TECHNICAL FIELD
This document relates to wall cladding planks, clips, systems, and methods of installation and use.
BACKGROUND
Wall cladding systems are used to finish the exterior of a building. Such systems use a plurality of parts that are assembled on site, such as insulative panels, rainscreens, vapor barrier membranes, fire retardants, and finishing coatings such as paint.
SUMMARY
A panel system is disclosed to provide a prefabricated exterior building façade. Various wall claddings and clips for hanging wall claddings are disclosed.
A wall cladding system is disclosed comprising: a building wall; a plurality of wall cladding planks; a plurality of fasteners extending through respective apertures in the plurality of wall cladding planks to secure the plurality of wall cladding planks to the building wall, in which each fastener has a head and a shaft, and the shaft mounts a spacer behind a rear face of the respective wall cladding plank to define a drainage gap between the wall cladding planks and the building wall.
A wall cladding plank clip is disclosed comprising: a fastener with a head and a shaft; a drainage gap spacer mounted on the shaft; and a front washer plate mounted on the shaft between the head and the drainage gap spacer.
A pre-fabricated wall cladding plank is disclosed comprising: a core of insulating material; a fire-resistant component; an integral drainage system defined on a rear face of the pre-fabricated wall cladding plank; corresponding tongue and groove profiles on opposing edges of the pre-fabricated wall cladding plank to mate with adjacent pre-fabricated wall cladding planks of identical dimensions; and an external decorative finishing layer.
A method is disclosed comprising mounting a pre-fabricated wall cladding plank on a building wall.
In various embodiments, there may be included any one or more of the following features: The plurality of wall cladding planks comprise a starter row of wall cladding planks mounted on a starter hanger that is secured to the building wall. The starter hanger comprises: a mounting strip secured to the building wall; and a flange that extends laterally off the mounting strip away from the building wall to support a base end of the plurality of wall cladding planks that form the starter row. The flange forms a hook that fits within respective slots in the base ends of the plurality of wall cladding planks that form the starter row. The starter hanger comprises a plurality of weeping holes. A base flashing strip mounted below the starter row. The plurality of wall cladding planks are arranged in two or more vertically stacked, horizontal rows. Each wall cladding plank of the plurality of wall cladding planks has corresponding tongue and groove profiles on opposing edges of the wall cladding plank and that mate with the corresponding tongue and groove profiles of adjacent of the plurality of wall cladding planks. The plurality of wall cladding planks are arranged in a plurality of stacked rows; the corresponding tongue and groove profiles of each wall cladding are located on opposing bottom and top edges of each of the plurality of wall cladding planks; and adjacent rows above and below one another connect by interlocking the respective corresponding tongue and groove profiles of the wall cladding planks of each of the adjacent rows. The building wall comprises in sequence from exterior to interior, a rainscreen, a drywall layer and a plurality of wall studs, in which the plurality of fasteners secure to the studs. Each of the plurality of wall cladding planks is a pre-fabricated wall cladding plank that comprises one or more of: a core of insulating material; a fire-resistant component; an integral drainage system; and an external decorative finishing layer. Each spacer may form part of a rainscreen. Each spacer comprises a sealing element that seals around the shaft. The sealing element comprises a resilient spool mounted coaxial with the shaft. Each resilient spool comprises a rubber spool. Each spacer comprises a coil spring mounted coaxial around the shaft and around the sealing element. Each spacer comprises opposed spacer washer plates mounted on the shaft adjacent opposed respective axial ends of the sealing element, with the coil spring mounted between the opposed spacer washer plates. Each spacer comprises a wall-facing washer plate at a distal axial end of the spacer. Each fastener comprises a front washer plate mounted on the shaft between the head and the spacer. Each spacer is axially spaced along the shaft away from the front washer plate and head to define a wall cladding plank receiving gap on the shaft. Each spacer comprises a head facing washer plate that is located at a proximal axial end of the spacer and that is spaced from the front washer plate to define the wall cladding plank receiving gap. The front washer plate and the head facing washer plate are rigidly connected. The front washer plate forms a wall cladding plank supporting lateral shelf. Each spacer has teeth at a distal axial end of the spacer. The drainage gap spacer comprises a sealing element that is structured to radially constrict under axial compression to seal around the shaft in use. The fastener is a self-tapping screw. The fire-resistant component comprises a fire-resistant layer between the core of insulating material and the external decorative finishing layer. The fire-resistant layer comprises fiberglass and poly-cement. The integral drainage system comprises drainage grooves contoured in the rear face. The drainage grooves run in one or more of overlapping curves, vertical lines, or lines angled between horizontal and vertical. The corresponding tongue and groove profiles are located on opposing bottom and top edges of the pre-fabricated wall cladding plank to, in use, mate with adjacent pre-fabricated wall cladding planks of identical dimensions below and above, respectively, the pre-fabricated wall cladding plank. A groove, of the corresponding tongue and groove profiles, is defined by an inner and an outer groove side wall, and the inner groove side wall defines a series of fastener apertures that extend to the rear face of the pre-fabricated wall cladding plank. Respective fasteners are passed through the series of fastener apertures. The front washer plate is mounted on the shaft between the head and the inner groove side wall. The head and front washer plate are inset within a fastener-receiving groove defined in the inner groove side wall. The insulating material comprises one or more of mineral wool, expanded polystyrene, and silica aerogel. The core has an R-value of 10 or higher. The external decorative finishing layer comprises a paint coating or a laminate layer. An external panel clipped on to the external decorative finishing layer. The external panel comprises a clip backing that grips opposed shoulders of an external panel seat defined in an external cross sectional profile of the external decorative finishing layer. The external panel comprises one or more of a glass panel, a lighting panel, a perforated metal decorative panel, and a solar panel.
These and other aspects of the device and method are set out in the claims, which are incorporated here by reference.
BRIEF DESCRIPTION OF THE FIGURES
Embodiments will now be described with reference to the figures, in which like reference characters denote like elements, by way of example, and in which:
FIG. 1 is a perspective view of a wall cladding plank clip.
FIG. 2 is a side elevation view of the wall cladding plank clip of FIG. 1.
FIG. 3 is a cross sectional view of the wall cladding plank clip of FIG. 1.
FIG. 3A is a cross sectional view of a different embodiment of a spacer from the wall cladding plank clip of FIG. 3.
FIG. 4 is a rear perspective view of a wall cladding plank mounting a plurality of wall cladding plank clips from FIG. 1.
FIG. 5 is a front elevation view of the wall cladding plank of FIG. 4, with ghost lines used to indicate edge profiles on the rear face that is hidden from view.
FIG. 6 is a rear elevation view of the wall cladding plank of FIG. 4.
FIG. 7 is a side elevation view of the wall cladding plank of FIG. 4.
FIG. 7A is a close up of the area enclosed within the dashed circle of FIG. 7.
FIG. 8 is a front elevation view of a system of three rows of interlocked wall cladding planks from FIG. 4 mounted on an exterior building wall.
FIG. 9 is a side elevation view of the system of FIG. 8.
FIG. 10 is a cross sectional view of the system of FIG. 8.
FIGS. 10A and 10B are close up views of respective areas enclosed within dashed circles in FIG. 10.
FIG. 10B is a close up view of the area enclosed within the dashed circle of FIG. 10.
FIG. 11 is a close up side elevation view of a starter row of wall cladding planks from the system of FIG. 9, with the base flashing removed.
FIG. 12 is a cross section view of the starter row of wall cladding planks from the system of FIG. 9, with the base flashing removed.
FIG. 13 is a close up side elevation view of a junction between starter and second rows of wall cladding planks from the system of FIG. 9.
FIGS. 14-20 are side elevation views (with the exception of FIG. 16, which is a cross sectional view) of various embodiments of wall cladding planks.
FIG. 21 is a front perspective view of a wall cladding plank.
FIG. 22 is a close up expanded front perspective view of a wall cladding plank with a hanger clip and examples of locations for fastener holes shown.
FIG. 23 is a cross sectional view of a portion of a wall cladding plank, with a finished exterior, and having clipped thereon an exterior panel.
FIG. 24 is a rear elevation view of a wall cladding plank, illustrating examples of drainage channels on the rear face of the plank.
FIGS. 25 and 26 are top plan views illustrating a corner wall cladding plank and a pair of wall cladding planks forming a corner, respectively.
FIGS. 27 and 28 are top plan views illustrating different embodiments of interlocking adjacent wall cladding planks side-by-side using tongue and groove connections.
FIG. 29 is a top plan view of a corner column in a wall cladding system.
FIG. 30 is a perspective view of the corner column of FIG. 29.
FIG. 31 is a rear side elevation view of the corner column of FIG. 29.
FIG. 32 is an end elevation view of a further embodiment of a wall cladding plank clip.
FIG. 33 is a second elevation view of the wall cladding plank clip of FIG. 32.
FIG. 34 is a side elevation view of the wall cladding plank clip of FIG. 32.
FIG. 35 is a perspective view of the wall cladding plank clip of FIG. 32.
FIG. 36 is a perspective view of a wall cladding plank system made using planks that lack a tongue and groove connection.
FIG. 37 is a front elevation view of the system of FIG. 36.
FIG. 38 is a side elevation view of the system of FIG. 36.
FIGS. 38A and 38B are close up views of the respective areas enclosed within dashed circles in FIG. 38.
FIG. 39 is a view taken along the 39-39 section lines of FIG. 37.
FIG. 39A is a close up view of the area enclosed within the dashed circle of FIG. 39.
FIG. 40 is a perspective view of a wall cladding plank system with a window defined therein.
FIG. 41 is a front elevation view of the system of FIG. 40.
FIG. 42 is a side elevation view of the system of FIG. 40.
FIGS. 42A and 42B are close up views of the respective areas enclosed within dashed circles in FIG. 42.
DETAILED DESCRIPTION
Immaterial modifications may be made to the embodiments described here without departing from what is covered by the claims.
In this document, various parts in the description are identified by reference characters, which appear in the drawings to identify the corresponding part or parts. In some cases, suffixes such as ′, ″, ′″, or ″″ are appended to reference characters in the description or drawings to differentiate between like parts. It should be understood that references to parts in the description, whether identified using such suffixes or not, may refer to the same part shown in the drawings, whether suffixes are used in the respective drawing or not.
Cladding refers generally to a layer or layers of material covering another providing a skin or layer. In construction, cladding typically refers to the materials that are applied in layers to the exterior of a building serving to provide a degree of thermal insulation, weather resistance and aesthetic finishing features. Cladding can be constructed using a variety of materials including wood, brick, metal, vinyl, cement blends, aluminum, and others. Broadly, cladding may be used as a control mechanism for varying elements including moisture, noise, heat, fire-resistance, and cold. Various types of barriers and layers may be used in a cladding system.
Referring to FIGS. 1, 4, and 8, a wall cladding plank clip 20, a wall cladding plank 12, and a wall cladding plank system 10 are illustrated, respectively. Each of clip 20, plank 12, and system 10 will be described, and should be understood as each forming parts of this disclosure that may be used independent of each other, or in combination, without limiting the claims that may be made to one or more such parts.
Referring to FIGS. 4-6, 7A, and 8, a wall cladding plank 12 is illustrated. Plank 12 may be structured for mounting to a building wall 11, alone or in combination with other planks 12. Referring to FIGS. 4-6, and 7A, the plank 12 may be pre-fabricated. Plank 12 may comprise a core 14 of insulating material. Plank 12 may have a fire-resistant component, such as a fire-resistant layer 16. Plank 12 may be configured to interlock with adjacent planks 12, such as by having a corresponding tongue 42 and groove 44 profiles on opposing edges, such as top and bottom edges 12C and 12D, respectively, of the pre-fabricated wall cladding plank 12. In use, each plank 12 may mate with one or more adjacent pre-fabricated wall cladding planks of identical dimensions. Plank 12 may have an integral drainage system 22, which may be defined on a rear face 12A of the plank 12. Plank 12 may have an external decorative finishing layer 18, for example a layer that simulates a wood, metal, or other desired finish.
Referring to FIGS. 4-6, 7A, and 8, a plank or slab shape refers to a shape where an encircling wall, such as defined collectively by end edges 12E, 12F, and top and bottom edges 12C, 12D, define a separation distance between front and rear faces 12A, 12B, respectively, the separation being relatively thin compared to the maximum or local maximum lateral dimensions of the faces 12A/12B, such as the length and width dimensions in the case of a rectangular plank 12. A plank 12 may also refer to a relatively thin, long flat item or sheet, and in some cases a thin square or rectangular sheet. Some or all of the external edges and corners of the external surfaces of the plank 12 may be rounded or beveled for ease of handling. A plank 12 may also include a rectangular box or rectangular cuboid, and other terms such as a slate, sheet, bar, tablet, and cell phone, may be used to describe the shape of the plank 12. Face 12A and 12B are shown as rectangular, but may have non-rectangular shapes such as circular, oval, polygonal, or other shapes. The rectangular plank shape shown has a low profile, which may be advantageous for storage and installation.
Prefabrication may mean that the plank 12 is assembled or otherwise constructed at a location remote from the building site or wall 11, in some cases five, ten, or more kilometers away, for example at a distance sufficient to warrant machine transport of the plank 12 to the building site as the only practical method of transporting the plank 12 to the building site. A building site is a location where a building is situated or being constructed, for example containing one or more walls 11, whether internal or exterior walls.
Referring to FIGS. 4-6, and 7A, in the example shown, the plank 12 may be constructed by a suitable method. Core 14 may be molded or pressed to create the desired tongue and groove design. Core 14 may be wrapped with a fiberglass reinforced mess and polymer modified cement, for example forming layer 16. A further coat or coats may then be applied with a sandable micro cement. The plank 12 may then be sanded, primed and paint to apply layer 18 and achieve an ultra-smooth look, metal like appearance, or any other desired appearance.
Referring to FIGS. 8-10, a wall cladding system 10 may be constructed using a plurality of planks 12. In use planks 12 may be situated in rows 24 either vertically, horizontally, or both. In the example shown planks 12 are arranged in rows, such as vertically stacked, horizontal rows 24. Planks 12 may come in a variety of shapes and sizes. Wall cladding slats or planks 12 may be made of a variety of different materials including wood, aluminum, and plastic. Planks may be hung or attached individually, or they may be attached to one another using an interlocking system where adjacent planks interlock with one another.
Referring to FIGS. 8-10, each plank 12 may be structured to interlock with adjacent planks 12. Planks 12 may use a joint system to interconnect. Planks 12, sometimes referred to as panels, may be secured together using some type of joint, such as a tongue and groove joint (shown), a shiplap joint, and “wet” or “dry” joints. Wet joint systems employ backer rod and sealant to provide water protection, while dry joint systems may employ a rainscreen system. In drier climates, a wet joint may be preferred, while in more moist climates a dry joint may be preferred. A lap joint or overlap joint is a joint in which the members overlap. A lap joint may be a full lap or half lap.
A rainscreen may be an exterior wall detail where the siding (wall cladding) stands off from the moisture-resistant surface of an air barrier applied to the sheathing (sheeting) to create a capillary break and to allow drainage and evaporation. The rain screen may be considered the siding itself, although the term rainscreen may imply a system of building. Ideally the rain screen prevents the wall air/moisture barrier on sheathing from getting wet. In some cases, a rainscreen wall is called a pressure-equalized rainscreen wall where the ventilation openings are large enough for the air pressure to nearly equalize on both sides of the rain screen.
Referring to FIGS. 10 and 10A, each plank 12 may be structured to interlock with adjacent planks 12 via a tongue 42 and groove 44 system. The design of the tongue and groove fastening system of the planks 12 shown incorporates a thermal break, thus reducing or eliminating negative heat conduction effects from metal fasteners that conduct temperature variations, or other thermal breaks. In some cases, the planks 12 may be structured to cooperate together to create a continuous insulated tongue and groove design that allows the system to retain its thermal breaks at lapped sections, providing a continuous thermal break across plural, in some case all, rows 24 of planks 12 arranged on a wall 11.
Referring to FIGS. 4, 7, 7A, and 9, the interlocking connection parts, such as tongue 42 and groove 44, may be located on suitable locations on each plank 12. In the example shown the corresponding tongue 42 and groove 44 profiles of each wall cladding plank 12 are located on opposing bottom and top edges 12D, 12C, respectively, of each of the plurality of wall cladding planks 12. When planks 12 are arranged in rows 24 as shown, adjacent rows above and below one another connect by interlocking the respective corresponding tongue 42 and groove 44 profiles of the wall cladding planks 12 of each of the adjacent rows 24. For example, grooves 44′ of planks 12′ of row 24′ may interlock with tongues 42″ of planks 12″ of row 24″, and so on. Tongues 42 may be located on top edges 12C, with grooves 44 of bottom edges 12D. In some cases, an edge of plank 12 may have both a tongue and a groove. An interlocking profile may permit adjacent wall cladding planks of identical dimensions to mate with one another.
Referring to FIGS. 25-28, in some cases side or end edges 12E, 12F may incorporate joints, such as tongue 42 and groove 44 profiles, for mating and interlocking with laterally adjacent planks 12 of the same row 24. FIGS. 27 and 28 illustrate in solid lines an example of a lap or shiplap joint. A shiplap joint may incorporate a tongue 42 and shoulder 42A on one plank 12, which mates with a corresponding groove 44 and ledge 44D. By contrast, dashed lines are used to indicate a tongue 42 and groove 44 joint, with additional shoulders 42B and ledges 44E incorporated to produce the structure shown.
Referring to FIGS. 4, 7, 7A, and 9, each plank 12 may incorporate one or more fastener apertures 46 to secure plank 12 to wall 11. In the example shown the apertures 46 are defined in an inner side wall, such as inner groove side wall 44A opposite outer groove sidewall 44C. A series of fastener apertures 46 may extend to the rear face 12A of the pre-fabricated wall cladding plank 12. Apertures 46 may be located at suitable positions, such as on front face 12B, on shiplap joint side walls (not shown), or at other locations. Apertures 46 may be oriented at suitable angles, such as positive angles relative to normal lines perpendicular with faces 12A or 12B or both. Referring to FIG. 22, an example is shown where apertures 46 are profiled in top edge 12C, on ledge 44D. Each mating part of a joint may be continuous from end to end, or discontinuous, such as if a plurality of spaced tongues or grooves are arrayed along all or a portion of a width of a plank 12.
Referring to FIGS. 8-10, a wall cladding system 10 is illustrated, formed of a building wall 11, a plurality of wall cladding planks 12, and a plurality of fasteners 36. Each fastener 36 may extend through respective apertures 46 in the plurality of wall cladding planks 12 to secure the plurality of wall cladding planks 12 to the building wall 11. The building wall 11 may incorporate various suitable parts, such as, in sequence from exterior to interior, a rainscreen/vapor barrier membrane 30, a drywall layer 28 and a plurality of wall studs 26. The plurality of fasteners 36 may secure to a suitable location on wall 11, such as to the studs 26. The spacers themselves may collectively define at least part of the rainscreen. Drywall layer 28 is an example of an inner sheathing member of a wall, the member being affixed to studs 26 or other supports. Other inner sheathing members may be used, such as plywood board, insulated concrete, a composite board, or any other material permitted by local building codes.
Referring to FIGS. 1-3, a suitable fastener 36 may be used to secure each plank 12 to wall 11 in use. Fastener 36 may have a head 36A and a shaft 36B. Fastener 36 may have other suitable parts, such as a narrow tip 36C for penetrating materials, and threading 36D. Fasteners 36 may be suitable fasteners, such as self-tapping screws. Head 36A may incorporate a suitable screwdriver connector, such as a Robertson, Phillips, hex, or other suitable connector. Other suitable fasteners may be used, such as nails (not shown).
Referring to FIGS. 9-10, and 10A-10B a water resistive barrier (WRB—such as membrane 30), may be installed inboard of the cladding as a secondary barrier to moisture to prevent water ingress, and to create a drainage gap between the cladding and WRB to allow drainage of water which penetrates past the cladding. Such an approach may be referred to as a rainscreen wall assembly. Rainscreen cladding is a detail attached to the exterior of a building wall to create a capillary break allowing for drainage and evaporation. A rainscreen may provide a weather barrier and prevent water from penetrating the cladding. A rainscreen may not need to be waterproof, as it may serve as a control mechanism for diverting water from the exterior wall. Ideally, a rainscreen functions to prevent the air and moisture barrier or wall sheathing from getting wet. A rainscreen may achieve such function first by means of directing the water away from the main exterior wall, preventing it from penetrating the cladding. A rainscreen may also provide a mechanism for the drainage of any water that has leaked into the system. A water or air resistant membrane may be situated between the sheathing and furring to prevent water from entering, and may direct water toward a special drip edge flashing. If the rainscreen proves effective, the structural frame and thermal insulation of the building remains dry and optimally functional.
An air barrier, such as is also provided by membrane 30 in the example shown, may be configured to control bulk air movement through the wall. A vapor barrier or membrane 30 may be installed to control diffusion of water vapor through the wall assembly. An impermeable material may be used for this function. An air barrier system may be used generally to control the flow of air into and out of a building. Control of such airflows may be important to limit energy loss due to exfiltration, to reduce the potential for air leakage and associated condensation, for occupant comfort, and for indoor air quality.
Referring to FIGS. 1-3 each fastener 36 may form part of a wall cladding plank clip 20, which is illustrated for mounting a wall cladding plank 12. Clip 20 may comprise a drainage gap spacer 38 mounted on the shaft 36B. A front washer plate 40 may be mounted on the shaft 36B between the head 36A and the drainage gap spacer 38. Referring to FIGS. 1-3, 9-10, and 10A-10B, in use with system 10, spacer 38 is positioned behind rear faces 12A of planks 12, sandwiched between planks 12 and wall 11 to define a drainage gap or system 22 between the wall cladding planks 12 and the building wall 11.
Referring to FIGS. 1-3, 9-10, and 10A, the wall cladding plank clip 20 may be structured to form a seal about fastener 36 shaft 36B. The drainage gap spacer 38 may comprise a sealing element, such as a rubber spool 38A or other resilient spool mounted coaxial with the shaft 36B. Spool 38A may be structured to radially constrict under axial compression (such as from tightening fastener 36 to secure plank 12 to wall 11, to seal around the shaft 36B in use. Respective fasteners 36 may be passed through the series of fastener apertures 46, each mounting a spacer 38, to create a stable, secure, and precise drainage gap between wall 11 and planks 12. When put into compression the clip 20 may function as a floating device for when a wall is uneven, thus working to keep the application of the plank 12 level.
Referring to FIGS. 1-3, 7A, 9-10 and 10A, a biasing device may be used to assist in securing the clip 20 to the plank 12 and wall 11. The core of the clip 20 may be wrapped by a spring, such as a coil spring 38C mounted coaxial around the shaft 36B and around the sealing element. When the fastener 36 is inserted, the resilient pressure cushion or spool 38B is put into compression, and radially constricts thus creating a tight seal the inner and outer part of the perforated rear face 12B of plate or plank 12. When the fastener 36 is tightened the spring 38C may allow for movement of the planks 12 thus allowing the system to be installed level even if the wall has minor imperfections.
Referring to FIGS. 1-3, 7A, 9-10 and 10A, the clip 20 may act as a fastener/pressure plate and rainscreen enabler. The clip 20 may maximize or increase air space behind the facades of planks 12 to allow for better pressure equalization. The clip's function may be to act as a structural component that holds the plank 12 in place and acts as an adjustable spacer to create a rainscreen cavity between the plank 12 and the wall 11.
Referring to FIGS. 1-3, 7A, 9-10 and 10A the spacer 38 may incorporate one or more washers, such as washer plates 38D and/or 38E. Opposed washer plates 38D, and 38E may be mounted on the shaft 36B adjacent opposed respective axial ends of the spool 38B. The coil spring 38C may be mounted between the opposed spacer washer plates 38D, 38E, constrained by the plates 38D, 38E. Plate 38D may function as a wall-facing washer plate at a distal axial end of the drainage gap spacer 38. Plate 38E may function as a head facing washer plate that is located at a proximal axial end of the drainage gap spacer.
Referring to FIGS. 1-3, 7A, 9-10 and 10A the clip 20 may mount a front washer plate 40. Each fastener 36 may comprise a front washer plate 40 mounted on the shaft 36B between the head 36A and the spacer 38. The drainage gap spacer 38 may be axially spaced along the shaft 36B away from the front washer plate 40 and head 36A to define a wall cladding plank receiving gap 39 along the shaft 36B. The clips 20 may fit snug, wrapping the top of each plank or panel. The clip/pressure cushion may have a continuous centered opening to allow the fastener (screw) to easily be centered. The face of the clip plate 40 may have a lip protruding from it. The cushion pad or spool 38B may be sandwiched between steel when fastened and compressed it-self seals the screw by protruding lightly.
Referring to FIGS. 1-3, 7A, 9-10 and 10A, the front washer plate 40 may have suitable dimensions and may engage plank 12 at a suitable location. In the example shown the front washer plate 40 is mounted on the shaft 36B between the head 36A and the inner groove side wall 44A of groove 44 of plank 12. The head 36A and front washer plate 40 may be inset within a fastener-receiving groove 45 defined in the inner groove side wall 44A. The plate 40 may have a structure that corresponds to the dimensions of groove 45, which may act as a seat for the plate 40. Plate 40 may have a base 40A, sidewalls 40B, and flanges 40C extending laterally from the sidewalls 40B to define a flared or lip structure that hugs the groove 45 for a secure fit that won't damage plank 12 under regular forces. Referring to FIGS. 1-3, plate 40 may define a fastener head receiving groove 40D countersunk and provided with an aperture 40E to accept head 36A of fastener 36. Other structures of plate 40 may be used, including that of a traditional ring washer (not shown).
Referring to FIGS. 8-10 and 10B, the installation of system 10 assembly may begin with the application of a base metal flashing 32. Flashing 32 may be levelled and fastened (using fasteners 36) at or near the base of an exterior wall 11. Flashing 32 may be formed by a mounting strip 32A that mounts to wall 11 and runs laterally across the face of the wall 11. A base flange 32B may extend laterally off the wall 11 from strip 32A. In the example shown flange 32B is sloped downward with increasing distance from wall 11, to direct fluids downward and away from wall 11 during draining. Referring to FIGS. 11-12, in some cases flashing 32 may omit the flange 32B. Other suitable structures of flashing 32 may be used, including a continuous strip as shown or discontinuous (discrete) strips.
Referring to FIGS. 8-10, 10B, and 11-12, the plurality of wall cladding planks 12 may be arranged in a starter row 24′ of wall cladding planks 12′. The row 24′ of planks 12′ may be mounted on a starter hanger, such as a start or mounting strip 34A, that is secured to the building wall 11. In the example shown the strip 34A mounts over flashing 32, and both are secured together and to the wall 11 by fasteners 36 or clips 20′. The starter hanger may have a suitable structure, including a continuous strip 34A as shown, or a series of discontinuous, discrete strips at intervals from one another. The hanger 34 may comprise a flange 34B that extends laterally off the mounting strip 34A away from the building wall 11 to support a base end (edges 12D) of the plurality of wall cladding planks 12 that form the starter row 24′.
Referring to FIGS. 8-10, 10B, and 11-12, in some cases the hanger 34 engages the planks 12, for example the flange 34B forms a hook (panel base receiver 34C formed by skirt wall 34D, base 34E, and sidewall 34F) for the plank 12′. The hook may fit within a respective slot 12D-1 in the base ends of the plurality of wall cladding planks 12 that form the starter row 24′. The starter hanger 34 may comprise a plurality of weeping holes 34G for drainage. Weep holes may be spaced at suitable intervals, such as 12″ on center (o.c) to allow for possible water intrusion to exit the system. Referring to FIGS. 8-10, 10B, and 11-12, the starter hanger 34 may take the shape of a double-j starter strip that allows the first starter panel or plank 12 to interlock in place with the double-j trim of the starter strip via an s-lock application. The rear flange or mounting strip 34A of the starter strip 34A may slide horizontally interlocking itself level with the base of wall flashing 32. After the installation of the starter strip 34A a primer adhered membrane 30 may be installed to cover any fastener holes and laps onto the wall, for example 6″ past the top of the starter/flashing flange.
Referring to FIGS. 8-10, 10B, and 11-12, once the flashing 32 and starter hanger 34 are in place, weatherproofing may be applied. The next step is to apply the weather proofing, which could be in the form of a vapor-permeable membrane 30, air barrier or water proofing membrane as specified, depending on the wall assembly. Once the wall is weather proofed the starter panel (planks 12′ of row 24′) may be installed.
Referring to FIGS. 8-10, 10B, and 11-12 suitable starter planks 12′ may be used for the starter row 24′. The starter plank 12′ may be slightly different at the base from the planks 12 of other rows 24. Such difference may be to allow for a tight, snug interlock with the starter hanger 34. Once the planks 12′ have been slid into place, such planks 12′ may be fastened to the wall studs 26 at suitable intervals, such as 16″ o.c., using a spacer/fastening system such as clips 20.
Referring to FIGS. 8-10, 10B, and 11-12, once the starter row 24′ is in place, subsequent rows 24 may be added to the system 10. The top edges 12C of each plank 12 may be secured to wall 11 one row 24 at a time using clips 20. Once the top edges 12C of a row 24 are secured by clips 20, a further row 24 may be added, by interlocking the adjacent rows 24, followed by securing the upper row 24 with clips 20, such as clips 20″ in the case of planks 12″ of row 24″ installed above row 24′. Using a continuous tongue and groove design as shown may eliminate any thermal bridging a typical exposed fastener panel design would experience. In some cases, no fasteners 36 are visible form the exterior of a finished system 10.
The clips 20 disclosed here may have various advantages. The clips 20 may form a structural component that holds the planks 12 in place. The clips 20 may create a drainage plane, air cavity, rainscreen system or other in between the plank 12 and the wall 11. The core (spool 38B) of the clip 20 may be made of a soft rubber like material, that, when put under pressure squeezes tight around the fastener 36 to create a perfect seal from water and air. The outer part of the core (rubber spool 38B) may be wrapped by a spring 38C that is welded to the mid and rear plates 38D and 38E. The spring 38C may allow the plates 38D, 38E to be put into compression, thus compressing and expanding the rubber around the fastener/screw creating an air and water seal. The spring 38C may allow for the leveling of the walls 11 with minor imperfections up to an ¼″ or wider.
The system 10 may reduce the amounts of fasteners 36 and washers that may otherwise be used to hold a mineral wool, z-girth application, thus reducing potential air and water leakage. The rubber air/water seal around the fastener 36 means the system may be used in lieu of other less expense weather proofing materials. The system may incorporate one or more of non-combustible, highly insulative, low profile (slim and lightweight) planking, a fastening/rainscreen system, and an easy and quick application process, thus forming a cost-effective architectural panel.
As the disclosed method shows a prefabricated system, quality may be consistent and installation time may be up to one third the time to install than current exterior cladding systems. Being the slimmest product on the market may make the installation and storage easier than competitive products, but over and above allows the user to leverage higher R-values than competitors with less material.
Referring to FIGS. 32-39, a further embodiment of the clip 20 and wall cladding system 10 is illustrated.
Referring to FIGS. 32-35 the drainage gap spacer 38 may be structured to grip the exterior surface of the wall 11 in use. For example, the spacer 38 may have teeth 64 at a distal axial end of the drainage gap spacer 38. Distal and proximal in this document refer to relative distance from the head 36A of the fastener 36 when the clip 20 is in an assembled state as shown. In the example shown teeth 64 are formed by a series of small radial cuts about the periphery of a circular washer plate 38D, followed by bending outward of portions of material adjacent the cuts. Other grip-increasing features may be used, such as texturing of plate 38D.
Referring to FIGS. 32-35 in some cases the front washer plate 40 and the spacer 38 may be connected. In the example shown the plate 40 is rigidly connected to the spacer 38, for example to the head facing washer plate 38E via arm 43. The resulting connection may form a bracket that holds the plates 38E and 40 at a predetermined spacing, to accommodate and maintain a preselected plank receiving gap 39.
FIG. 3A illustrates a further embodiment of a spacer 38 made of an insulating material 38F. The insulating material 38F may comprise a suitable insulator, such as silica or other aerogel. The material 38F may be provided in suitable shape and fashion, for example forming or replacing the entirety of rubber ring 38A in some cases, and in the example shown, forming an outer ring around a relatively smaller diameter rubber ring 38A than is shown in the embodiments of FIGS. 1-3. In some cases, dried caulking may be used instead of or in addition to rubber.
Referring to FIGS. 32-35, each clip 20 may be structured to support planks in adjacent rows above and below one another. For example, the front washer plate 40 may form a wall cladding plank supporting lateral shelf 41. Referring to FIG. 38B, shelf 41 may underlie bottom edges 12D″′ of planks 12′ of row 24′, while directly mounting planks 12″ of row 24″ directly below row 24′″. Such an arrangement facilitates the mounting of planks 12 in overlapping rows as shown. Referring to FIGS. 32-35 and 38, 38B, 39, and 39A, mounting of planks 12 at angles relative to vertical may be facilitated by angling one or more of the component parts of the clip 20. For example, plate 38D is shown angled with a positive angle 66 defined between a plane 68 defined by plate 38D and a plane 70 defined perpendicular to an axis of shaft 36B.
Referring to FIGS. 36-38, 38A-B, 39, and 39A as above the embodiment illustrated mounts rows 24 of planks 12 that do not incorporate tongue and groove interlocking, while mounting the planks 12 at a positive angle relative to vertical (increasing distance from wall 11 with decreasing height). Referring to FIGS. 38 and 38A, a suitable base flashing 32 may be used, along with a suitable starter hanger 34 and starter row 24′ of planks 12. In the example shown the planks 12 of row 24′ are the same as the planks 12 of all other rows 24, requiring no special modifications to mount to starter hanger 34. Each hanger 34 may have a mounting strip 34A, a flange 34B, and a plank base receiver 34C defined by skirt wall 34D, base 34E, and sidewall 34F of starter hanger 34.
Referring to FIGS. 25-31, various modifications may be made to accommodate planks 12 around corners of a building. Referring to FIG. 25, an example is shown where a plank 12 wraps around a corner to directly engage adjacent planks 12 (not shown) that run along either face of the building itself. Referring to FIG. 26, an example is shown where one plank 12″ extends past a corner of the building and has a second plank 12′ mount by tongue and groove interconnection to a rear face 12A″ of plank 12″.
Referring to FIGS. 29-31, a corner column 60 is illustrated. The column 60 may comprise a core column 60C, side flanges 60A-1 and 60B-1, and a pair of corner brackets 62. Flanges 60A-1 and 60B-1 extend along exterior faces 60A and 60B, respectively of column 60. Brackets 62 mount to interior faces 60D and 60E, to define respective plank end receptacles 60A-2 and 60B-2, which are sized to receive end edges 12E and 12F of adjacent planks 12. Brackets 62 may have a suitable structure, such as a corner mounting strip 62A mounting a wall mounting strip 62B via a step strip 62C to space and orient the strips 62A and 62B relative to one another in the desired configuration. Plural apertures 62D may be staggered along strip 62B to permit securing of corner columns 60 to wall 11.
Referring to FIGS. 40-42 and 42A-B, systems 10 may be modified to incorporate windows or other suitable access points such as a door. A window 72 (or door) opening may be formed into a plank 12 or a plurality of planks 12 when arranged together in a deployed configuration shown. Window 72 may be formed in planks 12 by a base 72A, side walls 72B, and a head 72C. Base 72A may be sloped with decreasing height with increasing distance from the wall 11 to facilitate sill drainage. Window 72 may align with a window formed by studs 26 and 74. Double-j shaped trim or insulated double-j trim may be used to complete each window 72, for example sill j-trim 76 along the sill or base 72A, with side window and head window j-trim 82 and 84, respectively located along the side walls 72B and head 72C of window 72. Caulking 80 or other sealant may be used were the easy to seal off the structure from water ingress as appropriate. One or more fire retardant panels 29 may be incorporated to improve the fire rating of the wall 11. Planks 12 may be cut to form windows 72, or may be formed to form windows 72. The space between the j-trim and the window or door opening may be treated with foam rod and sealant. Aesthetic grooves 18B or other aesthetic features may be incorporated in front faces 12B of the planks 12. Flashing 32 may be mounted to floor studs 27.
A wall cladding system may be configured to provide fire retardant characteristics. Many fire-resistant exterior walls are clad in fire-resistant materials such as stucco, brick or concrete. A wall that is clad in less fire-resistant materials such as vinyl or wood siding may also use fire-resistant wallboard or other materials to supplement fire retardancy. Slentex™ may be used to provide a non-flammable material. Such material may be a Silica Aerogel technology that gets away from petroleum based plastic technologies to further reduce pressure on greenhouse gas emissions. Slentex™ is the lightest non-combustible, non-petroleum base insulation on the market making it preferential over a mineral wool or standard foam product. Two aerogel-based high-performance insulating materials are SLENTITE™ and SLENTEX™. However, a suitable fire-resistant component such as layer 16, may comprise fiberglass and poly-cement.
Referring to FIGS. 14-22 and 24, each plank 12 may incorporate an integral drainage system 22. The integral drainage system may comprise one or more drainage grooves 22A contoured in the rear face 12B of the plank 12. Referring to FIGS. 24, drainage grooves may run in one or more of overlapping curves (grooves 22A″), vertical lines (grooves 22A′), or lines angled between horizontal and vertical. Referring to FIGS. 5 and 6, horizontal lines (groove 22A) may be used, as may other suitable groove shapes. In some cases, passages are contoured within the plank 12 itself, for example holes may be drilled directly through each plank 12.
Insulation may be installed to control the flow of heat (i.e. energy transfer) through the enclosure. Insulation cladding may serve many functions including thermal insulation, acoustic insulation, fire insulation, and impact insulation. Exterior insulation outboard may be installed as a continuous outer layer of a primary structure. Such a method may be more efficient than the traditional method of placing insulation between studs or inboard of the structural frame. A typical installation method may proceed as follows. Damp proofing or a waterproofing membrane may be installed on the exterior side of the foundation wall and footing. Rigid board insulation may be installed on the exterior wall from the top of the footing to the bottom of the cladding. An aluminum coil stock or sheet metal protective cover may be installed for the rigid insulating sheathing. Various types of insulation may be used, such as fiberglass, memory foam, or spray foam insulation.
Improving building insulation values may be considered by many the most effective approach to reducing greenhouse gas emissions. At minimum, such may pay back by lowering energy costs and if properly considered during design, and may also reduce the size of heating and cooling systems required, thus saving additional costs. Such may also “Future Proof” the owner from rising energy costs. In some cases, the planks 12 disclosed here, minimize air leakage, thereby reducing heat loss and air leakage from buildings and thereby reducing carbon emissions. When looking at building envelope parameters to maximize a buildings ability save energy, one must look at the conduction, solar radiation and air infiltration. Conduction relates to the buildings ability to conduct or resist heat flow. Solar radiation relates to wanted heat gains through windows. Infiltration relates to the air leakage through the building envelope. Such are all important considerations for new construction or the retrofit market. The components of the plank 12 may include a core 14, currently made of 2.5″ thick thus giving the panels a R18.25 R-value. Slentex™ may provide the first silica aerogel insulation, and may be molded to specifications. Other compounds may be used, such as one or more of mineral wool, expanded polystyrene, and silica aerogel. The planks 12 may be manufactured in a suitable thickness, such as thicknesses up to 4″ or larger potentially giving the panel an R 29.2 thus exceeding current building codes with exterior insulating not including interior insulation. By contrast, a panel with an R Value of 3.3 it would take nearly 9″ of mineral wool to achieve the same R value. In some cases, the core14 has an R-value of 10 or higher.
Referring to FIGS. 14-22 and 24, a wall cladding plank 12 may be configured to provide a finished, aesthetically pleasing exterior surface that adds curb appeal to the building. A suitable coating may be painted, coated, laminated, or applied in another suitable manner to the exterior of the cladding. The outer core layer 16 may comprise alkaline resistant reinforcing mesh and a polymer modified cement, with the finished product being made to emulate composite metal panel systems at half the cost, along with a metal look, by applying an appropriate finishing layer 18. Suitable layers 18 may include materials that appear similar to or identical with natural materials such as stone, granite, and glass. In some cases, the external decorative finishing layer comprises a paint coating or a laminate layer.
Referring to FIGS. 14-22 and 24, various plank 12 side profile shapes are shown. Each plank 12 designed may be used as desired. Referring to FIGS. 14 and 18, examples are shown with sloped front faces 12B. Referring to FIGS. 15-17 and 20, vertical front faces 12b are shown. Referring to FIG. 19, a textured front face 12B is shown with various texturing.
Referring to FIG. 23, each plank 12 may be structured to mount an external panel 58. In the example shown an external panel 58 is clipped on to the external decorative finishing layer 18. The external panel 58 may comprise a clip backing 54 that grips opposed shoulders 56 of an external panel seat defined in an external cross sectional profile of the external decorative finishing layer 18. A lock or locking system, such as the use of fasteners or latches, may be used to secure the external panel 58 to the plank 12 or groups of planks 12 (not shown). Quick release, clipping, friction fit, interference fits, and other mechanisms may be used. The use of an external panel interconnection system permits the external appearance of the building to be easily tailored, by selecting one of a variety of suitable exterior facades. For example, the external panel 58 may comprise one or more of a glass panel, a lighting panel, a perforated metal decorative panel, and a solar panel.
Referring to FIGS. 21 and 22, another embodiment of a plank 12 is illustrated, with a length greater than a height when in use. V-grooves 48 may be incorporated for drainage. Fastener apertures 46 (46′ and 46″) may be used to mount plank 12 to a wall 11. A mounting clip 20 (not shown) or hanger 50 may be used to mount the plank 12 to wall 11. Hanger 50 may have a suitable length, and may comprise one or more of a mounting arm 50A, a ledge receiver 50B, a ledge 50C, a skirt 50D, a flange 50E and a lip 50F, to fit within groove 44 of a plank 12 to support the base end edge 12D of a plank 12 above the plank shown. Apertures 52 may be provided in hanger 50 to align with apertures 46 in plank 12.
The plank 90 and rainscreen system may be stored or transported in a suitable fashion. The insulating plank 90, for example if made of aerogel, may be provided as a continuous sheet that is flexible to be dispensed over the building wall from a continuous roll of insulating plank material. In other cases, plank 90 may be provided in a stack of identical planks 90.
An aerogel is an insulative, lightweight component. An aerogel may be produced by extracting the liquid component of a gel through supercritical drying. This allows the liquid to be slowly dried off without causing the solid matrix in the gel to collapse from capillary action, as would happen with conventional evaporation. The first aerogels were produced from silica gels. Kistler's later work involved aerogels based on alumina, chromia and tin dioxide. Carbon aerogels were first developed in the late 1980s. Aerogel is not a single material with a set chemical formula, instead, the term is used to group all materials with a certain geometric structure. Despite the name, aerogels may be solid, rigid, and dry materials that do not resemble a gel in their physical properties. The name aerogel comes from the fact that the material is made from a gel.
Pressing softly on an aerogel typically does not leave even a minor mark, pressing more firmly will leave a permanent depression. Pressing extremely firmly may cause a catastrophic breakdown in the sparse structure, causing it to shatter like glass (a property known as friability), although more modern variations do not suffer from this. Despite the fact that it is prone to shattering, an aerogel may be very strong structurally. Its impressive load-bearing abilities may be due to the dendritic microstructure, in which spherical particles of average size 2-5 nm are fused together into clusters. These clusters may form a three-dimensional highly porous structure of almost fractal chains, with pores just under 100 nm. The average size and density of the pores can be controlled during the manufacturing process.
An aerogel is a material that may be 99.8% air or more or less. Aerogels may have a porous solid network that contains air pockets, with the air pockets taking up the majority of space within the material. The lack of solid material allows aerogel to be almost weightless. Aerogels may be good thermal insulators because they almost nullify two of the three methods of heat transfer—conduction (they are mostly composed of insulating gas) and convection (the microstructure prevents net gas movement). They are good conductive insulators because they are composed almost entirely of gases, which are very poor heat conductors. Silica aerogel is an especially good insulator because silica is also a poor conductor of heat—a metallic or carbon aerogel, on the other hand, would be less effective. Aerogels may be good convective inhibitors because air cannot circulate through the lattice. Aerogels may be poor radiative insulators because infrared radiation (which transfers heat) passes through them.
Silica aerogel may be used. Silica aerogel is silica-based and may be derived from silica gel or by a modified Stober process. A low-density silica nanofoam may weigh 1,000 g/m3, which is the evacuated version of the record-aerogel of 1,900 g/m3. By contrast, the density of air is 1,200 g/m3 (at 20° C. and 1 atm). The silica may solidify into three-dimensional , intertwined clusters that make up about 3% of the volume. Conduction through the solid may therefore be very low. The remaining 97% of the volume may be composed of air in extremely small nanopores. The air has little room to move, inhibiting both convection and gas-phase conduction. Silica aerogel may have a high optical transmission of ˜99% and a low refractive index of ˜1.05. Silica aerogel may have remarkable thermal insulative properties, having an extremely low thermal conductivity: from 0.03 W/(m·K) in atmospheric pressure down to 0.004 W/(m·K) in modest vacuum, which correspond to R-values of 14 to 105 (US customary) or 3.0 to 22.2 (metric) for 3.5 in (89 mm) thickness. For comparison, typical wall insulation is 13 (US customary) or 2.7 (metric) for the same thickness. SLENTEX™ material may be used. SLENTEX™ is a super hydrophobic product that may seal-seal to a penetrating fastener 36 sufficient to keep water out of the formed fastener bore without the use of adhesive being required.
Carbon aerogels may be used. Carbon aerogel may be composed of particles with sizes in the nanometer range, covalently bonded together. They have very high porosity (over 50%, with pore diameter under 100 nm) and surface areas ranging between 400-1,000 m2/g. They may be manufactured as composite paper: non-woven paper made of carbon fibers, impregnated with resorcinol-formaldehyde aerogel, and pyrolyzed. Depending on the density, carbon aerogels may be electrically conductive, making composite aerogel paper useful for electrodes in capacitors or deionization electrodes. Carbon aerogels may be extremely “black” in the infrared spectrum, reflecting only 0.3% of radiation between 250 nm and 14.3 μm, making them efficient for solar energy collectors.
Other insulative materials may be used. Metal oxide aerogels may be used. Aerogels made with aluminum oxide are known as alumina aerogels. These aerogels are used as catalysts, especially when “doped” with a metal other than aluminum. Nickel-alumina aerogel is the most common combination. Aerographite or aerographene may be used. Organic polymers may be used to create aerogels. SEAgel is made of agar. Cellulose from plants may be used to create a flexible aerogel. Chalcogel is an aerogel made of chalcogens (the column of elements on the periodic table beginning with oxygen) such as sulfur, selenium and other elements—metals less expensive than platinum have been used in its creation. Aerogels made of cadmium selenide quantum dots in a porous 3-D network or other arrangement may be used Aerogel performance may be augmented for a specific application by the addition of dopants, reinforcing structures and hybridizing compounds.
In use, the system 10 may be assembled upon a building wall 11, for example in a network or grid. Referring to FIG. 58, cap receivers 108 and wall cladding panels 112 may be arranged on a wall 11. The receivers 108 may be secured to the wall 11 before, during, or after install of panels 112. The wall panels 112 may incorporate double-sided tape 113 (FIG. 63) or some form of adhesive, such as a peel and stick strip or layer, on a rear (wall-facing) face, for example to temporarily hold the panel in place before the application of the pressure cap. In some cases, a method is carried out where a series of receivers 108 are secured to wall 11, a row of panels 112 is arranged on the wall 11 on the receivers 108, and a second series of receivers 108 are secured above the opposite edges of the panels 112, after which caps 110 are interlocked to secure and assemble the system 110 one row of panels at a time. Securing may include inserting fasteners 36 as appropriate. In the example shown, once fasteners 36 are in place, insulative strips 108f may be inserted within channels 108c and caps 110 installed.
In some cases, from exterior sheathing of building wall 11 to the exterior of the system 10, an embodiment may have a weather resistive barrier (WRB), with the panel including drainage, drying cavity, double sided tape on the panel against the WRB, insulation, and an external finishing layer, forming an all in one finished product. Embodiments of the system 10 may have one or more of the following advantages:
- 1) non combustibility;
- 2) continuous insulation to avoid thermal bridging;
- 3) drainage/air cavity;
- 4) double sided tape installed vertically against the rear of panel; and
- 5) a receiver cap with a thermal break.
Words such as above, below, over, under, horizontal and vertical, and others, are understood to be relative and not defined with respect to gravitational acceleration on the Earth, unless context dictates otherwise.
In the claims, the word “comprising” is used in its inclusive sense and does not exclude other elements being present. The indefinite articles “a” and “an” before a claim feature do not exclude more than one of the feature being present. Each one of the individual features described here may be used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the
Patent Application
20220162860
