Patent Publication Number: US-2006010823-A1

Title: Cladding assembly and method of cladding posts

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
      This application is related to commonly assigned U.S. patent application Ser. No. 10/725,768, entitled, “Single Piece Post Cladding Element, Method of Cladding a Post and Method of Forming a Cladding Element” filed Dec. 2, 2003, the entirety of which is hereby incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates to post cladding elements and assemblies, and methods of cladding posts.  
     BACKGROUND OF THE INVENTION  
      Posts for supporting outdoor structures such as porches, decks, boat piers and fences are clad for several reasons, including protection from the elements, reducing maintenance (e.g., painting), providing an aesthetic appearance and matching a fence system.  
      There are two common cladding methods. In a first method, a cladding sleeve is slipped over the post prior to installation of the post or if there is an unobstructed post end. This first cladding method and element cannot be retrofitted onto a post that is already installed (hereinafter, “pre-installed post”). If by choice or due to physical constraints (i.e., a preinstalled post) the first cladding method is not used, then the post is clad using a multi-piece cladding assembly installed around the post. Two to four piece assemblies are most common. An example of such an assembly is provided in U.S. Pat. No. 5,956,920 to Davis, entitled “Modular Post Cladding Element, Post Cladding Assembly, and Method of Cladding a Post”, issued Sep. 28, 1999.  
     SUMMARY OF THE INVENTION  
      A cladding assembly, a cladded building assembly and method of cladding a building structure using the cladding assembly are provided. The cladding assembly includes at least one cladding panel and at least one connection element, wherein the connection element includes an androgynous means for engaging the at least one cladding panel to secure the at least one cladding panel to a building structure. In one embodiment, the assembly includes a plurality of polymeric cladding panels and at least one polymeric connection element. The cladding panels may include at least one pair of outwardly or inwardly extending, oppositely disposed catches, and the polymeric connection element includes at least one pair of inwardly or outwardly extending, oppositely disposed catches, wherein the at least one connection element is secured to the plurality of cladding panels with the inwardly or outwardly disposed catches of the connection element mated to the outwardly or inwardly disposed catches of the cladding panels, respectively, to couple the cladding panels of this embodiment together in cladding the building structure.  
      The cladding assembly can, if desired, fully enclose a member, such as a wooden post, to provide a maintenance free and aesthetically pleasing building structure. The assembly can be used where the building structure is only partially enclosed, such as, for example, in a fascia cladding or siding corner trim applications, or deck sub-structure, columns, posts and rails. In such an application, one or more cladding panels could be applied to a building structure using connection elements to secure the cladding panels one to another, or to portions of the building structure equipped with a projection or flange suitably adapted for engaging a connection element. In this case, a portion of the building structure is clad, rather than completely surrounding the entire structure. The cladding assembly allows for easy retrofitting of an aesthetic appearance to either restore the appearance of a building structure to acceptability in the case of a deteriorated structure, or simply to change the desired aesthetics of the structure without removing it. The cladding can also be reversibly applied. If a change in appearance of a post is desired, the cladding can be removed and replaced with a cladding having a different aesthetic effect. For example, connection elements can be changed to produce different visual effects. Cladding panels could be provided with patterns, shapes or colors that could be used individually or with other patterns to yield cladded building structures having the desired attributes.  
      The cladding can be fit adjustably to a pre-installed structure. The connection system allows for some irregularities in the geometry of the post itself and allows a generally pleasing aesthetic effect when the cladding is fully assembled. The adjustability also enables accommodation of the cladding assembly to thermal expansion and contraction or other changes in dimension that can occur in use. The adjustability of the cladding assembly also can be beneficial when using the cladding with posts that are not of perfect dimensions. For example, if a post support structure were warped or twisted, the cladding would render a more desirable appearance.  
      The cladding assembly also lends itself to proper drainage. This attribute helps in drying and avoiding of water damage to the enclosed support structure over time. Further, as the cladding assembly, in one embodiment, is made up of a plurality of cladding panels, a cladding panel or panels can be easily replaced in the event of damage to a portion of the post or the cladding.  
      In the case of a four-sided square post, a cladding assembly can be produced by extrusion of identical cladding panels and connection elements. The cladding panels being of a single geometry simplifies the shipping and inventory needs. In the case of rectangular posts that do not have square cross sections, the cladding could be provided using one cladding panel type for the larger dimension and another cladding type for the smaller dimension, wherein the connection elements can be the same.  
      The cladding can also be used for more complexly shaped structures, such as, for example, hexagonal, octagonal, or higher order polygonally shaped posts or columns of varying sizes without the need for different cladding panels and connection elements for each contemplated shape to be clad.  
      The above and other features of the present invention will be better understood from the following detailed description of the preferred embodiments of the invention that is provided in connection with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The accompanying drawings illustrate preferred embodiments of the invention, as well as other information pertinent to the disclosure, in which:  
       FIG. 1  is a top plan view of a cladded building assembly;  
      FIGS.  2  an  2 A are profile views embodiments of cladding panels;  
       FIGS. 3, 3A  and  3 B are profile views of embodiments of connection elements;  
       FIGS. 4-4E  illustrate a method of cladding a post according to the present invention;  
       FIG. 5  is a top plan view of an alternative embodiment of a cladded building assembly;  
       FIG. 6  is a top plan view of another alternative embodiment of a cladded building assembly; and  
       FIG. 7  is a top plan view of another alternative embodiment of a cladded building assembly. 
    
    
     DETAILED DESCRIPTION  
      Described herein are a cladding assembly, cladded building assembly and method of cladding a building structure. In an exemplary embodiment, the cladding is designed to clad a wood post of rectangular geometry and square cross section, although the cladding may be applied to structures formed of other materials, shapes and types, such as piers of a deck or dock, mailbox posts, columns, lamp posts, etc.  
      Referring first to  FIG. 1 , a top plan view of a cladded building assembly  10  is provided. Cladded building assembly  10  includes a rectangular wooden post  12  having a square cross section. A cladding assembly is attached to the post and includes, in the illustrated embodiment, four cladding panels  14  and four connection elements  16 . The connection elements  16  provide an androgynous means of engaging the one or more cladding panels to secure the cladding panels  14  to the post  12  in cladding the post. By “androgynous” is meant that the connection between adjacent components  16  is made using geometry that is neither male nor female in the way the engagement is made.  
      In one embodiment, the androgynous engagement is performed by mating catches. For example, in one embodiment each connection element  16  includes a pair of inwardly extending, oppositely disposed catches  22  that mate with a pair of outwardly extending, oppositely disposed catches  20 , with a catch  20  being provided one from each of an adjacent pair of cladding panels  14 . As can be seen from  FIG. 1 , the pair of inwardly extending catches  22  of the connection elements  16  are preferably generally shaped like a pair of hooks that anchor the connection element to the outwardly extending catches  20  of a pair of adjacent cladding panels  14 .  
      As can also be seen from  FIG. 1 , each cladding panel  14  preferably comprises support structure for supporting the panel against the post  12 . In one embodiment, the support structure comprises support posts  18 , which provide the proper spacing for cladding panels  14  with respect to the side surfaces of post  12  and provide mechanical support for the cladding panel  14 .  
       FIG. 2  is a profile view of cladding panel  14 , which clearly illustrates support posts  18  and catches  20 . In the embodiment of  FIG. 14 , the catches  20  are angled, outwardly extending catches.  FIG. 2A  is a partial view of a second embodiment of a cladding panel  14 A illustrating that the catches  20 A can be generally semicircular shaped, u-shaped or squared catches.  
       FIG. 3  illustrates a generally right angle shaped connection element  16 , as also shown in  FIG. 1 .  FIGS. 3A and 3B  illustrate alternative embodiments, specifically generally flat shaped connection element  16 A and rounded or arched connection element  16 B, respectively.  
      The connection elements  16  and cladding panels  14  described herein are preferably made from a thermoplastic polymeric material. Polyvinyl chloride (PVC), polyolefins, acrylics or acrylic copolymers are preferred. The use of capstocks, over-molded or coextruded polymeric layers that are flame, UV and/or weather resistant, or contain additives for rendering their resinous compositions flame, UV and/or weather resistant, such as polypropylene, polyethylene, HMPE, PVC, ABS (acrylonitrile butadiene styrene), polyurethane, polystyrene, acrylic or ASA (acrylonitrile styrene acrylate) polymers, for example, can provide an element of increased surface durability while maintaining lower cost for the bulk of the materials making up the product. A weather resistant base polymer could be used for the connection element and cladding panels, as opposed to a capstock with a weather resistant overmold, coextrude or additive, although this embodiment may be more expensive than using a capstock. The cladding panels and connection elements may be formed by profile extrusion, sheet extrusion, stamping, thermoforming and vacuum forming, for example. Sizing dies can also be used for shaping the composites. In a preferred embodiment, the connection element and cladding panels are co-extrusions having a weather resistant capstock on a more economical base stock.  
      A method of installing the cladding assembly on a building structure is described in connection with  FIGS. 4-4E . As shown in  FIG. 4 , one or more cladding panels  100  is provided having outwardly extending catches formed along its entire length. The cladding panels  100  are cut to the appropriate length (designated “X”) for covering a building structure, such as a post  102 . As shown in  FIG. 4A , portions of the outwardly extending catches of the cladding panel are removed from at least one, and optionally both, ends of the cladding panel, forming cladding panel  100 ′. In one embodiment, from about 0.5-2.5″, and preferably between about 0.75-2.0″ and more preferably between about 1.0-1.5″, of the outwardly extending catches are removed from proximate to the top and/or bottom ends of the panel  100 . This removal step accommodates the application of trim or molding as described in more detail below. It should be understood, however, that the trimming step is optional and is used to accommodate the trim or molding, when used. For example, in another embodiment, the cladding is installed without the use of a trim or molding piece and no portions of the outwardly extending catches are removed.  
      Next, as shown in  FIG. 4B , one or more cladding panels  100 ′ are aligned on a post  102 . These cladding panels may be tacked using nails or otherwise directly secured to the post  102 . Although not shown, it should be understood that one, two, three or four cladding panels, depending on their shapes, can be used to cover a four-sided post  102 .  
      Referring to  FIG. 4C , an ornamental trim or molding section  104  is constructed around the base and/or top end of the post  102  and over the portion of the cladding panels where the catches were removed. Those of ordinary skill should be familiar with the construction of trim section  104  and its details are not repeated herein. An example of the construction of trim section  104  is provided in U.S. Pat. No. 5,956,920 to Davis discussed above, the entirety of which is hereby incorporated by reference herein.  
      As shown in  FIG. 4D , connection element  106  is cut to the proper length X. As shown in  FIG. 4E , the connection element is then snap fitted over an adjacent pair of outwardly extending catches to secure the connection element  106  to the adjacent cladding panels  100 ′ and the cladding panels  100 ′ to each other. The steps of  FIGS. 4B ,  4 D and  4 E can be repeated to clad the other sides of post  104 . Last, a second trim or molding section  104  (not shown) can be constructed to cover the top edge of post  104 , covering the area where the catches were removed from near the top edge of the panels  100 ′. Alternatively, cladding panels  100  may be held in place by constructed trim sections or, optionally, manually, while connection elements  106  are secured to the cladding panels to form the clad structure, such cladding holding itself in place once assembled.  
      It should be apparent from the foregoing that the cladding assembly can, if desired, fully enclose a member, such as a wooden post, to provide a maintenance free and aesthetically pleasing building structure. The assembly can be used where the building structure is only partially enclosed, such as, for example, in a fascia cladding or siding corner trim applications, or deck sub-structure. In such an application, one or more cladding panels could be applied to a building structure using connection elements to secure the cladding panels one to another, or to portions of the building structure equipped with a projection or flange suitably adapted for engaging a connection element. In this case, a portion of the building structure is clad, rather than completely surrounding the entire structure. Optionally, an additional anchoring means could be used, such as, for example, a screw, staple or nail, in attaching the cladding to the building structure. While fasteners may be optionally used, the cladding assembly lends itself to be applied without the need for additional fasteners or glue and may provide a self supporting structure.  
      The cladding assembly allows for easy retrofitting of an aesthetic appearance to either restore the appearance of a building structure to acceptability in the case of a deteriorated structure, or simply to change the desired aesthetics of the structure without removing it. The cladding can also be reversibly applied. If a change in appearance of a post is desired, the cladding can be removed and replaced with a cladding having a different aesthetic effect. For example, connection elements can be changed to produce different visual effects. Cladding panels could be provided with patterns, shapes or colors that could be used individually or with other patterns to yield clad building structures having the desired attributes.  
      It should be apparent that the cladding can be fit adjustably to an existing structure that is already in place. The cladding does not need to be slipped over one end of the post. The connection system allows for some irregularities in the geometry of the post itself and allows a generally pleasing aesthetic effect when the cladding is fully assembled. The adjustability also enables accommodation of the cladding assembly to thermal expansion and contraction or other changes in dimension that can occur in use. The adjustability of the cladding assembly also can be beneficial when using the cladding with posts that are not of perfect dimensions. For example, if a post support structure were warped or twisted, the cladding would render a more desirable appearance. Also, the cladding can be used on a support structure that is purely structural in its load-bearing capability, such as a pipe, floor jack or a section of angle iron, for example, to provide a pleasing finished look to a post so clad.  
      The cladding assembly also lends itself to proper drainage. This attribute helps in drying and avoiding of water damage to the enclosed support structure over time. Further, as the cladding assembly, in one embodiment, is made up of a plurality of cladding panels, a cladding panel or panels can be easily replaced in the event of damage to a portion of the post or the cladding.  
      In the case of a four-sided square post, a cladding assembly can be produced by extrusion of identical cladding panels and connection elements. The cladding panels being of a single geometry simplifies the shipping and inventory needs. In the case of rectangular posts that do not have square cross sections, the cladding could be provided using one cladding panel type for the larger dimension and another cladding type for the smaller dimension, wherein the connection elements can be the same.  
      The cladding can also be used for more complexly shaped structures, such as, for example, hexagonal, octagonal, or higher order polygonally shaped posts or columns of varying sizes without the need for different cladding panels and connection elements for each contemplated shape to be clad.  
      As noted above, a preferred building structure for cladding is a post. Four cladding panels could be provided along with four connection elements for cladding a square post. Alternatively, a given panel section could cover more than one side of the post such that, for example, two panel sections could be connected to wrap the post. Another approach would be to provide a single four sided panel that includes a subsection for each of the four sides with a connection element to close and hold the cladding in place. A single piece post cladding element that could be adapted for this purpose is disclosed in commonly assigned U.S. patent application Ser. No. 10/725,768, entitled, “Single Piece Post Cladding Element, Method of Cladding a Post and Method of Forming a Cladding Element” filed Dec. 2, 2003, the entirety of which is hereby incorporated by reference herein.  
       FIG. 5  is a top plan view of an alternative cladded building assembly  200 . Assembly  200  includes a rectangular wooden post  12  having a square cross section. A cladding assembly is attached to the post and includes, in the illustrated embodiment, four cladding panels  140  and four connection elements  160 . The connection elements  160  provide an androgynous means of engaging the one or more cladding panels to secure the cladding panels  140  to the post  12  in cladding the post. In this embodiment, the androgynous engagement is performed by a pair of outwardly extending, oppositely disposed catches  220  that mate with a pair of inwardly extending, oppositely disposed catches  210 , with a catch  210  being provided one from each of an adjacent pair of cladding panels  140 . As can be seen from  FIG. 5 , the pair of outwardly extending catches  220  of the connection elements  160  are preferably generally shaped like a pair of hooks that anchor the connection element to the inwardly extending catches  210  of a pair of adjacent cladding panels  140 . The assembly  200  can be constructed in the manner described above in connection with, for example,  FIGS. 4-4E .  
      In an alternative embodiment of a cladding panel assembly, the at least one connection element includes a pair of oppositely disposed male connectors, and the at least one cladding panel has a pair of oppositely disposed female connectors for mating with the oppositely disposed male connectors. Alternatively, the at least one connection element includes a pair of inwardly disposed female connectors, and the at least one cladding panel has a pair of oppositely disposed male connectors for mating with the oppositely disposed female connectors of the connection element.  
      In another alternative embodiment of a building assembly  300  shown in  FIG. 6 , the connection element is integral with the cladding panels  340 A,  340 B. In the illustrated embodiment including four cladding panels, the cladding assembly includes two cladding panels  340 A each including a pair of inwardly extending catches  342  and two cladding panels  340 B each including a pair of outwardly extending catches  344 . In this embodiment, catches  342  of a cladding panel  340 A mate with catches  344  of an adjacent cladding panel  340 B proximate to each corner of post  12 . As should be understood, this assembly can be constructed with one, two, three or four cladding panels.  
       FIG. 7  is a top plan view of another alternative embodiment of a building assembly  400  where the connection element is integral with the cladding panels  440 . Each cladding panel is identical and roughly shaped like an “S”. In this embodiment, each cladding panel has an inwardly extending catch  442  and an outwardly extending catch  444 . The inwardly extending catches  442  are similarly shaped and larger (though differently oriented) than the outwardly extending catches  444  such that an inwardly extending catch  442  of a first cladding panel  440  can fit around the outwardly extending catch  444  of an adjacent second cladding panel  440  to secure the cladding panels together.  
      The cladding assemblies have been described, in one embodiment, as including a 4″×4″ square post. A larger post, such as a 6″×6″ post, can be clad in at least two ways using inventory available for cladding the 4″×4″ post. In a first embodiment, the cladding panels used to clad the 4″×4″ post are used. Enlarged connection elements are then used to connect the cladding panels together and to cover the portion of the 6″×6″ post not covered by the cladding panels designed for the 4″×4″ post. In the second embodiment, wider cladding panels about 6″ or more in width can be secured to the 6″×6″ post with connection elements from the 4″×4″ post embodiment. These embodiments allow for larger post to be clad while utilizing inventory available to clad smaller posts. Alteratively, slightly wider (i.e., wider than the 4″×4″ post embodiment) cladding panels and slightly larger (larger than the 4″×4″ post embodiment) connection elements could be used.  
      Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly to include other variants and embodiments of the invention that may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.