The present invention pertains generally to the construction industry and more particular it relates to manufacture and installation of shadow screen structures.
In construction industry sunscreens have been used for various purposes including window solar screens, double facades, shaded facades (including controlled ones with various drives). U.S. Pat. No. 6,161,362 discloses a roof shading structure. U.S. Pat. No. 10,627,134 B2 teaches double facade heating and ventilation control. Also technically complex are the variety of rotary systems for creating shadows (US 2009/0320388 A1, US 2005/0022452 A1). Among major factors of a delay in the construction of the shaded facades are relatively high cost and complexity of installation and maintenance. However, more structurally simple and cheap shading facades also have a number of drawbacks.
Various structures containing tension screens are widely known. Their common features typically include a supporting frame structure (the most common frames are made of steel or aluminum), and the material stretched within these frames. Usually a semi-permeable plastic (mesh type PVC), as well as a tarpaulin or other shading fabrics are used for manufacturing of the screens. Common features of the erected shading facades are the relative constructive simplicity, reliability and cheapness of the. Examples of such designs are U.S. Pat. No. 9,512,670 B2 and US20170191262A1. The geometric shape of the surface of such shading facades is determined mainly by the shape of their frames.
Typically, majority of solar facades are mounted at a short distance from the outer building wall. For this reason, it is difficult to mount shading panels on facades having complex geometry. Also, it is quite difficult or impossible to provide shading facades where external units of air conditioners, satellite dishes are present.
Further, these shading screens cannot be erected if there are stairs and decks outside the rear of the buildings for maintenance of external enclosing structures or evacuation stairs.
Thus, it has been an acute need for a universal, easy-to-use, easy-to-handle shading system, which can also be placed on facades of complex shape, with installed air conditioners and other communications.
It has been also a need to update or repair facade screens without special equipment and the services of highly specialized labor, etc. There is a further need for a sun protection solutions, which are easy to maintain and repair, allowing a user to close facades of almost any shape and to provide quick access to its elements. The system of the invention is developed to satisfy these needs and requirements
The invention is aimed at simplifying the design, increasing the degree of factory readiness, increasing the installation rate, and expanding the architectural capabilities of the shading facade. The invention provides a shading facade of a modular type which incorporates the following technological solutions: a frame and a decorative module joined together, both vertically and horizontally, by fasteners located at the corners of these modules, into single entity of various configurations, shapes and numbers of floors.
This modular shading facade of the invention provides for placement of external blocks of various domestic devices, technical ladders and flooring for building maintenance (windows, roof, facade), as well as for more aesthetic appearance of the building.
The shading facade of the modular type boasts simplified design (the modules from which the structure is assembled have unified elements manufactured according to single technology and from the same material); increased degree of factory readiness (modules are 100% factory-assembled); increased installation rate (modules need to be just joined together into a single entity at construction site using fasteners); increase in design configuration options (due to joining together of modules of various dimensions, as well as possibility of their inclined placement).
The shading facade of the invention consists of reassembled elements: a framework module and a decorative module joined together into an architectural element. The modules of the shading facade can be of different dimensions, which allows one to shape various geometric forms necessary for creation of any fancy architectural design.
The frame module mainly consists of metal posts and crossbars, which can be supplied to the site as a single pre-assembled module or in elements. The decorative module consists of a spatial framework made of structural aluminum profile joined together with specialized fasteners (metal angle). Decorative material is stretched over the frame and affixed with a rubber tourniquet of circular cross-section.
Fixation of the decorative module on the frame of the shading facade is carried out using a sheet metal bracket. Lattice flooring and modular stairs are used for the maintenance of the shading facade. As for engineering networks, namely installation of an air conditioner external unit, a tubular steel frame bracket is used.
Installation of the modular shading facade is carried out on a floor-by-floor basis, its assembly starts with its placement on solid surface and connection of the framework modules at the same height in accordance with the project. The framework module consists of tubular steel or anodized aluminum elements and cross pieces made of 40×40 mm pipe bolted together through pre-drilled (cut-out) holes or welded flanges, with frame dimensions ranging between 500×500 mm and 3500×3500 mm with a width of up to 2000 mm. Protective polymer-powder coating is applied to all metal elements.
When assembling the shading facade for efficient and comfortable installation, a flooring made of galvanized lattice flooring is installed at each floor level.
After the assembly of the frame at a given floor level is completed, brackets for mounting decorative modules are installed at the module junctions. Decorative module framework consists of tubular elements joined together with the metal brackets. The decorative module framework dimensions are determined by the size of the framework module where it should be installed. At the frame corners, 600 mm lengths of square rods are attached at an angle of 90 degrees for attachment of frame to the elements of the shading facade. The decorative element of the module can be any material such as translucent PVC mesh, thick PVC film with (or without) UV printed pattern, tarpaulin, etc. Shading material is attached to the frame with a rubber harness pressed into the grooves of the profile.
The ladders may be located on different sides of the shading facade and made of 40×40 mm tubular steel for standards and 15×15 mm tubular steel for cross pieces. The ladder elements are interconnected by welding and painted with polymer-powder coating.
To fix the air conditioner external units, a tubular steel rack is fastened to the shading facade framework using bolts and nuts.
Features and advantages of the described shading facade are as follows:
In the following drawings, the same parts in the various views are afforded the same reference designators. Referring now to the drawings which are provided to illustrate and not to limit the invention, wherein:
The devices and methods discussed herein are illustrative of specific methods of making and using this invention only and should not be interpreted as an exclusive full description of the capabilities of the technology.
While the devices and methods are described herein with a certain degree of specificity, it should be noted that many modifications can be made to the design details and arrangement of the devices and components without departing from the spirit and scope of this disclosure. It is understood that the devices and methods are not limited to the embodiments set forth herein for purposes of illustration.
In general, the invention relates to a new, unique, lightweight modular shading system for building facades, which has an excellent appearance and has many applications. The system allows, in particular, to build a frame from ready-made modules floor by floor; a unique bracket allows you to adjust the distance between the shading screen and the bearing wall of the building, change the angle of the decorative shading elements relative to the vertical plane of the frame within certain limits, as well as place the necessary communications, remote elements of household appliances, gratings, stairs for people to move in the enclosed space, etc.
It is possible to simplify the manufacture/assembly of the shading facade according to the present invention. Most of the modules described can be assembled in five minutes or less, keeping labor costs at a reasonable level. All parts of the modules have standard dimensions and are made with sufficient accuracy, which are assembled into modules with the help of fasteners or even welding.
The system in the first approximation consists of a fairly rigid cellular modular frame (the shape of which is determined by structural and aesthetic considerations), which is completely or partially covered/surrounded by decorative modules, which in turn consist of a rigid frame, a shading/decorative material fixed on this frame, and as well as special square rods for fixing and adjusting the position of this decorative module in a specific cell of the shading facade frame using a special bracket.
Elements of the frame module and decorative module, as well as other necessary elements, can be solid or hollow and can be formed as one continuous “curved” frame for strength and uniformity, or a collapsible structure from parts (posts, crossbars, rods, diagonal braces). The frame can be made from a variety of materials such as galvanized steel pipes, aluminum, durable engineering plastic or fiberglass. If desired, you can also use some types of wood that have sufficient strength and load-bearing capacity, especially certified sustainable lumber. It is assumed that for the details of the frame and frame of the decorative module, a strong and lightweight galvanized steel pipe can be chosen. All the necessary connecting parts of the posts, longitudinal and transverse crossbars, diagonal braces can be welded (in the case of a steel pipe), screwed using fasteners (bolts or screws) if the material of the shading facade frame and decorative module frame is galvanized steel, structural plastic, aluminum or wood.
A description of the design of the facade shading system is given here using rolled metal (steel and aluminum) as an example. It is recommended to use a protective powder-polymer coating (for steel) or anodizing (for aluminum) when using this shade facade system in coastal, tropical or cold temperate regions. In the case of wood, it is recommended to use protective compounds against insect pests and weather factors.
The facade shading system consists of at least one frame module with a decorative module attached to it.
Referring now to
Among essential elements illustrated in
The rigid modular frame of the shading facade is formed by vertical posts 1, 2, 3, 4 (see also
The main functions of the frame include the adjustment of the position and fixation of decorative modules—individual elements, which include, for example, frame structures of various sizes and shapes (see also
For ease of explanation, the invention also singles out the outer, peripheral plane (part) of the facade, formed by posts and longitudinal crossbars, to which decorative modules are attached, as well as the near-wall plane (part), the longitudinal crossbars and posts of which are attached directly to the wall of the building.
The frame illustrated in
Referring now to
Posts 1 of the first, basic level are installed directly on the blind area of the building or on a special foundation designed and installed in accordance with local building codes. In one embodiment of the invention, elements of the posts, longitudinal and transverse crossbars can be made of steel square-shaped pipes. The design of the posts of the base level involves screw adjustment 17 (
Holes for attaching additional, special longitudinal and transverse crossbars and diagonal braces can be drilled during the manufacture of products at the enterprise according to the project or directly at the installation site, depending on the configuration.
Standard posts 2 of the next levels do not need screw adjustment, so their design is simpler. The extension of additional posts of all types to increase the height of the frame one level up is carried out, for example, by installing the next, upper post onto a special narrow part of the previous, lower post. The latter is formed by a spacer 19, followed by fixation using a clamp passing through both connected posts of the fasteners 21, i.e., through a hole in the spacer 19 of the lower post and the hole 20 in the upper post. Attachment (by welding for example) of a metal connecting spacer to the main pipe of the rack during the manufacture of the products or directly at the installation site, depending on the configuration, is carried out, for example, through holes under the upper mounting angles.
Post placement is not always taking place on the concrete base or spacer of the previous post. In such instances, a modification of the post 3 is used, where, for example, two mounting angles 22 are welded from below to fix the post with, for example, fasteners to the supporting elements of the frame, for example, longitudinal/transverse crossbars.
To complete the appearance of a shading facade, a post with a non-standard height may be required, such as the post 4 on the last level of the facade. Such post can be formed from a standard intermediate post 2 by cutting the element to the desired length and drilling a hole for the bolted connection 21 at the assembly site. If necessary, mounting angles 18 can be added in the right combination for a specific post.
Basically, use any combination of connection options, both the same at both ends of the post, and different ones, including those not specifically described are within the scope of the invention.
Referring now to
As noted above, the mounting angles 18 of the posts of the frame are elements for fastening standard transverse crossbars 5, and longitudinal crossbars 6, 7, which have holes for bolted connection at both ends of the pipe. Standard and special transverse crossbars are identical in design and set of functional elements with standard and special longitudinal crossbars, they differ mainly in a significantly shorter length.
The design of standard longitudinal and transverse crossbars, as in the case of standard posts, can be of various lengths. It is also possible to cut these elements to the desired size with drilling new mounting holes, if necessary, for example, at the assembly site. It is also possible to use special brackets 23 for fastening the crossbars from the near-wall plane of the frame to the wall of the building with using a stud 25 fixed at one end in this wall, while its other end is threaded through the bracket 23 and fixed, for example by tightening the nut.
Special horizontal elements such as longitudinal crossbars 8 can be either identical in length to standard ones or different. Also, if necessary, such elements can be supplied with brackets 23 for similar fastening to the wall by the stud 25. Special longitudinal and transverse crossbars are attached to the vertical posts, for example, by means of a bolted connection through brackets 24 at both ends of the crossbars. Holes in vertical posts for screwing brackets 24, using, for example, bolts, can be drilled directly at the assembly site. Special crossbars 8 are usually used in the near-wall plane of the frame, for example: a) changing the height of the opening in the facade frame, for example, for windows and doors; b) support of hinged elements inside the shading facade in near-wall space, for example, brackets for the external unit of the air conditioning system (
Posts, longitudinal and transverse crossbars, or their parts, can also form separate functional structures, for example, the platform frame 14 for accessing the roof from a shading facade, while simultaneously combining in its composition, for example, a frame structure, grating and stairs.
Basically, use of any combination of connection options, both the same at both ends of the longitudinal or transverse crossbar, and different ones, including those not described here, is within the scope of the invention.
Posts with longitudinal or transverse crossbars are connected, for example, using bolted fasteners, primarily for the possibility of changes and disassembly of the frame. However, other methods are also contemplated, including welding if metal is used as the main frame material.
The diagonal brace illustrated in
For additional vertical (and sometimes horizontal) structural rigidity, diagonal braces are installed in multi-level frames, for example, square shaped 9 or rectangular shaped 10 braces (
Parts of the shading facade frame can be supplied both assembled and as separate elements. As a finished product, assembled and fixed to the building facade, the shading facade frame is one/multiple frame cells, mainly used to install and adjust the position of one/multiple decorative modules (panels) (
The decorative module shown in
As illustrated in at least
As discussed in the application, in addition to be a part of the frame 51 periphery used in the decorative module 29, the receiving bracket 32 are also adapted to accommodate the legs 31 used to adjust and fix the decorative module 29 within the shading facade. This occurs by inserting the legs 31 into a primary bracket 57 (see
Referring now to
Similarly, a part 323 has a hole 327 for removable retaining the leg 31 and holes 328 and 329 for removable connection of the part 323 to the frame of the module 29.
The removable connection also involves the part 322 being provided with projections 332 and 333 for insertion into slots 335 and 334 of the base 321, respectively. Further, to assure the removable nature of the connection, protrusions 330 and 331 are also inserted into the grooves 334 and 335 of the base 321.
In this case, the flat base 321 of the receiving bracket faces surface of the stretched decorative material, thus preventing the end part of the legs 31 from damaging the material/fabric 33.
Segments 30 and 30A formed with a semicircular or square grooves 63 along the entire length thereof are utilized for stretching suitable, relatively soft and hard materials/fabrics 33 over the entire area of the frame. This is needed to provide partial or complete shading of the facade. Fixation of the position of the stretched material or fabric 33 to the frame is carried out by their pressing into the grooves 63. In such application, after placing an edge of the material/fabric into the respective groove, a resilient cord 34, having a diameter equal to or slightly smaller than the depth of the groove 63 is inserted there inside. Thus, the resilient cord 34 presses and retains the stretched edge of the material within the groove along the entire perimeter of the frame of the decorative module 29. This provides a secure fixation of the material without damaging its integrity, and also allows repeatedly and quickly mount and dismantle the material or fabric. It should be noted that attaching the stretched fabric to the frame of the decorative module 29 by any other convenient and accessible way is within the scope of the invention.
The primary bracket 57, illustrated in
Referring now to
The primary brackets 57 also serves as guides for adjusting the position of decorative modules 29 relative to the vertical plane of the frame of the facade shading system (
As more specifically illustrated in
The assembly illustrated in
Each socket 53 is defined by three regions interposed at an angle to each other, an eyelet with a hole 361 is provided for fixing to the uprights and rungs of the shading facade frame using a fastener 38 (see
When assembled the elements 36 and 37 are interconnected to form a continuous nest having a square or rectangular cross-section by inserting four protrusions 371 of the element 37 into the slotted grooves 365 of the corresponding element 36. The resulted structure can be permanently fixed by any conventional means including spot or continuous welding.
After the primary socket 53 is assembled, it is placed using multiple protrusions 362 and multiple protrusions 372 into recesses 351 at edges of the openings 51 in the base 35, as well as by positioning of protrusions 363 into the grooves 352 in the base 35.
The elements 36 are provided with four holes 364 to accommodate fasteners 39 for clamping the leg 39. For example, this can be done with a T-shaped nut in the case of using a square a cross section aluminum profile for the leg 31.
Four holes 373 can also serve for a similar purpose. There are multiple holes 353 are formed in the base 35 for additional fixation of the base 35 to the posts and beams of the frame of the shading facade
The length of the legs 31, which can be in the form of rods having square-shaped cross-section, is up to 600 mm. Adjusting the position of the decorative module 29 using the legs 31 includes setting the distance of each corner of the decorative module from the surface of the base 35, that is, the angle between the surface of the decorative module 29 frame and the peripheral plane of the shading facade's frame. Distance adjustment is carried out by inserting the legs 31 into the bracket 36 of the primary bracket 57 to a certain depth. The fixation of the predetermined position is carried out, for example, by clamping the fasteners 39 after the required position is set. To restore the possibility of adjusting such position, it is enough to loosen the fasteners 39. As illustrated in
The decorative module 29 can be decorated with various materials, in particular, various types of semi- or impermeable, resistant to environmental factors, artificial polymer fabrics, as well as those made from natural raw materials, for example, translucent reinforced PVC, linen fabric etc. These examples do not limit the range of possible materials, in fact, it is possible to use a material/fabric that are sufficiently flexible (“elastic”) so that the material/fabric can be stretched over the frame of the decorative module 29 and, with temperature changes, the material returns to its original shape. The material/fabric, after being pressed into the frame of the decorative module 29, should become self-tensioning, for example, due to its ability to slightly stretch and enclose the rigid frame of the module 29 of various sizes. The flexibility and slight “flexibility” of the preferred materials/fabrics for facing the frame of the module 29 will allow them to be stretched over any configuration of the frame of the decorative module 29. According to the inventor's knowledge, such modular decorative panels are unique and innovative as panels of this type have never been made from this material before (e.g., shading materials/fabrics used in horticulture, outdoor furniture fabrics, etc.). The width and length of the piece of fabric must exceed the width and length of the frame of the decorative module 29 by at least 150 mm in each change, it is also recommended to make square cutouts at the corners of the piece of fabric to facilitate wrapping the vertical and horizontal elements of the frame with the edges of the canvas.
Double or even triple overlay of materials/fabrics on each other can be performed before installing a decorative module 29 on the frame to give the canvas higher performance properties.
The material/fabric for the decorative module can be covered in different colors, have a three-dimensional (3D) texture, or combine different types of materials/fabrics, or a combination of colors/material types of the same kind.
For energy efficiency, environmental purposes, or other considerations, a material/fabric may be a single, versatile, high-performance material (or material of a single color). Logos, messages and/or any images can be applied to the decorative module material/fabric, for example by UV printing or by any other available method. Decorative modules can be swapped seasonally to increase the efficiency of the module and/or extend the life of the module as a whole or any of its components. Decorative modules do not have to be installed exactly parallel to the wall or other surfaces, they can be installed to a certain extent at any angle and at various distances from the peripheral surface of the facade frame, if necessary for decoration, durability, maintenance, performance or other reasons.
The shading facade, created by one or more decorative modules with a stretched semi-permeable or almost impermeable fabric, creates a volume around the shading surface of the building with a relatively slow-moving air space, the volume and thickness of which depend mainly on the depth of the selected frame. Thus, the volume of air enclosed in this space can also be used as an additional thermal insulator, similar to its use as part of double facades.
From the study of majority of materials it appears that most of the infrared heat is absorbed by the surface of the decorative module, namely on the canvas, and does not pass through it.
A substantial amount of air space inside the facade shading system can be created by increasing the depth of the frame module, i.e., increasing the distance between the near-wall plane of the shading facade and the peripheral plane formed by the surfaces of decorative modules. An increase up to approximately 2000 mm can be achieved: a) by using elongated (up to 1500 mm) transverse crossbars 5 as part of a rigid facade frame; b) due to extension into the outer space relative to the peripheral plane of the modular frame frames of decorative modules 29 (
With a sufficiently wide gap developed between the wall of the building and the shading facade, it is possible to place gratings in the resulting space (
Among essential elements of
By increasing the distance between the wall of the building and the shading facade also makes it possible to place in the resulting space, for example, brackets for external units of household air-conditioning split systems (
Among essential elements of
Together with gratings it is also convenient to place, for example, stairs (
One of the key advantages of the shading facade system of the invention is its reusability, ease of handling and manufacturing, as well as the ability to change, dismantle and recycle. If necessary, various modules or their components can be easily replaced or, for example, temporarily dismantled for repair. The design of the shading facade system makes it possible to remove any individual decorative module or several modules from the facade frame for maintenance or other reasons, without disturbing (or specifically removing) adjacent decorative modules. All components of the frame module and connecting components can be made from any material strong enough to maintain the required rigidity under any (or mostly expected) conditions while still providing the necessary support. In some cases, an overly rigid structure is not required; this means that some degree of flexibility of the entire decorative module (including the frame itself) may be preferred depending on where and for what purpose the module is intended to be used.
Modules, individually or as a group, can also be made waterproof for certain applications by stretching a waterproof material, such as a sheet or sheets of heavy-duty plastic, over the front of the module.
The shading facade according to the present invention, due to its design and insulation characteristics, can be used to create self-contained structures providing shelter from excessive heat, cold and wind, precipitation (including hail), even if they are not waterproofed. The decorative modules of the present invention can provide blocking/damping of light, heat transfer, hail and/or wind blows anywhere in many industries, including but not limited to: residential buildings, civil infrastructure buildings and structures, industrial plants, agriculture etc.
The decorative modules of the present invention can also be used as a sound absorbing panel or an acoustic panel.
The front side of the decorative module can be treated individually for UV protection or improved fire resistance. Therefore, the shading facade of the present invention may be important for building applications.
It has been discussed above that the present invention provides modular shading facade, spaced from the building wall, and consisting of various elements, including a set of frame module elements and a set of functional elements. The functional elements of the shading facade are decorative modules, stairs, grating, brackets for communications (for example, air conditioners, antennas, etc.). The frame module is attached to the facade of the building with a set of adjustable threaded studs.
This application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 63/233,911 filed Aug. 17, 2021, the entire disclosure of which is incorporated herein by reference.
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Number | Date | Country |
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Number | Date | Country | |
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20230279667 A1 | Sep 2023 | US |
Number | Date | Country | |
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63233911 | Aug 2021 | US |