The present invention is related to a paneling system, and more particularly, to a paneling system including a panel that is secured to a surface with one or more fastening elements that extend across a height of the panel.
In response to increasing concerns associated with the disposal of traditional asphalt roofing shingles as well as other roof products that cannot be recycled, numerous metal roofing and siding systems have been developed. Some metal roofing systems have employed standardized sized shingles that interconnect one another in an attempt to form a moisture proof barrier. Typically, the edges of each shingle are overturned in a manner that allows a specified side of the shingle to engage adjoining shingles. Although this system provides adequate results in mild weather conditions, the joint between the shingles often leaks in severe weather.
In an attempt to overcome this problem, a vertical seam panel system was developed where metal panels are provided that extend from the eaves of the building to the ridge. A plurality of panels are placed side-by-side along the length of the structure. Although this system removed the horizontal seams, the vertical seams were still subject to moisture penetration. Additionally, transportation of the relatively large panels can be costly and in some circumstances prohibitive.
Other prior art systems have been developed using continuous length panels rolled from coils of metal. The advantage of such a system is that the coil can be cut so a single panel can extend the entire length of the building. A plurality of panels can be attached to the roof starting at the eaves and working towards the ridge. As the panels are connected together, horizontal seams are formed that extend along the length of the building. While continuous length panels have the benefit of a reduced number of seams, one problem is the ability to properly secure the long panels to the underlying structure. Additionally, it has been difficult to retain the rigidity of the panels often resulting in buckling of the panels.
Prior art attempts to secure the panels to the underlying structure include clips that connect to the upper end of the panel and are then screwed to the roofing substrate. Typically, the clips are designed to be as short as possible in order to avoid being visible after the subsequent panel is installed. The drawback to such a system is that although the panels may be cut to the length of the building, the panels lack sufficient strength over a predetermined length. Therefore, the panels are subject to buckling, referred to as oil canning in the art, and damage in the event of severe weather. This is evidenced in U.S. Pat. No. 5,355,649, which discloses a horizontal roof panel system that includes an expansion joint that can be used to connect two adjoining panels side by side. The problem with such a system is that a vertical joint is created, which is generally not desired. Therefore, the expansion joint creates an additional location susceptible to leaking.
The present invention overcomes this and other problems and an advance in the art is achieved by providing a substantially continuous panel that reduces the number of seams thereby reducing the potential for moisture penetration. The present invention also provides a structurally strong and aesthetically pleasing paneling system. The present invention allows for a customized aesthetic appearance.
A paneling system is provided according to an embodiment of the invention. The paneling system comprises a panel and one or more fastening elements. The fastening elements are coupled to the panel. The fastening elements extend from a first edge of the panel to a second edge of the panel.
A fastening element for a paneling system is provided according to an embodiment of the invention. The fastening element includes a coupling tab formed at a first end of the fastening element. The coupling tab is adapted to couple to a first edge of a panel. The fastening element also includes an engagement lip. The engagement lip is formed at a second end of the fastening element. The engagement lip is adapted to couple to a second edge of the panel.
A method for paneling a surface of a building is provided according to an embodiment of the invention. The method comprises positioning one or more panels on the surface of the building. One or more fastening elements are coupled to a panel of the one or more panels. The fastening elements extend from a first edge of the panel to a second edge of the panel. The fastening elements are then coupled to the surface of the building.
Aspects
Preferably, the one or more fastening elements comprise a coupling tab.
Preferably, the coupling tab is provided at an angle (θ) with respect to a longitudinal axis of the fastening element.
Preferably, the paneling further comprises an aperture formed in the coupling tab and adapted to receive a fastening member.
Preferably, the paneling system further comprises an engagement lip formed on a fastening element of the one or more fastening elements.
Preferably, the one or more fastening elements further comprise a rib.
Preferably, the panel comprises one or more lips.
Preferably, the one or more fastening elements are coupled to the one or more lips.
Preferably, the one or more fastening elements include one or more stops.
Preferably, the fastening element further comprises an aperture formed in the coupling tab.
Preferably, the fastening element further comprises a rib.
Preferably, the fastening element further comprises a seal formed in at least one of the coupling tab and the engagement lip.
Preferably, the fastening element further comprises a stop.
Preferably, the method further comprises the step of extending the one or more panels substantially entirely across a length of the surface of the building.
Preferably, the method further comprises the step of coupling a first lip formed on a first panel to a second lip formed on a second adjoining panel to form a substantially water tight seal.
Preferably, the method further comprises the step of coupling a sealing member to at least one of the first lip or the second lip.
Preferably, the step of positioning the one or more panels on the surface of the building comprises positioning adjoining panels such that a horizontal seam is formed.
Preferably, the step of coupling one or more fastening elements to the panel comprises positioning the one or more fastening elements at substantially regular intervals along a length of the panel.
Preferably, the step of coupling one or more fastening elements to the panel comprises coupling the one or more fastening elements to a first lip and a second lip of the panel.
Preferably, the step of coupling one or more fastening elements to the panel comprises coupling the one or more fastening elements to a top surface of the panel.
Preferably, the method further comprises the step of coupling one or more stops to the one or more fastening elements.
The paneling system 100 comprises a panel 101 and one or more fastening elements 102. The panel 101 may comprise any desired metallic or synthetic material. Although, Kynar 500® painted Galvalume® and aluminum has been widely accepted in the art due to its durability, those skilled in the art will readily recognize alternative materials that may be used. The panel 101 may be painted to any desired color. In the embodiment shown in
The panel 101 comprises a length 103 and a height 104. Although not shown to scale, it should be appreciated that the panel 101 also comprises a thickness that is based primarily on the thickness of the metal coil or other material used to form the panel 101. According to an embodiment of the invention, the length 103 can be customized to extend substantially the entire length of the building (not shown). However, it should be appreciated that the panel 101 does not have to extend the entire length of the building. In some embodiments, multiple panels may be used to form a single row. This may be required in extremely long surfaces where thermal expansion makes extending a single panel the entire length prohibitive. In other embodiments, the particular material used to form the panel 101 may limit the desired length for a single panel to a predetermined length, for example sixteen feet. Further, the use of multiple panels to form a single row may be required in embodiments where the panels are formed away from the job site at predetermined lengths, for example ten feet. In this embodiment, the panels may be coupled together side by side according to known methods. Various methods are known from U.S. Pat. No. 5,613,337; U.S. Pat. No. 5,355,649; and U.S. Pat. No. 5,956,913, for example. The panel 101 may be formed from a metal coil using a metal roll former or similar device to form the panel 101 into a desired length. Advantageously, the panel 101 can be formed on the job site eliminating the need to custom order each panel 101 and then deliver pre-cut panels. This on site forming can reduce the cost of shipping as well as reduce the time required to finish the job in the event that a panel is not initially formed to the appropriate size.
In some embodiments, it may be desirable to provide a design on the panel 101. Therefore, the panel 101 may be embossed using an embossing roller prior to forming and cutting the panel 101. For example, a metal coil or a flat sheet may run through the embossing roller prior to being formed into the panel 101 and cut to the desired length. Embossing a design on the panel 101 can provide a number of advantages. One advantage is that the design can provide additional grip to the panel 101. This can reduce danger of walking on the panel 101 during installation, for example, when the paneling system 100 is installed on a roof. The embossed design may comprise a diamond or some other irregular shape. Another advantage is that the embossed design can be chosen to reflect sunlight. One of the major concerns with metal roofing is the sun glare experienced as the sun is reflected off from the metal. The embossed design can aid in dispersing the reflected light so as to create the appearance of a duller finish. There are numerous additional advantages in embossing a design onto the panel and the particular examples provided should not limit the scope of the invention.
According to an embodiment of the invention, the height 104 can be chosen depending on the particular application. For example, a standard height for metal coil may be approximately 12 inches. However, if other heights are desired, other metal coils, flat metal sheets, or panels 101 formed from other suitable materials may be chosen. Those skilled in the art will readily recognize other suitable materials that may be used to form the panel 101 based on the particular application.
According to an embodiment of the invention, the panel 101 also includes lips 105 and 106. The lip 105 is shown at the top edge 110 of the panel 101 while the lip 106 is shown at the bottom edge 111 of the panel 101. As can be seen, the lips 105, 106 are extending in opposite directions. The lip 105 folds over the top surface 107 of the panel 101 and extends towards a bottom edge 111, while the lip 106 folds beneath the panel 101, and faces the bottom surface 108 extending towards the top edge 110 of the panel 101. The lips 105, 106 of adjoining panels may engage one another to couple adjoining panels 101 together. In this manner, adjoining panels 101 can be coupled to one another. Additionally, the fastening elements 102 can engage the lips 105, 106 to retain the panels 101 as described in more detail below.
As shown in
According to an embodiment of the invention, the fastening elements 102 comprise a longitudinal axis X-X that extends substantially the entire height 104 of the panel 101. The fastening elements 102 can engage the lips 105, 106 at the top 110 and bottom 111 edges of the panel 101. The fastening elements 102 may also rest on the top surface 107 of the panel 101. According to an embodiment of the invention, the fastening elements 102 can include an engagement lip 115. The engagement lip 115 can be provided to engage the lip 106 formed on the panel 101. The engagement lip 115 may be sized and shaped to wrap around the lip 106 of the panel 101, for example. The engagement lip 115 can assist in securing the fastening element 102 to the panel 101. Furthermore, the fastening element 102 can include a coupling tab 112. The coupling tab 112 can engage the lip 105 formed at the top edge 110 of the panel 101. The coupling tab 112 therefore, can be provided to assist in coupling the fastening element 102 to the panel 101. The engagement of the lip 115 and coupling tab 112 is shown in greater detail below.
Because the fastening elements 102 extend substantially the entire height 104 of the panel 101 rather than being located only at the top as in the prior art, the fastening elements 102 can also strengthen the panel 101. This not only allows the paneling system 100 to be installed in severe weather climates, but also allows a single panel 101 to extend substantially the entire length of the building, if desired. With the fastening elements 102 extending across the height of the panel 101, an expansion joint as described in the prior art is not needed. Thus, the vertical seams of the prior art can be substantially reduced, or eliminated. Therefore, the panel system 100 of the present invention provides an improvement over the prior art.
The fastening elements 102 may also be used to couple the panel 101 to the roofing substrate (not shown) or other underlying surface. As shown in
According to an embodiment of the invention, the fastening elements 102 can also provide aesthetic enhancement to the panel system 100. Unlike prior art fasteners that are hidden from view, the fastening elements 102 of the present invention are visible. Therefore, the fastening elements 102 may take any number of shapes, colors, and materials, as desired. As shown in
While the fastening elements 102 and 202 are shown relatively narrow and occupy a small width of the panel 101, it should be appreciated that in other embodiments, the fastening element 102 may take the shape of a tile and comprise a much larger width, thereby covering a larger portion of the panel 101. Therefore, the particular width shown should in no way limit the scope of the present invention.
To couple the panels as shown in
Once the panel 101a is in position, the fastening elements 102 would then be coupled to the top surface 107 of the panel 101a. The fastening elements 102 can be coupled to the lip 106 using the engagement lip 115 as well as to the lip 105 using the coupling tab 112. As can be appreciated, the coupling tab 112 may be bent multiple times to correspond to the shape of the lip 105 in order to rap around the lip 105. This is shown in greater detail in
In some embodiments, the simple overlapping of the lips 105, 106 may provide a sufficient waterproof sealing. However, as can be appreciated, in other embodiments, a separate sealing member, such as foam, rubber, etc., may be positioned between the lips 105, 106 in order to increase the sealing capabilities of the paneling system 100. As shown in
In contrast, the fastening element 102 shown in
The upward movement of the fastening element 102 results in increased tension in the fastening element 102. This increased tension reduces movement of the fastening elements 102 along the length 103 of the panels 101 while being installed as well as during severe weather. Consequently, the fastening element 102 with the angled coupling tab 112 provides a stronger and more secure paneling system 100.
The embodiments described above include the coupling tab 112 coupling over the lip 105. It should be appreciated however, that in other embodiments, the lip 105 may comprise an aperture 650. The coupling tab 112 can then extend through the aperture 650. Such a configuration is shown in
According to an embodiment, because the curvature in the fastening elements 102 raise the panels 101 proximate the lip 106, a longer fastening element 102 and wider panel 101 is required in order to maintain contact with the underlying substrate.
The detailed descriptions of the above embodiments are not exhaustive descriptions of all embodiments contemplated by the inventors to be within the scope of the invention. Indeed, persons skilled in the art will recognize that certain elements of the above-described embodiments may variously be combined or eliminated to create further embodiments, and such further embodiments fall within the scope and teachings of the invention. It will also be apparent to those of ordinary skill in the art that the above-described embodiments may be combined in whole or in part to create additional embodiments within the scope and teachings of the invention.
Thus, although specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. The teachings provided herein can be applied to other paneling systems, and not just to the embodiments described above and shown in the accompanying figures. Accordingly, the scope of the invention should be determined from the following claims.
This application claims the benefit of U.S. provisional application No. 61/346,546 filed on May 20, 2010 entitled “Paneling System” which is hereby incorporated by reference into this application.
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