Patent Publication Number: US-8991127-B2

Title: Cladding system for building laminates

Description:
This application is filed as a divisional of U.S. application Ser. No. 13/700,516 filed on Feb. 6, 2013, which is a national stage entry of PCT/US2011/03781 filed on May 25, 2011, which claims priority to U.S. Provisional Application Ser. No. 61/349,353 filed May 28, 2010. 
    
    
     The present invention relates generally to laminate panels (also called facade cladding panels) to be applied to the facade of buildings, and specifically relates to cladding systems and methods for affixing the laminate panels to building facades more efficiently and with less cost. 
     According to one embodiment, a visible cladding system for attaching laminate panels onto a building wall is provided. The visible cladding system comprises at least one laminate panel support beam to be mounted onto a building wall, wherein the laminate panel support beam comprises at least one track. The visible cladding system also comprises at least one secondary support beam mounted to the at least one laminate panel support beam, at least one sliding clip slidingly coupled to at least one track, and at least one laminate panel coupled to at least one sliding clip and thereby slidable along the track, wherein the laminate panel is configured to be fastened to the secondary support beam. 
     According to yet another embodiment, a concealed cladding system configured for attaching laminate panels onto a building wall is provided. The system comprises at least two wall brackets horizontally spaced apart, wherein each wall bracket comprises an upper attachment component and a lower attachment component. The system also comprises at least one intermediate connector coupled to the wall brackets, wherein the intermediate connector comprises an upper coupling mechanism, a lower coupling mechanism, and a hanger member. The upper coupling mechanism of the intermediate connector is coupled with the upper attachment component of the wall brackets, and the lower attachment component of the intermediate connector is coupled with the upper attachment component of the wall bracket. The concealed cladding system also comprises at least one hanger clip having a laminate panel hanger member coupled with the hanger member of the intermediate connector; and a laminate panel fastened to at least one of the hanger clips. 
     The features and advantages of the present invention will become apparent from the following description and the accompanying drawings. 
    
    
     
       The following detailed description of the embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals. 
         FIG. 1  is a perspective view of a visible cladding attachment system according to one or more embodiments of the present invention. 
         FIG. 2A  is a horizontal cross-sectional view of a visible cladding attachment system according to one or more embodiments of the present invention. 
         FIG. 2B  is an exploded cross-sectional view of a visible cladding attachment system according to one or more embodiments of the present invention. 
         FIG. 3  is a perspective view of a concealed cladding attachment system according to one or more embodiments of the present invention. 
         FIG. 4A  is a horizontal cross-sectional view of a concealed cladding attachment system according to one or more embodiments of the present invention. 
         FIG. 4B  is an exploded cross-sectional view of a concealed cladding attachment system according to one or more embodiments of the present invention. 
         FIG. 4C  is a horizontal cross-sectional view of another concealed cladding attachment system according to one or more embodiments of the present invention. 
         FIG. 4D  is a horizontal cross-sectional view of yet another concealed cladding attachment system according to one or more embodiments of the present invention. 
     
    
    
     Referring to  FIGS. 1 ,  2 A and  2 B, a visible system  1  for fastening laminate panels  40  onto a building wall  10  is provided. As stated above, this system  1  is considered a visible cladding attachment system, because the cladding fastener component(s)  32  are not hidden behind the laminate panels  40 . As used herein, the building wall  10  may comprise many suitable structures familiar to one of ordinary skill in the art, such as a stud wall, exterior sheathing, a jam flashing membrane, a water resistive barrier, insulation, or any other building or foundation structure. 
     Referring again to  FIGS. 1 ,  2 A and  2 B, the system  1  comprises at least one laminate panel support beam  20 ,  25  mounted onto the building wall  10 , wherein the laminate panel support beam  20 ,  25  comprises at least one track  24 . In the embodiment of  FIGS. 1 ,  2 A and  2 B, the laminate panel support beam  20  may be mounted directly onto the building wall  10  or may be coupled to an additional mounting structure (not shown) mounted on the building wall  10 . Also, while the present discussion centers on a laminate panel support beam  20 ,  25  having a horizontal configuration, is it contemplated that the laminate panel support beam  20 ,  25  could be positioned vertically or diagonally if required by the structure and/or contours of the building wall  10 . 
     Referring again to the embodiment shown in  FIGS. 1 ,  2 A-B, the laminate panel support beam  20  may comprise two spaced parallel tracks  24 . In this embodiment, the laminate panel support beam  20  may define a W-shape configuration wherein the tracks  24  constitute raised portions of the laminate panel support beam  20 , and the portion between the tracks  24  is a non-raised beam  23  that abuts a building wall  10 . As shown, the laminate panel support beam  20  of  FIGS. 1 ,  2 A-B may be mounted onto the building wall  10  via one or more fasteners  22 . Many fasteners are contemplated herein, for example, screws, bolts, nails, or combinations thereof. The fasteners  22  may comprise any suitable rigid material, for example, metals or metal alloys such as stainless steel, aluminum, or combinations thereof. 
     In an alternative embodiment as shown in  FIG. 1 , the laminate panel support beam  25  may comprise one track  24 . In this embodiment, the laminate panel support beam  25  may define a J-shape configuration wherein the track  24  is a raised portion of the laminate panel support beam  25 . In the J-shape configuration, the nonraised portion adjacent the track  24  contacts the building wall  10 , and is fastened to the building wall  10  with a fastener  22 . As shown in  FIG. 1 , the laminate panel support beam  25  of  FIG. 1  may be mounted onto the building wall  10  via one or more fasteners  22 . Further as shown, the one track laminate panel support beam  25  may be mounted on the building wall  10  proximate a two track laminate panel support beam  20 . While the depicted laminate panel support beams  20  and  25  are depicted as having one or two tracks and a J-shaped or W-shaped geometry, other structures and configurations are contemplated herein. 
     Referring to  FIG. 1 , the system  1  may also comprise at least one secondary support beam  50  oriented generally perpendicular to the laminate panel support beam  20 ,  25  and mounted to at least one laminate panel support beam  20 ,  25 . While the present discussion centers on secondary support beams  50  having a vertical configuration, is it contemplated that the secondary support beam  50  could be positioned horizontally or diagonally if required by the structure and/or contours of the building wall  10 . As shown in the embodiment of  FIG. 1 , the secondary support beam  50  may be mounted to two laminate panel support beams  20 ,  25 . It is also alternatively contemplated that the secondary support beam  50  may be coupled to less than two or more than two laminate panel support beams  20 ,  25 . Moreover, it is also contemplated that the secondary support beam  50  may also define various structural shapes and structural profiles. As shown in the embodiment of  FIG. 1 , the secondary support beam  50  may comprise a pair of parallel raised beams  52  connected by a nonraised beam  53  disposed therebetween. As an alternative to this raised/nonraised profile, other embodiments may include a flat profile. 
     Referring again to  FIGS. 1 ,  2 A and  2 B, the system  1  may also comprise at least one sliding clip  30  that is configured for attaching laminate panels  40  to the laminate panel support beams  20 ,  25 . The sliding clips  30  may be slidingly coupled to track  24 , and are also attached to one or more laminate panels  40 , which are moveable with the sliding clips  30 . As shown in  FIGS. 1 ,  2 A and  2 B, the system  1  may comprise two sliding clips  30  slidingly coupled to the two spaced tracks  24  of the two track laminate panel support beam  20 , as well as a sliding clip  30  slidingly coupled to the one track laminate panel support beam  25 . While the FIGS depict only one sliding clip  30  per track, it is contemplated to have multiple sliding clips  30  on each track  24 . 
     Referring yet again to  FIGS. 1 ,  2 A, and  2 B, the two track laminate panel support beam  20  may comprise two laminate panels  40  coupled thereto. In another embodiment as shown, the laminate panel  40  may be coupled at one end to a sliding clip  30  attached to a track on the two track lateral support beam  20 , and coupled at an opposite end to a sliding clip  30  on the one track laminate panel support beam  25 . The laminate panel  40  may be coupled to the sliding clip  30  via a fastening component  32 . The fastening component  32  is a bolt, a screw, or any other suitable fastener. The fastening component  32  may comprise a rigid material, for example, aluminum, stainless steel, or combinations thereof. 
     When mounting the laminate panel  40  onto the laminate panel support beam  20 , various assembly sequences are contemplated. For example, the sliding clip(s)  30  may first be moved along the track(s)  24  to the desired position on the laminate panel support beam  20 ,  25 , at which point, the laminate panel  40  is then attached to the sliding clip  30 . Alternatively as shown in  FIG. 1 , the sliding clip(s)  30  is first attached to the laminate panel  40 , then the sliding clip(s)  30  and attached laminate panel  40  may be slidingly moved along the track(s)  24  to the desired position on the laminate panel support beams  20 ,  25 . In essence, the laminate panel  40  may be coupled to one or more of the sliding clips  30  before or after the sliding clips  30  are coupled to the tracks  24  of the laminate panel support beam  20 . After the laminate panel  40  is positioned at the desired position on the building wall  10 , the laminate panel  40  may then be secured to the secondary support beam  50  by means of a fastener  55 . Like the other fasteners described above, the fastening component  55  may comprise a bolt, screw, or another suitable fastening component known to one of ordinary skill in the art. Without being bound by theory, the sliding functionality of the track  24  and clip  30  assembly enables the laminate panel  40  to be quickly attached to the facade of a building, or quickly removed, thereby reducing labor costs. 
     Various materials and compositions are contemplated for the visible system  1 . In one embodiment, the laminate panel  40  may be a phenolic resin based material. A suitable commercial embodiment for the laminate panel  40  is the VIVIX™ laminate produced by Formica®. The laminate panel support beam  20 , the sliding clip  30 , and the secondary support beam  50  may all comprise rigid support material, for example, a metal, a metal alloy, or combinations thereof. In exemplary embodiments, these rigid support materials may be selected from the group consisting of aluminum, stainless steel, or combinations thereof. 
     In a further embodiment as shown in  FIGS. 2A-B , the system  1  may also comprise a joint closure  60  disposed between sliding clips  30  on adjacent yet separated laminate panels  40 . The joint closure  60  is positioned to block the opening between the adjacent yet separated panels  40 . The joint closure  60 , as shown in  FIG. 2A , defines a C-shape adapted for the joint closure  60  to fit snugly between a pair of sliding clips  30 ; however other geometries are contemplated herein. While many materials are contemplated for the joint closure  60 , the joint closure  60  may comprise a rigid metal material such as aluminum or stainless steel. 
     Referring to FIGS.  3  and  4 A- 4 D, a concealed cladding attachment system  100  for fastening laminate panels  40  onto a building wall  10  is provided. In contrast to the visible system  1 , this system  100  is considered a concealed cladding attachment system, because the support attachments are disposed behind the laminate panels  40 . Referring to  FIG. 3 , the system  100  may comprise at least two wall brackets  130  horizontally spaced apart and attached to vertical beams  120  supported by the building wall  10  as shown in  FIGS. 3 ,  4 A, and  4 B, or mounted directly to the building wall  10  as shown in  FIGS. 4C and 4D . As shown in  FIGS. 4A and 4B , the vertical beams  120  may be mounted onto the building wall  10  via a fastener  122  (e.g., a bolt, a screw, etc). 
     Various geometries and structures are contemplated for the wall bracket  130 . As shown in  FIGS. 4A-B , wall bracket  30  may define an L-shaped cross-sectional profile comprising a vertical portion  137  attached to vertical beams  120  and a horizontal portion  132  extending perpendicularly from the bottom of the vertical portion  137 . The vertical portion  137  is attached to the vertical beams  120  via fasteners  131 , such as screws or bolts. In one embodiment, the horizontal portion  132  of the wall bracket  130  is configured to extend the distance of a cavity  80  between the laminate panel  40  and the vertical beams  120 . As shown, the cavity  80  enables water drainage and air flow  90  in the concealed cladding attachment system  100 , or the visible cladding attachment system  1 . As an alternative to the L-configuration of  FIGS. 4A and 4B , referring to  FIG. 4C , the vertical portion  137  is attached to an outer surface of a building wall  10 ; however, the wall bracket  130  comprises a horizontal portion  132  and/or a horizontal arm  133  that extends behind the vertical portion  137  and at least partially through a building wall  10  or insulation  11 . 
     Moreover, as shown in  FIG. 4D , the wall bracket  130  may comprise a pair of spaced parallel vertical portions  137   a ,  137   b . As shown in the embodiment of  FIG. 4D , one of the vertical portions  137   b  may be disposed inside the insulation  11  of the building wall  10 , whereas the other vertical portion  137   a  may contact a surface of the building wall  10 . In this embodiment, the horizontal portion  132  of the wall bracket is parallel to the horizontal arm  133  of the upper attachment component  134 . As shown, the horizontal portion  132  and the horizontal arm  133  extend perpendicular between the vertical portions  137   a  and  137   b . Moreover as shown in  FIG. 4D , the horizontal portion  132  and the horizontal arm  133  also extend beyond the distance  95  between the parallel vertical portions  137   a ,  137   b . For example, the horizontal portion  132  and the horizontal arm  133  may extend the length of the insulation  11 . 
     Further as shown in  FIGS. 4A-B , the wall bracket  130  may comprise an upper attachment component  134  and a lower attachment component  136  for coupling with the intermediate connector  140 , as described in detail below. The lower attachment component  136  is attached to a horizontal arm  138  extending from the vertical portion  137  at a position above and parallel to the horizontal portion  132  of the wall bracket  130 . In one embodiment, the lower attachment component  136  may be a protrusion configured to interlock with a corresponding protrusion of the lower coupling mechanism  144  of the intermediate connector  140 . The upper attachment component  134  may comprise a hook insertable into a receptacle,  142 , i.e., the upper coupling mechanism  142  as described in further detail below. As shown in  FIGS. 4A and 4B , the hook of the upper attachment component  134  is attached to another horizontal arm  133  extending from the vertical portion  137  of the wall bracket  130 . Various other suitable structural components are contemplated for the upper attachment component  134  and the lower attachment component  136 . 
     Referring again to  FIGS. 3 , and  4 A- 4 D, the system  100  also comprises at least one intermediate connector  140  coupled to the wall bracket  130 . The intermediate connector  140  comprises an upper coupling mechanism  142  configured to be coupled with the upper attachment component  134  of the wall bracket  130 . In one embodiment, the intermediate connector  140  may matingly couple with the upper attachment component  134  of the wall bracket  130 . For example as shown in  FIGS. 4A-4D , the upper coupling mechanism  142  may comprise a receptacle  142  that receives the hook  134  of the wall bracket  130 . 
     As shown in  FIGS. 3 and 4B , the intermediate connector  140  also comprises a lower coupling mechanism  144  configured to couple with the lower attachment component  136  of the wall bracket  130 . In one embodiment, the lower coupling mechanism may interlockingly couple with the lower attachment component  136 . As shown, the lower attachment component  136  of the intermediate connector  140  is a protrusion, which causes the lower attachment component  136  of the wall bracket  130  to deflect inwardly to facilitate the interlocking coupling arrangement. When attaching the intermediate connector  140  to the wall bracket  130 , the intermediate connector  140  is rotated such that the receptacle  142  attaches to the hook  134 , then the intermediate connector  140  is further rotated such that the lower coupling mechanism  144  (e.g., the protrusion  144 ) deflects the lower attachment component  136  (e.g., the protrusion  136 ) inwardly. 
     Having multiple connections between the wall bracket  130  and the intermediate connector  140  as described above helps ensure the wall bracket  130  is secured to the intermediate connector  140 . That being said, the system  100  may also comprise a bumper  135  or extension coupled to the horizontal arm  133  of the wall bracket  130 , which is configured to engage an inward section  143  of the intermediate connector  140  to further secure the intermediate connector  140  on the wall bracket  130 . 
     Further as shown in  FIGS. 3 ,  4 A, and  4 B, the intermediate connector  140  also comprises an intermediate hanger member  146  used for coupling with the laminate panel hanger member  151  of the hanger clip  150 . Referring to  FIGS. 3 , and  4 A-B, the hanger clips  150 , which join the laminate panel  40  to the intermediate connector  140 , utilize their respective laminate panel hanger member  151  to matingly couple with the intermediate hanger member  146  of the intermediate connector  140 . Specifically as shown, the intermediate hanger member  146  is nested within the laminate panel hanger member  151 . 
     When attaching the laminate panel  40  in the system  100  of the present invention, various assembly sequences are contemplated. Specifically, the hanger clips  150  may be coupled to the laminate panels  40  prior to the attachment of the hanger clip(s)  150  to the intermediate connector(s)  140 . In an alternative embodiment, it is contemplated that the hanger clip(s)  150  may be attached to the intermediate connector(s)  140  prior to the laminate panels  40  being attached to the hanger clips  150 . The hanger clip  150  may be attached to the laminate panel  40  via any suitable fastener  155 , such as a screw or bolt. 
     The hanger clip  150  comprises additional components which ensure that the hanger clip  150  is securely attached to the intermediate connector  140 . As shown in  FIGS. 4A-4B , the hanger clip  150  may comprise an adjustable bolt  156 , which may be adjusted to engage the upper surface  145  of the intermediate connector  140  to stabilize the hanger clip  150  on the intermediate connector  140 . In a specific embodiment, the hanger clip  150  is manufactured and packaged with the adjustable bolt  156  and nut  157  attached, wherein the nut  157  is disposed in a slot  152  of the hanger clip  150 . Packaging the adjustable bolt  156  and nut  157  with the hanger clip  150  eliminates the need for the consumer to purchase a separate fastener to secure the hanger clip  150  to the intermediate connector  140 . 
     In further embodiments as shown in  FIGS. 4A-B , the hanger clip  150  may also comprise a flexible cushioning component  160 , which engages a surface  141  of the intermediate connector  140  to stabilize the hanger clip  150  on the intermediate connector  140 . As shown, the flexible cushioning component  160 , which may be embedded in the hanger clip  150 , has a flexible tip, which deflects upon engaging surface  141  of the intermediate connector  140 . By engaging the intermediate connector  140 , the flexible cushioning component  160  helps prevent the intermediate connector  140  or hanger clip  150  from moving relative to each other, thereby further securing the hanger clip  150  on the intermediate connector  140 . The flexible cushioning component  160  may comprise any suitable flexible material, for example, a flexible polymeric nondegradable material such as polyurethane, Santoprene™, other thermoplastic elastomers, or combinations thereof 
     In further embodiments as shown in  FIGS. 4A-B , the hanger clip  150  may also comprises recessed reservoir portions  153 ,  154  operable to collect condensed water. The recessed reservoir portions  153 ,  154  may be sloped to facilitate the removal of condensate present on the recessed reservoir portions  153 ,  154  of the hanging clip  150 . Similar to the visible cladding system  1 , the concealed cladding attachment system  100  may also comprise a joint closure  170  coupled to the wall bracket  130  via fastener  174 . As shown in  FIGS. 4A-B , the joint closure  170  is configured to block the opening between adjacent yet separated laminate panels  40 . Similar to the recessed reservoir portions  153 ,  154  of the hanger clip  150 , the joint closure  60  comprises a lower lip  172  operable to collect and remove water. 
     Moreover, it is contemplated to use various additional structural components for the cladding systems depending on the needs of the builder. For example, pieces with different shapes and curvatures may be specifically developed for the contours or corners of the building wall  10 . 
     It is further noted that terms like “preferably,” “generally”, “commonly,” and “typically” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention. 
     For the purposes of describing and defining the present invention it is additionally noted that the term “substantially” is utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The term “substantially” is also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. 
     Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.