Concealed-fastener exterior cladding panels for building construction

• US 9,127,451 B1
• Filed: 02/10/2014
• Issued: 09/08/2015
• Est. Priority Date: 02/10/2014
• Status: Active Grant

• Current Assignee: Lester Building Systems LLC (Bluescope Steel Limited)
• Original Assignee: Lester Building Systems LLC (Bluescope Steel Limited)
• Inventors: Boor, Paul A.
• Primary Examiner(s): GILBERT, WILLIAM V
• Application Number:
  US14/176,586
• Time in Patent Office: 575 Days
• Field of Search: 52519-521, 524/70, 524/71, 525/37, 525/38, 525/45, 525/49, 524/78, 525/22, 525/44, 525/43, 527/481.1
• US Class Current: 1/1
• CPC Class Codes: E04C 2/08 of metal, e.g. sheet metal E04C2/26 takes precedence
• CPC Class Codes: E04C 2/322 with parallel corrugations
• CPC Class Codes: E04D 13/1585 covering the verge of saddle roofs gable tiles E04D1/30
• CPC Class Codes: E04D 3/30 of metal
• CPC Class Codes: E04D 3/362 by locking the edge of one slab or sheet within the profiled marginal portion of the adjacent slab or sheet, e.g. using separate connecting elements
• CPC Class Codes: E04D 3/366 by closing the space between the slabs or sheets by gutters, bulges, or bridging elements, e.g. strips
• CPC Class Codes: E04F 13/22 Anchors, support angles or consoles not used, see E04F13/0801

Abstract

An exterior cladding panel assembly for covering an outside surface of a framed building is provided by the invention. A unique rib and batten system with overlapping raised female and male edge ribs on the adjacent installed panels, and raised interior ribs allow through fastening of the panels on the order of 32 inches or wider to the building'"'"'s underlying framing structure with complete concealment of the fasteners, and without the need for special fastener clips. The ribs have an inverted U-shaped end profile that creates an open cavity between the rib top wall and the underlying framing member. The fastener can be driven through the rib top walls into the framing member without the need for a solid filler cleating strip.

Claims

1. A method of securing two or more panels to substantially parallel, spaced framing members of a building, each panel comprising:

(a) a sheet of material having a top surface, a first lateral edge and a second lateral edge opposite the first lateral edge;

(b) at least one interior rib formed in and extending upwardly from the top surface of the sheet of material, the interior rib having a generally inverted U-shape including a top wall for receiving a fastener to secure the interior rib to a building framing member, a first side wall and a second side wall opposite the first wall, the interior rib being positioned at a point along the panel between the first lateral edge and the second lateral edge of the panel, the interior rib further having a first longitudinal detent formed along the first side wall and a second longitudinal detent formed along the second side to define a head, neck and body region of the interior rib;

(c) a female rib formed in and extending upwardly from the top surface of the sheet of material along the first lateral edge of the panel, the female rib having a generally inverted U-shape including a top wall, a first side wall and a second side wall opposite the first wall, a first longitudinal detent formed along the first side wall of the female rib and a second longitudinal detent formed along the second side wall of the female rib to define a head, neck and body section of the female rib;

(d) a male rib formed in and extending upwardly from the top surface of the sheet of material along the second lateral edge of the panel, the male rib having a generally inverted U-shape including a top wall, a first side wall and a second side wall opposite the first wall and an end profile slightly smaller than an end profile of the female rib, such that the female rib of a first panel will nest on top of the male rib of a second underlying panel so the male and female top walls are aligned for fasteners to pierce the top walls of the nested female and male ribs into a building framing member;

(e) a generally inverted U-shape batten sealing cap adapted to cover the head region of the interior and female ribs, the batten sealing cap having a top wall and two side walls with outer edges, the batten sealing cap being secured to the interior or female rib by engagement of the side wall edges with corresponding first and second longitudinal detents forming the neck of the interior or female rib, such that the top wall of the batten sealing cap is spaced from the top wall of the interior or female rib to accommodate a space required for the head of the fasteners,

the method comprising the steps of;

a. placing a first panel on framing members oriented perpendicular to the ribs of the first panel, aligning the female rib with an edge of the building area to be covered;

b. fastening the panel to the framing by driving fasteners through the female and interior ribs into each underlying framing member;

c. installing batten sealing caps onto the top of the female and interior ribs of the first panel;

d. placing a second panel in adjoining relation with the first panel with the female rib of the second panel placed over the male rib of the first panel;

e. installing fasteners through the female and interior ribs of the second panel into each underlying framing member; and

f. installing batten sealing caps onto the top of the female and interior ribs of the second panel.

2. A cladding panel assembly for attachment to a framing member of a building, the panel comprising:

(a) a sheet of material having a top surface, a first lateral edge and a second lateral edge opposite the first lateral edge;

(b) at least one interior rib formed in and extending upwardly from the top surface of the sheet of material, the interior rib having a generally inverted U-shape including a top wall for receiving a fastener to secure the interior rib to a building framing member, a first side wall and a second side wall opposite the first wall, the interior rib being positioned at a point along the panel between the first lateral edge and the second lateral edge of the panel, the interior rib further having a first longitudinal detent formed along the first side wall and a second longitudinal detent formed along the second side wall to define a head, neck and body region of the interior rib;

(c) a female rib formed in and extending upwardly from the top surface of the sheet of material along the first lateral edge of the panel, the female rib having a generally inverted U-shape including a top wall, a first side wall and a second side wall opposite the first wall, a first longitudinal detent formed along a first side wall of the female rib and a second longitudinal detent formed along an opposite second side of the female rib to define a head, neck and body section of the female rib;

(d) a male rib formed in and extending upwardly from the top surface of the sheet of material along the second lateral edge of the panel, the male rib having a generally inverted U-shape including a top wall, a first side wall and a second side wall opposite the first wall and an end profile slightly smaller than an end profile of the female rib, such that the female rib of a first panel will nest on top of the male rib of a second underlying panel so the male and female top walls are aligned for fasteners to pierce the top walls of the nested female and male ribs and their corresponding underlying building framing member;

(e) a generally inverted U-shape first batten sealing cap adapted to cover the head region of the interior rib, the first batten sealing cap having a top wall and two side walls with outer edges, the first batten sealing cap being secured to the interior rib by engagement of the side wall edges with corresponding first and second longitudinal detents forming the neck of the interior rib, such that the top wall of the first batten sealing cap is spaced from the top wall of the interior rib to accommodate the space required for the head of the fasteners; and

(f) a generally inverted U-shape second batten sealing cap adapted to cover the head region of the female rib, the second batten sealing cap having a top wall and two side walls with outer edges, the second batten sealing cap being secured to the female rib by engagement of the side wall edges with corresponding first and second longitudinal detents in the female rib, such that the top wall of the second batten sealing cap is spaced from the top wall of the female rib to accommodate the space required for the head of the fasteners.

3. The panel assembly of claim 2, wherein a second identical panel assembly is positioned adjacent to the first panel assembly with the supporting male rib of the second panel disposed inside the female rib of the first panel in a lapped configuration.

4. The panel assembly of claim 3, further comprising a fastener having a head end and an attachment end that pierces the lapped female and supporting male ribs with the attachment end engaging the framing member of the building to secure the panel assembly to the building, the head end being disposed between the female rib and the respective sealing batten cap to conceal it.

5. The panel assembly of claim 4, wherein there is no solid filler material disposed on the framing member of the building between an interior surface of the supporting male rib and the framing member.

6. The panel assembly of claim 3, wherein the lapped female and supporting male ribs forces proper alignment of the two panels with respect to each other.

7. The panel assembly of claim 4, wherein the fastener comprises an extended shank portion between the head end and attachment end so that the shank portion extends into the framing member thereby improving the strength and toughness of the fastener by eliminating stress risers associated with deformation of the fastener shank.

8. The panel assembly of claim 3 further comprising a void formed between the walls of the lapped female rib and male rib to break capillary action that draws migrating water between the rib walls.

9. The panel assembly of claim 2, wherein no separate clips are used to secure the panel assembly to the framing member of the building.

10. The panel assembly of claim 2 further comprising at least one minor rib having a pair of side walls and a bottom wall formed in the sheet of material extending downwardly from the surface of the sheet between two substantially flat pan regions formed in the sheet, such that when the panel is mounted to building framing members, the bottom wall of the minor rib will be disposed against the building framing members to space a greater portion of the pan regions of the panel away from the framing members to minimize the formation of the shape of the framing member within the pan regions of the panel.

11. The panel assembly of claim 2 further comprising at least one minor rib having a pair of side walls and a bottom wall formed in the sheet of material extending downwardly from the surface of the sheet between two substantially flat pan regions formed in the sheet to stiffen the flat pan regions of the panel to minimize undulations formed in the panel.

12. The panel assembly of claim 2, wherein at least one side wall of the interior rib is tapered with respect to the surface of the sheet adjacent to the interior rib.

13. The panel assembly of claim 12, wherein the tapered side wall of the interior rib enables nesting of two panels one on top of the other.

14. The panel assembly of claim 2, wherein at least one side wall of the female rib is tapered with respect to the surface of the sheet adjacent to the interior rib.

15. The panel assembly of claim 14, wherein the tapered side wall of the female rib enables nesting of two panels one on top of the other.

16. The panel assembly of claim 2, wherein the interior rib and female rib with the sealing batten caps engaged thereto appear substantially identical.

17. The panel assembly of claim 2, wherein when the panel assembly is installed to the building, it provides substantially waterproof protection to the building.

18. The panel assembly of claim 2, wherein the interior rib enhances the strength and stiffness of the panel to allow the panel to span multiple framing members on the building without structural sheathing disposed between the panel and framing members.

19. The panel assembly of claim 2 further comprising a longitudinal crease formed within the top wall of the female rib or interior rib to assist in the proper orientation of a fastener driven through the rib top wall into the building framing member below.