Patent Publication Number: US-11041316-B1

Title: Wall cladding system

Description:
This application is a continuation of U.S. patent application Ser. No. 15/994,565 filed May 31, 2018, which application is a divisional of U.S. patent application Ser. No. 15/223,081 filed Jul. 29, 2016 (U.S. Pat. No. 10,011,996 granted Jul. 3, 2018), the entirety of which are incorporated by reference herein. 
    
    
     BACKGROUND 
     This invention relates to building products and, more particularly, to clipless interlocking wall cladding. 
     There are various conventional methods of cladding exterior building walls with esthetically pleasing fascia. The use of metal composite material (MCM) panel systems for exterior building facades are known in the prior art. Such MCM panels are typically made from two sheets of metal material bonded to a thermoplastic core. The metal material, or skin, can be made of any type metal sheet or decorative plating of zinc, copper, steel, titanium, and the like. MCM panels are strong and lightweight and can be applied to new building facings or during remodeling of an existing structure. MCM panels can be fabricated to conform to very complex and intricate building wall designs. Individual wall panels are mounted on extruded aluminum frame members and attached to the underlying building substructure with fasteners in a grid-like pattern. This is a time-consuming process because various sized panels are required to complete an installation. 
     It would be economically advantageous if the cost of such panels and the installation time could be reduced and the use of extruded frame members could be eliminated. 
     SUMMARY 
     Disclosed is a section of wall cladding for decorating the facade of a building, and a system of cooperating sections of wall cladding for the same. The section of wall cladding comprises of a panel comprising a front side and a back side, a front hem at a top of the panel formed from a portion of material turned toward the front side of the panel and downward, and a rear hem at a bottom of the panel formed from a portion of material turned toward the back side of the panel and upward. The section of wall cladding can be t-shaped or any other shape to depending on the desired aesthetics. 
     More specifically, the section of wall cladding comprises of a first edge positioned between the front hem and the rear hem and extending across a portion of the panel, and a second edge positioned between the front hem and the rear hem and extending across a portion of the panel. The section of wall cladding can be dimensioned with the bottom of the panel having a dimension of “x” and the first edge and the second edge of the panel each have a dimension of “x/2”. 
     A system for decorating a facade of a building is also disclosed. The system comprises of a starter strip of cladding for attaching near a bottom of the facade of a building having a front facing hem. A first row of at least two sections of wall cladding can be positioned adjacent with each other with each section of wall cladding comprising of a panel comprising a front side and a back side, a front hem at a top of the panel formed from a portion of material turned toward the front side of the panel and downward, and a rear hem at a bottom of the panel formed from a portion of material turned toward the back side of the panel and upward. A starter shingle of cladding can be positioned between a gap between adjacent two sections of wall cladding of the first row. A second row of at least two sections of wall cladding have a portion of each of the two sections of wall cladding of the first row fit within the rear hem of the section of wall cladding of the second row. The portion of each of the two sections of wall cladding of the first row can comprise of a first edge of one section of wall cladding and a second edge of the other section of wall cladding. After the first row of sections of wall cladding, the subsequent rows can extend side-by-side in an interlocking relationship up the building facade. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a section of wall cladding of the present disclosure. 
         FIG. 2  is a front view of the section of wall cladding of  FIG. 1 . 
         FIG. 3  is a side view of the section of wall cladding of  FIG. 1 . 
         FIG. 4  is an overlapping array of sections of wall cladding of  FIG. 1 . 
         FIG. 4A  is a cross-sectional view taken along the line A-A of  FIG. 4 . 
         FIG. 4B  is a cross-sectional view taken along the line B-B of  FIG. 4 . 
         FIG. 4C  is the cross-sectional view of  FIG. 4A  with section of wall cladding  100   e  removed to show the slot. 
         FIG. 5  is a perspective view of a section of building with the wall cladding system of this disclosure. 
         FIG. 6  is a perspective view of a section of building with the wall cladding of a different design according to this disclosure. 
         FIG. 7  is a perspective view of a section of building with the wall cladding of a different design according to this disclosure. 
         FIG. 8  is a perspective view of a section of building with the wall cladding of a different design according to this disclosure. 
         FIG. 9  is a perspective view of a section of building with the wall cladding of a different design according to this disclosure. 
         FIG. 10  is a perspective view of a section of wall cladding of the present disclosure. 
         FIG. 11  is an overlapping array of sections of wall cladding of  FIG. 10 . 
         FIG. 11A  is a cross-sectional view taken along the line A-A of  FIG. 11 . 
         FIG. 11B  is a cross-sectional view taken along the line B-B of  FIG. 11 . 
     
    
    
     DETAILED DESCRIPTION 
     Disclosed is a section of wall cladding  100  for applying to building facades.  FIG. 1  shows section of wall cladding  100 , which comprises of a panel  102  with a front hem  104  and a rear hem  106 . This arrangement produces a system of clipless interlocking wall cladding that can be easily manufactured and installed while providing a pleasing esthetic appearance. The details of section of wall cladding  100  will be described more specifically below followed by a description of how multiple sections of wall cladding  100  cooperate to decorate the facade of a building. 
     As shown in  FIGS. 1-3 , panel  102  comprises of a metal composite material made from two sheets of metal material bonded to a thermoplastic core. Panel  102  is cut so that it is generally t-shaped with a first edge  108  and a second edge  110 . Panel  102  has a top  112  and a bottom  114 . Bottom  114  of panel  102  can be proportional in length to first edge  108  and second edge  110 . If the length of bottom  114  is a dimension of “x”, then the length of first edge  108  and second edge  110  is each “x/2”. It is generally preferable that the length of first edge  108  and second edge  110  is less than or equal to “x/2”. The reason for these dimensions will be apparent from the discussion of how multiple sections of wall cladding  100  cooperate together to form an aesthetically pleasing facade. 
     Section of wall cladding  100  comprises of front hem  104  and rear hem  106 . Front hem  104  and edges  108  and  110  and rear hem  106  provide the clipless interlocking function of multiple sections of wall cladding  100  with each other. Front hem  104  is at a to  112  of panel  102  and formed from a portion of material turned toward the front side of panel  112  and downward and pressed onto the front side of panel  112  with a front face  105  perpendicular to the front side of panel  112 . Front hem  104  provides a thickness of material to create a gap that allows the next section of wall cladding  100  to interlock. As shown in  FIG. 4A  and  FIG. 4C , front hem  104  creates a first layer of material. Section of wall cladding  100   a  is attached overtop of front hem  104  of section of wall cladding  100   c . A slot  109  remains in the area where front hem  104  of section of wall cladding  100   c  ends and edge  110  of section of wall cladding  100   a . Rear hem  106  of section of wall cladding  100   e  interlocks with edge  110  of section of wall cladding  100   a  by sliding into this slot  109 . More specifically, rear hem  106  of section of wall cladding  100   e  has an upward extending portion  111 . This upward extending portion  111  fits between panel  102  of section of wall cladding  100   c  and panel  102  of section of wall cladding  100   a . Front hem  104  is positioned at top  112  of panel  102  and formed from a portion of material turned toward the front side of panel  102  and downward. Rear hem  106  is positioned at bottom  114  of panel  102  formed from a portion of material turned toward the back side of panel  102  and upward. Rear hem  106  has a gap  118  (shown in  FIG. 3 ) that is slightly more than the thickness of edge  108  or edge  110  of section of wall cladding  100  in which to receive the same to interlock two sections of wall cladding  100 . More specifically, as shown in  FIG. 4A , panel  102  of section of wall cladding  100   a  fits into gap  118  of rear hem  106  of section of wall cladding  100   e.    
     Section of wall cladding  100  is mounted to the building facade by fasteners through one or more holes  120  through front hem  104 . At least two holes  120  are preferred, and three holes  120  are shown in the illustrated embodiment to firmly attach section of wall cladding  100  to a building. Another set of holes  122  can be positioned one hole  122  above each of first edge  108  and second edge  110 . This set of holes  122  secure bottom edge  114  when rear hem  106  engages over edges  108  and  110  of wall cladding  100 . 
       FIGS. 4 and 5  show multiple sections of wall cladding  100  secured in an interlocking relationship to the building facade. Sections of wall cladding  100  can be attached in a horizontal row across a side of the building. A starter strip of cladding  124  can be attached near the base of the building. Starter strip of cladding  124  has a front facing hem  125  and a hole  127  for receiving a fastener for attaching starter strip of cladding  124  to the building. Sections of wall cladding  100   c  and  100   d  show the beginning of a row. Sections of wall cladding  100   c  and  100   d  are each secured to the building with fasteners through holes  120  through front hem  104  and fasteners through the other set of holes  122  in panel  102 . In between sections of wall cladding  100 , which form the bottom row, above starter strip of cladding  124  and below sections of wall cladding  100   c  and  100   d , starter shingle of cladding  126  can be attached to fill in the gaps between adjacent sections of wall cladding  100 . Starter shingle of cladding  126  can be a rectangular shaped flat panel, and is installed prior to installation of sections of wall cladding  100 , and extends in the longitudinal direction lengthwise with starter strip of cladding  124 . 
     Thereafter, a section of wall cladding  100   b  is interlocked with sections of wall cladding  100   c  and  100   d  with rear hem  106  receiving first edge  108  of section of wall cladding  100   d  and second edge  110  of section of wall cladding  100   c . The corresponding hole  122  and its fastener above each of first edge  108  and second edge  110  are covered by a portion of panel  102 . An exposed portion of front hem  104  on sections of wall cladding  100   c, d  are also covered by a portion of panel  102 . Section of wall cladding  100   b  can be secured to the building with fasteners through holes  120  in front hem  104 . Section of wall cladding  100   a  is attached in a similar manner next to section of wall cladding  100   b . This interlocking attachment of multiple sections of wall cladding  100  continues until the side is covered as shown in  FIG. 5 . 
     In this regard, with respect to  FIG. 4A , a system for decorating a facade of a building is disclosed. The system comprises of a plurality of interlocking sections of wall cladding comprising section of wall cladding  100   c  comprising of panel  102  and a section of material, such as front hem  104 , which cooperates with a thickness of panel  102  to create a step  103 . A second section of wall cladding  100   a  comprises of a portion of material (near edge  110 ) overlaying first section of wall cladding  100   c  to form a space. A third portion of wall cladding  100   e  comprises of a rear hem  106  for hooking into the space to interlock section of wall cladding  100   c , section of wall cladding  100   a , and section of wall cladding  100   e . Section of wall cladding  100   c  and second section of wall cladding  100   a  are fastened to the building with fastener  120  through the portion of material from second section of wall cladding  100   a  and front hem  104  of section of wall cladding  100   c . Front hem  104  of first section of wall cladding  100   c  is pressed on to panel  102  to form a continuous section of material. 
     Sections of wall cladding  100  can be formed of a variety of shapes to provide a decorative appearance to a building facade.  FIGS. 6-9  show alternative shapes of sections of wall cladding  100 . These shapes function the same as section of wall cladding  100  with the double hem for clipless interlocking with each other. 
       FIG. 10  shows a section of wall cladding  200  with a rectangular shape to provide a rectangular appearance. Panel  202 , again comprises of a metal composite material made from two sheets of metal material bonded to a thermoplastic core. Panel  202  is cut so that it is generally rectilinear with a bottom edge  208  and a top edge  210 . Section of wall cladding  200  also comprises of front hem  204  and rear hem  206 . Front hem  204  and edges  208  and  210  and rear hem  206  provide the clipless interlocking function of multiple sections of wall cladding  200  with each other. Front hem  204  provides a thickness of material to create a gap that allows the next section of wall cladding  200  to interlock. 
     As shown in  FIG. 11A  front hem  204  creates a first layer of material. Section of wall cladding  200   b  is attached overtop of front hem  204  and a spacer  205  of a section of wall cladding  201 . Spacer  205  serves the same function as edge  208  and edges  108  and  110  of section of wall cladding  100 . Spacer  205  provides an interlock with gap  218  near the middle of the bottom edge of section of wall cladding  200 . 
     A gap remains in the area where front hem  204  of starter strip of wall cladding  201  ends. Rear hem  206  of section of wall cladding  200   b  interlocks with edge  208  of section of wall cladding  200   a  by sliding into this gap. Front hem  204  is positioned at the top of panel  202  and formed from a portion of material turned toward the front side of panel  202  and downward. Rear hem  206  is positioned at the bottom of panel  202  formed from a portion of material turned toward the back side of panel  202  and upward. Rear hem  206  has a gap  218  (shown in  FIG. 10 ) that is slightly more than the thickness of edge  208  of section of wall cladding  200  in which to receive the same to interlock two sections of wall cladding  200 . 
     More specifically,  FIG. 11  shows multiple sections of wall cladding  200  secured in an interlocking relationship to the building facade. Sections of wall cladding  200  can be attached in a horizontal row across a side of the building. A starter strip of cladding  201  can be attached near the base of the building. Starter strip of cladding  201  has a front facing hem  204 . Sections of wall cladding  200   a  and  200   b  start the beginning of a first row, and are each secured to the building with fasteners  212  through front hem  204 . Section of wall cladding  200   a  interlocks with tap  205  on starter strip of cladding  201 , and is secured to the wall with fastener  212 . Section of wall cladding  200   b  is installed in the same manner and bottom right corner of panel  202  of section of wall cladding  200   b  cooperates with edge  208  of section of wall cladding  200   a.    
     Thereafter, for the second row, a section of wall cladding  200   c  is interlocked with sections of wall cladding  200   a  and  200   b  with edge  208  of section of wall cladding  200   c  receiving rear hem  206  of section of wall cladding  200   d  and spacer  205  of section of wall cladding  200   d.    
     In this regard, with respect to  FIG. 11B , a system for decorating a facade of a building is disclosed. The system comprises of a plurality of interlocking sections of wall cladding  200  comprising section of wall cladding  200   b  comprising of panel  202  and a section of material, such as front hem  204 , which cooperates with a thickness of panel  202  to create a step. Section of wall cladding  200   c  comprises of a portion of material overlaying section of wall cladding  200   b  to form a space. Section of wall cladding  200   d  comprises of a rear hem  206  for hooking into the space to interlock section of wall cladding  200   b , section of wall cladding  200   c , and section of wall cladding  200   d . Section of wall cladding  200   c  and section of wall cladding  200   b  are fastened to the building with fastener  212  through the portion of material from section of wall cladding  200   c  and front hem  204  of section of wall cladding  200   b . Front hem  204  of section of wall cladding  200   b  is pressed on to panel  202  to form a continuous section of material. 
     The exposed portion of front hem  204  on sections of wall cladding  200   a, b  are also covered by sections of wall cladding  200   c . Section of wall cladding  200   d  is attached in a similar manner next to section of wall cladding  200   c . This interlocking attachment of multiple sections of wall cladding  100  continues until the side is covered. 
     What is noticeably distinct about the wall cladding system herein described is the aesthetically pleasing rectangular grid pattern created by multiple interlocking sections of wall cladding  100 ,  200 . In addition to the aesthetics of the wall cladding system, each section of wall cladding  100 ,  200  has a thin profile as thick as the double hemmed edges (front hem  104 ,  204  and rear hem  106 ,  206 ). All sections of wall cladding  100 ,  200  are the same size, which means the wall cladding system is less expensive to manufacture and easier to install. There are no custom-made parts required. No extruded frame members are needed between the panels and the building fascia. Furthermore, because of the interlocking nature of sections of wall cladding  100  where each section of wall cladding  100 ,  200  covers its neighboring section of wall cladding  100 ,  200  the tolerances are not as critical, which decreases the manufacturing time and cost. Furthermore, wall cladding  100 ,  200  has superior structural performance due to the interlocking nature of front hem  104 ,  204  and rear hem  106 ,  206  with other sections of wall cladding  100 ,  200 . 
     Although not specifically illustrated in the drawings, it should be understood that additional equipment and structural components will be provided as necessary and that all of the components described above are arranged and supported in an appropriate fashion to form a complete and operative cladding system incorporating features of the present invention. 
     Moreover, although illustrative embodiments of the invention have been described, latitude of modification, change, and substitution is intended in the foregoing disclosure, and in certain instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of invention.