MODULAR CLADDING PANELS FOR BUILDINGS AND ASSOCIATED METHODS

Description

TECHNICAL FIELD

The subject matter disclosed herein relates generally to the construction of modular construction units. In particular, the presently disclosed subject matter relates to a connector system for constructing a building by assembling a plurality of modular units to rigidly interconnect the modular units to resist separation forces in the vertical and/or lateral directions, as well as associated methods of manufacture thereof.

BACKGROUND

In the field of modular construction, buildings are constructed from a plurality of pre-fabricated modular building units assembled together according to a plan of assembly for the final structure of the building. Such modular building units can include, for example, one or more rooms within the building. Such modular building units are pre-fabricated at a location (e.g., a factory) away from the site where the building (e.g., any suitable structure, including a temporary or permanent structure) is being constructed, transported to the building site, and assembled per the specifications of the building being constructed. In order to ensure that the structure is sufficiently watertight, it is often necessary to affix an exterior cladding, which can be both decorative and functional, over the exposed surface of the modular units that are on an outer surface of the building after the modular units are assembled together during construction of the building. However, it is also required during assembly of the building being constructed to precisely align adjacent modular units and to attach the modular units rigidly together. Some modular units that are designated as being on an external surface of the building being constructed may have exterior cladding panels already affixed thereto during pre-fabrication of the building units. However, this pre-affixing of cladding panels is still disadvantageous in that there will inevitably be seams present between cladding panels of adjacent modular units that must be filled or otherwise hidden. Additionally, such pre-affixed cladding panels are much more likely to be cosmetically and/or structurally damaged during transport of the modular units and/or during assembly of the building being constructed. To the contrary, however, damage to an external surface of a modular unit to which a cladding panel is not affixed will likely not need to be remediated, unless structural in nature, because such damage would be hidden from view after the cladding panel(s) have been affixed to the modular unit. As such, a need exists for a suitable cladding panel for covering the exterior of a modular unit that can be precisely aligned to ensure fast and repeatable positioning and fastening of the cladding panel to the external surface of the modular unit, or units, and which is capable of providing a suitable weather-resistant barrier to prevent wind and/or water intrusion within the building after all of the modular units have been assembled together per the schematics of the building.

SUMMARY

According to an example aspect, a cladding panel for covering an external surface of a building is provided, the cladding panel comprising: a structural frame; a substrate attached to a first, external, surface of the structural frame; and a plurality of fasteners that are formed on a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to a predetermined pattern. Each of the plurality of fasteners is configured for attachment to a corresponding one of a plurality of cladding alignment features attached on the external surface of the building. The plurality of cladding alignment features are arranged on the external surface of the building according to the predetermined pattern, such that each of the plurality of fasteners is configured for alignment with, and attachment to, one of the plurality of cladding alignment features.

In some embodiments, the cladding panel comprises one or more openings formed entirely through a thickness of the substrate, each of the one or more openings corresponding to an opening formed in the external surface of the building.

In some embodiments, the cladding panel comprises a siding material attached to a surface of the substrate that is opposite a surface of the substrate by which the substrate is attached to the structural frame.

In some embodiments of the cladding panel, each of the plurality of fasteners comprises a tapered slot; each of the plurality of cladding alignment features comprises an alignment peg; each alignment peg comprises a collar and a head attached to an end of the collar, the head having a width that is greater than a width of the collar; the width of the head is greater than a width of a narrow end of the tapered slot; and each tapered slot is oriented such that, when the cladding panel is affixed to the building, the alignment peg is moved into the narrow end of the tapered slot and held in place by a gravitational force.

In some embodiments of the cladding panel, the substrate comprises a waterproof finish panel.

In some embodiments, the cladding panel comprises a gap between the substrate and the external surface of the building when the cladding panel is installed on the exterior surface of the building.

In some embodiments, the cladding panel comprises a gap between the substrate and the external surface of the building when the cladding panel is installed on the exterior surface of the building; the gap is filled, either partially or entirely, with a rigid insulation layer.

In some embodiments of the cladding panel, the plurality of fasteners are formed in the second surface of the structural frame in a unitary manner.

According to another example aspect, a system for covering an external surface of a building is provided, the system comprising: a plurality of cladding alignment features attached to the external surface of the building according to a predetermined pattern; and a plurality of cladding panels. Each of the plurality of cladding panels comprises: a structural frame; a substrate attached to a first, external, surface of the structural frame; and a plurality of fasteners that are formed on a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to the predetermined pattern, such that each of the plurality of fasteners is configured for alignment with one of the plurality of cladding alignment features. Each of the plurality of fasteners is configured for attachment to a corresponding one of the plurality of cladding alignment features. Each of the plurality of cladding panels is configured for affixing to one or more of the modular units.

In some embodiments of the system, one or more of the cladding panels has a width of at least two of the plurality of modular units that are laterally adjacent to each other.

In some embodiments of the system, the building comprises a plurality of modular units assembled together to form the building.

In some embodiments of the system, the building comprises a plurality of modular units assembled together to form the building and the system comprises a plurality of connectors affixed to exterior surfaces of each of the plurality of modular units, wherein the plurality of cladding alignment features are rigidly attached to and extend from the connectors for engagement with the fasteners, and wherein adjacent ones of the plurality of connectors interlock with each other to secure adjacent ones of the plurality of modular units together.

In some embodiments of the system, one or more of the plurality of cladding panels comprises one or more openings formed entirely through a thickness of the substrate thereof, each of the one or more openings corresponding to an opening formed in the external surface of the building.

In some embodiments of the system, each of the plurality of cladding panels comprises a siding material attached to a surface of the substrate that is opposite a surface of the substrate by which the substrate is attached to the structural frame.

In some embodiments of the system, for one or more of the plurality of cladding panels, each of the plurality of fasteners comprises a tapered slot; each of the plurality of cladding alignment features comprises an alignment peg; each alignment peg comprises a collar and a head attached to an end of the collar, the head having a width that is greater than a width of the collar; the width of the head is greater than a width of a narrow end of the tapered slot; and each tapered slot is oriented such that, when one of the plurality of cladding panels is affixed to the external surface of the building, the alignment peg is moved into the narrow end of the tapered slot and held in place by a gravitational force.

In some embodiments of the system, the substrate comprises a waterproof finish panel.

In some embodiments of the system, each of the plurality of cladding panels comprises a gap between the substrate and the external surface of the building when the cladding panel is installed on the exterior surface of the building.

In some embodiments of the system, the plurality of fasteners are integrally formed in the second surface of the structural frame.

According to another aspect, a method of covering an external surface of a building is provided, the method comprising: producing a plurality of cladding panels, each of the plurality of cladding panels comprising: a structural frame; a substrate attached to a first, external, surface of the structural frame; and a plurality of fasteners that are formed on a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to a predetermined pattern; arranging a plurality of cladding alignment features on the external surface of the building according to the predetermined pattern; aligning each of the plurality of fasteners with a corresponding one of the plurality of cladding alignment features on the external surface of the building; and attaching each of the plurality of fasteners to the corresponding one of the plurality of cladding alignment features.

In some embodiments of the method, producing the plurality of cladding panels comprises, for one or more of the plurality of cladding panels, forming one or more openings through an entire thickness of the substrate, each of the one or more openings corresponding to an opening formed in the external surface of the building, the method further comprising attaching a siding material to a surface of the substrate that is opposite a surface of the substrate by which the substrate is attached to the structural frame.

In some embodiments of the method, the building comprises a plurality of modular units assembled together to form the building.

In some embodiments of the method, the building comprises a plurality of modular units assembled together to form the building and the plurality of cladding alignment features are rigidly attached to connectors affixed to exterior surfaces of each of the plurality of modular units.

In some embodiments of the method, for one or more of the plurality of cladding panels, each of the plurality of fasteners comprises a tapered slot; each of the plurality of cladding alignment features comprises an alignment peg; each alignment peg comprises a collar and a head attached to an end of the collar, the head having a width that is greater than a width of the collar; the width of the head is greater than a width of a narrow end of the tapered slot; and orienting each tapered slot such that, when the cladding panel is affixed to the building, the alignment peg is moved into the narrow end of the tapered slot and held in place by a gravitational force.

In some embodiments of the method, the substrate comprises a waterproof finish panel.

In some embodiments of the method, the cladding panel is attached to the building such that a gap exists between the substrate and the external surface of the building.

In some embodiments of the method, the cladding panel is attached to the building such that a gap exists between the substrate and the external surface of the building, the method further comprising filling the gap, either partially or entirely, with a rigid insulation layer.

In some embodiments of the method, each of the plurality of fasteners is formed in the second surface of the structural frame in a unitary manner.

According to another example aspect, a building is provided, the building comprising: a plurality of modular units assembled together to form the building; a plurality of connectors affixed to exterior surfaces of each of the plurality of modular units, the plurality of connectors comprising a plurality of cladding alignment features, wherein the plurality of cladding alignment features are rigidly attached to and extend from an external surface of the building according to a predetermined pattern; and a plurality of cladding panels. Each of the plurality of cladding panels comprises: a structural frame; a substrate attached to a first, external, surface of the structural frame; and a plurality of fasteners that are formed on a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to the predetermined pattern, such that each of the plurality of fasteners is configured for alignment with one of the plurality of cladding alignment features. Each of the plurality of fasteners is configured for attachment to a corresponding one of the plurality of cladding alignment features. Each of the plurality of cladding panels is affixed to one or more of the modular units.

In some embodiments, the building comprises a plurality of modular units assembled together to form the building.

In some embodiments, the building comprises: a plurality of modular units assembled together to form the building; and a plurality of connectors affixed to exterior surfaces of each of the plurality of modular units, wherein the plurality of cladding alignment features are rigidly attached to and extend from the connectors for engagement with the fasteners, and wherein adjacent ones of the plurality of connectors interlock with each other to secure adjacent ones of the plurality of modular units together.

In some embodiments of the building, one or more of the plurality of cladding panels comprises one or more openings formed entirely through a thickness of the substrate thereof, each of the one or more openings corresponding to an opening formed in the external surface of the building.

In some embodiments of the building, each of the plurality of cladding panels comprises a siding material attached to a surface of the substrate that is opposite a surface of the substrate by which the substrate is attached to the structural frame.

In some embodiments of the building, for one or more of the plurality of cladding panels, each of the plurality of fasteners comprises a tapered slot; each of the plurality of cladding alignment features comprises an alignment peg; each alignment peg comprises a collar and a head attached to an end of the collar, the head having a width that is greater than a width of the collar; the width of the head is greater than a width of a narrow end of the tapered slot; and each tapered slot is oriented such that, when one of the plurality of cladding panels is affixed to the external surface of the building, the alignment peg is moved into the narrow end of the tapered slot and held in place by a gravitational force.

In some embodiments of the building, the substrate comprises a waterproof finish panel.

In some embodiments of the building, each of the plurality of cladding panels comprises a gap between the substrate and the external surface of the building when the cladding panel is installed on the exterior surface of the building.

In some embodiments of the building, the plurality of fasteners are integrally formed in the second surface of the structural frame.

According to another example aspect, a cladding panel for covering a surface of a building is provided, the cladding panel comprising: a structural frame; a substrate attached to a first, external, surface of the structural frame; and a plurality of fasteners that are attached to a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to a predetermined pattern; wherein each of the plurality of fasteners is configured for attachment to a corresponding one of a plurality of cladding alignment features on an external surface of the building; and wherein the plurality of cladding alignment features are arranged on the external surface of the building according to the predetermined pattern, such that each of the plurality of fasteners is configured for alignment with, and attachment to, one of the plurality of cladding alignment features.

In some embodiments, the cladding panel comprises a siding material attached to a surface of the substrate opposite a surface of the substrate by which the substrate is attached to the structural frame.

In some embodiments of the cladding panel, the building comprises a plurality of modular units assembled together to form the building.

In some embodiments of the cladding panel, the plurality of cladding alignment features are rigidly attached to connectors affixed to exterior surfaces of each of the plurality of modular units.

In some embodiments of the cladding panel, each tapered slot is oriented such that, when the cladding panel is affixed to the building, the narrow end of the tapered slot is configured such that gravity acts to retain the alignment peg within the narrow end of the tapered slot.

In some embodiments of the cladding panel, the substrate comprises a waterproof finish panel.

In some embodiments, the cladding panel comprises a gap between the substrate and the external surface of the building.

In some embodiments of the cladding panel, the gap is filled, either partially or entirely, with a rigid insulation layer.

In some embodiments of the cladding panel, the plurality of fasteners are integrally formed in the second surface of the structural frame.

According to another example aspect, a system for covering an exterior surface of a building is provided, the system comprising a plurality of any of the cladding panels described herein; wherein the building comprises a plurality of assembled modular units; and wherein each of the plurality of cladding panels is affixed to one or more of the modular units.

In some embodiments of the system, one or more of the cladding panels has a width of at least two of the plurality of modular units that are laterally adjacent to each other.

According to another example aspect, a method of covering an external surface of a building is provided, the method comprising: producing a cladding panel comprising a structural frame, a substrate attached to a first, external, surface of the structural frame, and a plurality of fasteners that are attached to a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to a predetermined pattern; the method further comprising: attaching each of the plurality of fasteners to a corresponding one of a plurality of cladding alignment features on the external surface of the building; and arranging the plurality of cladding alignment features on the external surface of the building according to the predetermined pattern, such that each of the plurality of fasteners is configured for alignment with, and attachment to, one of the plurality of cladding alignment features.

In some embodiments of the method, producing the cladding panel comprises forming one or more openings through an entire thickness of the substrate, each of the one or more openings corresponding to an opening formed in the external surface of the building.

In some embodiments, the method comprises attaching a siding material to a surface of the substrate opposite a surface of the substrate by which the substrate is attached to the structural frame.

In some embodiments of the method, the building comprises a plurality of modular units assembled together to form the building.

In some embodiments of the method, the plurality of cladding alignment features are rigidly attached to connectors affixed to exterior surfaces of each of the plurality of modular units.

In some embodiments of the method, each of the plurality of fasteners comprises a tapered slot; each of the plurality of cladding alignment features comprises an alignment peg; each alignment peg comprises a collar and a head attached to an end of the collar, the head having a width that is greater than a width of the collar; and the width of the head is greater than a width of a narrow end of the tapered slot.

In some embodiments of the method, each tapered slot is oriented such that, when the cladding panel is affixed to the building, the narrow end of the tapered slot aligned so that gravity acts to retain the alignment peg within the narrow end of the tapered slot.

In some embodiments of the method, the substrate comprises a waterproof finish panel.

In some embodiments of the method, the cladding panel is attached to the building such that a gap exists between the substrate and the external surface of the building.

In some embodiments, the method comprises filling the gap, either partially or entirely, with a rigid insulation layer.

In some embodiments of the method, the plurality of fasteners are integrally formed in the second surface of the structural frame.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric rear view of an example embodiment of a cladding panel for mounting to an exterior of a structure, particularly to a structure constructed from a plurality of modular units.

FIG. 2 is a top view of the example cladding panel of FIG. 1.

FIG. 3 is a side view of the example cladding panel of FIG. 1.

DETAILED DESCRIPTION

The accompanying figures and description are merely examples of a single example embodiment for modular cladding panels and cladding systems for buildings, as well as methods of production, assembly, and use therefor. As such, the foregoing description and accompanying figures are illustrative and are not to be used to limit the scope of the presently disclosed subject matter.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one having ordinary skill in the art to which the presently disclosed subject matter belongs. Although, any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are now described.

Following long-standing patent law convention, the terms “a”, “an”, and “the” refer to “one or more” when used in this application, including the claims. Thus, for example, reference to “a fastener hole” can include a plurality of such fastener holes, and so forth.

Unless otherwise indicated, all numbers expressing quantities of length, diameter, width, and so forth used in the specification and claims are to be understood as being modified in all instances by the terms “about” or “approximately”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in this specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by the presently disclosed subject matter.

As used herein, the terms “about” and “approximately,” when referring to a value or to a length, width, diameter, temperature, time, volume, concentration, percentage, etc., is meant to encompass variations of in some embodiments ±20%, in some embodiments ±10%, in some embodiments ±5%, in some embodiments ±1%, in some embodiments ±0.5%, and in some embodiments ±0.1% from the specified amount, as such variations are appropriate for the disclosed apparatuses and devices.

The term “comprising”, which is synonymous with “including” “containing” or “characterized by” is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. “Comprising” is a term of art used in claim language which means that the named elements are essential, but other elements can be added and still form a construct within the scope of the claim.

As used herein, the phrase “consisting of” excludes any element, step, or ingredient not specified in the claim. When the phrase “consists of” appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

As used herein, the phrase “consisting essentially of” limits the scope of a claim to the specified materials or steps, plus those that do not materially affect the basic and novel characteristic(s) of the claimed subject matter.

With respect to the terms “comprising”, “consisting of”, and “consisting essentially of”, where one of these three terms is used herein, the presently disclosed and claimed subject matter can include the use of either of the other two terms.

As used herein, the term “and/or” when used in the context of a listing of entities, refers to the entities being present singly or in combination. Thus, for example, the phrase “A, B, C, and/or D” includes A, B, C, and D individually, but also includes any and all combinations and sub-combinations of A, B, C, and D.

FIG. 1 is an isometric rear view of an example embodiment of a cladding panel system, generally designated 10, the system including a plurality of cladding panels, generally designated 100, which are suitable for attaching over an exterior of a building (e.g., as a cover for any suitable structure, including a residential and/or commercial structure) to resist and/or prevent the intrusion of wind, precipitation (e.g., rain, snow, sleet, etc.), or other flying objects or debris through the exterior surface of the building. As shown in FIG. 1, each cladding panel 100 comprises a substrate, or finish panel 110, that is rigidly attached to a lightweight structural frame 130. Non-limiting examples of materials that can be used in constructing and/or forming the finish panel 110 include plastics, metals, ceramic (e.g., cement and/or fiber cement), composite materials, wood (e.g., including man-made wood derivatives), and combinations thereof.

The structural frame 130 can have any suitably rigid construction, without limitation, based on the environmental conditions to which the cladding panel 100 will be exposed when installed on the building. In the example embodiment shown, the structural frame 130 comprises a plurality of vertical stiffeners 132 and a plurality of horizontal stiffeners 134. The vertical stiffeners 132 are attached to the horizontal stiffeners 134 at substantially 90° angles (e.g., +/−5°, +/−2°, +/−1°, exactly 90°, and the like, allowing for manufacturing and assembly tolerances). The structural frame 130 may also have stiffeners, instead of and/or in addition to the vertical stiffeners 132 and the horizontal stiffeners 134, that are arranged relative to other stiffeners and/or the gravity vector at neither 0° or 90°, such as between about 15° and about 75°, between about 30° and about 60°, and about 45°. Since the cladding panels 100 are supported by the modular unit(s) of the building to which they are each attached, respectively, the cladding panels 100 are not, in some embodiments, load=bearing structures of the building and, as such, the quantity of stiffeners can be minimized (e.g., only providing a sufficient quantity to achieve a specified rigidity for a cladding panel 100 in a particular installation environment). Non-limiting example of materials that can be used in the structural frame 130 can include plastics, metals, composite materials, wood (e.g., including man-made wood derivatives), and combinations thereof.

In some example embodiments, the finishing panel 110 is a substrate (e.g., a non-decorative panel) and acts as a surface to which any suitable type of siding material (e.g., wood boards, lap shingles, vinyl siding, masonry, stone, faux masonry, faux stone, and the like) may be affixed. The structural frame 130 is designed to have sufficient rigidity such that the cladding panel 100 can be securely (e.g., rigidly) attached onto the exterior surface of the modular unit(s) of the building. In some embodiments, the structural frame 130 may be designed to allow for amounts of deformation of the cladding panel 100 that would not damage (e.g., as may occur due to plastic deformation thereof) the finish panel 110. In some embodiments, the structural frame 130 is sufficiently rigid that the structural frame 130 is not deformed (e.g., only negligibly and/or imperceptibly) by the weight of the finishing panel 110 when the cladding panel 100 is suspended in the air (e.g., such as may be necessary during installation of the cladding panel onto the exterior of the modular unit(s) of the building).

In the example embodiment shown in FIG. 1, each finish panel 100 of the finish panel system 10 has two openings, generally designated 112, formed through the entire thickness of the finish panel 100. The structural frame 130 is designed such that no portion of the structural frame 130 (e.g., no vertical stiffeners 132 or horizontal stiffeners 134) is visible through the opening 112 from the side of the structural frame 130 on which the finish panel 110 is attached. The quantity of openings 112 in each finish panel 110 (and, therefore necessarily, in each cladding panel 100) is generally determined based on the number of openings in the exterior wall and/or surface of the modular unit(s) to which the cladding panel 100 is attached during construction of the building. Non-limiting examples of such openings can include windows, doors, vents, and the like. As such, each cladding panel 100 is specifically manufactured (e.g., during off-site pre-fabrication) such that the position and size of any openings 112 formed in each cladding panel 100 corresponds precisely to the position and size of any openings formed in the exterior of the modular unit(s) over which the cladding panel 100 is to be affixed. In embodiments in which the exterior wall of the modular unit(s) over which the cladding panel 100 is to be affixed has no openings formed therein, the cladding panel 100 may also have no openings 112 therein; thus, in some embodiments, one or more cladding panels 100 of the cladding panel system 10 are devoid of any openings 112. In some embodiments, the cladding panel may have, formed on an exterior surface thereof (e.g., on a surface opposite the structural frame 130), a faux opening that is merely decorative. Such a faux opening may thus be designed to have a substantially identical appearance to that of an opening 112 formed on the same cladding panel 100 and/or on another cladding panel 100 of the cladding panel system 10, but such faux opening is located on the cladding panel 100 at a position behind which, when the cladding panel 100 is attached to the building, there is no opening formed in the external wall of the modular unit(s) of the building. Such faux openings can be advantageous for maintaining symmetry of an exterior of a building. In some embodiments, the cladding panel 100 is pre-fabricated to have a solid finish panel 110 and openings 112 may be cut through the finish panel 110 on-site (e.g., away from the prefabrication site, before or after the cladding panel 100 is attached to the building) to accommodate openings 112 formed in the exterior wall of the modular unit(s) over which the cladding panel 100 is designated to be affixed. In such embodiments, it is advantageous for at least the vertical stiffeners 132 and/or horizontal stiffeners 134 of the structural frame 130 to be movable (e.g., to a position outside of the opening 112 to be cut) and/or for such vertical stiffeners 132 and/or horizontal stiffeners 134 to be provided redundantly so that the structural frame 130 is not compromised.

Fasteners 200 are rigidly affixed according to a predetermined pattern on and across the structural frame 130 (e.g., on the vertical stiffeners 132 and/or horizontal stiffeners 134). The fasteners 200 can be of any suitable type and/or sort that is compatible with a corresponding cladding alignment feature rigidly attached to the exterior of the building (e.g., such as connectors 2) on which the cladding panel 100 is designated to be installed. These cladding alignment features are rigidly affixed to the exterior of the building according to the same predetermined pattern as are the fasteners 200, such that the fasteners 200 of the cladding panel 100 aligns with the cladding alignment features on the exterior of the building. In the example embodiment shown, the fasteners 200 are tapered slots formed in a bracket that are configured to be inserted over an alignment peg in a connector 2, which is rigidly affixed to the exterior of the building and, particularly, to lower and upper edges and/or corners of each modular unit for a building being constructed of modular units. As such, the fasteners 200 are positioned such that the tapered slots associated therewith are positioned to that the alignment peg of the connector 2 rests within a wider portion of the tapered slot of the fastener 200; the cladding panel 100 is shifted (e.g., vertically, in the direction of the gravity vector) so that the alignment peg moves from the wider portion of the tapered slot into the narrower portion of the tapered slot, meaning that the alignment peg is positioned within the narrow end of the tapered slot. The fastener 200 is formed such that the alignment peg cannot be removed from the narrow portion, or end, of the tapered slot without shifting the cladding panel 100 in a reverse direction (e.g., vertically, in the direction opposite the gravity vector) so that the alignment peg is again positioned in the wider portion of the tapered slot. Thus, the wider portion of the tapered slot has a width that is wider than the diameter of the alignment peg and the narrower portion of the tapered slot has a width that is narrower than the diameter of the alignment peg, such that the alignment peg can be inserted within and removed from the tapered slot of the fastener 200 only via the wider portion. In such embodiments, the alignment peg has a collar that extends away from the exterior surface of the connector 2 to which the cladding panel 100 is to be affixed and, at an end of the collar away from the exterior surface, a head that extends away from the collar and has a width (e.g., diameter) that is greater than the width (e.g., diameter) of the collar, such that the head can extend into the tapered slot of the fastener 200.

In some embodiments, the positioning of the alignment peg and the tapered slots is reversed from that which is described hereinabove, such that the tapered slots are rigidly affixed to the exterior surface of the connector 2 to which the cladding panel 100 is to be affixed and the alignment pegs are rigidly attached to the structural frame 130 (e.g., to the vertical stiffeners 132 and/or horizontal stiffeners 134). In some embodiments, the tapered slots are formed so that the force of gravity will, during installation, pull the cladding panel 100 in a vertically downward direction to engage the alignment peg within the narrow portion of the tapered slot of the fastener 200. The fasteners 200 and the cladding alignment features of the connectors 2 provided and described herein are merely examples and different kinds of attachments, including lockable attachments, are also suitable for use herein. In some embodiments, the tapered slots have a pivoting, or rotating, member (e.g., in the form of a finger or arm) that pivots from a closed position, in which the pivoting member blocks some or all of the tapered slot of the fastener 200, into an open position, in which the pivoting member is configured to allow passage of the alignment peg into the narrower portion of the tapered slot, then the pivoting member returns to the closed position (e.g., by being spring loaded or gravity assisted), such that the alignment peg cannot be removed from the narrower portion of the tapered slot without first moving (e.g., manually, with a tool, etc.) the pivoting member into the open position, such that the pivoting member no longer obstructs the removal of the alignment peg from the narrower portion of the tapered slot (e.g., as may be necessary for removal of a cladding panel 100 from the building). As such, the pivoting member is configured to act as a lock of sorts.

FIG. 2 is a top view of a cladding panel 100 attached to an external surface of a volumetric box 1 (e.g., a modular unit, such as is used during construction of a building constructed by assembling and interconnecting together a plurality of modular units according to a construction plan, diagram, schematic, blueprints, and the like). Examples of structures contained within and/or defining the size of such volumetric boxes 1 include floors, ceilings, and walls that define and/or create interior one or more spaces within the building. These volumetric boxes 1 are then stacked and arranged in specific configurations per the schematics (e.g., design blueprints) for the building being constructed. The cladding panels 100 are advantageously pre-fabricated at a site (e.g., a factory) located a distance away from (e.g., by a distance requiring transport of the cladding panels 100 over public roadways) the site where the building to which the cladding panels 100 will be affixed is being constructed. After off-site prefabrication, the cladding panels 100 are transported to the site where the building is being constructed and, optionally, transferred to a staging area thereof. Once the cladding panels 100 are on-site at the construction site, the cladding panels 100 are moved (e.g., lifted or hoisted) into a position adjacent to an installation position on the building, the installation position being where the cladding panel 100 is designated for affixing to the exterior of the building being constructed. Once adjacent to the installation position, the cladding panels 100 are moved into the installation position and are securely attached to the building to cover the exterior surface of the building, or at least a portion of the exterior surface of the building. In some embodiments, the cladding panels 100 are pre-fabricated and/or stored for transport in an order of installation on the exterior of the building to which the cladding panels 100 are to be affixed, such that the cladding panels 100 can be installed on and/or over the exterior surface of the building in the order of manufacture, in the order of arrival at the construction site, and/or in the order of arrangement within a plurality of such cladding panels 100 that are transported together to the construction site (e.g., in such a manner that multiple cladding panels 100 can be said to arrive at the construction site substantially simultaneously.

The cladding panels 100 are configured for assembly over the exterior surface of the building (e.g., over a portion of a volumetric box 1, all of a volumetric box 1, portions of multiple volumetric boxes 1, all of one volumetric box 1 and one or more portions of at least one other volumetric box 1, or all of multiple volumetric boxes 1) to minimize the number of vertical seams present between laterally adjacent cladding panels 100 of the cladding panel system 10 on the finished building by spanning multiple volumetric boxes 1, or modular units. In some embodiments, the lateral sides, or ends, of the finish panel 110 of one or more of (e.g., each and/or all of) the cladding panels 100 may be staggered (e.g., have a geometric, non-linear, lateral end face, or edge) such that the lateral side of a first cladding panel 100 is shaped to interleave with a matching (e.g., having a reverse, or mirrored) shape of the lateral end face, or edge, thereof of a laterally adjacent (e.g., adjoining) second cladding panel 100, such that the vertical seam formed between laterally adjacent cladding panels is broken up (e.g., discontinuous, such as in the case of not being a single vertical line) along the height (e.g., along the lateral edge) of the cladding panel 100, such that one or more of the lateral edges of the cladding panel 100 is subdivided into and/or formed a plurality of shorter vertical seams (e.g., edges) that may be less easily visible to an observer standing outside of the building. Horizontally-extending joints formed between vertically adjacent cladding panels 100 can be expressed (e.g., left visible) or hidden, for example, by partially overlapping (e.g., in the style of a tongue-and-groove interface) a lower cladding panel 100 with an upper cladding panel 100.

As shown in FIG. 3, the cladding panels 100 of the cladding panel system 10 form, when affixed to an exterior of a volumetric box 1, a gap, generally designated 112, between the exterior weather-resistive surface of the volumetric box 1 and the adjoining surface of the cladding panel 100 (e.g., the surface of the cladding panel 100 that faces the volumetric box 1 when affixed thereto). In some embodiments, this gap 112 is left vacant and is operable as an air gap that can advantageously act as a rainscreen that is beneficial to the longevity of the exterior weather-resistive surface of the volumetric box 1. In some embodiments, however, the gap 112 may be filled with substantially rigid insulation (e.g., in sheet form, which can attach to the cladding panel 100 on a surface thereof, opposite the finish panel 110 or substrate, within the gap 112 or injected within the gap 112, such as in the manner of a foam). In such embodiments having insulation within the gap 112, a substantially continuous insulation barrier may be provided between the finish panel 110 and the exterior weather-resistive surface of the volumetric box 1 to improve the insulation of the building when fully constructed, thereby improving the energy loss characteristics of the building (e.g., by reducing heat loss during periods when the ambient temperature is less than an interior temperature of the building or heat gain during periods when the ambient temperature is greater than an interior temperature of the building).

In the example embodiment shown in FIG. 3, a connector 2 is rigidly attached to a surface (e.g., at a corner and/or along an edge) of a volumetric box 1. In order to provide isolation (e.g., acoustic, vibratory, and the like) between vertically adjacent volumetric boxes 1, it is advantageous for a vibration-reducing layer, or pad 4 attached to the bottom surface of the volumetric box 1, such that the pad 4 will be positioned between vertically stacked volumetric boxes 1, such that the pad 4 is in direct contact with the volumetric boxes 1 positioned directly below and directly above the pad 4. The connector 2 can be of the sort disclosed in U.S. Provisional Patent No. 63/112,484, the contents of which are incorporated herein in their entirety. Extending from the connector 2 is a cladding alignment feature 3, which is shown in this example embodiment in the form of a peg that protrudes from the surface of the connector and has a collar portion that is attached directly to the connector 2 and a head portion that is attached directly to the collar and is spaced apart from the connector 2 by the collar; the head has a diameter that is larger than the diameter of the collar.

The structural frame 130 has, as noted elsewhere herein, vertical stiffeners 132 and horizontal stiffeners 134, which are arranged substantially orthogonally to each other. At least some (e.g., all) of the vertical stiffeners 130 have a slot formed in a surface thereof. The slot has a tapering cross-sectional shape, such that the diameter of the head of the cladding alignment feature 3 is wider than the narrow end of the slot, such that the cladding alignment feature 3 cannot be removed from the slot of the vertical stiffener 132 unless vertical stiffener 132 is moved vertically, relative to the cladding alignment peg 3, such that the cladding alignment feature 3 is within the wider portion of the slot formed in the vertical stiffener 132; in some embodiments, the entire cladding panel 100 must be moved vertically for the cladding alignment feature 3 to be able to be removed from the slot formed in the vertical stiffener 132. In order for the horizontal stiffeners 134 to be attached to the vertical stiffeners 132, some or all of the vertical stiffeners 132 have a bracket 133 attached to a surface thereof (e.g., an opposite surface of the vertical stiffener 132 from the side in which the slot is formed), the bracket 133 having a channel into which one of the horizontal stiffeners 134 can be inserted for rigid attachment to the vertical stiffener 132.

In the example embodiment shown in FIG. 3, the gap 112 is defined by at least the thickness of the vertical stiffener 132 and the bracket 133. The horizontal stiffener 134 has a cross-sectional shape in the form of a step. The word “step,” as used immediately hereinabove, means a cross-sectional profile defined by first and second planar structures that are connected together at the adjacent edges thereof by a third planar structure that is inclined or orthogonal to the first and second planar structures, the first and second planar structures extending away from the third planar structure in opposite directions; in some embodiments, the first and second planar structures are positioned within planes that are parallel but offset from each other. As such, the gap 112 has a thickness that is greater than a combined thickness of one of the vertical stiffeners 132 and one of the horizontal stiffeners 134.

The horizontal stiffeners 134 are rigidly attached to the finish panel 110 (e.g., on the surface of the finish panel 110 that, when installed on the exterior surface of the building, faces towards the gap 112). Thus, in some embodiments, the vertical stiffeners 132 may be attached to the exterior surface of the building separately from (e.g., individually, separate from) the horizontal stiffeners 134. In some embodiments, the horizontal stiffeners 134 are rigidly attached to the vertical stiffeners 132 before the cladding panel 100 is installed to the exterior surface of the building. The finish panel 110 is advantageously constructed out of a waterproof material, such that water cannot pass through the finish panel 110 and be exposed to the gap 112, or to any insulation present within the gap 112. The components of the structural frame 130 are advantageously made of a material that does not corrode and/or degrade when exposed to water; examples of such materials can include, for example, aluminum, plastic, wood, and the like. In some embodiments, the components of the structural frame 130 can be partially and/or fully encapsulated to prevent corrosion caused by exposure to water before and/or while installed on the exterior surface of the building.

The present subject matter can be embodied in other forms without departure from the spirit and essential characteristics thereof. The embodiments described therefore are to be considered in all respects as illustrative and not restrictive. Although the present subject matter has been described in terms of certain specific embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the present subject matter.

Claims

1. A cladding panel for covering an external surface of a building, the cladding panel comprising: a structural frame;a substrate attached to a first, external, surface of the structural frame; anda plurality of fasteners that are formed on a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to a predetermined pattern;wherein each of the plurality of fasteners is configured for attachment to a corresponding one of a plurality of cladding alignment features attached on the external surface of the building; andwherein the plurality of cladding alignment features are arranged on the external surface of the building according to the predetermined pattern, such that each of the plurality of fasteners is configured for alignment with, and attachment to, one of the plurality of cladding alignment features.
2. The cladding panel of claim 1, comprising one or more openings formed entirely through a thickness of the substrate, each of the one or more openings corresponding to an opening formed in the external surface of the building.
3. The cladding panel of claim 1, comprising a siding material attached to a surface of the substrate that is opposite a surface of the substrate by which the substrate is attached to the structural frame.
4. The cladding panel of claim 1, wherein: each of the plurality of fasteners comprises a tapered slot;each of the plurality of cladding alignment features comprises an alignment peg;each alignment peg comprises a collar and a head attached to an end of the collar, the head having a width that is greater than a width of the collar; andthe width of the head is greater than a width of a narrow end of the tapered slot.
5. The cladding panel of claim 4, wherein each tapered slot is oriented such that, when the cladding panel is affixed to the building, the alignment peg is moved into the narrow end of the tapered slot and held in place by a gravitational force.
6. The cladding panel of claim 1, wherein the substrate comprises a waterproof finish panel.
7. The cladding panel of claim 1, comprising a gap between the substrate and the external surface of the building when the cladding panel is installed on an exterior surface of the building.
8. The cladding panel of claim 7, wherein the gap is filled, either partially or entirely, with a rigid insulation layer.
9. The cladding panel of claim 1, wherein the plurality of fasteners are formed in the second surface of the structural frame in a unitary manner.
10. A system for covering an external surface of a building, the system comprising: a plurality of cladding alignment features attached to the external surface of the building according to a predetermined pattern; anda plurality of cladding panels, each of the plurality of cladding panels comprising: a structural frame;a substrate attached to a first, external, surface of the structural frame; anda plurality of fasteners that are formed on a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to the predetermined pattern, such that each of the plurality of fasteners is configured for alignment with one of the plurality of cladding alignment features;wherein each of the plurality of fasteners is configured for attachment to a corresponding one of the plurality of cladding alignment features.
11. The system of claim 10, wherein the building comprises a plurality of modular units assembled together to form the building, and wherein one or more of the cladding panels has a width of at least two of the plurality of modular units that are laterally adjacent to each other.
12. The system of claim 10, wherein the building comprises a plurality of modular units assembled together to form the building, and wherein each of the plurality of cladding panels is configured for affixing to one or more of the plurality of modular units.
13. The system of claim 12, comprising a plurality of connectors affixed to exterior surfaces of each of the plurality of modular units, wherein the plurality of cladding alignment features are rigidly attached to and extend from the connectors for engagement with the fasteners, and wherein adjacent ones of the plurality of connectors interlock with each other to secure adjacent ones of the plurality of modular units together.
14. The system of claim 10, wherein one or more of the plurality of cladding panels comprises one or more openings formed entirely through a thickness of the substrate thereof, each of the one or more openings corresponding to an opening formed in the external surface of the building.
15. The system of claim 10, wherein each of the plurality of cladding panels comprises a siding material attached to a surface of the substrate that is opposite a surface of the substrate by which the substrate is attached to the structural frame.
16. The system of claim 10, wherein: for one or more of the plurality of cladding panels, each of the plurality of fasteners comprises a tapered slot;each of the plurality of cladding alignment features comprises an alignment peg;each alignment peg comprises a collar and a head attached to an end of the collar, the head having a width that is greater than a width of the collar; andthe width of the head is greater than a width of a narrow end of the tapered slot.
17. The system of claim 16, wherein each tapered slot is oriented such that, when one of the plurality of cladding panels is affixed to the external surface of the building, the alignment peg is moved into the narrow end of the tapered slot and held in place by a gravitational force.
18. The system of claim 10, wherein the substrate comprises a waterproof finish panel.
19. The system of claim 10, wherein each of the plurality of cladding panels comprises a gap between the substrate and the external surface of the building when the plurality of cladding panels is installed on an exterior surface of the building.
20. The system of claim 19, wherein the gap is filled, either partially or entirely, with a rigid insulation layer.
21. The system of claim 10, wherein the plurality of fasteners are integrally formed in the second surface of the structural frame.
22. A method of covering an external surface of a building, the method comprising: producing a plurality of cladding panels, each of the plurality of cladding panels comprising: a structural frame;a substrate attached to a first, external, surface of the structural frame; anda plurality of fasteners that are formed on a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to a predetermined pattern;arranging a plurality of cladding alignment features on the external surface of the building according to the predetermined pattern;aligning each of the plurality of fasteners with a corresponding one of the plurality of cladding alignment features on the external surface of the building; andattaching each of the plurality of fasteners to the corresponding one of the plurality of cladding alignment features.
23. The method of claim 22, wherein producing the plurality of cladding panels comprises, for one or more of the plurality of cladding panels, forming one or more openings through an entire thickness of the substrate, each of the one or more openings corresponding to an opening formed in the external surface of the building.
24. The method of claim 22, comprising attaching a siding material to a surface of the substrate that is opposite a surface of the substrate by which the substrate is attached to the structural frame.
25. The method of claim 22, wherein the building comprises a plurality of modular units assembled together to form the building.
26. The method of claim 25, wherein the plurality of cladding alignment features are rigidly attached to connectors affixed to exterior surfaces of each of the plurality of modular units.
27. The method of claim 22, wherein: for one or more of the plurality of cladding panels, each of the plurality of fasteners comprises a tapered slot;each of the plurality of cladding alignment features comprises an alignment peg;each alignment peg comprises a collar and a head attached to an end of the collar, the head having a width that is greater than a width of the collar; andthe width of the head is greater than a width of a narrow end of the tapered slot.
28. The method of claim 27, comprising orienting each tapered slot such that, when the plurality of cladding panels is affixed to the building, the alignment peg is moved into the narrow end of the tapered slot and held in place by a gravitational force.
29. The method of claim 22, wherein the substrate comprises a waterproof finish panel.
30. The method of claim 22, wherein the plurality of cladding panels is attached to the building such that a gap exists between the substrate and the external surface of the building.
31. The method of claim 30, comprising filling the gap, either partially or entirely, with a rigid insulation layer.
32. The method of claim 22, wherein each of the plurality of fasteners is formed in the second surface of the structural frame in a unitary manner.
33. A building comprising: a plurality of modular units assembled together to form the building;a plurality of connectors affixed to exterior surfaces of each of the plurality of modular units, the plurality of connectors comprising a plurality of cladding alignment features, wherein the plurality of cladding alignment features are rigidly attached to and extend from an external surface of the building according to a predetermined pattern; anda plurality of cladding panels, each of the plurality of cladding panels comprising: a structural frame;a substrate attached to a first, external, surface of the structural frame; anda plurality of fasteners that are formed on a second, internal, surface of the structural frame, the plurality of fasteners being arranged according to the predetermined pattern, such that each of the plurality of fasteners is configured for alignment with one of the plurality of cladding alignment features;wherein each of the plurality of fasteners is configured for attachment to a corresponding one of the plurality of cladding alignment features;wherein each of the plurality of cladding panels is affixed to one or more of the plurality of modular units.
34. The building of claim 33, wherein the building comprises a plurality of modular units assembled together to form the building.
35. The building of claim 34, comprising a plurality of connectors affixed to exterior surfaces of each of the plurality of modular units, wherein the plurality of cladding alignment features are rigidly attached to and extend from the connectors for engagement with the fasteners, and wherein adjacent ones of the plurality of connectors interlock with each other to secure adjacent ones of the plurality of modular units together.
36. The building of claim 33, wherein one or more of the plurality of cladding panels comprises one or more openings formed entirely through a thickness of the substrate thereof, each of the one or more openings corresponding to an opening formed in the external surface of the building.
37. The building of claim 33, wherein each of the plurality of cladding panels comprises a siding material attached to a surface of the substrate that is opposite a surface of the substrate by which the substrate is attached to the structural frame.
38. The building of claim 33, wherein: for one or more of the plurality of cladding panels, each of the plurality of fasteners comprises a tapered slot;each of the plurality of cladding alignment features comprises an alignment peg;each alignment peg comprises a collar and a head attached to an end of the collar, the head having a width that is greater than a width of the collar; andthe width of the head is greater than a width of a narrow end of the tapered slot.
39. The building of claim 38, wherein each tapered slot is oriented such that, when one of the plurality of cladding panels is affixed to the external surface of the building, the alignment peg is moved into the narrow end of the tapered slot and held in place by a gravitational force.
40. The building of claim 33, wherein the substrate comprises a waterproof finish panel.
41. The building of claim 33, wherein each of the plurality of cladding panels comprises a gap between the substrate and the external surface of the building when the plurality of cladding panels is installed on the exterior surface of the building.
42. The building of claim 41, wherein the gap is filled, either partially or entirely, with a rigid insulation layer.
43. The building of claim 33, wherein the plurality of fasteners are integrally formed in the second surface of the structural frame.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent Application Ser. No. 63/112,965, which was filed on Nov. 12, 2020, the disclosure of which is incorporated herein by reference in its entirety.

PCT Information

Filing Document	Filing Date	Country	Kind
PCT/US2021/059106	11/12/2021	WO

Provisional Applications (1)

	Number	Date	Country
	63112965	Nov 2020	US

MODULAR CLADDING PANELS FOR BUILDINGS AND ASSOCIATED METHODS

Information

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Date Filed

Date Published

Inventors

Original Assignees

CPC

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Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATION

PCT Information

Provisional Applications (1)