Patent Grant
10267045
The present invention relates to metal panel sidings and methods and tools for installing metal panel sidings.
A variety of metal sidings are used in the construction industry to provide the outermost barrier to wind and water on a building's exterior walls. Metal sidings can provide excellent weather resistance and durability and may have a service life of up to 40 years. One common type of metal siding utilizes rather elongated metal panels fabricated from sheet metal, so-called single skin panels. Each panel is typically about a foot to three feet in width. Though they may be cut to any length, they commonly are 30 to 40 feet long and may run as long as 200 feet. The lateral edges of the panels are bent into various lateral patterns to provide side laps. The laps of adjacent panels are overlapped, abutted, interlocked, or in some other fashion connected or “seamed” to form a cover.
Metal panel sidings will incorporate various flashings, trim pieces, sealants, and other components where the field of a wall terminates, such as at the top and bottom of a wall, interior and exterior corners, and around doors and windows. Even where a building has many intersecting walls, doors, windows, and the like, however, the basic assembly of metal panel sidings over the major expanse of walls is fairly uniform. The panels will be mounted on the wall by various clips and fasteners and their laps will be seamed. They perhaps are most commonly installed vertically, that is with the length of the panel running vertically across the wall. The panels, however, may be installed horizontally, that is, with the length of the panel running horizontally across the wall.
Siding systems incorporating single skin panels are commonly classified according to the manner in which they are installed on a wall. In an “exposed fastener” system, panels are configured so that the laps of adjacent panels will overlap. Fasteners, such as gasketed screws, are driven through the overlap and elsewhere on the panels to mount them to the wall. As their name implies, the fasteners are visible to the eye and exposed to the elements. Penetration of water around the fasteners can be a problem, particularly as the siding ages.
“Concealed fastener” systems may incorporate panels which have various prominent rib profiles. That is, the panel is bent along various lateral lines to create ribs running along the length of the panel. The ribs create space underneath the panels which provides clearance for a fastener driven through the overlap between adjacent panels. The panels will overlie the fasteners when the cover is complete, and thus water penetration around the fasteners is less likely.
Other panels are designed to be installed with concealed clips. In a typical concealed clip system, relatively small panel clips are installed on the wall in linear arrays. The arrays may run horizontally across the face of the wall or vertically, but in either event, they define what will become the seam line between adjacent panels. Panels then are installed and seamed on the clips. There are no penetrations through the panels when clips are used. Thus, concealed clip system may be less susceptible to water penetration.
One common type of concealed clip panel is provided with a “hook and cleat” interlock, such as the Wave Panel siding system manufactured by McElroy Metal Mill, Inc. In the Wave Panel system, the lap on one side of a panel is bent over laterally to form a hook running along the length of the panel. The other lap is closely doubled over to form a relatively narrow channel also running the length of the panel. The clips have a similar closely doubled over portion which may be mated with the channel on the panels. An array of clips is engaged with a first panel along its lap channel and mounted to the wall with fasteners. The clips and channel lap on the first panel, thus secured, provide a “cleat” into which the “hook” on the lap of a second panel may be inserted.
It will be appreciated that metal panels are exposed to a range of temperatures, particularly in certain geographic areas. Surface temperature of the panels may be 100° F. higher than ambient air temperature. A steel panel, for example, may expand and contract over a range of 1″ per 100 linear feet. An aluminum panel may expand and contract even more, perhaps over a range of 2″ per 100 linear feet. Panel temperatures will cycle daily and yearly, and over the life of the siding the panels may go through tens of thousands of cycles.
Neither exposed nor concealed fasteners, however, may adequately allow for thermal expansion of the panels. The panels cannot shift relative to the fasteners so changes in temperature can create uneven stress through the panels. Given the extremely high ratio of their length and width to their thickness, differential stress arising from other factors almost always is present in metal panels. Thermal expansion and contraction, however, can exacerbate such stresses and increase waviness and wrinkling of the panels. Such effects are commonly referred to as “oil canning” and reduce, in the eyes of many, the aesthetic appeal of a siding.
Oil canning may be made less conspicuous, and to a certain degree minimized by the design and finish of the panel. Panel ribs not only allow for more even, controlled distribution of stress, but they also break up the surface of the siding, making canning less obvious. Canning also is most apparent when viewed through reflected light. Thus, canning will be less visible when panels are made in lighter colors, or when panels have lower gloss or textured surfaces. Many exposed and concealed fasteners systems rely on such strategies to minimize noticeable canning.
On the other hand, canning is much more apparent in flat, unprofiled panels, or in panels where there are relatively few, more widely spaced ribs. Perhaps because highly profiled panels are so ubiquitous, there is an aesthetic appeal to cleaner, more flush siding finishes. Flatter, less profiled panels also may allow insulation to be installed under the panel without appreciably increasing the overall thickness of the siding. They also may provide an essentially continuous drain plane behind the panel.
Concealed clip fasteners typically will allow for thermal expansion and thereby reduce canning. Hook and cleat style laps and clips, however, cannot be used to provide sidings with a flush finish, that is, a siding where panels are arranged side to side with snug, even seams and “show” sides. Accordingly, manufacturers have developed concealed clip systems where a vertical seam is provided between flush, flat panels. The seams are referred to as “vertical” seams because they extend away from the wall. It will be noted too that “vertical” seams may run horizontally or vertically across the wall depending on the orientation of the panels.
The PermWall system manufactured by Imetco is an example of a “snap-in” system which joins flat panels at vertical seams. One lap of the panel, together with the clip, serves as a “socket.” The other lap serves as a “post” which may be snapped into the socket. Viewing the panel as oriented for installation, the socket lap of the panels is bent inward and then doubled over. It forms a relatively wide channel extending perpendicularly inward from the panel show side. The post lap extends perpendicularly inward as well, but it is bent into an outwardly facing barb. The clip is essentially a hook on a right-angle bracket. That is, the clip has a flat base with a perpendicular outward extension. The end of the outward extension is provided with an inward facing hook.
A seam may be formed between adjacent panels by first hooking an array of clips over the upper portion of the channel on the socket lap of a first panel. The clip hook extends only partially into the channel. The clips then are mounted to the wall by driving fasteners through their base. The post lap of a second panel then may be snapped into the socket lap of the first panel. That is, the post lap will flex allowing it pass over and beyond the clip hook. Once the second panel is snapped into place, interference between the outward barb on the post lap and the inward facing hook on the clips prevents the seam from disassembling. The panels, however, can “float” on the clips as they expand and contract.
Such panels, like the typical concealed fastener panels, are asymmetrical. That is, the panels do not have a lateral axis of symmetry. More to the point, the laps on asymmetrical panels are different, and typically may be thought of as mating male-female connections. Each panel has a male connection formed in one lap and a female connection formed in its other lap. Thus, installation must proceed in a certain direction across the wall, and removal for repair must proceed in the opposite direction. A damaged interior panel may only be accessed by removing the last panel installed and all other panels “down installation” from the damaged panel. More importantly, the process of removing the down installation panels is highly likely to damage the panels to the extent that they are not suitable for reinstallation.
Moreover, the process of forming asymmetrical panels may increase the susceptibility of the panel to canning. That it, their sides being different, each lap is bent in different ways and to different extents than the lap on the other side of the panel. The stress produced by such forming, like the panels themselves, is asymmetrical. It is not symmetrically distributed through the panel. As the panel attempts to relieve that differential stress, it is more likely to bend and twist.
The PermWall system also cannot easily accommodate panels of differing heights. That is, many architects and property owners may want to create a siding which in large part is flush and smooth. At the same time, by varying the extent to which the show side of panels extend from a wall, i.e., the height of the panels, patterns may be created to accent or enhance architectural features of the structure.
The statements in this section are intended to provide background information related to the invention disclosed and claimed herein. Such information may or may not constitute prior art. It will be appreciated from the foregoing, however, that there remains a need for new and improved systems, apparatus and methods for installing metal panel sidings. Such disadvantages and others inherent in the prior art are addressed by various aspects and embodiments of the subject invention.
The subject invention, in its various aspects and embodiments, is directed generally to metal panel siding systems. As will be appreciated from the full disclosure, various embodiments provide features which provide resistance to thermally induced oil canning. Other embodiments provide features which allow sidings to be more easily and economically repaired or which allow disengagement of panels without damage. Yet other embodiments provide tools which may be used to install novel sidings.
One broad embodiment of the subject invention provides for a metal panel siding system installed on a structure such as a building. The siding system comprises a plurality of panel clips and cover attached to the panel clips. The panel clips are mounted in linear arrays to a wall of the structure. The cover comprises a plurality of elongated metal panels having lateral side laps and a show side extending between the side laps. The side laps extend inward from the show side. The panel clips comprise a first catch engaging one of the side laps of a first one of the panels and a second catch engaging one of the side laps of a second, adjacent one of the panels. Thus, the side laps provide vertical seams between the adjacent panels.
The first catch of the panel clips is mounted to the wall. The second catch is coupled to the first catch for movement relative to the first catch. The second catch also is moveable during installation of the panels from an unset position to a set position. The second catch does not engage the side lap of the second panel in its unset position. The second catch engages the side lap of the second panel in its set position.
Various other aspects and embodiments provide such systems having reveal panels. The panel clips mentioned above may be referred to as standard panel clips and are used with a reveal panel clip. A plurality of reveal panel clips is mounted in linear arrays to a wall of the structure. The metal panels mentioned above may be referred to as standard or flush panels and together with the reveal panels, they provide a cover. The reveal panels have lateral side laps and a show side extending between the side laps. The side laps extend inward from the show side and support the show side of the reveal panel away from the wall at an elevation different from an elevation of the flush panels. The reveal panel is joined along its side laps to one of the side laps of a first one of the flush panels and to one of the side laps of a second one of the flush panels. Thus, first and second vertical seams join the reveal panel and the first and second flush panels.
The reveal panel clips have a catch. They are arrayed along the first seam such that the catch of the reveal panel clips engages the side lap of the first flush panel. The standard panel clips are arrayed along the second seam such that the second catch of the standard panel clips engages the side lap of the second flush panel.
Additional embodiments provide such siding systems where the side laps of the flush panels comprise a leg portion extending inward from the show side of the panels and a foot portion extending from the leg under the show side. The side laps of the reveal panels comprise a leg portion extending inward from the show side of the panels and a foot portion extending from the leg away from the show side. The foot on the side laps of the flush panels is a fold, and the foot on the side laps of the reveal panel is inserted into the fold.
Other aspects provide such siding systems where the first catch and the second catch are adapted to engage the panel side laps such that the clips do not restrict movement of the panels along the linear clip arrays.
Another aspect provides such siding systems where the second catch is coupled to the first catch for movement between the unset position and the set position.
Especially preferred embodiments include siding systems where the first catch has guides adapted to receive the second catch such that the second catch can slide from the unset position to the set position.
Yet another aspect provides siding systems where the second catch may be releasably locked in the unset position or the set position. Other aspects provide systems where the first catch and the second catch are provided with mating nubs adapted for releasable engagement to releasably lock the second catch in the unset or the set position.
Still other aspects provide siding systems wherein the standard panel clips comprise a vertical fence restricting lateral movement of the side laps of the panels and, especially on the second catch.
Additional embodiments provide siding systems where the standard clip comprises a stop limiting movement of the second catch past the set position, such as a tab on the second catch which is adapted to engage a track on the first catch.
Various aspects will provide systems where the panel clips are arranged in linear arrays running horizontally or vertically across the wall or where the panel clips are mounted to framing members of the wall or to other portions of the wall.
Other aspects provide siding systems where the side laps of the flush panels comprise a leg portion extending inward from the show side of the panel and a foot portion extending from the leg generally parallel to and under the show side. Another aspect provides siding system where the panels are symmetrical.
Yet other embodiments provide such siding systems which comprise a plurality of straps. The straps engage the side laps of one of the panels and extend therebetween to provide lateral flex in the panel. In other aspects, the system comprises a plurality of straps which have a hook at each end of the strap. The hooks are adapted to engage foot portions of the side laps of one of the panels and extend therebetween to provide lateral flex in the panel.
Still other broad embodiments provide methods of installing a wall cover for a structure such as a building. The method comprises installing a plurality of panel clips on a wall of the structure. The panel clips being installed in linear arrays running across the wall and have a mountable catch and a settable catch. The settable catch is moveable relative to the mountable catch. Metal panels are attached to the panel clips to form at least a portion of the wall cover. The panels having an inwardly extending side lap. The panel clips are installed, and the panels are attached to the panel clips by engaging one of the side laps of a first one of the panels with the mountable catches of one or more of the panel clips. The mountable catches are installed on the wall. One of the side laps of a second one of the panels is placed adjacent the side lap of the first panel. The settable catch of the panel clip then is moved into engagement with the side lap of the second panel. Other embodiments of the method comprise installing straps on the side laps of panels to provide lateral flex in the panels.
Various other broad aspects of the invention provide metal panel siding systems installed on a structure. The siding system comprise a plurality of elongated panel clips mounted to a wall of the structure. A cover is attached to the panel clips. The cover comprises a plurality of elongated metal panels having lateral side laps and a show side extending between the side laps. The side laps of the panels comprise a leg portion extending inward from the show side of the panel and a foot portion extending from the leg under the show side. The panels are joined along their side laps to provide vertical seams. The panel clips comprise a pair of deflectable catches. The catches are deflectable to accommodate the insertion of the feet on abutting legs of adjacent the panels into the deflectable catches and thereafter to engage the feet.
Other embodiments provide such siding systems where the deflectable catches comprise a riser extending upward from a base and a face extending downward and inward from the riser or where the clips extend continuously and are mounted across at least two frame members extending generally perpendicularly to the continuous clips.
Still other embodiments provide such siding systems which comprise a plurality of straps. The straps engage the side laps of one of the panels and extend therebetween to provide lateral flex in the panel.
Various other aspects and embodiments provide such systems having reveal panels. The panel clips mentioned above may be referred to as standard panel clips and used with a reveal panel clip. A plurality of reveal panel clips is mounted in linear arrays to a wall of the structure. The metal panels mentioned above may be referred to as standard or flush panels and together with the reveal panels, they provide a cover. The reveal panels have lateral side laps and a show side extending between the side laps. The side laps extend inward from the show side and support the show side of the reveal panel away from the wall at an elevation different from an elevation of the flush panels. The reveal panel is joined along its side laps to one of the side laps of a first one of the flush panels and to one of the side laps of a second one of the flush panels. Thus, first and second vertical seams join the reveal panel and the first and second flush panels.
The reveal panel clips comprise a pair of deflectable catches. The catches of the first panel clips are deflectable so as to accommodate the insertion of one of the side laps of the reveal panel and one of the side laps of a first one of the flush panels as well as the other side lap of the reveal panel and one of the side laps of a second one of the flush panels. Once inserted therein, the reveal panel catches engage the flush panel side laps and reveal panel side laps.
Other embodiments provide such systems where the side laps of the reveal panel comprise a leg portion extending inward from the show side of the panel and a foot portion extending from the leg away from the show side. The foot on the side laps of the flush panels is a fold and the foot on the side laps of the reveal panel is inserted into the fold.
Yet other aspects provide such systems where the deflectable catches of the reveal panel clips have a riser extending upward from a base and a face extending downward and inward from the riser. Additional embodiments provide such systems where the clips extend continuously and are mounted across at least two frame members extending generally perpendicularly to the continuous clips.
Various aspects will provide systems where the panel clips are arranged in linear arrays running horizontally or vertically across the wall or where the panel clips are mounted to framing members of the wall or to other portions of the wall.
Other aspects provide siding systems where the side laps of the flush panels comprise a leg portion extending inward from the show side of the panel and a foot portion extending from the leg generally parallel to and under the show side. Another aspect provides siding system where the panels are symmetrical.
Additional aspects are directed to methods of installing such siding systems.
Yet other broad embodiments provide metal panel siding systems installed on a structure. The siding systems comprise a plurality of panel clips mounted in linear arrays to a wall of the structure. A cover is attached to the panel clips. The cover comprises a plurality of elongated metal panels having lateral side laps and a show side extending between the side laps. The side laps extend inward from the show side. The panel clips comprise first and second catches. The first catch of a first panel clip engages a first side lap of a first panel and the second catch of the first panel clip engages a second side lap of the first panel. The first catch of a second panel clip engages a first side lap of a second panel and the second catch of the second panel clip engages a second side lap of the second panel. The second panel clip is mounted relative to the first panel clip such that the first side lap of the second panel abuts the second side lap of the first panel to provide a vertical seam between the first and second panels.
Other embodiments provide such siding systems where the panel clips comprise a fence. The fence has a first portion restricting lateral movement of the side laps of the panels and a second portion restricting vertical movement of a second panel clip engaging the panel clip.
Various aspects will provide systems where the panel clips are arranged in linear arrays running horizontally or vertically across the wall or where the panel clips are mounted to framing members of the wall or to other portions of the wall.
Other aspects provide siding systems where the side laps of the flush panels comprise a leg portion extending inward from the show side of the panel and a foot portion extending from the leg generally parallel to and under the show side. Another aspect provides siding system where the panels are symmetrical.
Yet other embodiments provide such siding systems which comprise a plurality of straps. The straps engage the side laps of one of the panels and extend therebetween to provide lateral flex in the panel. In other aspects, the system comprises a plurality of straps which have a hook at each end of the strap. The hooks are adapted to engage foot portions of the side laps of one of the panels and extend therebetween to provide lateral flex in the panel.
Other related broad embodiments provide methods of installing a wall cover for a structure. The method comprises installing a plurality of panel clips on a wall of the structure. The panel clips are installed in linear arrays running across the wall and have first and second catches. Elongated panels are attached to the panel clips to form at least a portion of the wall cover. The panels have an inwardly extending side lap. The panel clips are installed, and the panels are attached to the panel clips by engaging a first side lap of a first panel with the first catch of a first panel clip. The first panel clips are installed on the wall. The second catch of the first panel clip is engaged with a second side lap of the first panel. A second panel then is positioned such that a first side lap of the second panel abuts the second side lap of the first panel. The first lap of the second panel then is engaged by a first catch of a second panel clip. The second panel clip then is installed on the wall.
Other broad embodiments provide such methods where a plurality of straps is installed on the side laps of the panels. The straps provide lateral flex in the panels. Yet other embodiments provide such methods where straps have a hook at each end of the strap. The straps are installed by engaging the hooks with foot portions of the side laps on one of the panels. They extend across the side laps and provide lateral flex in the panels.
Various other broad embodiments provide metal panel siding systems which incorporate flush and reveal metal panels. The siding system also includes a plurality of elongated panel clips mounted to a wall of the structure. A cover is attached to the panel clips. The comprises elongated metal flush panels and at least one elongated metal reveal panel. The flush and reveal panels have lateral side laps and a show side extending between the side laps. The side laps of the flush panels comprise a leg portion extending inward from the show side of the panel and a foot portion extending from the leg under the show side. The side laps of the reveal panel comprise a leg portion extending inward from the show side of the panel and a foot portion extending from the leg away from the show side. The side laps support the show sides of the flush and reveal panels at different elevations away from the wall. The reveal panels are joined along their side laps to one of the side laps of a first one of the flush panels and to one of the side laps of a second one of the flush panels. Thus, first and second vertical seams are formed and join the reveal panel and the first and second flush panels. The panel clips comprise a pair of deflectable catches. The catches are deflectable so as to accommodate the insertion of a foot on one of the side laps of the reveal panel and a foot of one of the side laps of an adjacent flush panel into the deflectable catches and thereafter to engage the reveal panel and flush panel feet.
Other embodiments provide such siding systems which comprise a plurality of straps. The straps engage the side laps of one of the panels and extend therebetween to provide lateral flex in the panel. In other aspects, the system comprises a plurality of straps which have a hook at each end of the strap. The hooks are adapted to engage foot portions of the side laps of one of the panels and extend therebetween to provide lateral flex in the panel.
Preferred aspects of such systems include systems where the on the side laps of the flush panels is a fold and the foot on the side laps of the reveal panel may be inserted into the fold for insertion of the feet into the deflectable catches or where the deflectable catches comprise a riser extending upward from a base and a face extending downward and inward from the riser.
Other aspects of the invention include methods for installing such siding systems.
Various other broad aspects and embodiments include siding systems having a a cover comprising a plurality of elongated metal flush panels and at least one elongated metal reveal panel. The reveal panel is mounted to a wall of the structure. The flush and reveal panels have lateral side laps and a show side extending between the side laps. The side laps of the flush panels comprise a leg portion extending inward from the show side of the panel and a foot portion extending from the leg under the show side. The side laps of the reveal panel comprise a leg portion extending inward from the show side of the panel, a foot portion extending from the leg away from the show side, and a deflectable catch extending from the foot. The side laps support the show sides of the flush and reveal panels away from the wall at different elevations. The reveal panel is joined along its side laps to a side lap of a first flush panel and to a side lap of a second flush panel, thereby providing first and second vertical seams joining the reveal panel and the first and second flush panels. The catches are deflectable so as to accommodate the insertion of a foot on a side lap of an adjacent flush panel into the deflectable catches and thereafter to engage the reveal panel foot.
Other aspects of the invention include methods for installing such siding systems.
In other broad aspects and embodiments, the invention provides panel clips. The panel clips comprise a first catch engaging a side lap of a first panel and a second catch engaging a side lap of a second, adjacent panel. Thus, the panel clips facilitate joining of the side laps to provide vertical seams between the adjacent panels.
The first catch of the panel clips is mounted to the wall. The second catch is coupled to the first catch for movement relative to the first catch. The second catch also is moveable during installation of the panels from an unset position to a set position. The second catch does not engage the side lap of the second panel in its unset position, and engages the side lap of the second panel in its set position.
Another aspect provides such panel clips where the second catch is coupled to the first catch for movement between the unset position and the set position.
Especially preferred embodiments include such panel clips where the first catch has guides adapted to receive the second catch such that the second catch can slide from the unset position to the set position.
Yet another aspect provides such panel clips where the second catch may be releasably locked in the unset position or the set position. Other aspects provide panel clips where the first catch and the second catch are provided with mating nubs adapted for releasable engagement to releasably lock the second catch in the unset or the set position.
Still other aspects provide such panel clips wherein the standard panel clips comprise a vertical fence restricting lateral movement of the side laps of the panels and, especially on the second catch.
Additional embodiments provide such panel clips where the clip comprises a stop limiting movement of the second catch past the set position, such as a tab on the second catch adapted to engage a track on the first catch.
Still other broad embodiments provide tools for manipulating panel clips used in metal panel siding systems. The tool comprises a handle adapted for grasping and manipulation of the tool. A head is mounted at one end of the handle. The tool head adapted to engage a panel clip having a first component adapted for mounting to the structure and a second component carried on the first clip component for sliding movement relative to the first clip component. The tool head has a bearing surface adapted to bear on the second clip component and, thereby, to transmit force applied through the tool handle to the second clip component to push the second clip component in a first direction. The tool head also has a grabber adapted to engage the second clip component and, thereby, to transmit force applied through the tool handle to the second to pull the second clip component in a second, opposite direction. Preferred embodiments have a flat bearing surface.
The invention, in still other broad embodiments, also provides for metal panel siding systems installed on a structure such as a building. The systems comprise a cover installed on a wall of the structure and a plurality of straps. The cover comprises a plurality of elongated metal panels having lateral side laps and a show side extending between the side laps. The straps engage the side laps of the panels. They extend between the side laps to provide lateral flex in the panels.
Other such embodiments provide systems where the side laps of adjacent panels are engaged to provide vertical seams between the adjacent panels. Still other such embodiments provide systems where the panels are asymmetrical panels and the straps engage a side lap of a first panel and a side lap of a second panel. Yet other such embodiments provide systems where the panels are symmetrical panels and the straps engage the side laps of the same panel.
Finally, still other aspect and embodiments of the invention will have various combinations of such features as will be apparent to workers in the art.
Thus, the present invention in its various aspects and embodiments comprises a combination of features and characteristics that are directed to overcoming various shortcomings of the prior art. The various features and characteristics described above, as well as other features and characteristics, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments and by reference to the appended drawings.
Since the description and drawings that follow are directed to particular embodiments, however, they shall not be understood as limiting the scope of the invention. They are included to provide a better understanding of the invention and the manner in which it may be practiced. The subject invention encompasses other embodiments consistent with the claims set forth herein.
In the drawings and description that follows, like parts are identified by the same reference numerals. It also will be apparent from the discussion that follows that certain conventions have been adopted to facilitate the description of the novel systems which typically include large numbers of identical components. For example, as discussed below, various embodiments include a plurality of panels 20. Specific individual panels 20 may be identified in the drawings, or referenced in the discussion as 20a, 20b, 20c, etc. to distinguish a particular panel 20 from another panel 20. The drawing figures are not necessarily to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form and some details of conventional design and construction may not be shown in the interest of clarity and conciseness.
The present invention generally relates to metal panel sidings for the walls of buildings and other structures. Specific embodiments will be described below. For the sake of conciseness, however, all features of an actual implementation may not be described or illustrated. In developing any actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve a developer's specific goals. Decisions usually will be made consistent within system-related and business-related constraints. Specific goals may vary from one implementation to another. Development efforts might be complex and time consuming and may involve many aspects of design, fabrication, and manufacture. Nevertheless, it should be appreciated that such development projects would be routine effort for those of ordinary skill having the benefit of this disclosure.
Walls may have many different designs, but one common design incorporates a structural frame. The frame will incorporate vertical support members, such as columns and studs, and horizontal support members, such as girts. Barrier films and insulating panels may be installed on the frame. Similarly, the wall may incorporate sheathing, such as plywood or oriented strand board (OSB) sheets, or spaced boards (“nailers”). The sheathing provides additional structural support for the wall. A cover then is installed to provide the outermost barrier to wind, water, and the other elements.
The novel sidings provide wall covers which may be installed on many different walls in many different ways. The cover may be installed directly on framing or installed over sheathing. It may be anchored to frame members or to sheathing. The novel sidings may be used in new construction, and they may be installed over many types of existing wall covers. Moreover, the novel sidings may be installed on other types of walls, such as masonry walls.
Broader embodiments of the novel siding systems utilize panel clips where the clips are mounted in linear arrays along a wall. A plurality of metal panels is attached to the clips to form a cover. The panels have lateral side laps with a show side extending between the side laps. The side laps extend inward from the show side such that the side laps, once the panels are installed, provide vertical seams between the panels. The panel clips have a first catch and a second catch. The first catch is mounted to the wall and engages the side lap of a panel. The second catch is movably coupled to the second catch. During installation, it can move from an open or unset position to a closed or set position in which it engages the side lap of a second panel. Preferably, straps are installed to assist in minimizing oil canning through the panels.
For example, as shown in
Novel siding 10 generally comprises a plurality of metal wall panels 20, a plurality of panel clips 30, and preferably a plurality of panel straps 90. As best appreciated from
It also will be appreciated that panels 20 will be installed across frame 1 in a prescribed order. For example, as illustrated in
Panels 20 have side laps 23 which may be joined to form vertical seams 21. Side laps 23 are formed by bending the lateral edges of panels 20 into a desired configuration. For example, as best appreciated from
Transverse straps preferably are used in the novel siding systems to help further minimize oil canning or at least the visual perception of canning. For example, as shown in
The precise number and spacing of straps 90 required for a particular installation will vary. A typical installation may include straps 90 at spacings of approximately 5 feet. Greater or fewer straps 90, however, may be used. The spacing of straps may depend, for example, on the stiffness of panels 20, the degree of flex imparted by each strap 90, and the environmental conditions in which siding 10 is installed. It also will be appreciated that straps 90 may have various configurations which will allow them to be used with other types of panels. Likewise, while preferably incorporated therein, the novel siding systems do not necessarily require straps.
Panel clips are used to secure metal wall panels to a wall and to facilitate the formation of seams between the metal panels. Panel clips 30, for example, are used to secure metal panels 20 to studs 2 of frame 1 and to facilitate the formation of seams 21 between laterally adjacent panels 20 as seen best in
Greater or fewer clips 30 may be used in the arrays depending upon the conditions to which siding 1 will be exposed. Where wind uplift is of minimal concern, fewer clips 30 may be necessary. Clips 30 might be required, for example, only every other or every third stud 2. Thus, when studs 2 are relatively closely spaced, frame 1 may not necessarily incorporate girts 3. If studs 2 are widely spaced, or more clips 30 are otherwise required between studs 2, girts or other horizontal frame members may be incorporated into frame 1. Girts also will be necessary for most vertical installations as most studs or other vertical frame members might not be spaced the width of the panels.
In accordance with broad aspects of the invention, the clips have a first catch which is mounted to a wall and a second catch which is moveable from an unset position to a set position. Preferably, the second catch is moveable between its unset and set positions, i.e., back and forth. For example, as seen best in
Track 31 generally comprises a bottom plate or base 32 which has been shaped to provide a pair of guides 33 along its sides and a catch 34 at its forward end. Guides 33 may be provided, for example, by folded portions extending from base 32 which form a pair of relatively wide, relatively low clearance channels. Guides 33 extend along the substantial length of track 31. Catch 34 may be provided, for example, by an upward extension from base 32 which is doubled back to form a rearward-facing hook. Catch 34 extends across the substantial portion of the forward end of track 31. Preferably, as shown, track 31 also comprises a fence 35. Fence 35 may be provided, for example, by cutting out small portions of guides 33 and bending them upward to provide a pair of upstanding tabs.
Sled 41 generally comprises a bottom plate or base 42 which has been shaped to provide a catch 44 at its forward end and a grab 45 at its rearward end. Catch 44 is provided by an upward extension from base 42 which in turn is provided with a forward extension. Upward and forward extensions form a forward-extending, elevated tab. Grab 45 is provided by an upward extension which is doubled back to form a forward-facing hook.
Sled 41 is slidably carried on track 31. Lateral edges of sled 41 are inserted into guides 33 of track 31 such that sled 41 is carried therein and may slide between, i.e., back and forth between a rearward, open, unset position and a forward, closed, set position. As discussed in detail below, slidable sled 41 will allow a panel 20 to be engaged by and disengaged from clip 30.
One or more embossments, such as nubs 36, preferably are provided on base 32 of track 31. Nubs 36 provide a convex projection on the top surface of track base 32. Base 42 of sled 42 preferably is provided with two sets of embossments, such as nubs 46a and 46b. Nubs 46 provide concave recesses in the bottom surface of sled base 42. Nubs 36 and 46 are sized and configured such that they may be shifted into and out of mating engagement. Nubs 46a and 46b also are spaced from each other such that sled 41 may be selectively and releasably locked in its unset and set positions. That is, sled 41 may be releasably locked in its unset position by engaging nubs 46a on sled 41 with nubs 36 on track 31. Sled 41 may be releasably locked in its set position by engaging nubs 46b on sled 41 with nubs 36 on track 31.
It will be appreciated, however, that oversetting of clips 30 can induce stress in panels 20 and contribute to undesirable oil canning. Thus, clips 30 also preferably include a stop limiting the movement of sled 41 along track 31 beyond its set position. Sled 41, for example, comprises a stop 43. Stop 43 is provided by cutting out a small portion of sled base 42 and bending it upward to provide an upstanding tab. Stop 43 is adapted to engage one of guides 33 on track 31 to limit travel of sled 41 along track 31. More specifically, stop 43 will limit movement of catch 44 on sled 41 towards catch 34 on track 31, preventing catches 44 and 34 from creating excessive stress on panels 20. Other configurations, of course, may be used to provide interference between sled 41 and track 31 and minimize clip-induced canning.
Panel clips 30 are attached to studs 2 of frame 1 by fasteners, such as a pair of screws 70, extending through base 32 of track 31. A greater or lesser number of screws 70 or other fasteners may be used to mount panel clips 30 to studs 2. Typically, at least two fasteners will be used to resist torque about the connections and to provide greater stability for clips 30. Where wind uplift is of minimal concern, however, it may be possible to mount panel clips 30 with a single fastener. Conversely, additional screws 70 or other fasteners may be installed through track base 32 when more stability and strength is required in the connection between panel clips 30 and frame 1.
Preformed slotted apertures 37 preferably are provided in base 32 of track 31 to accommodate screws or other fasteners and to provide some flexibility in locating track 31. If desired, however, round fastener holes may be provided, or screws may be driven through base 32. The exact length of track 31 and base 32 thereof, as well as the placement, configuration, and number of apertures 37, preferably are coordinated to allow for some imprecision in placement of clips 30 during installation.
Siding 10 may be installed by installing a first panel 20a along the base of frame 1 as best appreciated from
Panel clips 30 will be used to attach, and facilitate and secure the formation of vertical seams 21 between base panel 20a and the rest of panels 20 installed. For example, and as shown in
Third, higher panel 20c then may be installed. Typically, straps 90c will be attached to panel 20c. The bottom side lap 23 of panel 20c then will be placed on guides 33 of track 31 between side lap 23 of second panel 20b and fence 35. Once panel 20c is thus positioned, sled 42 may be slid forward and releasably locked into its forward, closed, set position as shown in
Once third panel 20c has been installed on clips 30, its other side lap 23 will be installed on another array of clips 30c in the same manner as was side lap 23. Additional panels 20 then may be installed, continuing upward from panel 20c until frame 1 has been completely covered.
It will be appreciated that siding 10 has been exemplified in the context of a field portion of a wall. The field of a cover typically will constitute the clear majority of a siding installation and a major component of its cost. Walls, however, may incorporate many different architectural features and may have many different or intersecting fields. The novel siding systems may be adapted accordingly and will incorporate various components to complete certain portions of an installation either for functional purposes, such as weather sealing, or for aesthetic purposes.
For example, the walls of buildings almost always incorporate windows and often have doors or other openings. They may have bay windows or other projections as well. Special components may be required to install around openings or projections. The walls usually terminate at a base, a soffit, or an inside or outside corner. Special components also may be required for such features. Similarly, flashing, sealants, and finish components may be installed in around many wall features. A wide variety of such components and installation methods are known in the art and may be used in the novel siding systems. Many embodiments of the novel siding systems also may incorporate insulation, such as fiberglass bats or foam boards, without appreciably increasing the overall thickness of the siding. The panels in many installations are elevated well away from the wall surface or framing and provide adequate space for insulation.
The panels used in the novel recover metal roofs are the same type of single skin metal panels as are conventionally used in metal panel sidings and roofs. Thus, they may be fabricated from materials and by methods as are commonly employed in the art. Typically, such panels are fabricated from roll stock of painted or unpainted coated steel, such as Galvalume™ steel, zinc, copper, or aluminum. The roll stock is fed into a roll former which shapes the metal sheet into the desired configuration and cuts it to a desired length. Preformed panels may be used for a particular installation and cut as necessary, or a former may be mounted on a trailer or truck so that panels may be fabricated on a job site. It will be appreciated, however, that the panels may be made of other materials, such as rigid, moldable or extrudable plastic. The straps typically will be fabricated from the same materials and by the same methods as the panels.
It also will be appreciated that the novel metal panel sidings are exemplified as using symmetrical metal panels of a particular configuration. Other types of symmetrical panels may be used, however, as may be asymmetrical metal panels. A variety of conventional symmetrical and asymmetrical panels which form vertical seams are known and may be adapted for use in the subject invention. For example, 138T and 238T symmetrical metal panels sold by McElroy Metal may be used.
The clips used in the novel metal panel roof recovers preferably are made from steel, such as 16 to 24-gauge galvanized steel sheets that may be easily formed and bent and cut into a desired configuration by conventional metal forming equipment. Such materials provide a rugged, weather resistant clip that may be manufactured easily and economically. Other metals, such as extruded aluminum, may be used to fabricate the panel clips, however, as well as rigid, moldable or extrudable plastics.
The exact dimensions of novel panel clips and their various features are not especially critical and may be varied to provide as much or as little engagement with the panels as may be desired or necessary for a particular installation. The novel clips also may have various configurations including, but not limited to the specific preferred embodiments discussed herein. The size and configuration of the panel clips also will be coordinated with the choice of panels used in the novel siding systems.
Thus, it will be appreciated that the novel siding systems offer important advantages and benefits. Siding 1, for example, is resistant to thermally induced canning. That is, as appreciated from
At the same time, however, neither catch 34 on track 31 nor catch 44 on sled 41 restrict movement of panels 20 along the linear array of clips 30 to which they are engaged. Panels 20 are free to slide horizontally within and across clips 30 as they expand and contract due to changes in temperature. Panels 20 will remain securely engaged with clips 30, yet differential stress and canning that otherwise would arise if panels 20 were restricted from moving by clips 30 will be avoided.
As noted, straps 90 also help in reducing oil canning. By inducing uniform stress in panels 20, that is, a transverse bowing in panels 20, the tendency of the panel to warp irregularly is diminished. There will be tendency to relieve that stress created by straps 90 as panels 20 are subjected to thermal expansion and contraction.
It also will be appreciated that siding 10 may easily and economically repaired, especially as compared to conventional concealed fastener siding systems having a vertical seam between the panels. That is, panels 20 may be disengaged from clips 30 without damaging the panel. For example, installed upper panel 20c seen in
Other aspects of the subject invention provide tools which may be used to install the novel sidings. The novel tools provide a bearing surface by which moveable clip components may be pushed and a grabber by which they may be pulled. For example, tool 80, which is shown in
Head 81, as best seen in the exploded view of
Lip 84 is securely fastened to the end of base 83 with, for example, several set screws, thus providing head 81 with a bearing surface 85 and a grabber 86. That is, the front surface of head 81 is substantially flat and provides a bearing surface 85. By comparing, for example,
Lip 84 extends across and over the forward portion of body 83. As seen best in the cross-sectional view of
The head of the novel tools may be sized and configured in various ways consistent with its use in pushing and pulling sled 41. For example, grabber 86 of tool 80 may be rim or other simple downward extension from bearing surface 83. A rim or other forward extension may be provided on bearing surface 83 to help ensure that head 81 properly seats on grab 45 as tool 80 is used to push sled 41. Grab 45 and sled 41 in clips 30 also may be configured in various ways, and head 81 of tool 80 modified accordingly.
Likewise, the novel tools may be fabricated and assembled in various ways. The three-piece design of tool 80 allows it to be easily manufactured and assembled from durable materials such as steel. Head 81 or the entire tool 80, however, may be formed integrally. For example, tool 80 may be formed from molded rubber with or without a reinforcing core. Suitable cores may be fabricated from, e.g., metal or fiberglass, and may be simple rods or may have a shape generally conforming to the shape of the tool head and handle.
A second preferred embodiment 110 of the novel siding systems is shown in
As best seen in
Clips 130 will be installed across girts 3 in frame 1. Panels 20 then may be installed, as shown in
Because arms 134 are intended to flex, primarily at the bends forming riser 135 and flap 136, clips 130 will be fabricated from lighter gauge metal sheets, such as the metal sheets used to fabricate panels 20. Thus, it generally will be necessary or simply be expedient for clips 136 to extend continuously along panels 20. If resistance to wind lift is not a significant issue, however, clips 136 may not necessarily extend along the entire length of the panels. They may be made shorter, although generally they will still be viewed as “continuous” in the sense that they either extend a substantial distance along a support member or span a plurality of crossing support members.
Like clips 30, clips 130 will securely engage panels 20, but will allow them to float along an array of clips 130 to minimize thermally induced canning. Clips 130 also will allow disengagement of panels 20 without damage if repairs are required. Arms 134 may be flexed or bent away from feet 25 on side laps 23 without damaging panels 20. While disassembly may damage clips 130 to the extent that they may not be reinstalled, it will be appreciated that it will not be necessary to uninstall undamaged panels 20 to access and install a new panel 20. Thus, siding 110 perhaps may be repaired more easily and economically that siding 10.
It will be appreciated that siding 110, like siding 10, also may incorporate straps, such as straps 90. It will be necessary to provide breaks in clips 130 to accommodate installation of straps 90, but if desired, they may be used to help reduce canning in panels 20 of siding 110.
A third preferred embodiment 210 of the novel siding systems is shown in
As best seen in
Siding 210 will be installed in order, in a manner not entirely dissimilar to installation of siding 10. As appreciated from
Lower catch 233 on another array of clips 230c then may be slid over feet 25 on lower side lap 23 of panel 20c. Fence 235 on clips 230b will extend over, and between the tabs of lower catch 233 of clips 230c, thus securing the lower end of clips 230c. Clips 230c will be mounted on studs 2, for example, by driving fasteners 70 through holes 237 at their upper end. Feet 24 on the upper side lap 23 of panel 20c then may be inserted into upper catch 234 of clips 230c. A fourth panel 20d may be installed in a similar fashion. If desired, straps, such as straps 90, may be provided in siding 210. They may be installed in substantially the same manner as described in reference to siding 10.
Like clips 30, clips 230 will securely engage panels 20, but will allow them to float along an array of clips 230 to minimize thermally induced canning. Clips 230 also will allow disengagement of panels 20 without damage if repairs are required. Clips 230 must be uninstalled, and it will be necessary to remove down-installation panels 20 to access a damaged panel 20. Panels 20, however, may be disengaged from clips 230 without damage and may be reinstalled once a damaged panel 20 has been replaced.
It also will be noted that clips 230 are self-aligning. That is, because clip 230 engages both side laps 23 of a single panel 20, it may be sized accordingly. Once the initial array of clips 230b have been installed, there will be no need to measure, align or otherwise determine the placement of clips 230c or other clip arrays installed above clips 230b.
A fourth preferred embodiment 310 of the novel siding systems is shown in
Siding 310, as shown in
As best seen in
Reveal panels of the novel sidings, however, are elevated away from the wall to a greater or lesser extent than the flush panels. For example, as may be seen best in
As shown in
Catch 364 is like catch 34 on track 31 of standard clip 30. It may be provided, for example, by an upward extension from base 362 which is doubled back to form a rearward-facing hook. Catch 364 extends across the substantial portion of the forward end of reveal clip 360.
Preferably, base 362 of reveal clips 360 also is provided with embossments. For example, reveal clips 360 have three sets of paired nubs 366 provided in base 362. Nubs 366 project upward from base 362 and are substantially identical to nubs 36 of track 31 of standard clips 30. Thus, as described in detail below, a standard clip 30 may be registered in defined locations along the length of reveal clips 360 by registering nubs 36 on track 31 with one or the other set of nubs 366 on reveal clip 360.
The installation of siding 310 is best appreciated from the sequential, cross-sectional, partially exploded views of
A first panel 20a then may be installed by sliding foot 25 on its side lap 23 under catch 364 of reveal clips 360. Foot 355 on one side lap 253 of reveal panel 350 then will be inserted into the fold of foot 25 on first panel 20a, as shown in
After the first side lap 353 of reveal panel 350 is secured, an array of standard clips 30 may be mounted on reveal clips 360. Paired nubs 366 on reveal clip 360 are spaced along base 362 such that reveal panels 350 of various standard widths may be accommodated by selectively registering clip 30 along reveal clip 360. For example, as appreciated by comparing
The fold of foot 25 of side lap 23 of a second flush panel 20b then may be cupped around foot 365 of the other side lap 263 of reveal panel 350. So coupled, foot 25 of flush panel 30 and foot 255 of reveal panel 350 are inserted between catch 34 and fence 35 on track 31. Sled 41 on standard clip 30 then may be slid from its unset position to its set position such that catch 44 extends over foot 25 on the lower side lap 23 of second flush panel 20b. Straps, such as straps 90, also may be installed in siding 310 as in other novel siding systems. They may be used to help reduce oil canning in panels 20 of siding 310.
Like standard clips 30, reveal clips 360 will securely engage flush panels 20 and reveal panels 350, but will allow them to float along an array of reveal clips 360 to minimize thermally induced oil canning. Reveal clips 360 also will allow disengagement of reveal panels 350 without damage if repairs are required. It will be necessary to remove down-installation panels 20 and reveal panels 350 to access a damaged reveal panel 350. Down-installation panels 20 and 350, however, may be disengaged from standard clips 30 and reveal clips 360 without damage and may be reinstalled once a damaged reveal panel 350 has been replaced.
A fifth preferred embodiment 410 of the novel siding systems is shown in
In general, siding 410 comprises flush panels 20, reveal panels 350, and reveal clips 460. Reveal clips 460, like clips 130, are quite elongated and extend essentially continuously along side laps 23 of flush panels 20 and side laps 353 of reveal panels 350. As with clips 130, however, clips 460 may have varying lengths depending on the requirements of the installation or for the sake of expediency.
Reveal clips 460 also have a snap-in design similar to clips 130. As best seen in
Clips 460 will be mounted on girts 3, for example, by driving screws 70 or other fasteners through their base 462. Foot 25 of side lap 23 on a first flush panel 20a will be snapped into one flexible arm 464 on reveal clip 460. Foot 355 on one side lap 353 of reveal panel 350 then will be inserted into the fold of foot 25 on side lap 23 of first panel 20a as shown in
Clips 460 will securely engage panels 20 and reveal panels 350, but will allow them to float along an array of clips 460 to minimize thermally induced oil canning. Moreover, if a reveal panel 350 is damaged, it may be replaced without uninstalling any undamaged panels 20 and reveal panels 350. Once the damaged reveal panel 350 has been removed, side laps 23 of adjacent flush panels 20 may be disengaged from reveal clips 460. Feet 355 of side laps 353 on a replacement reveal panel 350 may be tucked into the fold of feet 25 on side laps 23 of adjacent flush panels 20 and then snapped into flexible arms 464 on reveal clip 460.
It will be appreciated that siding 410 also, like siding 110, also may incorporate straps, such as straps 90. It will be necessary to provide breaks in clips 430 to accommodate installation of straps 90, but if desired, they may be used to help reduce canning in panels 20 of siding 410.
A sixth preferred embodiment 510 of the novel siding systems is shown in
As best seen in
As shown in
Panels 550 will securely engage panels 20 and reveal panels 550, but will allow them to float along an array of panels 550 to minimize thermally induced canning. Moreover, if a reveal panel 550 is damaged, it may be replaced without uninstalling any undamaged panels 20 and reveal panels 550 in a manner similar to replacing reveal panels 350 in siding 410.
It will be appreciated that the novel straps may be used in siding systems other than those exemplified by siding 10 and the other siding systems disclosed above. For example, they may be incorporated into a seventh preferred embodiment 610 of the novel siding systems shown in
Novel siding 610 generally comprises a plurality of metal wall panels 620 and a plurality of panel straps 690. As best appreciated from
Panels 620 have side laps 623 which may be joined to form horizontally extending, vertical seams 621. Side laps 623 are formed by bending the lateral edges of panels 620 into a desired configuration. For example, as best appreciated from
As best appreciated from
In contrast to siding 10, for example, siding 610 is not installed with clips. It is installed on frame 601 with concealed fasteners 70. More particularly, as best appreciated from
The larger hook 695 on straps 690b then may be hooked over the folded portion of female foot 625b on first panel 620a. Fasteners 70 then will be driven through fastener portion of female foot 625b and into sheathing 603 to securely mount panel 620a to frame 601. As in siding 10, greater or fewer straps 690 may be used in siding 610. Greater or fewer fasteners 70 also may be used depending upon the conditions to which siding 610 will be exposed, and primarily on the degree to which wind uplift is a concern.
Once first panel 620a has been installed, the next panel 620b may be installed. More specifically, male foot 625a of second panel 620b will be inserted into the folded portion of foot 625b of panel 620a. Tabs 626 of female foot 625b will flex inward to allow insertion of male foot 625a, but will flex out again to secure male foot 625a within female foot 625b. Preferably, a sealant, such as a bead of silicone caulk or elastomeric tape, will be provided between male foot 625a and female foot 625b of side laps 623 of panels 620 to enhance the weather tightness of seams 621. In any event, male side lap 623a on second panel 620b will be securely engaged with female side lap 623b on first panel 620a to form a vertical seam 621 therebetween.
Once that seam 621 has been formed, the smaller hook 695 on straps 690b may be hooked over the fastener portion of female foot 625b of second panel 620b. Installation of strap 690b will induce slight, transverse bowing of second panel 620b. A second series of straps 690c then may be installed by first engaging the larger hook 695 of second series straps 690c over the folded portion of female foot 625b of second panel 620b. Fasteners 70 then will be driven through the fastener portion of female foot 625b of second panel 620b to complete its installation. The process then may be repeated to complete the installation of second series straps 690c and additional panels 620.
It also will be appreciated that the panel straps have been exemplified as being incorporated into panels of a particular configuration. Siding 10, for example, incorporates symmetrical panels 20. Siding 610 incorporates asymmetrical panels 620. Other types of asymmetrical panels may be used, however, and a variety of conventional symmetrical and asymmetrical panels which form vertical seams are known and may be adapted for use in the subject invention. For example, the novel straps may be used with Marquee-Lok, Marquee II, and FW Series asymmetrical metal panels sold by McElroy Metal.
While this invention has been disclosed and discussed primarily in terms of specific embodiments thereof, it is not intended to be limited thereto. Other modifications and embodiments will be apparent to the worker in the art.
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| Number | Date | Country | |
|---|---|---|---|
| Parent | 15382428 | Dec 2016 | US |
| Child | 15817067 | US |
