Abstract:
The present application discloses a wall panel and corner construction system for installation onto a building structure, and methods for installing same.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to construction of paneling, and more particularly to paneling for installation onto the exterior of structures. 
       BACKGROUND 
       [0002]    Wall panels are used as a siding or roofing material on various types of structures. The corners of these structures require weatherproof seals to prevent water from entering behind the wall panels. In prior art corner construction systems, wall panels are roughly installed up to a corner of a structure and then the ends of the panels are covered by corner caps or a corner post to conceal the ends of the wall panels and prevent water and debris from entering behind the wall panels. These corner structures are unsightly and stick out from the corner of the structure. 
         [0003]    Accordingly, there is a need for a corner construction system and method of installing same that are improvements over existing devices and methods. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    The corner construction system according to the present invention is further described with reference to the accompanying drawings, in which: 
           [0005]      FIG. 1  shows a perspective view of an embodiment of a corner construction system according to the present invention; 
           [0006]      FIG. 2  shows a front perspective view thereof; 
           [0007]      FIG. 3  shows a schematic sectional view of the embodiment of  FIG. 1  taken through a horizontal plane and viewed from the top; 
           [0008]      FIG. 4  show a top plan schematic view of a corner bracket thereof; and 
           [0009]      FIG. 5  is a flow chart showing the steps of installing an embodiment of the corner construction system according to the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0010]    The ensuing detailed description provides preferred exemplary embodiments only, and is not intended to limit the scope, applicability, or configuration of the herein disclosed inventions. Rather, the ensuing detailed description of the preferred exemplary embodiments will provide those skilled in the art with an enabling description for implementing the preferred exemplary embodiments in accordance with the herein disclosed invention. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention, as set forth in the appended claims. 
         [0011]    To aid in describing the invention, directional terms may be used in the specification and claims to describe portions of the present invention (e.g., upper, lower, left, right, etc.). These directional definitions are merely intended to assist in describing and claiming the invention and are not intended to limit the invention in any way. In addition, reference numerals that are introduced in the specification in association with a drawing figure may be repeated in one or more subsequent figures without additional description in the specification, in order to provide context for other features. 
         [0012]    For purposes of the present specification and accompanying claims, the term “adjacent” means either “in close vicinity to” or “in direct contact with.” 
         [0013]    For purposes of the present specification and accompanying claims, the term “overlies” means “located superficial to” or “located on top of.” 
         [0014]    For purposes of the present specification and accompanying claims, the term “substantially” used with respect to a geometric relationship, for example “substantially parallel” means within plus or minus 5 degrees of that relationship proper. 
         [0015]      FIGS. 1-3  generally show an embodiment of a corner construction system  10  in accordance with the present invention. In this embodiment, the system  10  comprises a first array of wall panels  12  that is attachable to such that it overlies a first wall  4  of a structure  2  and a second array of wall panels  14  that is attachable to such that it overlies a second wall  6  of the structure  2 . As shown in  FIG. 1 , the first array of wall panels  12  comprises a first wall panel  48  and the second array of wall panels  14  comprises a second wall panel  60 . The system  10  further comprises a corner bracket  22  that, once attached to the structure  2 , overlies a corner  8  of the structure  2 . The corner  8  of the structure  2  has an interior angle  9 , which in this embodiment has a value of 90 degrees. A suitable underlayment  3 , for example a housewrap material such as Tyvek® produced by E. I. du Pont de Nemours and Company of Wilmington, Del., is provided between the structure  2  and the corner construction system  10  prior to installation of the system  10  on the structure  2 . 
         [0016]      FIG. 4  shows the corner bracket  22  of the system  10 . In this embodiment, the corner bracket  22  comprises a first flange  28  having a flat portion  31  and a protruding portion  32 , a second flange  30  having a flat portion  33  and a protruding portion  34 , and a corner protrusion  24  having a length  25  and a bend  26  at a distal end thereof. Referring back to  FIG. 3 , the corner bracket  22  is installed onto the structure  2  by placing the corner bracket  22  adjacent to the structure  2  such that the corner protrusion overlies the corner  8  of the structure, the flat portion  31  is located adjacent to the first wall  4 , and the flat portion  33  is located adjacent to the second wall  6 , then the flat portion  31  is attached to the first wall  4  via a suitable fastener  80  and the flat portion  33  is attached to the first wall  4  via a suitable fastener  82 . It should be understood that  FIG. 3  is depicting a cross-sectional view of the system  10  viewed from the top, and that a vertical row of fasteners will be used to attach both the first flange  28  and the second flange  30  to the structure  2 . When the corner bracket  22  is attached to the structure  2  in this fashion, the corner protrusion  24  extends away from the first wall  4  a first distance  40  that is measured orthogonally from the first wall  4 , the corner protrusion  24  extends away from the second wall  6  a second distance  41  that is measured orthogonally from the second wall  6 , the protruding portion  32  extends away from the first wall  4 , and the protruding portion  34  extends away from the second wall  6 . 
         [0017]    The corner protrusion  24  has a first side  36  and a second side  38 . The corner protrusion  24  extends away from the flat portion  31  of the first flange  28  at a first protrusion angle  42  and extends away from the flat portion  33  of the second flange  30  at a second protrusion angle  43 . In this embodiment, both the first protrusion angle  42  and the second protrusion angle  43  have a value of 135 degrees, such that the corner bracket  22  is designed to be used for a structure  2  having a 90 degree (right angle) interior corner (i.e., a 270 degree exterior corner which is bisected by the corner protrusion  24 ). In alternate embodiments, the first protrusion angle  42  and second protrusion angle  43  could have different or equal values between 90 and 180 degrees (obtuse angles), or could have different or equal values less than 90 degrees (acute angles) if the corner bracket  22  is used for a corner of a structure having an interior angle greater than 180 degrees (i.e., a reflex angle). As would be appreciated by one of ordinary skill in the art, while the individual values of the angles are adjustable based on the geometry of the structure  2 , the sums of the first protrusion angle  42 , second protrusion angle  43 , and the interior angle  9  of the corner  8  of the structure  2  will sum to approximately 360 degrees. For example, if the interior angle  9  of the corner  8  of the structure  2  had a value of 120 degrees, the first protrusion angle  42  and second protrusion angle  43  would have a combined value of approximately 240 degrees, and could for example have values of approximately 120 degrees each. 
         [0018]    In this embodiment, the first wall panel  48  has an end  52 , an interior surface  46 , and an exterior surface  44  opposing the interior surface  46 . When the first wall panel  48  is attached to the first wall  4  of the structure  2  such that the end  52  of the first wall panel  48  is located adjacent to the first side  36  of the corner protrusion  24  and the interior surface  46  of the first wall panel  48  contacts the protruding portion  32  of the first flange  28 , a depth  72  of the first wall panel that is measured orthogonally between the first wall  4  and the exterior surface  44  of the first wall panel  48  is no greater than the first distance  40  (such that the exterior surface  44  of the first wall panel  48  does not extend out beyond the corner protrusion  24 ). In this embodiment, the second wall panel  60  has an end  64 , an interior surface  61 , and an exterior surface  59  opposing the interior surface  61 . When the second wall panel  60  is attached to the second wall  6  of the structure  2  such that the end  64  of the second wall panel  60  is located adjacent to the second side  38  of the corner protrusion  24  and the interior surface  61  of the second wall panel  60  contacts the protruding portion  34  of the second flange  30 , a depth  74  of the second wall panel  60  that is measured orthogonally between the second wall  6  and the exterior surface  59  of the second wall panel  60  is no greater than the second distance  41  (such that the exterior surface  59  of the second wall panel  60  does not extend out beyond the corner protrusion  24 ). 
         [0019]    In this embodiment, the first wall panel  48  is comprised of a main portion  56  and a return portion  58  that is separated from the main portion  56  by a bend  50 . The bend  50  has an interior angle  54 . In this embodiment, the value of the interior angle  54  is supplementary to the value of the first protrusion angle  42 , i.e., these values sum to 180 degrees, such that the return portion  58  is parallel to the first side  36  of the corner protrusion  24  once the first wall panel  48  is installed on the first wall  4  such that the exterior surface  44  of the first wall panel  48  lies in a plane that is parallel to a plane of the first wall  4 . In alternate embodiments, the return portion  58  of the first wall panel  48  is substantially parallel to the first side  36  of the corner protrusion  24  once the first wall panel  48  is installed. In further alternate embodiments, the return portion  58  of the first wall panel  48  need not be parallel or substantially parallel to the first side  36  of the corner protrusion  24  once the first wall panel  48  is installed, and optionally comes into contact with some portion of the first side  36  of the corner protrusion  24 . Although the return portion  58  is preferable because it prevents ingress of water and debris into the system  10 , in still further alternate embodiments the return portion  58  need not be provided at all and the end  52  of the first wall panel  48 , which is unbent, could be placed adjacent to the first side  36  of the corner protrusion  24 . 
         [0020]    In this embodiment, the second wall panel  60  is comprised of a main portion  68  and a return portion  70  that is separated from the main portion  68  by a bend  62 . The bend  62  has an interior angle  66 . In this embodiment, the value of the interior angle  66  is supplementary to the value of the second protrusion angle  43 , i.e., these values sum to 180 degrees, such that the return portion  70  is parallel to the second side  38  of the corner protrusion  24  once the second wall panel  60  is installed on the second wall  6  such that the exterior surface  59  of the second wall panel  60  lies in a plane that is parallel to a plane of the second wall  6 . In alternate embodiments, the return portion  70  of the second wall panel  60  is substantially parallel to the second side  38  of the corner protrusion  24  once the second wall panel  60  is installed. In further alternate embodiments, the return portion  70  of the second wall panel  60  need not be parallel or substantially parallel to the second side  38  of the corner protrusion  24  once the second wall panel  60  is installed, and optionally comes into contact with some portion of the second side  38  of the corner protrusion  24 . Although the return portion  70  is preferable because it prevents ingress of water and debris into the system  10 , in still further alternate embodiments the return portion  70  need not be provided at all and the end  64  of the second wall panel  60 , which is unbent, could be placed adjacent to the second side  38  of the corner protrusion  24 . 
         [0021]    The first wall panel  48  and second wall panel  60  may be delivered to the installation site without any bend, and an installer may cut each wall panel  48 , 60  to length and create the respective bend  50 , 62  once the relevant wall length and accompanying wall panel length has been determined. In the alternative, all wall panels could be pre-bent or pre-marked for the bend location before delivery to the installation site based on previously-collected measurements. The maximum lengths of the return portions of the wall panels that may be provided is determined by the depth of the particular wall panel being used (as measured between its interior and exterior surfaces) and the protrusion angles  42 , 43  of the corner protrusion  24  of the corner bracket  22 . Likewise, the length  25  of the corner protrusion  24  of the corner bracket  22  is determined by reference to the depths of the wall panels being used for the wall panel arrays  12 ,  14  and the protrusion angles  42 , 43  of the corner protrusion  24 . The corner bracket  22  may be delivered to the installation site pre-formed according to the height of the corner  8  of the structure  2  to which it is to be installed, could be pre-marked for the bend locations, or may be formed on-site by bending a sheet of metal of the appropriate length and width to form the corner bracket  22 . Thus, an advantage of the corner construction system  10  according to the present invention is that its components may be produced of sheet metal and shipped to the consumer flat, thus reducing the amount of shipping volume required to transport the components. An additional advantage is that an installer can use a flat piece of sheet metal to make corner brackets of various dimensions in accordance with the present invention based on the specifications of the structure and the wall panels that are to be used. If the corner bracket  22  is pre-formed, the corner protrusion  24  could be comprised of a single portion of the wall panel that extends from the flanges  28 , 30 . In other words, no bend  26  is necessary at the end of the length  25  of the corner protrusion  24 , as the corner protrusion  24  is formed in some way that does not necessitate bending a piece of metal in order to form it. 
         [0022]    In this embodiment, the protruding portions  32 , 34  of the corner bracket  22  are formed in a hooked, curved, or “J” shape. When the wall panels  48 , 60  are installed on the structure  2  and the respective interior surface  46 , 61  is placed in contact with the respective protruding portion  32 , 34 , a physical barrier is provided that prevents the flow of rain water or other debris that may enter the corner construction system  10  laterally past the protruding portions  32 , 34 . In alternate embodiments, the protruding portions  32 , 34  may be of other shapes, for example a squared-off hook, straight protrusion, or angled protrusion, or the protruding portions  32 , 34  may be omitted entirely. In the embodiment shown in  FIGS. 1-4 , the protruding portions  32 , 34  are each located at an end of a respective one of the flanges  28 , 30 . In alternate embodiments, the protruding portions  32 , 34  need not be located at the end of the flanges  28 , 30 . In the embodiment shown in  FIGS. 1-4 , the protruding portions  32 , 34  bend back towards the corner protrusion  24  of the corner bracket  22 . In alternate embodiments, the protruding portions  32 , 34  may run perpendicularly to the respective wall  4 , 6  of the structure  2 , or may be bent away from the corner protrusion  24 . 
         [0023]    In the present embodiment, the corner bracket  22  and wall panels  48 ,  60  are comprised of metal. In alternate embodiments, the corner bracket and wall panels could be comprised of other materials, for example vinyl or other plastics, various woods, or composites. 
         [0024]      FIG. 5  shows a flow chart outlining an embodiment of a method  100  of installing the corner construction system  10  on a structure  2  in accordance with the present invention. In step  101 , the corner bracket  22  is placed so that the corner protrusion  24  thereof is located adjacent to and overlies the corner  8  of the structure  2 . In step  102 , the first flange  28  of the corner bracket  22  is attached to the first wall  4  of the structure  2  via suitable fastener(s)  80 . In step  103 , the second flange  30  of the corner bracket  22  is attached to the second wall  6  of the structure  2  via suitable fastener(s)  82 . In optional step  104 , the first wall panel  48  is bent to create a main portion  56  and a return portion  58 , and in optional step  105  the second wall panel  60  is bent to create a main portion  68  and a return portion  70 . In step  106 , the first wall panel  48  is attached to the first wall  4  of the structure  2  such that an interior surface  46  of the first wall panel  48  contacts a protruding portion  32  of the first flange  28 , the end  52  of the first wall panel  48  is located adjacent to the corner protrusion  24 , and the first wall panel  48  does not extend out further than the corner protrusion  24 . Finally, in step  107 , the second wall panel  60  is attached to the second wall  6  of the structure  2  such that an interior surface  61  of the second wall panel  60  contacts a protruding portion  34  of the second flange  30 , the end  64  of the second wall panel  60  is located adjacent to the corner protrusion  24 , and the second wall panel  60  does not extend out further than the corner protrusion  24 . Additional wall panels and/or cornet brackets, as necessary, could then be installed onto the structure, in accordance with the steps set forth above. 
         [0025]    An exemplary order of steps of the method  100  according to the present invention has been set forth above. One of ordinary skill in the art would recognize that some of the steps could be reordered, combined, and/or omitted while keeping within the scope and spirit of the present invention. 
         [0026]    Although exemplary implementations of the herein described device and method have been described in detail above, those skilled in the art will readily appreciate that many additional modifications are possible in the exemplary embodiment(s) without materially departing from the novel teachings and advantages of the herein described device and method. Accordingly, these and all such modifications are intended to be included within the scope of the herein described device and method. The herein described device and method may be better defined by the following exemplary claims.