The present disclosure relates to building elements suitable for use in construction. In particular the disclosure relates to cladding elements suitable for use in a building envelope.
The embodiments have been developed primarily for use as cladding elements and will be described hereinafter with reference to this application. However, it will be appreciated that the embodiments are not limited to this particular field of use and that the embodiments can be used in any suitable field of use known to the person skilled in the art.
Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.
Wood cladding elements are sometimes used to protect and/or improve the aesthetic qualities of walls and other structures. However, wood can be difficult and expensive to install and can have limited durability.
It is an object of the present disclosure to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.
In one embodiment, a cladding system comprising a plurality of cladding elements is described. The system comprises first and second cladding elements, each of the first and second cladding elements having: a front face; a rear face opposite the front face; a first mating edge between the front face and the rear face, a second mating edge between the front face and the rear face opposite the first mating edge; a first joint end between the front face and the rear face; and a second joint end between the front face and the rear face, opposite the first joint end. The first mating edge comprises: a first recessed portion having a front-facing surface set rearward from the front surface of the cladding element; a first chamfer portion extending from the rear face of the cladding element toward the front face of the cladding element and away from a second mating edge of the cladding element; a first concave arcuate planar surface extending from the front face of the cladding element toward the first recessed portion and away from the second mating edge; and a first abutment face connecting the front-facing surface of the first recessed portion with the first concave arcuate planar surface. The second mating edge comprises: a second recessed portion having a rear-facing surface set forward from the rear face of the cladding element; a second chamfer portion extending in a direction from the rear face of the cladding element toward the front face of the cladding element and toward the first mating edge; a second concave arcuate planar surface extending from the front face of the cladding element toward the recessed portion and away from the first mating edge; and a second abutment face connecting the rear-facing surface of the recessed portion with the concave arcuate planar surface. The first mating edge of the first cladding element is mated with the second mating edge of the second cladding element. At least a portion of the first chamfer portion of the first cladding element contacts at least a portion of the second chamfer portion of the second cladding element. The first concave arcuate planar surface of the first cladding element is positioned adjacent the second concave arcuate planar surface of the second cladding element to form an arcuate v-groove profile.
In some embodiments, the first concave arcuate planar surface intersects the front face at a first angle t1 relative to the front face, and intersects the first abutment face at a second angle smaller than t1 relative to a plane parallel to the front face. In some embodiments, the first angle t1 is between approximately 32° and approximately 47.5°. In some embodiments, the first angle t1 is between approximately 40° and approximately 47.5°. In some embodiments, the first concave arcuate planar surface has a radius of curvature between approximately 67.61 mm and approximately 13.84 mm. In some embodiments, the first concave arcuate planar surface has a radius of curvature between approximately 26.30 mm and approximately 13.84 mm. In some embodiments, the first concave arcuate planar surface and the second concave arcuate planar surface intersect the front face at approximately the same tangential angle. In some embodiments, the first concave arcuate planar surface and the second concave arcuate planar surface have approximately the same radius of curvature. In some embodiments, the first and second cladding elements have a thickness of between approximately 11 mm and approximately 17 mm. In some embodiments, the arcuate v-groove profile extends along an entire length of each of the first and second cladding elements with no visibly perceptible variations in a width of the v-groove profile. In some embodiments, the first and second cladding elements comprise fibre cement.
In another embodiment, a cladding element comprises: a front face; a rear face opposite the front face; a first mating edge between the front face and the rear face; a second mating edge between the front face and the rear face, opposite the first mating edge; a first joint end between the front face and the rear face; and a second joint end between the front face and the rear face, opposite the first joint end. The first mating edge comprises: a first recessed portion having a front-facing surface set rearward from the front surface of the cladding element; a first chamfer portion extending from the rear face of the cladding element toward the front face of the cladding element and away from a second mating edge of the cladding element; a first concave arcuate planar surface extending from the front face of the cladding element toward the first recessed portion and away from the second mating edge; and a first abutment face connecting the front-facing surface of the first recessed portion with the first concave arcuate planar surface. The second mating edge comprises: a second recessed portion having a rear-facing surface set forward from the rear face of the cladding element; a second chamfer portion extending in a direction from the rear face of the cladding element toward the front face of the cladding element and toward the first mating edge; a second concave arcuate planar surface extending from the front face of the cladding element toward the recessed portion and away from the first mating edge; and a second abutment face connecting the rear-facing surface of the recessed portion with the concave arcuate planar surface.
In some embodiments, the first concave arcuate planar surface intersects the front face at a first angle t1 relative to the front face, and intersects the first abutment face at a second angle smaller than t1 relative to a plane parallel to the front face. In some embodiments, the first angle t1 is between approximately 32° and approximately 47.5°. In some embodiments, the first angle t1 is between approximately 40° and approximately 47.5°. In some embodiments, the first concave arcuate planar surface has a radius of curvature between approximately 67.61 mm and approximately 13.84 mm. In some embodiments, the first concave arcuate planar surface has a radius of curvature between approximately 26.30 mm and approximately 13.84 mm. In some embodiments, the first concave arcuate planar surface and the second concave arcuate planar surface intersect the front face at approximately the same tangential angle. In some embodiments, the first concave arcuate planar surface and the second concave arcuate planar surface have approximately the same radius of curvature. In some embodiments, the first and second cladding elements comprise fibre cement.
In a further embodiment, a cladding system comprises a plurality of cladding elements is described. The system comprises: a first cladding element having a front face and a first mating edge comprising a first concave arcuate planar surface intersecting the front face of the first cladding element along a first edge of the front face of the first cladding element; and a second cladding element having a front face and a second mating edge comprising a second concave arcuate planar surface intersecting the front face of the second cladding element along a second edge of the front face of the second cladding element. The first concave arcuate planar surface and the second concave arcuate planar surface together form an arcuate v-groove extending along a length of the first and second cladding elements between the front face of the first cladding element and the front face of the second cladding element.
In some embodiments, the first concave arcuate planar surface intersects the front face of the first cladding element at a first angle t1 relative to the front face of the first cladding element, and the second concave arcuate planar surface intersects the front face of the second cladding element at the first angle t1. In some embodiments, the first angle t1 is between approximately 32° and approximately 47.5°. In some embodiments, the first angle t1 is between approximately 40° and approximately 47.5°. In some embodiments, the first concave arcuate planar surface has a radius of curvature between approximately 67.61 mm and approximately 13.84 mm. In some embodiments, the first concave arcuate planar surface has a radius of curvature between approximately 26.30 mm and approximately 13.84 mm. In some embodiments, the first and second cladding elements have a thickness of between approximately 11 mm and approximately 17 mm. In some embodiments, the arcuate v-groove extends along the entire length of each of the first and second cladding elements with no visibly perceptible variations in a width of the v-groove. In some embodiments, the first and second cladding elements comprise fibre cement. In some embodiments, the first and second cladding elements have a thickness between approximately 11 mm and approximately 16 mm.
The embodiments will now be described more particularly with reference to the accompanying drawings, which show by way of example only cladding elements of the disclosure.
Although making and using various embodiments are discussed in detail below, it should be appreciated that the embodiments described provide inventive concepts that may be embodied in a variety of contexts. The embodiments discussed herein are merely illustrative of ways to make and use the disclosed devices, systems and methods and do not limit the scope of the disclosure.
In the description which follows like parts may be marked throughout the specification and drawing with the same reference numerals, respectively. The drawing figures are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat generalized or schematic form in the interest of clarity and conciseness.
Generally described, the present disclosure provides for relatively thin cladding elements that provide a desirable aesthetic appearance and retain suitable wind load resistance characteristics. In one example, cladding elements having a v-groove design include one or more chamfered or beveled edges along a front face. When the cladding elements are made relatively thin, a relatively shallow chamfer angle may be needed to retain sufficient strength and/or wind load characteristics. However, the shallow chamfer angle may result in undesirably large variation in the apparent width of the v-groove formed by adjacent cladding elements, caused by relatively minor variations in the thickness of the cladding elements. In some embodiments of the present technology, an arcuate surface is provided rather than a straight chamfer angle. The arcuate surface may be described by at least a tangential angle formed at the interface between the arcuate surface and the front face of the cladding element, and a radius of curvature of the arcuate surface. As will be described in greater detail, the arcuate surfaces described herein may improve the aesthetic appearance of the cladding elements by retaining the full v-groove thickness of straight chamfered cladding elements, while increasing the tangential angle between the chamfer and the front face of the cladding element, thus reducing the apparent variation in v-groove thickness to a visually imperceptible level.
There are a number of different methods used to install cladding elements in series on a building substrate, each method dependent on the type of cladding material used, the wind load requirements and the desired aesthetic effect.
There are also a number of options for aesthetics at the interface between two adjacent cladding elements in a series. The interface between two adjacent cladding elements are commonly profiled to have either a ‘v’ groove channel, a square channel or a rabbet profile. The rabbet profile was developed by the wood industry and is more commonly referred to as ship-lap. The rabbet profile appears as a step shaped recess or rebate between the two adjacent cladding elements.
There are substantially two main methods used when installing plank cladding elements namely lap side cladding or flat wall cladding.
Lap side cladding is used to describe cladding elements that are installed on a structural support such that there is an overlap between consecutive cladding elements, whereby the primary visible external surfaces of consecutive cladding elements are parallel but not coplanar.
In contrast, flat wall cladding is used to describe cladding elements that are installed on a structural support such that there is no overlap between consecutive cladding elements, whereby the primary visible external surfaces of consecutive cladding elements are parallel and coplanar.
There are a number of different installation methods used to achieve a flat wall cladding aesthetic, for example, stacking rabbet/ship-lap, tongue and groove, and clip. In each of the stacking rabbet/ship-lap and tongue and groove installation methods, the cladding elements are profiled such that the bottom edge of a first cladding element is able to overlap the top edge of a second cladding element when the second cladding element is positioned below the first cladding element whilst ensuring that the primary visible external surfaces of consecutive first and second cladding elements are parallel and coplanar. The thickness and configuration of the cladding elements enable a cladding system using said cladding elements and standard nailing methods to achieve a desired wind load requirement.
The clip installation method can take a number of forms but is characterized by a common or specialized fastener (clip) that engages the cladding elements positioned both above and below the fastener. The primary benefits of using a specialized fastener/clip to secure consecutive cladding elements is that clip can spread fastening load over a greater area than for example a traditional nail fastener. Typically, fibre cement cladding elements used in the clip installation method are approximately 12 mm thick. A clip installation method enables an installer to clad a building wall or other structure with thinner cladding elements and achieve a flat wall aesthetic that has similar and possibly better wind load performance over cladding elements installed without the specialized fastener.
A thinner board is typically lighter than an equivalent 16 mm board. Accordingly it is easier for an end user to handle this board. It is therefore desirable to provide a fibre cement cladding element that is as thin as or thinner than fibre cement cladding elements typically used in clip installation methods, that can be installed in a cladding system without a clip or specialized fastener whilst achieving the same or better wind loading.
Cladding elements can be assembled to produce cladding systems (e.g., wall portions). These cladding systems can be installed on an exterior or interior surface of a wall to provide aesthetic improvement, improved weather resistance, improved thermal efficiency, improved structural stability, and/or many other improvements to an existing wall. For example, the cladding systems disclosed herein can be installed on substructure such as a wooden frame or any other suitable wall structure which could be an interior or exterior wall structure.
The cladding element 1000 includes a first profiled edge 1004 extending between the front and rear faces 1001, 1002. The cladding element 1000 can include a second profiled edge 1005 extending between the front and rear faces 1001, 1002 on a side of the element 1000 opposite the first profiled edge 1004. The first profiled edge 1004 of a first element 1000A (
The first profiled edge (e.g., mating edge) 1004 of the cladding element 1000 can include a recessed portion 1007. The recessed portion 1007 can include a front face 1019 substantially parallel to and positioned rearward of the front face 1001 of the cladding element 1000. The first profiled edge 1004 can include a first angled portion 1008 extending from the front face 1001 of the cladding element 1000 toward the rear face 1002 of the element 1000 away from the second profiled edge 1005 of the element 1000. The first profiled edge 1004 can include a second angled portion 1012 extending from the rear face 1002 of the element 1000 toward the front face 1001 of the element 1000 and away from the second profiled edge 1005 of the element 1000.
The second profiled edge 1005 of the cladding element 1000 can include a first angled portion 1018 extending away from the front face 1001 of the element 1000 toward the rear face 1002 and away from the first profiled edge 1004 of the cladding element 1000. The second profiled edge 1005 of the cladding element 1000 can include a recessed portion 1010. The recessed portion 1010 can include a rear face 1023 substantially parallel to and positioned forward of the rear face 1002 of the cladding element 1000. The portion of the second profiled edge 1005 between the recess 1010 and the front surface 1001 of the cladding element 1000 can include an overlap portion 1009. The second profiled edge 1005 can include second angled portion 1003 having a sloped surface 1011 extending in a direction from the rear surface 1002 toward the front face 1001 and toward the first profiled edge 1004 of the cladding element 1000.
In some embodiments, the recessed portion 1007 of the includes an offset portion 1017 between the angled portion 1008 and the front face 1019 of the recessed portion 1007, as measured substantially perpendicular to the first face 1001 of the cladding element 1000. The overlap portion 1009 can include an abutment face 1021 between the angled portion 1018 and a rear face 1023 of the overlap portion 1009 as measured substantially perpendicular to the second face 1002 (e.g., the rear face) of the cladding element 1000.
As illustrated in the cladding system of
The overall shape of the groove 1020 can be altered through adjustment of certain parameters. For example, the angles (31, (32 of the angled portions 1008, 1018 as measured from the first surface 1001 (e.g. the front face) can be varied. In some instances, the angle β1 of angled portion 1008 is the same as the angle β2 of angled portion 1018. In some cases, the angle β1 of angled portion 1008 is greater than or less than the angle β2 of angled portion 1018. Increasing the value of one or more of the angles β1, β2 while maintaining the depth D of the groove 1020 can decrease the width W of the groove 1020. Many variations are possible.
As illustrated in
In some cases, a gap G can remain between the rear face 1023 of the overlap portion 1009 of a first cladding element 1000a and the front face 1019 of the recessed portion 1007 of a second cladding element 1000b when the first and second cladding elements 1000a, 1000b are connected to each other. The gap G can be between 0.01 inches and 0.1 inches when measured perpendicular to the first face 1001 of first cladding element 1000a. In some embodiments, the gap G is approximately 0.06 inches measured substantially perpendicular to the first face 1001 of the first cladding element 1000a. Many variations are possible. A second gap G2 in the cladding system can be formed between the abutment face 1021 of the second cladding element 1000b and the tip of the first profiled edge 1004 of the first cladding element 1000a. The second gap G2 can be connected to and/or continuous with the gap G.
The gaps G and/or G2 can be sized and/or shaped to accommodate adhesives, sealants, insulators, and/or other materials. For example, an adhesive material can be applied to the front face 1019 of the recessed portion of the first cladding element 1000B and/or to the rear face 1023 of the overlap portion 1009 of the second cladding element 1000A before the first and second cladding elements 1000A, 1000B are mated together. Positioning materials in the gap G between the front face 1019 of the recessed portion of the first cladding element 1000B and the rear face 1023 of the overlap portion 1009 of the second cladding element 1000A can increase the weather resistance of the assembled cladding elements 1000A, 1000B by reducing the likelihood that moisture (e.g., rain, condensation, etc.) will pass between the groove 1020 and the second surfaces 1002 of the cladding elements 1000A, 1000B. In some cases, sealant or other materials can be inserted into the second gap G2 without insertion of sealant into the other gap G.
In some embodiments, the interface between the first profiled side edge 1004 of the first cladding element 1000A and the second profiled side edge 1005 of the second cladding element 1000B can provide a tortuous (e.g., tedious, serpentine, labyrinthine) path through which moisture would be required to travel to reach the second surface 1002 of the cladding elements 1000A, 1000B from the groove 1020. For example, the interface can include a plurality of turns (e.g., 3 turns, 4 turns, 5 turns, etc.) through which the moisture would be required to pass. In some cases, the tortuous interface between the two cladding elements 1000A, 1000B would force the moisture to switch direction one or more time (e.g., vertically and/or laterally) when traveling from the groove 1020 to the second surfaces 1002.
In some embodiments, the interface between the first profiled side edge 1004 of the first cladding element 1000a constructed from fibre cement and the second profiled side edge 1005 of the second cladding element 1000b constructed from fibre cement can have significantly reduced water leakage (e.g., water through a thickness of the assembled elements 1000a, 1000b) as compared to two cladding elements constructed from wood. Such water-resisting characteristics are immediately apparent when conducting an ASTM E 331 test. The ASTM E 331 test comprises constructing a cladding element system (e.g., a cladding element wall) comprised of multiple mated cladding elements. In the present case, a 4′ by 8′ cladding system control specimen consisting of V-Groove wood elements was constructed, as was a 4′ by 8′ cladding system test specimen consisting of V-Groove fibre cement elements (e.g., elements 1000, described above). The respective walls were subject to incrementally-increased water pressure until leakage was detected on a back side of the wall. Water was applied for 5 minutes at each pressure increment. When water was detected on the back side of the wall, the pressure was maintained for 5 minutes and the leaked water was collected for measurement. When subject to the ASTM E 331 test, the fibre cement elements resisted water penetration for water pressures up to at least 225 psi, whereas wood elements having substantially the same geometric shapes as the elements 1000a, 1000b, permitted water penetration at 0 psi. In some cases, the water penetration through the fibre cement elements was less at 325 psi than the water penetration through the wood elements at 150 psi. Results of the test are reflected in
As illustrated in
In some embodiments, the use of cladding elements 1000 to cover a wall (e.g., to assembly a cladding system) can reduce the overall installation time of the cladding elements 1000 (e.g., as compared to the time required to install traditional wood cladding elements). For example, an installer may use a level or other tool to confirm the alignment of the first-installed cladding element 1000 (e.g., the bottom cladding element) when installing the cladding elements 1000. Subsequent cladding elements 1000 can be installed without the use of an alignment tool, as the mating of profiled edges 1004, 1005 of adjacent cladding elements align the subsequent cladding elements 1000 with the first-installed cladding element 1000. The self-alignment of the subsequent cladding elements 1000 can reduce the overall installation time of the cladding elements 1000 by 10-20%. In some cases, the self-alignment of the cladding elements 1000 can increase installation efficiency by over 25%. For example, on average, the self-alignment of the cladding elements 1000 can reduce the installation time to under two minutes. In some cases, the average installation time per cladding element can be approximately 100 seconds.
The shiplap-type labyrinthine connection between the first and second profiled edges 1004, 1005 of the cladding elements 1000 can facilitate either vertical installation (e.g., the length of each cladding element 1000 extends vertically) or horizontal installation (e.g., the length of each cladding element 1000 extends horizontally) of the cladding elements 1000 onto the wall of a structure. For example, as explained above, the labyrinthine connection between the first and second profiled edges 1004, 1005 can reduce the likelihood that moisture would pass from the grooves 1020 to the rear faces 1002 of the cladding elements 1000.
In some embodiments, the shiplap-type labyrinthine connection between the first and second profiled edges 1004, 1005 of the cladding elements 1000 in a cladding system can increase the overall wind resistance of the installed cladding elements. For example, the labyrinthine engagement between the cladding elements 1000 can reduce the amount of wind access between the cladding elements 1000 and the wall or other structure onto which the cladding elements 1000 are installed. In some cases, the labyrinthine engagement between the cladding elements 1000 can increase the wind resistance of the installed cladding elements by over 100% as compared to the wind resistance of plank cladding elements. In some cases, the cladding elements 1000 can withstand wind-induced loads of over 85 pounds per square foot. Reduction of wind access to a rear side of the cladding elements 1000 can reduce pressure build up between the cladding elements 1000 in a cladding system and the wall onto which they are installed.
Use of cladding elements 1000 can have a significant impact on the durability of a wall (e.g., cladding system). Such impact has been proven via testing of impact resistance on a test cladding system specimen 6′ by 8′ wall comprising fibre cement cladding elements 1000. The control cladding system specimen for the test was a 6′ by 8′ wall of fibre cement planks. Both the test specimen and the control specimen were subject to impacts of incrementally-increasing energy. The test results indicate that walls (e.g., cladding systems) constructed from cladding elements 1000 having the shiplap-type labyrinthine connections can realize an increased impact resistance of over 20% as compared to plank walls. In some cases, the cladding elements 1000 are capable of withstanding over 130 Joules of energy before cracking, as compared to 97 Joules for a plank wall. In some embodiments, the cladding elements 1000 are capable of withstanding over 160 Joules of energy before splitting, as compared to 130 Joules for a plank wall. In some cases, the shiplap-type labyrinthine connection of the cladding elements 1000 (e.g., the overlap realized in the labyrinthine connections) can facilitate energy distribution among adjacent cladding elements in a more efficient manner than is the case with plank walls. The use of joints to connect adjacent cladding elements, as described below, can further increase energy distribution and/or impact resistance of the cladding elements. Results of the testing are shown in
In some embodiments, a cladding element 1070 can include one or more channel features 1081 in the first surface 1071 of the cladding element 1070. The channel features 1081 can have the same shape (e.g., V groove, cove, wide cove, square channel, etc.) as the shapes of the grooves formed between mated cladding elements.
Cladding elements may be installed in cladding systems in conjunction with flashing strips, caulk, and/or other weatherproofing materials to reduce moisture transfer to the structure on which the cladding elements are installed. In some cases, it may be advantageous to provide weatherproofing structure on the cladding elements themselves to reduce or eliminate the need for additional weatherproofing materials and/or waterproofing installation steps. For example, the cladding elements may include one or more joint features configured to facilitate drainage of moisture from the assembled/installed cladding elements away from the structure on which the cladding elements are installed. The joint features can be configured to facilitate moisture drainage from the cladding elements as the cladding elements shrink and/or expand after installation (e.g., due to temperature change, evaporation, chemical processes, etc.). In some embodiments, the joint features create a tortuous and/or labyrinthine passage between a front side of the cladding elements and a back side of the elements, thereby reducing the amount of moisture passage between the front side of the cladding elements and the back side of the cladding elements when the cladding elements are installed on a wall or other structure. In some cases, cladding elements which include joint features are capable of being installed both vertically (e.g., having joint features on top and bottom sides of the cladding elements) and horizontally (e.g., having joint features on lateral sides of the cladding elements), depending on the application. Examples of such joint features are described below.
As illustrated in
The cladding element 2000 can include a first mating edge 2006. As illustrated, the cladding element 2000 can include a second mating edge 2008 distanced from and/or positioned opposite the first mating edge 2006. The first and second mating edges 2006, 2008 can be sized and/or shaped to couple with the first or second mating edges of an adjacent cladding element. In some embodiments, the cladding element 2000 is generally planar and has a generally rectangular shape bound on two opposite sides by the first and second joint edges 2002, 2004 and on the other opposite sides by the first and second mating edges 2006, 2008. As illustrated in
As illustrated in
In some embodiments, as illustrated in
As illustrated in
The use of joint edges (e.g., non-flat and perpendicular edges) to mate the ends of the cladding elements in a cladding system can increase the cladding system's resistance to moisture passage through the assembled cladding elements. For example, the joint edges 2043, 2045 of the cladding elements 2040 of
In some embodiments, cladding elements are advantageously arranged in a cladding system wherein a plurality of elements (e.g., any of the elements described above) are arranged such that the profiled edges of two elements are mated with each other. Additional elements can be arranged in connection with the two elements such that the joint edges of the adjacent elements in the cladding system are mated to each other. The cladding elements can be arranged in a number of different patterns, including, but not limited to, patterns in which the mating interfaces between the joint edges of pairs of elements align with each other in a direction parallel to the joint edges. In some cases, mating interfaces between joint edges of cladding elements in a respective row are offset in a direction perpendicular to the mating interfaces between the joint edges of cladding elements in adjacent rows (e.g., or columns in scenarios where the cladding elements are arranged vertically). For example, the cladding elements in a cladding system can be arranged in a stretcher bond pattern. Overlap between the respective mating interfaces (e.g., joint mating interfaces and profiled edge mating interfaces) of the adjacent cladding elements in the cladding systems can improve the overall characteristics of the system. These improved characteristics include, but are not limited to, wind resistance, water resistance, debris resistance, and/or impact resistance. For example, the interfaces between the profiled edges and the joint ends of the respective cladding elements can facilitate improved performance of the cladding system in both the vertical and horizontal directions (e.g., load and impact energy transfer between elements in both directions). Further, as discussed above, the mating interfaces between the cladding elements can increase the efficiency of constructing the cladding systems, as the interfaces can provide confirmation of alignment between the adjacent cladding elements.
Referring now to
In the embodiment shown in
Turning now to describe the contours of each of first and second contoured side sections 3006, 3008 of
First and second contoured side sections 3006, 3008 each comprise a beveled sloping surface 3010, 3012 extending in opposing directions from first surface 3002. A first abutment surface 3014 extends from beveled sloping surface 3010 whereby first abutment surface 3014 extends substantially perpendicular to both the first surface 3002 and second surface 3004.
A second abutment surface 3016 extends from beveled sloping surface 3012 whereby second abutment surface 3016 extends substantially perpendicular to both the first surface 3002 and second surface 3004.
First and second substantially planar surfaces 3020 and 3022 extend substantially orthogonally from first and second abutment surfaces 3014 and 3016 respectively whereby the first and second substantially planar surfaces 3020 and 3022 are substantially parallel with first and second surface 3002 and 3004 respectively.
A portion of first surface 3002, beveled sloping surface 3012, second abutment surface 3016 extending from beveled sloping surface 3012 and second substantially planar surface 3022 together form second flange portion 3034 whereby second substantially planar surface 3022 forms the base surface remote from the first surface 3002 of flange portion 3034.
First substantially planar surface 3020 terminates at junction 3024 from which first angled surface 3028 extends to meet second surface 3004. First substantially planar surface 3020, junction 3024, first angled surface 3028 and a portion of second surface 3004 together form first flange portion 3032. First substantially planar surface 3020 forms the nailing surface of flange portion 3032. Flange portion 3032 is recessed with respect to first surface 3002 defining a recessed portion 3036 between the first substantially planar surface 3020 and first surface 3002.
Second contoured side section 3008 further comprises an offset section 3026 which extends substantially orthogonally from second substantially planar surface 3022 thereby forming an open area or second recessed portion 3038 between the second substantially planar surface 3022 and the second surface 3004. A second angled surface 3030 extends from the offset section 3026 to meet the second surface 3004. The area between the second surface 3004 and second angled surface 3030 is referred to as the retention portion 3035.
The first and second contoured sections 3006, 3008 are configured such that when two cladding elements 3000 are seated together the second flange portion 3034 of second contoured section 3008 seats over the first flange portion 3032 of first contoured section 3006 whereby first flange portion 3032 is positioned within the second recessed portion 3038 and the second flange portion 3034 is positioned within the first recessed portion 3036. In such an arrangement, retention portion 3035 of second contoured side section 3008, specifically second angled surface 3030 of retention portion 3035 abuts first angled surface 3028 of first contoured side section 3006. In addition, first abutment surface 3014 of first contoured side section 3006 abuts second abutment surface 3016 of second contoured side section 3008 such that first and second beveled sloping surfaces 3010, 3012 form a v-groove profile 3013 at the interface between the two cladding elements 3000 as shown in
Cladding element 3000 may be installed in the form of a cladding system on a building (e.g. an interior or exterior wall), as illustrated in
In practice, a first cladding element 3000A is installed on substructure 3040 by inserting one or more fasteners 3042 through the first substantially planar surface 3020 of first contoured side section 3006. A second cladding element 3000B is then installed over the first cladding element 3000A whereby the second contoured side section 3008 interlocks with the first contoured side section 3006. One advantage of the cladding elements 3000 when assembling a cladding system such as that shown in
As shown in
The fasteners 3042 are hidden from view within the gap G by the second flange portion 3034 of the second cladding element 3000B when second cladding element 3000B interlocks with the first cladding element 3000A. Utilizing such a fastening process (e.g., “blind” nailing) can improve the aesthetics of an assembled cladding system comprising cladding elements 3000. In some cases, blind nailing can increase the durability of the assembled cladding elements 3000 by, for example, reducing exposure of the fasteners and their respective holes to moisture and other outside elements. In some applications, blind nailing can reduce the costs of installing the cladding elements 3000 on a wall by reducing the number of fasteners required to install the cladding elements 3000 and thereby reducing the amount of time required to install the cladding elements 3000. In addition, the geometry of the cladding element 3000 enables an end user to construct a cladding system 5000 as shown in
The gaps G and/or G2 can be sized and/or shaped to accommodate adhesives, sealants, insulators, and/or other materials.
Positioning materials in the gap G between first substantially planar surface 3020 of first contoured side section 3006 and second substantially planar surface 3022 of second contoured side section 3008 can increase the weather resistance of the assembled cladding elements 3000 by reducing the likelihood that moisture (e.g., rain, condensation, etc.) will enter pass between adjacent cladding elements 3000. In some embodiments, sealant or other materials can also be inserted into the second gap G2 in addition to or instead of sealant or other materials into gap G.
The configuration of the first and second contoured side sections 3006, 3008 provide an interlocking mechanism for the cladding elements 3000 of the cladding system 4000, 5000 that increases wind load performance particularly in the instance when thickness T is between approximately 11 mm±0.5 mm and approximately 13 mm±0.5 mm and more particularly at approximately 12 mm±0.5 mm.
A plurality of cladding elements 3000 wherein thickness T was approximately 12 mm±0.5 mm were arranged to form a cladding system which was tested for wind loading capabilities using a standard test method for structural performance of exterior cladding. The frame spacing used was 23″-⅝″ using a 4D ring shank fastener. The average wind load achieved for cladding elements 3000 was 83.75 psf.
Referring now specifically to
In a similar way, the angle at the junction between the end of the beveled sloping surface 3010 opposite the first surface 3002 and first abutment surface 3014, angle t2 is between approximately 122° and approximately 131°±1°. In a further embodiment, angle t2 is approximately 122°±1°.
Turning now to
Turning now to
Table 1, below, summarizes the selection of radius of curvature r, corresponding distances L1 and tangential angle t1 by which the beveled sloping surface 3010 can be adjusted through the introduction of a concave beveled surface 3011 as shown in
It was determined that by increasing the radius of curvature of the concave beveled surface 3011, it is possible to remove the visual variation whilst retaining a ‘v-groove’ aesthetic at the interface between two adjacent cladding elements 3000. However, if the radius of curvature is increased too much, then the ‘v-groove’ aesthetic at the interface between two adjacent cladding elements 3000 becomes an arc-like aesthetic which is less desirable. Accordingly, in one embodiment, it is preferable to adjust the beveled sloping surface 3010 by a distance L1 to achieve a preferred tangential angle t1. In one embodiment, the distance L1 is between 0.27 and 0.51 mm and the preferred tangential angle t1 is between approximately 40° and approximately 47.5°±1°.
In one preferred embodiment, cladding element 3000 is a fibre cement cladding element, comprising a hydraulic binder such as Portland cement, a silica source and fibres including cellulose fibres. It should be understood that other suitable materials known to a person skilled in the art, can also be included in the formulation. In one embodiment, the fibre cement cladding element is a medium density cladding element. In an alternative embodiment, the fibre cement cladding element is a low density cladding element.
In one embodiment, cladding element 3000 is provided with a either a smooth or a textured surface such as a wood effect texture or a render effect texture. Other suitable textures can also be provided as desired by an end-user, for example, brick or stone effect textures. For example, in some instances the first surface 3002 is provided with a smooth or textured surface. In other examples, both the first surface 3002 and the second surface 3004 are provided with a smooth or textured surface.
Cladding elements may be installed in cladding systems in conjunction with flashing strips, caulk, and/or other weatherproofing materials to reduce moisture transfer to the structure on which the cladding elements are installed. In some cases, it may be advantageous to provide weatherproofing structure on the cladding elements themselves to reduce or eliminate the need for additional weatherproofing materials and/or waterproofing installation steps. For example, the cladding elements may include one or more joint features configured to facilitate drainage of moisture from the assembled/installed cladding elements away from the structure on which the cladding elements are installed. The joint features can be configured to facilitate moisture drainage from the cladding elements as the cladding elements shrink and/or expand after installation (e.g., due to temperature change, evaporation, chemical processes, etc.). In some embodiments, the joint features create a tortuous and/or labyrinthine passage between a front side of the cladding elements and a back side of the elements, thereby reducing the amount of moisture passage between the front side of the cladding elements and the back side of the cladding elements when the cladding elements are installed on a wall or other structure. In some cases, cladding elements which include joint features are capable of being installed both vertically (e.g., having joint features on top and bottom sides of the cladding elements) and horizontally (e.g., having joint features on lateral sides of the cladding elements), depending on the application. Examples of such joint features are described below.
In further embodiments, the two further opposing side sections, not shown in the drawings which are located substantially perpendicularly to contoured side sections 3006, 3008 can also include features to enhance coupling with adjacent cladding elements located substantially perpendicular to contoured side sections 3006, 3008. Such features could include for example one or more of corresponding angled side surface or tongue and groove joints or stepped joints. In addition sealing elements such as for example caulk or other sealing materials can also be used to reduce moisture passage through the cladding system.
Although the embodiments has been described with reference to specific examples, it will be appreciated by those skilled in the art that the disclosure may be embodied in many other forms.
It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the disclosure. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed embodiment. Thus, it is intended that the scope of the present disclosure herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.
Similarly, this method of disclosure, is not to be interpreted as reflecting an intention that any claim require more features than are expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment.
This application is a continuation-in-part of U.S. patent application Ser. No. 15/686,037, filed Aug. 24, 2017 and entitled CLADDING ELEMENT, which is a continuation of U.S. patent application Ser. No. 14/838,217, filed Aug. 27, 2015 and entitled CLADDING ELEMENT, which claims the benefit of U.S. Provisional Patent Application No. 62/042,758, filed Aug. 27, 2014 and entitled CLADDING ELEMENT. This application is also a continuation-in-part of U.S. patent application Ser. No. 15/686,043, filed Aug. 24, 2017 and entitled CLADDING ELEMENT, which is a divisional of U.S. patent application Ser. No. 14/838,217, filed Aug. 27, 2015 and entitled CLADDING ELEMENT, which claims the benefit of U.S. Provisional Patent Application No. 62/042,758, filed Aug. 27, 2014 and entitled CLADDING ELEMENT. Each of the above-referenced patent applications are hereby incorporated by reference in their entirety and for all purposes.
Number | Date | Country | |
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62042758 | Aug 2014 | US | |
62042758 | Aug 2014 | US |
Number | Date | Country | |
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Parent | 14838217 | Aug 2015 | US |
Child | 15686043 | US |
Number | Date | Country | |
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Parent | 14838217 | Aug 2015 | US |
Child | 15686037 | US |
Number | Date | Country | |
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Parent | 15686037 | Aug 2017 | US |
Child | 16457249 | US | |
Parent | 15686043 | Aug 2017 | US |
Child | 14838217 | US |