Patent Publication Number: US-2005138865-A1

Title: Eave lining system

Description:
RELATED APPLICATIONS  
      This application claims priority to Australian Provisional Application No. 2003906615, filed Nov. 28, 2003, and Australian Provisional Application No. 2004903302, filed Jun. 17, 2004, and Australian Provisional Application No. 2004903567, filed Jun. 29, 2004, the entirety of each of which is hereby incorporated by reference.  
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates generally to building construction, and more particularly to eave lining systems for building structures and installation of the same.  
      2. Description of the Related Art  
      In the construction industry, the installation of eave linings is typically a multi-stage process. Eave sheet used to line the eaves is generally produced in set lengths and widths. The sheet must be transported to site, nailed into position on the building. The joint sections are typically set, concealed or connected using joining strips. A finish is then applied to the entire assembly after installation. In some cases, a paint or coating is applied to the assembly, and sometimes the eave sheets must be painted more than once with an undercoat and a topcoat.  
      These finishing processes after installation add greatly to the expense of installing eave linings. The labor, paint and setting costs as well as additional time taken to paint and/or set the eaves all add to the installation cost. Moreover, eaves are most often situated high up on building structures and therefore, the installation would incur additional costs for scaffolding equipment to elevate the tradesmen during the eave finishing and painting process. This is a particular problem in the construction of many project, kit and pre-finished buildings where the only parts of the entire building requiring painting are the eaves. Accordingly, painters must be brought in specifically and only for that task. As such the efficiency is reduced.  
      Another problem is the consistency of the painting when done onsite. It is often the case that the coverage applied by hand painting eaves is not uniformly thick. This may result in patchy protection and/or appearance. Similar problems also apply in relation to the setting and concealing of various joints where this is required.  
      It is an object of the present invention to overcome or ameliorate one or more of these disadvantages of prior art, or at least to provide a useful alternative.  
     SUMMARY OF THE INVENTION  
      In one aspect, the preferred embodiments of the present invention provide an eave lining sheet which is pre-finished on at least one exposed surface prior to installation on building structure. The at least one pre-finished surface comprises a layer selected from the group consisting of paint, coating, and laminate. In one embodiment, the sheet is pre-finished by the use of pigmented base materials and/or additives such that minimal further finishing is required. In another embodiment, the eave lining sheet comprises a release liner positioned adjacent to the exposed surface so as to protect the pre-finished surface from damage.  
      In another aspect, the preferred embodiments of the present invention provide an eave lining system for buildings. The system includes an eave lining sheet having at least one exposed surface that is pre-finished, and a securing member for affixing the eave lining sheet to a support surface. The eave sheet and the securing member are preferably configured such that minimal post installation finish is required. In one embodiment, the system further includes a joining strip for joining a peripheral edge of the eave sheet with a peripheral edge of a like eave sheet. The joining strip is preferably colored such that minimal post installation finishing is required.  
      In another embodiment, the system further includes a pre-finished corner trim system for concealing and finishing a joint area between the eave lining sheet and an adjacent building surface. Preferably, the trim system is a two-part system comprising an inner core element that is adapted to be secured to the support surface or the adjacent building surface, and an outer pre-finished clip-on cover element. In one embodiment, the cover element comprises standard straight length sections and custom pre-formed corner pieces. The corner pieces are preferably positioned over at least a portion of the straight length section to allow for expansion and reduce the need for accurate length cuts on the sections. The inner core trim element can be solid or hollow and has a shape selected from the group consisting of rectangular, quad, and fillet profile, wherein rebates are formed adjacent diametrically opposed corner edges for accepting in-turned lip portions on corresponding outer trim cover portions having a similar general profile as the exposed portion of the inner core element. In one embodiment, the rebates are preferably formed on all edges or multiple sets of corner edges of the trim element.  
      In certain embodiments, the inner core element has a thin walled profile defining one or more surfaces for connection to the eaves sheet or adjacent building surface, wherein the core element also includes a securing member to secure thereto a cover element of an external profile. In another embodiment, the inner core element has two substantially perpendicular arms wherein the ends of each arm are configured to accept and retain outer trim cover portions having the same or a different general profile to the inner element. Preferably, the securing element is selected from the group consisting of screws, nails, staples, plugs, glues, tapes, and combinations thereof. In a preferred embodiment, at least a portion of the screws, nails and plugs are color coordinated with the eave lining sheet. In yet another embodiment, one or more components of the system include openings or perforations configured to provide a predetermined amount of ventilation to selected parts of the building. Preferably, the openings or perforations are provided in one or more of parts selected from the group consisting of eave lining sheets, sheet joining strips, and trim components.  
      In yet another aspect, the preferred embodiments of the present invention provide a method of installing an eave lining on a building structure. The method comprises providing an eave lining sheet having at least one pre-finished surface and installing the eave lining sheet on the building structure with the pre-finished surface exposed. In one embodiment, the method further comprises securing the pre-finished eave lining sheet using at least one securing member selected from the group consisting of screws, nails, staples, plugs, glues, and tapes.  
      In yet another aspect, the preferred embodiments of the present invention provide a two-part trim system for concealing joint regions in building structures. The trim system comprises a base securable over or adjacent a joint region to be concealed and a cover element connectable to the base to conceal the joint region. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a partial sectional side view of a building showing an eave system in accordance with a preferred embodiment of the invention;  
       FIG. 2  is sectional plan view of the system shown in  FIG. 1 ;  
       FIG. 3A  illustrates a nail in accordance with a preferred embodiment of the invention;  
       FIG. 3B  illustrates a screw in accordance with a preferred embodiment of the invention;  
       FIG. 3C  illustrates a quick fix fastener plug in accordance with a preferred embodiment of the invention;  
       FIG. 4  is a view showing a protective hammer pad in accordance with a preferred embodiment of the invention;  
       FIG. 5  is a view showing a hammer protector cap in accordance with a preferred embodiment of the invention;  
       FIG. 6  is a sectional view of an abutment join “on frame” between two eave boards in accordance with a preferred embodiment of the invention;  
       FIG. 7  is a sectional view of an abutment join “off frame” between two eave boards in accordance with a preferred embodiment of the invention;  
       FIG. 8  is a sectional side view of part of a building showing an eave lining system in accordance with a preferred embodiment of the invention having an alternative two part trim system;  
       FIG. 9A  shows one embodiment of a straight inner trim section of the system shown in  FIG. 8 ;  
       FIG. 9B  shows an alternative embodiment of a straight inner trim section of the system shown in  FIG. 8 ;  
       FIG. 10  shows an embodiment of a straight outer trim section for use with the inner trim section of  FIG. 9 ;  
       FIG. 11  shows an embodiment of a partly assembled system using the inner and outer trim sections of  FIGS. 9 and 10  along with a custom outer external corner piece;  
       FIG. 12  shows a variety of alternative profiles for the two part trim system of FIGS.  8  to  11 ;  
       FIG. 13  shows a eave lining system in accordance with a preferred embodiment of the invention that incorporates a vented eave panel and/or eave panel trim arrangement.  
       FIG. 14  is a detailed view of the vented eave panel trim arrangement shown in  FIG. 13 ; and  
       FIG. 15  shows one embodiment of a ventilated eave panel end join strip particularly suited for, but not limited to use with the system of  FIG. 13 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
      The preferred embodiments of the invention will be described predominantly in the context of installation of eave linings. It will be appreciated, however, that the invention is not limited to this particular field of use, being also applicable to other areas of building and construction.  
      In general terms, certain preferred embodiments of the present invention provide a pre-finished eave system for buildings such that no additional painting or finishing of the eaves is required after installation. The pre-finished eave system generally includes a pre-finished eave lining sheet and a securing member for attaching the sheet to a building structure.  
      In one embodiment, the eave lining sheets are made of fiber reinforced cement (FRC), for example those classified as Type A Category 3 in accordance with AS/NZS 2908.2 ‘Cellulose-Cement Products’. However, in alternative embodiments, the sheets may be of other suitable materials. For example, it will be appreciated that sheets formed of wood, metal, plastics, or other suitable material may replace or be used in conjunction with the FRC sheets of this embodiment and are within the scope of the invention.  
      The sheets are preferably produced in a variety of standard lengths, widths and generally will be a standard thickness so that the sheets will be flush on installation. Table 1 below lists certain preferred sheet sizes, however it will be appreciated that the product may be produced in any size or thickness as required.  
               TABLE 1                          Product Sizes                         Length   Width   Thickness       (mm):   (mm):   (mm):                                 2400   450   4.5       2400   600   4.5       2400   750   4.5       2400   1200   4.5                  
 
      In some implementations, the eave lining sheets may also be perforated through their thickness with a predetermined number and arrangement of slots, holes, or other types of perforation. These perforations provide a predetermined amount of airflow through the sheet, in turn providing ventilation to the roof or wall cavity when the sheet is installed.  
      In one embodiment, the eave lining sheets are pre-finished on at least one side with a protective paint or coating. Painting can be an automated process conducted at a purpose built production facility and may be applied using conventional techniques, such as spraying, roll coating, curtain coating, or powder coating. The paint may be cured by thermal means or by radiation or a combination thereof. The paint may be applied in one or more coats with or without an undercoat layer, depending on the type and color of paint or thickness of paint layer required.  
      The sheets may also be pre-finished using durable laminates such as Formica® high pressure laminates or durable polymeric films such as Tedlar® fluoropolymer films. Such laminates are preferably applied to the surface of the sheet with a suitable adhesive, such as a polyurethane adhesive. The sheets may also be colored using organic or inorganic pigments incorporated directly into the fibercement. The sheets may also be coated with treatments to prevent the accumulation of mildew and fungus which may form during storage and when installed. Other possible coatings maybe applied to help fire retardation, repel insects or provide insulation characteristics. These coatings may be applied under or on top of the paint layer or may be additives to the paint itself.  
      While it is preferred that the sheets be painted in a factory and in a form which is substantially or completely pre-finished, it will be appreciated that the invention may be applied to sheets that are raw or unpainted and unfinished at purchase.  
      To reduce damage to the eaves during storage and shipment, the pre-finished eave sheet may be prepared by covering the surfaces of the sheet with a one or more removable protective coatings or laminates. This process is described in detail by the Applicant&#39;s corresponding, co-pending U.S. application Ser. No. 10/620,711 filed Jul. 16, 2003, which is hereby incorporated by reference in its entirety. Alternatively, the removable protective coating may be spray-applied or applied as a transfer film from a backing material. Preferably, the laminate forms a barrier substantially preventing the surface of the eaves from being damaged, marked or scratched. Once at the building site, the protective layer can be stripped off either before, after or during installation. In one embodiment, the removable protective layer is preferably stripped after installation is complete, in order to protect the pre-finished panel surfaces from fingerprints, scratches and the like.  
      Referring to the drawings,  FIG. 1  illustrates a eave lining sheet  1  of one preferred embodiment installed on a building structure. As shown in  FIG. 1 , the sheet  1  is attached to a eave support structure  4 . As shown in  FIGS. 1 and 2 , the support structure  4  is generally a frame work of eave battens made of steel or timber. In alternative embodiments, the eave lining sheet  1  may be attached to a substrate rather than the more common framework.  
      As can be seen in the embodiment shown in  FIG. 1 , the outer edge of the eave lining sheet fits into a groove  5  in an eave fascia board  6 . Additionally, a pre-finished trim  7  is used at the inner edge to fill the corner between the board  6  and the exterior wall.  
      The trim  7  can be a conventional wooden beading element, or instead can be an extruded plastic strip or similar, with or without pre-made straight section and/or corner connectors, the latter obviating the need to produce mitre cuts on site. Alternatively, a preferred two part trim system can be used as discussed below in reference to FIGS.  8  to  11 . In certain embodiments, the trim may also be made of a fibercement material.  
      In other embodiments such as where grooves are not usually provided in the fascia board, the eave lining sheet is nailed to a support and the fascia is installed afterwards. Any gap in the eave lining sheet and the fascia is then caulked or covered by a trim piece which can be of the kinds discussed above.  
      The eave lining sheet is preferably affixed to the supporting structure by a variety of methods. Such methods may include nails  8 , screws  9 , plugs  10 , staples, glues or adhesive tapes alone or in combination. However, it is preferable that the fixing method and procedure does not damage the eave board surface so that the need for any painting or touch up painting after installation is eliminated or kept to a minimum.  
      In certain preferred embodiments, screws and nails are fitted with colored or painted heads to match the eave board finish. Accordingly, as shown in  FIG. 4  special hammer pads  11  are provided so that the heads of the nails are not marked and the sheet not damaged. In an alternative embodiment shown in  FIG. 5 , a soft plastic or rubber hammer protective cap  11   a  is provided along with a sleeve  11   b  that allows the protective cap to be fitted to hammers having a smaller head size. Another method is to use colored caps in conjunction with screws and nails to cover the exposed head. Touch up may be required if non-prefinished fixers are used such as when stainless steel nails are specified in certain coastal areas.  
      As seen in  FIGS. 6, 7 , and  15 , a joining strip  12  is provided to facilitate joining of abutting boards. The joining strip  12  may be extruded plastic or another suitable material such as timber, rubber or a molded material. Preferably, the strip is color coordinated with the boards and do not require painting. The strips maybe used for joints between sheets either on frame as shown in  FIG. 6  or off frame as shown in  FIG. 7 . Alternatively, a strip may be pre-attached to one sheet with a suitable adhesive. While the strips of certain preferred embodiments are of a generally “H” shaped profile, typically one internal leg is extended to facilitate attachment to the support structure as shown in  FIG. 6 . H-moulds may have an extended width and contain perforations to provide venting as per the example shown in  FIG. 15 .  
      Referring next to FIGS.  8  to  11 , there is shown an alternative and preferred two part trim system for finishing and concealing the corner between the eave sheets and the adjacent wall. This system uses an inner trim section which in the form illustrated in  FIG. 9A  shows a first embodiment comprising a solid elongate core member  13 A of generally rectangular section, having rebates  14  adjacent to diametrically opposed corner edges as shown. An alternative embodiment  13 B is shown in  FIG. 9B  which has rebate on all four edges so that the section can be installed in multiple orientations thereby simplifying the installation process. This modification can be applied to any profile that could be installed in more than one configuration. These inner trim cores can be made of wood or a wood based composite like most of the conventional beadings and trim sections used in the building industry. However, any other firm nailable material would be suitable including, for example, polymeric expanded foam materials or the like.  
      In other forms (not illustrated), the core element may be of a simple thin walled structure effectively defining a base plate which can be secured to the eave sheet and/or the adjacent building surface and which includes retaining means to which a clip on cover can be connected. Such a base plate may be of a standard generally L shaped section and it is each cover element only which is configured to the desired external profile.  
      The second part of the system comprises a pre-finished outer cover element  15 A that is adapted to sit over the inner core element  13 . In the example provided, the outer core at a cover element has in-turned lip formations  16  along its outer edges, such that the cover  15  can be “snapped on” to the core element and be retained thereby engagement of the lip formations  16  with the corresponding rebates  14 . This cover element can again be made of any material that would provide a requisite resilience to effect a simple “snap-on” or “push-on” connection. Suitable materials may include various moulded or extruded polymers or pre-coated steel or aluminum sections.  
      Also, optionally forming part of the cover element portion of this trim system are pre-formed and pre-finished corner pieces such as  15   b  shown in  FIG. 11 . The corner pieces can be made available in all common configurations such as 90° (internal and external) and 135° external for bay windows and the like. Preferably, the custom corner sections are configured to sit over the straight section cover elements. This substantially eliminates the need for accurate length cutting on the long sections and allows for expansion and contraction which can be a problem over long lengths.  
      The advantages of the two part inner and outer trim system are significant, in that the need for a skilled carpenter is eliminated and a simplified fixing process should be fairly quick to install. In this regard, the inner core sections can be conveniently cut using, for example, suitable plier type cutters and nailed into position without the need to ensure a clean and accurate mitre join at the corner. The straight section cover elements can then be cut approximately to length in the same way and “snapped” onto the core elements. Finally, the corner pieces can be clipped on top of the adjacent straight section cover portions and the finishing processes complete. There is no need to finish or touch up joins, and no special skills are required as there are no mitre joints to be cut and accurate length cutting at the straight sections is not needed.  
      As can be seen from  FIG. 12 , the two part inner and outer trim system can be configured to any desired profile and is not limited to the examples shown, nor is it limited to the use of solid core elements as shown in this illustration. Additional advantages are that the hidden fixings of the two part trim section removes the need for touch up of nails or screws. Furthermore the snap on trim sections allow for thermal expansion of the building and the eaves components that is not possible using a 1 piece trim as is found in traditional eaves installation methods. This ability to accommodate thermal expansion provides a significant advantage over prior art systems. For example, for a fully fixed trim that can&#39;t accommodate thermal expansion, buckling of the trim can occur if the thermal expansion of the trim is greater than the wall resulting in an unsightly finish and possible nail pull out of the trim. Alternatively, if the wall/substrate/etc expands more than a fully fixed trim, the corner joints of the trim can open up and cause a deterioration in performance of the eaves system. These potential problems are avoided with the preferred system described above.  
      It will also be appreciated that while this two part trim system is particularly suited to use in eave lining systems as described, it is equally applicable to other building applications where corner or indeed planar joints need to be concealed in a simple manner that reduces the need for highly skilled labor.  
      Turning finally to  FIGS. 13, 14  and  15  there are shown further variations to the invention that incorporate venting means for enabling air and moisture vapor to flow from the wall and/or roof cavity to atmosphere. The arrangement shown in the accompanying figures is particularly well suited to externally clad timber frame structures. However, the concept is not limited to this particular type of building structure.  
      In order to provide ventilation to the wall cavity, a vented trim system is optionally provided. While the illustrated form is based on the preferred two part trim system, an equivalent single part trim component could also be used. The functional modification resides in the provision of a trim wall extension strip  17  which has ventilation apertures  18  provided therein.  
      In use, the vented eaves sheets are secured in the usual manner and an opening  19  is left between the external wall cladding and the sheet and/or eaves bearer. The modified trim element including the trim wall extension strip  17  is then secured to the eave sheet so that the extension strip bridges over the opening  19  as shown. If separate or additional ventilation is required into the roof cavity, then a suitably vented eaves sheet can also be used. Alternately, a roof space may be ventilated by using a similar strip and re-orienting it so that the vented extension strip bridges a gap between the eaves sheet and the eaves support structure. The eaves sheets, whether ventilated or un-ventilated, can also be joined using a ventilated end join strip  12  such as the kind shown in  FIG. 15  which further enhances the ventilation and also provides an easy means of providing ventilation without using perforated eave panels which may not be aesthetically acceptable.  
      It will be appreciated that all aspects of the invention provide significant advantages over the prior art by minimizing or at least significantly reducing the amount of time consuming and expensive in-situ post installation finishing required. This enables faster and more economical installation of eaves, particularly where scaffolding would have normally been required. Furthermore, the trim arrangement incorporating overlapping corner and end finishing components overcomes problems that can readily occur with fixed trim systems where there is some form of differential expansion between the trim and the adjacent sheets or elements of the building structure. Although the invention has been described with reference to specific examples it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.