curved inwardly over opposed sections of the
track, wherein the opposed portions of the track are at a
substantially right angle to one another with the lengthwise edges
of the track outside or extending from the substantially right
angle. A pair of elongated panels is included, each panel having a
pair of lengthwise edges curved inwardly over opposed portions of
the panel, wherein a lengthwise edge of each panel is adapted to be
interlocked with one of the lengthwise edges of the track. The
system also includes a pair of elongated mounting components. Each
mounting component has first and second lengthwise portions. The
first lengthwise portion of the mounting component is configured
and adapted to be affixed to an underlying structure. The second
lengthwise portion of the mounting component is configured and
adapted to be interlocked between a lengthwise edge of the track
and a lengthwise edge of one of the panels.
[0020] The invention also provides a system for cladding roofs and
facades at a jamb of a building. This system includes an elongated
end closure component having opposed lengthwise edges at a
substantially right angle to one another. An elongated panel has
lengthwise edges curved inwardly over opposed sections of the
panel. An elongated mounting component having first and second
lengthwise portions is also included, wherein the first lengthwise
portion is configured and adapted to be affixed to an underlying
structure, and wherein the second lengthwise portion is configured
and adapted to interlock the lengthwise edge of the elongated panel
between a lengthwise edge of the end closure component and the
second lengthwise portion of the mounting component.
[0021] These and other features of the systems and methods of the
subject invention will become more readily apparent to those
skilled in the art from the following detailed description of a
preferred embodiment taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] So that those skilled in the art to which the subject
invention appertains will readily understand how to make and use
the systems and methods of the subject invention without undue
experimentation, preferred embodiments thereof will be described in
detail herein below with reference to certain figures, wherein:
[0023] FIG. 1 is a cross-sectional plan view of portion of a
cladding system in accordance with the present invention, showing
edges of two panels interlocked between a track and a fin
component;
[0024] FIG. 2 is front view of a portion of the cladding system of
FIG. 1, showing the spacing between the fin and two panels
proximate therewith;
[0025] FIG. 3 is a perspective view of a portion of the cladding
system of FIG. 1, showing the fin extending away from the track,
between the panels and protruding beyond the outward faces of the
panels;
[0026] FIG. 4 is a front view of the cladding system of FIG. 1 in
place on an exterior wall of a building, showing the tiling pattern
of the panels;
[0027] FIG. 5 is a cross-sectional elevation view of a lap joint of
the cladding system of FIG. 1, showing ends of two adjacent panels
interlocked together with an end mounting component affixed to a
building;
[0028] FIG. 6 is a cross-sectional plan view of a cladding system
for an inside corner in accordance with the present invention,
showing a treatment at an inside corner of a building with edges of
two panels interlocked with an angled track and two mounting
components;
[0029] FIG. 7 is cross-sectional plan view of a cladding system for
an outside corner or overhang in accordance with the present
invention, showing a treatment at an outside corner of a building
with edges of two panels interlocked with an angled track and two
mounting components;
[0030] FIG. 8 is a cross-sectional plan view of a cladding system
for use adjacent to a door or window jamb in accordance with the
present invention, showing a panel interlocked with an end closure
component and a mounting component;
[0031] FIG. 9 is a cross-sectional plan view of a portion of a
cladding system in accordance with the present invention, showing a
track accommodating a fin component with a generally semi-circular
cross-sectional profile;
[0032] FIG. 10 is a cross-sectional plan view of a portion of a
cladding system in accordance with the present invention, showing a
track accommodating a fin component with a generally rectangular
cross-sectional profile;
[0033] FIG. 11 is a cross-sectional plan view of a portion of a
cladding system in accordance with the present invention, showing a
track accommodating a fin component with a generally T-shaped
cross-sectional profile;
[0034] FIG. 12 is a cross-sectional plan view of a portion of a
cladding system in accordance with the present invention, showing a
track accommodating a fin component with an elongate rectangular
cross-sectional profile;
[0035] FIG. 13, is a cross-sectional plan view of a portion of a
cladding system in accordance with the present invention, showing a
track accommodating a fin component with a generally square
cross-sectional profile, with two tandem fasteners anchoring the
track; and
[0036] FIG. 14 is a cross-sectional plan view of a portion of a
cladding system in accordance with a the present invention, showing
a track accommodating a fin component with a generally
paddle-shaped cross-sectional profile.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] Reference will now be made to the drawings wherein like
reference numerals identify similar structural features or aspects
of the subject invention. In accordance with the invention, a
system for cladding roofs and facades of buildings is provided,
including a plurality of elongated tracks, each track being
configured and adapted to be affixed to a building and having
opposed lengthwise edges curved inwardly over opposed sections of
the track. A plurality of elongated panels are provided, each panel
having opposed lengthwise edges curved inwardly over opposed
sections of the panel. Each panel is adapted to be interlocked
between two spaced, parallel tracks, with each lengthwise edge of
each panel interlocked with a lengthwise edge of a track. The
system also includes a plurality of elongated fin components. Each
fin component has two lengthwise edge portions defining a base of
the fin component. A fin extends substantially perpendicularly from
the base of the fin component. Each fin component is adapted to be
interlocked within a track with the fin extending away from the
track with lengthwise edges of two proximate panels interlocked
between the base of the fin component and the lengthwise edges of
the track.
[0038] For purpose of explanation and illustration, and not
limitation, a partial view of an exemplary embodiment of the system
in accordance with the invention is shown in FIG. 1 and is
designated generally by reference character 100. Other embodiments
of a system in accordance with the invention, or aspects thereof
are provided in FIGS. 2-8, as will be described. The system of the
invention can be used for cladding roofs or facades of buildings,
or in any other suitable application to provide an architecturally
sound covering of underlying building structures.
[0039] In accordance with the invention, cladding system 100
includes a plurality of elongated tracks 102, one of which is shown
in FIG. 1. Each track 102 is configured and adapted to be affixed
to an underlying structure 122 that is part of a building or static
structure. Opposed lengthwise edges 104 and 104' of track 102 are
curved inwardly over opposed sections 106 and 106' of track 102,
respectively.
[0040] The system also includes elongated panels 108. Each panel
108 has opposed lengthwise edges 110 and 110' curved inwardly over
opposed sections 112 and 112' of the respective panels 108. Each
panel 108 is adapted to be interlocked between two spaced, parallel
tracks 102, with each lengthwise edge 110/110' of each panel 108
interlocked with a lengthwise edge 104/104' of a track 102.
[0041] With further reference to FIG. 1, the system also includes
an elongated fin component 114 configured for interlocking with
each track 102. Each fin component 114 has two lengthwise edge
portions 116 and 116' defining a base 118 of the fin component 114.
A fin 120 extends substantially perpendicularly from base 118 of
fin component 114. Each fin component 114 is adapted to be
interlocked, as shown in FIG. 1, within a track 102 with fin 120
extending away from track 102 with lengthwise edges 110 and 110' of
two proximate panels 108 interlocked between base 118 of fin
component 114 and lengthwise edges 104 and 104' of track 102. While
fin 120 is shown an described extending substantially
perpendicularly from base 118 of fin component 114, those skilled
in the art will appreciate that fin 120 can be angled with respect
to base 118 at any suitable angle.
[0042] As indicated in FIGS. 1 and 2, tracks 102, panels 108, and
fin components 114 are configured and adapted to interlock together
so that each fin 120 extends between and is spaced apart from
panels 108 interlocked with the respective fin component 114 and
track 102. The gaps between fin 120 and neighboring panels 108 have
a width "w" as shown in FIGS. 1 and 2. Moreover, tracks 102, panels
108, and fin components 114 can be configured and adapted to
interlock together with portions of their lengthwise edges
104/110/116 and 104'/110'/116' parallel to a main section 107 of
tracks 102. Longitudinal edges 110 and 110' of panels 108 are
sandwiched between longitudinal edges 104 and 104' of tracks 102
and bases 118 of fin components 114, as shown in FIG. 1. In this
arrangement, panels 108 are securely affixed to cladding system
100, which is affixed to an underlying structure 122 or other
static structure with any suitable fasteners 124. Fin component 114
also forms a covering to help shield track 102 and fasteners 124
from exposure to the elements.
[0043] Tracks 102, panels 108, and fin components 114 can include
zinc, copper, aluminum, stainless steel, galvanized steel, terne,
terne coated stainless steel, Freedom Grey (available from Englert
Inc. of Perth Amboy, N.J.), Monel.RTM. (available from the Special
Metals Corporation of Huntington, W. Va.), nickel, lead, and lead
coated copper, or any other suitable materials. It is not necessary
for tracks 102, panels 108, and fin components 114 to be of the
same material, however, care should be exercised when using
dissimilar metals in combinations that are easily compromised by
galvanic corrosion. Copper and Zinc have various advantages for use
in cladding system 100, including ease of forming the various
components, malleability for the formation of relatively thin,
light weight cladding components, and the decorative surface
qualities produced as the cladding naturally weathers and
patinates.
[0044] Sections 106 and 106' of each track 102 define a central
longitudinal axis A, and each track is symmetrical across axis A.
Base 118 of each elongated fin component 114 can also define a
central longitudinal axis, which in FIG. 2 is the same as axis A.
Each fin component 114 is symmetrical across axis A. Similarly,
main section 113 of each elongated panel 108 can similarly define a
central longitudinal axis B, and each panel 108 can be symmetrical
across the axis B. Symmetrical parts facilitate interchangeability
and simplicity in orienting the various components during assembly.
However, those skilled in the art will readily appreciate that
while tracks 102, panels 108, and fin components 114 are
symmetrical, the symmetry is optional and any of these components
can be asymmetrical without departing from the spirit and scope of
the invention.
[0045] Referring now to FIG. 3, several panels 108 can be
interlocked with each pair of parallel tracks 102 to form a
substantially planar surface with main sections 113 of panels 108.
Fin 120 extends essentially perpendicularly away from track 102 and
protrudes beyond the substantially planar surface of main panel
sections 113. When several parallel tracks 102 have panels 108 and
fin components 114 interlocked therewith, tiling patterns can be
formed. FIG. 4 shows an exemplary tiling pattern on an exterior
wall of a building including windows 117. The pattern in FIG. 4
includes panels 108 joined end to end in the vertical direction and
interlocked with tracks 102 (not shown in FIG. 4) and fin
components 114 in the horizontal direction. Proximate columns of
panels 108 are staggered so that end joints 126 thereof are located
vertically at about the center of the length of proximate panels
108. However, those skilled in the art will readily appreciate that
system 100 can be oriented with the lengths of tracks 102, panels
108, and fin components 114 running in the horizontal direction
rather than the vertical, or on any other suitable angle. While end
joints 126 are shown as being substantially perpendicular to tracks
102, it is also contemplated that end joints 126 can be oriented at
any suitable angle with respect to tracks 102. Moreover, any
staggering pattern can be used, including patterns where panels 108
are of different lengths from one another to provide a random
staggering appearance, without departing from the spirit and scope
of the invention. It is advantageous for tracks 102 to run the
entire length of system 100 to provide a continuous anchor for
panels 108 to underlying structure 122.
[0046] Each end joint 126 between panels 108 provides for panels
108 to be physically interlocked together and anchored to the
underlying structure 122. As shown in FIG. 5, system 100 includes a
plurality of end mounting components 128, each of which is
configured and adapted to be affixed to underlying structure 122
between two parallel tracks 102 (not shown in FIG. 5) and to
interlock with adjacent ends of a pair of panels 108 that are
adjacent lengthwise to one another and are interlocked with the
same two parallel tracks 102. Each panel 108 includes a first end
130 curved under portion of the panel and a second end 132 opposite
first end 130 and curved over a portion of panel 108. Thus, first
end 130 of a first panel 108 and second end 132 of an adjacent
panel 108 can interlock together, as shown in FIG. 5, to form joint
126. End mounting component 128 is also interlocked with first and
second ends 130/132 to affix panels 108 to underlying structure
122.
[0047] Second end 132 of each panel 108 is set inward from main
portion 113 of panel 108 so that when interlocked end to end, main
sections 113 of interlocked panels 108 are substantially coplanar
with one another. This gives panels 108 a substantially sigmoid or
S-shaped cross section in the longitudinal direction. It is also
possible to have first end 130 protrude outward from main section
113 in lieu of or in addition to second end 132 being set inward.
Moreover, those skilled in the art will readily appreciate that
setting second end 132 inward is optional, since panels 108 can be
configured to ramp or protrude slightly out of the plane of tracks
102 at their first or second end 130/132. These configurations are
advantageous especially if panels 108 are oriented as shown in FIG.
5 with first ends 130 downward and second ends 132 upward, since
precipitation and condensation water tend to be shed over joint 126
without entering system 100 or reaching underlying structure
122.
[0048] It is envisioned that the components of system 100 can be
manufactured in various shapes, sizes, and configurations
individually, can be provided as a prefabricated kit, can be custom
formed on or off a building sight, or can be provided in any other
suitable way. Nails, screws, bolts, staples, rivets, and/or any
other suitable means can be used as fasteners to affix tracks 102
and end mounting components 128 to an underlying structure. Bores
can be pre-formed through tracks 102 for accommodating fasteners to
affix tracks 102 to an underlying structure. It is also possible to
form bores in tracks 102, such as by drilling, prior to applying
fasteners to tracks 102. The bores can be reinforced, for example
with threaded reinforcement means configured to engage bolts or
screws, if bolts or screws are used as fasteners. If tracks 102 are
of a material and thickness that can be easily punctured by
fasteners such as nails, bores through the tracks can be
omitted.
[0049] A method is provided in accordance with the present
invention for cladding roofs and facades of buildings. The method
includes providing a plurality of elongated tracks (e.g. tracks
102). The method further includes affixing the tracks to a building
in a spaced, parallel relationship to each other. As discussed
above, any suitable means can be used for affixing the tracks to
the underlying structure. A step is included for providing a
plurality of elongated panels (e.g. panels 108). With the tracks in
place, the panels can be interlocked to the tracks. It is possible
to deform the panels and/or tracks slightly to interlock the
panels. It is also possible to interlock an end of a panel with
ends of two adjacent, parallel tracks and slide the panel along the
tracks into place. An end mounting component (e.g. component 128)
can be provided between each endwise adjacent pair of panels, as
described above, and the panels can be interlocked therewith to
provide further anchoring to the underlying structure in addition
to the anchoring provided by the tracks.
[0050] The method also includes providing a plurality of elongated
fin components (e.g. fin components 114). The lengthwise edges of
proximate panels can be interlocked between the base of a fin
component and the lengthwise edges of each track to provide a
cladding over a portion of a building. As with the panels, the fin
components can be snapped into place by slightly deforming the fin
components and/or tracks, or the fin components can be slid down
their respective tracks from an end thereof. It is also possible to
interlock the fin component with the track prior to interlocking
the panels. Interlocking fin component 114 before or after
interlocking panels 108 can be made easier by squeezing fin 120 to
make it easier to slide fin component 114 along track 102. With the
components of system 100 interlocked in place, there can be some
play into and out of the plane of panels 108 for the components
interlocked in tracks 102. This play is desirable for ease of
installation and appearance, however, the play is optional since
system 100 can also be made without play.
[0051] System 100 has been described above in general for covering
flat portions of buildings or other static structures. It is also
contemplated that system 100 can be configured to clad portions of
buildings that are non-flat, such as curved or angled surfaces.
Additionally, system 100 can include components for treating inward
corners, outward corners, door/window jambs, and other portions of
buildings as needed. The following descriptions for special
conditions are exemplary, and those skilled in the art will readily
appreciate that system 100 can include other treatments as needed
without departing from the sprit and scope of the invention.
[0052] With reference now to FIG. 6, for cladding roofs and facades
at inside or inward corners, system 100 can include an elongated
L-shaped track 134 having opposed lengthwise edges 136 and 136'
curved inwardly over portions 138 and 138' of track 134. Portions
138 and 138' of track 134 comprise two lengthwise portions at a
substantially right angle .alpha. to one another with lengthwise
edges 136 and 136' of track 134 inside angle .alpha.. While the
inward corner shown in FIG. 6 is a substantially right angle, those
skilled in the art will readily appreciate that corners at any
other angle can be treated in a similar fashion with the two
lengthwise portions of track 134 angled to match.
[0053] A pair of elongated panels 108 can each be interlocked with
one of lengthwise edges 136 and 136' of track 134, much as
described above with respect to track 102. A pair of elongated
mounting components or cleats 140 are provided for affixing track
134 to underlying structure 122. Each cleat or mounting component
140 has a first lengthwise portion 142 and second lengthwise
portion 144, giving cleat 140 a generally S- or Z-shaped
cross-section as shown in FIG. 6. First lengthwise portion 142 is
configured and adapted to be affixed to the underlying structure
122, by any suitable fasting means as described above. Second
lengthwise portion 144 of cleat 140 is configured and adapted to be
interlocked between a lengthwise edge 136/136' of track 134 and one
of the panels 108. Cleats 140 do not need to run the entire length
of track 134, but can rather be spaced intermittently along the
length of track 134. To construct the corner treatment shown in
FIG. 6, track 134 can be affixed using cleats 140 with appropriate
fasteners, and then panels 108 can be interlocked at an end of
track 134 and then slid along track 134 into place. The ends of
panels 108 can be interlocked with a lap joint 126, as described
above. It may also be possible to snap panels 108 into place
without sliding them along track 134, depending on the dimensions
of the various components and the flexibility of the materials
used.
[0054] Referring now to FIG. 7, for cladding roofs and facades at
an outside or outward corners, system 100 can include an elongated
track 146 having opposed lengthwise edges 148 and 148' curved
inwardly over portions 150 and 150' of track 146. Portions 150 and
150' of track 146 have two lengthwise sections at a substantially
right angle .beta. to one another with lengthwise edges 148 and
148' of track 146 outside of angle .beta.. As with the treatment of
FIG. 6, while the outward corner shown in FIG. 7 is a substantially
right angle, those skilled in the art will readily appreciate that
corners at any other angle can be treated in a similar fashion with
the two lengthwise sections of track 146 angled to match.
[0055] A pair of elongated panels 108 can each be interlocked with
respective lengthwise edges 148 and 148' of track 146, much as
described above with respect to track 102. A pair of elongated
mounting components or cleats 152 are provided for affixing track
146 to underlying structure 122. Each cleat or mounting component
152 has a first lengthwise portion 154 and second lengthwise
portion 156. First lengthwise portion 154 is configured and adapted
to be affixed to underlying structure 122, by any suitable fasting
means as described above. Second lengthwise portion 156 of cleat
152 is configured and adapted to be interlocked between a
lengthwise edge 148 or 148' of track 146 and one of the panels 108.
A portion of cleat 152 can optionally wrap around edge 148 or 148'
of track 146 to be between track 146 and a lengthwise edge 110 of
panel 108, as shown in FIG. 7. Panels 108 have a special edge
configuration that is slightly wider than the normal panels 108 to
accommodate cleats 152. However, it is also possible to use the
same panels 108 used generally with system 100. To construct the
corner treatment shown in FIG. 7, the same techniques described
above with respect to the inner corner treatment shown in FIG. 6
can be used.
[0056] As shown in FIG. 8, system 100 includes a treatment for
jambs of windows, doors, or any other jamb treatment. An elongated
end closure component 158 is provided having opposed lengthwise
edges 160 and 160' at a substantially right angle to one another.
As described above, any suitable angle can be accommodated, with
edges 160 and 160' angled to match. End component 158 is affixed
between a jamb 162 and underlying structure 122. An elongated panel
108 can be interlocked with the lengthwise edge 110 thereof
proximate the exterior edge 160 of end component 158. An elongated
cleat or mounting component 140, such as those described above with
respect to FIG. 6, can be affixed to underlying structure 122 with
its second lengthwise portion 144 interlocked with lengthwise edge
110 of panel 108 so that lengthwise edge 110 of panel 108 is
located between the exterior portion of end closure component 158
and the second lengthwise portion 144 of cleat 140. End closure
piece 158 can run the entire length of the jamb. The treatment
shown in FIG. 8 can be constructed by affixing cleat 140 to
underlying structure 122, sliding or snapping panel 108 into cleat
140, affixing end component 158 around the jamb corner to be
interlocked between panel 108 and underlying structure 122, and
then assembling the jamb.
[0057] While FIGS. 5-8 have shown exemplary treatments for lap
joints, corners, and jamb conditions, those skilled in the art will
readily appreciate that the treatments described above are optional
and any suitable treatments can be used in conjunction with system
100 without departing from the spirit and scope of the invention.
Moreover, the variations of the components of system 100 are also
possible. FIG. 9 shows one such example, in which panels 108 are
interlocked with a track having width X wide enough to accommodate
a fin component 214 that is relatively wide compared to fin 120
described above. Fin 220 of fin component 214 has a cross-sectional
profile that is generally semi-circular. Similarly, FIG. 10 shows
another example in which a fin component 314 having a fin 320 with
a generally rectangular cross-sectional profile is accommodated by
track 202.
[0058] Further examples include fin component 414 having fin 420
with a generally T-shaped cross-section, as shown in FIG. 11, and
component 514 having a fin 520 with an elongate rectangular
cross-section shown in FIG. 12 having a tip that is flat as opposed
to pointed. FIG. 13 shows a fin component 614 having a fin 620 with
a generally square cross-sectional profile, and a track 602
accommodating two tandem fasteners 624. FIG. 14 shows an example in
which a fin component 714 has a fin 720 with a generally
paddle-shaped cross sectional profile. Those skilled in the art
will readily appreciate that the fin components, tracks, panels,
and other components of system 100 can have any suitable shapes,
profiles, proportions, and sizes without departing from the spirit
and scope of the invention.
[0059] The methods and systems of the present invention, as
described above and shown in the drawings, provide for cladding of
interior and exterior surfaces of buildings and other static
structures with superior properties including improved ease of
assembly while being structurally and architecturally sound.
Moreover, the systems described above are modular and have
assembly/installation that can go together rapidly, while providing
flexibility for variations in shape and proportion to give
different appearances as appropriate. While the apparatus and
methods of subject invention have been shown and described with
reference to preferred embodiments, those skilled in the art will
readily appreciate that changes and/or modifications may be made
thereto without departing from the spirit and scope of the subject
invention.
* * * * *